Manual of EFI System

DELPHI MT05 EFI SYSTEM

Instruction for Assemble and Maintenance（LXI450/NCI250）
SHANDONG ASIAWING MOTORS TECHNICAL DEPARTMENT
JUNE,2017
-1-
1. DELPHI MT05 EFI SYSTEM PARTS AND ATTENTIONS
EFI SYSTEM DIAGRAM
-2-
No Parts Name Model Parts No. Parts photos Notes

1 Different engine model
use different programs.
196MR-1210900 The ECU are not
LXI450 interchangeable, and
must use corresponding
ECU type.
450 type: YX450
250 type: YX250
NCI250 NC250D-1200400
2 Choose the type

LXI450 196MR-1210100 according to engine
Fuel injector fuel consumption.
LD450: 25384016
NCI250 NC250D-1200200
NC250: 25359853
-3-

3
Throttle valve
assembly LXI450 196MR-1220000
Choose the type

according to engine
displacement.
LD450: D42
NC250: D34
NCI250 NC250D-1210000
-4-

4
Oxygen sensor LXI450/NCI 196MR-1210300 450/250 same

250
Thread: M12×1.5
5
LXI450 196MR-1430000-1
Ignition coil
NCI250 NC250D-1200600
-5-
6 Fuel pump assy LXI450/ 450/250 same

NCI250 196MR-1210400
Water
7 temperature LXI450/ 196MR-1210700 450/250 same
sensor NCI250
LXI450 196MR-1210001
8 Fuel injector cap
NCI250
-6-

Front catalyst：
196MR-1210002
（63.5x70x60x200s）
LXI450
Rear catalyst：
196MR-1210003
（80x100x80x300s） Choose the catalyst
9 Catalyst type and formula
according to different
bike models
NC250D-1200002
NCI250 （53*130*300s）
10 Cables Details as 2.2
-7-
2、System assembly instructions

2.1 Stitches of ECU and engine wiring diagram
-8-
2.2 LXI450 EFI sub wiring harness：
Magnetic motor triggering

Connect EFI main warness Fuel injector connector sensor connector
ECU connector
Fuel pump connector (one black and one gray)
Water temperature
sensor connector
EFI system relay
Ignition coil connector ECU Diagnostic

communication connector
15A fuse
Stepper motor connector
Connect battery positive
Oxygen sensor connector Connect battery negative
Throttle position sensor connector Intake air pressure and temperature sensor connector
-9-
2.3 NCI250 EFI sub wiring harness：
Water temperature sensor ECU connector

Fuel pump connector
(one black and one gray) Throttle position
Sensor connector
Oxygen sensor
connector
Stepper motor
connector
Battery positive Attentions: Never connect other electric

Connect main
equipment to sub wiring harness.
Battery negative warness
Fuel injector connector

attery negative
Magnetic motor
triggering
ECU Diagnostic Intake air pressure

communication connector and temperature
15A fuse
EFI system relay sensor connector
Ignition coil connector
- 10 -
2.4. Oil system
Connect fuel injector cap
Use non-hollow type clamp, to avoid damage of

high pressure fuel hose
- 11 -
Attentions：
1、As fuel pressure of EFI system is 250 kpa, fuel hose must be special high pressure hose. Normal fuel pipe will cause hose burst and lead to
accident.
2、Fix the fuel pump on fuel tank with M4 bolt, tightening torque 1.6 N.m
2.5 EVAP Evaporative Emission Control System

6
LXI450: NCI250:
12
2.6 Assembly of ignition coil and high-tension cable

Assamply key point：Screw the tapping screw of ignition coil connection end into the clip of high-voltage cable, then cover the rubber sheath of
high-voltage cable on the ignition coil. High-voltage cap of LXI450 and NCI250 are different:
LXI450： NCI250：
2.7 Assambly of fuel injector and intake air pressure and temperature sensor
（1） LXI450： (2)NCI250:
13
The limit bulge of fuel injector should put

into the groove of throttle body
（3）Fuel injector assembly key points:
Attentions:
a. When assemble fuel injector, lubricant must be put on the o-ring .Otherwise the O-ring will be de damaged easily and influence the seal, and then
cause the unnormal of idle speed.
b. The limit bulge of fuel injector should be put into the groove of throttle body.
14
2.8 Attentions for assambly.

