GREMLINS - Intermittent Cut Out and Restart

My 650 C, which is my daily rider, has started to cut out on me while riding. What I mean by cut out is the bike totally dies, as if hitting the kill switch. Yesterday it cut out once for about 2 seconds and today it happened once for about 4 seconds. Both times I was rolling in gear so the engine was being forced to turn over and then she just started up again and I was on my way.

I checked all my wiring and everything seems clean and secure. I kick start her as the electric start is disconnected right now so it can't be a kill switch malfunction. She has a DYNA on her and otherwise has run beautifully and trouble free. I know it wouldn't be coils or spark either, as that would mean poor running and not complete death.

What do you guys think?

Would check integrity of the splice where power wire to Dyna (red?) splices into the harness wire.

Then connections at both ends of main fuse.

Good Fortune!

When mine was doing that it turned out to be the ignition switch.

Could also be internally frayed/broken wire to the dual connector that feeds batt+ to the coils.

Consider test run with hot wire from batt+ feeding both coils (instead of the dual connector from harness).
Disconnect hot wire immediately after shutting down engine.

Good Fortune!

As mentioned... the kill switch can cause this if its corroded inside. With enough vibration it can click off and on.

Bad coils can do this too, but usually dont until they get scorching hot, like after you stop for a few minutes after a decent ride. Everything under the tank get super hot then, and if your coils are going, they will start cutting in and out.

Anyways... Its an intermittent connection somewhere, so just check all the ones involved. Pull'em apart, scrape/scratch them up till they're nice and shiney, then make sure they fit nice and snug.

GL!

Or a faulty kill switch (maybe dirt inside?).

The main fuse itself could be failing.

The kill switch is cut at the bar, that's why I said I knew it couldn't be that. But I didn't think of the ignition switch though, I'll check that.

Patton, are there any external signs to a main fuse failing? I can replace it just in case, but it would be nice to be able to see it coming.

And both times it happened I had been on the bike for no more that 5 minutes, as it happened at the beginning of my rides.

MentalMike wrote:

...any external signs to a main fuse failing? I can replace it just in case, but it would be nice to be able to see it coming....

Fuse is probably okay if it looks all right inside, and the connectors at ends are clean and intact.

Am thinking here the problem is most likely either the ignition switch or at splice-in for power wire to Dyna-S.

It sounds like power to both coils is being interrupted. Which at least removes some suspicion as to coils and high tension circuits.

Are a voltmeter and an ohmmeter available for testing?

Good Fortune!

Yes I do have a multimeter. I will do a top to bottom check this weekend.

Thanks for the feedback, fellas.

Ok, here we go... I have to ask.... :whistle:

Do you have the coil mod installed? :pinch: :whistle:
If so, is it operating and passing ideal battery voltage...

OMR

LOL....Nope, no coil mod on this bike, or any of my bikes.

I've gone the old fashioned way in making sure my wiring and connections were clean and not stealing any voltage.