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GV250 GT250 EFI Service Manual
GV250 GT250 EFI Service Manual
SERVICE MANUAL
SERVICE MANUAL
99000-95610
FOREWORD
This manual contains an introductory description on
HYOSUNG
&
and procedures for its inspection / service and
overhaul of its main components.
It covers the differences from Carbure type and
please refer to the service manual of
(99000-95310),
&
(99000HR8310)and
&
(99000-94710) for others which are not covered in
this manual.
Other information considered as generally known is
not included.
Read GENERAL INFORMATION section to
familiarize yourself with outline of the vehicle and
MAINTENANCE and other sections to use as a guide
for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum
and quick service.
This manual has been prepared on the basis
of the latest specification at the time of
publication.
If modification has been made since then,
difference may exist between the content of
this manual and the actual vehicle.
Illustrations in this manual are used to show
the basic principles of operation and work
procedures.
They may not represent the actual vehicle
exactly in detail.
WARNING
This manual is intended for those who have
enough knowledge and skills for servicing
HYOSUNG vehicles. Without such knowledge and
skills, you should not attempt servicing by relying
on this manual only.
Instead, please contact your nearby authorized
HYOSUNG motorcycle dealer.
GROUP INDEX
GENERAL INFORMATION
FI SYSTEM DIAGNOSIS
4-1
4-2
ELECTRICAL SYSTEM
SERVICING INFORMATION
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing and
meaning associated with them respectively.
SYMBOL
DEFINITION
SYMBOL
DEFINITION
Apply oil.
Use engine oil unless otherwise specified.
Apply BOND1215
.
L
ABDC
AC
API
ATDC
LCD
LED
LH
Max
Min
: Maximum
: Minimum
O2 Sensor
RH
: Right Hand
M
B
BBDC
BDC
BTDC
D
DC
DOHC
: Direct Current
: Double Over Head Camshaft
S
ECU
ET Sensor
SAE
: Society of Automotive Engineers
SAV Solenoid : Secondary Air Valve Solenoid
F
FI
FP
FPR
GP Switch
IAP Sensor
TDC
TO Sensor
IAT Sensor
IG
ISC Solenoid
WIRE COLOR
B
: Black
Gr
: Gray
Sb
: Light blue
: Blue
Lg
: Light green
: White
Br
: Brown
: Orange
: Yellow
: Green
: Red
BL
BBr
BG
BO
BR
BW
BY
LB
LG
LR
LW
LY
BrB
BrW
GB
GR
GY
GrB
GrR
GrW
OB
OL
OG
OR
OW
OY
RB
RW
WB
WL
WR
YB
YL
YG
YR
GENERAL INFORMATION
1
CONTENTS
SPECIFICATIONS (
&
) 6 (1-8)
SPECIFICATIONS (
&
ENGINE
ITEM
Type
Number of cylinder
Bore
Stroke
Piston displacement
Fuel system
Starter system
Lubrication system
TRANSMISSION
ITEM
Clutch
Transmission
Gearshift pattern
Final reduction
Gear ratio, 1st
2nd
3rd
4th
5th
Drive chain
CHASSIS
ITEM
Front suspension
Rear suspension
Steering angle
Caster
Trail
Front brake
Rear brake
Front tire size
Rear tire size
Front fork stroke
Telescopic type
Swingarm type
40(right & left)
33
135 mm (5.32 in)
Disk brake
Drum brake
110/90 - 16 59S
150/80 - 15M/C 70S
120 mm (4.72 in)
Disk brake
110/70 - 17 54H
150/70 - 17 69H
90 mm (3.54 in)
Double disk brake
LED type
LED type
LED type
LED type
LED type (Level type)
12 V - H1 : 55 W 1
12 V - H3 : 55 W 1
17.0
400 2.5 cc
ELECTRICAL
ITEM
Ignition type
ECU
13B.T.D.C. at 2,000 rpm and
Ignition timing
30B.T.D.C. at 6,000 rpm
CR8E
Spark plug
12 V 12 Ah (MF)
Battery
30 A & 15 A
Fuse
12 V - H4 : 60 W 1
HI
12 V - H4 : 55 W 1
LO
Head lamp
12 V - W5 W 1
Position
Turn signal lamp
12 V - RY10 W 4
Brake / Tail lamp
12 V - P21/5 W 1
License plate lamp
12 V - W5 W 1
Illumination lamp
12 V - 1.7 W 2
High beam indicator lamp
12 V - 1.7 W 1
Turn signal indicator lamp(right & left)
12 V - 1.7 W 2
Neutral indicator lamp
12 V - 1.7 W 1
Fuel meter lamp
12 V - 1.7 W 1
FI(Fuel Injection) check lamp
LED type
CAPACITIES
ITEM
Fuel tank
Oil change
Engine oil Oil and filter change
Engine overhaul
Front fork oil capacity(One side)
14.0
1,450
1,500
1,800
250 cc
NOTE
The specifications are subject to change without notice.
