Hello
1989 XT600, I am not getting any power to the ignition coil (orange wire).
I am combining the best of 2 XTs, the wire harness is from previously running bike. The kick stand safety switch has been removed and the wire jumped.
The harness seems to be connected correctly as I have gauges, running lights and power to stator. Perhaps Kill switch is incorrect?
Looking for advice
Thanks
Greg

Hi Greg,

check your ignition switch assembly, and what it does on "ignition on" and "ignition off" positions: does the switch connect the two wires on "off" position and disconnect on "on" position? That would probably be correct, but you have to check the wiring diagram and what it shows on different ignition switch positions.

From my experience, I replaced my switch assembly (without starter button) with Yamaha R6 switch assembly, and after that I could not start the bike - it had no spark (the same - no voltage in the orange wire). It didn't occur to me that the switches were performing different tasks on the same "ign. on" and "ign. off" positions: XT switch disconnects the two wires when on "ON" position, and R6 connects them on "ON" position. So now I got to put my ignition switch on "OFF" to get my bike started anti-theft protection... Sort of. I would put a relay to correct the markings and action but I like it this way

Just try to put the switch on "OFF" and then check for voltage in the orange wire.

Cheers,
Tadas.

The 89 should be like the earlier models, look at the CDI under the tank, look for a bullet connector with a black/white stripe wire. That wire is the "KILL" wire from the ignition switch (when off) and the handlebar kill switch. Disconnecting it will remove any kill function and the CDI should output on the orange wire. If still no output, check the stator plug and individual red and brown wires for an AC voltage while kicking. If you get an upswing of voltage from the trigger coils and the CDI output for the stator then you probably have a defective CDI.

I recently had the same thing, no output on the orange wire on an 84 and an 86 xt I am rebuilding. Both had bad CDI modules.

FYI, I am getting ready to test a new programmable CDI made by Zeeltronics. I currently have a Hyperpak from New Zealand and it works fine on both bikes. Once I install the Zeeltronics PCDI-HT I'll report on it. Cost is 150.00 euros, but you get full programmability if you wish, comes programmed ready to use however. You can set a rev limit, adjust the advance curve as desired and set a minimum cranking speed to eliminate kickback. Comes set at 250 rpm. If RPM is lower then no spark. Kicking RPM is usually much higher so no problem.

Programming can be done with a standalone handheld programmer or with a software program and USB interface cable. I use the USB cable and have another Zeeltronics unit on a different model bike which works perfectly. They have a very good track record and ship quickly. Programmer and or cable is optional extra.

I am in no way connected to them, get nothing for telling about them, I am just testing a unit that I had requested. They did not have a unit on the shelf but decided to build one in short order. They even bought an XT550 to test with.

Thanks for replies
still dead
Frame and Motor from 1989 kick start
wire harness is from 1985 kick start
I have switched cdi with 1989 with same results
tested pick up coil -was within specs

Bike has no kick stand safety switch- wires jumped
also has no neutral switch wiring, has the sensor bolt in place but no wire connection to harness.
Seems like something simple and obvious. I seem to not get power down to the cdi, which feels like it should be the kill switch?
I disconnected the kill switch wire (black with white stipe) at cdi same results.
One thing I noticed was the ignition coil orange wire will light a test bulb when I was looking for a ground. Do I have something maybe switched up.
Many advance thanks.
Greg

Still frustrated
bike has running lights working.
seems to not get power back to cdi.
don't know what i'm missing, as I've not had this bike running
what I know is
kick stand safety switch is removed with its wires jumped
neutral light sensor has been removed- I don't know if I am missing a connection to bypass the sensor? or since the sensor was previously removed and most likely the bike ran that is should be ok?
I have disconnected the black/white kill switch still no power.
have tried clutch pulled in, doesn't seem to be a safety switch there.

Feel i'm just missing something that should be obvious.
advice is greatly welcomed

I think it is best to start at the basics and physically check each system start to end to track it down. I would check with a multi meter to verify the clutch switch is working. Then make sure the ignition switch is indeed opening up the spark system. Then verify that there is juice from stator to pulse generator. Then check that a signal is coming out of it and going to cdi. Verify continuity to the cdi, then verify the spark signal is coming out of cdi and going to coil, then out of coil to plug.

To start, take the wire harness apart somewhat and eyeball every inch of the wires for any broken wires, lightly pull on all terminals going into connectors for broken wires. Clean all contacts and all grounds. Then proceed with system checks above.

Thanks for the advice!! I now have spark. Went through all the wires over and over. Cleaning, reattaching, pulling tape and dielectric grease. Somewhere in the chain there was a loose connection or bad earth.
Checked spark and had!!
Thanks for the help
Greg

I have a 1990 XT 600 with a 1984 to 1987 motor on it was motor code 49-n and I can't find a wire diagram anywhere for the 49-n I'm trying to match it up to the 1990 wiring harness which was tci it's all switched over to a CDI I rewrapped my stater and exciter coil because they were giving bad readings now I have the right readings But my pick up coil has 2 eyes Tuesday's end is reading 140 on each but when I Test them together it's reading 280 ohms is it good or bad ?? Does anybody have any idea what the wearing coat is on a 49 end motor so I can match it up to the 1990 wiring harness my 1984 to 1987 motor has the 2 white wire system not the 3 white system !! Somebody please help all my readings on my coil all my readings on my CD stater are fine coil is fine My pick up eye is reading 281 tested together but 140 apiece when tested separately is it good or bad? I found forms for this year motor some of them had one white wire going to the regulator wrecked the fire and went to the CDI then other models had both white wires going to the regulator rectifier I don't know if this motor requires 1 of the white wires to go to the CDI and 1 to the rectifier or both white wires to the rectifier could somebody please help

open your own new thread, your problem is quite different to what the OP had 11 years ago.



When you do open your own thread, try to explain better what you are doing because its really hard to follow you, we are not there to look behind your back and see what you see.


posting pictures of the bike and the ignition components you have will help too



do that and then we'll continue.



PS - for the record, taking on someone else's basket case is always going to be a nightmare. if you'd asked here before we've have told ya