Sea (oy PA) <0) CF250-6 (Oe/As]0 pola CF300-3 ATAUEdition Date: 20191010 Edition Item: CF250-6 (6KM6-WX-02) SM-20191010INTRODUCTION This manual introduces CF250-6/CF250- GA/CF300-3 maintenance information, including disassembly procedure checking &adjustment methods, troubleshooting and technical specifications. There are some illustrations, drawing to guide your operation. The first three chapters mainly introduce general operation information, special tool, vehicle structure, basic specification, inspection&maintenance methods etc,. The rest chapters introduce vehicle part removal, installation, adjustment, service, fault diagnosis and etc.. CFMOTO has the copyright and final interpretation of this manual. Do not copy, translation without CFMOTO permit. Any transmission or recording is prohibited. This manual has been improved by using many ways to make it accuracy. But we are No response for any difference and missing CFMOTO reserves right to make improvements and modifications to the products without prior notice. Overhaul and maintenance should be done according to actual condition of vehicle. And CFMOTO is Not responsible for production improvements and modifications. This manual is only for reference. If any objections, please ask the nearest dealer to get the latest information. The information in this manual are the latest depends on latest productions on coming out. The images in this manual may not stand for real model assy and parts. Production CF250-6 is accordance with standard: QICFD 102. Production CF250-6A is accordance with standard: Q/CFD 103. The manual standard: GB/T9969-2008 and GB/T19678-2005. ICFMOTO reserves right to make improvements and modifications to he products without prior notice, Overhaul and maintenance should be} idone according to actual condition off vehicle. CFMOTO CO.LTD October , 2019 eneral Information jaintenance Information fechnical Information Body Covering Parts Fuel Tank ights, Dashboard and Switches lectrical System ‘ooling System luffler Assi heels and Brake System hock Absorbers and Rear Fork ngine Ass, jandlebar Assy and Triple Clamps leaning and Conservation [Start Diagram IN EFI Diagram ein) [Electrical Diagram NENG)Conversion table A [Ampere oy Pound ABDC [After bottom deaa|m Meter |center [AC [Alternating current ___|min [Minute IATOC [After top dead center__[N Newton IBBDC [Before bottom dead|Pa Pascal lcenter BDC [Bottom dead center__|PS [Metric horse power IBTDC _|BTDC Before top dead|Psi Pound/Square Inch lcenter PC ICentigrade r Revolutions Dc Direct current pm__|Revolutions per minute IF Farad [TDC |Top dead center PF Fahrenheit TIR [Total indicator reading ft Feet lV [Voit la Gram IW [Watt h Hour a (Ohm IL Litre in Inch US gal__|Galion(US) US qt__|Quart(US) loz [Ounce HP. British horsepower lemHg _|Centimeter of mercury |pint__|Pint lcuin [Cubic inch’ mL. MillliterForward This service manual is not only specially designed for professional machinist, but also it is used to instruct the vehicle's user how to do maintenance work. It is necessary to know mechanical knowledge, tools proper usage and have a well understanding of service procedure Conversion before you perfectly solve all service problems. If no, you should get the service support by professional machinist. Please read this service manual and understand it before operate for high efficiency work. And working in clean area. For vehicle mechanical performance and safety works. No tools replaced or use temporary tools since that we have been appointed the special service tools and equipment. All service and scheduled maintenance should be executed base on the instructions of service manual. Any consequences are responsible by the vehicle's owner resulted from any rule- breaking operations. How to get Long Service Life: ‘Follow scheduled maintenance and service operations base on service manual. ‘Non-periodical maintenance in special situations. ‘Use tools properly and use CFMOTO genuine parts. Special tools, dashboard and tester have been listed into this service manual for necessary genuine parts. Strictly operated bas on the correct service procedures. Keep fully service records and specify the date of new parts replacement. How to use this manual: In this manual, the production will be separated as several systems. All the systems are shows up in the contents. That will help you to lock the chapter. And each chapter has its ‘own contents. For example, If you wanna see ignition coil information, use the contents to find our the electrical system and find the ignition coil in electrical system chapter.Whenever you see the warning or warning symbol, you must keep attention and comply with the safety operation and maintenance method. INDANGER: This symbol means it will cause serious injuries even death if you ldon’t follow the procedure. [AWARNING: This symbol means the special steps. It may cause the vehicle] ldamage if you don’t follow the procedure. [ACAUTION: This symbol means the special steps for higher efficiency and easier| lworking. NOTE: It makes operation process easier or offers clearer information. It has no symbol.NOTE: IThe vehicle removal procedures are not included electrical parts, police implements| land engine. Electrical parts and engine are shown in the seperate chapters. |All connectors are unplugged by default during removal. IThe guide line without serial number in the picture indicates the direction of| lremoval.1.1 Operation Cautions 1.2 Disassembly and Assembly Caution: 1.3 VIN and EIN Location... 1.4 Fuel evaporation system diagram... 1.1 Operation Cautions DANGER: Hazardous components| in exhaust. Do not run the engine in aj lenclosed or poor ventilated piace for a| General Information ([AWARNING: Don’t touch the engine] jor muffler with bare hands when the| lengine has just stopped to avoid hurt, long time. [AWARNING: Battery liquid (dilute lsulfuric acid) is highly caustic and may| cause burns to skin and eyes. Flush] lwith water if splashed to skin and get immediate medical attention. Flush with] lwater if splashed to clothes to avoid burns. Keep battery and liquid away| lfrom reach of children. Wear long-sleeve work clothes. [AWARNING: Coolant is poisonous] |Do not drink or splash to skin, eyes or| Iclothes. Flush with plenty of soap water| lif splashed to skin. Flush with water| land consult doctors. If drinking the| lcoolant, induce vomiting and consult ldoctors. Keep coolant away from reach| lof children.General Information [AWARNING: Wear proper work clothes] lcap and boots. War dust-glass, gloves| land mask if necessary. JANGER: When charged, Battery may] lgenerate hydrogen which is explosive] ICharge the battery in a well-ventilated lace. DANGER: Be careful to get clamped by the turning parts like wheels and| Iclutch. [NDANGER: Coolant Gasoline is highly| lammable. No smoking or fire. Also lkeep against sparks. Vaporized gasoline| lis also explosive. Operate in a well-| lventilated place. [AWARNING: The asbestos dust on| the brake drum is carcinogenic. Do not| lclean off the dust with compressed air. lUse cleaning detergent to avoid dust| roliferation.General Information 1.2 Disassembly and Assembly Cautions laClean the mud, dust before overhauling. faUse genuine CFMOTO Parts, lubricants land grease. fmPlace and store the disassembled parts] lseparately in order for correct assemble. faClean and blow off the detergent after ldisassembling the parts. Apply lubricants| lon the surface of moving parts. laReplace the disassembled washers, O- Iings,piston pin circlip and cotter pin with] lnew ones. laElastic circlips might get distorted after| disassembled. Do not use the loosed kirctips. faMeasure the data during disassembly for] lcorrect assembly.General Information ali not know the length of screws, install Ithe screws one by one and tighten with] lsame torque. mCheck if the disassembled rubber parts| lare aged and replace it if necessary. Keep] Ithe rubber parts away from grease. laPre-tighten the bolts, nuts and screws, then tighten them according to the| lspecified torque, from big to small and from| linner side to outer side. [Apply or inject recommended lubricant to] the specified parts. falf the disassembling of pressed ball lbearing is done by pressing the balls, the| ldisassembled should not be used again.General Information lmTurn the ball bearing with hands to| make sure the bearing will turn smoothly, Replace if the axial or radial play is too} big. If the surface is uneven, clean with loil and replace. if the cleaning does not help. When pressing the bearing into| ithe machine or to the shaft, replace the| bearing if it could not be pressed tight. fsinstall the one-side dust-proof bearing] lin the right direction. When assembling] the open type or double-side dust-proof| bearing, install with manufacturer's mark] joutward. ine-sided dust /Iwo-sided dus roof type roof type S n type] (RG fainstall the elastic circlip after assembling] Ito make sure is has been installed into the| {slot Keep the bearing block still when blowing} ldry the bearing after washing clean. Apply} loil or lubricant before assembling. na Q faBrake fluid and coolant may