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Contact Breaker - Kawasaki KZ400 Service Manual

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@Turn on the tester switches.
DO not touch the coil or leads t o avoid
extremely high voltage shocks.
@Gradually slide the arcing distance adjusting knob from
left t o right (small distance t o large distance) carefully
watching the arcing.
@Stop moving the knob at the point where the arcing
begins t o fluctuate, and note the knob position in mm.
The reading should show the value in Table K5.
Table K5
Arcing Distance?
mm or more
Measure with the Kawasaki Electrotester
I f the distance reading i s less than the value shown
in the table, the ignition coil or spark plug caps are
defective. T o determine which part is defective, measure
the arcing distance again with the spark plug caps
removed from the ignition coil.
the arcing distance
i s subnormal as before, the trouble is with the ignition
coil itself.
I f the arcing distance is now normal, the
trouble i s with the spark plug caps.
I f an Electrotester is not available, the coil can be
checked for a broken or badly shorted winding with
an ohmmeter.
However, an ohmmeter cannot detect
layer shorts and shorts resulting from insulation break-
down under high voltage.
T o measure the primary winding resistance:
@Remove the fuel tank (Pg. 47)) and disconnect the
ignition coil leads.
@Set the ohmmeter to the x 1 S 2 range, and connect
one ohmmeter lead to the yellow/red lead and the
other to the green or black lead from the ignition coil.
A. Ignition Coil Leads
B. Ignition Coil
T o measure the secondary winding resistance:
@Unscrew the spark plug caps from the spark plug leads.
@Set the ohmmeter to the x 1 kS2 range, and connect
one ohmmeter lead to one o f the spark plug leads and
the other ohmmeter lead to the remaining spark plug
A. Spark Plug Leads
Table K6
lgnition Coil Resistance
(measured when cold)
A. Spark Plug Lead
B. Yellow/Red Lead
Primary Winding
Secondary Winding
Contact Breaker
The contact breaker consists o f one fixed and one
movable contact point. The movable point i s pivoted,
and the heel on one end is held against the cam surface
on the timing advancer by a single leaf spring. As the
crankshaft rotates, the heel rides on the cam surface,
and, as the crankshaft reaches the position where igni-
tion takes place, the high spot on the cam surface pushes
out on the heel, which opens the points. As the heel
wears down, the point gap narrows, affecting ignition
timing. Consequently, the ignition timing and point gap
must be periodically adjusted to compensate for heel
I f the coil does not produce an adequate spark, or
i f either the primary or secondary winding does not
have the correct resistance, replace the ignition coil.
With the highest ohmmeter range, check for conti-
nuity between each ignition coil yellow/red lead, and
one spark plug lead and the coil core (two tests on each
I f there is any reading, the coil is shorted and
must be replaced.
Also, replace the ignition coil i f
either spark plug lead shows visible damage.
Meter Range
x 1 L2
x 1 kL2
Meter Reading
3.2-4.8 S2


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