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1. DEALER Rr BRAKE FUELPUMP FUELPUMP HEAD LAMP MODE O SENSOR SWITCH MAIN RELAY RELAY RELAY FILTER CANTOOL SWITCH OFF ON OHO 3 2 f ECU ALII Il TT bei Lui IDU E EIGI EE 2 KOTA NGANTI DS ES ERMAN ag g as ET 8882BdaoshtERBEosdhoooBEBBaonsRondbz652Bs5z T 88 H I J Lg 1 Bw Bw 3 Rr TURN SIGNAL LAMP RH when 19 LICENSE PLATE LAMP I MR v ew 1 1 L an I I le 1 1 BRAKE 8 TAIL LAMP BW XJ BW 3 B 2 B Rr TURN SIGNAL LAMP LH L a 1 i 1 5 9 BB d P 3 P 88 DIODE BE lt B al i qu do Ux ME DE nE E rd h 1 1
2. 96 SPEEDOMETER HANDLE SWITCHRH SPEEDO SENSOR FUEL See CLUTCHLEVER SV GAUGE m ENGINE STOP HAZARD STARTER Ft BRAKE SWITCH SOLENOID Bg STOP OFF OFF bad RUN on 3 tals sts eee i be i e ore hy 385 d pf ___ ze 1 1 1111 a TER ST Zoo Lu 4 P i gt gt 52 lt gt gt 2 zg Zoo Ft TURN SIGNAL LAMP RH 1 Lo Lg d aw BW LOWBEAM Mi I E BW 1 BW Jr HIGHBEAM Leit 7 Wer 1 HEADLAMP Fon Bw Bw gt B Ft TURN SIGNALLAMP LH L I 235390380 P 1 gt o FBO ag 4 22 T n T 85 5 rl ag m Eo gt gt o gt 308 308 I AN iB LOCK PUSH ch 0 men PUSHI elo OFF HORN cr on 5 PASS DE HORN olo IGNITION IGNITION DIODE 1 TURN SIGNAL IGNITION SWITCH SIDE STAND COILNO 1 COILNO2 FILTER SWITCH X i HANDLE SWITCH LH DET EARTH EARTH SERVICING INFORMATION 7 32 2
3. ECU Coupler B4 El SYSTEM DIAGNOSIS 4 1 28 C15 ET SENSOR CIRCUIT MALFUNCTION ry 2772 2 EE CODE GV2530 Es CODE C15 DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 2 sec ET sensor circuit open or short and more ET sensor malfunction lt lt 0 08 V lt Sensor voltage lt 4 65 V ECU malfunction m INSPECTION 1 Turn the ignition switch OFF position 2 Check the ET sensor coupler for loose or poor contacts If OK then measure the ET sensor resistance 3 Disconnect the ET sensor coupler 4 Measure the resistance between the terminals 0 102 81 000 KQ When Engine ET sensor resistance temperature is 20 C 180 C 4 F 356 F Tester knob indication Resistance KQ 43 4 1 29 El SYSTEM DIAGNOSIS Resistance To ECU Engine Temp 20 C 4 F Approx 75 5 KQ 0 32 F Approx 28 7 KQ 20 C 68 F Approx 12 2 KQ 40 C 104 F Approx 5 6 KQ 60 140 F Approx 2 8 KQ 80 C 176 F Approx 1 5 KQ 120 C 248 F Approx 0 5 KQ 140 C 284 F Approx 0 3 Approx 0 2 KQ 160 C 320 F 180 C 356 F Approx 0 13 KQ Tester knob indication R
4. 53 4 1 39 El SYSTEM DIAGNOSIS C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION GT250 R Ei CODE GV230 Es CODE C32 3 2 3 2 3 2 C33 3 3 3 3 3 DETECTED CONDITION Injector signal is interrupted continuous for more than 1 sec when ECU confirm injector running surge at each combustion chamber POSSIBLE CAUSE Injector circuit open or short Injector malfunction ECU malfunction ms INSPECTION Step 1 1 Remove the fuel tank frame cover 2 Turn the ignition switch OFF position 3 Check the injector couplers NO 1 and NO 2 for loose or poor contacts If OK then measure the injector resistance X Fuel injector Fuel injector NO 2 4 Disconnect the injector couplers NO 1 and NO 2 and measure the resistance between terminals 11 4 12 6 Q at 20 Injector resistance 68 F Tester knob indication Resistance 5 If OK then check the continuity between injector terminals and ground Injector continuity Tester knob indication Resistance Q oo 0 Infinity Are the resistance and continuity OK YES Go to Step 2 NO Replace the Injector with a new one 54 El SYSTEM DIAGNOSIS 4 1 40 Step 2 1 Turn the ignition swit
5. DEALER O SENSOR Rr BRAKE FUEL PUMP FUELPUMP HEAD LAMP Se SWITCH MAINRELAY RELAY RELAY FILTER CANTOOL SWITCH OFF 5 Fon 5 5 5 gt ij BA m ER aE gt o 1 1 Ci 01 El Fi GI Hi Ji Li Mi A2 B2C2 D2E2 F2 G2 H2 J2 K2 L2 M2A3 03 F3 G3H3 J3 L3 A4 B4 C4 H4 JA K4 L4 83 3 SSse dses ES RBE ad ser st 0F FSS H aATHoAAESS SLES BS y ex LII Lg a tg 3 4 BW i Rr TURN SIGNAL LAMP RH YW YW F BW BW G t LICENSE PLATE LAMP 1 P YW YW 1 1 4 L 3 WB W I BRAKE amp TAIL LAMP BW Xj BW 3 B 2 B Rr TURN SIGNALLAMP LH 6 88 4 S DIODE 3 N ECH Lit 8 gE T FEI 5 1 op ER 858 5 iili Pur bi OR T 2 6 7 12V 10Ah ser Sp EARTH ouer ost 5 REGULATOR STARTER STARTER BATTERY LOB FUEL ET ISC IAT RO GP MAGNETO MOTOR RELY we pug RECTOR SENSOR SENSOR SOLENOID SENSOR SWITCH SWITCH ELE Boa 15 INJECTOR NO2 SENSOR SENSOR NO2 NO 1 NO 1 99 Prepared by 67 HYOSUNG S amp T Motors Co Ltd 1st Ed APR 2009 Manual No 99000 95620 Printed in Korea S amp T Motors Ltd
6. 40 4 1 25 C15 ET SENSOR CIRCUIT MALFUNCTION nee 43 4 1 28 C17 or C18 IAP SENSOR CIRCUIT MALFUNCTION 45 4 1 30 C21 IAT SENSOR CIRCUIT MALFUNCTION m 47 4 1 32 C22 OXYGEN SENSOR CIRCUIT MALFUNCTION 5 49 4 1 34 C23 RO SWITCH CIRCUIT MALFUNCTION 8 50 4 1 35 C24 or C25 IGNITION COIL MALFUNCTION 51 4 1 36 C27 ISC SOLENOID RANGE ABNORMAL e 52 4 1 37 C31 GP SWITCH CIRCUIT MALFUNCTION 53 4 1 38 C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION 54 4 1 39 C37 SAV SOLENOID MALFUNCTION 5 56 4 1 41 C41 FUEL PUMP RELAY CIRCUIT MALFUNCTION ee 57 4 1 42 C43 OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION 58 4 1 43 SENSORS ches a slim una unse 59 4 1 44 15 4 1 1 El 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 m 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 t
7. 5 be 5 ze d l 55 gt L 1 ji 8 z ti q o885 8 Ss 13573 Bos 1 P i gt 4 gt lt 259oz290o0g Ft TURN SIGNAL LAMP RH g Lg sw w w w b a Ww n 5 L AE li D HEADLAMP ech P n L ews aw b Ft TURN SIGNAL LAMP LH 2333080 LL gt 223090280 ox a d 4 ra I 8 II gt 85 gt og an L OJR _ Toto LOCK OFF i i ily E m mu 01655 HORN oN 010 L IGNITION IGNITION DIODE 1 TURN SIGNAL IGNITION SIDE STAND Q RELAY FILTER SWITCH xa HANDLE SWITCH LH SWITCH EARTH 5 EARTH 4 98 SERVICING INFORMATION 7 32 4
8. IB MALFUNCTION PART 1 II 1 Pick up coil 1 il 1 Throttle position sensor TPS ji IN 1 Engine temperature sensor ETS Intake air pressure sensor IAPS NO 1 1 7 7 1 8 1 Intake air pressure sensor IAPS NO 2 Ik 2 1 2 1 2 Intake air temperature sensor IATS 2 2 N N H 1 sensor 5 2 3 2 Il Il Roll over switch RO switch 12 4 2 4 H Ignition coil NO 1 2 5 5 271 Ignition 2 speed control solenoid ISC solenoid UL 3 1 1 1 Gear position switch GP switch Fuel injector NO 1 3 2 3 2 2 L3 Il Fuel injector 2 3 H 3 1 Secondary air valve solenoid SAV solenoid 4 3 d d 4 1 Fuel pump relay lal II Oxygen sensor heater O2S heater For 77 250 E For ev250 Ei 31 REMARKS No defective part For NO 1 oylinder For NO 2 oylinder For NO 1 oylinder For NO 2 oylinder For NO 1 oylinder For NO 2 oylinder 4 1 17 El SYSTEM DIAGNOSIS n C77 250 R Ei In the LCD DISPLAY panel D the malfunction code is indicated from small code to large code ul 42V 250 Ef In the FI check lamp 2 the malfunction code is displayed from small numeral blinks signal to large numeral blinks signal GT250 Ei EV250 Ei
9. 32 El SYSTEM DIAGNOSIS 4 1 18 El 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 or Blinks signal FI check lamp PROBLEM SYMPTOMS No code Malfunction code Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at Surging 0 cold warm always Abnormal knocking Other Engine rpm jumps briefly Other Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened High Low rpm Throttle valve is closed Unstable Load is applied
10. SO Ex 7 7 1 6 3 GENERAL INFORMATION EXTERIOR ILLUSTRATION 250 Ei Rear flect Tail lamp License plate lamp 9 oj o w m o 2 27 AR N Le Rear turn signal lamp Front turn signal lamp Passenger footrests Head lamp 1 520 WHEEL BASE 2 280 LENGTH GENERAL INFORMATION 1 7 1 EXTERIOR ILLUSTRATION G7 2se 2 7 Rear turn signal lamp Brake Tail lamp Rear _ reflector i T a z N LO Head lamp Front turn signal lamp Passenger footrests X 1 430 WHEEL BASE 2 095 LENGTH 1 7 2 GENERAL INFORMATION EXTERIOR ILLUSTRATION amp 7 50 amp 7 Rear turn signal lamp d Rear 2 f lamp ge A License plate lamp i a gt z E o dco RO EIS e Y Y Y Y Headlamp Fronttum signal lamp Passenger footrests 1 430 WHEEL BASE 2 095 LENGTH 10 GENERAL INFORMATION 1 8 1 FUNCTION OF El SENSOR ECU Engine Control Unit El Control Unit ECU decide the fuel injection volume and ignition time to adjust the fuel injector opening and closing rate which is
