Sym RV 250i, GTS 300i, GTS 250i, JOYMAX 300i Service Manual

FOREWORD

HOW TO USE THIS MANUAL

CONTENTS

SERIAL NUMBER

GTS 250i / RV 250i

GTS 300i / JOYMAX 300i

SERVICE MANUAL

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Contents

Foreword

This service manual contains the technical data of each component inspection and
repair for the SANYANG LM25W5 / LM30W series scooter. The manual is shown
with illustrations and focused on “Service Procedures”, “Operation Key Points”,
and “Inspection Adjustment”, providing technicians with service guidelines.

If the style or the mechanical structures of the scooter, LM25W5 / LM30W series
scooter are different from those of the photos or pictures shown in this manual, the
actual vehicle shall prevail. Specifications are subject to changes without notice.

Service Department

SANYANG INDUSTRY CO., LTD.

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Contents

How To Use This Manual

This service manual describes the basic information of different system parts and
system inspection & service for SANYANG LM25W5 / LM30W series scooter. In
addition, please refer to the manual contents in detail for the model you serviced in
inspection and adjustment.

The first chapter covers the general information and the trouble diagnosis.
The second chapter covers the periodic maintenance information and the special
tool models.
The third to the 11th chapters cover the engine and the driving systems.
The 12th chapter is the cooling system.
The 13th to the 16th chapter contain the relative parts of the body frame assembly.
The 17th chapter is the electrical system.
The 18th chapter is the emission control system.
The 19th chapter is the wiring diagram.
Please see index of content for quick having the special parts and system
information.

There are 4 buttons, “Foreword”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the PDF version, and can be access to these items by
click the mouse.

If user wants to look for the content of each chapter, selecting the words of each
chapter on the contents can reach to each chapter. There are two buttons,
“Homepage and contents, onto the top line of first page of the each chapter. Thus,
if the user needs to check other chapters, he can click the top buttons to back the
homepage or contents. The content of each chapter can be selected too.
Therefore, when needs to checking the content inside of the chapter, click the
content words of the chapter so that can back to the initial section of the content.
In addition, there is a “To this chapter contents” button at the second page of each
contents so that clicking the button can back to the contents of this chapter.

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Contents

Page Content Index

1-1 ~ 1-18

2-1 ~ 2-18

3-1 ~ 3-8

4-1 ~ 4-60

5-1 ~ 5-12

6-1 ~ 6-16

7-1 ~ 7-8

General Information

Maintenance Information

Lubrication System

Fuel Injection System

Engine Removal

Cylinder Head / Valve

Cylinder / Piston

1

2

3

4

5

6

7

8-1 ~ 8-14

9-1 ~ 9-8

10-1 ~ 10-10

11-1 ~ 11-8

12-1 ~ 12-14

13-1 ~ 13-14

14-1 ~ 14-12

15-1 ~ 15-10

16-1 ~ 16-6

V-Belt Drive System

Final Drive Mechanism

AC Generator / Start Clutch

Crankshaft / Crankcase

Cooling System

Body Cover

Brake System

Steering / Front Wheel / Front Cushion

Rear Wheel / Rear Fork / Rear Cushion

8

9

10

11

12

13

14

15

16

17-1 ~ 17-22

18-1 ~ 18-10

19-1 ~ 19-2

Electrical Equipment

Emission Control System

Electrical Diagram

17

18

19

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Contents

Serial Number

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Contents

Symbols and Marks····························1-1
General Safety····································1-2
Before Servicing·································1-3

Torque Values···································· 1-12
Trouble Diagnosis······························ 1-14
Lubrication Points ····························· 1-18

1. General Information

Specifications·····································1-9

Symbols and Marks

Symbols and marks are used in this manual to indicate what and where the special service is needed. If
supplemental information is needed for these symbols and marks, explanations will be added in the text
instead of using the symbols or marks.

Warning

Caution

Means that serious injury or loss of life may happen if procedures are not

correctly followed.

Means that equipment damages may result if procedures are not followed.

Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the

1

Engine oil

Grease King Mate G-3 is recommended.

Gear oil

Locking sealant

Oil seal

Renew

Brake fluid

Special tools

Correct

Wrong

damage that caused by not apply with the limited engine oil.

(Recommended oil: KING MATE G-3 oil)

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL

# 140)

Apply sealant; medium strength sealant should be used unless otherwise

specified.

Apply with lubricant.。

Replace with a new part before installation.

Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools

Meaning correct installation.

Meaning wrong installation.

Indication Indication of components.

Directions

Indicates position and operation directions

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).

1-1

To this chapter contents

1. General Information

General Safety

Carbon Monoxide

Before you start the engine, make sure the place
is well ventilated. Never start the engine in an
unventilated place. If you have to start the engine
in an unventilated place, an exhaust fume
extractor is needed.

Caution

Exhaust fume contains toxic gas which may
cause one to lose consciousness and even result
in loss of life.

Gasoline

Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark should be allowed in the work place or
where gasoline is being stored.

Caution

Gasoline is highly flammable, and may explode
under some conditions, keep it away from the
children.

Used Engine Oil

Caution

Prolonged contact with the used engine oil (or
transmission oil) may cause skin cancer although
it might not be verified yet. We recommend that
you wash your hands with soap right after
contacting. Keep the used oil beyond reach of the
children.

Hot Components

Caution

Components of the engine and exhaust system
can be extremely hot after engine running. They
remain very hot even after the engine has been
stopped for a period of time. Before performing
service work on these parts, wear the heat
insulation gloves or wait until the temperature
drops.

Battery

Caution

‧ Battery emits explosive gases; flame is strictly

prohibited. Keep the place well ventilated
when the battery is being charged.

‧ Battery contains sulfuric acid (electrolyte)

which can cause serious burns, be careful not
to spill it on your skin or eyes. If you get
battery fluid on your skin, flush it off with water
immediately. If you get battery fluid in your
eyes, flush it off immediately with water and
go to hospital to see an ophthalmologist

doctor.

‧ If you swallow the battery fluid by mistake,

drink a lot of water or milk, and take some
laxative such as Epsom salts or vegetable oil
and then go to see a doctor.

‧ Keep the battery and battery fluid beyond

reach of the children.

Brake Shoes

Do not use compressed air or brush to clean the
components of the brake system. Use a vacuum
cleaner or the equivalent to avoid dust drifting in
the air.

Caution

Inhaling brake shoes dust may cause disease or
even cancer of the respiratory system.

Brake Fluid

Caution

Brake fluid spilled on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the top of the parts for protection
when servicing the brake system. Keep the brake
fluid beyond reach of the children.

1-2

To this chapter contents

Before Servicing

y Always use SANYANG genuine parts and

recommended oil. Using improper parts may
cause damage to or destruction of the vehicle.

y Special tools are designed for removal and

installation of component parts without
damaging them. Using wrong tools may result in
parts damage.

y When servicing this vehicle, use only metric

tools. Metric bolts, nuts, and screws are not
interchangeable with the Britain system, using
wrong tools and fasteners may damage this
vehicle.

1. General Information

y Never bend or twist control cables to avoid

unsmooth control and premature worn out.

y Rubber parts may become deteriorated when

old, and be damaged by solvent and oil easily.
Check these parts before installation to make
sure that they are in good condition, replace if
necessary.

y When loosening a component which has

different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.

y Store complex components such as

transmission parts in the proper assemble order
and tie them together with a wire for ease of
installation later.

y Clean the outside of the parts or the cover

before removing it from the vehicle. Otherwise,
dirt and deposit accumulated on the part's
surface may fall into the engine, chassis, or
brake system to cause damage.

y Wash and clean parts with high flash point

solvent, and then blow dry with compressed air.
Pay special attention to O-rings or oil seals
because most of the cleaning agents have bad
effect on them.

y Note the reassemble position of the important

components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).

y Components not to be reused should be

replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.

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1. General Information

y The length of bolts and screws for assemblies,

cover plates or boxes is different from one
another, be sure they are correctly installed. In
case of confusion, Insert the bolt into the hole to
compare its length with other bolts, if its length
out side the hole is the same with other bolts, it
is a correct bolt. Bolts for the same assembly
should have the same length.

y Tighten assemblies with different dimension

fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.

y Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if
the contact surface has any damage.

y The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can go
to their connections so that there is enough
room below the enlarged ends for tightening the
clamps.

Groove

Clamp

Connector

y Rubber and plastic boots should be properly

reinstalled to the original correct positions as
designed.

y When oil seal is installed, fill the groove with

grease, install the oil seal with the name of the
manufacturer facing outside, and check the
shaft on which the oil seal is to be installed for
smoothness and for burrs that may damage the
oil seal.

Manufacturer's name

1-4

Boots

y The tool should be pressed against two (inner

and outer) bearing races when removing a ball
bearing. Damage may result if the tool is
pressed against only one race (either inner race
or outer race). In this case, the bearing should
be replaced. To avoid damaging the bearing,
use equal force on both races.

Both of these examples can result in
bearing damage.

To this chapter contents

y Lubricate the rotation face with specified

lubricant on the lubrication points before
assembling.

y Check if positions and operation for installed

parts is in correct and properly.

y Make sure service safety each other when

conducting by two persons.

1. General Information

y After service completed, make sure all

connection points is secured.
Battery positive (+) cable should be connected
firstly.

y And the two posts of battery have to be greased

after connected the cables.

y Make sure that the battery post caps are

located in properly after the battery posts had
been serviced.

y Note that do not let parts fall down.

y Before battery removal operation, it has to

remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not contact
with body to prevent from circuit short and
create spark.

y If fuse burned, it has to find out the cause and

solved it. And then replace with specified
capacity fuse.

Capacity
verification

1-5

To this chapter contents

1. General Information

y When separating a connector, it locker has to

be unlocked firstly. Then, conduct the service
operation.

y Do not pull the wires as removing a connector

or wires. Hold the connector body.

y Make sure if the connector pins are bent,

extruded or loosen.

y Insert the terminal completely.

Check if the terminal is covered by the boot.
Do not let boot open facing up.

y Secure wires and wire harnesses to the frame

with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.

y Insert the connector completely.

If there are two lockers on two connector sides,

make sure the lockers are locked in properly.

Check if any wire loose.

y Check if the connector is covered by the twin

connector boot completely and secured
properly.

y Wire band and wire harness have to be

clamped secured properly.

y Do not squeeze wires against the weld or its

clamp.

y Before terminal connection, check if the boot is

crack or the terminal is loose.

1-6

To this chapter contents

y Do not let the wire harness contact with rotating,

moving or vibrating components as routing the
harness.

y Keep wire harnesses far away from the hot

parts.

Never Touch

1. General Information

y Protect wires or wire harnesses with electrical

tape or tube if they contact a sharp edge or
corner. Thoroughly clean the surface where
tape is to be applied.

y Secure the rubber boot firmly as applying it on

wire harness.

y Route wire harnesses to avoid sharp edges or

corners and also avoid the projected ends of
bolts and screws.

y Route harnesses so that they neither pull too

tight nor have excessive slack.

y Never use wires or harnesses which insulation

has been broken. Wrap electrical tape around
the damaged parts or replace them.

y Never clamp or squeeze the wire harness as

installing other components.

Never clamp or
squeeze the wire
harness

Never too tight

1-7

To this chapter contents

1. General Information

y Do not let the wire harness been twisted as

installation.

y Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive
slack, be rubbed against or interfere with
adjacent or surrounding parts in all steering
positions.

y With sand paper to clean rust on connector

pins/terminals if found. And then conduct
connection operation later.

Clean rust

y Before operating a test instrument, operator

should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.

Do you know how to set the
instrument to its
measurement position and
the insert locations of its
two probes?

