Cannondale DIAGNOSTIC TOOL User Manual

C a n n on d a le D ia g n os tic Tool Manual

For vehicles (ATV & Motorcycles) equipped with the MC1000 Engine Management System

Software CD P/N 971-5001983

Data Cable P/N 971-5001984

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust gases.

WHAT CAN HAPPEN

Running the engine indoors will expose you to dangerous exhaust gases. Breathing carbon monoxide gas leads to poisoning, asphyxiation, and death. This will happen rapidly and without no tic e.

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods.

P/N 912-5001985

Printed : 11/8/01

S a fe ty A le rts

• FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

• Keep this Assembly manual in a safe place.

Messages with the Safety Alert Symbol

• Pay special attention to all messages preceded by the Safety Alert Symbol. The Safety Alerts symbols means: ATTENTION! BECOME ALERT! YOUR and YOUR CUSTOMER’S SAFETY IS INVOLVED.

Indicates that severe personal injury or

DANGER

death WILL result if instructions are not followed.

WARNING

CAUTION

Indicates a potential hazard that could result in vehicle damage if instructions are not followed.

NOTE :

Provides helpful info rmat ion

Indicates a potential hazard that COULD result in serious injury or death.

Cannondale Diagnostic Tool Manual.fm

Basics

WHAT IS THE CANNONDALE DIAGNOSTIC TOOL?

The Cannondale Diagnostic Tool is a Windows-based software program and special data cable that enables you to connect and communicate with vehicles using the MC1000 Engine Management System. The software is installed on a PC or Pocket PC, then the PC (or Pocket PC) is connected to the vehicle wiring harness via the special data cable. Once the software is installed in the PC and communication with the vehicle ECU is established, here’s what the tool can do:

• Send a calibration file from the PC t o the vehicle ECU.

• Receive a calibration file from the vehicle ECU to the PC.

• Set the vehicle throttle body and injector variables

• Monitor the (vehicle) ECU operating parameters

• Read system faults

INSTALLING THE SOFTWARE

To install the Cannondale Diagnostic Tool in your PC, insert the installation CD in your computer CDROM drive. Use the Windows explorer and open the program Setup.exe on the software CD. Follow the step-by-step instructions. When the installation is complete, go to the security set-up. See next heading.

SECURITY SET_UP

After the software has been installed on your PC, click on the Windows START button in the lower left corner of your desktop go to Cannondale DIagnostic and Maintenance Program group and open SecurityCode.exe. Follow the instructions that are displayed in program window. When the security code is entered (after you call Optimum Power to get it), you can begin using the software.

ALWAYS MAKE SURE THE VEHICLE BATTERY IS FULLY CHARGED

Before performing any diagnostic work on the vehicle make sure the battery is at full charge. If the battery voltage is low the ECU power relay may drop out and shut off the ECU. If the battery is not fully charged the ECU power relay can drop out while the engine is cranking over. Why? During crank over the battery voltage could drop below the needed latch voltage of 10 volts.

ALWAYS MAKE SURE THE ECU IS POWERED-UP

The vehicle’s ECU operates on a relay controlled power source which is separate from any lighting or starting electrical systems. The relay “latches-in” the ECU when the crankshaft sensor detects flywheel movement. If the ECU senses inactivity (no engine start or communications between the PC and ECU) for two minutes, it powers down. If you try to communicate with the ECU when it is powered-down or off, the “Failed to Unlock System 125” message will display.

POWERING-UP MOTO ECU’S

On motorcycles, power-up is relatively simple. Press the green start button and release it without starting the engine. When the system is powered-up the green LED on the data cable “block” will light.

P/N 912-5001985 Printed : 11/8/01

POWERING-UP AT V ECU’S

To power-up the ECU on ATVs you have to switch the ignition switch to the “ON” position, then switch the engine switch to the RUN position. Then, press the green start button and release it without starting the engine. When the system is powered-up the green LED on the data cable “block” will light.

After 2 minutes of inactivity, the ECU will power-down automatically except with the ATV the data cable block green LED will not go out. It will remain lit as long as the ATV ignition is in the “ON” position.

CONNECTING THE DATA CABLE

1. Serial connector (female to PC)

2. Serial connector (male to Pocket PC)

3. LED

4. Cable connector (to vehicle)

1. Motorcycle harness connector - on this model (2002 X440s) the connector is secured to the relay mounting plate on the frame spar. Components have been removed for this photo.

2. Cap

3. Data interface connector

1. ATV harness connector - located under the right front fender near the main fuse

2. Cap

3. Main fuse holder

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“FAILED TO UNLOCK SYSTEM 125”.

This message means that the Cannondale Diagnostic Tool was not able to communicate with the vehicle ECU. If you see this message check one or more of the following:

• Make sure that both the vehicle harness connector and data cable are undamaged (pins not bent or broken) and the connectors are properly locked together.

• Make sure the vehicle battery is fully charged.

• Make sure the vehicle ECU is powered-up. See page 3.

• Make sure the data cable is plugged securely into the PC.

• Click OK and start again.

P/N 912-5001985 Printed : 11/8/01

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