HYOSUNG GV250 EI Service Manual
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HYOSUNG GV250 EI Service Manual

HYOSUNG GV250 EI Service Manual

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SERVICE MANUAL
99000-95620

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  • Page 1 SERVICE MANUAL 99000-95620...
  • 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 (1-6-3) ……………………………… EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ 9 (1-7-1) …………………………… EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ 10 (1-7-2) ………………………………… FUNCTION OF EI SENSOR 11 (1-8-1) …………………………………………………………...

  • Page 7: Exterior Photograph

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

  • Page 9: Exterior Illustration

    1-6-3 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 1-7-1 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

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

  • Page 12: Function Of Ei Sensor

    GENERAL INFORMATION 1-8-1 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 13: Specifications

    1-8-2 GENERAL INFORMATION SPECIFICATIONS ⊙ ⊙ DIMENSIONS AND MASS I T E M ← Overall length 2,280 mm (89.8 in) 2,095 mm (82.5 in) Overall width 885 mm (34.8 in) 720 mm (28.4 in) 780 mm (30.7 in) Overall height 1,095 mm (43.1 in) 1,135 mm (44.7 in) 1,125 mm (44.3 in)
  • Page 14 GENERAL INFORMATION 1-9 ⊙ ⊙ CHASSIS I T E M Front suspension Telescopic type ← ← Rear suspension Swingarm type ← ← Steering angle 40˚(right & left) ← 27˚(right & left) Caster 34˚ 25.5˚ ← Trail 142 mm (5.59 in) 90 mm (3.54 in) ←...
  • Page 16 EI SYSTEM DIAGNOSIS CONTENTS 4 -1 PRECAUTIONS IN SERVICING ……………………………………… 16 (4-1-1) EI SYSTEM TECHNICAL FEATURES ……………………………… 20 (4-1-5) SELF-DIAGNOSIS FUNCTION ₩ ₩ ……………… 27 (4-1-12) SELF-DIAGNOSIS FUNCTION ₩ ₩ ………………… 29 (4-1-14) EI SYSTEM TROUBLESHOOTING ………………………………… 33 (4-1-18) CUSTOMER COMPLAINT ANALYSIS………………………………… 33 (4-1-18) SELF-DIAGNOSTIC PROCEDURES …………………………………...

  • Page 17: 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 18 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 19 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 20: 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.

  • Page 21: Ei System Technical Features

    4-1-5 EI SYSTEM DIAGNOSIS EI SYSTEM TECHNICAL FEATURES ⊙ ⊙ 『 『 』 』 & 『 『 』 』 EI SYSTEM’S CONTROL DIAGRAM FUEL IAT Sensor FUEL TANK AIR CLEANER ISC Solenoid FUEL PUMP TP Sensor THROTTLE BODY IAP Sensor SAV Solenoid INTAKE PIPE ET Sensor...
  • Page 22 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 23: 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 24 EI SYSTEM DIAGNOSIS 4-1-8 ⊙ ⊙ EI SYSTEM PARTS LOCATION ~ ~ ₩ ₩ ① Speedometer ⑤ GP switch ② Ignition coil, NO.1 ⑥ Fuel injector, NO.1 ③ Ignition coil, NO.2 ⑦ Fuel injector, NO.2 ④ Pick-up coil ⑧ TP sensor...
  • Page 25 4-1-9 EI SYSTEM DIAGNOSIS ⑨ ISC solenoid ⑭ IAP sensor, NO.1 ⑩ IAT sensor ⑮ ET sensor ⑪ RO switch ⒃ Oxygen sensor ⑫ Fuel pump relay ⒔ SAV solenoid ⑬ IAP sensor, NO.2...
  • Page 26 EI SYSTEM DIAGNOSIS 4-1-10 ⊙ ⊙ EI SYSTEM PARTS LOCATION ~ ~ ₩ ₩ ① Speedometer ⑥ Pick-up coil ② Fuel injector, NO.1 ⑦ Ignition coil, NO.1 ③ Fuel injector, NO.2 ⑧ Ignition coil, NO.2 ④ IAT sensor ⑨ TP sensor ⑤...
  • Page 27 4-1-11 EI SYSTEM DIAGNOSIS 13 14 ⑩ ISC solenoid ⑭ IAP sensor, NO.1 ⑪ Fuel pump relay ⑮ ET sensor ⑫ RO switch ⒃ Oxygen sensor ⑬ IAP sensor, NO.2 ⒔ SAV solenoid...

