Time for an overhaul!!!

[no1b4me]

Hate to tell ya but because of the design of the seat heater, it will fail again, and again, and again IF nothing is done to stop it. The wires flex right at the power chip causing them to eventually break (ever bent a wire coat hanger back and forth a bunch of times? Eventually they break).
The solution is to prevent flexing there. I have repaired 3 heated seats so far. Changed lead wires to super-flexible wire (from McMaster) and fabricated a plastic support piece to attach to power chip and prevent wires from flexing there. Problem solved.

Hi Turboflash.... What gauge of wire did you use to replace the lead wires from the chip to the connector plug? 18 or 20 AWG?
Thanks
Rob

 

[Turboflash]

I copied the factory size (22 ga.). Link to wire I used. I put some in my freezer and it's just as flexible when it's cold as when it's warm (silicone outer insulation!). https://www.mcmaster.com/7479K11

 

[no1b4me]

Hate to tell ya but because of the design of the seat heater, it will fail again, and again, and again IF nothing is done to stop it. The wires flex right at the power chip causing them to eventually break (ever bent a wire coat hanger back and forth a bunch of times? Eventually they break).
The solution is to prevent flexing there. I have repaired 3 heated seats so far. Changed lead wires to super-flexible wire (from McMaster) and fabricated a plastic support piece to attach to power chip and prevent wires from flexing there. Problem solved.

Hi Turboflash.... What gauge of wire did you use to replace the lead wires from the chip to the connector plug? 18 or 20 AWG?
Thanks
Rob

I copied the factory size (22 ga.). Link to wire I used. I put some in my freezer and it's just as flexible when it's cold as when it's warm (silicone outer insulation!). https://www.mcmaster.com/7479K11

Thanks for the info..
. Also, the plastic support channel, how did you affix it to the chip?.. Any close up pictures?
Thanks again

 

[murdered141]

Good luck on the heated seat under warranty , cost me $335.00.
Specifically excluded in Yamaha warranty papers.

Mine got warranted on the viper

 

[Turboflash]

Hi Turboflash.... What gauge of wire did you use to replace the lead wires from the chip to the connector plug? 18 or 20 AWG?
Thanks
Rob

Thanks for the info..
. Also, the plastic support channel, how did you affix it to the chip?.. Any close up pictures?
Thanks again

I glued the chip to the plastic support. I formed a little step in the plastic to try to keep the chip and support in the same line. The goal is to not have wires flex right there by chip as they will eventually break. Also, I removed a thin layer of seat foam under the support area to make sure the support w wires zip-tied to it remained level with seat cover and didn't stick out.
Can you zoom in on pic?

 

[no1b4me]

I glued the chip to the plastic support. I formed a little step in the plastic to try to keep the chip and support in the same line. The goal is to not have wires flex right there by chip as they will eventually break. Also, I removed a thin layer of seat foam under the support area to make sure the support w wires zip-tied to it remained level with seat cover and didn't stick out.
Can you zoom in on pic?

Thanks TF for those added details.... My seat heater randomly works, it is quite evident there is a weak/fractured connection, I have ordered the wire already, just need to find some plastic and mold it into shape as you did, i take it you used epoxy to attach the plastic support to the chip? What type of plastic did you use? and what thickness was it ? Will start this repair tomorrow.
Cheers

 

[Turboflash]

Thanks TF for those added details.... My seat heater randomly works, it is quite evident there is a weak/fractured connection, I have ordered the wire already, just need to find some plastic and mold it into shape as you did, i take it you used epoxy to attach the plastic support to the chip? What type of plastic did you use? and what thickness was it ? Will start this repair tomorrow.
Cheers

Yes, your wires are clearly fractured/broke. Very typical failure mode. See pic. Yes, any decent epoxy will attach a piece of plastic to the power chip. I used ABS black plastic from McMaster-Carr. I think it was 1/8" thick. ABS is very cheap. I just used a heat gun to warm it up and shape it. ABS doesn't take much heat to get soft. Just heat it up and form it. You'll want the down-side end to form a funnel down the chute in the seat foam. If you don't get it on the first try, just re-heat the ABS and form again. Cut off factory (cheap non-flexible wires) as close to power chip as possible and solder on good super-flexible 22 ga. wires. When you install, allow some excess wire in the the tunnel in the seat foam which will flex as you ride. The "brace" made from the ABS plastic will prevent the wires from flexing near the power chip which is where they always break.

