gv250 gt250 efi service manual
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SERVICE MANUAL
99000-95610
SERVICEMANUAL
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FOREWORD
This manual contains an introductory description on
HYOSUNG &
and procedures for its inspection / service and
overhaul of its main components.
It covers the differences from Carbure type and
please refer to the service manual of
(99000-
95310), &(99000HR8310)and &
(99000-94710) for others which are not covered in
this manual.
Other information considered as generally known is
not included.
Read GENERAL INFORMATION section to
familiarize yourself with outline of the vehicle and
MAINTENANCE and other sections to use as a guidefor proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum
and quick service.
ELECTRICAL SYS
GROUP
GENERAL INFOR
FI SYSTEM DIAGN
FUEL SYSTEM AN
SERVICING INFOR
This manual has been prepared on the basisof 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.
Illustrations in this manual are used to showthe basic principles of operation and work
procedures.
They may not represent the actual vehicle
exactly in detail.
WARNING
This manual is intended for those who have
enough knowledge and skills for servicing
HYOSUNG vehicles. Without such knowledge and
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HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARELOOKING FOR :
1. The text of this manual is divided into sections.
2. As the title of these sections are listed on the previous
page as GROUP INDEX, select the section where you are look-
ing for.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.4. On the first page of each section, its contents are listed. Find
the item and page you need.
SYMBOLListed in the table below are the symbols indicating instructions and other information neces
meaning associated with them respectively.
Apply THREA
Apply or use b
Measure in vo
Measure in re
Torque control required.Data beside it indicates specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply SUPER GREASEA.
DEFINITIONSYMBOL SYMBOL
Apply SUPER GREASEC.
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A
ABDC : After Bottom Dead Center
AC : Alternating Current
API : American Petroleum Institute
ATDC : After Top Dead Center
B
BBDC : Before Bottom Dead Center
BDC : Bettom Dead Center
BTDC : Before Top Dead Center
DDC : Direct Current
DOHC : Double Over Head Camshaft
E
ECU : Engine Control Unit,
FI Control UnitET Sensor : Engine Temperature Sensor
(ETS)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
G
GP Switch : Gear Position Switch
L
LCD : Liquid
LED : Light
LH : Left H
M
Max : Maxim
Min : Minim
O
O2 Sensor : Oxyg
R
RH : Right
S
SAE : Socie
SAV Solenoid : Seco
T
TDC : Top D
TO Sensor : Tip O
ABBREVIATIONS USED IN THIS MANUAL
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BL : Black with Blue tracer BBr : Black wit
BG : Black with Green tracer BO : Black wit
BR : Black with Red tracer BW : Black wit
BY : Black with Yellow tracer LB : Blue with
LG : Blue with Green tracer LR : Blue with
LW : Blue with White tracer LY : Blue with
BrB : Brown with Black tracer BrW : Brown w
GB : Green with Black tracer GR : Green w
GY : Green with Yellow tracer GrB : Gray with
GrR : Gray with Red tracer GrW : Gray with
OB : Orange with Black tracer OL : Orange w
OG : Orange with Green tracer OR : Orange w
OW : Orange with White tracer OY : Orange w
RB : Red with Black tracer RW : Red with
B : Black Gr : Gray Sb : Light blu
L : Blue Lg : Light green W : White
Br : Brown O : Orange Y : Yellow
G : Green R : Red
WIRE COLOR
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GENERAL INFORMATION
SPECIFICATIONS ( , &
CONTENTS
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1-8 GENERAL INFORMATION
2,270 mm (89.4 in)800 mm (31.5 in)
1,090 mm (42.9 in)
1,500 mm (59.1 in)
155 mm (6.1 in)
170 kg (375 lbs)
2,080 mm (81.9 in)760 mm (29.9 in)
1,120 mm (44.1 in)
1,455 mm (57.3 in)
180 mm (7.1 in)
Overall lengthOverall width
Overall height
Wheelbase
Ground clearance
Mass
I T E M
SPECIFICATIONS ( , &
DIMENSIONS 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 )
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 Clutch
I T E M
TRANSMISSION
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Telescopic type
Swingarm type
40(right & left)
33
135 mm (5.32 in)
Disk brake
Drum brake
110/90 - 16 59S
150/80 - 15M/C 70S
120 mm (4.72 in)
33(right & left)
25.585 mm (3.35 in)
Disk brake
110/70 - 17 54H
150/70 - 17 69H
Front suspension
Rear suspension
Steering angle
Caster
Trail
Front brake
Rear brake
Front tire size
Rear tire size
Front fork stroke
I T E M
CHASSIS
I T E M
ELECTRICAL
Ignition type
Ignition timing
Spark plug
BatteryFuse
Head lamp
Turn signal lamp
Brake / Tail lamp
License plate lamp
Illumination lampHigh beam indicator lamp
Turn signal indicator lamp(right & left)
Neutral indicator lamp
Fuel meter lamp
FI(Fuel Injection) check lamp
ECU
13B.T.D.C. at 2,000 rpm and
30B.T.D.C. at 6,000 rpm
CR8E
12 V 12 Ah (MF)30 A & 15 A
12 V - H4 : 60 W 1
12 V - H4 : 55 W 1
12 V - W5 W1
12 V - RY10 W 4
12 V - P21/5 W 1
12 V - W5 W 1
12 V - 1.7 W 212 V - 1.7 W 1
12 V - 1.7 W 2
12 V - 1.7 W 1
12 V - 1.7 W 1
LED type
LED typeLED type
LED type
LED type
LED type (Level type)
HI
LO
Position
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PRECAUTIONS IN SERVICING
FI SYSTEM TECHNICAL FEATURESSELF-DIAGNOSIS FUNCTION ( )
SELF-DIAGNOSIS FUNCTION ( )
FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
SELF-DIAGNOSTIC PROCEDURES ( )
SELF-DIAGNOSIS RESET PROCEDURE ( )
MALFUNCTION CODE AND DEFECTIVE CONDITION
C15ET SENSOR CIRCUIT MALFUNCTION
C17orC18IAP SENSOR CIRCUIT MALFUNCTION
C21IAT SENSOR CIRCUIT MALFUNCTION
C22OXYGEN SENSOR CIRCUIT MALFUNCTION
C24orC25IGNITION COIL MALFUNCTION
C27ISC SOLENOID RANGE ABNORMAL
C32orC33FUEL INJECTOR CIRCUIT MALFUNCTION
C37SAV SOLENOID MALFUNCTION
C41FUEL PUMP RELAY CIRCUIT MALFUNCTIONC43OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION
SENSORS
FI SYSTEM DIAGNOSIS
CONTENTS
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PRECAUTIONS IN SERVICINGWhen handling the component parts or servicing the
FI system, observe the following points for the safety
of the system.
ELECTRICAL PARTS
CONNECTOR / COUPLER
When connecting a connector, be sure to push itin until a click is felt.
With a lock type coupler, be sure to release thelock when disconnecting, and push it in fully till the
works when connecting it.
When disconnecting the coupler, be sure to holdthe 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 andcontamination.
The terminals must be clean and free of any
foreign material which could impede proper
terminal contact.
Inspect each lead wire circuit for poor connectionby shaking it by hand lightly. If any abnormal
condition is found, repair or replace.
4-1-1 FI SYSTEM DIAGNOSIS
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When connecting meter probe from the terminalside of the coupler (connection from harness side
not being possible), use extra care not to force
and cause the male terminal to bend or the female
terminal to open.
Connect the probe as shown to avoid opening of
female terminal.
Never push in the probe where male terminal is
supposed to fit.
Check the male connector for bend and femaleconnector for excessive opening. Also check the
coupler for locking (looseness), corrosion, dust,
etc.
FUSE When a fuse blows, always investigate the causeto 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 taken not to apply any sharp
impacts during removal and installation.
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Never connect an ohmmeter to the ECU with itscoupler connected. If attempted, damage to ECU
or sensors may result.
Be sure to use a specified voltmeter / ohmmeter.Otherwise, accurate 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 theandprobes may
cause the inside of the tester to burnout. If the voltage and current are not known, makemeasurements using the highest range.
After using the tester, turn the power off.
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4-1-5 FI SYSTEM DIAGNOSIS
FI SYSTEM TECHNICAL FEATURES
INJECTION TIME (INJECTION VOLUME)
The factors to determine the injection time include the basic fuel injection time, which
intake air pressure, engine speed and throttle opening angle, and various compensatio
These compensations are determined according to the signals from various sensor
driving conditions.
Intake Air Pressure Sensor(IAP Sensor)
Intake air pressure signal
CVarious Sensors
Injectors
Engine speed signal
Various signals
Injection signal
Pick-up coil
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COMPENSATION OF INJECTION TIME (VOLUME)
The following different signals are output from the respective sensors for compensa
(volume).
INJECTION STOP CONTROL
SIGNAL DESCRIPT
ENGINE TEMPERATURE
SENSOR SIGNAL
INTAKE AIR TEMPERATURE SENSOR
SIGNAL
BATTERY VOLTAGE SIGNAL
ENGINE RPM SIGNAL
STARTING SIGNAL
ACCELERATION SIGNAL /
DECELERATION SIGNAL
When engine temperature is low,
increased.
When intake air temperature is low
increased.
ECU operates on the battery voltag
monitors the voltage signal for compe
time (volume). A longer injection
injection volume in the case of low vo
At high speed, the injection time (volu
When starting engine, additional fue
engine.
During acceleration, the fuel injection
in accordance with the throttle open
During deceleration, the fuel in
decreased.
SIGNAL DESCRIPT
TIP OVER SENSOR SIGNAL
(FUEL CUT-OFF)
OVER-REV. LIMITER SIGNAL
When the motorcycle tips over, th
signal to the ECU. Then, this signal c
the fuel pump, fuel injector and ignitio
The fuel injectors stop operation whe
limit rpm.
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4-1-7 FISYSTEM DIAGNOSIS
FI SYSTEM PARTS LOCATION ( )
Speedometer Ignition coil, NO.1 Ignition coil, NO.2 Pick-up coil
GP switch Fuel injector, N Fuel injector, N ISC solenoid
ECU
3
4
2
6
5
7
8
1
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IAT sensor TO sensor Fuel pump relay IAP sensor, NO.2
IAP sensor, NO ET sensor Oxygen sensor SAV solenoid
ECU
15
10
11 14
1216
13
9
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FI SYSTEM PARTS LOCATION ( )
Speedometer Fuel injector, NO.1 Fuel injector, NO.2 IAT sensor GP switch
Pick-up coil Ignition coil, NO ISC solenoid Fuel pump rela
4-1-9 FISYSTEM DIAGNOSIS
ECU
3
4
2
6 5
7 8
9
1
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TO sensor Ignition coil, NO.2 IAP sensor, NO.1 IAP sensor, NO.2
ET sensor Oxygen sensor SAV solenoid
F
ECU
15
10
11
14
12
16
13
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4-1-11 FI SYSTEM DIAGNOSIS
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 FI system devices, the dealer mode is prepared
In this check, the special tool is necessary to read the code of the malfunction items.
USER MODEThe FI check lamp comes on for about three seconds whenever the position with the engine stopped as a test of the injection system operation. The chec
seconds.
If the check lamp comes on during normal engine operation, it means that the fuel inje
correctly.
When this is the case, inspect the fuel injection system to refer to Dealer mode.
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F
Mode select switch : 09900-27000
DEALER MODE
The defective function is memorized in the ECU.
Use the special tools coupler to connect to the dealer mode coupler. (Refer to page 4-
The memorized malfunction code is displayed on LCD (DISPLAY) panel.
Malfunction means that the ECU does not receive signal from the devices. These affe
the code form.
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4-1-13 FI SYSTEM DIAGNOSIS
SELF-DIAGNOSIS FUNCTION ( )The self-diagnosis function is incorporated in the ECU.
The function has a mode, USER MODE. The user and dealer can only be notified by
To check the function of the individual FI system devices, read blinks signal of the FI
The FI check lamp comes on for about three seconds whenever the ignitionwith the engine stopped as a test of the injection system operation. The check l
seconds.
If the check lamp comes on during normal engine operation, it means that the fuel inje
correctly.
When this is the case, inspect the fuel injection system to refer to blinks signal of the
The defective function is memorized in the ECU.
The memorized malfunction code is display with blinks signal of the FI check lamp
Malfunction means that the ECU does not receive signal from the devices. These af
blinks signal of the FI check lamp .
