GP1800 Wiring diagram errors, Yamaha Factory service manual

[RockvilleA]

im not good with diagrams per se, but are any of these pics of the harness up front? I need power and switch for a boost gauge. Thanks !!

[K447]

...

All four relays inside the GP1800 fuse box (6EX-82170-01 EBOX) are the same type CM1a-r-12V. These are normally open, single pole, rated for 35 amp max contact current.

The relays are very tightly held by friction from the four bottom tabs on each relay. The square plastic body shell of the relay is fragile, it is easy to fracture the relay with prying or pliers. They do pull straight up and out, how you do that without damaging anything is the challenge.

...

This is what a relay looks like when you try to use long needlenose pliers to simply pull it out

One side of the relay body was just marred, the other side I inadvertently crushed the thin plastic shell. A thin layer of silicone to seal the hole resulted in a non-working relay. Replaced with a new relay...

So yes, the relays just pull out. How to do so without damage, I would like to know.

[K447]

2017 GP1800 SVHO Labeled Fuse Box inside cover - Fuse locations

Fuses locations labeled on photo image.
Updated Sept 2020. Prior image had incorrect labels for RiDE/SCU and main battery fuses.

Note: SCU fuse and Battery fuse labels were previously incorrectly marked.
The 30 Amp green fuse is for the SCU (RiDE) and the 50 amp giant red fuse is the main BATTERY fuse.




Print the photo, laminate and glue into cover of fuse box. Now it is easy to see what fuse is for what.
I need to reprint mine with the updated main/RiDE fuse info

[K447]

GP1800 Fuse box

For completeness;

All four relays inside the GP1800 fuse box (6EX-82170-01 EBOX) are the same type CM1a-r-12V. These are normally open, single pole, rated for 35 amp max contact current.

The relays are very tightly held by friction from the four bottom tabs on each relay. The square plastic body shell of the relay is fragile, it is easy to fracture the relay with prying or pliers. They do pull straight up and out, how you do that without damaging anything is the challenge.




With the front cover removed, all the fuses are visible. The system has seven* mini fuses and one large 50 amp fuse. There is one spare fuse of every amp rating. The spare 50 is across the top. The four other mini fuse spares are grouped together in the lower right area.

The square white plastic item is a fuse removal tool. Very handy.

I labeled the relays, makes it easier to understand how it works.




Four spare mini fuses in the foreground, fully seated. The seven active mini fuses are shown here raised up, just loosely sitting in position. They must be pressed down flush to be ready for use.




If the twelve perimeter screws are removed (beware of the loose nuts on the backside) it is possible to separate the fuse block body, revealing the lower deck which houses the actual sockets for the relays and fuses.

The lower section also has a snubber diode visible for each relay coil, and hidden inside the plastic bottom sandwich are the metal circuits which connect the wire harness connectors to the various fuse and relay pins.

* One of the seven fuses (a 3 amp fuse) connects to a blank pin 8 on the 8-pin wire harness connector. This fuse has 12 volt power when the ‘main’ relay is engaged.

On other models (FX) this powers the bilge pump, I believe.

I suspect this fuse/pin could be used as a source of ‘engine on’ voltage to power other items, such as a 12 volt USB charger port. Or power another relay for bigger loads.

Do not attempt to draw more than a couple of amps through that 3 amp fuse.

[nmpeter]

There are supplements to these manuals and missing features are often documented in the manual for another model of that ski.

It does make for some real challenges in dealing with electrical problems caused by rat damage.

In a somewhat related story, back in another life, I worked with a company that did euro car conversions to US specs.

I got a call to rewire an older Ferrari that had the battery installed backwards.

What a surprise. ALL the wiring was THE SAME COLOR.

Needless to say, I took a nice holiday after finishing that mess.

Handbuilt for sure, I guess all they had that day was red.

[K447]

Yamaha manuals are infamous in my world for all sorts of wiring diagram errors, which by the way never get corrected.

...

I am finding other errors as I work through the entire wiring diagram.

For example, the Start and Stop buttons are documented (albeit without clear labels), but the left handlebar Trim buttons and RiDE lever connections are not actually shown on the diagram - just the wire harness ends with two plugs.



Tip: The Start/Stop Button functions are more clearly identified in the edited diagram.

Note: Lanyard PULL means the lanyard has been yanked out of the switch.
SET means the lanyard is inserted under the switch.

[nmpeter]

Yamaha manuals are infamous in my world for all sorts of wiring diagram errors, which by the way never get corrected.

