Keiths 400/4

[taysidedragon]

Check all earth connections. 

[Coppertop1234]

Checked wires and cleaned all joints and earths - all disconnected and cleaned replaced back in order

Headlight now not an issue  can turn lights on and off with engine running ok

Fusebox was a pain with fuses just collapsing, they were getting on a bit and silver ends were falling off when i touched them

(seem ok at moment will get a pack of new fuses to make sure)

Flasher unit was an led flasher unit ,took it off and it just packed in so i have ordered a new one
end of play for today till new units come tomorrow.

At the moment I am thinking the problem was related to the flasher unit, rather than wiring, but we will see tomorrow

Hope it was

[Bryanj]

Correct glass fuses have been getting hardercand harder to find in correct size, if you go to US site and look up Hondaman he mahes and sells a replacement that takes the blade type fuses

[Coppertop1234]

well one step forward 3 back
flasher unit fitted indicators all flashing as they should.
not started bike yet.
idiot console went blank no power
tank off checked harness connections all look fine
Headlight out all connections look fine no wires out or loose
checked fuses all ok
checked connections all ok
still no power to ignition
tried fuse between fuses yup powers up ignition and cranks over
not tried to start it at this point but think she would fire up
checked fuse box out all wires good and connections ok

next thing i can think of is ignition connections, but these power with fuse bypass ok so probably not

stumped at moment maybe its the diode at side of fuses? Rectifier?

Any comments appreciated

[Bryanj]

Not sure what you mean by fuse between fuses, the diode is only for thestarter interlock(neutral light on OR clutch lever pulled in)
It is not unusual for the block connector to come loose on ignition switch and/or the contacts in the switch part to fail

[Coppertop1234]

If you place a fuse inbetween the space where a fuse should not go it powers ignition as if a key is in bike

[Bryanj]

Then something is wired wrong as only 3 fuses do anything
1 main
2 tail and instruments
3 head

The other 2 are spares

[Oddjob]

It’s the old dodge/thieves trick to start a bike with that sort of fuse box Bryan. You fit a fuse between the main fuse and the next fuse inline. That acts as a direct short to power both circuits. However it should only work if the headlight switch is also moved to the on position. For some reason Honda powered the lighting circuit so it stayed on all the time. Most likely to run parking lights. It didn’t take long for the thieves to spot the fault. Everything lights up and the engine will start. Honda even provided the spare fuse to jump it with.

It was the main reason when I fitted my 500 with a 550f harness that I kept the old ignition switch under the tank. I still used the 550 switch between the clocks but until the 500 switch is in park, so I can remove the key, the rest of the systems stay completely dead. I wired it so the main feed wire to the fuse box runs through the 500 ignition switch and then back to the fuse box.

[Bryanj]

Never heard of that one Ken, perhaps i worked in a less theivefull area, from that info suggests the ignition switch contacts are bad so try unplugging the switch connector block and jumping red to black, if it all lights up then the contacts are duff so new switch or Emgo contact unit but i would fit a relay

[Oddjob]

I’d agree with Bryan, most likely a poor contact set in the switch. They can be disassembled though and cleaned up, done it a few times, just be careful you don’t snap the retaining lugs.

As Bryan also suggests jump the red and black wires together first. If it all lights up it’s the switch if not it’s something else.

[Coppertop1234]

Well later today when I land home we should see which parts iffy. Son has brought me all electrical parts to try 1 at a time from a bike we have not started on yet.
Unless I am unlucky and it has similar issues.
I will update as we progress further
Thanks for imput always helpful to have differing opinions and possible sources to investigate.

[Coppertop1234]

Stage 1 replaced  easy swaps
Fuse box
 rectifier
Dioder + Regulator
Flasher unit

No difference all original parts replaced and on to the ignition for stage 2

Looks like I found culprit loose wire on coupling block for ignition.

[Coppertop1234]

First proper test ride out to local car spares about a mile away for some fuses
Told wife I would be back in 5 or an hour all depends.
Little bike rode very nice and didn't fault on anything.
So hopefully problems solved.
Got some spare 15 amps but no 7s so I will order some on line to sort it.
may go to Chesterfield on Sunday to a classic meet and give her a bit more of a run.

[Coppertop1234]

Same fault returned when Indicating engine falters and stamers to flash speed.

Checked wiring and nothing visible found a few badly taped up wiring joints i was not happy with,so I can only presume its a earth leak somewhere in the bindings of the harness.

Previous owner wiring repairs were twist and tape  not a permanent fix so could be anywhere,

New harness on its way so.hopefully that will sort it.