HYOSUNG Aquila GT250 Ej Service Manual
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HYOSUNG Aquila GT250 Ej Service Manual

HYOSUNG Aquila GT250 Ej Service Manual

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Summary of Contents for HYOSUNG Aquila GT250 Ej

  • 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 looking 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: Table Of Contents

    GENERAL INFORMATION CONTENTS EXTERIOR PHOTOGRAPH 6 [1-6-1] EXTERIOR ILLUSTRATION 8 [1-7-1] EXTERIOR ILLUSTRATION 9 [1-7-2] EXTERIOR ILLUSTRATION 10 [1-7-3] EXTERIOR ILLUSTRATION 11 [1-7-4] FUNCTION OF EI SENSOR 12 [1-8-1] SPECIFICATIONS 13 [1-8-2]...

  • Page 7: 1-6-1 General Information

    1-6-1 GENERAL INFORMATION EXTERIOR PHOTOGRAPH...
  • Page 8 GENERAL INFORMATION 1-6-2 EXTERIOR PHOTOGRAPH...

  • Page 9: Exterior Illustration

    1-7-1 GENERAL INFORMATION EXTERIOR ILLUSTRATION Rear reflector Brake / Tail lamp License plate lamp Rear turn signal lamp Front turn signal lamp Passenger footrests Head lamp (WHEEL BASE) (LENGTH)

  • Page 10: Exterior Illustration

    GENERAL INFORMATION 1-7-2 EXTERIOR ILLUSTRATION Rear turn signal lamp Brake / Tail lamp Rear reflector License plate lamp Front turn signal lamp Head lamp Passenger footrests (WHEEL BASE) (LENGTH)

  • Page 11: Exterior Illustration

    1-7-3 GENERAL INFORMATION EXTERIOR ILLUSTRATION (Rear turn signal lamp & License plate lamp) (Rear turn signal lamp) (Front turn signal lamp) (GROUND CLEARANCE) (WHEEL BASE) (LENGTH)

  • Page 12: Exterior Illustration

    GENERAL INFORMATION 1-7-4 EXTERIOR ILLUSTRATION Rear turn signal lamp Brake / Tail lamp Rear reflector License plate lamp Front turn signal lamp Head lamp Passenger footrests (WHEEL BASE) (LENGTH)

  • Page 13: Function Of Ei Sensor

    1-8-1 GENERAL INFORMATION FUNCTION OF EI SENSOR ECU (Engine Control Unit, EI Control Unit) : ECU decide the fuel injection volume and ignition time to adjust the fuel injector opening and closing rate which is considered the engine speed, intake air pressure, intake air volume, engine temperature, oxygen volume and throttle opening angle, etc.

  • Page 14: Specifications

    GENERAL INFORMATION 1-8-2 SPECIFICATIONS DIMENSIONS AND MASS I T E M 2,280 mm (89.8 in) Overall length 2,090 mm (82.3 in) 885 mm (34.8 in) 700 mm (27.6 in) Overall width Overall height 1,095 mm (43.1 in) 1,130 mm (44.5 in) 1,520 mm (59.8 in) 1,435 mm (56.5 in) Wheelbase...
  • Page 15 1-8-3 GENERAL INFORMATION CHASSIS I T E M Front suspension Telescopic type Rear suspension Swingarm type Steering angle 40 (right & left) 27 (right & left) Caster 25.5 Trail 142 mm (5.59 in) 90 mm (3.54 in) Front brake Disk brake Double disk brake Rear brake Drum brake...
  • Page 16 GENERAL INFORMATION 1-9-1 DIMENSIONS AND MASS I T E M 2,090 mm (82.3 in) Overall length 780 mm (30.7 in) Overall width Overall height 1,095 mm (43.1 in) 1,125 mm (44.3 in) 1,435 mm (56.5 in) Wheelbase Ground clearance 175 mm (6.9 in) 170 kg (375 lbs) Mass ENGINE...
  • Page 17 1-9-2 GENERAL INFORMATION CHASSIS I T E M Front suspension Telescopic type Rear suspension Swingarm type Steering angle 27 (right & left) Caster 25.5 Trail 90 mm (3.54 in) Front brake Double disk brake Disk brake Rear brake Disk brake Front tire size 110/70 - 17 54H Rear tire size...
  • Page 18 EI SYSTEM DIAGNOSIS CONTENTS 4 -1 PRECAUTIONS IN SERVICING 18 [4-1-1] EI SYSTEM TECHNICAL FEATURES 22 [4-1-5] SELF-DIAGNOSIS FUNCTION 29 [4-1-12] SELF-DIAGNOSIS FUNCTION 33 [4-1-16] EI SYSTEM TROUBLESHOOTING 40 [4-1-23] CUSTOMER COMPLAINT ANALYSIS 40 [4-1-23] SELF-DIAGNOSTIC PROCEDURES 42 [4-1-25] SELF-DIAGNOSIS RESET PROCEDURE 44 [4-1-27] MALFUNCTION CODE AND DEFECTIVE CONDITION 45 [4-1-28]...

