Instruction Manual for DOCTOR API Yamaha Diagnostic Tool

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1 Instruction Manual for DOCTOR API Yamaha Diagnostic Tool APITech Company Facebook.com/apitechonline Tel Fax

2 Content Page 1. Product Package 3 2. Product details and features for Yamaha Diagnostic Tool Product Technical Details Product Features Product Detail 5 3. Instruction for Diagnostic Tool Real Time Monitoring Analysis Problem Analysis Mode Function Analysis Mode CO Adjustment Real Time Monitoring Analysis CO Adjustment Detail DTC Error Connection Process Doctor API to the motorcycle Sample Using with Yamaha R Function Bootloader 32 2

3 3 Product Package 3.2 DOCTOR API Yamaha Diagnostic Tool 3.3 Instruction Manual 3.4 Sticker API TECH 1.3 Warranty 3

4 2. Product details and features for Yamaha Diagnostic Tool 2.1 Product technical details 1. Battery Voltage Voltage 2. Electricity consumes 0.5 ampere 3. Processing 32Bit ARM Cortex 4. Temperature 0-50 C 5. Dimension Width 10 cm. Length 11 cm. Height 4 cm. 6. Weight 0.3 KG 2.2 Product Feature - Workable with Yamaha motorcycles from 1-4 Cylinders - K-Line communication provided - LCD screen 16x4 character and computer screen readable - Fault codes provided - Historical fault codes provided - clearing fault codes provided - Dynamic data stream provided - Upgradable - Wireless (Bluetooth) provided - Android OS provided 4

5 2.3 Product detail No. 1 No 2 DOWN Button MODE ENTER No 3 UP Button No 4 LCD screen 16x4 character and computer screen readable No 5 K-Line communication provided 5

6 3 Diagnostic Tool Instruction 3.1. Real Time Monitoring The system will show processing as real time monitoring. The ECM in each Yamaha motorcycles are different in each model, the data will be different. The data that will be shown on the screen will depend on the models. 1. The Input Signal consisted of - RPM_DATA (Revolution Per Minute) - ENGINE_TEMP (ECT=Engine Coolant Temperature or EOT= Engine Oil Temperature) - INTAKE_AIR_TEMP ( Intake Air Temperature) - ATMOSP_PRESSURE_SENSOR (Atmosphere Pressure Sensor) - VEHICLE_SPEED (Vehicle Speed) - BATTERY - THRO_POSITION_SENSOR_VOLTAGE (Throttle Position Sensor Voltage) - LEAN_ANGLE_SENSOR (Lean Angle Sensor) - AFR # 1 ( O2_SENSOR_1 ) - AFR # 2 ( O2_SENSOR_2 ) - INTAKE_AIR_PRESSURE_SENSOR_1 (Intake Air Pressure Sensor #1) - INTAKE_AIR_PRESSURE_SENSOR_2 (Intake Air Pressure Sensor #2) - THRO_POSITION_SENSOR_ANGLE ( Throttle Position Angle Sensor) - ACCELERATOR_POSSION_SENSOR_ANGLE ( Acceleration Position Angle Sensor) - MODE - SWITCH_1 (Switch #1) - SWITCH_2 (Switch#2) - PRIMARY_SHEAVE_POSITION_SENSOR_VOLTAGE - I_SHIFT_POSITION 6

7 2.Output Control consisted of - INJECTION_DUTATION (Injection duration) - NITION_TIMING (Ignition Timing) - ISC_VALVE (Idle Speed Con YCC ( YCC_AT_MOTOR_DUTY ) 3.Internal ECM - ( GEAR_POSITION ) Position of Gear - ( FAULT_CODE ) Fault Code - ( NUMBER_FAULT_DETECTION ) Number of Fault that detected - ( O2_SENSOR_FUEL_TRIM ) Oxygen Sensor Fuel Trim 7