11. When Intake air IAT sensor resistance temperature is 40 C 130 C 40 F 266 F Tester knob indication Resistance KQ 47 4 1 33 El SYSTEM DIAGNOSIS IAT sensor resistance Resistance Intake Air Temp 40 C 40 F 44 642 KQ 5 20 C 4 F 14 958 KQ 5 0 C 32 F 5 734 KQ 596 20 C 68 F 2 438 KQ 5 40 C 104 F 1 141 KQ 5 60 C 140 F 0 579 KQ 596 80 C 176 F 0 315 KQ 5 100 C 212 F 0 182 KQ 596 120 C 248 F 0 111 KQ 5 130 C 266 F 0 088 KQ 5 Tester knob indication Resistance KQ Is the resistance OK Lg or GR wire open or shorted to ground or poor 53 69 connection of ECU coupler f wire and connection OK YES intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection NO Replace the IAT sensor with a new one 48 52 Frc lt 20x 29 Tou UN Z ECU Coupler E El SYSTEM DIAGNOSIS 4 1 34 C22 OXYGEN SENSOR CIRCUIT MALFUNCTION Lag orb CODE GV230 Es CODE 22 TW 2 2 2 2 2 2 DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor signal is
12. ON position or cranking the engine for few seconds LCD DISPLAY FI CHECK LAMP INDICATION INDICATION MALFUNCTION INDICATION MODE NO C C code is indicated FI check lamp YES from small numeral to goes off large one For each 2 sec code is indicated 28 El SYSTEM DIAGNOSIS 4 1 14 SELF DIAGNOSIS FUNCTION EV250 Ei 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 FI check lamp 1 check the function of the individual El system devices the dealer mode prepared In this check the special tool is necessary to read the code of the malfunction items USER MODE The FI check lamp comes on for about three seconds whenever the ignition switch is set to ON position with the engine stopped as a test of the injection system operation The check lamp must go off after three seconds If the FI check lamp D comes on during normal engine operation it means that the electric fuel injection system is not operating correctly When this is the case inspect the electric fuel injection system to refer to Dealer mode 29 4 1 15 El SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the ECU Use the special tool s coupler to connect to the deal
13. Replace Clean Add oil Replace or clean Retighten or replace Change Clean or replace Repair or replace Repair or replace Repair or replace Replace Replace Replace Adjust SERVICING INFORMATION 7 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 springs 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 Repla
14. TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM NO FAULT DETECTED FAILURE CONDITION CHECK FOR Pick up coil The pick up coil signal does not reach ECU for more than 3 sec after ECU receiving the ignition switch signal 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 voltage lt 4 8 V Without the above range for 2 sec and more C14 is indicated Throttle position sensor lead wire coupler connection Engine temperature sensor ETS The sensor voltage should be the following 0 08 V lt sensor voltage lt 4 65 V Without the above range for 2 sec and more C15 is indicated Engine temperature sensor lead wire coupler connection C17 C18 Intake air pressure sensor IAPS NO 1 NO 2 The sensor should produce following voltage 0 5 V lt sensor voltage lt 4 5 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 voltage lt 4 75 V Without the above range for 6 sec and more C21 is indicated Intake air temperature sensor lead wire coupler connection Oxyg
15. GP SWITCH CIRCUIT MALFUNCTION cs mmm mnn DETECTED CONDITION POSSIBLE CAUSE GP switch voltage is out of the specified range for 2 GP switch circuit open or short sec and more GP switch malfunction 0 15 V lt Switch voltage lt 3 93 V ECU malfunction 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 switch 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 the O 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 100 Q 2 0 KQ GL L Tester knob indication Resistance KQ Is the resistance OK GL or L wire open or shorted to FD ground or poor F2 connection of ECU coupler ET x Oo u u ga m If wire and connection are OK intermittent trouble or faulty ECU 6 Recheck each terminal and wire harness for open circuit and poor 5 connection u 7 7 7 s Open or short circuit in the GL or L wire ECU Coupler YES 2 2 3
16. you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer NOTE e Ggv250 model Agua 250 e Icrr25o ze model Cerat 259 COPYRIGHT S amp T Motors Co Ltd GROUP INDEX GENERAL INFORMATION EI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY ELECTRICAL SYSTEM SERVICING INFORMATION HYOSUNG HOW TO 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 Apply THREAD LOCK 1324 Apply oil Use engine oil unless otherwise specified Apply SUPER GREASE A Measure in voltage range Apply SUPER GREASE C Measure in resistance range Apply SILICO
17. 2 check the function of the individual El system devices the dealer mode prepared In this check the special tool is necessary to read the code of the malfunction items USER MODE The FI check lamp comes on for about three seconds whenever the ignition switch is set to ON position with the engine stopped as a test of the injection system operation The check lamp must go off after three seconds LCD DISPLAY CHECK LAMP INDICATION MALFUNSLON INDICATION INDICATION MODE NO Speedometer YES Speedometer FI check lamp Each 2 sec and comes on Speedometer or Fl FI letters letters is indicated Engine can start Engine can not FI letters check lamp comes FI letters is indicated start on and blinks continuously When one of the signals is not received by ECU the fail safe circuit works and injection is not stopped In this case FI letters and speedometer are indicated in the LCD panel 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 ECU In this case FI letters is indicated in the LCD panel D Motorcycle does not run The LCD panel 1 indicates CHE letters when no communication signal from the
18. 4 2 2 REASSEMBLY AND INSTALLATION RH 64 4 2 3 FUEL PRESSURE 5 5 65 4 2 4 FUEL PUMP RELAY INSPECTION 65 4 2 4 FUEL MESH FILTER INSPECTION AND CLEANING 66 4 2 5 FUEL GAUGE INSPECTION deg ge ehren 66 4 2 5 THROTTLE BODY ccce ii sea ae 67 4 2 6 REMOVAL zu yaaa asus Qn UR Ses 68 4 2 7 CLEANING eeu i RR Aen tue za a adi eu ua AE 69 4 2 8 INSPECTION 69 4 2 8 INSTALLATION 22 Ba He 70 4 2 9 AN CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or spark 61 4 2 1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM lt 77250 R E 62 REMOVAL AND DISASSEMBLY Remove the front seat Remove the fuel tank mounting bolts and take off the hooks Disconnect the fuel gauge coupler 1 Remove the fuel pump coupler Remove the fuel injector hose A CAUTION After disconnecting the fuel injector hose insert a blind plug into the end to stop fuel leakage 63 FUEL SYSTEM AND THROTTLE BODY 4 2 2 4 2 3 FUEL SYSTEM AND THROTTLE BODY Remove the fuel tank rearward AN CAUTION As gasoline leakage may occur in this operation keep away from fire and sparks Remove the fuel pum
19. 58 H T UR H H H 8 o gt gee 228 ad ii 225 8 H N m OFF t 1 j PUSH OTO Lo Oo Pusu O R O19 SE E BS fR on OO BORN A er IGNITION a SIDE STAND COILNO 1 COIL NO 2 IGNITION SWITCH RELAY SENSOR HANDLE SWITCH LH SWITCH es nn sem A 94 SERVICING INFORMATION 7 31 2 O2 SENSOR Rr BRAKE MAINRELAY FUELPUMP FUEL PUMP HEAD LAMP SWITCH RELAY RELAY OFF E n ECU on OO 8 TT IET if CI DL EL FIGLI HE JI U MAZE E 2 C3 D3 G3 J3 K3 3 M3 B4 C4 J4
20. 6 Main fuse 30A 2 Ignition coil NO 2 Fuel pump relay ECU Head lamp relay Head lamp fuse 15A Battery NE gt 4 2 Y N Moi gt ki AM A el OI IAT sensor RO switch 0 Magneto Pick up coil GP switch 72 ELECTRICAL SYSTEM 5 2 ISC solenoid IAP sensor NO 1 D ET sensor IAP sensor NO 2 AA 0 Oxygen sensor Fuel injector NO 2 E Q2 Fuel injector NO 1 73 5 3 ELECTRICAL SYSTEM IGNITION SYSTEM MAIN RELAY O O ENGINE STOP SWITCH IGNITION SWITCH FUSE 12V 10AH IGNITION COIL NO 1 IGNITION COIL NO 2 9 INSPECTION m 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 magneto coil with a new one Stator coil resistance Standard Pick up coil G L Approx 85 105 Q Charging coil Y Y Approx 0 2 1 0 Q Tester knob indication Resistance Q AN CAUTION When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 74 ELECTRICAL SYSTEM 5 5 s IGNITION COIL RESISTANCE INSPECTION Disconnect the ignition coil lead wire Measure the ignition coil resistance in
21. 8 EM lt b pana La tB 25 858 55 BSE 69 Bs m oo B IE 12V 10Ah Rie EARTH er FUSE za REGULATOR STARTER STARTER BATTERY FUSE FUSE FUEL ET ES pm G MAGNETO MOTOR RELY MP E 805 rug SENSOR IAP SENSOR SOLENOID SENSOR SWITCH SWITCH 4 m en 459 INJECTOR 2 SENSOR SENSOR NO2 NO 1 97 7 32 3 SERVICING INFORMATION WIRING DIAGRAM 7227 SPEEDOMETER HANDLE SWITCH RH CLUTCHLEVER gay FUEL DISPLAY SPEEDOSENSOR SWITCH SOLENOID GAUGE gags PAE ESI L kak RUN is on oio PUSH OIO or oo box ee ee ee 8 ER BE og
22. Hunting rpm to rpm Other Other OTHERS 33 4 1 19 El SYSTEM DIAGNOSIS MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow 0 Always Other Temperature Hot Warm Cool Cold EI C O Always Frequency Always Sometimes times day month Only once Under certain condition Road Urban Suburb Highway Mountainous L 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 34 SELF DIAGNOSTIC PROCEDURES Don t disconnect couplers from ECU battery cable fro
23. KA L Md 5 82565 BE 88 8 gt 8882o d5os ftEBS8tcosdboooBPRB86 ons amp ondb5b658s8s897 LJ gt a 82 916 Rr TURN SIGNALLAMP RH cmi LICENSE PLATE LAMP lg lg w nw ad B A w WB WB WB 1 ino BRAKE amp TAILLAMP Lj Bw w Be LJ n Rr TURN SIGNAL LAMP LH i L 88 4 pac Ee88286a5db 88 e 54 el gt gt gt TIF CN LL tit ECKE TTT ID gt x gt gt gt 1 28 85 gt 8 a8 885 BEE Bo 25 T1 ZE EH 88 8 28 LL N l I e 3 5 L i DE EARTH FUEL ET ISC SOLENOID RO SWITCH ges MAGNETO REGULATOR STARTER STARTER em ner ruse SANTOOL DEALER rug INJECTOR SENSOR jap SENSOR GPSWITCH ARECTFER MOTOR RELAY Tt BOX BOX MODE SWITCH INJECTOR NO2 SENSOR NO2 NO 1 Not 95 7 32 1 SERVICING INFORMATION WIRING DIAGRAM 7 gt
24. Remove the front 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 GR and YL wires of the RO switch at horizontal place oo Q Infinity RO switch resistance at normal condition BGR 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 at leaned more than 60 Tester knob indication Resistance Q 50 El SYSTEM DIAGNOSIS 4 1 36 Is the resistance OK YL or GR wire open or shorted to ground or poor connection of ECU coupler Foe S YES If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection 2 e 3 x A x gt QD ou wo OND Loose or poor contacts on the ECU coupler ECU Coupler Open or short circuit in the YL wire or GR wire Replace the RO switch with a new one NO C24 or C25 IGNITION COIL MALFUNCTION Refer to the IGNITION COIL for deta
25. bolt the primary and secondary windings If the resistance is not within the standard range replace the ignition coil with a new one IGNITION COIL PLUG CAP RESISTANCE Primary 3 5 5 5 Q Terminal Terminal Secondary 20 31 KQ Plug Terminal Tester knob indication Resistance KQ 75 5 7 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator Rectifier Ignition switch Oo o A C generator N AN A Y m gt IC Y 8 St e Y scr 9 e e e e D gt INSPECTION m CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the DC voltage between the battery terminal and If the voltage is not within the specified value check the magneto no load performance and regulator rectifier A CAUTION When making this test be sure that the battery is full charged condition Charging output 13 5 15 0 V Regulated voltage at 5 000 rpm Tester knob indication Voltage 76 Ignition switch Regulator Rectifier Battery DCV m MAGNETO NO LOAD PERFORMANCE Disconnect the three lead wires from the magneto terminal Start the engine and keep it run
26. for loose or poor contacts If OK then check the insulation and continuity Refer to page 4 2 4 for details Head lamp relay Fuel pump relay Main relay Turn signal relay 0006 Is the Fuel pump relay OK GW or BBr wire open or shorted to ground or poor 4 or EI connection of ECU coupler Zr X c X o uN S o m lt If wire and connection are OK YES intermittent trouble or faulty ECU S Recheck each terminal and wire harness for open circuit and poor y x Bfya lt gt go gt connection Inspect the fuel injectors Refer to page 4 1 39 4 Coupler Replace the fuel pump relay with a new one NO 57 4 1 43 El SYSTEM DIAGNOSIS C43 OXYGEN SENSOR HEATER CIRCUIT MALFUNTION GT250 R Ei CODE GV230 Es CODE DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor Oxygen sensor heater circuit open or short Oxygen sensor Oxygen sensor heater malfunction ECU malfunction Oxygen sensor heater signal is not inputted in ECU m INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the Oxygen sensor heater coupler for loose or poor contacts If OK then measure the Oxygen sensor heater voltage 4 Disconnect the coupler and the
27. high speed range SERVICING INFORMATION 7 2 3 Symptom and possible causes Defective engine internal electrical parts 1 Weakened valve springs 2 Worn camshafts 3 Valve timing out of adjustment 4 Too narrow spark plug gaps 5 Ignition not advanced sufficiently due to poorly working timing advance circuit 6 Defective ignition coils 7 Defective pick up coil 8 Defective ECU 9 Clogged fuel hose resulting in inadequate fuel supply to injector 10 Defective fuel pump 11 Defective SAV solenoid 12 Clogged air cleaner element Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Sucking air from throttle body joint 4 Defective ECU Defective control circuit or sensor 1 Low fuel pressure 2 Defective IAT sensor 3 Defective pick up coil 4 Defective IAP sensor 5 Defective ECU 6 Defective SAV solenoid 85 Replace Replace Adjust Adjust Replace ECU Replace Replace Replace Clean and prime Replace Replace Clean Clean or replace Adjust or replace Repair or replace Replace Repair or replace Replace Replace Replace Replace Replace 7 3 1 SERVICING INFORMATION Complaint Engine lacks power Engine overheats Symptom and possible causes Defective engine internal electrical parts 1 Loss of tappet clearance 2 Weakened valve spr
28. 60 C 320 F 180 C 356 F 91 Approx 0 13 KQ 7 19 2 SERVICING INFORMATION THROTTLE BODY SPECIFICATION I D No 13400H88 Bore size 228 rpm 1 400 1 600 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 C 68 F Fuel injector voltage Battery voltage Fuel pressure of fuel pump Approx 3 4 3 7 kgf cm 333 363 kPa 48 4 52 6 psi 92 ELECTRICAL STANDARD SERVICING INFORMATION 7 20 Unit mm in Ignition timing BTDC 13 2 000 rpm 30 6 000 rpm Type CR8E Gap 0 7 0 8 0 028 0 032 Spark plug Hot type Standard type CR8E Cold type CR9E Spark performance More than 8 mm 0 32 in Ignition coil primary peak voltage 150 V and more 5 3 5 5 5 Q Ignition coil resistance Secondary 20 31 KQ Pick up coil Approx 85 105 Q G L Stator coil resistance Charging coil Approx 0 2 1 0 Q Y Y Magneto no load performance More than 60 V 5 000 rpm Charging output Regulated voltage 13 5 15 0 V 5 000 rpm Battery Type YTX12 BS Capacity Standard electrolyte S G 12V 10Ah 1 320 at 20 C 68 F Fuse size Main 30A Head lamp 93 15A 7 31 1 SERVICING INFORM
29. ATION WIRING DIAGRAM GV250 Ef SPEEDOMETER 2 HANDLE SWITCH RH Ft BRAKE SWITCH CLUTCH LEVER sav FUELGAUGE L H N R R ENGRESTOP HAZARD STARTER FIT SWITCH SOLENOID STOP OFF ON OFF SPEED 2 6 B RUN oto Lon oio Pusi oro 77 on TT og TT e 85 ge 8 a FUEL Sa F m LI og T DIODE 2 EE s 3 P TITI 111 oogzo EgnS9 I TT gt 9 z 1 Ft TURN SIGNAL LAMP RH d DH is esa 1 f HEAD LAMP 7 BW BW A A Y iJ Y 1 1 n o A e bal e A aw Bw s Ft TURN SIGNALLAMP LH gt ES d d gt ES d Fa Bo ss f th
