HYOSUNG Aquila GT250 Ej Service Manual Download Page 1

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Summary of Contents for Aquila GT250 Ej

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Page 2: ...ers of your optimum and quick service ELECTRICAL SYSTEM GROUP INDEX GENERAL INFORMATION 1 EI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY 4 2 4 1 5 SERVICING INFORMATION 7 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 Illustra...

Page 3: ...e you need SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing The meaning of each symbol is also included in the table Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Measure in diode test range Use special tool Measure in continuity test range Torque control required Data bes...

Page 4: ...nsor ETS F FP Fuel Pump 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 L LCD Liquid Crystal Display LED Light Emitting Diode LH Left Hand M Max Maximum Min Minimum O O2 Sensor Oxygen Sensor O2S P PV Purge control Valve R RH Right Hand RO Switch Roll Over Switch S SAE So...

Page 5: ...cer 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 Orange with Red tracer OW Orange with White tracer OY Orange with Yellow tracer RB Red with Black tracer RW Red with White tracer WB White with Black tracer WL White with Blue tracer WR White with Red tr...

Page 6: ...ION EXTERIOR PHOTOGRAPH 6 1 6 1 EXTERIOR ILLUSTRATION 8 1 7 1 EXTERIOR ILLUSTRATION 9 1 7 2 EXTERIOR ILLUSTRATION 10 1 7 3 EXTERIOR ILLUSTRATION 11 1 7 4 FUNCTION OF EI SENSOR 12 1 8 1 SPECIFICATIONS 13 1 8 2 CONTENTS 1 ...

Page 7: ...6 1 6 1 GENERAL INFORMATION EXTERIOR PHOTOGRAPH ...

Page 8: ...7 GENERAL INFORMATION 1 6 2 EXTERIOR PHOTOGRAPH ...

Page 9: ...1 7 1 GENERAL INFORMATION EXTERIOR ILLUSTRATION Rear reflector Brake Tail lamp Rear turn signal lamp License plate lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WIDTH ...

Page 10: ...GENERAL INFORMATION 1 7 2 EXTERIOR ILLUSTRATION Rear reflector Brake Tail lamp License plate lamp Rear turn signal lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WIDTH ...

Page 11: ...XTERIOR ILLUSTRATION Rear turn signal lamp Rear turn signal lamp License plate lamp Front turn signal lamp WIDTH HEIGHT License plate Rear reflector WHEEL BASE LENGTH Brake Tail lamp Head lamp Front turn signal lamp GROUND CLEARANCE ...

Page 12: ... GENERAL INFORMATION 1 7 4 EXTERIOR ILLUSTRATION Rear reflector Brake Tail lamp License plate lamp Rear turn signal lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WIDTH ...

Page 13: ...njector properly IAT sensor Intake Air Temperature Sensor IATS IAT sensor perceive the atmospheric temperature and is located the air cleaner case ISC solenoid Idle Speed Control Solenoid ISC solenoid is interlocked with the throttle body so ECU control the engine idle speed O2 sensor Oxygen Sensor O2S O2 sensor measure the oxygen volume from the exhaust gas and convert the oxygen volume into volt...

Page 14: ...NSIONS AND MASS Four stroke DOHC air cooled and oil cooled V 2 cylinder 57 0 mm 2 24 in 48 8 mm 1 92 in 249 15 2 in3 Electric fuel Injection Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system Lubrication system I T E M ENGINE Wet multi plate type 5 speed constant mesh 1 down 4 up 3 290 2 460 1 560 1 190 0 960 0 840 520HO 116 links 520HO 112...

Page 15: ...ont 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 Turn signal lamp Brake 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 B T D C at 2 000 rpm and 30 B...

Page 16: ...oled and oil cooled V 2 cylinder 57 0 mm 2 24 in 48 8 mm 1 92 in 249 15 2 in3 Electric fuel Injection Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system Lubrication system I T E M ENGINE Wet multi plate type 5 speed constant mesh 1 down 4 up 3 290 2 460 1 560 1 190 0 960 0 840 520HO 112 links Clutch Transmission Gearshift pattern Reduction ...

Page 17: ...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 Position lamp Turn signal lamp Brake 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 B ...

Page 18: ...CIRCUIT MALFUNCTION 51 4 1 34 0112 or 0113 IAT SENSOR CIRCUIT MALFUNCTION 53 4 1 36 0117 or 0118 ET SENSOR CIRCUIT MALFUNCTION 55 4 1 38 0122 or 0123 TP SENSOR CIRCUIT MALFUNCTION 57 4 1 40 0201 or 0202 FUEL INJECTOR CIRCUIT MALFUNCTION 60 4 1 43 0230 or 0232 FUEL PUMP RELAY CIRCUIT MALFUNCTION 62 4 1 45 0336 or 0337 PICK UP COIL CIRCUIT MALFUNCTION 63 4 1 46 0351 or 0352 IGNITION COIL MALFUNCTION...

Page 19: ...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...

Page 20: ...nector 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 VARIOUS SENSORS Since each component is a high precision part great care should be tak...

Page 21: ...e the components of the EI 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 electromotive force will be applied to the ECU which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check...

Page 22: ...rate 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 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...

Page 23: ...TROL DIAGRAM ECU IAT Sensor TP Sensor IAP Sensor ISCSolenoid AIR AIR CLEANER THROTTLE BODY FUEL TANK FUEL FUEL PUMP FUEL INJECTOR INTAKE PIPE CYLINDER EXHAUST PIPE O2 Sensor Electrical signal flow Air flow Fuel flow Exhaust gas flow Pick up Coil ET Sensor MUFFLER EXHAUST GAS ...

Page 24: ...and various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air pressure signal Basic fuel injection time Compensation Ultimate fuel injection time Pick up coil Throttle Position Sensor TP Sensor Various Sensors Injectors Engine speed signal Throttle opening sig...

Page 25: ...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 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 a...

Page 26: ...25 EI SYSTEM DIAGNOSIS 4 1 8 EI 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 TP sensor ...

Page 27: ...26 4 1 9 EI SYSTEM DIAGNOSIS ISC solenoid IAT sensor RO switch Fuel pump relay IAP sensor ET sensor Oxygen sensor NO 1 Oxygen sensor NO 2 ...

Page 28: ...27 EI SYSTEM PARTS LOCATION Speedometer Fuel injector NO 1 Fuel injector NO 2 IAT sensor GP switch Pick up coil Ignition coil NO 1 Ignition coil NO 2 TP sensor EI SYSTEM DIAGNOSIS 4 1 10 ...

Page 29: ...28 4 1 11 EI SYSTEM DIAGNOSIS 28 ISC solenoid Fuel pump relay RO switch IAP sensor ET sensor Oxygen sensor NO 1 Oxygen sensor NO 2 ...

Page 30: ...s FI letters and speedometer alternately and the FI check lamp comes on and remains lit when the ignition switch is set to ON position with the engine stopped as a test of injection system operation As soon as the engine starts the LCD display panel indicates speedometer continuously and FI check lamp should go out If the fuel injection system fails A the LCD display panel does not indicate FI let...

Page 31: ...e procedure 7 Check the malfunction code to determine the malfunction part 8 Pressing the select switch in the malfunction code mode for 0 6 1 seconds the malfunction code mode is changed into the CLOCK Mode select switch 09900 27000 NOTE This time if not connect the special tool the LCD display panel indicates the cHE letters Pressing the select switch for 0 6 1 seconds the cHE letters disappear ...

Page 32: ...currence FI check lamp comes on continually CLOCK SCREEN INDICATION INDICATION MODE FI CHECK LAMP INDICATION CAUTION Confirm the malfunction code after turning the ignition switch ON position and starting the engine separately The dealer mode coupler of the wiring harness is located under the rear seat FI check lamp comes on continually NO YES For each 2 sec code is indicated noEr code is indicate...

Page 33: ...e to determine the malfunction part MALFUNCTION NO YES Malfunction code is blinked in order of occurrence FI CHECK LAMP INDICATION Indicates FI letters and speedometer alternately FI check lamp comes on continually CAUTION Take special care when operating above procedure If the ignition switch is turned alternately ON and OFF position for 2 seconds by five times the ECU is initialized NOTE The mal...

Page 34: ...me on when the ignition switch is set to ON position with the engine stopped or fail to go out after the engine start SELF DIAGNOSIS FUNCTION The self diagnosis function is incorporated in the ECU The function has two modes USER MODE and DEALER MODE The user can only be notified by the FI check lamp To check the function of the individual EI system devices the dealer mode is prepared In this check...