8 3.2 Analysis mode Problem Analysis mode, the data will be found from the sensors - Throttle position sensor signal 1 - Atmospheric pressure sensor - Intake air pressure #1 sensor - Intake air pressure #2 sensor - Intake air temperature - Coolant temperature - Front/Rear wheel speed pulse sensor - Lean angle sensor - Fuel System voltage sensor (Battery voltage)) - Oil temperature sensor - Engine temperature sensor - Cooling fan temperature sensor - Throttle position sensor signal 2 - Accelerator position sensor signal 1 - Accelerator position sensor signal 2 - [Side stand switch][blue/yellow lead of the ECU] on/off - Neutral switch and clutch switch on/off - Throttle switch on/off - Gear position switch on/off - Cruise control resume switch on/off - Cruise control set switch on/off - Cruise control cancel switch on/off - Brake switch on/off - Mode switch on/off - Shift switch on/off 8

9 3.2.2 Function analysis mode is able to analyze and do testing the sensors which are - Grip warmer <ACTION> - Thumb warmer operation <ACTION> - Suspension solenoid valve on/off - Cylinder #1 or #1-1 ignition coil <ACTION> - Cylinder #2 or #2-1 ignition coil <ACTION> - Cylinder #3 or #1-2 ignition coil <ACTION> - Cylinder #4 or #2-2 ignition coil <ACTION> - Intake funnel servo motor <ACTION> - Wiper motor <ACTION> - Injector #1 <ACTION> - Injector #2 <ACTION> - Injector #3 <ACTION> - Injector #4 <ACTION> - Secondary injector #1 <ACTION> - Secondary injector #2 <ACTION> - Secondary injector #3 <ACTION> - Secondary injector #4 <ACTION> - Purge cut valve solenoid <ACTION> - Steering damper solenoid <ACTION> - Air induction system solenoid <ACTION> - Intake solenoid <ACTION> - Main relay/fuel pump relay <ACTION> - Radiator fan motor relay <ACTION> - Headlight relay <ACTION> - EXUP servo motor <ACTION> - ISC (Idle Speed Control) valve /FID (Fast Idle Solenoid)) <ACTION> 9

10 - Decompression solenoid <ACTION> - Sub-throttle servo motor <ACTION> - Grip warmer <ACTION> - Passenger grip warmer relay <ACTION> - EEPROM fault code Display Value - Malfunction history code display Value - Malfunction history code erasure <ACTION> - Malfunction code reinstatement <ACTION> - Setting history display Value - Setting map erasure <ACTION> - ISC correction value erasure <ACTION> - Switching correction value for ethanol mixed fuel <ACTION> - Program version number value - Primary sheave position voltage - Secondary sheave speed pulse - YCC-AT motor relay <ACTION> - Primary sheave position initialization <ACTION> 3.3 CO Adjustment mode Intensity CO Adjustment during the low RPM Adjustment Record - CO adjustment at #1,C1 Mixture - CO adjustment at #2,C2 Mixture - CO adjustment at #3,C3 Mixture - CO adjustment at #4,C4 Mixture 10

11 4. LCD Code Display and description for Real Time Monitoring LCD DISPLAY Description Unit REV RPM_DATA RPM ECT ENGINE_TEMP ⁰ C IAT INTAKE_AIR_TEMP ⁰ C APS ATMOSP_PRESSURE_SENSOR kpa Speed VEHICLE_SPEED Km/h VBAT BATTERY V Thro. THRO_POSITION_SENSOR_VOLTAGE V Lean/Oil LEAN_ANGLE_SENSOR V O2 #1 O2_SENSOR_1 V AFR # 1 O2 #2 O2_SENSOR_2 V AFR # 2 IAP#1 INTAKE_AIR_PRESSURE_SENSOR_1 kpa IAP#2 INTAKE_AIR_PRESSURE_SENSOR_2 kpa Thro. THRO_POSITION_SENSOR_ANGLE Deg Acc ACCELERATOR_POSSION_SENSOR_ANGLE Deg 11

12 MODE Gear SWITCH No.Fault Fault code MODE GEAR_POSITION SWITCH_1 NUMBER_FAULT_DETECTION FAULT_CODE INJ INJECTION_DUTATION ms IGN IGNITION_TIMING BTDC ISC ISC_VALVE % O2 Trim O2_SENSOR_FUEL_TRIM % YCC-AT YCC_AT_MOTOR_DUTY % Sheave PRIMARY_SHEAVE_POSITION_SENSOR_VOLTAGE V SWITCH2 SWITCH_2 I-Shift I_SHIFT_POSITION 12

