HYOSUNG COMET 250/R FI Service Manual
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HYOSUNG COMET 250/R FI Service Manual

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SERVICE MANUAL
99000-95610

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Summary of Contents for HYOSUNG COMET 250/R FI

  • Page 1 SERVICE MANUAL 99000-95610...
  • Page 2 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 relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer.

  • Page 3: How To Use This Manual

    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.

  • Page 4: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Liquid Crystal Display : Alternating Current : Light Emitting Diode : American Petroleum Institute : Left Hand ATDC : After Top Dead Center : Maximum BBDC : Before Bottom Dead Center : Minimum : Bettom Dead Center BTDC...
  • Page 5 WIRE COLOR : Black : Gray : Light blue : Blue : Light green : White : Brown : Orange : Yellow : Green : Red : Black with Blue tracer : Black with Brown tracer : Black with Green tracer : Black with Orange tracer : Black with Red tracer : Black with White tracer...

  • Page 6: General Information

    GENERAL INFORMATION CONTENTS SPECIFICATIONS ( & 6 (1-8) ……...

  • Page 7: Specifications

    1-8 GENERAL INFORMATION SPECIFICATIONS ( & ◉ ◉ DIMENSIONS AND MASS I T E M 2,270 mm (89.4 in) 2,080 mm (81.9 in) 2,060 mm (81.1 in) Overall length 800 mm (31.5 in) 760 mm (29.9 in) 655 mm (25.8 in) Overall width 1,090 mm (42.9 in) 1,120 mm (44.1 in)
  • Page 8 GENERAL INFORMATION 1-9 ◉ ◉ CHASSIS I T E M Front suspension Telescopic type ← ← Rear suspension Swingarm type ← ← Steering angle 40°(right & left) 33°(right & left) 27°(right & left) Caster 33° 25.5° ← Trail 135 mm (5.32 in) 85 mm (3.35 in) 90 mm (3.54 in) Front brake...

  • Page 10: Table Of Contents

    FI SYSTEM DIAGNOSIS CONTENTS 4 -1 PRECAUTIONS IN SERVICING ……………………………………… 10 (4-1-1) FI SYSTEM TECHNICAL FEATURES ……………………………… 14 (4-1-5) SELF-DIAGNOSIS FUNCTION ( ………………… 20 (4-1-11) SELF-DIAGNOSIS FUNCTION ( …………………… 22 (4-1-13) FI SYSTEM TROUBLESHOOTING ………………………………… 24 (4-1-15) CUSTOMER COMPLAINT ANALYSIS………………………………… 24 (4-1-15) ) ……………...

  • Page 11: Precautions In Servicing

    4-1-1 FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ◉ ◉ ELECTRICAL PARTS ▣ ▣ CONNECTOR / COUPLER ● When connecting a connector, be sure to push it in until a click is felt.
  • Page 12 FI SYSTEM DIAGNOSIS 4-1-2 ● 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.
  • Page 13 4-1-3 FI SYSTEM DIAGNOSIS ● When disconnecting and connecting the ECU, make sure to turn “OFF” the ignition switch, or electronic parts may get damaged. ● Battery connection in reverse polarity is strictly INCORRECT prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

  • Page 14: Using Testers

    FI SYSTEM DIAGNOSIS 4-1-4 ● Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to ECU or sensors may result. ● Be sure to use a specified voltmeter / ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.

  • Page 15: Fi System Technical Features

    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.

