Yamaha virago 535 unknown problem (possible its electrical)

Max88 · L Plate Warrior Joined: 28 Jul 2021 Karma :

Hello there. I own a yamaha virago 535 that has ben running grate for past cuple of years since I've owned it. But a month ago it died during my ride due to dead battery. I've had some issues with charging. Had to change my stator and regulator and still wouldn't charge with the new parts. I struggled finding the problem so i took my bike to a "friend" mechanic to take a closer look. He called me after a few hours and told me to come and pick up my bike, he fixed it by changing the regulator again. Supposedly i had a shorted battery and that killed my new regulator. He told me everything is ok and charging and that I can ride home so I did... Little did i know nothing was apparently fixed and my new battery drained and I was stranded on the highway. Long story short I got it home. Changed the battery and did some test to see if it's charging and it wasnt. Only 12.5v.. And discovered that my fuse box was getting hot. Figured it must be a bad connection so I went and bought a new fuse box and hooked it up. Tried again of it would charge the battery still nothing. After that i was a bit frustrated amd left it for the day. The nex day the bike wouldn't fire up. There is no spark on the spark plugs and my light flickers. Also im hearing the clicking nose from the front left compartment where are all of the relays and i think thats where the CDI is located. (i will put i google drive link of the video in the bottom) that clicking is is synced to my head light flashing. I have all of those relays and a new CDI as spares from my old 535 and thought it something must be fried from the bad battery so i switched it all and everything is still the same. I'm out of ideas. I would greatly appreciate all the help I can get.

P. S
I'm sorry for my bad English and the long text. Below I will link the Google drive link for the video.

https://drive.google.com/file/d/18GivBLoZ9pdVgUaJHlgpAN4UaXgCscbU/view?usp=drivesdk

https://drive.google.com/file/d/18GivBLoZ9pdVgUaJHlgpAN4UaXgCscbU/view?usp=drivesdk

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Un-plug the HID driver first thing, see if it cures the clicking.

The clicking sounds like the flasher relay and the fact that it affects the headlight points to a bad power connection. The fuse box getting hot isn't good but it does point to the fault not being anything to do with charging since the charging circuit is not fused.

First thoughts are - bad earth on the loom or on the engine.

If you have a good copy of the wiring diagram I'll take a look at it for you but I bloody hate Yamaha wiring.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

Max88 · L Plate Warrior Joined: 28 Jul 2021 Karma :

Max88 · L Plate Warrior Joined: 28 Jul 2021 Karma :

Here is the wiring diagram that I have found

WD Forte · World Chat Champion Joined: 17 Jun 2010 Karma :

Bit of a crap diagram innit?
small and faded colour

From what I can see the 'flasher relay' is lot more than that
as its connected to more than the flasher switch.
I suspect it's perhaps a compound device containing various
devices not just a simple relay.
____________________
bikers smell of wee

WD Forte · World Chat Champion Joined: 17 Jun 2010 Karma :

Is this a troll?
that diagram is for post 89 Viagra where the diagram shows a
'flasher relay' with 9 cables.
( in earlier diagrams this is called a relay assembly)

in the vid he holds what looks like a more conventional 3 wire device
so wtf is going on?
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____________________
bikers smell of wee

Max88 · L Plate Warrior Joined: 28 Jul 2021 Karma :

A100man · World Chat Champion Joined: 19 Aug 2013 Karma :

The 'relay' in question is probably this tin of tricks, as found on several Yams inc my FZ750..

https://yamaha-virago.blogspot.com/2018/10/relays.html

.. it has several functions the most minor of which is flashing the indicators.
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Max88 · L Plate Warrior Joined: 28 Jul 2021 Karma :

Followup, i have discovered that once I disconnect the fuel pump the relay stops clicking, still no spark. But at least I think that I narrowed it that maybe my fuel pump was shorted? Looking forward for your opinions.

A100man · World Chat Champion Joined: 19 Aug 2013 Karma :

Max88 · L Plate Warrior Joined: 28 Jul 2021 Karma :

Clicking is solved. The fuel pump was faulty. Still not charging the battery tho :/

I have installed the new stator and regulator/rectifier Shocked

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

The battery is charged via the 20A fuse in the fuse box. Run the engine and put a volt meter on one side of the fuse then the other. If one side reads battery voltage and the other side reads charging voltage then the fuse is blown.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy