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GV 650 GT 650 EI service

1. SPEEDOMETER DISPLAY En 1 HANDLE SWITCH RH 29009 anion ev FILTER CLUTCH LEVER SIW IGNTIONCOL 2 FAN MOTOR THERMO SIW ENGINE STOP HAZARD STARTER Fi BRAKE an FREE EARTH STOP a OFF OFF RIS 95 RUN ON PUSH oN T LOCK on TOO T OFF 11 85 og Jote D E 55 E SE b gt a of 11 M gt Fs089500 zo of Hin bt Lg Lg BW BW Ft TURN SIGNAL LAMP RH Y BW P w HEAD LAMP w w BW BW gt POSITION LAMP B B b BW BW b Ft TURN SIGNAL LAMP LH L 4 4 I i L p gt 88 gt lt gt d TH 885535 88 308o P 1 a g i 1 111 EXE 111 8 a 25 858 25 Sas 855 59 TT A LI
2. SPEEDOMETER DISPLAY gt 2885 1 t HANDLE SWITCH RH SIN FILTER CLUTCH LEVER SIW IGNTONCOLNO2 MOTOR ENGINE STOP HAZARD STARTER Fi BRAKE FREE EARTH STOP OFF OFF RO ON un Lon pusa olo ox 53 TDK 5 os BS 5 og OFO amp 8 amp uer i amri p 58 gt Bag m og I TT 2885 27 lt i ae 885 og b lg Lg BW BW Ft TURN SIGNAL LAMP RH BW Hew f wot w HEAD LAMP E BW POSITION LAMP BW BW Ft TURN SIGNAL LAMP LH SHAS 88 TABS lt p C lt 88 22g59a 8o ELO m Ego TT 5 mmo EEE UB 858 25 825 858 Bu 2B Li 11 11 HI DC PUSH PUSH O SPEED T PASS DIMMER HORN 4 SENSOR HORN ELTER EARTH FUEL FUEL TPSENSoR JAT SAV wr sensor EARTH 150 SOLENOID DIODE 2 HANDLE SWITCH LH INJECTOR INJECTOR SENSOR SENSOR SENSOR SOLENOID NO 1 NO2 NO1 NO2 IGNITIONCOILNO NO1 NO2 RO
3. SPEEDOMETER ues DISPLAY TACHO G d bis 1 HANDLE SWITCH RH 9996 FILTER CLUTCH LEVER SIW IGNITION COL 2 FAN MOTOR ENGINE STOP HAZARD STARTER Fi BRAKE FE EARTH STOP OFF OFF RIO T RUN OFO oN TOFO PUSH oto LOCK TT TT TT T Ss il 9 BS se og LL n 28 i L 4 15 55 Ul gt gt Eco 111 og EE i d ic LT 9 5 5 1 Lll i FLTURN HEAD LAMP POSITION LAMP 9585 o SIGNAL Ft TURN LAMP LH SIGNAL LAMP RH 4 L T eBB8n6245 8 7 Boo q gt gt Bine zm 8 87 5 88 gt 899 I 2 aag 5 5 5 DNE mae are 5 gt gt 8 1 846 25 SEE 8 og sas 58 on ATI JE LIL 5 H Toro N C e me pusa oto Lolo o PUSH 040 R 9 T PASS DIMMER HORN TURNSIGNAL 2222 HORN FILTER EARTH FUEL FUEL WP SAV wr sensor FARTH sc soLeNoin DIODE 2 HANDLE SWITCH LH i INJECTOR INJECTOR SENSOR SENSOR SENSOR SOLENOID N02 NO NO 2 IGNITION
4. Symptom and possible causes Compression too low 1 Tappet clearance out of adjustment 2 Worn valve guides or poor seating of valves 3 Mistimed valves 4 Excessively worn piston rings 5 Worn down cylinder bore 6 Starter motor cranks too slowly 7 Poor seating of spark plugs Plug not sparking 1 Fouled spark plugs 2 Wet spark plugs 3 Defective ignition coils 4 Open or short in high tension cord 5 Defective pick up coil 6 Defective ECU 7 Open circuited wiring connections No fuel reaching the intake manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective ECU 7 Open circuited wiring connections Incorrect fuel air mixture 1 TP sensor out of adjustment 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective TP sensor 5 Defective pick up coil 6 Defective sensor 7 Defective ECU 8 Defective WT sensor 9 Defective IAT sensor 74 Adjust Repair or replace Adjust Replace Replace See electrical section Retighten Clean Clean and dry Replace Replace Replace Replace Repair or replace Clean or replace Replace Replace Replace Replace Replace Check and repair Adjust Replace Replace Replace Replace Replace Replace Repl
5. ye B ES ME LE 55 ll EU 5 gt gt gt gt Aa 1 cuu GT IT T OO 2 12V 12 5 5 5 p Eng OFF di STARTER MOTOR STARTER RELAY BATTERY MF EARTH DIODE 1 FUSE BOX FUSE BOX LICENSE BRAKE amp Rr TURN Rr TURN SEALER FEAT is 009 TALLAMP SIGNAL SIGNAL Moe ARENAER LAMPLH LAMP RH SWITCH Prepared by 67 HYOSUNG S amp T Motors Co Ltd 1st Ed JUN 2009 Manual No 99000 51320 Printed in Korea S amp T Motors Ltd
6. YES gt lt C gt 4 ECU Coupler NO 52 EI SYSTEM DIAGNOSIS 4 1 38 SENSORS 9 PICK UP COIL INSPECTION The pick up coil is installed in the magneto cover Refer to page 4 1 21 amp PICK UP COIL REMOVAL AND INSTALLATION Remove the magneto cover Install the magneto cover in the reverse order of removal IAP SENSOR INSPECTION The intake air pressure IAP sensors NO 1 and NO 2 3 are installed at the downside of the air cleaner Refer to page 4 1 27 IAP SENSOR REMOVAL AND INSTALLATION amp Remove the fuel tank Remove the sensor from the downside of the air cleaner Install the IAP sensor in the reverse order of removal SENSOR INSPECTION The throttle position sensor is installed at the left side of the throttle body Refer to page 4 1 22 SENSOR REMOVAL AND INSTALLATION AN CAUTION Never remove or adjust the TP sensor 53 4 1 39 EI SYSTEM DIAGNOSIS WT SENSOR INSPECTION The water temperature WT sensor 1 is installed at the rear side of the thermostat case Refer to page 4 1 25 WT SENSOR REMOVAL AND INSTALLATION Remove the WT sensor Install the WT sensor in the reverse order of removal V WT sensor 5 8 N m 0 5 0 8
7. C14 TP SENSOR CIRCUIT MALFUNCTION m 8 37 4 1 22 C15 WT SENSOR CIRCUIT MALFUNCTION m 40 4 1 25 C17 or C18 IAP SENSOR CIRCUIT MALFUNCTION 42 4 1 27 C21 IAT SENSOR CIRCUIT MALFUNCTION m 44 4 1 29 C22 OXYGEN SENSOR CIRCUIT MALFUNCTION m 46 4 1 31 C23 RO SWITCH CIRCUIT MALFUNCTION m 47 4 1 32 C24 or C25 IGNITION COIL MALFUNCTION m 48 4 1 33 31 GP SWITCH CIRCUIT MALFUNCTION 49 4 1 34 C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION 50 4 1 35 C41 FUEL PUMP RELAY CIRCUIT MALFUNCTION e 52 4 1 37 SENSORS un a NGAKEN ee err eee Sa a 53 4 1 38 15 4 1 1 EI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the El system observe the following points for the safety of the system ELECTRICAL PARTS CONNECTOR COUPLER When connecting a connector be sure to push it in until a click is felt With a lock type coupler be sure to release the lock when disconnecting and push it in fully till the works when connecting it When disconnecting the coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper termi
8. HYOSUNG Made in Korea GV 650 650 service Elektrisk system indspr jtning 2009 Servicemanual SCANDINAVIAN MACHINERY IMPORT ApS Holtvej 8 10 H ruphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 FOREWORD This manual contains an introductory description on HYOSUNG BV650E i GTES0 STRES and procedures for its inspection service and overhaul of its main components It covers the differences from Carburetor type and please refer to the service manual of Agmillaesv 99000 51210 amp C meo 99000 94910 and 99000 94810 for others which are not covered in this manual Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service This manual has been prepared on the basis of the latest specification at the time of publication If modification has been made since then difference may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not rep
9. NOT ee KO SWITCH 90 SERVICING INFORMATION 8 30 6 FAN MOTOR 91 SIDE STAND HEAD LAMP TURN SIGNAL FUEL PUMP Rr BRAKE SWITCH 02 SENSOR RELAY RELY RELAY RELAY MAN RELAY RELAY THERMO SW FUEL PUMP FUEL GAUGE ECU 8 37 avl 8 6 i OFO f ci Li TBI CI DL EL FIGI HL JI Kr LL Mi AZ 82 C2 D2 E2 G2 H2 22 L2 2 C3 D3 F3 G3 H3 J3 L3 A4 BA G LA a pa LA 11 T MTT TT 8 45 ze 1 BEE TT REE EE a i T 88 TT Zo 1
10. Tester knob indication Resistance Q 47 4 1 33 EI SYSTEM DIAGNOSIS Is the resistance OK YES or GR wire open or shorted to ground or poor 62 connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection NO Loose or poor contacts on the coupler Open or short circuit in the B wire or GR wire Replace the RO switch with new one 32 T Xe I Ou uo 20 x 2 rouuocoN D ECU Coupler C24 or C25 IGNITION COIL MALFUNCTION Refer to the IGNITION COIL for details Refer to the service manual 99000 51210 page 6 5 Refer to the service manual 7222222200 99000 94810 page 6 5 48 EI SYSTEM DIAGNOSIS 4 1 34 C31 GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE GP switch output voltage is out of the specified range GP switch circuit open or short for 5 sec and more GP switch malfunction 0 15 V lt Switch output voltage lt 3 93 V ECU malfunction u INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the GP switch coupler for loose or poor contacts If OK then measure the GP sw
11. Water temperature sensor WTS The sensor voltage should be the following 0 08 V lt sensor output voltage lt 4 65 V Without the above range for 2 sec and more C15 is indicated Water temperature sensor lead wire coupler connection C17 C18 Intake air pressure sensor IAPS NO 1 NO 2 The sensor should produce following voltage 0 40 V lt sensor output voltage lt 4 75 V Without the above range for 6 sec and more C17 or C18 is indicated Intake air pressure sensor lead wire coupler connection Intake air temperature sensor IATS The sensor voltage should be the following 0 08 V lt sensor output voltage lt 4 75 V Without the above range for 2 sec and more C21 is indicated Intake air temperature sensor lead wire coupler connection Oxygen sensor O2S After the engine run the oxygen sensor signal is inputted in ECU since then 600 sec When this is the case ECU not receive the signal C22 is indicated Oxygen sensor lead wire coupler connection Roll over switch RO switch After holding the motorcycle vertically and the ignition switch turns position the switch resistance should be the following for more than 3 sec switch resistance oo Q Infinity Without the above value for 3 sec and more C23 is indicated Roll over switch lead wire coupler connection 72 SERVICING INFORMATION 8 1 2 MALFUNCTION DET
