SERVICE MANUAL
Contents
1. SPEEDPMETER parar cabs HANDLE SWITCH R 9009 KEE eh Beet ONTON SW EE CLUTCH LEVER S W RR IGNITION COL FAN MOTOR THERMO SIW ENGINE STOP HAZARD STARTER Ft BRAKE HER EE EARTH sep OFF OFF i RID ON JOO Ge i RUN 615 on oto pusHlofo on 515 LOCK ei o on O0 i TT fP i OFF i os i ON SE 5 E i 8 i 58 3 aa lol i M il 38 HI gt 5 gt E ES EF as gt nee a JL oBasE d plo d W ogas ol Lg Ly EM EM FR TURN R Y Jew W HRAD LAMP w Yw g BW BW POSITION LAMP B B Garaje ER TURN L 25858 gt 8235 gt 238208 SEER See lt 7 d b H gt L88 gt 82335 gt mg oo B2. TURN SIGNAL FAN MOTOR SIDE STAND HEAD LAMP FUEL PUMP RR STOP SWITCH AENOR es en pagi Ba MANRELAY RELAY FUEL PUMP FUEL GAUGE ECU OFF 5 5 hE 5 L fed BAd Peal Ra 22187 Le g o 1 _ Ti Li i Li Li TL 2 34 S STT 121314 1S 1718 1920 2122 23 24 28 28 29 33 36 39 40 41 4244 2748 49 50 51 53 58 59 60 Lo A KEE ERI Saad Saas a sorg 8 Lo AR AR EE OA g 83 8 gt 0707 dS 55245880 SERRA Bom BD 23 TE gt ze Bo os gt ET n os LT es EE u ek NG EF 5 sa i daj ae r U y W gt gt 7 8 EE me T 2 g ao EE SS a Laa LA LI LI S B2 85583 og OO ho sep ok E ETA gt GH i i gt YO U Ls A of STARTER MOTOR STARTER RELAY BATTERY MF EARTH DIODE 1 EN DES LICENSE LAMP TAL 8 STOP RR TURN L RR TURN R SIDE STAND SW REC amp REG Sa ATA MAGNETO 83 8 30 5 SERVICING INFORMATION WIRING DIAGRAM Casa FI amp
3. 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 I LCD No code Malfunction code PROBLEM SYMPTOMS 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 cold warm always Abnormal knocking Other Engine rom jumps briefly Other Poor ldling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened 0 High Low rpm Throttle valve is closed Unstable Load is applied Hunting rpm to rpm Other Other OTHERS 25 4 1 15 FI SYSTEM DIAGNOSIS Weather Fair Temperature Hot Frequency Always Road Urban Engine condition Cold MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Cloudy Rain Warm Cool Sometimes Under certain condition
4. 25 4 1 14 SELF DIAGNOSTIC PROCEDURES nn 27 4 1 16 SELF DIAGNOSIS RESET PROCEDURE 27 4 1 16 MALFUNCTION CODE AND DEFECTIVE CONDITION 28 4 1 17 C12 PICK UP COIL CIRCUIT MALFUNCTION 30 4 1 19 C14 TP SENSOR CIRCUIT MALFUNCTION 31 4 1 20 C15 WT SENSOR CIRCUIT MALFUNCTION ennen 34 4 1 23 C17 or C18 IAP SENSOR CIRCUIT MALFUNCTION 36 4 1 25 C21 IAT SENSOR CIRCUIT MALFUNCTION 38 4 1 27 C22 OXYGEN SENSOR CIRCUIT MALFUNCTION 40 4 1 29 C23 TO SENSOR CIRCUIT MALFUNCTION nenne 41 4 1 30 C24 or C25 IGNITION COIL MALFUNCTION nenn 42 4 1 31 C31 GP SWITCH CIRCUIT MALFUNCTION ee sesse see 43 4 1 32 C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION 44 4 1 33 C41 FUEL PUMP RELAY CIRCUIT MALFUNCTION 46 4 1 35 SENSORS 1 47 4 1 36 11 4 1 1 FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the Fl system observe the following points for the safety of the system ELECTRICAL PARTS Im CONNECTOR COUPLER O When connecting a connector be sure to push it in until a click is felt O With a lock type coupler be sure to release the lock when disconnecting and push it in fully till the works when connecting it
5. 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 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 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 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 WT sensor 6 Defective thermostat 7 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 c
6. 1 E gt E 19 46 SENSORS PICK UP COIL INSPECTION The pick up coil is installed in the magneto cover PICK UP COIL REMOVAL AND INSTALLATION 6 Remove the magneto cover 6 Install the magneto cover in the reverse order of removal 9 IAP SENSOR INSPECTION The intake air pressure IAP sensor NO 1 2 and NO 2 is installed at the side of the air cleaner Refer to page 4 1 25 IAP SENSOR REMOVAL AND INSTALLATION Remove the fuel tank O Remove the IAP sensor from the downside of air cleaner O Install the IAP sensor in the reverse order of removal TP SENSOR INSPECTION The throttle position TP sensor is installed at the left side of the throttle body Refer to page 4 1 20 TP SENSOR REMOVAL AND INSTALLATION AN CAUTION Never remove the TP sensor WT SENSOR INSPECTION The water temperature WT sensor is installed at the rear side of the thermostat case Refer to page 4 1 23 WT SENSOR REMOVAL AND INSTALLATION O Remove the WT sensor O Install the WT sensor in the reverse order of removal WT sensor 18 N m 1 8 kgf m 47 FISYSTEM DIAGNOSIS 4 1 36 4 1 37 FISYSTEM DIAGNOSIS 9 IAT SENSOR INSPECTION The intake air temperature IAT sensor is installed at the downside of the air cleane
7. 0 4 14V TO sensor voltage at normal condition OB O GR Also measure the voltage when leaning of the motorcycle 5 Measure the voltage when it is leaned more than 65 left and right from the horizontal level 3 7 44V LES AYE IM at leaned more than 65 O OB GR Tester knob indication Voltage Is the voltage OK OB Bor GR wire open or shorted to ground or poor 4 or 69 connection O If wire and connection are OK 33 WA intermittent trouble or faulty ECU K 2 O Recheck each terminal and wire ops harness for open circuit and poor El i 3 ME J YES 2 S ple EIS o SG connection 26 20 O Loose or poor contacts on the 69 ECU coupler ECU Coupler Open or short circuit in the OB wire or GR wire Replace the TO sensor with a new one NO C24 or C25 IGNITION COIL MALFUNCTION t Refer to the IGNITION COIL for details Refer to the service manual 7 Alguaillaeso 99000 51210 page 6 5 Refer to the service manual Cazateso 99000 94810 page 6 5 42 FI SYSTEM DIAGNOSIS 4 1 32 C31 GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage 6 GP switch circuit open or short Switch voltage is out of the specified range O GP switch
8. GW or GR wire open or shorted to ground or poor or 69 connection O If wire and connection are OK YES intermittent trouble or faulty ECU O Recheck each terminal and wire harness for open circuit and poor connection Replace the IAT sensor with a new one NOTE IAT sensor resistance measurement method is the same way as that of the WT sensor e Refer to the service manual denten 99000 51210 page 5 7 Refer to the service manual ee 99000 94810 page 5 7 39 FI SYSTEM DIAGNOSIS 4 1 28 3 a ECU Coupler 4 1 29 Fl SYSTEM DIAGNOSIS C22 OXYGEN SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor signal is not input in ECU since then Oxygen sensor Oxygen sensor heater circuit open more than 180 sec after the engine run or short O Oxygen sensor Oxygen sensor heater malfunction 6 ECU malfunction Iw 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 d O B or GR wire open or shorted to 44 ground or poor or 69 connection a y Sensor SG e OB or B wire open or shorted to ls AAA x ground or poor or connention le o BA Heate
