Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech

Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 20 Apr 2011
Registered Users
New on the HUBB
Join Date: Sep 2010
Location: Northampton
Posts: 14
XT600 Buggy Wiring Troubles!

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!

Reply With Quote
Old 21 Apr 2011
Registered Users
Veteran HUBBer
Join Date: Jan 2001
Location: Stockholm
Posts: 651
Cdi / Tci

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.
Reply With Quote
Old 21 Apr 2011
Registered Users
New on the HUBB
Join Date: Sep 2010
Location: Northampton
Posts: 14
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?

Reply With Quote
Old 22 Apr 2011
Registered Users
Veteran HUBBer
Join Date: Feb 2010
Location: Border Ranges Northern NSW, Australia
Posts: 741
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)
Reply With Quote
Old 25 Apr 2011
Registered Users
New on the HUBB
Join Date: Sep 2010
Location: Northampton
Posts: 14
Thanks guys! just bought tci unit, there abit pricey new but found one on german ebay! Sweet! will update with news!

Reply With Quote
Old 27 Apr 2011
Registered Users
Veteran HUBBer
Join Date: Dec 2008
Location: Denmark
Posts: 1,032
With that out of the way...

COOL BUGGY! Got more pics and/or specs? It looks awfully fun
Reply With Quote
Old 4 May 2011
Registered Users
New on the HUBB
Join Date: Sep 2010
Location: Northampton
Posts: 14
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.

Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Xt600 tenere 1986 wiring trouble Inkedkitch Yamaha Tech 5 25 Apr 2011 20:15
Xt600 IVJ / 3AJ wiring in english ( please ) mushroom supersnake Yamaha Tech 2 16 Oct 2010 22:20
XT600 (55W) Wiring Loom foggie Yamaha Tech 2 27 May 2009 13:53
XT600 Wiring Loom URGENT!!!!!!!!!! Martynbiker Yamaha Tech 0 6 Nov 2007 16:49


HU DVD Summer Special!

Now that summer is here, get On the Road! Take 30% off the Achievable Dream - On the Road! 2-DVD set until August 31 only. Get On the Road! Learn the tips to staying healthy, happy and secure on your motorcycle adventure!

Our veteran travellers share their tips (and great stories) for staying healthy, happy and secure on your motorcycle adventure.

"A fantastic, informative and inspirational DVD."

"It's brilliant - thank you very much!"

Check it out at the HU Store! Remember to use Coupon Code 'ONTHEROAD' on your order when you checkout.

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 10:42.