30. B wire or GR wire NO 40 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 LY and ground TP sensor continuity Q Infinity Ground GV Tester knob indication Resistance Is the continuity OK YES Go to Step 3 Replace the TP sensor with a new NO one 41 EI SYSTEM DIAGNOSIS 4 1 26 I e 7 Ground 4 1 27 El SYSTEM DIAGNOSIS Step 3 1 Connect the TP sensor coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Turn the ignition switch ON position Measure the TP sensor output voltage at the coupler between LY and O B GR by turning the throttle grip Throttle valve is closed Throttle valve is opened TP sensor output voltage Approx 0 3 V Approx 4 5 V Tester knob indication Voltage Is the output voltage OK YES OB LY or GR wire open or shorted to ground or poor 82 4 connection of ECU coupler 6 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 TP sensor with a new one 42 D XA T ur E Oo 0 e
31. DNNSOAH HYOSUNG SL Zi Er 7 250 rE SERVICE MANUAL 99000 95620 FOREWORD This manual contains an introductory description on HYOSUNG BvV250 E amp GT250 R es and procedures for its inspection service and overhaul of its main components It covers the differences from Carbure type and please refer to the service manual of 250 99000 95310 LOR amp 125 99000HR8310 and Corrast 250 8 99000 94710 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 a 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 represent 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
32. ECU is received for seconds For example The ignition switch is turned ON position and the engine stop switch is turned 52 position In this case the speedometer does not receive any signal from ECU and the LCD panel indicates CHE letters If CHE letters is indicated the LCD panel Q does not indicate the trouble code The possible cause of this indication is as follows Engine stop switch is in 7 position Ignition fuse is burnt It is necessary to check the wiring harness between ECU and speedometer couplers SCH AAN 4 Ex 00000000 D m 8 5 s 950 4 fe ABBE 27 4 1 13 El SYSTEM DIAGNOSIS 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 20 The memorized malfunction code is displayed on LCD DISPLAY panel 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 AN 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
33. ESTER Incorrectly connecting the and probes may cause the inside of the tester to burnout 6 If the voltage and current are not known make measurements using the highest range After using the tester turn the power off 19 EI SYSTEM DIAGNOSIS 4 1 4 4 1 5 El SYSTEM DIAGNOSIS El SYSTEM TECHNICAL FEATURES EV250 Ei amp c7 25o ze Ei El SYSTEM S CONTROL DIAGRAM FUEL INJECTOR Electrical signal flow Air flow Fuel flow 0 Exhaust gas flow 20 El 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 Een ze ee 1 Intake Air Pressure Sensor Intake air pressure signal gt IAP Sensor Basic Engi ignal pidur coi ngine speed signa gt fuel injection EY time Throttle Position Sensor Throttle opening signal MET Various signals Various Sensors Compensation Injection signal fuel Injectors lt ERAS i injection I 7 lt I i t
34. NE GREASE EN Measure in current range Apply MOLY PASTE Measure diode test range bana Apply BOND 1215 Measure in continuity test range EORK Use fork oil Use special tool 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 D O2 Sensor Oxygen Sensor O2S DC Direct Current R DOHC Double Over Head Camshaft RH Right Hand RO Switch Roll Over Switch E ECU Engine Control Unit S 2 e Society of Automotive Engineers SET K en SAV Solenoid Secondary Air Valve Solenoid Electric fuel Injector ET Sensor Engine Temperature Sensor T ETS TDC Top Dead Center F TP Sensor Throttle Position Sensor TPS FP Fuel Pump G GP Switch Gear Position Switch IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air Temperature Sensor IATS IG Ignition ISC Solenoid Idle Speed Control Solenoid WIRE COLOR Black Gr Gray L Blue Lg Light green Br Brown O G Green R BL Black with Blue tracer BG Black with Green tracer BR Black with Red t
35. TORQUE EI SYSTEM PARTS ITEM Engine temperature sensor sensor m kgf m 8 0 5 0 8 8 Fuel injector mounting bolt 0 5 0 8 Intake air temperature sensor IAT sensor 0 5 0 8 5 5 90 SERVICE DATA El SENSORS IAP sensor input voltage SERVICING INFORMATION 7 19 1 SPECIFICATION 4 5 5 5V IAP sensor output voltage TP sensor input voltage Approx 3 7 3 9 V when ignition switch ON 45 55 TP sensor output voltage IAT sensor resistance Closed Approx 0 3 V Opened Approx 4 5 V 0 081 48 352 KQ When Intake air temperature is 40 C 130 C 40 F 266 F IAT sensor resistance each temperature Refer to page 48 4 1 33 RO switch resistance oo Q Infinity at normal condition 0 Q at leaned more than 60 GP switch resistance 100 Q 2 0 KQ Oxygen sensor heater voltage Battery voltage SAV solenoid voltage Battery voltage ET sensor resistance 0 102 81 000 KQ When Engine temperature is 20 C 180 C 4 F 356 F 20 4 F Approx 75 5 KQ 0 C 32 F Approx 28 7 KQ 20 C 68 F Approx 12 2 KQ 40 C 104 F Approx 5 6 KQ ET sensor resistance To ECU 60 C 140 F Approx 2 8 KQ each temperature 80 C 176 Approx 1 5 KQ 120 C 248 F Approx 0 5 KQ 140 C 284 F Approx 0 3 KQ Approx 0 2 KQ 1
36. again e if C LCD INDICATION is indicates the malfunction codes are cleared amp 7 25e ze Ei If not blink check lamp the malfunction codes are cleared 3259 Ei Disconnect the special tool from the dealer mode coupler 36 67 259 ze Ei 2 Y 220 El SYSTEM DIAGNOSIS 4 1 22 MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR C NO FAULT The pick up coil signal does not reach ECU for more than 3 sec after ECU receiving the ignition switch signal C12 Pick up coil In this case the code C12 is indicated Pick up coil wiring and mechanical parts Pick up coil lead wire coupler connection C14 Throttle position sensor TPS The sensor should produce following voltage 0 1 V lt sensor voltage lt 4 8 V Without the above range for 2 sec and more C14 is indicated Throttle position sensor lead wire coupler connection C15 Engine temperature sensor ETS The sensor voltage should be the following 0 08 V lt sensor voltage lt 4 65 V Without the above range for 2 sec and more C15 is indicated Engine temperature sensor lead wire coupler connection C17 C18 Intake air pressure sensor IAPS NO 1 NO 2 The sensor should produce following v
37. brication system Wet sump 9 TRANSMISSION Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up Reduction ratio 3 290 1st 2 460 De 2nd 1 560 ec Gear ratio 3rd 1 190 4th 0 960 5th 0 840 22 GTITZ5s0 RR Ef Drive chain 520 116 links 520 112 links 12 CHASSIS GENERAL INFORMATION 1 9 ITEM GV250 Ei GTZoRr Ei ak ef 0 1 Front suspension Telescopic type Rear suspension Swingarm type Steering angle 40 right amp left 27 right amp left Caster 347 25 5 Trail 142 mm 5 59 in 90 mm 3 54 in Front brake Disk brake Double disk brake Disk brake Rear brake Drum brake Disk brake Front tire size 110 90 16 595 110 70 17 54H Rear tire size 150 80 15M C 70S 150 70 17 69H Front fork stroke 120 mm 4 72 in ELECTRICAL Ignition type Ignition timing 13 STDC 5 2000 rpm and M nan 30 B T D C at 6 000 rpm Spark plug CR8E Battery 12 V 10 Ah MF Fuse 30A amp 15A Headers HI 12 V H4 60W 1 12V H1 55W x 1 12 V H4 60W x 1 LO 12 V H4 55W 1 12V H3 55W x1 12V H4 55W 1 Turn signal lamp 12V RY10W x 4 Brake Tail lamp 12V P21 5 W x 1 LED ty
