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1. EFI Mechanism
Illustration...4-2
4. Precautions In Operation.4-5
EFI4-22
Operation4-23
EFI.4-10
7. Fuel Lines.4-13
8. Ignition System4-13
9. Crankshaft position sensor4-15
10. Temperature sensor4-16
11. Air By-Pass Valve4-17
12. O2 Sensor4-18
Data Scan
ECU
Error indicator
Battery
Fuel Tank
Ignition Coil
Fuel
Injector
Vacuum
Tube
O2 Sensor
Air-By-Pass
Valve
Crankshaft position sensor
4-1
Crankshaft position
sensor
Fuel Pump
O2 Sensor
4-2
Main Switch ON
Throttle Position
Sensor
ECU
Transistor Ignition
Coil
T-MAP Sensor
Battery Voltage
Fuel Injector
4-3
4-4
Do not bend or twist throttle cable. Damaged cable will make unstable drive ability.
When disassembling fuel system parts, pay attention to O-ring position, replace with new one
as re-assembly.
Specification
Item
Idle RPM
1660100 rpm
4-5
NG
OK
NG
Battery voltage over 12.5V?
The voltage difference between battery and ECU is
less than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the ECU connector.
3. Turn on the ignition switch.
4. With a multi-meter to measure the voltage
between the 17th pin(+) and the 1st pin (-).
5. Make sure the voltage difference between
battery and ECU is less than 0.2V.
The voltage difference between battery and active
components is less than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the connectors of the fuel injector,
by-pass valve, and ignition coil.
3. Measure the voltage between battery negative
side and the each connector (1).
4. Make sure the voltage difference between
battery and those active components is less than
0.2V.
The voltage difference between 5V-sensors is less
than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the connectors of throttle valve
position sensor and intake manifold
temperature/pressure sensors.
3. Turn on the ignition switch.
4. Measure the voltage between the pins(1)(4) of
throttle valve position, and the pins of intake
manifold temperature/pressure sensors (1) (3) is
within 5V0.2V.
4-6
1.
2.
3.
4.
Burnt Bulb?
Blown fuse?
Battery voltage too low?
Poor wire contact on ECU
circuit?
5. Poor contact on the master
switch?
6. Malfunction of ECU?
1.
2.
3.
OK
NG
1. Abnormal wire connection?
OK
NG
1.
OK
NG
OK
NG
OK
END
NG
OK
NG
1.
OK
1.
2.
NG
OK
NG
1.
2.
3.
4.
5.
6.
7.
8.
NG
1.
2.
3.
4.
5.
No valve clearance?
Incorrect ignition timing?
Stuck valve?
Worn out cylinder and piston ring?
Improperly adjustment of the air adjustment
screw onto the throttle valve body?
OK
OK
3.
4.
5.
6.
7.
END
4-7
1.
Replace with
new one for
confirmation
Is the vacuum hose leaking?
4-8
Is fuel enough?
4-9
Fuel Injector:
4. Powered by DC 8~16V, and has 2 terminals connector on the injector.
5. Its major component is the solenoid valve of high resistance driven by
electronic current.
6. The two terminals are connected to power source and ground
respective. It is controlled by ECU to decide the injection timing, and
the injector pulse width. Working with 4-valve engine, the unique
2-hole designed injector can provide each intake valve with suitable
fuel quantity to reduce HC emission.
Fuel Pump:
7. Powered by DC 8~16V, and has 2 terminals connector on the pump.
8. The two terminals are connected to power source and ground
respective. The ECU is to control and manage the operation of fuel
pump through electrical power.
9. Its major component is a driving fan pump that equipped with a low
electrical consuming DC motor. Powered by 12V voltage and keep
fuel pressure inside the fuel pump in 2.5 bars, which can offer 14 liters
of fuel per hour.
10. The fuel pump is located inside of the fuel tank, and installed a filter
in front of its inlet so that can prevent from foreign materials sucking
into the fuel pump to damage it and the fuel injector.
4-10
Throttle Body:
27. The throttle body is the air flow adjustment mechanism of the fuel
injection. (Its function is likely the carburetor.)
28. The throttle valve shaft is to turn the throttle valve position sensor in
synchronously so the ECU that can detect the throttle valve openness
in time.
29. The idle speed air by-pass valve controls the pipe in the throttle body.
ECU adjusts the idle speed air by-pass valve, and airflow is adjusted
by so, which stabilizes idle speed.
24-1 tooth
24 -1
30. It does not need power supply, and has 2-signal terminals connector on
the sensor.
31. Its major component is the magnetic pickup coil, and its output voltage
range is 0.8~100V.