I ran into one a few years ago, as I wasn't really all that familiar with yamaha ignitions.

Some 1200 triples have a single cdi trigger..others use a trio of triggers

[K447]

Corrected and color coded fuse diagram, annotated fuse and relay wiring

Note: This is a work in progress. If you see any errors or omissions, please let me know.

Attached are corrected and color coded GP1800 fuse diagram, fuse and relay wiring.
Also see attached PDF files for better image quality.






For the Remote Control solenoid control wiring the erroneous ground symbol has been grayed.
See attached PDF file

It is not helpful that in some wiring diagrams there is no mention of the wire color coding (such as the above). Also, the fuses are identified with letters on the big wire diagram, but numbered on this one?

...

The fuses on the colored diagram are not marked with the amp rating or function, nor am I seeing a straightforward way to correlate the physical location of the fuse in the fuse panel with the same fuse on this wiring diagram.

10. Fuse (3 A) (Not Used) is shown on the colored diagram as fuse b.
This appears to be relay switched 12 volt DC power for a (not installed) factory bilge pump or other add-on equipment.
I think it gets powered on when the engine starts, and stays powered on for a few seconds after the engine is stopped.
...

BTW, what is the 'entry box' listed for A above?

I still have not traced what the A connection goes to. Anyone have info?

[TimeBandit]

........ I suspect the solenoid coil is actually only connected into the remote control receiver, and is not directly connected to ground.

Correct - no added ground point there.

FWIW, I have a 2009-2012 FX HO SHO shop Manual (pdf only), and it does not show these errors.
LIT-18616-03-41
F2S-28197-1R-11
pdf file date is 4/14/2015

[K447]

At least it shows the correct style fuse box and where the fuses are at unlike the manual i got for the 2015 fz/fx svho's hahaha

PM from another member;

the vxs/vxr wiring shows the same error for the starter .

And the vxr/vxs/vx-ho have the liner cut around intake brackets just like the gp1800.

I expected the existing wiring diagrams were just revised each model and year with whatever was 'changed'. Which means that original/older errors are propagated forward.

The disappointing aspect would be that Yamaha clearly does not have a good feedback system for reporting of user/technition discovered documentation errors and then correcting the documents.

So, how many years back has the official wiring diagram for the Yamaha start solenoid been incorrectly 'grounded' on the wrong side of the starter motor?

[K447]

It is not helpful that in some wiring diagrams there is no mention of the wire color coding (such as the above). Also, the fuses are identified with letters on the big wire diagram, but numbered on this one?



The fuses on the colored diagram are not marked with the amp rating or function, nor am I seeing a straightforward way to correlate the physical location of the fuse in the fuse panel with the same fuse on this wiring diagram.

10. Fuse (3 A) (Not Used) is shown on the colored diagram as fuse b.
This appears to be relay switched 12 volt DC power for a (not installed) factory bilge pump or other add-on equipment.
I think it gets powered on when the engine starts, and stays powered on for a few seconds after the engine is stopped.




BTW, what is the 'entry box' listed for A above?

[K447]

Start solenoid coil is grounded in diagram, would bypass Remote Control Receiver?



Page 7-4 shows the start solenoid coil being connected to the Remote control receiver and connected to ground (circled by me in orange). I suspect the solenoid coil is actually only connected into the remote control receiver, and is not directly connected to ground.

[DaveMD13]

I will reply with the first word that came to mind when i read that... Damn it. Lol. That sux. How bad is the mix up? If yamaha is the publisher you may be able to get them on the phone and correct it. But if you keep finding errors they may need to pay you for doing their job at that point.

Edit.... We posted at same time almost so now i see the mix up lol

[K447]

Wiring diagram, start solenoid connected to ground at starter motor?



This portion of the wiring diagram (back page fold-out in the printed manual) seems to show the battery negative NOT connected to starter motor/engine ground. Instead the ground symbol is shown on the solenoid connection to starter motor, which seems rather incorrect.

Compounding the apparent error, the wire color from solenoid to starter motor is not shown as red. It is a black line marked with B.

[K447]

I have been bringing myself up to speed on the electrical system in my GP1800, including reviewing the wiring diagram in the back of the official Yamaha Waverunner GP1800 2017 Service Manual.

Purchased from the forum's online store.

LIT-18616-03-72
F3P-28197-ZV-11

I am finding what appear to be obvious errors in the wiring diagram, which makes me concerned that there are other less visible errors not yet noticed.