Page 35: ...tion switch alternately ON and OFF position for 2 seconds by three times 2 The memorized malfunction code is displayed with blinks signal of the FI check lamp 3 Check the malfunction code to determine the malfunction part MALFUNCTION NO YES Malfunction code is blinked in order of occurrence FI CHECK LAMP INDICATION FI check lamp comes on continually CAUTION Take special care when operating above p...

Page 36: ...ART REMARKS B CODE NO 1 O S heater Circuit Low Voltage For NO 1 cylinder NO 1 O S heater Circuit High Voltage For NO 1 cylinder NO 2 O S heater Circuit Low Voltage For NO 2 cylinder NO 2 O S heater Circuit High Voltage For NO 2 cylinder IAPS Circuit Low Voltage or Open IAPS Circuit High Voltage IATS Circuit Low Voltage IATS Circuit High Voltage or Open ...

Page 37: ...t Low Voltage or Open TPS Circuit High Voltage NO 1 O S Circuit Low Voltage For NO 1 cylinder NO 1 O S Circuit High Voltage For NO 1 cylinder NO 2 O S Circuit Low Voltage For NO 2 cylinder NO 2 O S Circuit High Voltage For NO 2 cylinder A CODE For LCD DISPLAY indication Applies only to B CODE For FI check lamp indication Applies both to ...

Page 38: ...uit Malfunction For NO 2 cylinder Fuel pump relay Circuit Low Voltage or Open Fuel pump relay Circuit High Voltage Pick up coil Noisy Signal Pick up coil No Signal NO 1 IG coil Malfunction For NO 1 cylinder NO 2 IG coil Malfunction For NO 2 cylinder A CODE For LCD DISPLAY indication Applies only to B CODE For FI check lamp indication Applies both to ...

Page 39: ...fornia model only PV Circuit Shorted California model only ISC Error Battery Voltage Low Battery Voltage High FI check lamp Circuit Malfunction GP or Clutch lever Switch Circuit Malfunction A CODE For LCD DISPLAY indication Applies only to B CODE For FI check lamp indication Applies both to ...

Page 40: ... malfunction code is blinked in order of occurrence In the clock screen the malfunction code is indicated in order of occurrence In the FI check lamp the malfunction code is blinked in order of occurrence A LCD DISPLAY INDICATION B FI CHECK LAMP INDICATION ...

Page 41: ... 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 combustion Back fire After fire No combustion Lack of power Poor starting at Surging cold warm always Abnormal knocking Other Engine rpm jumps briefly Other Poor Idling Engine Stall when Poor fast Idle Immed...

Page 42: ...old 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 at starting Immediately after start Racing without load Engine speed rpm During driving Constant speed Accelerating Decelerating Right hand corner Left hand corner At stop Motorcycle speed when proble...

Page 43: ...ayed in the code form on the clock screen or with blinks signal of the FI check lamp In case of the memorized malfunction code is displayed with blinks signal of the FI check lamp To check malfunction code read SELF DIAGNOSIS FUNCTION DEALER MODE Refer to page 29 39 4 1 12 22 carefully to have good understanding as to what functions are available and how to use it Be sure to read PRECAUTIONS for E...

Page 44: ...43 EI SYSTEM DIAGNOSIS 4 1 26 Refer to page 32 4 1 15 Refer to page 30 4 1 13 A LCD DISPLAY INDICATION B FI CHECK LAMP INDICATION Refer to page 34 4 1 17 A FI CHECK LAMP INDICATION KEY KEY ...

Page 45: ...ler mode coupler at the wiring harness B FI CHECK LAMP Repair the trouble Turn the ignition switch to the OFF position and return to the ON position and then wait for 10 seconds Repeat the above procedure 30 times In this case the malfunction codes are cleared A FI CHECK LAMP Repair the trouble Turn the ignition switch to the OFF position and return to the ON position and then wait for 10 seconds ...

Page 46: ...d Oxygen sensor lead wire coupler connection 0038 After engine running if oxygen sensor heater signal is happened the high short fault for 1 second by 10 times in 12 times test cycle the code 0038 is indicated Intake air pressure sensor lead wire coupler connection 0107 IAPS Circuit IATS Circuit The sensor should produce following voltage 0 15 V Sensor output voltage Without the above range for 2 ...

Page 47: ...ction 0131 NO 1 O S Circuit NO 2 O S Circuit After engine running the oxygen sensor signal is inputted in ECU since then 300 sec In this case the sensor voltage should be the following 30 mV Sensor output voltage Without the above range for 28 1 sec and more 0131 is indicated Oxygen sensor lead wire coupler connection 0132 After engine running the oxygen sensor signal is inputted in ECU since then...

Page 48: ...ter engine running if fuel pump relay signal is happened the high short fault for 1 second by 10 times in 20 times test cycle the code 0232 is indicated Pick up coil wiring and mechanical parts Pick up coil lead wire coupler connection 0336 Pick up coil NO 1 IG coil Malfunction NO 2 IG coil Malfunction After engine running if the magneto rotor tooth s error is happened continuously by 10 times in ...

Page 49: ...ction to ECU 0562 Battery Voltage FI check lamp Circuit Malfunction GP or Clutch lever Switch Circuit Malfunction The battery voltage should be the following 9 V Battery voltage Without the above range for 3 125 sec and more 0562 is indicated Battery wiring coupler connection to ECU 0563 The battery voltage should be the following Battery voltage 16 V Without the above range for 3 125 sec and more...

Page 50: ...ION 0131 0132 0137 or 0138 OXYGEN SENSOR CIRCUIT MALFUNCTION LCD DISPLAY INDICATION FI CHECK LAMP INDICATION DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor Oxygen sensor heater circuit open or short Oxygen sensor Oxygen sensor heater malfunction ECU malfunction Refer to page 45 46 4 1 28 29 ...

Page 51: ...orted to the wiring harness main relay output side Heater side If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the Oxygen sensor with a new one GR B W Sensor side Heater side YL INSPECTION 1 Remove the front seat and frame cover 2 Turn the ignition switch to the OFF position 3 Check the Oxygen sens...

Page 52: ... that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECU malfunction POSSIBLE CAUSE YES NO Loose or poor contacts...

Page 53: ...h a new one OB BL or GR wire open or shorted to ground or poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Tester knob indication Voltage Output voltage Input voltage 5 V ambient temp 25 C 77 F ALTITUDE Reference ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 2 001 5 000 611 ...

Page 54: ...K then measure the IAT sensor resistance 4 Disconnect the IAT sensor coupler 5 Measure the resistance between the terminals and DETECTED CONDITION POSSIBLE CAUSE Refer to page 45 4 1 28 IAT sensor circuit open or short IAT sensor malfunction ECU malfunction IAT sensor resistance 0 081 48 352 When Intake air temperature is 40 130 40 266 Tester knob indication Resistance LCD DISPLAY INDICATION FI CH...

Page 55: ...r faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the IAT sensor with a new one Resistance Intake Air Temp IAT sensor resistance 44 642 5 14 958 5 5 734 5 2 438 5 1 141 5 0 579 5 0 315 5 0 182 5 0 111 5 0 088 5 40 40 20 4 0 32 20 68 40 104 60 140 80 176 100 212 120 248 130 266 Tester knob indication Resistance ECU Coupler Gray Black B10 B8 ...

Page 56: ...he ET sensor resistance 3 Disconnect the ET sensor coupler 4 Measure the resistance between the terminals and of the ET sensor DETECTED CONDITION POSSIBLE CAUSE Refer to page 46 4 1 29 ET sensor circuit open or short ET sensor malfunction ECU malfunction ET sensor resistance 0 102 81 000 When Engine temperature is 20 180 4 356 LCD DISPLAY INDICATION FI CHECK LAMP INDICATION Tester knob indication ...

Page 57: ...ck each terminal and wire harness for open circuit and poor connection Replace the ET sensor with a new one Tester knob indication Resistance ECU Coupler Gray Black B14 B10 Resistance To ECU Engine Temp ET sensor resistance Approx 75 5 Approx 28 7 Approx 12 2 Approx 5 6 Approx 2 8 Approx 1 5 Approx 0 5 Approx 0 3 Approx 0 2 Approx 0 13 20 4 0 32 20 68 40 104 60 140 80 176 120 248 140 284 160 320 1...

Page 58: ...OB wire or GR wire TP sensor input voltage 4 9 5 1 V OB Ground OB GR Is the input voltage OK Tester knob indication Voltage 0122 or 0123 TP SENSOR CIRCUIT MALFUNCTION INSPECTION Step 1 1 Turn the ignition switch to the OFF position 2 Check the TP sensor coupler for loose or poor contacts If OK then measure the TP sensor input voltage DETECTED CONDITION POSSIBLE CAUSE TP sensor circuit open or shor...

Page 59: ...or with a new one Is the continuity OK Ground Tester knob indication Resistance Step 3 1 Connect the TP sensor coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Turn the ignition switch to the ON position Measure the TP sensor output voltage at the coupler between LY and GR by turning the throttle grip TP sensor output voltage Throttle valve is closed Throttle valve is opened A...

Page 60: ... to ground or poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection If check result is not satisfactory replace the TP sensor with a new one ECU Coupler Gray Black B16 B12 B10 ...

Page 61: ...O 1 and NO 2 and measure the resistance between terminals 5 If OK then check the continuity between injector terminals and ground DETECTED CONDITION POSSIBLE CAUSE Refer to page 47 4 1 30 Injector circuit open or short Injector malfunction ECU malfunction Injector resistance 11 4 12 6 at 20 68 Injector continuity Infinity Are the resistance and continuity OK YES NO Go to Step 2 Replace the Injecto...

Page 62: ...on YES NO YR NO 1 RB NO 2 wire open or shorted to ground or poor NO 1 NO 2 connection of ECU coupler If wire and connection are OK 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 79 4 2 4 Is the voltage OK Injector voltage Battery voltage NO 1 YL Ground NO 2 YL Ground Tester knob i...

Page 63: ...CAUSE Refer to page 47 4 1 30 Fuel pump relay circuit open or short Fuel pump relay malfunction ECU malfunction YES NO GW wire open or shorted to ground or poor connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Inspect the fuel injectors Refer to page 60 4 1 43 Replace the fuel pump...

Page 64: ...ign materiel being attached on the pick up coil and rotor tip Pick up coil circuit open or short Pick up coil malfunction ECU malfunction Refer to page 47 4 1 30 INSPECTION 1 Remove the frame cover 2 Turn the ignition switch to the OFF position 3 Check the pick up coil coupler for loose or poor contacts If OK then measure the pick up coil resistance 0336 or 0337 PICK UP COIL CIRCUIT MALFUNCTION LC...

Page 65: ...poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Loose or poor contacts on the pick up coil coupler or ECU coupler Replace the pick up coil with a new one ECU Coupler Gray Black Black B4 B13 ...

Page 66: ...65 EI SYSTEM DIAGNOSIS 4 1 48 LCD DISPLAY INDICATION FI CHECK LAMP INDICATION 0351 or 0352 IGNITION COIL MALFUNCTION Refer to the IGNITION COIL for details See page 89 90 5 5 1 2 ...

Page 67: ...CK LAMP INDICATION 5 If OK then check the continuity between each terminal and ground Purge control valve resistance 19 22 at 20 68 Pick up coil continuity Purge control valve continuity Infinity INSPECTION 1 Remove the frame cover 2 Turn the ignition switch to the OFF position 3 Check the PV coupler for loose or poor contacts 4 Disconnect the PV coupler and measure the resistance Tester knob indi...

Page 68: ...oor connection of ECU coupler YL coupler open or shorted to the wiring harness If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the purge control valve with a new one ECU Coupler California model only Gray Black G2 ...

Page 69: ... switch ON DETECTED CONDITION POSSIBLE CAUSE Refer to page 48 4 1 31 ISC solenoid malfunction ISC solenoid s step is out of the specified range ECU malfunction LY G BBr or YL wire loose or poor contacts on the ISC solenoid coupler or poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor co...

Page 70: ... with a new one B15 G9 B2 B18 DETECTED CONDITION POSSIBLE CAUSE Battery voltage circuit open and short Battery malfunction ECU malfunction Refer to page 48 4 1 31 0562 or 0563 BATTERY VOLTAGE MALFUNCTION LCD DISPLAY INDICATION FI CHECK LAMP INDICATION Battery voltage 11 16 V INSPECTION 1 Remove the front seat 2 Turn the ignition switch to the OFF position 3 Using the pocket tester measure the DC v...

Page 71: ...e battery terminal to the R 2 pins coupler wire and O 9 pins coupler wire of the instrument panel and the battery terminal to the BW 9 pins coupler wire of the instrument panel And then connect the LY 2 pins coupler wire of the instrument panel to the battery terminal directly 4 2 Connect the battery terminal to the R 1 pins coupler wire and O 9 pins coupler wire of the instrument panel and the ba...

