GV 250 GT 250 FI service

Transcription

1 GV 250 GT 250 FI service Servicemanual Kun indsprøjtningssystem Skovbyvej 99, Skovby 6470 Sydals Telefon: Fax: CVR:

2 FREWRD GRUP INDEX This manual contains an introductory description on HSUNG & and procedures for its inspection / service and overhaul of its main components. It covers the differences from Carbure type and please refer to the service manual of ( ), & (99000HR8310) and & ( ) for others which are not covered in this manual. ther information considered as generally known is not included. Read GENERAL INFRMATIN section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service. This manual has been prepared on the basis of the latest specification at the time of publication. If modification has been made since then, difference may exist between the content of this manual and the actual vehicle. Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail. GENERAL INFRMATIN 1 FI SSTEM DIAGNSIS FUEL SSTEM AND THRTTLE D 4-2 ELECTRICAL SSTEM SERVICING INFRMATIN 7 WARNING This manual is intended for those who have enough knowledge and skills for servicing HSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HSUNG motorcycle dealer. CPRIGHT S&T Motors Co., Ltd.

3 HW T USE THIS MANUAL T LCATE WHAT U ARE LKING FR : 1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previous page as GRUP INDEX, select the section where you are looking for. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. n the first page of each section, its contents are listed. Find the item and page you need. SML Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SML DEFINITIN SML DEFINITIN Torque control required. Data beside it indicates specified torque. Apply THREAD LCK Apply oil. Use engine oil unless otherwise specified. Apply or use brake fluid. Apply SUPER GREASE A. Measure in voltage range. Apply SUPER GREASE C. Measure in resistance range. Apply SILICNE GREASE. Measure in current range. Apply ML PASTE. Measure in continuity test range. Apply ND Use special tool. Use fork oil. 2

4 AREVIATINS USED IN THIS MANUAL A L ADC : After ottom Dead Center LCD : Liquid Crystal Display AC : Alternating Current LED : Light Emitting Diode API : American Petroleum Institute LH : Left Hand ATDC : After Top Dead Center DC DC : efore ottom Dead Center : ettom Dead Center M Max Min : Maximum : Minimum TDC : efore Top Dead Center D 2 Sensor : xygen Sensor (2S) DC DHC : Direct Current : Double ver Head Camshaft R RH : Right Hand E S ECU ET Sensor : Engine Control Unit, FI Control Unit : Engine Temperature Sensor SAE SAV Solenoid : Society of Automotive Engineers : Secondary Air Valve Solenoid F FI FP (ETS) : Fuel Injection, Fuel Injector : Fuel Pump T TDC T Sensor : Top Dead Center : Tip ver Sensor (TS) FPR : Fuel Pressure Regulator G GP Switch : Gear Position Switch I IAP Sensor : Intake Air Pressure Sensor (IAPS) IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition ISC Solenoid : Idle Speed Control Solenoid 3

5 WIRE CLR : lack Gr : Gray Sb : Light blue L : lue Lg : Light green W : White r : rown : range : ellow G : Green R : Red L : lack with lue tracer r : lack with rown tracer G : lack with Green tracer : lack with range tracer R : lack with Red tracer : lack with White tracer : lack with ellow tracer L : lue with lack tracer LG : lue with Green tracer LR : lue with Red tracer LW : lue with White tracer L : lue with ellow tracer r : rown with lack tracer rw : rown with White tracer G : Green with lack tracer GR : Green with Red tracer G : Green with ellow tracer Gr : Gray with lack tracer GrR : Gray with Red tracer GrW : Gray with White tracer : range with lack tracer L : range with lue tracer G : range with Green tracer R : range with Red tracer W : range with White tracer : range with ellow tracer R : Red with lack tracer RW : Red with White tracer W : White with lack tracer WL : White with lue tracer WR : White with Red tracer : ellow with lack tracer L : ellow with lue tracer G : ellow with Green tracer R : ellow with Red tracer 4

6 GENERAL INFRMATIN CNTENTS 1 SPECIFICATINS (, & ) 6 (1-8) 5

7 1-8 GENERAL INFRMATIN SPECIFICATINS (, & ) DIMENSINS AND MASS ITEM verall length verall width verall height Wheelbase Ground clearance Mass 2,270 mm (89.4 in) 800 mm (31.5 in) 1,090 mm (42.9 in) 1,500 mm (59.1 in) 155 mm (6.1 in) 170 kg (375 lbs) 2,080 mm (81.9 in) 760 mm (29.9 in) 1,120 mm (44.1 in) 1,455 mm (57.3 in) 180 mm (7.1 in) 2,060 mm (81.1 in) 655 mm (25.8 in) 1,125 mm (44.3 in) 1,435 mm (56.5 in) 130 mm (5.1 in) 185 kg (408 lbs) ENGINE ITEM Type Number of cylinder ore Stroke Piston displacement Fuel system Starter system Lubrication system Four-stroke, DHC, air-cooled and oil-cooled V-2 cylinder 57.0 mm (2.24 in) 48.8 mm (1.92 in) 249 cm3 (15.2 in 3 ) Fuel Injection Electric starter Wet sump TRANSMISSIN ITEM Clutch Transmission Gearshift pattern Final reduction Gear ratio, 1st 2nd 3rd 4th 5th Drive chain Wet multi-plate type 5-speed constant mesh 1-down, 4-up H, 116 links 520H, 112 links 6

