4-1.

FUEL INJECTION SYSTEM

EFI system components inspection……..13
Fuel Injection System Components………..1
Fuel line inspection……………………..…26
Precautions in servicing……………………..2
Fuel flow inspection……………………….27
General………………………………………..2
Fuel pump………………………………..…28
Fuel system………………………..…………2
Fuel pump relay……………………………29
Connector/coupler……………….…….…….3
Sensor circuit malfunction
Fuse……………………………….…….…….3
troubleshooting…………………..…………31
ECU/various sensors…………………..……3
Fault diagnosis………………………..……54
Electrical circuit inspection procedure. ……4
Integrated fault diagnosis program. …..…57
Parts location………………………………...8
Fault diagnosis note………………….……58
Wiring diagram…………………………..…..9
Use diagnosis tool..……………………..…60
ECU terminal…………………………..……10
Troubleshooting table…………………...…68
Customer complaint analysis…………..….11
Comprehensive maintenance list…………69

Fuel Injection System Components

Throttle Body Idle Speed Controller

ECU

Temperature Manifold Air

Pressure

Throttle Position Sensor

Fuel Pump

Injector

Ignition Coil Engine Coolant

Temperature Sensor
Roll Over Switch
Crank Position Sensor

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PRECAUTIONS IN SERVICING
When handling the Fuel Injection component parts or servicing the Fuel Injection system,
observe the following points for the safety of the system.

GENERAL
Be sure to relieve the fuel pressure while the engine is OFF.
Bending or twisting the control cables will impair smooth operation and could cause the cables
to stick or bind, resulting in loss of vehicle control.
Work in a well-ventilated area. Smoking or allowing flames or sparks in the work area or where
gasoline is stored can cause a fire or explosion.

FUEL SYSTEM
• Do not apply commercially available carburetor cleaners to the inside of the throttle bore,
which is coated with molybdenum.
• Do not snap the throttle valve from full open to full close after the throttle cable has been
removed. It may cause incorrect idle operation.
• Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from
entering the intake ports after the throttle body has been removed.
• Do not apply excessive force to the fuel pipe on the throttle body while removing or installing
the throttle body.
• Do not damage the throttle body. It may cause incorrect throttle and idle valve
synchronization.
• Prevent dirt and debris from entering the throttle bore, fuel tube and return tube, clean them
using compressed air.
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this
manual.
• Do not loosen or tighten the white painted bolts and screws of the throttle body. Loosening or
tightening them can cause throttle and idle valve synchronization failure.
• Do not push the fuel pump base under the fuel tank when the fuel tank is stored.
• Always replace the packing when the fuel pump is removed.
• Fuel injection system location, see page 8.
• A faulty EFI system is often related to poorly connected or corroded connectors. Check those
connections before proceeding.
• When disassembling the EFI parts, note the location of the O-rings. Replace them with new
ones upon reassembly.
• Before disconnecting the fuel hose, release the fuel pressure.
• Always replace the clamp when the fuel hose is removed or loosened.
• Use a diagnosis tool for EFI system inspection.

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 4-1. FUEL INJECTION SYSTEM

CONNECTOR/COUPLER
• When connecting a connector, be sure to push it in until a click is felt.
• With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to
engage the lock when connecting.
• When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead
wires.
• Inspect each terminal on the connector/coupler for looseness or bending.
• Inspect each terminal for corrosion and contamination. The terminals must be clean and free
of any foreign material, which could impede proper terminal contact.
• Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace.
• When taking measurements at electrical connectors using a tester probe, be sure to insert
the probe from the wire harness side (backside) of the connector/coupler.
• When connecting meter probe from the terminal side of the coupler where (connection from
harness side not being possible), use extra care not to force and cause the male terminal to
bend or the female terminal to open. Connect the probe as shown to avoid opening of
female terminal. Never push in the probe where male terminal is supposed to fit.
• Check the male connector for bend and female connector for excessive opening. Also check
the coupler for locking (looseness), corrosion, dust, etc.

FUSE
• When a fuse blows, always investigate the cause to correct it and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.

ECU/VARIOUS SENSORS
• Since each component is a high-precision part, great care should be taken not to apply any
sharp impacts during removal and installation.
• Be careful not to touch the electrical terminals of the ECU. The static electricity from your
body may damage this part.
• When disconnecting and connecting the ECU couplers, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
• Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will
damage the components of the FI system instantly when reverse power is applied.
• Removing any battery terminal of a running engine is strictly prohibited. The moment such
removal is made, damaging counter electromotive force will be applied to the ECU, which
may result in serious damage.
• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V
or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagnosis.
• Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECU when its coupler is
disconnected. Otherwise, damage to the ECU may result.
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4-1. FUEL INJECTION SYSTEM

• Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to
the ECU or sensors may result.
• Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not
be obtained and personal injury may result.

ELECTRICAL CIRCUIT INSPECTION PROCEDURE

While there are various methods for electrical circuit inspection, described here is a general
method to check for open and short circuit using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows.
As the cause can exist in the connector/coupler or
terminal, they need to be checked carefully.
• Loose connection of connector/coupler.
• Poor contact of terminal (due to dirt, corrosion or
rust, poor contact tension, entry of foreign object
ECU
etc.)
• Wire harness being open
• Poor terminal-to-wire connection
• Disconnect the negative cable from the battery. 1. Check for loose connection
• Check each connector/coupler at both ends of the
circuit being checked for loose connection. Also
check for condition of the coupler lock if equipped.
• Using a test male terminal, check the female
terminals of the circuit being checked for contact
tension.
Check each terminal visually for poor contact
(possibly caused by dirt, corrosion, rust, entry of
foreign object, etc.). At the same time, check to
make sure that each terminal is fully inserted in the
coupler and locked.
If contact tension is not enough, rectify the contact
to increase tension or replace.
The terminals must be clean and free of any foreign
material, which could impede proper terminal
contact.

• Using continuity inspect or voltage check

procedure as described below, inspect the wire 1. Looseness of crimping
harness terminals for open circuit and poor 2. Open
connection. Locate abnormality, if any. 3. Thin wire (a few strands left)

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 4-1. FUEL INJECTION SYSTEM

CONTINUITY CHECK
• Measure resistance across coupler B (between A
and C in the figure).
• If no continuity is indicated (infinity or over limit),
ECU
the circuit is open between terminals A and C.

• Disconnect the coupler B and measure resistance

between couplers A and B.
• If no continuity is indicated, the circuit is open
between couplers A and B. If continuity is indicated, ECU
there is an open circuit between couplers B’ and C
or an abnormality in coupler B’ or coupler C.

VOLTAGE CHECK
• If voltage is supplied to the circuit being checked,
voltage check can be used as circuit check.
• With all connectors/couplers connected and
voltage applied to the circuit being checked,
measure voltage between each terminal and body
ground.
• If measurements were taken as shown in the figure
at the right and results are as listed below, it means
that the circuit is open between terminals A and B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground: 0 V

• Also, if measured values are as listed below, a

resistance (abnormality) exists which causes the
voltage drop in the circuit between terminals A and
B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground: 3 V
(2 V voltage drop)

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4-1. FUEL INJECTION SYSTEM

SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)

• Disconnect the negative cable from the battery.
• Disconnect the connectors/couplers at both ends of
the circuit to be checked.

NOTE:
If the circuit to be checked branches to other parts
as shown, disconnect all connectors/couplers of
those parts. Otherwise, diagnosis will be misled.

• Measure resistance between terminal at one end of

circuit (A terminal in figure) and body ground. If
continuity is indicated, there is a short circuit to
ground between terminals A and C.

• Disconnect the connector/coupler included in

circuit (coupler B) and measure resistance between
terminal A and body ground. ECU
If continuity is indicated, the circuit is shorted to the
ground between terminals A and B.