Page 72: ...GP switch and the clutch lever switch resistance 4 Park the motorcycle on a firm flat surface vertically 5 Disconnect the GP switch coupler and then check the continuity between L wire and ground when gearshift lever is shifted from the neutral state DETECTED CONDITION POSSIBLE CAUSE Refer to page 48 4 1 31 GP switch circuit open or short GP switch malfunction Clutch lever switch circuit open or s...

Page 73: ...oor connection Replace the GP switch or Clutch lever switch with a new one Is OK ECU Coupler Gray Black Clutch lever switch continuity 0 GR Br 7 Measure the voltage between of the ECU and the LY wire of the wiring harness s GP switch coupler and measure the voltage between of the ECU and the GR wire of the wiring harness s clutch lever switch coupler If the measurement is out of 0 4 0 7 V replacce...

Page 74: ...SOR INSPECTION The intake air pressure IAP sensor is installed at the rear intake pipe Refer to page 51 4 1 34 IAP SENSOR REMOVAL AND INSTALLATION Remove the fuel tank Remove the IAP sensor from the rear intake pipe Install the IAP sensor in the reverse order of removal TP SENSOR INSPECTION The throttle position TP sensor is installed at the front throttle body Refer to page 57 4 1 40 TP SENSOR RE...

Page 75: ...reverse order of removal RO SWITCH REMOVAL AND INSTALLATION The roll over RO switch is located in the downside of the front seat striker Romove the front seat Remove the RO switch from the frame Install the RO switch in the reverse order of removal ET SENSOR INSPECTION The engine temperature ET sensor is installed at the front cylinder Refer to page 55 4 1 38 ET SENSOR REMOVAL AND INSTALLATION Rem...

Page 76: ...Y INSPECTION 79 4 2 4 FUEL MESH FILTER INSPECTION AND CLEANING 80 4 2 5 FUEL GAUGE INSPECTION 80 4 2 5 THROTTLE BODY 81 4 2 6 REMOVAL 82 4 2 7 CLEANING 83 4 2 8 INSPECTION 83 4 2 8 INSTALLATION 84 4 2 9 CONTENTS 4 2 FUEL SYSTEM AND THROTTLE BODY CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or spark ...

Page 77: ...76 4 2 1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM ...

Page 78: ...e front seat Disconnect the fuel gauge coupler Remove the fuel tank mounting bolts and take off the hooks CAUTION After disconnecting the fuel injector hose insert a blind plug into the end to stop fuel leakage Disconnect the fuel pump coupler Remove the fuel injector hose ...

Page 79: ...d 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 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 NOTE Apply a small quantity of the THREAD L...

Page 80: ... special tool turn the ignition switch to the OFF position and release the fuel pressure slowly Gasoline is highly flammable and explosive Keep heat sparks and flame away 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...

Page 81: ... 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 fuel gauge with a new one Inspect the instrument panel fuel level meter Fuel float position Resistance between terminals F 1 2 E Approx 95 105 Approx 38 Approx 4 10 First check the insulation between and terminals wit...

Page 82: ...81 FUEL SYSTEM AND THROTTLE BODY 4 2 6 THROTTLE BODY ...

Page 83: ...the throttle 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 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 ...

Page 84: ...ents 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 INSPECTION Check following items for any damage or clogging O ring Throttle shaf...

Page 85: ...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 adjuster CAUTION Never operate the idle nuts NO 1 and NO 2 to avoid variations of the carburetion setting ...

Page 86: ...85 LOCATION OF ELECTRICAL COMPONENTS 86 5 1 IGNITION SYSTEM 88 5 3 CHARGING SYSTEM 91 5 7 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 93 5 11 CONTENTS ELECTRICAL SYSTEM 5 ...

Page 87: ... 5 1 ELECTRICAL SYSTEM ISC solenoid Ignition coil NO 1 Ignition coil NO 2 Main fuse 30A Head lamp fuse 15A ECU Battery IAT sensor RO switch Magneto Pick up coil GP switch LOCATION OF ELECTRICAL COMPONENTS ...

Page 88: ...87 ELECTRICAL SYSTEM 5 2 IAP sensor ET sensor Fuel injector NO 2 Fuel injector NO 1 Oxygen sensor NO 1 Oxygen sensor NO 2 Main relay Fuel pump relay Head lamp relay ...

