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Leading the way

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SERVICE
GENERAL |NFORMAT|ON......... E
PGM.FI SYSTEM
@
AIR INDUCTION SYSTEM
E
FUEL DELIVERY SYSTEM
E
E!.ECTRONIC CONTROL SYSTEM
@
REAL T|ME MTLEAGE |ND|CATOR (RTM|)
E
PGH-FI MALFUNCTION DIAGNOSTIC PROCEDURE
E
M']TTI HALFUNCTION DIAGNOSTIC PROCEDURE
E
FiI.JEL DELIVERY SYSTEM INSPECTION AND TESTING
E
FII FCTRICAL WIRING DIAGRAMS / COLOUR CODES
E
TIA!il|TENAN C E SG H EDU LE

,:
ffiRrANr DEFlNtflONS.....*........ .....1..f......
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TJIIETTO
4T!IIOITTDA
 GENERAT INFORMATION

GENERAT SAFEW
CARBON MONOXIDE ELECTRICAL WIRES

e.rgine must be running to do some work, moke sure the

s rrell ventiloied. Never run the engine in on enclosed
o Route oll electricol wire/horness ond cobles. Keep
them owoy {rom shorp edges ond oreo where they might be
pinched beiween moving ports.

1e exhoust contoins poisonous corbon monoxide

gcs thot con couse loss of consciousness ond moy
ecd to deoth.

; - - --5 engine in on open oreo or wiih on exhoust evocuotion

: :-:- n on enclosed qreo.

GASOTINE

3:sciine is exiremely flommoble ond is explosive

-- ::' certoin condiiions.
, ::) CUT OF REACH OF CHILDREN.

ii{f(oTco}tPoNENTs

@@
*- I ^" ond exhousi system ports become very hot
: - :':-roin hotforsometime o{terthe engine is run.
'"suloted gloves
"::' or woil until the engine ond
:,-:,s- system hove cooled be{ore hondling these
::-:.
eeiNrTEF|lr

Trc@
-- ::-ery gives off explosive eoses: keep sporks,
: -: :-d cigorettes owoy. Provide odequote
:-- :- -^iorchorging.
GENERAL INFORMATION

GENERALSERVICE RUTES

Cfeoning of ports - Cleon the outside o{ o port or ossembly before removing ii frc- -'e r':-: ':... .' ccering its cover for
service.Did,whichhosoccumulotedontheoutside,moyfoll intotheengineorbrokesys-e-o^!::-s:::-::=.3ieonportswitho
high {losh point solvent ond dry it with compressed oir.

Controlcqbles-Neverbendordistortcontrol cobles.Thiswillleodtostiffopercticrc-::'.*:---::-: -'= -'-.

Rubber ports - Bewore of ports conioining O - rings or oil seols, since these 3'e ::,:-: -:s- of the cleoning
solvents.

Loosening o porl wirh multiple fosteners - Loosening o porl wlth r- 'E : t:s-:-:- :-: - -':- the outside to
inside in o criss-cross pottern, loosening the smoll fosteners iirst. Looseninq -'e . : -':s-:-:- - -:- s' :--ss ve force on the
smoller {osteners.

Reossembly Position of crilicol pqrls - Core should be token to nore --e ::: : :-: .. -,.e dismontling
the engine. This will ensure dimensions (depth, distonce or position) to be :c-:- ,

Non - reusqble pqrts - Alwoys reploce goskets, o -rings, oil sec s -:-: lir -,1 -3-sr pins while re
ossembling the engine.

Greosingoroilingof portsbeforeossembly-ltisimpo*criioc:: * -3tt--i-:f": -: =-:i=--:.^theengine

ports to ensure better bedding in ond preveniing ropid weor out.

Torque of multiple qnd differenl sized fosteners - Firsr -c-c - ;--:- : -:n?-a-: --:- ': -: -E : : -::-:-e's {irst followed
bytorqueo{smolleriostenersino criss-crosspofternfrominne.-3:--:--::.:::-.:--:-:- ---::::.:-:,::-s.

Oilseqls-Newoil seolstobeinstolledwithmulti purposeg!'ecserrr.3r --:-E:r r'' -:,- -:T: -:-:,::::',voyscheckthot

:: - : :r- : r: ** :e:
the shoft overwhich the seol fits is smooih ond free of burrs, whic-

Old goskel & seolonls removol - Old gosket ond seolonl .'.-e'. :- : - : :E : : *r: ;'*,,',=- -

re-ossembly
I
Rubber Hoses - Fuel orvocuum hoses should be instolled sc --:-:-: : :,:i'T:r-*: in: T::t',t'r-: M* :-', :- : ersJreodequote 't
oreo for the hose clip io g rip the hose beneoth the flo red end of .. e
t'- -:
 GENERAT INFORMATION

MODEL IDENTIFICATION

_.ti ry*=
al:::l:.a:r...;;&

I .',3 \E NUMBER FRAME NUMBER

b
I

re

ot

HINIGINE NUMBER FRAME NUMBER

-i :-: -e seriol number is stomped on the lower left side of The frome seriol number is siomped on the right side of the
tte ""'E :-:-.1:3Se steering heod.

THROTTLE BODY IDENTIFICATION NUMBER

The throttle body identificoiion number is stomped on the front
side oithe throttle body.
 GENERAL INFORMATION

PGIA- FI SERVI CE PRECAUTIONS

Soeciol instrumenls qnd Gouges - Use Speciol Instruments ond gouges wherever opplicoble. Speciol lnstruments ond
--:--=s:cr PGM-Fl system hove been developed fortesting, meosuring ond diognosis of molfunclion pertoining to PGM-Fl
'r :-:-
" -.'.-,sensureduringPDlthotthereqrenomqlfunctioncodesstoredintheECU'smemory.
* - * ),s ensure to hove o {ully chorged bottery before storling.
servicing ony of the fuel delivery system components olwoys ensure to relieve the fuel pressure be{ore removol.
- ,:.e'bendortwistthefuel feedhoseondolwoysreploceretoinersonddomperswheneverthe{uel feedhoseisdisconnected.
: -I , S remove the fuel feed hose quick connect coupling by hond only.

* , - jcid to prevent DUST ENTRY.

- : ".:,sensuretotorquethefuel pumpmountingboltsosperspecifiedtorqueinospecificcris-crosspottern.
* - :: :riy recommended Resistortype spork plug.
' - .:,sdischorgethe R.R. Unitbeforestorogeordisposol.
* : . : ' s ensure to colibrote throttle position sensor once ihe sensor unit is removed from the throttle body.
. ,:. -'snop the throttle volve once the throttle body is removed from the vehicle.
" - : -:- ccceleroie while storting.
' -:-:rdotorytomoinioinspecifiedtorqueonoll{ostenersmorkedby"yellowpoint"onceremoved.
- :-:-.^3rs morked by "white poini" should not be tompered strictly.
- :. : s;re oll ECU horness connectors ore {ostened securely.
' :" : -:-- c ll PGM-FI ports ond horness from roug h hond ling ond extreme temperotu re.
- - : -:- sproy high pressure woter directly to ony of the PGM-FI componenis or horness connector. Ensure to oir dry ofter woter
' ::-

ffiCLUSIVE INSTRUMENTS AND GAUGES FOR GTAMOUR PGM.FI

5R, NO DESCRIPTION APPLICATION PART NO
Doto link connector To reod ond erose molfunction code from the O/O HH KIRF OOI
ECU memory.
truel Pressure Gouge
To meosure the fuel pressure in fuel delivery OZO HH KI-RF OO3
system.

: \,4ultimeter Probe, Tip Dio-0.7mm

To meosu re volto ge, resisto nce, con nectivity. O7O HH KTRF OO4
Sonwo-TL-91M)

=uel Pressure Gouge Adoptor To connect the pressure gouge in the fuel O7O HH KIRF OO5
delivery system.

ling
PGM-FI SYSTEM

PGM-Fl (Progrommed Fuel lnieclion)

by its computer system' This {unction
progrommed rniection, pGM-Fr, iniects the fuer in on oppropriote omount corcuroted
Fuer iemperoture' lntoke
The
input doto ogorai;g-rh;i"r"ring .o"a''tr"" tn" engine, like engine speed &
is ossisted by sensors sending "+
u-kes, The pGM.F,sys,em nsie.d
il1il*:[:?J"J:o*:1:1lill*l'::;,::llil:[,.Hi[?t'qTi+1il;1":;,,"s,y.]:l
;iJronic {uer iniecf r. The sriucture of
pGM-Fl con be dtvlded into 2 moin
iniecis pressurised fuer ,"i, in" ,,"r.e
moniford o{
";,;;;;
;;""Er;.*rr"ic Contror iyrt"r'. The "Erectronic Conirol system' is composed
systems which ore tn"iir"t Derivery
system,'
Sensorswhichsend vorioussignoro{the"ngrnJop"roting.ot'ditionrt"iil"ii".itontcont'otUnit(ECU)which{urthercontrolsthe
;#;;;o o+ tr'rg doro ond conrrols ihe
{uel iniection bv
Erectronic .""ir.r IECU) does
engine operorion occordingry. The
,iu"r Derivery sy.t"J lonrlo ""'i o{ o {u"r pu*p-iti on intJgroted pressure regulotor which molntoins or
{uer derivery system. Th" volume of {uel os per
i" +""r lJr*"n ,ru"., oni on in1"oo,. *hicriiniects the oppropriote
reguroies the required i""r oi**r" ,'n"
by ECU'
the engine operoting .r"J'ii."l'"
ihe intoke moni{old which is controlled

Detects the volume ond pressure of

oir entering
the iniqke moni{old ond the engine operoting
SENSORS
conditions i.e' Engine temperoiure'

iniection
Colculotes ond conirols the oppropriote
ECU volume ond iiming.

pressure'
Feeds the engine wiih reguloted {uel
Fuel Delivery SYstem

Bosic concept cnd the iniection progromme it

ln pGM-Fl system the sensors detect the

vorious conditions os -aniinnr in the :cc e g
__--r:r:^^- ^. mentioned "e' ce r.,,
t

iiming'
*n" f CU colculoies the iniection volume ond

Throttle Position Sensor (TPS)

(EOT) To detect engine oil re- ce'c--'e

Engine Oil Temperoture Sensor
To deteci oirtemperc'-'c - --!(i -:- -' :
ntoke Ai r Tem perotu re Sensor (lAT)
- ^-l'': - :- -: :
I

To detect oir pressr-;re

Monifold Absolute Pressure Sensor (MAP)

Cronkcose Position Sensor (CPS)

 PGM.FI SYSTEM

I EI.ECTRONIC CONTROL SYSTEM

--e Electronic Control System is composed of Electronic Control Unit (ECU) ond the Sensors including other equipments. ECU
n -::eives elecironic signols from the Sensors ond then controls components such os iniector, fuel pump ond ignition coil.
:
id
in SENSORS ECU OPERATING UNITS
o{
le
by
DT TPS - Throttle Position Sensor Colculotes ond Controls Fuel
ET To detectthrottle opening ongle. iniection volume ond timing.

llAP - Monifold Absolute Pressure Controls Fuel Pump

To detect intoke oir pressure. Operotion.

IAT - lntoke Air Temperoture

To deteci intoke oir temperoture.

EOT - Engine Oil Temperoture to

cietect engine oil temperoture.

Controls ignition Timing. lgnition Coil

CPS - Cronk Position Sensor

-o deiect cronk posilion ond RPM

ln
Enobles Molfunction
loto Link Connector Diognosis o{ PGM Fl PGM-Fl lndicotor
System.

