FGKTM – A Retrofit Fuel Injection Kit

INSTALLATION & USER MANUAL

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IMPORTANT NOTICE:
This manual is prepared for Athe installation of FGK on a SYM e-Bonus
A 110cc motorcycle.
However, it can also be used as a guideline for installation of otherA FGK models for other
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motorcycle models. A
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Apt Touch will not be responsible for any damage or injuries caused by misuse or mishandling of
any part of FGK, including the tuning software Ignitus®.

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B R O U G H T TO Y O U B Y

©APT TOUCH SDN. BHD.

74 Jalan Perdagangan 3
Taman Universiti, 81300 Skudai
Johor, Malaysia
Phone/Whatsapp: +6016-721 4542

TABLE OF CONTENT

No. Content
1. Features & Functions ……………………………...…………………… 4
2. Safety Guidelines & Precautions …………………..………...………….. 4
3. Standards Compliance …………………………….………...………….. 5
4. Parts & Description of Parts ………………………………...…………. 6
5. Installation Procedures ……………………………………...………….. 8
Part A: Removing the Carburetor ……………………….. 8
Part B: Installing the FGKTM ……………………………. 9
Part C: Installing the Fuel Pump ………………………... 10
Part D: Connecting the Electronics Parts ……………….. 12
Part E: Testing the System ……………………………… 13
6. Warranty Statement ……………………………….………...………….. 14

1 FEATURES & FUNCTIONS

FGKTM is a kit designed to replace the carburetor system on a motorcycle with a fuel
injection system as the fuel delivery system to obtain higher torque, power and fuel
economy, depending on the selected mode of operation (via the selection switch on the
electronic control unit (ECU) box).

With its sleek and compact design, FGK integrates all the required components of a fuel
injection system to totally replace the carburetor. The throttle body controls the amount
of air that flows into the engine, housing a butterfly valve that rotates on a shaft, which
opens and allows air into the engine when the handle grip is twisted. The TPS measures
the opening of the valve and pass the information to the ECU. The air then enters the
combustion chamber via the intake manifold.

Apart from the throttle position, various other signal measurements are made. The ECU
uses the information from these sensors to carefully calculate the suitable amount of fuel
to be injected to obtain various engine performance specifications. The external fuel
pump that is housed in a specially-designed holder, delivers fuel from the tank to provide
high-pressure fuel for the injector, which then sprays the fuel at specific timings, to mix
with the intake air.

The angle of the intake manifold and the angle of the injector with respect to the intake
manifold have been carefully designed to achieve optimal engine performance.

All FGKTM models are for use on 4-stroke, single cylinder engines only.

SAFETY GUIDELINES & PRECAUTIONS

1) Connection
a. The kit must be installed correctly to avoid damage to the kit and to the
engine.
b. For details installation of the kit and its components, please refer to
installation procedure given in this manual.
c. Make sure all connections of electrical components of the kit are
connected correctly before starting or testing the kit. Please strictly follow
the intrusions given in the installation procedure.

2) Battery
a. The kit, by default, requires a 12-V, 7-Ah battery as the minimum, and
charging system for power supply.
b. If your existing battery has a charging deficiency, you may need to
upgrade your charging system using e.g an aftermarket stator.
c. Avoid long-period idling as this will drain you battery for some small
charging systems.
d. If you have leaved your engine off for a long time, the chance that your
battery is low is high. It is advisable to charge your 12-V battery before
you run your engine again.

3) Fuel Pump Installation

a. The fuel supply system must be installed correctly to provide the fuel to
injector, and maintain the fuel pressure. If the fuel supply system is not

installed correctly, you could have fuel starving issue, showing as some
erratic problems, or not able to start the engine at all.
b. The fuel pump must be installed below the fuel tank; or at least at the
bottom level of the fuel tank, because the fuel pump does not have
enough sucking power, it could be starving if it is located higher than the
tank.
c. The fuel pressure regulator must be connected correctly (inlet vs outlet).
or you will not get any fuel pressure.
d. Ensure that there is no air bubbles in the fuel line as this will prevent fuel
from being delivered to the injector.
e. Sometime, you have to manually purge out the air bubbles in the fuel
supply system. In this case the noise of fuel pump is little higher pitch
than with fuel pumping and you will not be able to start because thre is
no fuel pumping. To check whether the fuel supply system has air pocket
or air bubbles, you can un-plug the high pressure fuel line, pointing it into
a bottle, and key-on. You should see fuel sprout out if fuel pump is
working and no air bubbles.

