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HYOSUNG AQUILA 250 FI Service Manual Download Page 51

50

4-2-5  FUEL SYSTEM AND THROTTLE BODY

●

Remove the fuel tank rearward.

●

Remove the fuel pump assembly 

①

by removing

its mounting bolts.

●

Remove the fuel gauge 

③

.

REASSEMBLY AND INSTALLATION   

(                         )

Reassembly and installation the fuel tank, fuel pump
assembly and FPR in the reverse order of remval
and disassembly.

CAUTION

As gasoline leakage may occur in this operation,
keep away from fire and sparks.

WARNING

�

�

Gasoline is highly flammable and explosive.

�

�

Keep heat, spark and flame away.

①

③

②

●

Remove the FPR 

②

by removing its mounting

bolt.

※ FPR : Fuel Pressure Regulater

Summary of Contents for AQUILA 250 FI

Page 1: ...SERVICE MANUAL 99000 95610 SERVICE MANUAL...

Page 2: ...ur optimum and quick service ELECTRICAL SYSTEM GROUP INDEX GENERAL INFORMATION 1 FI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY 4 2 4 1 5 SERVICING INFORMATION 7 This manual has been prepared on th...

Page 3: ...page you need SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively Apply THREAD LOCK 132...

Page 4: ...njection Fuel Injector FP Fuel Pump 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...

Page 5: ...er GY Green with Yellow tracer GrB Gray with Black tracer GrR Gray with Red tracer GrW Gray with White tracer OB Orange with Black tracer OL Orange with Blue tracer OG Orange with Green tracer OR Oran...

Page 6: ...5 GENERAL INFORMATION SPECIFICATIONS 6 1 8 CONTENTS 1...

Page 7: ...oled V 2 cylinder 57 0 mm 2 24 in 48 8 mm 1 92 in 249 15 2 in3 Fuel Injection Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system Lubrication s...

Page 8: ...400 2 5 cc Fuel tank Engine oil Front fork oil capacity One side Oil change Oil and filter change Engine overhaul I T E M CAPACITIES Ignition type Ignition timing Spark plug Battery Fuse Head lamp Tur...

Page 9: ...8...

Page 10: ...18 C15 ET SENSOR CIRCUIT MALFUNCTION 29 4 1 20 C17 o or r C18 IAP SENSOR CIRCUIT MALFUNCTION 31 4 1 22 C21 IAT SENSOR CIRCUIT MALFUNCTION 33 4 1 24 C22 OXYGEN SENSOR CIRCUIT MALFUNCTION 35 4 1 26 C24...

Page 11: ...e 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 termina...

Page 12: ...ector 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 rep...

Page 13: ...the components of the FI system instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The moment such removal is made damaging counter elect...

Page 14: ...ate measurements may not be obtained and personal injury may result USING TESTERS Use well charged batteries in the tester Be sure to set the tester to the correct testing range USING THE TESTER Incor...

Page 15: ...re 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 Inta...

Page 16: ...itors 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 vol...

Page 17: ...FISYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION Speedometer Ignition coil NO 1 Ignition coil NO 2 Pick up coil GP switch Fuel injector NO 1 Fuel injector NO 2 ISC solenoid E EC CU U 3 3 4 4 2 2 6 6 5 5 7...

Page 18: ...17 FISYSTEM DIAGNOSIS 4 1 8 IAT sensor TO sensor Fuel pump relay IAP sensor NO 2 IAP sensor NO 1 ET sensor Oxygen sensor SAV solenoid E EC CU U 1 15 5 1 10 0 1 11 1 1 14 4 1 12 2 1 16 6 1 13 3 9 9...

Page 19: ...RTS LOCATION Speedometer Fuel injector NO 1 Fuel injector NO 2 IAT sensor GP switch Pick up coil Ignition coil NO 1 ISC solenoid Fuel pump relay 4 1 9 FISYSTEM DIAGNOSIS E EC CU U 3 3 4 4 2 2 6 6 5 5...

Page 20: ...19 TO sensor Ignition coil NO 2 IAP sensor NO 1 IAP sensor NO 2 ET sensor Oxygen sensor SAV solenoid FISYSTEM DIAGNOSIS 4 1 10 E EC CU U 1 15 5 1 10 0 1 11 1 1 14 4 1 12 2 1 16 6 1 13 3...

Page 21: ...heck the special tool is necessary to read the code of the malfunction items USER MODE The FI check lamp comes on for about three seconds whenever the ignition switch is set to ON position with the en...

Page 22: ...h 09900 27000 DEALER MODE The defective function is memorized in the ECU Use the special tool s coupler to connect to the dealer mode coupler Refer to page 4 1 17 The memorized malfunction code is dis...

