78 gs550 starter solenoid wires smoking need help bad

[bamzam35]

Looked up wire diagram it looks to be wired right but keeps blowing fuses and if you bypass the fuse wire gets hot and still can't post pic my computer is down so doing this through my phone

[bamzam35]

Ok the wire only gets hot when the kill switch is set to run the bulbs dim and wire gets hot

[bamzam35]

Also the wire always gets hot next to the solenoid fastest

[bamzam35]

Is there a way to ohm out that wire to see what the problem is

[Steve]

If the wire only gets hot when the kill switch is ON, your problem is in the ignition circuit. Disconnect the coils, try again. If it's better, try one coil then try again.

Just follow a systematic approach with each device, it won't take long to find the problem.

.

[JTGS850GL]

If you went from the red wire on the solenoid to the ignition switch and the wire got hot when you turned the switch on, then you have a short after the switch. Most likely not the switch it self. Like I said, it's not the solenoid that's the problem. Disconnect your igniter and the R/R and see if the wire still gets hot. Look for melted connectors between the switch and everything else. Does the wire get hot when the kill switch is off?

Like I said above. Your problem is upstream from the ignition switch. Disconnect the connectors to the igniter and the coils and see if it still gets hot. If not then the problem is in one of those two. If it still gets hot then the problem is going to be harness related. Check for melted connectors in line between the ignition switch and the Igniter, coils and R/R. One maybe melted and shorting out two or more connections.

[bamzam35]

Turns out it was a coil causing all the problems also what ohm coil should I run it has dyna s 3.0 ohm coils now and stock ignition other wise

[JTGS850GL]

3 ohms is what you need. Did you ohm out the "bad" coil? If you did, what did you read? Make sure it's not a wiring issue at the coil. Those coil connectors are known to corrode and get hot/melt.

[bamzam35]

Coil ohmed out at 0.00

[Steve]

Disconnect the connectors to the igniter and the coils and see if it still gets hot.

Unless it has been upgraded, his '78 bike will not have an ignitor, it will still have points.

Turns out it was a coil causing all the problems also what ohm coil should I run it has dyna s 3.0 ohm coils now and stock ignition other wise

It's nice that it has a Dyna coil, are you sure it still has points? There is is chance that if it has a Dyna coil, it might have been upgraded with electronic ignition.

3 ohms is what you need.

If you have electronic igniton, yes, 3 ohms is proper. However, if he still has points, the factory manual says the primary resitance in the coils is "Approx. 4 ohms".
Does not sound like much of a difference, but with 14 volts, a 4 ohm coil will pass 3.5 amps. A 3 ohm coil will pass 4.6 amps, which is 33% more. The points can only handle so much, so anything extra will definitely hurt.

.

[JTGS850GL]

Sorry, just assumed that it was upgraded from points because of the Dyna coils. Maybe not a good idea.

For what it's worth, I've seen a lot of systems running points and 3 ohm coils with no issues. These were in automotive applications but still relevant.

[bamzam35]

Stock points don't know why guy had the dyna s coils maybe that's why one took a dump they really don't look old so maybe it was to much for them