Page 89: ...ead wires in the following table If the resistance is not within the specified value replace the stator coil with a new one IGNITION SYSTEM IGNITION COIL NO 1 IGNITION COIL NO 2 ECU IGNITION SWITCH ENGINE STOP SWITCH 30A FUSE 15A FUSE REGULATOR RECTIFIER BATTERY 12V 10Ah NOTE When making above test it is not necessary to remove the magneto Tester knob indication Resistance Charging coil Pick up co...

Page 90: ...d NOTE Do not disconnect the ignition coil plug cap lead wire couplers Shift the transmission into the neutral and then turn the ignition switch to the ON position Squeeze the clutch lever Press the starter switch and allow the engine to crank for a few seconds and then measure the ignition coil primary peak voltage Repeat the above procedure a few times and measure the highest ignition coil prima...

Page 91: ...d 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 Tester knob indication Resistance IGNITION COIL PLUG CAP RESISTANCE 0 52 0 64 Terminal Terminal 6 4 7 8 Plug cap Terminal Secondary Primary ...

Page 92: ...ry 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 be sure that the battery is full charged condition Regulator Rectifier DCV Battery Ignition switch A C generator Ignition switch Battery LOAD Regulator Rectifier Tester knob indication Voltage IC ...

Page 93: ... 7 0 0 0 0 4 0 7 0 0 0 0 0 0 4 0 7 0 4 0 7 0 4 0 7 0 5 1 2 Tester probe Tester probe Unit Tester knob indication Voltage MAGNETO NO LOAD PERFORMANCE 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 wit...

Page 94: ...s the motorcycle from being started with side stand down The system is operated by an electric circuit provided between the battery and ignition coil The circuit consists of the neutral indicator light and switches The ignition coils will send voltage to the spark plugs depending on what gear the transmission is in and whether the side stand is either up or down The gear position and side stand sw...

Page 95: ...P GP SWITCH ON DIODE GP SWITCH OFF NEUTRAL INDICATOR LAMP DIODE SIDE STAND SWITCH SIDE STAND UP RIGHT POSITION SIDE STAND SWITCH SIDE STAND DOWN POSITION BATTERY BATTERY IGNITION COIL SIDE STAND RELAY ON SIDE STAND RELAY ON TRANSMISSION Neutral ON Side stand Down Clutch lever Squeeze TRANSMISSION Neutral OFF Side stand Up Clutch lever Squeeze 1 2 3 4 5 Possible Possible Impossible Impossible Impos...

Page 96: ... 96 7 1 1 SPECIAL TOOLS 107 7 8 TIGHTENING TORQUE 108 7 11 SERVICE DATA 109 7 19 1 WIRING DIAGRAM 112 7 31 1 WIRING DIAGRAM 114 7 32 1 WIRING DIAGRAM 116 7 32 3 WIRING DIAGRAM 118 7 32 5 CONTENTS SERVICING INFORMATION 7 ...

Page 97: ...s indicated Oxygen sensor lead wire coupler connection 0038 After engine running if oxygen sensor heater signal is happened the high short fault for 1 second by 10 times in 12 times test cycle the code 0038 is indicated Intake air pressure sensor lead wire coupler connection 0107 IAPS Circuit IATS Circuit The sensor should produce following voltage 0 15 V Sensor output voltage Without the above ra...

Page 98: ...ction to ECU 0562 Battery Voltage FI check lamp Circuit Malfunction GP or Clutch lever Switch Circuit Malfunction The battery voltage should be the following 9 V Battery voltage Without the above range for 3 125 sec and more 0562 is indicated Battery wiring coupler connection to ECU 0563 The battery voltage should be the following Battery voltage 16 V Without the above range for 3 125 sec and more...

Page 99: ...ection 0131 NO 1 O S Circuit NO 2 O S Circuit After engine running the oxygen sensor signal is inputted in ECU since then 300 sec In this case the sensor voltage should be the following 30 mV Sensor output voltage Without the above range for 28 1 sec and more 0131 is indicated Oxygen sensor lead wire coupler connection 0132 After engine running the oxygen sensor signal is inputted in ECU since the...

Page 100: ...fter engine running if fuel pump relay signal is happened the high short fault for 1 second by 10 times in 20 times test cycle the code 0232 is indicated Pick up coil wiring and mechanical parts Pick up coil lead wire coupler connection 0336 Pick up coil NO 1 IG coil Malfunction NO 2 IG coil Malfunction After engine running if the magneto rotor tooth s error is happened continuously by 10 times in...

