Quit while riding,have power to fuses and out but no power at ignition switch. checked etc switch and kill switch both good .The schematics show power on the yellow wire from fuse to ignition switch as direct , is there anything else they hid in line before I open the wiring harness to check the yellow line. Any help would be appreciated.

 

You disconnect the black cdi kill wire and see if it helps.. If it doesn't,the most problems we had were the fuse blocks themselves. These delphi type blocks were bad on the terminals shorting.Per 080 029 036 4 ATO ATC Delphi Fuse Block Panel 4 Gang 12 V Blade Style Fuse | eBay

 

Thanks will try this evening .

 

No CDI this machine has a regulator and ecm, power out on fuse wire but no power at ignition plug.

 

Ran a jumper wire in place of the yellow wire from fuse to ignition plug the dash fuel pump ect. cycled on, there must be a short in the existing wire. Will fish out existing wire to make sure it is one piece and no branch circuits.

 

Efi then...I was thinking carb model... Look up the harness leading to the fuse lock and relays.Iirc there is a sealed thermal circuit breaker than can short and break power to the fuel pump,etc and possibly the ignition. I know the 800 has this breaker,can't really remember on the 500,but the schematic seems to point to one. To the right of the fuse panel and relays. Shows a 10 amp breaker on the wiring diagram.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

I think on the 500 efi the fuse you mentioned is for the fan relay, here is a pic of one of the pages for the schematics it shows the yellow wire i mentioned earlier.

 

Yep,you're right,was thinking about the breaker for the fan relay.. Looking at the schematic,if you jumpered the yellow from the fuse block to the switch and regained power,then does sound like you have a short in it somewhere. My two cents,I'd run a new permanent wire and just bypass it completely rather than digging through the harness to find a short in the yellow. It's what a lot of techs would do in a case like this anyway whether it was in an atv or an auto.

 

A Great Thanks to you. I have been a away for the weekend ,I will run a wire just like you explained and will toast you with a beer.

4oml4