A forum for owners of Yamaha TTR250 trail and enduro bikes!

petenz · Super Guru

striping down the TTR

petenz · Super Guru

The loom has nothing to plug into these wires that are the power
to trigger the starter relay...

-- Edited by petenz on Sunday 13th of October 2013 04:59:56 AM

petenz · Super Guru

It's a ignition only loom...
Theres no starter curcuit.. No plug in the loom to power the starter relay up..
Theres also no power feed to the battrey for the charge current..
the only wires to/from the battrey are earth to the motor & positive
to the starter relay.. the positive wire with the 15A fuse has no wire in the
loom to plug it into.. Pretty sure it won't charge the battrey...
There is NO connection from the battrey to the loom.. either pos or neg
Even thow it has a few of the other componts there they don't do anything..

it dose spark with or with out the battrey..

EDIT.........

Going by the wireing dia you posted...

to get charge current to the batt... looks as if I have to run a wire from the red wire

on the reg/rec to the red wire from the batt with the fuse in it...

-- Edited by petenz on Sunday 13th of October 2013 06:47:54 AM

petenz · Super Guru

It's not to bad once opened up....
add a couple wires & remove the crimp joiners...
Ignition is all there , charge curcuit only requires one wire to the batt...

theres no start curcuit at all even though the diode is there..

-- Edited by petenz on Sunday 13th of October 2013 09:07:47 AM

-- Edited by petenz on Sunday 13th of October 2013 09:16:30 AM

-- Edited by petenz on Sunday 13th of October 2013 09:18:54 AM

petenz · Super Guru

TT-R250M wrote:
The area circled in the pic below is your starting circuit, all it needs is to be plugged into the starter relay somehow. The plug shown in circles could be this plug but I'm unsure how it is wired from the pic??

the plug in the circle is the diode according to the wireing dia colour codeing & plug shape....

blue/white wire AC current / red/black wire DC current & 2 pins at 90* to each other..

-- Edited by petenz on Sunday 13th of October 2013 10:09:14 AM

-- Edited by petenz on Sunday 13th of October 2013 10:10:16 AM

TT-R250M · Super Guru

From looking at the harness that you bought it shows the starter diode.

Wiring loom comparison.jpg

The starter relay is separate to the main wiring harness and plugs in like so...

Jarrah

TT-R250M · Super Guru

I can't see the picture but this wiring diagram may help???

TT-R250M · Super Guru

Here is another picture that may help???

I cannot see how you wired it properly from your picture, maybe you could take one and add what wire is joined to where??

Jarrah

petenz · Super Guru

With the wireing dia you posted...
I think I will have to strip the new loom out
and go over it....
Remove all the messy crimp conectors in side it & soilder every thing up..

TT-R250M · Super Guru

The charging circuit is easy- AC current comes from the stator (three white, the red one is for DC current) then goes through the Rectifier/Resistor, through a 15a fuse and to the battery. It also joins to the ignition circuit to power the coil.

Without the Rectifier/Resistor you will not be able to run the bike without a battery. It needs DC (direct current) current which it receives after going through the Rectifier/Resistor, before this it is AC current (alternating current) and will NOT run the ignition.

The starting circuit uses AC and DC current, the DC needed to run the starter motor and the AC to trigger it. The AC needs to join to the DC circuit via a Diode or it will burn the wiring out and blow fuses. AC current cannot touch DC! The red battery lead joins to the positive side of the starter relay and has a small wire leading to the fuse, the black battery lead earths to the motor and has one small black wire that joins to the main earth at the harness. The starter relay also has a plug that plugs into the starter diode. One side of this plug will be AC power leading from the start switch and the other is DC current leading from the On/Off switch.

Hope that helps?

Jarrah

TT-R250M · Super Guru

petenz wrote:
With the wireing dia you posted...
I think I will have to strip the new loom out
and go over it....
Remove all the messy crimp conectors in side it & soilder every thing up..

Good idea and good luck!

Jarrah

TT-R250M · Super Guru

The area circled in the pic below is your starting circuit, all it needs is to be plugged into the starter relay somehow. The plug shown in circles could be this plug but I'm unsure how it is wired from the pic??

TT-R250M · Super Guru

petenz wrote:

the plug in the circle is the diode according to the wireing dia colour codeing & plug shape....
blue/white wire AC current / red/black wire DC current & 2 pins at 90* to each other..

I can see that, I'm talking about the plug that the arrow is pointing to below, but it seems to be your handlebar switch plug...

petenz · Super Guru

TT-R250M wrote:

petenz wrote:

the plug in the circle is the diode according to the wireing dia colour codeing & plug shape....
blue/white wire AC current / red/black wire DC current & 2 pins at 90* to each other..

I can see that, I'm talking about the plug that the arrow is pointing to below, but it seems to be your handlebar switch plug...

it is for the handle bar switch block... start button / kill switch... it has 4 pins..

starter relay has a 2 pin pug... there no plug on the loom that fits the starter relay plug...

TT-R250M · Super Guru

Basically, this is what you need to do...

Run two wires from the starter diode (as pictured above), the blue with a white stripe is AC current and goes to the starter relay low voltage wire plug, the red with a black stripe is DC current, this needs to go to the other low voltage wire at the starter relay. The high voltage cables do the rest as pictured below..

