18. IGNITION SYSTEM SYSTEM DIAGRAM. swe 18-2 IGNITION SYSTEM INSPECTION------ 18-5 SERVICE INFORMATION cassena 18-3 _ IGNITION PULSE GENERATOR... 18-7 TROUBLESHOOTING -.-.. IGNITION TIMING 18-1IGNITION SYSTEM SYSTEM DIAGRAM ECM ENGINE STOP SWITCH IGNITION SWITCH DIRECT IGNITION COIL, CLUTCH SWITCH NEUTRAL SWITCH ENGINE STOP RELAY ‘CAM PULSE GENERATOR SPARK PLUG THROTTLE POSITION SENSOR IGNITION PULSE GENERATOR SIDE STAND SWITCH L= 18-2IGNITION SYSTEM SERVICE INFORMATION GENERAL NOTICE + The ECM may be damaged if dropped. Also if the connector is disconnected when current is lowing, the excessive volt- age may damage the module. Always turn off the ignition switch before servicing. + Use spark plug of the correct heat range. Using spark palug with an incorrect heat range can damage the engine + Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ign: tion switch is ON and current is present. + When servicing the ignition system, slways follow the steps in the troubleshooting sequence (page 18-4) This motoreycie's Ignition Control Module (ICM) is built into the Engine Control Module {ECMh, + The ignition timing does not normally need to be adjusted since the ECM is factory preset. + Afaulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure the battery is edequately charged. Using the starter motor with a weak battary asus in a slower engine cranking speed as ‘well 8s no spark at the spark plug + This motorcycles features direct ignition coils, where the ignition coil and spark plug cap ate integrated. There are four direct ignition coll. + Refer to the Throttle Position (TP) sensor inspection (page 6-91}, cam pulse generator inspection (page 6-90) and ECM inspection (page 6-4), SPECIFICATIONS [ Trew — ‘SPECIFICATIONS “Spark plug (iridium — IMREC-SHE (NGK) ‘Spark plug gap ~ zl B80 = 0.80 mmm (0.031 - 0.035 TAP [Monition coi! peak vonage 700V minimum 1 ignition pulse generator paak vokage 8.7 V minimum - Cignition timing CF*markd SS°BTDC atidie TORQUE VALUES Timing hole cap 18N-m (18 kgm, 13 bff) Apply groaso to the threads Spark plug 16 N-m (18 kgtm, 12 IBF Stator wire clamp bolt JEN.m (Lakgtim, loft) CT bolt Peak voltage adaptor IgnitionMate Peak voltage tester | 07HGJ-0020100 MTP07-0286 (U.S.A. only) | (not available in U.S.A} with commercially available digital multimeter (impedance 10 MQ/DCV minimum} 18-3IGNITION SYSTEM TROUBLESHOOTING + Inspect the following before diagnosing the system. ~ Faulty spark plug = Loose direct ignition coil and spark plug connection ~ Loose direct ignition coil connectors = Water got into the direct ignition cail (shorting the ignition coil secondary voltage) + If there is no spark at any cylinder, temporarily exchange the direct ignition coil with the other good one and perform the spark test. there is spark, the exchanged direct ignition coil is faulty. + “Initial voltage" of the ignition primary coll is the battery voltage with the ignition switch turned ON and engine stop switch turned * ()* (The engine is not cranked by the starter motor) No spark at all plugs Unusual condition __— Probable cause (Check in numerical or ignition coil | No initial voltage with the fgnition 1. Faulty engine stop switch, primary volt- | ONandengine stopswitchesturned 2. An open circuit in Blackwhite wire between the direct age + Q* (other electrical components ignition coil and ECM. . : are norman 3. Loose or poor connect of the direct ignition coll pri while disconnecting ECM connector) = : | 2 Cranking speed is too low (battery under charged) initial and peak voitage are normal, 7. Faulty spark plug or leaking ignition coil secondary oe [tree Initial voltage is normal, butit drops down to 2-4 V while cranking the engine. eel oP “Talia veliage Ts normal, butno peak | voltage while cranking tne engine. | ‘standard Ignition pulse Peak voltage Te lower t generator value. 10d is too low (battery under charged). ‘The sampling timing of the tester and measured pulse were not synchronized (system is normal if measured voltage is over the standard voltage at least once). 4. Faulty ECM (in case when above No. 1~3 are normal). Faulty peak voltage adaptor. Faulty ignition pulse generator: 2 a No peak voltage. 18-4IGNITION SYSTEM IGNITION SYSTEM INSPECTION + Hf there is no spark at any plug, check all connee- tions for loose or poor contact before measuring each peak voltage. + Use recommended digital multimeter or com: mercially available digital multimeter with an impedance of 10 MQ/DCV minimum, + The display value differs depending upon the internal impedance of the multimeter. + Ifthe Imrie diagnostic tester (made! 625) is used, follow the manufacturer's instruction, Connect the peak voltage tester or peak voltage adaptor to the digital multimeter. DIGITAL MULTIMETER TooLs: IgnitionMate peak voltage tester MTPO7-0286, (U.S.A. only) or Peak voltage adaptor 07HG4-0020100 (not available in USA) ‘with commercially available digital multimeter impedance 10 M2/DCV minimum} PEAK