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F
I th FI h k l th lf ti d i di l d f ll bli k i
C15
C17
C18
C21
C22
C24
C25
C27
C32
C33
C37
C41
C43
Engine temperature sensor (ETS)
Intake air pressure sensor (IAPS), N
Intake air pressure sensor (IAPS), N
Intake air temperature sensor (IATS
Oxygen sensor (O2S)
IG coil, NO.1
IG coil, NO.2
Idle speed control solenoid (ISC sole
Fuel injector, NO.1
Fuel injector, NO.2
Secondary air valve solenoid (SAV s
Fuel pump relay
Oxygen sensor heater (O2S heater)
MALFUNCTION PART
[ 1 5 1 5 1 ]
[ 1 7 1 7 ]
[ 1 8 1 8 ]
[ 2 1 2 1 12 2 1]
[ 2 2 222 2 ]
[ 2 4 42 2 ]
[ 2 5 52 2 ]
[ 2 7 72 ]
[ 3 3 32 22 ]
[ 3 3 333 ]
[ 3 37 ]
[ 4 41 1 14 ]
[ 4 3 34 ]
CODE
In the LCD (DISPLAY) panel , the malfunction code is indicated from small code to
CODE
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4-1-15 FI SYSTEM DIAGNOSIS
FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as describe
purpose, use of such an inspection form will facilitate collecting information to the poin
and diagnosis.
EXAMPLE : CUSTOMER PROBLEM INSPECTION FORMUser name : Model : VIN :
Date of issue : Date Reg. Date of problem :
FI Check lamp Always ON Sometimes ON Always O
No code Malfunction code ( )
PROBLEM SYMPTOMS
Difficult Starting Poor Driveability
No cranking Hesitation on acceleratio 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 Immediately after start
Abnormal idling speed Throttle valve is opened
( High Low) ( rpm) Throttle valve is closed
Unstable Load is applied
Malfunction display / code
(LCD) or
Blinks signal
( FI check lamp)
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F
MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROB
Environmental condition
Motorcycle condition
NOTE
The above form is a standard sample. If should be modified according to conditmarket.
Fair Cloudy Rain Snow Always
Hot Warm Cool Cold ( F / C)
Always Sometimes ( times / day, month)
Under certain condition
Urban Suburb Highway Mountainous (
Tarmacadam Gravel Other
Cold Warming up phase Warmed up Alw
Immediately after start Racing without load En
During driving : Constant speed Accelerating
Right hand corner Left hand corner At stop
Motorcycle speed when problem occurs ( km/h,
Other
Weather
Temperature
Frequency
Road
Engine condition
Motorcycle condition
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4-1-17 FI SYSTEM DIAGNOSIS
NOTEThe dealer mode coupler is located under the rear
seat.
Mode select switch : 09900-27000
SELF-DIAGNOSTIC PROCEDURES( )
Dont disconnect couplers from ECU, battery cable
from battery, ECU ground wire harness from engine
or main fuse before confirming malfunction code
(self-diagnostic trouble code) stored in memory.
Such disconnection will erase memorized information
in ECU memory.Malfunction code stored in ECU memory can be
checked by the special tool.
To check malfunction code, read SELF-DIAGNOSIS
FUNCTION DEALER MODE (Refer to 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 CircuitService (Refer to page 4-1-1) before inspection and
observe what is written there.
Remove the front and rear seat. Connect the special tool to the dealer mode
coupler at the wiring harness, and the ignition
switch is set to ON position.
Turn the special tools switch ON position and
check the malfunction code to determine themalfunction part.
SELF-DIAGNOSIS RESETPROCEDURE ( )
After repairing the trouble turn the ignition switch
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F
MALFUNCTION CODE AND DEFECTIVE CONDITION
C15
C17 / C18
C21
C22
Engine temperature
sensor (ETS)
Intake air pressure
sensor (IAPS),
NO.1 / NO.2
Intake air temperature
sensor (IATS)
Oxygen sensor (O2S)
Intake air temperature sensor, lead w
Intake air pressure sensor, lead wire
Engine temperature sensor, lead wir
Oxygen sensor, lead wire / coupler c
DETECTED ITEMDETECTED FAILURE
CHECK F
MALFUNCTIONCODE
The sensor voltage should be the fol
0.1 V sensor voltage < 4.6 VWithout the above range for 4 sec. a
The oxygen sensor signal is input in
120 sec. after the engine run.
When this is the case, ECU not
indicated.
The sensor voltage should be the fol
0.1 V sensor voltage < 4.6 VWithout the above range for 4 sec. a
The sensor should produce following
0.1 V sensor voltage 4.8 VWithout the above range for 4 sec
indicated.
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4-1-19 FI SYSTEM DIAGNOSIS
C24 / C25
C27
C32 / C33
C37
C41
C43
Ignition coil (IG coil),
NO.1 / NO.2
Idle speed control
solenoid (ISC solenoid)
Fuel injector, NO.1 / NO.2
Secondary air valve
solenoid (SAV solenoid)
Fuel pump relay
Oxygen sensor heater
(O2S heater)
Ignition coil, wiring / coupler connec
battery.
Idle speed control solenoid, lead wir
Injector, wiring / coupler connec
injector.
Secondary air valve solenoid, lead w
Oxygen sensor heater, lead wire / co
DETECTED ITEMDETECTED FAILUR
CHECK F
MALFUNCTIONCODE
When the IC of the ECU electric cur
or C25 is indicated.
The idle speed control solenoid step
O step solenoid step 100 stepWithout the above range, C27 is ind
The fuel injector not comes in volta
C33 is indicated.
When the secondary air valve sole
ECU, C37 is indicated.
Fuel pump relay, connecting lead wi
pump relay, fuel injector.
The oxygen sensor heater signal is
No voltage is applied to the both incontact of fuel pump relay is turned
applied to the both injectors, when
OFF position.
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F
C15 ET SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Turn the ignition switch OFF position.
2) Check the ET sensor coupler for loose or poorcontacts.
If OK, then measure the ET sensor voltage at the
wire side coupler.
3) Disconnect the coupler and turn the ignition switch
ON position.
DETECTED CONDITION POSSIBL
ET sensor circuit open o ET sensor malfunction.
ECU malfunction.
ET sensor voltage
Is the voltage OK?
Tester knob indication : Voltage ( )
CODE CO
[ 1 5 1 5
C15
Output voltage is out of the specified range.0.1 V Sensor voltage < 4.6 V
4) Measure the voltage between G wire terminal and
ground.
5) If OK, then measure the voltage between G wire
terminal and BW wire terminal.
4.5 ~ 5.5 V
(G-Ground )
(G-
BW )
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4-1-21 FI SYSTEM DIAGNOSIS
Step 21) Turn the ignition switch OFF position.
2) Measure the ET sensor resistance.
