ELECTRICAL AND IGNITION 2 A IGNITION SYSTEM

ELECTRICAL AND IGNITION 2 A IGNITION SYSTEM 54637

Tle of Contents Pge Ignition System.......................... 2A-1 Description........................... 2A-1 Ignition Trouleshooting................... 2A-2 Checking For Loss Sprk............... 2A-2 Trouleshooting Test Equipment......... 2A-2 Ignition Trouleshooting (Engines With Blck Sttor)............................. 2A-3 Ignition Trouleshooting (Engines With Red Sttor).............................. 2A-7 Ignition Component Testing............... 2A-10 Trigger Test.......................... 2A-10 Ignition Coil Test...................... 2A-10 Test For Sprk....................... 2A-12 Running Voltge Output Test........... 2A-12 Ignition (Key) Switch Test.............. 2A-13 Mercury (Tilt) Stop Switch Test......... 2A-13 Flywheel Removl nd Instlltion......... 2A-14 Flywheel Removl.................... 2A-14 Mnul Strt Model................ 2A-14 Electric Strt Model................ 2A-14 Flywheel Instlltion.................. 2A-15 Ignition Components..................... 2A-15 Sttor Assemly Removl............. 2A-15 Blck Sttor Assemly Instlltion...... 2A-17 Red Sttor Assemly Instlltion....... 2A-18 Trigger Plte Assemly Removl....... 2A-21 Trigger Plte Assemly Instlltion...... 2A-22 Ignition Coil Removl................. 2A-23 Ignition Coil Instlltion................ 2A-23 Switch Box Removl.................. 2A-23 Switch Box Instlltion................ 2A-24 2A-0 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition System Blck Sttor Models Red Sttor Models Adpter Module Description The ignition system is lterntor-driven with distriutor-less cpcitor dischrge. Mjor components of the ignition system re the flywheel, sttor ssemly, trigger ssemly, switch ox, ignition coils nd sprk plugs. The sttor ssemly is mounted elow the flywheel nd hs 2 coils. The flywheel is fitted with permnent mgnets inside the outer rim. As the flywheel rottes, the permnent mgnets pss the sttionry sttor ignition coils. This cuses the ignition coils to produce AC voltge. The AC voltge then is conducted to the switch oxes where it is rectified nd stored in cpcitor. The trigger ssemly (lso mounted under the flywheel) hs 2 coils. The flywheel likewise hs second set of mgnets (locted round the hu). As the flywheel rottes, the second set of permnent mgnets psses the trigger coils. This cuses the trigger coils, in turn, to produce n AC voltge tht is conducted to n electronic switch (SCR) in the switch ox. The switch dischrges the cpcitor voltge into the ignition coil t the correct time nd in firing order sequence. Cpcitor voltge is conducted to the ignition coil primry. The ignition coil multiplies this voltge to vlue high enough to jump the gp t the sprk plug. The preceding sequence occurs once-per-enginerevolution for ech cylinder. Sprk timing is chnged (dvnced/retrded) y rotting the trigger coil position in reltion to the permnent mgnets on the flywheel hu. Red Sttor Models Red sttors require n dpter module tht gets connected etween the sttor nd switch ox. Without the dpter module, the voltge supplied y the sttor would exceed the voltge cpility of the switch ox. 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-1