  • Page 28: Self-Diagnosis Function

    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 only be notified by the LCD(DISPLAY) panel ① and the “FI” check lamp “ ”...
  • Page 29 4-1-13 EI SYSTEM DIAGNOSIS ⊙ ⊙ 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 4-1-20) The memorized malfunction code is displayed on LCD (DISPLAY) panel Malfunction means that the ECU does not receive signal from the devices.

  • Page 30: Self-Diagnosis Function

    EI SYSTEM DIAGNOSIS 4-1-14 SELF-DIAGNOSIS FUNCTION ~ ~ ₩ ₩ The self-diagnosis function is incorporated in the ECU. The function has two modes, “USER MODE” and “DEALER MODE”. ” ①. 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.
  • Page 31 4-1-15 EI SYSTEM DIAGNOSIS ⊙ ⊙ 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 4-1-20) The memorized malfunction code is displayed with blinks signal of the “FI” check lamp “ ”...
  • Page 32 EI SYSTEM DIAGNOSIS 4-1-16 CODE CODE MALFUNCTION PART REMARKS No defective part None Pick-up coil Throttle position sensor (TPS) Engine temperature sensor (ETS) Intake air pressure sensor (IAPS), NO.1 For NO.1 cylinder For NO.2 cylinder Intake air pressure sensor (IAPS), NO.2 Intake air temperature sensor (IATS) Oxygen sensor (O Roll over switch (RO switch)
  • Page 33 4-1-17 EI SYSTEM DIAGNOSIS ▣ ▣ In the LCD (DISPLAY) panel ①, the malfunction code is indicated from small code to large code. ▣ ▣ ” ②, the malfunction code is displayed from small numeral blinks signal to large In the “FI” check lamp “ numeral blinks signal.

  • Page 34: Ei System Troubleshooting

    EI SYSTEM DIAGNOSIS 4-1-18 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 35 4-1-19 EI SYSTEM DIAGNOSIS 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 36: Self-Diagnostic Procedures

    EI SYSTEM DIAGNOSIS 4-1-20 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 37: Self-Diagnosis Reset Procedure

    4-1-21 EI SYSTEM DIAGNOSIS SELF-DIAGNOSIS RESET PROCEDURE ① ● After repairing the trouble, turn the ignition switch “OFF” position and turn “ON” position again. ● If “C ” (LCD INDICATION ①) is indicates, the malfunction codes are cleared. ( ● If not blink (“FI” check lamp ②), the malfunction codes are cleared.

  • Page 38: Malfunction Code And Defective Condition

    EI SYSTEM DIAGNOSIS 4-1-22 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT The pick-up coil signal does not reach ECU for more than 3 sec. after ECU receiving the ignition switch signal. In this case, the code C12 is indicated.
  • Page 39 4-1-23 EI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR Ignition signal is interrupted continuous by 31 times or more when ECU confirm ignition surge at each combustion chamber. Ignition coil (IG coil), In this case, the code C24 or C25 is indicated. C24 / C25 NO.1 / NO.2 Ignition coil, wiring / coupler connection, power supply from the...

  • Page 40: C12" Pick-Up Coil Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-1-24 “C12” PICK-UP COIL CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE The pick-up coil signal does not reach ECU for more ● Metal particles or foreign materiel being attached than 3 sec. after ECU receiving the ignition switch on the pick-up coil and rotor tip.