9. Tarmacadam Gravel Suburb Highway Warming up phase Immediately after start Motorcycle condition Racing without load Snow Always Other Cold F C Always times day month Only once Mountainous C Uphill Downhill Other Warmed up Always Other at starting Engine speed rpm Other Motorcycle condition During driving Right hand corner Motorcycle speed when problem occurs Left hand corner Constant speed Accelerating At stop km h Decelerating Mile h NOTE The above form is a standard sample If should be modified according to conditions characteristic of each market 26 FI SYSTEM DIAGNOSIS 4 1 16 SELF DIAGNOSTIC PROCEDURES Don t disconnect couplers from ECU battery cable from 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 12 13 carefully to have good unders
10. 1 a Si le Y t S SCR 7 gt D INSPECTION ul 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 0 2 lt 0 40 Pocket Tester 09900 25002 Tester knob indication Resistance Q AN CAUTION When mounting the stator on magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 63 6 10 ELECTRICAL SYSTEM m REGULATOR RECTIFIER O Disconnect the regulator rectifier couplers O Using the pocket tester measure the resistance between the terminals in the following table If the resistance checked is incorrect replace the regulator rectifier Unit MQ D Tester probe 2 Di D o E Pocket tester 09900 25002 Tester knob indication Resistance MO 64 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ee ee ee ee ee ees ee ee 66 8 1 1 SPECIAL TOOLS u uc sasana Su bees TIGHTENING TORQUE 76 8 12 SERVICE DATA sisir sapaa 05 Ee EE WIRING DIAGRAM Aquila SOFT ooo 80 8 30 1 WIRING DIAGRAM Comasior1 nn 82 8 30 3 WIRING DIAGRAM
11. YES O If wire and connection are OK LA intermittent trouble or faulty ECU E O Recheck each terminal and wire I T Es 7 s le harness for open circuit and poor 2 S 2 connection 36 O Inspect the fuel pump or fuel NO pump relay Refer to page 4 2 5 ECU Coupler 45 4 1 35 FISYSTEM DIAGNOSIS C41 FUEL PUMP RELAY CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION Voltage is applied continuous over 5 sec battery voltage 5 V when fuel pump relay is OFF position or battery voltage lt 5 V when fuel pump relay is ON position Fuel pump relay circuit open or short Fuel pump relay malfunction 6 ECU malfunction Iw INSPECTION Step 1 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 wire open or shorted to ground or poor 68 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Inspect the fuel injectors Refer to page 4 1 33 YES Replace the fuel pump relay with a NO new one O di
12. C24 C25 DETECTED ITEM Ignition coil IG coil NO 1 NO 2 FI SYSTEM DIAGNOSIS 4 1 18 DETECTED FAILURE CONDITION CHECK FOR Ignition signal is interrupted continuous by 32 times or more when ECU confirm ignition surge at each combustion chamber 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 when the gear position voltage is 0 1 V and less Gear position switch wiring coupler connection gearshift cam etc C32 C33 Fuel injector NO 1 NO 2 Injector signal is interrupted continuous by 16 times or more 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 over 5 sec battery voltage 5 V when fuel pump relay is OFF position or battery voltage lt SV when fuel pump relay is ON position Fuel pump relay connecting lead wire power source to fuel pump relay fuel injector 29 4 1 19 FI SYSTEM DIAGNOSIS C12 PICK UP COIL CIRCUIT MALFUNCTION DETECTED CONDITION The signal does not reach ECU for more than 2 sec after receiving the IAP signal POSSIBLE CAUSE 6 Metal particles or foreign materiel being attached on the pick
13. HORN Ve EARTH a RE oe Onan AE AAA up EARTH FRONT REAR AT SENSOR FRRMP RRMAP SA VALVE WT SENSOR Isc SOL DIODE 2 ZA Enq SENSOR TEE TO SENSOR ER HANDLE SWITCH L MER MER jp sensor ESOR e GEAR POSITION lt SENSOR FR IGNITION COIL 84 SERVICING INFORMATION 8 30 6 TURN SIGNAL FAN MOTOR TURN SIGNAL 02 sensor FANMOTOR SIDE STAND HEAD LAMP FUEL PUMP RR STOP SWITCH E RELAY RELAY RELAY RELAY MAIN RELAY RELAY FUEL PUMP FUEL GAUGE ECU
14. HYOSUNG Algona E50 FI COPEL EGO ST FZ FI SERVICE MANUAL 99000 51310 FOREWORD This manual contains an introductory description on HYOSUNG Alguailaes0Fl amp COAG S R Fly and procedures for its inspection service and overhaul of its main components lt covers the differences from Carbure type and please refer to the service manual of Aquallaezo 99000 51210 Comastes0s amp COPIES 99000 94910 and Carmaieso 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 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 lt 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 de 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 you should not attempt servicing by rely
15. SERVICE DATA FI SENSORS SPECIFICATION Pick up coil resistance 110 140 Q IAP sensor input voltage 45 5 5V IAP sensor output voltage Approx 2 7 V at idle speed TP sensor input voltage 45 5 5V Closed TP sensor resistance epos ON Opened Approx 4 37 KO Closed A 1 12 V TP sensor output voltage Se AE Opened Approx 4 26 V IAT sensor voltage 45 55V IAT sensor resistance Refer to page 39 4 1 28 10 it 0 4 1 4 V at normal condition pe eee 3 7 4 4 V at leaned more than 65 TO sensor resistance 19 1 19 7 KO GP switch resistance 1009 2 0KQ Oxygen sensor heater voltage Battery voltage THROTTLE BODY SPECIFICATION I D No HP948211 Bore size g39 Idle rpm 1 400 1 600 rpm Throttle cable play 0 5 1 0 mm 0 02 0 04 in FUEL INJECTOR FUEL PUMP SPECIFICATION Fuel injector resistance 11 0 13 00 at 20 C 68 F Fuel injector voltage Battery voltage Fuel pressure Approx 3 4 3 7 kgf cm 333 363 kPa 48 4 52 6 psi 77 8 19 SERVICING INFORMATION THERMOSTAT COOLING FAN COOLANT STANDARD Valve opening 88 C 190 Thermostat valve operating temperature Valve full open 100 C 212F Valve closing 83 181F Thermostat valve lift Over 8mm 0 32 in 100 C 212 F WT sensor voltage 4
16. 27 HANDLE SWITCH R TACHO TO Shi o EE EE FANMOTOR THERMO SW ENGINE STOP FL BRAKE FREE i sop OFF i RID 2 i RAN lolo oN oto i LOCK e on OF da on OO i TI OFF i g woe at ti 25 ad dd M d s8 os SS gt 35 gt gt ooparo zo Be LILIIIIIII o osa T EP TT eof Sok las LL TE oBaGE o g e Sy MEER N Ft TURN Rh B B pw Rr TURN Lh e Y L 5 BW BW w w HEAD LAMP BW BW er w Ft POSITION Ses Bagan Mid d d gt E TEECETE dt EEK a 1 d 2 so i 5 a A H or gt E BE 7e 285 EB 28 858 I 348 SES gg 088 508 Boga 253 5 Ll it lii 21 Lib AA Lii lii BETREE Ti d i 1 Jofo amp 6 1 H oro N i d U 6 E PUSH LO O PUSHTOTO R i LH i pd PASS DIMMER HORN TURN SIGNAL EARTH AN i UNT EARTH FRONT REAR AT SENSOR FRIAP RR IAP SA VALVE WT SENSOR Isc SOL DIODE 2 TO SENSOR SE HANDLE SWITCH L INJECTOR INJECTOR senso SENSOR SENSOR Kleed GEAR POSITION FR IGNITION COL 82 SENSOR SERVICING INFORMATION 8 30 4
