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Hi all!
Oh so happy to be here.
Building a wonderful TW for my girlfriend (Just a ploy for me to get more bikes honestly) and have reattached my wiring harness after painting the frame and put in a fresh, fully charged battery.
When I turn the key only the neutral light is lit and starter won't spin. Now this bike has been a kickstart only bike with a dead battery for a while, with a fresh battery should the headlights and taillight work with the key off? I'm sure the starter won't spin due to a poor ground somewhere,
just thought I'd check in and see if there is something I'm missing.

Thank you in advance
 

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Welcome to the board …..

The ’96 headlight won’t come on until the engine is running, though you should have all other lights working, including the tail light (with the key “on”)

If you have re-painted the frame, make sure that all “ground” points are clean of paint – not all of them re-connect back into the wiring loom

Check it through carefully – any problems and we’re here to help ….
 

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Welcome!! :D
 
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I’ve had a look at the wiring diagrams – (you’ll find them here - http://tw200forum.com/forum/technical-write-ups/70-service-repair-manuals.html - make sure you’re looking at the right one)

Seems like there’s quite a few “ground” points on the frame – make sure you get all of them

Another point to mention – don’t use “Locktite” on a “ground” point – it can insulate the connection …..
 

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Welcome to the board …..

The ’96 headlight won’t come on until the engine is running, though you should have all other lights working, including the tail light (with the key “on”)

If you have re-painted the frame, make sure that all “ground” points are clean of paint – not all of them re-connect back into the wiring loom

Check it through carefully – any problems and we’re here to help ….
Are you sure about this Purple? I think if memory serves me right, it often doesn't, on my 1991 when I turned the key on the headlight and front blinkers came on before the engine was started. 91 and 96 have the same wiring harness.

GaryL
 
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Although – having said that ……

I can’t see that Yamaha would have changed the loom around that much for the home market – I always figured that after 2001, they changed it to the switch rather than the magneto to account for front visibility when you were at a stop light with the engine off

Perhaps someone else could chime in at this point ?
 

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Although – having said that ……

I can’t see that Yamaha would have changed the loom around that much for the home market – I always figured that after 2001, they changed it to the switch rather than the magneto to account for front visibility when you were at a stop light with the engine off

Perhaps someone else could chime in at this point ?
Not to argue because you could have a EU model which could be different. I have owned 1987, 1988, 1991, 2001, 2006 and 2009 TWs and only the 87 didn't turn the headlights on when the key was in the on position. This could be an American thing because the law requires the headlight to be on while driving a MC so they make it idiot proof. 1987 had it's own electrical system I do believe required the magneto to run any electronics. After 1987 if you drove your bike into the garage and put the kick stand down while in gear the engine quit but the lights remain on until you turn the key off. If you shift into neutral then the engine can stay running with the stand down.

GaryL
 

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Whoops .....
The 87 has an AC magneto coil driving the headlight which is only on when the engine is running (or someone is spinning the magneto very fast by hand)..

Purple, not sure if your "whoops" means your bikes headlight actually comes on with the key or not. If it does not please confirm the year of the bike and tell me the color of the wires going to the rectifier regulator? Are there 3 white and one red wire - or are they: white, yellow, brown and red? I have a few conflicting schematics I'm trying to associate to the correct year bike. Thanks... :) (if you don't have the time no problem.. :)
 
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The 87 has an AC magneto coil driving the headlight which is only on when the engine is running (or someone is spinning the magneto very fast by hand)..

Purple, not sure if your "whoops" means your bikes headlight actually comes on with the key or not. If it does not please confirm the year of the bike and tell me the color of the wires going to the rectifier regulator? Are there 3 white and one red wire - or are they: white, yellow, brown and red? I have a few conflicting schematics I'm trying to associate to the correct year bike. Thanks... :) (if you don't have the time no problem.. :)
JJ, do not rely on what Purple's bike has until we confirm if the Japan/EU models are in fact different. I can confirm the 1987 do not come on with just the key and all the ones after 2001 do come on with the key. Where the issue seems to be is the bikes between 1988 and 2001. For the sake of argument let us consider the 1987 bikes as Generation 1 and the 1988-2000 as Generation 2 and all newer ones as Gen 3. All of my 1988-2000- Gen 2 bikes turned the front headlight and blinker primary lights on with the key but evidently the Japan/EU models do not.

Another way to research this would be in the wiring harness part numbers. The only way to change the headlight function is by changing the harness and if those numbers change at some point or from US to the Japan/EU models then there is the answer. It is not rocket science but it is electrical science and I suck at both. With a real HS internet connection I could do the research myself but where I live remains in the 20th century as far as internet goes.

GaryL
 
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JJ - "whoops" means I posted confusing info - but my Japanese market '98 headlight comes on with the engine, and not with the key .......
That is interesting and good to know Purple. I wonder if the part number for the wiring harness is different for your Japan model than it is for our US models? The US part number is 2YG-82590-10-00. I have no idea how to find the number for your side of the pond.

GaryL
 

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Although – having said that ……

I can’t see that Yamaha would have changed the loom around that much for the home market – I always figured that after 2001, they changed it to the switch rather than the magneto to account for front visibility when you were at a stop light with the engine off

Perhaps someone else could chime in at this point ?
M 03 works this way.... Ignition on=head light on!

Jim
 
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My '96 headlight comes on with the key on also.
 

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Seems the US bikes from 1988 right through the present all turn the headlight, front markers and tail lights on with just the key on and engine Not running. Evidently the EU/Japan models do not which tells us they probably have a different part number for the wiring harness. I tried a bunch today but I can't seem to bring up any of the EU/Japan parts diagrams to even do the research. Come on Purple, our US part number for our 1998 harness is 2YG-82590-10-00, Look it up on your end and let us know why your lights stay off when the key is turned on but no engine running.

GaryL
 
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Seems the US bikes from 1988 right through the present all turn the headlight, front markers and tail lights on with just the key on and engine Not running. Evidently the EU/Japan models do not which tells us they probably have a different part number for the wiring harness. I tried a bunch today but I can't seem to bring up any of the EU/Japan parts diagrams to even do the research. Come on Purple, our US part number for our 1998 harness is 2YG-82590-10-00, Look it up on your end and let us know why your lights stay off when the key is turned on but no engine running.

GaryL
My guess is an extra relay triggered by charging system output with "jumper" so headlight stays on if the engine stalls after initial start up.
 
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