38. ce gear 3 Weakened stopper spring on gearshift stopper Replace 87 7 4 SERVICING INFORMATION ELECTRICAL Complaint No sparking or poor sparking Spark plug soon become fouled with carbon Symptom and possible causes 1 Defective ignition coils or spark plug caps 2 Defective spark plugs 3 Defective pick up coil 4 Defective ECU 5 Defective RO switch 6 Open circuited wiring connections 1 Mixture too rich 2 Idling speed set too high 3 Incorrect gasoline 4 Dirty element in air cleaner 5 Spark plugs too cold Replace Replace Replace Replace Replace Check and repair Inspect El system Inspect El system Change Clean or replace Replace by hot type plug Spark plug become fouled too soon 1 Worn piston rings 2 Pistons or cylinders worn 3 Excessive clearance of valve stems in valve guides 4 Worn stem oil seal Replace Replace Replace Replace Spark plug electrodes overheat or burn 1 Spark plugs too hot 2 The engine overheats 3 Spark plugs loose 4 Mixture too lean Replace by cold type plug Tune up Retighten Inspect El system Magneto charge but charging rate is below the specification Lead wires tend to get shorted or open circuited or loosely connected at terminals Grounded or open circuited stator coils of magneto Defective regulator rectifier Defective cell pla
39. ch position 2 Measure the injector voltage between YR NO 1 RB NO 2 wire and ground Battery voltage Injector voltage INO 1 YR Ground NO 2 RB O Ground Tester knob indication Voltage NOTE Injector voltage can be detected only 3 seconds after ignition switch is turned ON position Is the voltage OK YR NO 1 or RB NO 2 wire open or shorted to ground or poor 1 or D NO 2 connection of ECU coupler YES f wire and connection are OK intermittent trouble or faulty ECU 6 Recheck each terminal and wire harness for open circuit and poor connection Inspect the fuel pump or fuel pump ECU Coupler SM Ac O uL O m lt gt E Ob gt relay Refer to 4 2 4 55 4 1 41 El SYSTEM DIAGNOSIS C37 SAV SOLENOID MALFUNCTION lt 7 250 ZI CODE 250 CODE C37 3 7 3 7 1 DETECTED CONDITION POSSIBLE CAUSE No voltage is applied from ECU to SAV solenoidby SAV solenoid circuit open or short 400 sec SAV solenoid malfunction ECU malfunction m INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the SAV solenoid coupler for loose or poor c
40. considered the engine speed intake air pressure intake air volume engine temperature oxygen volume and throttle opening angle etc El 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 ET sensor Engine Temperature Sensor ETS ET sensor communicate the perceived engine temperature to ECU ET sensor is located the outside of the cylinder to measure the engine temperature 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 sensor Intake Air Temperature IAPS IAP 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 ISC solenoid Idle Speed Control Solenoid ISC solenoid is interlocked with the throttle body so ECU control the engine idle speed O2 sensor Oxygen Sensor 25 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 fro
41. e 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 Vv250 5 fuel pump relay is located on the left side of the frame and amp z7 25e ze amp z s fuel pump relay is located in the rear side of the side cover Remove the frame cover GV250 Ei Remove the side cover lt 27 25 lt er Remove the fuel pump relay 3 65 FUEL SYSTEM AND THROTTLE BODY 4 2 4 4 2 5 FUEL SYSTEM AND THROTTLE BODY First check the insulation between and terminals with pocket tester Then apply 12 volts to and terminals to and O to and check the continuity between 1 2 If there is no continuity replace it with a new one FUEL MESH FILTER INSPECTION AND CLEANING 6 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 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 Approx 95 105 Q 1 2 Approx 38 Q E Approx 4 10 Q If the r
42. e order of removal TP SENSOR INSPECTION The throttle position TP sensor 2 is installed at the throttle body Refer to page 4 1 25 TP SENSOR REMOVAL AND INSTALLATION AN CAUTION Never remove or adjust the TP sensor EI SYSTEM DIAGNOSIS 4 1 44 59 4 1 45 El SYSTEM DIAGNOSIS ET SENSOR INSPECTION The engine temperature ET sensor 1 is installed at the front cylinder Refer to page 4 1 28 ET SENSOR REMOVAL AND INSTALLATION Remove the ET sensor Install the ET sensor in the reverse order of removal V ET sensor 5 8 N m 0 5 0 8 kgf m IAT SENSOR INSPECTION The intake air temperature IAT sensor 2 is installed at the downside of the air cleaner case Refer to page 4 1 32 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 is located in the downside of the front seat lock Refer to page 4 1 35 Romove the front seat Remove the RO switch from the frame Install the RO switch in the reverse order of removal 60 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM 0 1 62 4 2 1 REMOVAL AND DISASSEMBLY 63
43. eaning 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 shaft bushing and seal Injector cushion seal Fuel injector Throttle body Intake pipe Throttle valve Vacuum hose 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 69 4 2 9 FUEL SYSTEM AND THROTTLE BODY INSTALLATION Installation is in the reverse order of removal Pay attention to the following points AN CAUTION Never operate the idle nuts D NO 1 and NO 2 to avoid variations of the carburetion setting Connect the throttle cable to the throttle cable drum 6 Adjust the throttle cable play with the cable adjuster 70 ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS IGNITION SYSTEM CHARGING SYSTEM 71 5 1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENT S wes a dzee WANGEN QA D Ignition NO 1 3 Main relay
44. efective ECU 9 Defective fuel pump 10 Imbalanced throttle valve or SAV solenoid 11 Damaged or cracked vacuum hose Symptom and possible causes SERVICING INFORMATION 7 2 1 Adjust Replace or repair Replace Replace Adjust or replace Replace Replace Replace Replace Adjust Replace Engine stalls often Incorrect fuel air mixture 1 Defective IAP sensor or circuit 2 Clogged fuel filter 3 Defective fuel pump 4 Defective fuel pressure regulator 5 Defective ET sensor 6 Defective IAT sensor 7 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 Control circuit or sensor improperly operating 1 Defective ECU 2 Defective fuel pressure regulator 3 Defective IAT sensor 4 Defective pick up coil 5 Defective ET sensor 6 Defective fuel pump relay Engine internal parts improperly operating 1 Fouled spark plugs 2 Defective pick up coil or ECU 3 Clogged fuel hose 4 Tappet clearance out of adjustment 83 Repair or replace Clean or replace Replace Replace Replace Replace Replace Replace Repair or replace Repair or replace Replace or recharge Replace Replace Replace Replace Replace Replace Clean Replace Clea
45. en sensor 25 The oxygen sensor signal is inputted in ECU since then 600 sec after the engine run When this is the case ECU not receive the signal C22 is indicated Oxygen sensor lead wire coupler connection Roll over switch RO switch The switch resistance should be the following for more than 3 sec after holding the motorcycle vertically and ignition switch turns ON position switch resistance oo Q Infinity Without the above value for 3 sec and more C23 is indicated Roll over switch lead wire coupler connection MALFUNCTION CODE C24 C25 SERVICING INFORMATION 7 1 2 DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR Ignition coil IG coil NO 1 NO 2 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 Idle speed control solenoid ISC solenoid The idle speed control solenoid step should be the following O step lt solenoid step lt 250 step Without the above range C27 is indicated Idle speed control solenoid lead wire coupler connection Gear position switch GP switch It judges from gear position voltage engine speed and throttle position by ECU when 0 15 V lt Gear position voltage lt 3 93 V for more 2 sec If gear position voltage g
