ATV Ignition System Technical Manual

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Subsection 03 (IGNITION SYSTEM)

IGNITION SYSTEM

SERVICE TOOLS

Description Part Number Page

ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 2, 4

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 3–4

GENERAL

SYSTEM DESCRIPTION

The battery supplies the primary side of ignition coils through the main relay (R2) while the ECM completes the circuit for each cylinder by switching it to ground at the right moment. The ECM can detect an open and short circuit in the primary winding but it does not check the secondary winding.

The Engine Management System (EMS) controls the ignition system. For more information, refer

ENGINE MANAGEMENT

subsection.

Ignition Timing

Ignition timing is not adjustable.

TROUBLESHOOTING

It is good practice to check for fault codes using the B.U.D.S. software as a first troubleshooting step. Refer to

DIAGNOSTIC AND FAULT CODES

subsection. Always refer to the

WIRING DIAGRAM

when

troubleshooting an electrical circuit. Refer to

POWER DISTRIBUTION AND GROUNDS

for fuse and relay information. Refer to

WIRING HARNESS AND CONNECTORS

for vehicle wiring harness layout and component locations.

Refer to

ENGINE MANAGEMENT SYSTEM (EMS)

for powertrain wiring harness layout and component locations.

DIAGNOSTIC GUIDELINES

The following is provided to help in diagnosing the probable cause of a problem. It is a guideline and should not be assumed to list all possible causes.

ENGINE WILL NOT START (ENGINE TURNS OVER)

2. Defective CPS

- Check operation of CPS and replace if necessary. Refer to ELECTRONIC FUEL INJECTION (EFI) subsection.

3. Defective trigger wheel

- Inspect trigger wheel. Refer to MAGNETO AND STARTER subsection.

4. Defective ignition circuit

- Check fuse 5 of fuse box 1, ignition coil and wiring condition.

5. Defective fuel pump

- Check fuel pump, refer to FUEL TANK AND FUEL PUMP subsection.

6. Defective fuel injectors or circuit

- Check fuel injectors, refer to ENGINE MANAGEMENT SYSTEM subsection.

ENGINE HARD TO START

1. Spark plug faulty, fouled or worn out

- Check spark plug condition. Replace if necessary.

2. Low fuel pressure

- Test fuel pressure, refer to FUEL TANK AND FUEL PUMP subsection.

ENGINE MISFIRES, RUNS IRREGULARLY

1. Fouled, defective, worn spark plugs

- Check/verify heat range/gap/replace.

2. Damaged trigger wheel/loose CPS

- Inspect trigger wheel. Refer to MAGNETO AND STARTER subsection.

3. Defective ignition circuit

- Check ig nition coil, fu se 5, and wiring condition.

4. Poor engine grounds

- Check/clean/repair.

ENGINE CONTINUALLY BACKFIRES

1. Fouled, defective spark plugs

- Clean/replace spark plugs.

1. Fouled or defective spark plug

-Replace.

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Subsection 03 (IGNITION SYSTEM)

2. Damaged trigger wheel/defective or loose CPS

- Inspect trigger wheel and CPS , refer to MAGNETO AND STARTER and ELECTRONIC FUEL INJECTION (EFI) subsections.

PROCEDURES

IGNITION SWITCH

Ignition Switch Quick Test

Turn ignition switch to ON position. If multifunction gauge turns on (assuming it

works), the ignition switch is good. If multifunction gauge does not turn on, check the

following in this order:

– Battery – Fuse link 1 – Fuse 4, 5 and 8 of fuse box 1 – ECM is properly powered (refer to

TRONIC FUEL INJECTION (EFI)

subsection) – Ignition switch – Emergency engine stop switch.

Ignition Switch Access

Refer to side panel.

BODY

subsection and remove the LH

ELEC-

EMERGENCY ENGINE STOP SWITCH

Testing the Emergency Engine Stop Switch at ECM

1. Disconnect ECM connector and install it on the ECM adapter tool.

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TYPICAL

1. ECM

2. ECM connector cover

REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

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TYPICAL

on key

1. Igniti

2. Ignition switch conne ctor

3. ECM

2. Remove ignition key switch fuse (F8), refer to

POWER DISTRIBUTION AND GROUNDS

sub-

section.

3. Turn ignition key to ON position.

4. Test for continuity as per following table.

EMERGENCY ENGINE STOP SWITCH

TESTATECM

FUNCTION

RUN

position

STOP

position

FUSE BOX

CONTACT

5E A4

—

5E A4

—

If switch fails the test, refer to

ECM

ADAPTER

G2 to K3

RESULT

Close to

Open

circuit

Close to

TESTING THE EMERGENCY ENGINE STOP SWITCH AT MULTIFUNCTION SWITCH CONNECTORS

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Testing the Emergency Engine Stop Switch at Multifunction Switch Connectors

Refer to subsection for connector locations.

