Problem Engine Warning Light Illuminate due to Pin O2 Sensor Socket Bent

Model BKU2 FreeGo

Quality Assurance YIMMWJ

2023Y
 Phenomenon problem

When customer use his motorcycle, he found engine warning light illuminate while riding around 40-50 km/h and notice the Stop Start System unable to use.

No Frame No Engine Mileage Area

MH3SEJ920PJ001164 E31XE-0041168 51 KM Surabaya

Found Error Code P2195 (O2 Sensor)

OK NG Activity of dealer
- Mechanic tried to check overall motor condition ➔ There’s no modification
at motorcycle
- Mechanic Check by YDT ➔ found Er. Code P2195, related O2 sensor.
- Mechanic erase the error code ➔ Error code can be erased.
- Mechanic tried to test the motorcycle, when pass 40km/h mechanic found
engine warning light illuminate again and SSS not function.
OK NG - Mechanic check again by YDT and found same error code.
- Mechanic tried to check O2 sensor socket condition, found socket pin bend.
- Mechanic tried to repair the socket pin and erase error code again using
YDT ➔ problem solved
- Mechanic tried to ride the motorcycle again and not found engine warning
light illuminate again.
- Problem Solved.

Pin Connector O2 Sensor Bent

Based on confirmation by dealer found same phenomenon within customer happen.

 History actual unit claim

Data Henkaten ➔ No changing operator especially for process Connect Data handling at line (Pull of buzzer) ➔ No abnormal record
St.33 check Coupler O2 Sensor & St.41

Repair Problem SPR Final Inspects ➔ No abnormal record

VICS statues for actual unit Straight ➔ No found abnormal handling repair
VICS Status

Conclusion:
Straight Based on history of unit claim during manufacturing process Not
happen abnormal or handling ➔ Straight
 Abnormal simulation

Model Method Body assy Final inspection Under repair Additional drum test

TRIAL 2 O2 sensor with pin Not NO warning

(BKU2 / connect to socket light blinking
SSS) ➔ OK

Found error code when 2

minutes drum test but SSS
still normal for function
No abnormal for both P2195 Malfunction O2 Sensor 1
condition ➔ Meaning NO
abnormal during turn ON
main switch only and engine
ON condition

Trail within NO connect socket can’t detect by normal F/inspection and not found warning light abnormal
 Flow Process

Lay Out Engine Assy & Body Assy Main Line D →→→

Main Line Engine Assy Main Line Body Assy

Body Assy
① St.20 Engine Assy ② St.33 ③ St.41 ④ QE Final inspects
Assy O2 Sensor Connect Coupler O2 Sensor Check Connect Coupler O2 Check Function &
Sensor + Marking Check Appearance

Process install O2 sensor wire happen at body assy within click condition and guarantee marking after install at next station.
 Instruction Standard Process O2 Sensor BKU

St. Proses Point Proses Proses Standard

- Connect Coupler O2 Sensor
Attention Point :
• Until click and kuku coupler Lock

Connect
33 Coupler O2
Sensor

Connect Coupler Until click and

kuku coupler Lock
- Check Coupler O2 Thermo Sensor by push and give marking
Attention Point :
• Coupler Lock

Check Connect
Coupler O2
41 Sensor +
Marking Check

Push Kuku Coupler Marking Check at Coupler

Guarantee process was mentioned at IS for important point by click and marking for confirmation.
 Trial abnormal condition

1. Trial by moving condition (Un-position profile both of part)

Move to left ~ right side and up ~ down after assy

Part automatic insert to profile and result NO touching mark or bent

2. Trial by wire harness and O2 sensor with inverted condition

Can’t insert to both of part due to different profile

3. Trial condition part within bending

Pin socket bending ~ assy to socket by normal ~ re assy ~ check

Found same phenomenon if condition

pin has bent and continue assy with socket
O2 sensor

Bent
 Detail visual check and measurement

No Trial 1 Trial 2 Trial 3 Trial 4 Part claim

Socket O2 sensor (female socket)

1.441mm
3.513mm
4.209mm
Found mark touch
5.298mm

9.255mm
7.147mm
6.458mm
5.335mm

Pin Socket O2 sensor (male socket)

OK OK OK NG
➔ No touching mark ➔ No touching mark ➔ No touching mark ➔ Result pin O2
and bent for pin O2 and bent for pin O2 and bent for pin O2 sensor bent and found
sensor sensor sensor touching mark at
Pin deform / bent
socket O2 sensor
Note:
For trial number 4 feeling during locking NO mark touch
/ install socket need more force
Conclusion:
compare with other trial Deformation of pin O2 sensor happen
when part already have initial bending
before and additional process during
assembly
Touching mark and Bent
 Discuss WJ and supplier

Process function check part by moving toggle

Guarantee by function Guarantee by visual

Mention NO bent

Possibility problem happen bent of part during process inspection by toggle

➔ Still continue activity for progress duplication abnormal part (planning senin, 30 January ) genba check to Casuarina
 Temporary action check stock part and process

1. Receiving YIMMWJ 2. Sampling check at main line

Actual condition layout

Check before assy Normal assy Re-assy and check pin condition

Sampling check N10 unit motorcycle

MH3SEJ920PJ002631 ~ MH3SEJ920PJ002640
Check actual condition before assy and after assy related condition of pin socket O2sensor
3. Change method function by actual socket within modification ➔ Study 4. Additional check at main line by visual
Current condition use pokayoke JIG Modification by actual part difficult to process due to already mapping
layout at position and this part last
sequence for check

Already check by visual and give marking

For delivery check 100% by visual until 5 delivery
Already check 330pcs ➔ OK

Start No frame: MH3SEJ920PJ002640

Result check during receiving and main line related this problem NOT found same phenomenon