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HHSFg^
SERVICE
GENERAL
|NFORMAT|ON.........
PGM.FI SYSTEM
E
E
E
E
E
E
E
FII
AND TESTING
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.
: :-:-
n on enclosed
qreo.
GASOTINE
explosive
--
ii{f(oTco}tPoNENTs
@@
*-
I ^" ond
'"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
smoller {osteners.
:::
:c-:-
:-:
..
-,.e dismontling
Non - reusqble pqrts - Alwoys reploce goskets, o -rings, oil sec s -:-: lir
-,1
re
Greosingoroilingof portsbeforeossembly-ltisimpo*criioc::
-3tt--i-:f": -:
=-:i=--:.^theengine
Torque of multiple qnd differenl sized fosteners - Firsr -c-c - ;--:- : -:n?-a-: --:- ': -: -E : : -::-:-e's
bytorqueo{smolleriostenersino criss-crosspofternfrominne.-3:--:--::.:::-.:--:-:- ---::::.:-:,::-s.
{irst followed
the shoft overwhich the seol fits is smooih ond free of burrs, whic-
.'.-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
-:
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
I
I
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
' ::-
NO
DESCRIPTION
Doto link connector
truel Pressure Gouge
APPLICATION
PART NO
system.
ling
PGM-FI SYSTEM
PGM-Fl (Progrommed Fuel lnieclion)
";,;;;;
;;""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
iniection
Colculotes ond conirols the oppropriote
volume ond iiming.
ECU
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
(TPS)
(EOT)
Engine Oil Temperoture Sensor
To detect engine
To
To detect
deteci oirtemperc'-'c
t
cnd the iniection progromme
"e' ce r.,,
oir pressr-;re
- ^-l'': - :- -: :
it
PGM.FI SYSTEM
I
--e
:
id
OPERATING UNITS
ECU
SENSORS
in
o{
le
by
DT
ET
To
llAP
To detect intoke
lgnition Coil
ln
RPM
Enobles Molfunction
loto
Link Connector
Diognosis
o{ PGM
Fl
System.
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.
ir'
lnieciion Time
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
--'c-ie
,ld
tnl
rcl
DETAITS
Position Sensor
he
in
':^;old
T'ne
-
-:
: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
: -:;.: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.
:.-::-
THROTTLE BODY
MAP SENSOR
SENSOR
UNIT
IAT SENSOR
TP SENSOR
_..CTTLE BODY
SENSOR UNIT
ADJUSIING SCREW
THROTTLE VALVE
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
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.
-*
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.
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
FUEL PUMP
<
OFF CONDITION
[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
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
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
-:
^-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
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
IDLE ADJUSTING
2UUe;olbythepressureregulotlr.
SCREW
INJECTOR JOINT
Spring
Solenoid Coil
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
--
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.
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
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
---- 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 .
KEROSENE
sIN
--:
:---
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.
--=
IGNITION
i::l
SWITCH OPEN
SWITCH
PGM-FI SYSTEM
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
.
.
(TPS)
The Cronk Position Sensor is instolled on the left crqnkcose cover ond the Rotts ore on the {lywheel.
SITION SENSOR
FLYWHEEL
CRANK
N SENS
(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|
':lI
rI
ril
l!
li
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'
-'* 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
period.
ECU
--::-aine Oil
Temperoture
**::'gture.
.'
25
-lz
UJ
UZU
s15
rt-)
frr0
e.
20 40 60 80 too 120
TEMPERATURE OC
is
30
't5
LIJ
220
(/)
U)
LIJ
dlo
\
15
\
\
20 40 60
TEMPERATURE
B0 r00 r20
is
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
::'
: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
-:-
ytronsisiorisedignitionsystem,thelronsistorconbecomporedwithonelectricolreloywhichusessmoll
currenttostoporstort
hos three terminols, two o{ which corry the moin current with the third
--= emiiter ond collector of the tronsistor ore in series with the primory winding of the high tension coil. The bose corries only o very
:-:
@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.
::-:
: ":,
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
SECONDARY
CURRENT
Tln
RTMI is o unique {eoture which hos been provided in Glomour PGM-FI. li indicotes the riderwith o reoltime mileoge on o digitol
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
"ON"
IO
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
6)
Fuel meter
(17)
PGM-Fllndicotor
Neutrol position indicotor
(l
(l
(20)
(21)
B)
9)
lniector
Spork plus
Neutrol position switch
lgnition pulse generqtor
Engine oil temperoture sensor (EOT sensor)
Alternote current generotor (ACG )
DATA LINK
PGM-FI INDICATOR
CONNECTOR
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
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
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
-.)TE:
-:
-
PGM-FI INDICATOR
DATA LINK CONNECTOR
::-orm thefollowing:
fu{ALFUNCTION CODE READING PROCEDURE
-- -- the ignition switch to "OFF'.