  • Page 16: Injection Stop Control

    FI SYSTEM DIAGNOSIS 4-1-6 ◉ ◉ COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE TEMPERATURE When engine temperature is low, injection time (volume) is SENSOR SIGNAL increased.
  • Page 17 4-1-7 FISYSTEM DIAGNOSIS ◉ ◉ FI SYSTEM PARTS LOCATION ( E E C C U U ① ⑤ Speedometer GP switch ② ⑥ Ignition coil, NO.1 Fuel injector, NO.1 ③ ⑦ Ignition coil, NO.2 Fuel injector, NO.2 ④ ⑧ Pick-up coil ISC solenoid...
  • Page 18 FISYSTEM DIAGNOSIS 4-1-8 E E C C U U 1 1 6 6 1 1 2 2 1 1 3 3 1 1 0 0 1 1 4 4 1 1 1 1 1 1 5 5 ⑨ ⑬ IAT sensor IAP sensor, NO.1 ⑩...
  • Page 19 4-1-9 FISYSTEM DIAGNOSIS ◉ ◉ FI SYSTEM PARTS LOCATION ( E E C C U U 7 7 8 8 ① ⑥ Speedometer Pick-up coil ② ⑦ Fuel injector, NO.1 Ignition coil, NO.1 ③ ⑧ Fuel injector, NO.2 ISC solenoid ④...
  • Page 20 FISYSTEM DIAGNOSIS 4-1-10 E E C C U U 1 1 2 2 1 1 3 3 1 1 1 1 1 1 6 6 1 1 0 0 1 1 4 4 1 1 5 5 ⑩ TO sensor ⑭...

  • Page 21: Self-Diagnosis Function ( )

    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 notified by the “FI” check lamp “ ” ① . To check the function of the individual FI system devices, the dealer mode is prepared.

  • Page 22: Dealer Mode

    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 4-1-17) The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECU does not receive signal from the devices.
  • Page 23 4-1-13 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION ( The self-diagnosis function is incorporated in the ECU. The function has a mode, “USER MODE”. The user and dealer can only be notified by the “FI” check lamp “ ” ① . ” ① . To check the function of the individual FI system devices, read blinks signal of the “FI”...
  • Page 24 FI SYSTEM DIAGNOSIS 4-1-14 MALFUNCTION PART REMARKS CODE CODE Engine temperature sensor (ETS) For NO.1 cylinder Intake air pressure sensor (IAPS), NO.1 For NO.2 cylinder Intake air pressure sensor (IAPS), NO.2 Intake air temperature sensor (IATS) Oxygen sensor (O IG coil, NO.1 For NO.1 cylinder IG coil, NO.2 For NO.2 cylinder...

  • Page 25: Fi System Troubleshooting

    4-1-15 FI SYSTEM DIAGNOSIS 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.
  • Page 26 FI SYSTEM DIAGNOSIS 4-1-16 MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather � � � � � � Fair Cloudy Rain Snow Always Other Temperature � � � � � Warm Cool Cold ( °F / °C) Always Frequency �...

  • Page 27: Self-Diagnostic Procedures

    4-1-17 FI SYSTEM DIAGNOSIS 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.

  • Page 28: Malfunction Code And Defective Condition

    FI SYSTEM DIAGNOSIS 4-1-18 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR The sensor voltage should be the following. 0.1 V � sensor voltage < 4.6 V Engine temperature Without the above range for 4 sec. and more, C15 is indicated. sensor (ETS) Engine temperature sensor, lead wire / coupler connection.
  • Page 29 4-1-19 FI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR When the IC of the ECU electric current gets 6 A and more, C24 or C25 is indicated. Ignition coil (IG coil), C24 / C25 NO.1 / NO.2 Ignition coil, wiring / coupler connection, power supply from the battery.

  • Page 30: C15" Et Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-20 “C15” ET SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. ● ET sensor circuit open or short. 0.1 V � Sensor voltage < 4.6 V ● ET sensor malfunction. ●...
  • Page 31 4-1-21 FI SYSTEM DIAGNOSIS ◈ Step 2 1) Turn the ignition switch “OFF” position. 2) Measure the ET sensor resistance. ET sensor resistance Engine Temp. Resistance (To ECU) ㏀ 0 ℃ (32 ℉ ) Approx. 28.788 ㏀ 20 ℃ (68 ℉ ) Approx.

  • Page 32: C17 " " O O R R " " C18 " " Iap Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-22 “C17” or “C18” IAP SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is out of the specified range. ● Clogged vacuum passage between throttle body 0.1 V � Sensor voltage � 4.8 V and IAP sensors.
  • Page 33 4-1-23 FI SYSTEM DIAGNOSIS ◈ Step 2 ① 1) Connect the IAP sensor couplers NO.1 ① NO.2 ② . 2) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed. 4) Measure the IAP sensor output voltage at the wire side coupler (between BL(NO.1) or BY(NO.2) and BW wires).

