Untitled - Joa International
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1. WORKSHOP MANUAL TRZ O OSSA CONTENTS 1 Motorcycle specifications 2 Engine part 2 1 Assembling or dismantling the engine from the chassis 2 2 Assembly and disassembly of engine parts 2 2 1 Engine start 2 2 2 AUCH 2 2 3 Gears 2 2 4 Ignition 2 2 5 Cylinder head 2 2 6 Cylinder 2 2 Piston and rings 2 2 8 Ignition 2 2 9 Ignition inner cover 2 2 10 Crankshaft 2 2 11 Water pump 3 Cycle part 3 1 Periodic maintenance chart and torque values A Electrical part 4 1 Electrical diagrams 4 2 Injection 4 2 1 Kscan 4 2 2 Kwrite 5 Manintenance 5 1 Cylinder cover 5 2 Cylinder 5 3 Piston and rings 5 4 Crank 5 5 Crankshaft 5 6 Clutch 5 Gears 5 8 Transmission 5 9 Bearings 5 10 Seals 5 11 Sparkplug 5 12 Motor oil TECHNICAL FEATURES MOTOR Cubic capacity Type Cooling system Bore x stroke Fuel injection Ignition Clutch TRANSMISSION Gearbox Transmission Lubrication mixture Transmission and clutch oil CHASIS Type Front suspension Shock absorber Front brake Rear brake Front Wheel Rear wheel Engine protector Kickstart pedal Gearshift and brake pedals WEIGHT AND DIMENSIONS Wheelbase Seat heigth Ground clearance unloaded Fuel tank capacity Weight no fuel ZIZ 2CC Single cylinder two stroke Inverted engine with reed block air intake Liquid 70x60 mm EFI Kokusan Batery less System Volante magn tico digital CDI Kokusan Hydraulic 6 speed2. All Rights Reserved Warning Wider the copy laws this publication may not be reproduced or transmitted in any form electonic or mechanical in whole or in part without the prior riten consent of Kokusan Denki Co Lid Figure 23 About K Scan Dialog OK button Close this dialog MESSAGE LIST Message Cannot open K Scan txt 2 Cannot open GraphSetting txt 3 Cannot open PCodeSetting csv 4 Cannot open MakerCodeSetting txt d Cannot open Active TestSetting csv 6 Cannot load the language DLL Cannot connect to the ECU 8 The ECU connection is reconnected 9 The ECU returned invalid maker code Type OK OK OK OK OK OK OK OK OK BRS Remo i ELECTRICAL PARTS screen Case Title K Scan txt does not exist Title Graphsetting txt does not exist Title PCodesetting csv does not exist Title MakerCodesetting txt does not exist Title Active TestSetting csv does not exist Title The DLL file of selected langua ge does not exist Transfer The application cannot connect Data View to the ECU Data View Large Graph View Diagnosis Active Test Data Recording Throttle Setting ECU Information VIN Setting Operating time Transfer Data View Data View Large Graph View Diagnosis Active Test Data Recording Throttle Setting ECU Information VIN Setting Operating time Transfer Data View Data View Large Graph View Diagnosis Activ
3. TU 8 0 Deg E 450 100 ar 2 Engine Speed E E CH 2100 r min 20000 40 140 20000 5000 A NE 60 Ignition Timing 1 45000 4500 Seis he CH2 10 BTDC 40000 40000 4000 100 100 300 Boost Pressure 35000 os ad Eu 3500 CH3 34 kPa 12 ara 30000 30000 3000 Te Fr a Engine Temperature 10 as apo 20U 2000 2500 CH4 40 Deg C 40 40 R e s0 20000 2000 Intake Air Temperature FE 25 Deg C las 45000 la 60 6 15000 15000 1500 E e Injector 1 4 10000 10000 1000 pe ne CH6 4095 Micro S JU 100 CR 5000 300 Battery Voltage le ti D Es E ER CH 7 12 7 Volts al COM Disconnect Figure 15 Log File View Overlay Screen 1 Date Time Display date and time in a log file 2 Graph Display sensor values of Data Items There is no limitation to the x axis that means time span 3 Operation Mode Set mouse operation mode on graphs When Zoom is selected plot areas of graphs will be initia led Cursor You can drag a cursor to display the sensor values at the cursor position A passed time at the cursor position will be displayed in the text box Pan You can scroll graphs by dragging a plot area Zoom You can drag a plot area to zoom in plot area You can also click a plot area with Shift key to zoom out 4 Selected Data Item Display a value of Data Item at the cursor position a Toolbar View Setting button Show Log File View S
4. eh Ll se 71 TESS Mi Aah LITT PANOS V VP NG hr amp mn ug Remove the clutch discs OSSA ENGINE PARTS 3 GEAR SHIFTING ASSEMBLY Once you have taken out the clutch discs the clip that holds the countershaft sprocket the sprocket the bushing with its two O rings and the gear shifting pedal we can separate the gear assembly from the engine The gear system comes out toghether with the shift shaft and the gear selector assembly To take it out of the crankcase it is necessary to remove the 5 centering screwst and with some gear engaged proceed to take it out as shown Take off the elastic ring circlip the sprocket and the gear shifting pedal Remove the 5 bolts that fix the gear assembly to the crankcase To be able to take out the 3 bolts situated behind the clutch crown the crown must be turned until the rounded spaces for the key coincide with the bolt heads After removing them the gear assembly can be taken out of the crankcase 4 CYLINDER HEAD It is recommendable to take out the cooling system hoses which are connected to the cylin der head with zip ties and the temperature sensor After this the cylinder head can be disassembled by unscrewing the 8 bolts which hold it toghether with the cylinder THe x EA Kd op he 1 K 0 OSSA ENGINE PARTS 5 CYLINDER Before taking the cylinder appart from the engine it is recommendab