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 4-1. FUEL INJECTION SYSTEM

SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identification number
Starter valve vacuum difference
Idle speed 1500+/- 100 rpm
Throttle grip free play 2~4 mm
Intake air temperature sensor resistance Ω
Engine coolant temperature sensor
Ω
resistance
Fuel injector resistance Ω
Ignition pulse generator peak voltage V
Manifold absolute pressure at idle 420 +/- 30 mm Hg
Fuel pressure at idle 300 kPa

TORQUE VALUES
ECT sensor
Pressure regulator mounting bolt
Fuel pump mounting nut

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4-1. FUEL INJECTION SYSTEM

PARTS LOCATION

1 ECU 8 Fuel Pump (Reservoir)

2 Roll Over Sensor 9 Fuel Filter x 2
3 Injector 10 Ignition Coil
4 Speed Sensor 11 Throttle Position Sensor
5 Engine Coolant Temperature 12 Idle Speed Controller
6 Crank Position Sensor 13 Temperature Manifold Air Pressure
7 Pressure Regulator 14 Throttle Body

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WIRING DIAGRAM

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ECU TERMINAL

HARNESS ECU PLUG

Pin Pin Wire Pin Pin Wire

Circuit Note Circuit Note
No. Code Color No. Code Color
A1 1 Y/B VSENS Sensor voltage G1 7 Br/W
A2 13 Blank G2 19 Gr/R SGND2 Signal ground
A3 25 Blank G3 31 W/Br TPS Throttle position sensor
A4 37 Br/L VBK Key SW voltage G4 43 Blank
B1 2 P/W CAN_H Diagnosis Tool H1 8 Blank
B2 14 W/G RPM H2 20 W Gear B
B3 26 Y/G MIL Engine Check H3 32 Pu VEH Speed sensor
B4 38 R/W VBD Battery Voltage H4 44 L Gear C
C1 3 P/G CAN_L Diagnosis Tool J1 9 B Fuel Pump relay
C2 15 B/Y Temp. Temperature LED J2 21 Blank
C3 27 Gr/R SGND1 Signal Ground J3 33 R Gear A
C4 39 Br/B Stepper B J4 45 R/Gr Override switch
D1 4 LG/R CPS- Crank position sensor (-) K1 10 O/W Main relay
D2 16 Pu/B K2 22 B/W Fan relay
D3 28 G/B Stepper D K3 34 Blank
D4 40 L/B Stepper A K4 46 Blank
E1 5 L/Y CPS+ Crank position sensor (+) L1 11 R VBR Start relay voltage
E2 17 Blank L2 23 Blank
E3 29 Blank L3 35 B/W Starter
E4 41 B/Y Stepper C L4 47 L/G Injector
F1 6 G/Y Brake SW M1 12 B/Y Ignition
F2 18 W/Y MAP Manifold Air Pressure M2 24 Blank
F3 30 G/Br TIA Temperature Intake Air M3 36 Gr PGND Ground
F4 42 Y/R ECT E/G Temperature sensor M4 48 Gr PGND Ground

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 4-1. FUEL INJECTION SYSTEM

SYSTEM TROUBLSHOOTING CUSTOMER COMPLAINT ANALYSIS

Record details of problem (failure, complaint) and how it occurred as described by the
customer. For this purpose, use of an inspection form such as below will facilitate collecting
information required for proper analysis and diagnosis.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name: Model: VIN:
Date of issue Date Reg. Date of problem: Mileage:

Malfunction lamp
□Always ON □Sometimes ON □Always OFF □Good condition
condition (LED)
Malfunction code Malfunction code（ ）

PROBLEM SYMPTOMS
□ Difficult Starting □ Poor Drivability
□ No cranking □ Hesitation on acceleration
□ No initial combustion □ Back fire / □ After fire
□ No combustion □ Lack of power
□ Poor starting at □ Surging
（□cold □warm □always） □ Abnormal knocking
□ Other_______________ □ Engine rpm jumps briefly
□ Other _______________
□ Poor Idling □ Engine Stall when
□ Poor fast idle □ Immediately after start
□ Abnormal idling speed □ Throttle valve is opened
（□ High □ Low）（ rpm） □ Throttle valve is closed
□ Unstable □ Load is applied
□ Hunting（ rpm to rpm） □ Other __________
□ Other ________________
□ OTHERS:

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4-1. FUEL INJECTION SYSTEM

ATV ENVIROMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather □Fair □Cloudy □Rain □Snow □Always □Other __________
Temperature □Hot □Warm □Cool □Cold( ℃) □Always
Frequency □Always □Sometimes ( times/ day, month) □Only once
□Under certain condition
□Urban □Suburb □Highway □Mountainous (□Uphill □Down hill)
Road □Tar macadam □Gravel □Other __________

ATV condition
□Cold □Warming up phase □warmed up □Always
□Other at starting
Engine condition
□Immediately after start □Racing without load
□Engine speed ( rpm)
During driving: □Constant speed □Accelerating □Decelerating
□Right hard corner □Left hand comer
ATV condition
□At shop □ATV speed when problem occurs ( km/h, mile/h)
□ Other _____________

NOTE:
The above form is a standard sample. The form should be modified according to conditions
and characteristics of each market.

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 4-1. FUEL INJECTION SYSTEM

EFI SYSTEM COMPONENTS INSPECTION

T-MAP SENSOR
• Turn the ignition OFF.
• Disconnect the T-MAP sensor 4P connector.
• Check for loose or poor contact on the MAP sensor
connector.

• Connect the T-MAP sensor connector.

• Start the engine and check that the MIL light.
2.Vrev 3.Vout (℃)

1.Vout (p) 4.GND

MIL

• Turn the ignition switch OFF.

• Disconnect the MAP sensor 4P connector.
• Turn the ignition switch ON.
• Measure the voltage at the wire harness side
connector.
Connection: Yellow/Black (+)－Ground(-)
Standard: 5.0 +/- 0.1V

• Measure the voltage between the connector

terminals of wire harness side.
Connection: Yellow/Black (+)－Gray/Red(-)
Standard: 5.0 +/- 0.1V

• Turn the ignition switch OFF.

• Connect the TMAP sensor 4P connector.

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4-1. FUEL INJECTION SYSTEM

ECT SENSOR
INSPECTION
• Turn the ignition switch OFF.
• Disconnect ECT sensor 2P connector.
• Check for loose or poor contact on the ECT sensor
connector.

• Connect the ECT sensor connector.

• Turn the ignition switch ON.
• Check the MIL light.

• Turn the ignition switch OFF.

• Disconnect the ECT sensor connector.
• Measure the resistance at ECT sensor terminals.
Connection:
Standard:2.3~2.6 kΩ (at 20℃)

• Turn the ignition switch ON.

• Measure the voltage between the ECT sensor
connector terminal of the wire harness side and
ground.
Connection: Yellow/Red (+)－Ground(-)
Standard: 5.0 +/- 0.1V

• Measure the voltage at ECT sensor connector of the

wire harness side.
Connection: Yellow/Red (+)－Gray/Red(-)
Standard: 5.0 +/- 0.1V

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 4-1. FUEL INJECTION SYSTEM

REMOVAL / INSTALLATION
• Disconnect the ECT sensor 2P connector from the
sensor
• Remove the ECT sensor.
• Install the new ECT sensor.
TORQUE: 120 kgf/cm
• Connect the ECT sensor 2P connector.

Standard:
RESISTANCE
TEMPERATURE(℃) TOL. (OHM)
VALUES(OHM)
20 3500 ±250

60 704 ±45
90 260 ±20

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4-1. FUEL INJECTION SYSTEM

TP SENSOR
INSPECTION
• Turn the ignition switch OFF.
• Disconnect the TP sensor 3P connector.
• Check for loose or poor contact on the TP sensor
connector.

• Connect the TP sensor connector.

• Start the engine and check the MIL light.

• Turn the ignition switch OFF.

