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Help FZR250 Temp gauge rises when lights are turned on?

Discussion in 'Yamaha 250cc In-Line 4's' started by Brandon Otte, Mar 12, 2020.

  1. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Yes there is only 1 main earth i can see on my 2KR harness, it's around the seat area, medium diameter Black wire with a ring terminal on the end.
    The Black wire come's out of the main harness at the same point as the 3x white stator wire's
    When i was looking at the loom and taking some measurement's, i found i had 70 Ohm's resistance in the black earth wire, i cleaned up the ring terminal with a brass wire brush and now it has none

    When you've cleaned up the ring terminal make sure you also clean the frame or engine where it screw's/bolt's on so it contact's clean bare metal.
    Use some dielectric grease on the bare metal and terminal to help prevent corrosion
     
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Have u checked the main earth wire from the battery to the motor? I guess the 2KR will be the same as the 3LN ..... on the 3LN the frame earths from the motor being bolted to it but u can always run another decent earth cable from the battery to somewhere on your frame close by
    The points of contact have to be shiny bare metal

    My 3LN earth cable, battery to the motor

    earth.png
     
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  3. Brandon Otte

    Brandon Otte Well-Known Member

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    I haven't checked the main earths yet, wasn't sure what to look for but now I know, thanks @my67xr @GreyImport.
    I'll check them tomorrow morning after getting some dielectric grease, need some for the reg/rec I installed the other day too.
     
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  4. Brandon Otte

    Brandon Otte Well-Known Member

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    @my67xr where did you test the resistance through? Did you disconnect the earth wire off the frame and measure from the wire back to anywhere else on the frame or..?
     
  5. Brandon Otte

    Brandon Otte Well-Known Member

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    If I go direct to the frame and there's no improvement would it be safe to say the main earth wire is to blame or at least needs some attention? I'll try that first before checking the main earth wire just for reference. Cheers
     
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  6. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I measured from the main harness earth ring terminal right up to the temperature sender unit black wire, and to the black wire for the headlight's and dash light's etc
     
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    Last edited: May 8, 2020
  7. Brandon Otte

    Brandon Otte Well-Known Member

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    @my67xr awesome I'll post tomorrow morning my findings. Cheers :neo:
     
  8. Brandon Otte

    Brandon Otte Well-Known Member

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    Hey guys so I've wired in an extra earth wire from both headlight plugs to the frame and tested the gauge with lights on etc and she's not jumping as we all expected. I tested the resistance from the earth behind the temp gauge to the battery negative and it read 0.5 with the multi meter set to 200. I also removed and cleaned up the main earth wire from the battery negative to the engine and applied dielectric grease. Tested again and made no difference. Not sure exactly how many ohms 0.5 on the 200 scale reads but I'm sure you guys will.
    I've applied dielectric grease to the reg/rec and all the wiring contacts I've been playing with to the frame etc.
    So now I'm just letting her cool down and will flush the coolant system with 1/3 cleaning vinegar and 2/3 distilled water. I'll flush a couple times doing a heat cycle between each, I'll then flush it one last time with only distilled water before draining it and filling with coolant.
    I'll then take her for a ride and report back how the temp goes.
    The wiring is semi-temporary as I'm waiting on wire crimp fittings and a new tip for my soldering iron.
     
  9. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    FWIW - you can leave the vinegar & distilled water in there for many heat cycles, it's very mild, so as not to be too corrosive, so don't expect miraculous, immediate results.
    Just a way to save you some distilled water costs.

    I left it in my Subaru for ~1K KMS, but it did those 1K kms quite quickly timewise travelling interstate

    I am amazed that the earth on the gauge into the wiring harness was influencing that reading - perhaps there is some sort of comparison measurement going on inside the gauge with respect to what should be a straight ground value.

    0.5 OHMs may as well be the measurement of the wire itself, copper does have a resistance usually quoted as per metre - check that the meter reads zero when you connect just the leads together, often they don't as that measurement includes the meter leads themselves

    Anyway, it's such a small value, it's nothing to be concerned about

    Very interested to hear how the temp range is...do you have an actual, complete, i.e. not dismembered, thermostat in there right now?
     
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  10. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Sorry me again, lazy bastard. So how does the voltage dropping below 12 affect the meter? With the lights on, at what rpm does the charging system balance, meaning the amps are not negative?
     
  11. Brandon Otte

    Brandon Otte Well-Known Member

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    Ah okay I was under the impression that vinegar would do harm to any aluminium if left for a period of time. I’ve done two flushes so far, the first flush drained was very rusty and am just waiting for it to cool down before I drain it again and flush it with only distilled water.
    Yup the thermostat housing and thermostat in there atm is all complete.
    Ah that’s good news about the resistance - clearly not that clued up about reading ohms.
    Here’s a photo of the first flush fluid once drained, I’ll upload the next later tonight.
    The temp doesn’t get higher than half way now btw even with the fan off so looking positive.
     
  12. Brandon Otte

    Brandon Otte Well-Known Member

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    First two photos are the new earth wires.

    F5C67455-7293-4695-A4DC-40721C435421.jpeg F3FD6F71-3B3C-4207-ADD0-A5DB0A663E40.jpeg C809EA0C-F780-4BF7-96F1-41377E1907D5.jpeg
     
  13. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    For your final flush take the hose off the water pump and get the garden hose to give it a good flow through both ways and with the rad cap off. Then use your coolant.
     
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  14. Brandon Otte

    Brandon Otte Well-Known Member

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    No idea too be honest, what I imagine is there’s a poor earth somewhere in the loom and when I turn the lights on it’s drawing more current via the gauge earth and or sensor wire causing the gauge to read higher - or better yet WAS and no longer is with many thanks to 2fiftycc and everyone who’s been helping me along the way!
    Since running extra earth wires from the headlights to the frame there’s no longer any issue with the gauge and as I type the final flush is cooling before I drain it and fill with coolant. Here’s a photo of the second flush fluid.
    F42BA2B6-7B6B-463E-976B-2D0419F25DEC.jpeg

    The green container doesn’t help with imagery but it’s a lot cleaner than the first. The final is only distilled water which I’ll drain into a clear or white container.
     
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    Last edited: May 9, 2020
  15. Brandon Otte

    Brandon Otte Well-Known Member

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    From the water pump up and the radiator cap down?
    I take it the coolant will neutralise any unwanted ‘stuff’ in the tap water?
     
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  16. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Correct.
     
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  17. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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  18. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Did you clean up the earth ring terminal for the main harness to the frame?
     
  19. Brandon Otte

    Brandon Otte Well-Known Member

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    Yeah I cleaned it up so it was shinning, same with the bolt and where it meets the frame and also used dielectric grease. I know it's rough atm but with level 3 here in NZ it's a massive pain to get the parts I need to do it properly.
     
  20. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    You could add another earth wire from the frame to the engine too if you want.
    The frame earth rely's on the engine mount bolt's and earth from the battery to give it a good earth
     
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