Page 101: ...ing connections No fuel reaching the intake pipe 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 Open 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 D...

Page 102: ...fective 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 operating 1 Defective ECU 2 Defective fuel pressure regulator 3 Defective IAT sensor 4 Defective pick up coil 5 Defective ET sensor 6 Defective fuel pump relay 7 Defective TP sensor Engine internal parts improperly operati...

Page 103: ...ion 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 Weakened clutch dampers Noise seems to come from crankshaft 1 Rattling bearings due to wear 2 Worn and burnt big end bearings 3 Worn and burnt journal bearings Noise seems to come from transmission 1 ...

Page 104: ...g in inadequate fuel supply to injector 10 Defective fuel pump 11 Defective TP sensor 12 Clogged air cleaner element Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Sucking air from throttle body joint 4 Defective ECU Defective control circuit or sensor 1 Low fuel pressure 2 Defective IAT sensor 3 Defective pick up coil 4 Defective IAP sensor 5 Defective ECU 6 ...

Page 105: ...gine internal 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 cooler Lean fuel air mixture 1 Short circuited IAP sensor lead wire 2 Short circuited IAT sensor lead wire 3 Sucking air from intake pipe joint 4 Defective fuel injectors 5 Defective ET sens...

Page 106: ...d 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 gearshift forks 1 Worn shifting gears on driveshaft or countershaft 2 Distorted or worn gearshift forks 3 Weakened stopper spring on gearshift stopper Check with inspection win dow drain out excess oil ...

Page 107: ...se lead connections 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 internally shorted 3 Defective regulator rectifier 1 Battery run down 2 Defective switch contacts 3 Brushes not seating properly on commutator in starter motor 4 Defective starter relay igni...

Page 108: ...ICING 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 EI system sensor ...

Page 109: ...Engine temperature sensor ET sensor Fuel injector mounting bolt Intake air temperature sensor IAT sensor 0 5 0 8 0 5 0 8 0 5 0 8 kgf m 5 8 5 8 5 8 N m TIGHTENING TORQUE EI SYSTEM PARTS 7 11 SERVICING INFORMATION ...

Page 110: ...U each temperature 4 5 5 5 V 3 3 4 3 V when ignition switch ON 4 9 5 1 V 0 081 48 352 When Intake air temperature is 40 130 40 266 Refer to page 54 4 1 37 Infinity at normal condition 0 at leaned more than 60 100 2 0 Battery voltage 0 102 81 000 When Engine temperature is 20 180 4 356 SPECIFICATION NOTE 20 4 0 32 20 68 40 104 60 140 80 176 120 248 140 284 160 320 180 356 Closed Opened Approx 1 07 ...

Page 111: ...cable play 13400H88 28 1 500 1 700 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 of fuel pump 11 4 12 6 at 20 68 Battery voltage Approx 2 25 2 50 kgf cm2 220 245 kPa 32 0 35 6 psi SPECIFICATION NOTE ...

Page 112: ...Y ITEM STANDARD BTDC 13 2 000 rpm 30 6 000 rpm Over 60 V 5 000 rpm 13 5 15 0 V 5 000 rpm More than 8 mm 0 32 in 400 V and more NOTE 1 320 at 20 68 Unit mm in Ignition timing Spark plug Spark performance Ignition coil primary peak voltage Ignition coil resistance Stator coil resistance Magneto no load performance Battery standard charging voltage Battery Fuse size Type Gap Hot type Standard type Co...

Page 113: ...112 7 31 1 SERVICING INFORMATION WIRING DIAGRAM ...

Page 114: ...113 SERVICING INFORMATION 7 31 2 ...

Page 115: ...114 7 32 1 SERVICING INFORMATION WIRING DIAGRAM ...

Page 116: ...115 SERVICING INFORMATION 7 32 2 ...

Page 117: ...116 7 32 3 SERVICING INFORMATION WIRING DIAGRAM ...

Page 118: ...117 SERVICING INFORMATION 7 32 4 ...

Page 119: ...118 7 32 5 SERVICING INFORMATION WIRING DIAGRAM ...

Page 120: ...119 SERVICING INFORMATION 7 32 6 ...

Page 121: ...Prepared by 1st Ed JAN 2012 Manual No 99000HB8110 Printed in Korea ...

Page 122: ...S T Motors Co Ltd ...

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