Keihin EFI Components Brief-Check Manual: RV/Joymax/GTS 250i
Keihin EFI Components Brief-Check Manual: RV/Joymax/GTS 250i
Keihin EFI Components Brief-Check Manual: RV/Joymax/GTS 250i
Brief-Check Manual
RV/Joymax/GTS 250i
1
Index
4 、 TW (WATER
(WATER Temp. Sensor)
Sensor)
8 、 Fuel Pump
9 、 INJECTOR
11、
11、AT (Air Temperature Sensor)
12、
12、AISV (Air Injection Solenoid Valve)
2
1.ECU (Engine Control Unit):
1). Illustration:
1 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 24 25 31 32 35 36
3
2). Check procedure:
a). Connect the diagnostic to the vehicle through the connector onboard.
b). Key-on but don’t start the engine.
c). Check if the connection between ECU and Diagnostic is good.
d). We can check the ECU ID number by the following figure 2.
e). Check if the model number and the software version of ECU are both correct.
f). Check if there is any trouble code in the Diagnostic. If yes, please erase it.
g). Start the engine.
h). Check for the parameters in the Diagnostic to see if they are all in normal range.
Figure 2
3). Malfunction determination:
a). ECU ID correct
b). Trouble code can be erased and won’t show up again after re-start.
4
2. PM Sensor (Manifold Pressure Sensor)
1). Illustration:
5
e). Check the signal voltage value for sea-level air pressure: (Like the following figure 4)
‧Electric meter negative pole─ Connect to the third pin (Green / Red)
‧Electric meter positive pole─ Connect the middle pin (Black / Red)
☆Note that the detection pin must penetrate the skin of the electric wires to get the correct readings.
4). Malfunction determination:
a). Working voltage = 5.0 ± 0.1V
b). Signal voltage value for sea-level air pressure =2.87 V ± 0.03 V (Under 101.3kpa)
c). The higher altitude will reduce the voltage output.
☆ Sea-level air pressure = 1Atm = 101.3kpa = 760mmHg = 1013mbar
Fig.3 PM Sensor working Voltage measurement Fig.4 PM Sensor voltage signal output at sea level
6
3.TPS (Throttle Position Sensor):
1). Illustration:
Upper
Middle
Lower
7
Fig. 5 TPS working voltage measurement from ECU side
8
@ If a Diagnostic is available; we can check the TPS voltage output on the function menu.
a). Connect the Diagnostic; Key-On, but don’t start the engine
b). Use the Data Stream mode to view the readings of TPS sensor.
c). Twist the throttle grip to view the voltage value, as the following figure 7 shows.
9
2). Check procedure:
1. Electrical Resistance measurement.
a). Disassemble the TW sensor.
b). Use the Resistance mode on the electric meter to check the OHM value of TW
sensor (Like the following Figure 8)
10
5. Idle Speed Control (stepping
(stepping motor):
1). Illustration:
ISCBP ISCBN
ISCAP Pin2 Pin3 ISCAN
Pin1 Pin4
11
c). There are two phases in the ISC resistance measurement: Phase A and Phase B.
d). The two pins of ISC Phase A are ISCAP and ISCAN; on the other hand, ISC Phase
B are ISCBP and ISCBN.
2. Functional Test: (This test can only done with ISC unit on the throttle body)
a). Key off.
b). Hold the ISC unit with hand
c). Open the throttle fully
d). Key on
e). Feel if the ISC unit is activated or not.
12
6. O2 Sensor (Exhaust Gas Oxygen Sensor):
1). Illustration:
Use the electric meter negative pole to connect the second pin in the coupler
(Red/orange)
Use the electric meter positive pole to connect the first pin in the coupler (Red /
Yellow )
Green/Red(3) Blue/Orange(4)
Red/Yellow(1)
Red/Orange(2)
13
Figure 11. O2 Sensor heater voltage measurement
Use the electric meter negative pole to connect the second pin in the coupler (White)
Electric meter positive pole ─ connect to the first pin of coupler (White )
Black(3) Grey(4)
signal(+) signal (-)
white(2) White(1)
heater(+) heater(-)
14
Figure 13 O2 Sensor electrical resistance measurement
15
4). Malfunction determination :
a).Working Voltage = Over 10V.
b).Electrical resistance value = 6.7~~10.5Ω
a). If the O2 Sensor signal fluctuates between 100 ~ 900 mV, the close-loop pollution control
system is normal. If not in this range, the system is abnormal.
