IGNITION SYSTEM

COMPONENT LOCATION

05 - '07 shown:

IGNITION SYSTEM

THROTTLE POSITION SENSOR

IGNITION CONTROL MODULE (ICM)

IGNITION PULSE GENERATOR

ENGINE STOP BUTTON

ALTERNATOR

IGNITION COIL

SPARK PLUG

SYSTEM DIAGRAM

IGNITION SYSTEM

G/BIBI/Y

I I- &VG Y/Bu GW

SENSOR

G/W Bu/Y

IGNITION

PULSE GENERATOR

ВІЛЛ/

Ви ВІЯ

EXCITER

COIL

Bi : Black Y : Yellow W : White G : Green Bu : Blue R : Red

IGNITION SYSTEM

ENGINE STOP BUTTON

SERVICE INFORMATION

GENERAL

NOTICE

• The ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the module.

• Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.

• When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 18-4.

Ч..У

• The ignition timing cannot be adjusted since the Ignition Control Module (ICM) is factory preset.

• A faulty ignition system is often related to poor connections. Check connections before proceeding.

TORQUE VALUE

Timing hole cap

SPECIFICATIONS

ITEM	SPECIFICATION
Spark plug	Standard	(NGK)	IFR8H11
(DENSO)	VK24PRZ11
Optional	(NGK)	IFR9H11
(DENSO)	VK27PRZ11
Spark plug gap	1.0 - 1.1 mm (0.039 - 0.043 in)
Ignition coil resistance (at 20°C/68°F)	Primary	0.1 -0.3 а
Secondary with plug cap	9-16Ш
Secondary without plug cap	4-8 Ш
Ignition coil peak voltage	100 V minimum
Ignition pulse generator resistance (at 20°C/68°F)	180-280 £2
Ignition pulse generator peak voltage	0.7 V minimum
Alternator exciter coil resistance (at 20CC/68CF)	9 - 28 £2
Ignition timing ("F" mark)	8° ±2° BTDC/1,800 rpm
Throttle position sensor (Blue - Black) resistance (at 20°C/68°F)	4-6 Ш

10 N m (1.0 kgf-m, 7 lbf-ft) Apply grease to the threads

Peak voltage adaptor 07HGJ-0020100

IgnitionMate peak voltage tester MTP07-0286 (U. S.A. only)

IGNITION SYSTEM

with commercially available digital multimeter (impedance 10 Mfi/DCV minimum)

TOOLS

TROUBLESHOOTING

• Inspect the following before diagnosing the system.

- Faulty spark plug

- Loose spark plug cap or spark plug wire connection

- Water got into the spark plug cap (affecting the ignition coil secondary voltage)

• If there is no spark at cylinder, temporarily exchange the ignition coil with a known good one and perform the spark test. If there is spark, the original ignition coil is faulty.

No spark at plug

Unusual condition	Probable cause (check in numerical order)
Ignition coil primary voltage	Low peak voltage.	1. Incorrect peak voltage adaptor connections (System is normal if measured voltage is over the specifications with reverse connection). 2. The multimeter impedance is too low; below 10 MQJ DCV. 3. Cranking speed too slow. - Kickstarter is weak - Battery is undercharged 4. The sample timing of the tester and measured pulse were not synchronized (System is normal if measured voltage is over the standard voltage at least once). 5. Poorly connected connectors or an open circuit in the ignition system. 6. Faulty exciter coil (measure the resistance). 7. Faulty ignition coil (measure the resistance). 8. Faulty ICM (When above No. 1-7 are normal).
No peak voltage.	1. Incorrect peak voltage adaptor connections (System is normal if measured voltage is over the specifications with reverse connection). 2. Short circuit in engine stop button wire. 3. Faulty engine stop button. 4. Loose or poorly connected ICM connectors. 5. An open circuit or loose ignition coil wire. 6. Faulty exciter coil (measure the resistance). 7. Faulty ignition pulse generator (measure the peak voltage). 8. Faulty ICM (When above No. 1-7 are normal).
Peak voltage is normal, but no spark jumps at the plug.	1. Faulty spark plug or leaking ignition coil secondary current ampere. 2. Faulty ignition coil.
Ignition pulse generator	Low peak voltage.	1. The multimeter impedance is too low; below 10 M£2/ DCV. 2. Cranking speed is too low. - Kickstarter is weak - Battery is undercharged 3. The sampling timing of the tester and measured pulse were not synchronized (System is normal if measured voltage is over the standard voltage at least once). 4. Faulty ICM (when above No. 1-3 are normal).
No peak voltage.	1. Faulty peak voltage adaptor. 2. Faulty ignition pulse generator.

ANUAL SERVICE M

TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START 1. Fuel Line Inspection Check fuel flow to carburetor. Does fuel reach the carburetor? IMO - • Clogged fuel hose or …

WIRING DIAGRAM

STARTER SWITCH

INSPECTION '05 - '07: Remove the front visor. - '05 -'07: (page 3-5) - After '07: (page 3-6) Disconnect the starter switch 2P (Black) connector. STARTER SWITCH Check for continuity …

IGNITION SYSTEM

ANUAL SERVICE M

TROUBLESHOOTING

WIRING DIAGRAM

STARTER SWITCH

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