Small engine EFI conversion kits -Ninja250- user manual
Contents
1. Install the ProCAL coming in the CD or contact us for the latest version 3 1 ProCAL does not support Windows Vista at this moment Please use Windows XP the most tested environment or Win7 3 2 installed the ProCAL into my computer but it does not talk to the ECU please check your USB RS232 convert and the required USB driver Or better use an old computer which has a RS232 COM port built in to rule out the USB converter problem 3 3 Establish the communication between the ProCAL and the ECU menu gt run gt connect then menu gt run gt start measuring you should see the variables in the Display Variables window changing 3 4 Read diagnostic trouble codes by goto menu gt diagnosis gt run diagnosis gt read DTC 4 With the ProCAL communicating with ECU do the below tests 4 1 Try to start the engine with the engine spinning Read the variables in ProCAL 4 2 Does the signal RPM changing from 0 to some value gt 300rpm 4 3 Does the Map signal drops from about 1013hPa to below 600hPa If either of the above 2 is NO you could have some wiring problem If both the above are YES you could have fuel supply issue air bubbles in the fuel lines or fuel clogged somewhere To rule out the problem of the ignition pickup sensor do the below tests 5 1 Disconnect both CKP wire and GND wire from the ignition pickup sensor and tape them Make sure the stock ignition system is untouched2. Receive Data from RS232 IAT intake air temp KEYSW Key On Swith INJ2 Injector 2 LS Driver output INJ1 Injector 1 LS Driver output GND Power Ground COIL1 lIgnition 1 LS Driver output 4 15 2013 P19 P20 P21 P22 P23 P24 COIL2 Ignition 2 LS Driver output ROUT Power Relay LS Driver output ECT engine coolant temp O2HOUT2 02 Sensor 2 Heater LS Driver Output 02IN1 Oxyugen Sensor 1 Input CKP Crank Position Sensor connect to ignition pickup sensor signal VIGN 12V from Ignition on
3. 730 Det ES La Faling E 291493718 187988138 34456 Bia 3800 30 Det ES D adi 0 Pam 1012 1012 hPa ES Pl m 0 8700 0 870 Tabi 3800 3 Det fwmp 1 000 1 00 FI 3028 2985 04300 FI2 3314 33090 0500 Pid 2553 254 9 0 4000 hPa Last Rising E 291423567 287978033 3445504 Bus 1565 1572 7 000 Rpm rini 5521 543 88 Maf 8496 8 520 0 02400 kg h LdTp 283 283 004000 Last Rising Ex 291433176 287987599 34456 OfsLeAd 0 H LdPrd 2057 28 52 0 05000 H Tea 4808 480 2 0 6000 Det Ld 2857 28 52 0 05000 LamDsr 1 000 1 000 1 000 1 000 MT 0 001980 001980 Er Dark Gen 0 0 ECT 7300 730 De p 4 15 2013 Page 36 Confidential Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Another way to make sure the idle air is enough is to read the idle ignition angle after warm up the ignition angle IgaOut should be ree eT during stable idle after engine warmed up Further Idle Air adjustment If by only adjusting the idle air screws can t meet your idle air requirements such as the idle RPM is still high or low you need adjust the position of throttle valve plate this is not preferred until you have no other options The factory setting of the throttle plate is usually optimized You will risk the unbalanced 2 cylinders by doing this The steps are below 1 Please repair two tools one is screwdriver and other one is wrench The size of the Each tool you can see in below picture Confidential Pag
4. 9000 00 ti Confidential Page 44 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc SAS bera Treeview SEA b151 2 V10 5 3M L Stand Cofig NA 125cc SE Calibration Diagnostic Trouble Code Stop measuring VefColname Value rate Unt Min Max JDiseription Fl Syn D 3072 Relative fuel mass IgaDut Syn Ca 96 95 25 Ignition angle output value Ld Syn D 1536 Load or relative air charge LdPrd Syn D 1535 977 load predicted for injection time calculatio EEN 01535377 Syn kg h D 15 Syn hPa 0 2560 Intake manifold pressure measured with I Syn Rpm 0 15383 Engine speed in Rpm Syn D 65535 number of injections Syn ms o 65 535 injection time for injector 0 20ms D 2 Lambda controller output word 20ms D 1 boolean 20ms H 1 condition for lambda sensor ready for ope 20ms Rpm D 16383 75 Engine speed in rpm from LLD 20ms D 640 Actual position of stepper motor 20ms 0 1 condition for lambda sensor ready for ope 20ms D 100 throttle position with respect to lower mec 20ms V D 25 6 battery voltage scanned value of micropr 20ms V 1 4 Voltage signal from the lambda sensor bel 20ms V D 5 Voltage signal of manifold pressure senso 20ms V 0 5 ADC voltage of potentiometer sensor E 0 5 ADC voltage of throtle postion sensor 100ms
5. engine EFI conversion kits Ninja250 user manual v3 4 4 doc 4 Install the fuel pump assembly Rules the fuel pump assembly installation need to be done with the below rules Rule 1 the fuel hoses shall be made as short as possible especially the high pressure fuel hoses shall be as short as possible This way the fuel supply has less traveling and restrictions and the performance of the EFI system is not negatively impacted See below for example of fuel hose routing Previous small fuel pump with a bubble port Confidential Page 15 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc New small fuel pump without the bubble port from tank Fuel m gt Pumi Fuel filter V fuel regulator return to tak The difference of small fuel pump installation between previous and new fuel pump The new fuel pump supplied has a metal 5 16 or 8mm port on one side and 6mm plastic port on the other side next to the power connector 1 The larger metal 8mm port is the inlet 2 The smaller plastic 6mm port is the outlet 3 The is no fuel bubble port on this new pump correct YES The fuel pump is a new product it is more convenient installation and there is no fuel bubble port on it 4 An adapter was supplied to adapt the large 8mm inlet to 6mm so that it can match with the supplied fuel hose 5 How does one adapt the 6mm outlet to the 8mm hose Followed by the 8mm injector and 8mm fu
6. in Rpm nini Syn D number of injections DE Syn ms o 65 535 injection time for injector 0 fle 20ms D 2 Lambda controller output word IsChaoBan Wms D 1 boolean 20ms D 1 condition for lambda sensor ready for ope 20ms Rpm D 16383 75 Engine speed in rpm from LLD 20ms D 640 Actual position of stepper motor 20ms 0 1 condition for lambda sensor ready for ope 20ms D 100 throttle position with respect to lower mer 20ms V o 25 6 battery voltage scanned value of micropr Zen V 1 4 Voltage signal from the lambda sensor bel 20ms V 0 5 Voltage signal of manifold pressure senso 20ms V D 5 ADC voltage of potentiometer sensor 20ms V D 5 ADC voltage of throttle position sensor 100ms H 1 Error condition for crank sensor 100ms D 1 Error condition for MAP sensor no droppit 100ms D 1 condition end of start 100ms D 64 factor pre control fuel 100ms D 16 Desired Lambda 100ms 768 767 additive adaptive correction of the relative 100ms hPa D 2560 Ambient pressure 100ms DegC 50 205 Intake air temperature 100ms s D 6553 5 time after end of startflong tEngOff 100ms s D 65535 stop time Dest 50 205 Engine temperature A mM llbhmnnm nn nn Working Page E GaoHuiJun Data 9 B ff Stand Cofig NA_GY6125cc_SEA151 2_V10 5 3M_Celll 0 3 cal Supported DTC list TBD Confidential Page 45 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3
7. serial com diagnosis 10 In ProCAL menu Goto Diagnosis 11 Click read DTCs 12 Make sure there is no DTC shown up Otherwise go to section Diagnosis of the EFI kits 13 If there is no DTC key off wait 5s and then key on again You should hear some small noise from the fuel pump every time key on 14 If after 3 5 times tries and the engine still does not start then follow the diagnosis instructions in section Advanced Diagnosis ECOTRONS ProCAL v7 13 betal 3 File Settings Run Variables Calibrations Diagnostics SAS rea m Treeview Advanced Help Project Calibration Status SEA b151 2 V10 5 3M L Stand Cofig NA 125cc SE Copyright ECOTRONS all rights reserved Converting the file Parsing the file Linking the file File loaded successfully You should update the calibration data by click lt E You should update the calibration data by click lt E Stop measuring Working Page E GaoHuiJun ECU test V10 5 3 NEW Stand Cofig NA 125cc SEA151 2 V10 M Crlll 1 4 02 V12 testcal Engi ine Displacement Name VAL el r T Cylinder settings Ld i Je l Volumetri z T Engine RPM range ic Effi Volu c ICIENC T Start fuel factor o T Fuel injector chara Basic ignition RAM MAP Iga N YA 1200 00 1680 00 1980 00 2460 00 3000 00 3540 00 4020 00 4500 00 4980 00 5520 00 6000 00 7020 00 7980 00
8. the air filter Confidential Page 21 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Section 2 Install the ECU harness The new all in one ECU controls both fuel and ignitions The stock Ignition controller IC module is no longer needed The ECU controls the 2x stock coils directly New harness comes with PNP connectors for new gen 2008 and later models and old gen 1994 to 2007 models You do NOT need to cut and splice wires any more All connectors are plug and play and error proof The only wires that you need to manually tie are 12V and negative fuel pump positive an ground terminals See pictures below The only difference of pre gen harness and new gen harness 2008 and later is in the stock ignition control IC connectors Pre gen stock IC has 2 connectors and new gen IC has only one connector See below pictures Note 1 You must tell us which model year of your bike is so that we can ship the correct harness 2 For 1994 and earlier models the harness is different and we do not have enough info yet users are responsible to find out the pinout definitions and make sure they match on both sides Refer to this link it gives some good illustrations on pinout color coded http www ninjette org forums showthread php t 93006 Confidential Page 22 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 1 Harness picture Confidential 4 15 2013 S
9. the exhaust pipe Weld the O2 sensor bung provided on the hole Make sure the sensor head can be fully exposed to the exhaust gas yet NOT to block the exhaust pipe 3 4 install the sensor in the bung Connect the O2 sensor cable Confidential Page 30 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Section 3 Adjust two cylinders balance and idle RPM if need If you engine idle RPM is not stable or too high or too low if because of the idle intake air you need adjust it 1 How to adjust the idle air screw 1 Adjust the idle air screw in throttle body If your idle is too high or too low or the two cylinders are not in balance you need to adjust the intake air by adjusting the idle air screw Confidential Page 31 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc If you want to reduce the idle air turn the idle screw in clockwise And if you want to get more idle air turn the idle screw out in counter clockwise See below picture 2 Which variables in ProCAL can you refer to when you adjust the balance I d like to show you some data analysis and see how much you are interested Attached is a plot of the signals from the logged data And it shows how find out your cyl 2 has more idle air than cyl 1 Mainly there are 4 signals from O2 sensors you can check Confidential Page 32 4 15 2013 Small engine EFI conversion kits Ninja250 user manual
10. v3 4 4 doc uLsb voltage signal of lambda sensor 1 uLsb2 voltage signal of lambda sensor 2 fLe factor of lambda control cyl 1 fLc2 factor of lambda control cyl 2 Lambda means equivalent air fuel ratio The laptop tuning is all about data analysis You need to know what signals to look at in the logged data All the signals variables have descriptions in ProCAL if you only put your mouse onto it 1 Open ProCAL load the A2I and CAL file that we sent you Then change the Display Type from Gauge to List Go to menu gt Variables gt Display Type gt list ECOTRONS ProCAL v7 1 7 File Settings Run Variables Calibrations Diagnostics Advanced Help 385 RSC i Add Variables v Gauge Treeview Show oscilloscope Bar Variable properties Project Hide TreeView NA Nimja250cc S19 H6 L NA Ninja250cc S19 H6 L Calibration Then you will see below window Selected variables Ioj x Description H Syn 0 3072 Relative fuel mass IgaOut Syn Cr 96 95 25 Ignition angle output value I Ld Syn 0 1536 Load or relative air charge LdPrd Syn 0 1535 977 load predicted for injection I LdTp Syn 0 1535 97 Load through throttle valve Maf Syn kgh 0 1572 Mass air flow CH Map Syn hPa 0 2560 Intake manifold pressure me N E i Syn Rpm 0 16383 Engine speed in Apm E ninj Syn 0 65535 number of injections i E tnjo Syn ms 0 65 535 injection time for inject
11. 4 4 doc Supported DTC list TBD Diagnosis of your serial communications 1 1 Check your serial communication cable make sure the cable is pushed in completely The system works the best if you have an old computer which has a built in COM port The ECU can talk to the computer via RS232 directly 1 2If your computer does not have a COM port then an USB adaptor is needed We have developed an USB adaptor that works well with our ECU and is noise proof Other USB converters from electronics stores may be easily interfered by EMI noises Your ProCAL may be freeze frequently with those noises 1 3Make sure your communication settings are matching the ones you are using COM port USB and or the port s 1 4ProCAL runs best with Windows XP If your computer runs with Win 7 or Vista you need to set the ProCAL to be XP compatibility mode see below If you computer is installed with Windows Vista or Win7 do below NOOR Wh Right click on the ProCAL icon on the desk top Choose properties Click compatibility tab Check Run this program in compatibility mode Choose XP service pack 2 Check run this program as administrator Apply Advanced Diagnosis The advanced diagnosis documentations are still under development contact us for specific question It is always helpful if you can log the data with ProCAL and send us with your questions Confidential Page 46 4 15 2013 Small engine EFI conversion kits N
12. 535 977 load predicted for injec i LdTp 37 41 Syn 0 1535 97 Load through throttle Maf 10 70 Syn kg h 0 1572 Mass air flow m Map 472 46 Syn hPa 0 2560 Intake manifold press VE 1486 25 Syn Rpm 0 16383 Engine speed in Rpm be nini 4847 00 Syn 0 65535 number of injections E Pld 327 62 Syn hPa 0 2559 961 pressure in combustio Hr 1 87 Syn ms 0 65 535 injection time for inject i tn 1 74 Syn ms 0 65 535 injection time for inject E Current_Time 1557468695 00 20ms O 294967E 09 current timer of LLD Err CrankSer 512 00 20ms 0 65535 bitFields crank sensing V fLc 0 9519 20ms 0 2 Lambda controller out v fle2 0 9658 20ms 0 2 Lambda controller out ES FITrsCr 0 00 20ms 1536 1536 rel fuel mass transitior ls LamwO2 1 00 20ms 0 16 Actual Lambda meast Confidential Page 35 4 15 2013 a250 user manual v3 4 4 doc Small engine EFI conversion kits Ninj Time From 1221 895 to 18 1 6 14 12 ELSZ 238 1 0 358716 s 234 86 Zoom All 236 48 Vif Co Name Dat Cuso Dif JUnits Tps 0 0 ie 1 061 1 048 0 0030 IEN 01050 0 09280 0 01220 V HV Mush 009 A1 04895 V vi up 1168 ms 3970 396 8 0 2000 hPa 1 727 1 706 0 02100 ms galut 3 000 9 000 CA N 1537 1546 9 000 Rpm al 2095 2062 s Bent 0 0 s ena 4808 490 2 0 6000 Det Bim 7300
13. D 1 Enor condition for crank sensor 100ms o 1 Enor condition for MAP sensor no droppin 100ms 0 1 condition end of start 100ms a 64 factor pre control fuel 100ms o 16 Desired Lambda 100ms 768 767 additive adaptive correction of the relative 100ms hPa 0 2560 Ambient pressure 100ms DegC 50 205 Intake air temperature 100ms s 0 6553 5 time after end of start long 100ms s 0 65535 stop time 100ms DegC 50 205 Engine temperature 2 r Working Page E GaoHuilun ECU test V10 5 3 NEW Stand_Cofig_NA_125cc_SEAIS1 2_V10 M_Crlll 1 4_02_V12_testcal Click Read DTC SRS elm m Treeview Project SEA_b151 2_V10 5 3M_L Stand Cofig NA GY6125cc Calibration MAP Joa N La OX Ld b Load or Y N_b Rpm engine speed MAP Iga N Ld CrA r Diagnostic Trouble Code You should update the calibration data by click lt Bum To ECU gt Vis Col Name Value Rate Unit Min Max Discription FI Syn D 3072 Relative fuel mass IgaDut Syn CoA 3 95 25 Ignition angle output value Ld Syn D 1536 Load or relative air charge LdPrd Syn 0 load predicted for injection time caleulatio LdTp Syn D Load through throttle valve Mat Syn kg h o Mass air flow Map Syn hPa D Intake manifold pressure measured with I Wu E Syn Rpm D 83 Engine speed
14. Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc SE EFI Small Engine Electronic Fuel Injection Ninja 250r Conversion Kit ECOTRONS User Manual V3 4 4 Confidential Page I 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc COPY RIGHTS ECOTRONS ALL RIGHTS RESERVED Note This manual is based on a conversion of 1998 Ninja 250r model Not all modifications and installations are applicable to all Ninja 250r model years most modifications are applicable to 1994 2007 pre gen and 2008 now new gen Ninja 250r models harnesses are a little different for pre gen and new gen It can also apply to 1988 to 1993 models but the harness again is different If your bike looks different than any of the pictures included in this manual please contact us for exact installations of the whole kit Confidential Page 2 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Table of Contents Tal 010 Bei 10 EE 5 laten te Ree 9 Se E 9 1 Replace the dual carburetor with the dual throttle body assemblly 9 2 Install the dualihrottle body AAA 10 2 Fuel tank petcock replacement AE 14 4 Install the fuel pump assembhy rr rr rr rr rn nr ner rr nn nn 15 5 Install the engine temperature Sensor EE 21 6 Install the intake air temperature Sensor sm ssssssrrrrrrrrrserrrrrrrrrrrnnnrrrrr rr rr rr nanna 21 Section 2 Install the ECU harness x x2 c5 xascvarees
15. Try to start the engine and check the below 5 4 Does the signal RPM changing from 0 to some value gt 300rpm Does the Map signal drops from about 1013hPa to below 600hPa If either of the above 2 is NO you could have some wiring problem If both the above are YES you could have fuel supply issue air bubbles in the fuel lines or fuel clogged somewhere 6 With all the above questions and tests done you still can not figure out why the engine does NOT start please contact us directly info ecotrons com Confidential Page 43 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Diagnosis 1 Install the SE EFI tuning software ProCAL exe to a personal computer PC if you have not done so 2 Connect the PC to the ECU via the serial communication cable RS232 communication 3 If this computer does not have a serial com port you need a RS232 to USB adaptor 4 We have developed an USB adaptor which works well with our ECU and noise proof It does not need driver software to Windows But ProCAL must run in Windows XP and XP compatibility mode if it s Win7 or Vista OMNIA Run the diagnostic software ProCAL from Start gt Program ProCAL Use the ProCAL manual provided in the CD as your reference Make sure the ECU is key on KEWSW is on In ProCAL menu go to Run gt Connect If you can NOT establish the communications between your PC and ECU follow the next chapter for
16. cluding TPS sensor e 2x Fuel injector 128g min 4 Fuel pump assembly e Fuel pump 25L h e Fuel pressure regulator 3bar e Fuel filter e Fuel hoses and clamps 5 MAP sensor 1 05bar 6 Engine temperature sensor 7 Intake air temperature sensor 9 2x Oxygen sensor and bungs INCLUDED 10 Serial communication cable to a computer Confidential Page 5 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 11 USB adaptor included 12 CD free tuning software also downloadable EMI Electro Magnetic Interference This kit does NOT require tuning for stock engines With dual O2 sensors the ECU can do full self tuning for 2 cylinders individually Yet it is fully tunable with a laptop software ProCAL free downloadable for performance You may need some minor tuning if you have significantly changed the engine like high cams or customer exhaust manifolds Still many users have run the kit with some after market exhaust and air filters without having to re tune it This kit needs a 12V battery and charging system this kit is not certified for any emission regulations It is the user s responsibility to find out whether it s legal to use it MAP sensor Fuel pump assembly Confidential Page 6 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Throttles with adaptor hoses to be PNP rt AHA i Confidential Page 7 4 15 2013 Small eng
17. e 37 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 2 Begin to adjust now please see the help pictures First loose the nut ian lu x D Confidential Page 38 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Then use the screwdriver to turn the screw if you want more idle air you need turn the screw in clockwise and if you want reduce the idle air you need turn the screw in counter clockwise N T TT Be INTET tigi S TT f ki Last when you have finished adjusting the screw please tight the screw by using tools Confidential Page 39 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Finished Confidential Page 40 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Initial test N 8 9 After the engine starts if it s rough idling let it warm up and let the ECU Before you do the initial test of the EFI kit make sure the installation is done as the previous section Key on and KEY ON ONLY You should hear fuel pump noise running for a short while if this is not happening you must have some wiring problem Re check all your wires If you hear the fuel pump running and then stop this indicates the ECU is working Now you can fill the fuel tank with the regular gasoline Repeat the above step 3 times to make sure the fuel supply lines a
18. ed by the frame It should NOT be exposed to any external scratch or bump It should not touch the ground when the motorcycle fells onto the ground Below is an example location of the fuel pump this is illustration only your bike may need a different location depending on the model year Confidential Page 17 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc ZS 4 1 Connect the input fuel line from the fuel tank outlet to the inlet of the fuel filter fuel filter by default has been connected to the inlet of the fuel pump 4 2 Connect the high pressure fuel line outlet from the fuel pump to the fuel injector which is located on the intake manifold 4 3 Connect the fuel return line to the T pipe s outlet The T pipe has both fuel bubble line and the fuel pressure regulator return line connected 4 4 Secure all fuel lines with supplied clamps make sure no leak 4 5 The overview of the fuel supply system can be illustrated as the below picture fuel filter not visible and bubble line is not visible Confidential Page 18 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc See Appendix I Fuel supply system schematics Note e Correct levels of different fuel supply components should be the fuel pump and the fuel filter must be lower than the lowest point of the fuel tank The order of height is from the highest to the lowest tank fuel filter and pump The