8 GENERAL INFRMATIN 1-9 CHASSIS ITEM Front suspension Rear suspension Steering angle Caster Trail Front brake Rear brake Front tire size Rear tire size Front fork stroke Telescopic type Swingarm type 40 (right & left) mm (5.32 in) Disk brake Drum brake 110/ S 150/80-15M/C 70S 120 mm (4.72 in) 33 (right & left) mm (3.35 in) Disk brake 110/ H 150/ H 27 (right & left) 90 mm (3.54 in) Double disk brake ELECTRICAL ITEM Ignition type Ignition timing Head lamp Spark plug attery Fuse HI L Position Turn signal lamp rake / Tail lamp License plate lamp Illumination lamp High beam indicator lamp Turn signal indicator lamp(right & left) Neutral indicator lamp Fuel meter lamp FI (Fuel Injection) check lamp ECU 13.T.D.C. at 2,000 rpm and 30.T.D.C. at 6,000 rpm CR8E 12 V 12 Ah (MF) 30 A & 15 A 12 V - H4 : 60 W 1 12 V - H4 : 55 W 1 12 V - W5 W 1 12 V - R10 W 4 12 V - P21/5 W 1 12 V - W5 W 1 12 V W 2 12 V W 1 12 V W 2 12 V W 1 12 V W 1 LED type LED type LED type LED type LED type LED type (Level type) 12 V - H1 : 55 W 1 12 V - H3 : 55 W 1 CAPACITIES ITEM Fuel tank il change Engine oil il and filter change Engine overhaul Front fork oil capacity(ne side) 14.0 l 1,450 ml 1,500 ml 1,800 ml 250 cc 17.0 l 400 ± 2.5 cc NTE The specifications are subject to change without notice. 7

9 8

10 FI SSTEM DIAGNSIS CNTENTS PRECAUTINS IN SERVICING 10 (4-1-1) FI SSTEM TECHNICAL FEATURES 14 (4-1-5) SELF-DIAGNSIS FUNCTIN ( ) 20 (4-1-11) SELF-DIAGNSIS FUNCTIN ( ) 22 (4-1-13) FI SSTEM TRULESHTING 24 (4-1-15) CUSTMER CMPLAINT ANALSIS 24 (4-1-15) SELF-DIAGNSTIC PRCEDURES ( ) 26 (4-1-17) SELF-DIAGNSIS RESET PRCEDURE ( ) 26 (4-1-17) MALFUNCTIN CDE AND DEFECTIVE CNDITIN 27 (4-1-18) C15 ET SENSR CIRCUIT MALFUNCTIN 29 (4-1-20) C17 or C18 IAP SENSR CIRCUIT MALFUNCTIN 31 (4-1-22) C21 IAT SENSR CIRCUIT MALFUNCTIN 33 (4-1-24) C22 XGEN SENSR CIRCUIT MALFUNCTIN 35 (4-1-26) C24 or C25 IGNITIN CIL MALFUNCTIN 35 (4-1-26) C27 ISC SLENID RANGE ANRMAL 36 (4-1-27) C32 or C33 FUEL INJECTR CIRCUIT MALFUNCTIN 37 (4-1-28) C37 SAV SLENID MALFUNCTIN 39 (4-1-30) C41 FUEL PUMP RELA CIRCUIT MALFUNCTIN 40 (4-1-31) C43 XGEN SENSR HEATER CIRCUIT MALFUNCTIN 41 (4-1-32) SENSRS 42 (4-1-33) 4-1 9

11 4-1-1 FI SSTEM DIAGNSIS PRECAUTINS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CNNECTR / CUPLER When connecting a connector, be sure to push it in until a click is felt. With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully till the works when connecting it. When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires. Inspect each terminal on the connector / coupler for looseness or bending. Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material which could impede proper terminal contact. Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector / coupler. 10

12 FI SSTEM DIAGNSIS 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. Never push in the probe where male terminal is supposed to fit. Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc. FUSE When a fuse blows, always investigate the cause to correct it and then replace the fuse. Do not use a fuse of a different capacity. Do not use wire or any other substitute for the fuse. ECU / VARIUS SENSRS Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and installation. e careful not to touch the electrical terminals of the ECU. The static electricity from your body may damage this part. 11

13 4-1-3 FI SSTEM DIAGNSIS When disconnecting and connecting the ECU, make sure to turn FF the ignition switch, or electronic parts may get damaged. attery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied. INCRRECT Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the ECU which may result in serious damage. efore measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check at low battery voltage will lead to erroneous diagnosis. 12

14 FI SSTEM DIAGNSIS Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to ECU or sensors may result. e sure to use a specified voltmeter / ohmmeter. therwise, accurate measurements may not be obtained and personal injury may result. USING TESTERS Use well-charged batteries in the tester. e sure to set the tester to the correct testing range. USING THE TESTER Incorrectly connecting the and probes may cause the inside of the tester to burnout. If the voltage and current are not known, make measurements using the highest range. After using the tester, turn the power off. 13

15 4-1-5 FI SSTEM DIAGNSIS FI SSTEM TECHNICAL FEATURES INJECTIN TIME (INJECTIN VLUME) 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. ECU Intake Air Pressure Sensor (IAP Sensor) Pick-up coil Intake air pressure signal Engine speed signal asic fuel injection time Various Sensors Various signals Compensation Injectors Injection signal Ultimate fuel injection time 14

16 FI SSTEM DIAGNSIS CMPENSATIN F INJECTIN TIME (VLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL ENGINE TEMPERATURE SENSR SIGNAL INTAKE AIR TEMPERATURE SENSR SIGNAL ATTER VLTAGE SIGNAL ENGINE RPM SIGNAL STARTING SIGNAL ACCELERATIN SIGNAL / DECELERATIN SIGNAL DESCRIPTIN When engine temperature is low, injection time (volume) is increased. When intake air temperature is low, injection time (volume) is increased. ECU operates on the battery voltage and at the same time, it monitors the voltage signal for compensation of the fuel injection time (volume). A longer injection time is needed to adjust injection volume in the case of low voltage. At high speed, the injection time (volume) is increased. When starting engine, additional fuel is injected during cranking engine. During acceleration, the fuel injection time (volume) is increased in accordance with the throttle opening speed and engine rpm. During deceleration, the fuel injection time (volume) is decreased. INJECTIN STP CNTRL SIGNAL TIP VER SENSR SIGNAL (FUEL CUT-FF) VER-REV. LIMITER SIGNAL DESCRIPTIN When the motorcycle tips over, the tip over sensor sends a signal to the ECU. Then, this signal cuts FF current supplied to the fuel pump, fuel injector and ignition coil. The fuel injectors stop operation when engine rpm reaches rev. limit rpm. 15

