5-7
5
Regulator/Rectifier
The regulator/rectifier is located near the battery.
VOLTAGE
1. Set the meter selector to the DC Voltage position.
2. Test between the black and white wires (with the
regulator/rectifier plugged in).
3. With the engine running at a constant 3000 RPM,
the meter must read 12.1-15.2 DC volts.
Ignition Timing
The ignition timing cannot be adjusted; however, veri-
fying ignition timing can aid in troubleshooting other
components. To verify ignition timing, use the follow-
ing procedure.
1. Attach the Timing Light (p/n 0644-296) to the
spark plug high tension lead; then remove the tim-
ing inspection plug from the right-side crankcase
cover.
2. Using the Tachometer (p/n 0644-275), start the
engine and run at 4000 RPM; ignition timing
should be 28° BTDC (“F” mark).
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may be
damaged, the key may be sheared, the trigger coil
bracket may be bent or damaged, or the CDI unit may
be faulty.
Headlights
The connectors are the two-pronged white ones under
the front fender assembly.
BULB VERIFICATION
Visually inspect the bulb for broken filaments, black-
ening, or loose bulb base.
VOLTAGE
NOTE: Perform this test on the main harness side
of the connectors. The engine must be running for
this test.
1. Set the meter to the AC Voltage position.
2. Connect the black tester lead to one side of the
connector and the red tester lead to the other side.
3. With the engine running, the meter must show
9.0-13.5 AC volts.
NOTE: If the meter shows no voltage, inspect wir-
ing harness or connectors. If normal, perform a
stator coil test (see Stator Coil in this section).
Troubleshooting
Problem: Spark absent or weak
Condition
Remedy
1.
Ignition coil
defective
2.
Spark plug
defective
3.
Magneto
defective
4.
CDI unit
defective
1. Replace ignition coil
2. Replace plug
3. Replace magneto
4. Replace CDI unit
Problem: Spark plug fouled with carbon
Condition
Remedy
1.
Idle RPM
too high
2.
Gasoline
incorrect
3.
Air filter
elemen
t dirty
4.
Spark plug
incorrect (too cold)
1. Adjust carburetor
2. Change to correct gasoline
3. Clean element
4. Replace plug with proper heat range
Problem: Spark plug electrodes overheat or burn
Condition
Remedy
1.
Spark plug
incorrect (too hot)
2.
Engine
overheats
3.
Spark plug
loose
1. Replace plug
2. Check cooling fan air intake blockage - damage to fan -
cooling shroud
3. Tighten plug
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