13 5. Engine analysis mode LCD DISPLAY Code No. Description Unit ThroAngle1 D01 Throttle position sensor signal ⁰ AtmPR D02 Atmospheric pressure 0-126Kpa INAirP1 D03 Intake air pressure Kpa INAirP2 D04 Intake air pressure Kpa INAirTE D05 Intake air temperature ⁰ C CoolantTE D06 Coolant temperature ⁰ C Sp.Pulse D07 Front/Rear wheel speed pulse Tilt sensor D08 Lean angle sensor 0-5 V BAT volt D09 Fuel System voltage (Battery voltage) 0-18 V Oil Temp D10 Oil temperature ⁰ C Eng Temp D11 Engine temperature ⁰ C Fan Temp D12 Cooling fan temperature ⁰ C ThroAngle2 D13 Throttle position sensor signal 2 ⁰ Acc.Pos1 D14 Accelerator position sensor signal 1 ⁰ 13

14 Acc.Pos2 D15 Accelerator position sensor signal 2 ⁰ Wh.Pulse D16 Front wheel speed pulse Step Side stand SW D20 [Side stand switch][blue/yellow lead of the ECU] on/off Clutch SW D21 Neutral switch and clutch switch on/off Throttle SW D24 Throttle switch on/off Gear.Pos SW D25 Gear position switch on/off GripWarmer D26 Grip warmer <ACTION> ThumbWarmer D27 Thumb warmer operation <ACTION> Suspension D29 Suspension solenoid on/off <ACTION> it is show on/off IG coil#1 D30 Cylinder #1 or #1-1 ignition coil <ACTION> IG coil#2 D31 Cylinder #2 or #2-1 ignition coil <ACTION> IG coil#3 D32 Cylinder #3 or #1-2 ignition coil <ACTION> IG coil#4 D33 Cylinder #4 or #2-2 ignition coil <ACTION> In Funnel servo D34 Intake funnel servo motor <ACTION> Wiper moto D35 Wiper motor <ACTION> Injector#1 D36 Injector #1 <ACTION> Injector#2 D37 Injector #2 <ACTION> 14

15 Injector#3 D38 Injector #3 <ACTION> Injector#4 D39 Injector #4 <ACTION> SecInjtor#1 D40 Secondary injector #1 <ACTION> SecInjtor#2 D41 Secondary injector #2 <ACTION> SecInjtor#3 D42 Secondary injector #3 <ACTION> SecInjtor#4 D43 Secondary injector #4 <ACTION> Purge CutValve D46 Purge cut valve solenoid <ACTION> Steering Damper D47 Steering damper solenoid <ACTION> AirInducSystem D48 Air induction system solenoid <ACTION> IntakeSolenoid D49 Intake solenoid <ACTION> Main Relay D50 Main relay/fuel pump relay <ACTION> RadiatorFan D51 Radiator fan motor relay <ACTION> Head light D52 Headlight relay <ACTION> EXUPServo D53 EXUP servo motor <ACTION> ⁰ ISC D54 ISC(idle speed control) valve/fid (fast idle solenoid) <ACTION> 15

16 Decomp D55 Decompression solenoid <ACTION> V Sub-thro D56 Sub-throttle servo motor <ACTION> ⁰ GripWarmer D57 Grip warmer <ACTION> PasGripWarmer D59 Passenger grip warmer relay <ACTION> EEPROM DTC D60 EEPROM fault code display Value RStory DTC D61 Malfunction history code display Value Story DTC D62 Malfunction history code erasure <ACTION for erase> Value Reinstatement D63 Malfunction code reinstatement <ACTION for erase> Value SettingHis D64 Setting history display Value SettingMap D65 Setting map erasure <ACTION> Value ISC Erasure D67 ISC correction value erasure <ACTION for erase> Value EthanolMixed D68 Switching correction value for ethanol mixed fuel <ACTION for erase> value ECU Ver D70 Program version number value PriSheave D71 Primary sheave position voltage SecSheave D72 Secondary sheave speed pulse Mode SW D74 Mode switch on/off ShiftSW D75 Shift switch on/off YCC-AT Motor D77 YCC-AT motor relay <ACTION> PriSheave D78 Primary sheave position initialization <ACTION> CruiseResume D80 Cruise control resume switch on/off CruiseSet D81 Cruise control set switch on/off CruiseCancel D82 Cruise control cancel switch on/off BrakeSW D83 Brake switch on/off 16

