CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0
CHAPTER 8 ELECTRICAL PAGE.8-
7
Load test
CAUTION: Remove spark plug high tension leads and connect securely to engine ground before
proceeding.
NOTE: This test can only be performed on machines with electric starters. This test cannot be
performed with an engine or starting system that is not working properly.
A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still
may not have the storage capacity necessary to properly function in the electrical system. For this
reason, a battery capacity or load test should be conducted whenever poor battery performance is
encountered. To perform this test, hook a multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.6 volts or greater. Engage the electric starter and
view the registered battery voltage while cranking the engine. Continue the test for 15 seconds.
During this cranking period, the observed voltage should not drop below 9.5 volts. If the beginning
voltage is 12.6 or higher and the cranking voltage drops below 9.5 volts during the test, replace the
battery.
8.3 IGNITION SYSTEM
IGNITION SYSTEM TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
z Spark plug gap incorrect
z Fouled spark plug
z Faulty spark plug cap or poor connection to high tension lead
z Related wiring loose, disconnected, shorted, or corroded
zEngine stop switch or ignition switch faulty
z Terminal board or connections wet, corroded
z Poor ignition coil ground (e.g. coil mount loose or corroded)
z Faulty stator (measure resistance of all ignition related windings)
zIncorrect wiring (inspect color coding in connectors etc. )
z Faulty ignition coil winding (measure resistance of primary and secondary)
z Worn magneto (RH) end crankshaft bearings
z Sheared flywheel key
z Flywheel loose or damaged
z Trigger coil air gap too wide (where applicable) should be 0.030-0 .050" (0. 75-1.25 mm)
z Excessive crankshaft run out on magneto (RH) end should not exceed 0.005"
(0.13mm)
z Faulty CDI module
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