17 FISSTEM DIAGNSIS FI SSTEM PARTS LCATIN ( ) ECU 4 5 Speedometer Ignition coil, N.1 Ignition coil, N.2 Pick-up coil GP switch Fuel injector, N.1 Fuel injector, N.2 ISC solenoid 16

18 FISSTEM DIAGNSIS ECU IAT sensor T sensor Fuel pump relay IAP sensor, N.2 IAP sensor, N.1 ET sensor xygen sensor SAV solenoid 17

19 FISSTEM DIAGNSIS FI SSTEM PARTS LCATIN ( ) ECU Speedometer Fuel injector, N.1 Fuel injector, N.2 IAT sensor GP switch Pick-up coil Ignition coil, N.1 ISC solenoid Fuel pump relay 18

20 FISSTEM DIAGNSIS ECU T sensor Ignition coil, N.2 IAP sensor, N.1 IAP sensor, N.2 ET sensor xygen sensor SAV solenoid 19

21 FI SSTEM DIAGNSIS SELF-DIAGNSIS FUNCTIN ( ) The self-diagnosis function is incorporated in the ECU. The function has two modes, USER MDE and DEALER MDE. The user can only be notified by the FI check lamp 1. To check the function of the individual FI system devices, the dealer mode is prepared. In this check, the special tool is necessary to read the code of the malfunction items. USER MDE The FI check lamp 1 comes on for about three seconds whenever the ignition switch is set to N position with the engine stopped as a test of the injection system operation. The check lamp must go off after three seconds. If the check lamp comes on during normal engine operation, it means that the fuel injection system is not operating correctly. When this is the case, inspect the fuel injection system to refer to Dealer mode. 1 20

22 FI SSTEM DIAGNSIS DEALER MDE The defective function is memorized in the ECU. Use the special tool s coupler to connect to the dealer mode coupler. (Refer to page ) The memorized malfunction code is displayed on LCD (DISPLA) panel. Malfunction means that the ECU does not receive signal from the devices. These affected devices are indicated in the code form. Mode select switch : CAUTIN Do not disconnect the ECU lead wire couplers, before checking the malfunction code, or the malfunction code memory is erased and the malfunction code can not be checked. Confirm the malfunction code after turn the ignition switch N position or cranking the engine for few seconds. MALFUNCTIN N ES LCD (DISPLA) INDICATIN Speedometer C**code is indicated from small numeral to large one. INDICATIN MDE FI check lamp goes off. FI check lamp comes on continually. 21

23 FI SSTEM DIAGNSIS SELF-DIAGNSIS FUNCTIN ( ) The self-diagnosis function is incorporated in the ECU. The function has a mode, USER MDE. The user and dealer can only be notified by the FI check lamp 1. To check the function of the individual FI system devices, read blinks signal of the FI check lamp 1. The FI check lamp 1 comes on for about three seconds whenever the ignition switch is set to N position with the engine stopped as a test of the injection system operation. The check lamp must go off after three seconds. If the check lamp comes on during normal engine operation, it means that the fuel injection system is not operating correctly. When this is the case, inspect the fuel injection system to refer to blinks signal of the FI check lamp 1. The defective function is memorized in the ECU. The memorized malfunction code is display with blinks signal of the FI check lamp 1. Malfunction means that the ECU does not receive signal from the devices. These affected devices are displayed blinks signal of the FI check lamp

24 2 1 FI SSTEM DIAGNSIS CDE C15 CDE [ ] MALFUNCTIN PART Engine temperature sensor (ETS) REMARKS C17 [ ] Intake air pressure sensor (IAPS), N.1 For N.1 cylinder C18 [ ] Intake air pressure sensor (IAPS), N.2 For N.2 cylinder C21 [ ] Intake air temperature sensor (IATS) C22 [ ] xygen sensor (2S) C24 [ ] IG coil, N.1 For N.1 cylinder C25 [ ] IG coil, N.2 For N.2 cylinder C27 [ ] Idle speed control solenoid (ISC solenoid) C32 [ ] Fuel injector, N.1 For N.1 cylinder C33 [ ] Fuel injector, N.2 For N.2 cylinder C37 [ ] Secondary air valve solenoid (SAV solenoid) C41 [ ] Fuel pump relay C43 [ ] In the LCD (DISPLA) panel 1 xygen sensor heater (2S heater), the malfunction code is indicated from small code to large code. In the FI check lamp 2, the malfunction code is displayed from small blinks signal to large blinks signal. 23

25 FI SSTEM DIAGNSIS FI SSTEM TRULESHTING CUSTMER CMPLAINT ANALSIS 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. EXAMPLE : CUSTMER PRLEM INSPECTIN FRM User name : Model : VIN : Date of issue : Date Reg. Date of problem : Mileage : FI Check lamp Always N Sometimes N Always FF Good condition Malfunction display / code (LCD) or links signal ( FI check lamp) No code Malfunction code ( ) PRLEM SMPTMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion ack fire / After fire No combustion Lack of power Poor starting at Surging ( cold warm always) Abnormal knocking ther Engine rpm jumps briefly ther Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened ( High Low) ( rpm) Throttle valve is closed Unstable Load is applied Hunting ( rpm. to rpm) ther ther THERS : 24

26 FI SSTEM DIAGNSIS MTRCCLE / ENVIRNMENTAL CNDITIN WHEN PRLEM CCURS Environmental condition Weather Fair Cloudy Rain Snow Always ther Temperature Hot Warm Cool Cold ( F / C) Always Frequency Always Sometimes ( times / day, month) nly once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill Downhill) Tarmacadam Gravel ther Motorcycle condition Engine condition Cold Warming up phase Warmed up Always ther at starting Immediately after start Racing without load Engine speed ( rpm) Motorcycle condition During driving : Constant speed Accelerating Decelerating Right hand corner Left hand corner At stop Motorcycle speed when problem occurs ( km/h, Mile/h) ther NTE The above form is a standard sample. If should be modified according to conditions characteristic of each market. 25

27 FI SSTEM DIAGNSIS SELF-DIAGNSTIC PRCEDURES ( ) 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. Malfunction code stored in ECU memory can be checked by the special tool. To check malfunction code, read SELF-DIAGNSIS FUNCTIN DEALER MDE (Refer to page , 14) carefully to have good understanding as to what functions are available and how to use it. e sure to read PRECAUTINS for Electrical Circuit Service (Refer to page 4-1-1) before inspection and observe what is written there. Remove the front and rear seat. Connect the special tool to the dealer mode coupler at the wiring harness, and the ignition switch is set to N position. Turn the special tool s switch N position and check the malfunction code to determine the malfunction part. Mode select switch : NTE The dealer mode coupler is located under the rear seat. SELF-DIAGNSIS RESET PRCEDURE ( ) After repairing the trouble, turn the ignition switch FF position and turn N position again. If speedometer (LCD INDICATIN 1 ) is indicates, the malfunction codes are cleared. Disconnect the special tool from the dealer mode coupler. 26

28 FI SSTEM DIAGNSIS MALFUNCTIN CDE AND DEFECTIVE CNDITIN MALFUNCTIN CDE C15 C17 / C18 C21 C22 DETECTED ITEM Engine temperature sensor (ETS) Intake air pressure sensor (IAPS), N.1 / N.2 Intake air temperature sensor (IATS) xygen sensor (2S) DETECTED FAILURE CNDITIN CHECK FR The sensor voltage should be the following. 0.1 V sensor voltage < 4.6 V Without the above range for 4 sec. and more, C15 is indicated. Engine temperature sensor, lead wire / coupler connection. The sensor should produce following voltage. 0.1 V sensor voltage 4.8 V Without the above range for 4 sec. and more, C17 or C18 is indicated. Intake air pressure sensor, lead wire / coupler connection. The sensor voltage should be the following. 0.1 V sensor voltage < 4.6 V Without the above range for 4 sec. and more, C21 is indicated. Intake air temperature sensor, lead wire / coupler connection. The oxygen sensor signal is input in ECU since then more than 120 sec. after the engine run. When this is the case, ECU not receive the signal, C22 is indicated. xygen sensor, lead wire / coupler connection. 27

29 FI SSTEM DIAGNSIS MALFUNCTIN CDE C24 / C25 C27 C32 / C33 C37 C41 C43 DETECTED ITEM Ignition coil (IG coil), N.1 / N.2 Idle speed control solenoid (ISC solenoid) Fuel injector, N.1 / N.2 Secondary air valve solenoid (SAV solenoid) Fuel pump relay xygen sensor heater (2S heater) DETECTED FAILURE CNDITIN CHECK FR When the IC of the ECU electric current gets 6 A and more, C24 or C25 is indicated. Ignition coil, wiring / coupler connection, power supply from the battery. The idle speed control solenoid step should be the following. step solenoid step 100 step Without the above range, C27 is indicated. Idle speed control solenoid, lead wire / coupler connection. The fuel injector not comes in voltage from the battery, C32 or C33 is indicated. Injector, wiring / coupler connection, power supply to the injector. When the secondary air valve solenoid voltage is not input in ECU, C37 is indicated. Secondary air valve solenoid, lead wire / coupler connection. No voltage is applied to the both injectors 3 for 3 sec. after the contact of fuel pump relay is turned N position. r voltage is applied to the both injectors, when the contact of fuel pump is FF position. Fuel pump relay, connecting lead wire, power source to fuel pump relay, fuel injector. The oxygen sensor heater signal is not input in ECU. xygen sensor heater, lead wire / coupler connection. 28

30 FI SSTEM DIAGNSIS C15 ET SENSR CIRCUIT MALFUNCTIN CDE CDE C15 DETECTED CNDITIN utput voltage is out of the specified range. 0.1 V Sensor voltage < 4.6 V [ ] PSSILE CAUSE ET sensor circuit open or short. ET sensor malfunction. ECU malfunction. INSPECTIN Step 1 1) Turn the ignition switch FF position. 2) Check the ET sensor coupler for loose or poor contacts. If K, then measure the ET sensor voltage at the wire side coupler. 3) Disconnect the coupler and turn the ignition switch N position. 4) Measure the voltage between G wire terminal and ground. 5) If K, then measure the voltage between G wire terminal and wire terminal. ET sensor voltage 4.5 ~ 5.5 V ( G - Ground ) ( G - ) Tester knob indication : Voltage ( ) Is the voltage K? ES N Go to Step 2. Loose or poor contacts on the ECU coupler. pen or short circuit in the G wire or wire. 29

31 FI SSTEM DIAGNSIS Step 2 1) Turn the ignition switch FF position. 2) Measure the ET sensor resistance. ET sensor resistance Engine Temp. 0 (32 ) 20 (68 ) 40 (104 ) 60 (140 ) 80 (176 ) Resistance (To ECU) Approx kω Approx kω Approx kω Approx kω Approx kω Tester knob indication : Resistance ( kω ) Is the resistance K? ES N G or wire open or shorted to ground, or poor 8 or 5 connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. Replace the ET sensor with a new one. ECU Coupler 5 30

32 FI SSTEM DIAGNSIS C17 or C18 IAP SENSR CIRCUIT MALFUNCTIN CDE CDE C17 C18 DETECTED CNDITIN [ ] [ ] PSSILE CAUSE IAP sensor voltage is out of the specified range. 0.1 V Sensor voltage 4.8 V NTE : Note that atmospheric pressure varies depending on weather conditions as well as altitude. Take that into consideration when inspecting voltage. INSPECTIN Step 1 1) Remove the fuel tank. 2) Turn the ignition switch FF position. 3) Check the IAP sensor N.1 coupler 1 and N.2 coupler 2 for loose or poor contacts. If K, then measure the IAP sensor input voltage. Clogged vacuum passage between throttle body and IAP sensors. Air being drawn from vacuum passage between throttle body and IAP sensors. IAP sensor circuit open or shorted to ground. IAP sensor malfunction. ECU malfunction. 1 4) Disconnect the IAP sensor couplers N.1 1 and N ) Turn the ignition switch N position. 6) Measure the voltage at the wire and ground. If K, then measure the voltage at the wire and wire. IAP sensor input voltage 4.5 ~ 5.5 V ( - Ground ) ( - ) 2 Tester knob indication : Voltage ( ) Is the voltage K? ES N Go to Step 2. Loose or poor contacts on the ECU coupler. pen or short circuit in the wire or wire. 31

