lt

Leading the way

@
HHSFg^

SERVICE

GENERAL

|NFORMAT|ON.........

PGM.FI SYSTEM

E
E

AIR INDUCTION SYSTEM

FUEL DELIVERY SYSTEM

E!.ECTRONIC CONTROL SYSTEM

E
E
E
E
E

REAL T|ME MTLEAGE |ND|CATOR (RTM|)

PGH-FI MALFUNCTION DIAGNOSTIC PROCEDURE

M']TTI HALFUNCTION DIAGNOSTIC PROCEDURE

FiI.JEL DELIVERY SYSTEM INSPECTION

FII

AND TESTING

FCTRICAL WIRING DIAGRAMS / COLOUR CODES

TIA!il|TENAN

E SG

EDU LE

ffiRrANr DEFlNtflONS.....*........

,:

.....1..f......
,,..

.\i

l!

,;

TJIIETTO
4T!IIOITTDA

GENERAT INFORMATION
GENERAT SAFEW
ELECTRICAL WIRES

CARBON MONOXIDE
e.rgine must be running to do some work, moke sure the
s rrell ventiloied. Never run the engine in on enclosed

Route

oll electricol

wire/horness

ond cobles.

them owoy {rom shorp edges ond oreo where

pinched beiween moving ports.

1e exhoust contoins poisonous corbon monoxide

gcs thot con couse loss of consciousness ond moy
ecd to deoth.

; - - --5 engine in on open oreo or wiih on exhoust evocuotion

: :-:-

n on enclosed

qreo.

GASOTINE

3:sciine is exiremely flommoble ond is

explosive

::' certoin condiiions.

, ::) CUT OF REACH OF CHILDREN.

--

ii{f(oTco}tPoNENTs

@@
*-

I ^" ond

exhousi system ports become very hot

: - :':-roin hotforsometime o{terthe engine is run.

'"suloted gloves
or woil until the engine ond
system hove cooled be{ore hondling these

"::'
:,-:,s::-:.
eeiNrTEF|lr

Trc@
-- ::-ery gives off explosive eoses: keep sporks,
: -:
:-d cigorettes owoy. Provide odequote
:-- :- -^iorchorging.

they

Keep

might be

GENERAL INFORMATION
GENERALSERVICE RUTES

Cfeoning of ports - Cleon the outside o{ o port or ossembly before removing ii frc- -'e r':-: ':... .' ccering its cover for
service.Did,whichhosoccumulotedontheoutside,moyfoll intotheengineorbrokesys-e-o^!::-s:::-::=.3ieonportswitho
high {losh point solvent ond dry it with compressed oir.
Controlcqbles-Neverbendordistortcontrol cobles.Thiswillleodtostiffopercticrc-::'.*:---::-:

Rubber ports - Bewore of ports conioining O - rings or oil seols, since these 3'e

-'= -'-.

::,:-:

-:s-

of the cleoning

solvents.

Loosening o porl wirh multiple fosteners - Loosening o porl wlth r- 'E : t:s-:-:- :-: inside in o criss-cross pottern, loosening the smoll fosteners iirst. Looseninq -'e . : -':s-:-:- - -:- s'

-':-

the outside to

:--ss ve force on the

smoller {osteners.

:::
:c-:-

be token to nore --e

the engine. This will ensure dimensions (depth, distonce or position) to be

Reossembly Position of crilicol pqrls - Core should

:-:

..

-,.e dismontling

Non - reusqble pqrts - Alwoys reploce goskets, o -rings, oil sec s -:-: lir

-3-sr pins while

-,1

re

ossembling the engine.

Greosingoroilingof portsbeforeossembly-ltisimpo*criioc::

-3tt--i-:f": -:

=-:i=--:.^theengine

ports to ensure better bedding in ond preveniing ropid weor out.

Torque of multiple qnd differenl sized fosteners - Firsr -c-c - ;--:- : -:n?-a-: --:- ': -: -E : : -::-:-e's
bytorqueo{smolleriostenersino criss-crosspofternfrominne.-3:--:--::.:::-.:--:-:- ---::::.:-:,::-s.

{irst followed

Oilseqls-Newoil seolstobeinstolledwithmulti purposeg!'ecserrr.3r --:-E:r r'' -:,- -:T: -:-:,::::',voyscheckthot

:: - : :r- : r: ** :e:

the shoft overwhich the seol fits is smooih ond free of burrs, whic-

Old goskel & seolonls removol - Old gosket ond seolonl

.'.-e'.

:- : - : :E : : *r: ;'*,,',=-

re-ossembly

Rubber Hoses - Fuel orvocuum hoses should be instolled sc --:-:-: : :,:i'T:r-*: in: T::t',t'r-:
oreo for the hose clip io

t'rip the hose beneoth the flo red end of .. e

-:

M*

:-', :- : ersJreodequote

't

GENERAT INFORMATION

MODEL IDENTIFICATION

_.ti ry*=

al:::l:.a:r...;;&

.',3 \E NUMBER

FRAME NUMBER

re

ot

HINIGINE NUMBER

-i :-:

tte

""'E

-e seriol number

:-:-.1:3Se

FRAME NUMBER
is stomped on the lower left side of

The frome seriol number is siomped on the right side of the

steering heod.

I
I

THROTTLE BODY IDENTIFICATION NUMBER

The throttle body identificoiion number is stomped on the front
side oithe throttle body.

GENERAL INFORMATION
PGIA- FI SERVI CE PRECAUTIONS
Soeciol instrumenls qnd Gouges

--:--=s:cr
'r

- Use Speciol Instruments ond gouges wherever opplicoble. Speciol lnstruments ond
PGM-Fl system hove been developed fortesting, meosuring ond diognosis of molfunclion pertoining to PGM-Fl

:-:-

" -.'.-,sensureduringPDlthotthereqrenomqlfunctioncodesstoredintheECU'smemory.
* - * ),s ensure to hove o {ully chorged bottery before storling.
-

servicing ony of the fuel delivery system components olwoys ensure to relieve the fuel pressure be{ore removol.

,:.e'bendortwistthefuel feedhoseondolwoysreploceretoinersonddomperswheneverthe{uel

-I

feedhoseisdisconnected.

remove the fuel feed hose quick connect coupling by hond only.

* , - jcid to prevent

DUST ENTRY.

- : ".:,sensuretotorquethefuel pumpmountingboltsosperspecifiedtorqueinospecificcris-crosspottern.
* - :: :riy recommended Resistortype spork plug.
' - .:,sdischorgethe R.R. Unitbeforestorogeordisposol.
* : . : ' s ensure to colibrote throttle position sensor once ihe sensor unit is removed from the throttle body.
. ,:. -'snop the throttle volve once the throttle body is removed from the vehicle.
" - : -:- ccceleroie while storting.
' -:-:rdotorytomoinioinspecifiedtorqueonoll{ostenersmorkedby"yellowpoint"onceremoved.
- :-:-.^3rs morked by "white poini" should not be tompered strictly.
- :. : s;re oll ECU horness connectors ore {ostened securely.
' :" : -:-- c ll PGM-FI ports ond horness from roug h hond ling ond extreme temperotu re.
- - : -:- sproy high pressure woter directly to ony of the PGM-FI componenis or horness connector. Ensure to oir dry ofter woter
' ::-

ffiCLUSIVE INSTRUMENTS AND GAUGES FOR GTAMOUR PGM.FI

5R,

NO

DESCRIPTION
Doto link connector
truel Pressure Gouge

APPLICATION

PART NO

To reod ond erose molfunction code from the

ECU memory.

O/O HH KIRF OOI

To meosure the fuel pressure in fuel delivery

OZO HH KI-RF OO3

system.

ling

\,4ultimeter Probe, Tip Dio-0.7mm

Sonwo-TL-91M)

To meosu re volto ge, resisto nce, con nectivity.

O7O HH KTRF OO4

=uel Pressure Gouge Adoptor

To connect the pressure gouge in the fuel

delivery system.

O7O HH KIRF OO5

PGM-FI SYSTEM
PGM-Fl (Progrommed Fuel lnieclion)

by its computer system' This {unction

pGM-Fr, iniects the fuer in on oppropriote omount corcuroted
progrommed
rniection,
Fuer
iemperoture' lntoke
The
.o"a''tr"" tn" engine, like engine speed &
ogorai;g-rh;i"r"ring
doto
input
sending
"+
is ossisted by sensors

u-kes, The pGM.F,sys,em nsie.d

pGM-Fl con be dtvlded into 2 moin

il1il*:[:?J"J:o*:1:1lill*l'::;,::llil:[,.Hi[?t'qTi+1il;1":;,,"s,y.]:l
;iJronic {uer iniecf r. The sriucture of
moniford
iniecis pressurised fuer ,"i, in" ,,"r.e
system,'
systems which ore tn"iir"t Derivery

";,;;;;
;;""Er;.*rr"ic Contror iyrt"r'.

o{
The "Erectronic Conirol system' is composed

{uel iniection bv
Sensorswhichsend vorioussignoro{the"ngrnJop"roting.ot'ditionrt"iil"ii".itontcont'otUnit(ECU)which{urthercontrolsthe
o+ tr'rg doro ond conrrols ihe
does
.""ir.r
IECU)
Erectronic
The
engine operorion occordingry.
""'i o{ o {u"r pu*p-iti on intJgroted pressure regulotor which molntoins or
,iu"r Derivery sy.t"J lonrlo
Th"
volume of {uel os per
{uer derivery system.
oni on in1"oo,. *hicriiniects the oppropriote
,ru".,
lJr*"n
+""r
,'n"
i"
i""r
oi**r"
reguroies the required
by ECU'
ihe intoke moni{old which is controlled
the engine operoting .r"J'ii."l'"

;#;;;o

oir entering
Detects the volume ond pressure of

SENSORS

the iniqke moni{old ond the engine operoting

conditions i.e' Engine temperoiure'

iniection
Colculotes ond conirols the oppropriote
volume ond iiming.

ECU

Fuel Delivery SYstem

pressure'
Feeds the engine wiih reguloted {uel

concept
__--r:r:^^- ^. mentioned
-aniinnr in the :cc e g
vorious conditions os
ln pGM-Fl system the sensors detect the
iiming'
*n" f CU colculoies the iniection volume ond

Bosic

Throttle Position Sensor

(TPS)

(EOT)
Engine Oil Temperoture Sensor

To detect engine
To

Monifold Absolute Pressure Sensor (MAP)

To detect

Cronkcose Position Sensor (CPS)

oil re- ce'c--'e

deteci oirtemperc'-'c

ntoke Ai r Tem perotu re Sensor (lAT)

t
cnd the iniection progromme
"e' ce r.,,

oir pressr-;re

- --!(i -:- -' :

- ^-l'': - :- -: :

it

PGM.FI SYSTEM
I

EI.ECTRONIC CONTROL SYSTEM

Electronic Control System is composed of Electronic Control Unit (ECU) ond the Sensors including other equipments. ECU
-::eives elecironic signols from the Sensors ond then controls components such os iniector, fuel pump ond ignition coil.

--e

:
id

OPERATING UNITS

ECU

SENSORS

in

o{

le
by
DT

TPS - Throttle Position Sensor

ET

To

detectthrottle opening ongle.

llAP

Monifold Absolute Pressure

oir pressure.

To detect intoke

Colculotes ond Controls Fuel

iniection volume ond timing.

Controls Fuel Pump

Operotion.

IAT - lntoke Air Temperoture

To deteci intoke oir temperoture.

EOT - Engine Oil Temperoture to

cietect engine oil temperoture.
Controls ignition Timing.

lgnition Coil

CPS - Cronk Position Sensor

-o deiect cronk posilion ond

ln

RPM

Enobles Molfunction
loto

Link Connector

Diognosis

o{ PGM

Fl

System.