  • Page 19: Precautions In Servicing

    4-1-1 EI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the EI 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 20 EI 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 21 4-1-3 EI 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 EI system instantly when reverse power is applied.

  • Page 22: Using Testers

    EI 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. USING TESTERS Use well-charged batteries in the tester.
  • Page 23 4-1-5 EI SYSTEM DIAGNOSIS EI SYSTEM TECHNICAL FEATURES & EI SYSTEM’S CONTROL DIAGRAM FUEL IAT Sensor FUEL TANK AIR CLEANER ISC Solenoid TP Sensor FUEL PUMP THROTTLE BODY IAP Sensor INTAKE PIPE FUEL INJECTOR ET Sensor Pick-up Coil CYLINDER Sensor EXHAUST PIPE : Electrical signal flow MUFFLER...
  • Page 24 EI SYSTEM DIAGNOSIS 4-1-6 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 25: Injection Stop Control

    4-1-7 EI SYSTEM DIAGNOSIS 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 26 EI SYSTEM DIAGNOSIS 4-1-8 EI SYSTEM PARTS LOCATION Speedometer GP switch Ignition coil, NO.1 Fuel injector, NO.1 Ignition coil, NO.2 Fuel injector, NO.2 Pick-up coil TP sensor...
  • Page 27 4-1-9 EI SYSTEM DIAGNOSIS ISC solenoid ET sensor IAT sensor Oxygen sensor, NO.1 RO switch Oxygen sensor, NO.2 Fuel pump relay IAP sensor...
  • Page 28 EI SYSTEM DIAGNOSIS 4-1-10 EI SYSTEM PARTS LOCATION Speedometer Pick-up coil Fuel injector, NO.1 Ignition coil, NO.1 Fuel injector, NO.2 Ignition coil, NO.2 IAT sensor TP sensor GP switch...
  • Page 29 4-1-11 EI SYSTEM DIAGNOSIS ISC solenoid ET sensor Fuel pump relay Oxygen sensor, NO.1 RO switch Oxygen sensor, NO.2 IAP sensor...
  • Page 30 EI SYSTEM DIAGNOSIS 4-1-12 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 be notified by the LCD display panel and the “FI” check lamp “ ”...
  • Page 31 4-1-13 EI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the ECU. The memorized malfunction code is displayed on the clock screen or with blinks signal of the “FI” check lamp “ ” Malfunction means that the ECU does not receive signal from the devices or fault signal received. These affected devices are indicated in the code form on the clock screen or displayed with blinks signal of the “FI”...
  • Page 32 EI SYSTEM DIAGNOSIS 4-1-14 CAUTION Confirm the malfunction code after turning the ignition switch “ON” position and starting the engine separately. The dealer mode coupler of the wiring harness is located under the rear seat. CLOCK SCREEN “FI” CHECK LAMP INDICATION CLASSIFICATION MALFUNCTION...
  • Page 33 4-1-15 EI SYSTEM DIAGNOSIS B. “FI” CHECK LAMP To confirm the memorized malfunction code through the “FI” check lamp “ ” 1. Turn the ignition switch alternately, “ON” and “OFF” position, for 2 seconds by three times. CAUTION Take special care when operating above procedure. If the ignition switch is turned alternately, “ON”...
  • Page 34 EI SYSTEM DIAGNOSIS 4-1-16 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 “ ” To check the function of the individual EI system devices, the dealer mode is prepared. In this check, the additional operations is necessary to read the code of the malfunction items.
  • Page 35 4-1-17 EI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the ECU. The memorized malfunction code is displayed with blinks signal of the “FI” check lamp “ ” Malfunction means that the ECU does not receive signal from the devices or fault signal received. These affected devices are displayed with blinks signal of the “FI”...
