ELECTRICAL
10.20
IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
G Spark plug gap incorrect
G Fouled spark plug
G Faulty spark plug cap or poor
connection to high tension lead
G Related wiring loose, disconnected,
shorted, or corroded
G Engine Stop switch or ignition
switch faulty
G ETC switch misadjusted or faulty
G Wire harness or connections wet,
corroded
G Poor ignition coil ground (e.g. coil
mount loose or corroded)
G Faulty stator (measure resistance
of all ignition related windings)
G Incorrect wiring (inspect color
coding in connectors etc)
G Faulty ignition coil winding
(measure resistance of primary and
secondary)
G Worn magneto (RH) end
Crankshaft bearings
G Sheared flywheel key
G Flywheel loose or damaged
G Trigger coil air gap too wide (where
applicable) - should be .016-.040″
(.4-1.0 mm)
G Excessive crankshaft runout on
magneto (RH) end - should not
exceed .0024″
G Faulty CDI module
CDI OUTPUT TEST USING
PEAK READING ADAPT
OR
Re-connect all CDI wires to stator wires. Disconnect
CDI module wire from ignition coil primary terminal.
Connect one meter lead to engine ground and the
other to the ignition coil primary wire leading from the
CDI module. Crank engine and check output of CDI
wire to coil (130 DCV). Reconnect CDI to coil .
Output w/ Peak output tester
130 DCV
Average Output w/ Digital Voltmeter
20 DCV
CDI CRANKING OUTPUT
TEST WITH PEAK
READING
VOL
TMETER
The following peak voltage tests will measure the
amount of output directly from each component.
A
peak reading voltmeter must be used to perform
the
tests
. A variety of peak reading adaptors are
commercially available for use with the Fluke t 77
Digital Multimeter (PV--43568) and other digital VOMs
which will allow peak voltage tests to be performed
accurately. Follow the directions provided with the
adaptor. All measurements are indicated in DC Volts.
Readings obtained without a peak reading adaptor will
be significantly different.
Disconnect the stator connectors from the CDI
module. Test output from exciter coil, pulse (trigger)
coil, and compare to the chart. The following
measurements are obtained when cranking the
engine with the electric starter, spark plug installed.
The starter system must be in good condition and the
battery fully charged.
330 Watt 4 Stroke (Sportsman 600/700 Built
Before February 20, 2003
)
Coil
Connect
Meter
Wires To:
Reading
(With Peak Read-
ing V olt meter)
Capacitor
Charge coil
Brown and
Yellow
34 DCV
Pulse
(Trigger)
Black and
Red
3.3 DCV
330 Watt 4 Stroke (Sportsman 600/700 Built After
February 20, 2003
)
Coil
Connect Meter
Wires To:
Reading
(With Peak Read-
ing Volt met er)
Detection Orange and
White
3 DCV
Pulse
(Trigger)
Blue and Green 190 Ohms
CURRENT DRAW - KEY OFF
CAUTION: Do not connect or disconnect the battery
cable or ammeter with the engine running. Damage
will occur to electrical components.
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