:. tion Control Reloy

:co/er Source l2 volis

To supply power for the

functioning of Electronic
Circuits.

PGM-Fl lndicotor

PGM.FI

SYSTEII'I

tNJECT|ONVOtUtUtE
The PGM - Fl system does not control the volume o{ oir entering the intoke monifold but insteod controls the volume o{ fuel to be
iniected forthe oirentering the moni{old to provide on odequote oir{uel mixture in o sloichiomelric roiio.
The Progrommed Fuel lniection works undertwo differentconditions i.e. Low Lood condition ond High Lood condition.

ln cose the Throttle Volve is wide open the PGM - Fl syslem will use the signol from "Throttle Position Sensor" ond the Cronk RPhr
from "Cronk Position Sensor". l{ the Throttle Volve is nol wide open then the PGM - Fl system will use the signol from "Monifold
Absolute Pressure Sensor" ond Cronk RPM from "Cronk Position Sensor".
The PGM - Fl progrom colculotes the quontity o{ fuel to be iniected under oll engine operoting conditions using two supporling
foctors i.e. "Monifold Absoluie Pressure" ond "Throttle Position". Given below ore 3-Dimensionol grophs for the two differen"
conditions.
The two Fuel lniection Progroms ore designed

io enhonce the most oppropriote omount Fuel to be injected for vorious engine

operoting conditions.

A)When ThrollleVqlve is "NOTWIDE OPEN"

The most oppropriole volume o{ fuel to be iniected (occording to engine operoting condilion) is colculoted by the ECU's {ue
injection progrom. The ECU uses the inputs {rom "Moni{old Absolute Pressure Sensor" (MAP) io detect the Air Pressure or the
omount of oir entering ihe lntoke Moni{old ond the Cronkshoft RPM detected by the "Crqnk Position Sensol' (CPS) os doto

ir'

colculoting the iniection volume ond timing.

The 3 - Dimensionol groph given below shows ihe resultqnt fuel inlection when the "Moni{old Absolute Pressure Sensor" is used os
doto during lowloqd.

lnieciion Time

When Throttle Volve is'WIDE OPEN"

The most oppropriote volume o{ {uel to be injected (occording to engine operoling condition) is cqlculoted by the ECU's fue
B)

injection progrom. The ECU uses the inputs o{ opening o{ the ihrottle volve detecied by the "Throttle Position Sensor" (TPS) ond ihe
Cronkshoft RPM deiected by the "Cronk Position Sensor" (CPS) os doio in colculoting the in jection volume ond timing.
The 3 - Dimensionol groph given below shows the resultont fuel in jection when the "Throtile Position" is used os doto during high

lood.

lniection Time

HIGH IOAD

PGM.FI SYSTEM
FUEt INJECTION VOTUME AND TI'I,IING

--e

inputs {rom the below mentioned sensors ore used by the ECU for colculoting the volume of {uel to be iniected in the lntoke

.':nifoid.

SENSOR
M

INPUT SIGNAT

Air Temperoture

The inieciion volume is chonged with

chonge in ombient oir temperoture,
entering ihe throttle body.

i-:ire Oil Temperoiure Sensor

Engine oil temperoture

During cold storting ond during

engine wormup iime, this input to the
ECU is utilised in colculoting ihe
required in jeciion volume.

--'c-ie

Opening ongle of throttle volve.

,ld

--:ke Air Temperoture Sensor

ng

tnl

rcl

DETAITS

Position Sensor

The inieciion volume is chonged wiih

the chonge in the ongle of throttle
volve.

he
in

':^;old

T'ne
-

-:

Absolute Pressure Sensor

Air pressure in the intoke monifold

The inleciion volume is chonged with

ihe chonge in moss o{ oir entering the
intqke monifold.

fuel iniection syslem

:3'v1-Fl system uses the input from Mop sensor to determine the
suction stroke (vocuum in intoke moni{old) ond Cronk Position
- -c detect the posilion of the piston, to
j:
.
colculqte the iniection iiming, in orderto inieci the fuel once in every two rototions of the

. : -,

-.-o{i.
1) Suction Stroke

2) Compression Stroke
3) Power Stroke
4) Exhousi Stroke

uel
frre

I'cnk

Pulse

th
l:-ection of

: - :.essure in

-':<e monifold

AIR INDUCTION SYSTEM

THROTTLE BODY
-: -rrottle Body is composed of o Throttle Volve ond on ldle Adiusting Screw which controls the qmount
of oir enterinq the intoke
- : - 'cld' During idling the throtile volve is in o closed position, engine suction drows the oir in the intoke monifold thro"ugh idle oir
: :::.ge in the throttle body.

-: l.e oir possoge is designed with shorp curves in orderio prevent

deposition from fhe combustion chomber.
--: lle RPM con be odiusted by rototing the idle odiusting screw incorbon
Clockwise direction (Decreose ihe RPM) ond Anticlockwise
-

: -:;.:on(lncreoseRPM),thisconirolstheoirflowthroughtheidleoirpossogetotheintokemqnifold.

--:

Sensor Unit insiolled on the throttle body is compoct design consisiing oithree sensors i.e., Throttle Position Sensor (TPS) to
ihrottle ongle, Monifold Absolute Pressure Sensor (MAP) to detect qir pressure in the intoke moni{old, lntoke Air Temperoture
-:-::' (lAT) to detect oirtemperoture entering the ihrotfle body from oir{ilter.

:.-::-

IDLE ADJUSTING SCREW

THROTTLE BODY

MAP SENSOR

SENSOR
UNIT

IAT SENSOR
TP SENSOR

IDLE ADJUSTING SCREW

_..CTTLE BODY

SENSOR UNIT

ADJUSIING SCREW

THROTTLE VALVE

FUEI DETIVERY SYSTEM

RJEL DELIVERYSYSTEM

--e fuel delivery in PGM-FI

syslem is composed o{ o submerged " Fuel Pump" in the fuel tonk to deliver pressurised fuel, on
--egroted "Pressure Regu lotor" which moinioins o constont pressure in the fuel line, o solenoid type "Fuel lniecto/' to iniect fuel in the
--:ke monifold ond o "Throttle Body" which controls the omount of oir enfering the intoke monifold.
I -e to spoce consiroints in o motorcycle the components used in PGM-Fl {uel delivery system hove been designed smoller in size os
-: - po red to olher conventionol fuel iniection system.
--: suction pod hoving o primoryfuel filierof the fuel pump is instqlled qtthe lowest position of the fuel tonkio preventthe chonging
--: evel while lhe engine is occeleroted orwhile riding on o bumping rood.
--: ,niector is connected with fhe fuel pump with o fuel feed hose.
=-EL TANK

PRESSURE

FUEL PUMP

L_
I

i
I
I

FUEL FEED HOSE

THROTTLE BODY

"-:::=dhosedirectlyiotheinjectorhovingosecondory{ilterottheinletside.

*:

FUEL FILTER

INJECTOR

Fuiel Flow
- ": :- ei is filtered by o primory filter instolled oi the bottom of the fuel pump. The pressurised {uel is delivered through
o connecting

REGUIAIOR

:'essure regulotor mointoins the fuel pressure within the fuel delivery syslem ol 294 kpo (3.0 kgf/cm'). The ECU controls the

::-3'operolion

by

operoting the iniector for o colculoted durotion ot on oppropriqte time os per the engine RPM.

FUEI DELIVERY SYSTEM

Fuel Pump
PGM-FI sysiem hos q submerged type fuel pump instolled in the fuel tonk which is used to pump pressurised fuel to the inie:
fuel ionk. The Fuel Pump Assembly is composed of o Pump Body consisting o{ on Armoture, Vone type Rotor, ond o Chec<
moinioin the fuel pressure in the fuel delivery system when the engine is switched off).
The rotor inside the pump body hos vones on its outer edge ond is driven by the ormoture. When the motor operotes,
oround the outer edge of the rotor ond the pump body will suck the fuel into ihe moior. The fuel is thrown outwords due to cer
force, {lowing through the inner possoge in the pump body. When the pressure generoted by the {uel pump is enough to p-;r
the check volve, the fuel is releosed in to the fuel feed hose to the iniector.
,

-*

DELIVERY

LINE

PUMP COVER

TOR MAGNET

ARMAIURE

DELIVE;.

VANES

ROTOR CASING
CHECK VALVE

I'VIPORTANT

I
I

Although {uel posses through the motor; the interior is completely fllled with fuel ond no oxygen exists. Even if the ve.
runs out o{ fuel, oir connot enter the fuel line becouse it is {illed with petrol fumes, so there is no donger o{ explosion d r:
sporks from the brushes.
The fuel pump connot be disossembled, but m ust be reploced os one unit if de{ective.

Fuel Pump Operotion

I

2)
3)

The Fuel Pump (Armoture) circuit ground is controlled by ECU. The ECU operotes the Fuel Pump for 2 seconds ofterthe igswitch is turhed to "ON" position by grounding the fuel pump for 2 seconds.

The roior connected to the ormoture shofi rofotes olong with the ormoture creoting o suction, due centriiugol force the
tropped in the vones is pressurised ond pushed upwords from the delivery line in the Cosing. The fuel {lows orounc
ormoiure to the Check Volve which is pressed upwords opening o possoge out of the Fuel Pump into the Fuel Feed Hose.
On cronking the engine, ECU receives signol from Crqnk Position Sensor (CPS) ond gives o coniinuous ground to Fuel Poperoting it continuously. The fuel pump stops operoting once ihe engine is switched off ond no signol from CPS is ovoiloc
ECU.

4)

The Check Volve is designed to mointoin the fuel pressure in the fuel line even oftqr the fuel pump stops operoting ond will
the {uel pressu re in the delivery line stoble for o long durotion to enoble next engine sto rting eosy ond quick.
FUEL PUMP

PRESSURISED FUEL

ON

CONDITION

OPEN CHECK VALVE

FUEL PUMP

<

OFF CONDITION

CLOSED CHECK VAL"

FUEI DETIVERY SYSTEM

PRESSURE REGULATOR
rm

[to

--

e Pressure Regulotor is on integrol port of ihe Fuel Pump ossembly. lt is instolled in the fuel delivery line of the fuel pump ossembly.
ottoched io o diophrogm, ond spring. The iuel pressure ot the

--e Pressure Regulotor is composed o{ spring looded boll volve

- :cor is olwoys mointoined 294 kpo (3.0 kg/cm').

es
tol
en

PRESSURE

REGUIATOR
DIAPHRAGM

FUEL

FUEL INJECTOR

FUEL FILTER

Dressu re

Regulotor Operqtion

-: cump delivers o constont {uel pressure into the fuel delivery line upto the fuel iniector, os it is on electricol pump with constont
: t ,' I generotes o pressure o{ opproximotely 600 kpo ot oll times.
-:. the engine is storted the pump storis delivering pressurised fuel into the delivery line, the some pressure is olso exerted on the
:"::sJre reguloior diophrogm. When the engine RPM is low the iniected volume of fuel is low this increoses fuel pressure in lhe

::

ery line, pressing the diophrogm olong with the spring looded boll volve downwords. This creoies spoce ot the iop of the boll
is pushed upwordsfrom its seoi bythe spring, opening o possoge{orthe excessive{uel inthedelivery lineto be releosed
:< nto the {uel tonk.
.