19. el pressure regulator Confidential Page 16 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc The 8mm hose can connect to the 6mm outlet but the 6mm hose can t connect to the 8mm injector and others So you need 8mm hose then you can use the hose clamp to fasten them Rule 2 the fuel pump must be lower than the lowest part of the fuel tank Because the pump needs the gravity to get the fuel feed from the tank Otherwise the pump could be in starvation Rule 3 the fuel pump shall be positioned that outlet of the pump must be lower than the inlet of the pump so that the air bubbles will more likely float up to the bubble port not to the outlet port due to the gravity This is important especially for prime fuel At least the pump should be in level position if not able to be tilted Rule 4 the fuel pump shall not be immediately next to the engine cylinder head or engine block It shall be installed as far as possible from the engine so that the engine heat is not directly heating up the pump which causes bubbles in the fuel Obviously this rule can be conflicting with rules 1 2 3 so there will be some compromises to accommodate all requirements Rule 5 Find a safe place to install the fuel pump it should be between the fuel tank and the intake manifold so that both the input fuel line and the output lines can be short and it should be tied to the inside of the frame so that it is protect
20. es even though it s kind of tight Use the deceleration cable to connect the throttle on the left side of the bike See below picture You may buy an aftermarket throttle cable like Ninja 650 s throttle cables 2007 08 for example Note this was tried by some users successfully but some other users reported not suitable It is your own responsibility to find out Confidential Page 13 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 3 Fuel tank petcock replacement First drain the fuel tank completely WARNING modify the fuel tank with any fuel in it can cause fire A new fuel tank tap with a return tube is included in the kit and can be used to replace the stock petcock directly So no more hole drilling NOTE there is no shut off valve for the fuel tap Some users add 2x quick disconnectors inline of feed line and return line so that the service of the fuel tank is much easier Fuel return line 3 1 You must re use the stock seal ring from the petcock and pushed it into the groove of this part so that the whole part is sealed 3 2 You can also re use the stock in tank fuel filter to screw it into the feed line so the fuel is first filtered before it gets out of the tank During the tank modifications a Take the fuel tank off the bike if necessary b Clean the fuel tank if any debris falling into it c Install the fuel tank back Confidential Page 14 4 15 2013 Small
21. fuel pump must be the lowest component of the fuel supply system The fuel injectors can be higher than the pump if limited by the space Confidential Page 19 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 5 Install the Map sensor Note For the Map sensor you need install it on throttle body with using a short hose 5cm long is good not longer than 10cm and not is closed to engine block to avoid damage the Map sensor because of high temperature NOTE make sure the MAP sensor hose is not severely bent or not routed in circle so that there could be a pocket that the fuel puddle is formed Fuel puddle could damage the MAP sensor Too long a hose can cause big deviation of the sensor reading Incorrect installation of the MAP sensor can cause not able to start engine or it can short the MAP sensor life Confidential Page 20 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 6 Install the engine temperature sensor Find a place on the cylinder header where it has the lowest air flow usually the backside of the engine attach the sensor to a bolt and fix it 7 Install the intake air temperature sensor Insert the sensor into the air filter or somewhere between the air filter and the throttle body if a hole is drilled on the air hose make sure all the debris is cleaned immediately after the drilling For initial trial you can just tie the air temp sensor to
22. immediately switch to performance mode as he wants OFF gt ECO gt STOIC ON gt RICH gt POWER Confidential Page 47 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Appendix A Fuel supply system schematics Fuel bubble port Not used Previous small fuel pmp Confidential Page 48 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc no air bubble port Connector Fuel pressure regulator Fuel Pump inlet Fuel Pump outlet To injector New small fule pump Confidential Page 49 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Appendix B Wiring harness diagram Confidential Page 50 4 15 2013 user manual v3 4 4 doc Small engine EFI conversion kits Ninja250 OIL AT OZHOU Less VIGN GND A O2IN1 TPS GND 4 15 2013 Page 51 Confidential Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc P1 02HOUT1 P10 02 Sensor 1 Heater LS Driver Output P2 12V Pil Reverse Battery Protected Supply P3 GND P12 Power Ground P4 VCC P13 5 Volt supply output P5 RXD P Send Data to RS232 P6 PER SW P15 Performance Swith P7 TPS P16 Throttle Position Sensor input P8 GND A P17 Analog Ground P9 MIL LAMP P18 Malfuction Indicator Lamp Confidential Page 52 MAP Manifold Air Pressure Sensor input 021IN2 Oxyugen Sensor 2 Input TXD
