Hello all. New to this forum and want to give thanks to all for providing technical help. I have a 04 Yahama 450 Kodiak which has intermittent power to the key switch/dash lights. When the dash is lit up it will fire right up and run just fine, but when I turn the key off and back on most of the time there are no dash lights and therefore no start. Under the seat, I found that I can move the wiring harness around and sometimes get the dash lights to come on and starts it up. I can't seem to pinpoint which wire or component is responsible for the lack of power to the key. At first, I thought it was a bad key switch which I removed and discovered the red wire going to the switch would provide 12 volts when I moved the wiring harness around. Also once I left the key on with no dash lights on and came back later and they were on and I hadn't moved anything! Is there a component, relay, diode, or anything that would cause this situation? I took all the connections apart and used electrical contact cleaner even though I noticed no corrosion. I hate to unwrap the entire wiring harness in hopes of finding the wire that might be producing an intermittent open. Could I run an independent red wire from the positive post up to the red wire on the key switch without harming anything? I'm curious because I don't know where the other wires on the key go and what they do. Also, where are all the grounds located and could that be the problem? Has anyone else had this issue? Thanks again in advance.

 

I don't know that bike specifically, but it sounds like you have a fouled ground. You NEED to locate the frame ground, remove it, sand any rust off, clean the connector and reconnect. You can go to tradebit (tradebit.com - Yamaha Kodiak 450 service manual repair 2003-2006 YFM450and download the field service manual for cheap and hopefully be able to trace out the frame ground(s). I'd also completely clean all connectors to the battery posts and other ends of those leads as well... hard to know if that is already what you did as it wasn't specifically called out.

If that doesn't fix it, you may well have to start unwrapping the wiring harness to find what appears should be an open.

 

Thanks. I'll check and clean grounds. What about the idea of a separate fuse protected hot wire from the battery to the key? Could it cause any damage?

 

Started checking grounds and all were good. While pushing around on the connections I noticed when I pushed down really hard on the 30 amp fuse I would get dash lights. I pulled the fuse and sprayed contact cleaner in the holder plus wire brushed the spades on the fuse and bingo. It's up and running Thanks for taking the time to help me and maybe others with a similar issue.

 

Good to hear! That 30a fuse was probably the main fuse and from your note, was fouled on the connections. As you found, sometimes it just takes persistence in locating the source of an electrical problem. But you always want to start with the easiest, and cheapest, methods first.

Since you found crud in the fuse holder, that is a good sign that quad has been run into some deeper muck/water. You may want to go through all of your fuses, relays and other connections and get them clean. Since cleaning the ground connections didn't resolve your immediate issue, you may have avoided an issue down the road.

 

Regretfully it sounds like you will have to open up the wire loom to trace the wires.At least you narrowed it down to a specific area.

 

I also wrap the connectors in plastic and either seal with electrical tape or zip ties to avoid .future moisture