VOLTAGE ADAPTO IGNITION COIL PRIMARY PEAK VOLTAGE + Chock all system connections before inspection, If the system is disconnected, incorrect peak volt lage might be measured, + Check cylinder compression and check that the spark plugs are installed correctly, Disconnect the direct ignition coils from the spark plugs (page 4-7). - Connect the direct ignition coil 2P connectors to the direct ignition coil Shift the transmission into neutral. Connect a known-good spark plug to the direct igni- 2 = tion coil and ground the spark plug to the oylinder =A head as done in a spark test . With the ignition coll 6P (Black) connector con ected, connect the peak voltage adaptor or pesk voltage tester to the OP (Black) connector primary wire terminal and ground, CONNECTION: No.1 coil Blue/black terminal (+] ~ Body ground (-] No.2 coil; Yellow/white ten No. coil Red/blue terminal (+) ~ Body ground (+1 No.4 coil Red/yellow terminal (4) ~ Body ground (-) al (+) ~ Body ground (-)IGNITION SYSTEM ‘Avoid touching te Turn the ignition switch ON and engine stop switch spark plugs and * C) *, ‘ester probes 0 Check for initial voltage at this time. preverteiectic Battery voltage should be present. shock If the initial voltage cannot be measured, check the power supply circuit (refer to the troubleshooting, page 18-4). Crank the engine with the starter motor and read the ignition coil primary peak voltage. PEAK VOLTAGE: 100V minimum If the peak voltage is abnormal, check for an open Circuit or poor connection in Blue/black, Yellow! white, Rediblue and Red/yellow wires. If not defects are found in the hamess, refer to the troubleshooting chart on (page 18-4), IGNITION PULSE GENERATOR PEAK VOLTAGE + Check all system connections before inspection, the system is disconnected, incorrect peak volt: age might be measured. + Check cylinder compression and check that the spark plugs are installed correctly. Remove the fue! tank cover (page 3-15). l Disconnect the ECM 32P (Light gray) connector from the ECM. 32 (LIGHT GRAY) CONNECTOR Connect the peak voltage tester or peak voltage adaptor probes to the connector terminal of the wire PEAK VOLTAGE ADAPTOR hemes side. | Toots: IgnitionMate peak voltage tester MTPO7-0286 (USA. only) or Peak voltage adaptor 07HGJ-0020100 {not available in USA) with commercially available digital multimeter impedance 10 M2/DCV minimum) CONNECTION 22 (LIGHT GRAY) CONNECTOR ‘Yellow terminal (+) ~ Ground (-) : Crank the engine with the starter motor and read the peak volage. PEAK VOLTAGE: 0.7 V minimum If the peak voltage measured at ECM connector is abnormal, measure the peak voltage at the ignition pulse generator connector. 18-6IGNITION IGNITION IGNITION SYSTEM Lift and support the fuel tank (page 6-61) IGNITION PULSE GENERATOR Disconnect the ignition pulse generator 2P (Red) 2P (RED) CONNECTOR ‘connector and connect the tester probes to the ter- — minal (Yellow and Yellowswhite), In the sme manner as at the ECM connector, mea: sure the peak voltage and compare itto the voltage ‘measured at the ECM connector. + If the peak voltage measured at the ECM is abnormal and the one measured at the ignition pulse generator is normal, check the 2P (Red) connector for loose connection and the wire har- ‘ness for an open circuit or loose connection, + If both peak voltage measured are abnormal, check each item in the troubleshooting chart tpage 18-4). If all tems are normal, the ignition — pulse generator is faulty. See following steps for ignition pulse generator replacement, PULSE GENERATOR REPLACEMENT Remove the right crankcase cover (page 10-5). IGNITION PULSE GENERATOR eu Remove the wire grommet from the cover. PONITION BONES s Remove the bolts and ignition pulse generator. GRommer ‘Apply sealant to the grommet seating surfaca. Install a new ignition pulse generator and the grom- met into the cover groove properly. Apply locking agent to the threads of the bolts. Tighten the bolts securely Install the right crankcase cover (page 10-24) TIMING Remove the following: = Lower cowls (page 3-6) = Middle cowis (page 2-7) Werm up the engine. Stop the engine and remove the timing hole cap. 18-7IGNITION SYSTEM. Check the O- ight coil connector wire. Connect the timing light to the No.1 direet ignition Start the engine, let it idle and check the ignition timing, IDLE SPEED: 1,300 = 100rpm The ignition timing is correct if the index mark on the right crankcase cover aligns between the “F* mark and three punch marks on the ignition pulse ‘generator rotor as shawn, Increase the engine speed by turning the throttle stop screw and mark sure the "F" mark begins to move counterclockwise when the engine speed is approximately 2,500 rpm. Apply oll to the O-ring. Apply grease to the timing hole cap threads and install the O-ring and timing hole cap, Tighton the timing hole cap to the specified torque. TORQUE: 18 Nem (1.8 kgfm, 13 Ibf-f) Install the following: = Middle cowls page 3-8) ~ Lower cowls (page 3-6) 18-8