23. ine EFI conversion kits Ninja250 user manual v3 4 4 doc Confidential Page 8 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Installation Procedures Section 1 1 Replace the dual carburetor with the dual throttle body assembly 1 1 un install the carburetor and take off the intake boots too 1 2 Some EU models have a carb coolant loop which is not needed for the throttle body Connect the 2 water coolant pipes together which used to be the inlet and outlet of the carburetor s coolant Throttle body does not need to be cooled as the carburetor Confidential Page 9 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Replace the dual carb boots with Ecotrons s intake boots g 2 Install the dual throttle body 2 1 Injectors on the top and accel cable used only To make it easier to install the new dual throttle body tie the 2 intake boots onto the dual throttle body first then install the throttle body to the engine intake ports Note since May 2012 a new twin throttle body set is released it comes Confidential Page 10 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc with a fuel rail and a new throttle cable pully bracket etc The old throttle body does not have the fuel rail that is the immediate difference 2 1 1 With the new version of the Throttle body set the throttle body set should be installed with the in
24. inja250 user manual v3 4 4 doc How to use ProCAL to log data 1 Run ProCAL load the correct A2L and CAL file 2 go to menu gt run gt connect 3 go to menu gt run gt display gt select number instead of gauge 4 go to menu gt run gt start measuring the numbers in the display window should change now 5 go to menu gt run gt start recording 6 when you done the test go to menu gt run gt stop recording 7 go to menu gt run gt data analyzer 8 In Data Analyzer click load it will pop up a window show the folder xxx record that s where the logged files are 9 Note every time the ProCAL can log multiple files with the same name except the different suffix 20ms 100ms and or syn these files are logged at the same time but at different sampling rates You will need to copy all those log files and send them to us don t change file names How does the performance switch work Performance Switch has 2 positions ECO vs RICH In ECO position the EFI will run the base fuel map or stoicometric AFR normal cases which gives the best fuel economy and least emissions In RICH mode the EFI will run the enriched map or rich AFR at high load high RPM esp at WOT which gives more power Performance Switch is meant to let the user s easily switch between the economy and enrichment modes in real time so that he can run for economy when cruising around the town and can
25. jectors sitting on the top this requires the throttle cable to be moved to the left side from the right hand side of the bike and a longer throttle cable may be needed Many users have found that maybe only one cable can be reused that the deceleration cable is not long enough 2 1 2 MAP sensor must be connected to the 1 throttle body which is connected to the cylinder 1 cylinder 1 is the left cylinder if you look at the engine from the intake side The MAP sensor hose should be connected to the top side of the throttle body NOTE The MAP sensor hose must stay on the top of the throttle body and it should be short and straight meaning no severe bending or too long hose line Make sure the MAP sensor hose will not get the fuel puddle and MAP sensor can read the vacuum in the intake manifold NOTE The MAP sensor shall not be too close to the cylinder head MAP sensor temperature range is 30 C to 80 C degree Overheated MAP sensor can be damaged 2 1 3 The small tube on the throttle 2 must be sealed like in the below picture Do not connect it to any vacuum hose because that would cause 2 cylinders un balanced for idle Confidential Page 11 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Install the throttle body assembly Confidential Page 12 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 2 1 4 You can use the deceleration throttle cable of some model year bik
26. l work O2 sensor factor fLc and fLc2 will be changed you can know it is rich or lean according the factor If the factor is more than 1 it means the default value is lean otherwise it is rich Confidential Page 34 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc For example uLsb voltage of lambda sensor O2 sensor if it is less than 0 45V it means lean If it is more than 0 45V it means rich uLsb and uLsb2 should oscillate between rich and lean all the time because that is how the close loop works But if you see one of them stays low or high for too long which means you have too lean or too rich conditions O2 Sensors are used to read the Rich Lean conditions and that s how ECU knows And that s also how you can read it Note Engine runs in idle If fLc is bigger than fLc2 it means cly1 gets more air than cly2 you can turn the cly2 idle air screw of throttle body out make cly2 gets more air If fLc is smaller than fLc2 it means cly2 gets more air than cly1 you can turn the cly1 idle air screw of throttle body out make cly1 gets more air The target is to make fLc is closed to fLc2 it will mean the two cylinders are in balance Yis Col Name Value Rate Unit _ Min Max Discription Fl 34 69 Syn i 0 3072 Relative fuel mass V E IgaOut 9 75 Syn Cr 96 95 25 Ignition angle output Ld 37 22 Syn 0 1536 Load or relative air ck LdPrd 37 22 Syn 0 1