33 FI SSTEM DIAGNSIS Step 2 1) Connect the IAP sensor couplers N.1 1 and N ) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed. 4) Measure the IAP sensor output voltage at the wire side coupler (between L(N.1) or (N.2) and wires). IAP sensor output voltage Approx. 4.0 ~ 4.2 V when ignition switch N ([N.1] L - ) ([N.2] - ) Tester knob indication : Voltage ( ) Is the voltage K? ES N, L(N.1), (N,2) or wire open or shorted to ground, or poor, (N.1), 15 (N.2) or connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. If check result is not satisfactory, replace IAP sensor with a new one ECU Coupler utput voltage (Input voltage 5 V, ambient temp. 25 C, 77 F) ALTITUDE (Reference) ATMSPHERIC PRESSURE UTPUT VLTAGE (ft) (m) (mmhg) kpa (V) Approx. 4.0 ~ Approx. 3.6 ~ Approx. 3.3 ~ Approx. 3.0 ~

34 1 FI SSTEM DIAGNSIS C21 IAT SENSR CIRCUIT MALFUNCTIN CDE CDE C21 DETECTED CNDITIN utput voltage is out of the specified range. 0.1 V Sensor voltage < 4.6 V [ ] PSSILE CAUSE IAT sensor circuit open or short. IAT sensor malfunction. ECU malfunction. INSPECTIN Step 1 1) Remove the fuel tank. 2) Turn the ignition switch FF position. 3) Check the IAT sensor coupler for loose or poor contacts. If K, then measure the IAT sensor voltage at the wire side coupler. 4) Disconnect the coupler and turn the ignition switch N position. 5) Measure the voltage between Lg wire terminal and ground. 6) If K, then measure the voltage between Lg wire terminal and wire terminal. IAT sensor voltage 4.5 ~ 5.5 V ( Lg - Ground ) ( Lg - ) Tester knob indication : Voltage ( ) Is the voltage K? ES N Go to Step 2. Loose or poor contacts on the ECU coupler. pen or short circuit in the Lg wire or wire. 33

35 FI SSTEM DIAGNSIS Step 2 1) Turn the ignition switch FF position. 2) Measure the IAT sensor resistance. Intake Air Temp. -10 (14 ) 0 (32 ) 20 (68 ) 40 (104 ) 60 (140 ) Is the resistance K? IAT sensor resistance Resistance Approx kω Approx kω Approx kω Approx kω Approx kω Tester knob indication : Resistance ( kω ) ES N Lg or wire open or shorted to ground, or poor or 5 connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. Replace the IAT sensor with a new one. ECU Coupler 34

36 5 FI SSTEM DIAGNSIS C22 XGEN SENSR CIRCUIT MALFUNCTIN CDE CDE C22 DETECTED CNDITIN [ ] PSSILE CAUSE xygen sensor signal is not input in ECU since then more than 120 sec. after the engine run. xygen sensor, xygen sensor heater circuit open or short. xygen sensor, xygen sensor heater malfunction. ECU malfunction. INSPECTIN 1) Remove the front seat and frame cover. 2) Turn the ignition switch FF position. 3) Check the xygen sensor coupler 1 for loose or poor contacts. 1 Is K? ES N R or wire open or shorted to ground, or poor or 5 connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. Replace the xygen sensor. ECU Coupler C24 or C25 IGNITIN CIL MALFUNCTIN Refer to the IGNITIN CIL for details. (Refer to page 5-3) CDE CDE C24 C25 [ ] [ ] 35

37 FI SSTEM DIAGNSIS C27 ISC SLENID RANGE ANRMAL CDE CDE C27 DETECTED CNDITIN ISC solenoid s step is out of the specified range. step Solenoid step 100 step [ ] PSSILE CAUSE ISC solenoid malfunction. ISC solenoid s step is out of the specifie range. ECU malfunction. INSPECTIN 1) Remove the front seat. 2) Turn the ignition switch FF position. 3) Check the ISC solenoid coupler for loose or poor contacts. 4) Turn the ignition switch N position to check the ISC solenoid operation. [ When Ignition switch FF ] Is K? [ When Ignition switch N ] ES Gr, GR, or W wire loose or poor contacts on the ISC solenoid coupler, or poor 34, 32, 33 or 25 connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. N Replace the ISC solenoid with a new one ECU Coupler 36

38 2 1 FI SSTEM DIAGNSIS C32 or C33 FUEL INJECTR CIRCUIT MALFUNCTIN CDE CDE INSPECTIN C32 C33 DETECTED CNDITIN Fuel injector not comes in voltage from battery. Step 1 1) Remove the fuel tank and frame cover. 2) Turn the ignition switch FF position. 3) Check the injector couplers N.1 1 and N.2 2 for loose or poor contacts. If K, then measure the injector resistance. [ ] [ ] PSSILE CAUSE Injector circuit open or short. Injector malfunction. ECU malfunction. : Fuel injector N.1 : Fuel injector N.2 4) Disconnect the injector couplers N.1 1 and N.2 2 and measure the resistance between terminals. Injector resistance 11.5 ~ 13.5 Ϊ at 20 (68 ) 5) If K, then check the continuity between injector terminals and ground. Injector continuity Ϊ (Infinity) Tester knob indication : Resistance ( Ϊ ) Is the resistance K? ES N Go to Step 2 Replace the Injector with a new one. 37

39 FI SSTEM DIAGNSIS Step 2 1) Turn the ignition switch N position. 2) Measure the injector voltage between G(N.1), R(N.2) wire and ground. Injector voltage attery voltage ([N.1] G - Ground ) ([N.2] R - Ground ) Tester knob indication : Voltage ( ) NTE Injector voltage can be detected only 3 seconds after ignition switch is turned N position. 1 : Fuel injector coupler N.1 2 : Fuel injector coupler N.2 1 Is the voltage K? ES N G(N.1) or R(N.2) wire open or shorted to ground, or poor (N.1) or 10 (N.2) connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. Inspect the fuel pump or fuel pump relay. (Refer to page 4-2-6) ECU Coupler 38