damage| lcoating. plastic and rubber parts. Flush] these parts with water if splashed. fmAfter assembling, check if all the tightened pats are properly tightened and can move|General Information minstall oi! seal with the side o manufacturer's mark outward. Do not fold lor scratch the oil seal lip. Apply grease to] Ithe oil seal lip before assembling. faWhen installing pipes, insert the pipe till Ithe end. Fit the pipe clip, if any, into the| rove. Replace the pipes or hoses that| lcannot be tightened. Dent lanufacturer identification Crease S a SS () Clip Joint {aDo not mix mud or dust into engine or the] hydraulic brake system. {Do not twist or bend the cables too| ldistorted or damaged cables may cause| poor operation. faClean the gaskets and washers of the] lengine cases before assembling. Remove Ithe scratches on the contact surfaces by| jolishing evenly with an oll stone. When assembling the parts of protection] caps, insert the caps to the grooves, if an capGeneral Information 1.3 VIN and EIN LocationGeneral Information 1.4 Fuel evaporat n system diagram [AAttention: To fixed the anti roll-over valve as horizontal position. Don’t change |the fuel evaporation system. Tube connection should be well connected after| maintenance by disassembling without air leakage, blocking, squeezing, broken jand damage etc. Fuel steam will be released into carbon tank by absorption tube| lfrom fuel tank. Absorbing fuel steam by active carbon when engine stop; Fuel lsteam of carbon tank will follow into combustor for burning when engine working in order to avoid environment pollution if fuel stem released into air directly,| Meanwhile, Air pressure of fuel tank should be balanced by absorption tube. If inner] pressure of fuel tank is lower than outside, it is available to replenish air pressure) by air tube of carbon tank or absorption tube. So, All tube system should be smooth| running without blocking and squeezing, otherwise fuel pump will be damaged, fuel Itank will be deformed or broken. coo | 4<—Fuel pump assy L J pe ey 0108012.1 Maintenance before Operation 2.2 Break-in Maintenance Schedule 2.3 Periodic Maintenance Schedule. ACautions: Maintenance Information 1 ~2 3 > = Severe Use Item. Reduce interval by 50% on vehicles subjected to severe use. = = Have an authorized dealer perform repairs that involve this component or system. 2.1 Maintenance before Operation Maintenance before operation Item $$ | Hour [Calendar| km Remarks Fuel system Fuel hose 5 Daily = [inspect for aging Electrical system Switches - Daily = Tnspect Lights and horns Daily -Maintenance Information 2.2 Break-in Maintenance Schedule Break-in Maintenance Interval Item (Service whichever interval comes first) Hour [Calendar| km Remarks IEngine _[Engine oll and oil filter : : 1000 [Replace idle : : 1000 [Coolant : : 1000 _|inspect Throttle system : : 1000 [Electrical system 1_[Functions of electrical parts : : 1000 Battery : : 1000 |inspect Fuses or circuit breakers : : 1000 Brake system Brake discs : : 7000 Brake pads : : 1000 inspect Brake fuid level : : 1000 Brake lever : : 1000 _|inspect for free play a [Brake hoses - - 1000 pee damage| Wheels Tire condition : : 1000 Hire pressure = = 7000 ||"spect [Suspension system Inspect for leaking [Rear shock absorber and] . tooo (maintain parts| Iront forks laccording to the| requirement) [Cooling system [Coolant level : : 7000 = [Coolant 1000 —|inepect 1=_[Raciator fan function : : 1000 ICootant hoses : : 1000 [Steering system = [Steering bearings : : 7000 [Inspect [Other parts s_ [Diagnosis connector : : 1000 [Read with PDA [Mobile parts - - 1000 fparcare: Inspect for [Bolts and nuts ‘i : 71000 _|Inspect for fastness a [Cables and wires - - 1000 Inspect for damage, lbending and routingic Maintenance Schedule Maintenance Information Periodic Maintenance Interval Item (Service whichever interval comes first) Hour [Calendar| km Remarks Engine Engine oil and oil filter i : 3000 [Replace = [Clutch 5 : 12000 Idle : : 1200 _ Inspect = {Coolant = y 12000 : 24 | 36000 [Replace Throttle system zi = 12000 Inspect = [Throttle valve i : 6000 __|Clean >a Air filter element - = 42000 {inspect = 24M 7 Replace = [Spark plug zi = 12000 (Valve clearance = 40000 _|inspect Electrical system [Functions of electrical parts |__- 72M_| 10000 Battery : 6M 5000 __|inspect Fuses or circuit breakers : 6M 5000 a Wires . 12m | 10000 |Inspect for damage, lbending and routing Brake system zi f2M_| 10000 Front and rear brake system | — aM} 20S , : 12M_| 10000 Brake dises - au ae > |Brake pad : 72M, 10000__||"SPect rake pads 24M__| 20000 : 12M__| 10000 Brake fluid level = 2 Ta Brake lever = 2M 20000 Inspect for free play zi 24M__| 20000 inspect for damage| [Brake hoses : 42M __| 10000 land sealing 8 [Brake fuid 24M = [Replace Wheels Tire condition - 12M_|_ 10000 : 24M__| 20000 - : 12M _| 10000 Tire pressure - Sau poo00 Inspect ; : - 10000 a Whee! bearings = = 30000Maintenance Information Periodic Maintenance Interval Item (Service whichever interval comes first) Hour [Calendar| km Remarks [Suspension system : : 4000 a [Suspension system 5 5 8000__|Inspect 5 : 12000 Inspect for leakin IRear shock absorber andi - ™ oe (maintain parts ® |iront forks laccording to the| - 2am | 20000 ‘ requirement) - 70000 a [Swing arms = = 0000 |nsPect [Cooling system Coolant level = 12M _| 10000 : 24m__| 20000 Cook : 12M __| 10000 & [Coolant : 2aM__| 20000 Inspect a= Radiator fan function = 12M 10000 : 24m__| 20000 Coolant h = 12M_| 10000 & [foclant hoses z 48M__| 30000 [Frame system [Frame : 5 30000 inspect [Steering system a |Steering bearings = 12M 410000 Inspect : 2am_| 20000 Chain Ichain, rear sprocket and]__- 72M __| 10000 > engine sprocket : 2am 20000 [Inspect [Other parts = [Diagnosis connector - 72M | 10000 ead with PDA = 12M _| 10000 _|Lubricate; inspect for| a Mobile parts : 48M | 30000 _|fiexibility = [Bolts and nuts = 2M 30000 Inspect for fastness » Icables and wires : 12M_| 7500 _|inspect for damage, : 24M__| 15000 _|bending and routing « [Pipes, ducts, hoses and|__~ 12M 10000 inspect for cracks,| sleeves 4am | 30000 [sealing and routing3.2 Engine Specification .. 3.3 Maintenance Specifications 3.3.1 Front Wheel 3.3.2 Rear Wheel 3.3.3 Brake System 3.3.4 Lighting, Dashboard and Switc! 3.4 Service Specification .... 3.4.1 Valve Train&Cylinder Head . 3.4.2 Lubrication System 3.4.3 Cylinder, Piston, Piston Ring and Connecting Rod 3.4.4 Clutch and Transmission .. 3.4.5 Cooling System 3.4.6 Air Inlet System. 3.4.7 Electrical System 3.5 Tighten Torque..... 3.5.1 Tighten Torque Table for Vehicl 3.5.2 Tighten Torque Table for Engine 3.6 Consumption Materials& Assembling Mate 3.6.1 Vehicle Consumption Materials. 3.6.2 Engine Consumption Materials&Assem| SSSCOMHOINNVYO DOHA AARON oTTechnical Information 3.1 General Specifications Item Specifications [Model CF250-6/CF250-6A CF300-3 lLength 2010 mm| Width 750 mm [Height 41080 mm Wheel base 1360 mm lEngine model 172MM-24 178MN [Displacement 249 mL. 292 mL. [Fuel grace RG@-95 or above [Gross weight 150 kg Passengers Zpeople (including driver) lLoad 150 kg Lite Front 110/70R17 MIC 548 Rear 140/60R17 MIC 63S IMin. ground clearance 160 mm Turning circle diameter 4700 mm Right 35° Steering ‘Steering angle iS ae Front Hydraulic Disc Brake system Rear Hydraulic Disc Front wheel ‘Telescopic [Shock absorber Suspension | LOM MRCS. Cantieve. ype IFrame Steel tube item Standard [Fuel capacity 12L Injector Type: FOTROOMGT Fuel supplier Voltage: DC13.5V Pe Pressure: 0.35 MPa = 0.01 MPa Fuel pump Flow: 245U/h Current: $2.80A3.2 Engine Specification Technical Information Item Type/Specification CF250-6/CF250-6A | _CF300-3 Type Line Engine/signal cylinderifour strokes/water-| lcooled/top camshaft [Bore = Stroke 72mm x 61.2mm__| 78mmx 612mm [Displacement 249 mL 292 mL. Compression ratio 11.3:4 1144 Low idling speed (Idling) 1450 r/min # 145 r/min [Starting Electric Power 20.5 kw/9750rpm_| 21.4 kw/ 8750 rpm lignition type ECU lElectrical system coe plug/Electrode CR8EL/0.7 mm ~ 0.9mm Magneto type Out rotor, flywheel Combustion [Combustion chamber Triangular system lAir filter type Sponge filter [Gasoline RO-95 and above \Valves system [Valves type SOHCichain drive Lubrication type Pressure and splash Lubrication [Oil pump type. Rotor drive lsystem (Oil filter type Paper type, replaceable Engine oil type. SAE10W/40 SJ, JASOMA2 [Cooling [Cooling type Closed coolant circulation lsystem _ [Coolant type ~26°C anti-rust and anti-freeze fluid (Clutch Wet and multi-plate clutch [Transmission type 6-gear,constant mesh, step transmission Reducer gear 6 gears Gearshift methods/orders Mechanical reciprocating 1-0-2-3-4-5-6-5-4-3-2-0-1 [Drive train] [Primary ratio 28 lsystem @ [ist 3.333 8 (2nd 2.118 2 [ara 1.574 2 {4th 4.304, B (sth 1.115 5 |eth 0.963 L(mm)eW(mm)xH(mm): [Overall size 469 mm x 336 mm x 488 mm [Dry weight 35.3 kg [Output type Chain Rotation of engine output [When moving fonvard, counter clockwise (left!Technical Information 3.3 Maintenance Specifications 3.3.1 Front Wheel tem Standard Service limit Front wheel shaft bending = 0.2mm Longitudinal 0.8mm 2.0mm Rim run-out Front [Horizontal 0.8mm 2.0mm wheel Remaining . 