Ignition Trouleshooting WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components nd/or metl test proes while engine is running nd/or eing crnked. STAY CLEAR OF SPARK PLUG LEADS. To ssure personl sfety, ech individul sprk plug led should e grounded to engine. Before trouleshooting the ignition system, check the following:. Mke sure tht electricl hrness, lnyrd switch, ignition switch, nd mercury switch re not the source of the prolem.. Check tht plug-in connectors re fully engged nd terminls re free of corrosion. c. Mke sure tht wire connections re tight nd free of corrosion. d. Check ll electricl components, tht re grounded directly to engine, nd ll ground wires to see tht they re grounded to engine. e. Check for disconnected wires nd short nd open circuits. Trouleshooting Test Equipment Multimeter / Tester 91-99750 Sprk Tester 91-850439 Checking for Loss of Sprk The use of n inductive timing light while crnking or running the engine will show whether there is sprk present or not. The timing light will not show the strength of the sprk. Incorrect sprk strength my not llow the sprk plug to fire under compression The use of sprk gp or sprk gp ord will give visul indiction of the strength of the sprk. Norml ignition sprk is BLUE in color. A YELLOW or RED sprk indictes wek ignition. 2A-2 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Trouleshooting (Engines With Blck Sttor) Trouleshooting Sequence Chrt (Engines with Blck Sttor) Strt the ignition trouleshooting y first performing Step 1, then continue the series of steps to locte the prolem. Refer to the trouleshooting steps on the following pges. Step 1 Primry Voltge At The Ignition Coils Test Low or No Voltge t two coils Low or No Voltge t ll coils Low or No Voltge t one coil Good Voltge t ll coils Test Trigger Pge 2A-10 Go To Step 2 Go To Step 3 Test for Sprk Pge 2A-11 TESTS 9 AMP BLACK STATOR Tested Prt Selector Position Red Blck Reding At 300-1000 RPM Reding At 1000-4000 RPM Coil Primry Sttor Low Speed Sttor High Speed 400 VDC* 400 VDC* 400 VDC* Coil (+) Terminl Blue Sw. Box Term. Red Sw. Box Term. Coil (-) Terminl Ground Ground 160-250 210-310 25-90 180-275 Blck/Yellow Stop Circuit 400 VDC* Terminl Ground 200-360 200-360 190-310 140-310 TESTS 16 AMP BLACK STATOR (398-9710A33 & 398-9710A42) Tested Prt Selector Position Red Blck Voltge @ 300 RPM Voltge @ 1000 RPM Voltge @ 4000 RPM Coil Primry Sttor Low Speed Sttor High Speed 400 VDC* 400 VDC* 400 VDC* Coil (+) Terminl Blue Sw. Box Term. Red Sw. Box Term. Coil (-) Terminl Ground Ground 110-140 8-10 215-265 Blck/Yellow Stop Circuit 400 VDC* Terminl Ground 160-200 315-385 270-330 Switch Box Bis 20 VDC or 40 VDC Ground White/Blck Switch Box Terminl 160-200 * If using meter with uilt-in, plce selector switch in the /400 VDC position. 250-300 315-385 27-33 270-330 165-205 2-10 10-30 10-30 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-3