,: which

:^ the RPM is increosed the iniected

uel

volume of {uel increqses, ihis reduces fuel pressure in the delivery line ond olso on the

::^rogm. The diophrogm spring roises the spring looded boll volve ossembly upwords closing the fuel possoge, reducing the

he

-e

of fuel being releosed into the f uel tonk, ihus mointoining the pressure in the {uel delivery line at 294 kpo oi different engine

rP,

:^ the pump

r n*

)ep

is

notoperoiing the soring looded boll volve is pressed upwords bythe diophrogm spring instolled otthe bottom o{
regulotor body presses the boll into the volve seot closing the fuel possoge to

: :'essure regulotor. The upper tip o{ ihe pressure

-:

^-oin fuel pressure in the fuel delivery line even when the pump is not operotionol.

closE PosrTroN

-I

o
o
o
o
o
o

LVE

T]HRAGM SPRING

OPEN POSITION

SPRING

o
o
C
o
C
o
DIAPHRAGM

BALL SEAT

FUEI DETIVERY SYSTEM

FUEL INJECTOR
For fuel iniection PGM-Fl system uses o solenoid type 4- Pon fuel injector instolled on ihe throttle body. The
iniecior receives the
iniection signol from the ECU ond iniecls the fuel_ot on opiimum ongle into the intoke monifold. The in jector is
composed of the
nozzle plote, plunger, solenoid coils, spring ond o {uel stroiner.
The iniection volume of fuel increqse or decreqse depending on the durotion forwhich the plunger is open, qs the
li{i of the plunger

isolwoysthesomeondthefuel pressureinihefuel lineisolsomointqinedotoconsiontpressure

IDLE ADJUSTING

2UUe;olbythepressureregulotlr.

Fuel Stroiner Screen

SCREW

INJECTOR JOINT

Spring

Solenoid Coil

THROTTLE CABLE BRACKET

SENSOR UNIT

Fuel

Plunger
THROTTLE BODY

Nozzle Plote
s

lniector Operqtion
The ECU controls ihe lniector operotion by controlling the circuit ground. The timing ond durotion oi the ground results
in tl.e
iniection timing ond volume.
A direct current supply from the bottery to the ignition switch, through the ignition control reloy is given ot ihe in jector
solenoi:
terminol ond the ground locolion is ot ECU.
As the ECU provides groundlo the solenoid it gets mogneiised qnd pulls the plunger upwords
opening the possoge for the fuel to b:
injected into the intoke monifold.
When the solenoid ground is cut off by the ECU the plunger is pushed forword by the spring tension closing ihe possoge.

INJEC

O-RING

FUEL STRAINER

INJECT

JOINT

ETEGTRON IC CONTROL SYSTEN,I

FO}I.FI POWER SUPPTY CI RCUIT

--

moiorcycle hos 2 power supply circuiis to lhe PGM-Fl system, The bottery in good condition ond with o deod bottery.

Chorged bottery

i-e

bottery is in o good condition, it will supply the powerto the PGM- Fl system os the {irsi power source.

Eectric Current Flow:

- 'ris condition when the ignition switch

is turned to "ON" ond the engine is self or kick storted the power supply from the bottery will
the lgnition Control Reloy ond ihe BonkAngle Sensor, the BonkAngle Sensorfudherenobles o ground of lhe lgnition Control
;e cy. This ollows the flow of current {rom the lgniiion Control reloy lo ECU, lniector; Fuel Pump ond the lgnition coil os illustroted

j':*'lo
:

ow.

COMBINATION
SWITCH

D.C. LOAD

START-MAG
SWITCH

IGNITION. CONTROL
RELAY

le

A.C. LOAD

d
E

ENGINE EARTH

ffi

ETECTRONIC CONTROL SYSTEM

Deqd Bottery
l{the bottery is dischorged or deod, the voltoge of the olternotor during kick slqrt will be ihe second power source.
The regulotor / rectifier hos o copocitor which helps to mqintoin o consistent voltoge supply from the ACG to PGM-Fl sysiem during
kick stort. Though the emergency system con be used, but during riding, o chorged or o good botiery is still recommended becouse
the chonge in lhe engine RPM offects ihe voltoge resulting io ihe poor performonce of lhe electricol equipments'

Electric Gurrenl Flow:

ln this condition when the ignition switch is iurned to "ON" ond kick slorted, the power supply {rom the ACG will flow to the
Regulotor-Recti{ier unit (pulse {orm) ond chorge the copocitor which furlher will provide with o consistent flow o{ volioge to ihe
PGM-Fl system qs illustroted below.

COMBINATION
SWITCH

D.C. LOAD

START-MAG
SWITCH

IGNITION. CONTROL
RELAY

A.C. LOAD

ENGINE EARTH

AC

VOLT r -_

DC VOLT

ELECTRONIC CONTROT SYSTEM

BAN K ANGTE SENSOR/IGNITION CONTROL RETAY

---- i:nkAngleSensorond lgniiion Control Reloyore locoted inside righf motorcyclecoverbehindthe bottery. The BonkAngle
-e-::' is provided to cut-off the electricol supply to PGM-Fl system (ECU, lniector, Fuel Pump, lgnition Coil) in cose the motorcycle
--::.'erorfollsdown.
- ::se o{ o motorcycle with o corburettor, the iets come obove the fuel level ond the {uel supply to engine is cut-off, shutting down
r*-;-s,n, but in PGM-Fl system the ECU coniinues the fuel iniection ond ignition even ofter the moiorcycle turns over ond the
i - : -e will continue to run which con couse furlher iniury to the rider.

--: l:rk
:-":-

-.,.

Angle Sensor is used to cut-off the current supply from lgnition Control Reloy to PGM-FI system to shut down the engine
cn incose the motorcycle turns over or{qlls down. BonkAngle Sensor cuts 'OFF'the supply ot on ongle of 42.5o .

-]ON CONTROL RELAY

KEROSENE

BANK ANGLE SENSOR

sIN

K ANGLE SENSOR/IGN ITION CONTROL RETAY OPERATION

:onk ongle sensor consists o{ o lotch circuit, o reed switch, o pivoted weight {rom the center wiih mognets ot both ends
* -:.sed in kerosene which is used to domp ony vibrotion from the motorcycle or the rood, becouse kerosene olso hos o high

--:

^g point ond it is notvolotile so it con sustoin the exireme ombienttemperoture.

eciricol current{rom the lgnition switch when turned to "On" position, posses {rom the "Lotch Circuit" to the tronsistor bose, this
CN" the tronsistor. The tronsistor gives o ground to lgniiion conirol reloy which builds o mognetic {ield, closing the contoct
--s o{ the switch in the lgnition Control Reloy. The eleciricol current supply then posses {rom the ignition control reloy to PGM-Fl

:---

os shown in

fig

(A).

-::sethemotorcycleturnsoveror{ollsdownthemognetsoneithersideofthepivotedweightinthebonkonglesensorpullsdown
*e ':ed switch. This cuts off the electricol current supply to the tronsistor bose turning it "OFF". This results in breoking the circuii o{
; - - on Control Reloy which leods to turning "OFF " of ihe mognetic field ond opening the contoct points.
: eciricol supply to PGM-FI system is shut down which turns the engine "OFF" os show.n in fig (B).
--= -'cnsistor remoins "OFF" even qfterthe motorcycle is bockto its normol position (porollel to the floor) becouse ihe "Lotch Circuit"
: ' ::'pulled. The "Lotch Circuii" will be releosed only when the ignition switch turned to "OFF" position.

--=

(A) CLOSED CTRCUTT

(B) OPEN CTRCUTT

IGNITION

i::l

SWITCH OPEN

REED SWITCH CLOSED

SWITCH

PGM-FI SYSTEM

ETECTRONIC CONTROL SYSTEM

SENSOR
The word "Sensor" in generol meons on equipmeni used to detect the physicol number or quontity such os pressure/ iemperotue
ongle, speed etc. Sometimes, these equipments ore olso used lo deteci scientific dotq such os ion, gos etc. The mentioned doio

the trqnsformedtoelectricolsignolinordertobeusedproperlyforthenextoperotion.
The PGM-FI system hos odopted this concept for meosuring the oir ond engine oil temperoture, throttle opening ond moni{o
pressure. The resistor A is designed to hove o stoble resistonce volue while B is designed to hqve vorioble resistonce vol
depending on the chonge in the ombient condition. And the chonge in the volioge generoted to both ends of B is considered c
electricol signol.
5 Volis

Cro nk Position Sensor (GPS)

The Cronk Position Sensor gives the importont signol to the ECU to delermine the ignition timing ond rpm. lt is olso used io colcul
the pre determined fuel iniection volume ond fuel cut-off.
This signol is used to judge if the engine is being cronked so thoi ihe ECU con operote the fuel pump permonenily.
When the Rott on the flywheel posses the Cronk Posiiion Sensor it creotes o positive pulse (+) ond negotive pulse (-) signol which
sent to the ECU.
The ECU uses this signol forthe following {unctions

.
.

Colculote the fuel iniection timing.

Colculote the in jection volume bosed on ihe signol from Throttle Posiiion Sensor
Monifold Absolute Pressure Sensor (MAP) foroir pressure in the intoke monifold.

(TPS)

{or the ihrottle volve opening ongle o

The Cronk Position Sensor is instolled on the left crqnkcose cover ond the Rotts ore on the {lywheel.

SITION SENSOR

FLYWHEEL

CRANK

N SENS

ETECTRON IC CONTROT SYSTEM

.THROTTLE POSTTTON SENSOR (TPS)

-- -:Jle Position Sensor

is

(TPS) is locoted in the sensor unit ot the end of the throttle shoft o{ throttle volve, it directly detects the throitle
, :e^ing. The ihrottle shofi ond ihe sensor ore connected vio o spring which meosures the opening ongle of throttle volve. The ECU
::-ec.rs the chonge in position of th roitle vo lve by detecting the chonge in signol voltoge from TP sensor.
-CU colculotes the volume of {uel to be inlecied using the signol{rom TP sensor ond the engine RPM.

--:
id
JE

ECU

IN

TP SENSOR

-- -:*le Position Sensor (TPS) is on integroted port of the Sensor Unil which is locoted on the Throttle Body
SENSO

THROTTLE BODY

hls

rnd

THROTTLE SHAFT

)R

UNIT

il
r|

ETECTRONIC CONTROT SYSTEM

tr/tANlFOID ABSOLUTE PRESSURE SENSOR (MAP)
Monifold Absolute Pressure Sensor (MAP) meosures lhe oir pressure in the intoke monifold. The MAP sensor meosures this c r
pressure by detecting the vocuum in the lntoke Monifold. Moreover, it is olso used to meosure the position of the piston by deteciir'g
negolive pressure in the lntoke Moni{old.
MAP sensor meosures the oir pressure in the lntqke Moni{old by detecting the chonge in resistonce of the semi-conductor, ther
trons{orms this dotq lo qn electricol signol ond sends ii os on input to the ECU.
The ECU colculotes the volume o{{uelto be iniected using the signol{rom MAP sensorqnd the engine RPM.

':lI
rI
ril

l!
li

Moni{old Absolute Pressure Sensor (MAP)

is

on integroted port of the Sensor Unit which is locoted on ihe Throttle Body

u+
OI
lt

ol

LOW <--------------)
O-RING

MAP SENSOR

HIGH

ri'

ETECTRONIC CONTROT SYSTEM

s$GtNE Ott TEilIPERATURE SENSOR (EOT)
^e Oil Temperoture Sensor is used to meqsu_re the engine oil temperoture.
lt detects the chonge o{ the engine oil
q -:e-:-- re by meosu ring the
chonge in the resisto nce o{ the thermistor, then it tro nsforms this doto io on
electricol signol ond sends
' ::: t- -cUitothe ECU

-'* l-;
-

": : I '

't-

:olcu loies the volume o{ fuel to be iniected using ihe signol from EOT sensor
os the engine
temperoture chonges, which
J

:-seriiol during "Cold Siorting" ond olso during "Engine Worm_up"

period.

ECU

--::-aine Oil

Temperoture

is locoted in the cylinder, in

*i -:-,rn possoge of engineSensor
oil io sense the engine operoiing

**::'gture.

ENGINE OIL TEMPERATURE SENSOR

.'

25

-lz
UJ

UZU

s15

rt-)

frr0

e.

20 40 60 80 too 120
TEMPERATURE OC

is

ELECTRONIC CONTROT SYSTEM

INTAKE AtR TEI PERATURE SENSOR (rAT)
The lnioke Air Temperoture Sensor is used to detect the oir temperoture in the intqke monifold. The sensor deiecis the chonge in
temperoture in the intoke moni{old by meosuring the chonge of the resistonce of the thermistor, then it tronsforms this doto to
electricolsignolond sends itos on inputtothe ECU.
When the temperoture of the intoke oirfolls, the oir becomes denser. Therefore, even ihrough there is no chonge in the volume,
oir is heovier so oir-fuel rotio will increose. conversely, os the oirtemperoiure rises, the oir exponds so olthough the volume is r
some, the oir becomes lighter in weighl ond qir-fuel rotio decreoses.
The ECU colculotes the volume of fuel to be iniected using the signol from IAT sensor bosed on chonge in temperoture of oir in r
intoke moni{old.
The thermistor resistonce will increose when the iemperoture drops. Even o smoll chonge in temperoture will be detected by r
thermistor.

Intoke Air temperoture Sensor (lAT) is on integroted porf of the

Sensor Unit which is locoted on the Throftle Body..

INTAKE AIR TEMPERATUR SENSOR

30

't5

LIJ

220
(/)
U)
LIJ

dlo

\
15

\
\

20 40 60
TEMPERATURE

B0 r00 r20

ELECTRON IC CONTROT SYSTEM

FU rLY TRANSTSTORTSED

tGN ITION SYSTEM (FTt)

- I petrol engine, the combustion of qir/fuel mixture

::r:mum performonce ond minimol emission.

is

initioted by on electricol spork. Accuroie ond relioble ignition

is

essentiol for

-e spork, needed io igniie the oir /fuel mixture in the combustion chomber, is generoted by opplying o high voltoge to
: :Jrodes of o spork plug. The voltoge required to generote o suitoble spork depends on the compression rotio of ihe engine,

-: rty, rotio o{the oir/fuel mixture ond lhe spork plug construction.
- -ero Hondo two wheelers the CDI igniiion systems wos being used till now. With

the
the

:::cied

::'

the introduction PGM-Fl system we hove

the lotesttechnology in the ignition system i.e. FullyTronsistorised lgnition System.

:omplete combustion o{ oir-fuel mixture o longer durqiion of spork is required which enhonces the fuel efficiency ond lowers
emissions. As compored to CDI ignition which hos o shori spork durotion, tronsistorised igniiion system provides o longer

:r-:,rst

:,:,:'< durotion which improves combustion ond reduces exhoust emissions.

-:-

ytronsisiorisedignitionsystem,thelronsistorconbecomporedwithonelectricolreloywhichusessmoll
currenttostoporstort
hos three terminols, two o{ which corry the moin current with the third

l-::ow of o lorger current. Like the reloy the trqnsistor

:': ''Cing o "triggering" oction.

--= emiiter ond collector of the tronsistor ore in series with the primory winding of the high tension coil. The bose corries only o very

:-:

currenl obout 1 omp.

@FERATION

,-:"
* :,
"

"'

the ignition switch is turn io "ON" position, ihe current flows to the primory winding of ignition coil ond then gets ground
gh the tronsislor of the igniiion circuit in ECU.

-er the engine

::-:

: ":,

is cronked the voltoge signol from Cronk Posiiion Sensor is sent io the pulse inlet circuit which {urther sends
tothelogiccircuit.Thelogiccircuitcqlculqtestheigniiiontimingondcutsoffthebosecurrenttothetronsistorbreokingthe

r o{

primory winding of ignition coil. This induces high voltoge in the secondory winding which is sent to lhe spork plug.

LOGIC

I
il

CIRCUIT

PRIMARY CURRENT
BASE CURRENT

FLWVHEEL
BATTFRY

T
+
:t:

CRANK POSITION
SENSOR

PULSE INLET CIRCUIT

SECONDARY
CURRENT

REATTTME MTLEAGE tND|CATOR (RTM|)

REAL

Tln

E MTTEAGE |ND|CATOR (RTMI)

RTMI is o unique {eoture which hos been provided in Glomour PGM-FI. li indicotes the riderwith o reoltime mileoge on o digitol

-CD in km/lwhile riding the motorcycle.

RTMI colculotes ond disploys the mileoge bosed on the input signol received from Speed Sensor for the distonce troveled ond ECU
:cr the iniecied fuel volume of
o specific durotion of time.
-'re RTMI hos been progrommed to disploy the mileoge when speed of the motorcycle is equol to or more thon 5 km/hr ond wiih o
:cto of the post 20 seconds, therefore the first indicotion will be disployed ofter 20 seconds.
-:e next ond the subsequent disploys will be refreshed ofter every l0 seconds with q doto o{ the post 20 sec, which meons every
:dicotion will hove o doto of current I 0 seconds ond I O seconds of previous doto. The {ollowing illustrotion given below shows the
::t-tern in which RTMI indicotes the mileoge.

ECU

@ffi
REAI TIME MITEAGE
INDICATOR

SPEED SENSOR

affi
I

l0seconds ll0r"conds

l0seconds I lOseconds

5 km/hr

No lndicotion

lndicotion

*-: ,ndicotion
-:

given by RTMI when ignition swiich is turned to "ON" will be 188.8 " for o few seconds ond then disploy shows
_ " thot is no volue.
-"e rider storts to ride, the indicotion on the disploy will be shown ond refreshed ofter every 1O seconds.

..,] DISPLAY
DURING IGNITION "ON"

RTMI

RTMI DISPIAY AFTER 2 SECONDS IGNITION

"ON"

PGM-FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI SYSTEM DIAGRAM

IO

TURN SIGNAL LIGHT

BRAKE

LIGHI HORN

(2)

(3)

lgnition switch
Moin fuse (Kick Storf : I 5 A, Self Stort : 20 A)
Sub fuse (1 0 A)

Bottery

Regu

0)
l)

lotor/Rectifier

(12) lgnition Coil

(.l3) lntoke oir temperoture sensor (lAT sensor)
(.l4) Throttle position sensor (TP sensor)
(.l5) Monifold obsolute pressure sensor (MAP sensor)
(l

6)

Fuel meter

(17)

PGM-Fllndicotor
Neutrol position indicotor

(l
(l

Bonk ongle sensor

(20)
(21)

Doto Link Connector (DLC)

Fuel pump

B)
9)

lniector
Spork plus
Neutrol position switch
lgnition pulse generqtor
Engine oil temperoture sensor (EOT sensor)
Alternote current generotor (ACG )

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI SYSTEM MATFU NCTION DIAGNOSIS

DATA LINK

PGM-FI INDICATOR

CONNECTOR

DtC SHORT CONNECTC

PGM-Fllndicotor
The PGM-FI indicotor is o port o{ the molfunction diognostic system which helps in diognosis of o porticulor molfunction
system.

When the ignition switch is turned to "ON" the PGM-Fl indicqtor will illuminqte {or few seconds ond then it will go "OFF". l{ there
ony obnormolity then the PGM-Fl indicotorwill stort blinking.
l{ the PGM-Fl indicotor "BLINKS" or remoins "ON" other thon while the lgnition switch is turned to "ON" position, this indicotes
mol{unction reloted to the PGM-Fl system like o short or on open circuit.
ln cose ony molfunction occurswhile riding the motorcyclethe indicotorwill remoin "ON" continuouslyond the blink pottern w
only resume when either ihe engine RPM is lowerthon 2000 or if the ignition switch is in "ON" position.
The ECU records the molfunction {ound in {orm of o defect code in its memory. This molfunction code is stored In the ECU's mem
even when ihere is no electricol supply to it ond will remoin unchonged until the some is deleted using the molfunction code erosi
proced u re.

The PGM-Fl system is composed of the fqil-sofe function so thoi the engine cqn continuously work efficiently despite ony probl
within ihe sysiem using ihe dqto reserved in odvonce by the progrom. However, the engine will not run i{ ony problem occurs ot l
Fuel

jector or Cro nk Position Sensor.

To reod mol{unction codes from the ECU's memory o Doto Link Connector (DLC) hos been provided in the wiring horness.
shorting DLC with o speciol connector (DLC Short Connector) the ECU indicotes the molfunction code with PGM-Fl indicotor bli
from 0 to l2 times. The blinking is clossified in two types, long blinking (up to l .3 seconds) ond short blinking (0.3 second). Eoc
long blink indicotes "I O" eoch short blink indicotes ".l". As the ECU stores the doto o{ vorious defect codes, the PGM-Fl indic
will show these molfunction codes olwoys in on oscending order. The {ollowing poges will help us to diognosis ond correct

molfunction relqted to PGM-Fl sysiem.

PGM-FI INDICATOR

Molfunction

3.0

0.3
--| t-

rroNrr

code 7
,'OFF''

rroNrr

Molfunction code

l2

"OFF"

&
@

T
\J

'l'3,
<______r

---l

ii

i<--

0.5

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI MALFUNCTION
DIAGNOSTIC PROCEDURE

: ::e the motorcycle on its mo insto nd.

.

-.)TE:

en the ignition switch is iurned "ON" the PGM-Fl indiccitor

.
luminote forfew seconds ond then itwill go'OFF". l{there
: ^,i o bnormo lity then the PGM-Fl indicotor will blin k.

-- -^ ihe ignition switch to 'ON".

-:
-

PGM-Fl indicoior blinks, note the no. o{ blinks o{ PGM-Fl

: :oiorond deierminethe cquse of the problem.

-: PGM-Fl indicotordoes not blink, the system is normol.

PGM-FI INDICATOR
DATA LINK CONNECTOR

- ,:.r wish to reod the PGM - Fl memory for molfunction doto,

::-orm thefollowing:
fu{ALFUNCTION CODE READING PROCEDURE
-- -- the ignition switch to "OFF'.

::-ove

the left side cover.

::cnnect the connector cover from ihe doto link connector

_:)

CONNECTOR COVER

-:^rect the speciol

_

instrument

to the doto link connector

_:)

INSTRUMENT:
DLC

shorl conneclor: 070 HH KTRF OOf

DLC SHORT CONNECTOR

-- ''r the ignition switch to "ON".

j -ne
ECU hos no molfunciion doto, in the memory, PGM-Fl
- jicotorwill illuminote continuously.
.:

ba_ lGNlTloN swlTCH TO "ON"

--------1,/
ON
PGM-FI

&a

gtr

,'OFF"

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

the ECU hos ony Mol{unction doto in iis memory the PGM-FI
indicotor will stor"t blinking when you turn the ignition switch to
l{

,,oNu.

Note the number

of

PGM-FI indicotor blinks ond determine

the cquse of the problem.

MATFUNCTION CODE ERASING PROCEDURE

DATA LINK CONNECTOR

NOTE:
The molfunciion doto connot be erosed from the memory if you
disconnecithe bottery negoiive coble.

.l

2.

Turn the ignition switch to "OFF"..

Remove the left side cover.

Disconnect

the connector cover {rom the doto

link

connector (DLC).

DLC CONNECTOR CC

3. Connect the speciol instrument to the dotq link connector

(DLC).

INSTRUMENT:
DLG

shofi conneclor: 070 HH

KTRF OOI

DLC SHORT CONNEC-

4.
5.
6.

Turn the igniiion switch to "ON".

Disconnect the DLC shorl connector {rom the doto link

connector (DLC).
Re-connect the DLC short connector to the doto link
connector (DLC) within 5 seconds while the PGM-FI
indicotor lomp illuminotes.

DLC SHORT CONNECTOR

DLC SHORT CONNEC_

PGTI,I.

I N,IAIFU

N CTI O

N D IAG N OSTI C PROCE D U RE

SUCCESSFUT PATTERN
The mol{unciion doto is erosed from the ECU memory i{ the
PGM-Fl indicotorturns I'OFF" {or oboul 2-3 seconds ond storts
clinking continuously os shown below (successful pottern).

\______Y____,

FAILURE PATTERN

SUCCESSFUL PATTERN

RESET RECEIVING PATTERN

UNSUCCESSFUT PATTERN
jthe
DLC short connector is not reconnected within 5 seconds,
.re PGM-FI indicotor turns "OFF" {or obout 2-3 seconds ond
will illuminote continuously os shown below

-en it

r "rsuccessf u I

pottern).

within 5 sec.

2-3

sec

roNil
PGM.FI

"oFF"

----------

\-___-______-__
FAILURE PATTERN

re molfunction dqto in ECU memory is nol erosed

-e ignition switch "OFF" ond try ogoin from step-3.

RESET RECEIVI

then turn

. 1TC.

'*ote thoi the mollunction doto connot be erosed from the

*emory if you turn "OFF" the ignition switch before the PGM-

: indicotor storts blinking.

NG

__,

PATTERN

SUCCESSFUL PATTERN

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI MATFUNCTION CODE INDEX
The PGM-Fl indicotor denotes the foilure codes (the number of blinks from 0 to 1 2). The pGM-Fl indicotor
hos two types of blinks,
long blink ond o shori blink. The long blink losts for 1 .3 seconds, the short blinks iosts for 0.3 seconds.
When one'long blink or
two short blinks occur, the problem code is 12 (one long blink
I O blinks, two shori blink
2 blinks). Then go to th" f,"lo* gi*
code i ndex o nd refer the fol lowi ng poges for detoils.
When the Electronic Control Unit (ECU) stores more thon foilure codes, ihe PGM-FI indicotor shows the {oilure
codes in the ord
from the lowest number to highesi number. For exomple, when the PGM-Fl indicoior blinks once, then blinks seven times,
trr
foilure hove occurred. Follow the code indexforfoilure codes I ondT .
Given belowisihe PGM-Flindicotorcode index. Refertothe{ollowing poges{ordetoils.

PG'I,I.FI

Delection ltem

No blinks

lgniiion pulse Generotor

No blinks

Molfunction
lniector molfunction

No blinks

ECU molfunction

Foulty ECU

Engine does not sior.t

No bhnks

ECU power/ground
circuit Molfunction

Blown moin-fuse (15 A)

Engine does noi storl

PGM-Fl circuit

No blinks

Conlinuous Doto link or PGM-FI

illuminotion circuit molfunction

Cquses

Symploms

Foulty ignition pulse generotor.

. Clogged iniector filier.

. Sticking iniector needle.

Fouliy ECU Mol{unction.

. Open or shod circuit in PGM-FI lndicolor wire

. Short circuii in doto link connector.
(DLC)wire.
. Short circuit in PGM-Fl lndicotor wire.

. Short circuit in sensor unil power wire

Sensor unit power circuit

l,8oll

. Foulty sensor unit.

. Open circuit in sensor unit power wire

Blinks

Molfunction
Sensor unit power circuit
Molfunction

1,8,9 oll

Sensor unit ground

Blinks

circuit Molfunction

. Open or short circuit in sensor unit ground wire.

. Foulty sensor unit.

MAP sensor

Blink

r Loose or poor contocl on sensor connector.

circuit molfunction

.
7 Blinks

't,, , ;. p-' t i
..\-_-_**,circuit moltunction
EOT sensor

Loose or poor coniqct on sensor conneclor.

TP sensor circuil

molfunction

Blinks

IAT sensor circuit

mol{unction

Engine operotes
normolly

Engine does not stort

43

Engine does not slort

43

Engine does not slort

43
Engine operotes
normolly

45

Loor" or poor contoct on EOT

Hord siort ot o low

temperoture

46

Poor engine response

ond performonce

49

sensor connector.

sensor wire.

. Loose or poor contoct on sensor unit connector.

. Open or short circuit in TP sensor wire of the
sensor unit.

Engine operotes
normolly

Loose or poor contoct on sensor

unit connector.
Open or short circuii in MAP
sensor wire of the sensor unit.

. Open or shod circuit in EOT

. Foul! EOT sensor.
B Blinks

41

Foulty ECU.

No Blinks

Engine does not stort

Engine does not stort

. Open circuit ot ihe power input wire of the ECU.

. Foulty ignifion switch

Refer lr

. Foulty TP sensor.
. Loose or poor contoct on sensor unit connector.
. Open or short circuii in IAT sensor wire of the

when operoting
the throttle quickly.
Engine operotes
normolly.

50

sensor unit.
Foulty IAT sensor.

l2
i

Blinks

niector circuit mo l{unction

.
. Loose or poor contqct on in jector connector.
. Open or short circuit in iniector wire
. Foulty iniector.

tAi

Engine does not siort.

5t

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

ELECTRONTC CONTROL

UNIT (ECU) - INPUTS AND OUTPUTS

@@@@@@@@@@@
@@@@@@@@@@@
@@@@@@@@@@@
COTOUR CODE

ECU PIN

PIN NO.

COLOUR

R/B

DESCRIPTION

Block

ECU Power

Yellow

Loqic Ground

Blue

None
4
t

G/O
IG/B

Y/R

BR/W

P/L

LN

None

Brown

BR

Fuel Pump Driver

Oronge

Ground
Ground
lqnition Pulse Driver
Cronk Sensor lnpul
None

Sky Blue

SB

Liqht Green

LG

ntoke Air Temperotu re I npul

GR/L
L/R

Service Check Sionol lnput

P/G

lniector Driver

GR/B

20
21

22

23
24

Y/L

None
Wornino Liqht Outout
Fuel Counter Outpul
None
None
None
Pulse Ground
Engine Oil Temperoiure Sensor lnput

25

None

26

None

27

28
29
30
3r
32

LGN
G/R
Y/B

White

Red

Throttle Position Sensor lnout

VCC Output (For Sensod

Green

Sensor Grou nd

Monifold Absolute Pressure lnpui

None
Neutrol Switch lnput
Communicotion
None
None
None

- Line

Pink

Groy

GR

COMBINATION:
Bose Colour

e.g. Brown

BR/W

/ Morking Colour

White

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

ECU POWER/GROUND INSPECTION

.
.

This vehicle hos two types of power supply to operote the ECU'
l{ the bottery is in proper-working condition, it is used os the first power supply'
generoted bythe kickstorter is used osthesecond powersupply'
lf the bottery is not in proper-worklig condition,the olternotorvoltoge

lf the

does not stort wit[ the kickstorter, inspect the ECU POWER/GROUND {irst, then inspeci the oliernotor

"ngin"
regulotor/recti{ier os the secondory power supply

B"jor"inspectingtheECUPOWER/GROUNDlNSPECT|ON,besuretochorgeorreploce

withochorgedbottery.

ENGINEDoEsNoTSTART(PGM.FIINDICAToRDoESNoTBLINK)

. Turn ignition switch "OFF".

2. Disconnecl the ECU 33P connector.
I

Check {or loose or

poor connection on the ECU 33P connector'

ECU 33P CONNECTOR

Connect ECU 33P Connector. Stqd the engine. lf the

engine storts there hos been o loose or poorcontoct on the
ECU 33P Connector.

ECU 33P CONNECTOR

4.

5.

I
I

lf the engine does not stort then turn ignition swiich to

,,OFF".

the ECU 33P Connector. Check {or

the
continuity between ECU 33P connector o{ the wire horness
side ond ground.

Disconneci

GONNETION:
Green (ECU Pin-2) - Ground
Green (ECU Pin-9) - Ground
Green (ECU Pin-l0) - Ground
STANDARD: Gontinuity
lf there is no continuity, check the Green wire {or

open circuit'

oooooooo
oooooooo
oooooooo

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

6.

Turn the ignition switch to "ON" ond meosure the bottery

voltoge between the ECU 33P connector of ihe wire

horness side ond ground.

CONNECTION:
Red-Blqck (ECU Pin-l ) - Ground (-)
STANDARD: BotleryVoltoge - l.l Vminimum
lf

.
.

the bottery volioge is out o{ ronge checkforthe following.

Loose or poorconneclorcontoct

lnspectthe ignition switch.

Blown moin-fuse (Kick Stort : 1 5A, Self Stort : 20 A)

Open or short circuit in following wire horness:

Red wire

or RedAellow wlre belween the botfery ond

ignition switch

Red/Block wire between the ignition control reloy switch

ond ECU.

Red/Blue wire between ignition switch ond ignition

control reloy.

l{ volioge exists then reploce the ECU with o new one ond
inspecl it ogoin.

ECU 33P CONNECTOR

lr
I
h.

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

SENSOR UNIT POWER/GROUND

CIRCUIT INSPECTION

PGM-FI 1,

8 or 9 BIINKS (MAB TB IAT

SENSOR)
NOTE:
Before storting the inspeciion, recheck the PGM-FI indicotor
blinklng. lf the PGM-Fl indicotor does not blink, the sysiem is
normql.

1
2.
t

3.

Turn the ignition switch to "OFF".

Discon nect the sensor

un

it 5

SENSOR UNIT 5P CON

con nector.

Disconnect ECU 33P connector. Check for loose or poor

conioct on the sensor unit 5P connector ond ECU 33P
connector.

ECU 33P CONNECTOR

4.

Connect the sensor unit 5P connector.

SENSOR UNIT 5P CON

Connect ECU 33P connector. Turn the ignition switch to

"ON". Checkthe PGM-Fl indicqtor blinks.
6.

there is no blink in PGM-Fl indicotorthen check{or loose

or poor contoci on the sensor unit 5P connector ond /or
ECU 33P connector.

7.

l{there is 1,8,9 bllnks in PGM-Fl indicotorihen turn the

ignition switch to OFF.

lf

ECU 33P CONNECTOR

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

Disconnectthe sensor unit 5P connector.
Turn the ignition switch to ON.

B.

9.

r0 Meosure the voltoge between the sensor unit 5P connector

terminols otthe wire horness side.

CONNECTION:

Green/Oronge(-)
STANDARD 24.75 - 5.25V

Yel

loVRed

+ )-

exists then reploce ihe sensor unit wiih o new one

ond inspect ogoin.

I i . lf voltoge

SENSOR UNIT 5P CONNECTOR

I

2. lf voitoge is out o{ ronge then disconnect the ECU 33P

connector ond check {or continuity beiween the ECU 33P
connector ond sensor unit 5P connector of wire horness
side.

CONNECTION:
YelloVRed (Pin 6, ECU) -YelloVRed
Green/Orqnge (Pin 4, ECU) - Green/Oronge
STANDARD: Conlinuity

ooooooooooo
ooooooooooo
ooooooooooo

ECU 33P CONNECTOR

L,._-.-'-'

CONNECTION:

YelloVRed - Ground
STANDARD : No Continuity
LJ

lf

.
.
l4

there is ony obnormolity, this con be due to

Open circuit in Yellow/Red or Green/Oronge wire.

Shod circuit in Yellow/Red wir-e.

l{ oii obove connections ore normcl ihen repicrce the ECU

with o new one ond inspect cgcin.