7
FI SYSTEM DIAGNOSIS
CONTENTS
PRECAUTIONS IN SERVICING
FI SYSTEM TECHNICAL FEATURES
SELF-DIAGNOSIS FUNCTION (
)
SELF-DIAGNOSIS FUNCTION (
)
FI SYSTEM TROUBLESHOOTING
10 (4-1-1)
14 (4-1-5)
20 (4-1-11)
22 (4-1-13)
24 (4-1-15)
SELF-DIAGNOSTIC PROCEDURES (
SELF-DIAGNOSIS RESET PROCEDURE (
) 26 (4-1-17)
39 (4-1-30)
SENSORS 42 (4-1-33)
4 -1
PRECAUTIONS IN SERVICING
When handling the component parts or servicing the
FI system, observe the following points for the safety
of the system.
ELECTRICAL PARTS
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 it in fully till the
works when connecting it.
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.
10
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.
11
INCORRECT
12
USING TESTERS
Use well-charged batteries in the tester.
Be sure to set the tester to the correct testing
range.
13
Various Sensors
Injectors
Various signals
Injection signal
14
Basic
fuel
injection
time
Compensation
Ultimate
fuel
injection
time
SIGNAL
DESCRIPTION
ENGINE TEMPERATURE
SENSOR SIGNAL
STARTING SIGNAL
ACCELERATION SIGNAL /
DECELERATION SIGNAL
DESCRIPTION
When the motorcycle tips over, the tip over sensor sends a
signal to the ECU. Then, this signal cuts OFF current supplied to
the fuel pump, fuel injector and ignition coil.
The fuel injectors stop operation when engine rpm reaches rev.
limit rpm.
15
7
ECU
8
4
Speedometer
Ignition coil, NO.1
Ignition coil, NO.2
Pick-up coil
16
GP switch
Fuel injector, NO.1
Fuel injector, NO.2
ISC solenoid
9
1 2 13
ECU
10
16
14
11
15
IAT sensor
TO sensor
Fuel pump relay
IAP sensor, NO.2
17
4
2 3
ECU
Speedometer
Fuel injector, NO.1
Fuel injector, NO.2
IAT sensor
GP switch
18
Pick-up coil
Ignition coil, NO.1
ISC solenoid
Fuel pump relay
ECU
11
1 2 13
16
10
14
15
TO sensor
Ignition coil, NO.2
IAP sensor, NO.1
IAP sensor, NO.2
19
ET sensor
Oxygen sensor
SAV solenoid
SELF-DIAGNOSIS FUNCTION (
USER MODE
The FI check lamp
comes on for about three seconds whenever the ignition switch is set to ON
position with the engine stopped as a test of the injection system operation. The check lamp must go off after three
seconds.
If the check lamp comes on during normal engine operation, it means that the fuel injection system is not operating
correctly.
When this is the case, inspect the fuel injection system to refer to Dealer mode.
20
DEALER MODE
The defective function is memorized in the ECU.
Use the special tools coupler to connect to the dealer mode coupler. (Refer to page 4-1-17)
The memorized malfunction code is displayed on LCD (DISPLAY) panel.
Malfunction means that the ECU does not receive signal from the devices. These affected devices are indicated in
the code form.
CAUTION
Do not disconnect the ECU lead wire couplers, before checking the malfunction code, or the malfunction
code memory is erased and the malfunction code can not be checked.
Confirm the malfunction code after turn the ignition switch ON position or cranking the engine for few
seconds.
MALFUNCTION
LCD (DISPLAY)
INDICATION
INDICATION MODE
NO
Speedometer
YES
21
SELF-DIAGNOSIS FUNCTION (
22
CODE
MALFUNCTION PART
CODE
REMARKS
C15
[1
C17
[1
[1
C18
1
C21
1]
C22
C24
[ 2
C25
[ 2
IG coil, NO.1
IG coil, NO.2
2 ]
C27
C32
[ 3
C33
[ 3
2 ]
C37
C41
1 ]
C43
3
In the LCD (DISPLAY) panel , the malfunction code is indicated from small code to large code.
, the malfunction code is displayed from small blinks signal to large blinks signal.
23
FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis
and diagnosis.
Model :
VIN :
Date of issue :
Date Reg.
Date of problem :
FI Check lamp
Always ON
No code
Malfunction code (
Sometimes ON
Mileage :
Always OFF
PROBLEM SYMPTOMS
Difficult Starting
No cranking
No initial combustion
No combustion
Poor starting at
( cold warm
Other
Poor Idling
Poor fast Idle
Abnormal idling speed
( High Low) (
Unstable
Hunting (
rpm. to
Other
OTHERS :
always)
rpm)
rpm)
Poor Driveability
Hesitation on acceleration
Back fire / After fire
Lack of power
Surging
Abnormal knocking
Engine rpm jumps briefly
Other
24
Good condition
Fair
Temperature
Hot
Frequency
Always
Urban
Tarmacadam
Road
Cloudy
Warm
Rain
Cool
Sometimes (
Suburb
Always
Cold (
F /
times /
day, month)
Highway
Gravel
Snow
Other
C)
Mountainous (
Always
Only once
Uphill
Downhill)
Other
Motorcycle condition
Engine condition
Motorcycle condition
Cold
Warming up phase
During driving :
Constant speed
Warmed up
Always
Other
Other at starting
Engine speed (
Accelerating
rpm)
Decelerating
At stop
km/h,
Mile/h)
NOTE
The above form is a standard sample. If should be modified according to conditions characteristic of each
market.