17 6. CO Adjustment mode Intensity Adjustment in Low RPM - CO Adjustment in Cylinder #2,C2 Mixture - CO Adjustment in Cylinder #3,C3 Mixture - CO Adjustment in Cylinder #4,C4 Mixture LCD DISPLAY Description STEP C1 Mixture C1 Mixture Cylinder # C2 Mixture C3 Mixture C4 Mixture C2 Mixture Cylinder #2 C3 Mixture Cylinder #3 C4 Mixture Cylinder # DTC Error. is the recording function, it records the engine when abnormal Codes and description DTC Error Code of problem Description 11 - No normal signals are received from the cylinder identification sensor 12 - No normal signals are received from the crankshaft position sensor. Possible caused Wiring connector is damaged The circuit is open or shorted in the main wiring Crankshaft sensor is damaged Magneto wheel is broken The sensor is error installation 13 D03 Intake Air Pressure sensor#1 found Wiring connector is damaged 17

18 the open circuit or shorted circuit 14 D03 Intake Air Pressure sensor#1 found the error in hose system malfunction The circuit is open or shorted in the main wiring Intake Air Pressure sensor is broken Module sensor is loosen TPS is wrong installation IAP sensor is stuck 15 D01 TPS is broken or short circuit Wiring connector is damaged The circuit is open or shorted in the main wiring TPS is malfunction Module sensor is wrong installation 16 D01 Stuck of throttle position sensor is detected 17 D53 EXUP servo motor circuit (open or short circuit) Module sensor is wrong installation TPS is malfunction Connection is wrong The wiring is not connected 18 D53 EXUP servo motor is stuck The wiring is not connected Servo motor is malfunction 19 D20 Open circuit is detected in the input lead from the Side Stand switch to the ECM The connection of side stand switch is damaged The main wiring connection 20 D02 D03 When the main switch is On, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly The wiring connector is damaged the main wiring is open or short circuit Intake Air Pressure sensor is malfunction 18

19 21 D06 Cooling temperature sensor open or short circuit The wiring connector is damaged the main wiring is open or short circuit Intake Air Pressure sensor is malfunction 22 D05 Intake air temperature sensor open or short circuit The wiring connector is damaged the main wiring is open or short circuit Intake Air Temperature sensor is malfunction or module sensor is wrong installation 23 D02 Atmospheric pressure sensor open or short circuit The wiring connector is damaged the main wiring is open or short circuit Barometer sensor is malfunction 24 - No normal signal is received from the O2 Sensor, the O2sensor fault The wiring connector is damaged the main wiring is open or short circuit O2 sensor is malfunction or wrong installation Fuel pump is not stable 25 D04 The intake air pressure sensor#2 found the open or short circuit The wiring connector is damaged the main wiring is open or short circuit Intake Air Pressure sensor is malfunction 26 D04 Intake Air Pressure sensor#2 found the error in hose or tube system malfunction Module sensor is loosen Wrong installation for throttle body Intake air pressure sensor is stuck 27 D10 Oil temperature sensor The wiring connector is damaged 19

20 (Open or short circuit) 28 D11 Engine temperature sensor - open or short circuit is detected 29 - Decompression thermostat (open or short circuit) 30 D08 Rollover signal is received from the lean angle sensor The main wiring is open or short circuit EOT(Engine oil temperature) sensor is malfunction Wrong installation for the module sensor The wiring connector is damaged The main wiring is open or short circuit Engine temperature sensor is malfunction Wrong installation for the module sensor The bike gets accident Wrong installation for the angle sensor or malfunction 33 D30 Ignition coil#1 broken circuit or fault The wiring connector is damaged Found the error in Ignition coil #1 The Ignition coil#1 is malfunction 34 D31 Ignition coil#2 broken circuit or fault The wiring connector is damaged Found the error in Ignition coil #2 The Ignition coil#2 is malfunction 35 D32 Ignition coil#3 broken circuit Or fault 36 D33 Ignition coil#4 broken circuit Or fault The wiring connector is damaged Found the error in Ignition coil #3 The Ignition coil#3 is malfunction The wiring connector is damaged Found the error in Ignition coil #4 The Ignition coil#4 is malfunction 20

