Wiring diagram needed for 1990 XT600E

**test12345** · #1 28 Sep 2007

I have a 1990 XT600E bike that i need rewire the whole thing. Most of the wires are badly damaged and need to be replaced. I was thinking of making a whole new wiring harness. I was wondering if you knew if this model has a TCI unit or a CDI unit. The number stamp on the engine is 3AJ00 and the bigger of the two modules has this number - 3TB82305-00. I looked at the wiring diagram on xt 600 club house and it looks close. Do you have an exact diagram for this bike. Also i've attach a photos, i was wondering if you guys could help me identify this parts.

**test12345** · #2 28 Sep 2007

I found this diagram, i think this might be it, i just need help identifing the parts and if its a cdi or tci setup. http://www.xt600.de/xt_werkstatt/+te...grafik_3tb.gif

**cyberzar** · #3 29 Sep 2007

If you have electric starter only, or both kick and electric you can be 101% sure that it's TCI.

If it's kickstarter only it's CDI (but you said xt600E so don't think it's your case).

**cyberzar** · #4 29 Sep 2007

Ah forgot, the diagram you found is correct. You should only find now some electrical cables in different colors, and start the job. Otherwise consider that full wiring is usually available on ebay new at about 100 euro, or from a wreck at about 50. It only depends how much time you have. I did that work once, but only for the black (ground) cables.

**tufty** · #5 29 Sep 2007

First off, the number that matters for finding the model of the bike (and thus the wiring diagram) is the frame serial number, not the engine serial number - the first 3 characters will give you the model number. Finding a wiring diagram should then be easy enough, xt600.de have many of them (although some are in german).

If you can handle french labelling, I almost certainly have the diagram you want, all I'd need to know is the bike model.

Quote:

Originally Posted by cyberzar

If you have electric starter only, or both kick and electric you can be 101% sure that it's TCI.

No, you can't, especially not with 3AJ stamped on the engine casing. Well, you might be "sure", but you would almost certainly be wrong. The 3AJ motor, at least when fitted in a 3AJ frame, and despite its electric start, is equipped with a CDI.

The easiest way to tell what type of unit you have is to look at the wires coming from the alternator. There will be 2 or 3 (usually 3, usually white, but always identically coloured) wires running from the alternator to the reg/rect. There will also be a 2 or 3 pin connector running from the alternator to the ignitor box (feeds from the pulser coils). If you have a CDI, there will also be a single brown and a single red wire (both terminated with bullet connectors) running from the alternator to the ignitor box, these are the HV feed for the CDI. If you have a TCI, you won't have these.

Simon

**cyberzar** · #6 29 Sep 2007

Quote:

Originally Posted by tufty

First off, the number that matters for finding the model of the bike (and thus the wiring diagram) is the frame serial number, not the engine serial number

Simon, you are correct saying that 3AJ on cylinder does not matter, but considering that with these old bikes someone can have bought a bike with a transplanted engine, with all the related electrical parts, what matters IS the engine suffix, the one on the right half of the engine that comes with serial number after. There are ppl adapting engines from different models, so reading frame letters only could be misleading.
From that engine code, you can be sure 100% about what kind of engine you have.
My answer anyway was not based on 3AJ00 engine code, same for many models, but on the assumption that this bike is a 3TB model, having 3TB on ignition unit, grey frame, chromium rims.
The only exhisting 3TB with CDI is the kickstarter only model.
Otherwise a 3TB with starter motor, can only be a TCI, it could halso have the kick option if one of the owners added it.
Actually I have a XT600E 1990 too

but i'm too lazy to install the kick (and also do not want to kill that spare 43F engine with 35k km laying in the garage)

Nevertheless, your explanation about 3AJ engine electric is fully correct and is a good point for other situations

**tufty** · #7 29 Sep 2007

Quote:

Originally Posted by cyberzar

My answer anyway was not based on 3AJ00 engine code, same for many models, but on the assumption that this bike is a 3TB model, having 3TB on ignition unit

Oh, duh, I'm a twat. Missed that bit. Yeah, in that case, I concur - TCI.

Simon

**test12345** · #8 30 Sep 2007

In the first picture i'm not to sure were the two small wires are suppose to be going to, its the starter relay right? I have a 3 whites running from the alternator, green white, blue white, and blue. Its only a electric start so i agree with ya guys, its got to be a TCI. The third picture, is that just a relay? Also i found this number stamped on the bike JYA3UYCOLA005313

**cyberzar** · #9 30 Sep 2007

Quote:

Originally Posted by test12345

In the first picture i'm not to sure were the two small wires are suppose to be going to, its the starter relay right? I have a 3 whites running from the alternator, green white, blue white, and blue. Its only a electric start so i agree with ya guys, its got to be a TCI. The third picture, is that just a relay? Also i found this number stamped on the bike JYA3UYCOLA005313

first picture is the starter relay.

third picture is the starting circuit cut-off relay

From the starter relay the two small wires should be:
one red yellow that goes with same color till starting circuit cut-off relay
one blue white that goes with same color till start button on the handlebar, right side. All this can be seen in the wiring schematic, I have it in english, send me your address by PM and I'll mail you.

**test12345** · #10 30 Sep 2007

PM sent. I've re-wired some of it so far, with that english diagram, i should be able to finish it. Hey, why is there a fill cap on the top of the frame? For the oil for the engine right? Kind of a weird place to put it isn't?

**Brian E** · #11 30 Sep 2007

yes the frame holds the oil for the engine. dry sump engine and they have to put the oil somewhere.

**cyberzar** · #12 30 Sep 2007

Quote:

Originally Posted by test12345

PM sent. I've re-wired some of it so far, with that english diagram, i should be able to finish it. Hey, why is there a fill cap on the top of the frame? For the oil for the engine right? Kind of a weird place to put it isn't?

yessss kinda u should know (and check the level, otherwise engine will not be very happy)

. Oil tank in the frame makes possible to distribute the heat on a larger surface -> all the frame like a big radiator. On a 25 km ride on highway, at 110/120 kmh, 25C external temperature, I barely get 110C oil temperature... to verify it you can buy a thermometer that replaces that fill cap, you can find in on ebay at less than 50 euros.

**test12345** · #13 30 Sep 2007

hehe, ya i new that duh, (slap myself on the head) for some reason i thought it was a wet sump hehe. Thanks for the pdf. That really help out a lot so far!!! I can't figure out were this blue wire goes...its not on the wiring diagram, the 3 whites go to the rectifier, blue yellow & green white go to the TCI unit and that blue, i don't have a clue. Here's a picture of it. It comes out of the engine right next to the blue /yellow and green / white.

**cyberzar** · #14 30 Sep 2007

sorry u should see where it connect on the other side of the wire, probably it has been already changed and color is different.

**test12345** · #15 30 Sep 2007

Neutral switch maybe? but its blue instead of sky blue...i keep looking

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