XT600 Buggy Wiring Troubles!

[Inkedkitch]

I have my buggy that i built a while ago, ive been running xt600 engines in it and it has been great. But the only problem was if you stalled it you had to unbuckle the 3 point harness, undo the arm restraint mesh and go round kick start it and strap yourself back in! Now after a while this gets abit annoying!


So i purchased my new engine off a nice chap off ebay who said it has an electric start off a TT600, these engines are practically the same so i thought there would be no problem! I thought wrong! The wiring in the engine is different from an xt as it only has 3 white wires to the rectifier, one blue wire for the neutral indicator and 2 wires from the pick-up coil. It doesnt have the red and the brown wires for the charge for the coil!

Im no expert on electrics, i made myself a little harness for my previous xt600 engine and it worked fine but now i have to make a new one, now im stumped about where the charge for the coil comes from, i have the wiring diagram for the tt600 but its like talking german to me looking at it! I need HELP!

With my great artistic skills ive made a diagram on paint! which shows what i have and need wiring together and was hoping greatly if some one could point me in the right direction of what could possibly work or what i would need for it to work! Any help is appreciated as im getting depressed looking at it and not being able to use it! The CDI unit is off an xt600.

Here is little video of her in action
YouTube - Sidewinder Buggy - Day out in the mud!

[aukeboss]

If your CDI box has the connections brown and red, you have tghe older CDI system, where the energy for the ignition comes from a separate coil in the stator.
The newer systems, like on the TTRE, or the newer XT6s, use a TCI, where the energy comes from some kind of 12V supply - battery or directly from a RR / condenser system.
So, it makes sense that things do not make sense for you, if you see what I mean.

You cannot use a CDI box on a TCI system, or vice versa. So you either have to get a TCI box and build your wiring to suit that system, or convert the engine to a CDI system.
Second option: If you replace the starter gear / stator / flywheel on the engine with the same from the 1VJ / 3AJ models all would be plug and play to your harness. Note: I do not know whether these parts fit mechanically, but you have a good chance.
First option: the harness for the TCI is relatively simple, and this conversion would involve just getting a TCI and redoing some of the wiring. Probably easier and cheaper than the second option.

Differences between the systems you have:
CDI: no 12V supply needed, uses 2 pulse coils, runs independent from battery. Input/output CDI box is 8 wires (the 2 pulse coils use a common wire, green).
TCI: 12V supply needed (but you have a battery now), uses only 1 pulse coil. Battery / charging system dead, engine is dead. Input/output into the TCI box is 6 wires.

Hope this helps.
A

[Inkedkitch]

That is great thanks, i shall go for the tci option. Does anyone know if these tci units are used in a range of bikes or do i need on specific to the tt/xt600?

regards
Simon

[Mezo]

Simon, find the part number (online fiche) then put that number in to Google & it will give you all the other models that it fits.

Mezo (ex Newport Pagnell)

[Inkedkitch]

Thanks guys! just bought tci unit, there abit pricey new but found one on german ebay! Sweet! will update with news!

Regards
Simon

[Jens Eskildsen]

With that out of the way...

COOL BUGGY! Got more pics and/or specs? It looks awfully fun

[Inkedkitch]

I built this a few years back, its awesome fun. I decided to go with the xt600 engine because i heard that it was pretty tough. Its a pretty simple setup, engine mounted on r/h side, fuel tank on l/h side. Shortened steering rack off a ford escort. They race these in Australia, thats where i bought the plans to build this, the company is called The Edge. Heres few pictures of it how it stands, havnt had time to wire the new TCI unit in yet.