1.6mm [groove jime Sire presaure 225 KPa t 22.5kKPa pI (2.25 kgficm? + 0.225 kgf/cm?) 3.3.2 Rear Wheel item Standard Service limit IRim run-out Longitudinal 0.8mm 2.0mm Horizontal 0.8 mm 2.0 mm Rear Remaining 16cm bwhee!| |groove 7 : HTire pressure 225 kPa 22.5 kPa (2.25 kaflcm?+ 0.225 kgf/cm?) 3.3.3 Brake System Tem Standard Service limit Front brake ton (hand) brake free travel [10 mm ~ 20 mm Brake disc abrasion 4mm 3mm R Rear (foot) brake free travel_|_10 mm ~ 20mm fear brake Brake disc abrasion 4mm 3mm 3.3.4 Lighting, Dashboard and Switch Item Standard Fuse Primary 30A [Subsidiary 1x7.5A_1x10A_5x15A |Headiight (Hi/Lo) LED Position light LED Light, but Taillight LED Turn light LED License light LED3.4 Service Specification 3.4.1 Valve Train&Cylinder Head Technical Information Item Standard Service | Remark limit - N 28.9 mm = 20.1 mm — \Valve head diameter x 23.8.0m ~ 2.4 0m = \Valve clearance (cold IN 0.12mm~0.17mm = lengine) EX 0.17 mm ~0.22 mm = (Clearance, valve N 0.01 mm ~ 0.037 mm = guide bushing and ~ uide bush EX 0.03 mm ~ 0.057 mm - .D of valve guide ~ loosring IN & EX 45mm~45izmm | 458mm OD of vane stom N 4275mm~ 4400 mm | 446mm EX 4.455 mm ~ 4.470 mm. 4.44 mm [Valve head seal ring Naive h IN & EX 0.03 mm - Valve head sealring | iy g ex 0.9mm ~ 1.4mm — width Free length, valve vemm 398mm spring Compress to ae 455 N ~ 503 N - Nelve springforce gS mate ag mpress 422 N ~ 466 N — - N 36.743 mm ~ 36.857 mm [35.647 mm |CF250-61| [Camshaft lift EX 35.743 mm ~ 35.857 mm | 35.647 mm| CF250-6A iN 36.053 mm ~ 36.167 mm [35.657 mm [Camshaft uft EX 35.673 mm ~ 36.787 mm [35.677 mm| CF S003 ICamshaft to hole [Camshaft 0.028 mm ~ 0.071 mm | 0.150 mm IO.D of camshat oS 22.55 mm~ 22.972 mm [22.621 mm |.0 of camshaft 923 23 mm ~ 23.021 mm = Imating hole ICamshaft run-out 0.015 mm O.tmm ICylinder head junction surtace 0.03 mm — flatness Camshaft seat junction surface 0.04 mm — flatnessTechnical Information 3.4.2 Lubrication System Item Standard Service limit | Remark (Outer rotor to inner rotor] nov mmeOdsam _ [clearance (Outer rotor to pump body| 042mm ~04184 mm Iclearance : Oil pressure 0.1 MPa ~ 0.4 MPa : Oil type 10W-40/SJ, JASOMA2 - Oil capacits Change oil and filter |1400 mL = pacity lat overhaul 1600 mL. 3.4.3 Cylinder, Piston, Piston Ring and Connecting Rod - tem Standard Service limit | Remark [Cylinder pressure kPa Clearance between piston| 0.045 mm ~ 0.062 mm _ land cylinder : 71.950 mm ~ 71.965 mm, Pia. of piston skit measured at 10mm above skit | 718™ | |.D of cylinder 72mm~72.019mmM_ 72.07 mm. CF250-6A\ Cylinder junction surface 003mm 0.05 mm flatness Dia. of piston skirt 0.033MM=~0.052mm LD of oylinder 77.960 mm ~ 77.975 mm, PD of ey! measured at 10mm above skirt CF300-3, Cylinder junction surface 78 mm~ 78.019 mm flatness Piston ring closed 1 Ring 0.15 mm~0.3mm 0.55 mm 9 gap 2Ring|__0.1mm~03 mm 0.55 mm Clearance between piston|1Ring| 0.03mm~0.07mm_| 0.17 mm ring and groove ZRing| _0.03mm~0.07mm_| _0.17 mm. IThickness of piston rin 1Ring| 0.97 mm ~ 0.99 mm 0.9mm. p 9 2 Ring| 0.97 mm~ 0.99 mm 0.9mm Ring] 1.02mm~= 104mm _|_1.12mm lWidth of piston ring groove [2 Ring} 1.02mm~1.04mm_|_1.12mm Oilring] 2.01 mm~2.03mm_|__2.11 mm ||.D. of piston pin hole 17.002 mm ~ 17.008 mm = 0.0 of piston pin 16.995 mm ~ 17.000 mm = LD oF connecting rod small! 47 945 mm ~ 17.025 mm _ Connecting rod big end side| ~ Iclearance 0.25 mm ~ 0.45 mm 0.65 mm Connecting rod big end| 20.48 mm ~ 205mm _ thickness: (Crankshaft run-out <= 0.03 mm 0.08 mm 36Technical Information 3.4.4 Clutch and Transmission Tem Standard Service limit | Remark Friction disc 2.98 mm~3.08mm|__2.76 mm [Quantity 7 Friction pad thickness 30.3 mm ~ 31.2mm = Free length of clutch spring 35 mm ~ 36 mm 33.5mm [Quantity 6 je [6" driven gear 5.1 mm~ 5.17 mm 5.22 mm ere fork groove} = 4" ake gear | 5.1mm~5.17mm | _5.22mm 5" driven gear 5.1 mm~ 5.17 mm §.22 mm. [Shift fork (LH) 4.93mm~Smm_|__4.83mm [Shift fork thickness _|Shiftfork (Middle) |_4.93mm=5mm_|__4.83mm. Shift fork (RH) 4.93mm=5mm_ | 4.83 mm 3.4.5 Cooling System tem Standard/Specification Service limit [Remark CF250-6 [Start temp. of thermostat 80°C ~ 84°C 5 Lift range of thermostat| 28 mm at 95°C - \valve lOpen pressure of radiator| - cap 108Pa Temperature (°C) = |The relationship between Ithe resistance of water 20 temp. sensor and 80 temperature 120 ICootant type -35°C anti-rust and anti-freeze fluid 7 with high boiling point 3.4.6 Air Inlet System Item Specification Remark [Port size (mm) 938 mm. Idle speed (rimin) 1500 r/min + 150 r/min 3.4.7 Electrical System Item Specification Remark Spark plug (Model CR8EI (Gap 0.7mm ~ 0.9mm [Spark >8mm, 1MPa Ignition coil resistance [Primary 1230) ‘Secondary kQ ~ 7.4k0. Magneto coil resistance Trigger 4000 IMax power ‘280W at 5000 r/min [Stabilized voltage 13.5V ~ 15.0V [Primary peak voltage, ignition coll 227kV [Peak voltage, trigger coil 217Technical Information 3.5 Tighten Torque 3.5.1 Tighten Torque Table for Vehicle Item Torque Nem(kgfm) Item [Torque Nem(kgf-m) MS bolt, nut 541(05+0.1) ve screw 4£1(04+0.1) M6 bolt, nut 10 £1 (1.0 20.1) 9£1(0.940.1) M6 SH flange bolt M8 bolt, nut 20~ 30 (2.0~ 3.) | 1g fange bolt and nut M10 bolt, nut 30 ~ 40 (3.0 ~ 4.0) = : M8 flange bolt and nut MA2 bolt. nut | 40~ 50 (4.0~ 50) | prio ange bolt and nut 12£1(12£0.1) 20 ~ 30 (2.0 ~ 3.0) 30 ~ 40 (3.0 ~ 4.0) Please use standard torque if without torque value mentioned below table. NOTE: 1. Lubrication oil should be applied on screw thread and contact surface. 2. Replace with new ones if self-locking bolts are removed. Torque Nem Item Qty, | Thread damm) | (ote) | Remark IRear nut, engine 1 Ma 25 ~ 30 IRear bolt, engine 1 MB x 90 25~ 30 Front wheel shaft 1 M12 x 1.25 192 | _50~ 80 lLock nut, rear fork 4 Mi4 x45 80 = 100 lLock Nut, rear wheel shaft 4 M14 x15 80 ~ 100 lLock nut, front fork 1 M35 x1 20 lLock screw, upper triple clamp |_1 M26 x1 110 |Upper bolt, rear shock absorber| 1 Mi0 * 1.25 x45 35~ 40 lLower bolt, rear shock absorber| 1 M10 = 1.25 35~ 403.5.2 Tighten Torque Table for Engine Techi al Information Item aty. tee Torque Nem Remark Bolt, crankcase 15. M6 10 Bolt, gearshift drum cam 1 M6 10 With thread locker| Balt. position swing arm 1 M6 10___|With thread locker - With engine ol Bolt, cylinder head 4 Mio ‘We oe ci! (and MoS2 grease a (ratio 10: 1) Bolt, cylinder head 2 M6 10 [Pin shaft 1 M8 20 With thread locker| Limit bolt, sprocket guard 1 M6 10__|With thread locker Blt, timing tensioner 1_|_ M6 x 15 20 [Damping bolt, cylinderhead_| 1 M6 10 INut, output gear 1 M16 x4 700 INut, clutch 1 M16 = 4 100 Bolt, ol pump 3 M6 10 [With thread locker| Bolt, speed sensor 1 M6 8 Bolt, starter motor 2 Mé 10 |Lock bolt, overrunning clutch 6 M6 10 With thread locker| Lock bolt, magneto rotor 1 M12 * 1.25 120 IScrew, gear trigger 2 MS 5 With thread locker| Bolt, sprocket guard 2 M6 10 With thread locker| Bolt, cylinder head cover 4 M6 10 [Screw, oil trail 7 R208 15 [With thread locker| Drain bolt 1 [M2 «15 25 Filter cover 2 M35 « 1.5 25 Filler plug 1 3/4" Hand-tighten IHole cap, timing inspection 1 Mi2x15 4 Lock bolt, magneto stator 3 M6 15 |With thread locker Lock bolt. trigger 2 M5 8 With thread locker Spark plug 1 M10 x7 15 [Coolant temp. sensor 1 M12 «1.5 12.5 M5 45~6 lOther bolts. nuts and screws M6 10 ~ 12 MB 18~ 25Technical Information 3.6 Consumption Materials&Assi ;embling Materials Consumption materials include lubricant oil (engine oil), lubricant grease (butter) and coolant. Assembling materials include flange sealants, thread locker. 3.6.1 Vehicle Consumption Materials Application areas Notes Type \Vehicie's head pipe. bearing races Front wheel dust-proof seal lip IRear brake cam movable parts, cam Junction, dashboard soft shaft |Shaft joint, throttle cable Throttle handlebar part Pivot, rear pedal(LH), IPivot, rear pedal(RH), |Pivot, side stand [Rear fork oil seal lip ICounter gear/small gear surface and| Imovable parts IMain bracket shaft Multi-purpose lithium| base lubrication oil Thread of rear wheel axle nut and joint |Handle bar inner surface Engine oil lLower dust-proof seal lip of front Ishock absorber [Absorber oil 5# 3.6.2 Engine Consumption Materials&. “Assembling Materials Item ‘Specification Using parts Remark ISAE10W/40 SJ| lLubricant oil ASOMA2 head. Ichart. Rotation and moving section in cylinder, lcrankcase and cylinder |Details refer to lubricant| lOil Capacity: /1250mL (filter change) 450ml (at overhaul) Lubricant oil with Imolybdenum lvalve oil seal, camshaft IPiston pin, valve stem, #3 MoS2 lithium Lubricant grease lorease lwith sealant Oil seal, o-ring and| rubber seal face, bearing| -35°C anti-rust| land anti-freeze| Ifluid with high| boiling point |Coolant ICooling system, water seal installation Capacity depends on| radiator water pipes Flange sealant ICrankcase faying face lcrankcase and cylinde cylinder head cover joint jjoint cylinder head and! | [Tread locker Parts of threadSeat 4.1 Seat 4.1 Seat Removal Insert key into seat lock [1]. Unlock seat lock [1]. Remove rear seat [2]. Lift front seat comers [3]. Remove inner hex bolts [2] Remove front seat [5].Seat Installation Insert limit hook Lift front seat comers [3] Install inner hex bolt Insert limit hook [5] into buckle [6]. Press lock catct into seat lock [5] 040203]Body Covering Parts 5.1 Rear View Mirror and Front Winds! 