  • Page 34: C21" Iat Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-24 “C21” IAT SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. ● IAT sensor circuit open or short. 0.1 V � Sensor voltage < 4.6 V ● IAT sensor malfunction. ●...
  • Page 35 4-1-25 FI SYSTEM DIAGNOSIS ◈ Step 2 1) Turn the ignition switch “OFF” position. 2) Measure the IAT sensor resistance. IAT sensor resistance Intake Air Temp. Resistance ㏀ -10 ℃ (14 ℉ ) Approx. 53.30 ㏀ 0 ℃ (32 ℉ ) Approx.

  • Page 36: C22" Oxygen Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-26 “C22” OXYGEN SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor signal is not input in ECU since then ● Oxygen sensor, Oxygen sensor heater circuit open more than 120 sec. after the engine run. or short.

  • Page 37: C27" Isc Solenoid Range Abnormal

    4-1-27 FI SYSTEM DIAGNOSIS “C27” ISC SOLENOID RANGE ABNORMAL CODE CODE DETECTED CONDITION POSSIBLE CAUSE ● ISC solenoid malfunction. ISC solenoid’s step is out of the specified range. O step � Solenoid step � 100 step ● ISC solenoid’s step is out of the specifie range. ●...
  • Page 38 FI SYSTEM DIAGNOSIS 4-1-28 “C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Fuel injector not comes in voltage from battery. ● Injector circuit open or short. ● Injector malfunction. ● ECU malfunction. ▣ ▣ INSPECTION ◈...
  • Page 39 4-1-29 FI SYSTEM DIAGNOSIS ◈ Step 2 1) Turn the ignition switch “ON” position. 2) Measure the injector voltage between YG(NO.1), YR(NO.2) wire and ground. Battery voltage Injector voltage ([NO.1] � YG - � Ground ) ([NO.2] � YR - � Ground ) ②...

  • Page 40: C37" Sav Solenoid Malfunction

    FI SYSTEM DIAGNOSIS 4-1-30 “C37” SAV SOLENOID MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE ● SAV solenoid circuit open or short. SAV solenoid voltage is not input in ECU. ● SAV solenoid malfunction. ● ECU malfunction. ▣ ▣ INSPECTION 1) Remove the front seat. 2) Turn the ignition switch “OFF”...

  • Page 41: C41" Fuel Pump Relay Circuit Malfunction

    4-1-31 FI SYSTEM DIAGNOSIS “C41” FUEL PUMP RELAY CIRCUIT MALFUNCTION CODE CODE CODE CODE DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the both injectors for 3 sec. ● Fuel pump relay circuit open or short. after the contact of fuel pump relay is turned “ON” ●...

  • Page 42: C43 " " Oxygen Sensor Heater Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-32 “C43” OXYGEN SENSOR HEATER CIRCUIT MALFUNTION CODE CODE CODE CODE CODE CODE DETECTED CONDITION POSSIBLE CAUSE ● Oxygen sensor, Oxygen sensor heater circuit open Oxygen sensor heater signal is not input in ECU. or short. ● Oxygen sensor, Oxygen sensor heater malfunction. ●...

  • Page 43: Sensors

    4-1-33 FI SYSTEM DIAGNOSIS SENSORS ◉ ◉ IAP SENSOR INSPECTION The intake air pressure (IAP) sensors NO.1 ① ① NO.2 ② are installed at the upside of each intake pipe. (Refer to page 4-1-22) ◉ ◉ IAP SENSOR REMOVAL AND INSTALLATION ●...

  • Page 44: Iat Sensor Inspection

    FI SYSTEM DIAGNOSIS 4-1-34 ◉ ◉ IAT SENSOR INSPECTION ① The intake air temperature (IAT) sensor ① installed at the air cleaner case. (Refer to page 4-1-24) ◉ ◉ IAT SENSOR REMOVAL AND INSTALLATION ● Remove the fuel tank. ● Remove the IAT sensor from the air cleaner case. ●...
  • Page 46 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM …………………………………………………………… 46 (4-2-1) REMOVAL AND DISASSEMBLY ( ) ………………… 47 (4-2-2) ) …………… 48 (4-2-3) REASSEMBLY AND INSTALLATION ( 4 -2 ) ……………………… 49 (4-2-4) REMOVAL AND DISASSEMBLY ( ) ………………… 50 (4-2-5) REASSEMBLY AND INSTALLATION ( FUEL PRESSURE INSPECTION …………………………………………...

