electric box woes

[Motoman25]

well here is a pic of what my electric box just looked like once i split it open...

i found the reason why the start button just made a click


the solenoid still works, but the bolt is gone for the battery side of it.

im gonna clean up the box and maybe drill and tap the connection for the battery side of the solenoid. if that doesnt work ill pony up the couple bucks for a new solenoid



my main question is what is the best way to seal up the yamaha box so this doesnt happen to me again.


i read a few threads and it seems everybody hates the yamaha ebox design and its inherent water sealing flaws. how do you guys deal with this?

[crab]

grease on both sides of the seal

[Motoman25]

thats what i did over the winter when i removed the temp sensor.

grease on both sides.... guess it wasnt good enough.

now i got it all cleaned up and went to put it back together with no idea where a couple wires go. ill have to give it another go in the daylight tomorow.

luckily the only thing that happened was the bolt for the battery side of the solenoid disintegrated along with the terminal end. a new end and a new bolt fixes my problem. now i just gotta seal the box up a bit better.

[crab]

thats what i did over the winter when i removed the temp sensor.

grease on both sides.... guess it wasnt good enough.

now i got it all cleaned up and went to put it back together with no idea where a couple wires go. ill have to give it another go in the daylight tomorow.

luckily the only thing that happened was the bolt for the battery side of the solenoid disintegrated along with the terminal end. a new end and a new bolt fixes my problem. now i just gotta seal the box up a bit better.
Grease the fuse access washer and the rubber wire boots, and make certain water can't run down the battery cables on top.

[Motoman25]

will do.

[Matt_E]

The secrets to keeping your Superjet ebox watertight:

1. Use a new gasket.
2. Use some grease or vaseline on the rubber grommets and the fuse cap.
3. Use the right screws
4. Do not overtighten the screws

[Motoman25]

3. Use the right screws


stockers?

or something better?

[Matt_E]

I've had good luck with #14 sheet metal screws, 1 inch.

[Proformance1]

Took apart my un altered 05 box and same thing, full of water. I sillyconed all the wire inlets and greased the fuse gasket. We'll take it apart before Daytona and see how she looks.

[oxnard111]

The top where the power wires come through is a major water entrance, especially if your power wires are bending at extreme angles as the leave the ebox.

always use a new gasket. you would use a new gasket on your engine, why not on your ebox? in a pinch and temporarily I will use the old gasket with grease, but I replace it when possible.

[Mark44]

I have been meaning to have my shop make me an electrical box out of clear lexan and machine an o ring groove for the front cover gasket just need to get around to it.

Mark44

[oxnard111]

I have been meaning to have my shop make me an electrical box out of clear lexan and machine an o ring groove for the front cover gasket just need to get around to it.

Mark44

that would be pretty cool. i don't think the whole thing needs to be clear, but if just the front half was, that would be pimp.

[DrewNJ]

I got tired of having a box full of water and ended up drilling 2 1/4" holes in the bottom of the box. Figured if the water goes in at least it has a way out. :dunno: This worked fine for me all year with no issues so far..


Figured if it caused a problem I could just seal up the holes...

[Matt_E]

I've tried chasing water intrusion in eboxes in the past. It always comes down to this: use a NEW gasket, make sure the mating surfaces are clean, use good screws, and do not overtighten.
Also, make sure that the wire grommets and the fuse cap seal are good.

[Motoman25]

i just wound up removing the fuse cap after every ride. i put it under one of the gas tank straps... then when i fill up with gas before i ride i just screw the fuse cap back on.

no water since i started doing this.