:. tion Control Reloy To supply power for the

:co/er Source l2 volis functioning of Electronic
Circuits.
PGM.FI SYSTEII'I

tNJECT|ONVOtUtUtE
The PGM - Fl system does not control the volume o{ oir entering the intoke monifold but insteod controls the volume o{ fuel to be
iniected forthe oirentering the moni{old to provide on odequote oir{uel mixture in o sloichiomelric roiio.

The Progrommed Fuel lniection works undertwo differentconditions i.e. Low Lood condition ond High Lood condition.

ln cose the Throttle Volve is wide open the PGM - Fl syslem will use the signol from "Throttle Position Sensor" ond the Cronk RPhr
from "Cronk Position Sensor". l{ the Throttle Volve is nol wide open then the PGM - Fl system will use the signol from "Monifold
Absolute Pressure Sensor" ond Cronk RPM from "Cronk Position Sensor".

The PGM - Fl progrom colculotes the quontity o{ fuel to be iniected under oll engine operoting conditions using two supporling
foctors i.e. "Monifold Absoluie Pressure" ond "Throttle Position". Given below ore 3-Dimensionol grophs for the two differen"
conditions.
The two Fuel lniection Progroms ore designed io enhonce the most oppropriote omount Fuel to be injected for vorious engine
operoting conditions.
A)When ThrollleVqlve is "NOTWIDE OPEN"
The most oppropriole volume o{ fuel to be iniected (occording to engine operoting condilion) is colculoted by the ECU's {ue
injection progrom. The ECU uses the inputs {rom "Moni{old Absolute Pressure Sensor" (MAP) io detect the Air Pressure or the
omount of oir entering ihe lntoke Moni{old ond the Cronkshoft RPM detected by the "Crqnk Position Sensol' (CPS) os doto ir'
colculoting the iniection volume ond timing.
The 3 - Dimensionol groph given below shows ihe resultqnt fuel inlection when the "Moni{old Absolute Pressure Sensor" is used os
doto during lowloqd.

lnieciion Time

B)When Throttle Volve is'WIDE OPEN"

The most oppropriote volume o{ {uel to be injected (occording to engine operoling condition) is cqlculoted by the ECU's fue
injection progrom. The ECU uses the inputs o{ opening o{ the ihrottle volve detecied by the "Throttle Position Sensor" (TPS) ond ihe
Cronkshoft RPM deiected by the "Cronk Position Sensor" (CPS) os doio in colculoting the in jection volume ond timing.
The 3 - Dimensionol groph given below shows the resultont fuel in jection when the "Throtile Position" is used os doto during high
lood.

lniection Time

HIGH IOAD
 PGM.FI SYSTEM

FUEt INJECTION VOTUME AND TI'I,IING

--e inputs {rom the below mentioned sensors ore used by the ECU for colculoting the volume of {uel to be iniected in the lntoke
.':nifoid.

SENSOR INPUT SIGNAT DETAITS

M
,ld The inieciion volume is chonged with
--:ke Air Temperoture Sensor Air Temperoture chonge in ombient oir temperoture,
entering ihe throttle body.
ng
tnl
During cold storting ond during
engine wormup iime, this input to the
i-:ire Oil Temperoiure Sensor Engine oil temperoture
ECU is utilised in colculoting ihe
required in jeciion volume.

The inieciion volume is chonged wiih

rcl
--'c-ie Position Sensor Opening ongle of throttle volve. the chonge in the ongle of throttle
he volve.
in

The inleciion volume is chonged with

':^;old Absolute Pressure Sensor Air pressure in the intoke monifold ihe chonge in moss o{ oir entering the
intqke monifold.

T'ne fuel iniection syslem

- -: :3'v1-Fl system uses the input from Mop sensor to determine the
suction stroke (vocuum in intoke moni{old) ond Cronk Position
. - j: - -c detect the posilion of the piston, to
colculqte the iniection iiming, in orderto inieci the fuel once in every two rototions of the
. : -, -.-o{i.

1) Suction Stroke
2) Compression Stroke
3) Power Stroke
4) Exhousi Stroke

uel
frre
I'cnk Pulse

th
l:-ection of
: - :.essure in
-':<e monifold
 AIR INDUCTION SYSTEM

THROTTLE BODY
-: -rrottle Body is composed of o Throttle Volve ond on ldle Adiusting Screw which controls the qmount
of oir enterinq the intoke
- : - 'cld' During idling the throtile volve is in o closed position, engine suction drows the oir in the intoke monifold thro"ugh idle oir
: :::.ge in the throttle body.
--: l.e oir possoge is designed with shorp curves in orderio prevent
--: lle RPM con be odiusted by rototing the idle odiusting screw incorbon deposition from fhe combustion chomber.
Clockwise direction (Decreose ihe RPM) ond Anticlockwise
: -:;.:on(lncreoseRPM),thisconirolstheoirflowthroughtheidleoirpossogetotheintokemqnifold.
--: Sensor Unit insiolled on the throttle body is compoct design consisiing oithree sensors i.e., Throttle Position Sensor (TPS) to
:.-::-ihrottle ongle, Monifold Absolute Pressure Sensor (MAP) to detect qir pressure in the intoke moni{old, lntoke Air Temperoture
-:-::' (lAT) to detect oirtemperoture entering the ihrotfle body from oir{ilter.

IDLE ADJUSTING SCREW

MAP SENSOR THROTTLE BODY

SENSOR
UNIT

IAT SENSOR
TP SENSOR

IDLE ADJUSTING SCREW ADJUSIING SCREW

_..CTTLE BODY
SENSOR UNIT THROTTLE VALVE
 FUEI DETIVERY SYSTEM

RJEL DELIVERYSYSTEM
--e fuel delivery in PGM-FI syslem is composed o{ o submerged " Fuel Pump" in the fuel tonk to deliver pressurised fuel, on
--egroted "Pressure Regu lotor" which moinioins o constont pressure in the fuel line, o solenoid type "Fuel lniecto/' to iniect fuel in the
--:ke monifold ond o "Throttle Body" which controls the omount of oir enfering the intoke monifold.
I -e to spoce consiroints in o motorcycle the components used in PGM-Fl {uel delivery system hove been designed smoller in size os
-: - po red to olher conventionol fuel iniection system.
--: suction pod hoving o primoryfuel filierof the fuel pump is instqlled qtthe lowest position of the fuel tonkio preventthe chonging
--: evel while lhe engine is occeleroted orwhile riding on o bumping rood.
--: ,niector is connected with fhe fuel pump with o fuel feed hose.
=-EL TANK PRESSURE REGUIAIOR INJECTOR

FUEL PUMP FUEL FILTER FUEL FEED HOSE THROTTLE BODY

L_ Fuiel Flow
- ": :- ei is filtered by o primory filter instolled oi the bottom of the fuel pump. The pressurised {uel is delivered through
I o connecting
I "-:::=dhosedirectlyiotheinjectorhovingosecondory{ilterottheinletside.
*: :'essure regulotor mointoins the fuel pressure within the fuel delivery syslem ol 294 kpo (3.0 kgf/cm'). The ECU controls the
- ::-3'operolion by operoting the iniector for o colculoted durotion ot on oppropriqte time os per the engine RPM.

i
!

I
I

I
FUEI DELIVERY SYSTEM

Fuel Pump
PGM-FI sysiem hos q submerged type fuel pump instolled in the fuel tonk which is used to pump pressurised fuel to the inie:
fuel ionk. The Fuel Pump Assembly is composed of o Pump Body consisting o{ on Armoture, Vone type Rotor, ond o Chec< ,

moinioin the fuel pressure in the fuel delivery system when the engine is switched off).
The rotor inside the pump body hos vones on its outer edge ond is driven by the ormoture. When the motor operotes, -*
oround the outer edge of the rotor ond the pump body will suck the fuel into ihe moior. The fuel is thrown outwords due to cer
force, {lowing through the inner possoge in the pump body. When the pressure generoted by the {uel pump is enough to p-;r
the check volve, the fuel is releosed in to the fuel feed hose to the iniector.

DELIVERY
LINE

t PUMP COVER TOR MAGNET ARMAIURE DELIVE;.

VANES

ROTOR CASING
CHECK VALVE
I'VIPORTANT
I Although {uel posses through the motor; the interior is completely fllled with fuel ond no oxygen exists. Even if the ve.
runs out o{ fuel, oir connot enter the fuel line becouse it is {illed with petrol fumes, so there is no donger o{ explosion d r:
sporks from the brushes.
I The fuel pump connot be disossembled, but m ust be reploced os one unit if de{ective.

Fuel Pump Operotion

I ) The Fuel Pump (Armoture) circuit ground is controlled by ECU. The ECU operotes the Fuel Pump for 2 seconds ofterthe ig-
switch is turhed to "ON" position by grounding the fuel pump for 2 seconds.
2) The roior connected to the ormoture shofi rofotes olong with the ormoture creoting o suction, due centriiugol force the
tropped in the vones is pressurised ond pushed upwords from the delivery line in the Cosing. The fuel {lows orounc
ormoiure to the Check Volve which is pressed upwords opening o possoge out of the Fuel Pump into the Fuel Feed Hose.
3) On cronking the engine, ECU receives signol from Crqnk Position Sensor (CPS) ond gives o coniinuous ground to Fuel P-
operoting it continuously. The fuel pump stops operoting once ihe engine is switched off ond no signol from CPS is ovoiloc
ECU.
4) The Check Volve is designed to mointoin the fuel pressure in the fuel line even oftqr the fuel pump stops operoting ond will <
the {uel pressu re in the delivery line stoble for o long durotion to enoble next engine sto rting eosy ond quick.

FUEL PUMP ON CONDITION FUEL PUMP OFF CONDITION

PRESSURISED FUEL OPEN CHECK VALVE CLOSED CHECK VAL"

 FUEI DETIVERY SYSTEM

PRESSURE REGULATOR
rm -- e Pressure Regulotor is on integrol port of ihe Fuel Pump ossembly. lt is instolled in the fuel delivery line of the fuel pump ossembly.
[to --e Pressure Regulotor is composed o{ spring looded boll volve ottoched io o diophrogm, ond spring. The iuel pressure ot the
- :cor is olwoys mointoined 294 kpo (3.0 kg/cm').
es
tol
en

PRESSURE
REGUIATOR

DIAPHRAGM

FUEL

FUEL FILTER FUEL INJECTOR

Dressu re Regulotor Operqtion

-: cump delivers o constont {uel pressure into the fuel delivery line upto the fuel iniector, os it is on electricol pump with constont
: t ,' I generotes o pressure o{ opproximotely 600 kpo ot oll times.

-:. the engine is storted the pump storis delivering pressurised fuel into the delivery line, the some pressure is olso exerted on the
:"::sJre reguloior diophrogm. When the engine RPM is low the iniected volume of fuel is low this increoses fuel pressure in lhe
:: ery line, pressing the diophrogm olong with the spring looded boll volve downwords. This creoies spoce ot the iop of the boll
.