1-8

To this chapter contents

Specifications

MAKER SANYANG MODEL LM25W5-6/7

Overall Length

Overall Width

Dimension

Weight

Overall Height

Wheel Base

Front

Curb

Weight

Passengers/Weight

Rear

Total

Front

2165 mm

870 mm
1395 mm
1495 mm

79 kg
111 kg
190 kg

Two / 150 kg

134 kg

Suspension

System

Tire

Specifications

Brake System

Performance

1. General Information

Front

Rear

Front

Rear

Front

Rear

Max. Speed

Climb Ability

TELESCOPIC FORK

UNlT SWING
110 / 90-13 56P
130 / 70-13 57P

DISK (ø 240 mm)

DISK (ø 220 mm)

128 km/hr

<27°

Total

Weight

Type

Installation and

arrangement

Fuel

Cycle/ Cooling

Bore

Stroke

Cylinder

Number/Arrange

Engine

Displacement

Compression Ratio

ment

Max. HP

Rear

Total

206 kg

340 kg

4-STROKE ENGINE

Vertical, below center,

incline 80°

Above 92 unleaded

4-stroke/

Liquid-cooled

71 mm

63.3 mm

SINGLE CYLINDER

250.6 cc

10.5 : 1

23.4 ps / 8000 rpm

Primary

Reduction

Secondary

Reduction

Speedometer

Exhaust Pipe Position and

Direction

Lubrication System

n

Exhaust

Concentratio

Reduction

Clutch

Transmission

Horn

Muffler

CO

HC

NOx

Belt

Gear

Centrifugal, dry type

CVT

0 ~ 160 km/hr

<110 dB/A

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

<2.0 g/km
<0.3 g/km

<0.15 g/km

Max. Torque

Ignition

Starting System

2.3 kg-m / 5500 rpm

Full transistor ignition

Electrical starter

Catalytic reaction control

E.E.C. -

P.C.V. √

system

√

1-9

To this chapter contents

1. General Information

Specifications

MAKER SANYANG MODEL

Overall Length

Overall Width

Dimension

Weight

Overall Height

Wheel Base

Front

Curb

Weight

Passengers/Weight

Rear

Total

Front

Two / 150 kg

2165 mm

870 mm
1395 mm
1495 mm

79 kg
111 kg
190 kg

134 kg

Suspension

System

Tire

Specifications

Brake System

Performance

Front

Rear

Front

Rear

Front

Rear

Max. Speed

Climb Ability

LM25W5-P

LM25W7-7

TELESCOPIC FORK

UNlT SWING
110 / 90-13 56P
130 / 70-13 57P

DISK (ø 240 mm)

DISK (ø 220 mm)

128 km/hr

<27°

Total

Weight

Type

Installation and

arrangement

Fuel

Cycle/ Cooling

Bore

Stroke

Cylinder

Number/Arrange

Engine

Displacement

Compression Ratio

ment

Max. HP

Rear

Total

206 kg

340 kg

4-STROKE ENGINE

Vertical, below center,

incline 80°

Above 92 unleaded

4-stroke/

Liquid-cooled

71 mm

63 mm

SINGLE CYLINDER

249.4 cc

10.5 : 1

23.4 ps / 8000 rpm

Primary

Reduction

Secondary

Reduction

Speedometer

Exhaust Pipe Position and

Direction

Lubrication System

n

Exhaust

Concentratio

Reduction

Clutch

Transmission

Horn

Muffler

CO

HC

NOx

Belt

Gear

Centrifugal, dry type

CVT

0 ~ 160 km/hr

93~112 dB/A

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

<2.0 g/km
<0.3 g/km

<0.15 g/km

1-10

Max. Torque

Ignition

Starting System

2.3 kg-m / 5500 rpm

Full transistor ignition

Electrical starter

E.E.C. -

P.C.V. √

Catalytic reaction control

system

√

To this chapter contents

Specifications

MAKER SANYANG MODEL LM30W-6/T

Overall Length

Overall Width

Dimension

Weight

Overall Height

Wheel Base

Front

Curb

Weight

Passengers/Weight

Rear

Total

Front

2165 mm

870 mm
1395 mm
1495 mm

79 kg
111 kg
190 kg

Two / 150 kg

134 kg

Suspension

System

Tire

Specifications

Brake System

Performance

1. General Information

Front

Rear

Front

Rear

Front

Rear

Max. Speed

Climb Ability

TELESCOPIC FORK

UNlT SWING
110 / 90-13 56P
130 / 70-13 57P

DISK (ø 240 mm)

DISK (ø 220 mm)

128 km/hr

<27°

Total

Weight

Type

Installation and

arrangement

Fuel

Cycle/ Cooling

Bore

Stroke

Cylinder

Number/Arrange

Engine

Displacement

Compression Ratio

ment

Max. HP

Rear

Total

206 kg

340 kg

4-STROKE ENGINE

Vertical, below center,

incline 80°

Above 92 unleaded

4-stroke/

Liquid-cooled

73 mm

63 mm

SINGLE CYLINDER

263.7 cc

10.1 : 1

23.3 ps / 7500 rpm

Primary

Reduction

Secondary

Reduction

Speedometer

Exhaust Pipe Position and

Direction

Lubrication System

n

Exhaust

Concentratio

Reduction

Clutch

Transmission

Horn

Muffler

CO

HC

NOx

Belt

Gear

Centrifugal, dry type

CVT

0 ~ 160 km/hr

93~112 dB/A

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

<2.0 g/km
<0.3 g/km

<0.15 g/km

Max. Torque

Ignition

Starting System

2.5 kg-m / 5500 rpm

Full transistor ignition

Electrical starter

Catalytic reaction control

E.E.C. -

P.C.V. √

system

√

1-11

To this chapter contents

1. General Information

Torque Values

The torque values listed in below are for more important tightening torque values. Please see standard
values for those not listed in the table.

Standard Torque Values for Reference

Type Tighten Torque Type Tighten Torque

5 mm bolt、nut
6 mm bolt、nut
8 mm bolt、nut
10 mm bolt、nut
12 mm bolt、nut

Engine Torque Values

Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks

Cylinder stud bolt 4 10 1.0~1.4

Cylinder head nut 4 8 3.6~4.0

Cylinder head right bolt 2 8 2.0~2.4

Cylinder head side cover bolt 2 6 1.0~1.4

Cylinder head cover bolt 4 6 1.0~1.4

Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4

Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0

Air inject pipe bolt 4 6 1.0~1.4

Air inject reed valve bolt 2 3 0.07~0.09

Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread

Spark plug 1 10 1.0~1.2

Camshaft Chain Tensioner bolt 2 6 1.0~1.4

Carburetor insulator bolt 2 6 0.7~1.1

Oil pump screw 2 3 0.1~0.3

Water pump impeller 1 7 1.0~1.4

Engine left cover bolt 9 6 1.1~1.5

Engine oil draining bolt 1 12 3.5~4.5

Engine oil strainer cap 1 30 1.3~1.7

Mission draining bolt 1 8 0.8~1.2

Mission filling bolt 1 10 1.0~1.4

Clutch driving plate nut 1 28 5.0~6.0

Clutch outer nut 1 14 5.0~6.0

Drive face nut 1 14 8.5~10.5

ACG. Flywheel nut 1 14 5.0~6.0

Crankcase bolt 7 6 0.8~1.2

Mission case bolt 7 8 2.6~3.0

Muffler mounting bolt 3 10 3.2 ~3.8

Muffler mounting nut 2 8 1.0 ~1.2

0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m

0.8~1.2kgf-m

1.8~2.5kgf-m

3.0~4.0kgf-m

5.0~6.0kgf-m

6 mm screw、SH nut
6 mm bolt、nut
8 mm bolt、nut
10 mm bolt、nut

0.7~ 1.1kgf-m

1.0 ~1.4kgf-m

2.4 ~3.0kgf-m

3.5~4.5kgf-m

1-12

To this chapter contents

1. General Information

Frame Torque Values

Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks

Mounting bolt for steering handle
post

Lock nut for steering stem 1 BC1 1.0~2.0

Steering top cone race 1 BC1 2.0~3.0

Front wheel axle nut 1 12 5.0~7.0

Rear wheel axle nut 1 16 11.0~13.0

Front cushion mounting bolt 4 10 3.5~4.5

Rear cushion upper connection bolt 1 10 3.5~4.5

Rear cushion under connection bolt 1 8 2.4~3.0

Rear fork mounting bolt 2 10 4.0~5.0

Brake hose bolt 2 10 3.0~4.0

Brake air-bleeding valve 1 6 0.8~1.0

Front brake disc mounting bolt 5 8 4.0~4.5

Rear brake disc mounting bolt 5 8 4.0~4.5

Brake clipper mounting bolt 2 8 2.9~3.5

Engine hanger link bolt 2 12 7.5~9.5 On frame side

Engine hanger link nut 1 12 7.5~9.5 On engine side

Main standard nut 1 10 4.0~5.0

Air cleaner bolts 2 6 1.0~1.4

1 10 4.0~5.0

1-13

To this chapter contents

r

1. General Information

Trouble Diagnosis

A. Engine hard to start or can not be started

Check and adjustment Failure condition Possible causes

Loosen carburetor drain bolt

to check if there is gasoline

inside the carbureto

Fuel supplied tom

carburetor sufficient

Remove spark plug, install it

into spark plug cap, and

perform a spark test against

engine ground.

Check if sparks Weak sparks, no spark

Perform cylinder

compression pressure test.

No fuel is supplied to

carburetor

at all

1. No fuel in fuel tank

2. Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.

3. Float valve clogged

4. Lines in fuel tank evaporation system
clogged

5. Malfunction of fuel pump

6. Loosen or damaged fuel pump vacuum
hose

7. Fuel filter clogged

1. Malfunction of spark plug

2. Spark plug foul

3. Malfunction of CDI set

4. Malfunction of AC generator

5. Ignition coil is in open or short circuit

6. Ignition coil leads open or short circuit

7. Malfunction of main switch

Cylinder compression

pressure normal

Re-start by following the

starting procedures

No ignition There are some signs of

Remove the spark plug again

and check it.

Dry spark plug Wet spark plug

Remove carburetor after 30

minutes and connect a hose

onto fuel rich circuit. Then

blow the hose with air

Low compression

pressure or no pressure

ignition, nut engine can

not be started

1. Piston ring seized

2. Malfunction of cylinder valves

3. Worn cylinder and piston ring

4. Cylinder gasket leak

5. Sand hole in compression parts

1. Malfunction of throttle valve operation

2. Air sucked into intake manifold

3. Incorrect ignition timing

1. Fuel level in carburetor too high

2. Malfunction of throttle valve operation

3. Throttle valve opening too wide

1-14

Blowing in normal Blowing clogged

1. Malfunction of automatic by- starter

To this chapter contents

1. General Information

B. Engine run sluggish (Speed does not pick up, lack of power)

Check and adjustment Fault condition Probable causes

Try gradual acceleration and

check engine speed

Check ignition timing
(Using ignition lamp)

Engine speed can be

increased.

Ignition timing correct Incorrect ignition timing

Check cylinder compression

pressure (using compression

pressure gauge)

Compression pressure

correct

Engine speed can not be

increased.

No compression pressure

1. Air cleaner clogged

2. Poor fuel supply

3. Lines in fuel tank evaporation system
clogged

4. Exhaust pipe clogged

5. Fuel level too low in carburetor

6. Fuel nozzle clogged in carburetor.

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Seized piston ring

Check if carburetor jet is

clogged

No clogged Clogged

Remove spark plug

No foul or discoloration Fouled and discoloration

Check if engine over heat

Normal Engine overheat

Continually drive in

acceleration or high speed

No knock Knock

1. Remove foreign

1. Remove dirt

2. Incorrect spark plug heat range

1. Piston and cylinder worn out

2. Lean mixture

3. Poor fuel quality

4. Too much carbon deposited in
combustion chamber

5. Ignition timing too advanced

6. Poor circuit on the cooling system

1. Too much carbon deposited in
combustion chamber

2. Lean mixture

3. Poor fuel quality

4. Ignition timing too advanced

1-15

To this chapter contents

1. General Information

C. Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes

Check ignition timing
(Using ignition lamp)

Adjust the air screw of

carburetor

Normal Abnormal

Good Poor

Air sucked through

carburetor gasket

No air sucked Air sucked

Remove spark plug, install

spark plug into spark plug

cap and perform spark test

against engine ground

1. Incorrect ignition timing (malfunction

of CDI or AC alternator)

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket

2. Carburetor lock loose

3. Poor intake gasket

4. Poor carburetor O-ring

5. Vacuum hose crack

Good spark Poor

D. Engine runs sluggish (High speed)

Check and adjustment

Check ignition timing

Normal Abnormal

Check for fuel supplying

system in automatic fuel cup

Good Poor

Check if carburetor clogged

Fault condition Probable causes

1. Spark plug fouled

2. Malfunction of CDI

3. Malfunction of AC generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug

leads

6. Malfunction of main switch

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

1-16

No clogged Clogged

1. Cleaning

To this chapter contents

1. General Information

E. Clutch, Driving And Driving Pulley

FAULT CONDITIONS

Engine can be started but

motorcycle can not be moved.

Engine running and misfire as

motorcycle initial forward moving or

jumping suddenly (rear wheel
rotating as engine in running)

PROBABLE CAUSES

1. Driving belt worn out or deformation

2. Driving disk damaged

3. Driving pulley spring broken

4. Clutch ling broken

5. Driving slide-shaft gear groove broken

6. Transmission gear damaged

1. Clutch ling spring broken

2. Clutch outer cover stickled with clutch balance
weights

3. Connection parts in clutch and shaft worn out or
burned

1. Driving belt worn out or deformation

Poor initial driving

(Poor climbing performance)

2. Balance weight roller worn out

3. Driving sliding gear shaft worn out

4. Driving disk spring deformation

5. Driving sliding gear shaft worn out

6. Greased in driving belt and sliding gear.

1-17

To this chapter contents

1. General Information

Lubrication Points

Steering shaft bearing

Acceleration cable/
Front & rear brake lever pivot

Seat locker

1-18

Speedometer gear/
front wheel bearing

Side stand shaft

Main stand shaft

Clutch bearing

Home page

Contents

Precautions in Operation···················· 2-1
Periodical Maintenance Schedule······ 2-2
Engine Oil············································· 2-3
Engine Oil Strainer Clean···················· 2-3
Gear Oil················································· 2-4
Fuel Lines / Cable································ 2-4
Air Cleaner ··········································· 2-5
P.C.V. System ······································ 2-6
Valve Clearance··································· 2-6
Spark Plug············································ 2-7

Drive Belt··············································2-8
Steering Handle Top Bearing·············· 2-9
Cushion ················································2-9
Disk Brake System·······························2-10
Brake Light Switch / Start Switch·······2-12
Headlight Distance Adjustment·········· 2-12
Wheel / Tire···········································2-12
Battery ··················································2-13
Nuts, Bolts Tightness··························2-13
Special Tools List ································ 2-14

2. Maintenance Information

Cylinder Compression Pressure········ 2-8

Precautions in Operation

Model

Fuel Tank Capacity 12,000 c.c.

capacity 1,400 c.c.

Engine Oil

change 1,200 c.c.

LM25W5-6/7/P

LM25W7-7

2

LM30W-6/T

Transmission
Gear oil

Clearance of throttle valve 2~6 mm
Spark plug CR8E (gap:0.6~0.7 mm)
Timing advance idle speed BTDC 10º / 1,650 rpm
Full timing advanced BTDC 30º
Idling speed 1,650±100 rpm
Cylinder compression pressure 12 ± 2 kgf/cm²

Valve clearance
Tire dimension Front 110/90-13 56P

Tire dimension Rear 130/70-13 57P
Tire pressure

(cold)
Battery 12V10Ah (MF battery) / YTX12-BS

Capacity of

coolant

capacity 180 c.c.
change 160 c.c.