  • Page 47: Fuel System

    4-2-1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM...

  • Page 48: Removal And Disassembly ( )

    FUEL SYSTEM AND THROTTLE BODY 4-2-2 REMOVAL AND DISASSEMBLY ( ● Remove the front seat. ● Remove the fuel tank mounting bolt and take off the hooks. ● Disconnect the fuel gauge coupler ① . ① ● Remove the fuel pump coupler ② . ●...

  • Page 49: Reassembly And Installation

    4-2-3 FUEL SYSTEM AND THROTTLE BODY ● Remove the fuel tank rearward. CAUTION As gasoline leakage may occur in this operation, keep away from fire and sparks. ● Remove the fuel pump assembly ① by removing its mounting bolts diagonally. WARNING �...

  • Page 50: Removal And Disassembly

    FUEL SYSTEM AND THROTTLE BODY 4-2-4 REMOVAL AND DISASSEMBLY ● Remove the front seat. ● Remove the fuel tank mounting bolts and take off the hooks. ● Disconnect the fuel gauge coupler ① . ① ● Remove the fuel pump coupler ② . ②...

  • Page 51: Reassembly And Installation

    4-2-5 FUEL SYSTEM AND THROTTLE BODY ● Remove the fuel tank rearward. CAUTION As gasoline leakage may occur in this operation, keep away from fire and sparks. ● Remove the fuel pump assembly ① by removing its mounting bolts. WARNING �...

  • Page 52: Fuel Pressure Inspection

    FUEL SYSTEM AND THROTTLE BODY 4-2-6 FUEL PRESSURE INSPECTION ● Remove the front seat. ● Place a rag under the fuel injector hose. ● Disconnect the fuel injector hose from the fuel delivery pipe. ● Install the special tool between the fuel tank and fuel delivery pipe.

  • Page 53: Fuel Mesh Filter Inspection And Cleaning

    4-2-7 FUEL SYSTEM AND THROTTLE BODY First, check the insulation between ① and ② ① terminals with pocket tester. Then apply 12 volts to ③ ③ and ④ terminals, � to ③ and � to ④ , and check the continuity between ① and ②...

  • Page 54: Throttle Body

    FUEL SYSTEM AND THROTTLE BODY 4-2-8 THROTTLE BODY...

  • Page 55: Removal

    4-2-9 FUEL SYSTEM AND THROTTLE BODY REMOVAL ● Remove the fuel tank. ● Remove the air cleaner box. ● Disconnect the fuel hose. ● Remove the all coupler to related the throttle body. ● Loosen the throttle body clamp screws. ●...

  • Page 56: Cleaning

    FUEL SYSTEM AND THROTTLE BODY 4-2-10 CLEANING ● Clean all passageways with a spray-type throttle body cleaner and blow dry with compressed air. 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.

  • Page 57: Installation

    4-2-11 FUEL SYSTEM AND THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points : ● Connect the throttle cable to the throttle cable drum. ● Adjust the throttle cable play with the cable adjusters.

  • Page 58: Electrical System

    ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS ………………… 58 (5-1) IGNITION SYSTEM ……………………………………………………… 60 (5-3) CHARGING SYSTEM …………………………………………………… 61 (5-7)

  • Page 59: Location Of Electrical Components

    5-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS ⑥ ⑨ ② ① ⑤ ④ ③ ⑧ ⑦ ① ③ ⑥ Ignition coil NO.1 Main relay Main fuse (30A) ② Ignition coil NO.2 ④ Fuel pump relay ⑦ ⑤ Head lamp relay ⑧...
  • Page 60 ELECTRICAL SYSTEM 5-2 � � ⑮ � � ⑮ � � ISC solenoid IAP sensor NO.1 SAV solenoid � ET sensor � IAP sensor NO.2 � � � � Oxygen sensor � Fuel injector NO.2 � Fuel injector NO.1...

