IGNITION SYSTEM

2
Table of Contents
Page
Magneto Ignition System
(Models - 2.2/2.5/3.0 - 1992
and Earlier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Stop Switch Test (All Models) . . . . . . . . . . . . . . . . . . . . 2-2
Magneto Ignition System . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Breaker Points Cleaning and Inspection . . . . . . . . 2-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Abnormal Point Wear . . . . . . . . . . . . . . . . . . . . . 2-2
Burning of Points . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Primary Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . 2-2
Secondary Ignition Coil Test . . . . . . . . . . . . . . . . . . 2-3
Condenser Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Capacitor Discharge Ignition System
(Models - 2.5/3.3 - 1993) . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Capacitor Discharge Ignition Tests
(1993 Model - 2.5/3.3) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Capacitor Charging/Trigger Coil Test . . . . . . . . . . . 2-5
Secondary Ignition Coil Test . . . . . . . . . . . . . . . . . . 2-5
CD Module Test
(Diode Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Flywheel Removal and
Installation (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Secondary Coil Removal and Installation
(Magneto Ignition) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Ignition Primary Coil (Magneto Ignition) . . . . . . . . 2-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Breaker Point Assembly and Condenser . . . . . . . 2-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Breaker Point Adjustment . . . . . . . . . . . . . . . . . . . . 2-8
Capacitor Discharge Ignition . . . . . . . . . . . . . . . . . . . . . 2-9
Capacitor Charging/Trigger Coil . . . . . . . . . . . . . . . 2-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Secondary Ignition Coil . . . . . . . . . . . . . . . . . . . . . . 2-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Capacitor Discharge (CD) Module . . . . . . . . . . . . 2-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-0 IGNITION SYSTEM 90-44477--1 1192

Magneto Ignition System
(Models - 2.2/2.5/3.0 - 1992
and Earlier)

Description
When the breaker points are closed, a magnetic field is
built up in the primary coil (located below flywheel) as the
flywheel permanent magnets pass the coil. When breaker
points open, the magnetic field of the primary coil col-
lapses, discharging voltage into the primary winding of the
secondary coil. At this time the condenser also discharges
its stored voltage into the primary circuit. This current
creates an extremely high voltage in the secondary coil that
will jump the spark plug gap.

BREAKER
PRIMARY COIL
POINTS

STOP SWITCH

CONDENSER

SECONDARY COIL

SPARK PLUG

90-44477--1 1192 IGNITION SYSTEM 2-1

 3. If contact point opening is too small, points will be
Stop Switch Test (All Models) closed for too much operating time. Average current
1. Disconnect stop switch leads. flow thru points will be too high resulting in rapid burn-
ing. Arcing will occur between points and result in low
2. Use ohmmeter and connect leads to switch leads.
secondary voltage and engine miss.
3. Meter should show “continuity” with switch depressed.
4. High series resistance in condenser circuit will prevent
4. If meter shows other than in step 3, replace switch. normal condenser action, so contact points will burn
rapidly. This resistance may be caused by a loose con-
denser mounting or lead connection or by poor con-
nections inside condenser.
Magneto Ignition System
Primary Ignition Coil Test
Breaker Points Cleaning and
Breaker Points Must Be Open When Testing Coil
Inspection Meter Ohm
Test
Range Reading
CLEANING
Connect (+) Ohmmeter Lead to Coil BLACK/
1. Dirty contact points should be dressed with a clean, fi- x1 1.5 Ohms
WHITE Lead and (–) Lead to Coil Ground
ne-cut contact file. File should not be used on other
metals and should not be allowed to become greasy or
dirty. Normal point condition is overall grey color.
NOTE: DO NOT use emery cloth to clean contact points.
2. After use, contact surfaces may not appear bright and
smooth. This is not necessarily an indication that
points are not functioning satisfactorily. Do not attempt
to remove all roughness nor dress point surfaces down
smooth. Remove scale and dirt only.
3. Badly burned or pitted contact points should be re-
placed.

ABNORMAL POINT WEAR

1. Under normal operating conditions, contact points will
provide many hundreds-of-hours of service.
2. Points, which have been operated for a period of time,
develop a rough surface.
3. If the roughness between points match enough that a
large contact area is maintained, the points will contin-
ue to provide satisfactory service until most of the tung- 17359
sten is worn off.
4. If points burn or pit they must be replaced. Ignition sys-
tem must be inspected to determine the cause of fail-
ure. If cause is not corrected, new points will quickly
burn or pit.

BURNING OF POINTS
1. Contact point burning results from high voltage, pres-
ence of oil or other foreign material, defective con-
denser and improper point adjustment.
2. Oil or crankcase vapors on point surfaces cause points
to burn rapidly. The presence of oil will produce a
smudgy line under contact points.