  • Page 36 EI SYSTEM DIAGNOSIS 4-1-18 CODE CODE MALFUNCTION PART REMARKS For NO.1 cylinder NO.1 O S heater Circuit Low Voltage For NO.1 cylinder NO.1 O S heater Circuit High Voltage For NO.2 cylinder NO.2 O S heater Circuit Low Voltage NO.2 O S heater Circuit High Voltage For NO.2 cylinder IAPS Circuit Low Voltage or Open IAPS Circuit High Voltage...
  • Page 37 4-1-19 EI SYSTEM DIAGNOSIS CODE CODE MALFUNCTION PART REMARKS ETS Circuit Low Voltage ETS Circuit High Voltage or Open TPS Circuit Low Voltage or Open TPS Circuit High Voltage For NO.1 cylinder NO.1 O S Circuit Low Voltage NO.1 O S Circuit High Voltage For NO.1 cylinder For NO.2 cylinder NO.2 O S Circuit Low Voltage...
  • Page 38 EI SYSTEM DIAGNOSIS 4-1-20 CODE CODE MALFUNCTION PART REMARKS NO.1 Fuel injector Circuit Malfunction For NO.1 cylinder NO.2 Fuel injector Circuit Malfunction For NO.2 cylinder Fuel pump relay Circuit Low Voltage or Open Fuel pump relay Circuit High Voltage Pick-up coil Noisy Signal Pick-up coil No Signal NO.1 IG coil Malfunction For NO.1 cylinder...
  • Page 39 4-1-21 EI SYSTEM DIAGNOSIS CODE CODE MALFUNCTION PART REMARKS PV Circuit Open California model only PV Circuit Shorted California model only ISC Error Battery Voltage Low Battery Voltage High “FI” check lamp Circuit Malfunction GP or Clutch lever Switch Circuit Malfunction CODE : For LCD (DISPLAY) indication [Applies only to CODE : For “FI”...
  • Page 40 EI SYSTEM DIAGNOSIS 4-1-22 A. LCD (DISPLAY) INDICATION In the clock screen , the malfunction code is indicated in order of occurrence. B. “FI” CHECK LAMP INDICATION In the “FI” check lamp “ ” , the malfunction code is blinked in order of occurrence. In the “FI”...
  • Page 41 4-1-23 EI SYSTEM DIAGNOSIS EI 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 42 EI SYSTEM DIAGNOSIS 4-1-24 MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F / °C) Always Frequency Always Sometimes ( times / day, month) Only once Under certain condition Road Urban Suburb...
  • Page 43 4-1-25 EI 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. In case of the memorized malfunction code is displayed in the code form on the clock screen or with blinks signal of the “FI”...
  • Page 44 EI SYSTEM DIAGNOSIS 4-1-26 A. LCD (DISPLAY) INDICATION Refer to page 30 [4-1-13] B. “FI” CHECK LAMP INDICATION Refer to page 32 [4-1-15] A. “FI” CHECK LAMP INDICATION Refer to page 34 [4-1-17]...
  • Page 45 4-1-27 EI SYSTEM DIAGNOSIS SELF-DIAGNOSIS RESET PRO- CEDURE A. LCD (DISPLAY) PANEL After repairing the trouble, refer to page 30 [4-1- 13], move to the malfunction code mode . If the clock screen indicates the “noEr” letters, the malfunction codes are cleared. Disconnect the special tool from the dealer mode coupler at the wiring harness.
  • Page 46 EI SYSTEM DIAGNOSIS 4-1-28 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR noEr NO FAULT After engine running, if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in 12 0031 Low Voltage times test cycle, the code 0031 is indicated.
  • Page 47 4-1-29 EI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR The sensor voltage should be the following. 0.1 V Sensor output voltage 0117 Low Voltage Without the above range for 6.25 sec. and more, 0117 is indicated. Engine temperature sensor, lead wire / coupler connection.
  • Page 48 EI SYSTEM DIAGNOSIS 4-1-30 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if NO.1 fuel injector signal open or is happened the high / ground short fault for 1 second by 5 times NO.1 Fuel Injector 0201 in 10 times test cycle, the code 0201 is indicated.
  • Page 49 4-1-31 EI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if purge control valve signal open or is happened the ground short fault for 1 second by 10 times in 12 times test cycle, the code 0444 is indicated. 0444 Open Purge control valve, wiring / coupler connection, power supply...
