Xr600 & xr650l aussie owners

Discussion in 'Australia' started by Kenno, May 30, 2013.

  1. lookfar

    lookfar from the land of OZ

    Joined:
    Feb 13, 2011
    Oddometer:
    992
    Location:
    D'aguilar
    For a flasher relay, I'm using a $7.00, 2 wire unit from supercheap.
  2. Kenno

    Kenno Been here awhile

    Joined:
    Jul 11, 2011
    Oddometer:
    985
    Location:
    CAIRNS - AUSTRALIA
    XR250/400 are the same indicator units in case you are near a wrecker.

    The exhaust guard is still available for the 2000 model (PROTECTOR, EX. PIPE 18325-MG3-000) from Service Honda but a local shop can order it in for you, I burnt 2 sets of pants right through to the meat on my 94 without one. Also check to see if you need the bolts and order them with it, check the threads too, I had to remove a broken bolt and re-tap the thread.

    Hot starting should be easy, all I can say without wild speculation on the problem is that you must follow a process of elimination, you'll need a multimeter to check resistance values of ignition components and the actual wires between those components to rule out intermittent cable breaks (they read as a higher resistance than a good wire) and a good carb clean whether you think it needs it or not, any problems I have had always seem to be the carb even when I was dead sure it was electrical, problems are mainly float level which can self adjust on corrugation or grit from fuel bowl breathers blocking jets or galleries.
    Try and get a genuine Honda manual, the rest are below par.

    Cheers
  3. shtonkalot

    shtonkalot Adventurer

    Joined:
    Nov 5, 2013
    Oddometer:
    10
    Location:
    Western Sydney
    Still cant get the pics off my phone!

    Awesome, thanks. How did you wire it up? I have a 3 pin socket where the last one was.
    I am near a decent wrecker I'll check there first.
    Thank you, I didn't notice any mounting points on or around the header pipe, where are they/should they be?
    Cheers, I'd like to know a bit more about how to do these checks, basically where to test and what values to expect. Can I find that info in the service manual?

    I'm going to take of the carby and give it a good clean, I have been meaning to. Bike seems to bog out a little easy and I suspect that could be the cause
  4. Kenno

    Kenno Been here awhile

    Joined:
    Jul 11, 2011
    Oddometer:
    985
    Location:
    CAIRNS - AUSTRALIA
    Here you go, guard mount points. (unless you have aftermarket headers of course)
    [​IMG]

    With the electrical checks you will learn a hell of a lot about your bike, the Aussie XR wiring is different to the US versions but all component values will be the same as the Honda manual states, there are Aussie wiring diagrams available on the www.
    Edit: When you check any wiring for breakages wriggle the wiring harness when you test each wire.

    Cheers
  5. shtonkalot

    shtonkalot Adventurer

    Joined:
    Nov 5, 2013
    Oddometer:
    10
    Location:
    Western Sydney
    Thanks again Kenno!

    Yeah my header pipe may be aftermarket then, there is no added metal pieces to the pipes for mounting. I'd show a pic but I still cant get my phone to work.

    I'm still not convinced it's aftermarket pipes, it's got the oem black muffler on it and the pipes look the same as the diagram but without the mounts or extra metal around the pipe on the front mount.
    But I can definitely say the bits you've circled in red are not there.

    Anyone got a 93 that can tell me if they have any different mounting than shown?

    I just started checking electricals, if anyone has a link to the Aussie wiring I'd appreciate it. I've googled an image of the Aussie diagram but it's too low res to read the wire colours.

    **edit**
    Managed to get a couple of old pics from when I first brought her home, included a zoom in on the header pipe:

    [​IMG]

    [​IMG]

    [​IMG]
  6. shtonkalot

    shtonkalot Adventurer

    Joined:
    Nov 5, 2013
    Oddometer:
    10
    Location:
    Western Sydney
    *Prepare for noob questions*

    Sorry for the extra post but I could use with some help with wiring.
    I'm struggling to find a wiring diagram that matches what I have.

    I think my wiring has been messed with, I believe I have an aftermarket headlight surround and suspect perhaps some hand done wiring for some of the lights on the bike.

    First I'd like to know if an Aussie 93 xr600 has both high and low beam?