The emergency engine stop switch is wired into the LH multifunction switch connectors (MG1 and MG2).

1. Remove gauge support, refer to

GAUGE AND ACCESSORIES

2. Disconnect MG1 and MG2 connectors.

3. Test switch continuity as per following table.

EMERGENCY ENGINE STOP SWITCH PIN-OUT

RUN position

STOP position

If switch tests good, test continuity of wiring. Refer to

WIRING HARNESS AND CONNECTORS

LIGHTS,

subsection.

FUNCTION PROBE RESULT

MG1-3 to

MG2-3

MG1-1 to

MG1-2

MG1-3 to

MG2-3

MG1-1 to

MG1-2

WIRING DIAGRAM

Open circuit

Closeto0

Open circuit

Subsection 03 (IGNITION SYSTEM)

1-002_a

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TYPICAL

1. Ignition coil location

Installing

the Ignition Coil

Install a new elastic nut and tighten to the specified torque.

TIGHTENING TORQUE

Ignition coil retaining bolt

8N•m ± 1N•m

(71 lbf•in ±9lbf•in)

Testing the Ignition Coil Input Voltage

1. Disconnect the 3-pin connector from the ignition coil. Refer to

IGNITION COIL ACCESS

IGNITION COIL

06-018-100

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Ignition Coil Access

Refer to fender panel(s) for access to the ignition coil.

BODY

subsection and remove RH inner

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1. Ignition coil connector

2. Set emergency engine stop switch to RUN.

3. Turn ignition switch to ON.

4. Read voltage as per following table.

IRED TOOL

REQU

FLUKE 115 MULTIMETER

(P/N 529 035 868)

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Subsection 03 (IGNITION SYSTEM)

IGNITION COIL I

CONNECTORS VOLTAGE

Pin 2 with battery ground Battery voltage

NPUT VOLTAGE TEST

If battery voltage is NOT read, check continuity of ignition coil supply circuit. Refer to

GRAM

WIRING DIA-

Testing the Ignition Coil Ground Circuit Continuity

1. Disconnect the ECM connector and connect it to the ECM adapter tool. Refer to

TRONIC FUEL INJECTION (EFI)

subsection.

ELEC-

Testing the Ignition Coil Resistance

An ignition coil with good resistance measurement can still be faulty. Voltage leakage can occur at high voltage levels which is not detectable with an ohmmeter. Replacing the ignition coil may be necessary as a test.

Primary Windings

1. Disconnect HIC2 connector.

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TYPICAL

1. ECM

2. ECM connector cover

3. HIC2 connector

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TYPICAL

1. ECM

2. ECM conn

FLUKE 115 MULTIMETER

ector cover

REQUIRED TOOLS

ECM ADAPTER TOO L

(P/N 529 036 166)

(P/N 529 035 868)

2. Check wiring continuity as per following table.

IGNITION COIL GROUND CIRCUIT

CONTINUITY TEST

COMPO

Cylinder 1 (front)

Cylinder 2 (re ar)

NENT

(IGNITION

COIL

CONN

ECTOR)

3M2

(ECM

CONNECTOR)

2. Disconnect ECM connector and connect it to the ECM adapter tool.

REQUIRED

ECM ADAPTER TOOL

(P/N 529 036 166)

TOOL

3. Using a multimeter set to , check resistance in primary windings as follows.

ON COIL RESI STANCE TEST

IGNITI

PRIMAR

CIRCUIT

Cylinder 1

(front)

der 2

Cylin

(rear)

CONNECTOR

ENGINE

(HIC2)

Pin C

ECM

CONNECTOR

RESISTANCE

@ 20°C

(68°F)

.3 - .6

If any resistance is not good, measure resistance directly on coil. If second test is ok, check wiring.

Secondary Windings

o the integrated diode, it is not possible

Due t

ke any resistance measurement of the sec-

to ta

ry winding.

onda

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SPARK PLUG

For spark plug replacement procedure, refer to

PERIODIC MAINTENANCE PROCEDURES

section.

Troubleshooting Fouled Spark Plug

Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are: prolonged idling or low-speed riding, a clogged air filter, incorrect fuel, defective ignition system, incorrect spark plug gap, lubricating oil entering the combustion chamber, or too cold spark plug. The plug face of a fouled spark plug has either a wet black deposit or a black carbon fouling. Such coatings form a conductive connection between the center electrode and ground.

sub-

Subsection 03 (IGNITION SYSTEM)

Spark Plug Analysis

A00E0AA

TYPICAL

1. Overheated (light grey, white)

2. Normal (light brown, brown)

3. Fouled (black, wet or dry, dark deposits, grey, melted coating)

The plug face reveals the condition of the engine, operating condition, method of driving and fuel mixture. For this reason it is advisable to inspect the spark plug at regular intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber).

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