YBR 125 06 - Keep popping fuse.

[nelly18]

Long story short:

Yamaha YBR 125 (56 plate)
CDI had to be replaced just before bike's 1st MOT last October. Bought a 2nd hand CDI and it worked fine, got it through MOT.
Couldn't use bike over the winter. Sat in garage for most of nov - jan. Started using it again when better weather returned. Suddenly began to stall or refuse to start. Bought a new CDI thinking the 2nd hand one was done. Made no difference. Couldn't rely on it starting. Took it to garage, bloke cleaned carb and changed oil. Wouldn't start when i went to collect it. Bloke was well embarrassed! He kept it for another week to sort out intermittent starting problem. Said it was needing a new ignition barrel. Took bike home. Sent for new ignition barrel. Couldn't get a hold of garage to fit it. Partner decided to fit it.

Major difficulty Number 1: the new ignition had a different connector. Old one has 4 spades within plastic connector. New one had 3 spades within plastic connector with a stand alone metal rounded end on the black/white wire.
Partner painstakingly put a new spade on the black/white wire and removed the 4spade plastic connector and put the new wires into it.

Now it keeps blowing the 15amp fuse. Each wire meets it's corresponding coloured wire so can't think what the prob could be.

Any ideas? I'm running out of time to do my test here! I think I've been out a half dozen times since October. Getting well peed off!

I'm at the end of my tether and seriously thinking about getting rid of the flaming thing. Help!

[TUG]

Urm you've fitted an ignition barrell with the wrong pin to the bike and bodged it now it keeps blowing fuses?
Is it a genuine one or an after market one?
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Haz ER-5, innit!

[nelly18]

I ordered the ignition barrel for the 06 bike and that's what was sent. I thought the online shop had sent the wrong one but every site i've checked has the 3pin connector with the black/white wire separate.

Is what genuine? The new part is a genuine yamaha part. As for the bike, i'm beginning to seriously doubt it's credentials!

[Paxovasa]

[Vincent]

Your problem might not be the ignition switch - could be that you have a short somewhere. Check all the wires inside the headlight and inspect the loom where it runs down the headstock to make sure it hasn't got snagged in the steering locks. One way to test this might be to hot-wire the ignition and see if it still blows the fuse. If you don't have the wiring diagram but still have your old ignition switch you can find out which wires need to be conected to hot wire it.

[nelly18]

Bloke at the garage said he tried all the wires and did the hotwire thing too. He reported that it needed a new ignition. I've checked on internet and the 2005 -06 ignition and the 07-08 ignitions look the bleeding same.

[TUG]

I think i know what it is. You have a broken wire to your ignition, it can be fixed by removing and replacing that wire with one of a similair colour and thickness.
Now if i am correct this would cause it not to start and possibly short or spark. Like stated you need to take it apart and make sure every connection is clean, connected and in Good working order.
Where are you located if local to me i'll gladly come and help.
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Haz ER-5, innit!

[Vincent]

Could it be a foreign bike, some countries don't have the parking light or have the ignition so that the light is constantly on. Although you would have thought that if there's the same amount of wires and they're corresponding colours that it'd be ok The last ignition I bought had one wire seperately but it wired up and worked ok.

[TUG]

It is an odd one this tbh, They do break wires easy, but its finding it thats difficult, if you pull at it with your little finger and its already broken the plastic cover will snap, hey presto, thats your broken wire.
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Haz ER-5, innit!

[nelly18]

Thanks for all your help folks. It's given my partner somethings to mull over!

Tug, ta for the offer but your'e a wee bit too far away. We're Edinburgh. Appreciate the offer tho'

[nelly18]

It's now some months since I first posted my query. The bike has finally been fixed. Apparently, the ignition barrel was wrongly wired - a manufacturing fault! Sadly, i've been unable to get out on it since May and my CBT runs out in a month. Gonna cost me to do it all over again! Ah well.....

[N cee thirty]

ah abit of a fail,least you have the bike working now though
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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[HD]

Take your proper bike test
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Rusty '02 Vito Camper + CBR600F3

[Polarbear]

[Krimvarkie]

[dadioles]

I have just been through a similar process with my 2008 YBR125 custom.
The replacement ignition switch looked identical but the wiring was different.
You need to look very carefully at the wiring diagram for your specific bike and use a meter to check that the right wires are switching when the key is in the on and off position.
In my case the wiring diagram shows that in the off position no wires should be connected and in the on position pair 1 (red and brown) should be connected and pair 2 (black and black/white) should be connected.
The switch supplied to me as being the right one blew the fuse.
The wiring inside the switch was completely wrong.
When switched on, one pair connected and when switched off the other pair connected. Even worse it was the wrong wires making up each pair.
That is despite the switch looking right and having the correct type of connector.
So go back to basics and check that the switch is switching the appropriate contacts, assume nothing.
Now I have to try and resolve how to get the right switch as everyone seems to be selling the same thing.