84 xt600
 

New guy here. Been into quads and bikes my whole life and just just picked up a restoration project. 1984 xt600 in need of a full tear down. It seems 98% of the parts are intact and has great compression but no spark. The wire harness has been hacked and I am looking to replace the whole thing, or if I can find a wire diagram I will run my own wires. Most of the parts I need I can find with out much problem but everywhere that I look shows the harness NA. Any info on where to look or even any info on this specific bike or pictures would be great. I am looking to turn it into a street only bike and maybe even more of the super moto style. Thanks for all your help.

I started playing around with the bike. I pulled the stator cover off and cleaned everything up. Put it back together and turned the bike over. I have signal coming from the stator on the red and brown wire. I am cleaning up the wires for the coil and cdi box. Is there any way to test those components other then connecting them and checking for spark?

Also what size socket removes the spark plug? I can not seem to find the right size.

You can meter out the resistances of various ignition components using the values here:
Clicky

The plug is indeed an odd size. The best my local (and good) tool shop could do was a deep socket - 18mm AF in size. That works OK - just be careful to thread the plug in true and not to crack the ceramic insulator on the plug.

An iridium plug made a big difference to idling stability on mine. For a few quid extra it is highly recommended.

Thanks for the info. Does there have to be a battery in the bike to have spark kicking it over? Its been on my mind all day at work.

Manual is on its way. Still trying to figure out my electrical issue. I hope its just the coil.

Also I am messing with the clutch while I have it all tore apart. Something seems to be missing or messed up. The cable is connected, the rod and ball are in there, clutch is tight on the shaft but when I pull the lever the clutch barely moves, even at the tightest adjustment. Any ideas?

Did you take the plates apart because they go back in a special order cos there are two thickness,s of plates.Did you adjust the little screw in the center of the plates with the locknut on it and did you adjust it with the lever arm on the crankcase cover pulled and aligned with the marks on it?

No. The pulse coils on the stator provide the supply to the CDI and coil.

I haven't tried starting mine without the battery in place, but it started no differently when it had a battery that was putting out 6.3V that it does with a nice new battery putting out 12.8V.

There are also quite a few folks that have successfully replaced the battery with a capacitor, which provides a sink current for the regulator and some smoothing.

Some good info here. :thumbup1:

Mezo.