Page 1
15. IGNITION SYSTEM
15-0
MX’er SYSTEM
15
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IGNITION SYSTEM
__ __ ___ __ __ __ __ ___ __ __ __ __ _ __ __ __ __ ___ __ __ __ __ ___ __ __ __ __ _ __ __ __ __ ___ __ __ __ __ ___ __
SERVICE INFORMATION -------------------------------------------- 15- 2
TROUBLESHOOTING ------------------------------------------------- 15- 3
CDI UNIT INSPECTION----------------------------------------------- 15- 4
IGNITION COIL -------------------------------------------------------- 15- 6
PULSER COIL----------------------------------------------------------- 15- 7
15
Page 2
15. IGNITION SYSTEM
15-1
MX’er SYSTEM
IGNITION CIRCUIT
Ignition Switch
CDI Unit/Change Gear Control.
A.C. Generator/ Pulser Coil
Spark Plug
Ignition Coil
PULSER COIL
Page 3
15. IGNITION SYSTEM
15-2
MX’er SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• Check the ignition system according to the sequence specified in the Troubleshooting.
• The ignition system adopts CDI unit , change gear control and the ignition timing cannot be
adjusted.
• If the timing is incorrect, inspect the CDI unit, A.C. generator, change gear control 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 17-5.
• Inspect the spark plug referring to Section 3.
SPECIFICATIONS
Item
Standard
Standard type
CR8E
Spark plug
Hot type
Cold type
Spark plug gap
0.6_ 0.7mm
Ignition timing
“F” mark
Full advance
15ºBTDC/1,700±100rpm
Primary coil
0.2_ 0.3W
Ignition coil resistance
Secondary
with plug cap
3.2_ 4.8KW
coil
plug cap
4.2_ 5.2KW
Pulser coil resistance (20℃ )
50_ 60W
Exciter coil resistance (20℃ )
100_ 120W
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
Page 4
15. IGNITION SYSTEM
15-3
MX’er SYSTEM
TROUBLESHOOTING
High voltage too low No high voltage
• Weak battery or low engine speed • Faulty ignition switch
• Loose ignition system connection • Faulty CDI unit
• Faulty CDI unit • Poorly connected or broken CDI 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 CDI or incorrect ignition timing
• Faulty change gear control unit
• Improperly tightened A.C. generator flywheel
Page 5
15. IGNITION SYSTEM
15-4
MX’er SYSTEM
CDI UNIT INSPECTION
Remove the seat.
Disconnect the CDI coupler and remove the
CDI unit.
Measure the resistance between the
terminals using the electric tester.
.
Testing Range
Use the xKW range for the Sanwa Tester.
Use the xKW range for the Kowa Tester.
Note: The readings in this table are taken
with a Sanwa Tester.
Unit: KW
Black/White
• 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.
＊
Blue/Yellow
CDI Unit
Black/Red
Black/Yellow
Green/White
Green/Red
Probe⊕
(-)Probe
Black/
White
Black/
Red
Blue/
White
Green
Green/
White
Black/
Yellow
Black/
White
∞∞∞∞∞
Black/
Red
3-6K
∞
∞
∞
∞
Blue/
White
35-42K
18-22K
8-10K
8-10K
∞
Green
15-18K
4.5-5.5K
7-9K
There is
continuity
∞
Green/
White
15-18K
4.5-5.5K
8-9K
There is
continuity
∞
Black/
Yellow
∞∞∞∞∞
Needle
Swings then
Needle
Swings then
Change Gear Control
Page 6
15. IGNITION SYSTEM
15-5
MX’er SYSTEM
Test the CDI unit using the CDI tester.
Connect the special connector to the CDI
coupler and CDI tester.
Switch Range
Good CDI
Faulty CDI
1. OFF
2. P
3. EXT
4. ON1
5. ON2
No spark
No spark
No spark
Good spark
Good spark
ææ
ææ
Good spark
No spark
No spark
If the CDI unit is faulty, replace it with a
new one.
Remove the seat.
Disconnect the change gear control coupler
and remove the change gear control unit.
Measure the resistance between the
terminals using the electric tester.
Testing Range
Use the xKW range for the Sanwa Tester.
Use the xKW range for the Kowa Tester.
Note: The readings in this table are taken
with a Sanwa Tester.
Unit: KW
Probe⊕
(-)Probe
Black
Green
Green/
Yellow
Green/
Pink
Light Green/
Red
Blue/
Yellow
Yellow/
Brown
Black
5-50K
5-50K
5-50K
5-50K
5-50K
5-50K
Green
∞
5-50K
5-50K
5-50K
5-50K
0
Green/
Yellow
∞
5-50K
10-50K
10-50K
10-50K
5-50K
Green/
Pink
∞∞∞0∞
∞
Light Green/
Red
∞∞∞0∞
∞
Blue/
Yellow
∞
50-200K
50-200K
50-200K
50-200K
Yellow/
∞
0
5-50K
5-50K
5-50K
5-50K
Blue/Yellow
Yellow/Brown
Light Green/Red
Black
Green /Yellow
Green
Green /Pink
Spark
Window
Ignition Coil
CDI Unit
Spark Plug
CDI Tester
Operate the CDI tester by following the
manufacturer‘s instructions.
＊
Page 7
15. IGNITION SYSTEM
15-6
MX’er SYSTEM
IGNITION COIL INSPECTION
CONTINUITY TEST
Remove the front cover.
Remove the spark plug cap.
Disconnect the ignition coil wires.
Measure the resistance between the ignition
coil primary coil terminals.
Resistance: 0.2_ 0.3W/20℃
Remove the spark plug cap and measure the
secondary coil resistance between the spark
plug wire and the primary coil terminal.
Resistance: 3.2_ 4.8KW/20℃
Measure the spark plug cap resistance.
Remove the spark plug cap and measure the
spark plug resistance.
Resistance: 4.2_ 5.2KW/20℃
PERFORMANCE TEST
Test the performance with a CDI tester.
If the spark is weak, inspect the spark plug
and CDI unit. If both of them are normal,
replace the ignition coil with a new one.
Ignition Coil
This test is to inspect the continuity of
ignition coil.
＊
This test is for reference only. Accurate
test should be performed with a CDI
tester.
＊
Measure the resistance in the XKW range
of the electric tester.
＊
Ignition Coil
CDI Unit
Spark Plug
CDI Tester
• Operate the CDI tester by following
the manufacturer‘s instructions.
• Use the special connector to connect
the CDI unit.
＊
Page 8
15. IGNITION SYSTEM
15-7
MX’er SYSTEM
PULSER COIL
INSPECTION
Remove the front cover.
Disconnect the pulser coil wire coupler and
measure the resistance between the blue/
yellow and green/white wire terminals.
Resistance: 50_ 60W
EXCITER COIL
INSPECTION
Disconnect the exciter coil wire coupler and
measure the resistance between the black/red
wire terminal and ground.
Resistance: 100_ 120W
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