Ignition Trouleshooting (Engines With Blck Sttor) STEP 1 Primry Voltge At The Ignition Coils Test IGNITION VOLTAGE 9 AMP STATOR Tested Prt ( ) (+) 1. Use Multimeter / Tester 91-99750. 2. Crnk engine nd oserve meter reding. Coil Primry Tested Prt Selector Position Selector Position Red Red Blck TEST RESULTS No voltge output or low voltge output on ll coils. Go to STEP 2 Stop Circuit Test. Good voltge on two coils. Go to Trigger Test. Good voltge on ll coils. Go to Testing For Sprk. Blck IGNITION VOLTAGE 16 AMP STATOR (398-9710A33 & 398-9710A42) Coil Primry 400 VDC 400 VDC Coil (+) Terminl Coil (+) Terminl Coil (-) Terminl Coil (-) Terminl Voltge @ 300 RPM Reding At 300-1000 RPM Voltge @ 1000 RPM Reding At 1000-4000 RPM 160-250 180-275 Voltge @ 4000 RPM 110-140 215-265 250-300 STEP 2 Stop Circuit Test IGNITION VOLTAGE 9 AMP STATOR BLK/ YEL 1. Use Multimeter / Tester 91-99750. 2. Crnk engine nd oserve meter reding. TEST RESULTS Good voltge output. Go to STEP 3 Sttor Low Speed nd High Speed Test High voltge output. The trigger or switch ox is defective. Go to Trigger Test nd test trigger. If trigger tests OK, replce switch ox nd repet step. No voltge output or low voltge output. Remove BLK/YEL wires from switch ox terminl nd repet test. If voltge output is now OK, either the ignition switch, stop switch or wiring is defective. If no voltge or low voltge remins, go to STEP 5 Sttor, Low nd High Speed Test. Tested Prt IGNITION VOLTAGE 16 AMP STATOR (398-9710A33 & 398-9710A42) Tested Prt Selector Position Selector Position Red Red Blck Blck Voltge @ 300 RPM Reding At 300-1000 RPM Voltge @ 1000 RPM Reding At 1000-4000 RPM Blck/Yellow Stop Circuit 400 VDC Terminl Ground 200-360 200-360 Voltge @ 4000 RPM Stop Circuit 400 VDC Blck/Yellow Ground 160-200 315-385 270-330 Terminl 2A-4 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Trouleshooting (Engines With Blck Sttor) STEP 3 Sttor Low Speed nd High Speed Test Sttor Low Speed Test Sttor High Speed Test 1. Use Multimeter / Tester 91-99750. 2. Crnk engine nd oserve meter reding. IGNITION VOLTAGE 9 AMP STATOR Tested Prt Sttor Low Speed Selector Position 400 VDC Red Blck Reding At 300-1000 RPM Reding At 1000-4000 RPM Blue Sw. Box Term. Ground 210-310 190-310 Sttor High Speed 400 VDC Red Sw. Box Term. Ground 25-90 140-310 IGNITION VOLTAGE 16 AMP STATOR (398-9710A33 & 398-9710A42) Tested Prt Sttor Low Speed Selector Position 400 VDC Red Blck Voltge @ 300 RPM Voltge @ 1000 RPM Voltge @ 4000 RPM Blue Sw. Box Term. Ground 160-200 315-385 270-330 Sttor High Speed 400 VDC Red Sw. Box Term. Ground 8-10 165-205 27-33 TEST RESULTS If voltge output is low to either the sttor low speed or sttor high speed, the sttor or switch ox is defective. Go to sttor test nd test sttor. If sttor tests OK, replce switch ox nd repet step. If voltge output is good to either the sttor low speed or sttor high speed, replce the switch ox nd repet step 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-5

Ignition Trouleshooting (Engines With Red Sttor) Trouleshooting Sequence Chrt (Engine with Red Sttor) Strt the ignition trouleshooting y first performing Step 1, then continue the series of steps to locte the prolem. Refer to the trouleshooting steps on the following pges. Low or No Voltge t ll coils Go To Step 2 Step 1 Primry Voltge At The Ignition Coils Test High Voltge t ll coils Low or No Voltge t two coils Replce Adpter Module Test Trigger Pge 2A-10 Low or No Voltge t one coil Go To Step 5 Good Voltge t ll coils Test for Sprk Pge 2A-11 RED Sttor Test Test Selector Switch Position RED Led BLACK Led Voltge @ 300 RPM Voltge @ 1000 RPM Voltge @ 4000 RPM Coil Primry 400 VDC Coil (+) Terminl Coil ( ) Terminl 130 Volts Minimum 195 to 275 195 to 275 Stop Circuit 400 VDC Blck/Yellow Sw. Box Terminl Ground 190 Volts Minimum 275 to 320 260 to 320 Blue Sw. Box Terminl 400 VDC Blue Sw. Box Terminl Ground 190 Volts Minimum 275 to 320 260 to 320 Blue/White Sw. Box Terminl 400 VDC Blue/White Sw. Box Terminl Ground 190 Volts Minimum 275 to 320 260 to 320 2A-6 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Trouleshooting (Engines With Red Sttor) STEP 2 Stop Circuit Test STEP 1 Primry Voltge At The Ignition Coils Test BLK/ YEL (+) ( ) - Connect (+) Test Led To BLK/YEL Wire Terminl On Switch Box - Connect ( ) Test Led To Engine Ground - Connect (+) Test Led To (+) Coil Terminl - Connect ( ) Test Led To ( ) Coil Terminl 1. Use Multimeter / Tester 91-99750. Set switch position to 400. 2. Crnk engine nd oserve meter reding. Voltge t 300 RPM (crnking) Voltge t 1000 4000 RPM (Running) 130 Volts 195 to 275 Volts TEST RESULTS Voltge output is high on ll coils. The dpter module is defective. Replce dpter module. No voltge output or low voltge output on ll coils. Go to STEP 5 Sttor, Adpter Module, nd Switch Box Test. Good voltge on two coils. Go to Trigger Test. Good voltge on ll coils. Go to Testing For Sprk. 1. Use Multimeter / Tester 91-99750. Set switch position to 400. 2. Crnk engine nd oserve meter reding. Voltge t 300 RPM (crnking) Voltge t 1000 4000 RPM (Running) 190 Volts 275 to 320 Volts TEST RESULTS Voltge output is high. The dpter module is defective. Replce dpter module. Good voltge output. Go to STEP 3 Switch Box (BLU Wire) Circuit Test. No voltge output or low voltge output. Remove BLK/YEL wires from switch ox terminl nd repet test. If voltge output is now OK, either the ignition switch, stop switch or wiring is defective. If no voltge or low voltge remins, go to STEP 5 Sttor, Adpter Module, nd Switch Box Test. 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-7