  • Page 50 EI SYSTEM DIAGNOSIS 4-1-32 “0031”, “0032”, “0037” or “0038” OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION & “0131”, “0132”, “0137” or “0138” OXYGEN SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor, Oxygen sensor heater circuit open or short.
  • Page 51 4-1-33 EI SYSTEM DIAGNOSIS INSPECTION 1) Remove the front seat and frame cover. 2) Turn the ignition switch to the “OFF” position. 3) Check the Oxygen sensor coupler for loose or poor contacts. Is OK? B or GR (NO.1 O S) / R or GR (NO.2 O S) wire open or shorted to ground, or poor (NO.1 O S) /...
  • Page 52 EI SYSTEM DIAGNOSIS 4-1-34 “0107” or “0108” IAP SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE Clogged vacuum passage between throttle body Refer to page 45 [4-1-28] and IAP sensor. Air being drawn from vacuum passage between NOTE : throttle body and IAP sensor.
  • Page 53 4-1-35 EI SYSTEM DIAGNOSIS Step 2 1) Connect the IAP sensor coupler 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch to the “ON” position. 4) Measure the IAP sensor output voltage at the wire side coupler (between BL and GR wires).
  • Page 54 EI SYSTEM DIAGNOSIS 4-1-36 “0112” or “0113” IAT SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE IAT sensor circuit open or short. Refer to page 45 [4-1-28] IAT sensor malfunction. ECU malfunction. INSPECTION 1) Remove the fuel tank. 2) Turn the ignition switch to the “OFF”...
  • Page 55 4-1-37 EI SYSTEM DIAGNOSIS IAT sensor resistance Intake Air Temp. Resistance (-40 44.642 14.958 5.734 2.438 1.141 (104 (140 0.579 (176 0.315 (212 0.182 (248 0.111 (266 0.088 Tester knob indication : Resistance ( Is the resistance OK? Lg or GR wire open or shorted to ground, or poor connection of ECU coupler.
  • Page 56 EI SYSTEM DIAGNOSIS 4-1-38 “0117” or “0118” ET SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE ET sensor circuit open or short. Refer to page 46 [4-1-29] ET sensor malfunction. ECU malfunction. INSPECTION 1) Turn the ignition switch to the “OFF” position. 2) Check the ET sensor coupler for loose or poor contacts.
  • Page 57 4-1-39 EI SYSTEM DIAGNOSIS ET sensor resistance Engine Temp. Resistance (To ECU) Approx. 75.5 Approx. 28.7 Approx. 12.2 (104 Approx. 5.6 (140 Approx. 2.8 (176 Approx. 1.5 (248 Approx. 0.5 (284 Approx. 0.3 (320 Approx. 0.2 (356 Approx. 0.13 Tester knob indication : Resistance ( Is the resistance OK? G or GR wire open or shorted to ground, or poor...
  • Page 58 EI SYSTEM DIAGNOSIS 4-1-40 “0122” or “0123” TP SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE TP sensor circuit open or short. TP sensor malfunction. Refer to page 46 [4-1-29] ECU malfunction. INSPECTION Step 1 1) Turn the ignition switch to the “OFF”...
  • Page 59 4-1-41 EI SYSTEM DIAGNOSIS Step 2 1) Remove the frame cover. 2) Turn the ignition switch to the “OFF” position. 3) Disconnect the TP sensor coupler. 4) Check the continuity between (LY) and ground. (Infinity) TP sensor continuity - Ground) Tester knob indication : Resistance ( Ground Is the continuity OK?
  • Page 60 EI SYSTEM DIAGNOSIS 4-1-42 Is the output voltage OK? OB, LY or GR wire open or shorted to ground, or poor connection of ECU coupler. If wire and connection are OK, intermittent trouble or faulty ECU. Gray Black Recheck each terminal and wire harness for open circuit and ECU Coupler poor connection.
  • Page 61 4-1-43 EI SYSTEM DIAGNOSIS “0201” or “0202” FUEL INJECTOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE Injector circuit open or short. Refer to page 47 [4-1-30] Injector malfunction. ECU malfunction. INSPECTION Step 1 1) Remove the fuel tank and frame cover. 2) Turn the ignition switch to the “OFF”...