,: which is pushed upwordsfrom its seoi bythe spring, opening o possoge{orthe excessive{uel inthedelivery lineto be releosed
:< nto the {uel tonk.
:^ the RPM is increosed the iniected volume of {uel increqses, ihis reduces fuel pressure in the delivery line ond olso on the
uel
::^rogm. The diophrogm spring roises the spring looded boll volve ossembly upwords closing the fuel possoge, reducing the
he
- -e of fuel being releosed into the f uel tonk, ihus mointoining the pressure in the {uel delivery line at 294 kpo oi different engine

rP,
r n* :^ the pump is notoperoiing the soring looded boll volve is pressed upwords bythe diophrogm spring instolled otthe bottom o{
- : :'essure regulotor. The upper tip o{ ihe pressure regulotor body presses the boll into the volve seot closing the fuel possoge to
)ep -: ^-oin fuel pressure in the fuel delivery line even when the pump is not operotionol.

closE PosrTroN SPRING OPEN POSITION

-I o o
= o o
o C
o o
o C
o o
LVE , T]HRAGM SPRING DIAPHRAGM BALL SEAT
 FUEI DETIVERY SYSTEM

FUEL INJECTOR
For fuel iniection PGM-Fl system uses o solenoid type 4- Pon fuel injector instolled on ihe throttle body. The
iniecior receives the
iniection signol from the ECU ond iniecls the fuel_ot on opiimum ongle into the intoke monifold. The in jector is
composed of the
nozzle plote, plunger, solenoid coils, spring ond o {uel stroiner.
The iniection volume of fuel increqse or decreqse depending on the durotion forwhich the plunger is open, qs the
F li{i of the plunger
isolwoysthesomeondthefuel pressureinihefuel lineisolsomointqinedotoconsiontpressure
2UUe;olbythepressureregulotlr.

IDLE ADJUSTING Fuel Stroiner Screen

SCREW INJECTOR JOINT

Spring

THROTTLE CABLE BRACKET Solenoid Coil

SENSOR UNIT

Fuel
Plunger
THROTTLE BODY

Nozzle Plote
s

lniector Operqtion
The ECU controls ihe lniector operotion by controlling the circuit ground. The timing ond durotion oi the ground results
in tl.e
iniection timing ond volume.
A direct current supply from the bottery to the ignition switch, through the ignition control reloy is given ot ihe in jector
solenoi:
terminol ond the ground locolion is ot ECU.
As the ECU provides groundlo the solenoid it gets mogneiised qnd pulls the plunger upwords
opening the possoge for the fuel to b:
injected into the intoke monifold.
When the solenoid ground is cut off by the ECU the plunger is pushed forword by the spring tension closing ihe possoge.

INJEC O-RING INJECT JOINT

FUEL STRAINER
 ETEGTRON IC CONTROL SYSTEN,I

FO}I.FI POWER SUPPTY CI RCUIT

-- s moiorcycle hos 2 power supply circuiis to lhe PGM-Fl system, The bottery in good condition ond with o deod bottery.

Chorged bottery
i-e bottery is in o good condition, it will supply the powerto the PGM- Fl system os the {irsi power source.

Eectric Current Flow:

- 'ris condition when the ignition switch is turned to "ON" ond the engine is self or kick storted the power supply from the bottery will
j':*'lothe lgnition Control Reloy ond ihe BonkAngle Sensor, the BonkAngle Sensorfudherenobles o ground of lhe lgnition Control
;e cy. This ollows the flow of current {rom the lgniiion Control reloy lo ECU, lniector; Fuel Pump ond the lgnition coil os illustroted
:€ ow.

COMBINATION
SWITCH

D.C. LOAD

START-MAG
SWITCH

IGNITION. CONTROL
RELAY

le

A.C. LOAD
d

ENGINE EARTH

ffi
ETECTRONIC CONTROL SYSTEM

Deqd Bottery
l{the bottery is dischorged or deod, the voltoge of the olternotor during kick slqrt will be ihe second power source.
The regulotor / rectifier hos o copocitor which helps to mqintoin o consistent voltoge supply from the ACG to PGM-Fl sysiem during
kick stort. Though the emergency system con be used, but during riding, o chorged or o good botiery is still recommended becouse
the chonge in lhe engine RPM offects ihe voltoge resulting io ihe poor performonce of lhe electricol equipments'

Electric Gurrenl Flow:

ln this condition when the ignition switch is iurned to "ON" ond kick slorted, the power supply {rom the ACG will flow to the
Regulotor-Recti{ier unit (pulse {orm) ond chorge the copocitor which furlher will provide with o consistent flow o{ volioge to ihe
PGM-Fl system qs illustroted below.

COMBINATION
SWITCH

D.C. LOAD

START-MAG
SWITCH

IGNITION. CONTROL
RELAY

A.C. LOAD

ENGINE EARTH

AC VOLT r -_
DC VOLT
 ELECTRONIC CONTROT SYSTEM

BAN K ANGTE SENSOR/IGNITION CONTROL RETAY

---- i:nkAngleSensorond lgniiion Control Reloyore locoted inside righf motorcyclecoverbehindthe bottery. The BonkAngle
-e-::' is provided to cut-off the electricol supply to PGM-Fl system (ECU, lniector, Fuel Pump, lgnition Coil) in cose the motorcycle
--::.'erorfollsdown.
- ::se o{ o motorcycle with o corburettor, the iets come obove the fuel level ond the {uel supply to engine is cut-off, shutting down
r*-;-s,n€, but in PGM-Fl system the ECU coniinues the fuel iniection ond ignition even ofter the moiorcycle turns over ond the
i - : -e will continue to run which con couse furlher iniury to the rider.
--: l:rk Angle Sensor is used to cut-off the current supply from lgnition Control Reloy to PGM-FI system to shut down the engine
: :-":- cn incose the motorcycle turns over or{qlls down. BonkAngle Sensor cuts 'OFF'the supply ot on ongle of 42.5o .

-]ON CONTROL RELAY KEROSENE

-.,. BANK ANGLE SENSOR

sIN K ANGLE SENSOR/IGN ITION CONTROL RETAY OPERATION

--: :onk ongle sensor consists o{ o lotch circuit, o reed switch, o pivoted weight {rom the center wiih mognets ot both ends
* -:.sed in kerosene which is used to domp ony vibrotion from the motorcycle or the rood, becouse kerosene olso hos o high
^g point ond it is notvolotile so it con sustoin the exireme ombienttemperoture.
eciricol current{rom the lgnition switch when turned to "On" position, posses {rom the "Lotch Circuit" to the tronsistor bose, this
CN" the tronsistor. The tronsistor gives o ground to lgniiion conirol reloy which builds o mognetic {ield, closing the contoct
: : --s o{ the switch in the lgnition Control Reloy. The eleciricol current supply then posses {rom the ignition control reloy to PGM-Fl
:--- os shown in fig (A).
-::sethemotorcycleturnsoveror{ollsdownthemognetsoneithersideofthepivotedweightinthebonkonglesensorpullsdown
*e ':ed switch. This cuts off the electricol current supply to the tronsistor bose turning it "OFF". This results in breoking the circuii o{
; - - on Control Reloy which leods to turning "OFF " of ihe mognetic field ond opening the contoct points.
--= : eciricol supply to PGM-FI system is shut down which turns the engine "OFF" os show.n in fig (B).
--= -'cnsistor remoins "OFF" even qfterthe motorcycle is bockto its normol position (porollel to the floor) becouse ihe "Lotch Circuit"
: ' ::'pulled. The "Lotch Circuii" will be releosed only when the ignition switch turned to "OFF" position.

(A) CLOSED CTRCUTT (B) OPEN CTRCUTT

IGNITION SWITCH PGM-FI SYSTEM

i::l SWITCH OPEN REED SWITCH CLOSED

ETECTRONIC CONTROL SYSTEM

SENSOR
The word "Sensor" in generol meons on equipmeni used to detect the physicol number or quontity such os pressure/ iemperotue
ongle, speed etc. Sometimes, these equipments ore olso used lo deteci scientific dotq such os ion, gos etc. The mentioned doio
the trqnsformedtoelectricolsignolinordertobeusedproperlyforthenextoperotion.

The PGM-FI system hos odopted this concept for meosuring the oir ond engine oil temperoture, throttle opening ond moni{o
pressure. The resistor A is designed to hove o stoble resistonce volue while B is designed to hqve vorioble resistonce vol
depending on the chonge in the ombient condition. And the chonge in the volioge generoted to both ends of B is considered c
electricol signol.
5 Volis

Cro nk Position Sensor (GPS)

The Cronk Position Sensor gives the importont signol to the ECU to delermine the ignition timing ond rpm. lt is olso used io colcul
the pre determined fuel iniection volume ond fuel cut-off.
This signol is used to judge if the engine is being cronked so thoi ihe ECU con operote the fuel pump permonenily.
When the Rott on the flywheel posses the Cronk Posiiion Sensor it creotes o positive pulse (+) ond negotive pulse (-) signol which
sent to the ECU.
The ECU uses this signol forthe following {unctions :

. Colculote the fuel iniection timing.

. Colculote the in jection volume bosed on ihe signol from Throttle Posiiion Sensor (TPS) {or the ihrottle volve opening ongle o
Monifold Absolute Pressure Sensor (MAP) foroir pressure in the intoke monifold.
The Cronk Position Sensor is instolled on the left crqnkcose cover ond the Rotts ore on the {lywheel.

SITION SENSOR FLYWHEEL

CRANK N SENS
 ETECTRON IC CONTROT SYSTEM

.THROTTLE POSTTTON SENSOR (TPS)

-- -:Jle Position Sensor (TPS) is locoted in the sensor unit ot the end of the throttle shoft o{ throttle volve, it directly detects the throitle
, :e^ing. The ihrottle shofi ond ihe sensor ore connected vio o spring which meosures the opening ongle of throttle volve. The ECU
is
::-ec.rs the chonge in position of th roitle vo lve by detecting the chonge in signol voltoge from TP sensor.
--: -CU colculotes the volume of {uel to be inlecied using the signol{rom TP sensor ond the engine RPM.
id
JE
ECU
IN

TP SENSOR

-- -:*le Position Sensor (TPS) is on integroted port of the Sensor Unil which is locoted on the Throttle Body

THROTTLE BODY SENSO UNIT

hls

rnd

THROTTLE SHAFT
)R
il
r|

I ETECTRONIC CONTROT SYSTEM

tr/tANlFOID ABSOLUTE PRESSURE SENSOR (MAP)

Monifold Absolute Pressure Sensor (MAP) meosures lhe oir pressure in the intoke monifold. The MAP sensor meosures this c r
pressure by detecting the vocuum in the lntoke Monifold. Moreover, it is olso used to meosure the position of the piston by deteciir'g
negolive pressure in the lntoke Moni{old.
MAP sensor meosures the oir pressure in the lntqke Moni{old by detecting the chonge in resistonce of the semi-conductor, ther ri'

trons{orms this dotq lo qn electricol signol ond sends ii os on input to the ECU.

The ECU colculotes the volume o{{uelto be iniected using the signol{rom MAP sensorqnd the engine RPM.

':lI
rI
ril
l!
li

Moni{old Absolute Pressure Sensor (MAP) is on integroted port of the Sensor Unit which is locoted on ihe Throttle Body

u+
OI
lt
ol

LOW <--------------) HIGH

O-RING MAP SENSOR

 ETECTRONIC CONTROT SYSTEM

s$GtNE Ott TEilIPERATURE SENSOR (EOT)

-'* l-; ^e Oil Temperoture Sensor is used to meqsu_re the engine oil temperoture.
q -:e-:-- re by meosu ring the
lt detects the chonge o{ the engine oil
chonge in the resisto nce o{ the thermistor, then it tro nsforms this doto io on
' ::: t- -cUitothe ECU electricol signol ond sends
-
": : I ' :olcu loies the volume o{ fuel to be iniected using ihe signol from EOT sensor
os the engine temperoture chonges, which
J is
't- :-seriiol during "Cold Siorting" ond olso during "Engine Worm_up" period.
ECU

--::-aine Oil Temperoture

*i -:-,rn possoge of engineSensor is locoted in the cylinder, in
oil io sense the engine operoiing
**::'gture.

ENGINE OIL TEMPERATURE SENSOR

.' 25
-lz
UJ
UZU
z
s15
rt-)

frr0
e.

20 40 60 80 too 120
TEMPERATURE OC
ELECTRONIC CONTROT SYSTEM

INTAKE AtR TEI PERATURE SENSOR (rAT)

The lnioke Air Temperoture Sensor is used to detect the oir temperoture in the intqke monifold. The sensor deiecis the chonge in
temperoture in the intoke moni{old by meosuring the chonge of the resistonce of the thermistor, then it tronsforms this doto to
electricolsignolond sends itos on inputtothe ECU.
When the temperoture of the intoke oirfolls, the oir becomes denser. Therefore, even ihrough there is no chonge in the volume,
oir is heovier so oir-fuel rotio will increose. conversely, os the oirtemperoiure rises, the oir exponds so olthough the volume is r
some, the oir becomes lighter in weighl ond qir-fuel rotio decreoses.
The ECU colculotes the volume of fuel to be iniected using the signol from IAT sensor bosed on chonge in temperoture of oir in r
intoke moni{old.
The thermistor resistonce will increose when the iemperoture drops. Even o smoll chonge in temperoture will be detected by r
thermistor.

Intoke Air temperoture Sensor (lAT) is on integroted porf of the

Sensor Unit which is locoted on the Throftle Body..

INTAKE AIR TEMPERATUR SENSOR

30
\
A
I \
't5
LIJ
U
220
(/)
\
15
U)
LIJ
\
dlo \
\
20 40 60 B0 r00 r20
TEMPERATURE
 ELECTRON IC CONTROT SYSTEM

FU rLY TRANSTSTORTSED tGN ITION SYSTEM (FTt)

- I petrol engine, the combustion of qir/fuel mixture is initioted by on electricol spork. Accuroie ond relioble ignition is essentiol for
::r:mum performonce ond minimol emission.
-e spork, needed io igniie the oir /fuel mixture in the combustion chomber, is generoted by opplying o high voltoge to the
: :Jrodes of o spork plug. The voltoge required to generote o suitoble spork depends on the compression rotio of ihe engine, the
:-: rty, rotio o{the oir/fuel mixture ond lhe spork plug construction.
- -ero Hondo two wheelers the CDI igniiion systems wos being used till now. With the introduction PGM-Fl system we hove
:::cied the lotesttechnology in the ignition system i.e. FullyTronsistorised lgnition System.
::' :omplete combustion o{ oir-fuel mixture o longer durqiion of spork is required which enhonces the fuel efficiency ond lowers
:r-:,rst emissions. As compored to CDI ignition which hos o shori spork durotion, tronsistorised igniiion system provides o longer
:,:,:'< durotion which improves combustion ond reduces exhoust emissions.
-:- ytronsisiorisedignitionsystem,thelronsistorconbecomporedwithonelectricolreloywhichusessmoll currenttostoporstort
l-::ow of o lorger current. Like the reloy the trqnsistor hos three terminols, two o{ which corry the moin current with the third
:': ''Cing o "triggering" oction.
--= emiiter ond collector of the tronsistor ore in series with the primory winding of the high tension coil. The bose corries only o very
:-: currenl obout 1 omp.

@FERATION
,-:" the ignition switch is turn io "ON" position, ihe current flows to the primory winding of ignition coil ond then gets ground
* :, "
gh the tronsislor of the igniiion circuit in ECU.

-er the engine is cronked the voltoge signol from Cronk Posiiion Sensor is sent io the pulse inlet circuit which {urther sends o
"'
::-: tothelogiccircuit.Thelogiccircuitcqlculqtestheigniiiontimingondcutsoffthebosecurrenttothetronsistorbreokingthe
: ":, r o{ primory winding of ignition coil. This induces high voltoge in the secondory winding which is sent to lhe spork plug.

PRIMARY CURRENT
LOGIC CIRCUIT BASE CURRENT

I FLWVHEEL
il BATTFRY
T
+
:t:
I
t

i
CRANK POSITION PULSE INLET CIRCUIT
SENSOR SECONDARY
CURRENT
 REATTTME MTLEAGE tND|CATOR (RTM|)

REAL Tln E MTTEAGE |ND|CATOR (RTMI)

RTMI is o unique {eoture which hos been provided in Glomour PGM-FI. li indicotes the riderwith o reoltime mileoge on o digitol
-CD in km/lwhile riding the motorcycle.
RTMI colculotes ond disploys the mileoge bosed on the input signol received from Speed Sensor for the distonce troveled ond ECU
:cr the iniecied fuel volume of
o specific durotion of time.
-'re RTMI hos been progrommed to disploy the mileoge when speed of the motorcycle is equol to or more thon 5 km/hr ond wiih o
:cto of the post 20 seconds, therefore the first indicotion will be disployed ofter 20 seconds.
-:e next ond the subsequent disploys will be refreshed ofter every l0 seconds with q doto o{ the post 20 sec, which meons every
:dicotion will hove o doto of current I 0 seconds ond I O seconds of previous doto. The {ollowing illustrotion given below shows the
::t-tern in which RTMI indicotes the mileoge.

ECU
@ffi
REAI TIME MITEAGE
INDICATOR
SPEED SENSOR
affi
I I

l0seconds ll0r"conds l0seconds I lOseconds

5 km/hr

No lndicotion lndicotion

*-: ,ndicotion given by RTMI when ignition swiich is turned to "ON" will be 188.8 " for o few seconds ond then disploy shows
_ " thot is no volue.
-"e rider storts to ride, the indicotion on the disploy will be shown ond refreshed ofter every 1O seconds.
-:

..,] DISPLAY
DURING IGNITION "ON" RTMI

RTMI DISPIAY AFTER 2 SECONDS IGNITION "ON"

 PGM-FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI SYSTEM DIAGRAM IO TURN SIGNAL LIGHT

BRAKE LIGHI HORN
(2)

(3)

lgnition switch (12) lgnition Coil

Moin fuse (Kick Storf : I 5 A, Self Stort : 20 A) (.l3) lntoke oir temperoture sensor (lAT sensor)
Sub fuse (1 0 A) (.l4) Throttle position sensor (TP sensor)
Bottery (.l5) Monifold obsolute pressure sensor (MAP sensor)
: Regu lotor/Rectifier (l 6) lniector
Fuel meter (17) Spork plus
PGM-Fllndicotor (l B) Neutrol position switch
Neutrol position indicotor (l 9) lgnition pulse generqtor
Bonk ongle sensor (20) Engine oil temperoture sensor (EOT sensor)
0) Doto Link Connector (DLC) (21) Alternote current generotor (ACG )
l) Fuel pump
PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI SYSTEM MATFU NCTION DIAGNOSIS

PGM-FI INDICATOR DATA LINK CONNECTOR DtC SHORT CONNECTC

PGM-Fllndicotor
The PGM-FI indicotor is o port o{ the molfunction diognostic system which helps in diognosis of o porticulor molfunction
system.
When the ignition switch is turned to "ON" the PGM-Fl indicqtor will illuminqte {or few seconds ond then it will go "OFF". l{ there
ony obnormolity then the PGM-Fl indicotorwill stort blinking.
l{ the PGM-Fl indicotor "BLINKS" or remoins "ON" other thon while the lgnition switch is turned to "ON" position, this indicotes
mol{unction reloted to the PGM-Fl system like o short or on open circuit.
ln cose ony molfunction occurswhile riding the motorcyclethe indicotorwill remoin "ON" continuouslyond the blink pottern w
only resume when either ihe engine RPM is lowerthon 2000 or if the ignition switch is in "ON" position.
The ECU records the molfunction {ound in {orm of o defect code in its memory. This molfunction code is stored In the ECU's mem
even when ihere is no electricol supply to it ond will remoin unchonged until the some is deleted using the molfunction code erosi
proced u re.
The PGM-Fl system is composed of the fqil-sofe function so thoi the engine cqn continuously work efficiently despite ony probl
within ihe sysiem using ihe dqto reserved in odvonce by the progrom. However, the engine will not run i{ ony problem occurs ot l
Fuel I n jector or Cro nk Position Sensor.
To reod mol{unction codes from the ECU's memory o Doto Link Connector (DLC) hos been provided in the wiring horness.
shorting DLC with o speciol connector (DLC Short Connector) the ECU indicotes the molfunction code with PGM-Fl indicotor bli
from 0 to l2 times. The blinking is clossified in two types, long blinking (up to l .3 seconds) ond short blinking (0.3 second). Eoc
long blink indicotes "I O" eoch short blink indicotes ".l". As the ECU stores the doto o{ vorious defect codes, the PGM-Fl indic
will show these molfunction codes olwoys in on oscending order. The {ollowing poges will help us to diognosis ond correct
molfunction relqted to PGM-Fl sysiem.
PGM-FI INDICATOR

0.3 3.0
rroNrr
--| t-
Molfunction code 7
,'OFF''

rroNrr &
@ 'l'3,
<______r

Molfunction code l2
"OFF"
T
\J
---l
ii
i<--
0.5
 PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI MALFUNCTION
DIAGNOSTIC PROCEDURE
: ::e the motorcycle on its mo insto nd.
.
-.)TE:
en the ignition switch is iurned "ON" the PGM-Fl indiccitor
.
luminote forfew seconds ond then itwill go'OFF". l{there
: ^,i o bnormo lity then the PGM-Fl indicotor will blin k.
-- -^ ihe ignition switch to 'ON".

-: PGM-Fl indicoior blinks, note the no. o{ blinks o{ PGM-Fl

- : :oiorond deierminethe cquse of the problem.
PGM-FI INDICATOR
-: PGM-Fl indicotordoes not blink, the system is normol.
DATA LINK CONNECTOR
- ,:.r wish to reod the PGM - Fl memory for molfunction doto,
::-orm thefollowing:

fu{ALFUNCTION CODE READING PROCEDURE

-- -- the ignition switch to "OFF'.
::-ove the left side cover.

- ::cnnect the connector cover from ihe doto link connector

_ _:)

CONNECTOR COVER

-:^rect the speciol instrument to the doto link connector

_ _:)

INSTRUMENT:
DLC shorl conneclor: 070 HH KTRF OOf

DLC SHORT CONNECTOR

-- ''r the ignition switch to "ON".
j -ne
ECU hos no molfunciion doto, in the memory, PGM-Fl
- jicotorwill illuminote continuously.

.: ba_ lGNlTloN swlTCH TO "ON"

--------1,/ &a
gtr
w i

PGM-FI
ON
,'OFF" I

-
PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

l{the ECU hos ony Mol{unction doto in iis memory the PGM-FI
indicotor will stor"t blinking when you turn the ignition switch to
,,oNu.

Note the number of PGM-FI indicotor blinks ond determine

the cquse of the problem.

MATFUNCTION CODE ERASING PROCEDURE

DATA LINK CONNECTOR
NOTE:

The molfunciion doto connot be erosed from the memory if you

disconnecithe bottery negoiive coble.
.l Turn the ignition switch to "OFF"..

2. Remove the left side cover.

Disconnect the connector cover {rom the doto link
connector (DLC).

DLC CONNECTOR CC
3. Connect the speciol instrument to the dotq link connector
(DLC).