2-2 IGNITION SYSTEM 90-44477--1 1192

Secondary Ignition Coil Test
IMPORTANT: Ohmmeter test can only detect certain
faults in the secondary ignition coil. Replace ignition
coil if ohmmeter reading listed in chart are not as spe-
cified. If coil tests OK, and coil is still suspected of be-
ing faulty, use a magneto analyzer to thoroughly check
coil. Follow coil test outlined in analyzer manual.
Meter Ohm
Test Range Reading

Primary Winding Test

Connect (+) Ohmmeter Lead .81 to 1.09
to Coil BLACK/WHITE Lead x1
Ohms
and (–) Lead to Coil Ground

Secondary Winding Test

Connect (+) Ohmmeter Lead 4.250 to 5.750
to Spark Plug Lead Terminal x 100
Ohms
and (–) Lead to Coil Ground

Testing Secondary Winding 17360

Condenser Test
Check condenser using a magneto analyzer. Perform con-
denser tests outlined in analyzer manual. When checking
condenser capacity, reading should be 0.22 to 0.28 micro-
farads.

Testing Primary Winding 17356

90-44477--1 1192 IGNITION SYSTEM 2-3

 There is no timing advance or timing adjustment in this sys-
Capacitor Discharge Ignition tem.
System (Models - 2.5/3.3 - If engine will not idle down to trolling speed (runs exces-
sively fast with throttle closed), the bias circuit within the
1993) CD module may have failed. Replace the CD module.
If engine will not start (no spark at spark plug), use the DVA
chart, following, to determine the serviceabilty of each igni-
Description tion component.
The flywheel contains 4 magnets. As a north/south polarity
magnet passes the capacitor charging/trigger coil, (located
under flywheel), a magnetic field is built up within the wind-
ings and voltage is sent to the capacitor discharge (CD)
module to be stored. As a south/north polarity magnet
passes the capacitor charging/trigger coil, a triggering volt-
age is sent to the CD module. A bias/trigger circuit within
the CD module controls the release of this voltage to the
secondary ignition coil. The secondary coil increases this
voltage through its primary and secondary windings. The
secondary coil fires the spark plug at both the top of the pis-
ton stroke and the bottom of the stroke (or every 180° of
crankshaft rotation).

CAPACITOR CHARGING/
TRIGGER COIL CD MODULE

ORN
BRN

WHT

STOP IGNITION COIL

SWITCH

BLK/WHT SPARK PLUG

TOOL: MULTIMETER/DVA TESTER 91-99750

Multimeter Selector Reading at

Tested Part Connected To
Wires Position 300 - 2000 RPM

RED GROUND
Ignition Coil PRI BLACK 400 VDC 100 - 320
ORANGE

Capacitor
Charging Coil/ RED GROUND
400 VDC 120 - 320
Trigger Coil BLACK WHITE

RED BLACK
Stop Circuit 400 VDC 120 - 320
BLACK BLACK/WHITE

2-4 IGNITION SYSTEM 90-44477--1 1192

Capacitor Discharge Ignition
Tests (1993 Model - 2.5/3.3)

Capacitor Charging/Trigger Coil Test

CHECK METER OHM
RANGE READING
Connect (+) Ohm Lead to WHITE
Lead. Connect (–) Ohm Lead to R x 100 300-400
GROUND.

Secondary Ignition Coil Test

METER OHM
CHECK RANGE READING
PRIMARY WINDING TEST
Connect (+) Ohm Lead to ORANGE Less Than 1
Lead. Connect (–) Ohm Lead Rx1
Ohm
to GROUND.

SECONDARY WINDING TEST

Connect (+) Ohm Lead to Spark R x 1K 3000-4000
Plug Lead. Connect (–) Ohm Lead
to Ground.

CD Module Test
(Diode Test)
METER OHM
CHECK RANGE READING
Connect (+) Ohm Lead to WHITE
Lead. Connect (–) Ohm Lead to R x 1K Continuity
ORANGE Lead.

Connect (+) Ohm Lead to ORANGE

Lead. Connect (–) Ohm Lead R x 1K No Continuity
to
.
WHITE Lead.

90-44477--1 1192 IGNITION SYSTEM 2-5

Flywheel Removal and
Installation (All Models) a

Flywheel Removal
1. Remove rewind housing.
2. Remove rope cup.
3. Hold flywheel using Flywheel Holder 91-83163M.
4. Remove flywheel using Flywheel Puller 91-83164M.

Flywheel Installation
1. Hold flywheel using Flywheel Holder 91-83163M and
torque flywheel nut to 30 lb. ft. (40.6 N·m).
16999
2. Reinstall rope guide using 3 bolts. Torque bolts secure-
a - Flywheel Puller (91-83164M)
ly.
3. Reinstall rewind housing.

17424
a - Rope Cup Installed
17002
a - Flywheel Holder (91-83163M)
a

17423
a - Torqueing Flywheel Nut [30 lb. ft. (40.6 N·m)]

2-6 IGNITION SYSTEM 90-44477--1 1192

Secondary Coil Removal and 1. Install primary coil to stator plate with 2 screws as
shown. Verify ground wire (soldered terminal lug to coil
Installation (Magneto Ignition) winding) is fastened with coil mounting screw.
Remove and install secondary coil as shown. 2. Route wire lead below breaker points and fasten to bot-
IMPORTANT: Coil must be grounded to engine thru the tom side of stator plate with clamp.
mounting bolts. 3. Apply a drop of Loctite 271 to threads of stator plate
mounting screws and reinstall stator plate.

