Pick up wire maybe?

[Dan Tyson]

Registered it today. HOORAY! No problems with it at all today. New ignition switch on the way.  Time will tell.

[Dan Tyson]

Just bought this. The first thing I thought I'd do when this whole drama started was replace the ignition switch. I have one on my parts bike, but when I removed it, it turned out to be a four wire unit, not a three. My parts bike must be an '80!

Anyway, this is on the way now.  I'll install it when it gets here and see what happens from there.

http://www.ebay.com.au/itm/270807379221?_trksid=p2060353.m2749.l2648&ssPageName=STRK%3AMEBIDX%3AIT

[excess.11]

Dan........it s just a matter of perseverance and elimination.
If you believe the ignition sw does nt feel right.....replace it....and certainly there can be more than one issue at play as you mentioned.

Here s some of todays fault finding on one piece of equipment ..............still more to go 
Fried and dried skink anyone ?

[Dan Tyson]

maybe fatigued wires in the harness round the head stock region from 30 + years of back and forth with the handle bars?....i feel your pain, intermittent electrical probs suck and are sometimes unexplainable and ilogical.

I took that out of the equation when I fitted a brand new switch block (and harness, of course)

[Jonesy :-)]

maybe fatigued wires in the harness round the head stock region from 30 + years of back and forth with the handle bars?....i feel your pain, intermittent electrical probs suck and are sometimes unexplainable and ilogical.

[Dan Tyson]

 I think it must be in the ignition circuit somewhere.

It happened again today as I was leaving work. Everything running well then - dead -. A few seconds later, it fired right up. No problem on the run home.

If we know that the switch block is fine, and we know that what's happening was happening with the old switch block, only much worse ,then it must be that having replaced the switch block has gone some way to rectifying the problem, but not totally.

Remember, everything else electrical works fine when the problem occurs, and since the problem only seems to cut the engine and deny power to the starter button, the problem must be a power supply (12v) somewhere in the ignition circuit exclusively, otherwise other electrics would also fail, but it's just the starter button failing to activate after the engine shuts off (like it should when you hit the kill switch).

We know the starter button is fine. We know we are getting a good earth at the switch block and we know all other electricals are not affected.

Whatever supplies the power to both the ignition system and the starter button has a fault somewhere.

I'll keep thinking.

[Dan Tyson]

[Dan Tyson]

https://www.facebook.com/dan.tyson/videos/o.153474377495/10206681430655115/?type=2&theater

[Dan Tyson]

I think the problem was a combination of failures in the right switch block, either the kill switch or the starter button or both.

Fitted a new switch block (Mikes XS) after figuring out what wire went where.

At least I know my ignition module, pick up wires, starter motor, starter clutch, ignition switch and fuse box are all perfect.

What a pain in the arse this has been but at last I think it's been sorted. 

At least until something else gives up.

What time is it now?

Thanks everyone for your suggestions.

[Jonesy :-)]

Can you hot wire it to see if
1. The problems disappear
2. Proves the ignition key function is good or not
EDIT:
If you do get it to run normally, maybe give the ignition switch wires a jiggle to see if it cuts out again

[Dan Tyson]

I've cleaned the kill switch connectors and fitted new pigtail connectors for the switch block but I haven't touched the ignition switch. I noticed a couple of days ago that it was slightly harder for me to insert the ignition key but thought nothing of it.

[XSIIE]

Yep,

Could be that too.

Have you got inside and cleaned the connections?

Eddy

[Dan Tyson]

I'm leaning towards a faulty kill switch or faulty ignition switch. I've got a new fuse box with blade fuses so all is well there.

[XSIIE]

Concur with Jonesy,

Same thing happened to the RH a couple of weeks back.

Cleaned all the fuses and the "blades" holding them.

Eddy

[Jonesy :-)]

Mate. check your fuse box. If its an original item its probly rooted. sound similar to my problem a while back, shout the old girl a new fuse box if its anything like this.........search the "mcgyver run"