revtothelimit - motorbike forum

Trying to get my expired XT600 up & running & the pick up coil is duff,as is the spare one that I have.They've both failed at the same point & these things are unobtainium



If you look to the bottom right you can see where the 3rd wire failed.If I dremmel around there would I be able to solder a new wire on,or should I try to split the casing somehow?
I'd rather fit a new pick up,but they're so hard to get hold of that over the last few weeks I've read of people giving up and breaking the bikes.Rather than go down that route I'm trying to work out how to salvage this.I even took it down to Stafford classic bike show the other week & asked at the Electrex stand,but no joy..
Would it be possible to fit a different ignition,say from a later XT600E? They're TCI,these early 'Kicker ' XT's are CDI ,or is there some kind of generic single cylinder ignition out there?
The last resort is to fit a XT600E motor in there & wire up the E start,but that's very much Plan B!

I'm probably wrong, but isn't it just a hall sensor?

If you can find one off something else that you can make fit close enough to the pickup mark then just crimp it to the existing plug wiring?

I'm not a sparky, but surely a hall sensor is a hall sensor, it's just the way it's packaged that changes?

You could dremel the resin off and get to the connector
If you want a complete new ignition Zeeltec (might be called Zeeltronic) should be able to supply one.
I don't think an XT600E one will work

Le_Fromage_Grande wrote: Wed Nov 01, 2023 3:31 pm You could dremel the resin off and get to the connector
If you want a complete new ignition Zeeltec (might be called Zeeltronic) should be able to supply one.
I don't think an XT600E one will work

I forgot about Borut,about a decade ago I fitted a Zeeltronic CDI unit to it & when the bike stopped sparking I sent the CDI back to him to check it out, then I parked the thing up..

KungFooBob wrote: Wed Nov 01, 2023 3:31 pm I'm probably wrong, but isn't it just a hall sensor?

If you can find one off something else that you can make fit close enough to the pickup mark then just crimp it to the existing plug wiring?

I'm not a sparky, but surely a hall sensor is a hall sensor, it's just the way it's packaged that changes?

Yeah this sounds at least as easy/likely to work as repairing/fudging/butchering the existing one?

You won't be any worse off trying to get into the hole to access the wire....you can't make it work less than it does now. You might even be able to offer a repaur service......

Could you screw a little wood screw into the strands?

JackyJoll wrote: Wed Nov 01, 2023 10:09 pm Could you screw a little wood screw into the strands?

Maybe,but I think it will change the resistance value,nothing to lose in trying.

Le_Fromage_Grande wrote: Wed Nov 01, 2023 3:31 pm You could dremel the resin off and get to the connector
If you want a complete new ignition Zeeltec (might be called Zeeltronic) should be able to supply one.
I don't think an XT600E one will work

Borut's just emailed me,he doesn't know where to find a new pickup

JackyJoll wrote: Wed Nov 01, 2023 10:09 pm Could you screw a little wood screw into the strands?

Was going to suggest the same, brass screw into the strands and then solder wire onto screw. Finish of with some epoxy, heat shrink for insulation

Big Red wrote: Thu Nov 02, 2023 1:23 pm Finish of with some epoxy

Hot glue gun glue is handy for holding electrical stuff in place.

I'd have cut a bit off a paper clip and pushed that in and then soldered it.

Taipan wrote: Thu Nov 02, 2023 2:10 pm I'd have cut a bit off a paper clip and pushed that in

Typical office boy.

We’ve all got manly threaded fasteners in our rough-and ready sheds!

I think that'll be hard to solder, I suspect that the solder won't "stick" due to the age and contamination of the core

It will certainly need some heavy solvent based cleaning, though I can't imagine why a good clean soldered joint would provide any restance...

David wrote: Thu Nov 02, 2023 7:37 pm It will certainly need some heavy solvent based cleaning, though I can't imagine why a good clean soldered joint would provide any restance...

I'd be tempted to dab some plumber's flux on it, leave it for a few minutes to work then try soldering using earlier suggestions. If that doesn't work you have nothing to lose by breaking in to the casing. Whatever is in there can be re-housed in a suitable container and a good solder connection made to the internal post.

Well I tried the very small wood screw method earlier,put the meter on it,got continuity & the correct resistance.
It looks a proper bodge though so I'm wondering if anyone knows of a small,threaded electrical terminal that I can screw in there & solder to?

The resistance was always going to be practically infinity or practically zero.