5.2 Fuel Tank Guard .. 5.3 Reservoir Outer Panel 5.3.1 LH Reservoir Outer Panel 5.3.2 RH Reservoir Outer Panel 5.4 Front Lower Fender. 5.5 Headlight Guard... 5.6 LH&RH Middle Panel.. 5.7 LH&RH Frame Pane 5.8 Fuel Tank Front Panel 5.9 Front Inner Panel... 5.10 Engine Lower Panel 5.11 Rear Plastic Parts . 5.12 Front Plastic Parts. 5.13 Frame Cushion Bloc! 5.14 Fenders. 5.14.1 Front fender. 5.14.2 Rear Fender. OOQOHHMHAAGRAAWNNN 5.1 Rear View Mirror and Front Windshield z Removal Remove four inner hex bolts [7]. Remove rear view mirrors 2) =x 4M Remove inner hex bol Remove front windshielBody Cove: Parts 5.2 Fuel Tank Guard Removal Lift fuel tank cover panel Insert key and open fuel tank cover. Remove three inner hex bolts Remove fuel tank cover [3] Remove two inner hex bolts [3]. Remove two plastic clasps [5]. Remove fuel tank guard Reinstall fuel tank cover [7] in case of fuel leaking. 5.3 Reservoir Outer Panel 5.3.4 LH Reservoir Outer Panel Removal Remove plastic clasp [7]. Remove inner hex bolt(2}Body Covering Parts Remove four screws [3] Remove LH outer panel [Z], upper deco plate [5] and inner deco plate [6]. 5.3.2 RH Reservoir Outer Panel Removal Remove inner hex bolt (7) Remove oil fiter service cover [2] Remove screw [3] Remove four screws [2]. Remove RH outer panel, upper deco plate and inner deco plate.Body Covering Parts 5.4 Front Lower Fender Removal Remove four screws Remove front lower fender. 5.5 Headlight Guard Removal Remove two screws [7] Remove screw [5]. Remove screws [4]. Remove headlight RH guard [2]. NOTE: Screws [4] are self-tapping screws. Headlight LH guard applies the same removal procedures. 5.6 LH&RH Middle Panel Removal Remove screw [7] Remove bolt with washer [2]Remove screws [4]. Remove plastic clasps [5]. Remove RH panel [3]. LH panel applies the same removal procedures. 5.7 LH&RH Frame Panel Removal Remove three bolts Remove RH frame pa LH frame panel applies the same removal procedures. 5.8 Fuel Tank Front Panel Removal Remove four screws Remove two bolts Remove fuel tank LH front Panel 3]. RH front panel applies the same removal procedures. 5.9 Front Inner Panel Removal Remove two plastic clasps Remove four bolts [2]. Remove LH front inner panel [3]. RH front inner panel applies the same removal procedures.Body Covering Parts Lower Panel Remove engine lower panel [2]. 5.11 Rear Plastic Parts Removal Remove two screws [7] Remove panel front middle connecting plate Remove bolt[2]. Remove two screws [5] Remove screw [7]. Remove LH tail guard [5]. RH tail guard applies the same removal procedures. Remove plastic clasp Remove screw [5] Remove panel front LH connecting plate [3]. Front RH connecting plate applies the same removal procedures. Remove four screws [10, Remove LH&RH deflectors [7 050601Body Covering Parts Remove two plastic clasps [. Remove two screws Remove tear fender lower deco part Remove two screws [ig Remove rear fender upper deco part id. Remove four screws [77, Remove bolt [3 Remove diagnosis connector [f} Remove rear fender 2iJand tail light £9),Body Cove: Parts 5.12 Front Plastic Parts Remove plastic clasps [1] on both sides. Remove screws [Z] on both sides. Remove inner hex bolts [3]on both sides. Remove dashboard Remove dashboard guard [4]. Remove two screws [5] on each side. Remove headlight upper guard [6]. Remove one bolt [7Jon each side. Remove bolt [8]. Remove headlight assy [5] 5.13 Frame Cushion Block Removal Remove two inner hex bolts Remove LH frame cushion block [2] RH frame cushion block applies the same removal procedures.Body Covering Parts 5.14 Fenders 5.14.1 Front fender Removal Remove three inner hex bolts [1] on each side. Lift front fender [2]. Remove three screws [3]. Separate front fender front part [¥] and rear part [5] Remove front fender. 050902} 5.14.2 Rear Fender Removal Remove two inner hex bolts Remove inner hex boltsBody Covering Parts Remove bolt [3]. Remove rear fender [4]Fuel Tank 1 6.1 Fuel Tank.. [NDanger: lin some situations, the gasoline is highly flammable and explosive. [Do not overfill the fuel tank. When the fuel reaches the neck of the oil filler, it is the| maximum capacity. [The engine must be stopped when refueling and must be refueled in a well-| \ventilated area or outdoors INo smoking, open fire or sparkle in the refueling area or gasoline storage area. If gasoline spills onto the skin or clothing, wash immediately with soap and water or| Ichange the clothes. [Seek medical attention immediately if accidentally contact your eyes or swallow! jasoline. 6.1 Fuel Tank Removal Remove two bolts Remove nut 2] Remove bolt Lift fuel tank [2]. ~~ 060101: Pull out adsorption hose and quick joint [5] Remove fuel tank. "Danger: Never put fuel tank up side ta ee \down, in case of fuel leaking. ee 4 ) YS ai) (AWARNING: When installing fuel tank) lall hoses, pipes and cables can not be lextruded. 060102)Fuel Tank Inspection Inspect fuel tank if sunk, cracked or other damage. Replace if any defect is found. Inspect hose if cracked, aged or leaked. Replace if any defect is found. Installation Reverse the removal procedures for installation. NOTE: When installing fuel tank, all hoses, pipes and cables can not be extruded.Lights, Dashboard and Switches 7.1 Maintenance Information 7.1.1 Operation Caution .. 7.1.2 Inspection Standard 7.2 Trouble Shooting. 7.3 Ignition Switel 7.4 Front Brake Light Switch 7.5 Rear Brake Switch... 7.6 LH Handlebar Switch. 7.7 RH Handlebar Switch 7.8 Horn... 7.9 Fuel Level Sensor. 7.40 Battery 7.11 Vehicle Telematics 7.12 Ground Wire..... 7.4 Maintenance Information 7.4.4 Operation Caution [AX WARNING: If the Inspection has to be done check if the battery is normal. inspection of switch continuity can be done without removing the switches from the vehicle. |After the inspecting and overhauling of each part, cables and wires should be| outed properly. 7.1.2 Inspection Standard Item Standard Fuse Main fuse 30A\ Auxiliary fuse 3x10A_3x15A Headlight (Hi/Lo) LED Position light LED Light&Bulb Tail light LED Turn light LED License light LED 7-1Lights, Dashboard and Switches 7.2 Trouble Shooting Head light cannot turn on, Hi/Lo switch doesn’t work: Fuse is blown Switch is damaged Bulb is burnt Battery bad connection or no electricity Wire connector loosen Light Removal Headlight and tail light removal refers to 05 chapter. NOTE: The headlight and tail light are| Iconsisted of LED lights. When the light| damages, replace the whole set. 7.3 Ignition Switch Inspection Pull out the connectors between ignition switch [1] and main cable to check its performance. [ignition switch Action/Color | R] B| Cccusion reaches 070201 omens No a No ay Yes 7.4 Front Brake Light Switch Pull out the connectors between front brake light switch ind main cable to check its performance. 1) Grip front brake lever, the brake light is on 2) Loosen front brake lever, the brake light is off. 7.5 Rear Brake Switch Pull out the connectors between rear brake nd main cable. Inspect rear r its performance. 1) Press rear brake pedal, the rear brake light is on 2) Loosen rear brake light is off. 7-2Lights, Dashboard and S 7.6 LH Handlebar Switch Unplug the connectors between LH handlebar switch and main cable to check pe its performance. Co [Dimmer switch sider[7] [Mode switch(2] be [Sse]wJe-w[e wer] 6 we] S e ete ole is = 070301 sod e e e e fete| [Turn switch [4 Jase] O [Gr] Sb [Br] Br} G cleo, le Wististeis fefe [Override switch [5 Se] B Br |Br W] Br etele Bal feo r IN 070302/ 7.7 RH Handlebar Switch Unplug the connectors between RH handlebar switch and main cable to check | [6 its performance. [Star¥Stop switch side{6]| [StarV/Stop switch slder{s] [2] Br B|B Br| Br] G | |-.3S*|Br B] YR | Br| G oe [ote lele ee lee Bel a = ay (Warning switch [7 070303} [D|39) Joc] 0 |Gr] Sb | Br] G Ao jefe [Ac lilumination switch [8 2s] B:| WG] WL|Br G e ele 2e e+e oe x let e 7-3Lights, Dashboard and Switches 7.8 Horn Unplug horn connector. Connect with 12V battery to check If the horn works well and the sound is loud and clear. Otherwise, replace with a new horn. 7.9 Fuel Level Sensor Removal Remove four nuts [7]. Remove fuel lever sensor 2]. [ACAUTION: Remove fuel level sensor] slowly, in case it deforms. Inspection Inspect fuel level sensor seal ring for deformation, damage or hardening. Replace if it does. Check the electrical resistance of the oil level sensor at high and low poles. Resistance: High: 30sR<460 Low: 94OsRs1000 Connect fuel level sensor and main cable. Tur on ignition switch, the floater of fuel level sensor swings up and down slowly. See the fuel gauge pointer on dashboard. If the pointer can not reach F or E, it means the fuel gauge is not qualified, replace a new one. If the pointer swings unsteadily, it means the fuel gauge is not qualified, replace a new one. Installation Reverse the removal procedures for installation. [ACAUTION: Check leakage after fuel] level sensor installation. 7-4Lights, Dashboard and Switches 7.10 Battery (AWARNING: i. Battery acid and gas will produce serious corrosion, avoid contacting with| battery acid and gas. 2. Keep batteries out of reach of children. 