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Cannondale 5002401, Service Manual

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Cannondale 5002401 Service Manual Download Page 53

© 2002 Cannondale Corporation - All Rights Reserved

54

Electrical_EFI Service Manual.fm

 

Coolant Sensor Resistance Range

Resistance
(ohms)

Temp. 
(deg. C)

Temp.
(deg. F)

Resistance
(ohms)

Temp. 
(deg. C)

Temp. 
(deg. F)

Resistance
(ohms)

Temp.
(deg. C)

Temp. 
(deg. F)

45313 -40

-40

2500

20

68

322

80

176

34281

-35

-31

2057

25

77

280

85

185

26114

-30

-22

1707

30

86

243

90

194

20003

-25

-13

1412

35

95

213

95

203

15462

-20

-4

1175

40

104

187

100

212

12002

-15

5

988

45

113

164

105

221

9397

-10

14

834

50

122

144

110

230

7415

-5

23

703

55

131

127

115

239

5896

0

32

595

60

140

113

120

248

4712

5

41

508

65

149

100

125

257

3792

10

50

436

70

158

89

130

266

3069

15

59

374

75

167

N/A

N/A

N/A

Summary of Contents for 5002401

Page 1: ...Electrical EFI Service Manual ATV and Motorcycle P N 5002401 August 14 2002...

Page 2: ...anyone who is not familiar with standard safety practices and service techniques This manual does include warnings and cautions see descriptions above that if ignored could result in SEVERE PERSONAL I...

Page 3: ...ollowing notations The safety alert symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Indicates that DEATH or severe injury WILL result if the instructions are not followed Indicates a poten...

Page 4: ...application Or you can access this application by clicking on Security code exe through the program group 22 Common Problems 23 Interpreting Error Messages 24 Other Messages 25 Communication cable 27...

Page 5: ...fuel delivery for all engine speeds and loads based on its pro gramming It is sometimes referred to as the brain of the fuel injection system This brain calculates fuel delivery and ignition timing ba...

Page 6: ...is a combination of a specially developed Windows based software program and a data cable used to connect your PC or pocket PC computer to your vehicle With the tool you can read fault codes install...

Page 7: ...tion and pin condition before reconnecting Lubricate the connector seals with a high quality dielectric grease before reinstalling Use a commercially available pin gauge when performing pin point test...

Page 8: ...the connector or coupler with a clean lint free rag and blow off any moisture using compressed air 2 Remove corrosion rust stains or other foreign material by using contact cleaner on the termi nals 3...

Page 9: ...ing on page 39 3 Compare the known value with the one reported by the software tool If the comparison of the actual value and the reported value results in a wide disparity and no other faults are pre...

Page 10: ...consistent as described above the sensor can be tested further by removing it and reading the resistance values with an Ohmmeter 2 Attach a vacuum pump pressure pump to the hose end and monitor change...

Page 11: ...CU Monitor window If the value does not increase as the engine warms go to the next test Static Test Resistance 1 Disconnect the sensor harness connector 2 Use an Ohmmeter to measure the sensor resis...

Page 12: ...ts it as bottom dead center BDC The ECU uses this information to determine engine speed and crankshaft position in relation to the point where fuel is injected and ignition of the air fuel mixture occ...

Page 13: ...ra air needed for cold starting conditions is not available Enough air may be available to start a warm Engine idles too fast valve is stuck open Rough idle if the valve arm is malfunctioning Dynamic...

Page 14: ...ion excessive heat 2 Check the coil terminal pins Make sure they are in good condition 3 Check the condition of the tip insulator Make sure it is not cracked burned melted dried out 4 Make sure the sp...

Page 15: ...ing an Ohmmeter connect the positive probe onto terminal number 30 and the negative probe onto terminal number 87 Check the for continuity There should be no continuity If continuity is observed the r...

Page 16: ...is connected to the airbox via a small hose On ATVs the fuel pressure regulator is mounted on the main frame on the right side of the vehicle front Dynamic Test Pump and Regulator NOTE If you suspect...

Page 17: ...s connected to the fuel tank tank 6 Start the engine and read the generated fuel pres sure If the fuel pressure reading is OK the pump and regulator are OK If the fuel pressure reading is low quickly...