Resistance (To ECU)Engine Temp.
ET sensor resistance
Approx. 28.788
Approx. 12.209
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
NOReplace the ET sensor with a new
one.
EC
G or BW wire open or shorted toground, or poor or connection.
If wire and connection are OK,intermittent trouble or faulty ECU.
Recheck each terminal and wireharness for open circuit and poor
connection.
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F
C17 or C18 IAP SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the fuel tank.
2) Turn the ignition switch OFF position.
3) Check the IAP sensor NO.1 coupler and NO.2
coupler for loose or poor contacts.If OK, then measure the IAP sensor input voltage.
DETECTED CONDITION
Clogged vacuum passand IAP sensors.
Air being drawn from throttle body and IAP se
IAP sensor circuit open IAP sensor malfunction ECU malfunction.
POSSIBL
C17
C18
CODE CO
[ 1 7 1
[ 1 8 1
IAP sensor voltage is out of the specified range.
0.1 V Sensor voltage 4.8 VNOTE :
Note that atmospheric pressure varies depending on
weather conditions as well as altitude.
Take that into consideration when inspecting voltage.
4) Disconnect the IAP sensor couplers NO.1 and
NO.2 .5) Turn the ignition switch ON position.
6) Measure the voltage at the OB wire and ground.
If OK, then measure the voltage at the OB wire
and BW wire.
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4-1-23 FI SYSTEM DIAGNOSIS
IAP sensor
output voltage
Approx. 4.0 ~ 4.2 V
when ignition switch ON
([NO.1]BL-BW )([NO.2]BY-BW )
Is the voltage OK?
Tester knob indication : Voltage ( )
EC
YES
NO
OB, BL(NO.1), BY(NO,2) or BWwire open or shorted to ground,or poor , (NO.1), (NO.2) or connection.
If wire and connection are OK,intermittent trouble or faulty ECU.
Recheck each terminal and wireharness for open circuit and poorconnection.
If check result is not satisfactory,replace IAP sensor with a new one.
Step 21) 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.
4) Measure the IAP sensor output voltage at the wire
side coupler (between BL(NO.1) or BY(NO.2) and
BW wires).
Output voltage
(Input voltage 5 V, ambient temp. 25 C, 77 F)
ALTITUDE(Reference)
(ft) (m) (mmHg) kPa (V)
0 0 760 100
ATMOSPHERICPRESSURE
OUTPUTVOLTAGE
Approx.
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F
INSPECTION
Step 11) Remove the fuel tank.
2) Turn the ignition switch OFF position.
3) Check the IAT sensor coupler for loose or poor
contacts.
If OK, then measure the IAT sensor voltage at the
wire side coupler.
4) Disconnect the coupler and turn the ignition switch
ON position.
C21 IAT SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION POSSIBL
IAT sensor circuit open IAT sensor malfunction.
ECU malfunction.
IAT sensor voltage4.5 ~ 5.5 V
(Lg-Ground )(Lg
-
BW )
Is the voltage OK?
Tester knob indication : Voltage ( )
C21
CODE CO
[ 2 1 2 1 2
Output voltage is out of the specified range.
0.1 V Sensor voltage < 4.6 V
5) Measure the voltage between Lg wire terminal and
ground.
6) If OK, then measure the voltage between Lg wire
terminal and BW wire terminal.
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4-1-25 FI SYSTEM DIAGNOSIS
Step 21) Turn the ignition switch OFF position.
2) Measure the IAT sensor resistance.
Is the resistance OK?
YES
NO
EC
ResistanceIntake Air Temp.
IAT sensor 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 toground, or poor or connection.
If wire and connection are OK,intermittent trouble or faulty ECU.
Recheck each terminal and wireharness for open circuit and poor
connection.Replace the IAT sensor with a new
one.
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F
INSPECTION1) Remove the front seat and frame cover.
2) Turn the ignition switch OFF position.3) Check the Oxygen sensor coupler for loose or
poor contacts.
C22 OXYGEN SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
Oxygen sensor, Oxygeor short.
Oxygen sensor, Oxygen ECU malfunction.
POSSIBL
Is OK?
YES
C22
CODE CO
[ 2 2 22
Oxygen sensor signal is not input in ECU since thenmore than 120 sec. after the engine run.
BR or BW wire open or shortedto ground, or poor orconnection.
If wire and connection are OK,intermittent trouble or faulty ECU.
Recheck each terminal and wire
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4-1-27 FI SYSTEM DIAGNOSIS
INSPECTION1) Remove the front seat.
2) Turn the ignition switch OFF position.
3) Check the ISC solenoid coupler for loose or poor
contacts.4) Turn the ignition switch ON position to check the
ISC solenoid operation.
C27 ISC SOLENOID RANGE ABNORMAL
[ When Ignition switch OFF ]
C27
CODE CO
[ 2 7 2
DETECTED CONDITION POSSIBL
ISC solenoids step is out of the specified range.
O step Solenoid step 100 step
ISC solenoid malfunctio
ISC solenoids step is o
ECU malfunction.
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F
INSPECTION
Step 11) Remove the fuel tank and frame cover.
2) Turn the ignition switch OFF position.
3) Check the injector couplers NO.1 and NO.2for loose or poor contacts.
If OK, then measure the injector resistance.
: Fuel injector NO.1
: Fuel injector NO.2
4) Disconnect the injector couplers NO.1 andNO.2 and measure the resistance betweenterminals.
C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTI
DETECTED CONDITION POSSIBL
Fuel injector not comes in voltage from battery. Injector circuit open or s
Injector malfunction.
ECU malfunction.
Injector resistance 11.5 ~ 13.5 at 20 (68)
C32
C33
CODE CO
[ 3 3 22
[ 3 33
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4-1-29 FI SYSTEM DIAGNOSIS
Injector voltage
NOTEInjector voltage can be detected only 3
seconds after ignition switch is turned ON
position.
YES
NO
Is the voltage OK?
Tester knob indication : Voltage ( )
EC
Step 21) Turn the ignition switch ON position.
2) Measure the injector voltage between YG(NO.1),
YR(NO.2) wire and ground.
YG(NO.1) or YR(NO.2) wire open orshorted to ground, or poor (NO.1)or (NO.2) connection.
If wire and connection are OK,intermittent trouble or faulty ECU.
Recheck each terminal and wireharness for open circuit and poor
connection.