  • Page 61: Ignition System

    5-3 ELECTRICAL SYSTEM IGNITION SYSTEM RELAY ENGINE STOP SWITCH SWITCH REAR FRONT IGNITION IGNITION MAGNETO COIL COIL FUSE ◉ ◉ INSPECTION ▣ ▣ IGNITION COIL RESISTANCE INSPECTION ● Disconnect the ignition coil read wire. Measure the ignition coil resistance in bolt the primary and secondary windings.
  • Page 62 ELECTRICAL SYSTEM 5-4 ▣ ▣ MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. If the resistance is not within the specified value, replace the magneto coil, with a new one. Standard Magneto coil resistance G - L Approx.

  • Page 63: Charging System

    5-7 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator / Rectifier IG. switch A. C generator ◉ ◉ INSPECTION IG. switch ▣ ▣ CHARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Regulator Using the pocket tester, measure the DC voltage Rectifier between the battery terminal �...
  • Page 64 ELECTRICAL SYSTEM 5-10 ▣ ▣ REGULATOR / RECTIFIER ● Disconnect the regulator / rectifier couplers. ● 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 : MΪ...

  • Page 66: Servicing Information

    SERVICING INFORMATION CONTENTS TROUBLESHOOTING ………………………………………………… 66 (7-1-1) SPECIAL TOOLS ……………………………………………………… 75 (7-8) TIGHTENING TORQUE ……………………………………………… 76 (7-11) SERVICE DATA ………………………………………………………… 77 (7-19-1) WIRING DIAGRAM ( ………………………………… 80 (7-31-1) WIRING DIAGRAM ( ………………………………… 82 (7-31-3) WIRING DIAGRAM ( ……………………………… 84 (7-31-5)

  • Page 67: Troubleshooting

    7-1-1 SERVICING INFORMATION TROUBLESHOOTING ◉ ◉ MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR The sensor voltage should be the following. 0.1 V � sensor voltage < 4.6 V Engine temperature Without the above range for 4 sec. and more, C15 is indicated. sensor (ETS) Engine temperature sensor, lead wire / coupler connection.
  • Page 68 SERVICING INFORMATION 7-1-2 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR When the IC of the ECU electric current gets 6 A and more, C24 or C25 is indicated. Ignition coil (IG coil), C24 / C25 NO.1 / NO.2 Ignition coil, wiring / coupler connection, power supply from the battery.
  • Page 69 7-1-3 SERVICING INFORMATION ◉ ◉ ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low Adjust. start or is hard to 1. Tappet clearance out of adjustment. Repair or replace. 2. Worn valve guides or poor seating of valves. start.
  • Page 70 SERVICING INFORMATION 7-1-4 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn down camshafts. Replace. 5. Too wide spark plug gaps. Adjust or replace.
  • Page 71 7-1-5 SERVICING INFORMATION Complaint Symptom and possible causes Remedy 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.
  • Page 72 SERVICING INFORMATION 7-1-6 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal / electrical parts in high speed range. 1. Weakened valve springs. Replace. 2. Worn camshafts. Replace. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gaps. Adjust.
  • Page 73 7-1-7 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks Defective engine internal / electrical parts Adjust. power. 1. Loss of tappet clearance. Replace. 2. Weakened valve springs. Adjust. 3. Valve timing out of adjustment. Replace. 4. Worn piston rings or cylinders. Repair.
  • Page 74 SERVICING INFORMATION 7-1-8 Complaint Symptom and possible causes Remedy Dirty or heavy 1. Too much engine oil in the engine. Check with inspection win- dow, drain out excess oil. exhaust smoke. 2. Worn piston rings or cylinders. Replace. 3. Worn valve guides. Replace.
  • Page 75 7-4 SERVICING INFORMATION ◉ ◉ ELECTRICAL Complaint Symptom and possible causes Remedy 1. Defective ignition coils or spark plug caps. Replace. No sparking or 2. Defective spark plugs. Replace. poor sparking. 3. Defective pick-up coil. Replace. 4. Defective ECU. Replace. 5.

  • Page 76: Special Tools

    SERVICING INFORMATION 7-8 SPECIAL TOOLS Special tools Part Number∙ ∙ Part Name∙ ∙ Description 09900-27000 Mode select switch Inspect FI system sensor. (Only for 09915-54510 Fuel pump pressure gauge Measure fuel pressure of fuel pump.

