IGNITION SYSTEM/ALTERNATOR

2000
ENGINE STOP BUTION
ALTERNATOR
IGNITION PULSE
GENERATOR
After 2000
ENGINE STOP BUTION
ALTERNATOR
54 N-m (5.5 kgf-m, 40 lbf-ft)
2 N-m (0.2 kgf-m, 1.4 lbf-ft)
14-0
14. IGNITION SYSTEM/ALTERNATOR
SERVICE INFORMATION
TROUBLESHOOTING
IGNITION SYSTEM INSPECTION
14-1
14-2
14-4
ICM (IGNITION CONTROL MODULE) 14-6
IGNITION COIL 14-7
SERVICE INFORMATION
GENERAL
EXCITER COIL
IGNITION PULSE GENERATOR
ALTERNATOR
IGNITION TIMING
ENGINE STOP SWITCH
14-8
14-8
14-8
14-10
.14-11
If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed
area. The exhaust contains poisonous carbon monoxide gas that may cause lose of consciousness and may lead to death.
CAUTION
Some electrical components may be damaged if terminals or connectors are connected or disconnected.
When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 14-3.
The ignition timing does not normally need to be adjusted since the ignition Control Module (ICM) is factory preset.
The ICM may be damaged if dropped. Also if the connector is disconnected when current is flowi ng, the excessive
voltage may damage the module.
A faulty ignition system is often related to poor connections. Check those connections before proceeding.
Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
14-1
IGNITION SYSTEM/ALTERNATOR
SPECIFICATIONS
ITEM
Spark plug Standard (NGK)
Standard (DENSO)
Optional (NGK)
Optional (DENSO)
Spark plug gap
Ignition coil
Primary
resistance Secondary with plug cap
(at 20C/68F)
Secondary without plug cap
Ignition coil peak voltage
Ignition pulse generator resistance (at 20C/68F)
Ignition pulse generator peak voltage
Alternator exciter coil resistance (at 20C/68F)
Alternator exciter coil peak voltage
Ignition timing ("F" mark)
TORQUE VALUES
Flywheel nut
Alternator cover screw
TOOLS
Imrie diagnostic tester (model 625) or
Peak voltage adaptor
54 Nm (5.5 kgfm, 40 lbfft)
2 Nm (0.2 kgfm, 1.4 lbfft)
07HGJ- 0020100 with
SPECIFICATIONS
BR8EG
W24ESR-V
BR8EV
W24ESR-G
0.5- 0.6 mm (0.020- 0.024 in)
0.1-0.3 Q
9- 16 kQ
4 -8kQ
100 V minimum
180-280 n
0.7 V minimum
9-25 Q
100 V minimum
18 2BTDC at 3,000 rpm
Flywheel puller
Universal holder
Commercially available digital multi meter (impedance 10M 0 /DCV minimum)
07733- 0010000 or 07933- 0010000
07725- 0030000
TROUBLESHOOTING
Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
-Water in the spark plug cap (affecting the ignition coil secondary voltage)
14-2
IGNITION SYSTEM/ALTERNATOR
No spark at plug
Unusual conditi on Probable cause (Check in numerical order)
Ignition coi l Low peak voltage 1. Incorrect peak voltage adaptor connections (System is
primary volt- normal if measured voltage is over t he specificati ons
age with reverse connection).
2. The mult i meter i mpedance is too low; below 10M 0 /DCV.
3. Cranki ng speed too slow.
o Kickst arter is weak
4. The sample t i mi ng of the tester and measured pulse
were not synchronized (System i s normal if measu red
volt age is over the standard voltage at least once).
5. Poorl y connected connectors or an open circuit i n igni-
t ion system.
6. Faulty excit er coil (measure the peak voltage).
7. Faulty ignition coil.
8. Faulty ICM (when above No. 1 - 7 are normal ).
No peak voltage
1. Incorrect peak voltage adaptor connections (Syst em is
normal if measured voltage is over the specificat ions
with reverse connect ion).