Ignition Trouleshooting (Engines With Red Sttor) STEP 3 Switch Box (BLU Wire) Circuit Test STEP 4 Switch Box (BLU/WHT Wire) Circuit Test BLU/ WHT BLU - Connect (+) Test Led To BLU Wire Terminl On Switch Box - Connect ( ) Test Led To Engine Ground 1. Use Multimeter / Tester 91-99750. Set switch position to 400. 2. Crnk engine nd oserve meter reding. Voltge t 300 RPM (crnking) Voltge t 1000 4000 RPM (Running) 190 Volts 275 to 320 Volts TEST RESULTS Voltge output is high. The dpter module is defective. Replce dpter module. Good voltge output. Go to STEP 3 Switch Box (BLU/WHT Wire) Circuit Test. No voltge output or low voltge output. Go to STEP 5 Sttor, Adpter Module nd Switch Box Test. - Connect (+) Test Led To BLU/WHT Wire Terminl On Switch Box - Connect ( ) Test Led To Engine Ground 1. Use Multimeter / Tester 91-99750. Set switch position to 400. 2. Crnk engine nd oserve meter reding. Voltge t 300 RPM (crnking) Voltge t 1000 4000 RPM (Running) 190 Volts 275 to 320 Volts TEST RESULTS Voltge output is high. The dpter module is defective. Replce dpter module. Good voltge output.. No voltge output or low voltge output. Go to STEP 5 Sttor, Adpter Module nd Switch Box Test. 2A-8 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Trouleshooting (Engines With Red Sttor) 7. Disconnect the GRN/WHT nd WHT/GRN (sttor) leds from the dpter module. STEP 5 Sttor, Adpter Module, nd Switch Box Test Elimintion Test BLU BLU/ WHT 8. Mesure the resistnce etween the GRN/WHT nd WHT/GRN (sttor) leds. 1. Set multipurpose switch position to 400. 2. Disconnect only the BLU wire from the switch ox. Connect test leds etween BLU wire nd engine ground. 3. Crnk engine nd oserve meter reding. 4. Reconnect BLU wire. 5. Disconnect only the BLU/WHT wire from the switch ox. Connect test leds etween BLU/ WHT wire nd engine ground. 6. Crnk engine nd oserve meter reding. Test Leds To Between GRN/WHT nd WHT/GRN (Sttor) leds Ohm Scle R x 100 Meter Reding 660-710 Ohms TEST RESULTS If the resistnce is OK (660 to 710 ohms), the dpter module is defective. Replce dpter module. If the resistnce is incorrect, the sttor is defective. Replce sttor. Voltge t 300 RPM (crnking) 190 to 260 Volts TEST RESULTS If voltge output is good on oth wires, the switch ox is defective. Voltge output is low on either wire, continue with test. 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-9