 

[stevewithOCD]

So I literally had the worst day of my life!!!!!!
First thing this morning sled pops out of gear ride ruined!
Next I go get oil in town and get 650$ ticket for mobile device in hand
Then to top it off I had a urge to go to bathroom so I run to outhouse beside garage and find there is ice build up and couldn't get door open!!! Well guess what happened!!!!!!
Freek this it's bed time!!!!

---Blow your chain case to chit= $500
---Got fined for holding your "hand held" device=$650
---Had a Code Red...................turn into a Code Brown=$1 in baby wipes

Laughing on TY about your pathetic day= PRICELESS!!!!!

 

[Motorhead]

---Blow your chain case to chit= $500
---Got fined for holding your "hand held" device=$650
---Had a Code Red...................turn into a Code Brown=$1 in baby wipes

Laughing on TY about your pathetic day= PRICELESS!!!!!

(Holy crap), how did I miss that thread on this post?
Wow, that was a bad day. Just Shitty luck!!

 

[Dr. FeeLGooD]

Guys whose chain "popped out of gear". Did this happen under acceleration or just kind of rolling along, or slowing down? Did this cause any damage besides the wore out bushings like chewed off gears or broken chaincase or messed chain? Did your chain case lock up solid? Did it cause a crash? I have a deep interest in this.

 

[yamamarc]

Guys whose chain "popped out of gear". Did this happen under acceleration or just kind of rolling along, or slowing down? Did this cause any damage besides the wore out bushings like chewed off gears or broken chaincase or messed chain? Did your chain case lock up solid? Did it cause a crash? I have a deep interest in this.

I was lucky I was just riding at low speeds and it went in neutral and the teeth grinded
I pulled everything apart and closely examined all the gears and chains! The only damage was the teeth on both upper gear and the reverse gear also the clip on the upper gear popped out of the groove!!! Upon inspection I found the upper gear bushing wore!! The was a difference of .160" from the front the the back of bushing (bushing was tapered) I put a dial indicator on all the shafts to check run out and all was good
Just ordered both gears yesterday

 

[4strokes]

I was lucky I was just riding at low speeds and it went in neutral and the teeth grinded
I pulled everything apart and closely examined all the gears and chains! The only damage was the teeth on both upper gear and the reverse gear also the clip on the upper gear popped out of the groove!!! Upon inspection I found the upper gear bushing wore!! The was a difference of .160" from the front the the back of bushing (bushing was tapered) I put a dial indicator on all the shafts to check run out and all was good
Just ordered both gears yesterday

ditto plus shift fork pads

 

[PowderFalcon]

Guys whose chain "popped out of gear". Did this happen under acceleration or just kind of rolling along, or slowing down? Did this cause any damage besides the wore out bushings like chewed off gears or broken chaincase or messed chain? Did your chain case lock up solid? Did it cause a crash? I have a deep interest in this.

It has happened twice to me. once on my '17 where i'd be sifting along at a steady speed then it would out of no where come out of gear. I'd shift it into reverse then back into forward and it would be good for a day or 2! Took it apart and the top gear bushing was toast and the fork pads broken.

On my '19, i was going top speed when it came out of gear. The gears free wheeled for what seemed forever and ground the teeth off both the top and reverse gear so bad that they wouldnt mesh with the use of the reverse actuator. Got towed and had to replace both gears and both fork pads.

That coupled with the welfare chain adjuster design, it is a very frustrating chain case.

 

[Dr. FeeLGooD]

Mine has been in shop waiting for same parts and repair almost a month.

 

[yamamarc]

Mine has been in shop waiting for same parts and repair almost a month.

What are they missing?