17. Comeateso f SPEEDOMETER HANDLE SWITCH R TACHO CLUTCH LEVER S W RR IGNITION COIL FAN MOTOR THERMO S W i IGNITION SIN DIODE 3 EARTH A 2 FREE stop i RD OFF RN i LOCK alo d ON OFF I i N ER i i FT 55 25 i se Er MM d 8 os a 58 gt 5 Ww wh gt 3002308 3 oe d g 28 4 oT 088658 60588 A CE a o833 og FR TURN L HEAD LAMP POSITION LAMP FR TURN R gt FEBI080 d 5 52838 gt 583 35 gt F 32080 ill 11 CERN HEESE W I ve 1 Wakap T Foo ER i gt gt amg e erg 5 a SEE i EE ae 772 DIL 8 z BE 85S 25 Bas S55 Be agg o Bores e53 gt i i ERE EL E SI LI LL IS III LL ER i L Jo i LI i nl JOFO N i 6 i Pus Ot Lo O PUSH ORO R D LH bg i L Pass DIMMER HORN TURN SIGNAL
18. Cometexas FI amp COME EVER FI 84 8 30 5 65 8 1 1 SERVICING INFORMATION TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM NO FAULT DETECTED FAILURE CONDITION CHECK FOR Pick up coil The signal does not reach ECU for more than 2 sec after receiving the IAP signal 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 2 V lt sensor voltage lt 4 8 V Without the above range for 5 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 2 V lt sensor voltage lt 4 6 V Without the above range for 5 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 2 V lt sensor voltage lt 4 8 V Without the above range for 5 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 2 V lt sensor voltage lt 4 6 V Without the above range for 5 sec and more C21 is indicated Intake air temperature sensor lead wire coupler connecti
19. JE PEE 1 1 d OFF 37 8 8 H 9 y 3 H 26P 34P o de ON W Ci i TM 2 3 4 5 8 12 13 14 15 1718 19 20 212223 24 26 28 29 333 39 40 41 42 44 47 48 49 50 51 53 58 59 60 TITI ang Seef gao gt ooo o o gog cme ERR I ar aa E a MA 2 Sara Soene VAEBORBEEBEBBe BEMEHBrooGEBBEESE SS gt So ees fa A ES IL 2 FE 3 g sa ir gt gt STO H M la 1 gt gt gt lt a T SEE u PL 03 3 8 e Fl 98 4 U a U ee de E ne Um IB 16 a LT a de wW STARTER MOTOR STARTER RELAY BATTERY MF EARTH DIODE 1 FUSEBOX FUSEBOX ENSELAMP asrop RRIURNL RRTURNR SIDE STAND SW REC amp REG 15A Goa JUN see MAGNETO 85 MEMO MEMO Prepared by HYOSUNG S amp T Motors Co Ltd 1st Ed JUN 2008 Manual No 99000 51310 Printed in Korea S amp T Motors Co Ltd
20. O When disconnecting the coupler be sure to hold the coupler body and do not pull the lead wires O Inspect each terminal on the connector coupler for looseness or bending O Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact O Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnormal condition is found repair or replace O 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 12 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 O Check the male connector for bend and female connector for excessive opening Also check the coupler for locking looseness corrosion dust etc FUSE 6 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 O Sinc
21. 3 4 5 9 11 1213 14 15 17 18 19 20 21 22 23 24 26 2829 33 36 39 40 41 42 44 47 48 50 51 53 58 59 60 Kl Tit TEIT TIIT TINA r TI TITI Boas Sa a 8 1 IMAN Tl A AS aw oe es SEE 3 oro 3 rom 288830 BEaLi sooo SESESE SS EER ze Bo E a Eb A A 2532 d 4 Ta DERE A EE SH gi o SS as SS 235 52 a sa it oe des IG S DEER 7 E BE BEE aa CR e o lt 2 8 Sa za BEES as Lo oJ O LI LI WEI i id E 12V 12Ah LL E 9 9 JA on JO al 4 W ST BATTERY MF EARTH Dopp FUSEBOX FUSEBOX RRTURNL ES RR RURN R IARTER MOTOR STARTER RELAY BATTERY MF EARTH SA GR TAL amp STOP SIDE STAND SIW REC amp REG LICENSE LAMP MAGNETD 81 8 30 3 SERVICING INFORMATION WIRING DIAGRAM Caraezasorr SPEEDOMETER
22. by 16 times or more when ECU confirm injector running surge at each combustion chamber Injector circuit open or short Injector malfunction 6 ECU malfunction m INSPECTION lt gt Step 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 for loose or poor contacts If OK then measure the injector resistance 4 Disconnect the injector couplers NO 1 and NO 2 2 and measure the resistance between terminals 11 0 13 00 at 20 C 68 F 1 0 Injector resistance 5 If OK then check the continuity between injector terminals and ground Injector continuity E al Groun Tester knob indication Resistance O Are the resistance and continuity OK YES Go to Step 2 Replace the Injector with a new one NO 44 FISYSTEM DIAGNOSIS 4 1 34 Step 2 1 Turn the ignition switch ON position 2 Measure the injector voltage between YR NO 1 RB NO 2 wire and ground Battery voltage Injector voltage YRINO 1 Ground RBINO 2 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 O YR NO 1 RB NO 2 wire open or shorted to ground or poor NO 1 as NO 2 connection
23. charged batteries in the tester O Be sure to set the tester to the correct testing range Is USING THE TESTER 6 Incorrectly connecting the and probes may cause the inside of the tester to burnout O If the voltage and current are not known make measurements using the highest range O After using the tester turn the power off 15 FI SYSTEM DIAGNOSIS 4 1 4 4 1 5 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES 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 EE EGUS usan 7 Intake Air Pressure Sensor Intake air pressure signal am IAP Sensor I Basic Engine speed signal Pick up coil 9 p 9 gt Je injection time Throttle Position Sensor Throttle opening signal TP Sensor Various signals Various Sensors Compensation Ultimate Injection signal fuel ba Injectors a 4 dee injection I lt I I time 16 FI SYSTEM DIAGNOSIS 4 1 6 COMPENSATION OF INJECTION TIME VOLUME The following different signals are output fr
24. for open circuit and poor al sin ms Te a 9 a connection 09 Jo jo EL E GAL gt 2 20 Replace the WT sensor with a new one 59 ECU Coupler 35 4 1 25 Fl SYSTEM DIAGNOSIS C17 or C18 IAP SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION IAP sensor voltage is out of the specified range 0 2 V lt Sensor voltage lt 4 8 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage O Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground 6 JAP sensor malfunction 6 ECU malfunction ml 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 2 for loose or poor contacts If OK then measure the IAP sensor input voltage 4 Disconnect the IAP sensor coupler 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 B OB O Ground OB GR IAP sensor input voltage Tester knob indication Voltage Is the volta
25. fuel supply to injector 10 Defective fuel pump 11 Defective TP sensor 12 Defective SAV solenoid 13 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 TP sensor 3 Defective IAT sensor 4 Defective pick up coil 5 Defective IAP sensor 6 Defective ECU 7 TP sensor out of adjustment 8 Defective SAV solenoid 71 Replace Replace Adjust Adjust Replace ECU Replace Replace Replace Clean and prime Replace Replace Replace Clean Clean or replace Adjust or replace Repair or replace Replace Repair or replace Replace Replace Replace Replace Replace Adjust Replace 8 1 7 SERVICING INFORMATION 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 TP sensor out of adjustment 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 igni
