8.8
ELECTRICAL
Removal
1. Remove the CVT cover. The indicator switch will be
visible between the drive and driven clutch. Refer to CVT
Chapter for CVT cover removal and installation.
2. Remove the (2) screws and pull on switch to release from
crankcase.
3. Inspect the shift indicator contacts, shift drum, pin and
spring. Verify the pin is not sticking in the drum or is
damaged. Replace any worn or damaged components.
Installation
1. Install spring and pin into shift drum.
2. Install switch with new O-ring. Route wires through
crankcase.
3. Install retaining screws.
4. Torque screws to specification.
IGNITION SYSTEM
Overview
The ignition system consists of a simple magneto-driven system
that includes a stator pulser coil, CDI Box, ignition coil and
related wiring / connectors.
Timing is non-adjustable on this ignition system.
Ignition System Troubleshooting
No Spark, Weak or Intermittent Spark
• No 12 volt power on brown (BN) wire at CDI box or no
CDI box ground path from the black/white (BK/WH)
wire
• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high
tension lead
• Related wiring loose, disconnected, shorted, or
corroded
• Engine Stop switch or ignition switch faulty
• ETC switch faulty
• Poor ignition coil ground
• Faulty stator (measure resistance of all ignition related
windings)
• Incorrect wiring (inspect color coding in connectors
etc)
• Faulty ignition coil winding (measure resistance of
primary and secondary)
• Sheared flywheel key
• Flywheel loose or damaged
• Excessive crankshaft runout on magneto. (RH) end
should not exceed .005”
• Faulty CDI module
Indicator Switch Screw Torque:
39-52 in. lbs. (4.5-6 Nm)
PartShark.com
877-999-5686
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