7 SPECIFICATIONS BATTERY IGNITION TIMING SPARK OCCURRENCE Size 12 VDC Type Sealed SPARK PLUGS Size 12 mm Style 6R12 Gap 0.038-0.045 in. 0.96-1.14 mm 11-18 ft-lbs 14.9-24.4 Nm Torque value V.O.E.S. Idle Connected Disconnected World models 950-1050 RPM 20˚ BTDC Approximately 7.5˚ BTDC California models 1150-1250 RPM 20˚ BTDC Approximately 7.5˚ BTDC IGNITION COIL RESISTANCE Primary winding 2.5-3.
ITEM TORQUE NOTES Headlamp housing screws 5-7 ft-lbs 6.8-9.5 Nm Ignition coil mounting screws 2-6 ft-lbs 2.7-8 Nm page 7-17 12-20 in-lbs 1.4-2.3 Nm page 7-15 3-5 ft-lbs 4.0-6.8 Nm LOCTITE THREADLOCKER 242 (blue), page 7-42 90-110 in-lbs 10.2-10.4 Nm LOCTITE THREADLOCKER 242 (blue), page 7-30 Spark plugs 11-18 ft-lbs 14.9-24.4 Nm page 7-1 Stator mounting screws 30-40 in-lbs 3.4-3.
IGNITION SYSTEM GENERAL Ignition Module The vehicle uses a breakerless inductive-discharge ignition system. The system has both a primary and secondary circuit. The primary circuit consists of the battery, ignition switch, primary coil winding, computerized ignition timer and associated wiring. The secondary circuit consists of the secondary coil, spark plugs and associated wiring. See Figure 7-1.
Vacuum-Operated Electric Switch The vacuum-operated electric switch (V.O.E.S.) is attached to the carburetor. The V.O.E.S. senses intake passage vacuum through a carburetor hose connection. The switch is open during acceleration and high engine load conditions (low vacuum) and is closed during deceleration and low engine load conditions (high vacuum). The ignition module is programmed with two spark advance curves to meet varying engine loads.
b0241x7x ELECTRONIC IGNITION VACUUM SWITCH TIMER AND PICKUP BK BK TN NEUTRAL 2 1 BK V/W GN/W PK R/W BK/W W/BK BK V/W P7 R/W BK/W TN GN/W P10 P1 BE W/R GN/BK Y/O GY W/BK W/BK BK/R 1 2 3 4 BK V/W GN/W PK R/W BK/W W/BK IGN POWER IGN MODULE FROM (2) TO STARTER 8 7 6 5 4 3 2 1 A B C P16 NEUTRAL SWITCH P3 TN 12 11 10 9 8 7 6 5 4 3 2 1 S8 BK P14 TN/W 2 1 BK W SIDE STAND SWITCH S2 S1 TN S13 S11 MAIN CHASSIS GROUND S12 TN TN/GN S10 TN/GN BK R TN/GN MASTER 30A CIRCUIT BREAKER S7 T
Continuous or No Spark at Plug STEP 1 1. Ignition switch on. 2. Multimeter red wire to white wire terminal, black wire to ground. 3. Meter should register 12 VDC ± 1.0 volt. If meter is correct, proceed to STEP 2. 1. STEP 2 Remove pink (module) wire from coil terminal. 2. Ignition switch on. 3. Multimeter red wire alternately to white wire terminal and to pink wire terminal. 4. Meter should register 12 VDC at both terminals. If meter is correct, proceed to STEP 3. 1.
STEP 5 1. Ignition on. 2. Momentarily place screwdriver across black/white and green connector pins. Since the ignition module ignores the first four sensor inputs, repeat this step six to ten times. 3. Strong evidence of spark at spark plug when screwdriver is removed. If there is a spark, sensor is suspect. Install known, good sensor and test again. b0044a7x IF NO SPARK A B Check module resistance. See IGNITION RESISTANCE TESTIGNITION MODULE. Replace module if resistance is bad. C A.
Ignition Resistance Test-Ignition Module 1CAUTION If a resistance test is performed on a “live” circuit, the multimeter will be damaged. Turn off ignition and disconnect the battery before doing a resistance test. TEST Check for grounds METER SETTING PROBE 1 PROBE 2 RX1 To black/white wire in harness To chassis ground METER READING AT MODULE 0-1 Ohm Good More than 1 Ohm Check harness for opens. See next page. If harness checks OK, replace module. 2 b0080b3x 1 3 5 A B Chassis ground C 1.
Ignition Resistance Test-Ignition Module Harness TEST CONDITIONS: Engine stop switch on right handlebar must be in OFF position and 8-place ignition module connector [P10] and 3-place sensor connector [P16] must be disconnected for these tests. Shake or wiggle the harness to detect any breaks in the wiring.
VACUUM-OPERATED ELECTRIC SWITCH (V.O.E.S) ADJUSTMENT/TESTING See VACUUM-OPERATED ELECTRIC SWITCH (V.O.E.S) in Section 1. b0225x7x ELECTRONIC IGNITION MODULE BK BK P7 2 1 BK V/W GN/W PK R/W BK/W W/BK BK V/W REMOVAL Remove seat and fuel tank. See FUEL TANK, REMOVAL in Section 4. 2. See Figure 7-4. Disconnect V.O.E.S. connector [P7] from main wiring harness. 3. Remove V.O.E.S. from carburetor. P10 1. See Figure 7-4. Place a new V.O.E.S. on carburetor. 2. Attach V.O.E.S.