Ignition Component Testing Ignition Coil Test Trigger Test 1. Disconnect wires from coil terminls. 2. Pull sprk plug led out of coil tower. 3. Use VOA meter nd perform the following checks. Test Leds To Between (+) nd ( ) Coil Terminls Between Coil Tower nd ( ) Coil Terminl Ohm Scle R x 1 R x 100 Meter Reding.02-04* Ohms 800-1100** Ohms 1. Disconnect ll trigger leds form switch ox. 2. Use VOA meter nd perform the following checks. Test Leds To Between BRN led nd BLK led Between WHT led nd PUR trigger led Ohm Scle R x 100 R x 100 Meter Reding 700-1000 Ohms 700-1000 Ohms NOTE: Aove resistnce redings re for cold engine (room temperture). Resistnce will increse if engine is wrm. 3. If meter redings re not s specified, replce trigger. * The primry DC resistnce of these coils generlly is less thn one (1) OHM. If reding resemling short is otined, this would e cceptle. ** Copper wire is n excellent conductor, ut it will hve noticele difference in resistnce from cold to hot tempertures. Resonle vritions from these redings re cceptle. 4. If meter redings re not s specified, replce ignition coil. 2A-10 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Sttor Test (Red Sttor) Sttor Test (Blck Sttor) Electric Strt Engines Mnul Strt Engines 1. Disconnect ll sttor leds. 2. Use VOA meter nd perform the following checks. Electric Strt Engines Test Leds To Ohm Ohm Scle Reding GRN/WHT nd WHT/GRN R x 100 660-710 YEL nd YEL R x 1 0.165 0.181 Mnul Strt Engines Test Leds To Ohm Scle Ohm Reding GRN/WHT nd WHT/GRN R x 100 660-710 BLK/WHT nd BLK R x 100 130-145 YEL nd YEL R x 1 0.17 0.19 NOTE: Aove resistnce redings re for cold engine (room temperture). Resistnce will increse if engine is wrm. If meter redings re other thn specified, replce sttor. 1. Disconnect ll sttor leds. 2. Use VOA meter nd perform the following checks. 9 AMP Sttor Test Leds To Ohm Ohm Scle Reding Blue nd Blue/White R x 1000 5.7-8.0 Red nd Red/White R x 1 56-76 Blue nd Engine Ground R X 1000 No Reding Red nd Engine Ground R X 1000 No Reding YEL nd YEL R x 1.5-1.0 16 AMP Sttor (398-9710A33 & 398-9710A42) Test Leds To Ohm Scle Ohm Reding Blue nd Blue/White R x 1000 1000-1400 Red nd Red/White R x 1 15-30 Blue nd Engine Ground R X 1000 No Reding Red nd Engine Ground R X 1000 No Reding YEL nd YEL R x 1.10-.50 NOTE: Aove resistnce redings re for cold engine (room temperture). Resistnce will increse if engine is wrm. If meter redings re other thn specified, replce sttor. 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-11