  • Page 41: C14" Tp Sensor Circuit Malfunction

    4-1-25 EI SYSTEM DIAGNOSIS “C14” TP SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 2 sec. ● TP sensor circuit open or short. and more. ● TP sensor malfunction. 0.1 V Sensor voltage 4.8 V ●...
  • Page 42 EI SYSTEM DIAGNOSIS 4-1-26 ◈ Step 2 1) Remove the frame cover. 2) Turn the ignition switch “OFF” position. 3) Disconnect the TP sensor coupler. 4) Check the continuity between (LY) and ground. ∞ Ω (Infinity) TP sensor continuity - Ground) Tester knob indication : Resistance (Ω...
  • Page 43 4-1-27 EI SYSTEM DIAGNOSIS ◈ Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch “ON” position. Measure the TP sensor output voltage at the coupler ~between ( :LY) and ( :GR)₩by turning the throttle grip.

  • Page 44: C15" Et Sensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-1-28 “C15” ET SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 2 sec. ● ET sensor circuit open or short. and more. ● ET sensor malfunction. 0.08 V Sensor voltage 4.65 V ●...
  • Page 45 4-1-29 EI SYSTEM DIAGNOSIS ET sensor resistance Engine Temp. Resistance (To ECU) ㏀ -20 ℃ (-4 ℉ ) Approx. 75.5 ㏀ 0 ℃ (32 ℉ ) Approx. 28.7 ㏀ 20 ℃ (68 ℉ ) Approx. 12.2 ㏀ 40 ℃ (104 ℉ ) Approx.

  • Page 46: C17 " " O O R R " " C18 " " Iap Sensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-1-30 “C17” or “C18” IAP SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is out of the specified range for 6 ● Clogged vacuum passage between throttle bodies sec. and more. and IAP sensors. 0.5 V Sensor voltage 4.5 V...
  • Page 47 4-1-31 EI SYSTEM DIAGNOSIS ◈ Step 2 1) Connect the IAP sensor couplers NO.1 ① and NO.2 ②. 2) Insert the needle pointed probes to the lead wire coupler. ① 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 GR wires].

  • Page 48: C21" Iat Sensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-1-32 “C21” IAT SENSOR CIRCUIT MALFUNCTION CODE CODE CODE DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 6 sec. ● IAT sensor circuit open or short. and more. ● IAT sensor malfunction. 0.08 V Sensor voltage 4.75 V...
  • Page 49 4-1-33 EI SYSTEM DIAGNOSIS IAT sensor resistance Intake Air Temp. Resistance ㏀ -40 ℃ (-40 ℉ ) ± 5% 44.642 ㏀ -20 ℃ (-4 ℉ ) ± 5% 14.958 ㏀ 0 ℃ (32 ℉ ) ± 5% 5.734 ㏀ 20 ℃ (68 ℉ ) ±...

  • Page 50: C22" Oxygen Sensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-1-34 “C22” OXYGEN SENSOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor signal is not inputted in ECU since then ● Oxygen sensor, Oxygen sensor heater circuit open 600 sec. after the engine run. or short. ●...

  • Page 51: C23" Ro Switch Circuit Malfunction

    4-1-35 EI SYSTEM DIAGNOSIS “C23” RO SWITCH CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE The switch resistance should be the following for ● RO switch circuit short or leaned more than 60。 . more than 3 sec. after holding the motorcycle ●...

  • Page 52: C24 " " O O R R " " C25 " " Ignition Coil Malfunction

    EI SYSTEM DIAGNOSIS 4-1-36 Is the resistance OK? ●YL 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. ●Recheck each terminal and wire harness for open circuit and poor connection.

  • Page 53: C27" Isc Solenoid Range Abnormal

    4-1-37 EI 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 250 step ● ISC solenoid’s step is out of the specified range. ●...

  • Page 54: C31" Gp Switch Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-1-38 “C31” GP SWITCH CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE GP switch voltage is out of the specified range for 2 ● GP switch circuit open or short. sec. and more. ● GP switch malfunction. <...
  • Page 55 4-1-39 EI SYSTEM DIAGNOSIS “C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Injector signal is interrupted continuous for more than ● Injector circuit open or short. 1 sec. when ECU confirm injector running surge at ●...
  • Page 56 EI SYSTEM DIAGNOSIS 4-1-40 ◈ Step 2 1) Turn the ignition switch “ON” position. 2) Measure the injector voltage between YR(NO.1), RB(NO.2) wire and ground. Battery voltage Injector voltage ([NO.1] YR - Ground, [NO.2] RB - Ground) Tester knob indication : Voltage ( NOTE NO.1 Injector voltage can be detected only 3...