1. As EFI system has high requirment for power supply,the rectifier should be of reliable quality. Beyond the normal working voltage will cause
the unnormal of EFI system,even burn the components.
2. As all the components of EFI system are driven by electricity, and the mix working voltage is 9V, so the battery capacity should be as much as
possible, to assure that the battery voltage no less than 9V when electrical starting.
3. As EFI system is different from carburator system, and request highly for the signal,the ground signal of ECU must be connect to engine
individually, and seperated from the ground signal of the main warness. The power supply cable of EFI system can not connect to starting relay, and
need to connect on battery directly and separated with the body main current.
2.9 Explanation for some phenomenons of EFI bikes

1. The rotating speed is high when start bike, and then reduce to the normal idle speed gradually after successful starting.
Delphi EFI system has idle control valve(stepper motor).To assure good starting，the opening of stepper motor is a bigger when start,so the air intake of
engine is big accordingly(bigger than idling). After the engine start successfully, ECU will control the stepper motor automatically to decrease the
opening gradually.
15
2.10 Instruction about electrical starting
1. Put the engine shutdown switch in the position of “ ”.
2. Insert the key into the keyswitch, turn clockwisely to the on position of“ ”.
3. Make sure the transmission is in the neutral position.
4. Press and hold the clutch lever, put up the side stand and then press the starting button of“ ”
5. Wait until the engine warms up after engine starting, then you are ready to ride.
3. EFI System Maintenance Instruction
3.1 Special reminder: Please use original parts, otherwise, can not ensure the EFI system work normally.Though maybe the dimensions of some
other EFI parts are similar, the performance and datas are different.
3.2 Attentions during maintenance
① Turn off the ignition switch when disconnect or reconnect the connector assembly. Otherwise, it is possible to damage the electric parts.
② The oil pressure of EFI system is high(about 250kpa),the whole fuel pipeline use high pressure hoses. After a long time since engine stop, the oil
pressure in fuel pipeline still keeps high. So do not dismantle the fuel hose casually, and need to relief pressure before dismantling fuel hose as below:
 Make sure the transmission is in the neutral position.
16
 Disconnect the the connector between the fuel pump assy wireness and main wireness.
 Start the engine until it stall automatically, open and close the key switch two or three times continuously with interval of 3 seconds, then close
the key switch.
 Dismantle fuel hose after the above. After assembling the fuel hose again, reconnect the connector of fuel pump assy wireness.
③ Do not electrify the circuit when taking down the fuel pump from fuel tank, to avoid fire caused by spark.
④ Running test of fuel pump can not been taken in dry or water conditions.
⑤ Idle is adjusted completely by EFI system program, no need manual adjustment.The limit bolt of throttle body has been adjusted well before
leaving factory, not allowed to change the original position casually.
⑥ The battery is not allowed to be disassembled when engine is running.
4. System fault diagnosis function introduction
OBD is the abbreviation of On-Board Diagnostic.When the system fails,the Fault light(MIL) or Check Engine warning light is on, meanwhile
OBD system store the fault information into storage.The fault informations can be read in the form of fault codes, using standard diagnosis
instrument and diagnosis interface. According to the reminder of fault code, maintenance staff can confirm the character and position of the
fault rapidly and accurately.
17
4.1 Fault Information Record