25
SELF-DIAGNOSTIC PROCEDURES
(
)
Dont disconnect couplers from ECU, battery cable
from battery, ECU ground wire harness from engine
or main fuse before confirming malfunction code
(self-diagnostic trouble code) stored in memory.
Such disconnection will erase memorized information
in ECU memory.
Malfunction code stored in ECU memory can be
checked by the special tool.
To check malfunction code, read SELF-DIAGNOSIS
FUNCTION DEALER MODE (Refer to page
4-1-12, 14) carefully to have good understanding as
to what functions are available and how to use it.
Be sure to read PRECAUTIONS for Electrical Circuit
Service (Refer to page 4-1-1) before inspection and
observe what is written there.
Remove the front and rear seat.
Connect the special tool to the dealer mode
coupler at the wiring harness, and the ignition
switch is set to ON position.
Turn the special tools switch ON position and
check the malfunction code to determine the
malfunction part.
NOTE
The dealer mode coupler is located under the rear
seat.
SELF-DIAGNOSIS RESET
PROCEDURE (
26
C15
DETECTED ITEM
Engine temperature
sensor (ETS)
C17 / C18
C21
C22
The oxygen sensor signal is input in ECU since then more than
120 sec. after the engine run.
When this is the case, ECU not receive the signal, C22 is
indicated.
Oxygen sensor, lead wire / coupler connection.
27
MALFUNCTION
CODE
C24 / C25
C27
DETECTED ITEM
When the IC of the ECU electric current gets 6 A and more, C24
or C25 is indicated.
Ignition coil, wiring / coupler connection, power supply from the
battery.
The idle speed control solenoid step should be the following.
O step solenoid step 100 step
Without the above range, C27 is indicated.
Idle speed control solenoid, lead wire / coupler connection.
The fuel injector not comes in voltage from the battery, C32 or
C33 is indicated.
C32 / C33
C37
C41
C43
28
CODE
C15
[1
DETECTED CONDITION
INSPECTION
Step 1
1) Turn the ignition switch OFF position.
2) Check the ET sensor coupler for loose or poor
contacts.
If OK, then measure the ET sensor voltage at the
wire side coupler.
3) Disconnect the coupler and turn the ignition switch
ON position.
4.5 ~ 5.5 V
G - Ground )
( G - BW )
Go to Step 2.
Loose or poor contacts on the
NO
POSSIBLE CAUSE
ET sensor voltage
ECU coupler.
Open or short circuit in the G
wire or BW wire.
29
Step 2
1) Turn the ignition switch OFF position.
2) Measure the ET sensor resistance.
ET sensor resistance
Engine Temp.
0 (32 )
20 (68 )
Approx. 12.209
40 (104 )
Approx. 5.671
60 (140 )
Approx. 2.845
80 (176 )
Approx. 1.525
YES
NO
ECU Coupler
30
CODE
C17
7
[1
C18
[1
DETECTED CONDITION
POSSIBLE CAUSE
INSPECTION
Step 1
4.5 ~ 5.5 V
( OB - Ground )
( OB - BW)
Go to Step 2.
Loose or poor contacts on the
NO
ECU coupler.
Open or short circuit in the OB
wire or BW wire.
31
Step 2
IAP sensor
output voltage
YES
NO
ECU Coupler
Output voltage
(Input voltage 5 V, ambient temp. 25 C, 77 F)
ALTITUDE
(Reference)
ATMOSPHERIC
PRESSURE
(ft)
(m)
(mmHg)
kPa
760
100
2 000
610
707
94
2 001
611
707
94
5 000
1 524
634
85
5 001
1 525
634
85
8 000
2 438
567
76
8 001
2 439
567
76
10 000
3 048
526
70
OUTPUT
VOLTAGE
(V)
Approx.
4.0 ~ 4.3
Approx.
3.6 ~ 4.0
Approx.
3.3 ~ 3.6
Approx.
3.0 ~ 3.3
32
CODE
C21
[ 2
DETECTED CONDITION
POSSIBLE CAUSE
INSPECTION
Step 1
1) Remove the fuel tank.
2) Turn the ignition switch OFF position.
3) Check the IAT sensor coupler for loose or poor
contacts.
If OK, then measure the IAT sensor voltage at the
wire side coupler.
4) Disconnect the coupler and turn the ignition switch
ON position.
4.5 ~ 5.5 V
Lg - Ground )
( Lg - BW )
Go to Step 2.
Loose or poor contacts on the
NO
ECU coupler.
Open or short circuit in the Lg
wire or BW wire.
33
1]
Step 2
1) Turn the ignition switch OFF position.
2) Measure the IAT sensor resistance.
Approx. 53.30
0 (32 )
Approx. 31.52
20 (68 )
Approx. 12.33
40 (104 )
Approx. 5.19
60 (140 )
Approx. 2.42
YES
NO
ECU Coupler
34
CODE
C22
[ 2
DETECTED CONDITION
POSSIBLE CAUSE
INSPECTION
1) Remove the front seat and frame cover.
2) Turn the ignition switch OFF position.
3) Check the Oxygen sensor coupler
for loose or
poor contacts.
Is OK?
YES
NO
ECU Coupler
CODE
CODE
C24
[ 2
C25
[ 2
35
CODE
C27
[ 2
DETECTED CONDITION
POSSIBLE CAUSE
ISC solenoid malfunction.
INSPECTION
1) Remove the front seat.
