Page 16-0

16. IGNITION SYSTEM

Component locations

really big verson

color big verson

Page 16-1

SERVICE INFORMATION16-1
TROUBLESHOOTING16-2
IGNITION SYSTEM INSPECTION16-3
IGNITION COIL16-3
PULSE GENERATOR16-4
IGNITION TIMING16-4

SERVICE INFORMATION

WARNING



GENERAL

SPECIFICATIONS

Spark plug

  NGK ND
Standard DPR8EA-9 X24EPR-U9
For cold climate (below 5°C/41°F) DPR7EA-9 X22EPR-U9
For extended high-speed riding DPR9EA-9 X27EPR-U9

Ignition system

ITEMSTANDARDS
Ignition timingInitial (F mark)10° BTDC/idle
Ignition coil
resistance
(20°C/68°F)
Primary circuit 2.2-2.6 Ω
Secondary circuitWith plug wire30-36 kΩ
Without plug wire20-25 kΩ
Pulse generator coil resistance (20°C/68°F)450-550 Ω
Firing orderFront - (232°) - Rear (488°) - Front

Tools

Tester
07411—0020000(KOWA Digital type)
KS—AHM—32—003(KOWA Digital type; USA only)
07308—0020001(SANWA Analogue type)
TH—5H(KOWA Analogue type)

Page 16-2

TROUBLESHOOTING

WARNING



No spark at one spark plug


No spark at all plugs



No spark at either spark group (Front or Rear) - (CHECK WRONG SPARK GROUP)



Remove the seat and rear cowling (page 13-25). 

NOTE


  • Check the system components and lines step-by-step according to the troubleshooting chart on page 16-2.

Disconnect the spark unit connectors and check them for loose or corroded terminals.

Measure the data between connector terminals using the following chart.

ITEMTERMINALSSTANDARD (20° C/68°F)
Ignition primary coilY and Bl/W (Rear) Bu/Y and Bl/W (Front)2.2-2.6 Ω
DC power supply circuit lineBl (+) and G (-), Bu/Y (+) and G (-), Y (+) and G (-) with the
ignition switch "ON" and the engine stop switch "RUN"
Battery voltage should come

ITEMTERMINALSSTANDARD (20° C/68°F)
Pulse generator coilW/Y and Y (Front) W/Bu and Bu (Rear)450-550 Ω.
Each terminal and body groundNO CONTINUITY


INSPECTION

Remove the seat and fuel tank (page 13-25).
Measure the primary coil resistance of the front and rear ignition coils.

NOTE


  • The rear ignition coil is behind the swingarm pivot nut.

PRIMARY COIL RESISTANCE:
STANDARD: 2.2 - 2.6 Ω (20°C/68°F)



Disconnect the spark plug caps from the plugs and measure the secondary coil resistance with the spark plug caps in place.

STANDARD: 30-36 kΩ (20°C/68°F)

If the resistance is out of range, remove the spark plug caps and measure the resistance between the secondary coil terminals.

STANDARD: 20-25 kΩ (20°C/68°F)



INSPECTION

NOTE


  • It is not necessary to remove the pulse generator to make this inspection.

Remove the seat and rear cowling (page 13-25).
Disconnect the pulse generator 4P connector (WHITE).
Measure the resistances between the white/yellow and yellow wires (front pulse generator) and white/blue and blue wires (rear pulse generator)

STANDARD: 450 - 550 Ω (20°C/68°F)

For pulse generator replacement, refer to section 7.   <– Corrected ref.



NOTE


  • The spark unit system is factory pre-set and cannot be adjusted.  Ignition timing inspection procedures are given to inspect the function of the spark unit components.
  • Connect the timing light to the other spark plug wire if you see that the ignition timing is incorrect, and you might be able to see the timing is correct.



Warm up the engine to operating temperature.

WARNING


  • If the engine must be running to do some work, make sure the area is well-ventilated.  Never run the engine in an enclosed area.
  • The exhaust contains poisonous carbon monoxide gas that may cause loss of conciousness and lead to death.

Remove the timing inspection hole cap on the left crankcase cover.

Connect the timing light to the front spark plug wire.

The timing is correct if the "F" mark aligns with the index mark on the right crankcase cover at idle for each cylinder.

Raise the engine rpm and the "F" mark should begin to rotate counterclockwise for each cylinder.

If the ignition timing is incorrect, make a ignition system inspection (page 16-3) and replace any faulty parts.