Electronic control unit(ECU) keep monitoring the sensors, actuator, relative circuits, fault lights and battery etc, even the ECU itself, and
take reliability test of sensor output signal, actuator drive signal and internal signal(such as λ closed-loop control, temperature of
cylinder and coolant, idle speed control and battery voltage control etc ). Once find fault, or one signal is not credible, ECU will set fault
information record in fault storage of RAM. The fault informations are stored in the form of fault code. The current exisiting fault codes
are called current fault code, the transient faults caused by poor contact etc, and having been removed currently, are historical faults
codes. The faults that have been resolved, but without eliminating fault code operation, are also stored in the form of historical fault
codes.
4.2 Faults List
MT05 Fault list
Fault list Description
P0107 The intake pressure sensor opens or shorted to the ground.
P0108 The intake pressure sensor shorted to power source.
P0112 The intake temperature sensor shorted to the ground.
P0113 The intake pressure sensor opens or shorted to power source.
P0117 Cooling/cylinder temperature sensor shorted to the ground.
Cooling/cylinder temperature sensor opens or shorted to power
P0118 source.
P0122 Throttle position sensor opens or shorted to the ground.
P0123 Throttle body position sensor opens or shorted to power source.
P0131 Oxygen sensor(cylinder 1)shorted to the ground
18
P0132 Oxygen sensor(cylinder 1)shorted to power source.

P0031 Oxygen sensor heater shorted to the ground
P0032 Oxygen sensor heater shorted to power source.
P0201 Cylinder 1 nozzle fault
P0202 Cylinder 2 nozzle fault
P0230 Fuel pump(relay) opens or shorted to the ground.
P0232 Fuel pump(relay) shorted to power source.
P0336 Crankshaft position sensor has interference
P0337 Crankshaft position sensor no signal
P0351 Cylinder 1 igination coil fault
P0352 Cylinder 2 igination coil fault
P0505 Idle speed control fault
P0562 System voltage too low
P0563 System voltage too high
P0650 Fault light fault
P1693 The tachometer shorted to the ground
P1694 The tachometer shorted to the power source
4.3 Instructions about fault indicator

Fault indicator is a indicator light that can display on the meter and shape comply statutory and atandard requirements generally.
① In normal mode,and without current fault code:
Turn on the Igination lock, ECU initialize and fault light on.After engine starting successfully, MIL light goes off at once.
19
② When have current fault codes：

When current fault happen during the engine running, the fault light will go out and then be on for long time, reminding the driver faults exist.
When engine stall, the current fault will be translated into historical fault and stored in ECU.
③ When have fault codes:
In exceptional circumstances, can turn off the key switch for more than 10 seconds, and then thun on and off continuously and quickly, to reset
the ECU. ECU reset will eliminate all the self-study data, and maybe cause some abnormal conditions of the bike. ECU need finish
self-adaptive study again and then return to normal.
4.4 How to use diagnostic apparatus

Diagnostic apparatus function: Read fault codes, Eliminate fault codes, Data flow display, Status identification display.
①Connect diagnostic apparatus to diagnostic interface of EFI wire harness.
②Turn on the ignition switch.
③Read the fault codes; Refer the maintenance manual to confirm the fault parts and fault type; Make maintenance plan according to query
information and experience.
④After solving the fault, eliminate the historical fault coded.
20
Connect diagnostic apparatus to

diagnostic interface of EFI wire
harness.
4.5 Maintenance procedure according to fault codes

If the faults are cuased by open and short circuit and parts failure, check if the circuit and connectors are installed properly, or if the insert of connector
has been oxidized, cause poor contact and circuit intertuption.If the malfunction still can not be solved, change relevant sensors ot ECU.
21
Fault Code Description Possible causes
Crankshaft ①Connection circuit short or open intermittently.

position sen ②Rotate speed transmittor or magneto rotor are not installed
P0336 sor has properly.
interference ③Ignition coil and rotate speed transmittor are too closed and
interfer the rotate speed signal
Crankshaft ①Rotate speed transmittor connection open or short circuit.
P0337 position sen ②Rotate speed transmittor malfunction.
sor has no ③With wrong rotor type. Delphi use24-1 specified convex rotor.
signal
Idle speed EFI system lack power, battery transient is lower than minimum
control working voltage of steper motor when start.
P0505 malfunction
Low voltage Battery lack of electricity, need to recharge battery or change
P0562 of system battery with enough power
System The voltage supplied eo ECU is too high. Need to check the
voltage too whole charging ciucult and make sure the voltage regulator works
P0563 high normally.
Fault light Inspect if the fault light circuit is open or short circuilt.
P0650 malfunction
4.6 Diagnosis Procedure According to Fault Phenomenon

A、Initial inspection should be taken before diagnosis.
22
① Check if the malfuction light can work normally.

