Kymco MO MXer Service Manual - chap 01 (info generali)

1. GENERAL INFORMATION

1-0

MX’er SYSTEM

1

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__ __ __ _ __ __ __ __ ___ __ __ __ __ _ __ __ __ __ __ _ __ __ __ __ ___ __ __ __ __ _ __ __ __ __ __ _ __ __ __ __ ___ __

GENERAL INFORMATION

__ __ __ _ __ __ __ __ ___ __ __ __ __ _ __ __ __ __ __ _ __ __ __ __ ___ __ __ __ __ _ __ __ __ __ __ _ __ __ __ __ ___ __

SERIAL NUMBER ------------------------------------------------------ 1- 1

SPECIFICATIONS ------------------------------------------------------ 1- 2

SERVICE PRECAUTIONS--------------------------------------------- 1- 4

TORQUE VALUES ----------------------------------------------------- 1-12

SPECIAL TOOLS ------------------------------------------------------- 1-14

LUBRICATION POINTS----------------------------------------------- 1-15

CABLE & HARNESS ROUTING ------------------------------------- 1-18

WIRING DIAGRAM ---------------------------------------------------- 1-22

TROUBLESHOOTING ------------------------------------------------- 1-23

1

1. GENERAL INFORMATION

1-1

MX’er SYSTEM

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

1. GENERAL INFORMATION

1-2

MX’er SYSTEM

SPECIFICATIONS

Name & Model No.

LA30AA, AB

Motorcycle Name & Type

MX’er

Overall length (mm)

1600

Overall width (mm)

980

Overall height (mm)

990

Wheel base (mm)

1120

Engine type

O.H.C.

Displacement (cc)

149.4

Fuel Used

92# nonleaded gasoline

Front wheel

74

Net weight (kg)

Rear wheel

78

Total

152

Front wheel

80

Gross weight(kg)

Rear wheel

82

Total

162

Front wheel

20*7-8

Rear wheel

22*10-8

Ground clearance (mm)

130

Perform

-

Breaking distance

(m)(ANSI)

20.6 below

ance

Min. turning radius (m)

3

Starting system

Starting motor

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C., chain drive

Bore x stroke (mm)

62 x 49.5

Compression ratio

9.7:1

Compression pressure
(kg/cm_)

16.0

Max. output (ps/rpm)

11/7500

Max. torque (kg m/rpm)

1.1/5500

Intake

Open

5.5° BTDC

Port

(1mm)

Close

27.5° ABDC

timin
g

Exhaust

Open

36° BBDC

(1mm)

Close

4° ATDC

Valve clearance

Intake

0.06

(cold) (mm)

Exhaust

0.06

Idle speed (rpm)

1700rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.0 liter

Oil exchanging
capacity

0.9 liter

Cooling Type

Forced air cooling

Air cleaner type & No

Sponge

Fuel capacity

8.1 liters

Type

PD

Float lever

14.8mm

Venturi dia.(mm)

f25

Throttle type

PISTON

Type

CDI

Ignition timing

15°BTDC/1700rpm

Contact breaker

Non-contact point type

Spark plug

NGK

CR8E

Spark plug gap

0.6_ 0.7mm

Battery

Capacity

12V8AH

Clutch

Type

CVT

Type

Helical gear

Operation

Automatic centrifugal

type

Type

Chain drive

Reduction

1st

2.8-0.95

ratio

2nd

7.226

Counter gear ratio

26.902

Front

Caster angle

Axle

Trail length

Tire pressure

Front

0.2

(kg/cm_)

Rear

0.25

Turning

Left

44°

angle

Right

44°

Brake system

Rear

Disk brake

Drum brake

type

Front

Drum brake

Suspension

Front

Swing

type

Rear

Swing arm

Shock

Front

Swing

type

Rear

Swing arm

Frame type

SP pipe

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

1-3

MX’er SYSTEM

SPECIFICATIONS

Name & Model No.