  • Page 62 EI SYSTEM DIAGNOSIS 4-1-44 Step 2 1) Turn the ignition switch to the “ON” position. 2) Measure the injector voltage between YL(NO.1 & NO.2) wire and ground. Battery voltage Injector voltage ( NO.1 YL - Ground, NO.2 YL - Ground ) Tester knob indication : Voltage ( NOTE Injector voltage can be detected only 3...
  • Page 63 4-1-45 EI SYSTEM DIAGNOSIS “0230” or “0232” FUEL PUMP RELAY CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE Fuel pump relay circuit open or short. Refer to page 47 [4-1-30] Fuel pump relay malfunction. ECU malfunction. INSPECTION 1) Remove the frame cover.
  • Page 64 EI SYSTEM DIAGNOSIS 4-1-46 “0336” or “0337” PICK-UP COIL CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE Metal particles or foreign materiel being attached on the pick-up coil and rotor tip. Refer to page 47 [4-1-30] Pick-up coil circuit open or short.
  • Page 65 4-1-47 EI SYSTEM DIAGNOSIS Are the resistance and continuity OK? L or G wire open or shorted to ground, or poor connection of ECU coupler. If wire and connection are OK, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor Gray Black...
  • Page 66 EI SYSTEM DIAGNOSIS 4-1-48 “0351” or “0352” IGNITION COIL MALFUNCTION Refer to the IGNITION COIL for details. (See page 89 ~ 90 [5-5-1 ~ 2]) LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION...
  • Page 67 4-1-49 EI SYSTEM DIAGNOSIS “0444” or “0445” PURGE CONTROL VALVE CIRCUIT MALFUNCTION (California model only) LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE PV circuit open and short. Refer to page 48 [4-1-31] PV malfunction. ECU malfunction. INSPECTION 1) Remove the frame cover.
  • Page 68 EI SYSTEM DIAGNOSIS 4-1-50 Are the resistance and continuity OK? GW wire open or shorted to ground, or poor connection of ECU coupler. YL coupler open or shorted to the wiring harness. If wire and connection are OK, intermittent trouble or faulty ECU. Black Gray Recheck each terminal and wire...
  • Page 69 4-1-51 EI SYSTEM DIAGNOSIS “0505” ISC SOLENOID RANGE ABNORMAL LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE ISC solenoid malfunction. Refer to page 48 [4-1-31] ISC solenoid’s step is out of the specified range. ECU malfunction. INSPECTION 1) Remove the front seat.
  • Page 70 EI SYSTEM DIAGNOSIS 4-1-52 “0562” or “0563” BATTERY VOLTAGE MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE Battery voltage circuit open and short. Refer to page 48 [4-1-31] Battery malfunction. ECU malfunction. INSPECTION 1) Remove the front seat. 2) Turn the ignition switch to the “OFF”...
  • Page 71 4-1-53 EI SYSTEM DIAGNOSIS “0650” “FI” CHECK LAMP CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE “FI” check lamp circuit open and short. Refer to page 48 [4-1-31] “FI” check lamp malfunction. ECU malfunction. INSPECTION 1) Remove the frame cover.
  • Page 72 EI SYSTEM DIAGNOSIS 4-1-54 “0850” GP or CLUTCH LEVER SWITCH CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE GP switch circuit open or short. GP switch malfunction. Refer to page 48 [4-1-31] Clutch lever switch circuit open or short. Clutch lever switch malfunction.
  • Page 73 4-1-55 EI SYSTEM DIAGNOSIS 6) Disconnect the clutch lever switch coupler then check the continuity between GR wire and Br wire when the squeezing the clutch lever. Clutch lever switch continuity Tester knob indication : Resistance ( 7) Measure the voltage between of the ECU and the LY wire of the wiring harness’s GP switch coupler, and measure the voltage between...