Engine + radiator 850 c.c.

Reservoir upper 420 c.c.

IN 0.10±0.02 mm
EX 0.15±0.02 mm

single Front: 1.75 kg/cm² Rear: 2.25 kg/cm²
Load 90 Kg (full load) Front: 2.25 kg/cm² Rear: 2.5 kg/cm²

2-1

☆

A

R

☆

R

☆

R

☆

☆

RRep

k

☆

R R

☆

p

☆

☆

A

☆

☆

g

☆

R

☆

☆

A

A A

☆

☆

p

☆

☆

p

To this chapter contents

2. Maintenance Information

Periodical Maintenance Schedule

1 Month

every

1,000KM

ICC
ICC
II

II I I I
II I I I
II I I I
II I
II I
II I I I
II I I I
II

No item

1
2
3
4
5

ir cleaner
2nd air jet leaner
Fuel filter
Oil filter
Engine oil change

6 Tire pressure
7 Battery inspection
8 Brake & free ply check

9 Steering handle chec
10 Cushion operation check
11 Every screw tightening check
12 Gear oil check for leaking
13
14

Spark plug check or change
Gear oil change

Every

300KM

CC C

RRe

15 Frame lubrication
16 Exhaust pipe
17
18
19
20
21
22

Ignition timing
emission check in Idling
Throttle operation
Engine bolt tightenin
CVT driving device(belt﹞

CVT driving device(roller)
23 Lights/electrical equipment/multi-meters
24 Main/side stands & springs
25 Fuel lines

II I I I
II I I I

II I I
III I
III I

II I I I
II I
III I

26 Shock absorbers
27 Cam chain
28
29
30
31
32

Valve clearance
Crankcase evaporative control system
Crankcase blow-by over-flow pipe
2nd air jet system

Evaporative control system
33 Lines & connections in cooling system
34 Coolant reservoir
35 Coolant

III I
I
ICC C

IIC C
II I I I

II I I I
IRe

lace

36 ECU input voltage
37 EFi sensor coupler

Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication

Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the motorcycle at the optimum condition

The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference which ever comes first.
Remarks: 1. These marks “ ☆” in the schedule are emission control items. According to EPA regulations, these items must be

performed normally period ica l mainte nanc e fol lo wing the use r man ual i nstruc tions . They are prohibited to be
adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.

2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.

3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
motorcycle has accumulated a higher mileage.

4. Preventive maintenance

a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious

lower. Than ever

c. Replace worn out pistons, cylinder head.

II

3 month

every

3,000KM

6 month

every

6,000KM

lacement for every 1,000 km

lacement for every 5,000 km

L L

I

C C

II I

Re

lacement for every 2,000 km

II I

I

1 year

every

12,000KM

2-2

To this chapter contents

Engine Oil

Turn off engine, and park the motorcycle in flat
surface with main stand.
Check oil level with oil dipstick
So not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out recommended
oil to upper level.

Oil Change

Caution

y Drain oil as engine warmed up so that make

sure oil can be drained smoothly and
completely.

Place an oil pan under the motorcycle, and
remove oil drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value: 3.5~4.5kgf-m
Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.

Engine oil capacity:

Disassembly 1400c.c.
Replacement 1200c.c.

Install dipstick, start the engine for running several
minutes.
Turn off engine, and check oil level again.

Check if engine oil leaks.

Engine Oil Strainer Clean

Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.

Torque value：1.3~1.7kgf-m

2. Maintenance Information

2-3

To this chapter contents

2. Maintenance Information

Gear Oil

Oil level inspection
Park the motorcycle on flat surface with main
stand.
Turn off the engine.

Gear Oil Change

Remove oil inspection bolt.
Remove drain plug and drain oil out.
Install the drain plug after drained.

Torque value: 0.8~1.2kgf-m

Add gear oil to specified quantity from the
inspection hole.
Install the inspection bolt.

Torque value: 1.0~1.4kgf-m
Gear Oil Quantity: 170 c.c. when replacing

Make sure that the bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.

Fuel Lines / Cable

Remove luggage box.
Remove rear carrier.
Remove body covers.
Check all lines, and replace it when they are
deterioration, damage or leaking.

Warning

Drain plug

Oil inspection bolt

2~6 mm

y Gasoline is a low ignition material so any kind

of fire is strictly prohibited as dealing it.

Acceleration Operation

Have a wide open of throttle valve as handle bar in
any position and release it to let back original (full
closed) position.
Check handle bar if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth
Measure handle bar free play in its flange part.
Free play: 2~6 mm.

Adjustment can be done in either end.
Secondary adjustment is conducted from top side.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment nut.

Rubber

Adjustment nut

2-4

To this chapter contents

Primary adjustment is conducted from bottom
side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check acceleration
operation condition.

Air Cleaner

Air Cleaner Element

Remove 8 screws from the air cleaner cover and
then remove the cover.

Remove the body cover.
Loosen bolt from the air cleaner air hose.

Remove 6 screws, and then remove the air
cleaner element.

2. Maintenance Information

Adjustment nut

8 screws

Bolt

6 screws

Caution

y The air cleaner element is made of paper so

do not soap it into water or wash it with water.

2-5

To this chapter contents

2. Maintenance Information

P.C.V. system

Remove the plug from lower of the breather
chamber hose.
Release the dry internal deposit.
Every 2,000 kilometers release oil

Caution

y A In releases the breather chamber hose in

the transparent section as worthy of looking
at as any deposit

y In the multi- rain or the accelerator in the

situation rides, must reduce the maintenance
traveling schedule

y In releases the breather chamber hose in the

transparent section as worthy of looking at as
any deposit

Valve Clearance

Caution

y Checks and adjustment must be performed

when the engine temperature is below 35℃.

2 bolts

Breather chamber hose

Timing mark

Remove luggage box.
Remove cylinder head cover & side cover.
Remove ignition timing hole cap located in front
upper side of engine right cover
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket aligns with cylinder
head mark so that piston is placed at TDC position
in compression stroke.

Caution

y Do not turn the bolt in C.C.W. direction to

prevent from camshaft bolt looseness.

Valve clearance inspection and adjustment:

Check & adjust valve clearance with feeler gauge.

Valve clearance (IN)：0.10±0.02 mm.

Valve clearance (EX)：0.15±0.02 mm.

Loosen fixing nut and turn the adjustment nut for
adjustment.

Caution

y Re-check the valve clearance after tightened

the fixing nut.

Special tool: Tappet adjuster

SYM-9001200-08
SYM-9001200-09
SYM-9001200-10

Special tool: Tappet adjuster wrench

SYM-9001200

2-6

To this chapter contents

Spark Plug

Recommended spark plug: CR8E
Remove luggage box
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.

Spark plug gap: 0.6~0.7 mm

Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten the plug by turning 1/2 turn more with plug
socket after installed.

Tighten torque: 1.0~1.2kgf-m

Connect spark plug cap

2. Maintenance Information

Ground electrode

Central electrode

Spark plug

0.6~0.7mm

2-7

To this chapter contents

2. Maintenance Information

Cylinder Compression Pressure

Warm up engine.
Turn off the engine.
Remove luggage box and central cover
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.

Caution

y Rotate the engine until the reading in the

gauge no more increasing.

y Usually, the highest pressure reading will be

obtained in 4~7 seconds.

Compression pressure：12±2 Kg/cm²

Check following items if the pressure is too low:

y Incorrect valve clearance.
y Valve leaking.
y Cylinder head leaking, piston, piston ring and

cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.

Drive Belt

Remove mounting bolt located under air cleaner.
Remove the engine left side cover and the cover.
Check if the belt is crack or worn out.
Replace the belt if necessary or in accord with the
periodical maintenance schedule to replace it.

Width limit: 22.5 mm or above

Clutch Disc Wear

Run the motorcycle and increase throttle valve
opening gradually to check clutch operation.
If the motorcycle is in forward moving and shaking,
check clutch disc condition. Replace it

Spark plug cap

Teeth

Clutch lining

Compression gauge

Width

2-8

Clutch weight

To this chapter contents

Steering Handle Top Bearing

Caution

y Check all wires and cables if they are

interfered with the rotation of steering handle
bar.

Lift the front wheel out of ground.
Turn handle from right to left alternative and check
if turning is smoothly.
If handle turning is uneven and bending, or the
handle can be operated in vertical direction, then
adjust the handle top bearing.

Cushion

Caution

y Do not ride the motorcycle with poor cushion.
y Looseness, wear or damage cushion will

make poor stability and drive-ability.

Front cushion

Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Tighten all nuts and bolts.

Rear Cushion

Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Park motorcycle with main stand.
Turn the rear wheel forcefully and check if engine
bracket bushing worn out
Replace the bushing if looseness found.
Tighten all nuts and bolts.

2. Maintenance Information

2-9

To this chapter contents

2. Maintenance Information

Disk Brake System

Brake System Hose

Make sure the brake hoses for corrosion or
leaking oil.

Brake Fluid

Check brake fluid level in the brake fluid reservoir.
If the level is lower than the LOWER limit, add
brake fluid to UPPER limit. Also check brake
system for leaking if low brake level found

Caution

y In order to maintain brake fluid in the

reservoir in horizontal position, do not remove
the cap until handle stop.

y Do not operate the brake lever after the cap

had been removed. Otherwise, the brake
fluid will spread out if operated the lever.

y Do not mix non-compatible brake fluid

together.

Filling Out Brake Fluid

Tighten the drain valve, and add brake fluid.
Operate the brake lever so that brake fluid
contents inside the brake system hoses.

Added Brake Fluid

Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4 WELL
RUN brake fluid.

Caution

y Never mix or use dirty brake fluid to prevent

from damage brake system or reducing brake
performance.

Air Bleed Operation

Connect a transparent hose to draining valve.
Hold the brake lever and open air bleeding valve.
Perform this operation alternative until there is no
air inside the brake system hoses.

Caution

Air bubble

Master cylinder cap

Diaphragm

LOWER

Brake
Fluid

Drain valve

y Before closing the air bleed valve, do not

release the brake lever.

2-10

Transparent hose

To this chapter contents

Brake Lining Wear

The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark
closed to the edge of brake disc.

Caution

y It is not necessary to remove brake hose when

replacing the brake lining.

Remove the brake clipper bolt, and take out the
clipper.

Caution

y Do not operate the brake lever after the clipper

removed to avoid clipping the brake lining.

Pry out the brake lining with a flat driver if lining is
clipped.
Remove 2 cotter pins

2. Maintenance Information

Lining

Brake caliper

2 bolts

Brake disk

Cotter pins

Caution

y In order to maintain brake power balance, the

brake lining must be replaced with one set.

Remove the brake pad shafts and pads.

2-11

To this chapter contents

2. Maintenance Information

Brake Light Switch / Start Switch

The brake light switch is to light up brake lamp as
brake applied.

Make sure that starter motor can be operated only
under brake applying.

Headlight Distance Adjustment

Turn on main switch
Headlight beam adjustment. Turn the headlight
adjustment screw to adjust headlight beam high.

Caution

y To adjust the headlight beam follows related

regulations.

y Improper headlight beam adjustment will make

in coming driver dazzled or insufficient lighting.

Wheel / Tire

Stop switch

Headlight beam adjustment screws

Caution

y Tire pressure check should be done as cold

engine.。

Appointed tire pressure

Tire size Front tire Rear tire

Tire pressure as

cold engine

(Kg/cm²)

Check if tire surface is ticked with nails, stones or
other materials.
Check if front and rear tires’ pressure is in normal.
Measure tire thread depth from tire central
surface.
Replace the tire if the depth is not come with
following specification

Front tire：1.5 mm
Rear tire：2.0 mm

Load for

under 90 Kg

Full loaded 1.75 2.50

1.75 2.25

2-12

To this chapter contents

Battery

Open the inner box lid.
Loosen screw & remove the battery cover

Battery cable remove：

1. Disconnect the cable negative terminal (-),

2. then the cable positive terminal (+)

3. Remove the battery from the motorcycle.。

If there is some rust on battery posts, clean it with
steel brush

Install the battery in the reverse procedures of
removal

Caution

y If there is rust on the posts very serious,

spray some hot water on the posts. Then,
clean it with steel brush so that can remove
rust for more easily.

y Apply some grease on the posts after rust

removed to prevent from rust again.

2. Maintenance Information

Nuts, Bolts Tightness

Perform periodical maintenance in accord with the
Periodical Maintenance Schedule.
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose (pipe)
clamps, and wire holders for security.

2-13

To this chapter contents

2. Maintenance Information

Special Tools List

NAME

Left crank bearing puller

NO

SYM-9100100

R/L. crank case disassemble

NAME

tool

NO

SYM-1120000-HMA H9A

Valve cotter remove &

NAME

assembly tool

NO

SYM-1471110/20

NAME

L. Crank shaft puller

NO

SYM-1130000-HMA H9A

R. crank case bearing 6201

NAME

assembles tool

NO

SYM-9614000-HMA 6201

NAME

NAME

Tappet adjusting wrench

NO

SYM-9001200

Left crankshaft & oil seal
assembly socket.

NO

SYM-2341110- HMA RB1

NAME

Tappet adjusting

NO

SYM-9001200-08 09 10

NAME

Rocker arm shaft disassemble

NO

SYM-1445100

NAME

NO

2-14

(6204)

Bearing driver 6204
SYM-9110400

NAME

Assembly directs puller

NO

SYM-2341110

NAME

Drive shaft puller

NO

SYM-2341110- HMA RB1

To this chapter contents

NAME

NO

Inner bearing puller
SYM-6204022

NAME

Outer bearing puller

NO

SYM-6204001

2. Maintenance Information

NAME

Handle stand nut wrench

NO

SYM-5321100

NAME

Clutch nut wrench

NO

SYM-9020200

Steering head top thread

NAME

wrench

NO

SYM-5320010

NAME

Universal holder

NO

SYM-2210100

NAME

Bearing driver HK1516
SYM-9100200-HMA RB1

NO

HK1516

NAME

AC.G. Flywheel puller

NO

SYM-3110000-HMA

NAME

Bearing puller 6205

NO

SYM-9100400 HMA RAI 6205

NAME

Air operated bearing puller

NO

SYM-9100410-400 A6205

NAME

Oil seal driver 34*52*5

NO

SYM-9125500-HMA

Right crankcase cover bearing

NAME

6201 puller
SYM-9614000-HMA RB1 6201

NO

.

2-15

To this chapter contents

2. Maintenance Information

NAME

Bearing driver 6205

NO

SYM-9615000-6205

Drive shaft & oil seal (25*40*8)

NAME

socket

NO

SYM-9120200-HMA

NAME

Bearing puller 6303

NO

SYM-6303000-HMA H9A 6303

NAME

Bearing driver 6201

NO

SYM-9614000-6201

Water pump mechanical seal

NAME

driver

NO

SYM-1721700-H9A

(Ø30mm)

NAME

Crankcase bush puller

NO

SYM-1120310

Water pump bearing driver

NAME

6901

NO

SYM-9100100

NAME

Crankcase bush puller

NO

SYM-1120320

(Ø22mm)

Water pump oil seal driver

NAME

(inner)

NO

SYM-9120500-H9A

NAME

NO

2-16

Vacuum pressure gauge
SYM-HT07011

NAME

Fuel pressure gauge

NO

SYM-HT07010

NAME

Multi-meter

NO

SYM-HE07007-01

To this chapter contents

NAME

NO

Cylinder pressure gauge
SYM-HT07008

2. Maintenance Information

NAME

Vehicle circuit test tool kit

NO

SYM-HE170008

NAME

Vehicle circuit test harness kit

NO

SYM-HE170008-01

NAME

NO

EFi System Diagnostic tool

2-17

To this chapter contents

2. Maintenance Information

NOTE:

2-18

Home page

Contents

Mechanism Diagram······························ 3-1
Precautions in Operation······················ 3-2
Troubleshooting ····································3-2
Engine Oil··············································· 3-3

0BMechanism Diagram

Press-In Lubrication

Oil Route

3. Lubrication System

Engine Oil Strainer Clean······················3-3
Oil Pump·················································3-4
Gear Oil···················································3-7

3

Valve Rocker Arm

Cam Shaft

Con-Rod

Spray Lubrication

Press-In Lubrication

Spray Lubrication

Oil Route

Rotate Direction

Oil Pump

Oil Strainer

3-1

To this chapter contents

3. Lubrication System

1BPrecautions in Operation

General Information:

z This chapter contains maintenance operation for

the engine oil pump and gear oil replacement.

Specifications

Engine oil quantity Disassembly: 1400 c.c.

Change: 1200c.c.

Oil viscosity SAE 10W-30 (Recommended

King serial oils)

Gear oil Disassembly: 180c.c.

Change: 160c.c.

Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)

Unit: mm

Items Standard (mm) Limit (mm)

Inner rotor clearance 0.15 0.20

Oil pump

Clearance between outer rotor and body 0.15~0.20 0.25
Clearance between rotor side and body 0.04~0.09 0.12

Torque value

Torque value oil strainer cap 1.3~1.7kgf-m
Engine oil drain bolt 3.5~4.5kgf-m
Gear oil drain bolt 1.1~1.5kgf-m

Gear oil join bolt 1.0~1.4kgf-m
Oil pump connection screw 0.1~0.3kgf-m

2BTroubleshooting

Low engine oil level

y Oil leaking
y Valve guide or seat worn out
y Piston ring worn out

Low oil pressure

y Low engine oil level
y Clogged in oil strainer, circuits or pipes
y Oil pump damage

Dirty oil

y No oil change in periodical
y Cylinder head gasket damage
y Piston ring worn out

3-2

To this chapter contents

3BEngine Oil

Turn off engine, and park the scooter in flat
surface with main stand.
Check oil level with oil dipstick.
So not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out recommended
oil to upper level.

Oil Change

Caution

Drain oil as engine warmed up so that makes
sure oil can be drained smoothly and completely.

Place an oil pan under the scooter, and remove oil
drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.

Torque value：3.5~4.5kgf-m

4BEngine Oil Strainer Clean

Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.

3. Lubrication System

Drain bolt

Torque value：1.3~1.7kgf-m

Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.

Engine oil capacity: 1200c.c. when replacing

Install dipstick, start the engine for running several
minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.

Oil strainer cap

O-ring

Oil strainer

3-3

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3. Lubrication System

5BOil Pump

Oil Pump Removal

Remove generator and starting gear. (Refer to
chapter 10) 。

Remove cir clip and take out oil pump driving
chain and sprocket.

Make sure that pump shaft can be rotated freely.
Remove 2 screws on the oil pump, and then
remove oil pump.

Clip

Oil Pump Disassembly

Remove the screws on oil pump cover and
remove the cover.
Remove oil pump shaft roller and shaft.

3-4

2 screws

1 screw

Roller

To this chapter contents

Oil Pump Inspection

Check the clearance between oil pump body and
outer rotor.

Limit: 0.25 mm

Check clearance between inner and outer rotors.
Limit: 0.20 mm

Check clearance between rotor side face and
pump body

Limit: 0.12 mm

Oil Pump Re-assembly

Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of inner
rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins properly.

3. Lubrication System

Pins

3-5

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3. Lubrication System

Tighten the oil pump screw.

Oil Pump Installation

Install the oil pump, and then tighten screws.

Torque value：0.1~0.3kgf-m

Make sure that oil pump shaft can be rotated
freely.

Install oil pump drive chain and sprocket, and then
install cir clip onto oil pump shaft.

Install starting gear and generator.
(Refer to chapter 10)

1 screw

Roller

2 screws

Clip

3-6

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6BGear Oil

Gear Oil Change

Remove oil join bolt.
Remove drain bolt and drain gear oil out.
Install the drain bolt after drained.

Torque value: 1.1~1.5kgf-m

Make sure that the drain bolt washer can be
re-used.
Add oil to specified quantity from the join hole.

Gear Oil Quantity: 160c.c. when replacing

Make sure that the join bolt washer can be re-used,
and install the bolt.

Torque value: 1.0~1.4kgf-m

Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.

3. Lubrication System

Gear oil join bolt

Gear oil drain bolt

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3. Lubrication System

Notes:

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Contents

4. Fuel Injection System

EFi System Components····················· 4-1

EFi System Vehicle Configuration ····· 4-2

EFi System Operation ························· 4-3

EFi System Introduction······················ 4-4

Fuel System·········································· 4-5

Ignition System ···································· 4-6

Sensors / Drives··································· 4-7

Precautions in Operation ···················· 4-14

EFi System Components Description 4-15

EFi System Circuit ······························· 4-31

ECU Pin Configuration ························ 4-32

Troubleshooting ·································· 4-33

EFi System Components

Integrated Troubleshooting Procedure

······························································· 4-37

Air Cleaner ············································ 4-40

EFi System Diagnosis Methods ·········· 4-41

Check Light Fault Codes Differentiation

······························································· 4-42

Fault Code And Sensors Table ··········· 4-43

Fault Code and Check Light Flashing
Lighting Identification Table ···············4-44

EFi System Diagnostic Tool - V70 ······4-45

Diagnosis Use Note ····························· 4-46

Troubleshooting Table························· 4-58

Comprehensive Maintenance List ······ 4-59

4

Fuel

pump

TPS

TA

Sensor

ISC

(Stepper motor)

MAP

Sensor

Ignition coil

Injecto

Diagnostic tool

ISV

EFi Check light

Roll over

sensor

TW

Sensor

CPS

O2

Senso

Power

relay

Battery

ECU

4-1

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4. Fuel Injection System

EFi System Vehicle Configuration

Right

TPS

ISC

Injector

MAP Sensor

ECU

CPS

O2 Sensor

TW Sensor

Left

Fuel pump

EFi Check light

Rollover sensor

AISV

TA Sensor

Diagnostic coupler

Test switch

4-2

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4. Fuel Injection System

EFi System Operation

Crankshaft Position
Sensor

Manifold Absolute
Pressure Sensor

Throttle Position
Sensor

Engine Coolant
Temperature Sensor

O

2 Sensor

Roll Over Sensor

Intake Air
Temperature Sensor

Battery Voltage

CPS

MAP

TPS

TW

LAMBDA

K/S

TA

VBATT

Tuning tools Diagnostic tool

Engine Control

(ECU)

Unit

INJECTOR

IGN COIL

FUEL PUMP

CHECK LIGHT

AISV

ISC

Air Injection
Solenoid Valve

Idle Speed Control
Valve
(Stepper motor)

4-3

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4. Fuel Injection System

EFi System Introduction

Based on 4-stroke SOHC engine, displacement 250 c.c. electronically controlled fuel injection, fuel vapor
absorbed by activated carbon canister. The engine burns off the blow-by fuel-gas in the crankcase
through the fuel-air separating device. The O
by dynamically controlling the Fuel/Air ratio.

Electronic Fuel Injection Devices

Consist of fuel supply devices: fuel tank, fuel pump, fuel filter and fuel pressure regulator.
And fuel controll devices: fuel injector and ECU.
The fuel is pumped from electrical fuel pump in the fuel tank, to the injector on the inlet pipe. The fuel
pressure regulator keeps the fuel pressure around 294±6kPa. The signals from ECU enable the injector to
spray fuel into the combustion chamber once every two crankshaft revolutions. The excessive fuel flows
back to the fuel tank through the fuel pressure regulator. Fuel pump is placed within the tank to reduce the
working noise, and the complicity of fuel pipes. Electronically controlled ignition and injection system
effectively reduce the fuel consumption rate and pollution.

In the traditional gasoline engine, the carburetor supplies the fuel. The process is done by the engine
vacuum and the negative pressure in the carburetor by mixing fuel and air. Under this condition, three
major processes are done simultaneously in the carburetor: 1. Air quantity measurement. 2. Fuel quantity
determination. 3. Mixing of fuel and air.

Electronic Fuel Injection System distributes the three major processes to three different devices: 1. MAP /
TA sensor measures the air quantity and temperature and sends the signal to ECU as a reference. 2.
ECU determines the amount of fuel to be injected, according to the default A/F rate. 3. ECU enables the
injector to spray appropriate fuel amount. The independence of these three functions will raise the
accuracy of the whole process.

EFi engine uses computer-programmed fuel injection, the main features are:

1. The quantity of fuel injected is decided according the condition of the engine. The engine RPM, and

throttle position determines the fuel quantity and injection time-length. This throttle-controlled fuel
injection is better responding and more accurate.

2. The quantity of fuel injection, and the determination of injection time length, are all controlled by 16-bit

microcomputer.

3. The fuel pressure regulator maintains a 294±6 kPa pressure difference between intake pipe and fuel

pipe, raising the accuracy of fuel injection.

4. By measuring the air pressure of intake pipe, this system gives the vehicle better accommodation to the

environment.

5. Idle air by-pass system supplies fuel and air to stabilize the idle running, and cold starting.

6. O

2 sensor feeds back the signal to minimize the exhaust pollution.

2 sensor enhances the efficiency of the catalytic converter,

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4. Fuel Injection System

Fuel System

Fuel pump

Injector

Fuel pump

ECU

relay

Power relay

Battery

System Description

1. After Key-on, the sensors signal to be sent to the ECU. ECU controls the fuel pump relay to make the

fuel pump operate. If the engine is not started, the fuel pump will be shut down within 2 to 3 seconds in
order to save electricity. Fuel pressure regulator maintains fuel pressure at 294 ± 6kPa (about 3 kg / cm
²). According to the operating conditions and environmental compensation coefficient, appropriate fuel
will be injected. After Key-off or engine stopped operating, the fuel pump stops running.

2. Fuel impurities filtered by the fuel filter should be cleaned regularly.

3. When the engine can not be started, do not keep start motor running continuously which may lead to

lack of battery power (less than 10 V) and the fuel pump will not be able to operate. The correct way is
to use a new battery.

Injector

Double-hole type injector provides two intake valves fuel injection quantity, enhances the effect of fuel
atomization, and reduces HC emissions. Short-type injector cap can easily fix the injector, receive the fuel
from the fuel pump, and limit injector rotation sliding. The signals from ECU control the fuel pressure
regulator, using the diaphragm and spring to maintain the fuel pressure in 294 ± 6kPa (about 3 kg / cm ²),
and determine the fuel injection quantity by adjusting injection time width under different engine
conditions.

Fuel Pump

Electrical fuel pump is placed inside the fuel tank, powered by the battery and controlled by ECU.
Fuel pressure: 294 ± 6kPa (about 3 kg / cm ²)

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4. Fuel Injection System

Ignition System

Intake ai

Manifold absolute pressure

Engine coolant temperature

ACG/ Flywheel Gear
(23+1 Long teeth)

temperature

Throttle position

Oxygen content

Crankshaft

position

ECU

Ignition coil

Spark plug

Power relay

Battery

REG. REC.

Principle

The computer programmed ignition system receives the signals from the Crankshaft position sensor,
Throttle position sensor, O
temperature sensor. Calculating the engine RPM, the 16-bit microcomputer determines the appropriate
ignition timing, controls the ignition coil and triggers the spark plug. This way can not only make the
engine achieve the maximum power output, but also help improve fuel consumption rate.

2 Sensor, MAP sensor, Intake air temperature sensor, Engine coolant

Specifications

1. Ignition timing: BTDC 10 ° / 1650RPM

2. Spark plug: NGK CR8E Clearance: 0.6 to 0.7 mm

3. ACG crankshaft position sensor coil resistance: 80 ~ 160 Ω (Green / White - Blue / Yellow)

4. Ignition coil primary circuit resistance: 2.8 Ω ± 15% (20 º C) (Red / Yellow - Black / Yellow)

5. Battery Type / Capacity: YTX12A-BS or GTX12A-BS / 12V 12Ah

4-6

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4. Fuel Injection System

Sensors / Drives

Crankshaft Position Sensor (CPS)

Crankshaft position

Long tooth

Flywheel

sensor

ECU

Description

Right after the engine is started; the crankshaft position sensor identifies the TDC position by detecting
the logn tooth on the flywheel and ignites at the fixed angle. When the engine RPM reaches the specified
speed, the ignition timing will change to the software mode.

Function

Inducting the teeth sequence on the flywheel, conveying the voltage signals to ECU.

4-7

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4. Fuel Injection System

Roll Over Sensor

Function

As a safety device, when the motocycle tips over, it will cut off power supply of ECU and shut down the
engine.

Note

The pendulum-type roll over sensor will cut off the power supply of ECU. Main switch should be turned
Key-on again before the engine can be restarted.

ECU

To start switch

Side stand

warning lights

Fuse 20A

Power relay

Engine control

relay

Side stand switch

Engine stop

switch

Roll over

sensor

Main switch

Fuse 15A

Battery

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4. Fuel Injection System

Manifold Absolute Pressure (MAP) / Engine Water Temperature (TW) / Intake Air
Temperature (TA) Sensors

ECU

MAP Senso

TASensor

TW Senso

Engine water temperature / Intake air temperature sensor:

Use the variable resistor of negative temperature coefficient (thermistor) to sense the outside temperature.
The electrical resistance value goes down when the temperature rises. On the contrary, the electrical
resistance value becomes higher when the temperature falls. Sensors provide the temperature of the
engine coolant and intake air to ECU to determine the injection and ignition timing.

5V

Manifold absolute pressure sensor:

Manifold absolute pressure sensor (MAP Sensor) uses the piezoresistive resistor composed of silicon
diaphragm, forming the Wheatstone bridge circuit to measure the atmospheric pressure and the intake
manifold pressure, which are both transmitted to ECU for reference of engine control.

Output voltage

pressure

Inlet

Working voltage (5V)

Output voltage

Inlet pressure (kPa)

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4. Fuel Injection System

O2 Sensor

ECU

Battery

O2 Senso

2 Senso

O

Power relay

3

Output voltage

1

Rich ← 14.7 → Lean

2

4

1. Ceramics tube

2. Electrode

3. Emissions

4. Atmosphere

Function

O2 Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which adjusts
the air-fuel ratio by changing the fuel injection time. If the proportion of oxygen is too low, it means the rich
air-fuel mixture with higher HC & CO concentration in the exhaust gas. If the proportion of oxygen is too
high, it means the lean air-fuel mixture with higher temperature and higher NOx concentration.

1. O

Sensor outputs feedback signal to ECU which keeps the air-fuel mixture near the stoichometric ratio

2

approximately 14.6 and forms the closed loop control system.

2. When the air-fuel mixture is near the stoichometic ratio, CO / HC / NOx are converted most efficiently.

3. O

Sensor heater resistance: 6.7 ~ 10.5 Ω

2

4. O

Sensor amendment in the voltage value: between 100 ~ 900 mV

2

4-10

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4. Fuel Injection System

Throttle Position Sensor (TPS)

ECU

TPS

Battery

VC

VT

E

EC

5V

TPS output voltage

6

Voltage

4

2

0

Throttle valve opening angle

50 100 150

TPS

Basic Principle

TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage value
change, determining the throttle position.

Function

TPS determines the throttle valve position and sends signal to ECU as reference of engine control.

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4. Fuel Injection System

Idle Speed Control Valve (ISC stepper motor)

ISC

ECU

Battery

+Va

-Va

+Vb

-Vb

Step

N

S

Va

S

N

S

Vb

N

Function

ECU controls ISC stepper motor to adjust the bypass intake air quantity and stablize the idle speed.

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A

4. Fuel Injection System

Air Injection Solenoid Valve (AISV)

Function

AISV introduces appropriate air quantity to reduce pollutant emission.

Basic Principle

When the engine RPM and throttle opening are higher than the default value, ECU controls AISV opening
or closure.

ISV

Reed valve

Fresh ai

Power relay

ECU

Battery

ir Injection

Solenoid Valve

Power relay

ECU

4-13

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4. Fuel Injection System

Precautions in Operation

General information

Warning

● Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and flame is

strictly prohibited when working with gasoline.

● Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to prevent

fuel from splashing.

Cautions

● Do not bend or twist the throttle cable. Damaged cable will lead to unstable driving.

● When disassembling fuel system parts, pay attention to O-ring position, replace with new one as

re-assembly.

Specification

Item Specifications

Idle RPM 1650±100 rpm

Throttle handle free play 2~6 mm

Fuel pressure 294±6kPa (about 3.0kg/cm²)

Torque value

Engine Temperature sensor 0.74~0.88 kgf-m
O

2 Sensor 3.6~4.6 kgf-m

Special Tools

Vacuum Gauge
Fuel Pressure Gauge
EFi System Diagnostic Scanner
Fuel Pipe Pliers

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4. Fuel Injection System

EFi System Components Description

ECU (Electronic Control Unit)

Functional Description:

● Powered by DC 8~16V, and has 36-pin socket on the unit.

● The hardware component consists of a 16-bit microcomputer that is its

control center. It contains the functional circuit interface of engine
condition sensing and the driving actuator for the fuel injector, fuel
pump, as well as ignition coil.

● Its major software is a monitor strategy operation program that

includes controlling strategy and self-diagnosis programs.

Testing Procedures:

1. Connect the diagnostic scanner to the diagnostic coupler on the
vehicle.

2. Key-on but not to start engine, confirm ECU and the diagnostic
scanner can be connected or not.

3. Diagnostic scanner will automatically display Version "certification" of
the screen.

4. Confirm the application model, version is correct or not.

5. Check if the fault codes exist.

6. Remove the fault codes.

7. Start engine and check the parameters shown on the diagnostic
scanner.

Detection judge:

● Fault codes can be read and cleaned, and the fault codes will not

appear again after re-start.

Treatment of abnormal phenomena:

1. Can not connect→ First check whether the cartridge is correct and

ECU is normal or not.

2. Unable to start→ ECU or relevant parts abnormal. Re-confirm after the

replacement of abnormal parts.

3. Fault codes appear→ ECU or relevant parts abnormal. Troubleshoot

and re-confirm.

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4. Fuel Injection System

Throttle Body

Functional Description:

● Throttle body is the inlet air flow regulating device (similar to the

carburetor).

● Throttle valve pivot drives the throttle position sensor synchronously

and makes ECU detect the throttle opening immediately.

● Throttle valve positioning screw has been adjusted and marked on the

production line. Readjustment is not suggested.

Treatment of abnormal phenomena:

● If all fuel injection associated components identified no adverse, and

other traditional engine components are also normal, the engine is still
not smooth, please confirm whether the throttle body coke serious.

● If coke serious, please clean throttle body, and then adjust the injection

system.

Throttle positioning screw

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4. Fuel Injection System

MAP Sensor

Y/B B/R

G/R

Functional Description:

● Powered by 5V DC from ECU. It has 3-pin socket on the sensor. One

terminal is for power, and 1 terminal are for signal output. And, the
rest one is for ground.

● The major component of the intake pressure sensor is a variable

transistor IC. Its reference voltage is DC 5V, and output voltage range
is DC 0~5V.

● It is a sensor by sensing pressure, and can measure the absolute

pressure in intake process. It also conducts fuel injection quantity
correction based on environmental position level.

Pin Wire color Function

Left Yellor / Black 5V voltage input

center Black / Red Signal output

Right Green / Red Ground

Testing Procedures:

1. Inlet pressure sensor connector to properly (using the probe tool).

2. Open the main switch, but not to start engine.

3. Use "volteg meter" DC stalls (DCV) to check inlet pressure sensor
voltage.

4. Confirmed working voltage:

● Volteg meter negative access to the inlet pressure sensor third pin

(Green / Red).

● Voltage meter positive access to the inlet pressure sensor first pin

(Yellow / Black).

5. Confirmed plains output voltage values:

● Volteg meter negative access to the inlet pressure sensor third pin

(Green / Red).

● Voltage meter positive access to the inlet pressure sensor second

pin (Black / Red)

Working voltage

measurement

Output voltage measurement

plains

Cautions

● Attentions to the tools required close to the probe wire waterproof

apron penetrate skin and internal terminal before measurements to
the correct value.

Detection judge:

● Working voltage value: 5.0±0.1V

● Plains output voltage values: 2.87±0.03V (Conditions: In the plains

101.3 kPa Measurement)

Cautions

● The higher the altitude, the measurement value to the lower voltage.

● Sea-level atmospheric pressure = 1Atm = 101.3kPa = 760mmHg =

1013mbar

Treatment of abnormal phenomena:

● Inlet pressure sensor damaged, or poor contact couplers.

● Check whether the abnormal wire harness lines.

● Inlet pressure sensor anomaly, the proposed replacement of the

sensor to measure the output voltage.

● ECU anomaly, the proposed replacement of the ECU to measure the

working voltage.

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4. Fuel Injection System

TA Sensor

Functional Description:

y Use ECU DC 5V power supply provided, has the two-pin coupler, a

voltage output pin; another one for a grounding pin.

● Its main component is a negative temperature coefficient (resistance

temperature rise smaller) thermistor.

● Installed in the air cleaner on the intake temperature sensor within the

resistance, with the induction to the temperature change, and
converted into voltage signals sent to the ECU then calculated the
temperature and, in accordance with the ECU temperature and state
amendments injection time and ignition angle.

Testing Procedures:

Resistance Value Measurement:

● Dismantled inlet temperature sensor connector.

● Use of the "Ohmmeter" Ohm stalls, inspection sensor resistance.

Detection judge:

Resistance value and the temperature between relationships as follows

Temperature ( )℃ Resistance value (KΩ)

-20 18.8 ± 2.4
40 1.136 ± 0.1

100 0.1553 ± 0.007

Treatment of abnormal phenomena:

● Temperature sensor damage or connector poor contact.

● Check whether the abnormal wire harness lines.

● Temperature sensor anomaly, the proposed replacement of the

temperature sensor.

Resistance value measurement

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4. Fuel Injection System

TPS

Functional Description:

● Use ECU provided DC 5V power supply, has the three-pin coupler, one

for the power supply pin; one for a voltage output pin; one for a
grounding pin.

● Its main component is a sophisticated type of variable resistor.

● Installed on the throttle body beside the throttle through (the

accelerator) rotates, the output of linear voltage signal provided ECU
perception and judgement then throttle position (opening), and in this

W/BR

Y/B

G/R

Working voltage measurement

signal with have the most appropriate fuel injection and ignition timing
control.

Pins Wire color Function

Upper White / Brown Signal output

Center Yellow / Black 5V voltage input

Under Green / Red Ground

Testing Procedures:

1. Sensor connected properly (using the probe tool), or can be removed
connector to voltage measurements (direct measurement).

2. Opened the main switch, but not to start engine.

3. Use "volteg meter" DC stalls (DCV) to check sensor voltage.

4. Confirmed working voltage:

● Volteg meter negative access to the inlet pressure sensor third pin

(Green / Red).

● Voltage meter positive access to the inlet pressure sensor first pin

(Yellow / Black).

5. Throttle output signal recognition (using the probe tool)

● Volteg meter negative access to the sensor third pin (Green / Red).

● Voltage meter positive access to the sensor first pin (white / Brown).

● Measurements were full throttle at full throttle closed the values of

the output voltage.

Throttle output signal

measurement - full closed

Throttle output signal

measurement - full

Cautions

● Attentions to the tools required close to the probe wire waterproof

apron penetrate skin and internal terminal before measurements to
the correct value.

Detection judge:

● Working voltage value: 5.0±0.1V

● Full throttle voltage value: 0.6±0.02V

● Full throttle closed voltage value: 3.78±0.26V

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4. Fuel Injection System

Throttle output signal

measurement

Also, can be used for diagnosis tool confirm to the throttle output signal.

1. Connected to the "diagnosis tool", and open the main switch, but not to
start engine.

2. "Diagnosis tool" screen switches to a "data analysis (01 / 03)" screen.

3. Rotations throttle and check voltages.

Treatment of abnormal phenomena:

● Throttle sensor damage or connector poor contact.

● Check whether the abnormal wire harness lines.

● Throttle sensor anomaly, the proposed replacement of the throttle

sensor to measure the voltage.

Warning

● Throttle sensor prohibited removed from the throttle body to do any

testing.

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4. Fuel Injection System

TW Sensor

Resistivity measurements

Functional Description:

● Powered by 5V DC from ECU. It has the two-pin socket on the sensor.

One terminal is for power output, and 1 terminal are for ground.

● Its main component is a negative temperature coefficient (resistance

temperature rise smaller) thermistor.

● Installed in the cylinder head, the engine temperature sensor

resistance, with the induction to the temperature change, and
converted into voltage signals sent to the ECU was calculated engine
temperature, ECU accordance with the engine warm up to amendment
the injection time and ignition angle.

Testing Procedures:

● Dismantled engine temperature sensor.

● Use of the "meter" Ohm stalls, inspection sensor resistance.

Detection judge:

Resistance value and the temperature between relationships as follows:

Temperature ()℃ Resistance value (KΩ)

-20 18.8 ± 2.4
40 1.136 ± 0.1

100 0.1553 ± 0.007

Treatment of abnormal phenomena:

● Temperature sensor damage or couplers to poor contact.

● Check whether the abnormal wire harness lines.

● Temperature sensor anomaly, the proposed replacement of the

temperature sensor.

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4. Fuel Injection System

O2 Sensor

Functional Description:

● Use 8 ~ 16V DC power supply, has the 4-pin coupler, a power supply

G/R

R/O

Confirmed working voltage

B GR

W

L/O

R/Y

W

pins for heater; for a heater control pin; signal for a grounding pin; O
for a signal pin.

● O

Sensor output feedback signal to the ECU fuel ratio control in the

2

vicinity of 14.5 ~ 14.7, a closed-loop fuel control.

● When the air-fuel ratio control in the near equivalent, CO / HC / Nox to

have the highest conversion efficiency.

Testing Procedures:

1. Voltage confirmed:

● Removed O

● Open the main switch, but not to start engine.

● Use "voltage meter" DC stalls (DCV) to check inlet pressure sensor

voltage.

● Confirmed working voltage:

Volteg meter negative access to the wire harness sensor coupler

2nd pin (Red / Orange).
Voltage meter positive access to the wire harness sensor coupler
first pin (Red / Yellow).

2. Resistance Confirmation:

● Remove O

● Use of the "meter" Ohm stalls, Measurement O

resistance.

● Measurement resistance value

Ohm meter negative access to the O

(White).
Ohm meter negative access to the O
(White).

Sensor and the wire harness between the coupler.

2

Sensor and the wire harness between the coupler.

2

Sensor heater

2

sensor coupler 2nd pin

2

sensor coupler first pin

2

2

Resistance Confirmation

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4. Fuel Injection System

Numerical voltage changes that
the situation.

1. Used the diagnosis tool to confirm of O

● Connected the "diagnosis tool" to diagnosis coupler and open the

sensor work situations:

2

main switch to start the engine.

● Engine to be completely warm-up (idling state operation "5 minutes"

above).

● Screen will switch to the diagnosis tool of "DATA STREAM 01/01"

screen, select " O

Sensor" project, and switches to a wave of

2

images, turn the throttle engine speed to about 4500 rpm,

Observation O

● Observation O

Sensor actuator circumstances.

2

Sensor voltage values that the situation changes.

2

Detection judge:

● Working voltage value: above 10V

● Resistance value: 6.7~10.5Ω

● O

Sensor amendment in the voltage value of between 100 ~ 900 mV

2

beating; representatives pollution closed-loop control system to normal,
if contrary to maintain a fixed value for abnormalities.

Treatment of abnormal phenomena:

● O

sensor damage, heater damaged or couplers to poor contact.

2

● Check whether the abnormal wire harness lines.

● O

Sensor anomaly, the proposed replacement of the O2 Sensor，and

2

measurements again.

4-23

To this chapter contents

4. Fuel Injection System

Roll over sensor

Functional Description:

● Control power of the power relay coil, has the three-pin socket.

● When vehicles tilt angle greater than 65 degrees, roll over sensor will

be the implementation of ECU system power off. At this point once
again to restart the engine, the need to re-open a main switch.

● This as a safety device, when the dumping of vehicles, be cut off

power supply of ECU, and engine stop.

Testing Procedures:

● Because of the roll over sensor for the electronic control agencies, not

against removed after a single measurement.

● Normal state, after power is turned on the main switch, measurement

of ECU power relays red / yellow line to the Green Line (ground), the
power supply voltage measurement can determine whether it is normal
for the roll over sensor.

Detection judge:

Voltage: Supply voltage = Battery voltage

Treatment of abnormal phenomena:

Vehicle state vertical, power relays or ECU without electricity supply.

● Roll over sensor internal short circuit or open circuit, or coupler bad

contact.

● Check whether the abnormal wire harness lines.

● Roll over sensor anomaly, the proposed replacement of the roll over

sensor.

4-24

To this chapter contents

4. Fuel Injection System

ISC (stepper motor)：

Functional Description:

● Use ECU provided power, has the four-pin socket.

● 4-pin coupler for the two motor coils of the power supply and

grounding wire, grounding ECU power through the control and
management of the stepper motor actuators.

● If it’s mainly low-power DC motors, drives idle speed control valve

(ISC) of the movement to adjust the idle air flow channel size, control

ISCBP ISCBN

ISCAP

ISCAN

ISC PINS

A phase measurement of the

resistance value

of idle speed of the engine in the cold or hot.

Testing Procedures 1:

Resistance Confirmation:

● Idle Air Control Valve will be demolished down coupler (directly in the

body, can also measure).

● Use of the "meter" Ohm stalls (Ω), measurement of the two step

motor coil resistance values.

A phase: ISCAP and ISCAN
B phase: ISCBP and ISCBN

Inspection of the actuation (testing can only be on engine, not a single
test):

● Closure of the main switch.

● Use hand to touch Idle Air Control Valve body.

● Open the main switch.

● Feeling the Idle Air Control Valve Actuation.

Cautions

● Dynamic checking for Idle Air Control valve, can only be tested on

the engine, not a single test.

Detection judge:

1. Resistance value:

A phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 )℃
B phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 ℃)

2. Actuator inspection:
In the above steps Idle Air Control Valve (ISC) Idling motor actuator
control of inspection, ISC will be slightly vibration or "… da… da…"
continuous voice.

Treatment of abnormal phenomena:

● Idle air control valve damage, or poor coupler contact.

● Check whether the abnormal wire harness lines.

● Idle Air Control Valve anomaly, the proposed replacement of the Idle

Air Control Valve, further inspection of its actuator.

B phase

resistance value

measurement of the

4-25

To this chapter contents

4. Fuel Injection System

Fuel Pump

Functional Description:

y Powered by DC 8~16V, and has four-pin socket on the pump.
y The two terminals are connected to power source and ground

respective. The ECU is to control and manage the operation of fuel
pump through electrical power.

y Its major component is a driving fan pump that equipped with a low

electrical consuming DC motor. Powered by 12V voltage and keep
fuel pressure inside the fuel pump in 294±6kpa (about 3 kg / cm

Fuel unit

Fuel

G G

Y/W

Fuel pump & fuel unit coupler plan

B/PU

y The fuel pump is located inside of the fuel tank, and installed a filter in

front of its inlet so that can prevent from foreign materials sucking into
the fuel pump to damage it and the fuel injector.

Testing Procedures 1:

Fuel pump working voltage confirmed:

● Fuel pump coupler to properly (using the probe tool), or can be

removed coupler working voltage measurements (direct
measurement).

● Open the main switch, but not to start engine.

● Use "volteg meter" DC stalls (DCV) to check fuel pump voltage.

● Confirmed working voltage:

Volteg meter negative access to the wire harness fuel pump coupler
2nd pin (Green).
Voltage meter positive access to the wire harness fuel pump coupler
first pin (Black / Purple).

2

).

Confirmed working voltage

Fuel pump

G G

B/PU

Harness-face coupler plan

Fuel unit

Y/W

Cautions

● Conducting fuel pump voltage measurement, if the main switch to

open three seconds after the engine did not started, the ECU will
automatically cut off the fuel pump power supply.

Detection judge 1:

1. Working voltage value: Above 10V

2. Resistance value: 1.5±0.5Ω

3. Fuel pressure: 294±6kPa (about 3kg/cm

Testing Procedures 2:

Resistance Confirmation:

● Removed coupler on the fuel pump.

● Use of the "meter" Ohm stalls, Measurement fuel unit resistance (Yellow /

White & Green).

Detection judge 2:

● Fuel unit resistance value: 4~107.5Ω

2

)

Resistance Confirmation

4-26

To this chapter contents

4. Fuel Injection System

Testing Procedures 3:

Fuel pressure measurement:

● Use fuel pressure gauge, connected in series between the injector

and the fuel tank.

Cautions

● In the implementation of the fuel pressure measurement, will go to

the demolition of the fuel hose, such as: injector or fuel pump hose,
hydraulic measurements after, be sure to confirm whether there is a
leakage of fuel situation in order to avoid danger.

Fuel system pressure

measurement

Fuel pressure measurement

demolition - injector

Detection judge 3:

1. Fuel pressure: 294±6kPa (about 3kg/cm2)

Treatment of abnormal phenomena:

1. Fuel pump damage internal coil break, or coupler bad contact.

2. Fuel filter blockage.

3. Fuel pump anomaly, the proposed replacement of the fuel pump.

4. Fuel unit anomaly, the proposed replacement of the fuel unit.

Fuel pressure measurement

demolition - fuel pump

4-27

To this chapter contents

4. Fuel Injection System

Fuel Injector

Injector r

esistance confirmation

Injection-state

atomizing good

Functional Description:

● Powered by DC 8~16V, and has two-pin socket on the injector.

● Its major component is the solenoid valve of high resistance driven by

electronic current.

● The two terminals are connected to power source and ground

respective. It is controlled by ECU to decide the injection timing, and
the injector pulse width.

Testing Procedures:

1. Resistance Confirmation:

Use of the "meter" Ohm stalls (Ω), measurement of the injector
resistance value.

2. Injector injection state examination:

● Removed the injector fixed bolt and removed the injector from intake

manifold, but not removal of harness coupler.

● Injector and injector cap tightly by hands, fuel spills should not be

the case.

● Key-on and start the engine, injector injection state examination.

Detection judge:

1. Between the two pin resistance values: 11.7 ±0.6Ω

2. injection state:

● Fuel atomizing good, with a clear scattering angle → judged as

normal.

● Injection-state such as water, no obvious scattering angle → found

abnormal.

Treatment of abnormal phenomena:

1. Injector abnormal, the proposed replacement of the new one injector.

2. Injection-state abnormal, for the following reasons:

● Injector obstructive→the proposed replacement of the new one

injector.

● Fuel pressure shortage → confirmed hydraulic pressure, the

proposed replacement fuel pump to confirm.

Injection-state unusual

4-28

Warning

● Gasoline is lower ignited explosive materials, in the ventilation

premises operations, and prohibited fire.

● In the inspection injector fuel injection state, the outflow of gasoline,

and the application of appropriate collection containers, so as to
avoid danger.

To this chapter contents

4. Fuel Injection System

Transistor ignition coil

First circuit coil

measurement

resistance

Crankshaft position sensor

Long tooth

Measurement resistance value

Functional Description:

● Use 8 ~ 16V DC power supply, has the two-pin socket.

● Two-pin socket for the power supply and grounding. Its main

components for the high conversion ratio transformer.

● Through computer programs when the ignition is controlled, from

ignition timing (TDC) / crank position sensor, the throttle valve position
sensor, engine temperature sensor, the inlet pressure sensor and O
Sensor, issued by the signal, with the engine Speed through the ECU
to determine the appropriate ignition is, by the current of a crystal
intermittent control, a 25000-30000 volts of secondary hypertension,
flashover triggered spark plug, this approach will not only enable the
engine to achieve maximum output function, also help to improve the
efficiency of fuel consumption and pollution improvements.

Testing Procedures:

Resistance Confirmation:

● Removed coil first circuit plugs on the ignition coil (Red / Yellow &

Black / Yellow).

● Use of the "meter" Ohm stalls (Ω), measurement of the ignition coil

resistance value.

Detection judge:

● Ignition coil primary circuit: 2.8Ω±15% (20ºC)

Treatment of abnormal phenomena:

1. Ignition coil internal coil disconnection damaged, or plugs bad contact.

2. Ignition coil ignition is not abnormal, proposes to replace the ignition
coil.

Functional Description:

● Do not need for an external power supply, has two-pin of signal plug.

● Constitutes a major change in its reluctance induction coil.

● The spacing of flywheel and sensor should be 0.7 to 1.1 mm.

● Magnetic induction sensor is the use of flywheel on the Gear (23 +1

long tooth) rotary cutting induction coil changes in the magnetic field
sensor with the inductive voltage signal for ECU judgement, calculated
at the engine speed and crankshaft position, and with a most
appropriate time of fuel injection and ignition control.

Testing Procedures:

Resistance Confirmation:

● Removed crankshaft position sensor coupler (Blue / Yellow & Green /

White).

● Use of the "meter" Ohm stalls (Ω), measurement of the crankshaft

position sensor resistance value.

Detection judge:

● Resistance value: 80~160Ω(20ºC)

Treatment of abnormal phenomena:

1. Sensor internal coil interrupted damaged, or coupler bad contact.

2. Check whether the abnormal wire harness lines.

3. Sensor coil anomaly, the proposed replacement of the new one.

2

4-29

To this chapter contents

4. Fuel Injection System

AISV

Functional Description:

● Control power, has two-pin socket, one for the power supply pin, one

for grounding pin.

● Secondary air injection solenoid valve at the Idle (3500 rpm below)

actuator.

● At Idling, ECU control solenoid valve by the grounding circuit to be

moving or closing.

Testing Procedures:

Resistance Confirmation:

● Use of the "meter" Ohm stalls (Ω), measurement of the secondary air

injection solenoid valve resistance value.

Detection judge:

Resistance value = 26 ± 2.6Ω (20 )℃

Treatment of abnormal phenomena:

● Secondary air injection solenoid valve internal short circuit or open

circuit, or coupler bad contact.

● Check whether the abnormal wire harness lines.

● Secondary air injection solenoid valve anomaly, the proposed

replacement of the new one.