26. notified by the LCD DISPLAY panel and the Fl check lamp Gy To check the function of the individual Fl 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 FI CHECK LAMP INDICATION MALFUNGTION INDICATION INDICATIONO MODE NO Speedometer VES Speedometer FI check lamp Each 2 sec and comes on Speedometer or FI FI letters is indicated Engine can start 1 Engine can not FI letters FI check lamp comes Fl is indicated start 2 on and blinks continuously 1 When one of the signals is not received by ECU the fail safe circuit works and injection is not stopped In this case FI and speedometer are indicated in the LCD panel and motorcycle can run 2 The injection signal is stopped when the crankshaft position sensor signal tip over sensor signal 1 2 ignition signals 1 2 injector signals fuel pump relay signal or ignition switch signal is not sent to ECU In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHE when no communication signal from the ECU is received for 3 seconds For example The ignition switch is turned ON position and the engine stop switch is turned OFF position In this case the speedometer does not receive any sign
27. sensor circuit open or short 0 2 V lt Sensor voltage lt 4 8 V O TP sensor malfunction O 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 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 Na E OB O Ground 9 O OB O GR Tester knob indication Voltage Is the voltage OK YES Go to Step 2 O Loose or poor contacts on the ECU coupler O Open or short circuit in the OB wire or GR wire NO 31 4 1 21 FI SYSTEM DIAGNOSIS lt gt 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 A and ground TP sensor continuity E Seen 5 If OK then measure the TP sensor resistance between A and 8 6 Turn the throttle grip and measure the resistance TP sensor resistance La LANA Kal Approx 1 28 KO AL KANA IH Approx 4 37 KO Tester knob indication Resistance KO Are the resistance and continuity OK YES Go to Step 3 6 Reset the TP sensor position correctly O Replace the TP sensor with a new one NO
28. up coil and rotor tip 6 Pick up coil circuit open or short O Pick up coil malfunction 6 ECU malfunction m INSPECTION lt gt Step 1 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 pick up coil coupler and measure the resistance 110 1409 G L Pick up coil resistance 5 If OK then check the continuity between each terminal and ground oo Q 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 ord connection 6 If wire and connection are OK intermittent trouble or faulty ECU O Recheck each terminal and wire harness for open circuit and poor connection YES O Loose or poor contacts on the pick up coil coupler or ECU coupler O Replace the pick up coil with a new one NO di 1 ME 51 74 A TA 39 aloi ole lu le d 48 falo ANENE 1s ECU Coupler 30 FI SYSTEM DIAGNOSIS 4 1 20 C14 TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range O TP
29. 00 2 438 567 76 SE 8 001 2 439 567 76 Approx 27 3 10 000 3 048 526 70 37 4 1 27 Fl SYSTEM DIAGNOSIS C21 IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range 6 IAT sensor circuit open or short 0 2 V lt Sensor voltage lt 4 6 V AT sensor malfunction O ECU malfunction s INSPECTION Step 1 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 voltage at the wire side coupler 4 Disconnect the coupler and turn the ignition switch ON position 5 Measure the voltage between GW wire terminal and ground 6 If OK then measure the voltage between GW wire terminal and GR wire terminal 45 55V MIE IRA IETS D GW O Ground GW O GR Tester knob indication Voltage Is the voltage OK YES Go to Step 2 Loose or poor contacts on the ECU coupler Open or short circuit in the GW wire or GR wire NO 38 Step 2 1 Turn the ignition switch OFF position 2 Measure the IAT sensor resistance IAT sensor resistance Intake Air Temp Resistance 0 C 32 F Approx 5 4 6 6 KQ 80 C 176 F Approx 0 29 0 39 KO Tester knob indication Resistance KO Is the resistance OK
30. 32 7 Ground FI SYSTEM DIAGNOSIS 4 1 22 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 GR by turning the throttle grip TP sensor output voltage Throttle valve is closed Approx 1 12 V Throttle valve is opened Approx 4 26 V Tester knob indication Voltage Is the voltage OK OB LY or GR wire open or P NG gt A shorted to ground or poor 3111 1 Ia s sl Ja or 69 connection AS BE MMI F O If wire and connection are OK Dal lm 44 0 p s 1 14 0 ES intermittent trouble or faulty ECU 60 y 1 ME 2 3 2 Recheck each terminal and wire harness for open circuit and poor connection ECU Coupler If check result is not satisfactory replace TP sensor with a new one E NO 33 4 1 23 FI SYSTEM DIAGNOSIS C15 WT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range O WT sensor circuit open or short 0 2 V lt Sensor voltage lt 4 6 V O WT sensor malfunction O ECU malfunction m INSPECTION lt gt Step 1 1 Turn the ignition switch OFF position 2 Check the WT sensor coup
31. 5 5 5 V 0 32 F Approx 5 790 KQ 20 C 68 F Approx 2 450 KQ WT sensor resistance To ECU 40C 104 F Approx 1 148 KQ 60 C 140F Approx 0 586 KQ 80 C 176 Approx 0 322 KQ Cooling fan thermo switch operating OFF ON Approx 95 C 203F temperature ON OFF Approx 88 C 190 F Use an antifreeze coolant compatible with Engine coolant type aluminum radiator mixed with distilled water only at the ratio of 50 50 Reserve tank side 300 ml Engine coolant capacity Radiator side Engine side 78 ELECTRICAL STANDARD SERVICING INFORMATION 8 20 Unit mm in Battery Standard electrolyte S G Ignition timing BTDC 5 1 500 rpm Type CR8E Gap 0 7 0 8 0 028 0 032 Spark plug Hot type CR7E Standard type CR8E Cold type CR9E Spark performance Over 8mm 0 32 Ignition coil primary peak voltage 150 V and more Ignition coil resistance Primary 9 Secondary 20 31KO Magneto coil resistance Es dep 1104 1700 Charging coil 0 2 0 40 Y Y Magneto no load voltage Over 70 V 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 79 8 30 1 SERVICING INFORMATION WIRING DIAGRAM 4guzeorr
32. 6 3 in 150 mm 5 9 in Mass 220 kg 485 Ibs 205 kg 451 Ibs ENGINE ITEM Algal ESO FI COIIBSEESO FI 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 om 39 5 in Fuel system Fuel Injection Starter system Electric starter Lubrication system Wet sump TRANSMISSION ITEM Alquila Eso Fl CONTE CSO FI Clutch Wet multi plate type Transmission 5 speed constant mesh 6 speed constant mesh Gearshift pattern 1 down 4 up 1 down 5 up Final reduction 2 79 2 93 Gear ratio 1st 2 46 2 46 2nd 1 78 1 60 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 GENERAL INFORMATION 1 8 2 CHASSIS ITEM Aguila 650 FII Gras ESO Front suspension Telescopic type Rear suspension Swingarm type Steering angle 35 right 8 left 30 right 8 left 35 25 5 Caster Trail 160 mm 6 3 in 85 mm 3 35 in Front brake Double disk brake Rear brake Disk brake 120 60 ZR 17 55W Front tire size 120 70 ZR 18 59W 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 in ELECTRICAL ITEM Alquila ESO FI COIIBSEESO FI Ignition type ECU Igniti
