XT600E 1995 won't start
 

I have changed my piston kit about 2000km and everything was ok.
In the last trip it start to cuts off engine shortly very rare when I was using engine break and after that, accelerating it's cutting off and then runs great. When idle sometimes just cuts off. After a few hours of checking in the middle of nowhere it's starting and keep cutting off from time to time when accelerating. After a while I run out of battery, i supposed the regulator broke down and I started the bike with the backup regulator and i managed to get home.

The next day i went to see if it is still cutting off and yes, it starts to cut off badly and it wont work in lower RPM only in higher. After a few minutes died.

So now, my XT won't start, i have check everything i know:

compression (ok)
timing points (ok)
check the valve clearance (ok)
check spark (spark plug, pipe, ignition coil, pick-up coil) all ok
clean the carb

everything was like in the service manual

So i bought a timing strobe and I have noticed that the spark ain't within the |-| mark.

see the pdf attached


May the problem be TCI?


I have posted a video too here:

YouTube - MOV00181.MP4

Please HELP!

damn, I have no clue! :confused1:
Good luck with that!

The weirdest thing is that I didn't hear any sound coming from the cylinder...
Is the piston going up and down?

Vando :cool4:

Could it be that the camchain skipped a tooth?

You didn't hear the piston because I removed the spark plug to get easy to turn for the starter.

I have checked that too, it's where it should be.

This days I will try my TCI on another bike and get back to you all.

hmm try to see if rubber joints between carbs and head are intact.

They r made of rubber and metal melted together, but when they get old air beginss to pass inside.... remove carbs and joints, and check them carefully

I,d be tempted to agree and go for the cam chain out by a tooth,did you allow for the cam chain tensioner moving the chain when under tension.? also did you set it up counter rotating the engine ?.......

The bike ran for 2,000km after reassembly so unless the camchain jumped, and kept on jumping to cause the earlier intermittent problems, that is unlikely to be the problem. All the symptoms point to an electrical problem and as the strobe test indicates that the timing is out then the workshop manual's suggestion to check the pick up assembly appears logical.

All the best.

Vote for electrics too.

Eleminate the side stand switch an check aigain!

Check also ignition lock, battery connections and ground connections to engine and frame. Healthy battery?

Good luck!

its 100% electrical. if the timing hd jumped, you would have noticed a really HORRIFIC rattling and a lot of unfriendly noises.

check the neutral switch, and kickstand. usually the two are in line so if one fails, motor doesnt run. a faulty kickstand switch is a probable culprit too, since those usually do suffer a lot more abuse and vibration/beating than say, the neutral switch.

Cant see why it should be the neutral switch, the bike would run and start witout it, you just need to pull the clutch when starting.

I rode for a year with one working from time to time, it had a mind of its own. Changed it no so long ago and it was sticking.

Hope you get you're problems sorted out, I guess everything is fair game, go over the whole bike.

You can be just one tooth out and the bike will still run and not cause any short term damage.

Not always, but sometimes.. Depends on the bike and which way it's out.

It does sound electrical to me. Are you sure you're coil is ok ?? Is the spark strong and constant ??

I have checked the ignition coil, the pipe, the pick-up coil and other switches. The spark is nice big and blue.
The spark get to the plug without problem, in the video I have removed the spark-plug and put on the cylinder so I can see when it's sparks. Anyway, the strobe WONT work if there is no spark present to the spark-plug.

I will keep you all posted.

THANKS A LOT for your help.

Should have read the opening more carefully.

So if the bike now doesn't start at all - check flywheel position on crankshaft and wodruff key. Can be that the pick-up signal to ignition is now on wrong timing due to loose or position moved flywheel.

Good luck

Could also be the CDI/ECU unit...

I wouldnt just go and buy one though. Do you know anyone who you can borrow one from ???

The ignition advance could be screwed up..

hmm to check if timing is correct, you should mark on the cd a sector same as on flywheel, not an arrow... correct me if i'm wrong... is the arrow you marked in the middle of the sector on flywheel?

I have tested my TCI on another xt and it starts without problem.

Now i am really confused. I've got spark, I've got gas, timing is ok... still doesn't starts.

If i remove the airbox i get small explosion in the intake, but with the airbox on i don't hear it at all.

the arrow is set in the middle of the flywheel mark |-|

Valves/valve clearances O.K?

ok..

Try checking if its the carb... Spray some "powerstart" or similar highly flamable spray into the airbox while cranking it over. If that doesnt work and you're SURE the spark is good then it can ONLY be compression. Maybe you've broken a piston ring or headgasket..

Have you tried a new spark plug? Sometimes the spark looks good but breaks down under compression. Contaminated fuel? Drain and try fresh.

I have checked the compression and it's 11.

Valve clearance is ok.

I have measured the pick-up coil and it's 237 ohm and in the manual it's between 184 ~ 276 ohm.

I will buy a powerstarter spray and try it.

Here are pictures with distribution on, am I wrong?

http://motostart.ro/uploads/DSC00197.JPG
http://motostart.ro/uploads/DSC00199.JPG

11 in comp seems high if its a stock bike. I believe theyre around 8-9:1 from stock.

Did you meassure it in psi or such? I've got a factory workshop manual vere the "limits" probably are meansioned.

11 kg/cm2 wich would be 156 psi as in manual.

Which is very healthy compression.

Gotta be fueling then ! Get the powerstart in there asap.

After pulling the bike for a while with the car :laugh: the bike started. For about 2 minutes only in high rpm. The dead again. Went home checked the fuel level and spark... and no spark. I bought a new ignition coil (even the values are like in the book) and now the bike starts but it has erratic idle and misfire on intake alot and if i take it in high rpm bigger misfire occurs.
Now i am thinking if not the pick-up coil is faulty even if the values are ok according to the manual.

have you checked the carb rubbers?...mine looked ok but when taken apart they were badly cracked and letting in air which made it hard to start and run very badly..

now i have taken apart everything in the carb, is OK... after i rechecked everything I found the problem... spark plug gap too small... set to 0.9mm and now everything is OK.

Thanks to all.

Conclusion: Always test your ignition coil directly on battery... it is the best way to test it.