40 FI SSTEM DIAGNSIS C37 SAV SLENID MALFUNCTIN CDE CDE C37 DETECTED CNDITIN SAV solenoid voltage is not input in ECU. [ ] PSSILE CAUSE SAV solenoid circuit open or short. SAV solenoid malfunction. ECU malfunction. INSPECTIN 1) Remove the front seat. 2) Turn the ignition switch FF position. 3) Check the SAV solenoid coupler for loose or poor contacts. 4) Connect the SAV solenoid coupler. 5) Turn the ignition switch N position. 6) Measure the voltage at the wire side coupler between GL wire and ground. SAV solenoid voltage attery voltage ( GL - Ground ) Tester knob indication : Voltage ( ) Is the voltage K? GL wire open or shorted to ground, or connection. If wire and connection are K, ES intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. N Replace the SAV solenoid with a new one. ECU Coupler 39

41 FI SSTEM DIAGNSIS C41 FUEL PUMP RELA CIRCUIT MALFUNCTIN DETECTED CNDITIN No voltage is applied to the both injectors for 3 sec. after the contact of fuel pump relay is turned N position. r voltage is applied to the both injectors, when the contact of fuel pump is FF position. INSPECTIN C41 CDE CDE Step 1 1) Remove the frame cover. 2) Turn the ignition switch FF position. 3) Check the fuel pump relay coupler for loose or poor contacts. If K, then check the insulation and continuity. Refer to page for details. CDE [ ] PSSILE CAUSE Fuel pump relay circuit open or short. Fuel pump relay malfunction. ECU malfunction. : Head lamp relay : Fuel pump relay : Main relay : Turn signal relay Is the Fuel pump relay K? ES GW wire open or shorted to ground, or poor 2 connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. Inspect the fuel injectors. (Refer to page ) N Replace the fuel pump relay with a new one. ECU Coupler 40

42 FI SSTEM DIAGNSIS C43 XGEN SENSR HEATER CIRCUIT MALFUNTIN C43 CDE CDE DETECTED CNDITIN xygen sensor heater signal is not input in ECU. INSPECTIN 1) Remove the frame cover. 2) Turn the ignition switch FF position. 3) Check the xygen sensor heater coupler for loose or poor contacts. If K, then measure the xygen sensor heater voltage. 4) Disconnect the coupler and then the ignition switch N position. 5) Measure the voltage between wire terminal and (or ground) wire terminal. CDE [ ] PSSILE CAUSE xygen sensor, xygen sensor heater circuit open or short. xygen sensor, xygen sensor heater malfunction. ECU malfunction. xygen sensor heater voltage attery voltage ( - ) ( - Ground ) Tester knob indication : Voltage ( ) Is the voltage K? ES or wire open or shorted to ground, or poor or connection. If wire and connection are K, intermittent trouble or faulty ECU. Recheck each terminal and wire harness for open circuit and poor connection. N Replace the xygen sensor. ECU Coupler 41

43 FI SSTEM DIAGNSIS SENSRS IAP SENSR INSPECTIN The intake air pressure (IAP) sensors N.1 1 and N.2 2 are installed at the upside of each intake pipe. (Refer to page ) IAP SENSR REMVAL AND INSTALLATIN Remove the fuel tank. Remove the IAP sensor from the intake pipe. Install the IAP sensor in the reverse order of removal. ET SENSR INSPECTIN The engine temperature (ET) sensor 3 is installed at the engine case. (Refer to page ) ET SENSR REMVAL AND INSTALLATIN Remove the ET sensor. Install the ET sensor in the reverse order of removal. ET sensor : 18 N m (1.8 kgf m) 42

44 1 2 FI SSTEM DIAGNSIS IAT SENSR INSPECTIN The intake air temperature (IAT) sensor 1 installed at the air cleaner case. (Refer to page ) IAT SENSR REMVAL AND INSTALLATIN Remove the fuel tank. Remove the IAT sensor from the air cleaner case. Install the IAT sensor in the reverse order of removal. is T SENSR INSPECTIN, REMVAL AND INSTALLATIN The tip over (T) sensor 2 is located in the frame. Romove the seat. Remove the T sensor from the frame. Install the T sensor in the reverse order of removal. 43

45 44

46 FUEL SSTEM AND THRTTLE D CNTENTS FUEL SSTEM 46 (4-2-1) REMVAL AND DISASSEML ( ) 47 (4-2-2) REASSEML AND INSTALLATIN ( ) 48 (4-2-3) REMVAL AND DISASSEML ( ) 49 (4-2-4) 4-2 REASSEML AND INSTALLATIN ( ) 50 (4-2-5) FUEL PRESSURE INSPECTIN 51 (4-2-6) FUEL PUMP RELA INSPECTIN 51 (4-2-6) FUEL MESH FILTER INSPECTIN AND CLEANING ( ) 52 (4-2-7) FUEL GAUGE INSPECTIN 52 (4-2-7) THRTTLE D 53 (4-2-8) REMVAL 54 (4-2-9) CLEANING 55 (4-2-10) INSPECTIN 55 (4-2-10) INSTALLATIN 56 (4-2-11) 45

47 4-2-1 FUEL SSTEM AND THRTTLE D FUEL SSTEM 46

48 2 4 3 FUEL SSTEM AND THRTTLE D REMVAL AND DISASSEML ( ) Remove the front seat. Remove the fuel tank mounting bolt and take off the hooks. Disconnect the fuel gauge coupler 1. 1 Remove the fuel pump coupler 2. Remove the fuel injector hose 3 and return hoses 4. CAUTIN After disconnecting the fuel injector hose 3, insert a blind plug into the end to stop fuel leakage. 47

