Sym Joyride 125 Service Manual page 110

EFi Component Malfunction Check& Replacement Procedure
Parts No.
Item Parts Service schedule
Name
1 390-002 At least 20000km
Ignition coil life-expectancy
Check it every
3000km
2 379-010 At least 20000km
Air by-pass life-expectancy
valve Check it every
3000km
3 358-016 At least 20000km
fuel pump life-expectancy
and fuel Check it every
regulating 6000km
valve
4 366-005 At least 20000km
Engine life-expectancy
temperatur Check it every
e sensor 3000km.
To this chapter contents
Inspection Method
Use diagnostic tool to check if the
ignition coil has malfunction.
Erase the DTC codes and replace
with new coil and confirm again. If
the DTC codes disappear, then the
ignition coil is abnormal. Replace it
with new one.
If the DTC codes still exist, replace
the ECU for confirm. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new one
Before the ignition coil is verified for
malfunction, check the coil
resistance and connector wire for
short-circuit.
Check if the by-pass valve DTC code
appears on the diagnostic.
Erase the DTC codes and replace
with new one & confirm again. If the
DTC codes disappear, then the
by-pass valve is abnormal. Replace
it with new one.
If the DTC codes still exist, check if
the wire connector and by-pass valve
resistance are normal.
If the DTC codes still exist, replace
the ECU for confirmation. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new one.
Connect a pressure gauge between
the regulator and fuel injector.
Make sure fuel pressure is within
2.5bar. The pressure should reach
2.5 bars within 3 seconds after
turning on ignition switch.
If the fuel pressure is out of the
range, check if the fuel pipe is
leaking. And check if the fuel pump
voltage is over 12V?
Replace the fuel-regulating valve and
confirm again.
Is there any DTC code on the Data
Scan diagnostic?
Engine temperature has to reach to
environmental temperature after
engine stopped for a while.
Erase the DTC codes and replace
with new one and confirm again. If
the DTC codes disappear, then the
sensor is abnormal. Replace it with
new one.
If the DTC codes still exist, check if
wire connector and sensor's
resistance are in normal range
5
. Fuel Injection System
Adjustment & replacement procedure
If the ignition coil has to be changed,
erase the DTC codes with the
diagnostic tool.
Turn off ignition switch, and replace
the coil with new one.
Turn on ignition switch and make sure
the DTC codes disappear.
If the by-pass valve has to be
changed, erase the DTC codes with
the diagnostic tool first.
Turn off the ignition switch, and then
replace the valve with new one.
Turn on ignition switch and make sure
the DTC codes disappear.
Check idle speed CO value and adjust
if necessary.
The oil seal has to be replaced along
with replacement of the fuel-regulating
valve.
Oil seal has to be installed into the
outer cover before assembling.
If the sensor has to be changed, erase
the DTC codes with the diagnostic
tool.
Turn off ignition switch, and remove
connector.
Remove the sensor with tools.
Engine temp. Sensor tighten torque is
0.74~0.88kg-m.
Connect the coupler, and the
diagnostic tool. Then, turn on ignition
switch.
Check if the DTC codes disappear.
The value of stopped engine
temperature should approximate the
environmental temperature.
5-53