5. ENGINE FROM THE CHASSIS 5 Take off the rear wheel the swing arm the shock absor ber and the brake pump from the chassis 7 Empty the clutch oil and remove the hose from the engi ne 8 Disconnect the cables from the injector 9 Remove the bolts that hold the engine to the chassis to proceed with its disassembly OSSA ENGINE PARTS l STARTING SYSTEM Before taking appart the starting system you must make sure the engine has no oil in the crankcase leaning the bike to both sides Also the clutch oil removing the hose from the clutch cover Unscrew the 6 bolts that hold the clutch cover on the crankcase and take of the cover toghether with the ignition system kickstart pedal shaft and gear Be careful to avoid damaging the gasket when removing the cover 2 CLUTCH Once the clutch cover is out you can see the clutch system Follow these steps to take it appart AP o NE i Larl q as NY FE PN 7 Y EN i SU EN Ayo DES Ka gt ANO Ki a S Det y L al Te Take out the 18 bolts which hold the clutch spring support plate Take off the spring the pressure plate and the 18 clutch release arms to access the clutch discs die f III L AA TU Q aie T 2 S AT ile Je NO N TA SA Be 2 NO Le NGGE 2 Es Su 7 VERAO TT aS S27 MO Na LA L TF
6. View 1 Total operating time Display the Total operating time Can not be cleared 2 Operating time 1 Display the Operating time 1 3 Clear button Operating time 1 Clear Clear the Operation time 1 4 Operating time 2 Display the Operating time 2 a Clear button Clear the Operation time 2 Operating time 2 Clear 6 Operating time 3 Display the Operating time 3 7 Clear button Clear the Operation time 3 Operating time 3 Clear 8 Close button Close this dialog Transfer Setting This dialog is used to set the transfer Transfer Setting ELECTRICAL PARTS Transfer Type IRS 232C T R s Port Number CO T Figure 18 Transfer Setting Dialog 1 Transfer Type combo box 2 RS232C Port Number combo box 3 OK button 4 Cancel button Set the transfer type You can select the transfer type only RS232C in this version Set the COM port It is possible to select COM port from COMTI COM10 and Auto If Auto is selec ted COM port is searchedfrom COMTI to COMIO when the Back button is clicked Check ECU connection If succeeded to connect to the ECU close this dialog If failed to connect to the ECU the Message 13 will be shown Cancel settings and close this dialog KSCAN Language Setting This dialog is used to select a language Language Setting f English C Spanish Cancel Figure 19 Language Setting Dialog 1 English Select English as the
7. direction to the axle of the rod 5 5 CRANKSHAFT Check If it is centered and the possible wear on the are where the seals sit TO LL IT LH Check the flatness of the clutch discs and the total thickness of the pack 3 2 discs The minimum thickness Is 9 75mm 9 GEAR ASSEMBLY Check the state of the shift drum and the possible wear on the gear forks The minimum thickness on the contact part with the moving gears Is 2 55mm 9 8 TRANSMISSION Replace sprockets and chain if the chain has 4 mm of play between the sprocket teeth 9 9 BEARINGS Check their lateral play and smooth rolling 9 10 SEALS Check the state of the seal lips to make sure the wear has not made them flat 9 11 SPARK PLUG Ensure it is tightened to the recommended torque see page 18 5 12 ENGINE OIL Use 350 cm3 of Gear Extreme 5w oil Change after first ride and every 30 hours of use
8. 0 0 Deg O r min CH2 Ignition Timing 1 CH3 Pump Supply Voltage O BTDC 11 2 Vols CH Injector 1 CHB intake Air Temperature 0 Micro S 50 Deg C CHG Barometric Pressure CH7 Battery Voltage 69 0 kPa 11 0 Volts Ready SI COM1 Connect Figure 3 Data View Large Screen a OSSA ELECTRICAL PARTS 1 Engine Temperature Display Data Item Engine Temperature by meter and value 2 Engine Speed Display Data Item Engine Speed by meter and value 3 Intake Air Temperature Display Data Item Intake Air Temperature by meter and value Selected Data Item Display selected Data Item by value 5 Toolbar View Setting button Show Select Data Item dialog to select 8 Data Items 6 Toolbar Print button Print a screen image 7 Toolbar Unit Switch button Switch unit mode 8 When this screen is displayed When the ECU is not connected the ECU connection will be Started If failed to connect to the ECU the message will be shown See Message List SELECT DATA ITEMS This dialog is to select 8 Data Items select Data Items Throttle Position Sensor 9 Engine Speed 9 Cancel Ignition Timing 1 9 Boost Pressure 9 Engine Temperature 9 Intake Air Temperature 9 Injector 1 9 Battery Voltage 9 Figure 4 Select Data Items Dialog 1 CHO CH7 combo box select a Data Item from list The list is created when this dialog is created Z OK button Save selection of Data Items and close this dialog 3
9. Cancel button Cancel selection of Data Items and close this dialog DATA VIEW This screen is to display sensor values of Data Items Sensor values are updated by every 0 5 seconds Data View K Scan SAMY 4 BR AT Y b Hy __ Data Item Value Unit 1 Throttle Position Sensor 8 0 Deg 2 Engine Speed 2100 r min 3 Ignition Timing 1 10 BIDC 4 Boost Pressure 34 kPa 5 Injector 1 4095 Micro S 6 Engine Temperature 40 Deg C 7 Intake Air Temperature 25 Deg C 8 Battery Voltage 12 7 Volts SI COMI Disconnect 7 Figure 5 Data View Screen 1 List DOK Display all Data Items that the ECU corresponds Index Data Item name of each Data Item Value sensor values of each Data Item Unit units of each Data Item 2 Toolbar Save button Save a screen data as csv format file 5 Toolbar Print button Print a screen data 4 Toolbar Unit Switch button Switch unit mode 5 When this screen is displayed When the ECU is not connected the ECU connectionwill be Started If failed to connect to the ECU the message will be shown ELECTRICAL PARTS GRAPH VIEW This function is to display sensor values by graphs Graphs are updated every 0 1 seconds You can select 8 Data Items using Graph Setting Dialog that is shown by clicking View Setting menu or toolbar button You can also select a type of graph parallel and overlay using Graph Setting Dialog If you se lect less than 8 Data Items and parallel view mod
10. EMS This dialog is to select 8 Data Items Select Data Items CHO Throttle Position Sensor 9 CHI Engine Speed 9 Cancel ES Hgnition Timing 1 9 CH3 Boost Pressure 9 CH4 Engine Temperature 9 CH3 Intake Air Temperature 9 CHE In jector 1 bd CH Battery Voltage 9 Figure 12 Select Data ltems Dialog 1 CHO CH combo box select a Data Item from a list The list is created when this dialog is created Z OK button Save selection of Data Items and close this dialog 3 Cancel button Cancel selection of Data Items and close this dialog KSCAN DATA RECORDING SETTING This dialog is used to set Data Recording settings Data Recording Setting Recording Setting Recording Time File Marne M Trigger Channel CH3 M Selected Item Boost Pressure era Figure 13 Data Recording Setting Dialog 1 Recording Time Set the record time H hour M minute S second byspin controls 2 File Name Display a file name 3 Date Time button Set the filename by date and time Use Date Time will be shown 4 button Show a dialog to set the file name 9 Trigger check box Set the trigger mode enable or not 6 Channel Set a channel to a trigger It is possible to select CHO DHA Selected Item Display the Data Item names of the selected channel 8 Low Set the low level trigger value by a spin control If the value is O the trigger will be ignored 9 High Set the high level trigger
11. History Clear button The application failed to clear the Historic Error OK Data Recording OK Data Recording OK Data Recording YESNO Throttle Setting OK Throttle Setting OK _ Throttle Setting OK Throttle Setting OK _ Throttle Setting OK Throttle Setting OK _ Throttle Setting OK Throttle Setting OK _ Throttle Setting Throttle Setting Operating time The application failed to record data The recording was finished normally The application cannot open the recording file When you click the Set to ECUbutton When the ECU returned normal code When the ECU returned this error code When the ECU returned this error code When the ECU returned this error code When the ECU returned this error code When the ECU returned this error code When the ECU returned this error code When the ECU returned this error code When the ECU returned this error code 29 30 31 E 33 34 Would you like to write VIN code Cannot write VIN Code Cannot save screen data Cannot open selected log file Cannot print screen data Cannot open K Scan pdf YESNO OK OK OK OK OK VIN Setting VIN Setting Data View Diagnosis Log File View ECU Information Help ELECTRICAL PARTS When you click the Set to ECU button When the application failed to write the Histo ric Error When the application failed to save screen data When t
12. e EC710 Data Version Data Structure Version EOG Figure 21 ECU Information Dialog 1 ECU ID Display the ECU ID Serial Number 2 VIN Display a VIN Vehicle Identification Number code of the ECU 3 Software Type Display a software type of the ECU 4 software Version Display a hardware version of the ECU D Hardware Type Display a hardware type of the ECU 6 Data Version Display a data version of the ECU Data Structure Version Display a data structure version of the ECU 8 Print button Print ECU information data 9 OK button Close this dialog EE ia OSSA ELECTRICAL PARTS VIN SETTINGS This dialog is used to set a VIN code to the ECU YIH Settme Curent Code 1234567890 Vide Code Figure 22 VIN Setting Dialog 1 Current Code Display a VIN Vehicle Identification Number code ofthe ECU 2 Write Code text box Input a VIN code to be set to the ECU 3 Set to ECU button Set inputted VIN code to the ECU When you clicked the button the Message 29 will beshown If you select Yes button the VIN code will be set to theECU If it is succeeded to set Current Code will beupdated But if it is failed to set the Message 30 will be shown 4 Close button Close this dialog KSCAN About K Scan This dialog is used to display version information About K Scan for OSSA KOHUSAN KUKUSAN DENKI DENKI E S can tor 0554 vero Cooyright li2Z00 Kokusan Denki Co Ltd
13. e size of graphs will be automatically adjusted Figure Graph View K Scan File View Setting Help S 0 Y 4 BR Z Throttle Position Sensor CHO 8 0 Deg D U 16 15 ZU LE 16 18 20 gt CH1 2100 r min _ wal gets CH2 10 BTDC Boost Pressure CH3 34 kPa Eb 40 Deg C Pier Air Temperature CH5 25 Deg C Injector 1 CH6 4095 Micro S Battery Voltage CH7 12 7 Volts COM Connect 6 Graph View Parallel Screen KSCAN Graph View K Scan File View Setting Help Sammy RE 63000 gt 00 200 500 s000 500 ad Sen DUUUU jag 120 BO000 000 450 100 400 is hs E 45000 a at 450004500 Tam ee 16 t 40 SIRI a OO mue Peu G Re 35000 3500 z EE Ce 30000 30000 3000 PIT SI to 1035000 o gt 25000 2500 40 40 E 20000 in 20000 2000 20 20 60 15000 15000 1500 0 g 100 4 10000 10000 1000 4 nee de aa none tte S000 5004 40 40 on DENKI Throttle Position Sensor be 8 0 Deg Engine Speed Em 2100 r min Ignition Timing 1 Jata 10 BTDC Boost Pressure lee 34 kPa Engine Temperature jis 40 Deg C Intake Air Temperature Fe 25 Deg C Injector 1 one 4095 Micro S Battery Voltage jon 12 7 Volts COM Connect Figure 7 Graph View Overlay Screen 1 Graph Selected Data ltem Toolbar Print Toolbar View Setting button T
14. e Test Data Recording Throttle Setting ECU Information VIN Setting Operating time The ECU connection IS reconnected The ECU returned invalid maker code that is supported by MakerCodeSetting txt KSCAN 1Q 11 12 13 14 15 16 17 18 19 The ECU returned invalid code Please reset the ECU Push the stop button and try again This version does not Support this language Cannot connect to the ECU Would you like to clear all historic errors Cannot clear historic errors The recording error occurred The recording was finished Cannot open the recording Tile Have you set a throttle butterfly to the metal touch position Is the range of the current voltage normal 20 21 22 20 24 29 26 2 28 i Setting is succeeded TPS voltage is out of range TPS Sensor Error TPS Sensor Power Error Engine Is running Out of Battery There is no software in the ECU Unexpected error occurred This function is not supported by the ECU OK OK Diagnosis OK Graph View Active Test Running Data Recording OK The language OK The transfer YESNO Diagnosis OK Diagnosis When the ECU returned invalid code When you click the button to Switch Screen while each process of screens is running When you select except English The application cannot connect to the ECU with the setting when you click the back button When you click the
15. e the crankshaft it is necessary to use the special tools ref 1499960211 Follow these steps SAN ZN 9 94 gja RE ie Unscrew the long pin that locks the bearing of the crankshaft 1 Heat up the area in the circle 2 with a heat J blower so that the crankshaft expands and makes the extraction of the crankshaft easier 10 WATER PUMP To remove the water pump It is recommended to remove first the rubber water hoses which are attat ched to it with metal zipties Take out the 3 bolts that hold the pump onto the crankcase The water pump can be removed OSSA ENGINE PARTS RECOMMENDED TORQUE VALUES FOR THE ENGINE BOLTS Spark plug Ignition fixing points Clutch fixing points Cylinder bolts Reed block The 18 bolts for the clutch spring support plate Water pump Clutch cover Rotor Water tubing fittings Ignition cover Oil draining cap Bolts for the kickstart pedal Bolts for the gear shifting pedal Cylinder head Cylinder nut RECOMMENDED TOOLS FOR SERVICING THE OSSA TR280i ENGINE CLUTCH POSITION TOOL PRIMARY BEARING TOOL 1499960211 OSSA WORKSHOP KIT 1000960211 MOTOR SUPPORT TOOL OSSA CYCLE PARTS RECOMMENDED PERIODIC MAINTEINANCE Rear shock Everyride Every 2 years Front fork Every ride When re Every 2 years quired Front fork oil hrs Brakes Every ride When re If damaged quired Swingarm and linkage Eve
16. etting Dialog 6 Toolbar Print button Print a screen image 7 Toolbar Open Log File button Show common dialog to open a log file EE OSSA ELECTRICAL PARTS Log File View Setting This dialog is used to set graph parameter Log File View Setting Data Items c aw Tirone Postion Seer I Fc Eur M Fc igniter tng at 9 Fes eme mM Fc Enreremeanre M a nsearremmane H CHE Injector 1 e CHF Battery voltage E Ea View Mode Parallel Overlay Other Graph Back Color tS T Graph Cursor Color 7 Figure 16 Log File View Setting Dialog 1 Data Items Check box Set a channel to be displayed or not Checked channelsare displayed by graph 2 Data ltems Combo box select Data Item of a channel 3 Data Items button Select a plot color of a channel 4 View Mode Select a view mode Parallel Each channel is displayed in a separate graph Overlay All channels are displayed in one graph 5 Graph Back Color Select a back color of graphs 6 Graph Cursor Color Select a cursor color of graphs 7 OK button Save settings and close this dialog 8 Cancel button Cancel settings and close this dialog BSR Ramo KE WAN aan KSCAN OPERATING TIME VIEW This dialog is used to set Operating time view Operating time monitor Total operating time 00 03 25 Operating timel 00 01 32 Operating time 00 03 25 Operating times 00 03 25 Close Figure 17 Operating time
17. go Image for the Title Screen Active Test ID bmp Active Test Images Log Folder for Log DLL English dll DLL File for English ltaly dll DLL File for Italy French dil DLL File for French German dll DLL File for German Spanish dil DLL File for Spanish Portuguese dll DLL File for Portuguese KSCAN SPECIFICATION FUNCTION Title View This is the start screen of the application OA Title K Scan for OSSA File view Setting Help sHS SHRMYABR LOL BAO ni SI COML Disconnect 7 Figure 2 Title View Screen Data View Large This screen is to display sensor values of 8 Data Items and 3 fixed Data Items 3 fixed Data Items En gine Temperature Engine Speed and Intake Air Temperature are displayed by meters and values You can select 8 Data Items using Select Data Items Dialog that is shown by clicking View Setting menu or toolbar button If a selected Data Item does exist on ECU No Item will be shown The application remembers selected Data Items and save it to the setting file when you exit application Engine Speed meter is updated by 0 1 seconds and other Data Items are update by 0 5 seconds ON Data View Large K Scan for OSSA File View Setting Help AG MTS TY 4 BR rare e Engine Temperature Engine Speed Intake Air Temperature 100 an S 100 60 400 A 50 50 40 100 0 0 50 Deg C 20 140 7 r min Deg C DE S ff 160 oA J U CHO Throttle Position Sensor CH1 Engine Speed
18. he application failed to open a log file When the application failed to print screen data When the application failed to open the K scan pdr KSCAN OSSA ELECTRICAL PARTS QUICK SOFTWARE UPDATING 1 First of all disconnect the Capacitor Unit wires under the headlight mask and connect to a 12V Battery 2 Execute the Kwrite Pro software 3 Register the kds file in Kwrite Pro Note this process is necessary to execute only once for each update version Step 1 Start Kwrite Pro and click on KCM Step 2 Click on Add and set up the information path of the kds file Step 3 Input the information on the file i e Update date Step 4 Click here and select the kds file The registration of the kds file was completed by the above mentioned operation Step 5 Click on Back KWRITE PRO 4 Write Update the kds Tile in ECU step 1 Click on Pro Step 2 Click on Edit only the first time Step 3 The dks file registered by Pro cess 2 Is displayed Select the file that executes writing step 4 Click on Start Download Confirmation E Do vou want to start the download procedure Step 5 Click on Yes OSSA ELECTRICAL PARTS 5 Adjustment of Idle Position Execute the Kscan software FA Titulo K Scan para 055A Archiwa vista Aj
19. l button Cancel settings and close this dialog KSCAN ACTIVE TEST This function is to execute Active Test items There are 8 Data Items in one page and you can scroll page by clicking lt lt and gt gt buttons You cannot click any button during Active Test except Stop button ON Active Test K Scan for OSSA File View Setting Help US STEMTVABR AL OYVE MH Ignition Coil 1 Injector 1 nW Ready EA Ready Fuel Pump Driver Fan Driver Ba Ready se Ready TT Relay Output Tachometer Output 1000 Es Ready L Tachometer Output 5000 Tachometer Output 10000 Ready LA Ready no 102 lt lt Ready SI GOM1 Connect Figure 9 Active Test Screen 1 Active Test Item There are 8 Data Items in one page and you can scroll page to display all test items by clicking lt lt and gt gt buttons 2 Icon Display Active lest image E State text box Display operational information Ready Active Test has not been done Finish Active Test has already been done Running or XXX Sec Active Test is running now 4 When Active Test Error is occurred If failed to connect to the ECU while running Active Test the message will be shown and Active Test state becomes Ready Start button Start Active Test 6 Stop button Stop Active Test lt lt button Move to previous page 8 gt gt button Move to next
20. language setting 2 Spanish Select Spanish as the language setting 3 OK button Save settings and close this dialog 4 Cancel button Cancel settings and close this dialog OSSA ELECTRICAL PARTS Throttle Setting This function is to set a TPS Throttle Position Sensor voltage at closing point to the ECU In order to adjust differences of throttle body TH B on a vehicle it is possible to let the ECU to learn the TPS voltage at the metal touch position of throttle butterfly Throttle Setting TPS Voltage Current U 2691 Range of Permission High 0 922 Figure 20 Throttle Setting Dialog 1 TPS Voltage Current Display current TPC voltage If the voltage is not within a normal range it will bedisplayed in red 2 Range of permission High Display upper bound voltage within the normal range 3 Range of permission Low Display lower bound voltage within the normal range 4 Set to ECU button Set the TPS voltage to the ECU When you clicked the button the Message 19 will beshown If you select Yes button current TPS Voltage will be setto the ECU If it is succeeded to set the Message 20 willbe shown But if it is failedto set one of the Message 21 28 will be shown 5 Close button Close this dialog KSCAN ECU INFORMATION This dialog is used to see ECU information ECU Infomation ECU ID i UEUT EGO IN i 234567090 Software Type ELITE Software Version EOG UU Hardware Typ
