IGNITION SYSTEM SYSTEM DIAGRAM (icnirion (2) ENGINE STOP SWITCH SWITCH (3) STARTER SWITCH (4) IGNITION (8) ALTERNATOR *() STARTER MOTOR. STARTER SUB FUSE !aNITION SWITCH TOA SWITCH ELECTRIC —=vin: ST OnWiG-ON_O RB! o> STARTER tT 7 SYSTEM vir Joa -—~O= BI: [Teper st uD FUSE swiiTcn Bin Bur MAIN FUSE 208 6 Bl Pulse GENERATOR BATTERY €.0.1, UNIT 12V BAH IGNITION coll ‘SPARK PLUG Bee BLACK Br es BROWN Y veuow 0 ORANGE By ome BLUE Lb LIGHT BLUE = Gov GREEN Ugo LIGHT GREEN Revo RED P PINK Woes WHITE Gr sR 17-017. IGNITION SYSTEM SYSTEM DIAGRAM 17-0 IGNITION COIL 175 SERVICE INFORMATION 17-1 PULSEGENERATOR WT TROUBLESHOOTING 17-2 IGNITION TIMING WT SYSTEM INSPECTION 17-3 SERVICE INFORMATION GENERAL ‘© When inspecting the ignition system, check the system components end lines step-by-step according to the troubleshoot ing sequence on the next page. © Ignition timing cannot be adjusted since the CDI (Capacitive Discharge Ignition) unit is non-adjustable. For pulse generster 1emevsl and installation, see section 8. For alternator removal and inst: ‘© For spark plug gap inspection and adjustinent procedure, see pege 9-C. SPECIFICATIONS. ITEM STANDARD Spark plug - Standard DPRSEAS (NGK) X24EPR-UP (ND) For extended high speed riding DPR9EAS (NGK) X27EPR-UP (ND) | Spark plug aap | 0.80.9 mm (0.031—0.035 inl lonition timing Initial B° BTDC at idle - ull advance 28° BTDC at 4,000 «pm Ignition col rosiatanes Primary coil 1.0.68 (20°C68"F} Secondary coil (without spark plug can) | 10.5—16.5K2 Secondary coll (with spark plug eap) 14-23 Ka Puloo generator ragistance (20°C/63°F) 420—520 0 TOOLS Circuit tester {SANWA) or 973080020000 Circuit tester |KOWAD or TH 5H Digital multimeter IKOWA) 074110020000 or KS-AHM-32-003 1U.S.A. only)IGNITION SYSTEM TROUBLESHOOTING Weak or no spark at plug 1. Ty spark test with known good epark plug. |- WEAK OR NO SPARK 2. Check spark plug wire far lease or poor con tect at the spark plug cap, then ty spark tact again. WEAK OR NO SPARK a 3. Check CDI unit connectors far loose or poor contact, then try spark tost again NORMAL, ¥ Check the Also chec! resistance, continuity and voltage at the CDI unit connectors of the wire harness side (page 17 31, k the ignition secandary coil rasiatance (page 17-3, 41 GOOD SPARK spark plug GOOD SPARK + Loose oF p0or contact of spark plug cap ABNORMAL «Loose or peor contact of CDI unit connectors J ABNORMAL ye 5. Chack the related componente in that part of tho abnormal line. After checking, compare the measurements of (6) with those of 14). | 17-2 ALL NORMAL, + Faulty CDI unit NORMAL ABNORMAL (DIFFERENT (SAME MEASUREMENTS) MEASUREMENTS) Fauity related components Pulse generator ipage 17-4) electric starter system line VIR) ignition ecit (page 17-2, 4) — ignition switch ipage 19-6 — engine stop switch (page 19-8) ground wire {G) battery Ipags 16.3) fuse/108, Loose or poor contact of the releted carnpanent connectors Open oF short circuit in the wire hamess be ‘iveen the related component and CDI unitIGNITION SYSTEM SYSTEM INSPECTION NoTE + Check the system components and lines step-by-step ac- cording to the troubleshooting on page 17-2. + This method doas not include an inspection of the ienition timing advance system at the CDI unit. Remove the right fairing (page 16-2). Disconnect the CDI unit connectors and check them for loose contact or corroded terminals. Meacure the resistance, continuity and voltage between con- nector terminale of the wiro harness sido as follows: ITEM TERMINAL, ‘STANDARD Ignition coil primary coll BUY and G 0.40.6 0 (at 20°Ci68°F) Pulse generator coll Bul¥ and 6 420-520 0 (at 20°Ci6B°FY lgnttion switch anc engine stop switch (Turn the ig: ) BIW >) and G Battery voltege. nition switch ON and the engine stop switch RUN) - Electiic starer system line (Tura the ignition switch | YPR (4) and G (—! Batiory voltage ‘GN and push the starter switch) NOTE: D Transmission must ben neu. IGNITION COIL INSPECTION Remove the fuel tank (page 4.3) Measure the primary coil resistance betwsen terminal, STANDARD: 0.4—0.6 @ {at 20°C/68°F) Maasure the secondary coil resistance with the sperk plug cap in place by enacking for continuity between the plug cap ané green terminal D) stenoano 12-23 4 a 20rcveernIGNITION SYSTEM Remove the spark plug cap from the wires and measure the secondary coll resistance, STANDARD: 10.5—16.5 k@ lat 20°C, 68°F; PULSE GENERATOR NOTE + Itis not necessary to remove the fuel tank and fairing to make this test INSPECTION Disconnect the pul generator wire connector (2P mini). ‘Measure the resistance betwen the connector terminals. STANDARD: 420-520 0 {at 20°C/68°F) IGNITION TIMING NOTE + The Capacitive Discharge Ignition (CDI) eyetem is factory pre-set and does net require adjustment. To inspact the funcvon of the CDI components, ignition timing inspection procedures are givan here ‘Warm the engine up to the operating tampsrature. Remove the timing hole cap. Connect tachometer and timing light: Start the engine and allow it to dle. IDLE SPEED: 1,300 + 100 rom {Inspect the ignition timing, Timing is correct if the "F” mark on the altemater rotor is aligned with the indax mark on the left crankcase cover at idle. To check the advance, raise the engine speed to 4,000 + 100 rpm. The index maik should be between the advance marks. If the ignition timing ie incorrect, perform the sytem i tion (page 17-3) 43). 7F” MARK, (2) ADVANCE MARK 17-4