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Discussion Starter · #1 ·
Once again I am posting, looking for advice from all the snowmobile geniuses! My 1992 Exciter has been bogging since early February. I have tried almost everything to eliminate the bog: clutching work, bearings, fuel pump, carb work, plugs, etc. Today as I was putting the sled away for the summer, I decided to trace some wires, looking for shorts. I found three seperate wires in the steering column worn through. Two were for the hand warmers and one was a wire that was inline with a hefty harness and I didn't know what it was for. All of the wires were wore clean through and had exposed copper wire showing, one worn for over 2 inches! I fixed these shorts and continued my wire tracing under the hood. There is a wire harness on the MAG side of the sled. The wires are in a plastic/rubber, protective sheath that runs to the magnito I think. This plastic/rubber sheath was melted in several spots and I could see wires inside. I cut the plastic/rubber sheath open and found seven wires inside. The black coated wire was melted from about 2 inches from the harness, all the way down to the magnito as far as I could cut the plastic/rubber sheath. There was absolutely no insulation left on the wire and the copper was very deteriorated and crumbling apart. Something got hot for some reason. All the other wires part of this harness were OK, just the black one was ruined. Does anyone know what would have caused this meltdown? Could this be causing ignition issues and the bogging? Would I need to buy a new stator to fix this? Before I stick a different stator in it, does anyone know what would have caused that black wire to melt down so bad? Think it could have been just a bad stator or maybe one of the shorts I found? Maybe another short somewhere else? I attatched a couple pics if anyone can tell me what the black wire is for. Thanks for any help and opinions with this!



 

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I would replace that wire with one of a larger gauge. If it's a 14ga, go to a 12ga. Solder and heat-shrink. I had to do this on an older sled I worked on and no more problems. And keep checking for shorts. There's a reason that wire heated up like that.
 

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Discussion Starter · #3 ·
I can solder a new wire in in the stator? Would it be better to replace the stator because I think the wire is melted all the way to the stator. Think it could be the culprit for my bogging issues Hangman???
 

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I am not familiar with Yamaha wire harnesses, but I would guess the shorts you described and fixed are the culprit here. With out a fuse of any kind to open the circuit in a dead short situation something in the line has to fail. The best thing to do would be to get a wire diagram for the machine and trace out the damaged/fixed wires and see if they are in line with the black wire.

It would not hurt to pull the flywheel and inspect the stator if there is evidence of a wire melted just outside the block form the stator. The stator is just a bunch of wire wrapped around a metal core, it can heat up and damage it's insulation just like the external wire did. The older style mags that I am familiar with had separate windings for the ignition and lighting. Again, I am not familiar with Yamaha so tracing the wire diagram to see if the ignition circuit is inline with the damaged wires would be a good place to start.

Good luck.
 
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