49 FUEL SSTEM AND THRTTLE D Remove the fuel tank rearward. CAUTIN As gasoline leakage may occur in this operation, keep away from fire and sparks. Remove the fuel pump assembly 1 its mounting bolts diagonally. WARNING Remove the fuel gauge 2. by removing Gasoline is highly flammable and explosive. Keep heat, spark and flame away. 2 REASSEML AND INSTALLATIN ( ) Reassembly and installation the fuel tank in the reverse order of remval and disassembly. When installing the fuel pump assembly, first tighten all the fuel pump assembly mounting bolts lightly in diagonal stages, and then tighten them in the above tightening order. NTE Apply a small quantity of the THREAD LCK 1324 to the thread portion of the fuel pump mounting bolt. THREAD LCK

50 FUEL SSTEM AND THRTTLE D REMVAL AND DISASSEML ( ) Remove the front seat. Remove the fuel tank mounting bolts and take off the hooks. Disconnect the fuel gauge coupler 1. Remove the fuel pump coupler 2. Remove the fuel injector hose 3 4. CAUTIN and return hose After disconnecting the fuel injector hose 3, insert a blind plug into the end to stop fuel leakage. 49

51 FUEL SSTEM AND THRTTLE D Remove the fuel tank rearward. CAUTIN As gasoline leakage may occur in this operation, keep away from fire and sparks. Remove the fuel pump assembly 1 its mounting bolts. WARNING by removing Gasoline is highly flammable and explosive. Keep heat, spark and flame away. Remove the FPR 2 by removing its mounting bolt. FPR : Fuel Pressure Regulater Remove the fuel gauge 3. REASSEML AND INSTALLATIN ( ) Reassembly and installation the fuel tank, fuel pump assembly and FPR in the reverse order of remval and disassembly. 50

52 1 FUEL SSTEM AND THRTTLE D FUEL PRESSURE INSPECTIN Remove the front seat. Place a rag under the fuel injector hose. Disconnect the fuel injector hose from the fuel delivery pipe. Install the special tool between the fuel tank and fuel delivery pipe. Fuel pump pressure gauge : Turn the ignition switch N position and check the fuel pressure. Fuel pressure Approx. 3.4 ~ 3.7 kgf/cm 2 (333 ~ 363 kpa, 48.4 ~ 52.6 psi) If the fuel pressure is lower than the specification, inspect the following items : * Fuel hose leakage * Clogged fuel filter * Pressure regulator * Fuel pump If the fuel pressure is higher than the specification, inspect the following items : * Fuel pump check valve * Pressure regulator WARNING efore removing the special tool, turn the ignition switch to FF position and release the fuel pressure slowly. Gasoline is highly flammable and explosive. Keep heat, sparks and flame away. FUEL PUMP RELA INSPECTIN Fuel pump relay is located the left side of the frame. Remove the frame cover. Remove the fuel pump relay

53 FUEL SSTEM AND THRTTLE D First, check the insulation between 1 and 2 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. 1 FUEL MESH FILTER INSPECTIN AND CLEANING ( ) If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. low the fuel mesh filter with compressed air. NTE If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one. FUEL GAUGE INSPECTIN Measure resistance between the terminals when float is at the position instead below. Fuel float position Resistance between terminals F Approx. 90 ~ 105 Ϊ 1/2 E Approx. 38 Ϊ Approx. 4 ~ 10 Ϊ If the resistance measured is out of the specification, replace the gauge with a new one. Fuel level meter inspection. 52

54 FUEL SSTEM AND THRTTLE D THRTTLE D 53

55 4-2-9 FUEL SSTEM AND THRTTLE D REMVAL Remove the fuel tank. Remove the air cleaner box. Disconnect the fuel hose. Remove the all coupler to related the throttle body. Loosen the throttle body clamp screws. Disconnect the throttle cables from their drum. Dismount the throttle body assembly. CAUTIN e careful not to damage the throttle cable bracket when dismounting or remounting the throttle body assembly. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body. 54

56 1 FUEL SSTEM AND THRTTLE D 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. CAUTIN Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer s instructions for proper use and cleaning of the throttle body components. Do not apply throttle body cleaning chemicals to the rubber and plastic materials. INSPECTIN Check following items for any damage or clogging. * -ring * Secondary throttle valve * Throttle shaft bushing and seal * Injector cushion seal * Throttle valve * Vacuum hose Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank. CAUTIN Never operate the idle screws 1 (N.1) and 2 (N.2) to avoid variations of the carburetion setting. 2 55

57 FUEL SSTEM AND THRTTLE D INSTALLATIN Installation is in the reverse order of removal. Pay attention to the following points : Connect the throttle cable to the throttle cable drum. Adjust the throttle cable play with the cable adjusters. 56

58 ELECTRICAL SSTEM CNTENTS LCATIN F ELECTRICAL CMPNENTS 58 (5-1) IGNITIN SSTEM 60 (5-3) CHARGING SSTEM 61 (5-7) 5 57

59 ELECTRICAL SSTEM LCATIN F ELECTRICAL CMPNENTS 6 5 Ignition coil N.1 Ignition coil N.2 Main relay Fuel pump relay Head lamp relay Main fuse (30A) ECU Head lamp fuse (15A) attery 10 IAT sensor 11 T sensor 12 Magneto 13 Pick-up coil 14 GP switch 12 58

60 15 15 ELECTRICAL SSTEM 5-2 ISC solenoid IAP sensor N.1 ET sensor IAP sensor N.2 SAV solenoid xygen sensor Fuel injector N.2 Fuel injector N.1 59

61 5-3 ELECTRICAL SSTEM IGNITIN SSTEM RELA ENGINE STP SWITCH IG. SWITCH REAR IGNITIN CIL FRNT IGNITIN CIL ECU MAGNET FUSE INSPECTIN IGNITIN CIL RESISTANCE INSPECTIN 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. IGNITIN CIL / PLUG CAP RESISTANCE Primary Secondary Ϊ kω 3.5 ~ 5.5 ( Terminal - Terminal) 20 ~ 31 (Plug cap - Terminal) Tester knob indication : Resistance ( kω ) 60