16
8.Fuel Pump:
1). Picture Illustration :
Pump motor
Liquid-level gauge
Figure 16 Fuel pump working voltage measurement and coupler pin assign
If we don’t start the engine after Key–on for 3 seconds duration, ECU will cut off the working
voltage of fuel pump.
18
Liquid-level gauge electrical resistance measurement
a). Dissemble the coupler of Fuel Pump.
b). Use the Ohm function of the electrical meter to check the resistance value of
liquid-level gauge. Shown in Figure 17a. (Pin assign is shown in Figure 17b)
Fuel pump(-)
Pin (2) Liquid-level
gauge(-) Pin (4)
19
After measuring the fuel pressure, we MUST check the following joints to see if any leakage
found. For example, the injector or the fuel pump joints shown in figure 19. This must be done
to ensure safety.
9. Fuel Injector:
1). Picture illustration:
20
3). Check procedure:
Ⅰ). Electrical resistance measurement:
a). Use the Ohm function of electrical meter to check the resistance value of fuel injector.
(As shown in figure 20.)
22
2). Check procedure:
Measuring the electrical resistance:
a). Use the Ohm function of electric meter to check the resistance value of pulse sensor
(As shown in figure 23 )
11、
11、AT (Air Temperature sensor)
1). Picture illustration:
23
2). Check procedure:
Electrical resistance measurement:
a). Use the Ohm function of electric meter to check the resistance value of AT sensor
(As shown in figure 24 )
12、
12、AISV (Air Injection Solenoid Valve)
1). Picture illustration:
24
2). Check procedure:
Electrical resistance measurement:
a). Use the Ohm function of electric meter to check the resistance value of AISV
(As shown in figure 25 )
25
RV250 EMS SYSTEM COMPONENTS DIAGRAM
FUSE POWER
RELAY
IGN SW
FUSE
ROLL- OVER
FUSE
SENSOR
- + REGULATOR PG
FUEL
LG PG BATTERY PG PUMP
RELAY
19BATT 1 IGP
CPS
CRK-P 3 FUEL
11 FLPR PUMP
CRK-M 9
AISV PG
12 SOL
SOLENOID
PG 16 INJ INJECTOR
THROTTLE VCC 13
POSITION TH 18 IG IGN COIL
TH(A/D) 5
SENSOR CHK LIGHT
SG 24 21 MIL
VALVE
PG
MANIFOLD O2 HEATER
PM 17
PRESSURE PM(A/D) 6 HEGO HT HEGO
HEATER
SENSOR 7
HEGO A/D HEGO
SENSOR
COOLANT
TEMP. TW O2 SENSOR SG
SENSOR TW(A/D) 22
INTAKE
AIR TEMP TA
SENSOR
TA(A/D) 25
SG
IDLE ISCAP 14
SPEED ISC ISCAN 15 D
CONTROL 20 I
SW ISCBP 31 TEST (SW)
A
STEPPING G
MOTOR
CN N
O
ISCBN 32 K-LINE S
T
10 I
C
Appendix: 8 35 36
LG PG1 PG2
1. LG- Battery LG
negative pole
2. PG- Frame
grounding wire LG PG
26
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
WIRE
R/Y - L/Y - W/BR B/R L/O G G/W W/G O/W O/L Y/B G/B L/B L/G R/O B/Y
COLOR
IGP CRK TH PM HEGO LG CRK K- FLPR SOL VCC ISCBP ISCAP INJ HEGO IG
PARTS -P -M LINE HT
PIN 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
WIRE
R P/W Y/G R/GR - G/R G/BR - - - - - BR/B B/W - - G G
COLOR
PARTS BATT MIL TW SG TA ISCAN ISCBN PG1 PG2
Red Yellow Green White Brown Black Pink Blue Grey Orange
27
24 SG Sensor Ground
25 TA AIR TEMP. SENSOR
26 ------ ------
27 ------ ------
28 ------ ------
29 ------ ------
30 ------ ------
31 ISCAN IDLE SPEED CONTROL/A (- pole of ISC step motor reverse)
32 ISCBN IDLE SPEED CONTROL/B (- pole of ISC step motor advance)
33 ------ ------
34 ------ ------
35 PG1 Power Ground 1 Engine Grounding 1
36 PG2 Power Ground 2 Engine Grounding 2
28
SYM Keihin EFI System CHK light Diagnose
(LM25W1-T / JOYMAX 250)
CHK light error message chart and Counter Measure
If anything go wrong within the EFI system and causes engine rough running or
stopped, the check light in the speedometer (Picture A) will illuminate to alarm the
driver to perform system check.