21 37 D54 Engine Idle Speed Control is too high A: A indicates another part that not in the ISC ( will hear the sound of ISC working ) B: B indicates that the ISC part is malfunction ( will not hear the sound of ISC working) 39 D36 D37 D38 D39 Fuel Injector is open or short circuit 41 D08 Lean angle sensor is open or short circuit A-1: Use the Diagnostic tool to find the problem A-2: The signal from the front wheel is abnormal A-3: Throttle body is not closed properly, could be from the hose. A-4: The leaked air from the throttle body A-5: The leaked air from the ISC part A-6: Air for throttle body or the ISC part is too much A-7: ISC part doesn t work properly A-8: The ECM is malfunction B-1: Use the Diagnostic tool to find the problem B-2: The connection between the ISC connector is not connected properly B-3: The connection between the ECM connector is not connected properly B-4: The main wiring connection B-5: The installation for ISC part B-6: The battery is abnormal B-7: The ISC part doesn t work properly B-8: The ECM is malfunction B-9: Delete the error code The wiring connector is damaged The short or open circuit in main wiring Fuel Injector is malfunction The ECM is malfunction Wrong installation for module sensor The short or open circuit in main wiring The lean angle sensor is damaged The ECM is malfunction 21

22 42 A:D07 B:D21 C:D21 No normal signals received from the speed sensor or Neutral switch open or short circuit A: Wheel sensor didn t receive the signal B: Gear switch found the open or short circuit C: Clutch switch found the open or short circuit A-1: Use the Diagnostic tool to find the problem A-2: The connectors that connected between the wheel sensors(front /rear) may damaged A-3:The connection from ABS ECM may damaged A-4:The connection between wiring of wheel sensors( front/rear) may damaged A-5:The ECM is malfunction A-6:The ABS function in ECM is malfunction B-1: Use the Diagnostic tool to find the problem B-2:The connection at the gear switch connector B-3:The connection between ECM B-4:The connection between main wiring B-5: Gear switch position is abnormal B-6: Gear switch position is abnormal at Neutral gear B-7:The ECM is malfunction C-1: Use the Diagnostic tool to find the problem C-2: Clutch adjustment C-3: The connection at the clutch switch connector C-4: The connection between ECM C-5: The connection between main wiring C-6: Clutch switch is malfunction C-7: The ECM is malfunction 43 D09 D50 Power supply to the injectors and the fuel pump is abnormal 44 D60 Write or read EEPROM error (CO adjustment value) The ECM connection The connection at the main wiring The ECM is malfunction 00 The ECM is malfunction 01 The error data at EEPROM for CO adjustment 22

23 inside cylinder#1 02 The error data at EEPROM for CO adjustment inside cylinder#2 03 The error data at EEPROM for CO adjustment inside cylinder#3 04 The error data at EEPROM for CO adjustment inside cylinder#4 11 The error data at EEPROM in ISC part 45 - Power cutoff by oneself fault Wiring at the battery connection The Relay start connection Condition in spare Fuse The connection at main wiring The ECM is malfunction 46 - Power supply is abnormal: Charging system is malfunction regulator is abnormal 47 D56 Sub throttle Servo Motor fault 48 - AI System Solenoid 50 - ECU memory fault The ECM is malfunction 59 D14 D15 Throttle position sensor in throttle cable pulley is fault 60 D01 Throttle servo motor is open or short circuit The wiring connector Open or short circuit in main wiring TPS sensor The ECM is malfunction Wrong installation at module sensor The wiring connector Open or short circuit in main wiring TPS sensor The ECM is malfunction Wrong installation at module sensor 61 D54 ISC(Idle Speed Control is open The connection at the ISC connector 23

24 or short circuit 84 D45 VVA: Variable Valve Actuator is open or short circuit The connection at the ECM and the main wiring The main wiring connection The ISC set is malfunction The ECM is malfunction The connection at the VVA solenoid wiring The connection at the ECM and the main wiring The main wiring connection VVA solenoid is malfunction The ECM is malfunction 24