② Inspect with diagnosis apparatus,make sure no mulfunction record.
③ Confirm if the fault phenomenon complainted by bike owner exist, and confirm the faults happen conditions.
B、Appearance inspection
① Check if the fuel line has leakage.
② Check if the air intake pipe is blocked, air leak,squashed or broken.
③ Check if the high voltage wire of ignition system is broken or aging, and if the the ignition procedure is correct.
④ Check if the grounding wire is clear and firm.
⑤ Check each sensor and actuator if loose or poor contact.
⑥ Check if the fuel injector, pressure sensor, and connect pipe between air intake pipe negative mouth and carnist solenoid valve have leakage
or not.
Attentions: If the above problem exist, should be solved first. Otherwise, they will influence the further diagnosis.
4.7 General fault phenomenons.

4.7.1 Engine does not run or run slowly when start
General fault parts: 1. Battery; 2.starting motor; 3. wire harness and starting relay and related control circuit; 4. Engine mechanical parts
23
General diagnosis procedure:

No. Diagnosis Procedure Measures
Inspect the voltage between the 2 binding posts of battery with multimeter, if the
1 Change battery
voltage is between 9-12V
Inspect the relevant
Keep the ignition switch in start position,check if the voltage in starting motor
2 circuit of starting
positive binding post is above 9V with multimeter
motor.
Dismantle the starting motor and check the operating, especially if caused by Repair or replace the
3
short circuit or stuck by not sufficient lubrication. starting motor.
If happens in winter, check if it is caused by using improper engine oil, result in Repalce proper grand
4
too big resistance of starting motor. lubricating oil
Inspect if the engine inside mechanical resistance is too big, and if the starting Inspect the engine
5
transmission system works normally. inside
4.7.2 When start, The engine can be towed, but not successfully started.
General fault parts: 1. No fuel oil in fuel tank; 2. Fuel oil pump. 3. Rotator speed sensor; 4. Ignition coil; 5. Engine mechanical parts.
24

Connect EFI system adaptor, turn on the igination switch,
inspect if the power supply in J1-17、J2-15、J2-180 stitchs is
1 Repair relevant circuit.
normal; Inspect if the J1-9、J2-2 stitch grounding is normal;
Inspect if engine and battery grounding is good.
Connect EFI diagnosis apparatis, check the “engine RPM”data, Inspect the rotate speed sensor and circuit; Make
2
start the engine, and check if there is RPM signical output or not. sure the magneto motor rotor is 24-1 tooth.
Disassemble the spark plug cap and connect the spark plug, put
3 spark plug on engine body, start the engine and check if there Inspect the ignition system
will be continuous blue white high-voltage spark.
Connect the fuel oil pressure gauge, turn on the key switch,
check if the pressure is about 250KPa. If without pressure
4 Inspect the guel oil supply system
gauge, could pinch the high pressure hose with fingers to feel if
the hose is hard
Eliminate engine mechanical fault(Pay attention to
5 Inspect if the pressure of each cylinder is not enough
check if the engine valve clearance is too small)
25
Disassemble the fuel injector from the intake manifold(without

6 removing the connector of Fuel line and wire harness ) Start the Inspect the fuel injector wiring and fuel injector
engine and check if there is fuel injection
4.7.3 Starting difficult

General fault parts: 1. Fuel oil with water; 2. Fuel pump; 3.Coolant temperature sensor; 4.Fuel injector; 5. Ignition coil; 6. Throttle body and idle side
vent; 7. Air inlet; 8.Ignition timing; 9. spark plug; 10. Engine mechanical parts.