SENSOR UNIT 5P CONNECTOR

F;'

*r,

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

PGM- FI TROU BTESHOOTI NG
PGM-F|

BLINK (MAP SENSOR)

NOTE:
Before siorling the inspeciion, recheck the PGM-FI indicotor
blinking. lf the PGM-Fl indicotor does not blink, the system is
normol.

.
2.
1

l:

Erose the molfunction code {rom ECU memory. Turn the

ignition switch to "ON".

Turn the ignition switch to "OFF".

3. Checkthe PGM-Fl indicotorblinks.

4. lf there ore 1, B ond 9 blinks go to SENSOR

UNIT

POWER/GROUND CIRCUIT INSPECTION.

5.
6
7.

lf

there is

blinkthen turn the ignition switch to "OFF".

Disconnectthe sensor unit 5P connector.

the ignition switch to "ON" ond meosure the voltoge
between the sensor unit 5P connector of wire hqrness side

T.urn

ond ground.

CONNECTION:

LightgreenA'/ellow(+)

Ground (-)

STANDARD: 3.8 - 5.25V

B.
9.
I

lf volioge exists then reploce the sensor unit with o new one
ond inspect ogoin (foulty MAP sensor).
lf volioge is out of ronge then turn the igniiion switch to
"oFF".

0. Disconnectthe

ECU 33P connector.

I I . Check for continuity between the ECU 33P connector ond

sensor unit 5P connector of the wire horness side ond
ground.

Check

UNIT 5P CONNECTOR

for no continuity between the sensor unit

5P

ooooooooooo
o o oooo ooooo
ooooooooooo

connecior of ihe wire horness side ond g round.

GONNECTION:

lighr greenffellow (ECU

green/Yellow
STANDARD: Continuity

Pin - 2tl - Lighr

ECU 33P CONNECTOR

ONNEGTION:
Light green/fellow - Ground
STANDARD : No continuity
I

2.

lf

.
.

there is ony obnormolity, this con be due to :

Open circuit in Yellow/Red or Green/Oronge wire.
Short circuit in Yellow/Red wire

13. lf oll obove connections ore normol then reploce the

wiih o new one ond inspect ogoin.

ECU

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

EOT SENSOR 2P CONNECTOR

PGM-FI 7 BTTNKS (EOT SENSOR)

NOTE:
Before storting the inspection, recheck the PGM-FI indicotor
blinklng. lf the PGM-Fl indicotor does not blink, the system is
normol.

Turn the igniiion switch to "OFF".

2.
3.

Disconnectthe EOTsensor2P connector.

Check for loose or poor contoci on the EOT sensor 2P
connector.

EOT SENSOR 2P CONNECTOR

4.

Connect the EOT sensor 2P connector ond turn ihe

ignition switch to "ON". Check the PGM-Fl indicotor
blinks.

5.

l{ there is no blink in the PGM-Fl indicotor then check for

loose or poorcontoct in ihe EOT sensor2P connector.

lf there ore 7 blinks in the PGM-Fl indicotor then iurn the

ignition switch to "OFF".

EOT SENSOR 2P CONNECTOR

7

Disconnect the EOT sensor 2P connector ond meosure the

resistonce of the EOT sensorterminols.

STANDARD
l{there

is

:2.5- 2.8 kc)

(20"C/68oF)

ony obnormolity then inspect the EOT sensor.

r
t

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

EOT SENSOR

EOT (ENGTNE OtL TEMPERATURE) SENSOR

REMOVAL

B.

Disconnect the EOT sensor 2P connector from the sensor.

Remove the EOT sensor ond seoling wosher.

NOTE:

INSPECTION

EOT SENSOR 2P CONNECTOR

NOTE:
Keep oll ilommoble moieriols owoy from the electric heoting

element.

9.

o pon of pure coolont ond

distilled woter (50-50 mixture) on on electric heoting
element ond meosure the resisionce ot the EOT sensor
Suspend the EOT sensor in

terminols os the coolont heots up.

NOTE:

Sook the EOT sensor in cooloni up io its threods with ot

leost 40 mm (1 .57 in) from the bottom of the pon to the
botfom of the sensor.

Keep the iemperoture constont for 3 minutes before

testing. A sudden chonge of temperoture will result in
incorrect reoding. Do not let the thermometer or EOT
sensoriouch the pon.
Meosure the resistonce ot the EOT sensor ierminols os

'

shown.

20"c (68"F)
2.5 -2.BkO

TEMPERATURE
RESISTANCE

.l0.

100"c (212F)
0.21

-0.22ko

lf ihe resistonce is out of specificotion ot ony temperoture

listed, reploce the EOT sensor.
EOT SENSOR
SEALING

INSTATTATION
NOTE:

WASHER

EOT SENSOR

Alwoys reploce o seoling wqsherwith o new one

lnsioll the new seoling wosher qnd EOT sensor. Tighten the
EOT sensorto the speci{ied torque.

TORQUE:1.8kg-m
Conned the EOT sensor

2P

connecior.

EOI SENSOR 2P CONNECTOR

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

12.

l{ the resistonce is normol then check for

continuity

between the EOT sensorterminol ond ground.

STANDARD : No

continuity

there is ony obnormolity it meons foulty EOT sensor. Reploce

EOT sensor ond inspect ogoin.
l{

EOT SENSOR

-l3.

EOT SENSOR 2P CONNECTOR

l{ oll obove connections ore normol then meosure the

voltoge between the EOT sensor connector qt the wire
horness side.

CONNECTION

: YelloVBlue - Green/Orqnge

STANDARD 24.75 - 5.25V

14. l{voltogeisoutof ronge.Thiscon bedueto

.
.

Open circuit in Green/Oronge

:'i) : "

wire.

I 5. l{ voltoge exist then turn ihe ignition swiich to

- :..1r i
O

LooseorpoorcontociontheECUconnector.

"95t".

EOT SENSOR 2P CONNECTOR

I

6. Disconnect the ECU 33P connector ond check for

continuity between the ECU 33P connector ond EOT
sensor

2P

connecior of ihe wire horness side.

Check for no continuity beiween the

EOT sensor 2P

connectoroithe wire horness side ond ground.

CONNECTION:
Green /Oronge (EU Pin-4) - Green/Oronge
STANDARD: Continuily

CONNETION:

YelloVBlue

(ECU Pin-241 -

ECU 33P CONNECTOR

EOT SENSOR 2P CONNECTOR

YelloVBlue

STANDARD: Continuity
CONNEGTION:

Green/Orqnge - Ground
YelloVBlue - Ground
STANDARD : No continuity
I 7. lf there

.
.

is

ony obnormolity, the following con be due to

OpenorshortcircuitinYellow/Bluewire.

OpenorshortcircuitinGreen/Orongewire

li oll obove connections ore normol then reploce the ECU with
o new one ond inspect ogoin.
ECU 33P CONNECTOR

\{

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

PGM-FI 8 BTTNKS (TP SENSOR)
NOTE:
Before siorting the inspeciion, recheck the PGM-FI indicotor
blinking. lf the PGM-Fl indicotor does not blink, the system is
normol.
I

2.

Turn the igniiion switch to "OFF".

Erose

the mol{unction code from

Turn the ignilion switch

memory.

to "ON". Check ihe

PGM-FI

indicotor blinks.

lf there ore 1,8,9 or oll blinks then go to SENSOR UNIT

SENSOR UNIT 5P CONNECT

POWER/GROUN D CI RCU IT I NSPECTION.

3. lf there ore B blinks then

turn ihe ignition switch io

"oFF".

4.

Disconnect the sensor unit 5P connector. Turn the ignition

switch

to "ON". Meosure the voltoge

between the sensor

unit 5 P connector ot the wire horness side ond

round.

CONNECTION:Yellow/Red (+) - Ground (-)

STANDARDz4.75 - 5.25V
lf voltoge exist then reploce ihe sensor unit with o new one

ond inspect ogoin (Foulty TP sensor). lf voltoge is out o{

SENSOR UNtT 5P CONNECTOR

ronge then turn the ignition switch to "OFF".

6.

Disconnect the ECU 33P connector. Check for continuity

between the ECU 33P connector ond sensor unit 5P

connecior of the wire horness side.

Check {or no continuity between lhe sensor unit 5P

connectorotthe wire horness side ond ground.
CONNECTION : Light Green/Block (ECU ptN-s)-

Lighr Green/Blqck
STANDARD: Continuity
ECU 33P CONNECTOR

CONNECTION : lighr Green/Block

STANDARD : No continuity

- Ground

lf there is ony obnormolity then this con be due to

a

F.

.
.

Open circuii in Light Green wire

Short circuit in Light Green wire

lf oll obove connections ore normol ihen reploce the ECU

with o new one ond inspect ogoin.

SENSOR UNIT 5P CONNECIOR

PGM-FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM-FI 9 BUNKS (tAT SENSOR)
NOTE:
Before storting the inspection, recheck the PGM-Fl indicotor
blinking. lf the PGM-Fl indicqtor does not blink, the system is
normol.

t.

Turn the ignition switch to "OFF".

mqlfunction code {rom memory.

2.

Erose the

Turn the ignition switch

to "ON" check the PGM-FI

indicotor blinks.
lf there ore 1 ,8,9 or oll blinks then go to SENSOR UNIT
POWER/GROU ND CIRCUIT INSPECTION.
lf ihere ore 9 blinks then turn the ignition switch to'OFF".
SENSOR UNIT 5P CONNECTOR

Disconnect the sensor unii 5P connecior ond turn the

ignition switch to "oN".
Meosure the voltoge between the sensor unit 5P connector
oithe wire horness side ond ground.

CONNECTION

6.

GroylBlue (+)

Ground (-)

STANDARD 24.75Y - 5.25V

lf voltoge exist then check for resistonce ot the ECU 33P
connector.

ECU 33P CONNECTOR

GONNECTION:

GraylBlue (ECU Pin-1 4)-Green/Oronge (EU Pina)

STANDARD:2.3 kQ - 2.8 kO(20"C/68"t1
lf there is ony obnormolity then reploce ihe sensor unit with o
newone ond inspectogoin (Foulty lATsensor).
lf resisionce is normol then check for loose or poor conioct on
the sensor unit 5 P connectorond inspect ogoin.
l{

voltoge

7.

is

out of ronge then turn the ignition switch to "OFF".

Disconnect the ECU 33P connector ond check for

continuity belween the ECU 33P connector qnd sensor
unit 5 P con nector ot the wire ho rness side.

for no continuity between the sensor unit 5P

connectorotthe wire hqrness side ond ground.
Check

SENSOR UNtT 5P CONNECTOR

CONNETION:

GroylBf ue (ECU Pin-r 4) - Grsy/ Blue

STANDARD: Continuiry

CONNECTION: Grqy/Blue - Ground

STANDARD : No

continuify

l{there is ony obnormolity then the following con be due to :

Open circuit in Groy/Blue wire.
Short circuit in GroylBlue wire.
li oll obove connections ore normol ihen reploce the ECU with
o new one ond inspect ogoin.

.
.

ECU 33P CONNECTOR

il

PGM-FI MATFUNCTION DIAGNOSTIC PROCEDURE

l'

PGM-FI

l2

INJECT

2P CONNECIOR

BTTNKS (INJECTOR)

NOTE:
Be{ore storting the inspection, recheck the PGM-FI indicotor
blinking. lf the PGM-Fl indicotor does nol blink, the system is

normol.
I

Turn the ignition switch to "OFF".

i
!u

[l

INJECTOR 2P CONNECTOR

;lil
i
i

2.

i
I

Disconnect the sensor unit 2P connector ond check for

Ioose or poor contoci on the iniector 2P connector.

i
t

f
F

tr1

jector 2P connector. Turn the ignition switch

to "ON". Check the PGM-Fl indicotor blinks.

J. Connect the

INJECTOR 2P CONNECTOR

in

4.

lf there is no blink in the PGM-Fl indicotor then there hos

been loose or poor contoct on the iniector connector.

lf there ore 12 blinks in the PGM-Fl indicqtor ihen turn ihe

ignition swiich to "OFF".

IN]ECTOR 2P CONNECTOR
6.

Disconnect the iniector 2P connector ond iurn the ignition

switch to "oN".

Meosure

the boftery voltoge

between

the

iniector

connecior of the wire ho rness side ond grou nd.

CONNECTION

: Red/Blqck (+) - Ground (-)

I.l Vminimum

STANDARD: Botteryvoltoge 7.

lf voltoge is out of ronge then check for open or short circuit

in red/ blockwire.

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

2P CONNECTOR

B. lf voltoge exists ihen turn the ignition switch to "OFF".

Disconnect the ECU 33P connector ond check {or
continuity between the iniector connector ond ECU
connectorotthe wire horness side.
Check for no continuity between ihe iniector 2p connector
oi the wire horness side ond ground.

CONNECTION:

Pink/Green (ECU Pin-I6) - pink/Green

STANDARD: Continuify
CONNEGTION:

Pink/Green - Ground
STANDARD : No continuity.

ECU 33P CONNECTOR

there is ony obnormolity ihen this co n be d ue to open or shorl

circuit in Pink,/Green wire.
lf

9.

lf oll obove connections ore normol then meosure

resislonce of the

in

the

jectorterminols.

STANDARD : 10.3 - I

l.3O

(20oCl68"F)

lf resistonce is obnormol, this con be due to o {ouliy iniector.

Reploce the iniectorond inspect ogoin.
lf resistonce is normol then reploce the ECU with o new one
ond inspectogoin.

IN.JECTOR

PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

DATA LINK CONNECTOR

THROTTTE POSTilON (TP) SENSOR RESET

PROCEDURE

.
2.
I

Turn the ignition switch to "OFF".

Disconnect

the connector cover {rom the doto

link

connector (DLC).

CONNECTOR C

3.

Connectthe speciol instrumentto the Doto l-ink Connector

(DLC).

INSTRUMENT:
DLC

shorl conneclor: 070 HH

KTRF 001

DLC SHORT CONNECT

4.
5.

Disconneci the EOT sensor 2P connector.

Connectthe EOTsensorterminqlswitho iumperwire.

CONNECTION: Yellow/Blue - Green/Oronge

EOT SENSOR 2P CONNECTOR

6. Turn the igniiion

switch to "ON" then disconnectthe iumper

wire from the EOT sensor 2P connector within I O seconds
whlle the PGM-Fl indicotor blinks slowly .

I
I

EOT SENSOR 2P CONNECTOR

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

7

A{ter disconnecting the lumper wire, PGM-Fl indicotor

storts blinking foster indicoting o successful pottern (reset
receiving poitern shown below).

PGM-FI INDICATOR
SUCCESSFUL PATTERN

@]i..
i

,"..

-''^',.

;.n'

@:

0.3

sec.

0.3 sec.

ON
PGM-FI

OFF
RESET RECEIVING PATTERN

SUCCESSFUL PATTERN

UNSUCCESSFUL PATTERN
lf the iumper wire is not disconnected wiihin 1O seconds, ihe
PGM-Fl indicoior will illuminote continuously (unsuccessful
poltern; see below). To resetogoin siodfrom step 4.

@7

Withtn

l0

sec.

ON
PGM-FI
OFF
RESET RECEIVING PATTERN

UNSUCCESSFUL PATTERN

I
F

;;

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

j"

NOTE:
. When there is o Molfunction code stored in ECU memory

the PGM-Fl indicotor storts blinking indicoiing

Mol{unction code.

Be sure

to erose the molfunction code from the ECU

memory doto ond repeot procedure from step 5.

ignition switch to "OFF".

9. Connect the EOT sensor 2P connector.
B. Turn the

EOT SENSOR 2P CONNECTOR

il

,]0.

Disconnect the DLC short connector from the doto link

connector (DLC).

INSTRUMENT:
DLG

shorr conneclor: 070 HH KTRF 001

DLC SHORT CONNEC

DATA LINK CONNECTOR

I I . Connectthe connectorcoverlo dqto link connector (DLC)

CONNECTOR C

I 2. Plocethe motorcycle on iis moin stond.

IDLE ADJUSTING SCREW

Shiftthe ironsmission to neuirol.

Worm up the engine for oboui ten minutes.
Connect q tqchometer.
Checkthe engine idle speed.

lDtE SPEED: I 500 + I 00 RPM

TACHOMETER. PET I IOO
the engine idle speed is out o{ specificotion, turn the idle
screw os required to obtoin the speci{ied idle speed.

l{

NOTE:
While the vehicle is operoted ot higheroltilude it
,l500
+ 100 rpm.
odiustthe idle rpm to

is

odvisoble to
(A) TNCREASE rDLE RPM

(B) DECREASE IDLE

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

R

NOTE:

CONNE

Check thqt the locotion of the iniector connector is between the

stopper of the i n iector ioi nt o nd ih rottle body.

lnstollthe

inl".

lnsioll ond tighten ihe two injector joint mouniing bolts to the
specified lorque.

TORQUE:0.5 kg-m
lnstoll the throttle body/sensor unit.

THROTTLE BODY
BAS 3P CONNECTOR

BANKANGLE SENSOR
NOTE:

o sofety reloted control provided to minimize the

domoge in cqse of on occident by shutting down qll engine

This is

operotions.

REMOVAT
Remove the following:
- Remove seoi

- Remove right side cover.

Disconnect the bonk ong le sensor 3 P connector.
Remove the stoy BonkAngle Sensor mounting bolts.
Remove BonkAngle Sensor mounting screw.

BANK ANGLE

NORMAL POSITION

TIPPED

POSITION

INSPECTION
Turn the ignition swiich "ON" ond storlthe engine.

Tilt the motorcycle to the right or left side in the ronge o{

42.54.
lf

the engine stolls the working of Bonk Angle Sensor is normol.

NOTE:
To restort the engine bring the motorcycle to up-right
Turn the igniiion switch to "OFF" ond then "ON"

p*ition.
WEIGHT
BANK ANGLE SENSOR

INSTATTATION
nstoll the Bonk Angle Sensor with its,,U p,' mork focing
Tighten the screws on the stoy.
I

p.

lnstoll the stoy Bonk Angle Sensor ond tighten the mounting
bolts.

lnstqllthe removed porls in the reverse orderof removol.

WEIGHT

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

FUEL PUMP 5P CONNECTOR

FUEt METER/FU Et IEVEt SENSOR

FUEL METER INSPECTION
Turn the igniiion switch
disploy.

to 'ON" ond check for the {uel gouge

NOTE:
1

segment- I .5 litres of petrol(opprox).

lf the fuel meter does not indicote

properly, perform the

following:
Disconnectthe fuel pump 5P connector.
Turn the ignition switch 'ON" ond checkthe fuel meter.
l{the fuel meter indicotion is "Empty' , wire horness is normol.
l{ the fuel meter indicotion is "Full", check for short circuit in
Yellow/White wire.

FUEL PUMP 5P CONNECTOR

Turn the ignition switch to "OFF'.

Ground the fuel pump 5P connector terminols with o iumper

wire.

CONNEGTION:

YelloVWhite - Green
FUEL

Turn the ignition switch "ON" ond checkthe iuel meter.

lf the

fuel meter indicotion

is "Full",

wire horness is normol.

lf the {uel meter indicotion is 'Empty', check for open circuit in

Yellow/White wire ond green wire.

l{thewires ore normol, checkthefuel level sensor (see below).

FUEL

FUEL LEVET SENSOR INSPECTION

Remove the fuel pump.
Conneci the multimeter to ihe fuel level sensor ierminols o{ ihe
fuel pump 5P connector.

GONNETION:
From left pin (l ) ond (2).
lnspect the resistonce of the floot ot the top ond bottom
positions.

FUtL
Resisto nce (20'

68" F)

5-7

EMPTY

204-21]fl.

l{the fuel level sensor is normol, reploce the meter ponel with o
new one, ond inspect ogoin.

FUEL PUMP

RTMI MATFUNCTION DIAGNOSTIC PROCEDURE

REAI T|ME MtTEAGE tNDtcAToR (RTM|)
RTMI INSPECTION

.
2.
I

Turn the ignition switch to "ON,,

Check ihe RTMI disploy which will be,,lEB.$,, for o {ew

seconds ond then disploy shows "
. lf oll the
segments o{ lEE.8 " ore reodobt", tt* nfiVl disploy is

working.

3.

Putthe moiorcycle on moin stond, storilhe engine, shiftto

I stto 4ih geor, ond give constontthrottle (l/4ih opening).

Check the RTMI volue, ihe ,,yelue,,will be disployed

4.

initiolly ofter 20 sec, ond then will keep on refreshing oiter

every 1 0 sec.

5.

lf the disploy chonges ofter every 1 0 sec., then the RTMI

working.

is

lf there is no disploy then check the foilowing;

6. Turn the ignition swilch "OFF,,

7 . Remove seot.
B. Remove left side motorcycle cove, right side shroud

i
t

ond

visor.
9
'l

Disconneci the Speed Sensor 3p connector.

0. Disconnect the RTMI

9P

connecior.

.l

I . Disconnectihe ECU 33p connector.

Check for loose or poor contoci in the Speed sensor 3p

connector, RTMI 9P connector ond ECU 33p connector.

12. Connect the speed sensor 3p connector, RTMI gp

connector ond ECU 33p connector, turn the ignition
switch to

"oN".

lf RIMI working is normol then ihere hos been o loose or poor

connection between the speed sensor 3p connecior, RTMI 9p

connecior or ECU 33P connector.

lf srill no disploy then check the following;

.l4.
,,OFF,,
.l5.

Turn ihe ignition switch

Disconnect RTMI 9P connecior, turn the ignition switch to

"ON"ond check the fol lowing;

VOTTAGE

Connection: Block - Green/Blqck (-)

Stqndord: Boileryvoltoge.

CONTINUITY
Connection: Green/Blqck - Ground (_)
Stqndord: Continuity
l{

volue

is

out of ronge then check the following;

- Loose or poorcontoct
-

Open or shorf circuit in Block wire

in Green/Block wire

Open circuit

l{voltoge ond continuity existthen perform the following tesis.

GROUND

RTMI MATFUNCTION DIAGNOSTIC PROCEDURE

VSS 3P CONNECTOR

RTMI 9P CONNECTOR

Disconnect the VSS 3P connector ond check for continuity

between RTMI 9P connector ot wire horness side ond VSS
3P connector ot wire horness side.

CONNECTION:
Pink(VSS 3P) - Pink (RTMI eP)

Stondqrd: Continuily
Pink (9P)-Ground
Slondqrd: No Continuity

Whire/Green (VSS 3P) - White/Green (RTltll9P)

Slondord: ontinuity
While/Green (9P)- Ground
Stqndord: No Gontinuily

Green/Block (VSS 3P) - Green/Block (RTMI 9P)

Slohdqrd: Gonlinuity
Green / Block (9P)-Ground
Stqndqrd: Continuity

VSS 3P CONNECTOR

VSS 3P CONNECTOR

RTMI 9P CONNECTOR

lf no qbnormolity is found then inspectihe {ollowing;

RTMI 9P CONNECTOR
I

9 Turn the ignition

key "ON", check the voltoge ot VSS 3P

VSS 3P CONNECTOR

connector:

CONNECTION:

White / Green (VSS 3P) - Ground

Stqndord: Bottery Voltoge
lf volue is out of ronge then reploce RTMI ond inspect ogoin.
lf ok then inspect the following;

GROUND

RTMI MALFUNCTION DIAGNOSTIC PROCEDURE

VSS 3P CONNECTOR

20

Connect the VSS 3P connector, connect RTMI

9P

connecior ond ECU 33P connector.

Turn the ignition switch to "ON" ond stortthe engine.
CheckVSS input pulseto RTMI.

CONNECTION:
Pink(VSS 3P)-Green/Block (VSS 3P)

Slqndqrd:2-2.5V
l{ volue is out oi ronge ihen reploce Speed Sensor ond inspect
ogoin. l{ ok then inspect the {ollowing;

21

Turn the ignition switch "OFF". Disconnect the ECU 33P

connector ond check the continuity between ECU 33P
connector ot wire horness side ond RTMI 9P conneclor ot
wire horness side.

CONNECTION:
GroylBlock ((RTMI 9P)

GroylBlock (ECU ,

Pinl9)
Slondord: Gonlinuity
GroylBlock (9P) -Ground
Stqndqrd: No Conlinuity
ECU 33P CONNECTOR

lf no o bnormolity is {ou nd then inspect the {ollowing;

22

Connecl the VSS 3P connector, RTMI 9P connector ond

ECU 33P connector.

Check {or voltoge in ignition "ON" ond engine running

condiiion ot fuel counter output {rom ECU ot RTMI 9P
con nector.

GONNECTION:

GroylBlock (RTMI 9P) - Green/Blqck

Stondord: 4.75-5.25V
l{volue isoutof rongeihen reploce ECU ond inspectogoin.
RTMI 9P CONNECTOR

FUEI DELIVERY SYSTEM INSPECTION AND TESTING

FUEt LINE INSPECTION
FUEI PRESSURE RETIEVING/QUICK

FUEL PUMP 5 P CONNECTOR

CON NECT FITTING REMOVAT

Remove ihe seot.
Remove the le{t ond righlside covers.

Remove left ond right shroud.

Remove fuel tonk mounting bolt.

Disconnect the fuel pump 5P connector.

Stort the engine, ond let it idle untilthe engine stolls.
Turn the ignition switch to,OFF',.

CAUTION
Before disconnecting fuel feed hose, relieve pressure from the
system by disconnecting the fuel pump conneclor ond running
the engine iill it stolls.
Remove the utility box cover ond utility box.
Remove right side throttle body cover.
Remove left side throttle body cover.
Remove the fuel iniecior 2 P connector.

NOTE:

.
.

Alwoys ensure to cleon ony dust or dirt oround the quick

connect fitting o reo before removo l.
Use o shop towel to prevent the remoining {uel in ihe fuel
feed hose from folling out.
Be coreful notto domogethe hose orotherporfs.
Do noi use ony tool io press the retoinertobs.

INJECTOR 2P CONNECTOR

LOCKING

PAWLS

.
.
. lf the conneclor

does not move, keep ihe retoiner tobs

pressed down, ond olternotely pull ond push the connector
uniil it comes off eosily.

INJECTORSIDE
Ploce o shop towel overthe quick connect{itting.
Pull owoy lhe domper.

Hold the connector with one hond ond press the retoiner iobs

with the other hond ond releose them from the locking powls.
Pull the connector of{.

FUEt PUMPSIDE
)loce o shoptowel
overthe quick connectfitting.
?emove ihe hose from clomps
)ull owoy the
domper.

-lold the connector with one hond

ond press the retoiner tobs
.vith the other hond ond releose them from
the locking powls.
rull the connector
off.

PUMP 5P CONNECTOR

CTAMPS

FUEI DELIVERY SYSTEM INSPECTION AND TESTING

PLASTIC BAGS

FUEt HOSE INSPECTION

lnspect the fuel hose {or ony deteriorotion, domoge or
leokoge.
Reploce the {uel hose if necessory.

CAUTION

entry into the iuel delivery system olwoys

ensure io plug the fuel hose ond coverthe iniector iointwith o
plostic bog.
To prevent dust

INJECTOR JOINT

HOC.

QUICK CONNECT FITTING I NSTALLATION

NOTE:

Alwoys reploce the retoiner ond domper o{ the quick connecl

fiiting when the fuel feed hose is disconnected.
Cleon oround the fuel hose joint.
lnsert o new reioiner on both the ends of the fuel hose by
oligning the hooks of the retoiner with the locking powls with
the connector joint.
NOTE:
Do not bend ortwist the fuel feed hose.

CONNFCTOR

LOCKING

PAWLS

Alwoys ensure to cleon ony dusi or dirt oround the quick

con nect iittin g oreo be{ore insiol loiion.
FUEL PUMPSIDE
Setthe dompercorrectly onto the fuel pump joint.
l

Align the quick connectfiiting with ihe fuel pump ioint. Press the
quick connect fitiing uniil both the retoiner powls lock with o
,,CLICK".

lf it is hqrd to connect, put o smoll omount of engine oil on the

pipe end.
Seot ihe fuel tonk on the motorcycle.
DAMPER

INJECTORSIDE
lnstoll o new domper onto the iniector ioint.
Align the quick connect {itting with the iniector joint then press
the q uick connect fitting until both the retoiner powls lock with o
,,CLICK".

lf it is hord to connect, put o smoll omount of engine oil on the

pipe end.

RETAINER TABS

CONNECTOR

FUEI DETIVERY SYSTEM INSPECTION

AND TESTING
Moke sure the conneclion is secure
ond thot the powls ore
firmly locked into ploce, check visuolly;;
by pulling rhe

;[.

connector.

lnstolllhe removed ports

in the reverse

orderof the removor.

FUEI PRESSURE TEST

the,fuel

ond disconnect
|;]'"":
.pressure
lTTrng trom the iniector.

fn"..i

the quick connect

one side of pressure gouge odoptor to

lhe fuel hose ond

rne other side to the fuel ottochment

hose.

Attoch ihe oiher side of fuel ottochment

hose to the fuel
iniecior.

_tl"^i1l]n"
odaptor.
Tne

fuel hose of pressure gouge inro rhe hole

given in

INSTRUMENTS:
PRESSURE

Fuelpressuregouge

:070HHKTRFOO3
Fuel press_utegouleodoprol
ozo iix KTRFoo5
Fuel ottqchmenl hose.
Connect the fuel pump 5p connector.
Turn the ignition switch',ON,,.
Stortthe engine ond keep it in idling
rpm.
Reod the fuel pressure.
ID_LE

SPEED:

l5O0 + 100 rpm

FUEI PRESSURE:294

teo

iO.O

kgt/cm,l

lf the fuel pressure is higher thon

specified, reploce the {uel
pump
ossembly.

lf

,the fuel pressure is lower thon speci{ied, inspect

{ollowing:

- Fuel line leoking

- Fuel pump.
- Clogged fuelsuction

the

filter.

After inspection relieve the fuel pressure

from the fuel delivery
system. Remove the fuel pressure gouge
ond pressure gouge
odoptorfrom the fuel hose.

Connectfuel hose onto the

in

jector.

GAUGE ADAPTOR

FUEI DELIVERY SYSTEM INSPECTION AND TESTING

FUEL PUMP 5P CONNECTOR

FUEt PUMP
INSPECTION
Turn the ignition swiich to "ON" ond confirm thot the fuel pump
operotes for o {ew seconds.

l{the {uel pump does not operote, inspect os follows:

Turn the ignition switch to "OFF".

Remove left ond right body covers.

Remove left qnd righi shroud.
Remove {ueltonk mounting bolt.

Disconnect the iuel pump 5P (Block) connector.

FUEL PUMP 5P CONNECTOR

to "ON" ond meosure the voltoge

Turn the igniiion switch

between the terminols.

CONNECTION: Red/Blqck (+) - Green (-)

l.l Vminimum

STANDARD: Botteryvoltoge -

lf there is specified volue, inspectforcontinuity in BrownAVhite

wire from fuel pump connectorto ECU connector.
l{

continuiiy

is

OK then reploce ihe fuel pump.

lf there is out of speci{ied vo lue, inspect the following:

- Moin {use (kickstorl: l5 A, self stort: 20A)
-

Open circuit in Red/Block or Green wire

ECU
FUEL PUMP 5P CONNECTOR

REMOVAL
Remove the iollowing
Remove seol.

Remove boih side covers

Remove left ond right shrouds.

Remove fuel tonk mounting bolt.

Disconnect 5P connector from fuel tonk ond remove the {uel

tonk.

NOTE:

.
.

Alwoys ensure to cleon ony dust or dirt oround the fuel

pump be{ore removql.
Remove the fuel pump corefully so os not to domoge the
fuel level sensorfloot orm.

Remove the {uel pump mounting bolts.

Remove the se1 plote/{uel pump unit ossembly ond gosket

PUMP MOUNTING BOLT

FUEI DETIVERY SYSTEM INSPECTION AND TESTING

GASKET

INSPECTION

FUEL PUMP UNIT

Check the fuel pump unit forweor or domoge.

Check the fuel suciion filterforweor or domoge
Reploce the fuel pump unit ii necessory

NOTE:
Do not disossemble ihe fuel pump

orr".bly.

INSTATTATION

SET PIATE

NOTE:

.
.
.

Alwoys reploce the gosket wifh o new one

lnstoll the fuel pump corefully so os not io domoge
the {uel
level sensor{lootorm.
Be coreful not to pinch the dirt ond debris
between the fuel

pump ond gosket.

Ploce o new goskei onto the fuel pump unit.

lnstollthe {uel pump ossembly in the fuelionk.

lnstoll the set plote on ihe fuel pump ond then
olign the qrrow
mork on the set plote with the orrow mork on the

fueltonk.

f-uel pump mounting bolts in ihe sequence

shown.
I'gIl-tF
TORQUE:1.2kg-m

Conneci the quick connect fifiing.

Connect the {uel pump 5p conneclor.

FUEL PUMP 5P CONNECIOR

FUEL PUMP WIRE

ARROW MARKS

ETTCTRICAT WI

RING DIAGRAM

CHARGING SYSTEM (KICK START)

MAIN FUSE I5A

=o

ll

lL_

r,+\l
E TI

\I/l
J
-

ACG

GHARGING SYSTEM (SEIF START)

=o

ll

t=

G}I
\L/t
I
-

ACG

]n
]n

coMB. SW2

EI

R/G

RN2

ll _

Nr
tfr

STARTSW

----.?^ B

=
E
_

FUSE
10A

DC LOAD

o
F
=

RlW2
LT.

Illr
lrlrll
lfl
{
2
f)
F

R/B

2
o

z=

SW

E,

o
n
REC

lu

)-

-,/

cLUrcH

?
777-

sw

o.

fcHnr.rce sw

?+

Abbreviotion

:
TA :
ry
TO :
K-Line

,!

Communicotion Line
Temperoture Air
Pressure Borometric

Temperoture Oil

F.-

ELECTRICAT WI RI NG DIAGRAM

TIGHTING SYSTEM DIAGRAT

F
I

=r71
tl
- et
H
O
J

o
F
a

=l
Il

I H)r
>l
+lel
Nl
6[-

Ill
lt

d'n
dv

,ll

I rNrw

ETI
'-rrmV

t-----------=---

(91

___1 /-\
nllnn-----{-.uro-}+--lt
I ?l= 2
ft 9

76-l

rlE

\-l,

--__

o^

rQll

IL_Y/'*>O
AUr'&. "' 4
*lu
de
I

,+

=
u
u

o c =
e o c o
a 5
O

lill

Z o =

dV

fi

6=

Ei

=
o

U
I
=
O

o c