2) Turn the ignition switch OFF position.
3) Check the ISC solenoid coupler for loose or poor
contacts.
4) Turn the ignition switch ON position to check the
ISC solenoid operation.
YES
NO
34
36
33
32 ECU Coupler
CODE
C32
[
2 ]
C33
DETECTED CONDITION
POSSIBLE CAUSE
INSPECTION
Step 1
1) Remove the fuel tank and frame cover.
2) Turn the ignition switch OFF position.
3) Check the injector couplers NO.1 and NO.2
for loose or poor contacts.
If OK, then measure the injector resistance.
at 20 (68)
Injector continuity
(Infinity)
Go to Step 2
NO
37
Step 2
1) Turn the ignition switch ON position.
2) Measure the injector voltage between YG(NO.1),
YR(NO.2) wire and ground.
Injector voltage
Battery voltage
([NO.1] YG - Ground )
([NO.2] YR - Ground )
NOTE
Injector voltage can be detected only 3
seconds after ignition switch is turned ON
position.
YES
NO
ECU Coupler
38
CODE
C37
[
DETECTED CONDITION
POSSIBLE CAUSE
SAV solenoid circuit open or short.
INSPECTION
1) Remove the front seat.
2) Turn the ignition switch OFF position.
3) Check the SAV solenoid coupler for loose or poor
contacts.
4) Connect the SAV solenoid coupler.
5) Turn the ignition switch ON position.
6) Measure the voltage at the wire side coupler
between GL wire and ground.
Battery voltage
GL - Ground )
YES
NO
ECU Coupler
39
CODE
CODE
C41
[
DETECTED CONDITION
1 ]
POSSIBLE CAUSE
INSPECTION
Step 1
1) Remove the frame cover.
2) Turn the ignition switch OFF position.
3) Check the fuel pump relay coupler for loose or
poor contacts.
If OK, then check the insulation and continuity.
Refer to page 4-2-6 for details.
:
:
:
:
YES
NO
ECU Coupler
40
CODE
CODE
C43
[
DETECTED CONDITION
POSSIBLE CAUSE
Oxygen sensor, Oxygen sensor heater circuit open
or short.
Oxygen sensor, Oxygen sensor heater malfunction.
ECU malfunction.
INSPECTION
1) Remove the frame cover.
2) Turn the ignition switch OFF position.
3) Check the Oxygen sensor heater coupler for loose
or poor contacts.
If OK, then measure the Oxygen sensor heater
voltage.
4) Disconnect the coupler and then the ignition
switch ON position.
5) Measure the voltage between OB wire terminal
and B (or ground) wire terminal.
Oxygen sensor
heater voltage
Battery voltage
( OB - B )
( OB - Ground )
YES
NO
ECU Coupler
41
SENSORS
IAP SENSOR INSPECTION
The intake air pressure (IAP) sensors NO.1
and
NO.2 are installed at the upside of each intake
pipe. (Refer to page 4-1-22)
ET SENSOR INSPECTION
The engine temperature (ET) sensor is installed at
the engine case. (Refer to page 4-1-20)
m (1.8 kgf
m)
ET sensor : 18 N
42
is
TO SENSOR INSPECTION,
REMOVAL AND INSTALLATION
The tip over (TO) sensor is located in the frame.
Romove the seat.
Remove the TO sensor from the frame.
Install the TO sensor in the reverse order of
removal.
43
44
CONTENTS
FUEL SYSTEM 46 (4-2-1)
) 47 (4-2-2)
) 48 (4-2-3)
) 49 (4-2-4)
) 50 (4-2-5)
THROTTLE BODY
53 (4-2-8)
REMOVAL 54 (4-2-9)
CLEANING 55 (4-2-10)
INSPECTION 55 (4-2-10)
INSTALLATION 56 (4-2-11)
45
4 -2
FUEL SYSTEM
46
CAUTION
After disconnecting the fuel injector hose ,
insert a blind plug into the end to stop fuel
leakage.
47
CAUTION
As gasoline leakage may occur in this operation,
keep away from fire and sparks.
by removing
WARNING
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
Remove the fuel gauge .
NOTE
Apply a small quantity of the THREAD LOCK
1324 to the thread portion of the fuel pump
mounting bolt.
48
CAUTION
After disconnecting the fuel injector hose ,
insert a blind plug into the end to stop fuel
leakage.
49
CAUTION
As gasoline leakage may occur in this operation,
keep away from fire and sparks.
Remove the fuel pump assembly
its mounting bolts.
by removing
WARNING
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
50
Fuel pressure
WARNING
Before removing the special tool, turn the
ignition switch to OFF position and release
the fuel pressure slowly.
Gasoline is highly flammable and explosive.
Keep heat, sparks and flame away.
51
NOTE
If the fuel mesh filter is clogged with many
sediment or rust, replace the fuel filter cartridge
with a new one.
Approx. 90 ~ 105
1/2
Approx. 38
Approx. 4 ~ 10
52
THROTTLE BODY
53
REMOVAL
Remove the fuel tank.
Remove the air cleaner box.
Disconnect the fuel hose.
Remove the all coupler to related the throttle
body.
CAUTION
Be careful not to damage the throttle cable
bracket when dismounting or remounting the
throttle body assembly.
After disconnecting the throttle cables, do not
snap the throttle valve from full open to full
close. It may cause damage to the throttle
valve and throttle body.