4) This kit can only provide up to engine speed of 12000 rpm and is customized
solely for 110 cc engine.

1 STANDARDS COMPLIANCE

FGKTM has undergone and passed the following tests:

1) Environmental Quality Act 1974 (Act 127): Environmental Quality (Control of
Emission from Motorcycles) Regulations 2003
2) SIRIM JIS:D1601 Type 4 Class B Vibration Test for FGK’s Intake System
3) Electromagnetic Compatibility Test as recommended by UNECE Regulation 10
Uniform Provisions Concerning the Approval of Vehicles with Regard to
Electromagnetic Compatibility

1 PARTS & DESCRIPTION OF PARTS

FGKTM consists of 5 parts:

1) 1 x Intake System Assembly – Fig. 1(a)
The intake system assembly consists of a throttle body, an intake manifold, a
throttle position sensor (TPS), and a fuel injector – all assembled together into
one compact unit known as the ‘Intake System Assembly’.

2) 1 x Electronic Control Unit (ECU) – Fig. 1(b)

The brain of the system that controls the amount and timing of the fuel injection
to achieve various engine performance.

3) 1 x External Fuel Pump Assembly – Fig. 1(c)

The fuel pump for the system is housed in a specially designed holder to deliver
high-pressure fuel from the tank to the fuel injector.

4) 1 x Wire Harness & Connectors – Fig. 1(d)

A set of connecting wires to connect various electronic parts of the kit and the
electrical parts of the motorcycle.

5) 2 x Fuel Lines/Hoses – Fig. 1(e)

To connect:
i. the fuel tank on the motorcycle to the external fuel pump assembly, and
ii. the external fuel pump assembly and the fuel injector

6) 1 x Throttle Bracket – Fig. 1(f)

7) 1 x Mechanical Fitting Set

(a) Intake System Assembly (b) ECU

(c) External Pump Assembly (d) Wire Harness and Connectors

(e) Fuel Lines & Hose Clamps (f) Throttle Bracket

(g) Mechanical fittings set

Fig. 1: Components of FGKTM

INSTALLATION PROCEDURES

Tools Needed:
1) Phillips screwdriver
2) Spanner Size 8
3) Alan Key Size 4 & 1.5

Do the following procedures in order

Part A Part B Part C Part D Part E

• Removing • Installing • Installing • Connecting • Testing
Carburetor FGKTM Fuel Pump Electronic
Parts

Part A: Removing the Carburetor (Figures 2a – 2c)

1 Turn off the fuel switch and remove the fuel hose that connect the carburetor
and the fuel tank. There will also be an overflow hose coming out of the
carburetor, remove this hose too. Wipe the fuel if it spills out.

Figure 2(a): Carburetor is located above the engine block

Fuel Switch

Figure 2(b): Turn off the fuel switch

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2 Unscrew the screws connecting the carburetor and the air filter.

3 Remove the throttle cable by unscrewing the cap on top of the carburetor.
Then, remove the choke linkages from the carburetor.

Figure 2(c): Unscrew the carburetor cap to remove the throttle cable

4 Unscrew the screws connecting the carburetor and the engine block. Twist the
carburetor to remove it.

5 Once all the linkages have been disconnected, remove the carburetor from the
engine carefully as it contains fuel. Drain the fuel into a safe can and detach the
old gasket from its intake manifold.

6 Proceed to Part B to install the FGKTM .

Part B: Installing the FGKTM

1 Place the Intake System Assembly (Fig. 1(a)) at the location of the removed
carburetor. Secure the Throttle Body part to the air filter and the Intake Manifold
part to the engine block using the screws from the carburetor, as follows (Figure
3a):

Figure 3(a): Intake assembly

2 Pass the throttle cable around the throttle cable roller and tighten the screw. Insert
the throttle cable into the throttle cable barrel provided and position the barrel
accordingly by tightening the retaining screw (such that at maximum handle
throttle, maximum throttle valve opening is achieved). See Figure 3b.