46. er mode coupler Refer to page 4 1 20 The memorized malfunction code is displayed with blinks signal of the FI check lamp 4 Malfunction means that the ECU does not receive signal from the devices These affected devices are displayed blinks signal of the FI check lamp Mode select switch 09900 27000 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 lt Confirm the malfunction code after turn the ignition switch ON position or cranking the engine for few seconds MALFUNCTION FI CHECK LAMP INDICATION NO FI check lamp goes off YES Malfunction code is displayed from small numeral blinks signal to large one 30 C C12 C14 C15 C17 C18 C21 C22 C23 C24 C25 27 C31 C32 C33 C37 C41 C43 KIN CODE El CODE EI SYSTEM DIAGNOSIS 4 1 16
47. esistance KQ Is the resistance OK Br or GR wire open or shorted to ground or poor connection of ECU coupler 6 If wire and connection are OK NES intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection NO Replace the ET sensor with a new one 44 T X INO 3 2 e 29 TE Ob gt ECU Coupler El SYSTEM DIAGNOSIS 4 1 30 17 or C18 IAP SENSOR CIRCUIT MALFUNCTION GT250 R_ CODE GV250 CODE 17 1 7 1 7 C18 DUR 1 8 1 8 DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is out of the specified range for 6 Clogged vacuum passage between throttle bodies sec and more and IAP sensors 0 5 V lt Sensor voltage lt 4 5 V Air being drawn from vacuum passage between NOTE throttle bodies and IAP sensors Note that atmospheric pressure varies depending on IAP sensor circuit open or shorted to ground weather conditions as well as altitude IAP sensor malfunction Take that into consideration when inspecting voltage ECU malfunction m 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 cou
48. esistance measured is out of the specification replace the gauge with a new one Inspect the fuel level meter 66 FUEL SYSTEM AND THROTTLE BODY 4 2 6 THROTTLE BODY 67 4 2 7 FUEL SYSTEM AND 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 Disconnect the throttle cables from their drum 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 68 FUEL SYSTEM AND THROTTLE BODY 4 2 8 CLEANING Clean all passageways with a spray type throttle body cleaner and blow dry with compressed air A 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 a spray cleaner it may be necessary to use a dip type cl
49. et 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 Secondary air valve solenoid SAV solenoid No voltage is applied from ECU to secondary air valve solenoid by 400 sec In this case the code 37 is indicated Secondary air valve solenoid lead wire coupler connection Fuel pump relay Voltage is applied continuous for more than 5 sec battery voltage gt 3 2 V when fuel pump relay is OFF position or battery voltage lt 1 5 V when 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 Oxygen sensor heater gt 5 heater The oxygen sensor heater signal is not inputted in ECU Oxygen sensor heater lead wire coupler connection 81 7 1 3 SERVICING INFORMATION ENGINE Complaint Engine will not Compression too low start or is hard to 1 Tappet clearance out of adjustment 3 Mistimed valves 4 Excessively worn piston rings 5 Worn down cylinder bore 6 Starter motor cranks too slowly 7 Poor seating of spark
50. h terminal and wire harness for open circuit and poor connection Loose or poor contacts on the pick up coil coupler or ECU coupler Replace the pick up coil with a new one c u om lt 2 3 safe gt go D gt ECU Coupler 39 4 1 25 El SYSTEM DIAGNOSIS 14 TP SENSOR CIRCUIT MALFUNCTION lt 7250 2 lt CODE GV 250 5 CODE C14 1 4 1 4 1 DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 2 sec TP sensor circuit open or short and more 0 1 V lt Sensor voltage 4 8 V TP sensor malfunction ECU malfunction m INSPECTION Step 1 1 Turn the ignition switch OFF position 2 Check the TP sensor coupler for loose or poor contacts If OK then 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 45 55V TE OB Ground BOB OGR 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 O
51. he 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 terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnormal condition is found repair or replace 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 Coupler 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 FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse 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 installa
52. hes rev OVER REV LIMITER SIGNAL S limit rpm 22 El SYSTEM DIAGNOSIS 4 1 8 El SYSTEM PARTS LOCATION 27250 Ei A 25 U3 SS 9 GA AN d op e 4 7 CD Speedometer 5 GP switch Ignition coil NO 1 Fuel injector NO 1 3 Ignition coil NO 2 Fuel injector NO 2 Pick up coil TP sensor 23 4 1 9 El SYSTEM DIAGNOSIS ISC solenoid IAP sensor NO 1 IAT sensor ET sensor 1 RO switch Oxygen sensor Fuel pump relay SAV solenoid 43 IAP sensor NO 2 24 El SYSTEM DIAGNOSIS 4 1 10 El SYSTEM PARTS LOCATION 7 250 R Ei A 4 v 22 7 EN lt S D III aw CD Speedometer Fuel injector NO 1 Fuel injector NO 2 IAT sensor 5 GP switch Pick up coil Ignition coil NO 1 Ignition coil NO 2 9 TP sensor 4 1 11 El SYSTEM DIAGNOSIS ISC solenoid IAP sensor NO 1 Fuel pump relay 5 ET sensor 2 RO switch Oxygen sensor IAP sensor NO 2 7 SAV solenoid 26 El SYSTEM DIAGNOSIS 4 1 12 SELF DIAGNOSIS FUNCTION lt 772507 ee The self diagnosis function is incorporated in the ECU The function has two modes USER and DEALER MODE The user can only be notified by the LCD DISPLAY panel D and the FI check lamp
53. ils Refer to page 5 5 Zeche CODE GV250 Eis CODE 24 2 4 2 4 2 C25 HL HL 2 5 2 5 2 51 4 1 37 El SYSTEM DIAGNOSIS G27 ISC SOLENOID RANGE ABNORMAL GT250 Z2 Es CODE G V250 Ei CODE DETECTED CONDITION POSSIBLE CAUSE ISC solenoid s step is out of the specified range 5 solenoid malfunction O step lt Solenoid step lt 250 step 5 solenoid s step is out of the specified range ECU malfunction INSPECTION EV250 Er 1 Remove the front seat i 2 Turn the ignition switch OFF position 3 Check the ISC solenoid coupler for loose or poor contacts 4 Turn the ignition switch ON position to check the ISC solenoid operation G7250 R E When Ignition switch ON Is OK LY BBr or YL wire loose or poor contacts on the ISC solenoid coupler or poor K 2 3 or K2 Er lt 0m K connection of ECU coupler YES If wire and connection are OK intermittent trouble or faulty ECU 6 Recheck each terminal and wire harness for open circuit and poor connection NO Replace the ISC solenoid with a ECU Coupler new one 3 2 x gt OOD gt 52 El SYSTEM DIAGNOSIS 4 1 38 C31
54. ime 21 4 1 7 El 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 ENGINE TEMPERATURE When engine temperature is low injection time volume is SENSOR SIGNAL 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 enai gine During acceleration the fuel injection time volume is increased ACCELERATION SIGNAL in accordance with the throttle opening speed 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 reac
55. ings 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 Clogged air cleaner element 10 Sucking air from throttle valve or vacuum hose 11 Too much engine oil 12 Defective fuel pump or ECU 13 Defective pick up coil and ignition coils Defective control circuit or sensor 1 Low fuel pressure 2 Defective IAT sensor 3 Defective pick up coil 4 Defective IAP sensor 5 Defective ECU 6 Defective SAV solenoid 7 Defective GP switch 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 oil cooler 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 ET sensor The other factors 1 Ignition timing too advanced due to defective timing advance system ET sensor pick up coil GP switch and ECU 2 Drive chain is too tight 86 Adjust Replace Adjust Replace Repair Clean or replace Adjust or replace Clean Clean Retighten or replace Drain out excess oil Replace Replace Repair or replace Replace Replace Replace Replace Replace