Test For Sprk (Crnking) Primry Voltge Test (Engine Running) d -Sprk Tester 91-850439 -Connect Ground Led To Engine Ground 1. Remove the sprk plug leds from the sprk plugs. 2. Adjust the sprk tester to 1/2 in. (12mm) gp setting. 3. Connect the sprk plug leds to the tester. Attch the tester ground led to engine ground. 4. Crnk the engine. Sprk should jump ech tester gp. TEST RESULTS NOTE: Norml ignition sprk is BLUE in color. A YELLOW or RED sprk indictes wek ignition. Norml sprk on ll cylinders. Go to Primry Voltge Test (Engine Running). Intermittent, wek or no sprk output on ll cylinders usully indictes defective trigger. Go to Trigger Test. Intermittent, wek or no sprk output on ny one cylinder indictes d ground, defective ignition coil, defective sprk plug led, or switch ox. Go to Ignition Coil Test. -Plug into Meter -Attch to Approprite Terminls c -Attch to Engine Ground d -Selector Switch 1. If the ignition system tests OK, it my e necessry to check the output voltge while running the engine under lod up to 4000 RPM. Using Test Hrness 91-14443A1 llows performing Tests from the driver set inside the ot. Refer to Tests preceding. c 2A-12 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition (Key) Switch Test 1. Disconnect remote control wiring hrness nd instrument pnel connector. NOTE: Wiring digrm for control oxes is locted in SECTION 2D. 2. Set ohmmeter on R x 1 scle for the following tests: COMMANDER KEY SWITCH BLK BLACK PUR PURPLE RED RED YEL YELLOW (BLK/YEL) (RED) M B A (PUR) C M S (YEL/BLK) (BLK) (YEL/RED Mercury (Tilt) Stop Switch Test 1. Remove mounting screw tht secures mercury switch to outord. 2. Connect Ohmmeter (R x 1 scle) etween lck led nd lck/yellow led or terminl stud on mercury switch. 3. Test mercury switch s follows:. Position mercury switch s it would e instlled when engine is in down position. The meter should indicte no continuity.. Tilt mercury switch up. The meter should indicte continuity. c. If these redings re not otined, replce mercury switch. CONTINUITY SHOULD BE INDICATED KEY AT THE FOLLOWING POINTS: POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK OFF RUN START CHOKE* * Key switch must e positioned to RUN or START nd key pushed in to ctute choke, for this continuity test. 3. If meter redings re other thn specified in the preceding test, verify tht switch nd not wiring is fulty. If wiring checks OK, replce switch. c 20 10 30 0 40 0 2 4 6 8 10 x100x10 x1k x1 OFF 400 400 200 D D 200A C C 40 V 40 V 20 20 400 200 54638 - Red Ohm Led - Blck Ohm Led c - Mercury Switch 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-13

Flywheel Removl nd Instlltion Flywheel Removl 2. Use strp wrench to hold flywheel while removing flywheel nut nd wsher. CAUTION To prevent ccidentl strting of outord while removing engine components, on electric strt models - remove engine ttery cles from ttery nd verify ignition key is in the OFF position. When servicing mnul strt engines, verify lnyrd switch is in the OFF position. MANUAL START MODEL 1. Remove 3 olts securing rewind strter nd remove rewind from outord. - Strp Wrench - Flywheel 54639 ELECTRIC START MODEL 1. Remove 3 olts securing flywheel cover nd remove cover from outord. - Rewind Strter - Bolts - Flywheel Cover 54640 2A-14 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

2. Use flywheel holder (91-52344) to hold flywheel while removing flywheel nut nd wsher. 54641 - Flywheel Holder (91-52344) - Flywheel NOTE: Use flywheel puller (91-73687A1) on oth mnul nd electric strt type flywheel. Alwys instll crnkshft protector cp onto end of crnkshft efore threding flywheel puller into flywheel. Do not strike flywheel puller olt with hmmer s crnkshft my e dmged. CAUTION Do not pply het to flywheel or strike flywheel with hmmer s flywheel or electricl components under flywheel my e dmged. Flywheel Instlltion CAUTION Inspect mgnet side of flywheel for ny deris clinging to mgnets. Instlling flywheel with deris on mgnets will cuse dmge to flywheel nd/or electricl components locted under flywheel when outord is initilly strted. 1. Secure flywheel on crnkshft with flt wsher nd nut. 2. On electric strt type flywheel, use flywheel holder (91-52344) to hold flywheel while tightening flywheel nut. On mnul strt type flywheel, use strp wrench to hold flywheel while tightening flywheel nut. 3. Torque flywheel nut to 75 l. ft. (101.7 N m). 4. Reinstll rewind strter, if mnul strt, or flywheel cover, if electric strt, with 3 olts. Torque olts to 100 l. in. (11.3 N m). Ignition Components CAUTION To prevent ccidentl strting of outord while removing or instlling engine components, on electric strt models remove engine ttery cles from ttery nd verify ignition key is in the OFF position. When servicing mnul strt engines, verify lnyrd switch is in the OFF position. c Sttor Assemly Removl 1. Remove top cowl. 2. Remove 3 olts securing rewind strter or flywheel cover nd remove rewind or cover, whichever is pplicle. 3. Remove flywheel s outlined in FLYWHEEL RE- MOVAL AND INSTALLATION, preceding. 54642 - Flywheel - Flywheel Puller (91-73687A1) c - Crnkshft Protector Cp (Hidden); Plce on end of Crnkshft 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-15

