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CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC

System Voltage

P0562

System Voltage Low

KsDGDM_SysVoltLow

P0563

System Voltage High

KsDGDM_SysVoltHigh

MIL

P0650

MIL Circuit Malfunction

KsDGDM_MIL_Circuit

Tachometer

P1693

Tachometer Circuit Low Voltage

KsDGDM_TAC_Circuit_Low

P1694

Tachometer Circuit High Voltage

KsDGDM_TAC_Circuit_High

Oxygen Sensor 2

P0137

O2S 2 Circuit Low Voltage

KsDGDM_O2_2_ShortLow

P0138

O2S 2 Circuit High Voltage

KsDGDM_O2_2_ShortHigh

Oxygen Sensor Heater 2

P0038

O2S Heater 2 Circuit High Voltage

KsDGDM_O2_HeaterShortHigh

P0037

O2S Heater 2 Circuit Low Voltage

KsDGDM_O2_HeaterShortLow

Vehicle Speed Sensor

P0500

VSS No Signal

KsDGDM_VSS_NoSignal

Park Neutral Switch Diag

P0850

Park Neutral Switch Error

KsDGDM_ParkNeutralSwitch

CCP

P0445

CCP short to high

KsDGDM_CCP_CircuitShortHigh

P0444

CCP short to low/open

KsDGDM_CCP_CircuitShortLow

BLM MaxAdapt

P0171

BLM Max Adapt(Kohler Special)

KsFDIAG_BLM_MaxAdapt

BLM MinAdapt

P0172

BLM Min Adapt(Kohler Special)

KsFDIAG_BLM_MinAdapt

PE system Lean

P0174

PE syst Lean(Kohler Special)

KsFDIAG_PESystLean

Summary of Contents for CHILL 125 cc.

Page 1: ...1 CHILL 125 cc SERVICE MANUAL AND EFI SYSTEM DIAGNOSTIC...

Page 2: ...ment of the accelerator handgrip 9 Service and Maintenance for the Front Brake 9 Service and Maintenance for the Rear Brake 11 Adjustment of the rear braking light 12 Service and Maintenance for Front...

Page 3: ...le operation of the braking handgrip and ensure that the braking results fulfilled relevant requirements After the brake is released the brake should be able to be reset automatically and show no fric...

Page 4: ...sible 7 Within the run in period overload run should be strictly forbidden Otherwise the drive system will wear more faster Heavy load should be avoided 8 Avoid suddenly and long time braking 9 Strict...

Page 5: ...ether the rearview mirror is properly located 10 Check whether the electrical components of the whole motorcycle can work normally Level 3 Service and Maintenance Level 3 Service and Maintenance shoul...

Page 6: ...r screen sealing gasket spring O ring and oil drain plug are in good conditions If not replace them After replacing the lubricating oil tighten the oil drain plug and oil fill plug and check periodica...

Page 7: ...lug is dark black or there is serious oil stain or dark black carbon deposit on the surface Take off the spark plug If it is found that the color of the insulator skirt of the spark plug is brown it i...

Page 8: ...gasoline low ignition point solvent acid alkaline or organic volatile oil Take off the fastening screws of the air filter cover and remove the air filter cover Check whether there is too much dust on...

Page 9: ...en adjust the regulating solenoid 3 After adjustment tighten the locking nut Service and Maintenance for the Front Brake This model uses the front disc brake which is featured by secure and reliable b...

Page 10: ...nt brake If the travel of the front braking handgrip is too large it indicates that the wear of the front brake shoe is already beyond the limit Check the wear of the front disc brake If the surface o...

Page 11: ...ip the rear braking handgrip for several times and then loosen it Rotate the rear wheel assembly to check whether the rear wheel rotates freely First check the wear of the rear brake shoes If the trav...

Page 12: ...the driving safety the conditions of the braking light should be checked from time to time When the braking light can not work properly the braking light switch and the braking light bulb should be c...

Page 13: ...support to prop up the motorcycle Remove the nut of the front wheel shaft and take off the front wheel shaft Take off the front wheel Caution After taking off the front wheel make sure not to grip the...

Page 14: ...depth in the middle area of the tire of the motorcycle reaches the following limit the tire should be replaced immediately Minimum limit of tread depth Front wheel 2 0mm Rear wheel 2 0mm Caution Too...

Page 15: ...e electrode connection is loose 3 When the motorcycle is not used for a long time the battery must be charged once a month 4 Check whether the electrolyte level of the accumulator cell is between the...

Page 16: ...e time replace it with a fuse with appropriate specification Horn Service and Maintenance After the motorcycle has run for a certain period of time the horn fixing could be loose and its housing may c...

Page 17: ...orm slow charging for the battery once per month Wash the motorcycle and wipe it dry with soft rugs Wax the painted surfaces and apply a film of anti rust oil to the chromium plated surface Increase t...

Page 18: ...onnel When driving in an extremely moisture or highly dusty place the service and maintenance interval should be appropriately shortened Fuel filter C C C C Controller cable A A C A C A C Air filter e...

Page 19: ...R R R R Disc brake braking liquid DOT3 or DOT4 R Lubricating oil for front shock absorber Lubricating grease for shock absorber I I I T I I I Tachometer gear OKS 400 Multipurpose lithium based lubric...

Page 20: ...blocked or damaged Replace the air pump filter The intake rubber hose is aged or leaks Replace the intake rubber hose The clamp is loose or damaged Replace the clamp Ignition system Weak spark or no...

