Thanks Island Hopper!!

sagot

Member
Wow! Hats off to Island hopper!

Because of his 640 hiccup post I just fixed my ignition switch. It had one broken wire and one half broken. I had been having starting problems were if I turned the handle bars one way it would start and the other way it wouldn’t! :shoot:

After correcting this I was still blowing ignition fuses so I pulled every thing apart and checked the wiring harness. I found 3 separate wires that had worn through to ground!!:shock:(One especially bad with corresponding black spot on the connector plate) Soldered and shrink wrapped, taped and rerouted every thing and it’s looking good now. Yay!:clap: Almost traded it in for a Honda!!

Man the insulation is thin on these bikes.

Anyway now I just have to stop the brakes from skweeeeeeeeling
 

Island Hopper

New member
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Happy to see you found and solved the problem Sagot. When I put my switch back together I stuck a lump of silicone in the bottom cover before sliding it back on, I figured by doing this it might limit some of the twisting action that caused the broken wires in the first place. I made checking for wiring abrasions part of the regular maintence routine on the 640, the way the bike vibrates and the thin wire shielding make for an interesting combo.
 

sagot

Member
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Island Hopper wrote:
the way the bike vibrates and the thin wire shielding make for an interesting combo.
I wasn’t going to use the word interesting …:mad3: Ha!

I used a couple of zip ties to lock the wires but I suppose they can still twist. I’ll keep my eye on it.
 
E

ElChupacabra

Guest
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Guess I sold that bike just in time, huh Sagot?;)

:mb:

Just kidding. Sorry to hear about your "issues" but glad to hear you resolved it. Nice to see this forum working as intended. :tup:
 
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