4. Remove 4 screws which secure sttor to upper cp. 5. Remove 6 olts securing electricl ox ccess cover nd remove cover. - Screws - Sttor 54644 54645 - Bolts - Access Cover 6. Disconnect sttor wiring from their respective terminls nd remove sttor ssemly from outord. 2A-16 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Blck Sttor Instlltion 1. Apply Loctite Grde A (92-32609-1) to threds of 4 sttor ttching screws. 2. Instll sttor on upper end cp nd torque ttching screws to 35 l. in. (3.9 N m). 3. Route sttor wiring into electricl component ox. c c 54647 54646 - Sttor - Wiring c - St-Strp NOTE: Sttor wiring is routed ehind strter motor nd enters electricl ox through ccess holes under wrning module. - Wrning Module - Sttor Wiring to Switch Box c - Sttor Wiring to Rectifier 4. Reconnect wires to proper terminls. Refer to wiring digrms, Section 2D. Torque terminl nuts to 30 l. in. (3.4 N m). 5. Reinstll electricl ox ccess cover. 6. Reinstll flywheel s outlined in FLYWHEEL RE- MOVAL AND INSTALLATION, preceding. 7. On mnul strt models, reinstll rewind strter. On electric models, reinstll flywheel cover. On either mnul or electric models, rewind or cover ttching olts should e torqued to 100 l. in. (11.3 N m). 8. Reinstll top cowl. 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-17

Red Sttor Instlltion 1. Position sttor on powerhed s shown. Secure sttor with 4 screws. Apply Loctite 271 to screw threds. Torque screws to 35 l. in. (4.0 N m). 3. Instll dpter module routing dpter wires through opening in upper right corner of electricl ox. Connect sttor, dpter module nd switch ox wires per pproprite model wiring digrm in Section 2D Wiring Digrms. c 54952 - Sttor - Screws [Torque to 35 l. in. (4.0 N m)] c - Sttor Hrness 2. Instll BLUE nd BLUE/WHITE cle dpters to BLUE nd BLUE/WHITE terminls on switch ox. Torque terminl nuts to 30 l. in. (3.5 N m). Instll cp nuts on unused terminls. - Upper Right Corner - Adpter Module 54954 c c - BLUE Cle Adpter - BLUE/WHITE Cle Adpter c - Cp Nuts 54953 2A-18 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Electric Models Secure dpter module nd wiring with st-strps. i f c d h g f e 54957 - St-Strps - Adpter Module (Hidden) c - Adpter Module WHITE/GREEN Led d - Adpter Module GREEN/WHITE Led e - Sttor YELLOW Leds f - Cps g - Adpter Module BLUE Led h - Adpter Module BLUE/WHITE Led i - Adpter Module BLACK Led Torque olt to 40 l. in. (4.5 N m) 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-19

