TCI, did a boo boo.

[Shinto]

I am having a situation where my power comes on to everything when I hook the battery up with the key off. I'm guessing I messed the tci up by putting axle grease on the connectors for the rec/reg. Anybody else encountered this. Very upset with myself at the moment.  :'(

[Re-Vision]

Have you cleaned the connectors of grease?

[Shinto]

yeah used brake clean and tried leaving them unplugged from the rec/reg. It is for sure feeding the whole system through the red wire in the cdi/tci(?) box if I unplug the tci box then there is no power to the system. Is it probable that my tci is burnt?

[Shinto]

Yep pretty sure my brain box is toast. If I leave it unplugged then the key and everything works. If I plug it in power goes to everything regardless of key position. Dammit I was looking forward to tuning and riding it this weekend after replacing 7 of 8 valve shims and getting a colortune for dialing the pilots in. Bummer

[Re-Vision]

I've been looking at the schematics and I didn't see any path for 12 Volts except a possibly bad Rect/Reg and maybe the TCI Unit.    BDC                                     

[Shinto]

My luck I took out both and the stator  :'(

This has been a trying project.  I refuse to give up.  >:(

[Rikugun]

Is the R/R plug connected to the TCI and vice versa? They unfortunately will physically fit both but if accidentally reversed may destroy the TCI.

[Shinto]

IDK, checked the manual wiring diagram, and am kinda confused at the way they show the wires. I have the Black, Red, and Brown plug into the tci. The other is cloth wrapped Black, Red, and White plugged into r/r.

[Rikugun]

Reverse the two plugs - you have the plug for the R/R plugged into the TCI. You are not the first to do this. Unfortunately the plugs will go where they don't belong.

The TCI is making a connection between red and brown (like the key switch does) which powers up ignition and lights (except tail light) I think.

The R/R should have the plug with black, red and brown. The TCI should have the plug with the red, white, and blacks.

[PwrManDan]

I have done this and in my experience if the key is in the on position while you try to make the connection, the TCI will be destroyed.  This is right after some very pretty blue sparks and a little hint of burning plastic.

While doing the same thing, on the same Vision, different TCI, and the key in the off position; the TCI survived with the two connectors swapped incorrectly.

[Shinto]

Okay thanks guys, I really appreciate I was about to give up. I shoved the bike in the corner, I'll get it back out and try it. At least now if I get a new tci I won't fry it again, that might have been the last straw, lol. I really appreciate this site and you guys' collective knowledge. I had connected the plugs with the battery unhooked but I may have wrecked it screwing around trying to figure out what the hell was happening. There was no sparks or burnt smell, I opened up the 4 screws holding the cover on the tci and no burnt indicators, we will see if it has spark once I get it swapped and checked out........

[Rikugun]

No problem. Good luck with it and don't forget to post your progress when you begin work again. We love success stories!

[Shinto]

Switched the plugs around.  Checked the plugs for spark and no dice guess I've got to get a tci, that's just the way she goes. I'm thinking I'm going to label those wires ford future reference.  :(

[Shinto]

Got it going, bought a tci off the bay. Put it all back together yesterday and bang, zoom she went. Thanks for the help I would have scratched my head and probably went through a couple tci boxes. I didn't notice much change after doing the valves but they are spec now so that's good. I plugged her in to my carb sych rack and they were right on after changing 7 shims, weird, but oh well. I did the synch with the yics unhooked capped off. need to tweak the pilot screws a bit more possibly just the slightest little "uhh" when I roll on letting out the clutch, not bad though. No stumble anywhere else in it.

[Rikugun]

Glad you got her going. Your idea to mark those wires sounds like a great idea.

[fret not]

Time to repair the TCI box.  There is a section in the Technical section that touches on this.  I exchanged a couple 'fried' TCI boxes with Tiger as he was offering rebuilt ones.  Possibly he still does.