The ignition system fails to operate (no spark or intermittent spark).

 

Check:

 

11) main and ignition fuses

 

12) battery

 

13) spark plug

 

14) ignition spark gap

 

15) spark plug cap resistance

 

16) ignition coil resistance

 

17) crankshaft position sensor resistance

 

18) main switch

 

19) engine stop switch

 

10.sidestand switch

 

11.starting circuit cut-off relay 1 12.lean angle cut-off switch

 

13.wiring connections (of the entire ignition system)

 

NOTE:

• Before troubleshooting, remove the following part(s):

 

• battery cover

 

• rear cover

 

• front cowling

 

• leg shield

 

• footrest board

 

• inner fender

 

14. Troubleshoot with the following special tool(s).

 

Ignition checker 90890-06754, YM-34487

Pocket tester 90890-03112, YU-03112-C

 

14. Battery

 

Check the condition of the battery.

 

Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.

Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F)

 

• Is the battery OK?

 

		YES		NO

• Clean the battery terminals.

 

• Recharge or replace the battery.

 

EAS00741

3. Spark plug

 

The following procedure applies to all of the spark plugs.

 

18. Check the condition of the spark plug.

 

19. Check the spark plug type.

 

20. Measure the spark plug gap.

 

Refer to “CHECKING THE SPARK PLUGS” in chapter 3.

 

Standard spark plug

CR7E (NGK)

Spark plug gap

~ 0.8 mm (0.028 ~ 0.031 in)

20. Is the spark plug in good condition, is it of the correct type, and is its gap within spec-ification?

 

		YES		NO

 

EAS00738

 

 

14. Main and ignition fuses

 

Check the main and ignition fuses for con-tinuity.

 

Refer to “CHECKING THE FUSES” in chapter 3.

 

Are the main and ignition fuses OK?

 

		YES		NO

Re-gap or replace the spark plug.

 

Replace the fuse(s).

 

 

8 - 10

_{IGNITION SYSTEM} ELEC ^{– +}

 

EAS00743 EAS00745

 

4. Ignition spark gap

 

The following procedure applies to all of the spark plugs.

 

17. Disconnect the spark plug cap 1 from the spark plug.

18. Connect the ignition checker 2 as shown.

 

 

14. Set the main switch to “ON”.

 

15. Measure the ignition spark gap a.

 

16. Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.

 

Minimum ignition spark gap 6 mm (0.24 in)

 

15. Is there a spark and is the spark gap within specification?

 

		YES		NO

The ignition system is OK.

 

5. Spark plug cap resistance

 

The following procedure applies to all of the spark plug caps.

 

15. Remove the spark plug cap from the spark plug lead.

16. Connect the pocket tester (Ω Ч 1k) to the spark plug cap as shown.

17. Measure the spark plug cap resistance.

 

 

Spark plug cap resistance 10.0 k Ω at 20 °C (68 °F)

 

• Is the spark plug cap OK?

 

		YES		NO

Replace the spark plug cap.

 

8 - 11

_{IGNITION SYSTEM} ELEC ^{– +}

 

EAS00746 EAS00748

 

• Ignition coil resistance

 

Disconnect the ignition coil connectors from the ignition coil terminals.

Connect the pocket tester (Ω Ч 1) to the ignition coil as shown.

 

Positive tester probe → red/black Negative tester probe → orange

 

• Measure the primary coil resistance.

 

Primary coil resistance

1.87 ~ 2.53 Ω at 20 °C (68 °F)

 

• Connect the pocket tester (Ω Ч 1k) to the ignition coil as shown.

 

Negative tester probe → spark plug lead 1 Positive tester probe → spark plug lead 2

 

 

• Measure the secondary coil resistance.

 

Secondary coil resistance 12 ~ 18 k Ω at 20 °C (68 °F)

 

• Is the ignition coil OK?

 

		YES		NO

Replace the ignition coil.

 

Й Crankshaft position sensor resistance

 

Disconnect the crankshaft position sensor coupler from the wire harness.

Connect the pocket tester (Ω Ч 100) to the crankshaft position sensor terminal as shown.

 

Positive tester probe → gray 1 Negative tester probe → black 2

 

 

К Measure the crankshaft position sensor resistance.

 

Crankshaft position sensor resis-tance

 

189 ~ 231 Ω at 20 °C (68 °F) (between gray and black)

 

• Is the crankshaft position sensor OK?