32. The air gap between the sensor and flywheel must have .07~1.1mm.
By cutting the magnetic field, the magnetic sensor sends an inductive
voltage that is created with the rotation gear (24-1 tooth) on the
flywheel, and the pulse will be sent to the ECU. Then, the ECU
calculates current engine speed and crank position based on the
voltage so that controls fuel injection quantity and ignition timing
properly
4-11
2 PO141
3 PO171
4-12
Cause
Countermeasure
Connect it tight, or
exchange if
necessary
Check the water seal,
or replace the electric
wires.
Fuel filter
Fuel tank
Fuel injector
Fuel pump & pressure regulator
Vacuum hose
ECU
Battery
System Description:
1. After key-on, all sensors signals sent to the ECU first. The electrical fuel pump will be
activated by ECU signal. If the engine did not start for 2~3 seconds, then the fuel pump will
be turned off to save electricity. The pressure regulator maintains the fuel pressure around
2.5bar, and the fuel injector spray proper fuel quantity according to the conditions and
environmental coefficient. When key-off or engine stopped, the fuel pumps stop operating.
2. The fuel filter is to filter alien materials so it has to be replaced regularly.
3. Do not let the starting motor keep running when the engine cannot start. It will cause battery
voltage to decrease. If the voltage drops under 8V, the pump will not operate. The
countermeasure will be starting the engine by connecting a new battery or with kick-starter.
Injector
The double-hole injector provides each intake valve a fuel jet. This can reduce the
pollution of HC. The shortened version of fuel pump plate makes its size more compact,
and sturdier against shocks. ECU signal controls the regulator to maintain 2.5 bars
between the fuel pressure and the air pressure of inlet pipe. Through controlling the
time length of injection under steady fuel pressure, the system can optimize the fuel
injection quantity according to different engine workloads.
Fuel Pump
Electrical fuel pump is mounted inside the fuel tank. The power source is DC current
provided and controlled by ECU; the pump can provide 14L/hour under the pressure of
2.5 bars.
4-13
ECU
RPM/TD
C
Ignition coil
TDC/ crank
position sensor
ACG/flywheel gear
ring (24-1 tooth)
1.
Diode
Principle of operation:
The engine is equipped with a computerized ignition control system that collects signals
from TDC/crankshaft position sensor; throttle position sensor, temperature sensor, and intake
temperature as well as pressure sensor. Then, correspondence with engine RPM, this 8-bite
microcomputer in the system controls ignition timing properly. The secondary coil creates
25000~30000V high voltage to ignite the spark plug by means of the transistor operation of
the primary current entry from the ECU. This can maximize engine performance and also
decrease fuel consumption.
Specification
1. Ignition timing: BTDC 5~13/1600RPM
2. Spark plug: NGK CR7E
Gap: 0.8mm
3. A.C.G. Pulse generator coil:
4.
120+10% (G/W-LY)
Ignition coil:
Primary circuit: 0.63 0.03 (20)
5.
BatteryTTZ10S 8.6Ah
Capacity12 v 8.6Ah
4-14
No teeth
Flywheel
gear ring
ECU Signal
Secondary
voltage
Sensor signal
Closed
TDC
TDC
Ignition
Time flow
Description:
ECU receives all sensors signals to control the throttle valve openness with PWM, and adjust
airflow through the by-pass valve of the intake manifold. It can adjust idle speed for a stably
running engine.
1. When engine cold starting---the by-pass valve open for a while to increase airflow and to
stabilize engine idle speed within initial starting.
2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts airflow
according to engine temperature (engine oil temperature), and raises idle speed.
3. Speed decreasing--- ECU controls the by-pass valve in correspondence with throttle
operation, to provide inlet pipe with proper airflow quantity. Such operation will smooth
the engine rpm reduction process, preventing the engine from stalling, excessive negative
pressure, and also reduce HC emission.
4-15
ECU
Engine oil temperature sensor: According to the semiconductors characteristic, the sensor detects
the temperature of engine oil and metal parts and then send a voltage signal to
the ECU. On this base, the ECU can correct fuel injection and ignition timing.
NTC-Negative Temperature
Coefficient Resistor
Intake temperature and pressure sensor: Sensor combined both pressure and NTC can detect the
absolute pressure and temperature in the intake manifold, and then
provides the ECU with signal for adjustment fuel injection quantity
based on environmental temperature and air pressure difference from
elevation level change.
4-16
Fuel Injector
TPS
ECU
Air by-pass valve
Air temperature
Engine oil
Temperature
Engine speed
Manifold pressure
Throttle openness
Description:
ECU receives all sensors signals to control the throttle valve openness with PWM, and adjust
airflow through the by-pass valve of the intake manifold. It can adjust idle speed for a stably
running engine.