Page 23: ...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...

Page 24: ...NO 1 IG coil NO 2 Idle speed control solenoid ISC solenoid Fuel injector NO 1 Fuel injector NO 2 Secondary air valve solenoid SAV solenoid Fuel pump relay Oxygen sensor heater O2S heater For NO 1 cyl...

Page 25: ...ge FI Check lamp Always ON Sometimes ON Always OFF Good condition No code Malfunction code PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combu...

Page 26: ...ld F C Always Always Sometimes times day month Only once Under certain condition Urban Suburb Highway Mountainous Uphill Downhill Tarmacadam Gravel Other Cold Warming up phase Warmed up Always Other a...

Page 27: ...page 4 1 12 14 carefully to have good understanding as to what functions are available and how to use it Be sure to read PRECAUTIONS for Electrical Circuit Service Refer to page 4 1 1 before inspecti...

Page 28: ...on DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR MALFUNCTION CODE 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...

Page 29: ...CTED FAILURE CONDITION CHECK FOR MALFUNCTION CODE When the IC of the ECU electric current gets 6 A and more C24 or C25 is indicated The idle speed control solenoid step should be the following O step...

Page 30: ...DITION POSSIBLE CAUSE ET sensor circuit open or short ET sensor malfunction ECU malfunction YES NO ET sensor voltage Is the voltage OK Tester knob indication Voltage CODE CODE 1 5 1 5 1 C15 Output vol...

Page 31: ...209 Approx 5 671 Approx 2 845 Approx 1 525 0 32 20 68 40 104 60 140 80 176 Is the resistance OK Tester knob indication Resistance YES NO Replace the ET sensor with a new one ECU Coupler G or BW wire o...

Page 32: ...ion ECU malfunction POSSIBLE CAUSE YES NO IAP sensor input voltage 4 5 5 5 V OB Ground OB BW Is the voltage OK Tester knob indication Voltage C17 C18 CODE CODE 1 7 1 7 1 8 1 8 IAP sensor voltage is ou...

Page 33: ...not satisfactory replace IAP sensor with a new one Step 2 1 Connect the IAP sensor couplers NO 1 and NO 2 2 Insert the needle pointed probes to the lead wire coupler 3 Start the engine at idle speed...

Page 34: ...ED CONDITION POSSIBLE CAUSE IAT sensor circuit open or short IAT sensor malfunction ECU malfunction YES NO IAT sensor voltage 4 5 5 5 V Lg Ground Lg BW Is the voltage OK Tester knob indication Voltage...

Page 35: ...ensor resistance Approx 53 30 Approx 31 52 Approx 12 33 Approx 5 19 Approx 2 42 10 14 0 32 20 68 40 104 60 140 Tester knob indication Resistance Lg or BW wire open or shorted to ground or poor or conn...

Page 36: ...tion ECU malfunction POSSIBLE CAUSE Is OK NO YES Replace the Oxygen sensor ECU Coupler C22 C24 C25 CODE CODE CODE CODE 2 2 2 2 2 2 Oxygen sensor signal is not input in ECU since then more than 120 sec...

Page 37: ...pler When Ignition switch OFF When Ignition switch ON 32 33 34 C27 CODE CODE 2 7 7 2 DETECTED CONDITION POSSIBLE CAUSE ISC solenoid s step is out of the specified range O step Solenoid step 100 step I...

Page 38: ...nd measure the resistance between terminals C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION 5 If OK then check the continuity between injector terminals and ground DETECTED CONDITION POSSIBLE CAUSE Fuel...

Page 39: ...n 2 Measure the injector voltage between YG NO 1 YR NO 2 wire and ground YG NO 1 or YR NO 2 wire open or shorted to ground or poor NO 1 or NO 2 connection If wire and connection are OK intermittent tr...

Page 40: ...knob indication Voltage ECU Coupler C37 CODE CODE 3 3 7 INSPECTION 1 Remove the front seat 2 Turn the ignition switch OFF position 3 Check the SAV solenoid coupler for loose or poor contacts 4 Connec...

Page 41: ...O Replace the fuel pump relay with a new one ECU Coupler CODE CODE C41 CODE CODE 4 4 1 1 1 4 Head lamp relay Fuel pump relay Main relay Turn signal relay INSPECTION Step 1 1 Remove the frame cover 2 T...

Page 42: ...ion Voltage ECU Coupler CODE CODE CODE CODE C43 CODE CODE 4 3 3 4 OB or B wire open or shorted to ground or poor or connection If wire and connection are OK intermittent trouble or faulty ECU Recheck...

