4-1

Chapter 4
I9 n ition syste m
Contents
General information""""""""""""""""""" 1 Ignition timing - generalinformationand check. . . . . . . . . . . . . . .. 6
Ignition control unit - check,removaland installation. . . . . . . . . . .. 5 Neutral switch - check and replacement. . . . . . . . . . . . .see Chapter 8
Ignition (main) switch - check, removal and installation. .see Chapter 8 -
Pulsegeneratorcoil assembly check,removaland installation. .. 4
-
Ignition HT coils check,removaland installation. . . . . . . . . . . . .. 3 Sidestand switch - check and replacement. . . . . . . . . . .see Chapter 8
Ignition system-check 2 Sparkplug gap checkand replacement. . . . . . . . . . . . .seeChapter1

Degrees of difficulty
Easy,
suitablefa' ~ FMtyeasy,suitS)le~ ~ ~ ~ ~ SlitabIe
fa ~ V-v ~ ~
novice
witt)ittIe ~ fa'beginre-
witt) ~ ~ for~ ~ exP8'8"ICed
00 ~ ~ fa'expert
00 ~
exper8)Ce ~ some exper81Ce~ [)Ymechanic ~ mEK:hCI1ic ~ or professional ~

Specifications
General information
Cylinder identification. ......... Left (alternator side), Right (clutch side)
Ignition timing See Chapter 1
Sparkplugs
At idle
California models 50 BTDC
All other models 1~ BTDC
Full advance 400 BTDC 0 4(XX)rpm

Pulse generator coils

Resistance 250 to 420 ohms

Ignition HT coils
3.0 to 6.0 ohms
18 to 30 K ohms

17 to 23 Nm

The system uses two coils mounted on that most electrical parts. once purchased.
1 Generalinformation each side of the frame behind the steering cannot be returned. To avoid unnecessary
head. The right-hand coil supplies the right expense. make very sure the faulty
cylinder spark plug and the left-hand coil component has been positively identified
supplies the left cylinder plug. beforebuyinga replacementpart.
The ignition control unit incorporates an
4
All models are fitted with a fully
transistorlsed electronic ignition system.
which due to its lack of mechanical partsis
electronic advance system controlled by
signals genel'ated by the rotor and the pick-up 2 Ignition system -check
totally maintenance free. The system coil.
comprises a rotor, pulse generator coils, The system incorporates a safety intet1ock
ignition control unit and ignition HT coils (refer circuit which will cut the ignition if the
to the wiring diagrams at the end of Chapter 8 sidestand is put down whilst the engine is &. Warning: The energy levels in
for details). running and in gear, or if a gear is selected , electronic systems can be very
whilst the engine is running and the sidestand . high. On no account should the
The trigger on the rotor. which is fitted to
the right-hand end of the crankshaft, is down. ignition be switched on whilst
magnetically operates the pulse generator Because of their nature, the individual the plugs or plug caps are being held.
coils as the crankshaft rotates. The pulse ignition system components can be checked Shocks from the HT circuit can be most
generator coils send a signal to the ignition but not repaired. If ignition system troubles unpleasant. Secondly, it is vital that the
control unit which then supplies the ignition occur, and the faulty component can be engine is not turned over or run with either
HT coils with the power necessary to produce isolated, the only cure for the problem is to of the plug caps removed, and that the
a spark at the plugs. replace the part with a new one. Keep in mind plugs are soundly earthed (grounded)
4-2 Ignition system