 

		YES		NO

Replace the crank-shaft position sensor/ stator assembly.

 

EAS00749

 

Л Main switch

 

Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?

 

		YES		NO

Replace the main switch/immobilizer unit.

 

8 - 12

_{IGNITION SYSTEM} ELEC ^{– +}

 

EAS00750 EAS00753

 

 

П Engine stop switch

 

Check the engine stop switch for continu-ity.

Refer to “CHECKING THE SWITCHES”.

 

Is the engine stop switch OK?

 

		YES		NO

Replace the right handlebar switch.

 

EAS00752

 

10.Sidestand switch

 

Т Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”.

ТIs the sidestand switch OK?

 

		YES		NO

Replace the side-stand switch.

 

11.Starting circuit cut-off relay 1

 

У Remove the starting circuit cut-off relay 1.

 

У Connect the pocket tester (Ω Ч 1) to the starting circuit cut-off relay 1 terminals as shown.

 

У Check the starting circuit cut-off relay 1 for continuity.

 

Positive tester probe→
light green1	Continuity
Negative tester probe→
red/black2
Positive tester probe→
red/black2	No conti-
Negative tester probe→	nuity
light green1

 

 

XP500

XP500A

 

NOTE:

When you switch the positive and negative tester probes, the readings in the above chart will be reversed.

• Are the tester readings correct?

 

		YES		NO

 

Replace the starting circuit cut-off relay 1.

 

8 - 13

_{IGNITION SYSTEM} ELEC ^{– +}

 

12.Lean angle cut-off switch

ФRemove the lean angle cut-off switch.

 

ФConnect the pocket tester (Ω Ч 1) to the lean angle cut-off switch terminals as shown.

 

Positive tester probe → blue 1 Negative tester probe → yellow/green 2

 

 

Lean angle cut-off switch voltage Less than 45° a→

 

Approximately 1 V More than 45° b→

Approximately 4 V

EAS00754

 

13.Wiring

 

ХCheck the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”.

 

ХIs the ignition system’s wiring properly connected and without defects?

 

		YES		NO

Replace the ECU Properly connect or (engine). repair the ignition

 

system’s wiring.

 

• Is the lean angle cut-off switch OK?

 

		YES		NO

Replace the lean angle cut-off switch.

 

8 - 14

 

 

8 - 15

 

 

Mai

 

 

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Y/L

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Y/B

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G/R

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B

B/Y B/L

B/L

Gy

B

U

R/B

W

W

W

W

R

B/Y

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W

W

W

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B/L

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R/G BB

X

R

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(BLUE)

K L

Y/L G/L R/W

R/W Lg Y/L

L/R

Br/R

R/L

ON

L/W B

B/L

Br/W

B

R/L

OFF

G

(BLACK)

F

R/B

L/Y

(

R/G R/W Y/L

R

R

P

G/Y Lg

R/L L/Y

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G/LB B/W

Br/L

Br/L

H

L/W

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P/W

L/W

B

R/L

Gy/G

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Br/L

B/L

B/L P/W

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L/R

J

L/W

R/L

G

T

R/L O/B

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P/W

B

B

Y

B

B

M

L

(BLACK)

I

B

(BLACK)

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R/B

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B

G

B

R/L

B

Gy/G

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B/L

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B

B

Z R/L O/B

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(GREEN)

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R L/G

G/B G/B

R/L

R/L

B

L/G R/G

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B B

R/L B

R/G

R

L/W

Y/B

A

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Gy/G B/L

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Br/L

B

Br

Lg

(BLACK)

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C

R/Y

W

B/L

L

N

G/Y

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Y

D

R/W

R/B

Lg

L

B/L

Y/G

R

E

Br/R

Ch Br/W Dg

Dg Br/W Ch

O

P

Q

B/W

W/Y

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Y/R

L/R

L/R

Br/L L/Y

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SB B

Y/L

B/L

(BLACK)

(BLACK)

(BLUE)

Y/G

R/G R/L

L/R Br/R R/Y Br/L

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R R

L/R

R/W Br

R/W R/B G/Y

G/Y R/B R/W

B

B

B

B

Br L/W G/Y

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B/L

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Br/L R/Y Br/R L/R

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L/W

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Br G/Y

L

Br

R/W

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Br/L

B

Br/L

 

B
B	Y/B	A	Y/B
	Br	A	Br
B
B

 

B

Bswitch

B

B

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