21. le to remove the hoses from the cooling system To proceed the 4 bolts that fix the cylinder to the crankcase must be taken out AE 0 Sr 6 PISTON AND RINGS Once the cylinder is out the next step is to take out the cylinder and the rings removing the locking Snap rings and the piston pin we can take the piston appart from the rod and then remove the rings if desired ENT ENGINE PARTS 7 IGNITION SIDE If we remove the ignition cover we can access the rotor Once the rotor is out we can get to the stator Remove the 5 bolts from the ignition cover CoD T Using the special tool included in the tool kit Ossa ref 1499960211 we can take out the rotor We can proceed to remove the stator taking out the bolts that hold it toghether with the inner cranks haft cover toghether with the pick up ENGINE PARTS 8 INNER CRANKSHAFT COVER Once the stator and rotor are out the inner crankshaft cover can be removed It is held toghether with the crankshaft by 6 bolts It is necessary to use the extractor kit which is part of the Ossa workshop toolkit ref 1499960211 After this step the crankshaft can be accessed After unscrewing the 6 bolts we attatch the extractor tool at the centre of the Inner crankshaft cover and we pull it out using the extractor that fits in the crankcase while we screw the bolt in the middle ENGINE PARTS 9 CRANKSHAFT To remov
22. oolbar Unit Switch button When this screen is displayed O O1 W PY Display sensor values of Data Items by graphs These graphs keep sensor values for 10 seconds Leftpart of the graph will be discarded and the other partswill be shifted to the left after 10 seconds These graphswill be cleared when you move to other screens Display a current value of Data Item Print a screen image Show Graph Setting dialog Switch unit mode When the ECU is not connected the ECU connectionwill be started If failed to connect to the ECU themessage 7 will be shown EE E OSSA ELECTRICAL PARTS Graph Setting This dialog is used to set graph parameter Graph Setting A OK Cancel Throttle Position Sensor 7 an JIgnition Timing 1 7 Boost Pressure 9 Engine Temperature 9 intake Air Temperature 7 JInjector 1 9 Battery Voltage c View Mode Parallel Overlay Other Graph Back Color E r Figure 8 Graph Setting Dialog 1 Data Items Check box Set a channel to be displayed or not Checked channels will be displayed on the graph 2 Data Items Combo box Select Data Item of the channel 3 Data Items button select plot color of the channel 4 View Mode Select a view mode Parallel Each channel will be displayed in a separategraph Overlay All channels will be displayed in one graph D Graph Back Color Select a back color of a plot area 6 OK button Save settings and close this dialog 7 Cance
23. page 9 When this screen is displayed When the ECU is not connected the ECU connectionwill be Started If failed to connect to the ECU themessage will be Shown EE a OSSA ELECTRICAL PARTS Diagnosis This function is to display DTC Data Trouble Code of the ECU This screen displays DTC errors by 2 list boxes to show two types of DTC error current error and historic error Diagnosis K Scan File em Setting Help SsH4 AHBM YsABBR ET te a Ree Current 1 Engine Temperature Sensor Signal Voltage Too High 1 Engine Temperature Sensor Signal Voltage Too High 2 Intake Air Temperature Sensor Signal Voltage Too High El CO M1 Disconnect Figure 10 Diagnosis Screen KSCAN 1 Current list box 2 History list box Toolbar Save button Toolbar Print button Toolbar History Clear O1 LU 6 When this screen is displayed Display current DTC errors Index Description DTC Description Failure Type Failure Type name P Code P Code Display historic DTC errors Index Description DTC description Failure Type Failure Type name P Code P Code Save a screen data as csv format file Print a screen data Clear historic DIC errors When you clicked the button the Message 14 will beshown If you select Yes button historic errors are cleared But T the application failed to clear historic errors the Message 15 will beshown When the ECU is not connected
