Fuel Injection System

Unlike carburettors, which often need re-adjustment, fuel in- be used in the fuel tank when the motorcycle is not in use to
jection systems require minimal maintenance as long as all prevent resinous deposits. Also, the air filter service intervals
the electronic components are in working order and the system should always be adhered to.
is kept clean. To prevent soiling, a fuel system cleaner should

1 2 3

Vacuum connections/ Other fuel injection system Connecting synchroniser

rubber plugs installed without air filter vacuum tubes

4 5 6

Lift out tank and secure, Tank must be secured to Air filter housing must be
e.g. with a piece of wood prevent it slipping removed
1 Just like multiple carburettor setups, the fuel injec-
tion system in multi-cylinder engines has multiple
throttle valves, the synchronisation of which is crucial to
4 If the tank covers the fuel injection system, it must
be raised and supported on a plank of wood, for ex-
ample. Often the tank cannot be removed entirely because it
specify one – but to achieve the same value on all the throttle
valves. Then the system will work "in sync" for all cylinders.
If one gauge shows a completely different reading from the

Regular service |Fuel Injection System

smooth engine running. The throttle valves are opened and
closed by the throttle twistgrip, thereby regulating the quantity
of air and fuel supplied to the engine at a given moment. Due
to mechanical stress, the basic setting of the throttle valves
changes slightly over time and, as a result, the engine becomes
noticeably out of sync when idling. You can hear it from the
sound of the exhaust system and also see it from a fluctuating
engine idle speed on the tachometer – put simply, the engine
no longer runs smoothly. It's time to resynchronise the fuel
injection system.
contains the fuel pump. The pump is actuated by the control
electronics and is required for the engine to run.
5 When "propping up" the tank, make sure that it can-
not slip and cause injury or annoying damage to your
motorcycle!
6 In addition, on our demonstration bike, the airbox
must be removed to get at the fuel injection system.
others, this may indicate that the basic setting of that throt-
tle valve is completely wrong, or it may mean there is a fault
or damage such as loss of compression on one cylinder or a
leaking intake manifold. If you cannot find and rectify the fault
yourself, then you must go to a motorcycle workshop.
The throttle valves are adjusted using the so-called bypass
screws (see Fig. 8). Never touch other sealed or colour-coded
adjusting screws! All bypass screws should be open at least
half a revolution.

2 To adjust the fuel injection system, you need a syn-

chroniser, such as the ones from Rothewald for 2- or
4-cylinder engines. Also the adjustment tools are very useful for
some models. Before you start adjustment, warm up the engine
so that the cold-start device does not falsify the readings. Then
place the motorcycle securely on the stand – ideally in the
open air but, if inside in a garage, always so that the exhaust
fumes can escape directly to the outside without you breathing
them in while you work.
7 Now you can start the engine and begin adjusting
the throttle valves by screwing the bypass screws in
or out until all gauges show the same readings.
8 By doing this, you adjust the small air gap opened up
by the throttle valves when idling so that air is sucked
into the combustion chambers on all cylinders at exactly the
same vacuum and at the same rpm, and thus the engine works
uniformly on all cylinders. To enable you to correctly read the
gauges, they must first be calibrated to each other accord-
ing to their instructions for use, and the damping must be

3 Connect the tubes of the vacuum gauges to the con-

nection points on the fuel injection system after first
removing the rubber plugs or tubes from the connections.
adjusted so that the pointers flutter only slightly.
When adjusting the throttle valves, generally the aim is not to
set a specific vacuum – most motorcycle manufacturers do not

We recommend:
Rothewald Synchroniser
Rothewald supplies synchronisers for motor- 1. 2 gauges, 0 to -1 bar
cycles with two or four carburettors to ensure Order no. 10034216
flawless engine running. The easy-to-install 2. 4 gauges, 0 to -1 bar
and precise vacuum gauges enable you to Order no. 10034217 1|
set the correct balance via the adjustment 3. Replacement gauge 0 to -1 bar (not shown)
screws on the carburettor. The measuring Order no. 10034221
range is 0 to -1 bar.
Comprises: Sturdy metal frame § Two or
four vacuum gauges, measuring range 0 to -1 2|
bar § Vacuum tubes with all fittings
§ Adapters for 5 mm and 6 mm connections
§ Full installation and operating instructions

We have the right product for you at www.louis.eu

✆ 24h order hotline: 0049 40 734 193 60 @ E-mail: order@louis.eu  Online shop: www.louis.eu

7 8
These tips for DIY mechanics contain general recom-
Please note!

mendations that may not apply to all vehicles or all

individual components. As local conditions may vary
considerably, we are unable to guarantee the correct-
ness of information in these tips for DIY mechanics.
Thank you for your understanding.

Bypass screws: set same Adjust the pointer damping

values on all gauges