Ignition coil primary peak voltage

 

Shift the transmission into neutral and disconnect the spark plug cap (page 3-5).

 

Connect a known good spark plug [1] to the spark plug cap [2] and ground it to the cylinder head as done in a spark test.

 

[1]

 

[2]

 

Avoid touching the spark plug and tester probes to prevent electric shock.

 

With the ignition coil primary wire connected, connect

the peak voltage adaptor or Imrie tester to the ignition ^[1] coil primary terminal [1] and ground.

 

TOOL:

 

Imrie diagnostic tester (model 625) or

 

Peak voltage adaptor

07HGJ-0020100

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

 

CONNECTION: Green/red (+) – Ground (–)

 

Shift the transmission into neutral.

 

Turn the ignition switch ON and engine stop switch " ".

 

Crank the engine with the starter motor with the throttle grip fully opened and read ignition coil primary peak voltage.

 

PEAK VOLTAGE: 100 V minimum

 

If the peak voltage is abnormal, follow the checks described in the troubleshooting table (page 5-2).

 

 

5-4

IGNITION SYSTEM

CKP SENSOR PEAK VOLTAGE

 

Remove the reserve tank cover (page 2-4).

 

[1]

Disconnect the ECM 33P (Black) connector [1].

 

Connect the peak voltage tester or adaptor probes to
	[1]
the ECM 33P (Black) connector [1] terminals of the wire
harness side.
TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor [2]	07HGJ-0020100
with commercially available digital multimeter			Bu/Y	W/Y
(impedance 10 MΩ/DCV minimum)
Test probe	07ZAJ-RDJA110
CONNECTION: Blue/yellow (+) – White/yellow (–)
Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch " ".				[2]
Crank the engine with the starter motor and measure
the CKP sensor peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ECM 33P (Black)
connector is abnormal, measure the peak voltage at the
CKP sensor connector.
Turn the ignition switch OFF.
[1]
Remove the left side cover (page 2-3).
Disconnect the CKP sensor/neutral switch 3P (Black)
connector [1] and connect the tester probes to the
connector terminals of the CKP sensor side.
CONNECTION: Blue/yellow (+) – White/yellow (–)
In the same manner as at the ECM 33P (Black)
connector, measure the peak voltage and compare it to
the voltage measured at the ECM 33P (Black)
connector.
• If the peak voltage measured at the ECM is
abnormal and the one measured at the CKP sensor
is normal, the wire harness has an open or short
circuit or loose connection.
• If the peak voltage of the CKP sensor side is lower
than standard value, follow the checks described in
the troubleshooting table (page 5-2).
For CKP sensor replacement (page 13-4).
Install the removed parts in the reverse order of
removal.

 

 

5-5

IGNITION SYSTEM

IGNITION TIMING

 

Warm up the engine.
	[2]
Stop the engine and remove the timing hole cap using
the special tool.
TOOL:
Timing cap wrench	07709-0010001
		[3]

Connect the timing light [1] to the spark plug wire.

 

Start the engine and let it idle.

 

IDLE SPEED: 1,450 ± 100 min^-1 (rpm)

 

The ignition timing is correct if the "F" mark [2] on the
flywheel aligns with the index notch [3] on the left
crankcase cover.	[1]

 

Apply engine oil to a new O-ring and install it to the timing hole cap.

 

Apply engine oil to the timing hole cap threads.

 

Install and tighten the timing hole cap to the specified torque.

 

TORQUE:6.0 N·m (0.6 kgf·m, 4.4 lbf·ft)

 

IGNITION COIL

 

REMOVAL/INSTALLATION

 

Disconnect the spark plug cap [1].

Disconnect the primary wire connectors [2] from the ignition coil.

 

Release the spark plug wire [3] from the guides [4] on the fan motor shroud.

 

Remove the bolts [5], spacers [6] and ignition coil [7]. Installation is in the reverse order of removal.

 

[5]/[6] ^[2]

[4]

 

[7]

 

[3] _[1]

 

 

5-6

ELECTRIC STARTER SYSTEM

 

 

 

SERVICE INFORMATION·····························6-2 STARTER MOTOR ·······································6-4

 

TROUBLESHOOTING···································6-2 STARTER RELAY SWITCH ·························6-8

 

SYSTEM LOCATION·····································6-3 NEUTRAL DIODE ·········································6-9

 

SYSTEM DIAGRAM ······································6-3

 

 

6-1

ELECTRIC STARTER SYSTEM

SERVICE INFORMATION

 

GENERAL

 

• When servicing the starter system, always follow the steps in the troubleshooting flow chart (page 6-2).

• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.

 

TROUBLESHOOTING

 

	Unusual condition		Probable cause (Check in numerical order)
Starter motor	Starter motor does not turn	1.	Loose or poor contact on related connectors and terminals
		2.	Blown fuse
		3.	Weak battery
		4.	Faulty starter relay switch
		5.	Faulty starter motor
		6.	Faulty engine stop switch
		7.	Loose connection, open or short circuit in starter motor
			cable
		8.	Faulty starter switch
		9.	Open circuit in starter relay switch ground circuit
		10.Open or short circuit in starter relay switch power circuit
		11.Loose contact or open circuit in related wires
	Starter motor turns only when the	1.	Loose or poor contact on related connectors and terminals
	transmission is in neutral (Starter	2.	Faulty clutch switch
	motor does not turn when the	3.	Faulty sidestand switch
	transmission is in any gear with the	4.	Loose contact or open circuit in related wires
	sidestand retracted and clutch lever
	pulled in)
	Starter motor turns only when the	1.	Loose or poor contact on related connectors and terminals
	transmission is in any gear with the	2.	Faulty neutral diode
	sidestand retracted and clutch lever	3.	Faulty neutral switch
	pulled in (Starter motor does not turn	4.	Loose contact or open circuit in related wires
	when the transmission is in neutral with
	the sidestand lowered and clutch lever
	released)
	Starter motor turns slowly	1.	Low battery voltage
		2.	Poorly connected battery terminal cable
		3.	Poorly connected starter motor cable
		4.	Faulty starter motor
		5.	Poorly connected battery ground cable
	Starter motor turns, but engine does	1.	Starter motor is running backwards
	not turn		– Case assembled improperly
			– Terminals connected improperly
		2.	Faulty starter clutch
		3.	Damaged or faulty starter idle gear and/or reduction gear
	Starter relay switch "Clicks", but	1.	Crankshaft does not turn due to engine problems
	engine does not turn over

 

6-2

SYSTEM LOCATION

ENGINE STOP SWITCH

ELECTRIC STARTER SYSTEM

 

STARTER SWITCH

 

IGNITION SWITCH
CLUTCH SWITCH	BATTERY

 

MAIN FUSE (30 A)

 

FI. IGN FUSE (10 A)

 

STARTER MOTOR

 

NEUTRAL SWITCH

 

		STARTER RELAY
SIDESTAND SWITCH
	SWITCH

 

SYSTEM DIAGRAM

R/W

Bl/R

MAIN FUSE

(30 A)

FI. IGN

IGNITION SWITCH

FUSE (10 A)

BATTERY

Y/R

STARTER

STARTER

Bl/G

MOTOR

RELAY

STARTER

SWITCH

SWITCH

ENGINE STOP

SWITCH

G/R

Bl/Bu

NEUTRAL DIODE

G/R

G/R

CLUTCH

G/O

Lg/R

SWITCH

G

G/W

Bl: Black

Lg/Bl

SIDESTAND

NEUTRAL

Bu: Blue

SWITCH