2. Short ci rcuit i n engine stop switch wi re
3. Faulty engine stop switch wi re.
4. Loose or poorly connected ICM connect ors.
5. An open circuit or loose connection in Green wire.
6. Faulty excit er coi l (measure the peak voltage).
7. Faulty i gnition pulse generator (measure the peak voltage).
8. Fault y ICM (when above No. 1 - 7 are normal).
Peak voltage is normal, but no speak 1. Faulty spark plug or leaking igniti on coil secondary
j umps at pl ug current ampere.
2. Faulty ignition coi l.
Exciter coi l Low peak voltage 1. The multi meter impedance is too low; below 10M 0 / DCV.
2. Cranking speed is too low.
o Kickstarter is weak
3. The sampli ng t imi ng of the tester and measured pulse
were not synchronised (system is normal if measured
voltage is over the standard voltage at least once).
4. Fault y ICM (when above No. 1 - 3 are normal).
No peak voltage 1. Faulty peak voltage adaptor.
2. Faulty exciter coi l.
Ignition pulse
Low peak voltage 1. The mult i met er i mpedance is too low; below 10M 0 / DCV.
generat or 2. Cranking speed i s too low.
o Kickstarter is weak
3. The sampling timing of t he tester and measured pulse
were not synchronised (system is normal if measured
voltage is over the standard voltage at least once).
4. Faulty ICM (when above No. 1 - 3 are normal).
No peak voltage
I
1. Faulty peak voltage adaptor.
2. Faulty ignition pulse generator.
14-3
IGNITION SYSTEM/ALTERNATOR
IGNITION SYSTEM INSPECTION
14-4
NOTE
lfthere is no spark at any plug, check all connections
for loose or poor contact before measuring each
peak voltage.
Use recommended digital multi meter or commercially
available digital multimeter with an impedance
of 10 MQ/DCV minimum.
The display val ue differs depending upon the \
internal impedance of the multimeter.
If using Imrie diagnostic tester (model 625), follow
the manufacture' s instructions. PEAK VOLTAGE ADAPTER
Connect the peak voltage adaptor to the digital
multi meter, or use the Imrie diagnostic tester.
TOOLS:
Peak voltage tester or
Peak voltage adaptor 07HGJ- 0020100
with Commercially available digital multimeter
(impedance 10 MQ/DCV minimum)
IGNITION COIL PRIMARY PEAK VOLT-
AGE
Avoid touching the spark plugs and tester probes
to prevent electric shock.
NOTE
Check all system connections before i nspection.
If the system is di sconnected, i ncorrect peak
voltage might be measured.
Check cylinder compression and check that the
spark plug are installed correctly.
Shift the transmission into neutral and disconnect
the spark plug cap from the spark plug.
Connect a good known spark plugs to the spark plug
cap and ground the spark plug to the cylinder as
done in a spark test.
DIGITAL
MUL TITESTER
IGNITION SYSTEM/AlTERNATOR
With the ignition coil primary wire connected, connect BLACK/YELLOW WIRE
the peak voltage adaptor or Imrie tester to the
IGNITION COIL
ignition coil.
CONNECTION: Black/Yellow(+)- Body ground(-)
Crank the engine with the kickstarter and read ignition
coil primary peak voltage.
PEAK VOLTAGE: 100V minimum
If the peak voltage is abnormal, check for an open
circuit or poor connection in Black/Yellow wires.
If not defects are found in the harness, refer to the
troubleshooting chart on page 14-3.
EXCITER COil PEAK VOLTAGE
NOTE
Check cylinder compression and check that the spark
plug are installed correctly.
Remove the number plate (page 2-3).
Disconnect the ICM connector.
Connect the peak voltage adaptor or Imrie tester
probes to the connector terminals of the wire harness
side.