Mnul Models Secure dpter module nd wiring with st-strps. m j l c k d j e f g i h 54955 - St-Strps - Adpter Module c - Insultor Plug d - Sttor BLUE/WHITE Led (not used) e - Adpter Module WHITE/GREEN Led f - Adpter Module GREEN/WHITE Led g - Sttor YELLOW Leds h - Terminl Block i - Hrness Extension Secure to Terminl Block w/screws (retined) j - Cps k - Adpter Module BLUE Led l - Adpter Module BLUE/WHITE Leds m- Adpter Module BLACK Leds Torque olt to 40 l. in. (4.5 N m) 2A-20 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Trigger Plte Assemly Removl 1. Remove top cowl. 2. Remove 3 olts securing rewind strter or flywheel cover nd remove or cover, whichever is pplicle. 3. Remove flywheel s outlined in FLYWHEEL RE- MOVAL AND INSTALLATION, preceding. 4. Remove 4 screws which secure sttor ssemly to upper end cp. Lift sttor off end cp nd move to the side. 5. Remove locknut tht secures link rod swivel into sprk rm. Pull link rod swivel out of rm. 6. Remove 6 olts from electricl ox ccess cover nd remove cover. f e 54645 - Bolts - Access Cover 7. Disconnect trigger leds form their respective terminls on switch ox. Remove trigger plte ssemly from engine. c d - Trigger Plte Assemly - Link Rod Swivel c - Sprk Arm d - Lock Nut e - Trigger Hrness f - St-Strps 54648 54649 - Trigger Leds - Switch Box 8. If trigger is defective, remove nd retin link rod from trigger. 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-21

Trigger Plte Assemly Instlltion 1. If link rod ws removed from trigger, ressemle to trigger. 2. Plce trigger plte ssemly in upper end cp. Fsten link rod swivel to sprk rm lever with lock nut. 3. Route nd secure trigger hrness s shown. d 4. Reconnect trigger wires to proper terminls of switch ox. Refer to wiring digrm, Section 2D. Torque terminl nuts to 30 l. in. (3.4 N m). f e c - Lock Nut - Link Rod Swivel c - Sprk Arm d - Trigger Plte Assemly e - St-Strps f - Trigger Hrness (Route s Shown) 54648 54649 - Trigger Hrness - Switch Box 5. Reinstll electricl ox ccess cover nd secure cover with 6 olts. 6. Reinstll sttor s outlined in STATOR AS- SEMBLY INSTALLATION, previously. 7. Reinstll flywheel s outlined in FLYWHEEL INSTALLATION, previously. 8. Reinstll rewind strter if mnul strt or flywheel cover if electric strt. On either mnul or electric models rewind or cover ttching olts should e torqued to 100 l. in. (11.3 N m). 9. Reinstll top cowl. 2A-22 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Coil Removl 1. Remove top cowl. 2. Remove 6 olts from electricl ox ccess cover nd remove cover. Ignition Coil Instlltion 1. Instll sprk plug high tension led/coil tower oot ssemly (retined) onto new coil. 2. Position secondry coil into electricl ox. 3. Reconnect positive (+) nd negtive ( ) leds to their respective terminls on coil with 2 nuts. Torque nuts to 30 l. in. (3.4 N m). 4. Reconnect sprk plug oot to sprk plug. 5. Reinstll electricl ox ccess cover nd secure cover with 6 olts. 6. Reinstll top cowl. Switch Box Removl 1. Remove top cowl. 2. Remove 6 olts from electricl ox ccess cover nd remove cover. 54645 - Bolts - Access Cover 3. Disconnect wires from positive (+) nd negtive ( ) terminls on defective coil. 4. Remove sprk plug oot from sprk plug. 5. Remove sprk plug high tension led/coil tower oot ssemly from coil tower nd discrd defective coil. c d e - Bolts - Access Cover 54645 54650 - Positive (+) Led - Negtive ( ) Led c - High Tension Led d - Coil Tower Boot e - Coil 90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-23

3. Disconnect ll leds from switch ox. 4. Remove 4 olts from switch ox nd remove switch ox. Switch Box Instlltion 1. Secure switch ox to electricl component ox with 4 olts nd their respective ground leds. Torque olts to 40 l. in. (4.5 N m). 2. Reconnect leds to switch ox terminls. Refer to WIRING DIAGRAM, SECTION 2D. Torque switch ox terminl nuts to 30 l. in. (3.4 N m). 3. Reinstll electricl ox ccess cover nd secure cover with 6 olts. 4. Reinstll top cowl. 54651 - Bolts - Switch Box 2A-24 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996