Inspect the fuel pump or fuelpump relay. (Refer to page 4-2-6)
: Fuel injector c : Fuel injector c
Battery voltage
([NO.1]YG-Ground )([NO.2]YR-Ground )
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F
SAV solenoid voltageBattery voltage
(GL-Ground )
Is the voltage OK?
NO
YES
Replace the SAV solenoid with a new
one.
C37 SAV SOLENOID MALFUNCTION
DETECTED CONDITION POSSIBL
SAV solenoid voltage is not input in ECU. SAV solenoid circuit ope
SAV solenoid malfunctio
ECU malfunction.
Tester knob indication : Voltage ( )
C37
CODE CO
[ 3 7
INSPECTION1) Remove the front seat.
2) Turn the ignition switch OFF position.
3) Check the SAV solenoid coupler for loose or poorcontacts.
4) Connect the SAV solenoid coupler.
5) Turn the ignition switch ON position.
6) Measure the voltage at the wire side coupler
between GL wire and ground.
GL wire open or shorted to ground, orconnection.
If wire and connection are OK,intermittent trouble or faulty ECU.
Recheck each terminal and wire harnessfor open circuit and poor connection.
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4-1-31 FI SYSTEM DIAGNOSIS
C41 FUEL PUMP RELAY CIRCUIT MALFUNCTION
DETECTED CONDITION POSSIBL
No voltage is applied to the both injectors for 3 sec.
after the contact of fuel pump relay is turned ONposition.
Or voltage is applied to the both injectors, when the
contact of fuel pump is OFF position.
Fuel pump relay circuit o
Fuel pump relay malfun
ECU malfunction.
CODE COD
C41
CODE CO
[ 4 1 14
: Head lamp relay : Fuel pump relay : Main relay : Turn signal relay
INSPECTION
Step 1
1) Remove the frame cover.2) Turn the ignition switch OFF position.
3) Check the fuel pump relay coupler for loose or
poor contacts.
If OK, then check the insulation and continuity.
Refer to page 4-2-6 for details.
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F
C43 OXYGEN SENSOR HEATER CIRCUIT MALFUNT
Oxygen sensorheater voltage
Battery voltage(OB-B )
(OB-Ground )
Is the voltage OK?
YES
DETECTED CONDITION POSSIBL
Oxygen sensor heater signal is not input in ECU. Oxygen sensor, Oxygen
or short. Oxygen sensor, Oxygen ECU malfunction.
Tester knob indication : Voltage ( )
CODE CODCODE COD
C43
CODE CO
[ 4 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 each terminal and wire harnessf
INSPECTION1) Remove the frame cover.
2) Turn the ignition switch OFF position.
3) Check the Oxygen sensor heater coupler for loose
or poor contacts.
If OK, then measure the Oxygen sensor heater
voltage.
4) Disconnect the coupler and then the ignition
switch ON position.
5) Measure the voltage between OB wire terminal
and B (or ground) wire terminal.
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4-1-33 FI SYSTEM DIAGNOSIS
ET sensor : 18 Nm (1.8 kgfm)
ET SENSOR INSPECTION
The engine temperature (ET) sensor is installed atthe engine case. (Refer to page 4-1-20)
ET SENSOR REMOVAL ANDINSTALLATION
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 andNO.2 are installed at the upside of each intakepipe. (Refer to page 4-1-22)
IAP SENSOR REMOVAL AND
INSTALLATION Remove the fuel tank. Remove the IAP sensor from the intake pipe. Install the IAP sensor in the reverse order of
removal.
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F
IAT SENSOR INSPECTIONThe intake air temperature (IAT) sensor isinstalled at the air cleaner case.
(Refer to page 4-1-24)
IAT SENSOR REMOVAL ANDINSTALLATION
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 INSTALLATIONThe tip over (TO) sensor is located in the frame. Romove the seat. Remove the TO sensor from the frame. Install the TO sensor in the reverse order of
removal.
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FUEL SYSTEM
REMOVAL AND DISASSEMBLY ( )
REASSEMBLY AND INSTALLATION ( )
REMOVAL AND DISASSEMBLY ( )
REASSEMBLY AND INSTALLATION ( )
FUEL PRESSURE INSPECTION
FUEL PUMP RELAY INSPECTION
FUEL MESH FILTER INSPECTION AND CLEANING( )
FUEL GAUGE INSPECTION
THROTTLE BODY
REMOVAL
CLEANING
INSPECTION
INSTALLATION
CONTENTS
FUEL SYSTEM AND THROTTLE B
S S O BO
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4-2-1 FUEL SYSTEM AND THROTTLE BODY
FUEL SYSTEM
FUEL SYSTEM
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FUEL SYSTEM
REMOVAL AND DISASSEMBLY ( ) Remove the front seat.
Disconnect the fuel gauge coupler .
Remove the fuel tank mounting bolt and take offthe hooks.
4 2 3 FUEL SYSTEM AND THROTTLE BODY
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4-2-3 FUEL SYSTEM AND THROTTLE BODY
Remove the fuel tank rearward.
Remove the fuel pump assembly by removingits mounting bolts diagonally.
Remove the fuel gauge .
REASSEMBLY AND INSTALLATION
( )
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.
FUEL SYSTEM
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FUEL SYSTEM
REMOVAL AND DISASSEMBLY( )
Remove the front seat. Remove the fuel tank mounting bolts and take off
the hooks.
Disconnect the fuel gauge coupler .
Remove the fuel pump coupler .
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FUEL SYSTEM
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FUEL SYSTEM
FUEL PRESSURE INSPECTION Remove the front seat. Place a rag under the fuel injector hose. Disconnect the fuel injector hose from the fuel
delivery pipe.
Install the special tool between the fuel tank andfuel delivery pipe.
Fuel pump pressure gauge: 09915-54510
Turn the ignition switch ON position and check the
fuel pressure.
Fuel pressureApprox. 3.4 ~ 3.7 kgf/cm2
(333 ~ 363 kPa, 48.4 ~ 52.6 psi)
WARNING
Before removing the special tool, turn theignition switch to 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 :* Fuel pump check valve
* Pressure regulator
FUEL PUMP RELAY INSPECTION
Fuel pump relay is located the left side of the frame
4-2-7 FUEL SYSTEM AND THROTTLE BODY
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FUEL MESH FILTER INSPECTIONAND CLEANING( )
If the fuel mesh filter is clogged with sediment orrust, fuel will not flow smoothly and loss in engine
power may result.
Blow the fuel mesh filter with compressed air.
NOTEIf the fuel mesh filter is clogged with many
sediment or rust, replace the fuel filter cartridgewith a new one.
