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post #1 of 11 (permalink) Old 10-25-2013, 09:22 PM Thread Starter
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Exclamation starting problems.

ok I have a 2007 660 and I have turn signals on it. I smelt smoke while I was driving so shut it off to look and noticed the negative wire from the turn signals was melting. I took it and the rhino wont start. when I put it back on the battery the relay clicks but wont start and then the wire melts more. not sure why it is doing that.
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post #2 of 11 (permalink) Old 10-26-2013, 02:55 AM
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Sounds like user error cause rhinos don't come with turn signals. Got to be something shorted the turn signals. I know 660's have terrible grounds. Someone on here will chime in on how to improve the grounding or search it.

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post #3 of 11 (permalink) Old 10-26-2013, 07:23 AM Thread Starter
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yeah but its just two wires going to the battery. if I take the negative wire off no lights will come on at all. if I put back lights will come but will just click. I don't know why taking the turn signal wire off would do that.
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post #4 of 11 (permalink) Old 10-26-2013, 08:01 AM
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Originally Posted by cmitch45 View Post
yeah but its just two wires going to the battery. if I take the negative wire off no lights will come on at all. if I put back lights will come but will just click. I don't know why taking the turn signal wire off would do that.
We need to get a better picture of what you are talking about here.

You have turn signals. These are not Yamaha issue, so someone put them in. Who?

You talk about 2 wires connecting to the battery, are these 2 wires only for the turn signal wiring? When you disconnect the turn signal wire going to the battery negative terminal the lights will not come on, is this the turn signal lights only or is it all of the lighting on the machine? You say when the negative side is hooked up the lights will come ...'on'?... but it only 'clicks'. What are you trying to say here?

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post #5 of 11 (permalink) Old 10-26-2013, 08:38 AM Thread Starter
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the two wires come from the turn signal. when I say lights I mean all lights the rhino has no power at all. when I put it back on the battery the lights come on and the only thing that happens is the solenoid clicks. why would a pos and neg wire from a switch have anything to with that?
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post #6 of 11 (permalink) Old 10-26-2013, 09:30 AM Thread Starter
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well it just happens if neg wire is off the positive has nothing to do with it. is the rhino trying to make that turn signal wire its ground?
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post #7 of 11 (permalink) Old 10-26-2013, 09:50 AM
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well it just happens if neg wire is off the positive has nothing to do with it. is the rhino trying to make that turn signal wire its ground?
Exactly, something is not kosher about the grounding. The stock grounding setup provided by Yamaha is a small black wire that is siamesed into the lug for the big black ground cable that is attached to the battery negative cable. That small black wire goes to a bullet disconnect connector which connects on the other end to a black wire that comes out of the wire harness behind the battery. It sounds like this pigtail is not hooked up or somehow failed. This pigtail is the only deliberate ground connection for the entire electrical system, with exception of the starter motor itself (this is done with the big black ground cable at the battery negative terminal).

Check that grounding black pigtail wire and its connections. It comes out of the big lug on the battery negative terminal, side by side with the big black ground cable. The big cable and the little wire are crimped together into the big lug. If this little wire is not connected to the wire harness, the electrical system finds whatever other ground path that it can, which appears to be your add-on wire for the turn signal switch grounding. This would explain why that wire is overheating.

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post #8 of 11 (permalink) Old 10-26-2013, 11:36 AM Thread Starter
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the connector was messed up. I reconnected and it all works now. thanks for your help steves it was greatly appreciated
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post #9 of 11 (permalink) Old 10-26-2013, 04:13 PM
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the connector was messed up. I reconnected and it all works now. thanks for your help steves it was greatly appreciated
You are welcome. That Yamaha grounding scheme is quite borderline. Many people have had that pigtail burn up, some to the point where the wire harness is badly damaged as well. Some have resorted to replacing the entire wire harness at $300-400 for the part alone. It is a total bear to trouble shoot as to where to fix the potentially many burnt up places.

Read this thread regarding improving that ground connection, It essentially involves moving that pigtail connection away from the battery negative terminal and attaching it to the frame AND putting a very large wire from the engine case ground point to the frame alongside of the engine. Both of these fixes have to be done together, else it will not work. It may save you a lot of grief down the road.

http://www.rhinoforums.net/lighting-...-terminal.html

2004 Rhino 660
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post #10 of 11 (permalink) Old 10-26-2013, 10:22 PM Thread Starter
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I got one more for ya if you don't mind. since ive fixed the grounding problem my 4x4 don't work. I push the button and no 4wheel emblem comes on screen. I push diff lock it just flashes. the fuse is ok. what else should I look at? thanks
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post #11 of 11 (permalink) Old 10-28-2013, 12:36 PM
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I got one more for ya if you don't mind. since ive fixed the grounding problem my 4x4 don't work. I push the button and no 4wheel emblem comes on screen. I push diff lock it just flashes. the fuse is ok. what else should I look at? thanks
I am not at all familiar with the workings of the 4WD setup. If the problem is related to your disconnected ground wire, you had ground currents running in your harness in ways that were never intended while it was disconnected. It could have burnt out a portion of the grounding circuit within the harness or in one of the components that are connected to it. You could start by looking for a poor ground connection at the 4WD control components. The things to look at are the motor connections going to the front differential, the connections going to the 4WD control switch, and the connections going to the 2 double throw relays (5 leaded), and one single throw relay (4 leaded), involved in the 4WD circuitry. On a 660, these 3 relays all have a Brown with Red stripe wire running to them for power and a black wire for grounding. Use a multimeter to check for continuity from the black wire on the harness side of the respective connectors for each of the above devices to ground (negative battery terminal).

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