  • Page 77: Tightening Torque

    7-11 SERVICING INFORMATION TIGHTENING TORQUE ◉ ◉ FI SYSTEM PARTS N∙ ∙ m kgf∙ ∙ m ITEM Engine temperature sensor (ET sensor) 6 ~ 8 0.6 ~ 0.8 Fuel injector bolt...

  • Page 78: Service Data

    SERVICING INFORMATION 7-19-1 SERVICE DATA ◉ ◉ FI SENSORS ITEM SPECIFICATION NOTE IAP sensor input voltage 4.5 ~ 5.5 V IAP sensor output voltage Approx. 4.0 ~ 4.2 V when ignition switch “ON” IAT sensor voltage 4.5 ~ 5.5 V IAT sensor resistance Refer to page 34 (4-1-25) 4.5 ~ 5.5 V at normal condition...
  • Page 79 7-19-2 SERVICING INFORMATION ◉ ◉ THROTTLE BODY ITEM SPECIFICATION NOTE I.D. No. GT250 Bore size Idle rpm 1,400 ~ 1,600 rpm Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) ◉ ◉ FUEL INJECTOR + FUEL PUMP ITEM SPECIFICATION NOTE Ϊ...
  • Page 80 SERVICING INFORMATION 7-20 ◉ ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE BTDC 13� / 2,000rpm ~ 30� / 6,000rpm Ignition timing Type CR8E 0.7 ~ 0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E Over 8 mm (0.32 in) Spark performance...

  • Page 81: Wiring Diagram

    7-31-1 SERVICING INFORMATION WIRING DIAGRAM ( SPEEDOMETER HANDLE SWITCH R Ft. BRAKE S/W CLUTCH LEVER S/W SOLENOID ENGINE STOP LIGHTING STARTER STOP PUSH SPEED TACHO FUEL Ft. TURNSIGNAL R HEAD LAMP POSITION Ft. TURNSIGNAL L O R BW BR LOCK PUSH RR IGNITION DIMMER...
  • Page 82 SERVICING INFORMATION 7-31-2 FUEL PUMP DIODE #2 FUEL PUMP HEAD LAMP RR BRAKE S/W 02 SENSOR MAIN RELAY FUEL GAUGE DIODE #3 RELAY RELAY CAN TOOL ENGINE CONTROL UNIT 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 RR TURN SIG.

  • Page 83: Wiring Diagram

    7-31-3 SERVICING INFORMATION WIRING DIAGRAM ( HANDLE SWITCH R FUEL GAUGE SPEED SENSOR CLUTCH LEVER S/W DISPLAY SOLENOID ENGINE STOP LIGHT STARTER Ft. BRAKE STOP PUSH TACHO Ft TURNSIGNAL R HEAD LAMP POSITION Ft. TURNSIGNAL L LOCK PUSH PUSH HORN RR IGNITION TURN SIGNAL PASS...
  • Page 84 SERVICING INFORMATION 7-31-4 RR BRAKE S/W FUEL PUMP HEAD LAMP 02 SENSOR MAIN RELAY FUEL PUMP FUEL GAUGE DIODE #2 RELAY RELAY ENGINE CONTROL UNIT CAN TOOL SWITCH 1 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 RR TURN SIG.

  • Page 85: Wiring Diagram

    7-31-5 SERVICING INFORMATION WIRING DIAGRAM ( HANDLE SWITCH R FUEL GAUGE SPEED SENSOR CLUTCH LEVER S/W DISPLAY SOLENOID ENGINE STOP LIGHT STARTER Ft. BRAKE STOP PUSH TACHO Ft TURNSIGNAL R LOW BEAM HIGH BEAM POSITION HEAD LAMP Ft. TURNSIGNAL L LOCK PUSH PUSH...
  • Page 86 SERVICING INFORMATION 7-31-6 RR BRAKE S/W HEAD LAMP FUEL PUMP 02 SENSOR MAIN RELAY FUEL PUMP FUEL GAUGE DIODE #2 RELAY RELAY CAN TOOL ENGINE CONTROL UNIT SWITCH 1 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 RR TURN SIG.
  • Page 87 MEMO...
  • Page 88 MEMO...
  • Page 89 Prepared by 1st Ed. OCT. 2008. Manual No. 99000-95610 Printed in Korea...
  • Page 90 S&T Motors Co., Ltd.

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