DESPERATE! Please Advise! Wiring Pics

I hope someone can see what I have done wrong. To the best of my knowledge I have this wired just like the minimum wiring diagram says, however the only way I can get spark from the plugs is if i tap a ground wire to the negative on the battery which seems really odd to me. I know somethings wrong just don't know what.

 

looks good to me

 

*****! All I can say is that the negative of the battery SHOULD be connected to the frame and if there isn't a connection then the coils will not work.

 

ive hooked it up and unhooked it 3 times step by step. I'm running out of ideas here

 

:lol:

i'd bust out an ohm meter - if tapping a ground wire to the negative terminal on the battery makes it work, i'd guess you have a bad (or missing?) connection somewhere.

i'd bet you are missing the ground connection between the battery and the frame.

 

+1

The negative wire is all that seems to be the problem, make sure the ground from the battery is plugged proper on the frame/engine, also make sure the black wire coming to the tci is properly connected and grounded. do not try and short the wires of the tci in hopes of fixing the issue as it will only burn the tci itself. take your time and do it right, its not as big a issue as it seems to be.

 

looks like one of those roadside devices !!

 

I just ordered a new TCI from chacal. It's the only thing else it could be.

at least I hope so

 

nope those are both good, The green and brown wires from the pickup coils arn't working either, and i'm only getting spark from on coil, and the other gets hot. im so confused

 

The black wire from the pickup's needs to be connected on the tci for the coils to fire. both the coils do get warm gradually once the system starts. if one does not spark but gets warm suggests it might be working properly as well, might be the plug wires on it that may be corroded or unattached. you can also switch the non sparking coil with the sparking one, if after switching the non sparking one starts to fire than most likely the tci or the wiring is bad, however if the coil does not fire then chances of it being damaged is very likely. also check the working coil on the wiring of the non sparking coil, if the working coil sparks on it then you can consider your ignition system to be good, just a new/used working coil should get you through.

Also for checking spark you can use a magnetic screw driver and touch it one by one on each of the pick up's to test spark on the coils, 1 pickup fires 1 coil while the other fires another coil. this method prevents one from using the starter over and over again just for the purpose of checking spark, also saves the battery from draining altogether.

 

the wires coming from the pickup coil are actually red and green, not brown, it confused me too. that may be your issue...

 

Holy balls man you must be getting excited. Take your time, I learned that the hard way. I don't know how anybody could see anything with that mess, no offense, it really sounds like the prbolem is ground to me, double check all connections, to test if the coils are bad, take the cover off the pick up coils on the side and draw a metal objet across each pick up and it should spark the plugs 2 at a time, with the plug out and grounded on the engine, of course. Then you can see if both coils are good, IMO if the tci was bad niether coil would work.

 

shew i am getting excited. I just want this bike to run so bad. I've tested ever ground I know of, I think the problem may be the way the pickup coils are wired. where should the wires from the pickup coil run to exactly?

 

i have them going to the rectifier

 

I'm sure you don't want to hear this ...

But, I'd take a Pair of good Diagonals and cut that Rats Nest right out of there.
You want the Grade that wiring job deserves: F-
That wiring is a Jury-Rigged mess.
You need to undo the explosion at the spaghetti factory and lose that kindergarten special-needs look you got going on.

Start with a Yamaha Ignition Switch.
There's are Wiring Diagrams in the Service Manual.
Visit a Motorcycle Salvage Co and buy a big chunk of Yamaha Wiring Harness.
Use some wiring thats Colored and Coded right to help keep the job organized.

Get yourself one of these:
http://www.rjtool.com/p-1354-circuit-so ... an-72.aspx

 

well im not stupid im going to rewire it really nice, i already have brand new wiring to go back on the bike but no point in wiring it up really nice incorrectly, thats why i'm trying to figure it out now.

i wired it super nice with all the bells and whistle fasteners. heat wrapped everything the whole 9 yards. and nothing. thats what has me at the rats nest u see before you. even though it looks like a mess I know where every wires is going. Im going to clean it up just as soon as I can get some fire to the beast.

 

From the pick up coils you should have one with a orange and black, and one with a grey and black, they have factory ends that all just plug together and plug into the tci. Hopefully yours still do. I can look at my bike and see wich go where tomorow, there are 2 sets of black 2 sets of orange and 2 sets of grey coming out of the tci that are from/to the pick up coils and from/to the coils. and the red white from power. The rectifier has nothing to do with the ignition. Your rectifier dang near killdifier

 

from the pick up coils I only have one orange, one gray, and one black. It may split after it goes into the harness but i haven't touched it.

not two black.

I also have a black/white on the same 6 prong block which I think went to the side stand switch maybe

 

and coming out of the same wiring tube there is a blue wire and a red/black which was the oil level switch and side stand I do believe

 

Oh ya I was looking at a diagram the black goes over to the other p/up coil inside and comes out in one wire. the black/white is not used niether is the blue and red/black. so long as those orange and grays and blcks go where they are suppose to in the tci and also go to the coils as the same colors but coming out of the tci and power is fed and everything is grounded, it should go, if not make sure there are no safety relay gremlins, clutch override, killswitch, stuff like that.