FUEL GAUGE INSPECTION
Measure resistance between the terminals whenfloat is at the position instead below.
Fuel float position Resistance between terminals
F
1/2
E
Approx. 90 ~ 105
Approx. 38
First, check the insulation between andterminals with pocket tester. Then apply 12 volts to and terminals,to andto , and checkthe continuity between and .If there is no continuity, replace it with a new one.
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4-2-9 FUEL SYSTEM AND THROTTLE BODY
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REMOVAL Remove the fuel tank. Remove the air cleaner box. Disconnect the fuel hose. Remove the all coupler to related the throttle
body.
Loosen the throttle body clamp screws.
FUEL SYSTEM A
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Clean all passageways with a spray-type throttlebody cleaner and blow dry with compressed air.
CLEANING
WARNING
Some throttle body cleaning chemicals,
especially dip-type soaking solutions, are very
corrosive and must be handled carefully. Always
follow the chemical manufacturers instructions
on proper use, handling and storage.
CAUTION
Do not use wire to clean passageways. Wire can
damage passageways. If the components cannot
be cleaned with a spray cleaner it may benecessary to use a dip-type cleaning solution and
allow them to soak. Always follow the chemical
manufacturers instructions for proper use and
cleaning of the throttle body components. Do not
apply throttle body cleaning chemicals to the
rubber and plastic materials.
CAUTIONNever operate the idle screws (NO 1) and
INSPECTION
Check following items for any damage or clogging.
* O-ring * Secondary throttle valve
* Throttle shaft bushing and seal
* Injector cushion seal
* Throttle valve * Vacuum hose
Check fuel injector filter for evidence of dirt and
contamination. If present, clean and check for
presence of dirt in the fuel lines and fuel tank.
4-2-11 FUEL SYSTEM AND THROTTLE BODY
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INSTALLATIONInstallation is in the reverse order of removal.
Pay attention to the following points :
Connect the throttle cable to the throttle cabledrum.
Ad just the th ro tt le cable play wi th the cableadjusters.
ELECTRICAL SYSTEM
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LOCATION OF ELECTRICAL COMPONENTS
IGNITION SYSTEM
CHARGING SYSTEM
CONTENTS
ELECTRICAL SYSTEM
5-1 ELECTRICAL SYSTEM
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LOCATION OF ELECTRICAL COMPONENTS
Ignition coil NO.1 Ignition coil NO.2
Main relay Fuel pump relay Head lamp relay
Main ECU Head Batte
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SAV s IAP sensor NO.1 ET sensor IAP sensor NO.2
ISC solenoid
5-3 ELECTRICAL SYSTEM
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REAR
IGNITION
COIL
FRONT
IGNITION
COIL
RELAY
ENGINE STO
MAGECU
IGNITION SYSTEM
INSPECTION IGNITION COIL RESISTANCE
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 ignition coil
with a new one.
IGNITION COIL / PLUG CAP RESISTANCE
3.5 ~ 5.5 (Terminal -Terminal)
20 ~ 31 (Plug cap -Terminal)SecondaryPrimary
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Standard
G - L Approx. 85 ~ 105
Y - Y Approx. 0.2 ~ 1.0
MAGNETOUsing the pocket tester, measure the resistancebetween the lead wires in the following table.
If the resistance is not within the specified value,
replace the magneto coil, with a new one.
CAUTIONWhen mounting the stator on the magneto cover,
apply a small quantity of THREAD LOCK1324to the threaded parts of screws.
WIRE COLOR
L : Blue
G : GreenY : Yellow
BY : 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 ()
MAGNETO NO-LOAD PERFORMANCEDisconnect the three lead wires from the magneto
terminal.
Start the engine and keep it running at 5 000 rpm
Magneto coil resistance
Pick-up coil
Charging coil
THREAD LOCK1324
5-7 ELECTRICAL SYSTEM
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CHARGING SYSTEM
INSPECTION CHARGING OUTPUT CHECKStart the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the DC voltage
between the battery terminaland.If the voltage is not within the specified value, check
the magneto no-load performance and regulator /
rectifier.
CAUTION
When making this test, be sure that the battery is
full charged condition
Regulator
Rectifier
Ba
A. C generator
Regulator / Rectifier
IC
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REGULATOR / RECTIFIER Disconnect the regulator / rectifier couplers. Using the 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)
34
34
12
12
34
34
12
12
34
34
12
12
12
12
12
32
12
12
12
32
Tester probe
Testerprobe
Unit :M
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SERVICING INFORMATION
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TROUBLESHOOTING
SPECIAL TOOLS
TIGHTENING TORQUE
SERVICE DATA
WIRING DIAGRAM ( )
WIRING DIAGRAM ( )
WIRING DIAGRAM ( )
CONTENTS
7-1-1 SERVICING INFORMATION
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TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVE CONDITION
C15
C17 / C18
C21
C22
Engine temperature
sensor (ETS)
Intake air pressure
sensor (IAPS),
NO.1 / NO.2
Intake air temperature
sensor (IATS)
Oxygen sensor (O2S)
Intake air temperature sensor, lead w
Intake air pressure sensor, lead wire
Engine temperature sensor, lead wir
Oxygen sensor, lead wire / coupler c
DETECTED ITEMDETECTED FAILUR
CHECK F
MALFUNCTIONCODE
The sensor voltage should be the fo
0.1 V sensor voltage < 4.6 V
Without the above range for 4 sec. a
The oxygen sensor signal is input in
120 sec. after the engine run.
When this is the case, ECU not indicated.
The sensor voltage should be the fo
0.1 V sensor voltage < 4.6 VWithout the above range for 4 sec. a
The sensor should produce following
0.1 V sensor voltage 4.8 VWithout the above range for 4 sec
indicated.
SER
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C24 / C25
C27
C32 / C33
C37
C41
C43
Ignition coil (IG coil),
NO.1 / NO.2
Idle speed control
solenoid (ISC solenoid)
Fuel injector, NO.1 / NO.2
Secondary air valve
solenoid (SAV solenoid)
Fuel pump relay
Oxygen sensor heater(O2S heater)
Ignition coil, wiring / coupler connectbattery.
Idle speed control solenoid, lead wir
Injector, wiring / coupler connec
injector.
Secondary air valve solenoid, lead w
Oxygen sensor heater, lead wire / co
DETECTED ITEMDETECTED FAILURE
CHECK F
MALFUNCTIONCODE
When the IC of the ECU electric cur
or C25 is indicated.