12. Dismount the throttle body assembly AN CAUTION Be careful not to damage the throttle cable bracket when dismounting or remounting the throttle body assembly After disconnecting the throttle cables do not snap the throttle valve from full open to full close It may cause damage to the throttle valve and throttle body FUEL SYSTEM AND THROTTLE BODY 4 2 8 63 4 2 9 FUEL SYSTEM AND THROTTLE BODY CLEANING Clean all passageways with spray type throttle body cleaner and blow dry with compressed air WARNING Some throttle body cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instructions on proper use handling and storage AN CAUTION Do not use wire to clean passageways Wire can damage passageways If the components cannot be cleaned with spray cleaner it may be necessary to use dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and cleaning of the throttle body components Do not apply throttle body cleaning chemicals to the rubber and plastic materials INSPECTION Check following items for any damage or clogging O ring Throttle body Injector cushion seal Fuel injector Throttle valve Vacuum hose Intake pipe Throttle s
13. Intake air temperature sensor IATS The sensor voltage should be the following 0 08 V lt sensor output voltage lt 4 75 V Without the above range for 2 sec and more C21 is indicated Intake air temperature sensor lead wire coupler connection Oxygen sensor 25 After the engine run the oxygen sensor signal is inputted in ECU since then 600 sec When this is the case ECU not receive the signal C22 is indicated Oxygen sensor lead wire coupler connection Roll over switch RO switch After holding the motorcycle vertically and the ignition switch turns ON position the switch resistance should be the following for more than 3 sec switch resistance Q Infinity Without the above value for 3 sec and more C23 is indicated Roll over switch lead wire coupler connection 34 MALFUNCTION CODE C24 C25 DETECTED ITEM Ignition coil IG coil NO 1 NO 2 El SYSTEM DIAGNOSIS 4 1 20 DETECTED FAILURE CONDITION CHECK FOR Ignition signal is interrupted continuous by 31 times or more when ECU confirm ignition surge at each combustion chamber In this case the code C24 or C25 is indicated Ignition coil wiring coupler connection power supply from the battery Gear position switch GP switch It judges from gear position voltage engine speed and throttle position by ECU 0 15 V lt Gear position switch output voltage lt 3 93 V for more
14. amp dici mulos Lo EU 515 R 040 SPEED 9 9 PASS DIMMER HORN TURN SIGNAL FILTER SENSOR HORN EARTH FUEL FUEL TPSENSOR IAT WI sensor EARTH 152 SOLENOID DIODE 2 HANDLE SWITCH LH i INJECTOR INJECTOR SENSOR SENSOR SENSOR SOLENOID GP SWITCH IGNITION COLNO t NO1 NO2 NO2 RO SWITCH 86 SERVICING INFORMATION 8 30 2 FAN MOTOR gine STAND HEAD LAMP TURN SIGNAL FUEL PUMP Rr BRAKE SWITCH 02 0 RELAY MANREAY FUEL PUMP FUEL GAUGE ECU SE 37 37 ON 09 9 if AB Gr DEEL FL GT Ki MAD BE CODD ED F GA TD D TZ MEAD G DA EA PUGH JA KO T3 BA G TZ Bo TI o gt a m a I ae 844 S
15. 55 4 2 1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM GV650E AN 4 EN ee 56 FUEL SYSTEM AND THROTTLE BODY 4 2 2 77 5 SIRE 57 4 2 3 FUEL SYSTEM AND THROTTLE BODY REMOVAL AND DISASSEMBLY Remove the seat GV650 T Remove the front seat G7eso S R Ez Remove the fuel tank mounting bolts and fuel tank bracket mounting bolt 21450 z Remove the fuel tank mounting bolts and take off the hooks GTese S R Es Disconnect the fuel gauge coupler 1 Remove the fuel pump coupler 2 Remove the fuel injector hose 3 AN CAUTION After disconnecting the fuel injector hose insert a blind plug into the end to stop fuel leakage 58 Remove the fuel tank rearward AN CAUTION gasoline leakage may occur in this operation keep away from fire and sparks Remove the fuel pump assembly by removing its mounting bolts diagonally AN WARNING Gasoline is highly flammable and explosive Keep heat spark and flame away Remove the fuel gauge REASSEMBLY AND INSTALLATION Reassembly and installation the fuel tank in the reverse order of removal and disassembly When installing the fuel pump assembly first tighten all the fuel pump assembly mounting bolts lightly in diagonal
16. EXTERIOR ILLUSTRATION 77 eom RM 9 1 7 4 SPECIFICATIONS GV650 Ef amp GT eot 10 1 8 1 SPECIFICATIONS SEI amp eremo eee 12 1 9 1 FUNCTION OF EI SENSOR eee 14 1 9 3 1 7 1 GENERAL INFORMATION EXTERIOR PHOTOGRAPH GY DO 2 7 6 EXTERIOR ILLUSTRATION creso GENERAL INFORMATION 1 7 2 Rear turn signal lamp Brake Tail lamp Rear p License plate lamp reflector gt 785 WIDTH Head lamp Front turn signal lamp 1 445 WHEEL BASE 2 095 LENGTH Passenger footrests ee 1 7 3 GENERAL INFORMATION EXTERIOR ILLUSTRATION creso lt gt e reflector Rear turn signal lamp Brake Tail lamp License plate lamp 1 765 785 WIDTH Passenger footrests 1 135 HEIGHT 975 835 1 445 WHEEL BASE 360 2 095 LENGTH GENERAL INFORMATION 1 7 4 EXTERIOR ILLUSTRATION 772505 Headlamp f onttum signal lamp 700 WIDTH 655 850 Rear turn signal lamp A Brake Tail lamp 2 a ae Rear License plate lamp reflecto
17. KQ Is the resistance OK Lg or GR wire open or shorted to ground or poor 63 or 64 connection of ECU coupler GET FT VF VE ace If wire and connection are OK YES intermittent trouble or faulty ECU Recheck each terminal and wire S ep harness for open circuit and poor connection 2 4 3 ECU Coupler Replace the IAT sensor with a new one 45 4 1 31 EI SYSTEM DIAGNOSIS 22 OXYGEN SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE After the engine run the oxygen sensor signal is not Oxygen sensor Oxygen sensor heater circuit open inputted in ECU since then 600 sec or short Oxygen sensor Oxygen sensor heater malfunction ECU malfunction fm INSPECTION 1 Remove the seat 2 Turn the ignition switch OFF position 3 Check the Oxygen sensor coupler for loose or poor contacts Is OK B or GR wire open or shorted to ground or poor 8 connection of ECU coupler NEON Sensor side OB or B wire open or shorted to ground or poor or YES connection of ECU coupler Heater side If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open ci
18. Li Tr go L L 4 L L t d n oo Es 6 m z 3 L to x amp 11 5 lt TT 1 E 55 EE E e a az ES a gt LI 83 85 8 a 12V 12Ah 5 9 ye a ON 5 2 tm LOFF STARTER MOTOR STARTER RELAY BATTERY MF EARTH 1 FUSEBOX FUSE BOX GP SWITCH SIDE STAND S W REGULATOR ua CRANE 15 30A LICENSE BRAKE amp Rr TURN Rr TURN CAN TOOL DEALER MAGNETO A RECTIFIER PLATELAMP TAIL LAMP SIGNAL SIGNAL MODE k LAMPLH LAMP RH SWITCH 89 8 30 5 SERVICING INFORMATION WIRING DIAGRAM creso SEI 8 crei
19. Replace Replace Engine overheats Defective engine internal parts 1 Heavy carbon deposit on piston crowns 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit 4 Sucking air from intake pipes 5 Use incorrect engine oil 6 Defective cooling system Lean fuel air mixture 1 Short circuited IAP sensor lead wire 2 Short circuited IAT sensor lead wire 3 Sucking air from intake pipe joint 4 Defective fuel injectors 5 Defective WT sensor 6 Defective cooling system The other factors 1 Ignition timing too advanced due to defective timing advance system WT sensor pick up coil GP switch and ECU 2 Drive belt chain is too tight 78 Clean Add oil Replace or clean Retighten or replace Change See radiator section Repair or replace Repair or replace Repair or replace Replace Replace Consult radiator section Replace Adjust SERVICING INFORMATION 8 3 2 Complaint Symptom and possible causes Dirty or heavy 1 Too much engine oil in the engine Check with inspection win exhaust smoke dow drain out excess oil 2 Worn piston rings or cylinders Replace 3 Worn valve guides Replace 4 Cylinder wall scored or scuffed Replace 5 Worn valves stems Replace 6 Defective stem seals Replace 7 Worn side rails Replace Slipping clutch 1 Weakened clutch spri
20. battery ECU ground wire harness from engine or main fuse before confirming malfunction code self diagnostic trouble code stored in memory Such disconnection will erase memorized information in ECU memory Malfunction code stored in ECU memory can be checked by the special tool To check malfunction code read SELF DIAGNOSIS FUNCTION DEALER MODE Refer to page 4 1 13 14 carefully to have good understanding as to what functions are available and how to use it Be sure to read PRECAUTIONS for Electrical Circuit Service Refer to page 4 1 1 before inspection and observe what is written there Remove the seat amp V650 Ei Remove the rear seat c7 amp 5o 7z er Connect the special tool to the dealer mode coupler at the wiring harness and the ignition Switch is set to ON position Turn the special tool s switch ON position and check the malfunction code to determine the malfunction part Mode select switch 09900 27000 NOTE The dealer mode coupler is located under the seat GV650 Ei The dealer mode coupler is located under the rear seat GTes0 S R Ei 965047 EI SYSTEM DIAGNOSIS 4 1 18 SELF DIAGNOSIS RESET PROCEDURE 650 After repairing the trouble turn the ignition switch OFF position and turn ON position again e If C LCD INDICATION is indicates the malfunction codes are cleared Disc
