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Cannondale 5002401 Service Manual

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Electrical/EFI Service Manual
ATV and Motorcycle
P/N : 5002401
August 14, 2002

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  Summary of Contents for Cannondale 5002401

  • Page 1 Electrical/EFI Service Manual ATV and Motorcycle P/N : 5002401 August 14, 2002...
  • Page 2: Introduction

    The numbered steps of a few procedures are likely to be separate procedures themselves. When this is the case, the numbered step will include a page reference number. COMMENTS? Send your comments to: Cannondale Corporation, Technical Publications, 2 Corporate Drive, Bedford, PA 15522 Or e-mail: technical.publications@cannondale.com 8/14/02...
  • Page 3: Important Manual Information

    A CAUTION indicates that special precautions must be CAUTION :  taken to avoid damage to the machine. A NOTE provides helpful information intended to make NOTE: maintenance easier or the instructions presented clearer. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 4: Table Of Contents

    Communication cable - - - - - - - - - - - - - - 27 Cannondale Diagnostic and Maintenance tool Main Win- dow - - - - - - - - - - - - - - - - - - - - - - - - 28...
  • Page 5: Engine Management System (Ems)

    NOTE : In this manual, the engine control unit is referred to as the “ECU.” It is also sometimes called an “ECM” or engine control module. Either reference is OK. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 6: Ecu Programming

    ECU Fault Report window is selected in the software tool. A special communication cable is needed to connect the vehicle to a PC. Refer to "Cannondale Diag- nostic and Maintenance Tool Version 2.0" starting on page 21.
  • Page 7 1. Latch 2. Locking tab Reconnecting the ECU 1. Make sure the battery is disconnected. 2. Make sure the main fuse is removed. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 8: Servicing Connectors And Couplers

    3. Align the latch groove and tab on the ECU socket. Cleaning Rotate the latch in direction (b) until the latch is locked by the locking tab. The latch should oper- 1. Wipe the connector or coupler with a clean, lint- ate freely with your fingers;...
  • Page 9: Barometric Pressure Sensor

    Use the Cannondale Diagnostic and Maintenance Tool. Refer to "“Throttle Body Leakage” (also called Throttle Body Offset) (Input range 0 - 100) The equivalent amount, in percent, of throttle opening Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 10 The sensor contains no user serviceable items. Dynamic Test - ECU Monitor 1. Use the ECU Monitor windows of the Cannondale Diagnostic and Maintenance Tool and read the 1. TPS sensor (shown removed) Throttle position (%) field.
  • Page 11: Coolant Temperature Sensor

    Dynamic Test - ECU Monitor Never open the coolant system when the engine is hot. Coolant is hot and under 1. Use the ECU Monitor window of the Cannondale high pressure. It can spray out forcefully Diagnostic and Maintenance Tool to read the and burn or scald you severely.
  • Page 12: Crankshaft Position Sensor

    2. Compare the value with a reading taken manually This sensor detects movement of a toothed wheel in the vicinity of the air temperature tip. If the two that is molded into the flywheel and attached to the values do not correspond closely, the sensor may right side of the crankshaft.
  • Page 13: Idle Air Control Valve (Iacv)

    ECU is powered down. IACV Stepped positions 2. Remove the bypass housing from the throttle Fully Open Fully Closed (at 60°C) body with the IACV valve attached to it. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 14: Ignition Coil

    3. Check the condition of the tip insulator. Make sure it is not cracked, burned, melted, dried out. CAUTION :  Do not remove the valve from the housing when 4. Make sure the spring is installed with the larger performing this test. end facing the coil.
  • Page 15 Wiring diagrams are available on our website. observed, go to the next step. http://www.cannondale.com/motorsports/tech/ servman.html 4. Connect 12 V (+) battery voltage to the number 86 terminal and ground terminal Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 16: Fuel Pump And Fuel Pressure Regulator

    The fuel pressure regulator maintains the correct NOTE : fuel pressure in the fuel rail (hoses and injectors). It When the ignition switch is turned “ON,” the returns fuel to the tank after fuel passes the fuel installed relay will make an audible “click.” injectors.
  • Page 17 6. Start the engine and read the generated fuel pres- sure. If the fuel pressure reading is OK, the pump and Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 18 FUEL INJECTORS The fuel injectors are positioned as close as pos- sible to the back of the intake valves. The spray pattern is fixed. The length of time duration that the injectors stay open is calculated by the ECU using the calibration file and data received by the various sensors.
  • Page 19: Cooling Fan

    If it is more than 1 Ohm, replace the fan. If the fan circuit is OK, check the coolant sensor. If the coolant sensor is OK, replace the ECU. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 20: Cannondale Diagnostic And Maintenance Tool

    Cannondale Diagnostic MAINTENANCE TOOL VERSION 2.0 and Maintenance program group will be installed and a shortcut to the Cannondale Diagnostic and Maintenance tool will be placed on the your desk- This section of the manual describes how to use top.
  • Page 21: In The Windows Explorer, Double Click The Securitycode Application. Or, You Can Access This Application By Clicking On Security Code.exe Through The Program Group