33. ICAL 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 5 6 Defective ECU Defective TO sensor Open circuited wiring connections Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plugs too cold Replace Replace Replace Replace Replace Check and repair Inspect Fl system Adjust fast idle or throttle stop screw Change Clean or replace Replace by hot type plug Spark plug become fouled too soon Spark plug electrodes overheat or burn Worn piston rings Pistons or cylinders worn Excessive clearance of valve stems in valve guides Worn stem oil seal Spark plugs too hot The engine overheats Spark plugs loose Mixture too lean Replace Replace Replace Replace Replace by cold type plug Tune up Retighten Adjust carburetor Magneto charge but charging rate is below the specification Magneto overcharges Magneto does not charge 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 plates in the battery Internal short circuit in the batt
34. N Aguaillaesort y SX ECU Ni AY V MS HA 7 YT A 5 lt NN LT O gt Speedometer Fuel injector NO 2 Fuel pump relay GP switch 3 Fuel injector NO 1 Pick up coil TP sensor Ignition coil NO 1 6 IAT sensor 18 FISYSTEM DIAGNOSIS 4 1 8 TO sensor IAP sensor NO 1 AD Ignition coil NO 2 WT sensor 2 IAP sensor NO 2 Oxygen sensor 19 4 1 9 FISYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION casu s ze n H AN S HYOSUNG lt CH ECU Za 5 e 2 4 PP 13 SC ES 6 O kiss AN a Je gt LAS BY E 3 e D ES ay AS 4 dy SG KC Speedometer 6 IAT sensor Fuel injector NO 1 GP switch TP sensor Pick up coil Fuel injector NO 2 Ignition coil NO 1 20 FISYSTEM DIAGNOSIS 4 1 10 Sl ANS lt ss DOE SN ECU 13 PA y 10 12 u gt D 6 liis EE JY lt Oy DAG x Ma Sat DK 2 R le O gt DEA SUIS O ZAO s A EE AA OS Fuel pump relay 43 IAP sensor NO 2 TO sensor WT sensor Ignition coil NO 2 Oxygen sensor 2 IAP sensor NO 1 21 4 1 11 FI SYSTEM DIAGNOSIS 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
35. O 77 i Bee 35 i o gt SS Zag e u kd al Ed 1 111 dle 11 i Sr Et SS Bo 283 z 28 3 8 sg 838 85 Ba 28S ons Bores 953 i i 3 GE La LI LI 3 ES i 1 9 2 i S f TURN SIGNAL d pi SPEED HORN EARTH ed SENSOR EARTH FRONT REAR TP SENSOR FRIAP mm SAVALVE WT SENSOR ISC SOL DIODE 2 Eng HANOLE SWITCH L UNIT INJECTOR INJECTOR arsenson ZE SENSOR To SENSOR EN FR IGNITION COIL SENSOR 80 SERVICING INFORMATION 8 30 2 JEAN MOTOR SIDE STAND HEAD LAMP TURN SIGNAL FUEL PUMP SDE STAND HEAD LAMP MAN RELAY mam sured 0 en ReLay RELAY RELAY RELY MANREAY Teo FUEL PUMP FUEL GAUGE a een Er 37 37 b zt 3 Ze ECU Gei y on JOJO dy fl f rad of T 2
36. STEM AND THROTTLE BODY CLEANING N 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 O Clean all passageways with a spray type throttle body cleaner and blow dry with compressed air Ay 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 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 O Check following items for any damage or clogging O ring Secondary throttle valve Throttle shaft bushing and seal Injector cushion seal 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 AN CAUTION Never operate the idle screw to avoid variations of the carburetion setting INSTALLATION Installation is in the reverse order of removal Pay attention to the following points O Connect the throttle cable to the throttle cable drum O Adjust the throttle cable play with t
37. TION O Remove the seat O Place a rag under the fuel injector hose 6 Disconnect the fuel injector hose from the fuel delivery pipe 6 Install the special tool between the fuel tank and fuel delivery pipe Fuel pump pressure gauge 09915 54510 Turn the ignition switch ON position and check the fuel pressure Approx 3 4 3 7 kgf cm 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 A 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 O Remove the fuel pump relay 54 FUEL SYSTEM AND THROTTLE BODY 4 2 6 First check the insulation between and terminals with pocket tester Then apply 12 volts to O and terminals D to andO to and check the continuity between and If there is no continuity replace it with a new one FUEL MESH FILTER INSPECTION AND CLEANING Ds If the fuel mesh filter
38. acer 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 SPECIFICATIONS Agpailaesori amp CAMEO ln 6 1 8 1 SPECIFICATIONS CONAS ri amp CE eso EY ln 8 1 9 1 1 8 1 GENERAL INFORMATION SPECIFICATIONS Agmilaosori amp CornastesorT DIMENSIONS AND MASS ITEM leren COOK EGOFI Overall length 2 430 mm 95 7 in 2 060 mm 81 1 in Overall width 840 mm 33 1 in 740 mm 29 1 in Overall height 1 155 mm 45 5 in 1 090 mm 42 9 in Wheelbase 1 665 mm 65 6 in 1 435 mm 56 5 in Ground clearance 160 mm
39. al from ECU and the panel indicates CHE If CHE is indicated the LCD does not indicate the trouble code It is necessary to check the wiring harness between ECU and speedometer couplers The possible cause of this indication is as follows Engine stop switch is in OFF position Ignition fuse is burnt AquailaesoFi OIE SN ZE el OQ J A 22 FI SYSTEM DIAGNOSIS 4 1 12 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 16 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 Aangiieeeg 3 EAT Ke SAGE EE B A COMES AI AN CAUTION lt 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 second
40. continuity test range OJ I A Use fork oil OJ 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 A Max Maximum BBDC Before Bottom Dead Center Min Minimum BDC Bettom Dead Center BTDC Before Top Dead Center O D O2 Sensor Oxygen Sensor 025 DC Direct Current R DOHC Double Over Head Camshaft RH Right Hand E S ECU Engine Control Unit SAE Society of Automotive Engineers FI Control Unit SAV Solenoid Secondary Air Valve Solenoid F T FI Fuel Injection Fuel Injector TDC Top Dead Center FP Fuel Pump TO Sensor Tip Over Sensor TOS TP Sensor Throttle Position Sensor TPS G GP Switch Gear Position Switch W WT Sensor Water Temperature Sensor l WTS IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air Temperature Sensor IATS IG Ignition ISC Solenoid Idle Speed Control Solenoid WIRE COLOR B Black Gr Gray L Blue Lg Light green Br Brown O Orange G Green R REed 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 tr
41. e each component is a high precision part great care should be taken not to apply any sharp impacts during removal and installation O Be careful not to touch the electrical terminals of the ECU The static electricity from your body may damage this part 13 FI SYSTEM DIAGNOSIS 4 1 2 Coupler Probe Where male terminal fits 4 1 3 FI SYSTEM DIAGNOSIS e When disconnecting and connecting the ECU make sure to turn OFF the ignition switch or electronic parts may get damaged O Battery connection in reverse polarity is strictly prohibited Such a wrong connection will damage the components of the Fl system instantly when reverse power is applied O 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 O 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 14 INCORRECT O Never connect an ohmmeter to the ECU with its coupler connected If attempted damage to ECU or sensors may result O Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained and personal injury may result USING TESTERS Use well