  • Page 57: C37" Sav Solenoid Malfunction

    4-1-41 EI SYSTEM DIAGNOSIS “C37” SAV SOLENOID MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE ● SAV solenoid circuit open or short. No voltage is applied from ECU to SAV solenoid by 400 sec.. ● SAV solenoid malfunction. ● ECU malfunction. ▣...

  • Page 58: C41" Fuel Pump Relay Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-1-42 “C41” FUEL PUMP RELAY CIRCUIT MALFUNCTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE Voltage is applied continuous for more than 5 sec., ● Fuel pump relay circuit open or short. battery voltage 3.2 V when fuel pump relay is ●...

  • Page 59: C43 " " Oxygen Sensor Heater Circuit Malfunction

    4-1-43 EI SYSTEM DIAGNOSIS “C43” OXYGEN SENSOR HEATER CIRCUIT MALFUNTION CODE CODE DETECTED CONDITION POSSIBLE CAUSE ● Oxygen sensor, Oxygen sensor heater circuit open Oxygen sensor heater signal is not inputted in ECU. or short. ● Oxygen sensor, Oxygen sensor heater malfunction. ●...

  • Page 60: Sensors

    EI SYSTEM DIAGNOSIS 4-1-44 SENSORS ⊙ ⊙ PICK-UP COIL INSPECTION The pick-up coil ① is installed in the magneto cover. (Refer to page 4-1-24) ⊙ ⊙ PICK-UP COIL REMOVAL AND ① INSTALLATION ● Remove the magneto cover. ● Install the magneto cover in the reverse order of removal.

  • Page 61: Iat Sensor Inspection

    4-1-45 EI SYSTEM DIAGNOSIS ⊙ ⊙ ET SENSOR INSPECTION The engine temperature (ET) sensor ① is installed at the front cylinder. (Refer to page 4-1-28) ⊙ ⊙ ET SENSOR REMOVAL AND ① INSTALLATION ● Remove the ET sensor. ● Install the ET sensor in the reverse order of removal.
  • Page 62 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM …………………………………………………………… 62 (4-2-1) REMOVAL AND DISASSEMBLY ………………………………………… 63 (4-2-2) REASSEMBLY AND INSTALLATION …………………………………… 64 (4-2-3) 4 -2 FUEL PRESSURE INSPECTION ………………………………………… 65 (4-2-4) FUEL PUMP RELAY INSPECTION ……………………………………… 65 (4-2-4) FUEL MESH FILTER INSPECTION AND CLEANING ………………… 66 (4-2-5) FUEL GAUGE INSPECTION………………………………………………...

  • Page 63: Fuel System

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

  • Page 64: 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 ①. ① ● Remove the fuel pump coupler ②. ●...

  • Page 65: 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 ①...

  • Page 66: 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 67: Fuel Mesh Filter Inspection And Cleaning

    4-2-5 FUEL SYSTEM AND THROTTLE BODY First, check the insulation between ① and ② ① ③ terminals with pocket tester. Then apply 12 volts to ③ and ④ terminals, to ③ and to ④, and check the continuity between ① and ②. If there is no continuity, replace it with a new one.

  • Page 68: Throttle Body

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

  • Page 69: Removal

    4-2-7 FUEL SYSTEM AND THROTTLE BODY REMOVAL ● Remove the fuel tank. ● Disconnect the fuel hoses. ● Remove the all couplers to related the throttle body. ● Loosen the throttle body clamp screws. ● Remove the air cleaner box. ●...