LA25AB

Motorcycle Name & Type

MX’er

Overall length (mm)

1685

Overall width (mm)

980

Overall height (mm)

990

Wheel base (mm)

1120

Engine type

OHC

Displacement (cc)

124

Fuel Used

92# nonleaded gasoline

Front wheel

74

Net weight (kg)

Rear wheel

78

Total

152

Front wheel

80

Gross weight(kg)

Rear wheel

82

Total

162

Front wheel

20*7-8

Rear wheel

22*10-8

Ground clearance (mm)

130

Perform

-

Breaking distance

(m)(ANSI)

20.6 below

ance

Min. turning radius (m)

2.5

Starting system

Starting motor

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H..C., chain drive

Bore x stroke (mm)

56.5 x 49.5

Compression ratio

9.2:1

Compression pressure
(kg/cm_)

14.0

Max. output (ps/rpm)

9.8/7500

Max. torque (kg m/rpm)

0.98/5500

Intake

Open

5.5° BTDC

Port

(1mm)

Close

27.5° ABDC

T imin

Exhaust

Open

36° BBDC

(1mm)

Close

4° ATDC

Valve clearance

Intake

0.06

(cold) (mm)

Exhaust

0.06

Idle speed (rpm)

1700rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.0 liter

Oil exchanging
capacity

0.9 liter

Cooling Type

Forced air cooling

Air cleaner type & No

Sponge

Fuel capacity

8.1 liters

Type

PD

Piston dia. (mm)

14.8mm

Venturi dia.(mm)

f25

Throttle type

PISTON

Type

CDI

Ignition timing

15°BTDC/1700rpm

Contact breaker

Non-contact point type

Spark plug

NGK

CR8E

Spark plug gap

0.6_ 0.7mm

Battery

Capacity

12V8AH

Clutch

Type

CVT

Type

Helical gear

Operation

Automatic centrifugal

type

Type

Chain drive

Reduction

1st

2.8-0.95

ratio

2nd

7.226

Counter gear ratio

26.902

Front

Caster angle

Axle

Trail length

Tire pressure

Front

0.2

(kg/cm_)

Rear

0.25

Turning

Left

44°

angle

Right

44°

Brake system

Rear

Disk brake

Drum brake

type

Front

Drum brake

Suspension

Front

Swing

type

Rear

Swing arm

Shock

Front

Swing

type

Rear

Swing arm

Frame type

SP pipe

System

Tires

Engine

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

1-4

MX’er SYSTEM

SERVICE PRECAUTIONS

n Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when
reassembling.

n When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

n Use genuine parts and lubricants.

n When servicing the motorcycle, be sure to

use special tools for removal and
installation.

n After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION

1-5

MX’er SYSTEM

n Apply or add designated greases and

lubricants to the specified lubrication
points.

n After reassembly, check all parts for

proper tightening and operation.

n When two persons work together, pay

attention to the mutual working safety.

n Disconnect the battery negative (-)

terminal before operation.

n When using a spanner or other tools,

make sure not to damage the motorcycle
surface.

n After operation, check all connecting

points, fasteners, and lines for proper
connection and installation.

n When connecting the battery, the positive

(+) terminal must be connected first.

n After connection, apply grease to the

battery terminals.

n Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-6

MX’er SYSTEM

n If the fuse is burned out, find the cause

and repair it. Replace it with a new one
according to the specified capacity.

n After operation, terminal caps shall be

installed securely.

n When taking out the connector, the lock

on the connector shall be released before
operation.

n Hold the connector body when connecting

or disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is

bending, protruding or loose.

Confirm
Capacity

1. GENERAL INFORMATION

1-7

MX’er SYSTEM

n The connector shall be inserted

completely.

n If the double connector has a lock, lock

it at the correct position.

n Check if there is any loose wire.

n Before connecting a terminal, check for

damaged terminal cover or loose
negative terminal.

n Check the double connector cover for

proper coverage and installation.

n Insert the terminal completely.
n Check the terminal cover for proper

coverage.

n Do not make the terminal cover opening

face up.

n Secure wire harnesses to the frame with

their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

Snapping!

1. GENERAL INFORMATION

1-8

MX’er SYSTEM

n After clamping, check each wire to make

sure it is secure.

n Do not squeeze wires against the weld or

its clamp.

n After clamping, check each harness to

make sure that it is not interfering with
any moving or sliding parts.

n When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.

n Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of
bolts and screws.

n Route wire harnesses passing through the

side of bolts and screws. Avoid the
projected ends of bolts and screws.

No Contact !

1. GENERAL INFORMATION

1-9

MX’er SYSTEM

n Route harnesses so they are neither

pulled tight nor have excessive slack.

n Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge
or corner.

n When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.

n Do not break the sheath of wire.
n If a wire or harness is with a broken

sheath, repair by wrapping it with
protective tape or replace it.

n When installing other parts, do not press

or squeeze the wires.

Do not
pull too

Do not
press or
squeeze the

1. GENERAL INFORMATION

1-10

MX’er SYSTEM

n After routing, check that the wire

harnesses are not twisted or kinked.

n Wire harnesses routed along with

handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.

n When a testing device is used, make sure

to understand the operating methods
thoroughly and operate according to the
operating instructions.

n Be careful not to drop any parts.

n When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting.

