Ignition System

Ignition System
Model(s)
750MK (Midnight)
750ML (Midnight)
750K (Maxim)
xjcdadmin Sun, 05/30/2010 - 09:23

3.
Main switch

4. Main fuse (20 amp)

5. Battery (12V 14 AH)
9. Ignition fuse (10 amp)
10. Engine Stop switch
11. Starting circuit cut-off relay
12. Clutch switch
13. Sidestand relay
14. Sidestand switch
15. Ignitor unit
16. Ignition coil
17 Spark plug
18. Pickup coil
23 Neutral switch
B. Description

This model is equipped with a battery operated, fully transistorized, breakerless ignition
system. By using magnetic pickup coils, the need for contact breaker points is eliminated.
This adds to the dependability of the system by eliminating frequent cleaning and
adjustment of points and ignition timing. The TCI (Transistor Control Ignition) unit
incorporates an automatic advance circuit controlled by signals generated by the pickup
coil. This adds to the dependability of the system by eliminating the mechanic advancer.
This TCI system consists of two units; a pickup unit and an ignitor unit.

NOTE:

The ignition circuit can be operated only when the sidestand is up (the sidestand switch is
on) or the transmission is in neutral.

C. Operation

The TCI functions to the same principle as a conventional DC ignition system with the
exception of using magnetic pickup coils and a transistor control box (TCI) in place of
contact breaker points.

1. Pickup unit

The pickup unit consists of two pickup coils and a flywheel mounted onto the crankshaft.
When the projection on the flywheel passes a pickup coil, a signal is generated and
transmitted to the ignitor unit. The width of the projection on the flywheel determines the
ignition ad-vance.

2. Ignitor unit

This unit controls when form, duty control, switching, electronic ignition advance, etc. The
duty control circuit reduces electrical consumption by controlling the duration of the
primary ignition current.

The ignitor unit also has a protective circuit for the ignition coil. If the igni tion switch is on
and the crankshaft is not turning, the protectice circuit inter-

rupts the current flow to the primary coil after a few seconds. When the crankshaft is
turning, however, the ignitor unit sends current to the primary coil.

3. Sidestand relay

The sidestand relay operates by shorting the TCI control current. When the side-stand is
down, the sidestand relay is closed, and the TCI control current is grounded through the
sidestand relay. Thus, the engine will not run with the sidestand down unless the
transmission is in neutral.
1. TCI control current from TCI unit
2. Sidestand relay
3. From engine stop switch
4. From clutch switch
5. Neutral switch
6. Sidestand switch
7. From starting-circuit cut-off relay
8. When the sidestand is up.
9. When the transmission is in neutral and the sidestand is down.

D. Sidestand relay

1. Open the seat, and remove the fuel tank.

2. Remove the sidestand relay from the frame, and disconnect the connector.

1. Sidestand relay

3. Check the resistance of the relay coil windings with the pocket tester. If the resistance is
not within specification, replace the relay.
1. Sidestand relay

4. Check the relay contact breaker points with the pocket tester and a 12 volt battery.
Connect the leads as shown in the illustration. If the resistance readings do not equal those
shown in the illustration, replace the relay.

1. When the battery is connected.

2. When the battery is disconnected.
3. 12 volts battery

E. Ignition Coil

1. Coil spark gap test.

a. Remove the fuel tank and disconnect the ignition coil from wire harness and spark
plugs.

b. Connect the Electro Tester as shown.

1. Ignition coil
2. Battery

c. Connect fully charged battery to tester.

d. Turn on spark gap switch and the increase gap to maximum unless misfire occurs first.

Minimum spark gap: 6 mm (0.24 in)

2. Direct current resistance test. Use a pocket tester or equivalent ohmmeterto determine
resistance and continuity of primary and secondary coil windings.
Standard value:
Primary coil resistance: 2.5Ω ± 10% at 20°C(68°F)
Secondary coil resistance: 11KΩ ±20% at 20°C(68°F)

Primary coil check

1. Ignition coil

Secondary coil check

1, Ignition coil

F. Spark Plug

The life of a spark plug and its discoloring vary according to the habits of the rider. At each
periodic inspection, replace burned or fouled plugs with new ones of the specified type. It is
actually economical to install new plugs often since it will tend to keep the engine in good
condition and prevent excessive fuel consumption.

1. Inspection

a. Inspect and clean at the specified intervals and replace as required.

b. Clean the electrodes of carbon and adjust the electrode gap to the specification.

2. Installation

Be sure to use the proper reach, type and electrode gap plug(s) as a replacement to avoid
overheating, fouling or piston damage.

Type: BPR7ES (NGK) or W22EPR-U

Electrode gap: 0.7- 0.8 mm (0.028-0.031 in)
Tightening torque: 20 Nm (2.0m-kg, 14.5 ft-lb)

G. Troubleshooting/Inspection
1. The entire ignition system can be checked for misfire and weak spark using the Electro
Tester. If the ignition system will fire across a sufficient gap, the entire ignition system can
be considered good. If not, proceed with individual component tests until the problem is
fround.

a. Warm up engine thoroughly so that all electrical components are at operating

temperature.

b. Stop the engine and connect the tester as shown.

1. Electro tester

2. Spark plug wire

c. Start the engine and increase the spark gap until misfire occurs. (Test at various r/min
between idle and red line.)

Minimum spark gap: 6 mm (0.24 in)

CAUTION:

Do not run engine in neutral above 6,000 r/min for more than 1 or 2 seconds.

2. If the ignition system should become inoperative, the following troubleshooting aids will
be useful.

Poor connection
Check entire ignition for connections Correct
>>>

OK

Low voltage &

Check battery for voltage and specific gravity specific gravity Recharge battery
>>>

OK
 Weak connection
or open circuit Correct connection or
Check fuse and fuse connections
replace fuse
>>>

OK

Check resistance of ignition coil (primary and If other than

secondary) Primary: 2.5Ω± 10% at 20C(68°F) specified Replace ignition coil
Secondary: 11KΩ± 20% at 20°C(68°F) >>>

OK .

If other than
Check pick-up coils for resistance Pick-up coil: specified Replace pick-up coil
700Ω±20% at 20°C (68°F) assembly
>>>

OK

TCI unit is faulty, replace unit