No lights, tach etc

N

nitris223

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Nov 24, 2005
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49
Location
Saskatchewan
Guys I need some help as quick as possible. Last ride of the year is this weekend and my wife's sled is down. She lost her heat grips last week and I did all the test in the repair manual . Everything is within spec except for the stator which reads .5 . Spec is .34 to .45 ohms. Plugged everything back in to see if the temp light was flashing any codes and now I lost the headlights, tail lights, tach and dash lights.

Voltage regulator tested between the yellow/red wire and heat grip wire showed 9 volts at idle and would climb above 28v when throttle was applied. Is this normal.

The bulbs are all good also.
 
I keep forgetting to put that in. It's a 2002 SXR 600. I opulled the wiring harness out last night and looked over all the tape first. There was no rub through anywhere. I removed all the tape to see if there was any melted wires. They looked to be new. Never found any cracks in the wires either. I then tested each wire for continuity and that checked out ok. Everything has been retaped and wire loom put on under the motor.

I am going to try a voltage regulator this afternoon to see if that works. Time is running out. I might just pull the stator also just to be sure. If all else is good it just leaves the CDI which everyone says they don't usually fail.
 
j_k_auto said:
Does the sled still run without all this off?
Click to expand...

if answer is yes, above... then tie RED and BLUE wires of load control relay (white coupler) together... start sled and see if head/tail/tach lights come back on... if so, relay could be out or control cct for pick-up coil of relay is faulty... (if not more testing is required)

at least you'll have lights for the weekend...

success or failure, be sure to post back what the problems were or were not... It helps those following these posts for future problems..


also... you mentioned in another thread this all started after installing a bar riser... if this is the case, likely a wiring problem/ poor ground for the grips...
wouldn't get carried away with the stator just yet.. tj
 
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You may want to also check your ignition condenser,every problem you have i'm seeing it says check condenser capacity first off,you gota service manual??
 
Had the stator checked and it now reads .75 ohm, I was thinking about the risers also. This is when it all started to happen. The bottom pipe that the risers is attached to is painted but I made sure I scuffed the risers around the pipe. I might try putting he old riser back on just to try.

Never got the condenser checked. Is it normal for the regularor / rectifier to get warm after a few minutes of run time.
 
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Did the red wire blue wire connection and bam I have lights. Relay still test good for continuity. So now what do I need to test or replace.
 
nitris223 said:
Did the red wire blue wire connection and bam I have lights. Relay still test good for continuity. So now what do I need to test or replace.
Click to expand...

I sent back a PM, read it too...

Since you only lost lights after you were checking the relay (days back), I suspect the control cct to the relay... The CDI sends signal to that relay to turn on just at/after instant of start-up... Check all connections at CDI...

CDI also controls grips directly, so again, check connections at CDI so everything is snapped on properly, and tight..

If you have to, you can leave those wires tied so you can use the sled for the weekend... IF CONFIDENT YOU HAVE'NT A SHORT CCT... tj
 
Thanks TJ500. What about the stator reading higher then specs. When I connect the 12 battery to the relay to check it out I get a clicking sound just as I am attaching the second wire. Does that mean the relay is working . I tested it again last night and and it still has continuity.
 
nitris223 said:
Thanks TJ500. What about the stator reading higher then specs. When I connect the 12 battery to the relay to check it out I get a clicking sound just as I am attaching the second wire. Does that mean the relay is working . I tested it again last night and and it still has continuity.
Click to expand...

it means the relay clicks... it doesn't confirm that the contacts are closing and making a cct..

as for the stator... if it was ok before you put the riser on, it's likely ok now...

my guess is your control wires (the ones that are supposed to make the relay click) are not connected correctly.. check connectors/ conections and those at CDI as well...

something just got messed up while pulling it apart or putting it back together... tj..
 
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that reading vs spec looks ok... your winding on the stator that powers the lights works, you verified that... trace all wires and check connections...

do you have Yamaha's schematic for that sled?
 
Yes I have a CD manual.

I went through and traced the wires from the relay to the CDI connections. Even traced the condenser wires , all that I could get at and wiggled the wires again with the tape removed. Everything checked out ok. Looks like maybe I should try a relay. But first I am going to remove the risers and install the olds ones to verify it is not a grounding problem . Couldn't get to it tonight, had to install a motor back in a Polaris 800.
Looks like no ride this weekend. Might not get another one in by the looks of the weather to come. Should still be snow in Riding Mountain MB next week or so. Might just get lucky and go there..
 
it's going to be above zero in Manitoba/ sask this weekend... you bypassed the relay and got lights, you won't need grip warmers.... go riding!...



the relay has little to do with grips... except, it too is connected to CDI..
two grips are connected in series with one end grounded, the other end connects to CDI...

when testing relay coil with 12VDC battery source, you did first disconnect control wires to relay?... correct? tj
 
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First time around I connected the battery to the actual wiring harness. Reading the shop manual again it refers to the relay itself. Then I believe I hooked the pos/neg to the wrong termnials ( reading the wires and not pay attention to the numbers next to the wire color code) So I may have screwed the relay the first time around with reverse polarity. The load control relay works for the grips also does it not. If not I may have done some damage to the CDI when I hooked up to the wiring harness but it was only 12 volts and correct polarity.

Time to walk away from it for a bit and rethink things. I think there is either a bad ground or I buggered the relay. Just hate to pay $40 for a relay that I might not need. The price you pay for not paying attention I guess.
 
Back to testing the wiring again. Replaced both relays and still no lights or tac. This is starting to piss me off already and I haven't even hit the snow yet this year. Back to the jumper wire again for a while.
 
daman said:
You may want to also check your ignition condenser,every problem you have i'm seeing it says check condenser capacity first off,you gota service manual??
Click to expand...
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daman said:
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Click to expand...


I think I took the condensers into Yamaha last year and also a electrical shop. They both said they either work or not . Maybe I am getting B.S around. What kind of measurement am I looking for for a good condenser. I see some previous years did not run these. Any way of bypassing them.
 
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