Figure 3(b): Intake assembly

3 Proceed to Part C to install the Fuel Pump.

Part C: Installing the Fuel Pump

1 Empty the fuel tank. Find a suitable place to install the External Fuel Pump
(Fig. 1(c)). It should be between the fuel tank and throttle body but nearer to
the fuel tank so that the fuel will flow more smoothly.

a) The fuel pump should be protected by the motorcycle frame so it

will NOT touch the ground when the motorcycle lies on the
ground (e.g. as in Figure 4(a)).
b) The inlet/outlet part of the fuel pump must be connected correctly
or you will not get any fuel pressure.

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Figure 4(a): Suitable location for fuel pump

2 Use the provided Fuel Lines (Fig. 1(e)) to connect:
i. the fuel tank outlet to the inlet of the fuel pump assembly (labeled
‘INLET’), and
ii. the outlet of the fuel pump assembly (labeled ‘OUTLET’) to the injector

Secure all connection points with the provided hose clamps. The Fuel Line may
need to be cut to suitable lengths.

3 Check that there is no air bubbles trapped in the fuel hose, by doing the
following (Figure 4(b)):
i. Fill the fuel tank with some fuel and check if fuel from the tank flows
and fills up the fuel reservoir on the fuel pump assembly
ii. If not, loosen the locking nut of the reservoir a bit until you can see fuel
from the tank fills up the reservoir. You could also release fuel hose
from the injector cap and place it into an external fuel tank. Then,
switch on the switch until fuel running out from the hose.

Figure 4(b): Removing trapped air bubbles in the fuel hose

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Part D: Connecting the Electronics Parts

1 Take the Wire Harness (Fig. 1(d)) and connect the connector labeled ‘ECU’ to
the ECU (Fig. 1(b)).

2 Then, connect the wire harness labeled ‘TPS’ to the throttle position sensor on
the Intake Manifold (on the Intake System Assembly).

Figure 5(a): Connecting to the TPS

3 Next, clamp the YELLOW wire labeled ‘IPS+’ to the power supply wire of the
CDI unit (normally located on the left side of the motorcycle).

Then, clamp the GREEN wire labeled ‘IPS–‘ to the ground wire (normally
green) on the CDI unit.

Figure 5(b): Connecting to the power supply

4 Connect the wire labeled ‘INJ’ to the fuel injector port (on the intake system
assembly).

Figure 5(c): Connecting to the fuel pump injector

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5 Connect the BLACK wire labeled ‘FP+’ to the positive sign on the fuel pump
assembly and the BLUE wire labeled ‘FP-’ to the negative sign of the pump
assembly.

Figure 5(d): Connecting to the fuel pump

6 Connect the wire labeled ‘12VDC’ to the BLACK wire of the ignition switch,
and the wire labeled ‘GND’ to the nearest ground, for example, the motorcycle
body.

Figure 5(e): Connecting to the battery & ground.

DO NOT connect the ‘IPS+’ wire directly to the battery’s positive terminal
as this will switch on the ECU regardless of the position of the ignition switch
and could damage the ECU.

Part E: Testing the System

1 For testing the new system, turn the ignition switch key to ‘ON’ position. You
will hear the pump running for 5s and then the pump will turn off if there are
no ignition signal received. The pump will turn back on when ignition signal is
available by either pressing the electrical starter or using the starter kick when
starting the engine.

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1 WARRANTY STATEMENT

All FGKTM products are warranted against defects in material and workmanship for a
period of ONE (1) year from the date of shipment within Malaysia, and for a period of
SIX (6) months from the date of shipment outside of Malaysia. If you believe any
FGKTM product you have purchased has a defect in material or workmanship or has
failed during normal use within the warranty period, please contact Apt Touch Sdn Bhd
for assistance. If product repair or replacement is necessary, the Customer will be solely
responsible for all shipping charges, freight, insurance and proper packaging to prevent
breakage in transit, whether or not the product is covered by this warranty.

©APT TOUCH SDN. BHD.

74 Jalan Perdagangan 3
Taman Universiti, 81300 Skudai
Johor, Malaysia
Phone/Whatsapp: +6016-721 4542

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