Kymco MO FILLY 50LX Service Manual - chap 15 (imp accensione)

Page 1
15. IGNITION SYSTEM
15-0
FILLY LX 50
15
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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