27. mall engine EFI conversion kits Ninja250 user manual v3 4 4 doc Pre Gen Ignitor Controller Connectors Ecotrons connectors male Stock connectors female Confidential Page 24 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Gs SANS VARER pe Re ws RA H HA Ki BNE NA ASS AER GER 10 Sets Confidential Page 25 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 2 Label descriptions label Descriptions Notes ECU Electronic Control Unit RS232 Serial comm cable to a PC computer O2S1 Oxygen sensor for cylinder 1 0252 Oxygen sensor for cylinder 2 Fuel Pump Fuel pump power and ground 12V Battery 12V 12V Battery 12V IAT Intake Air Temperature sensor ECT Engine Coolant Temperature sensor Performance Manual switch to select fuel tables ECO switch mode vs Rich mode MIL Malfunction Indication Lamp TPS Throttle position sensor MAP Manifold absolute pressure INJ1 Injector for cylinder 1 INJ2 Injector for cylinder 2 CKP Crank Position sensor Orange Connect to Ignition pickup sensor also called VRS before COIL2 Ignition control output from ECU Brown GND Ground Green previously called Analog Ground KEYSW Key On switch Pink previously called IGNSW Note the wire color scheme may be different for old versions of our harness If your harness looks different than the one i
28. n the picture please contact us for exact wiring info Confidential Page 26 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 1 Ignition pickup sensor wire splice not needed any more with PNP harness 2 Install the ECU in a safe place it should be close to the EFI components for example under the seat or in the trunk 3 Connect all EFl components to the ECU with the provided harness all connectors are included 4 Connect the ECU to the 12V battery and battery 5 Make sure your 12V battery is connected to the chassis ground If your engine or vehicle did not have a 12V battery before and you just added one you must connect the 12V battery negative to chassis ground 6 Double check and make sure all wires are connected as they should be Confidential Page 27 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 3 O2 sensors If your kit includes 2x O2 sensors please follow the below steps to install the O2 sensors A good practice is to start and run the engine in the open loop mode first The easiest way to run open loop is NOT to install the 2xO2 sensors if you have welded 2 bungs just seal the holes with 2x plugs Without a comparatively stable engine running in open loop the exhaust from the engine could be erratically rich or lean or fuel flooding and causes random moistures in the exhaust etc These could damage the O2 sensor befo
29. neces ccetgeet egies totaal eae A 22 1 SIANNGSS PiCtUrEs nei niaii ea iaai an t aiins 23 ET lee 26 E E 28 Section 3 Adjust two cylinders balance and idle RPM if need 31 1 How to adjust the idle air Screw ssssmmesrsrrrsssrsssererrrrrrrrrnnnnnrrrrrrrrnnnn nn rr rr rr rr nanna 31 2 Which factor can you reference when you adjust the balance 32 a ce dee avse eet ee ee ee 41 My engine lee n GU E 42 Ee e 44 Supported DTC list TBD Diagnosis of your serial communications 46 How to se ProGAl to log E KEE 47 How does the performance switch work itissessssssssersrrrrsrrrsnnnnnrrrrrrrrnnnnrrr rr rn rr rna nn 47 Appendix A Fuel supply system schematics mmsssmmmssrrrssrrrssererrrrrrrrrnnnnnrrr rn rr rna ann 48 Appendix B Wiring harness dagram rer rrn nn rr rr rr rr rna non 50 Confidential Page 3 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc www ecotrons com USB RS232 IAT Communication Cable ECT EE er Throttle body amp Harness Fuel injectors Software CD amp I ww 4 r vr MAP Sensor R Fuel return Ze ren Fuel fifter Fuel pressure Oxygen sensors High pressure fuel line regulator T pipes SE EFI Kit Confidential Page 4 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Introduction Kawasaki Ninja 250cc EFI PNP kit is a Plug aNd Play PNP EFI conversion kit to convert the Ninja 250 twin cylinder carbure
30. or 0 Si fle 20ms 0 2 Lambda controller output 1 Nraw 20ms Rpm 0 16383 75 Engine speed in rpm from L a Tps 20ms 0 100 throttle position with respec E Ub de 20ms V 0 25 6 battery voltage scanned vi 2 Find the useful variables for adjustment right click on the Selected Confidential Page 33 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc variables window and then choose Show All Variables Maf Syn kg h 0 157 BH Map Syn hPa 0 2561 N i Gun Anm 0 1638 SS vin Add Variables 0 6553 tnd Show All Variables 0 65 538 DP tic 0 7 Naam 0 163837 DP Tps 0 100 ET Ub de 0 25 ulsb 1 uMap 0 F DY uPot 20ms V 0 S uTps 20ms V 0 S MB Cker 100ms 0 BSG ManDimFr 1fMms n fLc and fLc2 are the factor of lambda sensor you can see whether it is rich or lean Ei LdPrd Syn 0 1535 977 loa BS Late Syn D 1535 977 Lo Maf Syn kg h 0 1572 Ma HE Syn hPa 0 2560 Inte N Syn Rpm 0 16383 Em ET Syn 0 65535 nur Pld Syn hPa 0 2559 961 pre ed Hr Syn ms 0 65 535 inje E Hr Syn ms 0 65 535 inje Fe Current_Timer 20ms 0 294967E 09 cur PT ranks erma 20ms D 65535 but annnnnnnnnan 20ms 0 2 Lar SS 20ms 0 2 Lar G ae 20ms 0 2 bas Lamwo2 20ms 0 16 Ac A Last Falling Edge Tir 20ms 0 294967E 09 LLI E I act Risinn F ne Tir Pime N GA9R7F 409 IIT 3 After start the engine engine runs about 3 minutes in idle closed loop control of lambda sensor wil