56. m 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 Refer to page 4 1 13 15 16 amp 17 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 rear seat lt 77 250 ze Er Remove the front seat 250 7 Connect the special tool to the dealer mode coupler at the wiring harness and the ignition Switch is set to ON position 6 Turn the special tool s switch 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 rear seat GT250 R Ei The dealer mode coupler is located under the front seat BV250 Ei 35 EI SYSTEM DIAGNOSIS 4 1 20 Ce 7 250 R Ee SS D WE a N 2250 A 4 1 21 El SYSTEM DIAGNOSIS SELF DIAGNOSIS RESET PROCEDURE After repairing the trouble turn the ignition switch OFF position and turn ON position
57. n Adjust 7 2 2 SERVICING INFORMATION Complaint Noisy engine Symptom and possible causes Excessive valve chatter 1 Too large tappet clearance 2 Weakened or broken valve springs 3 Worn tappet or cam surface 4 Worn and burnt camshaft journal Noise seems to come from piston 1 Worn down pistons or cylinders 2 Combustion chambers fouled with carbon 3 Worn piston pins or piston pin bore 4 Worn piston rings or ring grooves Noise seems to come from cam chain 1 Stretched chain 2 Worn sprockets 3 Tension adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of clutch plates 3 Distorted clutch plates driven and drive 4 Worn clutch release bearing 5 Weakened clutch dampers Adjust Replace Replace Replace Replace Clean Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace the primary driven gear Noise seems to come from crankshaft 1 Rattling bearings due to wear 2 Worn and burnt big end bearings 3 Worn and burnt journal bearings Noise seems to come from transmission 1 Worn or rubbing gears 2 Worn splines 3 Worn bearings 4 Worn or rubbing primary gears 84 Replace Replace Replace Replace Replace Replace Replace Complaint Engine runs poorly in
58. n turn the ignition switch ON position 5 Measure the voltage between OB wire terminal and B or ground wire terminal Battery voltage 80B OB heater voltage OB Ground Tester knob indication Voltage Oxygen sensor Sensor side Heater side GR Is the voltage OK OB or B wire open or shorted to ground or poor amp or df connection of ECU coupler If wire and connection are OK lt 2 e 3 amp intermittent trouble or faulty ECU 6 Recheck each terminal and wire lx Gr GS K u S harness for open circuit and poor connection NO Replace the Oxygen sensor with a ECU Coupler new one 58 SENSORS PICK UP COIL INSPECTION The pick up coil 1 is installed in the magneto cover Refer to page 4 1 24 PICK UP COIL REMOVAL AND INSTALLATION Remove the magneto cover 6 Install the magneto cover in the reverse order of removal IAP SENSOR INSPECTION The intake air pressure IAP sensor NO 1 and NO 2 are installed at each intake pipe Refer to page 4 1 30 IAP SENSOR REMOVAL AND INSTALLATION Remove the fuel tank Remove the IAP sensor NO 1 amp NO 2 from each intake pipe e Install the IAP sensor NO 1 NO 2 in the revers
59. ning at 5 000 rpm Using the pocket tester measure the AC voltage between the three lead wires If the voltage is under the specified value replace the magneto with a new one Magneto no load Standard I EECH More than 60 V at 5 000 rpm Tester knob indication Voltage m REGULATOR RECTIFIER Disconnect the regulator rectifier couplers Measure the voltage between the terminals using the pocket 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 amp prob i D O 0 0 0 04 07 0 0 0 04 07 0 0 o 04 07 A 0 4 0 7 0 4 0 7 0 4 0 7 0 5 1 2 0 0 0 0 Tester knob indication Diode test 77 ELECTRICAL SYSTEM 5 9 78 SERVICING INFORMATION CONTENTS 80 7 1 1 SPECIAL TOOLS 89 7 8 TIGHTENING TORQUE eR emm 90 7 11 SERVICE DATA 91 7 19 1 WIRING DIAGRAM 2250 Ei iru E AR anga ERE READ Wa Lau 94 7 31 1 WIRING DIAGRAM sozemp Mm 96 7 32 1 WIRING DIAGRAM vm dig naa 98 7 32 3 79 7 1 1 SERVICING INFORMATION
60. nnection YES If check result is not satisfactory ne replace IAP sensor with a new one 32 WU T Do du gt ECU Coupler R Output voltage Input voltage 5 V ambient temp 25 C 77 F ALTITUDE ATMOSPHERIC OUTPUT Reference PRESSURE VOLTAGE ft m mmHg kPa V 0 0 760 100 Approx 2000 610 707 94 as 2 001 611 707 94 Approx 3 37 5 000 1524 634 85 5 001 1 525 634 85 8 000 2 438 567 76 8 001 2 439 567 76 Approx 27 3 10 000 3 048 526 70 gt 46 El SYSTEM DIAGNOSIS 4 1 32 C21 IAT SENSOR CIRCUIT MALFUNCTION GT250 R 7 CODE GV2530 Eis CODE 21 DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 6 sec IAT sensor circuit open or short and more IAT sensor malfunction lt lt 0 08 V Sensor voltage lt 4 75 V e ECU malfunction m 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 1 2 0 081 48 352
61. not inputted ECU since then Oxygen sensor Oxygen sensor heater circuit open 600 sec after the engine run or short Oxygen sensor Oxygen sensor heater malfunction e ECU malfunction m INSPECTION 1 Remove the front seat and frame cover 2 Turn the ignition switch OFF position 3 Check the Oxygen sensor coupler 1 for loose or poor contacts Sensor side Heater side E ies Is OK BR or GR wire open or shorted to ground or poor 3 or connection of ECU coupler YES 6 If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor 2 connection Z X c I Ou u O Om lt 3 2 2 gt uo gt NO Replace the Oxygen sensor ECU Coupler C4 49 4 1 35 El SYSTEM DIAGNOSIS 23 RO SWITCH CIRCUIT MALFUNCTION GV250 Ee CODE GT250 R Ei CODE DETECTED CONDITION The switch resistance should be the following for more than 3 sec after holding the motorcycle vertically and ignition switch turns ON position Switch resistance lt oo Q Infinity POSSIBLE CAUSE RO switch circuit short or leaned more than 60 RO switch malfunction ECU malfunction m INSPECTION 1
62. nt and rear cylinder s engine speed and realtime of piston position RO switch Roll Over Switch RO switch is the fuel cut 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 11 1 8 2 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND MASS Overall length GV250 Ei 2 280 mm 89 8 in 2 095 mm 82 5 in Overall width 885 mm 34 8 in 720 mm 28 4 in 780 mm 30 7 in Overall height 1 095 mm 43 1 in 1 135 mm 44 7 in 1 125 mm 44 3 in Wheelbase 1 520 mm 59 8 in 1 430 mm 56 3 in Ground clearance 150 mm 5 9 in 155 mm 6 1 in 175 mm 6 9 in Mass 175 kg 386 Ibs 185 kg 408 Ibs 175 kg 386 Ibs ENGINE Type GV250 Ei Four stroke DOHC air cooled and oil cooled Number of cylinder V 2 cylinder Bore 57 0 mm 2 24 in Stroke 48 8 mm 1 92 in Piston displacement 249 cm 15 2 in Fuel system Electric fuel Injection Starter system Electric starter Lu
63. oltage 0 5 V lt sensor voltage lt 4 5 V Without the above range for 6 sec and more C17 or C18 is indicated Intake air pressure sensor lead wire coupler connection C21 Intake air temperature sensor IATS The sensor voltage should be the following 0 08 V lt sensor voltage lt 4 75 V Without the above range for 6 sec and more C21 is indicated Intake air temperature sensor lead wire coupler connection C22 Oxygen sensor 25 The oxygen sensor signal is inputted in ECU since then 600 sec after the engine run When this is the case ECU not receive the signal C22 is indicated Oxygen sensor lead wire coupler connection C23 Roll over switch RO switch The switch resistance should be the following for more than 3 sec after holding the motorcycle vertically and ignition switch turns ON position switch resistance lt oo Q Infinity Without the above value for 3 sec and more C23 is indicated Roll over switch lead wire coupler connection 37 4 1 23 El SYSTEM DIAGNOSIS MALFUNCTION CODE C24 C25 DETECTED ITEM Ignition coil IG coil NO 1 NO 2 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 batter