3. When battery acid contacts skin, wash with plenty of water. If battery acid| enters the eye, flush with water for at least 15 minutes and seek for medical] help. |4. Please wear protective clothing and goggles. Keep the battery away from sparks and open fire. Only charge the battery in a well-ventilated room. Is. Do not mis-connect the positive and negative pole of battery. Remove the| negative wire first if disassembling battery, in case it damages electrical elements. The system of this vehicle uses negative earth mode. I6. Battery wires are not allowed to be removed while the engine is working. 7. Battery positiveinegative wires and electrical control units have to be removed| before welding on the vehicle. 8. It is forbidden to puncture the wire to test the input/output electrical signals. 9, Establish the awareness of environmental protection and effective disposal off waste generated during maintenance. (A\CAUTION: 1. Even if the battery is not used, it also loses power every day. 2. Charging condition and charging mode are very important for the service life| of the battery. Using high charging current will have a negative impact on the| service life. 3. If the charging current, charging voltage and charging time are exceeded, the| battory will be damaged. |4. If the battery becomes empty due to repeated start of the vehicle, it needs to be charged immediately. ls. When the battery is stored in the discharge condition for a long time, deep| discharge and sulfuric acid salination will occur, which damages the battery. Ib. The battery does not need to be maintained, which means the acid level does| not need to be checked. Removal Remove seat. Remove battery negative wire lock bolt. Remove negative wire [1] from the battery. Remove battery positive wire lock bolt Remove positive wire [2] from the battery. Remove battery [A CAUTION: Negative wire must bel removed first. Otherwise, it will causo lbattery short circuit. Installation Reverse the removal procedures for installation. 7-5Lights, Dashboard and Switches Charge Shut down all the electrical devices and engine. Remove battery. Connect charger and battery. After charging, remove the charger from the battery. INOTE: If the vehicle is not used,| recharge the battery every three| months. Charging Voltage Inspection The battery has proper performance and is fully charged Start the vehicle and measure the voltage. Measuring point is positive pole (+), the other measuring point connects ground (-). Charging Voltage '5000;pm 13.5V-15.0V. If less than specification: Inspect the connectors between engine and regulator. Inspect the connectors between regulator and cables. Inspect engine electronic winding If more than specification: Replace regulator. 7.14 Vehicle Telematics Removal Remove telematics [7] Inspect connectors for performance. Installation Reverse the removal procedures for installation. 7.12 Ground Wire Shut down engine and all electrical parts. Inspect ground wire. Inspect bolt 76Electrical System 8.1 Service Tool ... 8.2 Charging System. 8.2.1 Charging Diagram. 8.2.2 Magneto Coil Resi: 8.2.3 MAG Non-loaded Performanc: 8.2.4 Starter Rela) 8.2.5 Regulator 8.3 EFI System 8.3.1 EFI Structure .. 3.1.1 Sensors .2 ECU... 8.3.1.3 Actuators. 8.3.2 EFI System Maintenance Notice... 8.3.3 Structure and Performance of EFI Parts 5 Oxygen Sensor.. 6 Trigger. 92 G0 00 00 G9 Gd C0 CD Co 10 Idle stepping moto 8.3.3.11 Ignition coil 8.3.4 Self-diagnosis 8.3.4.1 Malfunction In 8.3.4.2 PDA... 8.3.5 Fault Code .. 8.4 Fault Diagnosis and Treatment . 8.5 Trouble Diagnosis In Accordance With Engine Error ing Lamp (MIL) 8-1Electrical System 8.1 Service Tool Function: Read erase trouble code of EFI system, observe data flow and accessories test etc. Function: Inspect the parameter of EFI system like voltage, current and resistant etc. 080201 8-28.2 Charging System 8.2.1 Charging Diagram 8.2.2 Magneto Coil Resistance resistance. replace with a new stator. coil and core. Turn multimeter to 1x10 MAG Coil Resistance: 0.50~1.5 (Yellow-Yellow) Resistance between Stator Coil and Core: #0 (Yellow-Ground) ie) 080301 1 [Magneto | 3 [Fuse 5 Load 2 [Stable Voltage| 4 [Battery | 6 [Regulator Measure 3-phase magneto stator coil lf the resistance is out of specification, ~~ *Check for the insulation between stator ( i \ | em TT 2 | ee | — 080302| 8.2.3 MAG Non-loaded Performance Start the engine and allow it run at 5000r/ min. Use multimeter to measure the voltage between 3 output lines. *lf the reading is below specification, replace with a new magneto. Turn Multimeter to V(AC).. Voltage between Output Lines When MAG Non-loaded: >50V(AC) at 5000r/min 080303}Electrical System 8.2.4 Starter Relay Put DC12V between positive and negative terminal. Use multimeter to check connection between 2 contacts. If multimeter clicks, there is connection. If DC12V is removed,no connection between contacts. If both above 2 items are proved, it indicates the replay is good. Turn multimeter to DIODE |AACAUTION: The voltage loaded| between terminals can not exceed 2! minutes. Otherwise, starter relay may| loverheat or burn. Use multimeter to measure the start relay coil resistance. If the resistance is out of standard, replace with a new one. Turn multimeter to 1X100 Start auxiliary relay resistance: 30~50 Auxiliary Relay Put 12V between auxiliary starter relay positive and negative terminal. Use multimeter to check the continuity between AandB. Turn multimeter to DIODE. If multimeter clicks, it indicates there is connection between A and B. If 12V is removed, no connection remains between contacts. If both above 2 items are proved, it indicates the replay is good. Tum multimeter to 11000 to measure the relay resistance. Auxiliary starter relay resistance: 900~1000 8-4 080401 080403}8.2.5 Regulator [Yellow | 2 [Red [3 |Green After engine running and at the state of battery full charged, of which the RPM is about 5000r/min, if the voltage between positive and negative terminal exceeds 15V or is lower 13.5V, replace with a new regulator. 8-5Electrical System 8.3 EFI System 8.3.1 EFI Structure 080604] 1 [Air filter 5 [Roll-over sensor | 9 |Water temp. sensor 2 |ECU 6 injector 10|Trigger 3 [Stepping motor| 7 Ignition coil 11|Fuel pump assy 4 [Throttle body | 8 [Oxygen sensor 8.3.1.1 Sensors A sensor is a device that measures a physical quantity and converts it into a signal Which can be read by an observer or by an instrument. Sensors in EFI system include: Air pressure sensor (Air density and pressure information) Air temp. sensor (Air density information) TPS (Load, load range, speed information) Trigger (crankshaft information) Water temp. sensor (engine temp.) Spoedomoter sensor (Output shaft RPM information) Oxygen sensor (Air factor= A>1 or <1) Roll-over gear sensor (Output vehicle gradient information) 8.3.1.2 ECU Electronic Control Unit, the brain of EFI system,which determines the amount of fuel injection, ignition timing and other parameters a engine needs to keep running by calculating and analyzing values provided by sensors. 8-6 8.3.1.3 Actuators Actuators execute the EF! instruction. Main actuators include: Fuel Pump (Provide high-press fuel) Fuel Injector (Inject the fuel to make it spray better) Ignition Coil (Provide high ignition energy to spark plug) Idle Air Control Valve (Provide idle inlet air)8.3.2 EFI System Maintenance Notice *Always use genuine CFMOTO parts for maintenance. Otherwise it can not assure a normal performance to EFI system. During the maintenance procedure. never try to break down the EFI components. eln the course of maintenance, EFI parts must be handled carefully. elgnition switch must be shut off before connecting or disconnecting connectors. Otherwise, it may cause the EFI parts damage. When removing fuel pump from fuel tank, do not energize the fuel pump. Otherwise, a spark can cause a fire «Fuel pump is not allowed to operate in a dry environment or under water. Otherwise, its life would be shortened. Besides, reverse connections between positive and negative terminal of fuel pump is not permitted. The fuel pressure in EFI fuel supply system is very high (about 330kPa), accordingly, all fuel lines are high pressure resisting. Even if the engine is not running, the fuel pressure is high. Therefore. not disassemble the fuel line unless it's necessary. When the fuel line needs to be repaired, release the fuel pressure as follow shows: Remove fuel pump relay, start the engine and allow it to idle until the engine stalls automatically. Fuel line removal and fuel filter replacement should be practiced by a professional person in a well-ventilated place. Electrical System elf possible, don't do the spark test. If spark test is done unavoidably, try to complete the test as soon as possible. Besides, dor't open the throttle, otherwise, a large quantity of unburnt fuel would enter muffler, causing the catalytic converter damage. eldle speed is controlled by ECU, so it's unadjustable. The throttle limiter screw has been adjusted by manufacturer before sale. Therefore, it's not recommended to adjust it by the user. Don't reverse the battery cable connections. This may damage electrical components. eNever remove the battery cables When the engine is running. eAlways remove cables and electrical control units which are connected with battery terminals. eNever test the component input and output electric signal by piercing the cable plastic jacket. Respect the environment and dispose of the waste left during maintenance. 8-7Electrical System 8.3.3 Structure and Performance of EFI Parts 8.3.3.1 ECU Electronic control unit , is the brain of EFI system. It analyzes and cope with the information provided by sensors, and send the conclusion in the form of instruction to actuator, then make the engine run in the ‘optimal condition. INOTE: Do not load on the cover. Gently ECU pin function: [Stepping motor phase Uninterrupted battery] 4411) [Nut 781) 33(F3) | Uap) aq.) [Ovgen sensor Heated aq [SEPP ING MoI Phase ey Ine 3(M2) |Ignition 1 19(K2) Oxygen sensor signal] 35/3) |Neutral switch (L2) [Null 20(02) [Null 36(C3) ignition diagnosis 5(M3) |Ignition to ground __|21(H2)|Clutch switch 37(B3) [Null 6(L3)_|Null [22(G2)|Null 38(A3) [Null (Ma) [Null 23(F2)|Side stand switch |39(Ka) [Mode switch a(L4) jrterupabte battery!>4(€2)|Null 40(J4) [RPM output Intak oka) ee. 13s) | 25(02)|Null /41(H4)|Speed sensor T0(U1) [Sensor to ground 1_[26(C2)|Starter relay 42(G4)|RPM sensor (DGB) intake air temp. sensor] [Stepping motor phase| 11(H1) Tangy 27(82)|- 43(F4) |RPM sensor A (DGA) 12(G1) TPS (DKG) 28(A2) seme motor phase} 44(E4)|Null Engine temp. sensor 1301) [gory 29(«3)|Mu. 45(04) |Fan relay Ta(E7) [Main relay 30(03) [SV output 7 [46(C4) |Fuel pump relay 15(D1)|CAN1 VE TLow _[31(H2)|Null 47(B4) Null 16(C1)|CANt VE 1 High |32(G3)[Ignition switch KL15 |48(A4) [Fuel injector 1 Value ‘tem Min. | Standard | Max. Unit Battery voltage Normal 9 1440.1 16 Vv 'y vollag© [Limit function | _6.0~9.0 16.0~18.0 Vv Limit and time| K tof funct lof battery over|26.0V ‘eep part of function, can 5 min ldiagnose the trouble voltage Working temperature -40 70 °C [Storage temperature -40 70 °C 8-88.3.3.2 Throttle Body Connect with air filter and the engine, contro! the on-off angle of throttle by throttle cable. Send out the angle signal through TPS to ECU. Pin Function: 5V power [2]Ground [3] Output voltage signal TPS Circuit connecting with ECU. (ACAUTION: Engine idle is completely controlled by EFI system. Do not adjust] idle limit screw [5] manually. It is not allowed to load on housing or| cover. Gently handle it. Do not drop it} lon the ground. il) [5 6a. =) wr Sogg Ope WwElectrical System 8.3.3.3 T-MAP This sensor monitor inlet air pressure, which provides the engine load signal to. ECU. Pin Function: intake air pressure signal V power intake air temperature signal Ground Circuit connecting with ECU. The right picture shows the allowable mounting range, which ensures that condensation does not form inside the sensor, as the condensation damages pressure sensitive elements within the sensor. 8-10 081001 iff GH3 8 id 2525 = Eu T-MAP 081002] 081003}The relationship between output voltage and pressure. Pressure range: 10~115kPa 5 4.65) Output Voltage out in V 15 Absolute Pressure Pabs in KPA 081101 The relationship between sensor temperature and resistance. 60000 50000 40000 30000 20000 10000 0 “10-0 20-10 9 10 20 30 40 50 60 70 80 90 100 110 120 130 -10000 —@-Femp. (°C HEF Resistance (OHM) 081102 8-11Electrical System 8.3.3.4 Water Temp. Sensor This sensor is a NTC thermo resistance. The resistance becomes lower when the air temperature becomes higher, but it is not a liner relationship. One group of parameters is sent to ECU to. monitor engine temperature condition, One group is sent to dashboard to monitor coolant temperature condition. A and C are one group which provides water temperature signal to the ECU. Through ECU, B sends the water temperature signal to dashboard. Circuit connecting with ECU The right table shows the relationship between temperature and resistance. This signal is sent to ECU. 8-12 I 081201 on wr | =] FS] ov = ECU Water temp. Sensor 93,499 Temp. °C [Resisiance between B and housing (KQ) -2020.1 13.71~16.94 2540.1 1.825~2.155 8020.1 0.303-0.326 1020.7 0.1383~0.14518.3.3.5 Oxygen Sensor This sensor is used in closed-loop feedback controlled fuel injection to improve the air-to-fuel ratio accuracy and control the emission. It's located in the exhaust stream to measure the amount of oxygen in exhaust and send the signal to ECU, which can revise the fuel injector output, so as to reduce the amounts of unbumt fuel and make catalytic converter convert HC, CO and NOx of Nitrogen efficiently. Pin Function: Output signal voltage + [2] Heated ground - [3] Output signal voltage - (2) Heated power + Circuit connecting with ECU. Electrical System 081301 wr vn ee 8 ECU ‘Oxygen sensor 081302 8-13Electrical System 8.3.3.6 Trigger The trigger transfers signal of engine speed to ECU and by which ECU to confirm engine speed ignition angle and injecting phase. Circuit connecting with ECU. Measure trigger resistance Set multimeter to 1*1000 range. Trigger coil resistance: 1000~1600(20°C) Replace a new one when resistance is not within above value range. Measure trigger peak voltage Connect multimeter and peak voltage adapter as shown as right picture +Probe: Green (B) wire -Probe: Blue (A) wire NOTE: Refer to owner manual when lusing peak value voltage adapter. Set multimeter to ACV range. Set engine to Neutral gear, turn on ignition switch. Press starter button and keep engine Tuning for seconds, then measure trigger coil peak value voltage. Repeat a few times and record the highest value. Trigger coil peak value voltage: 22V (300r/ min) Replace a new one when peak value voltage is not within above value range. 8-14 A] | \6) . 081401 \ = ne Trigger -————— tk aa a EU 081402} [Trigger resistance 081403} Magneto Peak voltage gauge aL Trigger peak voltage 081404}8.3.3.7 Speed Sensor This sensor provides engine output shaft speed to ECU. Then ECU can calculate the speed according to this signal. It is a hall switch type device. which outputs square wave by the change of the magnetic field Pin Function: [)+DC 12V ground Power [3] Output voltage signal (>80% of input voltage) Circuit connecting with ECU. Speed Sensor Inspection Ground pin 1 and pin 2 with +12V power. Fix the gear [i] 2.5mm away from the speed sensor as the picture shows. Turn multimeter to DCV. Slowly turn the gear and measure the voltage between pin 2 and pin 3 to determine that if the reading varies from ov~12V If the reading doesn't vary, it indicates the sensor is defective and needs to be replaced. Electrical System g 081501 ecu} Ground 2 Hall switch Speed sensor 3 #12V voltage 081502 081503] 8-15Electrical System 8.3.3.8 Fuel Pump The right picture shows the fuel pump assy, fuel pump relay and ECU wiring diagram. This fuel pump assy consists of fuel pump, plastic bracket, fuel strainer, fuel filter element and pressure-regulating valve. It delivers fuel from the tank to the engine at a certain oil pressure and flow rate. Pin function: Ground tue! pump relay output port Performance parameter: Pressure-regulating valve open pressure: 0.33MPaz0.01MPa Flow rate: 45Lh Do not run the fuel pump assy when there is no fuel inside the fuel tank, in case of fuel pump damage. Handle the fuel pump gently. Do not drop it ‘on hard surfaces. The battery supplies power to the fuel pump through the relay. Only when starting or running the engine can the circuit be switched on. Measure fuel pressure: Connect oil pressure gauge and fuel pump il port, lock with clamp to ensure there is no leak form the junction. Connect the circuit as the picture shows. Tur on ignition switch and stop switch. The fuel pump will work for 5 seconds. When stop working, the oil pressure should reach the specified value. Otherwise, replace with a new fuel pump. After stopping working, the pressure should maintain 0.2MPa for at least 5 minutes. Otherwise, replace fuel pump assy. Fuel hose pressure release method: The fuel supply pressure in EFI system is high, all fuel hoses are high-pressure resistance. Even the engine does not work, the pressure in fuel passage is still high. So when in the maintenance process, be careful not to remove the fuel hose causally. When servicing EFI system, release the pressure before removing the fuel hose. Remove the fuel pump relay. Start the engine and make it idle until the engine stops automatically. 