Oh well back to the drawing board. Whatever i did on the tci box hasnt changed anything. Bike cut out three times on a 5 mile road test. :(

Not good at all, best if you have another box testing bike with. How about the G/W wire signal to TCI from magneto, just thinking what happens if its bad connection. If you can try to disconect only this wire or isolate the pin so it wont connect in the TCI box see what happens.

I will look to get a replacement off ebay as soon as i get paid
In the meantime i will check the green/white wire you suggested xtrock. Thanks again! :thumbup1:

It really sounds like something is shorting, especially when ypu say if often happens when you turn.

I'd check the wiring loom, and doublecheck around the headlight/front forks.

Hi Jens!
The only part of the wiring loom i havent disscected is from under the tank to the back of the headlight. Im guessing constant turning can break the wires but is this quite common on xts? Regardless im going to go over it, so thanks for the suggestion!

How about if you put the bike on a stand, mid or rear stand. Start bike and let it run in different gears, wriggle cables and turn steering. You can tap on relay, TCI etc. I use this one and you can strap bike to the jack. Shop Kobalt 3/4 Ton ATV/Motorcycle Jack at Lowes.com

Xtrock...THAT is an excellent idea! I will give that a go when im off next!

I'd completely disable the stop switch on the right handle bar and check those wires down to the cdi. IIRC the plug for it can just be unplug to eliminate it. The switch can get corroded and it will kill the motor. With the motor shutting down as opposed to light flickers or some other thing, it is in the ignition circuit. Grounding the tci out is what kills the motor.

Put dielectric grease in every connection you take apart to stop any corrosion down the road.

.

Thanks jjrider. I have dismantled that switch and cleaned all contacts, but certainly worth disconnecting and checking for faults further along the loom. Cheers!