xt600e cut out

[awolxt]

Okay.. been trying to get to the bottom of this cutting out problem with my bike. It seems it cuts out when it feels like it. It starts up instantly no problem but its not nice when youre turning a corner and it conks out. Its embarassing also. Things ive looked at are as follows. In no particular order.
Check valve clearances
Clean carb (several times)
Replace needle valve and float height
Replace carb inlet rubbers
Replace ignition coil
Check spark plug
Check wiring
All the above were fine

What do i look at next? Tci ignitor box ?
Bike starts every time hot or cold no problem but my fear is one day whatever is causing this problem is going to cause it to not start at all.

Any ideas guys?

Bill

[xtrock]

Have you tried to disconect the switch for sidestand?iam thinking you have a bad connection somewhere.

[awolxt]

Hi xtrock

Yeah. Meant to put that in the list of things done!
When i checked the sidestand wiring one spade connector practically fell off . It was then i discovered that a long section of this wiring was rusty and i thought this was where the fault lay. I bypassed the switch and was hopeful id solved the problem, but no! Cut out twice on the way home from work.

[xtrock]

Ok, what is the km on this bike? thinking about the ignition switch, cut switch, i would go over and check all wires and the connections. Does it cut out when in special ways of driving or random?

[awolxt]

28000 miles on the clock. Put a test meter on the cut off switch and cleaned the connections. Ignition switch is stiff/difficult to turn in operation
So i put a meter on the disconnected wires (the ones behind the headlight) and wiggled the key every which way to see if that made a difference. It didnt so i figured ignition switch is ok. Is there any other tests i can do with the switch?

[xtrock]

Its hard to find error that are not constant, to really know its not the ignition you must unplug it and hotwire it. Yes it can be the TCI, maybe open it and check for bad connection spots. When is the problem coming up, corners, hills or just straight flat?

[awolxt]

From memory its mostly on corners, but it has done it on the straights as well. If i unplug the ignition switch and hotwire it(dont know how?) Could i still use it and have lights indicators etc?

[xtrock]

ok, is like its sudden dead or does it start misfire first? and if you stop, you can start easy and ride again? Yes its possible to wire everything outside the switch.

[awolxt]

Stops suddenly and restarts just as quick. Bumpstarts itself if im in gear
If im slowing/stopped for lights etc i can restart it instantly with the electric start. I will have a go at bypassing the ignition switch.

[xtrock]

Yes then it really sounds like a connection problem somewhere, dont forget the TCI box. Best is if you can get a spare or loan from another bike.

[awolxt]

Been looking for a spare tci to try and eliminate. I have looked at a couple of sites that suggest ways of looking for faults and repairs of the tci box. I will have a look tomorrow . Thanks for taking the time to offer up help xtrock. Much appreciated !

[xtrock]

When you search ebay use CDI search name, TCI its almost never used for name on this boxes.

[awolxt]

Right ive dismantled the tci box. I think i can see cracks around about 3 joints but im not an expert and im only going by what ive seen /read on websites etc. What do others think?

[xtrock]

Hard to tell looking at a picture, but it seem fine. Doesnt hurt to fix what you think is not good, just dont get any shorting to other connections.

[awolxt]

Been and resoldered the ones i think are cracked and im going to test ride it before work.

Remembered a couple of years ago discovering two or three of the white wires from the stator had been burnt . Dont know why they were burnt, came across it cos i noticed the wiring loom black tape was of a different type and it made me suspicious. I seem to remember sections had been cut out and new sections replaced. The trouble was old and new joints werent soldered, just twisted together and covered with clear sticky tape. I re did them properly but would any of that be linked to my issues now?