when the system is checked for sparking. b) Faulty HT I8Id or SPIr* plug C4), laity
The ignition system components can be SP8fkplug, ditty, WQ'rtor corroded ~
.eriously amaged " the HT circuit eI8ct1oc»s, or inconect 8I8CtIocMgap.
becomeal8ol8ted. c) Faulty ignition switch or engine kH1awftch
1 As no means of adjustment is available, any (see Chipt8f' 8).
failure of the system can be traced to failure of d) Faulty neutta/ or sJdestandswitch (sa
a system component or a simple wiring fault. Chl¥'fW 8).
Of the two possibilities, the latter is far more e} Fau#rypufae generator colis or d8m8Q8d
likely. In the event of faillA, check the system rotor.
in a logical fashion, as described below. f) Faulty ignition HT calIfs).
2 Disconnect the HT lead from both cylinder gJ Faulty ignition control unit.
spark plugs. Connect each lead to a spare 7 If the above checks doo't reveal the cause
spark plug and lay each plug on the engine of the problem, have the ignition systn tested
with the threads contacting the engine. If by a Suzuki dealer. Suzuki produce a tester
necessary, hold each spark plug with an which can perform a complete diagnostic
insulated tool. analysis of the ignition system.
.& Warning: Do not remove the

. perform this check - atomised

spark plugs from the engine to

3 Ignition HT coils - check,

fuel pumped out of the open removal and installation
.park plug hole could ignite, causing
8eV8IW injuIyl
3 Having observed the above precautions.
check that the kill switch Is in the RUN position, Check
tum the ignition switch ON and tum the engine conditiona regular, fat blue spark should be
1 In order to determine conclusively that the
over on the starter motor. If the systemis in S8«1 to jump the gap between the nail ends.
ignition coils are defective. they should be
good corxiltkx1 a ~, fat bkJe sper1<~ Repeat the test for the other coil. If the test tested by a Suzuki dealer equipped with the
be evident at each pkJg electrode. If the sp8'1< results are good the ~re ignltm system can special diagnostic test...
appears thin or yellowish, or is non-existent, be considered good. If the spark appears thin 2 Howevw, the coils can be checked visually
further investigation will be necessary. Before or yellowish, or is non-existent, further (for cracks and other damage) and the Plimary
proceedingfurther, turn the ignition off and investigation will be necessary. and secondary coil resJstances can be
~ the key as a safety mNSUre. 8 Ignition faults can be divided into two meesured with a multimeter. If the coils are
4 The 91ition system must be ~ to ~uce categories. namely those where the Ignition ~, and if the resistance reedings are
a sp8t< which is ~ of jumping a particular syst8n has failed completely, and thoee which as specified at the beginning of the Chapter,
size gap. Suzuki specify that a healthy system are due to a partial failure. The likely faults are they are probably capa~e of proper operation.
shoukJ ~ a spark capable of jumping 8 listed below, starting with the most probable 3 Remove the seat (see Chapter 7) and
1Tm. A s8npe ~ tOO C8'\ be made to test source of failure. Work through the list disconnect the battery negative (-ve) Ieed. To
the minimum gap across which the spark will systematically, referring to the subsequent gain access to the coils, remove the fuel tank
j\J!np (see Tool ~). sections for full details of the necessary checks (see Chapter 3). The coils are mounted on
5 Connect one of the spark plug HT leads and tests. Note: Before checking the following each side of the frame behind the steering
from one coli to the protruding electrode on Items ensure that the battery Is fully charped stem (see H~).
the test tool, M)d clip the tool to a good earth wKJ tf-.t ~ fuses &'8 in good C(N'dtkxJ. 4 Disconnect the primary circuit electrical
(ground) on the engine or frame. Check that a) Loose, corroded or acT,agec; wiring connectors from the coil being tested and the
the kill switch is in tha RUN position, tum the connections, broken or shorted wiring HT lead from the sparl< plug (see illustr8tlon).
ignition switch ON and turn the engine over on between any of the component petta of Marl< the locations of all wires and leads
the starter motor. If the system is in good the #grWbJ sysI8m (lee c".,. 8). befcwe dieconnecting them.