TOOLS:
Peak voltage tester or
Peak voltage adaptor 07HGJ- 0020100
with Commercially available digital multimeter
(impedance 10 MQ/DCV minimum)
CONNECTION: Blue (+) -White (-)
Crank the engine with the kickstarter and read the
peak voltage.
PEAK VOLTAGE: 100 V minimum
If the peak voltage measured is abnormal, check the
wire harness for open circuit or loose connection.
If the wire harness is normal, check each item in the
troubleshooting chart. If all items are normal, the
exciter coil is faulty. See page 14-9 for exciter coil
replacement.
NUMBER PLATE
14-5
IGNITION SYSTEM/ALTERNATOR
IGNITION PULSE GENERATOR PEAK
VOLTAGE
NOTE
Check cylinder compression and check that the spark
plug are installed correctly.
Remove the number plate (page 2-3).
Disconnect the ICM connector.
Connect the peak voltage adaptor or Imrie tester
probes to the connector terminals of the wire harness
side.
TOOLS:
Peak voltage tester or
Peak voltage adaptor 07HGJ- 0020100
with Commercially available digital multimeter
(impedance 10 Mf.!/DCV minimum}
CONNECTION: Blue/Yellow(+}- Green/White (-}
Crank the engine with the kickstarter and read the
peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured is abnormal, check the
wire harness for open circuit or loose connection.
If the wire harness is normal, check each item in the
troubleshooting chart. If all items are normal, the
exciter coil is faulty. See page 14-9 for exciter coil
replacement.
ICM (IGNITION CONTROL MODULE}
14-6
Remove the number plate (page 2-3}.
Disconnect the ICM connector.
Remove the ICM from the rubber case.
Installation is in the reverse order of removal.
NUMBER PLATE
-
ICM CONNECTOR
IGNITION COIL
INSPECTION
Remove the spark plug cap.
Disconnect the ignition coil primary wire.
Measure the ignition primary coil resistance between
the primary terminal and body ground.
STANDARD: 0.1 - o.3 n (20 C/68 FJ
If resistance is out of range, replace the ignition coil.
Measure the ignition secondary coil resistance between
the primary terminal and plug cap.
STANDARD: 9-16 kil (20 C/68 F)
If resistance is out of range, remove the spark plug
cap and measure the ignition secondary coil resis-
tance between the primary terminal and spark plug
wire.
STANDARD: 4 - 8 k n (20 C/68 FJ
If resistance is out of range, replace the ignition coil.
REMOVAL/INSTALLATION
Remove the spark plug cap.
Disconnect the ignition coil primary wire.
Remove the bolts and ignition coil.
Installation is in the reverse order of removal.
IGNITION SYSTEM/ALTERNATOR
GROUND WIRE
14-7
IGNITION SYSTEM/ALTERNATOR
EXCITER COIL
INSPECTION
Remove the number plate (page 2-3).
Disconnect the ICM connector.
Measure the resistance between the Blue and White
terminals.
STANDARD: 9- 25 n 120 C/68 f)
If the resistance is out of range, replace the stator
(page 14-10).
IGNITION PULSE GENERATOR
INSPECTION
Remove the number plate (page 2-3).
Disconnect the ICM connector.
Measure the resistance between the Blue/Yellow and
Green/White terminals.
STANDARD: 180-280 n 120 C/68 fJ
If resistance is out of range, replace the stator (page
14- 10).
ALTERNATOR
14-8
REMOVAL
Remove the fuel tank (page 2-5).
Disconnect the alternator connector and ignition
pulse generator connector.
Remove the wire bands.
Remove the screws, alternator cover and rubber
gasket.
Hold the flywheel with the universal holder and
remove the nut and washer.
TOOL:
Universal holder 07725 - 0030000
CONNECTOR
CONNECTOR
Remove the flywheel using the flywheel puller.
TOOL:
Flywheel puller 07733- 0010000
Not available in
U.S.A. or
07933-0010000
Remove the grommet, woodruff key, bolts and stator.
