ELECTRICAL COMPONENTS
Ignition Coil
2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-27
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2. Remove the cap (2) from the wire by turning the cap counterclockwise three or four revolutions while
gently pulling it off the wire (Figure 12-28, Page 12-26).
3. Remove the gasket (1) and protector tube (3) from the old coil.
NOTE: Moisten the spark plug wire with water to make gasket removal and installation easier.
4. Remove the grommet (4) from the old spark plug wire. Clean the grommet and place it on the new
spark plug wire (5).
5. Install the protector tube onto the new wire.
6. Slide the gasket onto the end of the new spark plug wire.
7. Install the cap on the new coil spark plug wire by rotating it clockwise three or four revolutions while
applying light pressure on the cap.
8. Install the gasket (1) on the cap (2).
9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two
mounting bolts (6) to finger tight at this time.
10. Rotate the flywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012”
(0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet.
Tighten the two mounting bolts (6) to 30 in-lb (3.4 N·m) (Figure 12-29, Page 12-26).
11. Connect the 18 gauge black wire to the spade terminal on the coil.
12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch
on the housing.
13. When installing fan housing, make sure the top front corner of the housing is above the upper cylinder
shroud. The front edge of the fan housing should be behind the lower cylinder shroud. Align the slots in
the housing with the flanged bolts loosened earlier.
14. Install the four remaining flange bolts that secure the fan housing to the engine crankcase. Tighten all
seven mounting bolts to 90 in-lb (10.2 N·m) (Figure 12-26, Page 12-26).
15. Install the stiffener with four hex head bolts and lock nuts. Tighten the hardware to 23 ft-lb (30.5 N·m)
16. Install the fan shroud with four pan head bolts. Tighten the hardware to 50 in-lb (5.7 N·m) (Figure 12-
17. Secure the wire harness to the stiffener with a wire tie. Place the wire tie through the lower hole at the
back of the stiffener (Figure 12-25, Page 12-25).
∆ CAUTION
• Make sure wire harness is routed and secured away from the muffler.
18. Install the muffler. See Section 15 – Exhaust System.
19. Connect the spark plug wire to the spark plug.
20. Connect battery cables, positive cable first and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi-
nals with Battery Protector Spray (CCI 1014305).
