Page 1
15. IGNITION SYSTEM
15-0
FILLY LX 50
15
Pulser Coil
Ignition Switch
CDI Unit
A.C. Generator
CDI Unit
15
Ignition
Switch
G
Spark Plug
Battery
BYW
G
L/Y
B/Y
Fuse
Pulser Coil
Ignition Coil
Spark Plug
Page 2
15. IGNITION SYSTEM
15-1
FILLY LX 50
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• Check the ignition system according to the sequence specified in the Troubleshooting. (!15-2)
• The ignition system adopts CDI unit and the ignition timing cannot be adjusted.
• If the timing is incorrect, inspect the CDI unit and A.C. generator and replace any faulty parts.
Inspect the CDI unit with a CDI tester
• Loose connector and poor wire connection are the main causes of faulty ignition system. Check
each connector before operation.
• Use of spark plug with improper heat range is the main cause of poor engine performance.
• The inspections in this section are focused on maximum voltage. The inspection of ignition coil
resistance is also described in this section.
• Inspect the ignition switch according to the continuity table specified in page 17-3.
• Inspect the spark plug referring to Section 3.
• Remove the A.C. generator and pulser coil referring to Section 14.
SPECIFICATIONS
Item
Standard
Standard type
(NGK) C7HSA
Spark plug
Hot type
(NGK) C6HSA
Cold type
(NGK) C8HSA
Spark plug gap
0.6_ 0.7mm
Ignition timing
“F” mark
Full advance
13° BTDC
/1,700rpm±100RPM
28° BTDC
/4,000rpm±100RPM
Primary coil
0.1_ 1.0W
Ignition coil resistance
Secondary
with plug cap
7_ 12KW
coil
without plug cap
3_ 5KW
Pulser coil resistance (20℃ )
40_ 300W
Ignition coil primary side max. voltage
12V min.
Pulser coil max. voltage
2.1V min.
TESTING INSTRUMENT
Kowa Electric Tester
or commercially available electric tester with resistance over 10MW/CDV
SERVICE INFORMATION
......................
15-1 IGNITION COIL
.....................................
15-4
TROUBLESHOOTING
............................
15-2 PULSER COIL
.........................................
15-5
CDI UNIT INSPECTION
.........................
15-3
Page 3
15. IGNITION SYSTEM
15-2
FILLY LX 50
TROUBLESHOOTING
High voltage too low No or intermittent high voltage
• Weak battery or low engine speed • Faulty ignition coil
• Loose ignition system connection • Weak battery
• Faulty ignition coil • Faulty charging system
• Faulty CDI unit
• Faulty pulser coil
Intermittent high voltage
• Faulty ignition switch
• Poorly connected CDI unit coupler
• Poorly connected or broken CDI ground wire
• Faulty pulser coil
• Loose high tension wire connection
• Faulty CDI unit
Normal high voltage but no spark at plug
• Faulty spark plug
• Faulty spark plug cap
No high voltage
• Faulty ignition switch
• Dead battery or faulty regulator/rectifier
• Faulty charging circuit
• Faulty ignition coil
• Faulty CDI unit
Page 4
15. IGNITION SYSTEM
15-3
FILLY LX 50
CDI UNIT INSPECTION
Remove the three battery cover screws.
Disconnect the CDI coupler and remove the
CDI unit.
Measure the resistance between the terminals
using the electric tester.
Unit: KW
Probe⊕
(-)Probe
Black
Black/
Yellow
Blue/
Yellow
Green
Black
∞
1K~10~60
Black/
Yellow
30~80
150~40
5~15
Blue/
Yellow
100~25
∞
40~90
Green
10~30
∞
60~200
Blue/
Yellow
• Due to the semiconductor in circuit, it is
necessary to use a specified tester for
accurate testing. Use of an improper
tester in an improper range may give
false readings.
• Use a Sanwa Electric Tester or Kowa
Electric Tester.
• In this table, “Needle swings then
returns” indicates that there is a charging
current app lied to a condenser. The needle
will then remain at “∞ ” unless the
condenser is discharged.
＊
Green
CDI Unit
Black
Black/
Yellow
Page 5
15. IGNITION SYSTEM
15-4
FILLY LX 50
IGNITION COIL
REMOVAL
Remove the met-in box. (!2-3)
Remove the spark plug cap.
Disconnect the ignition coil wires and remove
the ignition coil bolt and ignition coil.
INSPECTION
CONTINUITY TEST
Measure the resistance between the ignition
coil primary coil terminals.
Resistance: 0.1_ 1.0W
Measure the secondary coil resistances with
and without the spark plug cap.
Resistances:
(with plug cap) : 7_ 12KW
(without plug cap) : 3_ 5KW
The CDI unit is not adjustable. If the
timing is incorrect, inspect the CDI unit,
pulser coil and A.C. generator and
replace any faulty parts.
＊
Ignition Coil
Correctly operate the tester following the
manufacturer‘s instructions.
＊
Page 6
15. IGNITION SYSTEM
15-5
FILLY LX 50
PULSER COIL
INSPECTION
Remove the frame body cover. (!2-3)
Disconnect the A.C. generator connector.
Measure the pulser coil resistance between
the blue/yellow and green wire terminals.
Resistance: 80_ 160W
Refer to page 14-6 for the A.C. generator
removal.
IGNITION TIMING INSPECTION
Remove the timing hole cap.
Warm up the engine and check the ignition
timing with a timing light.
When the engine is running at the ignition
timing is correct if the “F” mark aligns with
the index mark within ±2°.
Ignition Timing: BTDC28°/4000rpm
This test is performed with the stator
installed in the engine.
＊
The CDI unit is not adjustable. If the
ignition timing is incorrect, inspect the
CDI unit, pulser coil and A.C. generator
and replace any faulty parts.
＊
Timing Hole Cap
“F“ Mark
Pulser Coil Coupler
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