54
CLEANING
Clean all passageways with a spray-type throttle
body cleaner and blow dry with compressed air.
WARNING
Some throttle body cleaning chemicals,
especially dip-type soaking solutions, are very
corrosive and must be handled carefully. Always
follow the chemical manufacturers instructions
on proper use, handling and storage.
CAUTION
Do not use wire to clean passageways. Wire can
damage passageways. If the components cannot
be cleaned with a spray cleaner it may be
necessary to use a dip-type cleaning solution and
allow them to soak. Always follow the chemical
manufacturers instructions for proper use and
cleaning of the throttle body components. Do not
apply throttle body cleaning chemicals to the
rubber and plastic materials.
INSPECTION
Check following items for any damage or clogging.
* O-ring
* Secondary throttle valve
* Throttle shaft bushing and seal
* Injector cushion seal
* Throttle valve
* Vacuum hose
Check fuel injector filter for evidence of dirt and
contamination. If present, clean and check for
presence of dirt in the fuel lines and fuel tank.
CAUTION
Never operate the idle screws (NO.1) and
(NO.2) to avoid variations of the carburetion
setting.
55
INSTALLATION
Installation is in the reverse order of removal.
Pay attention to the following points :
Connect the throttle cable to the throttle cable
drum.
Adjust the throttle cable play with the cable
adjusters.
56
ELECTRICAL SYSTEM
CONTENTS
LOCATION OF ELECTRICAL COMPONENTS 58 (5-1)
IGNITION SYSTEM 60 (5-3)
CHARGING SYSTEM 61 (5-7)
57
Main relay
Fuel pump relay
Head lamp relay
IAT sensor
TO sensor
58
Magneto
Pick-up coil
GP switch
ISC solenoid
Oxygen sensor
SAV solenoid
59
IGNITION SYSTEM
RELAY
REAR
IGNITION
COIL
FRONT
IGNITION
COIL
ECU
INSPECTION
IGNITION COIL RESISTANCE
INSPECTION
Disconnect the ignition coil read wire.
Measure the ignition coil resistance in bolt the
primary and secondary windings. If the resistance is
not within the standard range, replace the ignition coil
with a new one.
3.5 ~ 5.5
Secondary
20 ~ 31
Terminal -
(Plug cap -
Terminal)
Terminal)
60
MAGNETO
IG.
SWITCH
FUSE
MAGNETO
Using the pocket tester, measure the resistance
between the lead wires in the following table.
If the resistance is not within the specified value,
replace the magneto coil, with a new one.
Standard
G - L Approx. 85 ~ 105
Charging coil
CAUTION
When mounting the stator on the magneto cover,
THREAD LOCK1324
WIRE COLOR
L
: Blue
G
: Green
Y
: Yellow
BY : Black with Yellow tracer
OB : Orange with Black tracer
Br
: Brown
BW : Black with White tracer
WL : White with Blue tracer
YG : Yellow with Green tracer
61
CHARGING SYSTEM
Regulator / Rectifier
IG. switch
Battery
A. C generator
LOAD
IC
INSPECTION
IG. switch
Regulator
Rectifier
Battery
CAUTION
When making this test, be sure that the battery is
full-charged condition.
Standard charge
62
DCV
REGULATOR / RECTIFIER
Disconnect the regulator / rectifier couplers.
Using the pocket tester, measure the resistance
between the terminals in the following table.
If the resistance checked is incorrect, replace the
regulator / rectifier.
Unit : M
Tester probe
Tester probe
34
34
34
12
12
34
12
12
12
12
34
34
12
12
12
12
12
12
32
32
63
64
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 66 (7-1-1)
SPECIAL TOOLS 75 (7-8)
TIGHTENING TORQUE 76 (7-11)
SERVICE DATA 77 (7-19-1)
WIRING DIAGRAM (
) 80 (7-31-1)
WIRING DIAGRAM (
) 82 (7-31-3)
WIRING DIAGRAM (
) 84 (7-31-5)
65
TROUBLESHOOTING
MALFUNCTION CODE AND DEFECTIVE CONDITION
MALFUNCTION
CODE
C15
DETECTED ITEM
Engine temperature
sensor (ETS)
C17 / C18
C21
C22
The oxygen sensor signal is input in ECU since then more than
120 sec. after the engine run.
When this is the case, ECU not receive the signal, C22 is
indicated.
Oxygen sensor, lead wire / coupler connection.
66
MALFUNCTION
CODE
C24 / C25
C27
DETECTED ITEM
When the IC of the ECU electric current gets 6 A and more, C24
or C25 is indicated.
Ignition coil, wiring / coupler connection, power supply from the
battery.
The idle speed control solenoid step should be the following.
O step solenoid step 100 step
Without the above range, C27 is indicated.
Idle speed control solenoid, lead wire / coupler connection.
The fuel injector not comes in voltage from the battery, C32 or
C33 is indicated.
C32 / C33
C37
C41
C43
67
ENGINE
Complaint
Engine will not
start or is hard to
start.
Remedy
Adjust.
Repair or replace.
Adjust.
Replace.
Replace.
See electrical section.
Retighten.
Clean.
Clean and dry.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
68
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Complaint
Remedy
Adjust.
Replace or repair.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
Repair or replace.
