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Help Zeal Indicators/Brake Lights not working - It's not the fuses...

Discussion in 'Maintenance' started by james1234, Nov 27, 2016.

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  1. james1234

    james1234 Member

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    Hi there!

    I've got no indicator or brake lights going on my Yamaha Zeal 250.

    Fuses are all fine, horn still works, engine starts and bike rides fine. Lights on the front panel (neutral/hi-beam/overheat) work fine. The head light's working on hi beam only (but I think that's a faulty bulb/the low beam has died somehow.)

    The bike konked out a few weeks ago, and it just turned out the battery was a POS. Replaced the battery and it's going fine besides these new issues.

    What do I check next? Could it be a faulty charging system or something similar? I've had like 3 head lamps go in the last year, so I'm thinking this could be related....

    Cheers :)
     
    james1234, Nov 27, 2016
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  2. james1234

    james1234 Member

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    I reckon it could still be a fuse issue - even though they're all visibly fine.
     
    james1234, Nov 27, 2016
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  3. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    With the headlights blowing and now no indicator or brake lights, I'd suggest you have a faulty reg/rec. I had this on my zeal and it overcharged the battery, blew every globe on the bike and killed the tacho, along with all the fuses. This happened 10PM at night on my way to Sydney. I also had recently replaced the TCI box which thankfully survived the bad regulator.

    The reg/reg is under the right hand side panel just below the riders seat. It's the same unit as the FZR250 and FZR400 and perhaps others. Would recommend finding a new place for it to live as under that panel it doesn't get any airflow and they tend to die.

    http://www.ebay.com.au/itm/YAMAHA-R...AGO-XV250-1989-FZR600-1989-1993-/282168503559

    http://www.ebay.com.au/itm/Voltage-...-TW125-TW200-XT600-FZR400-XJ400-/232078824917

    They are cheap and easy to replace. Test the charging voltage with a multimeter and let us know what the max voltage you see is.
     
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    Linkin, Nov 27, 2016
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  4. james1234

    james1234 Member

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    Okay, I have it out! But no multimeter at home. Time to google how to rig one up or buy one tomorrow..
     

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    james1234, Nov 27, 2016
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  5. james1234

    james1234 Member

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    Man that's ******* scary to have it happen on a long trip. I've had a headlight blow at dusk out in the bush and ever since I've never left home without a spare.
     
    james1234, Nov 27, 2016
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  6. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Go to your local Jaycar shop or stockist and buy the cheapest multimeter they have. The test is simple - set the meter to DC Voltage and put the leads on the battery terminals with the bike running. Set the meter somewhere and slowly increase the revs and watch the voltage. The service manual will state the maximum voltage. Generally speaking 14.4v will be the max safe charge voltage with the bike running.

    When you have a multimeter you can also check the condition of the stator/ac magneto
     
    Linkin, Nov 27, 2016
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  7. james1234

    james1234 Member

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    Ah. So I'll have to reinstall the reg/rec haha. Thanks for the taking the time to write that up. So if it exceeds the max voltage, then the reg/rec is buggered?
     
    james1234, Nov 27, 2016
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  8. james1234

    james1234 Member

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    Also, replacing the reg/rec won't fix those lights then, right? Could they have all blown? I imagine I can also check all the fuses properly using the multimeter then.
     
    james1234, Nov 27, 2016
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  9. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Yeah new reg/rec only fixes the high voltages causing the globes to blow. Just take the blown globes out and go somewhere like supercheap auto and buy a box of each. They are very common across bikes of all makes.
     
    Linkin, Nov 27, 2016
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  10. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    And for headlight globes, don't get phillips ones, they are shite
     
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  11. james1234

    james1234 Member

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    Okay! I'm getting >17V. And all the lights were blown, and work upon replacement. Do I need to replace the Reg/Rec? :/
     
    james1234, Nov 29, 2016
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  12. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Yes! Don't run the bike until you can get the reg/rec replaced. Blowing globes is lucky. Being unlucky means worse
     
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    Linkin, Nov 29, 2016
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  13. james1234

    james1234 Member

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    Cool! Won't run it until I've got a new reg/rec in there. Just to be sure - would the bike have started/ have a 17v reading if there was no reg/rec installed? (i.e if I didn't reinstall it properly.)

    This is how I installed it:

    [​IMG]
     
    james1234, Nov 29, 2016
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  14. james1234

    james1234 Member

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    Could it also potentially be the stator? Is there a way to check if the reg/rec itself is buggered? I tried searching up for tutorials but only found ones with this kind of wiring:
     
    james1234, Nov 29, 2016
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  15. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    The reg/rec on the zeal has a single white plug where it goes into the wiring harness and a black wire with a ring terminal that connects to the frame and backing plate of the reg/rec.

    If the reg/rec was not connected you would either be running direct loss from the battery, or pumping AC voltage into your electrical system. I assume that Yamaha are smart enough to stop the latter from occuring when the reg/rec is unplugged.

    Here is the wiring diagram for the zeal

    [​IMG]
     
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  16. james1234

    james1234 Member

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    Also, I have to clear a silly vicroads defect notice for having no signals (as they were blown..), by Friday. If I replaced the globes and took it down for an inspection, and just removed the reg/rec for the little ride, would that do any damage besides discharging the battery? Not 100% sure I can source the reg/rec before I have to clear the notice.
     
    james1234, Nov 29, 2016
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  17. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    my67xr, Nov 29, 2016
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  18. james1234

    james1234 Member

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    Ha! No car, not trailer, unfortunately. Wonder how much damage I'd do with a 20min ride to vicroads and home. I've got until the 24th to take it to vicroads, but it can't be ridden from the 4th. There's a guy on the forums with a spare reg/rec, so hopefully he responds asap - otherwise it's just a shitty situation because I have no trailer. I'm not even in any rush to get it sorted as I'm coping fine with the bicycle for the time being...
     
    james1234, Nov 29, 2016
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  19. james1234

    james1234 Member

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    james1234, Nov 29, 2016
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  20. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    No bike wrecker's near you?
    The one used on the FZR is the same as your's
    I replaced mine with one of an R6 Yamaha, just needed to modify the wiring into the reg/rect, the one i bought was second hand and cost me $40

    I have a spare genuine Yamaha used reg/rect which came with a spare engine i bought, i'll measure it tomorrow with the multimeter and check it's ok,
    if it is and you want it i'll sell it to you and can send it express post to you for $25 all up.
     
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    my67xr, Nov 29, 2016
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