(06-09-13, 04:59 PM)Fazerider link Wrote: I'd be surprised if it's the source of the problem.
The current through the kill switch is normally not very large, it supplies 12v to the coils and the ignition cut-out relay. A fault with it could cause the sparks to die, but I can't think how it would make the ignition unit overheat. It's possibly an indication of the route that the excess current is taking though, do the coils get hot too? Of course, if one coil gets hot and the other doesn't, that could be the cause of the problem, though it's usual to have a duff coil that still provides a decent spark. My money's still on the ignition unit.
The pong isn't really coming from the main light switch is it? That supplies a high current so slight contact resistance would easily result in overheating and a burning smell in the same area. ...mmmm?..see what you mean there fazerider!..going to strip the unit down later and will have a close look at it?..also i will chk on the coils!  ...thanks for that!
Since the kill switch wiring and lights wiring are in the same switch unit and folow the same route to the loom it is possible that damage to the wiring could be the cause of the problem. The current in the Kill Switch circuit is in mAmps, whereas the current in the lighiting circuit is in Amps and and connecting together of both circuits would have serious consequnces for the Kill Switch, Starter cut circuit and the ECU.
Follow the wiring back from the switch to the connector box under the tank to see if there is any problems of insulation wear or damage which could result in the two circuit coming together.
hi clive,sorry mate got no spare switch gear........sounds like you getting closer to the problem ...nothing too serious at the hospital i hope ...
One, is never going to be enough.....
06-09-13, 10:19 PM
(This post was last modified: 06-09-13, 10:32 PM by CRH.)
(06-09-13, 09:40 PM)red98 link Wrote: hi clive,sorry mate got no spare switch gear........sounds like you getting closer to the problem ...nothing too serious at the hospital i hope ... .....hi paul, think the culprit as been found?...stripped the switchgear down tonight and its fkd!!..all melted together inside!!...looks like its the light switch that was at fault?..fazerider mentioned it earlier and it looks like he was spot on ...and i think ive found out why :rolleyes ....some twat previously" had put 100watt bulbs in the headlights  ...and seeing i run with lights on all the time i think it as overloaded the switchgear and fried it? didnt notice the other day but my headlights had packed up!! the switch itself was moving but not moving the inner bits!! they where toast!...so now ive got to sort out the mess and replace the unit and hopefully it should be ok? :rolleyes ...just a bit bothered about the ecu though? will it have done any long term damage or have i been lucky???....oh and it doesnt get much better?...just been scanned for prostrate cancer today!! got to go again tuesday for camera up me ..jackseye :'(
unfazed it looks like you was right too?...looks like you said and the wiring had fazered together ....cant find anything else wrong so think we cracked it men ...thanks!
Wow. It'll be fuse 2 playing up. Had that on mine. Plus fuse 3 gets hot and melts arond the terminals if 100w bulbs are used. Swap fuse 2 and try it, squeeze the terminals if it is loose
07-09-13, 08:29 AM
(This post was last modified: 07-09-13, 09:07 AM by red98.)
hi clive........not a fan of these high watt bulbs got to put extra strain on the wiring etc....iam sure i dont have the switch gear but will still look through my spares mountain,i`ll be surprised if the ecu is focced as they are tough old things,as mentioned i have a spare that your welcome to but replacing the switch and checking the temp on the ecu will soon tell you...and give you peace of mind that you have found the fault rather than masking it..
i wish you well for tuesday,nhs gets lots of stick,but do a fantastic job,your in safe hands matey .......rather you than me though :\ [size=78%] [/size]
One, is never going to be enough.....
thanks for that paul ....not one of my favourite places (spent 22months in one in 73)...bike hit me head on, on a bend and put me through a stone farmhouse wall.his front wheel hit my engine on rd250...trouble was my right foot was there :rolleyes ....he and a mate of mine following me wasnt as lucky though!! ....killed them both!!...police had been chasing him for several miles and where only feet behind him when he hit me!!!!......any way enuf of that shit!!....going to see if i can get it running later up to temp to see what that ecu,s doing...will let you know later!! :rolleyes
bloody hell matey.......got to look after yourself you aint getting any younger :rolleyes .....good luck with the test,will keep an eye on forum for results
One, is never going to be enough.....
(07-09-13, 09:10 AM)red98 link Wrote: bloody hell matey.......got to look after yourself you aint getting any younger :rolleyes .....good luck with the test,will keep an eye on forum for results ....hey"...not only me thats getting older :eek :eek :eek :eek :eek :eek :eek ....its ya BIRTHDAY..ya old git!!!! who would a thought it hey?.....71...yet in your pici ya only look in ya 60"S......... :rollin :rollin :rollin :rollin :rollin :rollin :rollin :rollin :rollin :rollin :rollin
cheeky bastid :lol :lol :lol :lol :lol get back out to the garage and sort those sparks out :lol
One, is never going to be enough.....
ok, after bypassing the burnt out kill switch have now got her up and running !...so whilst she is warming up ime having a cuppa!!....will know in bt 15mins if its a cure or not :rolleyes .....
ok gooood news  .......ecu only getting slightly warm thats after nearly 45mins idling....think :rolleyes ...its going to be ok?....just got to get a r/h switch unit to double chk nothing else is lurking?....oh and if thers any of you out there thinking of fitting 100watt bulbs?....my advice ...DONT!!!!!.....
well done old man....will keep an eye out for a new switch
One, is never going to be enough.....
07-09-13, 04:43 PM
(This post was last modified: 07-09-13, 04:46 PM by CRH.)
(07-09-13, 04:32 PM)red98 link Wrote: well done old man....will keep an eye out for a new switch ....cheers ..son  ....
(07-09-13, 04:43 PM)CRH link Wrote: [quote author=red98 link=topic=9726.msg99894#msg99894 date=1378567960]
well done old man....will keep an eye out for a new switch ....cheers ..son ....
[/quote]
:lol :lol thats my boy :lol :lol
One, is never going to be enough.....
Well so much for my theory… totally wrong!
I'm baffled as to exactly how it caused the ignition unit to overheat, perhaps the heavily loaded lighting circuit dragged the supply volts to the coils down. If the unit is clever it might increase the dwell time to compensate, but without a circuit diagram of the innards that's just guesswork.
Anyway, I'm glad you solved it. :thumbup
(07-09-13, 08:55 PM)Fazerider link Wrote: Well so much for my theory… totally wrong!
I'm baffled as to exactly how it caused the ignition unit to overheat, perhaps the heavily loaded lighting circuit dragged the supply volts to the coils down. If the unit is clever it might increase the dwell time to compensate, but without a circuit diagram of the innards that's just guesswork.
Anyway, I'm glad you solved it. :thumbup ....its not 100% yet fazerider?....still got to get a new switch unit and connect it up!! yes its proved the fault is there in that region and yes it does look like it was the high wattage bulbs at fault?....but i dont know yet if anything else is fkd do i? :rolleyes ....if its been contained in that switch unit fine? but i havnt looked any further into the loom for any more damage yet? i could still have more burnt wiring yet?...
fazer put back together minus switch gear!...should be here thursday ebay £10.00...cheap fix if thats all it is? :rolleyes ...run out today 20miles not missed a beat!! ecu nice and cool ...100watt bulbs hit with hammer!!...replaced with std...
just wired up new switch unit!...after sorting out burnt wiring etc !!....fitted correct headlight bulbs :rolleyes ....going out for a run now to make sure its sorted!!.....been running for twenty mins now and ecu still cool so hopefully its fixed :rolleyes .....
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