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Repair or replace.
Replace or recharge.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
69
Clean.
Replace.
Clean.
Adjust.
Complaint
Noisy engine.
Remedy
Adjust.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace the primary driven gear.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
70
Complaint
Engine runs poorly
in high speed range.
Remedy
Replace.
Replace.
Adjust.
Adjust.
Replace ECU.
Replace.
Replace.
Replace.
Clean and prime.
Replace.
Replace.
Clean.
Clean or replace.
Adjust or replace.
Repair or replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
71
Complaint
Engine lacks
power.
Remedy
Adjust.
Replace.
Adjust.
Replace.
Repair.
Clean or replace.
Adjust or replace.
Clean.
Clean.
Retighten or replace.
Drain out excess oil.
Replace.
Replace.
Engine overheats.
Clean.
Add oil.
Replace or clean.
Retighten or replace.
Change.
Clean or replace.
Repair or replace.
Repair or replace.
Repair or replace.
Replace.
Replace.
72
Replace.
Adjust.
Complaint
Remedy
Slipping clutch.
Replace.
Replace.
Replace.
Dragging clutch.
Replace.
Replace.
Transmission will
not shift.
Replace.
Replace.
Replace.
Transmission will
not shift back.
Replace.
Repair or replace.
Replace.
Transmission
jumps out of
gear.
Replace.
Replace.
Replace.
Dirty or heavy
exhaust smoke.
73
ELECTRICAL
Complaint
Remedy
No sparking or
poor sparking.
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
Inspect FI system.
Adjust fast idle or throttle
stop screw.
Change.
Clean or replace.
Replace by hot type plug.
Spark plug
become fouled
too soon.
Replace.
Replace.
Replace.
Replace.
Spark plug
electrodes
overheat or burn.
Magneto charge,
but charging
rate is below the
specification.
Repair or retighten.
Magneto
overcharges.
Unstable charging.
Repair or replace.
Recharge or replace.
Replace.
Repair or replace.
Replace.
Replace.
Starter switch is
not effective.
74
Replace.
Replace.
Replace the battery.
Replace.
Replace.
SPECIAL TOOLS
Special tools Part Number
Part Name
Description
09900-27000
Mode select switch
Inspect FI system sensor.
(Only for
09915-54510
Fuel pump pressure gauge
Measure fuel pressure of fuel pump.
75
TIGHTENING TORQUE
FI SYSTEM PARTS
ITEM
Engine temperature sensor (ET sensor)
Fuel injector bolt
76
m
N
m
kgf
18
1.8
6~8
0.6 ~ 0.8
SERVICE DATA
FI SENSORS
ITEM
SPECIFICATION
4.5 ~ 5.5 V
4.5 ~ 5.5 V
Battery voltage
Battery voltage
ET sensor voltage
4.5 ~ 5.5 V
0 (32)
Approx. 28.788
20 (68)
Approx. 12.209
40 (104)
Approx. 5.671
60 (140)
Approx. 2.845
80 (176)
Approx. 1.525
77
NOTE
THROTTLE BODY
ITEM
SPECIFICATION
I.D. No.
NOTE
GT250
Bore size
28
Idle rpm
SPECIFICATION
11.5 ~ 13.5
at 20 (68)
Battery voltage
Approx. 3.4 ~ 3.7 kgf/cm2 (333 ~ 363 kPa, 48.4 ~ 52.6 psi)
78
NOTE
ELECTRICAL
Unit : mm (in)
ITEM
Ignition timing
Spark plug
STANDARD
BTDC 13/ 2,000rpm ~ 30/ 6,000rpm
Type
CR8E
Gap
Hot type
CR7E
Standard type
CR8E
Cold type
CR9E
Over 8 mm (0.32 in)
Spark performance
Primary
3.5 ~ 5.5
Secondary
20 ~ 31
Pick-up coil
Approx. 85 ~ 105
G-L
Charging coil
Y-Y
Battery
Fuse size
NOTE
STX14-BS
Capacity
12V 12Ah
Standard
electrolyte S.G.
