Ignition always on in any key position

[VisionaryDan]

I have a strange problem where the ignition is always on no matter what position the key switch is located. The only way to shut off the ignition is to pull the main fuse. I swapped out the key switch with another and problem still remains. If I try to start the bike it blows the main fuse. Does anyone have a suggestion on how to troubleshoot this problem?

Thanks,
Dan

[VisionaryDan]

I found a previous post that suggested that the plug on the TCI was swapped out with the r/r plug - that was the problem. The pain is I already swapped in my spare TCI - I hope that I didn't blow it out. Need to re-assemble the bike to see if it starts. I checked ebay no replacement TCI available right now.   

[skucera]

At least you found the answer here before we could chip in a suggestion.  Let's hope that you didn't damage either TCI.

Scott

[fret not]

2 or 3 years ago I sent my old TCI unit to Tiger in Canada and exchanged for a refurbished one.  He had someone local to him that was fixing the old ones, so Tiger could keep a unit on hand for someone in need.  I don't know if he is still offering an exchange like this but it can't hurt to ask.

Also there is the Ignitech company in the Czech Republic offering new units of various types, and they apparently can provide a unit for the XZ550.  The Ignitech products seem to get good comments from racers, and their prices are quite reasonable. :police:

[The Prophet of Doom]

TCI boxes are often listed as an "ignitor" rather than a TCI
There's one on ebay now, just don't open this link with your mouth full


http://www.ebay.com/itm/YAMAHA-XZ550-82-83-IGNITOR-UNIT-ASSEMBLY-NOS-OEM-11H-82305-10-00-/400962915166?hash=item5d5b408b5e&vxp=mtr

[VisionaryDan]

Do you have a website or a contact number for Tiger in Canada?

[The Prophet of Doom]

You can PM him from the members list

[Tiger]

Do you have a website or a contact number for Tiger in Canada?

Sorry but I sold all mine...

Tiger.

[VisionaryDan]

I was able to fix both my original and spare TCI. A trace on the circuit board blew out on both and I was able to solder a lead across the break. I got spark and the bike started right up after 3 years of sitting.  The only thing noticeably not working is the tack. Is the tack connected to the TCI? Or could I have blown out the tack when I had it wired in correctly?

Thanks,
Dan