Trouble with 200 yamaha

[badbass]

I just traded my Suzuki DT115 in on a yamaha 200.<br />The guy that had it before me disconnected the oil injection so the motor runs on premix and the brightspark cut off the controll box wiring right at the motor and somewhere along the line lost the controll box.<br /><br />I got a controll box from another shop and tried reconnecting all the wiring as per the wiring diagram in the service manual.<br /><br />I got the motor started this afternoon but as soon as the motor starts and you rev it up the first time it revs fine then the motor starts missing at around 2000 rpm, I havent figured out the buzzer connections yet but I am working on it. I guess that this is related to the disconnected oil injection as I think that the motor detects a problem.<br /><br />There are three wires from the CDI that I cant figure out what they are for. They simply come from the CDI to Controll box..... it's a Green,Pink and Yellow wire. What are they for?<br /><br />Thanks<br />Rudie

 

[rodbolt]

Re: Trouble with 200 yamaha

hello<br />need a year model really<br /> and you really should have an alarm horn someplace. shoot me a model# or tell me the year and ill try to help. at the CDI yellow can be bypass or key on 12v. pink is the alarm wire that triggers speed reduction. we will get to that later. your going to have to keepmore specific. if we are working with the 10pin harness at the key switch lets stay there for a bit. then we will work back to the motor then from the keyswtich to the tach.what control box do you have ?

 

[Ray Neudecker]

Re: Trouble with 200 yamaha

It does sound like the emergency system is kicking in to limit RPM's to 2000. Most likely related to the oil injection removal. It would take longer for the overheat to go off. The yellow is a switched hot, green is tach,pink is over heat. They are for wiring to guages. Buzzer should be going off. What year model is the engine? What all was removed in the oil injection disconnect?

 

[rodbolt]

Re: Trouble with 200 yamaha

ray<br /> he said pink from the CDI. that is both alarms at the CDI I believe. thats why I wish to work with one end at a time. and a year model that way we can help him without me getting all con-fuzed

 

[Ray Neudecker]

Re: Trouble with 200 yamaha

True enough, we must have both tried to answer at the same time. If he has only hooked up the factory box and harness, the only problem there might be with the buzzer. I have seen a lot of goof ups where they did away with the oil injection. If you don;t jumper the plug that goes from the motor mounted tank sensor. It goes into emergency mode. Early models you just disconnected everything and went on. I had one come in the other day where they left the sensor hooked up and laying in the cowling. In rough water it would go into emergency mode sometimes. A little more info would help to cure his problem.If the harness was cut on the engine side of the disconnect and he is having to hard wire a plug on, it is tougher.

 

[rodbolt]

Re: Trouble with 200 yamaha

yep<br /> man I have seen some abotions in the past ten years or so. and the alarms seem to get neglected

 

[badbass]

Re: Trouble with 200 yamaha

I hope this helps.<br />Model: 200 BETO<br />Serial: 666L 404035<br /><br />I would also like to know what model this is, as for the controll box I would have to get the number during the day. What makes this so much more interesting is that the motors wiring was cut off just after the 10pin connecter and the controll box 10p connector is missing so I am joining wires from the diagram.<br /><br />The buzzer is not going off because it is not yet connected, I see that the + comes from the ignition switch and there should be a negative from the motor to activate the buzzer and I dont know which wire connects to the buzzer. <br /><br />Cheers<br />Rudie

 

[badbass]

Re: Trouble with 200 yamaha

Controll Box is a Yamaha 703

 

[Ray Neudecker]

Re: Trouble with 200 yamaha

The buzzer should have a yellow lead to one leg and pink to the other. Since they used a different number system for overseas, I am still not sure of the year model, hoefully Rodbolt will have a way of knowing. It would be a good idea to hook 12 volts across the buzzer to test it before getting too deep into the wiring. Turn the switch on, confirm 12 volts on the yellow wire and then jumper the other side to ground to test the buzzer. If the 12 volts is there you can also take one of the pink leads at the thermal sensor and touch to ground to test for continuity from the powerhead to the control box.