  • Page 74: Iap Sensor Inspection

    EI SYSTEM DIAGNOSIS 4-1-56 SENSORS PICK-UP COIL INSPECTION The pick-up coil is installed in the magneto cover. (Refer to page 63 [4-1-46]) PICK-UP COIL REMOVAL AND INSTALLATION Remove the magneto cover. Install the magneto cover in the reverse order of removal.

  • Page 75: Iat Sensor Inspection

    4-1-57 EI SYSTEM DIAGNOSIS ET SENSOR INSPECTION The engine temperature (ET) sensor is installed at the front cylinder. (Refer to page 55 [4-1-38]) ET SENSOR REMOVAL AND INSTALLATION Remove the ET sensor. Install the ET sensor in the reverse order of removal.
  • Page 76 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM 76 [4-2-1] REMOVAL AND DISASSEMBLY 77 [4-2-2] REASSEMBLY AND INSTALLATION 78 [4-2-3] 4 -2 FUEL PRESSURE INSPECTION 79 [4-2-4] FUEL PUMP RELAY INSPECTION 79 [4-2-4] FUEL MESH FILTER INSPECTION AND CLEANING 80 [4-2-5] FUEL GAUGE INSPECTION 80 [4-2-5] THROTTLE BODY...

  • Page 77: 4-2-1 Fuel System And Throttle Body

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

  • Page 78: Removal And Disassembly

    FUEL SYSTEM AND THROTTLE BODY 4-2-2 REMOVAL AND DISASSEMBLY Remove the front seat. Remove the fuel tank mounting bolts and take off the hooks. Disconnect the fuel gauge coupler Disconnect the fuel pump coupler Remove the fuel injector hose CAUTION After disconnecting the fuel injector hose insert a blind plug into the end to stop fuel leakage.

  • Page 79: 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 by removing its mounting bolts diagonally. WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away.

  • Page 80: Fuel Pressure Inspection

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

  • Page 81: Fuel Mesh Filter Inspection And Cleaning

    4-2-5 FUEL SYSTEM AND THROTTLE BODY First, check the insulation between terminals with the pocket tester. Then apply 12 volts terminals, , and check the continuity between If there is no continuity, replace it with a new one. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine...

  • Page 82: Throttle Body

    FUEL SYSTEM AND THROTTLE BODY 4-2-6 THROTTLE BODY...