Unplug the coolant temperature (cylinder temperature)
Inspect the circuit or replace the coolant temperature
1 sensor connector, start the engine and check if the engine can
(cylinder temperature) sensor
be started successfully.
Connect the fuel oil pressure gauge, turn on the key
2 switch,check if the fuel oil pressure is about 250KPa(can not Inspect the fuel supply system
be judged by hand)
3 Disassemble the spark plug cap and connect the spark Inspect the ignition system.
26
plug,connect spark plug on engine body, start the engine and

check if there will be continuous blue white high-voltage
spark.
4 Throttle a little,and see if it is easy to start. Wash the throttle valve and idle airway
Inspect if the air cleaner is blocked, and if there is air leakage
5 Repair the air intake system
of air intake(especially the connecting area of air intake)
Inspect the spark plug, check if the type and clearence
6 Adjust or replace
conform to the specification.
Eliminate engine mechanical fault(Pay attention to
7 Inspect if the cylinder pressure is not enough
check if the engine valve clearance is too small)
Check if fuel oil number(including ethanol or not) confirm to
8 Replace the fuel oil
the specification.
4.7.4 Starting normal but idling unstable

General fault parts: 1. Fuel oil with water; 2. Fuel injector; 3. Spark plug; 4.Throttle body and idle side vent; 5. Air inlet; 6. Idle regulator; 7. Ignition
timing; 8. Spark plug; 9. Engine mechanical parts; 10.Coolan temparature(cylinder temperature) sensor
27

Diagnosis Procedure Measures Notes
No.
Inspect if the air cleaner is blocked, and if there is

Repair the air intake
1 air leakage of air intake(especially the connecting
system
area of air intake)
2 Inspect if the throttle body get stuck Wash or replace
Inspect the spark plug, check if the type and
3 Wash or replace
clearence conform to the specification.
Inspect if throttle body and idle side vent pipe has
4 wash
carbon fouling
Inspect if fuel oil number(including ethanol or not)
5 Replace the fuel oil
confirm to bike requirements.
Eliminate engine
mechanical fault(Pay
6 Inspect if the cylinder pressure is enough
attention to check if the
engine valve clearance is
28
too small)
Inspect the ignition procedure and if the starting is
7 Inspect the ignition timing.
conform to the specification.
Inspect if the fuel injector has leakage, block or
8 Replace if fault
excess flow
Disassemble the connector of coolant temparature Idle speed is unstable during
Repair the line or replace
9 sensor, start the engine and check if the idle speed warm-up process.
the sensor
is unstable during warm-up process.
4.7.5 Starting normally, but idle speed too high.

General fault parts: 1. Throttle body and idle side vent; 2.Idle regulator; 3.Coolan temparature sensor; 4. Ignition timing

Inspect if the throttle cable is stuck or too tight, cause the throttle
1 Adjust
body does not close completely
2 Inspect if the air intake system has leakage Inspect the air intake system
29
Disassemble the idle speed regulator, inspect if the throttle body,

3 Wash relevent parts
idle speed regulator and idle side vent pipe have carbon fouling
Unplug the connector of coolant temperature sensor, start the
4 Inspect circuit or replace the sensor
engine and check if the idle speed is too high
5 Inspect if the ignition timing of engine conform to specification Inspect the ignition timing
4.7.6 Low RPM or stalling when accelerate, accelerate slow reponse, or weak acceleration.
General fault parts：1.Fuel oil with water; 2.The intake pressure sensor and throttle position sensor; 3. Spark plug; 4. Throttle body and idle side vent; 5.
Air inlet; 6. Idle regulator;7. fuel injector; 8.Ignition timing; 9. Exhaust
No. Diagnosis Procedure Measures Notes
1 Inspect if air cleaner is blocked Inspect air intake system
Connect the fuel oil pressure gauge, start the engine, Inspect fuel oil supply
2
check if the fuel oil pressure is about 250KPa. system
Inspect the spark plug, check if the type and
3 Adjust or replace
clearence conform to the
30
specification.
Disassemble the idle speed regulator, inspect if the
4 throttle body, idle speed regulator and idle side vent Wash relevant parts
pipe have carbon fouling
Inspect if the intake pressure sensor, Inspect circuit or replace
5
throttle position sensor and their circuit are normal sensor
6 Inspect if fuel injector has leakage or blocked Replace if broken
7 Inspect if fuel oil number(including ethanol or not) Replace fuel oil