17361
a - Secondary Coil
b

Ignition Primary Coil (Magneto

Ignition)
17357
REMOVAL a - Ground Wire
b - Clamp
1. Remove flywheel as outlined in “Flywheel Removal
and Installation,” preceding.
2. Remove stator plate.
3. Remove 2 screws and clamp. Remove coil from stator
plate.

b
c
e
a

d
b

17000
a - Stator Plate
b - Screws (2)
c - Clamp
d - Coil
e - Ground Wire

INSTALLATION

90-44477--1 1192 IGNITION SYSTEM 2-7

Breaker Point Assembly and Breaker Point Adjustment
Condenser 1. Reinstall flywheel as outlined in “Flywheel Installa-
tion.”
REMOVAL 2. Rotate flywheel to position high point on cam against
1. Remove screw, retaining clip and disconnect wire. the rubbing block of the breaker point assembly.
2. Remove breaker point assembly from plate. 3. Check point gap using a feeler gauge. Point gap
should be 0.012 in. to 0.016 in. (0.3mm to 0.4mm).
3. Remove screw and lift condenser from plate.
4. If necessary, loosen adjustment screw and reposition
INSTALLATION breaker point base to obtain correct point gap.

1. Position condenser at location shown and secure with 5. Verify that felt pad is making light contact with cam.
screw and lockwasher.
Felt Pad should be Moistened with Oil
2. Verify felt pad is in place and moistened with oil. and Making Light Contact with Cam

3. Install breaker points and connect wires as shown.

Base
e
Adjustment
Screw
f

Cam
g High Point .012 in. to .014 in.
on Cam (.3mm to .4mm)
b Point Gap
d
Rubbing Block

a
c

17000
a - Screw
b - Retaining Clip
c - Wire
d - Breaker Point
e - Screw
f - Condenser
g - Felt Pad

Checking Breaker Point Gap 16987

2-8 IGNITION SYSTEM 90-44477--1 1192

 5. Remove 2 screws, clamp and disconnect bullet con-
Capacitor Discharge Ignition nector. Remove charge/trigger coil from stator.

Capacitor Charging/Trigger Coil

d
REMOVAL b
1. Remove top cowling.
a
2. Remove lower PORT side cowling.

52053
a - Screws
b - Clamp
c - Bullet Connector
d - Coil

INSTALLATION
a
1. Secure charge/trigger coil to stator plate with 2 screws.
52053 2. Secure coil wire lead with clamp to stator.
a - Screws
3. Reconnect coil bullet connector.
3. Remove recoil assembly.
4. Reinstall flywheel. Refer to “Flywheel Removal and
Installation,” preceding.
5. Reinstall recoil starter.
6. Reinstall PORT side lower cowl.
7. Reinstall top cowl.

52052
a - Bolts

4. Remove flywheel as outlined in “Flywheel Removal

and Installation,” preceding.

90-44477--1 1192 IGNITION SYSTEM 2-9

Secondary Ignition Coil Capacitor Discharge (CD) Module
REMOVAL REMOVAL
1. Remove top cowl. 1. Remove top cowl.
2. Remove PORT side lower cowl. 2. Remove PORT side lower cowl.
3. Disconnect spark plug lead from spark plug. 3. Disconnect WHITE bullet connector.
Disconnect ORANGE bullet connector.
4. Disconnect ORANGE bullet connector.
Disconnect BROWN lead from BLACK/WHITE bullet
5. Remove bolt securing coil to block and remove coil. connector.
Disconnect BLACK ground lead from secondary igni-
tion coil attaching bolt.
4. Remove bolt securing module to block.

d f

b
c
b
a
a e
52054
a - Coil
b - Spark Plug Lead c
c - Orange Lead
d - Bolt 52054
a - WHITE Lead
INSTALLATION b - ORANGE Lead
c - BROWN Lead
1. Position coil on block with BLACK/WHITE ground lead d - BLACK Lead
between coil and block. Secure both coil and ground e - Bolt
f - Capacitor Discharge Module
lead with attaching bolt.
2. Connect ORANGE lead to bullet connector. INSTALLATION
3. Connect spark plug lead to spark plug. 1. Secure CD module to block with attaching bolt.
4. Reinstall PORT side lower cowl. 2. Fasten BLACK ground lead to block with secondary ig-
5. Reinstall top cowl. nition coil attaching bolt.
3. Reconnect WHITE bullet connector.
Reconnect ORANGE bullet connector.
Reconnect BROWN lead to BLACK/WHITE bullet con-
nector.
4. Reinstall PORT side lower cowl.
5. Reinstall top cowl.

2-10 IGNITION SYSTEM 90-44477--1 1192