Ignition System
16. Ignition system
Service Information 16-1 Pulse Generator Inspection 16-5
Troubleshooting 16-2 A.C Generator Inspection 16-5
CDI Unit Inspection 16-3 Ignition Timing Check 16-6
Ignition Coil Inspection 16-4 Side Stand Cut-off Switch 16-6
Service Information
General Safety
ƃ Carry out inspection in sequence based on the troubleshooting table.
ƃ If the CDI unit is dropped, or if strong shock is applied thereto, CDI unit malfunction may result. Take due
precautions when handling it. Also, if the connector or coupler is connected or disconnected when there is
current flowing, overvoltage may occur on the unit leading to circuit damage. Always turn off the main
switch prior to servicing.
ƃ Ignition timing cannot be adjusted because the ignition system is of CDI type.
ƃ Spark plug check. (ड 3 - 5)
ƃ Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the
same color couplers.
ƃ The resistance value may slightly differ from the standard values depending on each measuring situation.
Specifications
Item Standard value
Primary coil 0.1~0.2
Ignition coil
With plug cap 7.3~11k
Resistance value
Secondary coil
20Ű(68ș)
Without plug cap 3.6~4.6K
Pulse generator coil resistance value 20Ű(68ș) 50~170
A.C. generator coil resistance value 20Ű(68ș) 50~350
Tools
Measuring instruments
Digital circuit tester
PVA multi-tester
Inspection adapter
Spark adapter
16-1
Ignition System
Troubleshooting
No spark at plug
ƃ Poorly connected, broken or shorted wires
- Between the A.C. generator and CDI unit
- Between the CDI unit and ignition coil
- Between the CDI unit and main switch
- Between the ignition coil and plug
ƃ Faulty main switch
ƃ Faulty ignition coil
ƃ Faulty CDI unit
ƃ Faulty A.C. generator
ƃ Faulty pulse generator
Poor Engine Running
ƃ Primary ignition circuit
- Faulty ignition coil
- Faulty wire connection
- Faulty CDI unit
ƃ Secondary ignition circuit
- Faulty plug
- Faulty high-tension cord
- Faulty pulse generator
- Faulty spark plug cord
ƃ Ignition timing
- Faulty A.C. generator
- Faulty CDI unit
- Faulty pulse generator
16-2
Ignition System
CDI Unit Inspection
CDI ignition circuit inspection
NOTE
Ү Inspect the ignition system in proper sequence
based on the troubleshooting table.
- Remove the luggage box. (ऻ 4-5)
- Remove the body cover. (ऻ 4-6)
ƃ Remove the coupler from the CDI unit, and
check the ignition system circuits from the wiring
coupler side.
Inspection item Terminal Standard value
Pulse generator Blue/yellow and green/white 50-170 20Ű (68ș)
Ignition coil (primary coil) Black/yellow and earth 3.6-4.6 20Ű (68ș)
A.C. generator Black/red and earth 50-350 20Ű (68ș)
Main switch Black/white (+) and earth(-) No power connection when the main switch is ON
Wire harness earth Green and earth Power connected
Testing by CDI Tester
ƃ Check the CDI unit spark performance by using a
CDI tester.
Tool: Inspection adaptor
CDI tester
CD unit Adapter
NOTE
Ү Read tester manual carefully prior to using the
tester.
ƃ Replace defective CDI unit.
16-3
Ignition System
Ignition Coil Inspection
ƃ Remove the luggage box. (ऺ 4-5)
ƃ Remove the body cover. (ऺ 4-6)
ƃ Remove the center cover. (ऺ 4-4)
ƃ Remove the primary wire.
NOTE
Ү This test is inaccurate. Conduct the ignition coil
performance test with an ignition coil tester.
ƃ Measure the primary resistance between the
ignition coil terminal and earth.
Standard value: 0.1-0.2 Ingnition Coil
ƃ Remove the spark plug cap from the plug. Generator connector
ƃ Measure the secondary resistance between the
ignition coil spark plug cap and earth.
Standard value: 7.3-11K
ƃ If the measured value deviates from the
prescribed value, remove the plug cap from the
high-tension cord, and measure the secondary
resistance.
Standard value: 3.6-4.6K
Replacement
Ingnition Coil
ƃ Remove the high-tension cord from plugs and
clamps. Remove the primary wire from the
Generator connector
ignition coil. Loosen 2 bolts to disassemble the
ignition coil.
ƃ Install in the reverse order of removal.
16-4
Ignition System
Performance Test CDI Tester
ƃ Remove the ignition coil.
ƃ Use a CDI unit to test spark performance of the
ignition coil. If there is no spark from the spark Ignition coil
cap of the spark adaptor, replace coil.
Tools: Spark adaptor
Inspection adaptor
NOTE
Ү Read the tester manual carefully prior to using
the tester. CDI unit Adaptor
Pulse Generator Inspection
ƃ Remove the luggage box. (ऺ 4-5)
ƃ Disconnect the A.C. generator 4P coupler and the
green/white wire connector.
ƃ Measure the resistance between the green/white
and blue/yellow wire.
Standard value: 50-170(20Ű/68ș)
NOTE
Ү Even if the resistance value slightly deviates from
the standard value, sometimes performance is
not affected. In such case, check all related parts
to determine if the cause of trouble exists in other Ingnition Coil
areas.
Ү For information on pulse generator change, refer Generator connector
to section 8.
A.C. Generator Inspection
ƃ Disconnect the A.C. generator coil wire
(black/red).
ƃ Measure the resistance between the black/red
wire and the earth.
Standard value: 50-350(20Ű/68ș)
NOTE
Ү Even if the resistance value slightly deviates
from the standard value, sometimes function is
not affected. In such case, check all related pats
to determine if the cause of trouble exists in
other areas.
Ү Carry out this test with the stator mounted on
the engine.
Ү The tester measuring range is Ŧ1
16-5
Ignition System
Ignition Timing Check Timing light Hole cap
NOTE
ҮAs the system uses the CDI unit, the ignition
timing need not be adjusted. Check the ignition
system if the ignition timing is incorrect.
ƃ Start and warm up the engine.
ƃ Connect the timing light to the high-tension cord.
NOTE
ҮRead the timing light manual prior to using it.
ƃ Remove the timing hole cap from the shroud, and
start the engine.
ƃ Align the “F” mark on the rotor with the index
mark on the case when the engine is idling to
specified rpm.
Idle speed: 8ŭ BTDC 1,600 rpm. “T” mark
ƃ Gradually increase the engine speed. If the index
mark is set within the advanced “F” mark at the
engine speed greater than 3,900(rpm), it indicates
Headlight
the advance system is correct.
Front cover
Side Stand Ignition Cut-off Switch
Inspection
ƃ Remove the front cover.(ਨ 4-3)
ƃ Remove the headlight.(ਨ 18-2)
ƃ Remove the coupler of the side stand switch.
ƃ Check for continuity between the terminal as
shown below ;
ITEM TERMINAL SPECIFICATION
ON BLACK/WHITE NO
(side stand
is lowered) AND GREEN CONTINUITY
OFF BLACK/WHITE
(side stand CONTINUITY
is retracted) AND GREEN
16-6
Ignition System
Removal
ƃ Remove the front cover.(ਨ 4-3)
ƃ Remove the headlight.(ਨ 18-2)
ƃ Remove the coupler of the side stand switch.
ƃ Remove the L. side cover.(ਨ4-5)
ƃ Loosen the side stand switch mounting 2 bolts.
ƃ Release the wire clamps and remove the side
stand switch.
Side stand switch
Installation
ƃ Install in the reverse order of removal. L. side cover
16-7
MEMO
