Tt600r no spark or power to coil

[Steve116]

Hi all,

I have just joined this form and would like to say hello to all. I have found the detail and knowledge on here to be great and helpful.

I'm now retired and decided to purchase a project, I have a Italian emport tt600r, kick start only, which I think is a 1997 with a 3ajoo engine.

The bike has been standing a number of years and is part stripped down.

The issue I have is I can't seem to get a voltage out of the cfi to the coil, I have 2 cdis and both done appear to work.

I have done a number of checks which include the following.
Removed ignition switch from system
Removed kill switch
Removed side stand switch

Refitted these back in, I have power to capacitor when kicking over and it holds charge with cdi connected, once you turn ignition on it looses power.

I have checked both cdis and one it holds some power but still no voltage out to coil from cdi.

I have run a 12v feed from a battery to cdi terminal which takes feed from capacitor, bit I'm not sure on is both cdis show 12 v on earth feeds when checking
, does thismean they are both gone.

This only has a 6 wire cdi fitted, I found a wiring diagram for a tt600r 1997 will matchs the loom, apart from no clutch cut-out, I also think coil gone, as main terrain in also goes to earth, but not buying one until I can sort out feed to it.

Any help would be greatly appreciated

Thanks

Steve

[motorang]

Hi
just some thoughts
The bike has a CDI system (brown box) so feeding 12V should not be necessary and will not work to power the CDI - ist needs a pulse from the red and brown wire. Some aftermarket stators have the respective coil wound differently (it has a handedness to it) so you may get a spark if you connect the wires the wrong way round - brown to red and red to brown.

The pickup may be a problem, did you check for continuity there?

The ignition coil rarely fails, but the spark plug may be a cheap swap.

Andy

[dzl]

Hi
just some thoughts
The bike has a CDI system (brown box) so feeding 12V should not be necessary and will not work to power the CDI - ist needs a pulse from the red and brown wire. Some aftermarket stators have the respective coil wound differently (it has a handedness to it) so you may get a spark if you connect the wires the wrong way round - brown to red and red to brown.

The pickup may be a problem, did you check for continuity there?

The ignition coil rarely fails, but the spark plug may be a cheap swap.

Andy

No that is wrong info for the TTR. The CDI is fed from the alternator/ regulator on these.

[dzl]

Hi all,

I have just joined this form and would like to say hello to all. I have found the detail and knowledge on here to be great and helpful.

I'm now retired and decided to purchase a project, I have a Italian emport tt600r, kick start only, which I think is a 1997 with a 3ajoo engine.

The bike has been standing a number of years and is part stripped down.

The issue I have is I can't seem to get a voltage out of the cfi to the coil, I have 2 cdis and both done appear to work.

I have done a number of checks which include the following.
Removed ignition switch from system
Removed kill switch
Removed side stand switch

Refitted these back in, I have power to capacitor when kicking over and it holds charge with cdi connected, once you turn ignition on it looses power.

I have checked both cdis and one it holds some power but still no voltage out to coil from cdi.

I have run a 12v feed from a battery to cdi terminal which takes feed from capacitor, bit I'm not sure on is both cdis show 12 v on earth feeds when checking
, does thismean they are both gone.

This only has a 6 wire cdi fitted, I found a wiring diagram for a tt600r 1997 will matchs the loom, apart from no clutch cut-out, I also think coil gone, as main terrain in also goes to earth, but not buying one until I can sort out feed to it.

Any help would be greatly appreciated

Thanks

Steve

Hi Steve, check these things in this order and your bike will run if the CDI is good!

- put all wiring back to standard.

- Ensure black negative/ earth wires at the voltage reg and coil have good connection to frame. Clean lugs and frame connection points.

- Ensure there is no high resistance on ignition switch/ kill switch contacts. Check this by unplugging CDI and turning both switches on and checking resistance between the red wire at voltage regulator plug and red/ white wire at the CDI plug. This checks resistance through both. Would want to see under 5 ohms max reading. If higher find out why. Temporarily short out ignition or kill switch if needed to get low resistance in this circuit.

- Ensure all lights/ brake lights are off when kicking bike over. You want ALL power generated from the alternator when kicking, to power the CDI only

- With the CDI unplugged are you getting voltage between the red/ white wire and the black wire at the CDI plug when you kick the bike over? If yes how many volts. Should be around 13V with no loading. The neutral light on dash should also glow when kicking and have alternator output. If it doesnt glow, find out why.

- with the CDI unplugged check the resistance of the pick up/ trigger coil at the CDI plug, between green/ white and black wire..should be between 190 to 280 ohms depending on temperature. If not check resistance at blue/ yellow and green/ white wires coming out of stator

- with wires off ignition coil, check resistance of primary coil is about 1 to1.5 ohms

- Put primary ignition wires back on. Check resistance from spark plug cap to the engine. Should be 15 to 22k ohms. I always like to unscrew plug cap off lead and trim end of cable and screw plug cap back on.

- if all above is good plug CDI back in and ign/ kill switches on and turn engine over with spark plug out of engine so can turn over by hand. Should get pulses of at least 5 volts at the orange/ black wires of the ign coil

- if getting voltage pulses put spark plug on the lead and rest on engine and turn engine over? Have spark? May need to do at night as spark can be very weak and will not see in the light.

If no voltage pulses let me know and can advise further

[Steve116]

Hi,

Thanks for replying I will look at this over the next few days,

Couple if things I have done in last couple of days.

1. Removed kill switch and ignition switch from system, joining wires to give direct feed to cdi. When killing over now it charges capacitor to about 15v and gives me a feed to cdi.
2. Connected and checked earth's, but Removed lights, side stand and from circuit
3.when connecting cdi all power goes from capacitor in a few seconds, on kicking over I get power to capacitor but nothing coming out on coil wire.
4. Tried a battery straight to cdi by removing capacitor, earthed to chassis and cdi earth, same as 3 happened.

I've have a new coil and a new regular on order, stator wiring seems OK, with same reading on all 3 wires.

I will try reconnection everything, but both cdis I have do the same thing

Thanks

Steve

[Steve116]

Hi dzl,

Did all your checks thanks it was a great help.

The bike is cut down as a flat tracker so some of the loom has been cut.

I now have a spark with the kill switch wired in no key at this time.

Managed to get a couple of bangs via exhaust when kicking over but has not started yet.

I need to get some new fuel,

Is it worth checking the timing?

Decompresser on handle bars, I kicked over slowly until compression feel right then kick hard, has kicked back a couple of times, choke fully open.

Will sort new fuel in a couple of days and try it again

Cheers

Steve

[dzl]

how did you go? I never use full choke unless it is very cold ie under 10C. Always have better success with starting pulling choke out about 2/3 and always fresh fuel. If bike has been sitting for a while always drain out any fuel in the carb bowl and let it refill from tank. The carb bowls are vented so any fuel in the bowl tends to loose its volatility after sitting in bowl for a few weeks.

[motorang]

Kickback is a sign that something is severely wrong with ignition or carb. Not just a setting slightly off.
Maybe a dying pickup, it MAY be the old fuel though.

ANdy