2002 Yamaha 660 solenoid Wiring

2736 Views 16 Replies 5 Participants Last post by QuadManiac, 12 d ago

Javierhuertaa660

Discussion Starter · Mar 23, 2022

hey y’all, I just bought my oem solenoid for my 660 but my question how it’s supposed to be wired on the 4 pins
i have the yellow/black from cdi, blue wire which I believe it’s the start button wire and I’m missing the red wire is it the red from the reg?

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Is this red wire the one that is supposed to go to one of the solenoid pins? Thanks In advance! @QuadManiac

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lojak86

· #2 · Mar 23, 2022

2

Yes you are correct. There's only 3 wires that run to the connector terminal and one pin is left empty. There's a red and black wire that runs out of the rectifier, the red wire should end at the solenoid connector.

Font Parallel Pattern Circle Technical drawing

I'm also attaching a wiring diagram, you can find it on the last page of your service manual.

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Javierhuertaa660

Discussion Starter · #3 · Mar 23, 2022

lojak86 said:
Yes you are correct. There's only 3 wires that run to the connector terminal and one pin is left empty. There's a red and black wire that runs out of the rectifier, the red wire should end at the solenoid connector.

View attachment 142816

I'm also attaching a wiring diagram, you can find it on the last page of your service manual.

Thanks really appreciate it🙏🏽

Javierhuertaa660

Discussion Starter · #4 · Mar 24, 2022

lojak86 said:
Yes you are correct. There's only 3 wires that run to the connector terminal and one pin is left empty. There's a red and black wire that runs out of the rectifier, the red wire should end at the solenoid connector.

View attachment 142816

I'm also attaching a wiring diagram, you can find it on the last page of your service manual.

Quick question how do they go on the pins? I cant figure it out

lojak86 said:
Yes you are correct. There's only 3 wires that run to the connector terminal and one pin is left empty. There's a red and black wire that runs out of the rectifier, the red wire should end at the solenoid connector.

View attachment 142816

I'm also attaching a wiring diagram, you can find it on the last page of your service manual.

hey one last question hope you can help I have the 3 wires but can’t figure out what pins they go

lojak86 said:
Yes you are correct. There's only 3 wires that run to the connector terminal and one pin is left empty. There's a red and black wire that runs out of the rectifier, the red wire should end at the solenoid connector.

View attachment 142816

I'm also attaching a wiring diagram, you can find it on the last page of your service manual.

hey quick question hope you can help me out, I can’t figure out what pins the wires go on the pins

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I have the does the red one go on the left top?

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lojak86

· #5 · Mar 24, 2022

The image I attached in my last post is color coded with which wires go where, however it looks like you have the wrong wires going to the relay.

You should have a red wire coming from your Rectifier, a Yellow and Black wire from the CDI box, and a Blue and Black wire also from the CDI.

Javierhuertaa660

Discussion Starter · #6 · Mar 24, 2022

lojak86 said:
The image I attached in my last post is color coded with which wires go where, however it looks like you have the wrong wires going to the relay.

You should have a red wire coming from your Rectifier, a Yellow and Black wire from the CDI box, and a Blue and Black wire also from the CDI.

no I added those wires because they were cut short but the red is from rectifier, yellow and black is the yellow red and the greenish blue colored it the blue and black, my question is if there is a specific pin where they belong

lojak86

· #7 · Mar 24, 2022

My apologies then,
If your looking at the relay from the leads on the bottom, the red pin is top left, yellow/black bottom left, blue/black bottom right

Javierhuertaa660

Discussion Starter · #8 · Mar 24, 2022

lojak86 said:
My apologies then,
If your looking at the relay from the leads on the bottom, the red pin is top left, yellow/black bottom left, blue/black bottom right

no worries, so it should be like this?

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lojak86

· #9 · Mar 24, 2022

Looks correct to me according to the diagram. You might have issues with vibration shaking those connections loose if you do alot of rough riding.

Reactions: 1

Javierhuertaa660

Discussion Starter · #10 · Mar 24, 2022

lojak86 said:
Looks correct to me according to the diagram. You might have issues with vibration shaking those connections loose if you do alot of rough riding.

Its no turning over, it turns over when I touch the blue/black wire to both the right side pins

lojak86

· #11 · Mar 24, 2022

Do you get anything from the start button? I think by bridging those pins you are bypassing your start button and turning over.

Javierhuertaa660

Discussion Starter · #12 · Mar 24, 2022

lojak86 said:
Do you get anything from the start button? I think by bridging those pins you are bypassing your start button and turning over.

the start button is toast but I’m joining both the start button wires and should crank like that too, but it doesn’t do nothing no buzz or anything if I try joining the cables,

QuadManiac

· #13 · Mar 28, 2022 (Edited)

Connecting red directly to yellow/black can damage the CDI... it blows the drive transistor for the yellow/black wire.. you have likely done this.

There's a work around if you don't want to replace the CDI... interested?

Ultimateduster

· #14 · Mar 28, 2022

Quad maniac has me interested with his workaround.

QuadManiac

· #15 · Mar 29, 2022

Simplest? Cut yellow/black, connect solenoid end of yellow black to red/black. Now solenoid will work if run/stop switch is is run.

Problem? WIll also be able to start in gear. Fix that by rewiring the clutch switch - interested?

dewitt736

· #16 · 17 d ago

QuadManiac said:
Connecting red directly to yellow/black can damage the CDI... it blows the drive transistor for the yellow/black wire.. you have likely done this. There's a work around if you don't want to replace the CDI... interested?

I’m interested in this as I believe I’m in the same boat

QuadManiac

· #17 · 12 d ago

Cut the yellow black and tie the solenoid side of the cut to the red/black wire - will start now when kill switch is on... but ignores the neutral switch (not so safe). If you want a safer way, I can tell you that too.

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