Do you understand
the instrument? Is
the instrument set
correctly?

Remove Rust

1. GENERAL INFORMATION

1-11

MX’er SYSTEM

n Symbols:

The following symbols represent the
servicing methods and cautions included
in this service manual.

: Apply engine oil to the

specified points. (Use
designated engine oil for
lubrication.)

: Apply grease for

lubrication.

: Transmission Gear Oil

(90#)

: Use special tool.

: Caution

: Warning

Engine Oil

Grease

Gear Oil

Special

1. GENERAL INFORMATION

1-12

MX’er SYSTEM

TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (kgf-m)

Item

Torque (kgf-m)

5mm bolt, nut
6mm bolt, nut

8mm bolt, nut
10mm bolt, nut
12mm bolt, nut

14mm bolt, nut

0.45_ 0.6

0.8_ 1.2

1.8_ 2.5

3.0_ 4.0

5.0_ 6.0

6.0_ 8.0

4mm screw
5mm screw

6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut

0.15_ 0.4

0.3_ 0.5

0.7_ 1.1

1.0_ 1.4

2.4_ 3.0

3.5_ 4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (kgf-m)

Remarks

Stud bolt
Oil filter screen cap
Seat ball stopper bolt
Bearing hold
L cover
Stud bolt
Cam holder
Tappet ADJ nut
Pivot tensioner
Lifter tensioner
Lifter tensioner
MISTON oil drive bolt
Driver face
Clutch outer
Oneway clutch
Balancer shaft
ACG flywheel
Spark plug
Drain bolt mission
Drain plug
Clamper wre harness
Motor srart
Oil pump
Oil pump sprocket
Head CYL bolt
Starting clutch
Startor

4
1
1
1
8
4
4
2
1
2
1
9
1
1
3
1
1
1
1
1
1
2
2
2
2
1
4

8
30
14

6

6

6

8

6

8

6

6

6
12
12

8
16
14

8

8
12

6

6

6

6

6
22

5

0.7_ 1.1

1.0_ 2.0

4.5_ 5.0

1.0_ 1.2

1.0_ 1.4

0.7_ 1.1

1.8_ 2.2

1.4_ 1.8

0.8_ 1.2

1.0_ 1.4

0.35_ 0.5

0.8_ 1.2

5.5_ 6.5

5.0_ 6.0

2.4_ 3.0

4.0_ 5.0

5.0_ 6.0

1.1_ 2.3

0.8_ 1.2

2.0_ 3.0

0.8_ 1.2

0.8_ 1.2

0.8_ 1.2

0.8_ 1.2

0.8_ 1.2

0.9_ 10.0

0.8_ 1.2

1. GENERAL INFORMATION

1-13

MX’er SYSTEM

Item

Q‘ty

Thread dia.(mm)

Torque (kgf-m)

Remarks

R cover

Head cover

Cap R cover

Guide star change handle

Sprocket drive plate

Carburetor

Check bolt oil

9

4

1

3

2

2

1

6

6

6

6

6

6

10

0.8_ 1.2

0.8_ 1.2

0.8_ 1.2

0.8_ 1.2

1.0_ 1.6

0.8_ 1.2

1.0_ 1.5

FRAME

Item

Q‘ty

Thread dia.(mm)

Torque (kgf-m)

Remarks

Steering stem nut

Swing arm nut

Rear wheel nut

Front wheel nut

Rear shock absorber upper mount bolt

Front shock absorber upper mount bolt

Front shock absorber lower mount bolt

Rear fork axle

Rear hub nut

Rear wheel shaft nut

Rear engine bracket up bolt

Rear engine bracket bolt

Engine hanger bracket bolt

Exhaust muffler lock bolt

1

4

2

2

1

2

2

1

4

2

1

1

1

2

14

10

14

14

10

10

10

14

12

32

10

10

10

8

6.0_ 8.0

4.0_ 5.0

6.0_ 8.0

6.0_ 8.0

3.5_ 4.5

3.5_ 4.5

3.5_ 4.5

6.0_ 8.0

6.0_ 8.0

11.0_ 13.0

3.5_ 4.5

3.5_ 4.5

3.5_ 4.5

3.2_ 3.8

1. GENERAL INFORMATION

1-14

MX’er SYSTEM

SPECIAL TOOLS

Tool Name

Tool No.