4-30

To this chapter contents

4. Fuel Injection System

EFi System Circuit

Charging Indicator

Battery

REG. REC. ACG. O2 Sensor

Crankshaft

position

sensor

position

Throttle

sensor

Y Y Y

(20A)

(15A)

(20A)

G

R

B

Other

appliances

G/W

L/Y

Y/B

W/BR

G/R

G

08

09

03

13

05

24

R

ECU

LG

CRK-P

CRK-M

VCC

TH

SG

MIL

TSSM

K-LINE

BAT

IGP

21

20

10

19

01

SB/O

W/R

R

B

Y/G

P/W

W/G

R/Y

Power

relay

R/Y

G

G

G

R

Main switch

G

Injection System

warning lights

coupler

switch

Test

tool coupler

Diagnosis

Roll over

sensor

B/O

Security

unit

Start SW.

Inlet pipe

pressure

sensor

tempture

sensor

tempture

sensor

control

valve

Air

Engine

L/B

Idle speed

B/W

BR/B

G/B

B/R

G/BR

R/GR

L/O

R/O

R/Y

PM

06

25

TA

TW

22

07

HEGO A/D

HEGO HT

17

15

ISCAP

32

ISCBN

31

ISCAN

14

ISCBP

PG

PG1

FLPR

INJ

IG

SOL

36

35

11

16

18

12

Eng. Con.

relay

Eng. Stop SW.

G

Fuel pump

relay

O/W

L/G

B/Y

Tachometer

O/L

L/W

W/R

B/G

B/PU

Side stand

switch.

Fuel pump

Fuel unit

Injector

Ignition

coil

Side stand
Indicator

Y/W

Fuel meter

solenoid valve

Secondary air

4-31

To this chapter contents

4. Fuel Injection System

ECU Pin Configuration

(ON ECU)

ECU Pin Note

Pin

NO.

01

02

Wire

color

Pin code Note

R/Y IGP

rive components Power +

o use

Pin

NO.

19

20

Wire
color

Pin

code

R BAT

P/W TSSM

Note

CU power +

est switch signal (A/D)

L/Y CRK-P

03

04

05

06

07

08

09

10

11

12

13

14

15

W/BR TH

B/R PM

L/O

G LG

G/W CRK-M

W/G K-LINE

O/W FLPR

O/L SOL

Y/B VCC

G/B ISCBP

L/B ISCAP

HEGO

A/D

rankshaft pos. Sensor+

o use

hrottle position [A/D]

anifold Press. SNSR I/P [A/D]

Sensor [A/D]

2

CU ground

rankshaft pos. Sensor-

equence transmission signal

utput / input

Fue pump relay O/P

ISV O/P

ensor power + (DC 5V)

tep motor A phase power +

tep motor B phase power +

21

22

23

24

25

26

27

28

29

30

31

32

33

Y/G MIL

R/GR TW

G/R SG

G/BR TA

BR/B ISCAN

B/W ISCBN

arning Lights O/P

ng. Water Temp. Sensor (A/D)

o use

ensor ground

ntake air temperature sensor (A/D)

o use

o use

o use

o use

o use

tep motor A phase power -

tep motor B phase power -

o use

16

17

18

4-32

L/G INJ

R/O

B/Y IG

HEGO

Fuel injector O/P

HT

Ignition coil O/P

Sensor heater ground

2

34

35

36

G PG1

G PG

o use

rive components ground

rive components ground

To this chapter contents

4. Fuel Injection System

Troubleshooting

EFi Circuit inspection

Warning lights extinguished after 2 seconds?

Battery voltage above 12.5V?

Battery voltage & ECU voltage of less than 0.2 V?

1. Main switch OFF

2. Removed ECU coupler

3. Main switch ON

4. Use voltage meter measurement of the power-pin

voltage difference

5. Confirmed ECU and battery supply voltage

differential pressure within the 0.2 V voltage

Battery voltage – drive parts voltage of less than 0.2
V?

1. Main switch OFF

Removed the injector, fuel pump, O2 sensor, roll

2.

over sensor, ignition coil couplers
Measurement of the voltage between the couplers

3.

and ground of the voltage difference

4.

Confirmed voltage difference and battery voltage
of 0.2 V gap within?

ECU 5V voltage - sensor voltage of less than 0.2 V?

1. Main switch OFF

Use probe inserted throttle sensor, engine

2.

temperature sensor, the inlet pressure sensor
power connector

3. Main switch ON

4.

Use voltage meter measurement of the sensor
connector voltage

Voltage standard value: 5.0±0.1V

5.

Battery voltage - fuel pump voltage of less than 0.2
V?

1. Main switch OFF

Removed fuel pump power coupler

2.

Potential probe then pumped two-pin connector

3.

4. Main switch ON

Pumped in three second record supply voltage

5.

values

6.

Confirmed pump and battery supply voltage
differential pressure within the 0.2 V voltage

Main switch on

OK

OK

NG

OK

OK

NG

OK

NG

OK

End

1. Bulbs broken?

2. Fuse broken?

NG

NG

NG

3. Battery voltage is too low?

4. ECU Power line bad contact?

5. Poor contact the main power

switch?

6. ECU fault？

1. Charging line anomaly?

2. Unable electrical storage

batteries?
Short-circuit leakage?

3.

1. Lines anomaly?

1. Lines anomaly?

1. Lines anomaly?

2. ECU

1. Lines anomaly?

2. Relay fault?

3. ECU anomaly?

anomaly?

4-33

To this chapter contents

4. Fuel Injection System

Can not Start the engine or difficult to start inspection

Warning lights extinguished after 2
seconds?

Difficulties or can not to start engine

NG

OK

1. Inspection process in accordance with

circuit inspection

Display warning lights Fault Code?

NG

OK

1. Use diagnosis tool to view EMS fault

content

2.

In accordance with Troubleshooting
procedures on troubleshooting

Fuel system anomaly?

NG

OK

1. Fuel tank inadequate?

2.

Fuel injector pressure-less than 294 ±
6kpr?

3.

Pipeline fuel spills?

4.

Pressure Regulating Valve anomaly?

5.

Fuel pump pipe leakage?

6.

Fuel pump anomaly?
Fuel injector anomaly?

7.

Circuit anomaly?

NG

OK

1. Spark plug there sparks?

2.

Spark plug humid?

3.

Spark plug cover loose?

4. Crankshaft position sensor

Circuit

5.

The high-voltage power lines loose?

6. ECU

7.

anomaly?

Leaking oxygen sensor connector
corrosion short circuit?

Short

Engine anomaly?

NG

OK

1. Without valve clearance?

2.

Valve timing, is not correct?

3. Valve jam?

4.

Cylinder and piston ring wear?

5.

Throttle adjustment screw adjustment
of the air improper?

End

4-34

To this chapter contents

4. Fuel Injection System

Idle flameout diagnosis

Idle flameout

1. Link diagnosis tool to
view EFI fault content

2. In accordance with
Troubleshooting
procedures on
troubleshooting

Throttle line is not too
jammed to revert to full
closure?

Gasoline whether
enough?

Whether loose battery
connecter?

Idle CO value is set beyond
the scope of (1.5% ~

2.5%)?

Throttle body whether
coke serious?

Idle Air Control Valve
Actuation whether or
failure?

EFi system more relevant
institutions, each recognized by the
detection, if still unable to rule out
the idling flameout problem, it is
recommended that engine checks
whether there are other traditional
institutions abnormal.

4-35

To this chapter contents

4. Fuel Injection System

CO value revised anomaly

O2 Sensor equipped with the system, in principle, not adjusted CO value, such as CO value deviated from the
normal range, check O

Idle flameout

Link diagnosis tool to view EFI fault
content, it’s Idle CO value amend
anomalies

Gasoline whether enough?

Whether loose battery connecter?
Voltage is adequacy?

2 Sensor and other agencies anomaly.

Throttle line is not too jammed to
revert to full closure?

Connect with the
diagnosis tool, into to
view data steam
screen.

Start engine and warm-to 70 º C ~
95 º C, confirmed engine speed, idle
control valve and fuel injection
timing, oxygen sensor is abnormal?

Idle CO value is set beyond the
scope of (1.5% ~ 2.5%)?

Idle functioning of 3 ~ 5 minutes, to
confirm the engine is running
normally after engine flameout,
eliminating fault code operations?

EFi system more relevant
institutions, each recognized by the
detection, if still unable to rule out
the idling flameout problem, it is
recommended that engine checks
whether there are other traditional
institutions abnormal.

4-36

To this chapter contents

4. Fuel Injection System

Integrated Troubleshooting Procedure

Checking,

adjusting

Project

Battery
voltage

Diagnosis
fault code

inspection

Fuel

quantity and

fuel

pressure

Ignition

situation

Detection of

maintenance projects

and steps

● Use meter direct

measurement
battery voltage

● Use diagnosis

tool detection
battery voltage

● Use of the

diagnosis tool
detection fault
code

● Elimination of

fault codes, and
then start engine

● Removed the

injector on the
intake manifold,
but not removal of
harness coupler.
(Injector and
injector cap tightly
by hands, fuel
spills should not
be the case)

● Start the engine

● Examine whether

injector fuel
injection

● Between the tank

and injector
installation the
pressure gauge

● check fuel

pressure
adequacy

● Removed the

spark plug from
the cylinder
head, but then
power lines still
ring

● Start the engine

● check spark plug

sparks

determination

● Battery voltage

is 10 V above?

● Diagnosis tool

show whether
the voltage of 10
V above?

YES

● Diagnostic tool

show whether or
not a fault code?

● Fault Code

cleared after
show again?

NO

● Injector whether

injection?

● Injector spray

angle is normal?

● Fuel pressure

enough?

YES

● Examine

whether the
spark plug
ignition?

● Check spark

plug sparks
strength is
normal?

YES

Continued next page

NO

YES

NO

NO

Fault reasons Fault status

● Battery electricity

● Battery connector

loose

● Harness circuit

opening

● ECU coupler not

connected properly

● TPS fault

● ETS fault

● CPS fault

● MAP fault

● O2 sensor fault

● ROS fault

● ECU fault

● less than fuel tank

● Injector fault

● Fuel pump relay

fault

● Fuel pump fault

● ECU fault

● Fuel pump filter

obstructive

● Spark plug fault

● Roll over sensor

fault

● ECU fault

● Ignition coil fault

● Crankshaft position

sensor fault

Parts specifications

● Diagnosis tool

display voltage
required to
achieve more
than 10 V

● The sensor

detection
methods and
specifications,
please refer to
repair manual

● Pressure fuel

specifications:

Open the main
switch three
seconds after
but not start
engine →more
than 250 kPa

Idle →
294±6kPa

● Injector

resistance
specifications:

11.7±0.6Ω

● Spark plug

specifications:
NGK-CR8E

4-37

To this chapter contents

4. Fuel Injection System

Closed-loop

systems for

mobility

● Observation O2

sensor voltage
changes (Standed
motorcycle so that
engine speed
refueling between
4500 to 5500 rpm

Continued from previous page

YES

● O2 sensor

voltage is
maintained in a
long time within
a certain range
beating

NG

● O2 sensor fault

● ECU fault

● O2 sensor

voltage beating
specifications:
100 ~ 900 mV
from the two
groups within
the interactive
beating

YES

Engine

vacuum

● Use diagnosis

tool to detect of
the manifold
pressure

● Diagnosis tool

manifold
pressure for
compliance with
specifications?

NG

● Valve clearance is

not normal

● Intake system leak

● Manifold

pressure
Specifications:
32~38 kPa

YES

Normal starting Can not starting or starting difficulties

Finish

In traditional engine overhaul way to
maintenance

4-38

r

To this chapter contents

4. Fuel Injection System

Remove fuel pump/fuel unit

Remove side cover.
Remove rear carrier
Remove rear bodycover.
Remove floor panel.
Remove under cover.
(refer to chapter 14)

Remove fuel pump lines coupler.
Release the fuel tube folder, removed the fuel tube.

Remove the fuel tank fixed bolts (Bolt × 3), remove the
fuel tank.

Remove / Install fuel pump and fuel unit

Remove fuel pump
pump.
Install In the anti-demolition order.

fixed bolts (Bolt × 6), remove fuel

Fuel pump

Bolt × 3

Pressure Regulating Valve

Cautions

z Then remove fuel pump, fuel in fuel tank

internal to confirm not excessive.

z Then install fuel pump and fuel unit, attention

direction.

z Confirm whether the fuel filter dirt,

obstructive.

z Fuel pump installation, to confirm whether it

is normal to the fuel out (the pressure about 3
kg/cm2).

Fuel filte

4-39

To this chapter contents

4. Fuel Injection System

Air Cleaner

Remove

Remove left side body cover and luggage box.
Remove rear carrier and body cover.
Remove fuel gas recover tube.
Remove waste gas purification system pipes.
Remove intake temperature sensor coupler.

Remove intake tube fixed bolt (bolt×1).
Remove air cleaner fixed bolts (bolt×2).
Remove air cleaner.

Install

Install In the anti-demolition order.

Clean air cleaner element

Remove air cleaner cover (bolt×8).
Remove air cleaner filter (bolt×6).
Use compressed air to remove the adhesion of dirt,
if not too much dirt cleared, please new
replacement.

Bolt × 8

Bolt × 2

Air catheter fixed bolts × 1

Cautions

● Air cleaner filter for paper products, must not

soak or cleaning by water.

Install air cleaner element

Install In the anti-demolition order.

Cautions

● Air cleaner filter and air filter cover should be

covered formation is the installation, not to
skew a seam, resulting dust, foreign body
aspiration in the engine.