::-ove
CONNECTOR COVER
instrument
_:)
INSTRUMENT:
DLC
--------1,/
ON
PGM-FI
&a
gtr
,'OFF"
,,oNu.
of
NOTE:
The molfunciion doto connot be erosed from the memory if you
disconnecithe bottery negoiive coble.
.l
2.
Disconnect
link
connector (DLC).
DLC CONNECTOR CC
INSTRUMENT:
DLG
KTRF OOI
4.
5.
6.
PGTI,I.
I N,IAIFU
N CTI O
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
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
RESET RECEIVI
then turn
. 1TC.
*emory if you turn "OFF" the ignition switch before the PGM-
NG
__,
PATTERN
SUCCESSFUL PATTERN
PG'I,I.FI
Delection ltem
No blinks
No blinks
Molfunction
lniector molfunction
No blinks
ECU molfunction
Foulty ECU
No bhnks
ECU power/ground
circuit Molfunction
PGM-Fl circuit
No blinks
Cquses
Symploms
l,8oll
Blinks
Molfunction
Sensor unit power circuit
Molfunction
1,8,9 oll
Blinks
circuit Molfunction
MAP sensor
Blink
circuit molfunction
.
7 Blinks
't,, , ;. p-' t i
..\-_-_**,circuit moltunction
EOT sensor
TP sensor circuil
molfunction
Blinks
Engine operotes
normolly
43
43
43
Engine operotes
normolly
45
46
49
sensor connector.
sensor wire.
Engine operotes
normolly
41
Foulty ECU.
No Blinks
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
.
. Loose or poor contqct on in jector connector.
. Open or short circuit in iniector wire
. Foulty iniector.
tAi
5t
@@@@@@@@@@@
@@@@@@@@@@@
@@@@@@@@@@@
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
Oronge
Ground
Ground
lqnition Pulse Driver
Cronk Sensor lnpul
None
Sky Blue
SB
Liqht Green
LG
GR/L
L/R
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
Green
Sensor Grou nd
- Line
Pink
Groy
GR
COMBINATION:
Bose Colour
e.g. Brown
BR/W
/ Morking Colour
White
.
.
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)
4.
5.
I
I
,,OFF".
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
CONNECTION:
Red-Blqck (ECU Pin-l ) - Ground (-)
STANDARD: BotleryVoltoge - l.l Vminimum
lf
.
.
Red wire
ignition switch
ond ECU.
l{ volioge exists then reploce the ECU with o new one ond
inspecl it ogoin.
lr
I
h.
PGM-FI 1,
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.
un
it 5
con nector.
4.
7.
lf
B.
9.
CONNECTION:
Green/Oronge(-)
STANDARD 24.75 - 5.25V
Yel
loVRed
+ )-
I i . lf voltoge
CONNECTION:
YelloVRed (Pin 6, ECU) -YelloVRed
Green/Orqnge (Pin 4, ECU) - Green/Oronge
STANDARD: Conlinuity
ooooooooooo
ooooooooooo
ooooooooooo
CONNECTION:
YelloVRed - Ground
STANDARD : No Continuity
LJ
lf
.
.
l4
F;'
*r,
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:
UNIT
5.
6
7.
lf
there is
T.urn
ond ground.
CONNECTION:
LightgreenA'/ellow(+)
Ground (-)
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
Check
UNIT 5P CONNECTOR
5P
ooooooooooo
o o oooo ooooo
ooooooooooo
GONNECTION:
ONNEGTION:
Light green/fellow - Ground
STANDARD : No continuity
I
2.
lf
.
.
ECU
2.
3.
4.
5.
STANDARD
l{there
is
(20"C/68oF)
r
t
B.
NOTE:
INSPECTION
NOTE:
Keep oll ilommoble moieriols owoy from the electric heoting
element.
9.
'
shown.
20"c (68"F)
2.5 -2.BkO
TEMPERATURE
RESISTANCE
.l0.
100"c (212F)
0.21
-0.22ko
INSTATTATION
NOTE:
WASHER
EOT SENSOR
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.
continuity
STANDARD : No
continuity
EOT SENSOR
-l3.
CONNECTION
: YelloVBlue - Green/Orqnge
.
.
:'i) : "
wire.
- :..1r i
O
LooseorpoorcontociontheECUconnector.
"95t".
2P
EOT sensor 2P
CONNECTION:
Green /Oronge (EU Pin-4) - Green/Oronge
STANDARD: Continuily
CONNETION:
YelloVBlue
(ECU Pin-241 -
YelloVBlue
STANDARD: Continuity
CONNEGTION:
Green/Orqnge - Ground
YelloVBlue - Ground
STANDARD : No continuity
I 7. lf there
.
.
is
OpenorshortcircuitinYellow/Bluewire.
OpenorshortcircuitinGreen/Orongewire
li oll obove connections ore normol then reploce the ECU with
o new one ond inspect ogoin.
ECU 33P CONNECTOR
\{
2.
Erose
memory.
PGM-FI
indicotor blinks.
"oFF".
4.
switch
round.
Lighr Green/Blqck
STANDARD: Continuity
ECU 33P CONNECTOR
- Ground
F.
.
.
t.
2.
Erose the
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
CONNECTION
6.
GroylBlue (+)
Ground (-)
GONNECTION:
voltoge
7.
is
CONNETION:
continuify
.
.
il
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
i
!u
[l
INJECTOR 2P CONNECTOR
;lil
i
i
2.
i
I
i
t
f
F
tr1
J. Connect the
INJECTOR 2P CONNECTOR
in
4.
IN]ECTOR 2P CONNECTOR
6.
Meosure
between
the
iniector
CONNECTION
STANDARD: Botteryvoltoge 7.
CONNECTION:
Pink/Green - Ground
STANDARD : No continuity.
9.
in
the
jectorterminols.
STANDARD : 10.3 - I
l.3O
(20oCl68"F)
IN.JECTOR
.
2.
I
Disconnect
link
connector (DLC).
CONNECTOR C
3.
INSTRUMENT:
DLC
KTRF 001
4.
5.
I
I
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
;;
j"
NOTE:
. When there is o Molfunction code stored in ECU memory
Mol{unction code.
Be sure
il
,]0.
INSTRUMENT:
DLG
CONNECTOR C
l{
NOTE:
While the vehicle is operoted ot higheroltilude it
,l500
+ 100 rpm.
odiustthe idle rpm to
is
odvisoble to
(A) TNCREASE rDLE RPM
NOTE:
CONNE
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:
This is
operotions.
REMOVAT
Remove the following:
- Remove seoi
BANK ANGLE
NORMAL POSITION
TIPPED
POSITION
INSPECTION
Turn the ignition swiich "ON" ond storlthe engine.
42.54.
lf
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.
WEIGHT
NOTE:
1
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.
CONNEGTION:
YelloVWhite - Green
FUEL
is "Full",
FUEL
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
.
2.
I
working.
3.
4.
5.
is
i
t
ond
visor.
9
'l
9P
connecior.
.l
"oN".
VOTTAGE
Stqndord: Boileryvoltoge.
CONTINUITY
Connection: Green/Blqck - Ground (_)
Stqndord: Continuity
l{
volue
is
- Loose or poorcontoct
-
Open circuit
GROUND
RTMI 9P CONNECTOR
CONNECTION:
Pink(VSS 3P) - Pink (RTMI eP)
Stondqrd: Continuily
Pink (9P)-Ground
Slondqrd: No Continuity
VSS 3P CONNECTOR
VSS 3P CONNECTOR
RTMI 9P CONNECTOR
RTMI 9P CONNECTOR
I
VSS 3P CONNECTOR
connector:
CONNECTION:
GROUND
20
9P
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
CONNECTION:
GroylBlock ((RTMI 9P)
GroylBlock (ECU ,
Pinl9)
Slondord: Gonlinuity
GroylBlock (9P) -Ground
Stqndqrd: No Conlinuity
ECU 33P CONNECTOR
22
GONNECTION:
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:
.
.
INJECTOR 2P CONNECTOR
LOCKING
PAWLS
.
.
. lf the conneclor
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.
PUMP 5P CONNECTOR
CTAMPS
CAUTION
INJECTOR JOINT
HOC.
CONNFCTOR
LOCKING
PAWLS
Align the quick connectfiiting with ihe fuel pump ioint. Press the
quick connect fitiing uniil both the retoiner powls lock with o
,,CLICK".
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".
RETAINER TABS
CONNECTOR
;[.
connector.
in the reverse
ond disconnect
|;]'"":
.pressure
lTTrng trom the iniector.
fn"..i
_tl"^i1l]n"
odaptor.
Tne
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:
FUEI PRESSURE:294
teo
iO.O
kgt/cm,l
lf
{ollowing:
the
filter.
in
jector.
GAUGE ADAPTOR
FUEt PUMP
INSPECTION
Turn the ignition swiich to "ON" ond confirm thot the fuel pump
operotes for o {ew seconds.
STANDARD: Botteryvoltoge -
continuiiy
is
REMOVAL
Remove the iollowing
Remove seol.
NOTE:
.
.
INSPECTION
NOTE:
Do not disossemble ihe fuel pump
orr".bly.
INSTATTATION
SET PIATE
NOTE:
.
.
.
fueltonk.
ARROW MARKS
ETTCTRICAT WI
RING DIAGRAM
=o
ll
lL_
r,+\l
E TI
\I/l
J
-
ACG
=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
=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