1. When engine cold starting---the by-pass valve open for a while to increase airflow and to
stabilize engine idle speed within initial starting
2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts airflow
according to engine temperature (engine oil temperature), and raises idle speed.
3. Speed decreasing--- ECU controls the by-pass valve in correspondence with throttle
operation, to provide inlet pipe with proper airflow quantity. Such operation will smooth the
engine rpm reduction process, preventing the engine from stalling, excessive negative
pressure, and also reduce HC emission.
4-17
1. O2 sensor feedback the signal to ECU, the signal is the base of air/fuel ratio
adjustment toward the optimized value of 14.6. This is the close-loop system.
2. When A/F ratio is 14.6, the exhaust pollution like CO, HC, NOx conversion rate will
be optimized.
3. The heating coil resistance <200K ohm (3045kohm)
4-18
bolt2
nut2
Fuel overflow pipe
Fuel-filling guide
bolt5
4-19
Caution
Check if the seal is broken. Change if
necessary
float
Float
Fuel Pipe
Fuel Pump
Bolt1
Caution
4-20
Fuel backflow
pipe
Pressure
regulating
valve
Screw6
Caution
The air cleaner is paper-base; please
blow it clean with compressed air. Dont
use water or other solvent
Installation:
Install the air cleaner in reverse procedure of
removal.
Application of fuel injection system
diagnostics
Open the front luggage cover.
Connect the ECU connector and then turn on the
main switch.
Operate the diagnostic according to its operation
instruction.
4-21
Lit up types
ON
OFF
0.3 sec
ON
OFF
ON
OFF
To show FLASH CODE:
Before turning the KEY ON, wide open the throttle valve. Then, turn the KEY ON, the CHK lamp lit
up for 2 seconds and off. But, the CHK lamp will light up again after 3 seconds. In the means time,
close the throttle valve. Finally, it is to determine what problem occurred based on the flash time of
CHK lamp.
Before show up, CHK lamp will light up for 4 seconds first. Then, according to the lamp flash
times (every 0.5 second), the problem will be determined by comparing with the operation message
table. If there has the 2nd problem in the system, the CHK lamp will have flash operation again after
its lit up for 4 seconds.
=Light up
Full Throttle on
0.
5
0.
5
0.
5
0.
5
0.
5
0.
5
0.
5
0.
5
3 seconds delay
4-22
=Light off
Message
Solution Operation
1. Stopping the motorcycle immediately, and solve it with
priority
2. Check if the lubricant system for abnormal?
3. Is the ignition or fuel supply system in normal?
4. Has the engine shown burnt?
5. Make sure if the engine temperature sensor is in normal.
6. Make sure if the connector is in normal.
1. Check if the connection of the crank position sensor is
open-circuit.
2. Check if the air gap between the sensor and gear tooth is
within specification.
3. Check if the crank rotation is run-out.
4. Check if the sensor is in normal according to the new
component replacement procedure.
1. Connect the diagnostic and reset the throttle valve position.
Make sure if the idle speed position is within standard
range.
2. Make sure if the wire circuit of the throttle valve position
sensor is loosen or short.
3. Check if the openness of idle speed by-pass valve is within
specification. (40~100%)
4. Adjust the idle speed CO value to specified range.
(0.5%~2.0%)
5. If this problem symptom still existing, check if the throttle
position sensor (TPS) is in normal according to the new
component replacement procedure.
1. Make sure if the wire circuit of the throttle valve position
sensor is loosen or short.
2. If this problem symptom still existing, check if the throttle
position sensor (TPS) is in normal according to the new
component replacement procedure.
P0217
Engine
temperature
overheat
P0335
Crank position
sensor
P1120
Poor contact
of the throttle
valve sensor
Application
malfunction of
the throttle
position sensor
Rotation speed 1. Make sure if the wire circuit of the throttle valve position sensor
is loosen or short.
malfunction of
2. If this problem still existing, check if the throttle position sensor
the throttle
(TPS) is in normal according to the new component replacement
position sensor
procedure.
P1121
P1122
P0560
P0110
P0410
4-23
P0505
P0251
P0350
Flash
code
10
Message
Solution Operation
Application 1.
range
abnormal of 2.
the air by-pass
3.
valve
11
Abnormal
ignition
circuit
P0230
12
Abnormal
fuel pump
relay
P0219
13
Engine
over-RPM
14
Abnormal
5V driving
voltage
Too high
RPM when
starting
engine
P1560
P0700
15
P0115
16
P0650
18
P0105
4-24
P0141
P0171
Flash
code
Message
Solution Operation
O2 sensor
wire abnormal
O2 sensor
heating coil
damaged
Oil supply
too lean or
too rich.