 

One of the WORST Gremlins to Troubleshoot on a "No Start Bike"
is the Safety Relay.

If the PO replaced the Safety Relay with a Standard Power Relay, ... everything gets messed-up BAD!

The ONLY way the Bike WILL Start is to be Neutral.

Un-Plug the Safety Relay and Select Neutral and see it it will go.

 

the red and black can be left alone but you must ground the blue one to bypass the neutral safety switch. that is the problem, guaranteed!

 

where does the neutral safety switch wire come out of the bike at? is it blue because i cut a blue wire that i thought was the side stand wire. I hope i didnt mess this thing up for good

 

there are no relays on the bike anywhere that I know of. where is it?

 

i know its a light blue wire but there are none on the bike that I see anywhere.

 

im pretty sure the neutral relay is gone. and I know everything else is hooked up right. thats what leads me to believe the tci has gone bad. unless you all can help me find the light blue neutral switch wire I cant seem to find

 

I don't have the blue hooked to anything and my bike runs.

 

thats what i thought too. it really must be the tci. ill let u know it about 5 days when mine comes in the mail

 

did you test the coils with a screw driver or such on the magnet?

 

yeah, they are working fine, except only one side works, but i swapped them out and they both work, but the grey wire from the tci is dead and not giving one coil any signal

 

all relays are gone, i mean this thing is bare bones wired. no safety's anywhere. sooooo that means TCI correct?

 

[quote="streetbrawler750
I don't have the blue hooked to anything and my bike runs.[/quote]
mine did nothing until I grounded the blue one that is next to the red/black one. grounded it and bam, the starter worked.

 

mine did nothing until I grounded the blue one that is next to the red/black one. grounded it and bam, the starter worked.[/quote]

my starter works fine, and that's weird bc i checked and that indeed goes to the side stand switch. should have nothing to do with the starter

 

my starter works fine, and that's weird bc i checked and that indeed goes to the side stand switch. should have nothing to do with the starter[/quote]Try grounding the blue wire like he said above. grounding the wire would be like the switch does when the stand is up. BTW it has a lot to do with your starter.

 

so what would I do in the case that there is no longer a side stand switch there. because there's not haha. so I would be grounding a blue wire that goes to nothing lol

 

grounded the blue wire. no change

 

I mean i'm going by this diagram exactly...

 

the ONLY thing that is different is that I don't have an orange and brown wire coming out of my reg/rectifier.

I have a brown and green

 

but I just assumed they had the same function, and they still have a factory connect on them that I haven't touched. Really all it can be is the TCI bad. I've checked and rechecked everything else.

I did some welding on the bike with the TCI hooked up by accident and I think that prob did the damage. I mean I've had several mechanics and an electrical engineer look at it for gods sake and they say they don't know.

does anyone else think it could be the TCI?

 

Yes.

When welding is going to be done on the Bike ... The TCI belongs "On the Bench" until the welding is completed.

Same for the Voltage Regulator.

Member -- "Robert" -- services TCI's replacing Components and Soldering fractures to the I-C.

Contact him via PM and see what he suggests.

 

thanks RickCoMatic but i've already purchased a new one from Chacal

 

shew man i hope the reg/rec isn't fried too?

don't tell me more bad news

 

Try grounding the blue wire like he said above. grounding the wire would be like the switch does when the stand is up. BTW it has a lot to do with your starter.[/quote]the blue wire comes out of the motor, not the sidestand and then becomes sky blue and goes to the neutral light. If you have no neutral light then you must ground the blue wire and the pairing red/black (oil light) can be left open...

 

hmmm mine must be a freak cuz it is definately not grounded. it dead heads inside black tape so I know it is not grounding on anything. I dunno what up with dat man

 

the blue wire comes out of the motor, not the sidestand and then becomes sky blue and goes to the neutral light. If you have no neutral light then you must ground the blue wire and the pairing red/black (oil light) can be left open...[/quote]
did that and still no cigar. I don't know. I'll check back in a few days. if anyone has any suggestions, please share.

 

This may be of help

 

thanks man

I've got another question, which wires coming out of the reg/rec should have power on them and when?

 

If you look at the diagram, the red wire is connected to the battery and black to ground, when you switch the ignition on there should be 12v+ on the brown wire.
With the engine running, the regulator will control the current flowing through the coil (Via the brushes and alternator) and the voltage on the green wire will rise as the battery charges/revs rise - because less current is flowing, i know it sounds the wrong way round.

The AC current on the 3 white wires is converted into DC current by a rectifier and comes out of the regulator on the red wire - which is connected to the battery.

 

that's what i thought. I have no power on the brown wire with the ignition on. what could be the problem if i have good 12v and good ground to the regulator?

 

Polock said

His sarcasm always gives me a good lmao.