Connect the Doctor API wiring with the connector

After the connection is completed, it will show

The picture 2 shows the modes - Monitoring Mode

25 8. Connection Process Step 1. Turn the key at the switch off Step 2. Connect the Doctor API wiring with the connector Step 3. After the connection is completed, it will show at picture Picture 1 Picture 2 Step 4. The picture 2 shows the modes - Monitoring Mode as real time - Analysis Mode - Special Func: Step 5. To choose a mode 5.1 Press the M button 5.2 Turn the key at Ignition On 25

26 5.3 The screen shows the chosen mode 6. Every time when need to change the mode, the process must be repeated from step 1 9. Sample when using the Doctor API with Yamaha R3 1. Monitoring Mode 2. Analysis ThrottleAngle1=Throttle angle degree#1 ( D01) INAirPR1 = Intake Air Pressure#1 ( D03) INAir TE = Intake Air Temperature( D05) 26

27 Coolant TE = Coolant Temperature/ Engine Oil Temperature (D06) Sp. Pulse = Signal that received from the Speed Pulse( D07) Tilt Sensor = Lean Angle Sensor( D08) BAT volt = Battery Voltage( D09) Sidestand SW = Side Stand Switch( D20) Clutch SW = Clutch Switch( D21) IG Coil#1 = Ignition Coil# 1 ( D30) <M> ACT = press Mode to test the function for Coil# 1 27

IG Coil#2 = Ignition Coil# 2( D31) <M> ACT = press Mode to test the function

function for Injector#1 Injector#2 = Injector# 2( D37) <M> ACT = press Mode

Valve(D48) <M> ACT = press Mode to test the function for Air Induction

function for Main Relay RadiatorFan = Radiator Fan( D51) < Down> Next =

28 IG Coil#2 = Ignition Coil# 2( D31) <M> ACT = press Mode to test the function for Coil# 2 Injectorl#1 = Injector#1( D36) <M> ACT = press Mode to test the function for Injector#1 Injector#2 = Injector# 2( D37) <M> ACT = press Mode to test the function for Injector#2 AirInducSystem = Air Induction System Valve(D48) <M> ACT = press Mode to test the function for Air Induction System Valve Main Relay = Main Relay( D50) <M> ACT = press Mode to test the function for Main Relay RadiatorFan = Radiator Fan( D51) < Down> Next = press Down to see the next data <M> ACT = press Mode to test the function for Radiator Fan 28

Head light = Head Light( D52) <M> ACT = press Mode to test the function for Head light

Control EEPROM DTC = The error data that recorded in memory EEPROM( D60) RStory DTC = The

of the error sensor that recorded in memory( D62) <M> ACT = press Mode to delete the

29 Head light = Head Light( D52) <M> ACT = press Mode to test the function for Head light ISC = Idle Speed Control ( D54) <M> ACT = press Mode to test the function for Idle Speed Control EEPROM DTC = The error data that recorded in memory EEPROM( D60) RStory DTC = The error code that recorded in memory ( D61) CStory DTC = The no. of the error sensor that recorded in memory( D62) <M> ACT = press Mode to delete the error data that recorded in the memory Reinstatement = Reinstatement Valve( D63) <M> ACT = press Mode to test the function 29

Exit = press Up to increase input <M> ACT = Exit the system 10. Function Bootloader This function will be used for upgrading the new firmware.

30 2. CO Adjustment for intensity during Idle Stage C1 Mixture = Adjust the CO in cylinder #1 <Down> Next = press Down to reduce input <Up> Exit = press Up to increase input <M> ACT = Exit the system C2 Mixture = = Adjust the CO in cylinder #2 <Down> Next = press Down to reduce input <Up> Exit = press Up to increase input <M> ACT = Exit the system 10. Function Bootloader This function will be used for upgrading the new firmware. When new motorcycle model launched in the market, the program will be updated. The upgrading will be processed by Wireless (Bluetooth) systems. 30

Instruction Manual for Diagnostic Tool DOCTOR API HONDA

Instruction Manual for Diagnostic Tool DOCTOR API HONDA API Tech Co.,Ltd. www.apitechonline.com Facebook.com/apitechonline Tel.02-948-8680 Fax.02-948-8980 Diagnostic Tool1 Content Page 1. Product s components