    As the light was wired up I have a low/high switch that was light off when switched low / low beam (one of two filaments lit up) when switched to high. As I could measure it there was only 3 volts getting to the light when switched to high.

    I've been trying to make sense of the output from the wires, I could really use a confirmed wiring diagram of an aussie 93.

    Can anyone tell me what 3 wires I'm looking for from my high low switch?

    Is there a difference between 92, 93 or 94 wiring?

    Sorry for all the queries, I'll do my best to help others as soon as I learn what I'm doing ;)

    I'm keen to get the bike registered, I'm guessing I need a working high and low beam.
  7. lookfar

    lookfar from the land of OZ

    Joined:
    Feb 13, 2011
    Oddometer:
    992
    Location:
    D'aguilar
    You are looking for blue, white and green.

    blue is high beam, wire goes into a dual connector and up to the high beam indicator in the speedo.

    White is low beam.

    Green is earth, plugs into a 3 way connector.

    See if you can find a wiring diagram for the german version, theirs is the same as ours.
    Failing that, you may have to get one from your Honda bloke..that's what I did.
  8. rmhrc628

    rmhrc628 Long timer

    Joined:
    Feb 6, 2006
    Oddometer:
    3,076
    Location:
    Melbourne

    Def aftermarket header.
  9. Kenno

    Kenno Been here awhile

    Joined:
    Jul 11, 2011
    Oddometer:
    985
    Location:
    CAIRNS - AUSTRALIA
    My 92 wiring diagram confirms Lookfars but it is in the back of my original owners booklet as XR600R(U), none of my workshop manuals have the Aussie versions in them.
    I tried to scan this one but it is way too useless to bother, i need 2 sets of magnifiers to read it.
    XR650R is similar in the manual with enough colour differences to confuse users.
    Try and get the little owners handbook if you can, it has the diagram in the back, I bought mine on (that)bay for 10 bucks.
  10. shtonkalot

    shtonkalot Adventurer

    Joined:
    Nov 5, 2013
    Oddometer:
    10
    Location:
    Western Sydney
    :clap THANK YOU!
    It appears The output wires are all in order then, at least they are the right colours ;)

    I have followed your descriptions and it does match mine. Unfortunately I think I have a problem. Measuring voltage across the blue and green when switched to high I read only just over 1v! The light looks like it's getting more than that though... maybe not full (or half full only 1 filament lit) brightness but surely mostly lit.

    When switched to low (or high) I get no voltage across the green and white.

    Thanks, think I have the german service manual in pdf files, I'd like to get a Aussie one on paper. Know what Honda charge for them?

    Thanks for the confirmation. This bike has more history than I'm aware of for sure.

    I feel like my speedo and decomp cables are a bit too long to be original. They just stick out from the bike further than I think they should though they are running through retainers.

    Do others have a bit too much length in these cables?
  11. lookfar

    lookfar from the land of OZ

    Joined:
    Feb 13, 2011
    Oddometer:
    992
    Location:
    D'aguilar
    shtonkalot, check your PM's
  12. shtonkalot

    shtonkalot Adventurer

    Joined:
    Nov 5, 2013
    Oddometer:
    10
    Location:
    Western Sydney
    Replied, cheers mate!

    Thank you very much for your effort. You guys are awesome help.
  13. shtonkalot

    shtonkalot Adventurer

    Joined:
    Nov 5, 2013
    Oddometer:
    10
    Location:
    Western Sydney
    Big thanks to lookfar and Kenno, got my wiring somewhat sorted, I had dodgy connections. Need a LED capable flasher next. Borrowed a mates flasher from his nx650 Dominator (direct plug in) but as I have a couple of LED indicators mixed with the rest it wasn't very effective.

    I'm hoping to add a battery just as Kenno showed here. Does anyone know how large a battery I can go, I was hoping to use a 9ah AGM battery I have here.

    I'm going to head out to jaycar and grab some diodes and maybe a flasher relay?
    Maybe I should go check out the wreckers too, yeah shopping adventures!