Page 21: ...n ring The piston ring is improperly mounted Remount the piston ring There is scratch or wear on the piston or cylinder wall Replace the piston or cylinder The cylinder head leaks The air valve stem o...

Page 22: ...The shock absorber is improperly adjusted Re adjust the shock absorber Braking system The braking performance is poor The brake malfunctions Adjust and repair the braking system The brake shoe wears...

Page 23: ...CHILL 125 cc SERVICE MANUAL AND EFI DIAGNOSTIC 23...

Page 24: ...U is below 80 If the fuel pressure is too high about 250kPa so please do not disassemble the fuel pipe arbitrarily If have to please release the pressure at first and make sure the operation is done i...

Page 25: ...auge Measure the fuel pressure Cylinder pressure Measure the cylinder pressure 4 Maintenance depending on the malfunction code Description If the issuer cannot repeat the issuer analysis may be wrong...

Page 26: ...7 Information MAP Circuit Low Voltage or Open ITEM OPERATION RESULT NEXT STEP 1 Connect the diagnostic tool and ignition on next 2 Check the data of BARO Make sure whether it is about 100kPa depending...

Page 27: ...e you are Yes Step 5 No next 3 Remove the connector and use the multimeter to check whether the voltage between pinB and D is about 5V Yes Step 5 No Next 4 Check whether the following pins is short to...

Page 28: ...r and use the multimeter to check whether the resistance between pinB and D is reasonable according to the temperature Yes Step 5 No Next 4 Remove the connector and check whether the voltage between p...

Page 29: ...se the multimeter to check whether the resistance between pinB and D is reasonable according to the temperature Yes Step 5 No Next 4 Remove the connector and check whether the voltage between pin B an...

Page 30: ...or and use the multimeter to check whether the resistance between pinA and C of the sensor is reasonable according to the temperature Yes Step 5 No Next 4 Use the multimeter to measure whether the vol...

Page 31: ...nector and use the multimeter to check whether the resistance between pinA and C of the sensor is reasonable according to the temperature Yes Step 5 No Next 4 Use the multimeter to measure whether the...

Page 32: ...Open the throttle to 100 slowly check whether the data of throttle opening goes to between 90 100 Yes Step 5 No Next 4 Repeat Step 3 check whether the data jumps when open thethrottle slowly Yes Chan...

Page 33: ...Open the throttle to 100 slowly check whether the data of throttle opening goes to between 90 100 Yes Step 5 No Next 4 Repeat Step 3 check whether the data jumps when open thethrottle slowly Yes Chan...

Page 34: ...the oxygen sensor and pin J2 17 of the ECU is open and whether the pin B of sensor is short to pin A Yes Harness issue No Next 3 Crank the engine and stay idle When the engine gets warm use multimete...

Page 35: ...Step 4 No Next 3 Check whether the connection between pin A and the main power relay is short to ground or open Yes Harness issue No Next 4 Use multimeter to measure whether the resistance between pin...

Page 36: ...elay feeder ear is about 12V Yes Change the pump No Next 3 Check whether thefeeder ear is short to ground or open Yes Harness issue No Help Malfunction code P0351 Information Cylinder 1 Ignition Coil...

Page 37: ...2 of the coil and J2 01 ofECU is open or short to battery ground Yes Harness issue No Help Malfunction code P0505 Information Idle Speed Control Error ITEM OPERATION RESULT NEXT STEP 1 Connect the di...

Page 38: ...e When the malfunction code comes again note the conditions Check the following Whether there is leakage of the fuel pipe or not Whether there is block leakage or damage of the intake pipe Aging level...

Page 39: ...timing and fuel quality Change the ECU and repeat the test if the issue is gone then the root cause is the ECU Or change the old one back to check the root cause Engine cannot start ITEM OPERATION RE...

Page 40: ...o Help ITEM OPERATION RESULT NEXT STEP 1 Check whether the fuel pump pressure is about 250kPa at idle Yes Next No Check the pump 2 Check whether the RMP data on the diagnostic tool shows the realengin...

Page 41: ...sensor and check whether the engine start well Yes Check the engine temperature sensor No Next 4 With a little bigger throttle check whether the engine starts well Yes Clean the throttle body and byp...

Page 42: ...it at the throttle body and bypass channel Yes Clean the TB No Next 3 Check whether the IACV workswell Yes Next No Check the IACV 4 Check whether thefuel pressure is about 250kPa Yes Next No Check the...

Page 43: ...High idle ITEM OPERATION RESULT NEXT STEP 1 Check whether the throttle cable is stuck Yes Adjust the cable No Next 2 Check whether the idle inlet has been adjusted Yes Change the TB No Next 3 Check w...

Page 44: ...the spark plug check whether it is wet or not Yes Dry the plug and combustion chamber No Next 4 Check whether theTMAP TPSand the connections works well Yes Next No Change the sensor or harness mainten...

Page 45: ...ark over is normal Yes Next No Check the ignition system 2 Check whether the timing is right Yes Next No Adjust the timing 3 Check whether there is leakageof the valve Yes Adjust the valve No Next 4 C...

Page 46: ...ON RESULT NEXT STEP 1 Pull out the spark plug check whether the spark over is normal Yes Next No Check the ignition system 2 Check whether the timing is right Yes Next No Adjust the timing 3 Check the...

Page 47: ...High Voltage KsDGDM_TPS_ShortHigh Oxygen Sensor P0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh Oxygen Sensor Heater P0032 O2S Heater Circui...

Page 48: ...ge KsDGDM_O2_2_ShortHigh Oxygen Sensor Heater 2 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow Vehicle Speed Sensor P...

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