10.27
ELECTRICAL
10
Ignition System Testing Flow Chart
Whenever troubleshooting an electrical problem first check all terminal connections to be sure they are clean and tight. Also be sure
that colors match when wires are connected. Use the following pages as a guide for troubleshooting. The resistance values are also
given on the specification pages.
Condition: No spark or intermittent spark.
Verify 12 Volt DC power is present on the red wire entering the CDI module. Replace Spark Plug.
Disconnect the black wire from the 3 wire connector
attached to the CDI module to isolate the ignition
Disconnect the pulse (trigger) coil connector from
the CDI module. Measure the resistance of the
trigger coil. Refer to the exploded view or the
wiring schematic for meter connections
and specifications?
Check coil ground connection between engine and coil
mount using an ohmmeter. The coil mount should
have good continuity to ground on the engine (0-.2 Ω
).
Disconnect and check the ignition coil.
Resistance values should be:
Primary Side
- Primary Wire Tab to Ground
(on coil mount or engine): 0.11Ω
Secondary Side
- High Tension Wire to Engine Ground
Cap installed - 11,700Ω
Cap removed - 6700Ω
Are these values within specs?
If all of the above tests are within specifications, and all grounds, connections, and wire color coding
have been inspected, perform voltage output tests on page 10.25 or replace the CDI module.
- Test the ignition switch and speed
limiter circuit for shorts to ground.
- Check connectors for moisture,
wire color matching or corrosion.
Inspect connectors, wiring and
grounds to the component in
question. Replace the component
if a wiring problem cannot be found.
Clean coil mounting area.
Repair ground wire connections.
Replace the ignition coil.
No
Yes
Yes
Yes
Yes
No
No
No
Does it have spark?
ground path (Brown) for operation.
from the kill system. Verify the CDI has a good
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