hi all, having a 'mare at the mo & thought someone might be able to point out where im going wrong, as im in danger of pulling out me last few remaining hairs lol.
i've got a '97 xt600e, a tb3, which developed an intermittent ignition problem late last year, would usually occur when on dual carriageways/motorway runs when running at steady 70ish, sometimes she would pop/backfire or cut out completely......tiny tap or fiddle with the ignition key & it would fire up again........made me think something was worn there.
few weeks ago i stripped the front off inc complete ignition, opened the ignition up to reveal rotary switch with a number of brass contacts on one side, leading to the soldered loom on the other side........one of the brass contacts, namely the main/red live in to the ignition had pretty much disintegrated, so i fed some solder in to the hole & then re-soldered it bout 6 times, each time getting the solder to sit flatter so it resembled the other contact points.
loosely assembled it today, basically all plugs back together with the exception of the headlight unit, dash & ignition plugged in but resting on the handlebars........just in case nothing works & i have to take it all apart again.
NOW THE PUZZLER.....turn on ignition & indicators,headlight,horn all work.........starter switch does nothing & no green neutral light on dash but if i put a spanner across starter solenoid terminals bike fires up & runs, & stops if i flick killswitch to off position or turn off ignition......used a simple circuit tester to check killswitch/starter switch loom, if kill switch is in off position i have both lives running in to switch but nothing coming out......but if kill switch is in the "run" position i have 2 lives in & 2 lives out, surely the starter switch should only have a live out when its pressed, making a temporary contact............im really stuck on this & would appreciate any advice........many thanks........mark

it sounds like one of 2 things either the neutral switch is faulty so its not putting a negative to the starter solinoid or the contact repair you made is a bit to high and its not putting power down to the ignition correctly if its not lighting the neutral light it wont feed the starter button.

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XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover

Does it help to pull the cluthandle?

thanks for the fast reply guys, losing the light here now but tried it with clutch in & nothing happened.........also i took a lot of time soldering the contact, i knew it had to be perfectly flat to make good bridging contacts so i can rule that out.
i dont have a manual, can you point me in the direction of the neutral switch, i'll check it in the morning.

neutral switch is near the gear shift it has a cross head screw in the centre of it short the wire to a good earth if the neatral light still not lighting up you have either a blown bulb or not getting a positive feed via the ignition

__________________
XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover