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payne

Yamaha Bear Tracker 250 Where to start?

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Ok so i spent a little time going through the diagram and highlighted some stuff. 

Im going to try to explain as best as i can since its been a while with a Yamaha for me.  
#4 battery/power goes to #3 (orange highlight) main switch and also to the rectifier.  When it leaves the main switch the wire is brown (purple highlight) sends 12v positive to the #13/12 indicator lights for the neutral and reverse. NOW they need a ground source for them to come on. Thats where the neutral safety switch #14 (green) comes into play as well as the reverse #15 switch. 
When you shift the atv into neutral it grounds the sky blue wire thats on the neutral safety switch (green highlight) and sends that ground to the neutral indicator light and the light comes on.   The sky blue wire also splits off to the starter safety circuit relay 
#8 (pink highlight) and gives that relay a ground as well. That relay also already should have a 12v positive power source from the cdi box #9 (red/white stripe) wire color. Check that wire for power with the key on.  By these two wires 
(sky blue -)and (red/white stripe+) giving that relay power it closes the starter circuit relay and sends power to the dashboard and start button. 
ALSO important is the rear brake switch #16 (blue highlight) it has to be pulled in for the bike to crank as well. At least it did on mine. It was located on the left handlebar brake lever. 
Make sure that switch is there and working.  
 
Testing:  
You can take a piece of wire and jump the blue/white stripe  and the red/white stripe going to #8 safety starter relay for a second and see if you get dash lights and see if the starter button  works but since it sounds like your starter is stuck or bad you would have to keep a tester or test light on the wire at the starter to see if the starter button works and is in fact sending power to the starter. 
YOU SHOULD also hear a clicking from the starter relay if the start button works.  
 
 
Try to tap on the starter lightly with a  rubber mallet or hammer to maybe free it up while cranking but be gentle.  
 
Also,
Pull the safety starter relay out and make sure its clean and wires are good. Take apart all the wiring one at a time and clean and plug or reconnect so you don't get them mixed up. 

I circled the starter safety relay in light blue, that relay has the blue white stripe and res white stripe to jump. 
 

I hope this helps and let me know how it goes.   
Good luck brother.  
 

 

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7 hours ago, Frank Angerano said:

Ok so you may have a bad starter as well with the other things.  
First thing i would do is reconnect the neutral safety switch and reverse wires. 
Take a tester and put it on the wire going to the starter.  Jump the coil again and see if you get voltage at the starter.  If so the starter has either bad brushes or its no good.   You may be able to pull the starter out and clean and bench test it.  
 

As far as the 12v going to the starter relay thats a good thing.
The starter circuit relay is the next plug you see by the starter relay.   I circled in yellow. 
After you reconnected the neutralimageproxy.php?img=&key=146d28d1ce7626ea safety switch and reverse wires i want you to take a tester and see what you have on that plug as far as power goes.  See if any of the wires have power with the key on.   If any have power let me know.  
Timageproxy.php?img=&key=146d28d1ce7626eahen set your tester to continuity and see if any of the wires have continuity from the negative terminal on the battery to any of the wires in that plug.  What im trying to see is if any of the wires going to that plug have a ground source.  imageproxy.php?img=&key=146d28d1ce7626ea

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Grounded both neutral and reverse wires. Got both light to light up. Checked for 12v on the wires going into started circuit relay (circled in yellow) no power was detected. The other 3 wires had continuity to negative post on battery. 

I connected 12v with test light to red/w white stripe wire and the relay buzzes al over the place, but to cranking from starter. 

 

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Ok thats progress.  Did you reconnect the neutral safety and reverse wires to the switches to see if your dash lights come on?  If not do a continuity test from ground to the probe on the neutral safety switch while the bike is in neutral.  If you do NOT get a reading then the switch is most likely bad.  
Have you tried to jump the two wires on the starter relay like i mentioned and hit the start button to see if the starter relay clicks?

And don't forget to have a tester on the wore of the starter to see if your getting voltage when trying to crank.   

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I didnt reconnect them yet, but I will once I can get it to crank. Believe you wanted me to jump blue w/ white and red w/ white? I did that and nothing happened.

Red with white should have 12v correct? If yes, than that explains why nothing happened when I jumped them. 

8 hours ago, Frank Angerano said:

Ok so you may have a bad starter as well with the other things.  
First thing i would do is reconnect the neutral safety switch and reverse wires. 
Take a tester and put it on the wire going to the starter.  Jump the coil again and see if you get voltage at the starter.  If so the starter has either bad brushes or its no good.   You may be able to pull the starter out and clean and bench test it.  
 

As far as the 12v going to the starter relay thats a good thing.
The starter circuit relay is the next plug you see by the starter relay.   I circled in yellow. 
After you reconnected the neutralimageproxy.php?img=&key=146d28d1ce7626ea safety switch and reverse wires i want you to take a tester and see what you have on that plug as far as power goes.  See if any of the wires have power with the key on.   If any have power let me know.  
Timageproxy.php?img=&key=146d28d1ce7626eahen set your tester to continuity and see if any of the wires have continuity from the negative terminal on the battery to any of the wires in that plug.  What im trying to see is if any of the wires going to that plug have a ground source.  imageproxy.php?img=&key=146d28d1ce7626ea

98376F90-F507-4CF3-B0D3-A7A4F4412E1A.jpeg

Grounded both neutral and reverse wires. Got both light to light up. Checked for 12v on the wires going into started circuit relay (circled in yellow) no power was detected. The other 3 wires had continuity to negative post on battery. 

I connected 12v with test light to red/w white stripe wire and the relay buzzes al over the place, but to cranking from starter. 

 

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Yes that relay needs power to close and need to get it from someplace. So when you grounded the neutral safety switch and reverse wires and lights came on the starter button did not make the starter relay click ? 

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12 minutes ago, Frank Angerano said:

Yes that relay needs power to close and need to get it from someplace. So when you grounded the neutral safety switch and reverse wires and lights came on the starter button did not make the starter relay click ? 

Yes, when grounded lights came on but button didnt engage starter. And there is no power coming from red and white wire.

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Ok but any click coming from the start relay? 
Put a tester on the the relay and and check each wire for power on the small plug when you hit the start button.   
 

One test lead on the ground and the other test lead on each wire one at a time. Press the start button and see if you get any readings. 
Did you pull the brake handle in as well and check that it has wires coming from it ? 

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Oh, ok. So that red wire is only gonna be hot once the starter button is pushed?

Yes, brake handle is pulled, I'm confident the switch is in there, because the wires are still running out of it. 

Do these bikes only have 1 ground? I found the one under the battery tray a d is very corroded.

I will check for power to those wires when I get home.

The bike must have been left out in the weather because every screw, bolt and nut are corroded when trying to remove them.

Wanted to look inside of the kill/starter/headlight switch, but cant get the 2nd screw out to look at it.

Kill switch doesnt move, but its stuck in the on position.

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Posted (edited)

The kill switch is a common suspect with atvs that are left outside. Water gets inside and eventually fills and corrodes the inside. 
But if its in the on position and the engine starts like you said i think its ok for now. 

Try to use a bigger philips head  screwdriver on that screw for the kill switch.  If it still does not come out then drill out the head only and when you get the control off you can grab the rest of the stud with a pair of vice grips and spin it out.   
 

Take the ground wire off and clean it good and put it back on.  You may want to go get a can of dielectric grease clean and add it to all the electrical connections.  
 

So back to that red wire, it has voltage when you press the start button? If so thats good. 
Now do the same thing on the starter relay. Test all wires like we said in the last post and see if any get voltage when start button is pressed. This will tell you that the start button is working should you get power upon pressing the start button to any of those wires and thats a good thing if you do. 
  
Keep in mind a new relay may be needed and its cheap enough to get and easy to find.  I say this because if you get power to any of the wires on that relay when you press the start button means the relay is getting power and it should click. UNLESS there is a ground issue and that will be the next step.   
 

Back to the starter, i feel like you should disconnect the starter if its bad. Once you get that relay to click its going to send power to the starter and if you jumped the wires like you said and that starter is not  moving you could burn wires up so be careful.
 

Edited by Frank Angerano
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I will check for power to those wires when I get home.

The bike must have been left out in the weather because every screw, bolt and nut are corroded when trying to remove them.

Wanted to look inside of the kill/starter/headlight switch, but cant get the 2nd screw out to look at it.

Kill switch doesnt move, but its stuck in the on position.

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7 minutes ago, Frank Angerano said:

The kill switch is a common suspect with atvs that are left outside. Water gets inside and eventually fills and corrodes the inside. 
But if its in the on position and the engine starts like you said i think its ok for now. 

Try to use a bigger philips head  screwdriver on that screw for the kill switch.  If it still does not come out then drill out the head only and when you get the control off you can grab the rest of the stud with a pair of vice grips and spin it out.   
 

Take the ground wire off and clean it good and put it back on.  You may want to go get a can of dielectric grease clean and add it to all the electrical connections.  
 

So back to that red wire, it has voltage when you press the start button? If so thats good. 
Now do the same thing on the starter relay. Test all wires like we said in the last post and see if any get voltage when start button is pressed. This will tell you that the start button is working should you get power upon pressing the start button to any of those wires and thats a good thing if you do. 
  
Keep in mind a new relay may be needed and its cheap enough to get and easy to find.  I say this because if you get power to any of the wires on that relay when you press the start button means the relay is getting power and it should click. UNLESS there is a ground issue and that will be the next step.   
 

Back to the starter, i feel like you should disconnect the starter if its bad. Once you get that relay to click its going to send power to the starter and if you jumped the wires like you said and that starter is not  moving you could burn wires up so be careful.
 

I believe the state is fine. I have  connected the starter directly to a battery and it turns and starts the quad no problem. Just not with the start button.

I checked those wires earlier, but not with the button pushed in though. I will do that and let you know what I get.

Thanks for all your help. Are we able to message directly to one another on this forum?

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If you know that starter is working thats great. But the starter should have cranked when you jumped the two big lugs on the starter relay. Definitely take the wires off that relay and clean asap and see what you get. If that battery is good then you should get a crank by jumping the wires. 
And check that ground for a good connection. 

 

 

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Removed and cleaned terminals on really, reconnected and jumped them out. Still no crank. Also none of the wires on the other realy are getting power when the button is depressed.

Thinking maybe the starter switch is bad?

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Also, took apart starter switch assembly and verified no power going to it. 

Jumped out both wires at the switch and nothing

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What color wires do you have at the control? Post a few pics.

Should be a red wire and that should be coming from the main fuse block.  You should trace that wire back to the fuse.  

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Ok so start to trace that wire back to the source.  If you have to pull plastics and start exposing the harness do so.  You can also do continuity testing.  Find that same wire on the other  side and put the tester on each end.  Tester on continuity / ohms setting 

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Should the orange wire have 12v when the key is on?

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Orange wire has power now, I found a broken wire.

Red wire going to key was nearly broke

15837092948318438392615353589613.jpg

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Now when I jump the 2 wires at the starter switch, the relay clicks but starter isnt cranking

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Ok so relay clicks is a great thing.  I would remove, clean and reconnect all wires going to the starter and try that again.  

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