Step 1. Confirm SYSTEM error message: After key on, the EFI CHK LIGHT will
illuminate as normal, and then the light goes off. If any things go wrong
in the system the light will illuminate again and keep bright. If this
situation is found, perform checks to diagnose.
Step 2. Keep Key on, and then use a clip or wire to connect two joints in the
CHK LIGHT Test Switch (Picture B). After the joints connected, the EFI
CHK LIGHT will start to blink. This is the error message. Read the error
message to diagnose.
WARINING!
The CHK LIGHT blinking error message is for reference only! Please use SYM
Diagnostic tool for problem confirmation.
It is very easy to MISREAD the error message by the blinking check lights, thus causing
wrong diagnostic and repair treatment.
PLEASE USE SYM OFFICIAL DIAGNOSTIC TOOL.
Step 3. Please read time gap chart below (Picture C) to learn how to read the error
message correctly.
Picture C
The error messages are combined with two different blinking, long or short. Please read the error
message very carefully. In order to identify each error message from each other,
There are two kinds of time gaps in Keihin blinking error message.
Step 4. The check light will stop blinking after problem fixed, however there would
be a trouble code record in the ECU. The trouble code record can be
removed by either manually or by Diagnostic tool.
1. Removed TB code by Diagnostic Tool: Connect the Diagnostic tool with the
scooter. Choose “Erase TB Code” (Picture D). Please erase the TB code after
repair every time.
Picture D
2. Removed TB code manually:
A. Key Off.
B. Use a clip or wire to connect two joints in the CHK LIGHT Test Switch
(Picture B). The connection must be solid without any loosen, the electrical
conduction must be good.
C. Keep throttle full opened.
D. Key On (Throttle is still full opened.)
E. After Key turned ON, keep throttle full opened for at least 5 seconds.
F. The Check Light will blink twice, which means the TB codes are removed.
G. Release throttle, Key off, remove the connected clip / wire on the CHK LIGHT
Test Switch. Operation completed.
Roll over Sensor Blinking Long 1 Short 5 Check Roll over Sensor and wiring.
5 1630
Fuel Injector Blinking Long 3 Short 3 Check Fuel Injector and wiring.
7 0201
Ignition Coil Blinking Long 3 Short 7 Check Ignition Coil and wiring.
8 0351
Please diagnose by traditional way.
Fuel Pump Blinking Long 4 Short 1 Check Fuel Pump and wiring.
9 0230
O2 sensor heater Blinking Long 4 Short 5 Check O2 sensor heater and wiring.
10 0135
ISC motor Blinking Long 4 Short 9 Check ISC motor and wiring.
11 1505
Crank sensor Blinking Long 6 Short 6 Check Crank sensor and wiring.
13 0335
WARINING!
The CHK LIGHT blinking error message is for reference only! Please use SYM
Diagnostic tool for problem confirmation.
It is very easy to MISREAD the error message by the blinking check lights, thus
causing wrong diagnostic and repair treatment.
PLEASE USE SYM OFFICIAL DIAGNOSTIC TOOL.