  • Page 83: Removal

    4-2-7 FUEL SYSTEM AND THROTTLE BODY REMOVAL Remove the fuel tank. Remove the air cleaner chamber. Disconnect the fuel hoses. Remove the all couplers connected to the throttle body. Loosen the throttle body clamp screws. Disconnect the throttle cables from their drum. Dismount the throttle body assembly.

  • Page 84: Cleaning

    FUEL SYSTEM AND THROTTLE BODY 4-2-8 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 85: Installation

    4-2-9 FUEL SYSTEM AND THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points : CAUTION Never operate the idle nuts (NO.1) and (NO.2) to avoid variations of the carburetion setting. Connect the throttle cable to the throttle cable drum.
  • Page 86 ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS 86 [5-1] IGNITION SYSTEM 88 [5-3] CHARGING SYSTEM 91 [5-7] STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 93 [5-11]...

  • Page 87: 5-1 Electrical System

    5-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Ignition coil NO.1 ISC solenoid Main fuse (30A) Ignition coil NO.2 Head lamp fuse (15A) Battery IAT sensor RO switch Magneto Pick-up coil GP switch...
  • Page 88 ELECTRICAL SYSTEM 5-2 Main relay ET sensor IAP sensor Fuel pump relay Head lamp relay Oxygen sensor NO.1 Fuel injector NO.2 Fuel injector NO.1 Oxygen sensor NO.2...

  • Page 89: Ignition System

    5-3 ELECTRICAL SYSTEM IGNITION SYSTEM IGNITION SWITCH ENGINE STOP SWITCH FUSE FUSE REGULATOR RECTIFIER BATTERY 12V 10Ah INSPECTION MAGNETO Using the pocket tester, measure the resistance Pick-up coil 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.

  • Page 90: Voltage Inspection

    ELECTRICAL SYSTEM 5-5-1 IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION Remove the fuel tank and frame cover. Disconnect the two spark plug caps. With the spark plug cap connected, place a new spark plug on the engine to ground it. NOTE Check that all the couplers are connected.
  • Page 91 5-5-2 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE INSPECTION Remove the fuel tank. Disconnect the ignition coil read wire. Measure the ignition coil resistance in bolt the primary and secondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.

  • Page 92: Charging System

    ELECTRICAL SYSTEM 5-7 CHARGING SYSTEM Regulator / Rectifier Ignition switch A. C generator INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC voltage between the battery terminal If the voltage is not within the specified value, check the magneto no-load performance and regulator / rectifier.
  • Page 93 5-9 ELECTRICAL SYSTEM MAGNETO NO-LOAD PERFORMANCE Disconnect the three lead wires from the magneto terminal. Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the AC voltage between the three lead wires. If the voltage is under the specified value, replace the magneto with a new one.

  • Page 94: Starter System And Side Stand Ignition Interlock System

    ELECTRICAL SYSTEM 5-11 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components : the starter motor, starter relay, clutch lever switch, side stand switch, GP switch, starter switch, engine stop switch, ignition switch and battery. Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.
  • Page 95 5-12 ELECTRICAL SYSTEM TRANSMISSION : Neutral - ON Side stand - Down Clutch lever - Squeeze SIDE STAND RELAY IGNITION SWITCH BATTERY IGNITION COIL BATTERY NEUTRAL INDICATOR LAMP DIODE SIDE STAND SWITCH SIDE STAND GP SWITCH DOWN POSITION TRANSMISSION : Neutral - OFF Side stand - Up Clutch lever - Squeeze SIDE STAND RELAY...

  • Page 96: Servicing Information

    SERVICING INFORMATION CONTENTS TROUBLESHOOTING 96 [7-1-1] SPECIAL TOOLS 107 [7-8] TIGHTENING TORQUE 108 [7-11] SERVICE DATA 109 [7-19-1] WIRING DIAGRAM ( 112 [7-31-1] WIRING DIAGRAM ( 114 [7-32-1] WIRING DIAGRAM ( 116 [7-32-3] WIRING DIAGRAM ( 118 [7-32-5]...

