81 SRX flywheel and lighting coil.

[rlester]

Hey guys,

I recently obtained an SRX 440 that runs great. It just has had no lights since I got it. I narrowed it down to the lighting coil. It ohmed out correctly, but the lights barely lit up. Its not the light bulbs as when I pulled the coil wires off, and clipped on a battery, all the lights work perfectly.

Turns out, when I pulled the flywheel off, there was a lot of surface rust on the inside of the flywheel. I'm surprised the engine had spark. I've cleaned that up with some 400 grit sandpaper. This sled sat for many years in somebodys garage.

Anyway, I'm picking up a lighting coil tomorrow, but I have a few questions.

Should I try to snake the new yellow wire through the grommet, or just crimp it to the existing yellow wire inside? Seems impossible to put the wire through the grommet, and I don't want to pull the other two coils out in fear of messing something up.

Also, what torque should the flywheel nut be? I don't have a manual.

How much oil should be in that white inspection plug?

Ryan.

[Vmax540]

Hi, Rlester and Welcome to V.V. !

If the lighting coil has the correct resistance (ohms) I have to wonder if you have a bad voltage regulator, a poor ground at the voltage regulator or a wire that is rubbed bare possibly under the seat, under the engine or in the steering assembly area. A good battery can likely over come the higher resistance and still provide the amperage necessary to run the lights. Later Chuck S.

[rlester]

Pretty sure its not the wiring as I unplugged stuff and metered the wires etc. Also tried another voltage regulator to no avail.

There was a lot of rust on the lighting coil, and the inside of the flywheel. I probably could have cleaned up the coil and re-installed it, but I figured I should just replace it since I have it apart. It did look discolored too.

Ryan.

[Vmax540]

Lighting Coil
http://www.psep.biz/store/yamaha_snowmo ... _coils.htm
V-MAX 83-91 YAM VMX540 L/C ADLP010854 17.95


*I always make sure my headlight is off (Down Position) before starting and turning off the Vmax to avoid a surge on the electrical system. ** Hold your hand on the head light cover when releasing the latch to avoid the assembly from being jarred.

[rlester]

but thanks for the link, that was a better deal. I would have picked it up today, but they forgot to order it from their warehouse.

Anyway, I could still use some help with the other questions, torque value, oil level. As for the wire, I think I'll solder the new wire onto the old yellow one.

Ryan.

[tyler440]

hmmmm im not sure what to think about the oil level in the water pump drive.... the 81 was the only one that had just a screw in plug like that... from 83 on they had a little dipstick in there.... the manual calls for .25 of a quart of 75 to 85 weight gear oil... i would probably just fill it up till it runs out....

as far as the flywheel torque... it is... looking looking looking.... hmmm i cant even find it in the manual..... its gonna be tight tho... if i had to guess and this is only a guess... i'd say 65 foot pounds maybe some more, i really dont know... put a little anitsieze on that taper too

[rlester]

It was the lighting coil, the new one did the trick. Changed a couple of motor mounts while I was at it. Nice to see at night finally.

Thanks for the tips...

Ryan.