• Disconnect the TP sensor 3P connector.
• Turn the ignition switch ON.
• Measure the voltage between the wire harness side
connector terminal and ground.
Connection: Yellow/Black (+)－Ground(-)
Standard: 5.0 +/- 0.1V

• Measure the voltage at TP sensor terminals of the

wire harness side.
Connection: Yellow/Black (+)－Gray/Red(-)
Standard: 5.0 +/- 0.1V
B.OUTPUT A.GROUND(-)
• Working voltage value: 5.0±0.1V
C.INPUT(+) 5V
• Full throttle open voltage: 3.9±0.2V
• Full throttle closed voltage: 0.5±0.05V
• WARNING!
Never loosen the screw of TPS, result the
unsteady idle.

• Using diagnosis tool to confirm the throttle output screw

signal.
1. Connected to the "diagnosis tool", and open
the main switch, but not to start engine.
2. "Diagnosis tool" selects to a "Live Data"
screen.
3. Rotations throttle and check voltages.

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 4-1. FUEL INJECTION SYSTEM

VEHICLE SPEED SENSOR

• Turn the ignition switch OFF.
• Disconnect the vehicle speed sensor 3P connector.
• Check for loose or poor contact on the vehicle
speed sensor connector.

• Connect the vehicle speed sensor 3P connector.

• Start the engine.
• Ride the vehicle and keep the engine more than
5,000 RPM about 20 seconds or more.
• Check the MIL light.

• Turn the ignition switch OFF.

• Disconnect the vehicle speed sensor 3P connector.
• Turn the ignition switch ON.
• Measure the voltage at the wire harness side
connector.
Connection: Red (+)－Black/White(-)
Standard: 12 V

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4-1. FUEL INJECTION SYSTEM

INJECTOR
• Turn the ignition switch OFF.
• Disconnect the injector 2P connector.
• Check for loose or poor contact on the injector 2P
connector.

• Connect the injector 2P connector.

• Turn the ignition switch ON.
• Check the MIL light.

• Turn the ignition switch OFF.

• Disconnect the injector 2P connector and measure
the resistance of the injector.
Connection: Red (+) － Blue/Green(-)
Standard:12.0+/-0.6Ω

• Check for continuity between the injector and

ground.
Connection: Red (+) － Ground(-)
Standard: continuity

• Turn the ignition switch ON.

• Measure the voltage between the injector connector
of the wire harness side and ground.
Connection: Red (+) － Ground(-)
Standard: battery voltage

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 4-1. FUEL INJECTION SYSTEM

INSPECTION
• Start the engine and let it idle.
• Confirm the injector operating sounds with a
sounding rod or stethoscope.
• If the injector does not operate, replace the injector.

REMOVAL
• Disconnect the injector 2P connector.
• Remove the bolts and fuel rail assembly.
• Remove the injector from the intake pipe.

INSTALLATION
• Install injector on the intake pipe.
• Being careful not to damage the O-ring of injector.
• Install fuel rail assembly and tighten the bolt.
TORQUE: 120 kgf-cm
• Connect the injector 2P connector.

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4-1. FUEL INJECTION SYSTEM

CRANK POSITION SENSOR

• Turn the ignition switch OFF.
• Disconnect the crank position sensor 2P connector.
• Check for loose or poor contact on the crank
position sensor 2P connector.

• Connect the crank position sensor 2P connector.

• Turn the starter motor more than 10 seconds and
then check that the MIL light.

• Turn the ignition switch OFF.

• Disconnect the crank position sensor 2P connector.
• Check for continuity between the crank position
sensor connector terminal and ground.
Connection: Blue (+) － Ground(-)
Standard: No continuity

• Crank the engine with the starter motor, and

measure the crank position sensor peak voltage at
the crank position sensor 2P connector.
Connection: Blue (+) － Sky Blue(-)
Standard: 0.7V

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 4-1. FUEL INJECTION SYSTEM

IGNITION COIL
• Turn the ignition switch OFF.
• Disconnect the ignition coil 2P connector.
• Check for loose or poor contact on the ignition coil
2P connector.

• Connect the ignition coil 2P connector.

• Turn the starter motor more than 10 seconds and
then check that the MIL light.

• Turn the ignition switch OFF.

• Disconnect the ignition coil 2P connector.
• Check for continuity between the ignition coil
connector terminal and ground.
Connection: Red (+) － Ground(-)
Standard: No continuity

• Crank the engine with the starter motor, and

measure the ignition coil peak voltage at the
ignition coil 2P connector.
Connection: Red (+) － Black/Yellow(-)
Standard: 0.7V

• Check for resistance between the ignition coil

connector terminal and ground.
Standard: 0.63±0.05Ω

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4-1. FUEL INJECTION SYSTEM

THROTTLE BODY
REMOVAL
NOTE:
• Before disconnecting the fuel hose, release the fuel
pressure by loosening the clamp.
• Always replace the clamp when the fuel hose is
removed or loosened.

DISASSEMBLY
• Disconnect the TP sensor, T-MAP sensor and ISC
sensor connector from the throttle
• Disconnect intake pipe rubber tube from the throttle
body.
• Disconnect the throttle body from the air cleaner
case.
NOTE:
• Do not damage the throttle body. It may cause
incorrect throttle and idle valve.
• The throttle body is factory pre-set. Do not
disassemble in a way other than shown in this
manual.
• Do not loosen or tighten the white painted bolts
and screws of the throttle body. Loosening or
tightening them can cause throttle and idle
valve failure.

• Disconnect the throttle cable end from the throttle

drum.

ASSEMBLY
• Connect the throttle cable end to the throttle drum.
• Connect the TP, T-MAP and ISC sensor connector
on the throttle body.
• Install and tighten the intake pipe rubber tube on the
throttle body.
• Install the throttle body to the air cleaner case.

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 4-1. FUEL INJECTION SYSTEM

PRESSURE REGULATOR
REMOVAL / INSTALLATION
NOTE:
• Remove the pressure regulator mounting bolts and
cover then remove the pressure regulator.

• Disconnect injector fuel hose (2) to release

fuel pressure.
• Disconnect fuel supply hose (1).
• Disconnect fuel return hose (3).

NOTE:
• Recommends that hose clamp be discarded and
replaced each time they are removed or loosened.
They are one time usage only.

Special Tool:

• Install the pressure regulator in the reverse order of

removal.

TORQUE: 100kgf-cm

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ROLL OVER SENSOR

INSPECTION
• Remove the seat set.
• Turn the ignition switch ON and measure the voltage
between the following terminals of the Roll Over
sensor connector with the connector connected.
TERMINAL STANDARD

• Turn the ignition switch OFF.

• Remove the screws, washers, nuts and roll over
sensor.
• Place roll over sensor horizontal as shown and turn
the ignition switch ON.
• The roll over sensor is normal if the power supply is
closed.
• Incline the roll over sensor approximately 65
degrees to the left or right with the ignition switch
ON.
• The roll over sensor is normal if the power supply is
open.
• If you repeat this test, first turn the ignition switch
OFF then turn the ignition switch ON.

REMOVAL / INSTALLATION
• Disconnect the roll over sensor 2P connector.
• Remove the two screws, nuts and roll over sensor.
• Installation is in the reverse order of removal.
• Tighten the mounting screws securely.

NOTE: Install the roll over sensor with its

“UP” mark facing up.

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 4-1. FUEL INJECTION SYSTEM

ECU
REMOVAL / INSTALLATION
• Remove the seat set.
• Disconnect the ECU 48P connectors.

POWER INPUT LINE

• Turn the ignition switch ON.
• Measure the voltage between the ECU and ground.
• There should be battery voltage.
• If there is no voltage, check for an open circuit in
Black/White wire between the ECU and roll over
sensor/relay.
• If the wire is OK, check for the roll over sensor/relay.

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FUEL LINE INSPECTION

FUEL PRESSURE INSPECTION

NOTE:
• Before disconnecting fuel hose, release the fuel
pressure by loosening the pressure regulator fuel
hose clamp on the injector hose.
• Always replace the clamp when the hose is
removed or loosened.

• Disconnect the battery negative cable from the

battery terminal.

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 4-1. FUEL INJECTION SYSTEM

• Disconnect the pressure regulator output hose and

plug the hose.
• Slowly catch the remaining fuel using an approved
gasoline container.

• Install the 3-way connector and attach the fuel

pressure gauge as shown.

• Connect the battery negative cable.

• Start the engine.
• Read the fuel pressure at idle speed.
IDLE SPEED: 1500+/-100 RPM
STANDARD:300 kPa

• If the fuel pressure is higher than specified, inspect

the following:
- Pinched or clogged fuel return hose.
- Pressure regulator
- Fuel pump

• If the fuel pressure is lower than specified, inspect

the following:
- Fuel line leaking.
- Clogged fuel filter
- Pressure regulator
- Fuel pump

• After inspection, remove the fuel pressure gauge

and reinstall and tighten the fuel hose clamp using
the new clamp.
• Always replace the clamp when the fuel hose is
removed or loosened.
• Connect the pressure regulator output hose.
• Install the removed parts in reverse order of
removal.

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4-1. FUEL INJECTION SYSTEM

FUEL FLOW INSPECTION

• Disconnect the fuel pump relay.
• Jump the Black/Purple and Red/Orange wire
terminals of the wire harness side using a jumper
wire.
• When the fuel return hose is disconnected, gasoline
will spill out from the hose. Use an approved
gasoline container to drain the gasoline.
• Wipe off spilled gasoline.
• Disconnect the fuel return hose on the top of fuel
tank; plug the fuel tank inlet joint.
• Turn the ignition switch ON for 10 seconds.
• Measure the amount of fuel flow.
Amount of fuel flow:
300 cm3 minimum/*10 seconds at 12V
• If the fuel flow is less than specified, inspect the
following:
- Pinched or clogged fuel hose and fuel return hose
- Clogged fuel filter
- Pressure regulator
- Fuel pump
• After inspection, connect the fuel return hose.
• Start the engine and check for leaks.

FUEL PUMP
INSPECTION
• Turn the ignition switch ON and confirm that the fuel
pump operates for a few seconds.
• If the fuel pump does not operate, inspect as follow:
• Disconnect the fuel pump 2P connector.
• Turn the ignition switch ON and measure the voltage
between the terminals.
Connection: Gray (+) Black/Purple (-)
The standard is 4±1Ω
• There should be battery voltage for a few seconds.
• If there is battery voltage, replace the fuel pump.
• If there is no battery voltage, inspect the following:
- Main fuse 30A
- Fuel pump relay
- Roll Over sensor
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- ECU
REMOVAL
NOTE:
• Before disconnecting the fuel hose, release the fuel
pressure.
• Always replace the clamp when the fuel hose is
removed or loosened.
• Remove the fuel tank
• Remove the fuel pump mounting nuts.
• Remove the fuel pump assembly and packing.

FUEL FILTER REPLACEMENT

• Disconnect the fuel hose from the fuel filter.
• Remove the screw, clamp and fuel filter.
• Install the fuel filter in the reverse order of removal.
NOTE: The direction of fuel filter with “IN” mark.

INSTALLATION
• Place new packing onto the fuel tank.
• Install the fuel pump, being careful not to damage
the fuel pump wire.
• Install and tighten the fuel pump mounting nuts in
the sequence shown.
TORQUE: 120 kgf/cm.

FUEL PUMP RELAY

• Disconnect the fuel pump relay 5P connector,
remove the fuel pump relay.
• Connect the ohmmeter to the fuel pump relay
connector terminals 30 and 87.

CONNECTION:
• Connect the 12V battery to the fuel pump relay
connector terminals 85 and 86.

CONNECTION:
• There should be continuity only when the 12V
battery is connected.
• If there is no continuity when the 12V battery is
connected, replace the fuel pump relay.
4-1-29
4-1. FUEL INJECTION SYSTEM

FUEL TANK/RESERVOIR (FUEL PUMP ASSEMBLY)

ROMOVAL
• Loosen the fuel tank mounting bolt/nut.
• Release the fuel pressure.
Gray
• Disconnect the fuel tank air vent hose and supply
hose. Air Vent hose
• Remove the clamp then disconnect the fuel hose.
• Remove the following: To Regulator
- Fuel tank supply hose Black/Purple
- Fuel tank air vent hose
- Fuel pump/reserve sensor 2 P connector
NOTE: The clamp for one time use only.
• Clamp the fuel return hose.
• Disconnect the fuel return hose at the pressure
regulator.
• Install the following:
- Fuel hose (with “▲” mark)
- Air vent hose
- Fuel pump/reserve sensor 2P connector
NOTE:
• Always replace new clamp while disassemble or
loosen.
• Connect the fuel hose to the pressure regulator.
• Connect the fuel pump/reserve sensor 2P
connector.
• Connect the fuel output hose to the fuel rail with new
clamp.
• While pushing the fuel hose to the fuel rail, install
and tighten the clamp.
NOTE: Do not apply excessive force to the fuel
pipe.

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 4-1. FUEL INJECTION SYSTEM

SENSOR CIRCUIT TROUBLESHOOTING

CPS SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION POSSIBLE CAUSE
The signal does not reach ECU for 3 sec. or • Metal particles or foreign material being
more, after receiving the starter signal. stuck on the CPS sensor and rotor tip
• CPS sensor circuit open or short
• CPS sensor malfunction
• ECU malfunction

INSPECTION
Step 1
1) Remove the seat set.
2) Remove the left side cover.
3) Turn the ignition switch OFF.
4) Check the CPS sensor coupler for loose or
poor contacts.
If OK, then measure the CPS sensor
resistance.
5) Disconnect the CPS sensor coupler and
measure the resistance.
　CPS sensor resistance: 115 +/- 10 Ω
(Blue –Sky Blue)
6) If OK, then check the continuity between
each terminal and ground.
　CPS sensor continuity: ∞ Ω (Infinity)
(Blue – Ground)
(Green – Ground)

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4-1. FUEL INJECTION SYSTEM

Are the resistance and continuity OK?

YES Go to next step 2
NO Replace CPS sensor with new one
7) After repairing the trouble, clear the DTC
using Diagnosis Tool.

Step 2
1) Crank the engine a few seconds with the
starter motor, and measure the CPS sensor
peak voltage at the coupler.
2) Repeat the above test procedure a few times
and measure the highest peak voltage.
　CPS sensor peak voltage: 4.0 V and more
(+ Blue – - Sky-Blue)

Is the voltage OK?

•Blue or Sky-Blue wire open or
shorted to ground
• Loose or poor contacts on the CPS
sensor coupler or ECU coupler
(terminal 4 or 5)
• If wire and connection are OK,
YES
intermittent trouble or faulty ECU.
• Recheck each terminal and wire
harness for open circuit and poor
connection.
• Replace the ECU with a known good 4 5
one, and inspect it again.
• Inspect that metal particles or foreign
material stuck on the CPS sensor
and rotor tip.
NO
• If there are no metal particles and
foreign material, then replace the
CPS sensor with a new one.

3) After repairing the trouble, clear the DTC

using Diagnosis tool.

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 4-1. FUEL INJECTION SYSTEM

TMAP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
T-MAP sensor voltage low or high • Clogged vacuum passage between throttle
(0.1 V Sensor voltage < 4.8 V) body and T-MAP sensor
NOTE: • Air being drawn from vacuum passage
Note that atmospheric pressure varies between throttle body and T-MAP sensor
depending on weather conditions as well as • T-MAP sensor circuit open or shorted to
altitude. ground
Take that into consideration when inspecting • T-MAP sensor malfunction
voltage. • ECM malfunction

INSPECTION
Step 1
1) Loosen and lift up the fuel tank.
2) Turn the ignition switch OFF.
3) Check the T-MAP sensor couple for loose or
poor contacts.
If OK, then measure the T-MAP sensor input
voltage.
4) Disconnect the T-MAP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Yellow/Black wire
and ground.
7) Also, measure the voltage at the
Yellow/Black wire and Gray/Red wire.
　T-MAP sensor input voltage: 4.5 – 5.5 V
(+Yellow/Black – - Ground)
(+Yellow/Black – - Gray/Red)

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4-1. FUEL INJECTION SYSTEM

Is the voltage OK?

