Section 02 TROUBLESHOOTING
Sub-Section 05 (ELECTRICAL SYSTEM)
02-05-6
SYMPTOM ENGINES DOES NOT START – NO SPARK AT SPARK PLUG.
CONDITION AT ENGINE CRANKING.
Test / Inspection 1. Verify spark plug condition.
a. Defective, improperly set, worn-out, fouled.
Identify source of problem and correct. Replace spark plug.
2. Verify spark plug cap resistance with an ohmmeter.
a. Defective part.
Replace cap.
3. Verify if problem originated from electrical system wiring harness and / or ac-
cessories and / or ignition cut-out switches by unplugging the 4-wire connec-
tors between the magneto / generator and the vehicle wiring harness. Check
condition of connectors.
a. Heating, rotating or sharp part in contact with harness. Improper harness routing.
Defective switch(es). Corroded connector terminals.
Replace or repair damaged wires. Reroute where necessary. Replace defective
switch(es). Clean terminals and apply silicone dielectric grease.
4. Verify trigger coil resistance with an ohmmeter and connector condition.
a. Defective coil. Corroded connector terminals.
Replace defective coil. Clean terminals and apply silicone dielectric grease.
5. Verify condition of ignition coil.
a. Mechanically damaged part. Vibration problem. Electrically damaged part.
Tighten mounting screws. Replace ignition coil.
6. Verify condition of ignition generator coils.
a. Mechanically damaged part. Vibration problem. Electrically damaged part.
Tighten mounting screws. Replace coils.
7. Verify CDI (Capacitor discharge ignition) module.
a. Mechanically damaged part. Vibration problem. Electrically damaged part.
Tighten mounting screws. Replace CDI module, retest and verify ignition timing.
SYMPTOM ENGINE STALLS.
CONDITION AT LOW SPEED.
Test / Inspection 1. Verify items 4, 5 and 6 above.
SYMPTOM IRREGULAR ENGINE SPEED.
CONDITION AT HIGH SPEED.
Test / Inspection 1. Verify items 4, 5 and 6 above.
CONDITION AT LOW SPEED.
Test / Inspection 1. Verify items 4 and 5 above and trigger coil / flywheel protrusion air-gap.
a. Air-gap too large.
Readjust air-gap.
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