Well been through the dreaded TTR600 want start on all 3 of my TTR600's
and finally found what I believe is the biggest issue .. The coil & the spark plug lead which is joined to the coil .. I pulled the lead out of the coil & found it is a Carbon type core with a single wire wrapped around it along with just a small piece of s/steel pin pushed into the end of the lead to try and make contact for transferring this to the plug cap & spark plug .. Not going to be any good at all hence why there is such a pathetic spark when you try to check it against the cylinder head .. My fix which clearly worked 100% was I took my CDI coil of my TT500 which is fitted with a SR500 electronic ignition system and which has a screw in Wire core lead & screw in type spark plug cap also .. This just plugs straight into the OEM plug on the TTR600 wiring which is perfect .. Bolted SR500 coil to frame & put a new NGK silicon straight plug cap on with a iridium plug & kicked it over with plug just sitting on the engine by its own weight & massive big blue spark !!!! ... Bike fire's hot / cold / warm doesn't matter .. The main issue I see is the Carbon core ignition lead along with a pathetic connection to the spark plug cap is coursing the coil to over heat trying to push enough current to the plug & is unable to do this while you kick the bike over , even worse when it is hot and are trying to re-start the bike .. It just isn't providing enough spark to fire the fuel / air mix ... Sold 2 TTR600 because of this hard starting & now am happy to have the bike which starts

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