21. between BL NO 1 or BY NO 2 and GR wires IAP sensor output voltage Approx 2 7 V at idle speed NO 1 BL GR NO 2 GR Tester knob indication Voltage Is the voltage OK YES OB NO 1 OB NO 2 BL NO 1 BY NO 2 or GR wire open or shorted to ground or poor NO 1 42 NO 2 D NO 1 52 2 84 connection of ECU coupler If wire and connection are intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection NO If check result is not satisfactory replace the IAP sensor with a new one EI SYSTEM DIAGNOSIS 4 1 28 We ECU Coupler Output voltage Input voltage 5 V ambient temp 25 C 77 F ALTITUDE ATMOSPHERIC OUTPUT Reference PRESSURE VOLTAGE 8 mmHg kPa V 0 0 760 100 Approx 2 000 610 707 94 EVA 2 001 611 707 94 Approx 5 000 1524 634 85 5 001 1525 634 85 8 000 2438 567 76 8 001 2 439 567 76 10 000 3 048 526 70 43 4 1 29 EI SYSTEM DIAGNOSIS 21 IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION Output voltage is out of the specified r
22. case FI letters is indicated in the LCD panel D continuously Motorcycle does not run CHE The LCD panel indicates CHE letters when no communication signal from the ECU is received for seconds For example The ignition switch is turned ON position and the engine stop switch is turned position In this case the speedometer does not receive any signal from the ECU and the LCD panel indicates CHE letters If CHE letters is indicated the LCD panel does not indicate the trouble code The possible cause of this indication is as follows Engine stop switch is in 6 position Ignition fuse is burnt It is necessary to check the wiring harness between the ECU and speedometer couplers BV650 EF lt 7650 2 ES SELECT OG 27 4 1 13 EI SYSTEM DIAGNOSIS 9 DEALER MODE The defective function is memorized in the ECU Use the special tool s coupler to connect to the dealer mode coupler Refer to page 4 1 17 The memorized malfunction code is displayed on LCD DISPLAY panel 4 Malfunction means that the ECU does not receive signal from the devices These affected devices are indicated in the code form Mode select switch 09900 27000 V650 C e Xa cic c me
23. kgf IAT SENSOR INSPECTION The intake air temperature IAT sensor is installed at the downside of the air cleaner case Refer to page 4 1 29 IAT SENSOR REMOVAL AND INSTALLATION Remove the fuel tank Remove the IAT sensor from the air cleaner case Install the IAT sensor in the reverse order of removal RO SWITCH INSPECTION REMOVAL AND INSTALLATION The roll over RO switch 9 is located in the downside of the fuel tank mounting bolts Refer to page 4 1 32 6 Romove the seat Remove the RO switch from the frame Install the RO switch in the reverse order of removal 54 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM 56 4 2 1 REMOVAL AND DISASSEMBLY 58 4 2 3 REASSEMBLY AND INSTALLATION mM 59 4 2 4 FUEL PRESSURE OF FUEL PUMP INSPECTION 60 4 2 5 FUEL PUMP RELAY 60 4 2 5 FUEL MESH FILTER INSPECTION AND CLEANING 6 61 4 2 6 FUEL GAUGE INSPECTION ss op siio oat ene 61 4 2 6 THROTTLE BODY ii reo 62 4 2 7 REMOVAL 63 4 2 8 CLEANING eu AS 64 4 2 9 INSPECTION idea sete E rire 64 4 2 9 INSTALLATION Seen 64 4 2 9 AN CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or spark
24. page 45 4 1 30 oo Q Infinity at normal condition RO switch resistance 00 atleaned more than 60 GP switch resistance 100 Q 2 0 KQ Oxygen sensor heater voltage Battery voltage THROTTLE BODY SPECIFICATION Bore size 2 39 1 300 1 500 rpm Throttle cable play 0 5 1 0 mm 0 02 0 04 in FUEL INJECTOR FUEL PUMP ITEM SPECIFICATION Fuel injector resistance 11 4 12 6 Q at 20 68 Fuel injector voltage Battery voltage Fuel pressure of fuel pump Approx 2 96 3 16 kgf cm 290 310 kPa 42 06 44 96 psi 83 8 19 SERVICING INFORMATION 9 COOLING FAN COOLANT Thermostat valve operating temperature STANDARD Valve opening 88 C 1907 Valve full open 100 C 2127 Valve closing 83 C 181 F Thermostat valve lift Over 8 mm 0 32 in 100 C 2127 WT sensor resistance 0 1163 48 1400 When Water temperature is 40 C 120 C 40 F 248 F WT sensor resistance To ECU each temperature Cooling fan thermo switch operating temperature 40 C 40F Approx 48 140 KQ 0 C 32F Approx 5 790 KQ 20 C 68 F Approx 2 450 KQ 40 C 104 Approx 1 148 60 C 140 Approx 0 586 KQ 80 176 F Approx 0 322 KQ 120 C 2487 Approx 0 1163 OFF ON Approx 95 C 203F ON OFF Approx 88 C 190 Engine coolant
25. relay 1 60 First check the insulation between terminals with pocket tester Then apply 12 volts to and 4 terminals to Q and to and check the continuity between 1 If there is no continuity replace it with new one FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result Blow the fuel mesh filter with compressed air FUEL SYSTEM AND THROTTLE BODY 4 2 6 NOTE If the fuel mesh filter is clogged with many sediment or rust replace the fuel filter cartridge with a new one FUEL GAUGE INSPECTION Measure resistance between the terminals when float is at the position instead below Fuel float position Resistance between terminals F Approx 90 1000 1 2 Approx 38 Q E Approx 4 10 Q e f the resistance measured is out of the specification replace the gauge with a new one 6 Inspect the fuel level meter 61 lt 4 2 7 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY REMOVAL Remove the fuel tank Disconnect the fuel hoses Remove the all couplers to related the throttle body Loosen the throttle body clamp screws Remove the air cleaner box amp Disconnect the throttle cables from their drum
26. rpm to rpm Other Other OTHERS 30 EI SYSTEM DIAGNOSIS 4 1 16 MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Hot Warm Cool Cold F Always Frequency Always Sometimes times day month Only once Under certain condition Road Urban Suburb Highway Mountainous 1 Uphill Downhill Tarmacadam Gravel Other Motorcycle condition Engine condition Cold Warming up phase Warmed up Always Other at starting Immediately after start Racing without load Engine speed rpm Motorcycle condition During driving Constant speed Accelerating Decelerating Right hand corner Left hand corner At stop Motorcycle speed when problem occurs km h Mile h Other NOTE The above form is a standard sample If should be modified according to conditions characteristic of each market 31 4 1 17 EI SYSTEM DIAGNOSIS SELF DIAGNOSTIC PROCEDURES Don t disconnect couplers from ECU battery cable from
27. to adjust the fuel injector opening and closing rate which is considered the engine speed intake air pressure intake air volume engine temperature oxygen volume and throttle opening angle etc EI Electric fuel Injector El spray the fuel to intake pipe by ECU s injection signal Fuel which is needed combustion in the combustion chamber is supplied from the fuel tank GP switch Gear Position Switch GP switch is used when start stop and control ECU as the converted electrical signal of the gear position is supplied ECU IAP sensor Intake Air Pressure Sensor IAPS sensor measure the pressure which is generated from the intake pipe and compare with the provided absolute pressure then analogize the air volume indirectly and help to work the fuel injector properly IAT sensor Intake Air Temperature Sensor IATS IAT sensor perceive the atmospheric temperature and is located the air cleaner case 5 solenoid Idle Speed Control Solenoid ISC solenoid is interlocked with the throttle body so ECU control the engine idle speed sensor Oxygen Sensor 02S O2 sensor measure the oxygen volume from the exhaust gas and convert the oxygen volume into voltage value then communicate the output voltage to ECU Pick up Coil Pick up coil perceive the front and rear cylinder s engine speed and realtime of piston position RO switch Roll Over Switch RO switch is the fuel c
28. 5 sec If gear position switch voltage get out of the above voltage C31 is indicated Gear position switch wiring coupler connection gearshift cam etc C32 C33 Fuel injector NO 1 NO 2 Injector signal is interrupted continuous for more than 1 sec when ECU confirm injector running surge at each combustion chamber C32 or C33 is indicated Injector wiring coupler connection power supply to the injector Fuel pump relay Voltage is applied continuous for more than 5 sec battery voltage gt 3 2 V when the fuel pump relay is OFF position or battery voltage lt 1 5 V when the fuel pump relay is ON position In this case the code 41 is indicated Fuel pump relay connecting lead wire power source to fuel pump relay fuel injector 35 4 1 21 EI SYSTEM DIAGNOSIS C12 PICK UP COIL CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE After ECU receiving the ignition switch signal the Metal particles or foreign materiel being attached pick up coil signal does not reach ECU for more than on the pick up coil and rotor tip 3 Pick up coil circuit open or short Pick up coil malfunction ECU malfunction m INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the pick up coil coupler for loose or poor contacts If OK then measure the pick up coil resistance 4 Disconnect the p