  • Page 70: 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 71: 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 ① Never operate the idle nuts ① ① (NO.1) and ② ② (NO.2) to avoid variations of the carburetion setting. ●...
  • Page 72 ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS ………………… 72 (5-1) IGNITION SYSTEM ……………………………………………………… 74 (5-3) CHARGING SYSTEM …………………………………………………… 76 (5-7)

  • Page 73: Location Of Electrical Components

    5-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS ⑥ ⑨ ① ② ⑧ ⑦ ④ ⑤ ③ ① Ignition coil NO.1 ③ Main relay ⑥ Main fuse (30A) ② Ignition coil NO.2 ④ Fuel pump relay ⑦ ECU ⑤ Head lamp relay ⑧...
  • Page 74 ELECTRICAL SYSTEM 5-2 ⒃ ⒕ ⒔ ⑮ ⒖ ⑮ ISC solenoid ⒃ IAP sensor NO.1 ⒖ SAV solenoid ⒔ ET sensor ⒕ IAP sensor NO.2 (22) ⒗ (21) ⒗ Oxygen sensor (21) Fuel injector NO.2 (22) Fuel injector NO.1...

  • Page 75: Ignition System

    5-3 ELECTRICAL SYSTEM IGNITION SYSTEM MAIN RELAY IGNITION ENGINE STOP SWITCH SWITCH IGNITION IGNITION COIL, COIL, MAGNETO NO.2 NO.1 FUSE 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 magneto coil, with a new one.
  • Page 76 ELECTRICAL SYSTEM 5-5 ▣ ▣ IGNITION COIL RESISTANCE INSPECTION Disconnect the ignition coil lead 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 77: Charging System

    5-7 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator / Rectifier Ignition switch A. C generator ⊙ ⊙ INSPECTION Ignition switch ▣ ▣ CHARGING OUTPUT CHECK Regulator Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC voltage Rectifier between the battery terminal Battery...
  • Page 78 ELECTRICAL SYSTEM 5-9 ▣ ▣ 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 80 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ………………………………………………… 80 (7-1-1) SPECIAL TOOLS ……………………………………………………… 89 (7-8) TIGHTENING TORQUE ……………………………………………… 90 (7-11) SERVICE DATA ………………………………………………………… 91 (7-19-1) WIRING DIAGRAM ( ………………………………… 94 (7-31-1) WIRING DIAGRAM ( ……………………………… 96 (7-32-1) WIRING DIAGRAM ( ………………………………… 98 (7-32-3)

  • Page 81: Troubleshooting

    7-1-1 SERVICING INFORMATION TROUBLESHOOTING ⊙ ⊙ MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT The pick-up coil signal does not reach ECU for more than 3 sec. after ECU receiving the ignition switch signal. In this case, the code C12 is indicated.
  • Page 82 SERVICING INFORMATION 7-1-2 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR Ignition signal is interrupted continuous by 31 times or more when ECU confirm ignition surge at each combustion chamber. Ignition coil (IG coil), In this case, the code C24 or C25 is indicated. C24 / C25 NO.1 / NO.2 Ignition coil, wiring / coupler connection, power supply from the...
  • Page 83 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 84 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 85 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 86 SERVICING INFORMATION 7-2-3 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 87 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 88 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 89 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 90: 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 91: Tightening Torque

    7-11 SERVICING INFORMATION TIGHTENING TORQUE ⊙ ⊙ EI SYSTEM PARTS ITEM N· · m kgf· · m 5 ~ 8 Engine temperature sensor (ET sensor) 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 92: Service Data

    SERVICING INFORMATION 7-19-1 SERVICE DATA ⊙ ⊙ EI SENSORS SPECIFICATION ITEM NOTE IAP sensor input voltage 4.5 ~ 5.5 V IAP sensor output voltage Approx. 3.7 ~ 3.9 V when ignition switch “ON” TP sensor input voltage 4.5 ~ 5.5 V Closed Approx.
  • Page 93 7-19-2 SERVICING INFORMATION ⊙ ⊙ THROTTLE BODY ITEM SPECIFICATION NOTE I.D. No. 13400H88 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 Ω...
  • Page 94 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...

  • Page 95: Wiring Diagram ( )

    7-31-1 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 96 SERVICING INFORMATION 7-31-2...

  • Page 97: Wiring Diagram ( )

    7-32-1 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 98 SERVICING INFORMATION 7-32-2...
  • Page 99 7-32-3 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 100 SERVICING INFORMATION 7-32-4...
  • Page 101 Prepared by 1st Ed. APR. 2009. Manual No. 99000-95620 Printed in Korea...
  • Page 102 S&T Motors Co., Ltd.

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