INSTRUMENT:
DLG shofi conneclor: 070 HH KTRF OOI

DLC SHORT CONNEC-

4. Turn the igniiion switch to "ON".

5. Disconnect the DLC shorl connector {rom the doto link
connector (DLC).
6. Re-connect the DLC short connector to the doto link
connector (DLC) within 5 seconds while the PGM-FI
indicotor lomp illuminotes.

DLC SHORT CONNECTOR DLC SHORT CONNEC_

 PGTI,I. F I N,IAIFU N CTI O N D IAG N OSTI C PROCE D U RE

SUCCESSFUT PATTERN
The mol{unciion doto is erosed from the ECU memory i{ the
PGM-Fl indicotorturns I'OFF" {or oboul 2-3 seconds ond storts
clinking continuously os shown below (successful pottern).

\______Y____,

FAILURE PATTERN RESET RECEIVING PATTERN SUCCESSFUL PATTERN

UNSUCCESSFUT PATTERN
jthe
DLC short connector is not reconnected within 5 seconds,
.re PGM-FI indicotor turns "OFF" {or obout 2-3 seconds ond
-en it will illuminote continuously os shown below
r "rsuccessf u I pottern).

within 5 sec. 2-3 sec

roNil
PGM.FI
"oFF" ----------
\-___-______-__ __,
FAILURE PATTERN RESET RECEIVI NG PATTERN SUCCESSFUL PATTERN

t
re molfunction dqto in ECU memory is nol erosed then turn
-e ignition switch "OFF" ond try ogoin from step-3.

. 1TC.

'*ote thoi the mollunction doto connot be erosed from the

*emory if you turn "OFF" the ignition switch before the PGM-
: indicotor storts blinking.
 PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM.FI MATFUNCTION CODE INDEX

The PGM-Fl indicotor denotes the foilure codes (the number of blinks from 0 to 1 2). The pGM-Fl indicotor
hos two types of blinks,
long blink ond o shori blink. The long blink losts for 1 .3 seconds, the short blinks iosts for 0.3 seconds.
When one'long blink or
two short blinks occur, the problem code is 12 (one long blink :
I O blinks, two shori blink :
2 blinks). Then go to th" f,"lo* gi*
code i ndex o nd refer the fol lowi ng poges for detoils.
When the Electronic Control Unit (ECU) stores more thon foilure codes, ihe PGM-FI indicotor shows the {oilure
codes in the ord
from the lowest number to highesi number. For exomple, when the PGM-Fl indicoior blinks once, then blinks seven times,
trr
foilure hove occurred. Follow the code indexforfoilure codes I ondT .
Given belowisihe PGM-Flindicotorcode index. Refertothe{ollowing poges{ordetoils.

PG'I,I.FI Delection ltem Cquses Symploms Refer lr

No blinks lgniiion pulse Generotor . Foulty ignition pulse generotor. Engine does not stort
Molfunction
No blinks lniector molfunction . Clogged iniector filier. Engine does not stort
. Sticking iniector needle.
No blinks ECU molfunction . Foulty ECU Engine does not sior.t
No bhnks ECU power/ground . Blown moin-fuse (15 A) Engine does noi storl
circuit Molfunction . Open circuit ot ihe power input wire of the ECU. 41
. Foulty ignifion switch
No blinks PGM-Fl circuit . Fouliy ECU Mol{unction. Engine operotes
. Open or shod circuit in PGM-FI lndicolor wire normolly
Conlinuous Doto link or PGM-FI . Short circuii in doto link connector. Engine operotes
illuminotion circuit molfunction (DLC)wire. normolly
. Short circuit in PGM-Fl lndicotor wire.
. Foulty ECU.
No Blinks Sensor unit power circuit . Short circuit in sensor unil power wire Engine does not stort 43
Molfunction . Foulty sensor unit.
l,8oll Sensor unit power circuit . Open circuit in sensor unit power wire Engine does not slort 43
Blinks Molfunction r Loose or poor contocl on sensor connector.
1,8,9 oll Sensor unit ground . Loose or poor coniqct on sensor conneclor. Engine does not slort
Blinks circuit Molfunction . Open or short circuit in sensor unit ground wire.
43
. Foulty sensor unit.
I Blink MAP sensor . Loose or poor contoct on sensor Engine operotes
circuit molfunction unit connector. normolly 45
. Open or short circuii in MAP
sensor wire of the sensor unit.
't,, , ;. p-' t i
7 Blinks EOT sensor Loor" or poor contoct on EOT
..\-_-_**,-
circuit moltunction
Hord siort ot o low
sensor connector. temperoture 46
. Open or shod circuit in EOT sensor wire.
. Foul! EOT sensor.
B Blinks TP sensor circuil . Loose or poor contoct on sensor unit connector. Poor engine response
molfunction . Open or short circuit in TP sensor wire of the ond performonce 49
sensor unit. when operoting
. Foulty TP sensor. the throttle quickly.
9 Blinks IAT sensor circuit . Loose or poor contoct on sensor unit connector. Engine operotes
mol{unction . Open or short circuii in IAT sensor wire of the normolly. 50
sensor unit.
. Foulty IAT sensor.
l2 Blinks I niector circuit mo l{unction . Loose or poor contqct on in jector connector. Engine does not siort.
. Open or short circuit in iniector wire
5t
i . Foulty iniector.

@
tAi
 PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

ELECTRONTC CONTROL UNIT (ECU) - INPUTS AND OUTPUTS

@@@@@@@@@@@
@@@@@@@@@@@
@@@@@@@@@@@
ECU PIN COTOUR CODE
PIN NO. COLOUR DESCRIPTION Block B

I R/B ECU Power Yellow Y

2 G Loqic Ground Blue L
None
Green G
4 G/O Sensor Grou nd
t Red R
IG/B Throttle Position Sensor lnout
VCC Output (For Sensod White
6 Y/R
7 None Brown BR

8 BR/W Fuel Pump Driver Oronge U

I G Ground Sky Blue SB
0 G Ground Liqht Green LG
I P/L lqnition Pulse Driver Pink P
2 LN Cronk Sensor lnpul
Groy GR
J None
4 GR/L I ntoke Air Temperotu re I npul
COMBINATION:
5 L/R Service Check Sionol lnput
Bose Colour / Morking Colour
6 P/G lniector Driver
e.g. Brown / White
7 None
BR/W
B Wornino Liqht Outout
9 GR/B Fuel Counter Outpul
20 None
21 None
22 None
23 Pulse Ground
24 Y/L Engine Oil Temperoiure Sensor lnput
25 None
26 None
27 LGN Monifold Absolute Pressure lnpui
28 None
29 G/R Neutrol Switch lnput
30 Y/B Communicotion K - Line
3r None
32 None
None
 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

ECU POWER/GROUND INSPECTION

. This vehicle hos two types of power supply to operote the ECU'
l{ the bottery is in proper-working condition, it is used os the first power supply'
lf the bottery is not in proper-worklig condition,the olternotorvoltoge
generoted bythe kickstorter is used osthesecond powersupply'
. lf the does not stort wit[ the kickstorter, inspect the ECU POWER/GROUND {irst, then inspeci the oliernotor
o
"ngin"
regulotor/recti{ier os the secondory power supply
. B"jor"inspectingtheECUPOWER/GROUNDlNSPECT|ON,besuretochorgeorreploce withochorgedbottery.

ENGINEDoEsNoTSTART(PGM.FIINDICAToRDoESNoTBLINK)
I. Turn ignition switch "OFF".
2. Disconnecl the ECU 33P connector. Check {or loose or
poor connection on the ECU 33P connector'

ECU 33P CONNECTOR

Connect ECU 33P Connector. Stqd the engine. lf the

engine storts there hos been o loose or poorcontoct on the
ECU 33P Connector.

ECU 33P CONNECTOR

4. lf the engine does not stort then turn ignition swiich to

,,OFF".

5. Disconneci the ECU 33P Connector. Check {or the oooooooo

continuity between ECU 33P connector o{ the wire horness
oooooooo
i
side ond ground.

GONNE€TION:
oooooooo
Green (ECU Pin-2) - Ground
I
I Green (ECU Pin-9) - Ground
Green (ECU Pin-l0) - Ground
STANDARD: Gontinuity
lf there is no continuity, check the Green wire {or open circuit'
 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

6. Turn the ignition switch to "ON" ond meosure the bottery

voltoge between the ECU 33P connector of ihe wire
horness side ond ground.

CONNECTION:
Red-Blqck (ECU Pin-l ) - Ground (-)
STANDARD: BotleryVoltoge - l.l Vminimum
lf the bottery volioge is out o{ ronge checkforthe following.
. Loose or poorconneclorcontoct
. lnspectthe ignition switch.
a Blown moin-fuse (Kick Stort : 1 5A, Self Stort : 20 A) ECU 33P CONNECTOR
a
Open or short circuit in following wire horness:
- Red wire or RedAellow wlre belween the botfery ond
ignition switch
- Red/Block wire between the ignition control reloy switch
ond ECU.
. Red/Blue wire between ignition switch ond ignition
control reloy.
l{ volioge exists then reploce the ECU with o new one ond
inspecl it ogoin.
 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE
lr
I
SENSOR UNIT POWER/GROUND
h.
; CIRCUIT INSPECTION
PGM-FI 1, 8 or 9 BIINKS (MAB TB IAT
SENSOR)

NOTE:
Before storting the inspeciion, recheck the PGM-FI indicotor
blinklng. lf the PGM-Fl indicotor does not blink, the sysiem is
normql.

1 Turn the ignition switch to "OFF". SENSOR UNIT 5P CON

2. Discon nect the sensor un it 5 P con nector.

t
3. Disconnect ECU 33P connector. Check for loose or poor
conioct on the sensor unit 5P connector ond ECU 33P
connector.

ECU 33P CONNECTOR

4. Connect the sensor unit 5P connector.

SENSOR UNIT 5P CON

Connect ECU 33P connector. Turn the ignition switch to

"ON". Checkthe PGM-Fl indicqtor blinks.
6. lfthere is no blink in PGM-Fl indicotorthen check{or loose
or poor contoci on the sensor unit 5P connector ond /or
ECU 33P connector.

7. l{there is 1,8,9 bllnks in PGM-Fl indicotorihen turn the

ignition switch to OFF.

ECU 33P CONNECTOR

 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

B. Disconnectthe sensor unit 5P connector.

9. Turn the ignition switch to ON.
r0 Meosure the voltoge between the sensor unit 5P connector
terminols otthe wire horness side.
CONNECTION:
Yel loVRedGreen/Oronge(-)
( + )-
STANDARD 24.75 - 5.25V

I i . lf voltoge exists then reploce ihe sensor unit wiih o new one
ond inspect ogoin.

SENSOR UNIT 5P CONNECTOR

I 2. lf voitoge is out o{ ronge then disconnect the ECU 33P

connector ond check {or continuity beiween the ECU 33P
connector ond sensor unit 5P connector of wire horness
side.
CONNECTION: ooooooooooo
YelloVRed (Pin 6, ECU) -YelloVRed
ooooooooooo
ooooooooooo
Green/Orqnge (Pin 4, ECU) - Green/Oronge
STANDARD: Conlinuity

ECU 33P CONNECTOR

SENSOR UNIT 5P CONNECTOR
L,._-.-'-'

CONNECTION:
YelloVRed - Ground
STANDARD : No Continuity

LJ lf there is ony obnormolity, this con be due to :

. Open circuit in Yellow/Red or Green/Oronge wire.