29. 9 Fuel pump relay RO switch Ignition coil NO 2 IAP sensor NO 1 26 3 IAP sensor NO 2 WT sensor Oxygen sensor EI SYSTEM DIAGNOSIS 4 1 12 SELF DIAGNOSIS FUNCTION The self diagnosis function is incorporated in the ECU The function has two modes USER MODE and DEALER MODE The user can only be notified by the LCD DISPLAY panel 1 and the FI check lamp To check the function of the individual El system devices the dealer mode is prepared In this check the special tool is necessary to read the code of the malfunction items USER MODE LCD DISPLAY CHECK LAMP INDICATION MALEUNG ION INDICATION INDICATION MODE NO Speedometer YES Speedometer FI check lamp Each 2 sec and comes on Speedometer or FI FI letters letters is indicated Engine can start Engine can not letters FI check lamp comes FI letters is indicated start on and blinks continuously When one of the signals is not received by the ECU the fail safe circuit works and injection is not stopped In this case FI letters and speedometer are indicated in the LCD panel 7 and motorcycle can run El The injection signal is stopped when the pick up coil signal roll over switch signal NO 1 amp NO 2 ignition signals NO 1 amp NO 2 injector signals fuel pump relay signal or ignition switch signal is not sent to the ECU In this
30. D DISPLAY panel the malfunction code is indicated from small code to large code 4 1 15 EI SYSTEM DIAGNOSIS EI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem failure complaint and how it occurred as described by the customer For this purpose use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis m EXAMPLE CUSTOMER PROBLEM INSPECTION FORM User name Model VIN Date of issue Date Reg Date of problem Mileage FI Check lamp Always ON Sometimes ON Always OFF Good condition Malfunction display code LCD panel No code Malfunction code PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration O No initial combustion Back fire After fire No combustion Lack of power Poor starting at Surging cold warm always Abnormal knocking Other Engine rpm jumps briefly Other O Poor idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened L High Low rpm Throttle valve is closed Unstable Load is applied Hunting
31. EA BB 10 OO OG e 1000 28 EI SYSTEM DIAGNOSIS 4 1 14 CAUTION Do not disconnect the ECU lead wire couplers before checking the malfunction code or the malfunction code memory is erased and the malfunction code can not be checked Confirm the malfunction code after turn the ignition switch position or cranking the engine for few seconds LCD DISPLAY LAMP INDICATION MALFUNGTJON INDICATION INDICATION MODE NO te indi FI check lamp C code is indicated YES from small numeral to goes off in eann 2 A code is indicated large one CODE MALFUNCTION PART REMARKS defective part C12 Pick up coil C14 Throttle position sensor TPS C15 Water temperature sensor WTS C17 Intake air pressure sensor IAPS NO 1 For NO 1 cylinder C18 Intake air pressure sensor IAPS NO 2 For NO 2 oylinder C21 Intake air temperature sensor IATS C22 Oxygen sensor O2S C23 Roll over switch RO switch C24 Ignition coil NO 1 For NO 1 oylinder C25 Ignition coil NO 2 For NO 2 oylinder C31 Gear position switch GP switch C32 Fuel injector NO 1 For NO 1 oylinder C33 Fuel injector NO 2 For NO 2 oylinder C41 Fuel pump relay In the LC
32. ECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR Ignition signal is interrupted continuous by 31 times or more when ECU confirm ignition surge at each combustion chamber Ignition coil IG coil In this case the code C24 or C25 is indicated 024 Ges NO 1 2 Ignition wiring coupler connection power supply from the battery It judges from gear position voltage engine speed and throttle position by ECU 0 15 V lt Gear position switch output voltage lt 3 93 V for more 5 sec If gear position switch voltage get out of the above voltage C31 is indicated Gear position switch wiring coupler connection gearshift cam etc Gear position switch GP switch Injector signal is interrupted continuous for more than 1 sec when ECU confirm injector running surge at each combustion Fuel injector AES chamber C32 or C33 is indicated NO 1 NO 2 Injector wiring coupler connection power supply to the injector Voltage is applied continuous for more than 5 sec battery voltage gt 3 2 V when the fuel pump relay is OFF position or battery voltage lt 1 5 V when the fuel pump relay is Fuel pump relay position In this case the code 41 is indicated Fuel pump relay connecting lead wire power source to fuel pump relay fuel injector 73 8 1 3 SERVICING INFORMATION ENGINE Complaint Engine will not start or is hard to start
33. ISC Solenoid Idle Speed Control Solenoid WIRE COLOR Black Gr Gray L Blue Lg Light green Br Brown O Green R Red BL Black with Blue tracer BG Black with Green tracer BR Black with Red tracer BY Black with Yellow tracer LG Blue with Green tracer LW Blue with White tracer BrB Brown with Black tracer GB Green with Black tracer GY Green with Yellow tracer GrR Gray with Red tracer OB Orange with Black tracer OG Orange with Green tracer OW Orange with White tracer RB Red with Black tracer WB White with Black tracer WR White with Red tracer YL Yellow with Blue tracer YR Yellow with Red tracer Sb BBr BO BW LB LR LY BrW GR GrB GrW OL OR OY RW WL YB YG Light blue White Yellow Black with Brown tracer Black with Orange tracer Black with White tracer Blue with Black tracer Blue with Red tracer Blue with Yellow tracer Brown with White tracer Green with Red tracer Gray with Black tracer Gray with White tracer Orange with Blue tracer Orange with Red tracer Orange with Yellow tracer Red with White tracer White with Blue tracer Yellow with Black tracer Yellow with Green tracer GENERAL INFORMATION CONTENTS EXTERIOR PHOTOGRAPH 6 1 7 1 EXTERIOR ILLUSTRATION sores e T 1 7 2 EXTERIOR ILLUSTRATION r esee M 8 1 7 3
34. SWTCH 88 SERVICING INFORMATION 8 30 4 FAN MOTOR SIDE STAND HEAD LAMP TURN SIGNAL FUEL PUMP Rr BRAKE SWITCH 02 SENSOR RELAY RELAY RELAY peLay THERMO SIW FUEL PUMP FUEL GAUGE T gt ECU u 20 Ge TOO cf DL FI GT HI JL Li AZ 8202 02 E2 F2 G2 H2 J2 T2 MAAS D F GS 33 KS L3 M3 CA J L4 UT H BLE LETE 85
35. Telescopic type GENERAL INFORMATION 1 8 2 Rear suspension Swingarm type Steering angle 35 right amp left 30 right amp lett Caster 357 25 5 Trail 160 6 3 in 85 mm 3 35 Front brake Double disk brake Rear brake Disk brake Front tire size 120 70 ZR 18 59W 120 60 ZR 17 55W Rear tire size 180 55 ZR 17 73W 160 60 ZR 17 69W Front fork stroke 130 mm 5 12 in 120 mm 4 72 ELECTRICAL BV650E cCTesoE Ignition type ECU Ignition timing 5 B T D C at 2 000 rpm Spark plug CR8E Battery 12 V 12 Ah MF Main 30 A Head lamp 15A a HI 12V H4 60W 1 LO 12V H4 55W x1 Position 12V W5 W 1 Turn signal lamp 12V RY10W x 4 Brake Tail lamp LED type License plate lamp 12V W5W x 1 Illumination lamp LED type High beam indicator lamp LED type Turn signal indicator lamp right amp left LED type Neutral indicator lamp LED type lt Fuel indicator lamp LED type Level type Coolant temperature indicator lamp LED type Level type Fl Fuel Injection check lamp LED type 5 GV650Ei 8 Fuel tank 16 00 17 00 Oil change 3 000 ml Engine oil Oil and filter change 3 200 m0 Engine overhaul 3 400 m Front for
36. Tester knob indication Voltage Is the output voltage OK OB LY or GR wire open or shorted to ground or poor 82 82 F3 84 connection of ECU Er Om coupler If wire and connection are intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection 2 4 YES ECU Coupler 84 If check result is not satisfactory NO replace the sensor with new one 39 4 1 25 EI SYSTEM DIAGNOSIS 15 WT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 2 sec WT sensor circuit open or short and more WT sensor malfunction lt lt 0 08 V lt Sensor output voltage lt 4 65 V e ECU malfunction INSPECTION 1 Turn the ignition switch OFF position 2 Check the WT sensor coupler for loose or poor contacts If OK then measure the WT sensor resistance amp Refer to the service manual 1000659 99000 51210 page 5 7 Refer to the service manual 99000 94810 page 5 7 3 Disconnect the WT sensor coupler 4 Measure the resistance between the terminals 1 and Q 0 1163 48 1400 When Water WT sensor resistance