8-16 vu Fuel pump 081601) 081602| 1 JECU pin 46[3 [Battery + | 5 [Stop switch 2 [Fuel pump |, Fuel pump « |lgnition rela) [* lassy Iswitch8.3.3.9 Fuel Injector One end of fuel injector mounts into fuel injector seat, and the other end attaches to the injector cap, which connects with a fuel line. Fuel injector is controlled by ECU to inject fuel at stated time into the engine. This injector nozzle is a 4-hole style. Don't turn injector after the joint between injector and injector cap is installed. Pin function: + connects fuel pump relay output - connects ECU pin 48 Fuel injector resistance: 12.5010 ( 20°C) Circuit connecting with ECU. Fuel Injector Installation Install fuel injector manually. Never knock fuel injector with a hammer. When removing and installing fuel injector, the O-rings on both ends must be replaced. Perform pressure relief before fuel injector removal if necessary. Test the fuel injector sealing after installation to ensure no leaks. Electrical System 081701 [Fuel pump relay Fuel injector] lseat 081702| 4lecu | 2\Fuel pump relay 3 |Fuel injector 8-17Electrical System 8.3.3.10 Idle stepping motor This is used to control the air flow of by- pass. ECU calculates the engine load and controls stepping motor through electrical pulse duration and frequency (commonly known as duty ratio). It allows different air flows passed through under different pres- sure. Therefore, it should be connected properly. Otherwise, idle speed may be in- correct. Pin function: A connects ECU pin 27 (stepping motor phase A) B connects ECU pin 28 (stepping motor phase B) D connects ECU pin 18 (stepping motor phase C) C connects ECU pin 17 (stepping motor phase D) Circuit connecting with ECU. 8-18 Idle stepping motor 081801 me aS wees ers Pe. a 0 ECU Stepping motor 9g +928.3.3.11 Ignition coil Ignition coil transforms the low voltage of primary coil to high voltage of secondary coil needed to spark the spark plug and ignite the mixture of air and fuel in cylinder. Pin function: [Ground Power + GJECU pin 3 Circuit connecting with ECU. Secondary Ignition Voltage Test: Connect the engine according to EFI wiring diagram. Connect the peak voltage tester according to the right diagram. #Start the engine. Secondary ignition voltage should be more than 15 kV. Ignition coil 1 [Ground [3 JECU pin 3] 5 [Secondary 2|Power +[4 [Primary _| 6 [High voltage| 081903 1 [Peak voltage gauge | 3 [Battery Ignition coil parameter chart table: 2|ECU 4 [Spark plug item Value Min Standard Max Unit Stated Voltage 14 Vv. Operating Voltage 6 765 Vv Resistance | Primary 0.74 0.76 0.78 Q (20°C~25°C) | Secondary 10.1 10.6 11.4 ka. Primary Current 7 A 8-19Electrical System 8.3.4 Self-diagnosis ECU constantly monitor sensors, actuators and circuits, MIL and battery voltage, etc, even ECU itself and inspect the sensor output signal, actuator drive signal and internal signal (such as close loop control, coolant temperature, idle speed control and battery voltage control, etc.) for reliability. If any process or signal is suspect, ECU records the trouble code in the RAM memory. Faulty information is recorded in the form of trouble code, and in the sequence of which trouble comes first. When servicing, using PDA and MIL, the defective parts can be promptly found to improve the service efficiency and quality. EFI system is mainly diagnosed by MIL and PDA. 8.3.4.1 Malfunction Indicating Lamp (MIL) It indicates different fault codes through the flashes in different frequency. The right picture is the MIL connection circuit. The current in pin 29 to ECU should be less than 0.5 A. MIL Flash Principle: If the ECU detects MIL is in flash code mode, MILL indicator flashes to show trouble code. A. MIL in code-flashing mode without fault in memory: From ECU formating, MIL is lightened for 4 seconds. After 1 second interval, MIL indicator flashes every 0.6s. It means there is no fault. MIL indicator goes off until engine starts and find RPM B. MIL in code-flashing mode with fault in memory: From ECU formating, MIL is lightened for 4 seconds. After 1 second interval, MIL light flashes to display fault code. If all faults in memory are shown, MIL goes off and quites flash code mode. K-line should connect to ground in code- flashing mode. C. Read the trouble information by flashing code: Turn on ignition switch with K-line to ground for more than 2.5 seconds. If the ECU memory has trouble code, MIL indicator will display the code by flashing. Take P0203 as an example, its flashing method is: flashing 10 times-off-flashing twice-Off-flashing 10 times-Off-flashing three times. 8-20 Resistant #12V power = LED 082001Electrical System 8.3.4.2 PDA PDA has 3 pins, power, ground wire and data cable K. These pins are connected with related ECU pins. The right photo refers to operation panel of PDA. When it comes to detailed keys function, refer to PDA manual. 082101 UP Key | 4 |EXIT Key | 7 Power switch| LH Key | 5 |OK Key RH Key] 6 [Down Key joo] Key function: LH Key: Page up UP Key: Scroll Up RH Key: Page Down Down Key: Scroll Down OK Key: Entrance EXIT Key: Exit PDA Function: (A) Version Information Display 082102 PDA can display engine,ECU hardware PDAwiring diagram and soft ware information 4 [H12V power] 2 [ECU pin 34] 3 [Ground ®) Fault Display’ A monitors IAP sensor, IAT sensor,coolant temperature sensor, TPS, 02S, O2S heater circuit, air-to-fuel ratio revision, fuel injector, fuel pump relay, CPS, speed signal, idle speed, idle air control valve, system voltage, ECU, FI indicator and displays the fault code. {C) Engine Data stream Display PDA can display battery voltage, RPM, desired idle speed, vehicle speed, coolant temperature, coolant temperature sensor signal voltage, inlet air temperature, IAT sensor signal voltage, inlet air pressure, inlet air flow, ACV target position, TPS signal voltage, throttle body position, throttle body relative position, canister duty. charging time, Fl pulse width, park advance angle, 02S voltage, engine relative load, canister load, IACV position, atmospheric pressure, altitude multiplier, engine operation time. (0) EFI Status Display Starter switch, main relay, fuel pump relay, idle speed, idle speed, full load status, deceleration activation, acceleration activation, Fl close loop activation, lambda control activation, canister control valve activation, MIL status. {E) Actuator Test Function MIL, fue! pump, IACY, canister control valve, ignition, fuel injection. 8-21Electrical System 8.3.5 Fault Code No. Code instruction 1 P0030 __ [Oxygen Sensor Heated Control Circuit Open 2 P0031 [Oxygen Sensor Heated Control Circuit Short to Ground 3 P0032 [Oxygen Sensor Heated Control Circuit Short to Power 4 P0107 _ |Intake Air Pressure Sensor Short to Ground 5 P0108 _|intake Air Pressure Sensor Short to Power 6 P0112 __|intake Air Temperature Sensor Low Voltage 7 P0113 |intake Air Temperature Sensor High Voltage 8 P0117 [Water Temperature Sensor Circuit Low Voltage 9 P0118 [Water Temperature Sensor Circuit High Voltage 10 P0122 _ [Throttle Position Sensor Circuit Low Voltage 11 P0123 _ [Throttle Position Sensor Circuit High Voltage 12 P0130__ [Oxygen Sensor Signal Abnormal 13 P0131 [Oxygen Sensor Signal Circuit Low Voltage 14 P0132 [Oxygen Sensor Signal Circuit High Voltage 15 P0134 [Oxygen Sensor Signal Circuit Error 16 P0201 __ |Injector Control Circuit Open 17 P0261 _ |injector Control Circuit Short to Ground 18 P0262 _ |injector Control Circuit Short to Power 19 P0321 |RPM Signal Point Malfunction 20 P0322 __ |No Speed Sensor Signal (Open Circuit Or Short Circuit) 21 P0501 |Speed Signal Error 22 P0560 __ [Battery Voltage Signal Abnormal 23 P0562__ [Battery Low Voltage 24 P0563 _ [Battery High Voltage 25 P0627 |Fuel Pump Relay Control Circuit Open 26 P0628 _ [Fuel Pump Relay Control Circuit Short to Ground 27 P0629 _|Fuel Pump Relay Control Circuit Short to Power 28 P0650 __|MIL Circuit Error 29 P0691 __ |Fan Control Circuit Short to Ground 30 P0692__|Fan Control Circuit Short to Power 8-228.4 Fault Diagnosis and Treatment Electrical System Engine Body: Troubles Possible Cause Countermeasures cylinder pressure too low 1. Cylinder wom [Replace \2. Piston ring worn Replace 3. Air leakage of cylinder gasket. Replace Cannot start or| difficult to start |4. Valve stem worn or unsuitable valve| seat 5. Spark plug loosen \6. Starting motor rotate too slowly 77. Improper valve timing 8. Improper valve clearance ‘Spark plug cannot ignite or weak| ignition 1. Improper spark plug clearance 2. Spark plug dirty or wet 3. Defect ignition coil |4. Trigger short circuit or open circuit 5. Magneto malfunction Insufficient fuel inside throttle body| 1. Breather hole block [2. Injector blocked or failure 3. High Pressure oil pump failure |4. Low pressure,oil pump 5. Oil pump Filter net blocked IRepair or replace [Tighten |Check electrical parts Adjust [Adjust |Adjust or replace [Clean & dry or replace Replace Replace IReplace [Clean or replace [Clean or replace Inspect or replace Inspect or replace [Clean or replace INo idle speed or| lunstable speed 1. Improper valve clearance l2. Unsuitable valve seat 3. Defective vaive l4. Rocker or rocker arm wear 5. Dirty spark plug |6. Incorrect valve clearance 7. Ignition coil failure 8. In & Ex a air hose blocked, idle lvalve 19. Magneto failure lAdjust IRepair or replace Replace Replace Replace IReplace or adjust Replace lAdjust or replace [Replace 8-23Electrical System [High RPM unstable 13. Spark plug dirty |4. Spark plug gap too narrow |S. Valve timing incorrect 6. lgnition coil failure 7. Low pressure,oil pump 8. Air filter too dirty Troubles Possible Cause Countermeasures 1. Valve spring getting wom Replace I2. Camshaft worn Replace Clean or replace lAdjust or replace Adjust Replace lAdjust or replace Clean or replace Engine Power not lenough . Piston ring worn . Improper valve seat Spark plug dirty 18. Improper spark plug gap 19. Injector blocked 10. Insufficient