YES Go to next step 2
• Loose or poor contacts on the ECU
coupler terminal 1 or 27
NO
• Open or short circuit in the
Yellow/Black wire or Gray/Red wire
8) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 2
1) Connect the T-MAP sensor coupler.
2) Insert the needle pointed probes to the lead
wire coupler.
3) Start the engine at idle speed and measure
the T-MAP sensor output voltage at the wire
side coupler.
　T-MAP sensor output voltage: Approx. 2.6 V
at idle speed
(+Yellow/Black – - Gray/Red)
Is the voltage OK?
YES •Yellow/Black or Gray/Red wire open
or shorted to ground, or poor 18, 30
or 1 connection.
• If wire and connection are OK,
intermittent trouble or faulty ECU.
• Recheck each terminal and wire
harness for open circuit and poor
connection.
• Replace the ECU with a known
good one, and inspect it again.
• If check result is not satisfactory,
NO
replace new T-MAP (throttle body).
5) After repairing the trouble, clear the DTC
using Diagnosis tool.

4-1-34
 4-1. FUEL INJECTION SYSTEM

TP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
Output voltage is not within the following • TP sensor maladjusted
range. • TP sensor circuit open or short
Difference between actual throttle opening • TP sensor malfunction
and opening calculated by ECU is larger • ECU malfunction
than specified value.
0.1 V Sensor voltage < 4.8 V
Sensor voltage is higher than specified • TP sensor circuit shorted to VSENS or
value. ground circuit open
Sensor voltage is lower than specified value. • TP sensor circuit open or shorted to ground
or VSENS circuit open

INSPECTION
Step 1
(When output voltage is out of specified)
1) Loosen and lift up the fuel tank.
2) Turn the ignition switch OFF.
3) Check the TP sensor coupler for loose or
poor contacts.
If OK, then measure the TP sensor input
voltage.
4) Disconnect the TP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire B and
ground.
7) Also, measure the voltage at the
Yellow/Black wire and Gray/Red wire.
　TP sensor input voltage: 4.5 – 5.5 V
(+Yellow/Black – - Ground)
(+Yellow/Black – - Gray/Red)

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4-1. FUEL INJECTION SYSTEM

Is the voltage OK?

YES Go to next step 2
• Loose or poor contacts on the ECU
coupler (terminal 1 or 27)
NO
• Open or short circuit in the
Yellow/Black wire or Gray/Red wire

Step 1
(When sensor voltage is higher than specified)
1) Loosen and lift up the fuel tank.
2) Turn the ignition switch OFF.
3) Check the TP sensor coupler for loose or
poor contacts.
If OK, then check the TP sensor lead wire
continuity.
4) Disconnect the TP sensor coupler.
5) Check the continuity between W/Br wire and
Y/B wire.
If the sound is not heard from the tester, the
circuit condition is OK.
6) Disconnect the ECU coupler.
7) Check the continuity between W/Br wire and
terminal 31.
8) Also, check the continuity between Gr/R wire
and terminal 27.
　TPS lead wire continuity: Continuity (sound)
Is the continuity OK?
YES Go to next step 2
W/Br wire shorted to VSENS or
NO
SGND1 wire open
9) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 1 31
(When sensor voltage is lower than specified)
1) Loosen and lift up the fuel tank.
2) Turn the ignition switch OFF.
3) Check the TP sensor coupler for loose or
poor contacts.
If OK, then measure the TP sensor lead wire
continuity.
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 4-1. FUEL INJECTION SYSTEM

4) Disconnect the TP sensor coupler.

5) Check the continuity between W/Br wire and
ground.
6) Also, check the continuity between W/Br wire
and Gr/R wire
C. If the sound is not heard from the tester, the
circuit condition is OK.
7) Disconnect the ECU coupler.
8) Check the continuity between W/Br wire and
terminal 31.
31
9) Also, check the continuity between Y/B wire
and terminal .
　TPS lead wire continuity: Continuity (sound)
Is the continuity OK?
YES Go to step 1 and step 2
Y/B wire or Gr/R wire open, or Gr/R
NO
wire shorted to ground
10) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 2
1) Turn the ignition switch OFF.
2) Disconnect the TP sensor coupler.
3) Check the continuity between W/Br wire and
ground.
　TP sensor continuity: ∞ Ω (Infinity)
(White/Brown – Ground)
4) If OK, then measure the TP sensor
resistance at the terminals (between Bottom
and Center pin).
5) Turn the throttle grip and measure the
resistance.
　TP sensor resistance
Throttle valve is closed: Approx. 1.1 kΩ
Throttle valve is opened: Approx. 4.4 kΩ
6) If OK, then measure the TP sensor
resistance at the terminals (between Upper
and Center pin).
　TP sensor resistance: Approx. 4.66 kΩ
(Upper pin – Center pin)

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4-1. FUEL INJECTION SYSTEM

Are the continuity and resistance OK?

YES Go to step 3
• Reset the TP sensor position
correctly.
NO
• Replace the new TP sensor (throttle
body).
7) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 3
1) Connect the TP sensor coupler.
2) Insert the needle pointed probes to the lead
wire coupler.
3) Turn the ignition switch ON.
4) Measure the TP sensor output voltage at the
coupler (between W/Br wire and Gr/R wire )
by turning the throttle grip.
　TP sensor output voltage
Throttle valve is closed: Approx. 1.1 V
Throttle valve is opened: Approx. 4.4 V
Is the voltage OK?
• Y/B, W/Br or Gr/R wire open or
shorted to ground, or poor 1, 31 or
27 connection
• If wire and connection are OK,
intermittent trouble or faulty ECU.
YES
• Recheck each terminal and wire
harness for open circuit and poor
connection.
• Replace the ECU with a known
good one, and inspect it again.
If check result is not satisfactory,
NO replace new TP sensor (throttle
body).
5) After repairing the trouble, clear the DTC
using Diagnosis tool.

4-1-38
 4-1. FUEL INJECTION SYSTEM

ECT SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
Output voltage is not within the following • ECT sensor circuit open or short
range. • ECT sensor malfunction
0.1 Sensor voltage < 4.6 V • ECU malfunction
Sensor voltage is higher than specified
value. • ECT sensor circuit open or ground circuit
Sensor voltage is lower than specified value. open
• ECT sensor circuit shorted to ground

INSPECTION
Step 1
(When output voltage is out of specified)
1) Turn the ignition switch OFF.
2) Check the ECT sensor coupler for loose or
poor contacts.
If OK, then measure the ECT sensor voltage
at the wire side coupler.
3) Disconnect the ECT sensor coupler and turn
the ignition switch ON.
4) Measure the voltage between Y/R wire
terminal and ground.
5) Also, measure the voltage between Y/R wire
terminal and Gr/R wire terminal.
　ECT sensor input voltage: 4.5 – 5.5 V
(+Y/R – - Ground)
(+Y/R – - Gr/R)

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4-1. FUEL INJECTION SYSTEM

Is the voltage OK?

YES Go to step 2
• Loose or poor contacts on the ECU
coupler (terminal 42 or 27)
NO
• Open or short circuit in the Y/R wire
or Gr/R wire

Step 1
(When sensor voltage is higher than specified)
1) Turn the ignition switch OFF.
2) Check the ECT sensor coupler for loose or
poor contacts.
If OK, then check the ECT sensor lead wire
continuity.
3) Remove the left side cover.
4) Disconnect the ECT sensor coupler.
5) Remove the ECU coupler.
6) Check the continuity between Y/R wire and
42
terminal 42.
7) Also, check the continuity between Gr/R wire
and terminal 27.
　ECTS lead wire continuity: Continuity (sound)
Is the continuity OK?
YES Go to step 2
NO Y/R or Gr/R wire open
8) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 1
(When sensor voltage is lower than specified)
1) Turn the ignition switch OFF.
2) Check the ECT sensor coupler for loose or
poor contacts.
If OK, then check the ECT sensor lead wire
continuity.
3) Disconnect the ECT sensor coupler.
4) Check the continuity between Y/R wire and
ground.
5) If the sound is not heard from the tester, the
circuit condition is OK.
　Tester knob indication: Continuity (sound)
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 4-1. FUEL INJECTION SYSTEM

6) Connect the ECT sensor coupler.

