Voltage at TCI to low when cranking?

Ok guys, so I read through a good trouble shooting guide for the ignition on here and have discovered that the voltage is too low while cranking the engine. I'm getting 12 volts at the red/white wire at the TCI and then it drops to about 7 while cranking. The battery is new, (I've run it down a tad), cleaned the TCI and coil connectors and reinstalled with dielectric grease. Sidestand switch is bypassed. Ignition switch is new. I also tried disconnecting the black/white wire at the TCI with the same result. Fuse box replaced with a blade type fuse box. Anymore ideas of what to check next? I'm getting no fire.

 

new batterys can be bad would be my bet. put it on a charger and charge it then try to start bike if you get the same voltage drop it is a bad battery
do you have a car battery you can jump it with with car not running?

did you clean the run/kill switch could be the problem.
what you need to do is chase the voltage from the fuse to the kill switch then to the tci check each connection to see if you get voltage drop . be very carefull with the kill switch there is a little ball bearing inside of it that is easy to loose.

 

I haven't cleaned or checked the kill switch wires. It won't turn over when off and will when set to run so I figured they were good.

 

Alright, disassembled the kill switch, cleaned all the contacts and the wire terminals and screws and reassembled. Same result. I'm pretty sure the battery is good, I just bought it and also had it tested last week at the parts store and they said it was good. Probably needs a little charge but the bike wasn't firing when it was topped off either.

 

charge battery buy a battery tender to keep the charge at full level.
after a full charge battery should sit at 12.8 volts over night still should be 12.8 volts

and to sound like a broken record if the battery is at full charge and drops below 9.8 volts when trying to start bike, battery is bad. I do not care what the parts store guy says return it and get a new one. many new batterys are bad off the shelf.

if the second battery does the same thing it is most likely time to rebuild your starter as it may be drawing to many amps.
the starter should spin fast even when battery is well below 10 volts
you could get a new soleinoid to see if that is the problem. test voltage at battery and output side of solinoid to test internal contacts voltage drop.

bottom line here is why should you spend money trying out other parts to come to the conclusion of a bad battery, bring it to a different parts store to test it they may tell you it is bad but that could be just to sell you a new battery.

read about your charging system in this thread
The Ultimate Relay, Switch, Sensor, and Diodes Guide

 

Ok, so I had already bypassed the sidestand switch by tying the wires together. I saw something about removing the sidestand relay so I just walked out and pulled the relay and guess what? I see some spark!! Problem is the battery is about dead now. I'll get it charged and see what happens. Don't have much hair left in my head at this point! LOL

 

if pulling the side stand relay got spark you have a bad side stand switch you can spray electrical cleaner into it then some silicon

 

does your neutral light come on ?

 

Does tying the switch wires together bypass it? I ask because something doesn't look right with it. There appears to be nothing that moves the switch in and out! It's just sitting there. I don't see how it could work. Raising or lowering the stand doesn't touch the switch at all.

 

Yes, neutral light has always come on

 

Then sombody swapped the kickstand, or took the part off that depresses the switch, or the switch is stuck in, or the wrong switch, etc.....

Temporarily disconnect the switch at the connector, then jumper the two harness leads to re-complete the circuit

 

side stand parts do you have #50 part is still available from dealership
Link, Side Standl

2KT-27315-00-00 3VD-27315-00-00

$9.51

 

ebay link shows a lot of photos
https://www.ebay.com/sch/i.html?_fr...RS2&_nkw=xj+550+sidestand+kick+stand&_sacat=0

 

Looks like I'm missing that part.

 

i posted 2 part numbers for the yamaha dealership 10$ for the part 3VD-27315-00-00
do you have the 2 springs ?