I have an 87 TB 250. Have completely rebuilt it and got it running great. Just got the elec. starter going. Yesterday I was replacing some wires that had bad connections and for some reason it will not shut off. Starts great, but neither the on/off switch or the key will kill it. There is a black wire that appears to come from the cdi box and one from the rev limiter that are unhooked and it is still running but no way to kill it without removing the cap from the plug. I just got all the lights working and the key will cut them off. Everything was fine before other than the rev box black wire was still clipped from its plug. Did I mess something up or is my wirirng wrong? I haven't a clue. It appears to be right with my clymer manual.

 

sounds like you unhooked the ground wire that is used to kill the engine. just try grounding the wire out, to see if it shuts it off. imo

 

Well I have checked this like 3 times and am still at a loss for what is wrong. The wire from the cdi will kill it instantly. But that is a hot wire with power coming from it. My neighbor has wortked on his 4 harleys and claimed he could fix it. He kept killing it with that hot wire. But even then the key and auxillary on/off didn't do anything. The diagram in the Hanes manual and this wiring seem to be correct or the same. Have cleaned and checked all grounds. Checked the key switch and aux and they seem fine with a multimeter. Lost.

 

Cant remember on the the older ones,but if has a separate black wire off the cdi and it kills the engine when plugged in,then cdi kill circuit bad internally!

 

Well, the cdi wire is seems to be connected into the reverse limiter. That limiter has a black coming from it, going under the light where they connect and then to the key and on/off switch. If that helps.

 

This thing runs fine. Is there a way I can bypass the switch, other then the lights, and use that as a killswitch? Having that ground the black wire out?

The key works for the lights and it won't turn over without the key on. So in theory that sounds like it would work if only I could figure out the wiring. What is supposed to be in and out for those other wires and just connect them without the going through that switch.

 

I was working on a 250 the other day. I couldn't get it started and in the Trouble shooting guide they talk about disconnecting this Black wire that goes to the CDI. It said if it started that you have a Bad Kill switch.
I'm betting that you need to look at the switch and see if it grounds that black wire when you hit the kill switch.
Same with the Key switch.
If yours is like mine there were about 4 or 5 wires grounded to the mounting ears on the Coil. Also need to make sure both the holes on the mounting of the coil have a good Tight nut and bolt in them. My problem was the lower part didn't have a bolt and thats where the Ground tab was for the coil.
Good luck
Tom