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XT600E Electrical Probs.... XT600E Electrical Probs....
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 7 Jul 2009
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XT600E Electrical Probs....
Have a wierd electrical snag.
The starter circuit remains closed (active) even when the main-switch, and cut-off switches have been removed from the wiring harness. I Cannot locate the short no matter what I test, as connecting the battery only seems to flash and initiate the starter motor, simultaneously.

Anyone help?
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Old 7 Jul 2009
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Stuck relay ???
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  #3  
Old 7 Jul 2009
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Quote:
Originally Posted by Dubbs View Post
Have a wierd electrical snag.
The starter circuit remains closed (active) even when the main-switch, and cut-off switches have been removed from the wiring harness. I Cannot locate the short no matter what I test, as connecting the battery only seems to flash and initiate the starter motor, simultaneously.

Anyone help?

Dubbs,im not a Yamaha boffin but it sounds to me that it could be the stater solenoid that is the problem. Disconnect the battery before you start.There should be a thick wire that runs directly to the solenoid and then on to the starter motor from the positive terminal of the battery. Locate the solenoid and disconnect any other wires that go to the solenoid. Leave the thick wires connected and then reconnect the battery. Nothing should happen. If the starter motor runs it proves that the solenoid is at fault. The solenoid requires a 12 volt signal to make it operate. Try this first,if the problem is not solved i have a cunning plan!
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Old 7 Jul 2009
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Stuck relay, tab it with a hammer a few times, and it is as good as new.
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  #5  
Old 8 Jul 2009
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hi there it do,s sound like the solanoid is stuck , you can dismantal these sometimes and clean it up .but to be honest i would get a replacement one .if it jams on you outside the chippy you are going to have to disconect the battery bloody quick or the starter motor is going to have a corranary not a good look ,plus your chips will get cold. zigzag
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Old 8 Jul 2009
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haha.. stories of a stuck solenoid....



Once when that happened to me I got so "scared" and had an adrenaline rush because the XT would just NOT stop trying to start...was constantly kicking away just like if someone was starting the bike, putting it in first gear and just letting go of the clutch with the front brake on and dieing...did I mention it did that CONSTANTLY?? lol

the adrenaline rush made me take the keys out of the ignition and throw them away... when I tried to reach for the solenoid wires and jiggled them the bike finally stopped!
After that I just spent about an hour trying to find the keys..they were over 20meters away

Get a new solenoid I tell ya..


btw, anyone had something like this happen to yourself?


Vando
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Old 8 Jul 2009
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XT600E electrical Probs....RESOLVED!
Thanks everyone for your welcomed suggestions.
It seems, however, that the starter solenoid was not at fault. After another half day of multitesting everything again, I layed the multitester down and thought there must be another way to do this. Then I began disconnecting all the ancilliary components ie indicators, lights, horn etc, and low and behold, the wire from the wiring harness leading to the horn was exposed and rubbing on the main frame (chassis). Ever hopeful, but cynically sniping that this couldn't have anything to do with the problem, I removed the Horn and wrapped the exposed wire in electrical tape. Then I reconnected the main switches and reattached them to their rightful place on the frame, and connected the battery. No adverse reaction. I was thrilled. The starter engaged as it should when the I pressed the start button, then shut off when released.
I couldn't believe it. Something so simple and, well - out of left field, so to speak.
NOw I have a bike tht works as it should, and a new, bigger horn!
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