The idle speed control solenoid step
O step solenoid step 100 stepWithout the above range, C27 is ind
The fuel injector not comes in voltaC33 is indicated.
When the secondary air valve sole
ECU, C37 is indicated.
Fuel pump relay, connecting lead wi
pump relay, fuel injector.
The oxygen sensor heater signal is n
No voltage is applied to the both inj
contact of fuel pump relay is turned
applied to the both injectors, when
OFF position.
7-1-3 SERVICING INFORMATION
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ENGINEComplaint Symptom and possible causes
Engine will not
start or is hard to
start.
Compression too low1. Tappet clearance out of adjustment.
2. Worn valve guides or poor seating of valves.
3. Mistimed valves.
4. Excessively worn piston rings.
5. Worn-down cylinder bore.
6. Starter motor cranks too slowly.
7. Poor seating of spark plugs.
Plug not sparking1. Fouled spark plugs.
2. Wet spark plugs.
3. Defective ignition coils.
4. Open or short in high-tension cord.
5. Defective pick-up coil.
6. Defective ECU.
7. Open-circuited wiring connections.
No fuel reaching the intake manifold1. 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 mixture1. Defective fuel pump.
2. Defective fuel pressure regulator.
3. Defective pick-up coil.
4. Defective IAP sensor.
5. Defective ECU.
6. Defective ET sensor.
7. Defective IAT sensor.
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Complaint Symptom and possible causes
Engine idles poorly. 1. Tappet clearance out of adjustment.2. Poor seating of valves.
3. Defective valve guides.
4. Worn down camshafts.
5. Too wide spark plug gaps.
6. Defective ignition coils.
7. Defective pick-up coil.
8. Defective ECU.
9. Defective fuel pump.
10. Imbalanced throttle valve or SAV solenoid.
11. Damaged or cracked vacuum hose.
Incorrect fuel / air mixture1. Defective IAP sensor or circuit.
2. Clogged fuel filter.
3. Defective fuel pump.
4. Defective fuel pressure regulator.5. Defective ET sensor.
6. Defective IAT sensor.
7. Damaged or cracked vacuum hose.
Fuel injector improperly operating1. 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 operating1. 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.
Engine internal parts improperly operating1. Fouled spark plugs.
2. Defective pick-up coil or ECU.
3. Clogged fuel hose.
Engine stalls often
7-1-5 SERVICING INFORMATION
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Complaint Symptom and possible causes
Noisy engine. Excessive valve chatter1. Too large tappet clearance.
2. Weakened or broken valve springs.
3. Worn tappet or cam surface.
4. Worn and burnt camshaft journal.
Noise seems to come from piston1. Worn down pistons or cylinders.
2. Combustion chambers fouled with carbon.
3. Worn piston pins or piston pin bore.
4. Worn piston rings or ring grooves.
Noise seems to come from cam chain1. Stretched chain.
2. Worn sprockets.
3. Tension adjuster not working.
Noise seems to come from clutch1. 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 crankshaft1. Rattling bearings due to wear.
2. Worn and burnt big-end bearings.
3. Worn and burnt journal bearings.
Noise seems to come from transmission1. Worn or rubbing gears.
2. Worn splines.
3. Worn bearings.
4. Worn or rubbing primary gears.
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Complaint Symptom and possible causes
Engine runs poorly
in high speed range.
Defective engine internal / electrical parts1. Weakened valve springs.
2. Worn camshafts.
3. Valve timing out of adjustment.
4. Too narrow spark plug gaps.
5. Ignition not advanced sufficiently due to poorly working timing
advance circuit.
6. Defective ignition coils.
7. Defective pick-up coil.
8. Defective ECU.
9. Clogged fuel hose, resulting in inadequate fuel supply to injector.
10. Defective fuel pump.
11. Defective SAV solenoid.
12. Clogged air cleaner element.
Defective air flow system1. Clogged air cleaner element.
2. Defective throttle valve.
3. Sucking air from throttle body joint.
4. Defective ECU.
Defective control circuit or sensor1. Low fuel pressure.
2. Defective IAT sensor.
3. Defective pick-up coil.
4. Defective IAP sensor.5. Defective ECU.
6. Defective SAV solenoid.
7-1-7 SERVICING INFORMATION
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Complaint Symptom and possible causes
Engine lacks
power.
Defective engine internal / electrical parts1. Loss of tappet clearance.
2. Weakened valve springs.
3. Valve timing out of adjustment.
4. Worn piston rings or cylinders.
5. Poor seating of valves.
6. Fouled spark plugs.
7. Incorrect spark plugs.
8. Clogged injectors.
9. Clogged air cleaner element.
10. Sucking air from throttle valve or vacuum hose.
11. Too much engine oil.
12. Defective fuel pump or ECU.
13. Defective pick-up coil and ignition coils.
Defective control circuit or sensor1. Low fuel pressure.2. Defective IAT sensor.
3. Defective pick-up coil.
4. Defective IAP sensor.
5. Defective ECU.
7. Defective SAV solenoid.
8. Defective GP switch.
Defective engine 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 mixture1. 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 sensor.
Engine overheats.
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Complaint Symptom and possible causes
Dirty or heavy
exhaust smoke.
Slipping clutch.
1. Too much engine oil in the engine.
2. Worn piston rings or cylinders.
3. Worn valve guides.
4. Cylinder wall scored or scuffed.
5. Worn valves stems.
6. Defective stem seals.
7. Worn side rails.
1. Weakened clutch springs.
2. Worn or distorted pressure plates.
3. Distorted clutch plates or pressure plates.
1. Some clutch springs weakened while others are not.
2. Distorted 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.
Dragging clutch.
Transmission willnot shift.
Transmission will
not shift back.
Transmission
jumps out ofgear.
7-4 SERVICING INFORMATION
ELECTRICAL
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ELECTRICAL
Complaint Symptom and possible causes
No sparking or
poor sparking.
1. Defective ignition coils or spark plug caps.
2. Defective spark plugs.
3. Defective pick-up coil.
4. Defective ECU.
5. Defective TO sensor.
6. Open-circuited wiring connections.
1. Mixture too rich.
2. Idling speed set too high.
3. Incorrect gasoline.
4. Dirty element in air cleaner.
5. Spark plugs too cold.
1. Worn piston rings.2. Pistons or cylinders worn.
3. Excessive clearance of valve stems in valve guides.
4. Worn stem oil seal.
1. Spark plugs too hot.
2. The engine overheats.
3. Spark plugs loose.
4. Mixture too lean.
1. Lead wires tend to get shorted or open-circuited or loosely
connected at terminals.