24. ryride If damaged After washing Secondary transmis Every ride When re If damaged Every ride After washing sion quired Steering bearings Everyride If damaged After washing Wheel bearings 30hours If damaged After washing Disc brake rotors Every ride When re If damaged quired Tyres Every ride Ifdamaged im henne damaged Every rae Chassis Every ride lfdamaged Every ride_ ue tank Everyride ifdamaged Every ride Bolts nuts Every ride When re If damaged Every ride quired Crankcase protector Firstride feamaged Everyre protective sikers eye Weamaged RECOMMENDED TORQUE VALUES FOR CYCLE PARTS Handblebars Y CC lt QA lt L 2 nd O Lu Lu lt E go E J Q S Om amp 9 o IGT l 2 0 E q lt T 12 a 7 gt amp SE an T D e a 9 tO Ja a C 09 O ESQUEMAS EL CTRICOS o amp eco D o Fe O Mi Pa L o EB O A O X q ES O EN HE SN S3 CP N N NA DS o 14 le ELECTRICAL PARTS TESTIGO GAS PARO TESTIGO AVERIA r CONDENSADOR 7 S 5 4 si 7 E 2 8 U g LU K v gt O O e an a U C g g G 0 0 a u ue T gg a O l a O D 12 REGULADOR te iz CONEXION LUCES Ms UNIDAD DE Lu
25. s transmission by gears final transmission by chain 100 synthetic oil lubrication 0 9 350 cc of Gear Extreme type 75 W oil Cr Mo Forged aluminium with patented Fuel Tank by OSSA Marzocchi Hydraulic Fork with 40 mm al stanctions Adjustable rebound and compression Progressive hydraulic monoshock TIK OHlins with adjustable rebound and compression g 185 mm disc and 4 piston caliper 150 mm disc with 2 piston caliper 28 spoke rims and 2 5x21 tires 28 spoke rims and 4 00x18 tubeless tire Made of AA 0 5 T6 Forged aluminium Forged aluminium with retactable tips 1 328 mm 655 mm 340 mm 2 6 litros 64 Kg OSSA Factory S L reserves the right to modify this manual without notice Kokusan Marzocchi OHlins are registered brands and the use of their name is under license OSSA ENGINE PART All operations on the engine of TR280i can be done without taking it appart from the chassis except when it is needed to work on the fuel pumps situated at the bottom of the fuel tank For this case or to work more comfortably on other operations this is the procedure to disassemble the engine from the chassis 1 Take off the plastic filter cover and seat base 2 Take off the exhaust 3 Take off the reed block and the throttle body assembly i BIC j NB Ps RENZA TIAA Lg HE NZ ZT NT 4 l ie 4 Empty the cooling circuit and take off the radiator ASSEMBLY AND DISASSEMBLY OF THE
26. tart recording A filename will be given such as LOG2007_ Jan_01_12_00_00 csv 3 Record Time Display a record time If the record time is 00 00 00 it will works as ManualStop Mode The recording will be continued till the Stopbutton is clicked 4 Channel Display a selected trigger channel If there is no trigger blank will be displayed J Low Display the limit value of low level trigger When sensor value of the Data Item becomes less than the limit value the recording will be started 6 High Display the limit value of high level trigger When sensor value of the Data Item becomes more equal than the limit value the recording will be star ted Time Display an elapsed time of the recording 8 State Display three recording state 1 Ready Before click a start button 2 Waiting Waiting a trigger 3 Recording Recording sensor values 9 Toolbar View Setting button Show Select Data Items Dialog 10 Toolbar Recording Setting button Show Data Recording Setting Dialog 11 Start button Start recording sensor values If there is a trigger Waiting is displayed After thetrigger is taken Re cording will be displayed and therecoding will be Started 12 Stop button Stop recording or waiting 13 When this screen is displayed When the ECU is not connected the ECU connec tionwill be started If failed to connect to the ECU the Message 7 will be shown OSSA ELECTRICAL PARTS SELECT DATA IT
27. the ECU connection will be started If failed to connect to the ECU theMessage will be shown ELECTRICAL PARTS DATA RECORDING This function is to record sensor values of 8 Data Items You can select 8 Data Items using Select Data ltems Dialog that is shown by clicking View Setting menu or toolbar button You can also give the file name recording time and trigger setting using Data Recording Setting Dialog that is shown by clicking Data Recording Setting menu or toolbar button If there is no trigger the recording will be started after the start button clicked Else if there is a trigger the recording will be started after the trigger taken After finishing the recording the Messagel will be Shown Data Recording K Scan File View Setting Help He GE Y 4 BRAL AT 8 B Recording Setting Trigger Setting File Name Use Date Time Defined Channel CH3 Record Time 1 59 59 Low 18 Selected Items Data Jt Position Sensor Engine Speed Ignition Timing 1 Boost Pressure Engine Temperature Intake Air Temperature Injector 1 Battery Voltage Status SI CG M1 Disconnect F Figure 11 Data Recording Screen 1 List box Display 8 Data Items CH Index of Channel Data Item name of each Data Item Value sensor values of each Data Item Unit units of each Data Item 2 File Name Display a filename When Use Date Time is displayed the filename is created by date and time before s
