viper electrical problems...help

Alright, after the sled sat all night i went out and tryed starting it. I gave me lots of pops so i pulled the plugs and pulled it over a few times...may have flooded it last night Threw some fresh plugs in and i got it running withe the relay disconnected. It did rev up also. I then shut her off and plugged the relay back in. Started her back up and still ran, and revved up nicely. I then shut it off and plugged th headlights both in. Ran fine on restart but no lights and dash is still not working at all. I grabbed my test light and checked the wire going to my hand warmers. It has power up there and are working properly. I still have my seat disconnected but asume that wouldn't make any difference.At least it is running.
 
so now we have both relays plugged back in and it revs up good, but the lights dont work? the headlights are out as well?

1.)what happens now if you start it up with everything plugged in and you start to grab the harness by the cdi box and tug and yank on it?

2.)then over by the recoil?

3.)then over by the right side where the relays are, does it studdder or flicker the lights or make them come on?

If no power to lights you need to check the wire at the headlight relay, check both sides, going in is what voltage? coming out of relay is what voltage?

all this with sled running
 
i started up sled tonight.Both relays plugged in, all lights...headlights ,taillights all plugged in. I have absolutely no lights at all. Dash has nothing also. Sled revs up fine. wiggled all wires by the cdi, relays, smoothing coils, wires by recoil, wires that run up and over the steering hoop, wires under the engine and all wires by the headlights/dash, and alll wires going up the hood to them. Pretty much the entire wire harness. Got no spitting /sputtering, and absolutely no lights...not even so much as a flicker.Moving on...while sled running checked power coming in to the lighting relay... checked all 5 wires...absolutely nothing going in.
 
hmm, ok, coming into the main relay there is a red wire, check that for power when running, volts?


coming out of relay will be a blue, volts? then it will come out and go to a connetor from there its is a blue/white, volts?

If you have no power at any of these, then go in front of theregulator/rectifier, on the 3 white wires coming from stator and check voltage there, if good you have a bad regulator/rectifier.
 
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ok ...checked voltage going into the main relay...have 14.49 vdc on red wire. checked voltage on blue wire and got nothing. Brown and brown/white wires both have 14.4 volts.I figure the main relay is bad? This sucks...found it having a crack in it saturday and replaced it with a brand new on...new one must be bad also? I also checked red wire at regulator has 14.49 vdc also.All 3 white wires have voltage going in also. So am i thinking correct? Change out the relay again?
 
Hello there,I've been experiencing the exact problems you're discribing.My dash started cutting out but nothing serious, but now I have major power loss when i try to punch it from idle.wide open the sled goes good but if i press the brake or high beam switch the dash cuts out.and i tryed playing in snow but soon as snow goes over the hood i get a bog like it's running on 1 cyclinder or something.I just installed pipes and jet,reeds clutch kit and can't ride.problem was there before the mods.we checked all visible wires no sign of shorting,just getting to pull motor but seen your thread,sounds like the same probl;em.When i unhook my headlights the dash doesn't cut out but didn't try riding it.very fraustrating i know but hang in there,maybe we can help each other.I going to keep testing electrical,but probroly not a bad idea to call yamaha and ask the pro's.any way if you have any luck or if i do i let u know asap.Thanks and good luck jeremy
 
Sounds like relay isnt working then, I would try just for a split second to jump the red to the blue around the relay, if the lights come on youll know.Just a second to see, that way if theres a short somewhere you dont fry it. When the red goes in the relay it comes out blue and feeds the headlight dimmer switch on handlebars, then to bulbs.
 
MrViper you are the man. I jumped the red to blue around the main relay and had lights. Guess I got a dud relay. I really appreciate all the help you gave me. At least I know if I would have gotten a good relay, It would have been fixed on my own. At least I don't feel too stupid now. Thanks again!!! :letitsnow :2strokes:
 
I am no smarter then you are or anybody else, its just a matter of checking things in order to track down the source of the problem. When you put on the new relay, if it shuts off the lights again quickly, then you have a direct short somwhere. Your more then welcome, I like to troubleshoot stuff, its like a crossword puzzle to me....LOL
 
Guess I spoke too soon! :o| Maybe I should just parts it out. lol.I bought a new relay and installed it started it up and no difference! Checked voltage again...still 14.4 @red wire,brown, and brown/white. Nada at blue. Jump across red to bhlue everything works. I think i'm more frazzled now than before!!!!help. #$%&*
 
Ok, well this means we have a short then in the blue wire coming from relay, after it comes from the relay, it goes to the dimmer switch, then to the tach. Gonna have to start checking each stretch of wire then, the relay senses the short and wont complete the circuit due to the short, its protecting you from melting the wiring, or shorting something else out. take the meter and check continuity from the blue wire out of relay to the dimmer switch? then check the operation of dimmer switch, should change the readig of reistance if its working correctly.

A old trick I learned from a old cooter who was pretty sharp fixin cars is to use a battery charger and a test light to check sections of harness, hook up the ground to the blue after the relay and then check the power at the dimmer switch with the test light, with the pos. lead on the test light if its a good circuit it wont light up, if its grounded(shorted) it lights up and the test light will act like a fuse for it. this only checks the sections of wire harness not the componets.
 
:o| Checked continuity on blue/white wire at dimmer switch to blue out of relay, checks out fine. Checked switch itself has continuity on one setting, push it and have resistance. ...so that checks out. checked light green wire from dimmer to light relay checks out fine.checked blue from main relay to light relay bl/wh ...good.And so on and so on.I followed the entire wiring diagram to the tee on the lighting side down to even checking the continuity in all the bulbs and through the dash....all the way down to the taillight. I have found absolutely no issues. Ihave unwrapped all wires and checked them over for any type of damage....I have to believe the cdi is at fault now. Does that seem out of line. If I jump the red wire to the blue wire across the main relay everything works perfectly. The Brown wire comes from the cdi to the relay and brown/white comes out and back to the cdi box. I have to believe the cdi isn't making the circuit. ...Not pulling in the relay.I have checked all switches etc. also. does this sound totally out of line? Also I pulled the cdi box off and it kind if looks like something may have blown inside of the epoxy...there are specs of white you can see throught the epoxy.Maybe this would explain why the sled was spitting and sputtering the night it took a crap also.Let me know. Thanx
 
Just throwing this out there.
My hand warmers quit for a while yesterday, so I started looking @ parts of the harness I could see.
I have a rub through starting to show up on the right side near the carb rack just behind the coolant hose coming off the coolant resivoir.
These wires then drop down under the motor.
You probably looked at these, but thought i'd just let you know.
good luck.
 
Thanx snoway but i have pulled the wiring harness 2 times and actually unravelled all the tape and checked all the induvidual wires, and them checked continuity through all of them. I'm about at my whits end with this thing.
 
I'm still in the same boat.I pulled my harness everything is ok there.Only thing I have left is to check cdi and stator.my sled been's down for 3 weeks all wires are good.Does your dash cut out when you hit the brake with headlight unplugged.there is a thread with same problem and it turned out tobe the stator.He also says he has a cdi in good condition for sale.It's called another electrical problem.good luck
 
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