Oh right.

is it up at the TCI box? in that diagram from Erik_g, the connection is by the 'boitier CDI'. i have a red/black and orange wired 2pin connection going into the box and a white/blue, green/white and blue/black 3 pin connection going in. are these what Erik_g means?

https://ibb.co/LJs3H7L

thanks for all the attention.

no never been in the water as far as I know.

Its the plug you measured first time in the thread, coming from engine, 2pin plug is from pickup.

Why not check on your local sale internet sites for this bike and ask seller if you can test your TCI, cant harm anything other doing this. Must be someone near with XT, stop them and ask, we bikers help everyone!

NO I am not talking about pickup cables.
They are two,
But from the power coils there are three.

Trouble shooting shooting shall be done systematic.
And by elimination,.
Not by guessing + trail an errror

You have
1) Power coils
2) Pick up Coils
3) CDI/TCI box
4) Ignition coil (incl high voltage cable)


Number 1,2 and 4 is easy to measure and test.
One by one.
And if all of them are working perfect.
Maybe you can find instructions for testing the box.
If not => Replace the box.

=
But I will not spend any more time on this.
I hope you get things sorted
=

One time I was testing all parts. And they worked one by one. But not together.
=> I was confused for some time.
But is was oxide in the 3-pin connector. That resulted in not good enough contact.
So the final step was to clean the 3-pin connector to get the system working

Thanks Erik.

I can't find anything that is out of spec with 1,2 and 4 and have ordered the tci box. I have cleaned all the oxidation off the connectors, but will check again the 3 pin for cleanliness.

Much appreciate your efforts and everyone else who has made suggestions. I will post the result of the new box, for the interest of others in this situation.

Ben

Well you talked about the 3wires and confuse him because you are looking at wrong diagram for this engine, the 3wires comes from stator and goes into rectifier. And not colours like you statet, they are all white.

Strange noone can give you a hand with testing box on another bike, XT is not a rare bike in UK?its like 12 years you have for options. FB maybe better to reach out for help than this forum that is almost dead! Maybe bike will run better, i think it was the TCI that removed HP from 3TB to 4PT, emission standards?

i have not seen a recent xt600 while living in Kent but you are probably right. Not so many old bikes on the road around here now. Got hacked on FB and pleased to be off Meta now, so can't use it to reach out to other users. will be good to get a bit more kick out of it if so.

Is this fixed yet ?

__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

Yes, lotta of us wondering if your sorted the problem?

__________________
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Hi all

Sorry didn't write earlier, didn't want to be a drag as only have negative info.

CDI/TCI came but didn't make any difference. Same lazy spark pattern.

It got me thinking to the last issue bike had when it stopped working at the end of Octiber. The starter relay did that thing where it stopped on and wouldn't switch off without battery disconnection. It did this when it was in a garage getting an MOT so may well have been doing it for a while and damaged the brushes before the mechanic noticed it. He replaced the relay for a better one and I ran it for about a week during which it got harder to start and finally wouldn't.

I got the battery checked at a workshop and it has enough amps.

So I am now thinking the starter motor is damaged and only able to turn weakly and not generate enough sparks. I had a damaged floor polisher which still span but wouldn't polish floors, as it was too slow and weak, which is kind of the same thing!

I have connected my battery to the post on the starter to rule out a bad wire from the starter and still same slow crank.

Yesterday I got a universal joint socket adapter so I can try and get the starter out without getting the exhaust off. I dont want to risk getting the exhaust studs out.

Will let you know next couple of days.

Hope this makes sense.

Ben

well you didnt do the check on the coil manually, if you get fat spark when on/off on batt you know problem. Anyway good to have an extra TCI for later..Btw there is no easy way out on the starter motor remove, oilpipe line must out too and exhaust, motor is propably stuck too. Take your time and do this correct and remove carb for a clean when you are doing this. Order new seals gasket oilpipe and gasket starter motor. The 3tb starter runs much faster than the 4pt, sounds almost wrong but seems ok on the ones i have tried.

Connect coil straight to battery? Can do that tomorrow and should get fat spark.

Disconnect wires and give it ground and do fast tap on the +. We are now back at the starter cut off relay and maybe cable problem, the r/w wire comes that way thru the engine stop switch. Beep out the cable from ign coil and all way to starting relay, maybe bad wire or connection will solve it. You had testet and measure different coils so we can rule out this, like i told you earlier measure what happens to the power on the coil when cranking, measuring is the solution to find problem here. Get a car battery for real testing, maybe your battery is toasted and amp goes down when crank.