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Electrical Issues

PostPosted: Tue Oct 01, 2019 9:46 am
Author: TheBeast
Hi Folks

Some advice please, please, please...

Bike died the other day while out riding. Would not restart after it died.
Pushed home and found the main fuse had blown.
Replaced main fuse and tried to start, nothing.

I then noticed that all the wiring from the ignition key switch to the connector and a short distance past the connector has melted together.
I have subsequently replaced the wiring from the key to the connector and beyond as well as the main fuse.
The head lights, horn, indicators, are all working, but the neutral light will not come on and the bike is completely dead when I try and start it.????
-Battery is fully charged and in order
-Main fuse is replaced
-Checked battery terminal connections
-Checked neutral switch and side stand switch - all good
-Checked kill switch and started button - all good
-Inspected all wiring and cannot see any shorts

Where to from here ?
Contemplating dynamite, but that will not solve the problem long term...:-)

Re: Electrical Issues

PostPosted: Tue Oct 01, 2019 6:05 pm
Author: mark75
battery? - age, load test?

use your multimeter to trace power [key switch, coils, etc.]

make sure your grounds / battery connections are good

have you a wiring schematic?

Re: Electrical Issues

PostPosted: Tue Oct 01, 2019 8:44 pm
Author: Arjay
A few experiences of mine.

The rectifier/regulator burnt my main fuse. The r/r shorted to ground.

The Tci are fairly robust. Thought mine was bad, wasnt. I found out hard way that not all connector plugs are unique. I assumed each unique and therefore idiot proof. Nope, the pickup and fuel pump connectors are identical except wire colors.

I also found out that in 1991 Yamaha changed from two pickups to one. This effects engine swapping and tci configuration. Probably not related to your concerns.

Tracing a shorted wire physically I peeled apart main trunk of wire harness. I broke a lone diode that was protected insidd neoprene tubing piece wrapped inside harness.

Everything works fine now. So dont give up. That one stupid assumption I made about the connections had my bike grounded nearly a month, about ready to torch it. Even spent extra $225 on another tci, $60 on new stator-pickup and then still no spark...!

I kept blaming my tci. The mysterious black box had to be the reason. I couldnt understand why no spark, no fuel pump... Hmmmmm....? Then, aw dang, I switched them and all was well.

Rj
TheBeast wrote:Hi Folks

Some advice please, please, please...

Bike died the other day while out riding. Would not restart after it died.
Pushed home and found the main fuse had blown.
Replaced main fuse and tried to start, nothing.

I then noticed that all the wiring from the ignition key switch to the connector and a short distance past the connector has melted together.
I have subsequently replaced the wiring from the key to the connector and beyond as well as the main fuse.
The head lights, horn, indicators, are all working, but the neutral light will not come on and the bike is completely dead when I try and start it.????
-Battery is fully charged and in order
-Main fuse is replaced
-Checked battery terminal connections
-Checked neutral switch and side stand switch - all good
-Checked kill switch and started button - all good
-Inspected all wiring and cannot see any shorts

Where to from here ?
Contemplating dynamite, but that will not solve the problem long term...:-)

Re: Electrical Issues

PostPosted: Tue Oct 01, 2019 9:07 pm
Author: Arjay
My neutral switch is connected under bike by one screw and has black boot over to protect it. Though unrelated it is snaked in same wire housing as the 3 stator wires. I say snaked, but hidden with the stator wires and the neutral safety wire is a single wire that plugs into female end of another single wire, near where stator and rectifier plug together.

You can and should test you stator output voltage as AC when unplugged from rectifier. There is a rectifier test also. The Clymer book is best IMHO

Re: Electrical Issues

PostPosted: Wed Oct 02, 2019 4:33 am
Author: TheBeast
Thanks very much for all the feedback so far...
Much appreciated.
Maybe I won't torch the bike just yet.

I am okay with mechanical, but this electrical thing is not my forte...