Page 43: ...TALLATION Remove the ET sensor Install the ET sensor in the reverse order of removal SENSORS IAP SENSOR INSPECTION The intake air pressure IAP sensors NO 1 and NO 2 are installed at the upside of each...

Page 44: ...ENSOR REMOVAL AND INSTALLATION Remove the fuel tank Remove the IAT sensor from the air cleaner case Install the IAT sensor in the reverse order of removal TO SENSOR INSPECTION REMOVAL AND INSTALLATION...

Page 45: ...44...

Page 46: ...SSEMBLY AND INSTALLATION 50 4 2 5 FUEL PRESSURE INSPECTION 51 4 2 6 FUEL PUMP RELAY INSPECTION 51 4 2 6 FUEL MESH FILTER INSPECTION AND CLEANING 52 4 2 7 FUEL GAUGE INSPECTION 52 4 2 7 THROTTLE BODY 5...

Page 47: ...46 4 2 1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM...

Page 48: ...seat Disconnect the fuel gauge coupler Remove the fuel tank mounting bolt and take off the hooks CAUTION After disconnecting the fuel injector hose insert a blind plug into the end to stop fuel leaka...

Page 49: ...ssembly 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 CAUTION As gasolin...

Page 50: ...nt seat Remove the fuel tank mounting bolts and take off the hooks Disconnect the fuel gauge coupler CAUTION After disconnecting the fuel injector hose insert a blind plug into the end to stop fuel le...

Page 51: ...STALLATION Reassembly and installation the fuel tank fuel pump assembly and FPR in the reverse order of remval and disassembly CAUTION As gasoline leakage may occur in this operation keep away from fi...

Page 52: ...48 4 52 6 psi WARNING Before removing the special tool turn the ignition switch to OFF position and release the fuel pressure slowly Gasoline is highly flammable and explosive Keep heat sparks and fla...

Page 53: ...tridge with a new one FUEL GAUGE INSPECTION Measure resistance between the terminals when float is at the position instead below If the resistance measured is out of the specification replace the gaug...

Page 54: ...53 FUEL SYSTEM AND THROTTLE BODY 4 2 8 THROTTLE BODY...

Page 55: ...hrottle body clamp screws Disconnect the throttle cables from their drum Dismount the throttle body assembly CAUTION Be careful not to damage the throttle cable bracket when dismounting or remounting...

Page 56: ...r 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 n...

Page 57: ...D THROTTLE BODY INSTALLATION 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...

Page 58: ...57 LOCATION OF ELECTRICAL COMPONENTS 58 5 1 IGNITION SYSTEM 60 5 3 CHARGING SYSTEM 61 5 7 CONTENTS ELECTRICAL SYSTEM 5...

Page 59: ...SYSTEM LOCATION OF ELECTRICAL COMPONENTS Ignition coil NO 1 Ignition coil NO 2 Main relay Fuel pump relay Head lamp relay Main fuse 30A ECU Head lamp fuse 15A Battery TO sensor IAT sensor Magneto Pick...

Page 60: ...59 ELECTRICAL SYSTEM 5 2 SAV solenoid IAP sensor NO 1 ET sensor IAP sensor NO 2 ISC solenoid Fuel injector NO 1 Fuel injector NO 2 Oxygen sensor...

Page 61: ...ANCE INSPECTION 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 ig...

Page 62: ...Black with Yellow tracer OB Orange with Black tracer Br Brown BW Black with White tracer WL White with Blue tracer YG Yellow with Green tracer Tester knob indication Resistance Tester knob indication...

Page 63: ...ttery terminal and If the voltage is not within the specified value check the magneto no load performance and regulator rectifier 13 5 15 0 V at 5 000 rpm Standard charge CAUTION When making this test...

Page 64: ...pocket tester measure the resistance between the terminals in the following table If the resistance checked is incorrect replace the regulator rectifier Tester knob indication Resistance M 3 4 3 4 1 2...

Page 65: ...64...

Page 66: ...TROUBLESHOOTING 66 7 1 1 SPECIAL TOOLS 75 7 8 TIGHTENING TORQUE 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 CONTENTS SERVICING INFORMATION...

Page 67: ...r connection DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR MALFUNCTION CODE 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...

Page 68: ...CTED FAILURE CONDITION CHECK FOR MALFUNCTION CODE When the IC of the ECU electric current gets 6 A and more C24 or C25 is indicated The idle speed control solenoid step should be the following O step...

Page 69: ...ircuited 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...

Page 70: ...operating 1 Defective fuel injectors 2 No injection signal from ECU 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operatin...

Page 71: ...n adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of clutch plates 3 Distorted clutch plates driven and drive 4 Worn clutch release bearing 5 We...