7) Turn the ignition switch ON.
8) Measure the voltage between Y/R wire and
ground.
　Output voltage: 0.1 – 4.6 V
(+ Y/R – - Ground)
Are the continuity and voltage OK?
YES Go to step 2
NO Y/R wire shorted to ground.
9) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 2
1) Turn the ignition switch OFF.
2) Disconnect the ECT sensor coupler.
3) Measure the ECT sensor resistance.
　ECT sensor resistance:
Approx. 2.3 – 2.6 kΩ at 20 °C (68 °F)
(Terminal – Terminal)
Is the resistance OK?
• Y/R or Gr/R wire open or shorted to 42
ground, or poor 42 or 27 connection 27
• If wire and connection are OK,
intermittent trouble or faulty ECU.
YES • Recheck each terminal and wire
harness for open circuit and poor
connection.
• Replace the ECU with a known
good one, and inspect it again.
NO Replace ECT sensor with a new one.
4) After repairing the trouble, clear the DTC
using Diagnosis tool.

ECT sensor specification

Engine Coolant
Resistance
Temperature
20 °C (68 °F) Approx. 2.45 kΩ
40 °C (104 °F) Approx. 1.148 kΩ
60 °C (140 °F) Approx. 0.587 kΩ
80 °C (176 °F) Approx. 0.322 kΩ

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4-1. FUEL INJECTION SYSTEM

IGNITION SYSTEM MALFUNCTION

TROUBLESHOOTING
No spark or poor spark
NOTE:
Check that the transmission is in neutral and check that the fuse is not blown and the battery
is fully charged before diagnosing.
Step 1
1) Check the ignition system couplers for poor
connections.
Is there connection in the ignition switch couplers?
YES Go to step 2
NO Poor connection of couplers

Step 2
1) Measure the battery voltage between input
lead wires at the ECU with the ignition switch
in the “ON” position.
Is the voltage OK?
YES Go to step 3
• Faulty ignition switch
• Broken wire harness or poor
NO
connection of related circuit
couplers
11 12

4-1-42
 4-1. FUEL INJECTION SYSTEM

Step 3
1) Measure the ignition coil primary peak voltage.

NOTE:
This inspection method is applicable only with the multi circuit tester and the peak volt
adaptor.
Is the peak voltage OK?
YES Go to step 4
NO Go to step 5

Step 4
1) Check the plug caps for poor contacts.
2) If OK, then inspect the spark plugs.
Are the spark plugs OK?
YES Go to step 5
NO Faulty spark plug (-s)

Step 5
1) Inspect the ignition coils.
Are the ignition coils OK?
YES Go to step 6
NO Faulty ignition coil (-s)

Step 6
1) Measure the CPS sensor peak voltage and its resistance.
NOTE:
The CPS peak voltage inspection is applicable only with the multi-circuit tester and peak volt
adaptor.
Are the peak voltage and its resistance OK?
• Faulty ECU
YES • Open or short circuit in wire harness
• Poor connection of ignition couplers
• Faulty CPS sensor
• Metal particles or foreign material
NO
being stuck on the CPS sensor and
rotor tip

4-1-43
4-1. FUEL INJECTION SYSTEM

FUEL INJECTOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
CPS signals produced but fuel injector • Injector circuit open or short
signal is interrupted continuous by 4 times • Injector malfunction
or more. • ECU malfunction

Step 1
1) Turn the ignition switch OFF.
2) Check the injector coupler for loose or poor
contacts.
If OK, then measure the injector resistance.
3) Disconnect the injector coupler and measure
the resistance between terminals.
Injector resistance:
Approx. 11.7 Ω at 20 °C (68 °F)
(Terminal – Terminal)
4) If OK, then check the continuity between
each terminal and ground.
　STP sensor continuity: ∞ Ω (Infinity)
Are the resistance and continuity OK?
YES Go to step 2
NO Replace the injector with a new one.
5) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 2
1) Turn the ignition switch ON.
2) Measure the injector voltage between R wire
and ground.
Injector voltage: Battery voltage
(+ R – - Ground)

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 4-1. FUEL INJECTION SYSTEM

NOTE:
Injector voltage can be detected only 3
seconds after ignition switch is turned ON.

Is the voltage OK?

• L/G wire open or shorted to ground,
or poor 47 connection (cylinder
side)
• If wire and connection are OK,
intermittent trouble or faulty ECU.
YES
• Recheck each terminal and wire
harness for open circuit and poor 47
connection.
• Replace the ECU with a known
good one, and inspect it again.
NO Open circuit in the R wire
3) After repairing the trouble, clear the DTC
using Diagnosis tool.

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4-1. FUEL INJECTION SYSTEM

FP RELAY CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
No voltage is applied to fuel pump although • Fuel pump relay circuit open or short
fuel pump relay is turned ON, or voltage is • Fuel pump relay malfunction
applied to fuel pump, although fuel pump • ECU malfunction
relay is turned OFF.

INSPECTION
Step 1
1) Remove the seat.
2) Turn the main switch OFF.
3) Check the FP relay coupler for loose or poor
contacts.
If OK, then check the FP relay.
Is the FP relay OK?
• Blue wire open or shorted to
ground, or poor 9 connection
• Red wire open or poor 11
connection
• If wire and connection are OK,
YES intermittent trouble or faulty ECU. Battery

• Recheck each terminal and wire

harness for open circuit and poor
connection.
• Replace the ECU with a known
good one, and inspect it again.
NO Replace the FP relay with a new one.
4) After repairing the trouble, clear the DTC
9 11
using Diagnosis tool.

4-1-46
 4-1. FUEL INJECTION SYSTEM

ROLL OVEWR SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
The sensor voltage should be the following • TO sensor circuit open or short
for 2 sec. and more, after ignition switch is • TO sensor malfunction
turned ON. • ECU malfunction
0.2 Sensor voltage < 4.6 V
Sensor voltage is higher than specified •TO sensor circuit open or shorted to
value. VSENS or ground circuit open
Sensor voltage is lower than specified value. •TO sensor circuit shorted to ground or
VSENS circuit open

INSPECTION
Step 1
(When output voltage is out of specified)
1) Remove the seat set.
2) Turn the ignition switch OFF.
3) Check the Roll over sensor coupler for loose
or poor contacts.
If OK, then measure the Roll over sensor
resistance.
4) Disconnect the Roll over sensor coupler.
5) Measure the resistance between terminal A
and terminal C.
Roll over sensor resistance: 19.1–19.7 kΩ
(Terminal A – Terminal C)
Is the resistance OK?
YES Go to step 2
Replace the Roll over sensor with a
NO
new one.

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4-1. FUEL INJECTION SYSTEM

Step 1
(When sensor voltage is higher than specified)
1) Remove the seat set.
2) Turn the ignition switch OFF.
3) Check the Roll over sensor coupler for loose
or poor contacts.
If OK, then check the Roll over sensor lead
wire continuity.
4) Disconnect the Roll over sensor coupler.
5) Check the continuity between Y/B wire and
Pu/B wire.
If the sound is not heard from the tester, the
circuit condition is OK.
6) Disconnect the ECU coupler.
7) Check the continuity between Pu/B wire and
terminal 16.
Is the continuity OK?
YES Go to step 2
NO Pu/B wire shorted to VBR 16
8) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 1
(When sensor voltage is lower than specified)
1) Remove the seat set.
2) Turn the ignition switch OFF.
3) Check the Roll over sensor coupler for loose
or poor contacts.
If OK, then check the Roll over sensor lead
wire continuity.
4) Disconnect the Roll over sensor coupler.
5) Check the continuity between Pu/B wire and
ground. If the sound is not heard from the
tester, the circuit condition is OK.
7) Disconnect the ECU coupler.
8) Check the continuity between Y/B wire and
terminal 1.
9) Also, then check the continuity between Pu/B
wire B and terminal 16.
1
　Roll over sensor lead wire continuity:
Continuity (sound)
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 4-1. FUEL INJECTION SYSTEM

Is the continuity OK?