TT-R250M · Super Guru

This is more detailed but it may be harder to understand??? confuse The high voltage wires I have made larger than the low voltage so it is easy to define between the low voltage wires. Also, the black earth wire circled in green needs to be longer so it reaches from the battery to the main earth at the regulator..

Hope that helps?

Jarrah

petenz · Super Guru

TT-R250M wrote:
This is more detailed but it may be harder to understand??? The high voltage wires I have made larger than the low voltage so it is easy to define between the low voltage wires. Also, the black earth wire circled in green needs to be longer so it reaches from the battery to the main earth at the regulator..
Hope that helps?
Jarrah

kool... we are thinking along the same lines.... must work...

TT-R250M · Super Guru

petenz wrote:

kool... we are thinking along the same lines.... must work...

Well you know what they say- great minds think alike. biggrin wink

Glad you could understand that as most would have trouble.

Enjoy!

Jarrah

petenz · Super Guru

Jarrah....
run your eye over this & see if I have missed anything before I wrap it up..

(the earth symbol should be Neg to the battery...)

Should be a working loom now...
Ignition / Charge / starter curcuits.....

Hey Brian...
No probs.... It gave me a start point... I didn't have to cut up my loom
to get the plugs etc...

THIS SHOULD BE A WORKING BASIC LOOM...

-- Edited by petenz on Monday 14th of October 2013 10:33:07 AM

-- Edited by petenz on Monday 14th of October 2013 10:34:55 AM

-- Edited by petenz on Monday 14th of October 2013 10:37:27 AM

TTRfan · Super Guru

Sorry that the loom caused so many problems for you Pete - I had no idea!

Good job Jarrah is here to help you through the issues biggrin

You would do us a great service by getting some good pics of your finished loom wink

Brian

TT-R250M · Super Guru

According to the wiring diagram the wiring job you did is correct but if you have any problems let me know.

The diode with the ''?'' (part 1 of the starter diode) on it should have a blue wire, a light blue wire and a blue wire with a white stripe attached to each pin though and the diode should be a three way connector.

Jarrah

petenz · Super Guru

the one with the qustion mark on it... dose have a 3 way connector one of the wires has been
cut off.... I can't find it on the wireing diagram.. so I asume its for the full road legal version with
flashers / horn etc... I have no real idea what it dose... It was in there so I left it in...

TT-R250M · Super Guru

petenz wrote:
the one with the qustion mark on it... dose have a 3 way connector one of the wires has been
cut off.... I can't find it on the wireing diagram.. so I asume its for the full road legal version with
flashers / horn etc... I have no real idea what it dose... It was in there so I left it in...

If it is the light blue wire that is missing, don't worry about it, it doesn't need it.

That diode is part 1 of the starter diode. Without it you will not have a Neutral light so you will not be able to use your starter motor (contrary to the wiring diagram). The other diode is just there to stop it blowing fuses or burning the wiring out (like a resistor).

Jarrah

petenz · Super Guru

Yes it the light blue or sky blue ones that has been cut off...
There is no neutral light...

TT-R250M · Super Guru

petenz wrote:
Yes it the light blue or sky blue ones that has been cut off...
There is no neutral light...

Okay, good to go!

I only mentioned the Neutral light because the diode is before the Neutral light. It will make no difference whether you have a Neutral light or not, it will NOT electric start without the Diode marked with a ''?''.

Let me know how you go please.

Jarrah

TT-R250M · Super Guru

So you can understand better I have included the 3 way Diode into the following wiring diagram...

Oh, that sky blue wire that you are missing from the 3 way Diode is for the Neutral light (see diagram above).

Jarrah

petenz · Super Guru

The loom works...
Have ignition & starter... Charge? guess I will find out if I get a flat battery.....

Was bit of a worry for a couple minutes..No spark... just a bad connection
into the CDI plug..

TT-R250M · Super Guru

petenz wrote:
The loom works...
Have ignition & starter... Charge? guess I will find out if I get a flat battery.....

Was bit of a worry for a couple minutes..No spark... just a bad connection
into the CDI plug..

If you want to test the charging circuit, disconnect the positive battery lead (red) and kick-start it while testing the red wire leading from the R/R. This voltage should be around 12.8VDC.

The other method that works is to test without disconnecting the battery but this will interfere with the reading. It should be from 12-15VDC using this method.

If you don't have a multimeter, just disconnect the red battery terminal and kick-start or roll-start. If it starts and runs well, it must be charging.

Thanks for all the help (sarcastically) lol wink

Glad you got it sorted!

Jarrah

petenz · Super Guru

TT-R250M wrote:

petenz wrote:
The loom works...
Have ignition & starter... Charge? guess I will find out if I get a flat battery.....

Was bit of a worry for a couple minutes..No spark... just a bad connection
into the CDI plug..

Thanks for all the help (sarcastically) lol

Jarrah

LOL..... Did I not say thanks..... confuse

THANKS.........

............................................................................

TT-R250M · Super Guru

petenz wrote:
TT-R250M wrote:

Thanks for all the help (sarcastically) lol

Jarrah

LOL..... Did I not say thanks.....
THANKS.........
............................................................................

Cheers mate and thanks for keeping us updated

Jarrah