28. tional treaties Unauthorized duplication or distribution of this program or any portion of it may result in severe civil or criminal penalties and will be prosecuted to the masimum extent possible under the law Cancel B Select installation folder and user button in a Select Installation Folder screen then click Next i K Scan 055 4 Select Installation Folder The installer will install E Scan 0S558 to the following folder To install in this folder click Next To install to a different folder enter it below or click Browse Folder O Program Files KokusanDenki k Scan OSs A79 Install K ScantOSsS D for yourself or for anyone who uses this computer Everyone Ce Just me Cancel OSSA ELECTRICAL PARTS FOLDER COMPOSITION C Program Files K Scan OSSA K Scan exe Execute File K Scan ini Main Setting File GraphSetting txt Graph Setting File MakerCodesetting txt Maker Code Setting File A ctivelestSetting txt Active Test Setting File PCodesetting csv PCode Setting File K Scan pdf User Manual this document lmage English bmp American National Flag for the Language Screen Italy bmp Italian National Flag for the Language Screen French bmp French National Flag for the Language Screen German bmp German National Flag for the Language Screen Spanish bmp Spanish National Flag for the Language Screen Portuguese bmp Portuguese National Flag for the Language Screen Logo bmp Lo
29. uste Ayuda Step 1 Click the icon Ajuste de la aceleracion TPS Voltaje Corriente 0 591 Volto Gama de permiso Alto 1 465 Voltio Bajo 0 049 Cerrar Step 2 With the thottle on the base position idle position click Set de ECU q 7 iHa establecida una mariposa de aceleracion a la posicion de tocar metal N representa el rango de la normalidad la tension actual Step 3 Click Yes to confirm Ajuste de la aceleracion DNA x TPS volta He Step 4 Corriente 0 591 volto K Scan E The adjustment ot the idle Gama de perm gates se as position is done i Click Ok Bajo Set de ECU Cerrar 6 IMPORTANT In order to ensure correct updating of the ECU please restart the Battery voltage before starting the engine If not updates will not be saved BSR Ramone E E KWRITE PRO oss A MAINTENANCE 5 1 CYLINDER HEAD Check the flatness of the surface and the state of the rubber O rings If the O rings are deteriorated they should be replaced 9 2 CYLINDER Check the state of the Nikasil plating There should be no abnormal vertical scratches 5 3 PISTON AND RINGS Check the wear using a 0 25mm gauge for the maximum separation space on the rings If the space is larger replace the rings 5 4 PISTON ROD Check if there is play on the rod Without taking out the crankshaft from the crankcase tapping it by hand in a perpendicular
30. value by a spin control If the value is O the trigger will be ignored 10 OK button Save settings and close this dialog 11 Cancel button Cancel settings and close this dialog a aaa ELECTRICAL PARTS LOG FILE VIEW This function is to display graphs of sensor values in a log file created by Data Recording function of this application or K Scan PDA application You can open a log file using common dialog that is shown by clicking View Setting menu or toolbar button You can also select a type of graph parallel or over lay using Graph Setting Dialog If you select less than 8 Data Items and parallel view mode size of graphs will be automatically adjusted Log File View K Scan File View Setting Help h e AE UT 4 ER SrO ga 2007 07 26 16 03 18 amp Cursor 42 4 Pan C Zoom SS Ne fg ag CHO 8 0 Deg CL Pez U U 5 10 15 ZU 25 30 35 dU 45 50 55 CH1 2100 r min q Era Lure U 5 10 15 ZU 25 s30 35 40 45 BU B CH2 10 BTDC P aaa sina 05 c CH3 34 kPa Engine Temperature CH4 40 Deg C Intake Air Temperature 20 2 30 3 4 44 o CHS 25 Deg C S pe on CH6 4095 Micro S se pi bewi 12 7 Volts Ready SI COM Disconnect Figure 14 Log File View Parallel Screen KSCAN Log File View K Scan File View Setting Help US EEMTABR FA 2007 07 26 16 03 18 Cursor 65000 00 200 00 65000 6 00 120 70 0000 490 180 60000 5000
31. x MANDO M 6 OD ESQUEMAS EL CTRICOS EU PE ete PE U cr LZ GE PAP PS PAPA PA PS 2 n Innis S INYECTOR 6 BOMBA 2 IIS meses VOLANTE 7 NP 9 N TAH T E H RJ NG LESnn MAGNETICO E Di peka PICK UP ms SENSOR TEMP AIRE ADMISION Wee UM ooo ni Na TT x SENSOR INA sn wc a MAP T UNIT DE _ mew POTENCIOMETRO AHO o HINS o HE IN bns CIO 5 SHR HS 1 N ess a RR E a R L CODIGO COLORES MR MARRON GR ers OSSA ELECTRICAL PARTS INTRODUCTION This document describes the K Scan System for PC Figure 1 shows the system composition The K Scan gives instructions of Active Test gathers and displays sensor values of the ECU Figure 1 System Composition Chart INSTALLATION 1 Execute setup exe to show component setup wizard 2 Click Install button in component install screen to install Visual C Runtime Libraries x86 ES K Scan Setup Do vou wish to install these components IF you choose Cancel setup will exit Cancel KSCAN 3 After installed the component K Scan setup wizard will be shown A Click Next button in a Welcome to the K Scan Setup Wizard screen E ix K Scan Welcome to the K Scan Setup Wizard The installer will guide vou through the steps required to install Scan on your computer WARNING This computer program is protected by copyright law and interna
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