. Shod circuit in Yellow/Red wir-e.

l4 l{ oii obove connections ore normcl ihen repicrce the ECU

with o new one ond inspect cgcin.
F;'

*r,
PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

PGM- FI TROU BTESHOOTI NG

PGM-F| r BLINK (MAP SENSOR)

NOTE:
Before siorling the inspeciion, recheck the PGM-FI indicotor
blinking. lf the PGM-Fl indicotor does not blink, the system is
normol.

1. Turn the ignition switch to "OFF".

2. Erose the molfunction code {rom ECU memory. Turn the
ignition switch to "ON".
l:
i

i
3. Checkthe PGM-Fl indicotorblinks.
4. lf there ore 1, B ond 9 blinks go to SENSOR UNIT
POWER/GROUND CIRCUIT INSPECTION.
5. lf there is I blinkthen turn the ignition switch to "OFF".
6 Disconnectthe sensor unit 5P connector.
7. the ignition switch to "ON" ond meosure the voltoge
T.urn
between the sensor unit 5P connector of wire hqrness side
ond ground.
CONNECTION:
LightgreenA'/ellow(+) - Ground (-)
STANDARD: 3.8 - 5.25V

B. lf volioge exists then reploce the sensor unit with o new one
UNIT 5P CONNECTOR
ond inspect ogoin (foulty MAP sensor).
9. lf volioge is out of ronge then turn the igniiion switch to
"oFF".
I 0. Disconnectthe ECU 33P connector.
I I . Check for continuity between the ECU 33P connector ond
sensor unit 5P connector of the wire horness side ond ooooooooooo
ground. o o oooo ooooo
Check for no continuity between the sensor unit 5P ooooooooooo
connecior of ihe wire horness side ond g round.
GONNECTION:
lighr greenffellow (ECU Pin - 2tl - Lighr
green/Yellow
STANDARD: Continuity
ECU 33P CONNECTOR
€ONNEGTION:
Light green/fellow - Ground
STANDARD : No continuity

I 2. lf there is ony obnormolity, this con be due to :

. Open circuit in Yellow/Red or Green/Oronge wire.
. Short circuit in Yellow/Red wire
13. lf oll obove connections ore normol then reploce the ECU
wiih o new one ond inspect ogoin.
 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE
EOT SENSOR 2P CONNECTOR

PGM-FI 7 BTTNKS (EOT SENSOR)

NOTE:
Before storting the inspection, recheck the PGM-FI indicotor
blinklng. lf the PGM-Fl indicotor does not blink, the system is
normol.

Turn the igniiion switch to "OFF".

2. Disconnectthe EOTsensor2P connector.

3. Check for loose or poor contoci on the EOT sensor 2P
connector.

EOT SENSOR 2P CONNECTOR

4. Connect the EOT sensor 2P connector ond turn ihe

ignition switch to "ON". Check the PGM-Fl indicotor
blinks.
5. l{ there is no blink in the PGM-Fl indicotor then check for
loose or poorcontoct in ihe EOT sensor2P connector.
lf there ore 7 blinks in the PGM-Fl indicotor then iurn the
ignition switch to "OFF".

EOT SENSOR 2P CONNECTOR

7 . Disconnect the EOT sensor 2P connector ond meosure the

resistonce of the EOT sensorterminols.
STANDARD :2.5- 2.8 kc) (20"C/68oF)
l{there is ony obnormolity then inspect the EOT sensor.
r
t PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE
EOT SENSOR
EOT (ENGTNE OtL TEMPERATURE) SENSOR
REMOVAL

B. Disconnect the EOT sensor 2P connector from the sensor.

Remove the EOT sensor ond seoling wosher.

NOTE:

INSPECTION EOT SENSOR 2P CONNECTOR

NOTE:
Keep oll ilommoble moieriols owoy from the electric heoting
element.
9. Suspend the EOT sensor in o pon of pure coolont ond
distilled woter (50-50 mixture) on on electric heoting
element ond meosure the resisionce ot the EOT sensor
terminols os the coolont heots up.
NOTE:
. Sook the EOT sensor in cooloni up io its threods with ot
leost 40 mm (1 .57 in) from the bottom of the pon to the
botfom of the sensor.
. Keep the iemperoture constont for 3 minutes before
testing. A sudden chonge of temperoture will result in
incorrect reoding. Do not let the thermometer or EOT
sensoriouch the pon.

' Meosure the resistonce ot the EOT sensor ierminols os

shown.

TEMPERATURE 20"c (68"F) 100"c (212F)

RESISTANCE 2.5 -2.BkO 0.21 -0.22ko

.l0.
lf ihe resistonce is out of specificotion ot ony temperoture
listed, reploce the EOT sensor.

INSTATTATION EOT SENSOR

NOTE:
SEALING WASHER EOT SENSOR

Alwoys reploce o seoling wqsherwith o new one

I 1 lnsioll the new seoling wosher qnd EOT sensor. Tighten the
EOT sensorto the speci{ied torque.

TORQUE:1.8kg-m
Conned the EOT sensor 2P connecior.

EOI SENSOR 2P CONNECTOR

 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

12. l{ the resistonce is normol then check for continuity

between the EOT sensorterminol ond ground.

STANDARD : No continuity
there is ony obnormolity it meons foulty EOT sensor. Reploce
l{
EOT sensor ond inspect ogoin.

EOT SENSOR
-l3. EOT SENSOR 2P CONNECTOR
l{ oll obove connections ore normol then meosure the
voltoge between the EOT sensor connector qt the wire
horness side.

CONNECTION : YelloVBlue - Green/Orqnge

STANDARD 24.75 - 5.25V
14. l{voltogeisoutof ronge.Thiscon bedueto :'i) : "
. Open circuit in Green/Oronge wire. - :..1r i
O
i
. LooseorpoorcontociontheECUconnector.
I 5. l{ voltoge exist then turn ihe ignition swiich to "95t".

EOT SENSOR 2P CONNECTOR

I 6. Disconnect the ECU 33P connector ond check for
continuity between the ECU 33P connector ond EOT
sensor 2P connecior of ihe wire horness side.
Check for no continuity beiween the EOT sensor 2P
connectoroithe wire horness side ond ground.

CONNECTION:
Green /Oronge (E€U Pin-4) - Green/Oronge
STANDARD: Continuily

CONNE€TION: ECU 33P CONNECTOR

YelloVBlue (ECU Pin-241 - YelloVBlue EOT SENSOR 2P CONNECTOR
STANDARD: Continuity
CONNEGTION:
Green/Orqnge - Ground
YelloVBlue - Ground
STANDARD : No continuity
I 7. lf there is ony obnormolity, the following con be due to :

. OpenorshortcircuitinYellow/Bluewire.
. OpenorshortcircuitinGreen/Orongewire
li oll obove connections ore normol then reploce the ECU with
o new one ond inspect ogoin.
ECU 33P CONNECTOR

\{
 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE

PGM-FI 8 BTTNKS (TP SENSOR)

NOTE:
Before siorting the inspeciion, recheck the PGM-FI indicotor
blinking. lf the PGM-Fl indicotor does not blink, the system is
normol.

I . Turn the igniiion switch to "OFF".

2. Erose the mol{unction code from memory.

Turn the ignilion switch to "ON". Check ihe PGM-FI
I indicotor blinks.

lf there ore 1,8,9 or oll blinks then go to SENSOR UNIT SENSOR UNIT 5P CONNECT
POWER/GROUN D CI RCU IT I NSPECTION.

3. lf there ore B blinks then turn ihe ignition switch io

"oFF".
4. Disconnect the sensor unit 5P connector. Turn the ignition
switch to "ON". Meosure the voltoge between the sensor
unit 5 P connector ot the wire horness side ond g round.

CONNECTION:Yellow/Red (+) - Ground (-)

STANDARDz4.75 - 5.25V

lf voltoge exist then reploce ihe sensor unit with o new one
ond inspect ogoin (Foulty TP sensor). lf voltoge is out o{ SENSOR UNtT 5P CONNECTOR
ronge then turn the ignition switch to "OFF".

6. Disconnect the ECU 33P connector. Check for continuity

between the ECU 33P connector ond sensor unit 5P
connecior of the wire horness side.
Check {or no continuity between lhe sensor unit 5P
connectorotthe wire horness side ond ground.

CONNECTION : Light Green/Block (ECU ptN-s)-

Lighr Green/Blqck
STANDARD: Continuity

ECU 33P CONNECTOR

SENSOR UNIT 5P CONNECIOR
CONNECTION : lighr Green/Block - Ground
STANDARD : No continuity
lf there is ony obnormolity then this con be due to :
a
. Open circuii in Light Green wire
F.
l
. Short circuit in Light Green wire
lf oll obove connections ore normol ihen reploce the ECU
with o new one ond inspect ogoin.
 PGM-FI MATFUNCTION DIAGNOSTIC PROCEDURE

PGM-FI 9 BUNKS (tAT SENSOR)

NOTE:
Before storting the inspection, recheck the PGM-Fl indicotor
blinking. lf the PGM-Fl indicqtor does not blink, the system is
normol.
t. Turn the ignition switch to "OFF".
2. Erose the mqlfunction code {rom memory.
? Turn the ignition switch to "ON" check the PGM-FI
indicotor blinks.
lf there ore 1 ,8,9 or oll blinks then go to SENSOR UNIT
POWER/GROU ND CIRCUIT INSPECTION.
lf ihere ore 9 blinks then turn the ignition switch to'OFF".
SENSOR UNIT 5P CONNECTOR
Disconnect the sensor unii 5P connecior ond turn the
ignition switch to "oN".
Meosure the voltoge between the sensor unit 5P connector
oithe wire horness side ond ground.
CONNECTION : GroylBlue (+) - Ground (-)
STANDARD 24.75Y - 5.25V
6. lf voltoge exist then check for resistonce ot the ECU 33P
connector.

ECU 33P CONNECTOR

GONNECTION:
GraylBlue (ECU Pin-1 4)-Green/Oronge (E€U Pina)
STANDARD:2.3 kQ - 2.8 kO(20"C/68"t1
lf there is ony obnormolity then reploce ihe sensor unit with o
newone ond inspectogoin (Foulty lATsensor).
lf resisionce is normol then check for loose or poor conioct on
the sensor unit 5 P connectorond inspect ogoin.
l{ voltoge is out of ronge then turn the ignition switch to "OFF".
7. Disconnect the ECU 33P connector ond check for
continuity belween the ECU 33P connector qnd sensor
unit 5 P con nector ot the wire ho rness side.
Check for no continuity between the sensor unit 5P
connectorotthe wire hqrness side ond ground. SENSOR UNtT 5P CONNECTOR
CONNE€TION:
GroylBf ue (ECU Pin-r 4) - Grsy/ Blue
STANDARD: Continuiry
CONNECTION: Grqy/Blue - Ground
STANDARD : No continuify
l{there is ony obnormolity then the following con be due to :
. Open circuit in Groy/Blue wire.
. Short circuit in GroylBlue wire.
li oll obove connections ore normol ihen reploce the ECU with
o new one ond inspect ogoin.

ECU 33P CONNECTOR

 PGM-FI MATFUNCTION DIAGNOSTIC PROCEDURE
il
t
l'
INJECT 2P CONNECIOR
PGM-FI l2 BTTNKS (INJECTOR)
NOTE:
Be{ore storting the inspection, recheck the PGM-FI indicotor
blinking. lf the PGM-Fl indicotor does nol blink, the system is
normol.
I . Turn the ignition switch to "OFF".

i
!u

[l INJECTOR 2P CONNECTOR
;lil
i
i 2. Disconnect the sensor unit 2P connector ond check for
i
I
Ioose or poor contoci on the iniector 2P connector.
I
i
t
f
F

tr1

INJECTOR 2P CONNECTOR
J. Connect the jector 2P connector. Turn the ignition switch
in
to "ON". Check the PGM-Fl indicotor blinks.

