Honda XL200 2001-2016 Service Manual
SERVICE INFORMATION 16-1
TROUBLESHOOTING 16-2
CDI SYSTEM INSPECTION 16-3
IGNITION COIL 16-3
PULSE GENERATOR 16-4
EXCITER COIL 16-5
IGNITION TIMING 16-6
SERVICE INFORMATION
GENERAL
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• When checking the ignition system, always follow steps in the troubleshooting flow chart (page 16-2).
• The CDI unit may be damaged if dropped. Also, if the connector is disconnected when current is present, the excessive
voltage may damage the unit. Always turn off the ignition switch before servicing.
• Ignition timing cannot be adjusted since the CDI unit is non-adjustable. If ignition timing is incorrect, check the system
components and replace any faulty parts.
• A faulty ignition system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
• Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
• For stator removal and installation, see section 9.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition
switch is ON and current is present.
• 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 loose of consciousness and may lead to death.
XL200
16. IGNITION SYSTEM
16-1
ITEM STANDARD
Spark plug
DP8EA-9(NGK) X24EP-U9 (DENSO)
Spark plug gap 0,8—0,9 mm (0.031 - 0.035 in)
Ignition timing “F” mark 15° BTDC a 1300 rpm
Full advance 32° BTDC a 5.500 rpm
Ignition coil Primary coil resistance 0,4—0,6
(20°C/68°F)
Secondary coil without plug cap 10,8—16,2k
resistance
with plug cap 15—22k
Exciter coil resistance 100-300 (20°C/68°F)
Pulse generator resistance (20°C/68°F) 293—358
SPECIFICATION
16
XL200
IGNITION SYSTEM
16-0
(5) CDI UNIT
(2) ENGINE STOP SWITCH
B/W
B/R
B/R
L/Y
L/Y
B/Y
G
G/W
(3) IGNITION COIL
(9) PULSE
GENERATOR
(1) IGNITION
SWITCH
(8) ALTERNATOR (10) SPARK PLUG
B…BLACK
R…RED
L…BLUE
Y…YELLOW
W…WHITE
G…GREEN
XL200
16-2
TROUBLESHOOTING
• Inspect the followings before diagnosing the system.
– Faulty spark plug.
– Loose spark plug cap or spark plug wire connections.
– Water got into the spark plug cap (Leaking the ignition coil secondary voltage).
• Temporarily exchange the ignition coil with the other good one and perform spark test. If there is spark, the exchanged
ignition coil is faulty.
Weak or no spark at plug
IGNITION SYSTEM
Check the ignition secondary coil
resistance (page 16-3).
Normal
Abnormal
Abnormal
Abnormal
Normal Abnormal
Abnormal
Check the CDI unit connectors for loose or
poorly contact.
Normal
Check the ignition coil resistance at the CDI
unit 4P connector (page 16-3).
Normal
Measure voltage between Black/White and
Green terminals of CDI unit.
Continuity should exist with ignition switch
“ON”.
Normal
Check the pulse generator resistance at the
CDI unit 4P connector.
• Faulty ignition coil
• Faulty spark plug wire
• Loose or poorly contact connectors
• Check the ignition coil.
Abnormal
Normal Abnormal
• Check the pulse generator.
• Open or short circuit
in wire harness
• Faulty ignition switch
• Open or short circuit in wire harness
• Faulty ignition coil
• Open or short circuit
in wire harness
• Loose or poorly
contact connectors
• Faulty CDI unit.
• Faulty pulse
generator
Normal
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