INSTAllATION
Install the woodruff key to the groove on the crank-
shaft.
Install the stator and tighten the bolts securely.
Install the grommet to the groove on the left crankcase.
Install the f lywheel to the crankshaft by aligning the
groove on the flywheel and woodruff key.
Install the washer and nut.
Hold the f lywheel with the special tool and tighten
the nut to the specified torque.
TOOL:
Universal holder 07725 - 0030000
TORQUE: 54 Nm (5.5 kgfm, 40 lbf.ft)
NOTE
When replacing the flywheel, stator or ICM, check
and adjust the ignition timing (see below).
Check the rubber gasket in good condition.
Install the rubber gasket to the alternator cover.
Install the alternator cover and tighten the screws
to the specified torque.
TORQUE: 2 Nm (0.2 kgfm, 1.4 lbfft)
Install the wire bands.
Connect the alternator connector and ignition pulse
generator connector.
Remove the fuel tank (page 2-5).
IGNITION SYSTEM/AlTERNATOR
~
~ F L Y W H L PULLER
14-9
IGNITION SYSTEM/AlTERNATOR
IGNITION TIMING
14-10
If the engine must be running to do some work,
make sure the area is well ventilated. Never run the
engine in an enclosed area. The exhaust contains
poisonous carbon monoxide gas that may cause
loss of consciousness and may lead to death.
NOTE
The ignition timing is factory preset and need only
be checked when an electrical system component
is replaced.
Warm up the engine to normal operating tempera-
ture.
Stop the engine.
Remove the alternator cover (page 14-10).
Check that the stator index mark is aligned with the
index mark on the crankcase.
Attach the timing light and tachometer.
Start the engine and hold it at 3,000 rpm while pointing
the timing light towards the index mark.
If the stator's original index mark aligns between
the "F" marks, the engine is timed correctly.
Remove the testing equipment and reassemble the
motorcycle.
If the stator's original index mark does not al ign
between the "F" marks, scri be a temporary index
mark on the stator setting pl ate that will align
between the "F" marks at 3,000 rpm.
Stop the engine and do the following:
NOTE
This procedure is to be done after replacing the
ICM, ingition pulse generator/stator assembly or
flywheel.
If you have checked the ignition timing as a
troubleshooting method and the marks did not
align, inspect the ICM, ignition pulse generator
and stator, before performing this procedure.
Remove the stator mounting bolts, setting plate
screw and setting plate.
Elongate the setting plate mounti ng bolt hole, then
reinstall it with its temporary index mark aligned
with the index mark on the crankcase.
"F" MARK
CRANKCASE INDEX MARK
TEMPORARY INDEX MARK
ELONGATE

SCREW
Install and tighten the stator mounting bolts and
setting plate screw.
Recheck the ignition timing.
The stator setting plate index mark should now align
between the "F" marks on the flywheel.
Repeat the steps if the ignition timing is not correct.
Grind off the old index mark.
'-- ENGINE STOP SWITCH
INSPECTION
Disconnect the engine stop switch connectors.
Check the engine stop switch for continuity with the
switch button pressed. There should be no continuity
when the button is not pushed.
IGNITION SYSTEM/ALTERNATOR
OLD INDEX MARK
14-11
IGNITION CONTROL MODULE
Bl: BLACK Br: BROWN
y
YELLOW 0 ORANGE
Bu : BLUE Lb: LIGHT BLUE
G GREEN Lg: LIGHT GREEN
R RED
p
PINK
w: WHITE Gr : GRAY
r
15. WIRING DIAGRAM
ENGINE STOP SWITCH
Eff<G
H
ii'i " ii'i
81---- --___.J I
91/W------_J
91/Y

9u----------------,
w- - ------- - -----.
9u/Y-------- -,
G/W ----------------,
ENGINE STOP
SWITCH
IG E
FREE - -
PUSH
o-kr
Q_
COLOR 91/W 91
-
1 SPAe< PCUG
15-1