4. lf there is no blink in the PGM-Fl indicotor then there hos

been loose or poor contoct on the iniector connector.

4 lf there ore 12 blinks in the PGM-Fl indicqtor ihen turn ihe

ignition swiich to "OFF".

IN]ECTOR 2P CONNECTOR
6. Disconnect the iniector 2P connector ond iurn the ignition
switch to "oN".
Meosure the boftery voltoge between the iniector
connecior of the wire ho rness side ond grou nd.

CONNECTION : Red/Blqck (+) - Ground (-)

STANDARD: Botteryvoltoge - I.l Vminimum
7. lf voltoge is out of ronge then check for open or short circuit
in red/ blockwire.
 PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE
2P CONNECTOR
B. lf voltoge exists ihen turn the ignition switch to "OFF".
Disconnect the ECU 33P connector ond check {or
continuity between the iniector connector ond ECU
connectorotthe wire horness side.
Check for no continuity between ihe iniector 2p connector
oi the wire horness side ond ground.
CONNECTION:
Pink/Green (ECU Pin-I6) - pink/Green
STANDARD: Continuify
CONNEGTION:
Pink/Green - Ground
STANDARD : No continuity.
ECU 33P CONNECTOR
lfthere is ony obnormolity ihen this co n be d ue to open or shorl
circuit in Pink,/Green wire.
9. lf oll obove connections ore normol then meosure the
resislonce of the in jectorterminols.

STANDARD : 10.3 - I l.3O (20oCl68"F)

lf resistonce is obnormol, this con be due to o {ouliy iniector.
Reploce the iniectorond inspect ogoin.
lf resistonce is normol then reploce the ECU with o new one
ond inspectogoin.

IN.JECTOR
 PGM.FI MALFUNCTION DIAGNOSTIC PROCEDURE
DATA LINK CONNECTOR

THROTTTE POSTilON (TP) SENSOR RESET

PROCEDURE
I. Turn the ignition switch to "OFF".
2. Disconnect the connector cover {rom the doto link
connector (DLC).

CONNECTOR C

3. Connectthe speciol instrumentto the Doto l-ink Connector

(DLC).

INSTRUMENT:
DLC shorl conneclor: 070 HH KTRF 001

DLC SHORT CONNECT

4. Disconneci the EOT sensor 2P connector.

5. Connectthe EOTsensorterminqlswitho iumperwire.

CONNECTION: Yellow/Blue - Green/Oronge

EOT SENSOR 2P CONNECTOR

6. Turn the igniiion switch to "ON" then disconnectthe iumper

wire from the EOT sensor 2P connector within I O seconds
whlle the PGM-Fl indicotor blinks slowly .

EOT SENSOR 2P CONNECTOR

 PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

7 . A{ter disconnecting the lumper wire, PGM-Fl indicotor

storts blinking foster indicoting o successful pottern (reset
receiving poitern shown below).

PGM-FI INDICATOR

SUCCESSFUL PATTERN

@]i..
i I
,"..
:
-''^',.
: i ;.n'
@: 0.3 sec.

0.3 sec.

ON
PGM-FI
OFF

RESET RECEIVING PATTERN SUCCESSFUL PATTERN

UNSUCCESSFUL PATTERN
lf the iumper wire is not disconnected wiihin 1O seconds, ihe
PGM-Fl indicoior will illuminote continuously (unsuccessful
poltern; see below). To resetogoin siodfrom step 4.

@7 Withtn l0 sec.

ON
PGM-FI
OFF

RESET RECEIVING PATTERN UNSUCCESSFUL PATTERN

I
F
;; PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE
j"

NOTE:
. When there is o Molfunction code stored in ECU memory
the PGM-Fl indicotor storts blinking indicoiing o
Mol{unction code.
. Be sure to erose the molfunction code from the ECU
memory doto ond repeot procedure from step 5.

ignition switch to "OFF".

B. Turn the
9. Connect the EOT sensor 2P connector.

EOT SENSOR 2P CONNECTOR

il ,]0.
Disconnect the DLC short connector from the doto link
connector (DLC).

INSTRUMENT:
DLG shorr conneclor: 070 HH KTRF 001

DLC SHORT CONNEC

DATA LINK CONNECTOR

I I . Connectthe connectorcoverlo dqto link connector (DLC)

CONNECTOR C
I 2. Plocethe motorcycle on iis moin stond. IDLE ADJUSTING SCREW
Shiftthe ironsmission to neuirol.
Worm up the engine for oboui ten minutes.
Connect q tqchometer.
Checkthe engine idle speed.

lDtE SPEED: I 500 + I 00 RPM

TACHOMETER. PET I IOO
l{the engine idle speed is out o{ specificotion, turn the idle
screw os required to obtoin the speci{ied idle speed.
NOTE:
While the vehicle is operoted ot higheroltilude it is odvisoble to
,l500
odiustthe idle rpm to + 100 rpm.
(A) TNCREASE rDLE RPM (B) DECREASE IDLE
 PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE

R CONNE
NOTE:
Check thqt the locotion of the iniector connector is between the
stopper of the i n iector ioi nt o nd ih rottle body.
lnstollthe inl".
lnsioll ond tighten ihe two injector joint mouniing bolts to the
specified lorque.

TORQUE:0.5 kg-m
lnstoll the throttle body/sensor unit.

THROTTLE BODY
BAS 3P CONNECTOR

BANKANGLE SENSOR
NOTE:
o sofety reloted control provided to minimize the
This is
domoge in cqse of on occident by shutting down qll engine
operotions.

REMOVAT
Remove the following:
- Remove seoi
- Remove right side cover.
Disconnect the bonk ong le sensor 3 P connector. BANK ANGLE
Remove the stoy BonkAngle Sensor mounting bolts. NORMAL POSITION TIPPED R POSITION
Remove BonkAngle Sensor mounting screw.

INSPECTION
Turn the ignition swiich "ON" ond storlthe engine.
Tilt the motorcycle to the right or left side in the ronge o{
42.54.
lf the engine stolls the working of Bonk Angle Sensor is normol.
NOTE:
To restort the engine bring the motorcycle to up-right p*ition.
Turn the igniiion switch to "OFF" ond then "ON"

WEIGHT WEIGHT

BANK ANGLE SENSOR

INSTATTATION
Instoll the Bonk Angle Sensor with its,,U p,' mork focing u p.
Tighten the screws on the stoy.
lnstoll the stoy Bonk Angle Sensor ond tighten the mounting
bolts.

lnstqllthe removed porls in the reverse orderof removol.

PGM.FI MATFUNCTION DIAGNOSTIC PROCEDURE
FUEL PUMP 5P CONNECTOR
FUEt METER/FU Et IEVEt SENSOR
FUEL METER INSPECTION

Turn the igniiion switch to 'ON" ond check for the {uel gouge
disploy.

NOTE:
1 segment- I .5 litres of petrol(opprox).
lf the fuel meter does not indicote properly, perform the
following:
Disconnectthe fuel pump 5P connector.
Turn the ignition switch 'ON" ond checkthe fuel meter.
l{the fuel meter indicotion is "Empty' , wire horness is normol. FUEL PUMP 5P CONNECTOR
l{ the fuel meter indicotion is "Full", check for short circuit in
Yellow/White wire.

Turn the ignition switch to "OFF'.

Ground the fuel pump 5P connector terminols with o iumper
wire.

CONNEGTION:
YelloVWhite - Green
FUEL
Turn the ignition switch "ON" ond checkthe iuel meter.
lf the fuel meter indicotion is "Full", wire horness is normol.
lf the {uel meter indicotion is 'Empty', check for open circuit in
Yellow/White wire ond green wire.
l{thewires ore normol, checkthefuel level sensor (see below).

FUEL

FUEL LEVET SENSOR INSPECTION

Remove the fuel pump.
Conneci the multimeter to ihe fuel level sensor ierminols o{ ihe
fuel pump 5P connector.
GONNE€TION:
From left pin (l ) ond (2).
lnspect the resistonce of the floot ot the top ond bottom
positions.

FUtL EMPTY

Resisto nce (20' C / 68" F) 5-7 A 204-21]fl.

l{the fuel level sensor is normol, reploce the meter ponel with o
new one, ond inspect ogoin. FUEL PUMP
 RTMI MATFUNCTION DIAGNOSTIC PROCEDURE

REAI T|ME MtTEAGE tNDtcAToR (RTM|)

RTMI INSPECTION
. I Turn the ignition switch to "ON,, .

2. Check ihe RTMI disploy which will be,,lEB.$,, for o {ew

seconds ond then disploy shows " . lf oll the
segments o{ lEE.8 " ore reodobt", tt* nfiVl disploy is
working.
3. Putthe moiorcycle on moin stond, storilhe engine, shiftto
I stto 4ih geor, ond give constontthrottle (l/4ih opening).
4. Check the RTMI volue, ihe ,,yelue,,will be disployed
initiolly ofter 20 sec, ond then will keep on refreshing oiter
every 1 0 sec.
5. lf the disploy chonges ofter every 1 0 sec., then the RTMI is
working.
lf there is no disploy then check the foilowing;
i 6. Turn the ignition swilch "OFF,,
7 . Remove seot.

t B. Remove left side motorcycle cove, right side shroud ond

visor.
9 . Disconneci the Speed Sensor 3p connector.
'l
0. Disconnect the RTMI 9P connecior.
.l
I . Disconnectihe ECU 33p connector.
Check for loose or poor contoci in the Speed sensor 3p
connector, RTMI 9P connector ond ECU 33p connector.
12. Connect the speed sensor 3p connector, RTMI gp
connector ond ECU 33p connector, turn the ignition
switch to "oN".
lf RIMI working is normol then ihere hos been o loose or poor
connection between the speed sensor 3p connecior, RTMI 9p
connecior or ECU 33P connector.
lf srill no disploy then check the following;
.l4. ,,OFF,,
Turn ihe ignition switch
.l5.
Disconnect RTMI 9P connecior, turn the ignition switch to
"ON"ond check the fol lowing;
VOTTAGE
Connection: Block - Green/Blqck (-)
Stqndord: Boileryvoltoge.

CONTINUITY
Connection: Green/Blqck - Ground (_)
Stqndord: Continuity
l{ volue is out of ronge then check the following;
- Loose or poorcontoct
- Open or shorf circuit in Block wire
- Open circuit in Green/Block wire

l{voltoge ond continuity existthen perform the following tesis.

GROUND
RTMI MATFUNCTION DIAGNOSTIC PROCEDURE
VSS 3P CONNECTOR RTMI 9P CONNECTOR
I B Disconnect the VSS 3P connector ond check for continuity
between RTMI 9P connector ot wire horness side ond VSS
3P connector ot wire horness side.

