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Old 07-08-2020, 02:18 PM   #1
CHagerty
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Join Date: Jul 2020
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Default G1 Blowing fuse on ground w/ key off.

Another G1 with electrical issues Ground side fuse keeps blowing with the key off. Found +12 volts on one side of ground fuse holder at all times.

Cleaned battery posts / clamps
Removed all grounds, cleaned & reinstalled.
Removed and cleaned starter generator wires.
Thoroughly inspected wiring harness for damage.
Disconnected voltage regulator.
Disconnected buzzer.
Disconnected keyed.
Solenoids tested out.

By chance I still had a test light stuck in the fuse holder and tapped on the starter/generator with a wrench - light went out. I tapped on it again and made the light come back on. Got it back in the "no-light" condition, put a fuse in the holder and it fired up. Tapped on the starter while it was running, blew the fuse again.

Starter / Generator shot?
Replacing just the brushes fix it?
Thoughts on the aftermarket starters? Tough to spend $300-400 on an OEM starter for a $700 rig.

Thanks!
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Old 07-08-2020, 04:47 PM   #2
smallblock450sl
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Join Date: Oct 2007
Location: Tacoma Washington
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Default Re: G1 Blowing fuse on ground w/ key off.

There are 4 connectors coming out of the engine CDI magneto (passenger side,rearward part of the engine). See if the ground wire is bare or melted and touching the frame.
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Old 07-08-2020, 04:48 PM   #3
Lochlin
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Default Re: G1 Blowing fuse on ground w/ key off.

It does sound like it could be something internal to the starter as well.

You could take it to an alternator shop and have them take look at it. They will tell you right then and there if it's the issue and, if it is, will be able to fix it for a lot less than a new one.
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Old 07-09-2020, 11:14 AM   #4
mikeasis
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Default Re: G1 Blowing fuse on ground w/ key off.

if it is the starter gen, have them rebuild it if possible, the aftermarket ones are garbage
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Old 07-13-2020, 04:26 PM   #5
CHagerty
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Default Re: G1 Blowing fuse on ground w/ key off.

Narrowed the issue down to the starter / generator. Tore it down for inspection and found one brush spring broken and floating around. Aside from being grubby, the rest of it looked good. Brush sets are easy to find but the brush springs are no longer available from Yamaha. Any thoughts on the aftermarket starter / generators? Good / Bad?

Thanks!
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Old 07-14-2020, 07:55 AM   #6
mikeasis
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Default Re: G1 Blowing fuse on ground w/ key off.

they are garbage!
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