yamadad or anyone help?! 79 exciter headlight problem

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You're reading: yamadad or anyone help?! 79 exciter headlight problem

66 posts

discussion starter · #1 · jul 23, 2011

my dads got a 79 exciter 440, it keeps blowing the headlight at high rpms..ive read a couple other threads about this but all they really say is check voltage reg. he put a new lighting coil and voltage reg on it but still blowin bulbs? also all the other lights work. we were looking at the wiring and came across something kinda confusing, theres a blue wire that comes off the magneto and goes into the cdi, anyways when you unplug this wire from magneto both sides of the wire have power comin from them (the magneto puts off current and the cdi is to?) its like theres 2 positives connected to each other is this normal? please help any suggestions would be great! thanks

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26,344 posts

there are 2 power wires from the mag, both ends of the same wire! they should go into the regulator and a third will come out as the main power!

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5,737 posts

without digging up an electrical diagram for that sled, if i even have one, using whats left of my memory, typically the blue wire would be your power output from the magneto’s lighting coil. at some point it should connect to a yellow wire. should be at the voltage regulator. yellow then becomes the main clean regulated power for the lighting curcuit.

i would take a close look at the ground connection at the voltage regulator(black wire to a bolt). make sure its making a good contact and is not rusted or corroded at the bolt or frame attachment. check all the ground connections(all the black wires).

next look at the wiring at the headlight plug itself for any abnormalities. corrosion, frayed wires, etc. as well as tracing the yellow wire back for any rubs or frays.

sounds like classic regulator problem or even excess output from the lighting coil, perhaps incorrect parts for your sled. confirm proper headlight bulb as well.

is it only blowing the headlight and none of the other lights? you may even need to look at the hi/lo beam switch.

i will see if i can dig some output specs up for the mag. regulator is not testable without special equipment. keep at it, its probably something simple if you know the regulator to be good.

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66 posts

discussion starter · #4 · jul 24, 2011

ya the only bulb that blows is the headlight. we still have some wire tracing to do but right now all i kno is the blue hotwire that comes off the mag is connected to a seperate blue hotwire which goes to the cdi box (++) im not sure where its going after that tho. ill look at the high/low switch. i dont think its the regulator tho, i think its from the lighting coil. when he got the sled it needed a new lighting coil the one that was on it was bad but maybe the new ones not the right one.

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5,737 posts

since i was cleaning the extra garage today on a part hunt, i ran across the 1980 supplement for that exciter. the 79 was in sad conditon and barely ledgible but i did see your blue wires. heres what i know:

the cdi, mag, and wiring harness was changed in 1980 and was not interchangable for the previous years, according to yamaha. basically what yamaha did was eliminate the ability to turn off the headlights at the key switch and made it a constant on while the engine is running.

the yellow wire at some point does connect to blue wire. could be that the wrong lighting coil was used hence the back feed, or the wrong regulator. regulator should be either a hitachi tr12-24b or toshiba s8516b.

just for fun, lets do a year confirmation based on vin number starting prefixes:

1978-8g6

1979-8h6

1980-8j7

if yours dont match, post your first 3 digits.

once we know what we are dealing with, i may be able to give you some lighting coil specs.

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31 posts

hello yamadad4 this is the dad to 80trailcat4000 the first 3 didgits are 79 8h6 done all wire tracking several times no cuts or bare wires regulator changed out 2 times can you get the specs for lighting coil also have good ground going to check the hi/lo switch next any thing i can check next also what size head light bulb should it take the one our local yam dealer sells me is 12v60/60w has a rounded point to the top of it thanks ( harley05 )

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88 posts

i’m thinking both (++) is your problem here cause lets say your getting i duno

12v from both wires on a bulb that’s made to run 12v yeah it’s gona blow cause your runing 24v so there you got your problem the reason why other lights work maybe they can just handle a higher surge of current

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88 posts

get a voltagemeter and check both wires if there the same tape one up and conect the other to see the out and tape it up with electricall tape and if there diferent curent in wires looks up they right current on ronniesmailorder.com if you know this site if not i’ll look it up and connect the right current wire to the voltage regulator and tape the other one up

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31 posts

hello vincaety im not familiar with that site ok with the 2 blue wires i put a light tester on each end one end tester light worked good put it on the other wire it blew tester bulb instantly makes sence what you are saying what is the wire not being used for then thanks be a few days before i can put volt meter on 2 blue wires

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5,737 posts

based on the vin, your working with a 79 model.

heres what i have, based on the blue wire configuration from 79. although as not as complete as i would like to think it is, take it for what its worth. i may need to dig deeper. i dont actually have the complete manual, just bits of tattered info.

this may or may not apply, but it gives you a starting point.

pulse coil resistance 78ohms between the white/red and the black.

charge coil resistance 113 between the brown and the black wires.