37. ace Replace Complaint Engine idles poorly 1 Tappet clearance out of adjustment 2 Poor seating of valves 3 Defective valve guides 4 Worn down camshafts 5 Too wide spark plug gaps 6 Defective ignition coils 7 Defective pick up coil 8 Defective ECU 9 Defective TP sensor 10 Defective fuel pump 11 Imbalanced throttle valve or SAV solenoid 12 Damaged or cracked vacuum hose Symptom and possible causes SERVICING INFORMATION 8 1 4 Adjust Replace or repair Replace Replace Adjust or replace Replace Replace Replace Replace Replace Adjust Replace Engine stalls Incorrect fuel air mixture often 1 Defective IAP sensor or circuit 2 Clogged fuel filter 3 Defective fuel pump 4 Defective fuel pressure regulator 5 Defective WT sensor 6 Defective thermostat T Defective IAT sensor 8 Damaged or cracked vacuum hose Fuel injector improperly operating 1 Defective fuel injectors 2 No injection signal from ECU 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage 1 Defective ECU 2 Defective fuel pressure regulator 3 Defective TP sensor 4 Defective IAT sensor 5 Defective pick up coil 6 Defective WT sensor T Defective fuel pump relay 1 Fouled spark plugs 2 Defective pick up coil or ECU 3 Clogged fuel hose 4 Tappet clearance out of adjustment 75 Control
38. amp Oxygen sensor Fuel injector NO 1 67 6 3 ELECTRICAL SYSTEM IGNITION SYSTEM ENGINE STOP SWITCH IGNITION SWITCH O Y o ECU IGNITION COIL NO 2 IGNITION COIL NO 1 REGULATOR NN 5 FUSE BATTERY 12V 12Ah 9 INSPECTION MAGNETO Using the pocket tester measure the resistance between the lead wires in the following table If the resistance is not within the specified value replace the stator coil with a new one Stator coil resistance Standard Pick up coil G L 110 1400 Charging coil Y Y 02 040 Tester knob indication Resistance Q AN CAUTION When mounting the stator on magneto cover apply small quantity of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 68 ELECTRICAL SYSTEM 6 7 CHARGING SYSTEM Regulator Rectifier Ignition switch QUO A C generator ZX IN Y Tp Y i EUM Y 5 SCR e e e DM REGULATOR RECTIFIER Disconnect the regulator rectifier couplers Measure the voltage between the terminals using the p
39. ange for 2 sec and more 0 08 V lt Sensor output voltage lt 4 75 V POSSIBLE CAUSE IAT sensor circuit open or short IAT sensor malfunction ECU malfunction INSPECTION 1 Remove the fuel tank 2 Turn the ignition switch OFF position 3 Check the IAT sensor coupler for loose or poor contacts If OK then measure the IAT sensor resistance 4 Disconnect the IAT sensor coupler 5 Measure the resistance between the terminals and 0 081 48 352 When Intake air IAT sensor resistance temperature is 40 C 130 C 40 F 266 F Tester knob indication Resistance KQ NOTE IAT sensor resistance measurement method is the same way as that of the WT sensor Refer to the service manual 99000 51210 5 7 Refer to the service manual 99000 94810 page 5 7 r 2066650 44 EI SYSTEM DIAGNOSIS 4 1 30 IAT sensor resistance Intake Air Temp Resistance 40 C 40 F 44 642 KQ 5 20 C 4 F 14 958 KQ 5 0 C 32 F 5 734 KQ 5 20 C 68 F 2 438 KQ 5 40 104 F 1 141 KQ 5 60 C 140 F 0 579 KQ 5 80 C 176 F 0 315 KQ 5 100 C 212 F 0 182 KQ 5 120 C 248 F 0 111 KQ 5 130 266 F 0 088 KQ 5 Tester knob indication Resistance
40. circuit or sensor improperly operating Engine internal parts improperly operating Repair or replace Clean or replace Replace Replace Replace Replace Replace Replace Replace Repair or replace Repair or replace Replace or recharge Replace Replace Replace Replace Replace Replace Replace Clean Replace Clean Adjust 8 2 1 SERVICING INFORMATION Complaint Symptom and possible causes Noisy engine Excessive valve chatter 1 Too large tappet clearance Adjust 2 Weakened or broken valve springs Replace 3 Worn tappet or cam surface Replace 4 Worn and burnt camshaft journal Replace Noise seems to come from piston 1 Worn down pistons or cylinders Replace 2 Combustion chambers fouled with carbon Clean 3 Worn piston pins or piston pin bore Replace 4 Worn piston rings or ring grooves Replace Noise seems to come from cam chain 1 Stretched chain Replace 2 Worn sprockets Replace 3 Tension adjuster not working Repair or replace Noise seems to come from clutch 1 Worn splines of countershaft or hub Replace 2 Worn teeth of clutch plates Replace 3 Distorted clutch plates driven and drive Replace 4 Worn clutch release bearing Replace 5 Weakened clutch dampers Replace the primary driven gear Noise seems to come from crankshaft 1 Rattling bearings d
41. d and engine rpm DECELERATION SIGNAL During deceleration the fuel injection time volume is decreased INJECTION STOP CONTROL SIGNAL DESCRIPTION When the motorcycle rolls over the roll over switch sends a signal to the ECU Then this signal cuts OFF current supplied to the fuel pump fuel injector and ignition coil ROLL OVER SWITCH SIGNAL FUEL CUT OFF The fuel injectors stop operation when engine rpm reaches rev OVER REV LIMITER SIGNAL F limit rpm 22 EI SYSTEM DIAGNOSIS 4 1 8 EI SYSTEM PARTS LOCATION 98V 650 amp CD Speedometer 6 Fuel injector NO 2 2 Fuel pump relay 7 GP switch 3 Fuel injector NO 1 Pick up coil TP sensor 9 Ignition coil NO 1 5 IAT sensor 23 4 1 9 EI SYSTEM DIAGNOSIS d RO switch 43 IAP sensor NO 1 Ignition coil NO 2 WT sensor IAP sensor NO 2 amp Oxygen sensor 24 EI SYSTEM DIAGNOSIS 4 1 10 EI SYSTEM PARTS LOCATION G7650 S CD Speedometer 5 IAT sensor 2 Fuel injector NO 1 6 GP switch 9 TP sensor 7 Pick up coil Fuel injector NO 2 Ignition coil NO 1 25 4 1 11 EI SYSTEM DIAGNOSIS 9 ECU O 0 415 1311 7 12 WE Y C P c 9 6 SOUS
42. e After using the tester turn the power off 19 EI SYSTEM DIAGNOSIS 4 1 4 4 1 5 EI SYSTEM DIAGNOSIS EI SYSTEM TECHNICAL FEATURES GV650 Ei 147 650 55 22 Es EI SYSTEM S CONTROL DIAGRAM ECU amp AIR CLEANER x FUEL TANK Sensor S0 Sono a FUEL qu THROTTLE BODY SAV Solenoid NANA A re SENSA ss 4 IAP Sensor INTAKE PIPE lt Sy _ FUEL INJECTOR Pick up Coil CYLINDER ene Sensor EXHAUST PIPE gt Electrical signal flow MUFFLER Air flow EXHAUST GAS gt Fuel flow gt Exhaust gas flow 20 EI SYSTEM DIAGNOSIS 4 1 6 INJECTION TIME INJECTION VOLUME The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of intake air pressure engine speed and throttle opening angle and various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions HQ E sassa pass 1 Intake Air Pr
43. egulator rectifier Repair or replace Replace Replace Starter switch is not effective Battery run down Defective switch contacts Brushes not seating properly on commutator in starter motor Defective starter relay ignition interlock switch Defective main fuse Recharge or replace Replace Repair or replace Replace Replace 80 SERVICING INFORMATION 8 9 SPECIAL TOOLS Special tools Part Number Part Name Description 09900 27000 Mode select switch PUES o 2 Inspect El system sensor 09915 54510 Fuel pump pressure gauge j Measure fuel pressure of fuel pump 81 8 12 SERVICING INFORMATION TIGHTENING TORQUE 9 EI SYSTEM PARTS ITEM kgf m Water temperature sensor WT sensor 5 8 0 5 0 8 Fuel injector bolt 5 8 0 5 0 8 Intake air temperature sensor IAT sensor 0 5 0 8 82 SERVICING INFORMATION 8 18 SERVICE DATA EI SENSORS SPECIFICATION IAP sensor input voltage 45 55 IAP sensor output voltage Approx 2 7 V at idle speed TP sensor input voltage 49 5 1V Closed Approx 1 02 1 22 V TP sensor output voltage Opened Approx 4 30 4 70 V 0 081 48 352 KQ IAT sensor resistance When Intake air temperature is 40 130 C 40 F 266 F IAT sensor resistance each temperature Refer to
44. en measure the TP sensor input voltage 3 Disconnect the TP sensor coupler 1 4 Turn the ignition switch ON position 5 Measure the voltage at the OB wire and ground 6 If OK then measure the voltage at the OB wire and GR wire 49 54V TE OB Ground 9 Tester knob indication Voltage Is the input voltage OK YES Go to Step 2 Loose or poor contacts on the ECU coupler Open or short circuit in the OB wire or GR wire NO 37 4 1 23 EI SYSTEM DIAGNOSIS Step 2 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Disconnect the TP sensor coupler 4 Check the continuity between B LY and ground oo Q Infinity amp Ground TP sensor continuity Tester knob indication Resistance Is the continuity OK YES Go to Step 3 NO Replace the sensor with new one 38 Q 7 Ground EI SYSTEM DIAGNOSIS 4 1 24 Step 3 1 Connect the TP sensor coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Turn the ignition switch position Measure the TP sensor output voltage at the coupler between 8 LY and 8 by turning the throttle grip TP sensor output voltage Approx 1 02 1 22 V ER ENE Approx 4 30 4 70 V
45. ep 1 1 Remove the fuel tank and frame cover 2 Turn the ignition switch OFF position 3 Check the injector couplers NO 1 and NO 2 Q for loose or poor contacts If OK then measure the injector resistance 4 Disconnect the injector couplers NO 1 and NO 2 and measure the resistance between terminals 11 4 12 6 Q Injector resistance N at 20 C 68 F Tester knob indication Resistance Q 5 If OK then check the continuity between injector terminals and ground Injector continuity oo Infinity Tester knob indication Resistance Q Are the resistance and continuity OK YES Go to Step 2 Replace the Injector with new one NO 50 Step 2 1 Turn the ignition switch position 2 Measure the injector voltage between YR NO 1 or RB NO 2 wire and ground Battery voltage NO 1 YR Ground NO 2 RB Ground Tester knob indication Voltage NOTE seconds after ignition switch is turned position Injector voltage can be detected only 3 Is the voltage OK YR NO 1 RB NO 2 wire open or shorted to ground or poor NO 1 NO 2 connection of ECU coupler YES If wire and connection are intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Inspec