Page 18: ...r the fuel 3 Check the air filter element If it is dirty or blocked this will severely impede air flow and fuel econ omy 4 Check the airbox and throttle body assemblies for possible air leaks that wou...

Page 19: ...rom the cooling fan coupler 2 Connect a 12 V battery voltage source to the red fan lead Connect the 12V lead to the black fan lead If the fan runs it is OK Check to make sure the airflow is correct th...

Page 20: ...parameters Read system faults A special interface cable is needed to connect the PC to the vehicle once the software is installed and authorized for use INSTALLATION Installing the software 1 Insert...

Page 21: ...ecurityCode 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 Techno...

Page 22: ...ecialist to resolve the problem If there is only a connector icon note the Communications Port Name COM1 COM3 etc Run your Dealer Cal software Under File Change Port change your Active Port to the abo...

Page 23: ...ble will light when the engine manage ment circuits are powered up NOTE On ATVs after 2 minutes of inactivity ECU power down the interface cable block green LED will not go out It will remain lit as l...

Page 24: ...CD drive OTHER MESSAGES Progress Indicator Whenever data is being transferred between the vehicle ECU and the PC a progress indicator displays in the upper right area of the main screen Data transfers...

Page 25: ...checks are performed by the diagnostic tool software to ensure that the data is not damaged during the transfer Each small packet is checked during the transfer If data errors are detected in the pack...

Page 26: ...cle models the diag nostic connector is located near the ignition coil at the top of the cylinder head Vehicle components must be removed to access the connector On 2003 Motorcycles the diagnostic con...

Page 27: ...ored in ECU 3 Buttons 4 Throttle position sensor min and max values from vehicle 5 Throttle Body Leakage also Throttle Body Offset Factory dyno value 6 Fuel injector flow rate Factory dyno value 7 Inj...

Page 28: ...is displayed in the top left corner of the main window no calibration file has been opened from a saved file or received from the vehicle ECU ECU OPERATING CODE The ECU operating code is installed at...

Page 29: ...low rate injector offset The engine calibration file and vehicle variables must be reinstalled into the ECU following the operating code update Receive the installed engine calibration file FIRST As l...

Page 30: ...art button Click Download The progress indicator will display while the trans fer take place When the transfer is complete release the start button Click Close 4 Reinstall the correct engine calibrati...

Page 31: ...map and variables starting on page 33 To open a saved calibration file NOTE In version 2 0 of the software when the program is launched the last engine calibration file that was opened is automatical...

Page 32: ...just the throttle body and injector variables or calibrations In case of PC failure it is a good idea whenever a file is received from the vehicle ECU to write down the throttle body and injector var...

Page 33: ...open using the program You ll want to pay close attention to what engine calibration file is actually open before you send the file to the ECU in the following steps Click the OPEN Calibration File s...

Page 34: ...ate 2 Make sure the interface cable is connected to the computer and vehicle securely 3 Open the Cannondale Diagnostic and Maintenance Tool software on your PC 4 Power up the vehicle engine management...

Page 35: ...ancel at the Send Calibrations to ECU prompt the new values will be updated in the currently open engine calibration file and remain until the file is closed another new engine calibration file opened...

Page 36: ...y and fuel injector calibrations The Update Calibrations window enables you to calibrate or set the vehicle specific variables which are included in the engine calibration file data Throttle body leak...

Page 37: ...mechanical device and there is a delay from the time the electrical signal to open is delivered until the mechanical parts move and allow fuel to flow This delay time is added to all pulse widths In...

Page 38: ...e 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 t...

Page 39: ...without ECU interface accessories The MIL fault does not indicate a problem with normal engine operations just the accessories Once a fault has been cleared through corrective action close and reopen...

Page 40: ...002 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 Also for the sample faul...

Page 41: ...point Tests Test Result Action 1 Check wire and terminal integrity P1 B3 OK Disconnect throttle position sensor air temperature sensor and coolant sensor and go to Test 2 Faulty Correct and go to Test...

Page 42: ...nsure regulator output voltage is within specified range Pinpoint Tests Test Result Action 1 Check wire and terminal integrity P2 E1 OK Go to Test 2 Faulty Correct and go to Test 3 2 With ignition on...