    When the DealerCal window displays (see next illustration), call: Optimum Power Technology at 1-800-727-9520 (Monday through Friday, (9 am to 5 pm EST) to obtain the security code needed to activate the software. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 22: Common Problems

    Enter the Serial provided by the service rep in the ’Device Manager’ Button. DealerCal window. Click Next. 5. Click the ’+’ next to ’Ports’ to expand the available ports detail. If there is a red ’X’ or a yellow ’!’ in front of the Communications Port, a problem exists with your Port Driver.
  • Page 23: Interpreting Error Messages

    Make sure the vehicle engine management system is powered-up. See page 23. • Click “OK” and start again. • If the “Failed to Unlock System” message displays repeatedly, vehicle Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 24: Other Messages

    Data transfers should take no more than 1 minute. If the progress indicator freezes for a long time, close the Cannondale Diagnostic and Maintenance Tool software and try again, Make sure the cables are connected properly and that the vehicle battery is fully charged.
  • Page 25 If data errors are detected in the packet, the message “Retrying Checksum...” will display in the progress indicator: Typically, this is due to electrical “noise” or other interference during the process. The diagnostic tool will keep trying automatically. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 26: Communication Cable

    COMMUNICATION CABLE Connecting the communication cable Motorcycles and ATVs have a “diagnostic” con- nector integrated into the main wiring harness. The communication cable connects the PC to the vehicle using the connector. CAUTION :  Connect the communication cable with the vehicle engine management system OFF. On 2001 and 2002 Motorcycle models, the diag- nostic connector is located near the ignition coil at the top of the cylinder head.
  • Page 27: Cannondale Diagnostic And Maintenance Tool Main Window

    6. Fuel injector flow rate (Factory dyno value) 7. Injector offset (Factory dyno value) 8. Progress indicator 9. Button to access software version information and Cannondale internet files: http://www.cannondale.com/motorsports/tech/maps/ Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 28: Ecu Operating Code

    Always consult the Cannondale website for the compatibility of calibration files for a specific vehicle VIN number. A database of Cannondale authorized engine cali-...
  • Page 29 1. On ATVs turn the ignition switch ON. On Motorcycles, disconnect the starter solenoid so that the engine will not turn over when the start button is held down in a later step. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 30 3. In the ECU Reprogramming Tool window, select the operating code file to send. Click Download. Have an assistant press and continue to hold the The progress indicator will display while the trans- start button. fer take place. When the transfer is complete release the start button.
  • Page 31 Use the Windows explorer to locate (browse for) the saved engine calibration file. Select the file and click OK. 2. The file is now “loaded” to the main window. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 32 “calibrations.” To receive 1. Connect the interface cable to the PC and vehicle. 2. Open the Cannondale Diagnostic Tool software on your PC. 3. Power-up the ECU. 4. Click the RECEIVE Calibration File (from ECU) button.
  • Page 33 2. Open the Cannondale Diagnostic and Mainte- Position button. nance Tool software on your PC. The CDMT pro- gram will automatically open the last engine calibration file that was open using the program. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 34 2. Make sure the interface cable is connected to the computer and vehicle securely. 3. Open Cannondale Diagnostic Maintenance Tool software on your PC. 4. Power-up the vehicle engine management system.
  • Page 35 File” column are the values of the current engine calibration file open in the CDMT. The values of the “From ECU” column are the old values. Click OK to send the values to the ECU. Watch Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 36: Calibrations

    the progress indicator. When the send is com- CALIBRATIONS plete, the Send complete prompt will display, click Click Cancel and the “From File” values will not Updating throttle body and fuel injector be sent. They will remain in the currently open calibrations engine calibration file.
  • Page 37 3. Click “OK” and the typed-in values will display in the CDMT main window. Now, you have to send these values to the ECU for them to take effect. Click the “SEND Calibration File (to ECU)” button. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 38: Ecu Monitor

    ECU MONITOR 1. Open the Cannondale Diagnostic Tool software on your PC. 2. Power-up the vehicle ECU. 3. Click the MONITOR ECU Parameters button. The ECU monitor window will be displayed. Select “Continuous” to view live data. Select “Hold” to take a snap shot and hold the val- ues displayed.
  • Page 39: Reading Fault Codes

    These are “live” faults not stored faults. The GP Control MC1000 ECU programming does not store faults in memory, therefore the faults displayed in the window are the faults the ECU reports when the Fault Report but- Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 40 Fault Report window The Fault Report window sample above was taken while the Cannondale Diagnostic Tool was connected to an 2002 X440s motorcycle. This vehicle does not have a cooling fan. The “Cooling Fan open fault” will report when the tool is con- nected to a motorcycle, however, it can be disre- garded.
  • Page 41: Fault Troubleshooting

    FAULT TROUBLESHOOTING Consult the following troubleshooting tables when diagnosing a fault reported by the Cannondale Diag- nostic and Maintenance Tool Fault Report window function. Refer to "Reading Fault Codes" starting on page 40. SENSOR SUPPLY VOLTAGE Fault Reported Possible Cause...
  • Page 42: System Voltage