4-40

Bolt × 6

r

To this chapter contents

4. Fuel Injection System

EFi System Diagnosis Methods

When the motorcycle injection system in the wrong signal, causing abnormal functioning of the engine or
can not start engine, warning light at the meter will be lighting, to inform drivers to carry out maintenance.

Overhaul, the diagnosis tool can be used for troubleshooting (refer to diagnosis tool use guide), or
manually by the meter warning light inspection revealed that the fault codes (refer to checking signal fault
codes discriminant method), the two methods for maintenance.

If the fault has been ruled out or repair after the inspection light will be extinguished, but ECU fault code
will be recorded, so the need to get rid of fault codes. If a fault exists, this system has two kinds of
methods to eliminate fault codes respectively in the diagnosis tool removal and manual removal.

Using diagnostic tool for overhaul

Diagnosis tool will connect to the motorcycle for coupler diagnosis, according to the use of diagnostic tool
testing methods, when belong fuel injection system fault or parts fault, according to the diagnosis tool of
the fault code display messages do describe parts of the inspection testing maintenance and replacement
parts. When after the maintenance, the need to get rid of fault codes (Please refer to detailed steps
diagnosis tool of instructions), or fault code will always be stored in the ECU.

Manual inspection

Use of cross-wiring (wire or paper clips, etc.) to cross-Joints Test Switch for grounding, in the meter of
this check light are flashing, it means that the injection system or parts of abnormal situations, but not in
the diagnosis tool can be - for the detection, inspection can enjoy for a long time flashing lights flashing
and the short period of time to inform the cause of the malfunction (refer to check light fault information
fault code table).

Test switch coupler

Diagnostic tool couple

Diagnostic tool couplerand test switch coupler plant

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4. Fuel Injection System

Check Light Fault Codes Differentiation

Check light flashing mode

If problem without diagnosis tool to be detected, it can be cross-access the test switch coupler, the
motorcycle from the CHK lights flashing signal interpretation, and then the basis for the diagnosis of
dynamic information tables on the priorities of light, and prompts you to the motorcycle to the emergence
of some warning, or FLASH CODE is to determine what kind of fault, and exclusion.

1

Fault Code manual removal procedure:

When there is without diagnosis tool, can be manually cleared Fault Code, the implementation of the
following steps:

1. Main switch OFF

2. Cross-access the test switch for interconnection access, and without opening up (cross-access

movement must indeed).

3. Full throttle and do not open up.

4. Main switch ON

5. Described above, the No. 3 with the No. 4 movements continued liberalization of 5 seconds later, about

5 seconds after inspections at carnivals "flash twice" to complete the removal of fault code.

6. Then remove the cross-wiring.

Test switch Throtrtle

switch

Main

Check

light

1

1

Fault code 22 Continuous repeated Fault code 12

0.5 1 0.5

1 3 1 6

Cross-access

Full throttle

At least 5 seconds

ON

OF

Not lit

Lighting

Not to cross-access

Full throttle closed

Lighting

2nd inspection lights flash

Not lit

Unit: second

OF

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4. Fuel Injection System

Fault Code and Sensors Table

No.

1

2 0105

3 0115

4 0195

5 0110

6 1630

7 0130

8 0201

9 0351

Fault

codes

0120

Fault Description Parts Inspection

Throttle position sensor fault TP Sensor and wire

Manifold absolute pressure sensor fault MAP sensor and wire

Engine temperature sensor fault (water) TW Sensor and wire

Engine oil temperature sensor fault (oil) Engine temperature sensor and wire

Intake air temperature sensor fault TA Sensor and wire

Roll over sensor fault Roll over sensor and wire

O

sensor fault O2 Sensor and wire

2

ＩＮＪ #1 fault

IG #1 fault Ignition coil and wire

Injector and wire

10 0230

11 0135

12 1505

13 1410

14 0335

15 1205

16 0603

Fuel pump fault Fuel pump and wire

O

sensor heater fault O2 Sensor and wire

2

ISC Idle_speed control motor fault ISC stepper motor and wire

Exhaust 2

nd

air control solenoid valve fault AISV and wire

Crankshaft position sensor fault Crankshaft position sensor and wire

MAP wire fault

EEPROM fault EEPROM

MAP sensor and wire

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4. Fuel Injection System

Fault Code and Check Light Flashing Lighting Identification Table

No.

Fault

codes

1 0120

2 0105

3 0115

4 0195

5 0110

6 1630

Fault Description

Throttle position sensor fault Lighting

Fault detection procedures Please refer to the "EFI System components description" throttle position sensor
(TPS) chapter

Manifold Absolute Pressure sensor fault lighting

Fault detection procedures Please refer to the "EFI System components description" manifold Absolute

Engine temperature sensor fault (water) lighting

Fault detection procedures Please refer to the "EFI System components description" engine temperature

Engine oil temperature sensor fault (oil) lighting

Intake temperature sensor fault lighting

Fault detection procedures Please refer to the "EFI System components description" intake temperature

Roll over sensor fault lighting

Fault detection procedures Please refer to the "EFI System components description" Roll over sensor chapter.

Check

light

Pressure sensor (MAP) chapter

Check light flashing

state

long 0，short 6

long 0，short 9

long 1，short 2

sensor (WPS) chapter.

long 1，short 1

The current reservation

long 1，short 3

sensor (TAS) chapter.

long 1，short 5

Parts Inspection

Throttle position sensor and wire

MAP sensorand wire

Engine temperature sensor and wire

Engine temperature sensor and wire

Intake temperature sensorand wire

Roll over sensor and wire

7 0130

8 0201

9 0351

10 0230

11 0135

12 1505

13 1410

14 0335

15 1205

16 0603

O2 sensor fault lighting

Fault detection procedures Please refer to the "EFI System components description" O2 sensor chapter.

ＩＮＪ #1 fault

Fault detection procedures Please refer to the "EFI System components description" fuel injector chapter.

IG #1 fault lighting

Fault detection procedures to adhere to the traditional way

Fuel pump fault lighting

Fault detection procedures Please refer to the "EFI System components description" fuel pump chapter.

O2 sensor heater fault lighting

Fault detection procedures Please refer to the "EFI System components description" O2 Sensor chapter.

ISC motor fault lighting

Fault detection procedures Please refer to the "EFI System components description" idle speed control valve

Exhaust 2nd air solenoid valve fault lighting

Fault detection procedures Please refer to the "EFI System components description" 2nd air solenoid valve

Crankshaft position sensor fault lighting

Fault detection procedures Please refer to the "EFI System components description" Crankshaft position

PM wire fault lighting

Fault detection procedures Please refer to the "EFI System components description" Manifold absolute

EEPROM fault Not lit

lighting

pressure sensor (MAP) chapter.

This fault Please direct replacement ECU

long 1，short 7

long 3，short 3

long 3，short 7

long 4，short 1

long 4，short 5

long 4，short 9

(ISC) chapter.

long 5，short 4

chapter.

long 6，short 6

sensor chapter.

long 6， short 8

long –，short –

O2 Sensorand wire

Injector and wire

Ignition coil and wire

Fuel pump and wire

O2 Sensorand wire

Step motor and wire

2nd air control valve and wire

Crankshaft position sensor and wire

Manifold absolute pressure sensor

and wire

EEPROM

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4. Fuel Injection System

EFi System Diagnostic Tool - V70

LCD
monitor

Function
set Button

Leave
buttom

Cable connector

Information
transmission indicator

Button to turn the
pages, and numerical
adjustment

Executive
Function button

Link cable

Digital
buttom

Software cartridge slots

Software
cartridge

Note:

● When problems arise, can be used for diagnosis tool of the fault is detected, and exclusion.

● In addition to testing, troubleshooting, another of the operation can be carried out data analysis-type

monitor.

Method of Use:

1. Maintain engine flameout state, do not open main switch.

2. Opened the luggage box lighting light cover (screw x2), connected to the diagnostic connector for

diagnosis tool.

3. Then open the main switch and the diagnosis tool power switch after diagnosis display screen

appeared the words connection.

4. Press the "ENTER" button into the main screen (there are 6 major functions: ECU ID, DATA STREAM,

FREEZED DATA, TROUBLE CODE, ERASE TB CODE and CO ADAPTION)

5. Use ▲, ▼ select button under the function, press the "ENTER" button access into various functions.

Example: select "DATA STREAM," by the "ENTER" button, the screen showed that the existing fault

codes; indicates no fault "system is OK."

6. Press "EXIT" buttom to leave of the various functions.

7. Must to close the main switch or power switch of the diagnosis tool after, and then can removal of

diagnosis tool coupler.

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r

4. Fuel Injection System

Diagnostic Tool Use Note

Diagnosis of connectivity

1. For the diagnostic tool coupler access to the
motorcycle injection system diagnostic signal
coupler.

2. main switch ON.

3. Open the diagnosis left power switch, which turn
on the LCD screen, the screen brightness
adjustment knob to the appropriate brightness.

4. SYM and cartridge content display on screen
(such as icon), by the beginning of the
implementation of any button.

5. Display diagnostic software release; press the
"ENTER" buttom to the implementation.

Test switch

Diagnostic couple

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4. Fuel Injection System

Options main functional areas:

1. ECU ID

2. DATA STREAM

3. FREEZED DATA

4. TROUBLE CODE

5. ERASE TB CODE

6. CO ADAPTION

Use "▲" "▼" button, select mobile anti-white subtitles implementation of the project, and then press the
"ENTER" key to the implementation.

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4. Fuel Injection System

1. ECU ID

In the directory functions used "▲" "▼" button, select ECU ID project, press the "ENTER" buttom to
the implementation of information systems function.

ECU ID containing two functions:

1-1. ECU ID Datas
1-2. ECU Pin Assign

1-1. ECU ID Datas

Use "▲" "▼" button, select ECU ID projects, press the "ENTER" buttom to the implementation.
A total of 2 page, use "◄ left" and "right ►" button, view ECU information.

DIAG. ID: 0002000000020 (Diagnosis tool ID)
S/H VER: 001 (Software Version)
DIAG. VER: 03 (Diagnosis Version)
MODEL: SYM GTS250
NAME: HML 00203

H/W VER: (Hardware version)
S/H VER: 001 (Software Version)
CALI ID:
ECU NO: 001

(Correction ID Code)

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1-2. ECU Pin Assign

Use "▲" "▼" button, select the ECU pin project, press the "ENTER" buttom to the
implementation of the ECU pin functions.
ECU pin assign total of 5 pages that can be used "◄ left" and "right ►" button, view the page
note.

4. Fuel Injection System

Page 1:

1: IGP [R/Y] B+
2:
3: CRK-P [G/W] Crankshaft pos. Sensor­4:
5: TH [W/Br] Throttle angle [A/D]
6: PM [B/R] Manifold Press. SNSR I/P [A/D]
7: HEGO [Pink/B] O2 sensor [A/D]
8: LG [G] shild GND

Page 2:

9: CRK-M [L/Y] Crankshaft pos. Sensor+
10: K-LINE [W/G] K-Line
11: FLPR [O/W] Fuel pump relay O/P
12: SOL [O/L] 2
13: VCC [Y/B] Sensor V+ (DC 5V)
14: ISCBP [G/B] Step MTR B+ (RV250)
15: ISCAP [L/B] Step MTR A+ (RV250)
16: INJ [L/G] Injection O/P

Page 3:

17: HEGOHT [R/O] O2 Sensor heater
18: IG [B/Y] Ignition O/P
19: BAT [R] Battery B+ (RV250)
20: TRIG [Pink] Test sw
21: MIL [Y/G] MIL O/P
22: TE [R/Gr] Eng. Temp. Sensor (A/D)
23:
24: SG [G/R] Sensor (A/D) GND

nd

air (RV250)

Page 4:

25: TA [G/Br] IAT Sensor (RV250)
26:
27:
28:
29:
30:
31: ISCAN [Br/B] Step MTR A- (RV250)
32: ISCBN [B/W] Step MTR B- (RV250)

Page 5:

33:
34:
35: PG1 [G] System GND
36: PG [G] System GND

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4. Fuel Injection System

2. DATA STREAM

In the directory functions used "▲" "▼" button, select "DATA STREAM" project, press the "ENTER"
key to the implementation.

A total of 3 pages, are able to use "◄ left" and "right ►" button, view injection system information.
On the any screen, press the "EXIT" button, the function can return to the directory screen.

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4. Fuel Injection System

Data stream (1/3)

The screen showed the ECU captured by the engine of the state immediately.
The following data for the benchmark idling state:

● Engie SPD--- RPM (Idle:1550~1750) →Engine idle speed

● FAULT NO.-------- (Normal:0) →Fault code number

● BATT. VOLT---- V (Above 12V) →Battery voltage

● FUEL PUMP--------- (Idle:ON) →Fuel pump actuator state

● MAP------------ kPa (Idle:32~38kPa) →Manifold pressure

● TPS position------ % (Idle:﹤1.5%) →Throttle opening

● TPS position---- V (Idle:0.58~0.62) →Throttle sensor voltage

● O

SENSOR---- mV (Idle:50~200mV) →O2 sensor voltage

2

● O

HEATER--------- (Idle:﹥3500rpm=ON) →O2 heater actuator state

2

● ENGINE TEMP-- ºC (Stable:85~95ºC) →Engine temperature (cooling water temperature)

In the "DATA STREAM" of the screen use "▲" "▼" button to move the left side of the project "→"
symbol selected items, press the "ENTER" buttom lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use "◄ left" and "right ►" button, can transform View wave numerical size.

Numerical analysis of images (1 / 3), the waveform can be displayed as shown in the following items:

y Engie SPD
y BATT. VOLT
y MAP
y TPS position %
y TPS position Voltage
y O

SENSOR Voltage

2

y ENGINE TEMP

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