Electrical problems

53 Battery dead or weak

Battery faulty. Battery life should not be expected to exceed 3 to 4 years, particularly where a starter motor is used regularly. Gradual sulphation of the plates and sediment deposits will reduce the battery performance. Plate and insulator damage can often occur as a result of vibration. Complete power failure, or intermittent failure, may be due to a broken battery terminal. Lack of electrolyte will prevent the battery maintaining charge.

Battery leads making poor contact. Remove the battery leads and clean them and the terminals, removing all traces of corrosion and tarnish. Reconnect the leads and apply a coating of petroleum jelly to the terminals.

Load excessive. If additional items such as spot lamps, are fitted, which increase the total electrical load above the maximum alternator output, the battery will fail to maintain full charge. Reduce the electrical load to suit the electrical capacity.

Regulator/rectifier failure.

Alternator generating coils open-circuit or shorted.

Charging circuit shorting or open circuit. This may be caused by frayed or broken wiring, dirty connectors or a faulty ignition switch. The system should be tested in a logical manner. See Section 60.

Rectifier/regulator faulty. Overcharging is indicated if the battery becomes hot or it is noticed that the electrolyte level falls repeatedly between checks. In extreme cases the battery will boil causing corrosive gases and electrolyte to be emitted through the vent pipes.

Battery wrongly matched to the electrical circuit. Ensure that the specified battery is fitted to the machine.

55 Total electrical failure

Fuse blown. Check the main fuse. If a fault has occurred, it must be rectified before a new fuse is fitted.

Battery faulty. See Section 53.

Earth failure. Check that the frame main earth strap from the battery is securely affixed to the frame and is making a good contact.

Ignition switch or power circuit failure. Check for current flow through the battery positive lead (red) to the ignition switch. Check the ignition switch for continuity.

56 Circuit failure

Cable failure. Refer to the machine's wiring diagram and check the circuit for continuity. Open circuits are a result of loose or corroded connections, either at terminals or in-line connectors, or because of broken wires. Occasionally, the core of a wire will break without there being any apparent damage to the outer plastic cover.

Switch failure. All switches may be checked for continuity in each switch position, after referring to the switch position boxes incorporated in the wiring diagram for the machine. Switch failure may be a result of mechanical breakage, corrosion or water.

Fuse blown. Refer to the wiring diagram to check whether or not a circuit fuse is fitted. Replace the fuse, if blown, only after the fault has been identified and rectified.

57 Bulbs blowing repeatedly

Vibration failure. This is often an inherent fault related to the natural vibration characteristics of the engine and frame and is, thus, difficult to resolve. Modifications of the lamp mounting, to change the damping characteristics may help.

Intermittent earth. Repeated failure of one bulb, particularly where the bulb is fed directly from the generator, indicates that a poor earth exists somewhere in the circuit. Check that a good contact is available at each earthing point in the circuit.

Reduced voltage. Where a quartz-halogen bulb is fitted the voltage to the bulb should be maintained or early failure of the bulb will occur. Do not overload the system with additional electrical equipment in excess of the system's power capacity and ensure that all circuit connections are maintained clean and tight.

YAMAHA H 610/110

Check list

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