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CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC

System or Component

DTC Number

DTC Description

Related Calibration

Manifold Absolute Pressure Sensor (MAP)

P0107

MAP Circuit Low Voltage or Open

KsDGDM_MAP_ShortLow

P0108

MAP Circuit High Voltage

KsDGDM_MAP_ShortHigh

Intake Air Temperature Sensor (IAT)

P0112

IAT Circuit Low Voltage

KsDGDM_IAT_ShortLow

P0113

IAT Circuit High Voltage or Open

KsDGDM_IAT_ShortHigh

Coolant/Oil Sensor

P0117

Coolant/Oil

Temperature

Sensor

Circuit Low Voltage

KsDGDM_CoolantShortLow

P0118

Coolant/Oil

Temperature

Sensor

Circuit High Voltage or Open

KsDGDM_CoolantShortHigh

Throttle Position Sensor (TPS)

P0122

TPS Circuit Low Voltage or Open

KsDGDM_TPS_ShortLow

P0123

TPS Circuit 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 Circuit High Voltage

KsDGDM_O2_HeaterShortHigh

P0031

O2S Heater Circuit Low Voltage

KsDGDM_O2_HeaterShortLow

Fuel Injector

P0201

Injector 1 Circuit Malfunction

KsDGDM_INJ_CYL_A_Fault

Fuel Pump Relay (FPR)

P0230

FPR Coil Circuit Low Voltage or Open

KsDGDM_FPP_CircuitShortLow

P0232

FPR Coil Circuit High Voltage

KsDGDM_FPP_CircuitShortHigh

Crankshaft Position Sensor (CKP)

P0336

CKP Sensor Noisy Signal

KsDGDM_CrankNoisySignal

Crankshaft Position Sensor (CKP)

P0337

CKP Sensor No Signal

KsDGDM_CrankNoSignal

Ignition Coil

P0351

Cylinder 1 Ignition Coil Malfunction

KsDGDM_EST_A_Fault

P0352

Cylinder 2 Ignition Coil Malfunction

KsDGDM_EST_B_Fault

Idle Control System

P0505

Idle Speed Control Error

KsDGDM_IdleControl

Содержание CHILL 125 cc.

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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