2. Grounded or open-circuited stator coils of magneto.
3. Defective regulator / rectifier.
4. Defective cell plates in the battery.
1. Internal short - circuit in the battery.
2. Resistor element in the regulator / rectifier damaged or defective.
3. Regulator / rectifier poorly grounded.
1 Open or short circuited lead wirse or loose lead connections
Spark plug soon
become fouled
with carbon.
Spark plugbecome fouled
too soon.
Magneto charge,
but charging
rate is below the
specification.
Magneto
overcharges.
Magneto does not
Spark plug
electrodes
overheat or burn.
S
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Special tools Part NumberPart NameDescription
09915-54510
Fuel pump pressure gauge
Measure fuel pressure of fuel pump.
SPECIAL TOOLS
09900-27000
Mode select switch
Inspect FI system sensor.
(Only for )
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SER
SERVICE DATA
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FI SENSORS
ITEM
IAP sensor input voltage
IAP sensor output voltage
IAT sensor voltage
IAT sensor resistance
TO sensor voltage
SAV solenoid voltage
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 switc
4.5 ~ 5.5 V
Refer to page 34 (4-1-25)
4.5 ~ 5.5 V at normal condition(To sensor switch - ON at leaned more
Battery voltage
Battery voltage
4.5 ~ 5.5 V
SPECIFICATION
0 (32)
20 (68)
40 (104)
60 (140)
80 (176)
Approx. 28.788
Approx. 12.209Approx. 5.671
Approx. 2.845
Approx. 1.525
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7-31-1 SERVICING INFORMATION
WIRING DIAGRAM ( )
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WIRING DIAGRAM ( )
TACHOSPEED
FUEL
SPEEDOMETER
O O YBW B YB
WLYLg L
LO O YBW B YB
WLYLg
HANDLESWITCHR
ENGINESTOP
STOP
RUN
LIGHTING
OFF
ON
STARTER
PUSH
OOB O G
rOB
YR
OOB
Gr
YR
OOB
Gr
YR
Ft.TURNSIGNALL
BW
B
BW
B
POSITION
HEADLAMP
W
BW
W
BW
Y
W
BW
Y
O
BW
Ft.TURNSIGNALR
Lg
BW
Lg
BW
SER
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YR
BW
YR
GR
DIODE#3 FUELGAUGE
BW
YB
BW
YB
02SENSOR DIODE#2
O RB
O RB
OBBB
WBR
RRBRAKES/W
OFF
ON
OWB
OWB
FUELPUMP
BBr
BW
MAINRELAY
R B RRB
FUELPUMP
RELAY
HEADLAMP
RELAY
OBW OY
WOB
GW OB
Br
BGW
BBr
BWL
YBW G R
BYRG L Y
B L BY
W OB
YG
OB
BL
Br
Lg
1 2 4 5 6 7 8 9 10 11 1 2 13 1 4 15 1 6 17 1 8 19 2 0 21 22 2
ENGINECONTROLUNIT
7-31-3 SERVICING INFORMATION
WIRING DIAGRAM ( )
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( )
TACHO
DISPLAY
HANDLESWITCHR
ENGINESTOP
STOP
RUN
LIGHT
OFF
ON
Ft.BRA
OFF
ON
STARTER
PUSH
OOB
OOB
Gr
YR
WB
BW G OYB
WW
YBWW R
R BY L Y
B B W Lg
YW O L
WL
LYYB B W L
g O O L BW G O
OOB
Gr
YR
WB
O Gr
OB
YR O
Ft.TURNSIGNALL
POSITION
HEADLAMP
FtTURNSIGNALR
BW
B
W
BW
Lg
BW
Lg
BW
W
BW
Y
W
BW
Y
O
BW
BW
B
SER
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UELGAUGE02SENSOR
DIODE#2
RRBRAKES/W
FUELPUMP MAINRELAYFUELPUMP
RELAY
HEADLAMP
RELAY
OFF
ON
BW
YB O R
B
OWB
BBr
BW R B RR
BGr
BW OY
WBG
WBBr
BW
BW G R
BYRG LY
B L BYW O
BYG
OB
BL
Br
Lg
YL
BYW G
L B GL
BY
BR
WL
GRY G
r
1 2 4 5 7 8 9 10 11 12 1 3 14 1 5 16 1 7 18 1 9 20 2 1 22 2 3 24 2 5 26 2 7 28 2 9 30 3 1 32 3 3 34
ENGINECONTROLUNIT
34P
OB
GW O B
Br
OWB
OBBB
WBR
BW
YB
7-31-5 SERVICING INFORMATION
WIRING DIAGRAM ( )
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TACHO
DISPLAY
HANDLESWITCHR
ENGINESTOP
STOP
RUN
LIGHT
OFF
ON
Ft.BRA
OFF
ON
STARTER
PUSH
OOB O G
rOB
YR O
BW G OYB
WW
YBWW R
R BY L Y
B B W Lg
YW O L
WL
LYYB B W L
g O O LBW G O
OOB
Gr
YR
WB
OOB
Gr
YR
WB
Ft.TURNSIGNALL
BW
B
BW
B
POSITION
HIGHBEAM
LOWBEAM
HEADLAMP
W
BW
W
BW
Y
BW
W
BW
Y
O
BW
FtTURNSIGNALR
Lg
BW
Lg
BW
SER
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UELGAUGE02SENSOR
DIODE#2
BW
YB O R
BOBBB
WBR
BW
YB
RRBRAKES/W
FUELPUMP MAINRELAYFUELPUMP
RELAY
HEADLAMP
RELAY
OFF
ON
OWB
BBr
BW R B RR
BGr
BW OY
WOB
GW OB
Br
OWB
BGW
BBr
BW
BW G R
BYRG L Y
B L BY
W OB
YG
OB
BL
Br
Lg
YL
BY
W GL B G
LBY
BR
WL
GRY G
r
1 2 4 5 7 8 9 10 11 1 2 13 1 4 15 1 6 17 1 8 19 2 0 21 2 2 23 2 4 25 2 6 27 2 8 29 3 0 31 3 2 33 3 4
ENGINECONTROLUNIT
34P
MEMO
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MEMO
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Prepared by
1st Ed. OCT. 2008.
Manual No. 99000-95610
Printed in Korea
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S&T Motors Co., Ltd.
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