  • Page 97: Troubleshooting

    7-1-1 SERVICING INFORMATION TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT noEr After engine running, if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in 12 0031 Low Voltage times test cycle, the code 0031 is indicated.
  • Page 98 SERVICING INFORMATION 7-1-2 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if purge control valve signal open or is happened the ground short fault for 1 second by 10 times in 12 times test cycle, the code 0444 is indicated. 0444 Open Purge control valve, wiring / coupler connection, power supply...
  • Page 99 7-1-3 SERVICING INFORMATION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR The sensor voltage should be the following. 0.1 V Sensor output voltage 0117 Low Voltage Without the above range for 6.25 sec. and more, 0117 is indicated. Engine temperature sensor, lead wire / coupler connection. ETS Circuit The sensor voltage should be the following.
  • Page 100 SERVICING INFORMATION 7-1-4 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if NO.1 fuel injector signal open or is happened the high / ground short fault for 1 second by 5 times NO.1 Fuel Injector 0201 in 10 times test cycle, the code 0201 is indicated.
  • Page 101 7-1-5 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low Adjust. start or is hard 1. Tappet clearance out of adjustment. Repair or replace. 2. Worn valve guides or poor seating of valves. to start. Adjust.
  • Page 102 SERVICING INFORMATION 7-2-1 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 103 7-2-2 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 104 SERVICING INFORMATION 7-2-3 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal / electrical parts in high speed 1. Weakened valve springs. Replace. 2. Worn camshafts. Replace. range. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gaps. Adjust.
  • Page 105 7-3-1 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 106 SERVICING INFORMATION 7-3-2 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 107 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. Defective RO switch. Replace.

  • Page 108: Special Tools

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

  • Page 109: Tightening Torque

    7-11 SERVICING INFORMATION TIGHTENING TORQUE EI SYSTEM PARTS ITEM kgf m Engine temperature sensor (ET sensor) 5 ~ 8 0.5 ~ 0.8 Fuel injector mounting bolt 5 ~ 8 0.5 ~ 0.8 5 ~ 8 Intake air temperature sensor (IAT sensor) 0.5 ~ 0.8...

  • Page 110: Service Data

    SERVICING INFORMATION 7-19-1 SERVICE DATA EI SENSORS SPECIFICATION NOTE ITEM IAP sensor input voltage 4.5 ~ 5.5 V IAP sensor output voltage 3.3 ~ 4.3 V when ignition switch “ON” TP sensor input voltage 4.9 ~ 5.1 V Closed Approx. 1.07 V ~ 1.17 V TP sensor output voltage Opened Approx.
  • Page 111 7-19-2 SERVICING INFORMATION THROTTLE BODY ITEM SPECIFICATION NOTE I.D. No. 13400H88 Bore size Idle rpm 1,500 ~ 1,700 rpm Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) FUEL INJECTOR + FUEL PUMP ITEM SPECIFICATION NOTE 11.4 ~ 12.6 at 20 (68 ) Fuel injector resistance...
  • Page 112 SERVICING INFORMATION 7-20 ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE BTDC 13 / 2,000 rpm ~ 30 / 6,000 rpm Ignition timing Type CR8E 0.7 ~ 0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E Spark performance More than 8 mm (0.32 in)

  • Page 113: Wiring Diagram ( )

    7-31-1 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 114 SERVICING INFORMATION 7-31-2...
  • Page 115 7-32-1 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 116 SERVICING INFORMATION 7-32-2...
  • Page 117 7-32-3 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 118 SERVICING INFORMATION 7-32-4...
  • Page 119 7-32-5 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 120 SERVICING INFORMATION 7-32-6...
  • Page 121 Prepared by 1st Ed. JAN. 2012. Manual No. 99000HB8110 Printed in Korea...
  • Page 122 S&T Motors Co., Ltd.

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