42. erall height 1 125 mm 44 3 in Wheelbase 1 435 mm 56 5 in Ground clearance 150 mm 5 9 in 130 mm 5 1 in Mass 215 kg 474 lbs 220 kg 485 lbs ENGINE ITEM CO ed Fl 2mazzsp FI 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 cr 39 5 in Fuel system Fuel Injection Starter system Electric starter Lubrication system Wet sump TRANSMISSION ITEM CE EN CGR Clutch Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down 5 up Final reduction 2 93 Gear ratio 1st 2 46 2nd 1 60 3rd 1 32 4th 1 13 5th 0 96 6th 0 85 Drive chain RK525XSO 108 links GENERAL INFORMATION 1 9 2 CHASSIS ITEM COPIED FI Lay ene FL ss Front suspension Telescopic type Rear suspension Swingarm type Steering angle 27 right amp left Caster 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 ti
43. ery Resistor element in the regulator rectifier damaged or defective Regulator rectifier poorly grounded 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 retighten Replace Replace Replace the battery Replace the battery Replace Clean and tighten ground connection 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 74 Recharge or replace Replace Repair or replace Replace Replace SERVICING INFORMATION 8 9 SPECIAL TOOLS Special tools Part Number Part Name Description 09900 27000 Ba KA Mode select switch K Inspect Fl system sensor 9 09915 54510 Fuel pump pressure gauge Measure fuel pressure of fuel pump 75 8 12 SERVICING INFORMATION TIGHTENING TORQUE FI SYSTEM PARTS Water sensor WT sensor Fuel injector bolt 76 SERVICING INFORMATION 8 18
44. ge OK YES Go to Step 2 Loose or poor contacts on the ECU coupler NO e Open or short circuit in the OB wire or GR wire 36 FI SYSTEM DIAGNOSIS 4 1 26 Step 2 1 Connect the IAP sensor coupler 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 IAP sensor output voltage at the wire side coupler between BL and GR wires IAP sensor Approx 27V output voltage at idle speed i 9 O BL O GR Tester knob indication Voltage Is the voltage OK OB BL NO 1 BY NO 2 or GR wire open or shorted to ground or poor 3 D NO 1 8 NO 2 7 or 69 connection VA O If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire 3 As 59 24 28 5 YES harness for open circuit and poor connection If check result is not satisfactory ECU Coupler NO replace IAP sensor with a new one 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 2 000 610 707 94 MED 2 001 611 707 94 Approx 3 37 5 000 1 524 634 85 SE 5 001 1 525 634 85 Approx 8 0
45. he above range for 5 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 2 V lt sensor voltage lt 4 6 V Without the above range for 5 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 2 V lt sensor voltage lt 4 8 V Without the above range for 5 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 2 V lt sensor voltage lt 4 6 V Without the above range for 5 sec and more C21 is indicated Intake air temperature sensor lead wire coupler connection Oxygen sensor 025 The oxygen sensor signal is input in ECU since then 180 sec after the engine run When this is the case ECU not receive the signal C22 is indicated Oxygen sensor lead wire coupler connection Tip over sensor TOS The sensor voltage should be the following for more than 5 sec after ignition switch turns ON position 0 2 V lt sensor voltage lt 4 6 V Without the above value for 5 sec and more C23 is indicated Tip over sensor lead wire coupler connection 28 MALFUNCTION CODE
46. he cable adjusters 58 ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS IGNITION SYSTEM CHARGING SYSTEM 59 6 1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Kal TT O Ignition coil NO 1 Cooling fan motor relay Fuel pump relay d Battery 2 Main fuse 30A 6 Head lamp relay Turn signal relay ECU Head lamp fuse 15A 6 Regulator Rectifier TO sensor Side stand relay Main relay TP sensor IAT sensor Magneto Pick up coil GP switch 60 ELECTRICAL SYSTEM 6 2 i SAV solenoid IAP sensor NO 2 2 ISC solenoid Oxygen sensor Fuel injector NO 1 5 Fuel injector NO 2 61 6 3 ELECTRICAL SYSTEM IGNITION SYSTEM IG SAW ENGINE STOP S W O LE O O O 9 va Rr IGNITION COIL Y ECU BO REG FUSE REC BATTERY _L 12V 12Ah N MN 62 ELECTRICAL SYSTEM 6 7 CHARGING SYSTEM Regulator Rectifier EI Kei we Pi SES IG switch o e i O A C generator PEN IN x EE Y I 5
47. ing on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer COPYRIGHT S amp T Motors Co Ltd GROUP INDEX GENERAL INFORMATION FI SYSTEM DIAGNOSIS ELECTRICAL SYSTEM SERVICING INFORMATION GE 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 look ing 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 and meaning associated with them respectively SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque a w N ES Apply THREAD LOCK 1324 Apply BOND 1215 gt ME o A o Use special tool Q aet oil unless otherwise specified Apply or USE Drake fuid CH Apply SUPER GREASE A Ed Measure in voltage range SCH Apply SUPER GREASE C El Measure in resistance range AH Apply SILICONE GREASE A Measure in current range SCH Apply MOLY PASTE Measure in
48. is clogged with sediment or lt NP rust fuel will not flow smoothly and loss in engine AN EJ power may result 7 O 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 LEVEL GAUGE INSPECTION O Measure resistance between the terminals when float is at the position instead below Fuel float position Resistance between terminals F Approx 90 1009 1 2 Approx 38 Q E Approx 4 10 Q O If the resistance measured is out of the specification replace the gauge with a new one Fuel level meter inspection 55 4 2 7 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY REMOVAL Remove the fuel tank 6 Remove the air cleaner box O Disconnect the fuel hose O Remove the all coupler to related the throttle body Loosen the throttle body clamp screws 6 Disconnect the throttle cables from their drum Dismount the throttle body assembly As CAUTION lt 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 57 FUEL SYSTEM AND THROTTLE BODY 4 2 8 4 2 9 FUEL SY