pressure,oil pump 11. Air filter too dirty 12. Rocker arm or camshaft worn 13. Air leakage of inlet pipe 14. Engine oil too much Replace or repair Clean or replace Clean or replace Clean or replace lAdjust or replace Clean or replace Replace [Tighten or replace Check oil level and Ichange 1. Engine oil too much Check cil level and drain 2. Piston ring worn Replace Blue or black|3. Valve wom Replace lexhaust gas l4. Cylinder worn or scraped Replace IS. Vaive stem worn Replace 6. Oil seal of valve stem damaged Replace 1. Valve clearance improper Revebe 2. Valve spring getting weak Pees 13. Valve timing incorrect enlace l4. Cylinder worn R P 5. eplace je 7 lEngine Overheating 1. Carbon deposit on piston head 12. Engine oil too less or too much 3. Oil pump failure 4. Fuel hose blocked IS. Air leakage of inlet pipe |6. Unsuitable engine oil 17. Cooling system failure(see7-5) Clean Check and add or drain Replace Clean [Tighten or replace Change oil 8-24Electrical System Troubles Possible Cause Countermeasures |Valve abnormal noise 1. Valve clearance too big lAdjust 2. Valve spring worn or broken Replace 3. Swing arm or camshaft wom IReplace IPiston abnormal noise 1. Piston wom IReplace 2. Cylinder worn Replace 3. Carbon deposit inside combustion|Clean Ichamber |4. Piston pin or pin hole worn Replace I5. Piston ring or groove worn IReplace Timing chain abnormal noise 1. Chain stretched out [Engine abnormall2. Chain sprocket worn Replace chain and Isprocket Replace chain and lhoise 13. Tensioner failure Isprocket Repair or replace |Clutch abnormal noise 4. Clutch gear worn or damaged Replace clutch gear 12. Cushion rubber aging or damaged Replace clutch gear |Crankshaft abnormal noise 1. Bearing noise Replace 12. Crankshaft pin bearing down Replace 3. Clearance too big Replace \Transmission abnormal noise 1. Gear worn or damaged Replace 2. Main shaft or counter shaft wom Replace 3. Bearing worn Replace |4. Bushing worn Replace 1. Clutch drive disc worn Replace Clutch slippery |2. Clutch driven disc worn or damaged —_|Replace I3. Clutch spring getting weak Replace Ignition System: Troubles Possible Cause Countermeasures 4. Flame ignitor malfunction Replace l2. Spark plug burnt In ve a '3. Incorrect spark plug clearance Clean No spark or weak\*: C@"®0n deposit in spark plug Replace (6. Battery low voltage spark I ery 9 ICharge or replace ignition coil malfunction Replace 8. Trigger coil malfunction Replace 19. Incorrect trigger clearance lAdiust 10. Other circuit malfunction linspect 8-25Electrical System 8.5 Trouble Diagnosis In Accordance With Engine Error Before trouble diagnosis by engine problems, initial checking should be done as follows. 1. Confirm if trouble light is ok. 2. Confirm there's no trouble code record by PDA checking. 3. Confirm there's really trouble existing complained by end-users. Then check the following points: » Check fue! hoses if any fuel leakage. . Check vacuum pipes if any broken, twist or improper connection. . Check intake manifold if any blocked, air leakage or damaged. . Check high-tension cable if any damaged, aging or ignition order is correct. . Check wiring close to ground if it’s clean and firm. . Check connector of all sensors and actuator if any loose or improper connection. Important note: In case there are some problems as above-mentioned, then removal work should be done firstly, then go to next diagnosis. PaRONS Diagnosis helps: 41. Confirm engine without any trouble record. 2. Confirm there's really trouble existing. 3. During checking. do not neglect vehicle periodic maintenance. cylinder pressure. valve timing, fuel supply and so on. 4. Replace ECU to test. In case trouble disappears, then it's a problem of ECU. If trouble still exists, then assemble original ECU and check other points. Frequent troubles list: When starting the engine, engine cannot rotate or rotate slowly. © When starting engine, starter motor can rotate but cannot start engine. + Difficult to start warm or hot engine. © Difficult to start cold engine © RPM is ok, but difficult to start engine. © Starting is ok, but idle speed is unstable at any time. © Starting is ok, but idle speed is unstable during engine warm-up period. * Starting is ok, but idle speed is unstable after engine warm-up. © Starting is ok, idle speed is unstable or engine stop when switch on some lights or other electric components. © Starting is ok, but too high idle speed. ‘© RPM cannot go up or engine stop when acceleration. * Slow acceleration. ¢ Insufficient power and bad performance when acceleration 8-26(1) Starting Failure/Hard Starting General failure part: Engine mechanism part. Electrical System . Battery; 2. Starter motor; 3. Witings harness or ignition switch; 4. General diagnosis procedures: Item Procedures Results Next lUse multi-meter to check battery voltage if| YES |Next step 1 Nottege is between 8-12V or not when engine! "4 |repiace battery [Turn on ignition switch, stop switch side stand|_YES |Next step normally. 2 |switch and check if voltage of ECU pin 32 is| NO Repair switches or| laround 12V. Ichange hamess Keep ignition switch “on”, use multimeter tol YES [Next step 3. |check if voltage of starting motor anode is over] Repair switches or av. change hamess Disassemble starting motor and check its|_ yp |Repair or replace 4 |working status, especially whether there was| |starting motor broken circuit or jammed by bad lubrication. NO Next step If error only occur in Winter, check if starting] eg [Change to proper 5. |motor resistance is too big caused by improper| lubricant loil used. NO INext step |Check if mechanical resistance is too big inside| YES Check engine inside} g [engine. resistance no [Repeat above procedures (2) When starting, engine can rotate but cannot start General failure part: 1. No fuel; 2. Fuel pump; 3. Trigger; 4. Ignition coil; 5. Mechanical parts of engine General diagnosis procedures: item! Procedures Results Next [Connect fuel pressure gauge, turn on ignition| YES |Next step 1. |switch or start engine, check if fuel pressure is Check and repair fuel laround 300kpa. NO |eupply system [Connect PDA. check if there's signal of RPM YES Nex: step capa RPM data after starting engine NO isensor circuit Disconnect high-tension cable, connect spark] yES |Next step 4, [plug and set its electrode 5mm to engine body, Ithen start engine to check if blue and white] yo [Check and repair Ispark appears. ignition system : - Eliminate engine 4 est cna pressure and check if pressure is] YES [fF liminate eng : NO [Next step Use PDA to test, turn on ignition switch,| yes Use PDA to check 5 [oheck if power supply of ECU pin 32 and pin 133 is normal; check if pin 5 and pin 10 works| iQ. |Repair related circuit 8-27Electrical System (3) Difficult to start hot engine General failure part: 1. Water in fuel tank; . Fuel pump; 3. Water temp. sensor: Ignition coil. General diagnosis procedures: item Procedures Results Next [Connect fuel pressure gauge, tun on ignition|_YES [Next step 1 |switch or start engine, check if fuel pressure is| jj [Check and repair fuel laround 300kpa. lsupply system [Disconnect high-tension cable, connect spark| YES |Next step 2 [plug and set its electrode Smm to engine body, - Ithen start engine to check if blue and white| jo [Check and repair| spark appears. ignition system Disconnect water temp. sensor connector, lcheck whether the engine can be started or not, 3 |(Or replace water temp. sensor with a 3000) resistance. Check whether the engine can be| NO |Next step started or not.) Check whether the failure happens right after|_YES [Use PDA to check ltueling NO [Repair related circuit lUse PDA to test, tum on ignition switch, check! YES |Use PDAto check 5 |if power supply of ECU pin 32 and pin 33 is — lnormal: check if pin 5 and pin 10 works normally.|_ NO _ [Repair related circuit YES [Change fuel 8-28(4) Difficult to start cold engine General failure part: 1. Water in fuel tank; 2. Fuel pump; 3. Engine temp. sensor; 4. Injector, 5. Ignition coil; 6. Throttle body and by-pass; 7. Mechanical parts of engine General diagnosis procedures: Electrical System Item Procedures Results Noxt : YES _|Nextstep Connect fue! pump gauge ,start engine, check - 1 lit pressure is pein pes nr ° No [Check and repair fuel lsupply system Disconnect high-tension cable, connect spark! yES |Next step 2 [plug and set its electrode Smm to engine| - body, then start engine to check if blue and] jy [Check and repair ignition lwhite spark appears. [system Disconnect water temp. sensor connector, Repair circuit or replace| check whether the engine can be started or| YES [concor 3 |not. (Or replace water temp. sensor with al 25000 resistance. Check whether the engine] No |Next step |can be started or not.) 4. [Slightly draw throttle cable and check if engine] YES bone rote body and Icould start easily. NO Retstep jg [Disassemble injector and use special tool tol YES _|Replace injector Icheck if there is leakage or block. NO |Next step [Check whether the failure happens right after| YES [Change fuel filing fuel. NO |Next step Yes [Eliminate engine 7. Check if cylinder pressure is insufficient. Imechanical failures NO__|Next step 8-29