31. re filled up with fuel Try to key start the engine First time you start the engine there may be still some air bubbles in the fuel supply system needs to be purged So don t be surprised that the first start takes longer or even you need to start multiple times to be successful If the engine does not start go to the next section for diagnosis self adapting to the engine for a while 10 After the idle stabilizes drive the vehicle in a steady state constant throttles or constant speeds at different throttle speeds Let the ECU self adapting further 11 Then you can try different transient conditions like fast opening of the throttle etc Confidential Page 41 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc My engine does not start why Please follow the below trouble shooting procedures 1 Have you followed the installation manual completely 1 1 1 2 1 3 1 4 Can you tell that the ECU is controlling the fuel pump 1 1 1 When you turn on the key do you hear the fuel pump running for a few seconds and then stop If not you have wiring issues 1 1 2 Key off for 3s and key on do you hear the fuel pump running for a few seconds and then stop If not you have wiring issues 1 1 3 Every time when you try to start the engine engine spins for a few revolutions do you hear the fuel pump running until engine stalls If yes your wiring is good Do yo
32. re you even have a chance to run close loop controls In open loop mode ECU is reading the MAP sensor signal TPS signal and temperature signals to calculate the fuel and control the fuel comparatively precisely In open loop mode you can drive the vehicle around and tip in tip out and you can do almost everything except that the ECU does not really know whether you are running rich or lean Only after you have a comparatively stable running engine then you can install O2 sensors and run close loop and let the ECU do the self learning Confidential Page 28 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc 3 1 The sensor needs to install with a tilt angle meaning the sensor head must point down with certain degree see the picture below Otherwise the condensation could damage the sensor O2 sensor installation 3 5 downstream of exhaust port Confidential Page 29 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc Dual O2 sensor installations gt 10 degree tilt angle 3 2 find the correct the location to install the O2 sensor It needs to be close to the exhaust port but not too close 3 5 downstream the exhaust heads Rule of thumb the O2 sensor can take the advantage of the exhaust heat so it does not have to be heated all by itself But you don t want it to be heated too much because the good temperature range is 300C to 900C 3 3 drill a hole on
33. ted engine to the fuel injected engine This kit is designed to replace the twin 30mm carburetor with the twin the 28mm throttle body and with some other minimal modifications it can make the engine fuel injected at the low cost This twin throttle body mimics the OEM s twin throttle body 2x28mm European models and it can be dropped into the place of the twin carburetor and make the EFI kit a Plug aNd Play PNP kit for Kawasaki Ninja 250cc engines Note the correct and complete installations are vital to make the kit running with the engine even though it s designed for PNP After all there are a lot of components to be removed replaced and installed and modified The total conversion need quiet amount of efforts Contact us if you are not sure whether you can do it yourself This EFI kit has below features e Electronic fuel injection EFI e ECU controlled ignition system via CDI optional not included e Plug and Play PNP with 2x O2 sensors e Dual fuel maps selectable by a manual switch Performance Switch ECO vs RICH Mode e High fuel efficiency and low carbon emissions e Decel fuel cut off e On board self diagnosis with a MIL lamp e Fully tunable with a laptop tuning software free No need to add any other piggyback device e On the fly calibration Parts 1 ECU aluminum housing full water proof and EMI proof 2 Harness including the connectors waterproof 3 Throttle Body e twin 28mm Throttle body in
34. u have the fuel pump installed correctly 1 1 4 Is the fuel pump lower than the tank The fuel pump must be lower than the tank to avoid fuel starvation The fuel pump can be higher than the injector if limited by the space 1 1 5 Have you replaced the petcock tank valve with a manual valve EFI does not work with the petcock 1 1 6 Do you have a fuel return line back to the fuel tank Our EFI kit currently needs a way to return the fuel to the tank 1 1 7 Is there impurity in the gasoline Check your fuel filter Do you have the ignition pick up sensor connected correctly 1 2 1 Do you have a correct pick up signal input to ECU CKP wire on the harness 1 2 2 Do you have the ground wire of pickup sensor connected to ECU ground wire GND wire on the harness 1 2 3 Are you using the stock ignition system to isolate the starting problem please use the stock ignition system 1 2 4 Can you tell the spark plug is firing whey you try to start Do you have the MAP sensor installed correctly 1 3 1 Is the MAP sensor connected to the throttle tube via the small hose included in the kit 1 3 2 Is the intake air system air tight no other way for free air going into the cylinder except through the throttle 2 Do you have the MIL Lamp on if your harness comes with a MIL Lamp Confidential Page 42 4 15 2013 Small engine EFI conversion kits Ninja250 user manual v3 4 4 doc installed If yes go to next step ao
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