49. just 72 Complaint Dirty or heavy exhaust smoke 2 Worn piston rings or cylinders 3 Worn valve guides 4 Cylinder wall scored or scuffed 5 Worn valves stems 6 Defective stem seals 7 Worn side rails Symptom and possible causes 1 Too much engine oil in the engine SERVICING INFORMATION 8 1 8 Check with inspection win dow drain out excess oil Replace Replace Replace Replace Replace Replace Slipping clutch 1 Weakened clutch springs 2 Worn or distorted pressure plates 3 Distorted clutch plates or pressure plates Replace Replace Replace Dragging clutch 1 Some clutch springs weakened while others are not 2 Distorted pressure plates or clutch plates Replace Replace Transmission will not shift 1 Broken gearshift cam 2 Distorted gearshift forks 3 Worn gearshift pawl Replace Replace Replace Transmission will not shift back 2 Rubbing or sticky shift shaft 3 Distorted or worn gearshift forks 1 Broken return spring on shift shaft Replace Repair or replace Replace Transmission jumps out of 2 Distorted or worn gearshift forks gear 3 Weakened stopper spring on gearshift stopper 1 Worn shifting gears on driveshaft or countershaft 73 Replace Replace Replace 8 5 SERVICING INFORMATION ELECTR
50. king 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 due to wear Replace 2 Worn and burnt 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 70 SERVICING INFORMATION 8 1 6 Complaint Engine runs poorly in high speed range 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
51. ler for loose or poor contacts If OK then measure the WT sensor voltage at the wire side coupler 3 Disconnect the coupler and turn the ignition switch ON position 4 Measure the voltage between Br wire terminal and ground 5 If OK then measure the voltage between Br wire terminal and BW wire terminal 4 5 5 5 V WT sensor voltage B Br Ground D Br O BW Tester knob indication Voltage Is the voltage OK YES Go to Step 2 O Loose or poor contacts on the ECU coupler O Open or short circuit in the Br wire or BW wire NO 34 FI SYSTEM DIAGNOSIS 4 1 24 lt gt Step 2 1 Turn the ignition switch OFF position 2 Measure the WT sensor resistance Refer to the service manual 4gulaezo 99000 51210 page 5 7 t Refer to the service manual Cass 99000 94810 page 5 7 WT sensor resistance Engine Coolant Temp Resistance To ECU 0 C 32 F Approx 5 790 KQ 20 C 68 F Approx 2 450 KO 40 C 104 F Approx 1 148 KO 60 140 F Approx 0 586 KO 80 C 176 F Approx 0 322 KO Tester knob indication Resistance KO Is the resistance OK Br or BW wire open or shorted to ground or poor or 69 connection 3 6 If wire and connection are OK YES intermittent trouble or faulty ECU l N O Recheck each terminal and wire sl Ta 5 LID harness
52. malfunction Switch Voltage lt 0 1 V O ECU malfunction fm INSPECTION lt gt Step 1 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 Support the motorcycle with a jack 5 Turn the side stand to up right position 6 Make sure the engine stop switch is in 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 BW wire when shifting the gearshift lever from 1st to Top GP switch resistance 1000 2 0KQ GL BW Tester knob indication Resistance KO Is the resistance OK e GL wire open or shorted to ground or poor connection O If wire and connection are OK I YES intermittent trouble or faulty ECU MT I e Recheck each terminal and wire lt C aA k TT T T harness for open circuit and poor af 4 Es 0 el a mb connection al 58 s 2 NO Open or short circuit in the GL wire ECU Coupler 43 4 1 33 FISYSTEM DIAGNOSIS 4032 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION Injector signal is interrupted continuous
53. om 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 speed and engine rpm DECELERATION SIGNAL During deceleration the fuel injection time volume is decreased INJECTION STOP CONTROL SIGNAL DESCRIPTION When the motorcycle tips over the tip over sensor sends a signal to the ECU Then this signal cuts OFF current supplied to the fuel pump fuel injector and ignition coil TIP OVER SENSOR SIGNAL FUEL CUT OFF The fuel injectors stop operation when engine rpm reaches rev OVER REV LIMITER SIGNAL E limit rpm 17 4 1 7 FISYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATIO
54. on Oxygen sensor 025 The oxygen sensor signal is input in ECU since then 180 sec after the engine run When this is the case ECU not receive the signal C22 is indicated Oxygen sensor lead wire coupler connection Tip over sensor TOS The sensor voltage should be the following for more than 5 sec after ignition switch turns ON position 0 2 V lt sensor voltage lt 4 6 V Without the above value for 5 sec and more C23 is indicated Tip over sensor lead wire coupler connection 66 SERVICING INFORMATION 8 1 2 MALFUNCTION DETECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR Ignition signal is interrupted continuous by 32 times or more when ECU confirm ignition surge at each combustion chamber Ignition coil IG coil C24 or C25 is indicated pares NO 1 NO 2 Ignition coil wiring coupler connection power supply from the battery It judges from gear position voltage engine speed and throttle position by ECU when the gear position voltage is 0 1 V and Gear position switch less GP switch Gear position switch wiring coupler connection gearshift cam etc Injector signal is interrupted continuous by 16 times or more when ECU confirm injector running surge at each combustion C32 C33 Fuel injector NO 1 NO 2 chamber C32 or C33 is indicated Injector wiring coupler connection power supply to the injector Voltage is applied c
55. on timing 5 B T D C at 1 500 rpm Spark plug CR8E Battery 12 V 12 Ah MF Ss Main 30 A gt Ed Head lamp 15 A Headlamp HI 12 V 60 W x1 12 V 60 W x1 LO 12 V 55 W x1 12V 55 W x1 Tum signal lamp 12V 10W x 4 12V 10W x 4 Brake Tail lamp LED type 12V 21 5W x 1 Illumination lamp LED type License plate lamp 12V 5Wx 1 12V 5W x1 High beam indicator lamp LED type LED type Turn signal indicator lamp right amp left LED type LED type Neutral indicator lamp LED type LED type LED type Level type Fuel indicator lamp LED type Level type LED type Level type Coolant temperature indicator lamp LED type Level type FI Fuel Injection check lamp LED type LED type CAPACITIES ITEM AG nika ESO FI COIIBELESO FI Fuel tank 16 00 17 00 Engine oil oil change 3 000 m with filter change 3 200 ml overhaul 3 400 ml Front fork oil capacity One side 420 cc 380 cc NOTE The specifications are subject to change without notice 7 1 9 1 GENERAL INFORMATION SPECIFICATIONS Getas Hi 8 Cassie FI DIMENSIONS AND MASS ITEM COME 60 S FII Standard type 2 2 S El Sport type GETREF EO FI Overall length 2 060 mm 81 1 in Overall width 740 mm 29 1 in 655 mm 25 8 in Ov
56. onnection 4 Defective battery or low battery voltage Control circuit or sensor improperly operating 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 7 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 69 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 1 5 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 wor
57. ontinuous over 5 sec battery voltage gt 5 V when fuel pump relay is OFF position or battery voltage lt 5 V when fuel pump relay is ON position Fuel pump relay Fuel pump relay connecting lead wire power source to fuel pump relay fuel injector 67 8 1 3 SERVICING INFORMATION ENGINE Complaint Engine will not start or is hard to start 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 IAP sensor 7 Defective ECU 8 Defective WT sensor 9 Defective IAT sensor 68
