Testing Ignition Switches
1. Disconnect the engine wires from the main wiring
harness.
2. At the main wiring harness engine connector, connect
the red tester lead to the violet wire; then connect the
black tester lead to the engine ground (brown wire).
3. With the ignition switch in the RUN position, the
emergency stop switch in the ON position, and the
tether cord connected, the meter must read no resis-
tance. If the meter reads resistance, disconnect the
ignition switch from the main wiring harness. If the
meter now reads no resistance, replace the ignition
switch.
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4. If the meter continues to read resistance with the igni-
tion switch disconnected, disconnect the emergency
stop switch. If the meter now reads no resistance,
replace the emergency stop switch.
5. If the meter continues to read resistance with both the
ignition switch and the emergency stop switch dis-
connected, disconnect the wires to the tether switch.
If the meter now reads no resistance, replace the
tether switch.
6. If the meter continues to read resistance with all three
switches disconnected, replace the main wiring har-
ness.
Testing Electrical
Resistances
NOTE: The following test procedure starts by test-
ing the resistance for the spark plug cap and working
back to the stator under the flywheel. Replace any
component that does not have a test value within spec-
ifications.
SPARK PLUG CAP
1. Remove the spark plug cap from the high tension lead
by rotating it counterclockwise.
2. Set the selector in the OHMS position.
3. Connect one tester lead to one end of the cap and the
other tester lead to other end of the cap.
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4. Spark plug cap resistance must be between 4000-
6000 ohms.
MAGNETO
1. Disconnect the two white wires from the main har-
ness.
2. Set the meter selector to the OHMS position; then
connect the red and black tester leads to each of the
two white wires.
3. The meter must show less than 1 ohm.
EXTERNAL COIL
Primary
1. Disconnect the single black/white wire lead of the
coil from the main harness.
2. Set the meter selector to the OHMS position; then
connect the red tester lead to the black/white wire and
the black tester lead to the metal post of the coil.
3. Resistance must be within 11.25-11.75k ohms.
Secondary
1. Remove the spark plug end cap from the high tension
lead of the coil.
2. Set the meter selector to the OHMS position; then
connect the red lead of the tester to the high tension
lead to the coil and the black tester lead to ground.
3. Resistance must be within 6000-7000 ohms.
LIGHTING COIL
1. Disconnect the two yellow wires from the main wir-
ing harness.
2. Set the selector to the OHMS position.
3. Connect the tester leads to the two yellow leads on
the engine-side connectors.
4. Lighting coil resistance must be between 0.46-0.68
ohm.
Testing Handlebar Warmer
Elements
NOTE: Resistance will vary due to temperature;
therefore, this test should be made at room tempera-
ture of 22° C (72° F).