46. er 25 5 Trail 74 mm 2 91 in Front brake Double disk brake Rear brake Disk brake Front tire size 120 60 ZR 17 55W Rear tire size 160 60 ZR 17 69W Front fork stroke 120 4 72 in ELECTRICAL ITEM G T 650 SE Ignition type ECU Ignition timing 5 B T D C at 2 000 rpm Spark plug CR8E Battery 12 V 12 Ah MF T Main 30A EXER Fuse Head lamp 15A Head tarp 12V H1 55W 1 LO 12V H3 55W x1 Position 12 V W5W 1 Turn signal lamp 12V RY10W x 4 Brake Tail lamp LED type License plate lamp 12V W5W x 1 Illumination lamp LED type High beam indicator lamp LED type Turn signal indicator lamp right amp left LED type Neutral indicator lamp LED type Fuel indicator lamp LED type Level type Coolant temperature indicator lamp LED type Level type Fl Fuel Injection check lamp LED type 5 m Fuel tank 17 00 Oil change 3 000 m Engine oil Oil and filter change 3 200 m Engine overhaul 3 400 m Front fork oil capacity One side 400 cc NOTE The specifications are subject to change without notice 13 1 9 3 GENERAL INFORMATION FUNCTION OF EI SENSOR ECU Engine Control Unit El Control Unit ECU decide the fuel injection volume and ignition time
47. err ETE 08 5 95 208 88 5720445488 6 1 L 4 4 gt 4 L 7 3 TH ct on L Eg f ES a gt gt gt lt gt M EE i rele LL T T 12V 12 B 5 amp La 4 OFF STARTER RELAY BATTERY MF EARTH STARTER MOTOR DIODE 1 FUSE BOX FUSE BOX DESDEN REGULATOR ARTER MOTOR TE SA GOA RrTURN LICENSE _BRAKE amp Rr TURN CANTOOL DEALER MAGNETO amp RECTIFIER SIGNAL PLATE LAMP TAILLAMP SIGNAL MODE Gr LAMP LH LAMP RH SWITCH 87 8 30 3 SERVICING INFORMATION WIRING DIAGRAM lt 77 252
48. essure Sensor Intake air pressure signal IAP Sensor Basic Engine speed signal Pick up coil 9 9 I gt Tual injection DUE Throttle Position Sensor Throttle opening signal gt Sensor Various signals Various Sensors Compensation I Injection signal fuel Injectors lt ERAS i injection 1 lt i time 21 4 1 7 EI SYSTEM DIAGNOSIS COMPENSATION OF INJECTION TIME VOLUME The following different signals are output from the respective sensors for compensation of the fuel injection time volume SIGNAL DESCRIPTION WATER COOLANT TEMPERATURE When engine coolant temperature is low injection time volume SENSOR SIGNAL is increased INTAKE AIR TEMPERATURE SENSOR When intake air temperature is low injection time volume is SIGNAL increased ECU operates on the battery voltage and at the same time it monitors the voltage signal for compensation of the fuel injection BATTERY VOLTAGE SIGNAL time volume A longer injection time is needed to adjust injection volume in the case of low voltage ENGINE RPM SIGNAL At high speed the injection time volume is increased When starting engine additional fuel is injected during cranking STARTING SIGNAL engine During acceleration the fuel injection time volume is increased ACCELERATION SIGNAL in accordance with the throttle opening spee
49. haft bushing and seal Check fuel injector filter for evidence of dirt and contamination If present clean and check for presence of dirt in the fuel lines and fuel tank INSTALLATION Installation is in the reverse order of removal Pay attention to the following points CAUTION Never operate the idle screw to avoid variations of the carburetion setting amp Connect the throttle cable to the throttle cable drum Adjust the throttle cable play with the cable adjusters 64 ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS IGNITION SYSTEM CHARGING SYSTEM 65 6 1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS X 4 4 a e D NW CD Ignition NO 1 2 Cooling fan motor relay Fuel pump relay 40 Battery Main fuse 30 5 Head lamp relay Turn signal 2 ECU Head lamp fuse 15 6 Regulator Rectifier RO switch Side stand relay Main relay 2 27 CB A p V 7 5 LT sensor 5 IAT sensor Magneto 7 Pick up coil GP switch 66 ELECTRICAL SYSTEM 6 2 SAV solenoid IAP sensor NO 2 03 Starter motor relay Ignition NO 2 ISC solenoid AP sensor NO 1
50. ick up coil coupler and measure the resistance 110 140 Q Pick up coil resistance G L Tester knob indication Resistance Q 5 If OK then check the continuity between each terminal and ground T oo Q Infinity Pick up coil continuity G Ground L Ground Tester knob indication Resistance Q Are the resistance and continuity OK L or wire open or shorted to ground or poor 2 or 13 connection of ECU coupler e If wire and connection OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor EN connection EE Loose or poor contacts on the pick NO coupler or ECU coupler J3 Replace the pick up coil with a new one c r o u u oom lt YES 2 e 5 36 EI SYSTEM DIAGNOSIS 4 1 22 14 SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 2 sec sensor circuit open or short and more 0 1 V lt Sensor output voltage 4 8 V TP sensor malfunction 6 malfunction INSPECTION Step 1 1 Turn the ignition switch OFF position 2 Check the TP sensor coupler for loose or poor contacts If OK th
51. itch resistance 4 Park the motorcycle on a firm flat surface vertically 5 Turn the side stand to up right position 6 Make sure the engine stop switch is in the position 7 Insert the needle pointed probes to the GP switch coupler 8 Turn the ignition switch ON position 9 Measure the resistance at the wire side coupler between GL wire and L wire when shifting the gearshift lever from 1st to Top GP switch resistance 1000 2 0 KQ GL L Tester knob indication Resistance KQ Is the resistance OK GL or L wire open or shorted to F2 ground or poor F2 or connection of ECU coupler r If wire and connection are intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor 5666 KANG connection YES 2 4 Open or short circuit in the GL or L wire ECU Coupler NO 49 4 1 35 EI SYSTEM DIAGNOSIS C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Injector signal is interrupted continuous for more than 9 Injector circuit open or short 1 sec when ECU confirm injector running surge at Injector malfunction each combustion chamber malfunction u INSPECTION St
52. k oil capacity One side 420 cc 400 cc NOTE The specifications are subject to change without notice 11 1 9 1 GENERAL INFORMATION SPECIFICATIONS lt 77 7 amp GY DIMENSIONS AND MASS E Overall length 2 095 mm 82 5 in Overall width 785 mm 30 9 700 mm 27 6 in Overall height 1 135 mm 44 7 in Wheelbase 1 445 mm 56 9 in Ground clearance 185 mm 7 3 in 165 mm 6 5 in Mass 210 kg 463 Ibs 215 kg 474 165 ENGINE Type Four stroke DOHC Liquid cooled Number of cylinder V 2 cylinder Bore 81 5 mm 3 21 in Stroke 62 0 mm 2 44 in Piston displacement 647 39 5 Fuel system Electric fuel Injection Starter system Electric starter Lubrication system Wet sump TRANSMISSION ITEM Ei Ef Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down 5 up Final reduction 2 93 1st 2 46 2nd 1 60 Gear ratio 82 4th 1 13 5th 0 96 6th 0 85 Drive chain 525 50 108 links 12 GENERAL INFORMATION 1 9 2 9 CHASSIS lt 7652 Es Front suspension Telescopic type Rear suspension Swingarm type Steering angle 27 right amp left Cast
53. nal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnormal condition is found repair or replace 6 When taking measurements at electrical connectors using a tester probe be sure to insert the probe from the wire harness side backside of the connector coupler 16 D Coupler 2 Probe When connecting meter probe from the terminal side of the coupler connection from harness side not being possible use extra care not to force and cause the male terminal to bend or the female terminal to open Connect the probe as shown to avoid opening of female terminal Never push in the probe where male terminal is supposed to fit Check the male connector for bend and female connector for excessive opening Also check the coupler for locking looseness corrosion dust etc 9 FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse 6 Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse ECU VARIOUS SENSORS Since each component is a high precision part great care should be taken not to apply any sharp impacts during removal and installation Be careful not to touch the electrical terminals of the ECU The static electricity from your body may damage this part 17 EI SYSTEM DIAGNOSIS 4 1 2 D Couple
54. ngs Replace 2 Worn or distorted pressure plates Replace 3 Distorted clutch plates or pressure plates Replace 1 Some clutch springs weakened while others are not 2 Distorted pressure plates or clutch plates Replace Replace Dragging clutch Transmission will 1 Broken gearshift cam Replace not shift 2 Distorted gearshift forks Replace 3 Worn gearshift pawl Replace Transmission will 1 Broken return spring on shift shaft Replace not shift back 2 Rubbing or sticky shift shaft Repair or replace 3 Distorted or worn gearshift forks Replace Transmission 1 Worn shifting gears on driveshaft or countershaft Replace jumps out of 2 Distorted or worn gearshift forks Replace gear 3 Weakened stopper spring on gearshift stopper Replace 79 8 5 SERVICING INFORMATION ELECTRICAL Complaint Remedy No sparking or 1 Defective ignition coils or spark plug caps Replace poor sparking 2 Defective spark plugs Replace 3 Defective pick up coil Replace 4 Defective ECU Replace 5 Defective RO switch Replace 6 Open circuited wiring connections Check and repair Spark plug soon 1 Mixture too rich Inspect El system become fouled 2 Idling speed set too high Inspect El system with carbon 3 Incorrect gasoline Change 4 Dirty element in air cleaner Clean or replace 5 Spark plugs too cold Replace by hot type plug Spa