3.3 The coils are mounted on each side of the frame behind the
steering stem, and are secured by two bolts (8T0W8)
 Ignition system 4-3

5 Set the meter to the ohms x 1 scale and damaged or broken wire from the coil to the
measure the resistance between the primary 4 Pulse generator coils - connector; pinched or broken wires can
circuit terminals (see illustration). This will check, removaland installation
~ usually be repaired. Note that the pick-up
give a resistance reading of the primary ~
~ coils are not available individually but corne as
windings and should be consistent with the a pair along with their mounting plate.
value given in the Specifications at the
beginning of the Chapter. Check I Removal
S To check the condition of the secondary 1 Remove the seat and the I~-hand side 5 Remove the seat and the left-hand side
windings, set the meter to the K ohm scale. panel (see Chapter 7) and di~onnect the panel (see Chapter 7) and disconnect the
Connect one meter probe to one of the battery negative (-ve) lead. battery negative (-ve) lead.
primary circuit terminals and the other probe 2 Trace the pulse generator coil wiring back S Trace the pulse generator coil wiring back
to the spark plug cap on the HT lead (see from the right-hand side crank~ cover and from the right-hand side crankcase cover and
Illustration 3.5). If the reading obtained is not disconnect it at the 4-pin conn~tor. Using a disconnect it at the 4-pin connector. Free the
within the range shown in the Specifications, multi meter set to the ohms J( 100 scale, wiring from any clips or ties.
it is likely that the coil is defective. measure the resistance first ~etween the 7 Unscrew the three bolts securing the
7 Should any of the above checks not brown and black/blue wires, and 'hen between circular pulse generator assembly cover to the
produce the expected result, have your the green/white and black/blue "ires. on the right-hand side crankcase cover (see
findings confirmed on the diagnostic tester pick-up coil side of the connect~. illustration). Remove the cover.
(see Step 1). If the coil is confirmed faulty, it 3 Compare the reading obtai~ with that S Using a 19 mm spanner to counter-hold the
given in the Specifications at thej beginning of timing rotor hex, unscrew the bolt in the
must be replaced;the coil is a sealed unit and
this Chapter. The pick-up coils must be centre of the rotor which secures it to the end
cannot therefore be repaired.
replaced if the reading obtained 4iffers greatly of the crankshaft (see illustration). Remove
from that given, particularly If the meter the rotor, noting how the pin in the end of the
Removal indicates a short circuit (no measurable crankshaft locates in the slot in the rotor.
8 Remove the seat (see Chapter 7) and resistance) or an open circuit (infinite, or very 9 Slacken the screw securing the wire to the
disconnect the battery negative (-ve) lead, high resistance). i terminal on the oil pressure switch and detach
then remove the fuel tank (see Chapter 3).
4 If one or both pick-up coils alte thought to the wire (see illustration).
be faulty, first check that this is !not due to a 10 Unscrew the two screws securing the
9 The coils are mounted on each side of the
4
frame behind the steering stem. Disconnect
the primary circuit electrical connectors from
the coils (see iHustr8tion 3.4) and disconnect
the HT leads from the spark plugs. Mark the
locations of all wires and leads before
disconnecting them.
10 Unscrew the two bolts securing each coil
to the frame, noting the position of the spacers,
and remove the coils (see illustration 3.3).
Note the routing of the HT leads.

Installation
11 Installation is the reverse of removal. 4.8 Use a spanner on the hex (A) to 4.9 Slacken the screw (arrow)and
Make sure the wiring connectors and HT counter-hold the rotor, then unscrew the disconnect the oil pressure switch wire
leadsaresecurelyconnected. rotor bolt (B)
4-4 Ignition system

4.10 The pulse generator coli assembly Is 4.158 Make sure the slot in the timing
secured by two screws (arrows) rotor (A) locates over the pin (8)

4.15b Install the rotor bolt . . . 4.15c ... and tighten it to the specified
torque while counter-holding the rotor

pulsegeneratorcoil assemblymountingplate 3 Trace the wiring from the ignition control