YES Go to step 2
Y/B or Pu/B wire open or Pu/B wire
NO
shorted to ground
10) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 2
1) Connect the Roll over sensor coupler.
2) Insert the needle pointed probes to the lead
wire coupler.
3) Turn the ignition switch ON.
4) Measure the voltage at the wire side coupler
between Pu/B and B wires.
Also, measure the voltage when leaning the
vehicle.
　Roll over sensor voltage (Normal): 0.4 – 1.4 V
(+ Pu/B – - B)
5) Dismount the Roll over sensor from its
bracket and measure the voltage when it is
leaned 65° and more, left and right, from the
horizontal level.
　Roll over sensor voltage (Leaning): 3.7 – 4.4
V (+ Pu/B – - B)
Is the voltage OK?
• Y/B or Pu/B wire open or shorted to
ground, or poor 1 or 16 connection
• If wire and connection are OK,
intermittent trouble or faulty ECU.
YES • Recheck each terminal and wire
harness for open circuit and poor
1 16
connection.
• Replace the ECU with a known
good one, and inspect it again.
• Loose or poor contacts on the ECU
coupler
NO • Open or short circuit
• Replace the Roll over sensor with a
new one.
6) After repairing the trouble, clear the DTC
using Diagnosis tool.
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4-1. FUEL INJECTION SYSTEM

IDLE SPEED CONTROLLER CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
The operation voltage does not reach the • ISC malfunction
ISC. • ISC circuit open or short
ECU does not receive communication signal • ISC motor malfunction
from the ISC.

INSPECTION
Step 1
1) Remove the fuel tank.
2) Turn the ignition switch OFF.
3) Check the ISC lead wire coupler for loose or
poor contacts.
4) Remove the air cleaner rubber tube.
5) Turn the ignition switch ON to check the ISC
operation.
(ISC operating order: 95% open → full open
→ 95% open)
Is the operating OK?
YES Go to step 2.
• Loose or poor contacts on the ISC
coupler
• Open or short circuit in the Br/B,
NO
G/B, Y/B or B/Y wires
• If wire and connection are OK, go to
Step 2.
6) After repairing the trouble, clear the DTC
using Diagnosis tool.

Step 2
1) Turn the ignition switch OFF.
2) Disconnect the ISC lead wire coupler.
3) Check the continuity between each terminal
and ground.
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 4-1. FUEL INJECTION SYSTEM
　ISC continuity: ∞ Ω (Infinity)
(Terminal – Ground)
4) If OK, then measure the ISC resistance
(between Br/B, G/B, Y/B and B/Y wires).
　ISC resistance: Approx. 6.5 Ω
Is the resistance OK?
•Br/B, G/B, Y/B and B/Y wire open or
shorted to ground, or poor 28, 39,
40 and 41 connection
• If wire and connection are OK,
intermittent trouble or faulty ECU.
YES
• Recheck each terminal and wire
harness for open circuit and poor
connection.
• Replace the ECU with a known
good one, and inspect it again.
• Loose or poor contacts on the ECU
NO coupler
• Replace new ISC (throttle body).
5) After repairing the trouble, clear the DTC
using Diagnosis tool.

• Measure the resistance between A-D and B-C

as below
• The standard are all follow 50±0.5Ω.

A D B C

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4-1. FUEL INJECTION SYSTEM
Fault Diagnosis
EFI Circuit inspection

4-1-52
 4-1. FUEL INJECTION SYSTEM
Can not Start the engine or difficult to start inspection

4-1-53
4-1. FUEL INJECTION SYSTEM

Idle flameout diagnosis

4-1-54
 4-1. FUEL INJECTION SYSTEM

Integrated Fault Diagnosis Program

4-1-55
4-1. FUEL INJECTION SYSTEM
Fault Diagnosis Note
When the motorcycle injection system in the wrong signal, causing abnormal functioning of
the engine or can not start engine, MIL light at the dashboard will be lighting, to inform drivers
to carry out maintenance.

Overhaul, the diagnosis tool can be used for troubleshooting. If the fault has been ruled out or
repair after the MIL light will be extinguished, but ECU fault code will be recorded, so the need
to get rid of fault codes.

Diagnosis 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.

4-1-56
 4-1. FUEL INJECTION SYSTEM
Fault Code And The Sensors Of The Table

No. Fault codes Fault Description

1 XXXXX Un define
2 B2225 Tilt switch diagnosis (SCP)
3 B2226 Tilt switch diagnosis (SCG_OL)
4 P0000 No DTC
5 P0031 Sensor heater diagnosis #0 (SCG/OL)
6 P0032 Sensor heater diagnosis #0 (SCP)
7 P0051 Sensor heater diagnosis #1 (SCG/OL)
8 P0052 Sensor heater diagnosis #1 (SCP)
9 P0107 MAP sensor diagnosis (SCG_OL)
10 P0108 MAP sensor diagnosis (SCP)
11 P0112 Intake air temperature sensor diagnosis (SCG)
12 P0113 Intake air temperature sensor diagnosis (SCP_OL)
13 P0114 Electrical intake air temperature intermittent diagnosis (failure)
14 P0117 Coolant Temperature Sensor (SCG)
15 P0118 Coolant Temperature Sensor (SCP_OL)
16 P0119 Coolant temperature intermittent diagnosis (failure)
17 P0121 TPS position sensor adaptation diagnosis (out of range)
18 P0122 Throttle Position Sensor 1 (SCG_OL)
19 P0123 Throttle Position Sensor 1 (SCP)
20 P0131 Lambda sensor #0 diagnosis (SCG)
21 P0132 Lambda sensor #0 diagnosis (SCP)
22 P0133 Lambda sensor #0 diagnosis (OL)
23 P0151 Lambda sensor #1 diagnosis (SCG)
24 P0152 Lambda sensor #1 diagnosis (SCP)
25 P0153 Lambda sensor #1 diagnosis (OL)
26 P0171 Lambda control diagnosis #0 (too high)
27 P0172 Lambda control diagnosis #0 (too low)
28 P0174 Lambda control diagnosis #1 (too high)
29 P0175 Lambda control diagnosis #1 (too low)
30 P0217 Engine coolant over temperature protection diagnosis
31 P0219 Engine over speed detection diagnosis
32 P0231 Electric fuel pump diagnosis (SCG/OL)
33 P0232 Electric fuel pump diagnosis (SCP)
34 P0261 Injection valve diagnosis #0 (SCG/OL)
35 P0262 Injection valve diagnosis #0 (SCP)
36 P0264 Injection valve diagnosis #1 (SCG/OL)
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37 P0265 Injection valve diagnosis #1 (SCP)

38 P0351 Ignition diagnosis #0 (SCP)
39 P0352 Ignition diagnosis #1 (SCP)
40 P0370 Loss of synchronization diagnosis
41 P0371 Crankshaft sensor diagnosis
42 P0373 Crankshaft sensor diagnosis
43 P0462 FUEL sensor diagnosis (SCG)
44 P0463 FUEL sensor diagnosis (SCP_OL)
45 P0484 Cooling fan diagnosis (SCP)
46 P0485 Cooling fan diagnosis (SCG/OL)
47 P0530 Light relay diagnosis
48 P0560 Battery voltage diagnosis (too low)_VBR
49 P0561 Battery voltage diagnosis (too high)_VBR
50 P0562 Battery voltage diagnosis (too low)_VBK
51 P0563 Battery voltage diagnosis (too high)_VBK
52 P0608 Reference voltage diagnosis (SCP)
53 P0609 Reference voltage diagnosis (SCG_OL)
54 P0615 Starter 1 diagnosis (OL)
55 P0616 Starter 1 diagnosis (SCG)
56 P0617 Starter 1 diagnosis (SCP)
57 P0630 VIN coherence
58 P0651 MIL diagnosis (SCG/OL)
59 P0652 MIL diagnosis (SCP)
60 P1352 Ignition diagnosis #0 (SCG_OL)
61 P1353 Ignition diagnosis #1 (SCG_OL)
62 P1508 Stepper motor diagnosis (SCG_OL)
63 P1509 Stepper motor diagnosis (SCP)
64 P1615 Starter 2 diagnosis (OL)
65 P1616 Starter 2 diagnosis (SCG)
66 P1617 Starter 2 diagnosis (SCP)
67 U1600 IMMO sensor diagnosis (exist)
68 U1601 BUS error handling (OFF)
69 U1602 Frame 20 diagnosis
70 U1603 IMMO sensor diagnosis (aerial)
71 U1604 IMMO sensor diagnosis (unknown)