62 ELECTRICAL SSTEM 5-4 MAGNET Using the pocket tester, measure the resistance between the lead wires in the following table. If the resistance is not within the specified value, replace the magneto coil, with a new one. Magneto coil resistance Pick-up coil Charging coil Standard G - L Approx. 85 ~ 105 Ϊ - Approx. 0.2 ~ 1.0 Ϊ Tester knob indication : Resistance ( Ϊ ) CAUTIN When mounting the stator on the magneto cover, apply a small quantity of THREAD LCK 1324 to the threaded parts of screws. THREAD LCK 1324 WIRE CLR L : lue G : Green : ellow : lack with ellow tracer : range with lack tracer r : rown : lack with White tracer WL : White with lue tracer G : ellow with Green tracer MAGNET N-LAD PERFRMANCE 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. N-load performance of magneto Standard ver 60 V (at 5,000 rpm) Tester knob indication : Voltage ( ) 61

63 5-7 ELECTRICAL SSTEM CHARGING SSTEM Regulator / Rectifier IG. switch A. C generator IC LAD attery INSPECTIN IG. switch CHARGING UTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC voltage between the battery terminal and. If the voltage is not within the specified value, check the magneto no-load performance and regulator / rectifier. Regulator Rectifier attery DCV CAUTIN When making this test, be sure that the battery is full-charged condition. Standard charge V (at 5,000 rpm) Tester knob indication : Voltage ( ) 62

64 ELECTRICAL SSTEM 5-10 REGULATR / RECTIFIER Disconnect the regulator / rectifier couplers. Using the pocket tester, measure the resistance between the terminals in the following table. If the resistance checked is incorrect, replace the regulator / rectifier. Unit : MΪ Tester probe Tester probe kω kΩ Tester knob indication : Resistance (MΪ ) 63

65 64

66 SERVICING INFRMATIN CNTENTS TRULESHTING 66 (7-1-1) SPECIAL TLS 75 (7-8) TIGHTENING TRQUE 76 (7-11) SERVICE DATA 77 (7-19-1) WIRING DIAGRAM ( ) 80 (7-31-1) WIRING DIAGRAM ( ) 82 (7-31-3) WIRING DIAGRAM ( ) 84 (7-31-5) 7 65

67 7-1-1 SERVICING INFRMATIN TRULESHTING MALFUNCTIN CDE AND DEFECTIVE CNDITIN MALFUNCTIN CDE C15 C17 / C18 C21 C22 DETECTED ITEM Engine temperature sensor (ETS) Intake air pressure sensor (IAPS), N.1 / N.2 Intake air temperature sensor (IATS) xygen sensor (2S) DETECTED FAILURE CNDITIN CHECK FR The sensor voltage should be the following. 0.1 V sensor voltage < 4.6 V Without the above range for 4 sec. and more, C15 is indicated. Engine temperature sensor, lead wire / coupler connection. The sensor should produce following voltage. 0.1 V sensor voltage 4.8 V Without the above range for 4 sec. and more, C17 or C18 is indicated. Intake air pressure sensor, lead wire / coupler connection. The sensor voltage should be the following. 0.1 V sensor voltage < 4.6 V Without the above range for 4 sec. and more, C21 is indicated. Intake air temperature sensor, lead wire / coupler connection. The oxygen sensor signal is input in ECU since then more than 120 sec. after the engine run. When this is the case, ECU not receive the signal, C22 is indicated. xygen sensor, lead wire / coupler connection. 66

68 SERVICING INFRMATIN MALFUNCTIN CDE C24 / C25 C27 C32 / C33 C37 C41 C43 DETECTED ITEM Ignition coil (IG coil), N.1 / N.2 Idle speed control solenoid (ISC solenoid) Fuel injector, N.1 / N.2 Secondary air valve solenoid (SAV solenoid) Fuel pump relay xygen sensor heater (2S heater) DETECTED FAILURE CNDITIN CHECK FR When the IC of the ECU electric current gets 6 A and more, C24 or C25 is indicated. Ignition coil, wiring / coupler connection, power supply from the battery. The idle speed control solenoid step should be the following. step solenoid step 100 step Without the above range, C27 is indicated. Idle speed control solenoid, lead wire / coupler connection. The fuel injector not comes in voltage from the battery, C32 or C33 is indicated. Injector, wiring / coupler connection, power supply to the injector. When the secondary air valve solenoid voltage is not input in ECU, C37 is indicated. Secondary air valve solenoid, lead wire / coupler connection. No voltage is applied to the both injectors 3 for 3 sec. after the contact of fuel pump relay is turned N position. r voltage is applied to the both injectors, when the contact of fuel pump is FF position. Fuel pump relay, connecting lead wire, power source to fuel pump relay, fuel injector. The oxygen sensor heater signal is not input in ECU. xygen sensor heater, lead wire / coupler connection. 67

69 7-1-3 SERVICING INFRMATIN ENGINE Complaint Symptom and possible causes Remedy Engine will not start or is hard to start. Compression too low 1. Tappet clearance out of adjustment. 2. Worn valve guides or poor seating of valves. 3. Mistimed valves. 4. Excessively worn piston rings. 5. Worn-down cylinder bore. 6. Starter motor cranks too slowly. 7. Poor seating of spark plugs. Adjust. Repair or replace. Adjust. See electrical section. Retighten. Plug not sparking 1. Fouled spark plugs. 2. Wet spark plugs. 3. Defective ignition coils. 4. pen or short in high-tension cord. 5. Defective pick-up coil. 6. Defective ECU. 7. pen-circuited wiring connections. No fuel reaching the intake manifold 1. Clogged fuel filter or fuel hose. 2. Defective fuel pump. 3. Defective fuel pressure regulator. 4. Defective fuel injector. 5. Defective fuel pump relay. 6. Defective ECU. 7. pen-circuited wiring connections. Incorrect fuel / air mixture 1. Defective fuel pump. 2. Defective fuel pressure regulator. 3. Defective pick-up coil. 4. Defective IAP sensor. 5. Defective ECU. 6. Defective ET sensor. 7. Defective IAT sensor. Clean. Clean and dry. Repair or replace. Clean or replace. Check and repair. 68