- ch~.
to the crankcase cover (8.. IIlu8tration).
Removethe rubber wiring grommet from its
recessin the crankcasecoverand ~ the
5 Ignition control unit
removaland installation, ~
~
unit and disconnect it at the comectors (888
Illustration).
4 Unscrew the two screws securing the
coil assembly,notinghow It fits. ignition control unit to the frame and remove
11 Examinethe rotor for signs of damage the unit.
and replaceit if necessary. Check
1 If the tests shownin the precedingSections Installation
Installation havefailed to isolatethe causeof an ignition 5 Installation is the reverse of removal. Make
sure the wiring connectors are correctly and
12 Install the pulse generatorcoil assembly fault. it is likely that the ignition control unit
itself is faulty. No test details are available securely connected.
onto the crankcase cover and tighten the
assembly mounting screws securely (see with which the unit can be tested on home
II~ 4.1Ot. workshopequipment.Take the maChineto a 6 Ignition timing - general ~",
13 Apply a smear of sealant to the rubber Suzuki dealer for testing on the clagnostic informationandcheck
~
wiringsealand fit the grommetin its recessin tester. ~
~
the crankcase(see ilt8tr8tion). Removal
14 Connectthe 011pressureswitch wire to its
2 Remove the seat and the left-hand side Generalinfolmatlon
terminalon the switch and tighten the screw
panel
battery(see Chapter
negative 7) and disco.,nect
(-ve)lead. ' the
securely(see Ilustration 4.9). 1 Since no provision exists for adjusting the
15 Installthe timing rotor onto the end of the ignition timing and since no component Is
crankshaft,making sure the slot in the rotor subject to mechanical wear, there Is no need
locatesconectIyover the pin In the end of the fcw'regular checks; only If ~ a fault
crankshaft(see llu8tration). Using a 19 mm such as a loss of power or a misfire, should
spannerto counter-holdthe rotor, Installthe the ignition timing be checked.
rotor bolt and tighten it to the torque setting 2 The ignition timing is checked dynamically
specifiedat the beginni1gof the Chapter(see (~ ~ usi1g a stroboscoPC ig1t. The
illustrations). inexpensive ~ ~ ~ be adequate In
18 Installthe pulsegeneratorassemblycover ~ , ~ in IX8:tk:e may P'oduC8 a ~ of
andtightenits bolts~ (see 8I8tration). ax:h k)w rrta"8ty that tt18 tW1W1gnwt( Ien\M18
17 Routethe wiring up to the connectorand indistinct. If PO8i~, one of tt18 more preciae
reconnectit. Securethe wiring in its clips or x~ tube lamps shoukj be used, powered by
ties. ., ext.nal SOtIC8 of tt18 ~ voltage.
18 Reconnectthe battery negative(-ve)lead Note: ~ not ~ the macIine's own b8tI8fy 8$
and install the seat and side panel (see 5.3 Disconnectthe two ignition control an incorrect reading may result from stray
Chapter7). unit wiring connectors iIrJ>uIssswitIVn tt. mecfine's "'--I;-',;;:a'system.
 Ignition system 4-5

Check 8 With the machine idling at the specified

3 Warm the engine up to normal operating speed, the timing mark should align with the
temperature then stop It. static timing mark.
4 Unscrew the three bolts securing the 9 Slowly increase the engine speed whilst
circularpulsegeneratorassemblycoverto the observing the timing mark. The timing mark
right-hand side crankcase cover (se. should move anti-clockwise, increasing in
illustration 4.7). relation to the engine speed until it reaches
5 The timing marl<on the rotor is an F which full advance (no identification mark).
indicatesthe firing point at idle speed for the 10 As already stated, there is no means of
right-hand cylinder (s.. illustration). The adjustment of the ignition timing on these
static timing mark with which this should align machines. If the ignition timing is incorrect, or
is the contact on the pulse generator coil. suspected of being incorrect, one of the
6.5 Ignition rotor timing mark ignition system components is at fault, and
;; The rotor timing mark can be the system must be tested as described in the
H.. highlighted with white paint 6 Connect the timing light to the right-hand
cylinder HT lead as described in the preceding Sections of this Chapter.
I {typist's correction fluid is
ideal} to make it more visible manufacturer's instructions. 11 When the check is complete, install the
under the stroboscopic light. 7 Start the engine and aim the light at the cover and tighten its bolts securely (s..
static timing mark. IIlusb"ation
4.16).

4
4-6 Notes