Page 43: ...sconnect the fuel pump and go to Test 2 Faulty Locate and correct and go to Test 2 2 Check for short circuit between P1 H1 to ground Open Go to Test 3 Shorted Locate and correct wiring fault go to Tes...

Page 44: ...nition coil and go to Test 3 Open circuit Go to Test 4 Short circuit Disconnect ignition coil and go to Test 5 3 Check wire for short circuit between P2 H1 to ground Short circuit Locate and correct w...

Page 45: ...d terminal integrity P2 G1 P2 G2 OK Disconnect cooling fan and go to Test 2 Faulty Locate and correct wiring fault and go to Test 5 2 Check wire for short circuit P2 G1 to ground P2 G2 to ground OK Go...

Page 46: ...open circuit Pinpoint Tests Test Result Action 1 Check wire and terminal integrity P1 H2 P1 H3 OK Go to Test 2 Faulty Locate and correct wiring fault and go to Test 7 2 Check resistance value Motorcy...

Page 47: ...ighting connector CN26 remove EMS power relay Measure between relay socket terminal 30 and relevant injector pin 1 P1 H3 to CN6 pin 2 Right injector P1 H2 to CN7 pin 2 Left injector ATV Disconnect the...

Page 48: ...0 switch engine stop button to OFF position Measure between P2 E1and P1 H3 P1 H2 OK Go to Test 6 Short circuit Locate and correct wiring fault proceed to Test 7 6 Check injector resistance relevant in...

Page 49: ...B4 OK Disconnect TPS sensor and go to Test 2 Faulty Locate and correct wiring fault and go to Test 5 2 Check for short circuit between P1 E3 to ground OK Go to Test 3 Short circuit Locate and correct...

Page 50: ...e table OK Disconnect temperature sensor and go to Test 6 Open circuit Go to Test 3 Short circuit Disconnect temperature sensor and go to Test 4 3 Check wire continuity P1 D1 to CN5 pin 2 P1 E4 to CN5...

Page 51: ...Temp deg F Resistance ohms Temp deg C Temp deg F 15071 20 4 1700 30 86 331 80 176 11739 15 5 1414 35 95 287 85 185 9215 10 14 1181 40 104 250 90 194 7290 5 23 992 45 113 219 95 203 5808 0 32 837 50 12...

Page 52: ...ested see table OK Disconnect temperature sensor and go to Test 6 Open circuit Go to Test 3 Short circuit Disconnect temperature sensor and go to Test 4 3 Check wire continuity P1 B2 to CN4 pin 2 P1 E...

Page 53: ...C Temp deg F 45313 40 40 2500 20 68 322 80 176 34281 35 31 2057 25 77 280 85 185 26114 30 22 1707 30 86 243 90 194 20003 25 13 1412 35 95 213 95 203 15462 20 4 1175 40 104 187 100 212 12002 15 5 988 4...

Page 54: ...circuit Go to Test 4 Short circuit Disconnect IACV and go to Test 5 3 Check cable for short circuit P1 E1 to ground P1 E2 to ground P1 F1 to ground P1 F2 to ground OK Go to Test 7 Short circuit Locat...

Page 55: ...nd P1 B1 to ground OK Go to Test 3 Short circuit Locate and correct wiring fault and go to Test 8 3 Check cable continuity P1 A1 to CN2 pin 2 P1 B1 to CN2 pin 1 OK Go to Test 4 Open circuit Locate and...

Page 56: ...ontinuity 4 Test for continuity between both black output wires and the rectifier regulator housing There should be no continuity 5 Connect the positive multi meter probe to the red output wire of the...

Page 57: ...least 100 VAC Make sure you do not switch to DCV or Vdc by mistake Connect the multi meter leads between two of the yellow wires emerging from the stator Start the engine and bring to 5000 r min Check...

Page 58: ...the engine start button On ATVs the additional step of turning the ignition key ON and pulling in the clutch lever is required before pressing the start button The solenoid is normal if the solenoid c...

Page 59: ...er is required before pressing the start button Test for 12V voltage between the starter cable and ground There should be 12V when the button is pressed If no voltage is found and the solenoid is OK c...

Page 60: ...ode application Or you can access this application by clicking on Security code exe through the program group 22 Common Problems 23 Interpreting Error Messages 24 Other Messages 25 Communication cable...

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