IGNITION/HEADLAMP SWITCH GENERAL 5755 2 1 1WARNING 3 DO NOT modify the ignition/headlamp switch wiring to circumvent the automatic-on headlamp feature. Visibility is a major concern for motorcyclists. Failure to have proper headlamp operation could lead to personal injury. 4 See Figure 7-5. The three-position combination ignition/headlamp switch is not repairable. Replace the unit if it fails. 5 Switch positions are explained in Table 7-1.
1. Insert ignition switch into hole of switch bracket. The word “TOP” stamped on the switch body should face upward toward the lettering on the switch position decal. Loosely install face nut. 2. See Figure 7-6. Attach ignition switch connector [P8] to main wiring harness. 3. Tighten face nut to secure switch within cover. b0226x7x R R/GY R/BK INSTALLATION R/BK R/GY R R/GY R/B K 4. A B C D IGN P8 Secure main wiring harness to frame with a new cable strap.
IGNITION MODULE GENERAL 5682 Ignition module See Figure 7-7. The ignition module is located on a plate which is a portion of the frame. The ignition module is not repairable. Replace the unit if it fails. See IGNITION SYSTEM on page 7-3 for information on the function and testing of the ignition module. REMOVAL Remove seat and tail section. See TAIL SECTION, REMOVAL in Section 2. 2. Disconnect battery cables, negative cable first. 3.
IGNITION SENSOR PLATE AND ROTOR GENERAL REMOVAL See Figure 7-9. The ignition sensor plate assembly (8) and trigger rotor (9) are located in the gearcase cover (11) on the right side of the vehicle. The rotor is mounted on the camshaft and operates at one-half crankshaft speed. The sensor plate wiring is connected to the ignition module (23) wiring harness. See IGNITION SYSTEM on page 7-3 for information on the function, testing and adjustment of the ignition sensor plate and trigger rotor assembly.
2. 3. Remove sprocket cover. See SPROCKET COVER in Section 2. 5630 Cut cable straps holding sensor plate wiring at the following locations: a. Top of starter. b. Edge of gearcase cover. c. Oil line. 4. See Figure 7-9. Disconnect sensor plate (8) wiring at connector (20) [P16] located below the starter motor. 5. Note position of each sensor plate wiring terminal in plug end of connector (20). 6. Remove terminals. See DEUTSCH ELECTRICAL CONNECTORS on page 7-46. 7.
IGNITION COIL GENERAL dyn808 The ignition coil is mounted on the frame underneath the fuel tank and behind the steering neck. Ignition coil primary circuit test See Figure 7-9. The ignition coil (13) is a pulse-type transformer. Internally, the coil consists of primary and secondary windings with a laminated iron core. The contents are sealed in a waterproof insulating compound. The ignition coil is not repairable. Replace the unit if it fails.
REMOVAL 5731 1WARNING To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before proceeding. Always disconnect the negative cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion producing personal injury. 2 3 1 1CAUTION 5 Hold battery cable when loosening battery terminal hardware. Failure to hold cable may cause battery damage. 1.
SPARK PLUG CABLES GENERAL INSPECTION Resistor-type high-tension spark plug cables have a carbonimpregnated fabric core (instead of solid wire) for radio noise suppression and improved reliability of electronic components. Use the exact replacement cable for best results. 1. REMOVAL 1WARNING Never disconnect a spark plug cable with the engine running. If you disconnect a spark plug cable with the engine running, you may receive a potentially fatal electric shock from the ignition system.
STARTER INTERLOCK GENERAL Ignition Circuit The starter interlock system is designed to prevent unintended start-up and/or forward motion of the motorcycle with the vehicle’s side stand not retracted. Two circuits make up the starter interlock system. The ignition circuit prevents the motorcycle from operating unless a ground is established at the ignition relay. If this ground is not established, the ignition system will be not turned on and the motorcycle will not run.
7-20 b0241x7x ELECTRONIC IGNITION VACUUM SWITCH TIMER AND PICKUP BK BK TN NEUTRAL 2 1 BK V/W GN/W PK R/W BK/W W/BK BK V/W P7 R/W BK/W TN GN/W P10 P1 BE W/R GN/BK Y/O GY W/BK W/BK BK/R 1 2 3 4 BK V/W GN/W PK R/W BK/W W/BK IGN POWER IGN MODULE FROM (2) TO STARTER 8 7 6 5 4 3 2 1 A B C P16 NEUTRAL SWITCH P3 TN 12 11 10 9 8 7 6 5 4 3 2 1 S8 BK P14 TN/W 2 1 BK W SIDE STAND SWITCH S2 S1 TN S13 S11 MAIN CHASSIS GROUND S12 TN TN/GN S10 TN/GN BK R TN/GN MASTER 30A CIRCUIT BREAKER
TESTING/REPLACEMENT b0244x7x Side Stand Switch Side stand up switch closed (0 ohms) See Figure 7-14. The side stand switch is a simple spring loaded plunger. The switch completes a path to ground for the ignition relay when the side stand is in the retracted position. Test the switch as follows. 1. Unplug the 2-place side stand switch connector [P14]. 2. Test the switch using an ohmmeter. 3. a. When the switch is open (side stand down), the switch should show ∞ ohms (infinite ohms). b.
TESTING DIODE S14/S15 5732 1. 2. Disconnect the following connectors: a. Instruments and indicator lamps [P3]. b. Clutch switch [P5]. c. Ignition relay [P12]. Test for continuity in both directions between ignition relay [P12] wire 85 (TN/W) and clutch switch [P5] wire 1 (TN/GN). Ohmmeter should show continuity in one direction, but not the other. Replace the diode with a new diode if necessary. 3. Ignition relay Circuit breaker Attach connectors separated in Step 1.