    Thanks for the great support here guys. I was getting a bit annoyed with the wiring yesterday and the help here kept me calm and patient.
  14. Mike the Yank

    Mike the Yank Long timer

    Joined:
    Jun 27, 2012
    Oddometer:
    1,295
    Location:
    MILLJURAH Vic. Aus
    battery size depends on what you want to do with it. I bought a battery but ended up leaving it out as I just run a GPS and the intenal battery keeps it going between rest stops.
  15. shtonkalot

    shtonkalot Adventurer

    Joined:
    Nov 5, 2013
    Oddometer:
    10
    Location:
    Western Sydney
    Cheers for the response. I want to run extra lighting from it when camping and use it as a 5v USB charger with an adapter I have. I've used the battery for lots of things and know I can get a night of light from the battery no problem.

    It's more the charging I was concerned with. I don't know how many amps I can have the battery draw before it may be a problem. By problem I mean lights not getting enough power or other electrical stuff being affected. Not sure how long I'd need to run the bike to charge it either but I guess time will tell on that one.

    I'm pretty good with batteries and small DC electronics but bike electricals are new to me.
  16. Mike the Yank

    Mike the Yank Long timer

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    Jun 27, 2012
    Oddometer:
    1,295
    Location:
    MILLJURAH Vic. Aus
    I don't know all the figures but if you run a diode (which you will need) then it lowers the voltage and provides some resistance. Should be enough to keep all your other DC electrics going while charging your battery.
    I think stock system is about 35 watts dc, divided by 12V gives you roughly 3 amps, or divided by 14V gives you 2.5 amps to work with.
    9 AH battery dead flat, 3.5-4 hours charge time without anything else running (at a good speed).
    Personally I would stick to Kenno's 1.3 ah battery and carry a led torch.
  17. Kenno

    Kenno Been here awhile

    Joined:
    Jul 11, 2011
    Oddometer:
    985
    Location:
    CAIRNS - AUSTRALIA
    If you have the 5 wires coming out of your alternator then it is the same as both my 94 & 2000 XR600's with three separate circuits, AC for AC lights, AC for conversion to DC and a third for the CDI power so charging via the DC circuit will only affect indicators and they will work via your battery if you want and therefore not affect blinking rate unless the battery is stone cold flat. Try it out, got nothing to lose and you will not damage anything unless you short it out. Maybe go to LED lights for camping too. I had zero probs with mine which is off the bike for now since I tend to use the 650's for traveling.
    I could charge my phone and camera overnight without my little 1.3 amp battery going flat so you would have a lot longer life, just charge your battery before installing it in the system then it'll only use mousepower to top it up from your bike.
    I'm not even sure what the output of our stator is on the Aussie AC/DC circuit, I should find out but the US version has 45 watts at 5000rpm and it would be around the same I'd imagine (35/45) since it uses the same amount of coils as far as I am aware but you could prove it with a multimeter and load.
    Reason I chose the 1.3amp originally was because it was just the right size for the gap between the bars and speedo, I did consider larger batteries though but in hindsight this was a good choice.
    The U.S. XR650L crowd are the go to guys for hiding batteries around the bike, they like to get rid of that left side bulge and are like battery squirrels when it comes to storing voltage out of sight.


    Cheers
  18. ZEmann

    ZEmann want to be riding

    Joined:
    Jul 19, 2013
    Oddometer:
    659
    Location:
    Arizona
    :lol3
    you called that one
  19. Kenno

    Kenno Been here awhile

    Joined:
    Jul 11, 2011
    Oddometer:
    985
    Location:
    CAIRNS - AUSTRALIA
    This Stator Diagram is as shown in the 1992 XR600R Owners Manual and is identical to that fitted on my own 1994 and 2000 model XR600R's.
    The part number for the complete Aussie wiring diagram is 0030Z-MN1-9210.
    The Harness from the stator has these colours right up to the protective harness boot under the seat.
    I have linked this post in post #1 for future reference.
    [​IMG]

    1994 and 2000 XR600R AUSSIE STATOR
    [​IMG]

    Wiring harness from the 1992 Australian owners manual[​IMG]
  20. Kenno

    Kenno Been here awhile

    Joined:
    Jul 11, 2011
    Oddometer:
    985
    Location:
    CAIRNS - AUSTRALIA
    You almost need a shoulder harness to lift the arse on the 650L when it gets stuck in a hard place because of that bulge:lift, I love em though.