58. r 09 Je ali Holet fr O If wire and connection are OK 6 s 414411811 E a i 24 YES intermittent trouble or faulty ECU Recheck each terminal and wire 6 harness for open circuit and poor ECU Coupler connection NO Replace the Oxygen sensor 40 FI SYSTEM DIAGNOSIS 4 1 30 C23 TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION Output voltage is out of the specified range 0 2 V lt Sensor voltage lt 4 6 V POSSIBLE CAUSE TO sensor circuit short or leaned more than 60 O TO sensor malfunction O ECU malfunction m INSPECTION Step 1 1 Remove the seat 2 Turn the ignition switch OFF position 3 Check the TO sensor coupler for loose or poor contacts If OK then measure the TO sensor resistance 4 Remove the TO sensor 5 Measure the resistance between B wire and GR wire terminals Tester knob indication Resistance KO Is the resistance OK YES Go to step 2 Replace the TO sensor with a new NO one 41 4 1 31 FI SYSTEM DIAGNOSIS lt gt Step 2 1 Connect the TO sensor coupler 2 Insert the needle pointed probe to the lead wire coupler 3 Turn the ignition switch ON position 4 Measure the voltage at the wire side coupler between OB and GR wires of the TO sensor at horizontal
59. r case Refer to page 4 1 27 IAT SENSOR REMOVAL AND INSTALLATION 6 Remove the fuel tank Remove the IAT sensor from the air cleaner case O Install the IAT sensor in the reverse order of removal TO SENSOR INSPECTION REMOVAL AND INSTALLATION The tip over TO sensor 2 is located in the upside of the battery Refer to page 4 1 30 6 Romove the fuel tank Remove the TO sensor from the frame O Install the TO sensor in the reverse order of removal 48 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM eee 50 4 2 1 REMOVAL AND DISASSEMBLY 52 4 2 3 REASSEMBLY AND INSTALLATION 53 4 2 4 FUEL PRESSURE INSPECTION e 54 4 2 5 FUEL PUMP RELAY INSPECTION ee ees ees ee ees ees ees see 54 4 2 5 FUEL MESH FILTER INSPECTION AND CLEANING nr 55 4 2 6 FUEL LEVEL GAUGE INSPECTION e 55 4 2 6 THROTTLE BODY ee see ees ee ees ee men ne ees 56 4 2 7 ie TEE N 57 4 2 8 CLEANING EE 58 4 2 9 INSPECTION EE N 58 4 2 9 INSTALLATION EE N 58 4 2 9 49 4 2 1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AlquatillaesoFl 50 FUEL SYSTEM AND THROTTLE BODY 4 2 2 CX 650 S 51 4 2 3 FUEL SYSTEM AND THROTTLE BODY REMOVAL AND DISASSEMBLY O Remove the seat Aquaillaeso
60. re size 160 60 ZR 17 69W Front fork stroke 120 mm 4 72 in ELECTRICAL ITEM ree Ee di H Cometas Ignition type ECU Ignition timing 5 B T D C at 1 500 rpm Spark plug CR8E Battery 12 V 12 Ah MF Fuse Main 30 A Head lamp 15A Pasa ama HI 12V H1 55W x1 LO 12 V H3 55 W x1 Turn signal lamp 12V 10W x 4 Brake Tail lamp 12V 21 5W x 1 lllumination lamp LED type License plate lamp 12V 5W x 1 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 FP Fuel Injection check lamp LED type CAPACITIES ITEM ER CAUSE eps Fuel tank 17 00 Engine oil oil change 3 000 ml lt with filter change 3 200 ml DEE overhaul 3 400 m Front fork oil capacity One side 380 cc NOTE The specifications are subject to change without notice 9 10 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING narar ee see see ee 92 4 1 1 FI SYSTEM TECHNICAL FEATURES 16 4 1 5 SELF DIAGNOSIS FUNCTION e 22 4 1 11 FI SYSTEM TROUBLESHOOTING ee ee ee ee 25 4 1 14 CUSTOMER COMPLAINT ANALYSIS
61. rt O Remove the front seat Comas S ze FI 6 Remove the fuel tank mounting bolts and fuel tank bracket mounting bolt AlguzilaexoFt O Remove the fuel tank mounting bolts and take off the hooks Cormasi0 S Hl O Disconnect the fuel level gauge coupler O Remove the fuel pump coupler O Remove the fuel injector hose 3 and return hose O AN CAUTION After disconnecting the fuel injector hose 9 insert a blind plug into the end to stop fuel leakage 52 Remove the fuel tank rearward N CAUTION As gasoline leakage may occur in this operation keep away from fire and sparks Remove the fuel pump assembly by removing its mounting bolts diagonally N WARNING Gasoline is highly flammable and explosive lt 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 remval and disassembly O 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 53 FUEL SYSTEM AND THROTTLE BODY 4 2 4 4 2 5 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPEC
62. s LCD DISPLAY FI CHECK LAMP INDICATION MALPUNCTION INDICATION INDICATION MODE NO C00 kk indi FI check lamp C code is indicated YES from small numeral to goes off jy ES E 2 large one code is indicated 23 4 1 13 FI SYSTEM DIAGNOSIS C00 C12 C14 C15 C17 C18 C21 C22 C23 C24 C25 C31 C32 C33 C41 MALFUNCTION PART None Pick up coil Throttle position sensor TPS Water temperature sensor WTS Intake air pressure sensor IAPS NO 1 Intake air pressure sensor IAPS NO 2 Intake air temperature sensor IATS Oxygen sensor 0 5 Tip over sensor TOS IG coil NO 1 IG coil NO 2 Gear position switch GP switch Fuel injector NO 1 Fuel injector NO 2 Fuel pump relay REMARKS No defective part For NO 1 cylinder For NO 2 cylinder For NO 1 cylinder For NO 2 cylinder For NO 1 cylinder For NO 2 cylinder In the LCD DISPLAY panel the malfunction code is indicated from small code to large code 24 FI SYSTEM DIAGNOSIS 4 1 14 FI 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 Is EXAMPLE CUSTOMER PROBLEM INSPECTION FORM
63. tanding 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 O 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 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 SELF DIAGNOSIS RESET PROCEDURE O After repairing the trouble turn the ignition switch OFF position and turn ON position again 6 If COO LCD INDICATION is indicates the malfunction codes are cleared O Disconnect the special tool from the dealer mode coupler ET 27 4 1 17 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM NO FAULT DETECTED FAILURE CONDITION CHECK FOR Pick up coil The signal does not reach ECU for more than 2 sec after receiving the lAP signal 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 2 V lt sensor voltage lt 4 8 V Without t
64. tion coils Defective control circuit or sensor 1 Low fuel pressure Adjust Replace Adjust Replace Repair Clean or replace Adjust or replace Clean Adjust Clean Retighten or replace Drain out excess oil Replace Replace 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 TP sensor out of adjustment Adjust 8 Defective SAV solenoid Replace 9 Defective GP switch Replace Engine overheats Defective engine internal parts 1 Heavy carbon deposit on piston crowns Clean 2 Not enough oil in the engine Add oil 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 lgnition 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 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 Ad
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