Electrical Problem
 

Im not great on electrics, but just been working on my 2002XT600e to cure an Oil leak. So the left side alternator side casing was off and the starter motor (which is also new).

Put it all back together and it started fine yesterday but today the starter seemed to by pass the ignition switch and would not stop turning over until I pulled the battery. If I re connect the battery with the key switched off the engine stop off the bike turns over. Obviously a short but where do I start with finding it. Is this a common issue. New battery, new relay all the wires look good. Any ideas anyone .

cholo, have a look at a wiring diagram of an XT600 and explain to us how squashing a cable in the alternator/starter cover cause this problem. we are listening with attention :)

Marcus, until we get a convincing reply from Cholo, I suggest you focus on the starter relay that commands the starter.

It's quite simple. just disconnect the plastic connector with two thin wires that controls the starter relay, now turn the key, if the problems stops, then your relay is ok but for some reason you still get the command to start, might be something as stupid as the button being stuck

if the problem continues, then its the relay itself that is shot, you need to change it

start form there

Many thanks both, I was wondering myself about the alternator wire advice and more relieved than anything that I don't have to take it off again as that was where I had part of the oil leak which now seems cured. This is the second relay I have had, but they were cheap and I see from an earlier post that it might be the relay getting stuck. Could be the weather as well. Anyway I will start from there. This did happen once before and I went through the switchgear and it all looked good. But it will keep me out of mischief and can't go anywhere :rolleyes2:Thanks again

it shouldn't be weather dependent, thats for sure :)

also had a bad luck with starter relays, especially with cheap ones. ended up with something much more powerful like this.

yes those cheap chinese relays are a failure waiting to happen. If you want them to last then you need to ensure you are using a very good condition battery. If you have a battery that is in poor condition the starting current will be a lot higher as compared to a battery in good condition. A good battery will hold good voltage when cranking and cranking current will be a lot lower. These cheap relays dont like high current and the contact tips will weld together and cause your problem. The yamaha genuine relays are a quality item and last!

Cholo be like. https://www.tenere.co.uk/forum/images/smilies/LoL.gif

https://media1.giphy.com/media/4pMX5rJ4PYAEM/200.gif

Mezo.

Stuck relay. (Give it a whack with a heavy screw driver handle) It's a mechanical switch you see.

Stuck starter button. Common on older bikes.

I don't think you can short out a relay to power the starter motor. As it's usually always a switched live to power the relay. The starter button being the switch.

on the starter mounted relay in my V50 guzzi (very accessible), shortening the two starter poles was usual practice :) always had a wrench in my pocket to do it...

good piece of electrical info. seems that my knowledge alone was not enough to get to this deduction.

could imagine how that wrench would look like after a while : )
- also had to do this practice on my xt during a month or so, special tool in this case was camshaft rod from unknown small bike. and this rod used to slightly weld on the poles time after time :nuke:

wrenches are cheap at the 1$ shop :)