55. ocket tester as indicated in the table below If the voltage is not within the specified value replace the regulator rectifier with a new one Unit V Tester probe 0 0 0 Tester probe Tester knob indication Diode test 69 70 SERVICING INFORMATION CONTENTS TROUBLESHOOTING 72 8 1 1 SPECIAL TOOLS SN ee 81 8 9 TIGHTENING TORQUE 82 8 12 SERVICE DATA nguras 83 8 18 WIRING DIAGRAM GV650 amp 86 8 30 1 WIRING DIAGRAM e 88 8 30 3 WIRING DIAGRAM SEF amp 90 8 30 5 71 8 1 1 SERVICING INFORMATION TROUBLESHOOTING 9 MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM NO FAULT DETECTED FAILURE CONDITION CHECK FOR Pick up coil After ECU receiving the ignition switch signal the pick up coil signal does not reach ECU for more than 3 sec In this case the code C12 is indicated Pick up coil wiring and mechanical parts Pick up coil lead wire coupler connection Throttle position sensor TPS The sensor should produce following voltage 0 1 V lt sensor output voltage lt 4 8 V Without the above range for 2 sec and more C14 is indicated Throttle position sensor lead wire coupler connection
56. onnect the special tool from the dealer mode coupler s ond d S IDDDNIIDDD ED BEAR zm 33 4 1 19 EI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM NO FAULT DETECTED FAILURE CONDITION CHECK FOR Pick up coil After ECU receiving the ignition switch signal the pick up coil signal does not reach ECU for more than 3 sec In this case the code C12 is indicated Pick up coil wiring and mechanical parts Pick up coil lead wire coupler connection Throttle position sensor TPS The sensor should produce following voltage 0 1 V lt sensor output voltage lt 4 8 V Without the above range for 2 sec and more C14 is indicated Throttle position sensor lead wire coupler connection Water temperature sensor WTS The sensor voltage should be the following 0 08 V lt sensor output voltage lt 4 65 V Without the above range for 2 sec and more C15 is indicated Water temperature sensor lead wire coupler connection C17 C18 Intake air pressure sensor IAPS NO 1 NO 2 The sensor should produce following voltage 0 40 V lt sensor output voltage lt 4 75 V Without the above range for 6 sec and more C17 or C18 is indicated Intake air pressure sensor lead wire coupler connection
57. place 4 Defective ECU Replace Defective control circuit or sensor 1 Low fuel pressure Repair or replace 2 Defective TP sensor Replace 3 Defective IAT sensor Replace 4 Defective pick up coil Replace 5 Defective IAP sensor Replace 6 Defective ECU Replace 7 Defective SAV solenoid Replace 77 8 3 1 SERVICING INFORMATION Complaint Engine lacks power Symptom and possible causes Defective engine internal electrical parts 1 Loss of tappet clearance 2 Weakened valve springs 3 Valve timing out of adjustment 4 Worn piston rings or cylinders 5 Poor seating of valves 6 Fouled spark plugs 7 Incorrect spark plugs 8 Clogged injectors 9 Defective TP sensor 10 Clogged air cleaner element 11 Sucking air from throttle valve or vacuum hose 12 Too much engine oil 13 Defective fuel pump or ECU 14 Defective pick up coil and ignition coils Defective control circuit or sensor Low fuel pressure Defective TP sensor Defective IAT sensor Defective pick up coil Defective IAP sensor Defective ECU Defective SAV solenoid Defective GP switch Adjust Replace Adjust Replace Repair Clean or replace Adjust or replace Clean Replace Clean Retighten or replace Drain out excess oil Replace Replace Repair or replace Replace Replace Replace Replace Replace
58. put voltage lt 4 75 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor 6 lAP sensor circuit open or shorted to ground sensor malfunction ECU malfunction u INSPECTION Step 1 1 Remove the fuel tank 2 Turn the ignition switch OFF position 3 Check the IAP sensor NO 1 coupler and NO 2 coupler for loose or poor contacts If OK then measure the IAP sensor input voltage 4 Disconnect the IAP sensor couplers NO 1 3 and 2 4 5 Turn the ignition switch position 6 Measure the input voltage at the OB wire and ground If OK then measure the input voltage at the OB wire and GR wire 45 55V IAP pulla input 4 OB O Ground voltage 0B OGR Tester knob indication Voltage Is the input voltage OK YES Go to Step 2 Loose or poor contacts on the ECU coupler NO Open or short circuit in the OB wire or GR wire 42 Step 2 1 Connect the IAP sensor couplers NO 1 and NO 2 2 Insert the needle pointed probes to the lead wire coupler 3 Start the engine at idle speed 4 Measure the sensor output voltage at the wire side coupler
59. r wo 8 5 8 iD gt e 2 095 LENGTH hd 1445 WHEEL BASE 1 8 1 GENERAL INFORMATION SPECIFICATIONS 21650 Ef amp 7 amp 50 E7 9 DIMENSIONS AND MASS ITEM GV650Ei G7e650 Overall length 2 430 mm 95 7 in 2 095 mm 82 5 in Overall width 890 mm 35 0 in 785 mm 30 9 in Overall height 1 155 mm 45 5 in 1 125 mm 44 3 in Wheelbase 1 665 mm 65 6 in 1 445 mm 56 9 in Ground clearance 160 mm 6 3 in 185 mm 7 3 in Mass 220 kg 485 Ibs 210 kg 463 Ibs ENGINE ITEM GV650Ei Maxed 9 Four stroke DOHC Liquid cooled Number of cylinder V 2 cylinder Bore 81 5 mm 3 21 in Stroke 62 0 mm 2 44 in Piston displacement 647 39 5 Fuel system Electric fuel Injection Starter system Electric starter Lubrication system Wet sump 9 TRANSMISSION ITEM GV630 ts Moyer Clutch Wet multi plate type Transmission 5 speed constant mesh 6 speed constant mesh Gearshift pattern 1 down 4 up 1 down 5 Final reduction 2 69 2 93 1st 2 46 2 46 2nd 1 78 1 60 Beatie 3rd 1 38 1 32 4th 1 13 1 13 5th 0 96 0 96 6th 0 85 Drive belt chain Poly chain belt RK525XSO 108 links 10 CHASSIS Kimura Front suspension
60. r 2 Probe Where male terminal fits 4 1 3 EI SYSTEM DIAGNOSIS When disconnecting and connecting the ECU make sure to turn OFF the ignition switch or electronic parts may get damaged Battery connection in reverse polarity is strictly prohibited Such a wrong connection will damage the components of the El system instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The moment such removal is made damaging counter electromotive force will be applied to the ECU which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11V or higher Terminal voltage check at low battery voltage will lead to erroneous diagnosis 18 INCORRECT Never connect an ohmmeter to the ECU with its coupler connected If attempted damage to the ECU or sensors may result Be sure to use specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained and personal injury may result USING TESTERS Use well charged batteries in the tester Be sure to set the tester to the correct testing range f USING THE TESTER Incorrectly connecting the probes may cause the inside of the tester to burnout the voltage and current are not known make measurements using the highest rang
61. rcuit and poor connection 2 4 5 gt 2x gt O W gt ECU Coupler G Replace the Oxygen sensor with a NO new one Sensor side Heater side ss 46 EI SYSTEM DIAGNOSIS 4 1 32 23 RO SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE After holding the motorcycle vertically and the ignition RO switch circuit short or leaned more than 60 switch turns position the switch resistance RO switch malfunction should be the following for more than 3 sec Switch resistance Infinity 2 maneter INSPECTION 1 Remove the seat 2 Turn the ignition switch OFF position 3 Check the RO switch coupler for loose or poor contacts If OK then measure the RO switch resistance 4 Disconnect the RO switch coupler 5 Measure the resistance at the wire coupler switch side between BW and YL wires of the RO switch at horizontal place oo Q Infinity RO switch resistance at normal condition BW OYL Also measure the resistance when leaning of the motorcycle 6 Measure the resistance when it is leaned more than 60 left and right from the horizontal level 09 drug atleaned more than 60 YL
62. resent the actual vehicle exactly in detail AN WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer NOTE 50 model s model Creta ss COPYRIGHT S amp T Motors Ltd GROUP INDEX GENERAL INFORMATION El SYSTEM DIAGNOSIS ELECTRICAL SYSTEM SERVICING INFORMATION 57 HYOSUNG HOW USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 As the title of these sections are listed on the previous page as GROUP INDEX select the section where you are looking for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing The meaning of each symbol is also included in the table DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque C zo A Apply THREAD LOCK 1324 Apply oil Use engine oil unles
