350 warrior wiring problem? - Yamaha ATV Forum
 
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post #1 of 9 Old 01-31-2012, 04:01 PM Thread Starter
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350 warrior wiring problem?

Im working on this 350 warrior and rebuilt the motor, and wired it all up and the headlight wont come on and the starter button doesnt do anything. It doesnt have a key so i cut the positvie and negative wires and tied them together. When you touch the two together a click comes from the relay between the exhaust canister and rectifier. Ive replaced the solenoid, didnt fix it, tried diddferent rectifier, replaced that relay, cleaned all connections, and with the two wires connected jumping the solenoid will turn the motor over. But the hand controls dont work. Im stumped
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post #2 of 9 Old 02-01-2012, 09:40 PM Thread Starter
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Bump if anyone has ANY ideas let me kniw. Im stumped. Ive tried a different wiring harness but it think this ones before 96 and all of the connections are different.
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post #3 of 9 Old 02-01-2012, 09:41 PM Thread Starter
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The headlights are down low by the bumper so i can garauntee its early model
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post #4 of 9 Old 02-02-2012, 08:28 PM
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Thompson, that relay is a starter inhibit relay. the click you hear may be the relay opening the circuit to the soleniod. It ties in with the neutral switch and other safety switches. PM me if you haven't figured it out by tomorrow and I'll look at a wiring diagram for you and try to help you figure out where to start. Also the positive and negative wires probably shouldn't be tied together. If it's a 4 wire key it probably has a positive input that the key sends back to the start and ignition systems when in the on position and a negative circuit that when off grounds the cdi to kill the ignition.
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post #5 of 9 Old 02-02-2012, 08:46 PM Thread Starter
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im thinking it is the hand control since with a circuit tester the connections have power but the button and headlight switch do nothing
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post #6 of 9 Old 02-05-2012, 12:17 PM Thread Starter
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Okay, i tested the headlights and they work, so i traced it to a bad ground. I followed the green ground wire all the way down and then it curves toward what i think is the stator. a small bundle of wires that turn and connect to the bundle coming from the engine
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post #7 of 9 Old 02-05-2012, 12:30 PM
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I looked at the wiring for another member yesterday. Is your problem electric start or headlights? or both still? If I remember right the start button sends a ground signal to the soleniod and the power to the soleniod comes trough the inhibit relay which is controled by the CDI.
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post #8 of 9 Old 02-05-2012, 12:33 PM
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I copied my pasted my post from yesterday that covers the start system.

I looked up a 91', I'm not sure what year your machine is. Your start button should send ground when you press it. You should have a ground signal on the Red/white wire from your start button to the soleniod. The blue/white at the soleniod is power that comes from the inhibit relay. The inhibit relay needs a signal from the CDI to let the machine start. this is a ground signal on the yellow/black wire. My guess is you're not getting a signal from the CDI because of a safety switch. Just jump the Brown and Blue/white wires at the inhibit relay and as long as you're getting ground from the start button it should start. Using a test light for this kind of troubleshooting can be tricky because your light may light up from the voltage passing through the soleniod and not because there's power there. In other words, you may not have power at the button, you may be seeing the power coming into the soleniod on the blue/white, traveling through the soleniod coil and then up the red/white to the button. It's not as complicated as it may sound, start at the button, look for a ground. If you're not getting a ground signal out that's your problem. If you are getting ground out of the button, it's your starter inhibit relay. hope this helps you.
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post #9 of 9 Old 02-05-2012, 01:20 PM Thread Starter
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i am thinking it is the wires coming from behind where the pull start panel is. Ill try jumping those two together and see if it works. This one is a 87-88 model
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