Page 1
15. IGNITION SYSTEM
15-0
Mongoose/KXR 90/50
15
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
IGNITION SYSTEM
__________________________________________________________________________________
SERVICE INFORMATION -------------------------------------------- 15- 3
CDI UNIT INSPECTION----------------------------------------------- 15- 5
IGNITION COIL -------------------------------------------------------- 15- 7
PULSER COIL----------------------------------------------------------- 15- 8
IGNITION TIMING INSPECTION ----------------------------------- 15- 8
15
Page 2
15. IGNITION SYSTEM
15-1
Mongoose/KXR 90/50
A.C. Generator/ Pulser Coil
Spark Plug
Ignition Coil
Page 3
15. IGNITION SYSTEM
15-2
Mongoose/KXR 90/50
IGNITION CIRCUIT (Mongoose/KXR 90)
IGNITION CIRCUIT (Mongoose/KXR 50)
Page 4
15. IGNITION SYSTEM
15-3
Mongoose/KXR 90/50
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• Check the ignition system according to the sequence specified in the Troubleshooting.
• The ignition system adopts ignition unit, change gear control and the ignition timing cannot be
adjusted.
• If the timing is incorrect, inspect the ignition unit, A.C. generator, change gear control and replace
any faulty parts. Inspect the ignition unit with a ignition unit 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 spark plug referring to chapter 3.
SPECIFICATIONS (Mongoose/KXR 90)
Item
Standard
Spark plug
Standard type
NGK-C7HSA
Spark plug gap
0.6_ 0.7mm
Ignition timing
“F” mark
Full advance
28º±1ºBTDC/4000RPM
Primary coil
2.2_ 2.6W
Ignition coil resistance (20¢J)
Secondary
without plug cap
3.14KW
coil
with plug cap
8.39KW
Pulser coil resistance (20¢J)
121.1W
SPECIFICATIONS (Mongoose/KXR 50)
Item
Standard
Spark plug
Standard type
BR8HAS
Spark plug gap
0.6_ 0.7mm
Ignition timing
“F” mark
Full advance
15ºBTDC/1700±100rpm
Primary coil
3.7_ 15.2W
Ignition coil resistance (20¢J)
Secondary
without plug cap
3.51KW
coil
with plug cap
8.81KW
Pulser coil resistance (20¢J)
80_ 160W
Page 5
15. IGNITION SYSTEM
15-4
Mongoose/KXR 90/50
TROUBLESHOOTING
High voltage too low No high voltage
• Weak battery or low engine speed • Faulty ignition switch
• Loose ignition system connection • Faulty ignition unit
• Faulty ignition unit • Poorly connected or broken ignition unit
ground wire
• Faulty ignition coil •Dead battery or faulty regulator/rectifier
• Faulty pulser coil • Faulty ignition coil connector
Normal high voltage but no spark at plug • Faulty pulser coil
• Faulty spark plug
• Electric leakage in ignition secondary circuit
• Faulty ignition coil
Good spark at plug but engine won‘t start
• Faulty ignition unit or incorrect ignition timing
• Faulty change gear control unit
• Improperly tightened A.C. generator flywheel
Page 6
15. IGNITION SYSTEM
15-5
Mongoose/KXR 90/50
CDI UNIT INSPECTION
Remove seat. (!2-3)
Disconnect the CDI coupler and remove the
CDI unit.
Measure the resistance between the
terminals using the electric tester.
Mongoose/KXR 90(OFF ROAD) Unit:
MW
Probe⊕
(-)Probe
Black
Black/
Yellow
Blue/
Yellow
Green
Black
°¤°¤°¤
Black/
Yellow
°¤°¤°¤
Blue/
Yellow
°¤°¤°¤
Green
4.9~5.5
4.9~5.5
4.9~5.5
Note: The readings in this table are taken
with a YF-3501 Tester.
CDI Unit
Green
Black
Black/Yellow
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 YF-3501 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.
＊
Page 7
15. IGNITION SYSTEM
15-6
Mongoose/KXR 90/50
KXR 90(ON ROAD) Unit: MW
Probe⊕
(-)Probe
Black
Black/
Yellow
Blue/
Yellow
Green
Black
°¤°¤°¤
Black/
Yellow
°¤°¤°¤
Blue/
Yellow
°¤°¤°¤
Green
6.1~6.8
6.1~6.8
6.1~6.8
Note: The readings in this table are taken
with a YF-3501 Tester.
Mongoose/KXR 50(OFF ROAD) Unit:
MW
Probe⊕
(-)Probe
Black/
Yellow
Black/
Red
Black/
White
Blue/
Yellow
Green
Black/
Yellow
°¤°¤°¤
°¤
Black/
Red
°¤°¤15.73
4.63
Black/
White
°¤
8.52°¤°¤
Blue/
Yellow
°¤°¤°¤
°¤
Green
°¤°¤°¤
8.07
Note: The readings in this table are taken
with a YF-3501 Tester.
KXR 50(ON ROAD) Unit: MW
Probe⊕
(-)Probe
Black/
Yellow
Black/
Red
Black/
White
Blue/
Yellow
Green
Black/
Yellow
°¤°¤°¤
°¤
Black/
Red
°¤°¤°¤
9.98
Black/
White
°¤
10.2°¤°¤
Blue/
Yellow
°¤°¤°¤
°¤
Green
°¤°¤°¤
6.91
Note: The readings in this table are taken
with a YF-3501 Tester.
Blue/Yellow
Green
Black/Yellow
Black/ Red
Black/White
Green
Black
Black/Yellow
Blue/Yellow
Blue/Yellow
Green
Black/Yellow
Black/ Red
Black/White
Page 8
15. IGNITION SYSTEM
15-7
Mongoose/KXR 90/50
IGNITION COIL
REMOVAL
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:
Mongoose/KXR 90) : 2.2_ 2.6W/20°C
Mongoose/KXR 50) : 3.7_ 15.2W/20°C
Measure the secondary coil resistances with
and without the spark plug cap.
Resistances:
(Mongoose/KXR 90)
(with plug cap) : 8.39KW/20°C
(without plug cap) : 3.14KW/20°C
Mongoose/KXR 50)
(with plug cap) : 8.81KW/20°C
(without plug cap) : 3.51KW/20°C
Note: The readings in this table are taken
with a YF-3501 Tester.
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.
＊
Correctly operate the tester following the
manufacturer‘s instructions.
＊
Ignition Coil
Page 9
15. IGNITION SYSTEM
15-8
Mongoose/KXR 90/50
PULSER COIL
INSPECTION
Disconnect the A.C. generator connector.
Measure the pulser coil resistance between
the blue/yellow and green wire terminals.
Resistance:
Mongoose/KXR 90): 121.1W/20°C
Mongoose/KXR 50): 80_ 160W/20°C
Note: The readings in this table are taken
with a YF-3501 Tester.
REMOVAL
Refer to chapter 14 for the A.C. generator
removal.
IGNITION TIMING INSPECTION
Remove the fan cover.
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:
Mongoose/KXR 90): BTDC28°/4000rpm
Mongoose/KXR 50): BTDC15°/1700rpm
Advance Mark
“F” Mark
This test is performed with the stator
installed in the engine.
＊
Pulser Coil Lead
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.
＊
Loading...