63. rk plug 1 Worn piston rings Replace become fouled 2 Pistons or cylinders worn Replace too soon 3 Excessive clearance of valve stems in valve guides Replace 4 Worn stem oil seal Replace Spark plug 1 Spark plugs too hot Replace by cold type plug electrodes 2 The engine overheats Tune up overheat or burn 3 Spark plugs loose Retighten 4 Mixture too lean Inspect El system Magneto charge but charging Lead wires tend to get shorted or open circuited or loosely connected at terminals Repair or retighten rate is below the 2 Grounded or open circuited stator coils of magneto Replace specification 3 Defective regulator rectifier Replace 4 Defective cell plates in the battery Replace the battery Magneto 1 Internal short circuit in the battery Replace the battery overcharges 2 Resistor element in the regulator rectifier damaged or defective Replace Regulator rectifier poorly grounded Clean and tighten ground connection Magneto does not charge Open short circuited lead wirse or loose lead connections Short circuited grounded or open stator coil Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Unstable charging Lead wire insulation frayed due to vibration resulting in intermittent shorting Magneto internally shorted Defective r
64. s otherwise specified PRP or USR Apply SUPER GREASE Measure in voltage range Apply SUPER GREASE jal Measure in resistance range Apply SILICONE GREASE Measure current range Apply MOLY PASTE Measure diode test range Apply BOND 1215 Measure in continuity test range Use fork oil Use special tool A o o LLC Use engine coolant ABBREVIATIONS USED IN THIS MANUAL A L ABDC After Bottom Dead Center LCD Liquid Crystal Display AC Alternating Current LED Light Emitting Diode API American Petroleum Institute LH Left Hand ATDC After Top Dead Center M B Maximum BBDC Before Bottom Dead Center Min Minimum BDC Bettom Dead Center BTDC Before Top Dead Center O2 Sensor Oxygen Sensor 025 DC Direct Current R DOHC Double Over Head Camshaft RH Right Hand RO Switch Roll Over Switch E ECU Engine Control Unit 5 El Control Unit SAE Society of Automotive Engineers El Electric fuel Injection SAV Solenoid Secondary Air Valve Solenoid Electric fuel Injector T F TDC Top Dead Center FP Fuel Pump TP Sensor Throttle Position Sensor TPS G W GP Switch Gear Position Switch WT Sensor Water Temperature Sensor WTS IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air Temperature Sensor IATS IG Ignition
65. stages and then tighten them in the above tightening order NOTE Apply a small quantity of the THREAD LOCK 1324 to the thread portion of the fuel pump mounting bolt THREAD LOCK 1324 59 FUEL SYSTEM AND THROTTLE BODY 4 2 4 4 2 5 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE OF FUEL PUMP INSPECTION Remove the seat Place rag under the fuel injector hose Disconnect the fuel injector hose from the fuel hose joint Install the special tool between the fuel tank and fuel hose joint Fuel pump pressure gauge 09915 54510 Turn the ignition switch position and check the fuel pressure of the fuel pump Fuel pressure Approx 2 96 3 16 kgf cm ll 290 310 kPa 42 06 44 96 psi If the fuel pressure is lower than the specification inspect the following items Fuel hose leakage Clogged fuel filter Pressure regulator Fuel pump If the fuel pressure is higher than the specification inspect the following items Fuel pump check valve Pressure regulator WARNING Before removing the special tool turn the ignition switch to OFF position and release the fuel pressure slowly Gasoline is highly flammable and explosive Keep heat sparks and flame away FUEL PUMP RELAY INSPECTION Fuel pump relay is located the left side of the frame Remove the frame cover Remove the fuel pump
66. t the fuel pump or fuel pump NO relay Refer to page 4 2 5 51 EI SYSTEM DIAGNOSIS 4 1 36 X lt I u lt 727 gt ECU Coupler 4 1 37 EI SYSTEM DIAGNOSIS 41 FUEL PUMP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Voltage is applied continuous for more than 5 sec Fuel pump relay circuit open or short battery voltage 3 2 V when the fuel pump relay is Fuel pump relay malfunction OFF position or battery voltage lt 1 5 V when the ECU malfunction fuel pump relay is position u INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the fuel pump relay coupler for loose or poor contacts If OK then check the insulation and continuity Refer to page 4 2 5 for details Is the Fuel pump relay OK GW or BBr wire open or shorted to ground or poor 4 61 connection of ECU coupler ry If wire and connection are intermittent trouble or faulty ECU d 6 Recheck each terminal and wire harness for open circuit and poor connection Inspect the fuel injectors Refer to page 4 1 35 Replace the fuel pump relay with new one
67. temperature 15 40 C 120 C 40 F 248 F Tester knob indication Resistance 40 EI SYSTEM DIAGNOSIS 4 1 26 WT sensor resistance Engine Coolant Temp Resistance ECU 40 40 F Approx 48 140 KQ 0 C 32 F Approx 5 790 KQ 20 68 F Approx 2 450 40 104 F Approx 1 148 KQ 60 140 F Approx 0 586 KQ 80 176 F Approx 0 322 120 248 F Approx 0 1163 KQ Tester knob indication Resistance KQ Is the resistance OK G or GR wire open or shorted to ground or poor 5 4 connection of ECU coupler c u o O m lt GV6E50E Br or GR wire open or shorted to ground or poor 6 64 YES connection of ECU coupler erresor zur f wire and connection are intermittent trouble or faulty ECU Coupler ECU ECU Coupler Recheck each terminal and wire harness for open circuit and poor connection Replace the WT sensor with a new one 2 2 5 20x 5 oar 41 4 1 27 EI SYSTEM DIAGNOSIS 17 or C18 IAP SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION IAP sensor output voltage is out of the specified range for 6 sec and more 0 40 V lt Sensor out
68. type Engine coolant capacity Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50 50 Reserve tank side Radiator side Engine side 84 amp ELECTRICAL STANDARD SERVICING INFORMATION 8 20 Unit mm in Battery Standard electrolyte S G Ignition timing BTDC 5 2 000 rpm Type CR8E Gap 0 7 0 8 0 028 0 032 Spark plug Hot type Standard type CR8E Cold type CR9E Spark performance Over 8 mm 0 32 in Ignition coil primary peak voltage 150 V and more Ignition coil resistance comely Secondary 20 31 KQ Stator coil resistance Charging 0 2 0 4 Q Y Y Magneto no load voltage Over 70 5 000 rpm Battery standard charging voltage 13 5 15 0 V 5 000 rpm Type STX14 BS Capacity 12V 12Ah 1 320 at 20 C 68 F Fuse size Main 30A Head lamp 15A 85 8 30 1 SERVICING INFORMATION WIRING DIAGRAM GV650 Ei
69. ue to wear Replace 2 Worn and big end bearings Replace 3 Worn and burnt journal bearings Replace Noise seems to come from transmission 1 Worn or rubbing gears Replace 2 Worn splines Replace 3 Worn bearings Replace 4 Worn or rubbing primary gears Replace Noise seems to come from water pump 1 Too much play on pump shaft bearing Replace 2 Worn or damaged impeller shaft Replace 3 Worn or damaged mechanical seal Replace 4 Contact between pump case and impeller Replace 76 SERVICING INFORMATION 8 2 2 Symptom and possible causes Engine runs poorly Defective engine internal electrical parts in high speed range 1 Weakened valve springs Replace 2 Worn camshafts Replace 3 Valve timing out of adjustment Adjust 4 Too narrow spark plug gaps Adjust 5 Ignition not advanced sufficiently due to poorly working timing Replace ECU advance circuit 6 Defective ignition coils Replace 7 Defective pick up coil Replace 8 Defective ECU Replace 9 Clogged fuel hose resulting in inadequate fuel supply to injector Clean and prime 10 Defective fuel pump Replace 11 Defective TP sensor Replace 12 Defective SAV solenoid Replace 13 Clogged air cleaner element Clean Defective air flow system 1 Clogged air cleaner element Clean or replace 2 Defective throttle valve Adjust or replace 3 Sucking air from throttle body joint Repair or re
70. ut off system when the motorcycle is leaned over 60 for upset accident SAV solenoid Secondary Air Valve Solenoid SAV solenoid supply the fresh air to the exhaust pipe for decrease of the exhaust gas TP sensor Throttle Position Sensor TPS TP sensor detect the throttle opening angle and is located the throttle body It decide the fuel injection volume and compensate the ignition time as inform idle acceleration deceleration condition and throttle full opening etc to ECU WT sensor Water Temperature Sensor WTS WT sensor is located on the cylinder block s water jacket the intake pipe or the cylinder head coolant passage s thermostat part for contact with the coolant WT sensor is the NTC Negative Temperature Coefficient resister that measure the coolant temperature and inform ECU 14 EI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING 16 4 1 1 EI SYSTEM TECHNICAL FEATURES 20 4 1 5 SELF DIAGNOSIS FUNCTION 27 4 1 12 EI SYSTEM TROUBLESHOOTING 30 4 1 15 CUSTOMER COMPLAINT MH 30 4 1 15 SELF DIAGNOSTIC PROCEDURES RH 32 4 1 17 SELF DIAGNOSIS RESET PROCEDURE M 33 4 1 18 MALFUNCTION CODE AND DEFECTIVE CONDITION 34 4 1 19 C12 PICK UP COIL CIRCUIT MALFUNCTION m nr 36 4 1 21

GV 650 GT 650 EI service

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