4-25
Parts No.
Parts Name
life-expectancy
Ignition coil
Check it every
3000km
4-26
Service schedule
life-expectancy
Check it every
3000km
Inspection Method
life-expectancy
Engine
Check it every
temperature
3000km.
sensor
366-008
Intake
temperature/
pressure
sensor
At least 20000km
life-expectancy
Check every
3000km
1.
4-27
Parts No.
Service schedule
Inspection Method
Parts Name
308-008
At least 20000km
1. Please refer to idle speed adjustment
life-expectancy
section for the idle speed CO
Throttle
adjustment.
Check
every
3000km
body
2. Connect the Data Scan and check if
the throttle position DTC code
appears.
3. If the code appears, replace the
throttle body to make sure the code
can be erased.
4. If the code disappears, replace the
throttle body.
If the code still exists, replace the ECU
with new one.
337-004
At least 20000km
1. Check if the fuel injector DTC code
Fuel injector life-expectancy
appears.
Check every 3000km 2. If the code appears, replace a new
fuel injector for confirmation. If the
code can be erased, then, replace the
fuel injector.
3. If the code still is there after
changing a new injector, check if
connector wire is short.
4. If the code still exists, replace the
ECU with new one. If the code can be
erased after changing the ECU, this
ECU has to be replaced.
Confirmation or replacement
procedure for the fuel injector:
1. Erase the DTC code with the
Data Scan.
2. Turn off ignition switch and
disconnect the fuel injector
coupler.
3. Connect to a new fuel injector.
4. Connect the Data Scan, and
turn on the ignition switch.
5. Make sure the DTC code had
been cleared.
6. Please refer to idle speed
adjustment section for idle speed
CO value confirmation.
(Firstly, make sure if the fuel
injector DTC code had been clear,
and then install a new fuel injector.)
325-002
ECU
4-28
At least 20000km
1.
life-expectancy
2.
Check every 3000km
Parts No.
Parts Name
Service schedule
Inspection Method
1.
2.
3.
4.
1.
4-29
15A
(G/W)
(G/W)
(R)
(B)
Main
Switch
Battery
(R)
(B)
(G)
ECU
ECUP
17
(B)
4 LSD2
Check
Lamp
Regulator
(G/W)
(R)
(Gr)
DRVG
01
ACG
(Y)
21 COMK
(G/W)
(Y)
CPS
(L/Y)
CPS+
(G/W)
CPS-
(R/W)
19
(Y/B)
XDRP
18
(L/R)
TPIM
07
(B/R)
XDRG
(P/G)
ETSM
16
FDPP
(B/L)
(R)
15 DRVP(R)
03 FIND
(R)
(G/L)
(R)
(Y/B)
MAPM
08
(B/Y)
MATM
22
1
(B/R)
(B)
O2
(Gr)
(W)
(W)
10
LSD4
main switch
14
13 AIND
(W/B)
12 IGND
(B/W)
(R)
1
2
Coil
T-MAP
(W/B)
By-Pass
Valve
ET
09
A
3
4
2
Injector
TPS
(G)
(B)
20
5
4-30
(G/B)
(B)
(Y)
O2
ETSM
MAPM
TPIM
FDPP
LSD2
FIND
DRVG
11
10
09
08
07
06
22
21
20
19
18
17
05
04
03
02
01
16
15
14
13
12
ASTM
COMK
CPSCPS+
XDRP
ECUP
XDRG
DRVP
LSD4
AIND
IGND
ECU learning
Perform timing:
a. After exchanging ECU, Air by-pass valve, O2 sensor, throttle body.
b. After cleaning the throttle body or the air by-pass valve.
c. After disassembling and rebuilding the engine. Or after adjusting the tappet clearance.
d. After adjusting the idle CO value.
Method:
a. Warm the engine by driving the scooter by 50km/h for 5 minutes. ,The engine
temperature should be around 90--120 (The standard engine temperature
depends on different models or conditions.)
b. Maintain idle for 35 Minutes
Turn on the ignition switch, and enter the reset/zeroing menu. Then press enter.
Turn off the ignition switch, hold the throttle on WOT position.
Turn on the ignition switch under WOT position.
Hold WOT position for 2 or 3 seconds, and release the throttle.
Turn on and off the switch for one time.
Make sure the throttle openness are on zero and 100% WOT position.
4-31
4-32