1.320 at 20 (68)
Main
30A
Head lamp
15A
79
WIRING DIAGRAM (
SPEEDOMETER
HANDLE SWITCH R
STARTER
SAV
SOLENOID
OFF
ON
O
WB
PUSH
O
GL
Br
GR
OB
YR
O
Gr
TACHO
LIGHTING
OFF
ON
O
OB
SPEED
ENGINE STOP
STOP
RUN
Br
GR
O
O
YB
W
B
Y
BW
LY
Lg
O
O
YB
W
B
Y
BW
LY
Lg
O
OB
Gr
YR
O
OB
Gr
YR
O
WB
FUEL
Ft. TURNSIGNAL R
Lg
BW
W
BW
Y
HEAD LAMP
W
BW
Y
W
BW
BW
B
O
BW
BW
B
HANDLE SWITCH L
EARTH
Sb
O
COIL
SWITCH
80
DIODE #1
TURN SIGNAL
RELAY
EARTH
YR
YG
O
RR IGNITION
COIL
FT IGNITION
SIDE STAND
LY
L
GR
OFF
ON
HORN
IGNITION S/W
OB
WL
OB
BY
Br
BW
O R BW BR
LOCK
OFF
ON
BW
L
N
R
TURN SIGNAL
B
BL
Lg
B
Sb
G
BW
PUSH
HORN
BW
HI
LO
DIMMER
O
R
BW
BR
RB
Br
BW
O
R
BW
RB
Y
W
YW
BW
G
Lg
B
Sb
Y
W
YW
BW
BL
Lg
B
Sb
Ft. TURNSIGNAL L
W
Y
YW
POSITION
Lg
BW
INJEC
INJECTOR #1
02 SENSOR
DIODE #2
RR BRAKE S/W
MAIN RELAY
FUEL PUMP
FUEL PUMP
RELAY
HEAD LAMP
RELAY
34P
OFF
ON
O
RB
B
GW
BBr
BW
LY
BW
G
RB
YR
G
L
YB
L
BY
W
OB
YG
OB
BL
Br
Lg
YL
BY
W
GL
B
GL
BY
BR
WL
GR
Y
Gr
O
BW
O
YW
OB
GW
O
BBr
BBr
BW
R
B
R
RB
O
WB
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
O
WB
O
RB
OB
B
BW
BR
BW
YB
BW
YB
YR
BW
YR
GR
CAN TOOL
BBr
YB
BW
O
BY
FUEL GAUGE
DIODE #3
Lg
BW
Lg
BW
RR TURN SIG. R
Gr
BW
Gr
BW
Lg
Gr
BW
WB
B
Lg
Gr
BW
WB
B
Gr
BW
WB
Gr
BW
WB
TAIL & STOP LAMP
BW
B
BW
B
BL
BY
LY
OB
BW
Lg
BL
BY
LY
OB
BW
Lg
R
BW
INJECTOR #1
ENGINE
TEMPERATURE
SENSOR
IAP
SENSOR #2
R
O
MAGNETO
GEAR SHIFT
IAP
SENSOR #1
R
R
Eng.
SENSOR
I.S.C
FUSE BOX
(15A)
Y
Y
Y
R
BW
Y
Y
Y
GL
L
12V 12Ah
TIP OVER
INJECTOR #2
FUSE BOX
(30A)
BW
Lg
LY
BW
OB
OB
BW
BY
OB
BW
BL
G
BW
W
Y
Gr
GR
YR
O
YG
O
BW
YL
G
L
GL
L
GR
YR
R
BW
Y
Y
Y
G
L
BW
YL
GR
YR
BW
BW
YG
YR
O
W
Y
Gr
GR
G
YG
YR
O
W
Y
Gr
GR
G
RR TURN SIG. L
INTAKE
AIR
THROTTLE TEMPERATURE
POSITION
SENSOR
SENSOR
SWITCH
81
REGULATOR
STARTER
MOTOR
STARTER
RELAY
BATTERY(MF)
EARTH
WIRING DIAGRAM (
HANDLE SWITCH R
SPEED SENSOR
DISPLAY
Ft. BRAKE
OFF
ON
PUSH
FUEL GAUGE
BW
G
O
BW
G
O
BY
L
YB
B
W
Lg
YW
O
L
WL
LY
YB
B
W
Lg
O
O
L
Y
BW
W
Y
BW
W
O
OB
Gr
YR
WB
O
OB
Gr
YR
WB
Br
GR
BW
YB
O
G
BW
O
WB
OB
YR
O
Gr
SAV
SOLENOID
OFF
ON
TACHO
O
OB
BW
YB
STARTER
O
GL
LIGHT
OFF
ON
Br
GR
ENGINE STOP
STOP
RUN
Ft TURNSIGNAL R
Lg
BW
W
BW
Y
HEAD LAMP
W
BW
Y
O
BW
W
BW
BW
B
BW
B
G
BW
LY
L
GR
Br
BW
BW
O
Sb
OB
WL
OB
BY
BW
B
BBr
Lg
B
Sb
W
Y
YW
G
BW
O
R
B
BBr
Br
BW
O
R
B
BBr
Y
W
YW
BW
G
Lg
B
Sb
O
Y
W
YW
BW
BBr
Lg
B
Sb
O
Ft. TURNSIGNAL L
O
Y
DIMMER
PUSH
HORN
L
N
R
TURN SIGNAL
LOCK
OFF
ON
HORN
OFF
ON
FT IGNITION
SIDE STAND
IGNITION S/W
NOISE
FILTER
HANDLE SWITCH L
82
BW
HI
LO
BW
O R
PUSH
PASS
BW
POSITION
Lg
BW
COIL
TURN SIGNAL
DIODE #1
RELAY
ENGINE
SWITCH
EARTH
RR IGNITION
COIL
EARTH
TEMPERATUR
SENSOR
RR BRAKE S/W
02 SENSOR
FUEL GAUGE
FUEL PUMP
DIODE #2
MAIN RELAY
FUEL PUMP
HEAD LAMP
RELAY
RELAY
34P
OFF
ON
CAN TOOL
SWITCH
BY
WL
BBr
YB
BW
O
BY
B
GW
BBr
BW
BW
G
RB
YR
G
L
YB
L
BY
W
OB
YG
OB
BL
Br
Lg
YL
BY
W
GL
B
GL
BY
BR
WL
GR
Y
Gr
Gr
BW
O
YW
OB
GW
O
BBr
R
B
R
RB
O
WB
BW
BBr
O
RB
BW
YB
BW
YB
OB
B
BW
BR
O
WB
1 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Lg
BW
Lg
BW
RR TURN SIG. R
Gr
BW
O
BW
O
BW
WB
Gr
BW
WB
TAIL & STOP LAMP
BW
B
BW
B
BW
BW
YR
O
YR
O
R
O
BW
FUSE BOX
(30A)
FUSE BOX
(15A)
R
R
12Ah
Y
Y
Y
R
BW
GR
YR
R
BW
Y
Y
Y
Y
Y
Y
G
L
12V
BW
YL
BW
BY
OB
IAP
SENSOR #2
BW
Lg
BW
BL
OB
ENGINE
IAP
SENSOR #1
W
Y
GR
Gr
G
BW
GL
L
G
L
GL
L
BW
YL
GR
YR
YG
O
YG
O
G
BW
BL
OB
BY
G
BW
BL
OB
BY
RR TURN SIG. L
EARTH
Eng.
TEMPERATURE
SENSOR
INJECTOR #2
INJECTOR #1
I.S.C
INTAKE
AIR
TEMPERATURE
SENSOR
TIP OVER
GEAR SHIFT
SENSOR
SWITCH
MAGNETO
83
REGULATOR
STARTER
MOTOR
STARTER
RELAY
BATTERY(MF)
WIRING DIAGRAM (
HANDLE SWITCH R
SPEED SENSOR
DISPLAY
Ft. BRAKE
OFF
ON
SAV
SOLENOID
FUEL GAUGE
BW
YB
BW
G
O
BW
G
O
BY
L
YB
B
W
Lg
YW
O
L
WL
LY
YB
B
W
Lg
O
O
L
Y
BW
W
Y
BW
W
O
OB
Gr
YR
WB
O
OB
Gr
YR
WB
Br
GR
BW
YB
O
G
BW
O
WB
OFF
ON
O
GL
PUSH
Br
GR
STARTER
O
Gr
O
OB
TACHO
LIGHT
OFF
ON
OB
YR
ENGINE STOP
STOP
RUN
Ft TURNSIGNAL R
Lg
BW
W
BW
Y
O
BW
HEAD LAMP
BW
B
BW
B
G
BW
LY
L
GR
Br
BW
BW
O
Sb
OB
WL
OB
BY
BW
B
BBr
Lg
B
Sb
G
BW
O
R
B
BBr
Br
BW
O
R
B
BBr
Y
W
YW
BW
G
Lg
B
Sb
O
Y
W
YW
BW
BBr
Lg
B
Sb
O
Ft. TURNSIGNAL L
W
Y
YW
DIMMER
PUSH
HORN
L
N
R
TURN SIGNAL
LOCK
OFF
ON
HORN
OFF
ON
FT IGNITION
SIDE STAND
IGNITION S/W
NOISE
FILTER
HANDLE SWITCH L
84
BW
HI
LO
BW
O R
PUSH
PASS
BW
POSITION
W
BW
Y
BW
W
BW
O
Y
LOW BEAM
HIGH BEAM
Lg
BW
COIL
SWITCH
EARTH
EARTH
RR IGNITION
COIL
DIODE #1
TURN SIGNAL
RELAY
ENGINE
TEMPERATUR
SENSOR
RR BRAKE S/W
02 SENSOR
FUEL GAUGE
FUEL PUMP
DIODE #2
MAIN RELAY
FUEL PUMP
HEAD LAMP
RELAY
RELAY
34P
OFF
ON
CAN TOOL
SWITCH
BY
WL
BBr
YB
BW
O
BY
B
GW
BBr
BW
BW
G
RB
YR
G
L
YB
L
BY
W
OB
YG
OB
BL
Br
Lg
YL
BY
W
GL
B
GL
BY
BR
WL
GR
Y
Gr
Gr
BW
O
YW
OB
GW
O
BBr
R
B
R
RB
O
WB
BBr
BW
O
RB
BW
YB
BW
YB
OB
B
BW
BR
O
WB
1 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Lg
BW
Lg
BW
RR TURN SIG. R
O
BW
Gr
BW
O
BW
WB
Gr
BW
WB
TAIL & STOP LAMP
BW
B
BW
B
BW
BW
YR
O
YR
O
R
O
FUSE BOX
(15A)
R
R
BW
R
R
GR
YR
R
BW
G
L
Y
Y
Y
Y
Y
Y
Y
Y
Y
R
BW
FUSE BOX
(30A)
BW
YL
BW
BY
OB
IAP
SENSOR #2
BW
Lg
BW
BL
OB
ENGINE
IAP
SENSOR #1
W
Y
GR
Gr
G
BW
GL
L
G
L
GL
L
BW
YL
GR
YR
YG
O
YG
O
G
BW
BL
OB
BY
G
BW
BL
OB
BY
RR TURN SIG. L
12V
12Ah
EARTH
Eng.
TEMPERATURE
SENSOR
INJECTOR #2
INJECTOR #1
I.S.C
INTAKE
AIR
TEMPERATURE
SENSOR
TIP OVER
GEAR SHIFT
SENSOR
SWITCH
MAGNETO
85
REGULATOR
STARTER
MOTOR
STARTER
RELAY
BATTERY(MF)
MEMO
86
MEMO
87
Prepared by
SERVICE MANUAL
SERVICE MANUAL
99000-95610