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Use diagnosis tool

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. Connected to the diagnostic connector for diagnosis tool.
NACS→TGB interface→Transfer Cable→TGB 3 pin/6 pin Diagnosis Cable→Vehicle.
2. When the IG of the motorcycle is on, the system starts to run, entering into boot screen.
3. Key ON and the diagnosis display screen appeared the words connection.
4. Press the “ENTER” button and the system will identify the vehicle model automatically and
display the vehicle info on the screen, as following picture

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5. Press “ENTER” button again for more detailed vehicle information. Press ▲▼ button to
view all information.

Diagnosis Use Note

Press ”ENTER” button to the function menu.

Options main functional areas:

1. Vehicle Info
2. Diagnostic Trouble Code
3. Live Data
4. Actuator
5. Special Function
Press ▲▼ button to choose one function.

1. Vehicle Info
Move the cursor to ”Vehicle Info” and press ENTER to see the content
This is the page of “Vehicle Info”, press ▲▼ button to view all vehicle info.

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2. Diagnostic Trouble Code

Move the cursor to “Diagnostic Trouble Code” and press ENTER to see the content.

2-1. Current
Current＂ is for the Diagnostic Trouble Code occurred at the time
2-2. History
“History” is for Diagnostic Trouble Code occurred in the past.

Move the cursor to ”Current” and press “ENTER” to continue

After entering the page, press ▲▼ to view all the Diagnostic Trouble Code.

After viewing the Diagnostic Trouble Code, press ESC to return to the previous page.

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Move the cursor to “History” and press “ENTER” to continue

After entering the page, press ▲▼ to view all the Diagnostic Trouble Code occurred in the
past.
After viewing the Diagnostic Trouble Code, press ESC to return to the previous page.

※
After viewing the content of “Current” or “History” Diagnostic Trouble Code, press ESC to
return to the previous page, you will see two more items on the screen - “Freeze Data” and
“Erase DTC”.
“Freeze Data” is the data recorded when FIRST Diagnostic Trouble Code occurred, and one
time only record one Diagnostic Trouble Code freeze data, it’s for saving the engine dynamic
data for further analysis.
“Erase DTC” is the function to erase all Diagnostic Trouble Code in both “Current” and
“History”.

2-3. Freeze Data

This is the content you will see when entering into the “Freeze Data”. Press ▲▼ to view the
Freeze Data.

★ NOTE: not all ECU support this function.

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

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Freeze Data (01/03)
Number of data
DTC
Engine speed
Throttle valve volt
Intake pressure MAP

Freeze Data (02/03)

Engine temp
Lambda Control volt
Battery volt
Atmospheric pressure
Intake air temp

2-4. Erase DTC

Move the cursor to “Erase DTC” item and press ENTER to EARSE ALL DIAGNOSTIC
TROUBLE CODE DIRECTLY!

When you see the following picture on the screen, the Diagnostic Trouble Code erasure is
completed. Press ESC button back to the main menu.

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3. Live Data
Back to the main menu, move the cursor to “Live Data” and press ENTER to view the
content.

Press ▲▼ button to view all Live Data

4. Actuator
Move the cursor to “Activator” and press ENTER to see the content (To perform this function,
IG must be ON and engine stop running.)

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This is the page after entering the “Activator” function

Take one activation function for example: move the cursor to “Ignition coil” item and press
ENTER to continue.
When pressing “Actuating “▲ button, the test is activated and the “Value” column shows
Open.
When pressing “Stop Actuating” ▼ button, the test is de-activated and the “Value” column
shows close.

5. Special Function
Move the cursor to “Special Function” and press ENTER to view the content

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There are two items under “Special Function”: “Reset TPS” and “Reset Adaptive”.

Move the cursor to “Reset TPS” and press ENTER. Then you will see the following picture,
which means the RESET is completed. Press ESC button to return to the previous page.

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Troubleshooting Table

Notes: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list"

implementation.
2. Spare parts, according to the "EFI System components description" implementation.

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Comprehensive Maintenance List
Maintenanc
No. Testing Procedures Test items Determine benchmarks Fault reasons
e Project
• Use meter direct • Battery • Battery voltage = 10 V • Battery electricity
measurement battery above • Battery connector
voltage loose
Power and
1 • Use diagnosis tool • Harness circuit
voltage
detection of battery opening
voltage • ECU coupler not
connected properly
• Use fuel pressure • Open the main • Open main switch but not • Fuel not enough
gauge connected in switch but not to start: • Fuel pump relay
series between the start the engine of Pressure = 250 kPa (stable fault
injector and the pressure value) • Fuel pump fault
pressure regulating • Pressure in Idle • Idle state: • Injector fault
valve • Rotating throttle, Pressure = 300+/-6 kPa • ECU fault
• Main switch ON but situation of (Beating situation from top
Fuel not start engine pressure changes to bottom)
2
pressure • Check fuel pressure • Rotating throttle moment:
• Start engine (Idle) Pressure=300+/-6kPa(sligh
• Check change of fuel tly beating)
pressure
• Throttle several
rotation
• Check to the change
of fuel pressure again
• The spark plug • Spark plug • Specifications: NGK-CR7H • Spark plug fault
removed from the specifications • Ignition conditions: • Roll over sensor
cylinder head but the • Whether the With traditional engines fault
Ignition power lines still ring spark plug ignition found ways • ECU No. 12 pin fault
3
state • Start engines or use • Spark plug sparks • Ignition coil fault
for the diagnosis tool of whether it is • Crankshaft position
output view spark plug normal strength sensor fault
ignition conditions
• Diagnosis tool to • Manifold pressure• Manifold pressure = 32~38 • Valve clearance
Engine
4 detect the use of of diagnosis tool kPa abnormal
vacuum
• Intake system leak
• The injector removed • Open the main • Not started, Injector not • Fuel pump relay
from the throttle body switch but did not leaking fuel fault
but not dismantle start engine the • In started, the injection • Fuel pump fault
pipeline injection situation state must show fan shape • Injector fault
• Main switch ON but • Injector state • ECU fault
not start engine when start
• Investigation the
Injection
5 injector it’s leaking
state
fuel?
• Start engines again or
use for the diagnosis
tool of output function
• Check injector fuel
injection and the
injection situation
• Use of diagnosis tool • Diagnosis toll of • Without any residual Fault • Throttle position
existing fault detection the fault code is it Code sensor fault
code or historical Fault can be eliminated • If residual Fault Code, • Engine temperature
Code • Start engine, the according to the “Fault Code sensor fault
• Eliminated of the fault is it will Maintenance Form” • Intake temperature
Fault Code implementation of fault happen again implementation of
6 sensor fault
Detection codes, check can be troubleshooting • Manifold pressure
eliminated sensor fault
• Start engine again • CPS fault
• Check fault is it • ECU fault
happen again • Tilt sensor fault
Notes: 1. Fuel pressure gauge connected between the fuel tank and injector, open the main switch to
repeatedly shut down, fuel system makes pressure stability.
2.Injector and injector cap tightly by hands, fuel spills should not be the case.

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