Re resurecting my old XT600

[KungFooBob]

Put the grommet in a jamjar with some brake fluid, that'll soften it up.

[Skub]

I've been doing more research & I found a thread on a Kawasaki forum were someone replaced their stator & had problems getting the new wiring through the grommet holes,they resorted to enlarging the holes by pushing a bullet connector through.I think I'll do the same,or use a small drill bit & seal it when the wires are through

I have a tool given to me by a sparky mate,it's used for stretching rubber ID markers over wires and connectors heat shrink etc. It looks like a pair of pliers with a single point which splits into 3 and spreads the rubber.

Linky.
https://www.zoro.co.uk/shop/electrical- ... GAQAvD_BwE

[David]

What you realy need is a vet's tool for castrating rams.

[Bustaspoke]

Ah well,time to ressurect this thread again.
I got the unobtainium pick up sorted & cables through the grommet just before Christmas & then placed it on the 'do it after Christmas'list...
Yesterday I fitted the pick up & stator casing back on the bike,gave it a few kicks & still no spark,no surprise really.This afternoon I had another look & tried kicking it with the ignition swiched off,same for the kill switch,still no spark.I then went through the wiring & noticed the brown wire wasn't connected .Connected the wire,kicked the bike over & now,after 7 years we have a spark.
I'll now have to go through everything to make sure everything is tight & permanent,then try & start it.
The only worry that I have is that there's 3 wires from the pick up,one is common & I'm presuming the other 2 are advanced & retarded ignition.When the originals crumbled there was no colour coding on them so you couldn't work out which of the 2 wires went to which terminal on the pick up & I'm wary of the bike kicking back.Any ideas on how to tell before this thing launches me over the bars?
If I can find a set I might try it on some starter rollers to be safe.
I've been laid low with Covid for the last couple of weeks,I don't need to now go & knacker my ankle/knee starting this thing

[Bustaspoke]

I've decided to get the bike running before years end & as a result I've spent a few hours messing around with the old XT600 again.
The original wiring was bodged in a few places so the other year I had a go at rewiring it,it's my first attempt at making a wiring loom & no doubt I've cocked something up but after a few 'teething problems' everything works as it should .The problem now is fitting it all around the headstock as the headlight doesn't have a bowl to fit the wiring in.Here's the wiring,I can see some modifications happening later...



After a couple of attempts to fit the headlight & get all the wiring behind it I checked eveything & found that the sidelight had stopped working,took it all apart again to find that the earth wire had failed where it joins the light holder,it's one of the few original electric parts still on the bike & it's failed like almost everything else ..



I also got out the Superglue,glued the damaged stems on a coule of indicators & glued this neoprene shock protector back to the airbox



Next task when I get some time is to remove the carbs & blast them with carb cleaner.When the bike was running they were great but that was 2017 & now the twist grip doesn't automatically close so I'll sort that out before I try & start it,

[weeksy]

Lol @ wiring pic

[ChrisW]

Stilmotor! Now that's a name I've not heard for a long time.

[Ian]

Lol @ wiring pic

Looks like someone chewed a wiring harness and vomited

[Bustaspoke]

I'll either modify that loom & try to place the connectors under the tank,or start again.First task is to get it running again...

[Skub]

To be fair a lot of that era of bikes hid all the wiring in the headlamp bucket. Some required real effort to refit the headlight!

[cheb]

Every bike I've had with a headlight bucket has had wiring like that shoved into the bucket and the lens reflector wobbled and shoved about until it fitted.

[Bustaspoke]

Same here,but there's no headlight bucket with this old XT

[Skub]

Same here,but there's no headlight bucket with this old XT

Buy a big one.

[ZRX61]

I have a tool given to me by a sparky mate,it's used for stretching rubber ID markers over wires and connectors heat shrink etc. It looks like a pair of pliers with a single point which splits into 3 and spreads the rubber.

Linky.
https://www.zoro.co.uk/shop/electrical- ... GAQAvD_BwE

A dwarfs speculum.....