Remarks Ref. Page

Flywheel puller

E003

Lock nut wrench

E009

Valve adjuster

E012

Valve spring compressor

E040

Oil seal and bearing install

E014

Universal holder

E017

Flywheel holder

E021

Clutch spring compressor

E027

Bearing puller

E008

Bearing puller

E018

Bearing puller

E020

Bearing puller

E031

Nut wrench

F010

Float level gauge

1. GENERAL INFORMATION

1-15

MX’er SYSTEM

LUBRICATION POINTS

ENGINE

Lubrication Points

Lubricant

Valve guide/valve stem movable part

Cam lobes

Valve rocker arm friction surface

Cam chain

Cylinder lock bolt and nut

Piston surroundings and piston ring grooves

Piston pin surroundings

Cylinder inside wall

Connecting rod/piston pin hole

Connecting rod big end

Crankshaft right side oil seal

Crankshaft one-way clutch movable part

Oil pump drive chain

Balance gear

A.C. generator

Starter one-way clutch

Bearing movable part

O-ring face

Oil seal lip

•Genuine KYMCO Engine Oil (SAE15W-40)

•API SG Engine Oil

Transmission gear and movable parts

Gear oil: SAE90#

1. GENERAL INFORMATION

1-16

MX’er SYSTEM

FRAME

The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.

Steering knuckle/Thrust
Cover/Bush/Collar

Steering Column Upper

Rear Brake Cable

Front Brake
camshaft/Oil
Seal/O-ring

Throttle Cable

Front Brake Cable

Steering Column Lower

Front Wheel
Oil Seal

Front Arm Bush

Front Brake
camshaft/Oil
Seal/O-ring

Front Wheel
Oil Seal

Steering knuckle/Thrust
Cover/Bush/Collar

Front Arm Bush

1. GENERAL INFORMATION

1-17

MX’er SYSTEM

Sprocket hub/Rear
Axle Hub Collar/Oil
Seal/Bearing

Rear Brake Cam/ Axle
Hub Collar/Oil
Seal/Bearing

Driven Sprocket

Swing arm Thrust
Cover

1. GENERAL INFORMATION

1-18

MX’er SYSTEM

CABLE & HARNESS ROUTING

Throttle Cable

Rear Brake Cable

Right Front Brake Cable

Handlebar Switch Lead

Front Brake Cable

Left Front Brake Cable

1. GENERAL INFORMATION

1-19

MX’er SYSTEM

Main Switch

Inlet Hose

Breather
Hose

Breather Hose (CYL
Head Cover)

1. GENERAL INFORMATION

1-20

MX’er SYSTEM

Wire Harness

Fuse

Breather Hose

Rectifier/Regulator

Ignition Coil

Outlet Hose

1. GENERAL INFORMATION

1-21

MX’er SYSTEM

Battery Negative
Cable

Change Gear Control

A.C.G Wire
Connector

Battery

Starter Relay

Positive Cable

CDI Unit

Fuse

Breather Hose (CYL
Head Cover)

1. GENERAL INFORMATION

1-22

MX’er SYSTEM

WIRING DIAGRAM

COLOR CODE

CODE

COLOR

CODE

COLOR

B

Black

Sb

Sky blue

Y

Yellow

W

White

G

Green

B/W

Black/White

R

Red

Y/R

Yellow/Red

L

Blue

G/Y

Green/Yellow

O

Orange

G/L

Green/Blue

Br

Brown

L/W

Blue /White

P

Pink

R/W

Red/White

1. GENERAL INFORMATION

1-23

MX’er SYSTEM

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel tank cap breather
hole
Clogged fuel filter
Clogged fuel valve passage

Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty change gear control unit
Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery

Faulty starter clutch
Valve clearance too small
Valve stuck open
Worn cylinder, piston and piston
rings
Leaking cylinder head gasket

Air leaking through intake

pipe
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted air*/ screw

Flooded carburetor
Clogged air cleaner
Throttle valve excessively

open

Check if fuel reaches
carburetor by
loosening drain screw

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground

Inspection/Adjustment

Probable Cause

Spark jumps

Normal
compression

Engine does not
fire

Weak or no spark

Low or no
compression

Engine fires but
does not start

Test cylinder
compression

Start engine by follow­ing normal starting
procedure

Remove spark plug and
inspect again

Symptom

Fuel reaches
carburetor

Fuel does not
reach carburetor

Wet spark plug

Dry spark plug

1. GENERAL INFORMATION

1-24

MX’er SYSTEM

ENGINE LACKS POWER

Clogged air cleaner
Restricted fuel flow
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Carburetor fuel level too low

