Electrical nightmare on 03 - Yamaha Raptor Forum
 2Likes
  • 1 Post By QuadManiac
  • 1 Post By QuadManiac
 
LinkBack Thread Tools Display Modes
post #1 of 8 (permalink) Old 04-25-2019, 06:28 AM Thread Starter
Junior Member
 
Join Date: Apr 2019
Posts: 7
Electrical nightmare on 03

Bought an 03 from a guy, didn't run. I popped the lid and this is what I found. Jumping the solenoid with a switch. Battery was toast, wouldn't take a charge. For the price, I figured I couldn't pass it up. How hard could it be to fix?

Put a new battery in it and a fresh solenoid in (old was still good with fuses good too). No dice.

So, I called the guy just to see what happened. He said his girlfriend took it for a ride, stalled it, turned the switch on but never turned it off and brought it back smoking.

Key turns on, N light comes on, brake light works, haven't checked reverse, but it will not start. I tried jumping the posts of the new solenoid just to see if it would turnover... Nothing, not even a spark.

Anybody know how to troubleshoot the wiring on these? Thanks.
3rd Monkey is offline  
Sponsored Links
Advertisement
 
post #2 of 8 (permalink) Old 04-25-2019, 06:32 AM Thread Starter
Junior Member
 
Join Date: Apr 2019
Posts: 7
Here's the burned up wiring.
Attached Thumbnails
Click image for larger version

Name:	image_1556191847451.jpg
Views:	32
Size:	98.8 KB
ID:	132687  
3rd Monkey is offline  
post #3 of 8 (permalink) Old 04-25-2019, 01:23 PM
Master of the Electron

 
QuadManiac's Avatar
 
Join Date: Apr 2007
Location: San Diego, CA
Posts: 14,374
He butchered it. None of that burned green stuff is original.

Download the manual, learn the wiring diagram (it's pretty simple) and return it to stock.

1st, you need 12V at the CDI on the red/black wire.

What do you mean by "Nothing, not even a spark"? Did the starter at least turn the engine over?
Scotscockney likes this.

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo

Last edited by QuadManiac; 04-25-2019 at 01:27 PM.
QuadManiac is offline  
 
post #4 of 8 (permalink) Old 04-25-2019, 02:12 PM Thread Starter
Junior Member
 
Join Date: Apr 2019
Posts: 7
Yea I could tell none of it was factory. It ran to a 30amp toggle switch and came out just hanging under the seat.

I will have to check the wire and report back.

The solenoid in there was not a factory Yamaha, but I found the same one on Amazon for $7 and bought it to blow it up if it happens instead of the real deal. I tested both the old and new solenoid on a battery, both clicked from the pins only, not from the lugs. No action there. I also tested the resistance and it came out good. If I try to jump those 2 lugs with a wrench, similar to his switch setup, it doesn't even click.

With the wires hooked up to the solenoid, I have 12V at the yellow/black, blue/black, and red/black with the key on in neutral. Battery is fresh and charged.

I haven't tried to popstart it yet because the pet cock is leaking, so I'm putting that in tonight.

I'll check that red and black and let know. Thanks a ton.
3rd Monkey is offline  
post #5 of 8 (permalink) Old 04-25-2019, 02:44 PM Thread Starter
Junior Member
 
Join Date: Apr 2019
Posts: 7
The red and black wire reads battery voltage, but when I pulled it I noticed these cut wires and spliced wires. A yellow/black and a black/yellow spliced together and what looks like a black spliced or just taped. It's cut from the CDI and spliced together.
Attached Thumbnails
Click image for larger version

Name:	image_1556221412117.jpg
Views:	26
Size:	87.2 KB
ID:	132689  
3rd Monkey is offline  
post #6 of 8 (permalink) Old 04-25-2019, 07:37 PM
Master of the Electron

 
QuadManiac's Avatar
 
Join Date: Apr 2007
Location: San Diego, CA
Posts: 14,374
Here's a low res image of the wiring diagram, if it will help.
Attached Thumbnails
Click image for larger version

Name:	wd2.JPG
Views:	22
Size:	31.7 KB
ID:	132691   Click image for larger version

Name:	wd1.JPG
Views:	29
Size:	97.5 KB
ID:	132693  
Scotscockney likes this.

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo

Last edited by QuadManiac; 04-25-2019 at 07:44 PM.
QuadManiac is offline  
post #7 of 8 (permalink) Old 04-26-2019, 06:44 AM Thread Starter
Junior Member
 
Join Date: Apr 2019
Posts: 7
Thanks Quadmaniac. I was going to try to jump the starter and solenoid like Dezperado suggested, but my cables won't fit on the battery and can't get them to the solenoid post. I'll have to get a smaller pair or build a set.

I pulled the plastics and found another splice above the clutch side headlight. So, I'll definitely put that schematic to work.

Couldn't get a manual to download yesterday. I'll try again today.

Thanks a lot.
3rd Monkey is offline  
post #8 of 8 (permalink) Old 04-26-2019, 12:40 PM
Master of the Electron

 
QuadManiac's Avatar
 
Join Date: Apr 2007
Location: San Diego, CA
Posts: 14,374
Use this one:

https://www.filedropper.com/raptor

And click on the button near bottom of page: "DOWNLOAD THIS FILE" (it looks like the attached image) then enter the code and click "download now" - ignore all the other links on their page.
Attached Thumbnails
Click image for larger version

Name:	dlb.JPG
Views:	10
Size:	10.5 KB
ID:	132697  

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
QuadManiac is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Yamaha Raptor Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
electrical nightmare raptorbrother General 660 Discussion 15 12-30-2013 03:03 PM
03 660 nightmare, Need expert plz kildragon6 General 660 Discussion 14 05-26-2011 08:24 AM
electrical nightmare JoElO Raptor 660 Maintenance 15 05-07-2010 06:25 PM
My first raptor, nightmare maybe someone help! prodirt2004 General 660 Discussion 10 02-26-2008 08:36 PM
What a nightmare! wreckless123 Off-Topic Lounge 4 09-19-2007 02:31 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome