Cushman TURF-TRUCKSTER, Service & Repair Manual, Page: 36 / 263

GENERAL
The gasoline engine used on your vehicle is either a
3-cylinder Suzuki 660 or 4-cylinder Suzuki 970.
Service manuals for both these engines are available
from the manufacturer.
Instructions in this section apply to both engines
unless otherwise stated.
IGNITION SYSTEM —
4-CYLINDER ENGINE (SUZUKI 970)
GENERAL
The principal components of this ignition system
are the 4 spark plugs, distributor, contact breaker,
ignition coil and, as the source of igniting energy, the
battery. The ignition coil has two windings, primary
and secondary.
Current from the battery flows through the primary
winding and then the contact breaker; the contact
point in the breaker opens and closes to interrupt this
current intermittently.
Each time the primary current is interrupted, a very
high voltage develops in secondary winding. It is this
intermittent high voltage that the distributor passes
sequentially to the 4 spark plugs to fly a spark across
the gap in each, one plug at a time.
IGNITION COIL TEST (See Figure 3E-1)
Measure resistances of primary and secondary wind-
ings of the ignition coil. Take readings when coil is
hot, about 176°F (80°C). If resistance is out of specifi-
cation replace coil with a new one.
SPARK PLUG WIRES
1. Remove high tension coil cable at ignition coil
while gripping its cap.
2. Remove distributor cap with spark plug wires
installed.
3. Remove high tension cable clamp from cylinder
head cover.
4. Pull out spark plug wire from each spark plug
while gripping its cap.
5. Use an ohmmeter to measure spark plug wire
resistance. Resistance should be 10 to 22 k
Ω
(kilohms).
6. If resistance is outside of specified reading,
inspect and replace the distributor cap and/or
spark plug wires as required.
SPARK PLUGS
1. Pull out spark plug wires by gripping their caps
and then remove the spark plugs.
2. Inspect for electrode wear, carbon deposits and
insulator damage.
3. If any problem is found, adjust spark plug air gap,
clean with spark plug cleaner or replace them with
specified new plugs.
4. Gap spark plugs to 0.032 to 0.035 inch (0.8 to
0.9 mm).
5. Torque spark plugs to 18.5 to 21.5 ft-lbs. (25 to
30 N.m).
6. Install spark plug wires securely by gripping their
caps.
SECTION 3E. GASOLINE ENGINES
3E-1
3E
ENGINE
Figure 3E-1. Ignition Coil Test, 4-Cylinder Engine
Primary Winding About 3.40
Ω
(ohms) (between
Resistance B and – terminals) (inclusive
of 1.30
Ω
(ohms) resistor)
Secondary Winding About 19.9 k
Ω
(kilohms) (between
Resistance high tension terminal and –
terminal)
!
CAUTION
Removal of spark plug wires together with
clamps is recommended so as not to damage
their inside wire. For the same reason, pull out
each connection by gripping at the cap.
!
CAUTION
Never use metal conductor high tension wires as
replacement parts. Insert each cap portion fully
when installing spark plug wires.