Page 72: ...inadequate fuel supply to injector 10 Defective fuel pump 11 Defective SAV solenoid 12 Clogged air cleaner element Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3...

Page 73: ...rnal parts 1 Heavy carbon deposit on piston crowns 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit 4 Sucking air from intake pipes 5 Use incorrect engine oil 6 Defective oil...

Page 74: ...pressure plates or clutch plates 1 Broken gearshift cam 2 Distorted gearshift forks 3 Worn gearshift pawl 1 Broken return spring on shift shaft 2 Rubbing or sticky shift shaft 3 Distorted or worn gear...

Page 75: ...ctions 2 Short circuited grounded or open stator coil 3 Short circuited or punctured regulator rectifier 1 Lead wire insulation frayed due to vibration resulting in intermittent shorting 2 Magneto int...

Page 76: ...INFORMATION 7 8 Special tools PartNumber PartName Description 09915 54510 Fuel pump pressure gauge Measure fuel pressure of fuel pump SPECIAL TOOLS 09900 27000 Mode select switch Inspect FI system sen...

Page 77: ...76 ITEM Engine temperature sensor ET sensor Fuel injector bolt 1 8 0 6 0 8 kgf m 18 6 8 N m TIGHTENING TORQUE FI SYSTEM PARTS 7 11 SERVICING INFORMATION...

Page 78: ...Oxygen sensor heater voltage ET sensor voltage ET sensor resistance To ECU 4 5 5 5 V Approx 4 0 4 2 V when ignition switch ON 4 5 5 5 V Refer to page 34 4 1 25 4 5 5 5 V at normal condition To sensor...

Page 79: ...rottle cable play GT250 28 1 400 1 600 rpm 0 5 1 0 mm 0 02 0 04 in SPECIFICATION NOTE FUEL INJECTOR FUEL PUMP ITEM Fuel injector resistance Fuel injector voltage Fuel pressure 11 5 13 5 at 20 68 Batte...

Page 80: ...Y Y ITEM STANDARD BTDC 13 2 000rpm 30 6 000rpm Over 60 V 5 000 rpm 13 5 15 0 V 5 000 rpm Over 8 mm 0 32 in 150 V and more NOTE 1 320 at 20 68 Unit mm in Ignition timing Spark plug Spark performance Ig...

Page 81: ...ON Br GR Br GR SAV SOLENOID O GL INJEC INJECTOR 1 YR YG O TURN SIGNAL RELAY DIODE 1 RR IGNITION COIL Sb O LY L GR OB WL FT IGNITION COIL EARTH EARTH OB BY Br BW Br BW SIDE STAND OFF ON SWITCH BW BW H...

Page 82: ...CAN TOOL Lg BW Lg BW RR TURN SIG R Gr BW Gr BW LICENSE PLATE LAMP Gr BW WB Lg Gr BW WB B Lg Gr BW WB B Gr BW WB TAIL STOPLAMP BW B BW B RR TURN SIG L R O R R FUSE BOX 15A FUSE BOX 30A B EARTH R BATTE...

Page 83: ...O G BW Br GR O GL BW YB BW YB Br GR G G G BW BW O Sb LY L GR OB WL OB BY Br BW B BBr B BBr B BBr O R Lg B Sb G BW W Y YW O Y O R Y W YW BW G Lg B Sb O Y W YW BW BBr Lg B Sb O BW BW Br BW BW BW ENGINE...

Page 84: ...25 26 27 28 29 30 31 32 33 34 ENGINE CONTROLUNIT 34P OB GW O BBr O WB OB B BW BR BW YB CAN TOOL SWITCH RR TURN SIG R LICENSE PLATE LAMP TAIL STOPLAMP RR TURN SIG L R O R R R B B Y Y Y R BW Y Y Y G L...

Page 85: ...GR O GL BW YB BW YB Br GR ENGINE TEMPERATUR SENSOR G G G BW TURN SIGNAL RELAY DIODE 1 RR IGNITION FT IGNITION COIL COIL EARTH EARTH BW O Sb LY L GR OB WL OB BY Br BW Br BW SIDE STAND OFF ON SWITCH O R...

Page 86: ...CONTROLUNIT 34P BBr YB BW O BY BY WL CAN TOOL SWITCH Lg BW Lg BW RR TURN SIG R O BW O BW WB BW B BW B Gr BW WB Gr BW LICENSE PLATE LAMP TAIL STOPLAMP RR TURN SIG L R O R R B FUSE BOX 15A FUSE BOX 30A...

Page 87: ...86 MEMO...

Page 88: ...87 MEMO...

Page 89: ...Prepared by 1st Ed OCT 2008 Manual No 99000 95610 Printed in Korea...

Page 90: ......

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