    Less than battery voltage - P2 E1 Done 3 . R u n e n g i n e c h e c k f o r presence of fault. Fault still present Contact Cannondale Dealer Service. Circuit Diagram 8/14/02...
  • Page 43: Fuel Pump

    Replace ECU and go to Test 7. start button is pressed. Done 7. Run engine and check for presence of fault. Fault still present Contact Cannondale Dealer Service. Circuit Diagram Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 44: Ignition Coil

    0.6 Ohms primary Go to Test 7. resistance across coil pins 1 and Faulty Replace coil, go to Test Done 7. Reconnect ECU, run engine check for presence of fault. Fault still present Contact Cannondale Dealer Service. Circuit Diagram 8/14/02...
  • Page 45: Cooling Fan (Atv Only)

    Replace ECU and go to Test 7. 80°C cool ant te mperatur e). Verify correct airflow. Done 7. Run engine and check for presence of fault. Fault still present Contact Cannondale Dealer Service. Circuit Diagram Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 46: Fuel Injectors

    FUEL INJECTORS Fault Possible Cause Action Damaged injector or ECU, Injector A short fault (left) harness short circuit Component test the injector. Refer to Injector B short fault (right) - flooding indicates short "Fuel Injectors" starting on page 19. circuit Damaged injector, injector Check that injector harness connector is connector disconnected or...
  • Page 47 OFF position. Measure between P2 E1and: - relevant injector pin 1 - P1 H3 to CN6 pin 2 (Right injector) - P1 H2 to CN7 pin 2 (Left injector) Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 48 Go to Test 7. 2°C - relevant injector across ter- minals 1 to 2 Faulty Replace injector go to Test 7. Done 7. Run engine and check for presence of fault. Fault still present Contact Cannondale Dealer Service. Circuit Diagram 8/14/02...
  • Page 49: Throttle Position Sensor (Tps)

    Test 5. - P1 E3 to P1 E4 5. Reconnect harness, run Done engine and check for presence Fault still present Contact Cannondale Dealer Service. of fault. Circuit Diagram Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 50: Air Temperature Sensor

    6. Check wire for short circuit” Locate and correct wiring fault and go to Short circuit - P1 D1 to ground Test 7. 7. Reconnect harness, run Done engine and check for presence Fault still present Contact Cannondale Dealer Service. of fault. 8/14/02...
  • Page 51: Air Temperature Sensor

    Temp. (ohms) (deg. C) (deg. F) (ohms) (deg. C) (deg. F) (ohms) (deg. C) (deg. F) 15071 1700 11739 1414 9215 1181 7290 5808 4659 3763 3058 2500 2056 Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 52: Coolant Sensor

    6. Check wire for short circuit” Locate and correct wiring fault and go to - P1 B2 to ground Short circuit Test 7. 7. Reconnect harness, run Done engine and check for presence Fault still present Contact Cannondale Dealer Service. of fault. Circuit Diagram 8/14/02...
  • Page 53 (deg. F) (ohms) (deg. C) (deg. F) (ohms) (deg. C) (deg. F) 45313 2500 34281 2057 26114 1707 20003 1412 15462 1175 12002 9397 7415 5896 4712 3792 3069 Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 54: Idle Air Control Valve (Iacv)

    - IACV pin A to pin D - IACV pin B to pin C Faulty Replace IACV, go to Test 7. 7. Reconnect harness, run Done engine and check for presence Fault still present Contact Cannondale Dealer Service. of fault. Circuit Diagram 8/14/02...
  • Page 55: Crankshaft Position Sensor

    Clean / replace toothed wheel, go to Test Faulty - Magnetic debris contamination 8. Reconnect harness, run Done engine and check for presence Fault still present Contact Cannondale Dealer Service. of fault. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 56: Component Testing (Non-Efi)

    COMPONENT TESTING (NON-EFI) Test for continuity between both black wires; there should be continuity. Test for continuity between both red wires; there BATTERY should be continuity. Test for short circuit between one of the red wires and the two blacks; there should be no continuity. 1.
  • Page 57: Flywheel

    If three equal readings are obtained, all higher than 50 VAC, the stator is ok. A problem may Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 58: Engine Stop Switch (Atv)

    ENGINE STOP SWITCH (ATV) STARTER SOLENOID 1. Disconnect the engine stop switch from the main Dynamic Test - Solenoid Function harness. 1. Press the engine start button. On ATVs, the 2. Slide the switch to the RUN position. There additional step of turning the ignition key ON and should be continuity between the two switch pulling in the clutch lever is required before leads.
  • Page 59 4. Connect the starter motor positive terminal directly to the vehicle battery positive terminal with a heavy lead similar in size to starter motor harness cable. If the starter motor turns, check the vehicle wiring Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 60 Communication cable - - - - - - - - - - - - - - 27 Cannondale Diagnostic and Maintenance tool Main Win- dow - - - - - - - - - - - - - - - - - - - - - - - - 28...