 

[badbass]

Re: Trouble with 200 yamaha

The buzzer works it is just that It is not connected yet, I am guessing that the Pink would be used for the buzzer since this is a overheat warning. There is also a Red wire from the rectifier that is not connected anywhere. There is a + wire from the battery and three green wires from a 3p connecter then there is this red wire with a half of a 30a fuse holder and nowhere to go.

 

[rodbolt]

Re: Trouble with 200 yamaha

hello<br /> nope I am no help on the model number. but I belive the old alha characters will put itfairly old.<br /> badbass. is there anyway you can shoot us some pics of the sides and back of the motor? if you can we can ID what ign/ ign controls you have and the rest wil be simple

 

[badbass]

Re: Trouble with 200 yamaha

<br />

<br /><br />I hope this helps, the wire at the bottom left hand corner of the of the rectifier is the red wire I was refering to. The left hand plug of the CDI is disconnected and I think this is the wire for the oil level sensor.<br /><br />Cheers<br />Rudie

 

[Ray Neudecker]

Re: Trouble with 200 yamaha

I have several sets of the electronics from different years in the shop. I will check in the morning to get us closer than from 1990-1994. The jets in the carbs limit it to that. It appears the sensor circuit was cut instead of unplugged. Are any of the wires jumpered there?

 

[badbass]

Re: Trouble with 200 yamaha

I have the buzzer connected now and it keeps buzzing from the moment that I switch the ignition on. It does not look like there is any wires cut at the oil level sensor but I have looped out the black and blue green wire to simulate a full tank.

 

[rodbolt]

Re: Trouble with 200 yamaha

hello<br /> loop the blue white to black. blue green to black is oil transfer pump on. loop them at the cdi. the red lead from the oil level switch to the CDI,if grounded or attached to anything will trigger an oil alarm. <br /> at the harness with the pink,black orange and gray leads. unplug the gray lead. that may help with the horn. on that harness its for trim to the tach, the gray lead is for visual overheat indicate. with some 703 boxes it triggers the warning horn. the red wire that is cut is either battery positive or battery positivce for an aux battery. I need to see the other side of the regulator. I have a 93 200 outback Ill try to look at. do you have the cut harness to splice back? and dou you have enough tag ends at the box and at the harness to spilce? my reccomendation is to find a new harness. what kind of tach do you have ? I realize that in your area of the world the harness may be hard to find. any 10 pin yamaha harness will work regardless of the HP it came from.<br /> now for some wire colors. <br /> all colors are from the engine harness.<br /> red is batt to the key switch, yellow is key on 12v from the switch to the engine and accesories, black is ground, white is engine kill when attaced to the black, pink is warning system. green is tach send,blue is choke,light blue is trim up, light green, is trim down. the 4 wire engine harness with brown,blue, black and black red went to the remote oil tank. the other 4 wire harness with gray,orange,pink and black is trim and overheat visual. the two wire harness with green red and green black is oil alarm visual indicate. at the thermoswitch bullet connectors the lead changes wire colors from pink to gray/ black. from the port pink bullet connection the gray black goes two places. one is to the CDI for power reduction signal and the other is the gray bullet coinnector that goes to the 4 wire trim connetion. leave that gray wire bullet connector unplugged.<br /> hope that helps a bit

 

[Ray Neudecker]

Re: Trouble with 200 yamaha

Best I can tell the cut wire is for auxilary battery charging. I belive you will cure the emergency warning by wiring the oil sending unit the way Rodbolt stated. Good Luck.

 

[badbass]

Re: Trouble with 200 yamaha

Wow...... Thanks so much for the help the engine warnings and missing at 2000 rpms is sorted now, but there is another problem with the motor but I will start a new post for this one.<br /><br />Again thanks for all the trouble you went through to help.<br /><br />Rudie