64. ontacts 4 Connect the SAV solenoid coupler 5 Turn the ignition switch ON position 6 Measure the voltage at the wire side coupler between BL wire and ground 2 Battery voltage SAV solenoid voltage 698 Ground Tester knob indication Voltage Is the voltage OK 6 BL wire open or shorted to ground or poor 3 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 Z T X I Ou u O Om lt YES A e 279 D gt Replace the SAV solenoid with a new NO one ECU Coupler 56 El SYSTEM DIAGNOSIS 4 1 42 C41 FUEL PUMP RELAY CIRCUIT MALFUNCTION GI250 7 Ef CODE GV2530 Es CODE C41 4 1 4 1 4 1 DETECTED CONDITION POSSIBLE CAUSE Voltage is applied continuous for more than 5 sec 6 Fuel pump relay circuit open or short battery voltage 2 3 2 V when fuel pump relay is Fuel pump relay malfunction SAS lt OFF position or baten voltage lt 1 5 V when fuel ECU malfunction pump relay is ON position m INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the fuel pump relay coupler
65. p assembly by removing its mounting bolts diagonally A WARNING Gasoline is highly flammable and explosive Keep heat spark and flame away Remove the fuel gauge 2 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 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 64 FUEL PRESSURE INSPECTION Remove the front seat Place a 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 ON position and check the fuel pressure Fuel pressure Approx 3 4 3 7 kgf cm KIT 333 363 kPa 48 4 52 6 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 AN WARNING Before removing the special tool turn th
66. pe License plate lamp 12V W5W x 1 Illumination lamp 12V 1 7W x2 LED type High beam indicator lamp 12V 1 7W x 1 LED type Turn signal indicator lamp right amp left 12V 1 7W x 2 LED type Neutral indicator lamp 12V 17W x 1 LED type a Fuel meter lamp 12V 17W x 1 LED type Level type Fl Fuel Injection check lamp LED type LED Light Emitting Diode 9 CAPACITIES Fuel tank 14 0 Q 17 0 Q Oil change 1 450 ml Engine oil Oil and filter change 1 500 ml Engine overhaul 1 800 ml Front fork oil capacity One side 260 cc 400 2 5 cc NOTE The specifications are subject to change without notice 13 14 El SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING 2 224 16 4 1 1 EI SYSTEM TECHNICAL FEATURES 20 4 1 5 SELF DIAGNOSIS FUNCTION exr2se ze 27 4 1 12 SELF DIAGNOSIS FUNCTION EV250 amp z e 29 4 1 14 EI SYSTEM TROUBLESHOOTING 33 4 1 18 CUSTOMER COMPLAINT ANALYSIS 33 4 1 18 SELF DIAGNOSTIC PROCEDURES 35 4 1 20 SELF DIAGNOSIS RESET PROCEDURE MM 36 4 1 21 MALFUNCTION CODE AND DEFECTIVE CONDITION 37 4 1 22 C12 PICK UP COIL CIRCUIT MALFUNCTION 39 4 1 24 14 TP SENSOR CIRCUIT MALFUNCTION
67. pler 2 for loose or poor contacts If OK then measure the IAP sensor input voltage 4 Disconnect the IAP sensor couplers NO 1 and NO 2 5 Turn the ignition switch ON position 6 Measure the voltage at the OB wire and ground If OK then measure the voltage at the OB wire and GR wire 45 5 5V IAP postica input OB O Ground voltage GOB OGR Tester knob indication Voltage Is the input voltage OK YES Go to Step 2 6 Loose or poor contacts on the ECU coupler 6 Open or short circuit in the OB wire or GR wire NO 45 4 1 31 El SYSTEM DIAGNOSIS Step 2 1 Connect the IAP sensor couplers NO 1 NO 2 2 Insert the needle pointed probes to the lead wire coupler 3 Start the engine at idle speed 4 Measure the IAP sensor output voltage at the wire side coupler between BL NO 1 or BY NO 2 and GR wires Approx 3 7 3 9 V when ignition switch ON 11 BL G GR NO 2 BY GR IAP sensor output voltage Tester knob indication Voltage Is the output voltage OK OB NO 1 OB NO 2 BL NO 1 BY NO 2 or GR wire open or shorted to ground or poor NO 1 2 2 D NO 1 2 NO 2 8 connection of ECU coupler If wire and connection are intermittent trouble or faulty ECU 6 Recheck each terminal and wire harness for open circuit and poor co
68. 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 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 Defective fuel pump 2 Defective fuel pressure regulator 3 Defective pick up coil 4 Defective IAP sensor 5 Defective ECU 6 Defective ET sensor 7 Defective IAT sensor 82 Symptom and possible causes start 2 Worn valve guides or poor seating of valves No fuel reaching the intake manifold 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 Replace Replace Replace Replace Replace Replace 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 D
69. racer 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 eene 6 1 6 1 EXTERIOR ILLUSTRATION BV250 Ei 8 8 1 6 3 EXTERIOR ILLUSTRATION zv zsez 7 nen 9 1 7 1 EXTERIOR ILLUSTRATION zz zsoergg A 10 1 7 2 FUNCTION OF El SENSOR seems 11 1 8 1 SPEGIFIGATIONS een este 12 1 8 2 1 6 1 GENERAL INFORMATION EXTERIOR PHOTOGRAPH GENERAL INFORMATION 1 6 2 EXTERIOR PHOTOGRAPH RDO KE
70. relay fuel injector C43 Oxygen sensor heater gt 5 heater The oxygen sensor heater signal is not inputted in ECU Oxygen sensor heater lead wire coupler connection 38 El SYSTEM DIAGNOSIS 4 1 24 12 PICK UP COIL CIRCUIT MALFUNCTION c12 LA LIII 1 2 DETECTED CONDITION POSSIBLE CAUSE The pick up coil signal does not reach ECU for more Metal particles or foreign materiel being attached than 3 sec after ECU receiving the ignition switch on the pick up coil and rotor tip signal Pick up coil circuit open or short Pick up coil malfunction ECU malfunction INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the pick up coil coupler 7 for loose or poor contacts If OK then measure the pick up coil resistance 4 Disconnect the pick up coil coupler and measure the resistance Approx 85 105 Q Pick up coil resistance G L Tester knob indication Resistance Q 5 If OK then check the continuity between each terminal and ground Em oo Infinity Pick up coil continuity G Ground L Ground Tester knob indication Resistance Q Are the resistance and continuity OK L or G wire open or shorted to ground or poor 2 or 03 connection of ECU coupler YES If wire and connection are OK intermittent trouble or faulty ECU Recheck eac
71. tes in the battery Repair or retighten Replace Replace Replace the battery Magneto overcharges Internal short circuit in the battery Resistor element in the regulator rectifier damaged or defective Regulator rectifier poorly grounded Replace the battery Replace Clean and tighten ground connection Magneto does not charge Open or 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 regulator 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 88 Recharge or replace Replace Repair or replace Replace Replace SERVICING INFORMATION 7 8 SPECIAL TOOLS Special tools Part Number Part Name Description qu 09900 27000 N Mode select switch Inspect El system sensor 9 09915 54510 N Fuel pump pressure gauge Measure fuel pressure of fuel pump 89 7 11 SERVICING INFORMATION TIGHTENING
72. tion 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 Coupler 2 Probe Where male terminal fits s 4 1 3 El 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 11 V 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 ECU or sensors may result Be sure to use a 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 m USING THE T
73. y C27 Idle speed control solenoid ISC solenoid The idle speed control solenoid step should be the following O step lt solenoid step lt 250 step Without the above range C27 is indicated Idle speed control solenoid lead wire coupler connection C31 Gear position switch GP switch It judges from gear position voltage engine speed and throttle position by ECU when 0 15 V lt Gear position voltage lt 3 93 V for more 2 sec If gear position 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 C37 Secondary air valve solenoid SAV solenoid No voltage is applied from ECU to secondary air valve solenoid by 400 sec In this case the code 37 is indicated Secondary air valve solenoid lead wire coupler connection C41 Fuel pump relay Voltage is applied continuous for more than 5 sec battery voltage gt 3 2 V when fuel pump relay is OFF position or battery voltage lt 1 5 V when 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

1 - Hyosung

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