29 ohms between the blue and the black.

simple ohm readings using a quality electrical multimeter.

i offer to help you as best i can with the info i have.

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31 posts

yamadad4 with the 2 blue wires one is a single the other has a 2 wire harness one blue wire other wire is white with a black stripe is something else need plugged to that if i plug blue to blue white w/black has no wire to plug into also i left blue unplugged have tail light /brake lights no head light i will be testing the ohms this week end thanks

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5,737 posts

take a look at the plugs from the stator.(magneto) these are the wires i listed for the testing procedure. should come out somewhere near where the recoil housing and rope mounts to the engine. if these wire colors dont jive with your existing wires, that gives us a direction based on wire colors.

see if this resembles your magneto wires. you should have a yellow lead with a split plug, a white lead with a red stripe, a brown lead, a blue lead and somewhere in there a black lead.

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these are the wires your testing for resistance as offered previously. throw this into the test as well:yellow to black 22ohms.

at this point we are working on stator outputs based on resistance per wire color combos.

as for your headlight wattage, i show both a 45/40 and a 60/60. based on your model year with a 100w light system, the 45/40 would better suit your needs. one would think the 60/60 may appear dim as you would be exceeding the output of the mag.

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31 posts

yamadad tested all wires came out to what you gave for ohms wires coming out are brown /white with red stripe these have a 2 plug end they connect to same color wires next a blue /white wire with black stripe these have a 2plug end blue to blue the white wire with black stripe is not plugged into nothing next single yellow to yellow next single black to black

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66 posts

discussion starter · #14 · jul 29, 2011

we put the old voltage regulator back on (the original) as the new one that was put on is the wrong reg. so now we hav another bulb 12v 60/60 non halogen, goin to start it up and see if it blows. …what i dont understand is the blue wire that comes off mag and plugs into other blue which goes to cdi, the cdi side of blue wire is harnessed with a white and black wire but theres nothing to plug the white and black into on the magneto side. so the w/b and blue wire harness go’s up and plugs into the cdi box but the other side of that wire harness (magneto to cdi) only the blue plugs into magneto w/b isnt plugged in to anything as theres nowhere to plug it to. maybe causing (++)? sorry for long post, just trying to figure this out.

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5,737 posts

if i am reading correctly, the wire that is black with the white stripe should end up at either the tether switch (if equipped) or the push button stop switch on the bars, throttle side.

the blue wire should go from the mag to the cdi and be done.

the yellow wire from the mag(lighting circuit) will branch into a blue wire at some point, at or near the tether. if your sled is not equipped with the safety tether, or it has been removed, that particular 4 wire white connection plug was usually the changing point on the wire colors. look for a plug with the following colored wires: green/yellow, black/white, blue, and black.

a missing tether or someone redoing the wiring could come into play.

voltage regulator should have a blue wire and a provision to ground if its oem.

report back and see where we are at.

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31 posts

hello yamadad sorry for delay sled does have both tether and push button stop switch they both work properly i put the correct voltage regulator on lights seem to be working so far lifted track up off floor ran sled about quater to half throttle about 3 minutes did not blow headlight bulb maybe that took care of problem i hope is there any other way to check to see if bulb will not blow thanks again i just purchased a 1993 artic cat 580 z couple hundred bucks good shape what ya think needs couple things fixed nothing major runs great wife wants the 79 yam 440 for her self she loves it

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5,737 posts

if you have access to a volt/ohmeter, simply check the dc voltage between the green wire and the black wire and then check between the yellow and black. you shouldnt show much more than 14 volts on dc current.

congrats on the arctic cat purchase! (i think)

as you found out in this section(yamaha), you will also find all the info you should need in the arctic section.

lots of good info on this site, but you already figured that out.

think snow!

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Category: Headlights