CONNECTION:
Pink(VSS 3P) - Pink (RTMI eP)
Stondqrd: Continuily
Pink (9P)-Ground
Slondqrd: No Continuity

VSS 3P CONNECTOR
Whire/Green (VSS 3P) - White/Green (RTltll9P)
Slondord: €ontinuity
While/Green (9P)- Ground
Stqndord: No Gontinuily

RTMI 9P CONNECTOR
VSS 3P CONNECTOR
Green/Block (VSS 3P) - Green/Block (RTMI 9P)
Slohdqrd: Gonlinuity
Green / Block (9P)-Ground
Stqndqrd: Continuity
lf no qbnormolity is found then inspectihe {ollowing;

RTMI 9P CONNECTOR
VSS 3P CONNECTOR
I 9 Turn the ignition key "ON", check the voltoge ot VSS 3P
connector:
CONNECTION:
White / Green (VSS 3P) - Ground
Stqndord: Bottery Voltoge

lf volue is out of ronge then reploce RTMI ond inspect ogoin.

lf ok then inspect the following;

GROUND
 RTMI MALFUNCTION DIAGNOSTIC PROCEDURE
VSS 3P CONNECTOR
20 Connect the VSS 3P connector, connect RTMI 9P
connecior ond ECU 33P connector.
Turn the ignition switch to "ON" ond stortthe engine.
CheckVSS input pulseto RTMI.

CONNECTION:
Pink(VSS 3P)-Green/Block (VSS 3P)
Slqndqrd:2-2.5V
l{ volue is out oi ronge ihen reploce Speed Sensor ond inspect
ogoin. l{ ok then inspect the {ollowing;

21 Turn the ignition switch "OFF". Disconnect the ECU 33P

connector ond check the continuity between ECU 33P
connector ot wire horness side ond RTMI 9P conneclor ot
wire horness side.

CONNECTION:
GroylBlock ((RTMI 9P) - GroylBlock (ECU ,
Pinl9)
Slondord: Gonlinuity

GroylBlock (9P) -Ground

Stqndqrd: No Conlinuity
lf no o bnormolity is {ou nd then inspect the {ollowing; ECU 33P CONNECTOR

22 Connecl the VSS 3P connector, RTMI 9P connector ond

ECU 33P connector.
Check {or voltoge in ignition "ON" ond engine running
condiiion ot fuel counter output {rom ECU ot RTMI 9P
con nector.

GONNECTION:
GroylBlock (RTMI 9P) - Green/Blqck
Stondord: 4.75-5.25V

l{volue isoutof rongeihen reploce ECU ond inspectogoin.

RTMI 9P CONNECTOR
 FUEI DELIVERY SYSTEM INSPECTION AND TESTING

FUEL PUMP 5 P CONNECTOR

FUEt LINE INSPECTION
FUEI PRESSURE RETIEVING/QUICK
CON NECT FITTING REMOVAT
Remove ihe seot.
Remove the le{t ond righlside covers.
Remove left ond right shroud.
Remove fuel tonk mounting bolt.
Disconnect the fuel pump 5P connector.
Stort the engine, ond let it idle untilthe engine stolls.
Turn the ignition switch to,OFF',.

CAUTION
Before disconnecting fuel feed hose, relieve pressure from the
system by disconnecting the fuel pump conneclor ond running
the engine iill it stolls.

Remove the utility box cover ond utility box.

Remove right side throttle body cover.
Remove left side throttle body cover.
Remove the fuel iniecior 2 P connector.

NOTE:
. Alwoys ensure to cleon ony dust or dirt oround the quick
INJECTOR 2P CONNECTOR
connect fitting o reo before removo l.
. Use o shop towel to prevent the remoining {uel in ihe fuel LOCKING PAWLS
feed hose from folling out.
. Be coreful notto domogethe hose orotherporfs.
. Do noi use ony tool io press the retoinertobs.
. lf the conneclor does not move, keep ihe retoiner tobs
pressed down, ond olternotely pull ond push the connector
uniil it comes off eosily.

INJECTORSIDE
Ploce o shop towel overthe quick connect{itting.
Pull owoy lhe domper.
Hold the connector with one hond ond press the retoiner iobs
with the other hond ond releose them from the locking powls.
Pull the connector of{.

FUEt PUMPSIDE
)loce o shoptowel
overthe quick connectfitting.
?emove ihe hose from clomps
)ull owoy the
domper.
-lold the connector with one hond
ond press the retoiner tobs
.vith the other hond ond releose them from
the locking powls.
rull the connector
off.

PUMP 5P CONNECTOR CTAMPS

 FUEI DELIVERY SYSTEM INSPECTION AND TESTING

PLASTIC BAGS
FUEt HOSE INSPECTION
lnspect the fuel hose {or ony deteriorotion, domoge or
leokoge.
Reploce the {uel hose if necessory.

CAUTION
To prevent dust entry into the iuel delivery system olwoys
ensure io plug the fuel hose ond coverthe iniector iointwith o
plostic bog.
INJECTOR JOINT
HOC.
QUICK CONNECT FITTING I NSTALLATION
NOTE:
Alwoys reploce the retoiner ond domper o{ the quick connecl
fiiting when the fuel feed hose is disconnected.
Cleon oround the fuel hose joint.
lnsert o new reioiner on both the ends of the fuel hose by
oligning the hooks of the retoiner with the locking powls with
the connector joint.

NOTE:

Do not bend ortwist the fuel feed hose. CONNFCTOR LOCKING PAWLS

Alwoys ensure to cleon ony dusi or dirt oround the quick

con nect iittin g oreo be{ore insiol loiion.

FUEL PUMPSIDE
Setthe dompercorrectly onto the fuel pump joint.
l

Align the quick connectfiiting with ihe fuel pump ioint. Press the
quick connect fitiing uniil both the retoiner powls lock with o
,,CLICK".

lf it is hqrd to connect, put o smoll omount of engine oil on the

pipe end.

Seot ihe fuel tonk on the motorcycle.

DAMPER

INJECTORSIDE
lnstoll o new domper onto the iniector ioint.
Align the quick connect {itting with the iniector joint then press
the q uick connect fitting until both the retoiner powls lock with o
,,CLICK".

lf it is hord to connect, put o smoll omount of engine oil on the

pipe end.

RETAINER TABS CONNECTOR

 FUEI DETIVERY SYSTEM INSPECTION
AND TESTING
Moke sure the conneclion is secure
ond thot the powls ore
firmly locked into ploce, check visuolly;;
connector.
;[.
by pulling rhe

lnstolllhe removed ports in the reverse orderof the removor.

FUEI PRESSURE TEST

the,fuel ond disconnect the quick connect
|;]'"": .pressure
lTTrng trom the iniector.

one side of pressure gouge odoptor to

fn"..i
rne other side to the fuel ottochment
lhe fuel hose ond
hose.
Attoch ihe oiher side of fuel ottochment
hose to the fuel
iniecior.
fuel hose of pressure gouge inro rhe hole
_tl"^i1l]n"
Tneodaptor.
given in

INSTRUMENTS:
PRESSURE GAUGE ADAPTOR
Fuelpressuregouge :070HHKTRFOO3
Fuel press_utegouleodoprol
ozo iix KTRFoo5
Fuel ottqchmenl hose.

Connect the fuel pump 5p connector.

Turn the ignition switch',ON,,.
Stortthe engine ond keep it in idling
rpm.
Reod the fuel pressure.

ID_LE SPEED: l5O0 + 100 rpm

FUEI PRESSURE:294 teo iO.O kgt/cm,l
lf the fuel pressure is higher thon
specified, reploce the {uel
pump ossembly.

,the fuel pressure is lower thon speci{ied, inspect

lf
the
{ollowing:
- Fuel line leoking
- Fuel pump.
- Clogged fuelsuction filter.
After inspection relieve the fuel pressure
from the fuel delivery
system. Remove the fuel pressure gouge
ond pressure gouge
odoptorfrom the fuel hose.
Connectfuel hose onto the in jector.
FUEI DELIVERY SYSTEM INSPECTION AND TESTING
FUEL PUMP 5P CONNECTOR
FUEt PUMP
INSPECTION
Turn the ignition swiich to "ON" ond confirm thot the fuel pump
operotes for o {ew seconds.
l{the {uel pump does not operote, inspect os follows:
Turn the ignition switch to "OFF".
Remove left ond right body covers.
Remove left qnd righi shroud.
Remove {ueltonk mounting bolt.
Disconnect the iuel pump 5P (Block) connector.

FUEL PUMP 5P CONNECTOR

Turn the igniiion switch to "ON" ond meosure the voltoge

between the terminols.
CONNECTION: Red/Blqck (+) - Green (-)
l.l Vminimum
STANDARD: Botteryvoltoge -
lf there is specified volue, inspectforcontinuity in BrownAVhite
wire from fuel pump connectorto ECU connector.
l{ continuiiy is OK then reploce ihe fuel pump.
lf there is out of speci{ied vo lue, inspect the following:
- Moin {use (kickstorl: l5 A, self stort: 20A)
- Open circuit in Red/Block or Green wire
ECU

FUEL PUMP 5P CONNECTOR

REMOVAL
Remove the iollowing :

Remove seol.
Remove boih side covers .

Remove left ond right shrouds.

Remove fuel tonk mounting bolt.
Disconnect 5P connector from fuel tonk ond remove the {uel
tonk.

NOTE:
. Alwoys ensure to cleon ony dust or dirt oround the fuel
pump be{ore removql.
. Remove the fuel pump corefully so os not to domoge the
fuel level sensorfloot orm.

Remove the {uel pump mounting bolts.

Remove the se1 plote/{uel pump unit ossembly ond gosket

PUMP MOUNTING BOLT

 FUEI DETIVERY SYSTEM INSPECTION AND TESTING

INSPECTION GASKET FUEL PUMP UNIT

Check the fuel pump unit forweor or domoge.
Check the fuel suciion filterforweor or domoge
Reploce the fuel pump unit ii necessory

NOTE:
Do not disossemble ihe fuel pump orr".bly.

INSTATTATION SET PIATE ARROW MARKS

NOTE:
. Alwoys reploce the gosket wifh o new one
. lnstoll the fuel pump corefully so os not io domoge
the {uel
level sensor{lootorm.
. Be coreful not to pinch the dirt ond debris
between the fuel
pump ond gosket.

Ploce o new goskei onto the fuel pump unit.

lnstollthe {uel pump ossembly in the fuelionk.

lnstoll the set plote on ihe fuel pump ond then
olign the qrrow
mork on the set plote with the orrow mork on the
fueltonk.

f-uel pump mounting bolts in ihe sequence

I'gIl-tF
TORQUE:1.2kg-m
shown.

FUEL PUMP 5P CONNECIOR

Conneci the quick connect fifiing.
Connect the {uel pump 5p conneclor.

FUEL PUMP WIRE

 .
ETTCTRICAT WI RING DIAGRAM

CHARGING SYSTEM (KICK START)

MAIN FUSE I5A

=o
ll
lL_
r,+\l
E TI
\I/l
J ACG
-

GHARGING SYSTEM (SEIF START)

=o
ll
t=
G}I
\L/t
I ACG
-
 o
z
I
{
6
z
]n
]n
coMB. SW2 {
EI
R/G

RN2 =
ll _
Nr STARTSW FUSE
E
_
tfr ----.?^ B 10A
Illr
o
F lr-
lrll
DC LOAD lfl
{
= 2
f)

RlW2
1 R/B
F

2
z=
LT. SW

o
E,
I
D
o
n
-,/
REC lu cLUrcH sw
o. =
?
777- fcHnr.rce sw
)- ?+

Abbreviotion
:
K-Line Communicotion Line
TA : Temperoture Air
ry
TO :
Pressure Borometric
Temperoture Oil

,!
F.-

ELECTRICAT WI RI NG DIAGRAM

TIGHTING SYSTEM DIAGRAT

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t-----------=--- (91

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