confirm to the bike requirements.
Inspect if the ignation order and ignition timing of Inspect and repair ignition
8
engine conform to specification timing.
9 Inspect if the exhaust is fluent. Rectify or replace exhaust
Disassemble the spark plug cap and connect
the spark plug,connect spark plug on engine body,
10 Repair ignation system
start the engine and check if there will be continuous
blue white high-voltage spark.
Weak acceleration
11 Inspect if these problems exist: Clutch slip, low air Repair
31
pressure of tires, brake drag, or if customer has adjust

the end transmission ratio etc.
32

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DELPHI MT05 EFI SYSTEM

DELPHI MT05 EFI SYSTEM

SHANDONG ASIAWING MOTORS TECHNICAL DEPARTMENT

1. DELPHI MT05 EFI SYSTEM PARTS AND ATTENTIONS

EFI SYSTEM DIAGRAM

No Parts Name Model Parts No. Parts photos Notes

2 Choose the type

No Parts Name Model Parts No. Parts photos Notes

Choose the type

No Parts Name Model Parts No. Parts photos Notes

Oxygen sensor LXI450/NCI 196MR-1210300 450/250 same

No Parts Name Model Parts No. Parts photos Notes

6 Fuel pump assy LXI450/ 450/250 same

8 Fuel injector cap

No Parts Name Model Parts No. Parts photos Notes

10 Cables Details as 2.2

2、System assembly instructions

2.2 LXI450 EFI sub wiring harness：

Magnetic motor triggering

Ignition coil connector ECU Diagnostic

Oxygen sensor connector Connect battery negative

2.3 NCI250 EFI sub wiring harness：

Water temperature sensor ECU connector

Battery positive Attentions: Never connect other electric

Fuel injector connector

ECU Diagnostic Intake air pressure

Ignition coil connector

2.4. Oil system

Connect fuel injector cap

Use non-hollow type clamp, to avoid damage of

2.5 EVAP Evaporative Emission Control System

2.6 Assembly of ignition coil and high-tension cable

（1） LXI450： (2)NCI250:

The limit bulge of fuel injector should put

（3）Fuel injector assembly key points:

2.8 Attentions for assambly.

2.9 Explanation for some phenomenons of EFI bikes

2.10 Instruction about electrical starting

1. Put the engine shutdown switch in the position of “ ”.

3. Make sure the transmission is in the neutral position.

3. EFI System Maintenance Instruction

4. System fault diagnosis function introduction

4.1 Fault Information Record

P0132 Oxygen sensor(cylinder 1)shorted to power source.

4.3 Instructions about fault indicator

② When have current fault codes：

4.4 How to use diagnostic apparatus

Connect diagnostic apparatus to

4.5 Maintenance procedure according to fault codes

Fault Code Description Possible causes

Crankshaft ①Connection circuit short or open intermittently.

4.6 Diagnosis Procedure According to Fault Phenomenon

① Check if the malfuction light can work normally.

4.7 General fault phenomenons.

General diagnosis procedure:

General diagnosis procedure:

Disassemble the fuel injector from the intake manifold(without

4.7.3 Starting difficult

General diagnosis procedure:

plug,connect spark plug on engine body, start the engine and

4.7.4 Starting normal but idling unstable

General diagnosis procedure:

Inspect if the air cleaner is blocked, and if there is

4.7.5 Starting normally, but idle speed too high.