Faulty CDI unit

Faulty pulser coil

Improper valve clearance
adjustment
Excessively worn valve seat
(protruded valve stem)

Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing

Clean and unclog

Fouled spark plug
Incorrect heat range plug

Oil level too high
Oil level too low
Oil not changed

Clogged oil line

Faulty oil pump

Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon build-up in
combustion chamber
Ignition timing too early

Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early

Start engine and accelerate
lightly for observation

Inspection/Adjustment

Symptom

Probable Cause

Engine speed
increases

Correct timing

Engine speed does not
increase sufficiently

Incorrect timing

Check ignition timing
(using a timing light)

Test cylinder compression

Check carburetor for
clogging

Rapidly accelerate or run
at high speed

Remove spark plug and
inspect

Check if engine overheats
Check valve clearance

Correct

Incorrect

Normal

compression

Abnormal
compression

Remove oil dipstick and
check oil level and condition

Remove cylinder head oil
pipe bolt and inspect

Engine overheats

Engine does not
overheats

Plug not fouled or
discolored

Plug fouled or
discolored

Correct and not
contaminated

Incorrect or
contaminated

Valve train lubricated
properly

Valve train not
lubricated properly

Engine does not knock

Engine knocks

Not clogged

Clogged

1. GENERAL INFORMATION

1-25

MX’er SYSTEM

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty CDI unit
Faulty pulser coil

Mixture too rich (turn screw
out)
Mixture too lean (turn screw

in)

Deteriorated O-ring
Carburetor not securely
tightened
Damaged insulator rubber

Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Check carburetor
gasket for air leaks

Check carburetor air
screw adjustment

Correct timing

Incorrect timing

Correctly adjusted

No air leak

Air leaks

Good spark

Weak or inter­ mittent spark

Incorrectly

1. GENERAL INFORMATION

1-26

MX’er SYSTEM

POOR PERFORMANCE (AT HIGH SPEED)

Faulty CDI unit
Faulty pulser coil

Improperly adjusted valve
clearance
Worn valve seat

Empty fuel tank
Clogged fuel tube or filter

Clogged Fuel tank cap breather
hole

Clean and unclog

Cam timing gear aligning
marks not aligned

Faulty spring

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Check carburetor jets
for clogging

Check fuel pump for
fuel supply

Correct timing

Incorrect timing

Check valve spring
tension

Check valve clearance

Fuel flows freely

Fuel flow restricted

Correct

Incorrect

Not clogged

Clogged

Correctly adjusted

Incorrectly adjusted

Not weakened

Weak spring

Check valve timing

1. GENERAL INFORMATION

1-27

MX’er SYSTEM

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Dead battery
Faulty battery

Faulty A.C. generator coil
Broken yellow wire
Shorted pink and yellow
wires

Broken red wire

Faulty regulator/rectifier
Poorly connected coupler

Faulty A.C. generator

Overcharging

Broken green wire

Poorly connect ed coupler

Faulty regulator/rectifier

Start engine and test
limit voltage of
battery terminals

Connect battery (+)
wire to
regulator/rectifier
coupler red wire and
battery (-) wire to engine

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Battery has
voltage with
ignition switch

Normal

Voltage does not
increase

Battery has no
voltage wit h
ignition swit ch

Resistance t oo

Normal voltage

No voltage

Measure resistance
between AC generator
coil terminals

Normal

Abnormal

Check
regulator/rectifier
coupler for loose

Normal

Abnormal

Connect battery (+)
wire to
regulator/rectifier
coupler green wire and
battery (-) wire to engine

Check
regulator/rectifier
coupler for loose

1. GENERAL INFORMATION

1-28

MX’er SYSTEM

NO SPARK AT SPARK PLUG

Faulty spark plug

Loose spark plug cap

Poorly connected coupler

Faulty ignition switch
Weak battery
Faulty pulser coil
Faulty ignition coil
Faulty charging system

Broken wire harness
Poorly connected coupler

Faulty CDI unit
Faulty change gear control
unit

Faulty ignition coil

Replace with a new
spark plug and inspect
again

Check CDI unit
coupler for looseness

Inspection/Adjustment

Symptom

Probable Cause

Normal

Abnormal

Normal

Abnormal

Normal

Abnormal

Abnormal

Measure resistance
between terminals of
CDI unit coupler

Check related parts

Check ignition coil
with a CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Good

Good

Check spark plug cap
and high-tension wire
for looseness

Check CDI unit with a
CDI unit tester