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I'm looking for help on a 1981 Interstate that has melted both spark units. I have found two to replace them but I'm looking for help on WHAT would make this happen? The guy that had the bike before me put on a bunch of lights and switches that have turned into a spagetti farm could that be part of the problem? anyhow thanks for any help...Rod :cooldj:
 

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Rod wrote:
I'm looking for help on a 1981 Interstate that has melted both spark units. I have found two to replace them but I'm looking for help on WHAT would make this happen? The guy that had the bike before me put on a bunch of lights and switches that have turned into a spagetti farm could that be part of the problem? anyhow thanks for any help...Rod :cooldj:
Rod, it's really just a guessing game over the Internet.

Things that will fry an E.I spark unit are:

Too high of a voltage to the unit while running (check your charging voltage while in operation)

A unit that stays powered with the engine turned off & a closed trigger transistor (make sure the uint(s) power down with the ign switch turned off)

High resistance in a spark plug, or plug wires, or resistor caps (probably would only happen on one unit not two but worth a look)

Excess heat in the area those units are operating in (look for proper heat baffling & missing heat shields)

Some sort of a high voltage spike traveling back down the unit's power wires or trigger wires (make sure ANY added light or accessory control relays have clipping resistors or clipping diodes added across theinternal coilsto remove any high voltage reverse spikes when the relay is shut down)

Just plain old units to begin with maybe cracks in the cases or any other way moisture could get into the units.

Possibly someone jumped the bike from a high voltage supply or hooked jumper cables up backwards at one time with the ign switch left on (just a guess here)

You really should cut out all that crappy wiring & start fresh & make a new neat wire harness with everything neatly accounted for & powered correctly.

Twisty
 

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YES!!!!!...check out all wiring,connectors and fuses.......have fun!!
 

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My bike was running great for about two weeks when I first got it. Then I left the KEY ON!!!! ( only for about 12 hours ) When I came back I noticed the spark unit tar on the floor :?and yep, you guessed it, both of them fried:X

Fred
 

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Any little upset on an old sparker can melt them Rod. Ignition on, overloading etc. Probably wouldn't matter too much when the bike is new, but after 24 years...
 

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I had mine melt down also.Before they did, my Voltage regulator also went out.All connectors were bright ,clean and pretty.After replaceing the voltage regulator and spark units they wre still getting very hot fast [within two minutes off starting].

Took me 4 days of stareing at wireing harness to find the fix. At some point in the last 24 years someone had plugged a gray wire wire 12 volts in it to a green wire.Gray wire was a live instrument feed and the green wire is a ground wire.

Now I even have a fuel guage and temp guage.Wire was found behind the fairing weight.If you have a wireing mess, by all means clean it up.I cut close to 10 pounds of excess wire out of my fairing and did not lose anything electrical.

Keep it vertical.Fred
 

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Hi I'd like to thank litefuse-guru-bajja 65-daveizonbikes=and the world famous twisty for all the help. looks like I'm on knees and diggin around for bad wireing and calling Texas for some new spark ingniters... Would love to give MANA but too new to this siteand don't know how. If your any where near Boston Mass USA come on by for dip in pool and beer come in summer pool is quite hard for 3-6 months of year...

Rod:cheeky1:
 

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Rod where in texas are you calling for those spark units?I am down in Bridge City Texas close to the Gulf. When you water gets too hard to wash your face in, come on down.Litfuse
 

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Hello to litefuse I'm calling Houston motor cycle works or something like that. Next week though. This week I get to remove engine from 1984 1200 that I just bought out of a garage in SOOOObeautiful condition only to drain battery and find out it has abad stator......... Only thing I'm riding this summer is bad luck..rod
 

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Thank you for the come back Rod.At this moment I am doing ok in the parts department but no telling when I might need 1 little small part that i can't find.Keep it vertical.Fred
 

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Rod wrote:
Hello to litefuse I'm calling Houston motor cycle works or something like that. Next week though. This week I get to remove engine from 1984 1200 that I just bought out of a garage in SOOOObeautiful condition only to drain battery and find out it has abad stator......... Only thing I'm riding this summer is bad luck..rod
Have you thought about putting in an external auto type alternator? Lots of info on the forum if you search for it. Could be easier and cheaper than replacing the stock.

Just a thought,

Bob :11grey:
 

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WELL about the auto starter..........Yes I did think of it but alas too late I had my friend who has the same bike as mine and has done the stator before to buy it and put it in.... I have an 81 interstate and should that blow I'll try the auto type........ And I saw one last year and the guy just ran off the front timeing gear and got a chrome alternator and it even looked good .....I'll be back with any info thanks to all ...Rod :stumped:
 
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