gv250 gt250 efi service manual

8/11/2019 GV250 GT250 EFI Service Manual

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SERVICE MANUAL

99000-95610

SERVICEMANUAL


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FOREWORD

This manual contains an introductory description on

HYOSUNG &

and procedures for its inspection / service and

overhaul of its main components.

It covers the differences from Carbure type and

please refer to the service manual of

(99000-

95310), &(99000HR8310)and &

(99000-94710) for others which are not covered in

this manual.

Other information considered as generally known is

not included.

Read GENERAL INFORMATION section to

familiarize yourself with outline of the vehicle and

MAINTENANCE and other sections to use as a guidefor proper inspection and service.

This manual will help you know the vehicle better so

that you can assure your customers of your optimum

and quick service.

ELECTRICAL SYS

GROUP

GENERAL INFOR

FI SYSTEM DIAGN

FUEL SYSTEM AN

SERVICING INFOR

This manual has been prepared on the basisof the latest specification at the time of

publication.

If modification has been made since then,

difference may exist between the content of

this manual and the actual vehicle.

Illustrations in this manual are used to showthe basic principles of operation and work

procedures.

They may not represent the actual vehicle

exactly in detail.

WARNING

This manual is intended for those who have

enough knowledge and skills for servicing

HYOSUNG vehicles. Without such knowledge and


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HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARELOOKING FOR :

1. The text of this manual is divided into sections.

2. As the title of these sections are listed on the previous

page as GROUP INDEX, select the section where you are look-

ing for.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.4. On the first page of each section, its contents are listed. Find

the item and page you need.

SYMBOLListed in the table below are the symbols indicating instructions and other information neces

meaning associated with them respectively.

Apply THREA

Apply or use b

Measure in vo

Measure in re

Torque control required.Data beside it indicates specified torque.

Apply oil.

Use engine oil unless otherwise specified.

Apply SUPER GREASEA.

DEFINITIONSYMBOL SYMBOL

Apply SUPER GREASEC.


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A

ABDC : After Bottom Dead Center

AC : Alternating Current

API : American Petroleum Institute

ATDC : After Top Dead Center

B

BBDC : Before Bottom Dead Center

BDC : Bettom Dead Center

BTDC : Before Top Dead Center

DDC : Direct Current

DOHC : Double Over Head Camshaft

E

ECU : Engine Control Unit,

FI Control UnitET Sensor : Engine Temperature Sensor

(ETS)

F

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

G

GP Switch : Gear Position Switch

L

LCD : Liquid

LED : Light

LH : Left H

M

Max : Maxim

Min : Minim

O

O2 Sensor : Oxyg

R

RH : Right

S

SAE : Socie

SAV Solenoid : Seco

T

TDC : Top D

TO Sensor : Tip O

ABBREVIATIONS USED IN THIS MANUAL


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BL : Black with Blue tracer BBr : Black wit

BG : Black with Green tracer BO : Black wit

BR : Black with Red tracer BW : Black wit

BY : Black with Yellow tracer LB : Blue with

LG : Blue with Green tracer LR : Blue with

LW : Blue with White tracer LY : Blue with

BrB : Brown with Black tracer BrW : Brown w

GB : Green with Black tracer GR : Green w

GY : Green with Yellow tracer GrB : Gray with

GrR : Gray with Red tracer GrW : Gray with

OB : Orange with Black tracer OL : Orange w

OG : Orange with Green tracer OR : Orange w

OW : Orange with White tracer OY : Orange w

RB : Red with Black tracer RW : Red with

B : Black Gr : Gray Sb : Light blu

L : Blue Lg : Light green W : White

Br : Brown O : Orange Y : Yellow

G : Green R : Red

WIRE COLOR


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GENERAL INFORMATION

SPECIFICATIONS ( , &

CONTENTS


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1-8 GENERAL INFORMATION

2,270 mm (89.4 in)800 mm (31.5 in)

1,090 mm (42.9 in)

1,500 mm (59.1 in)

155 mm (6.1 in)

170 kg (375 lbs)

2,080 mm (81.9 in)760 mm (29.9 in)

1,120 mm (44.1 in)

1,455 mm (57.3 in)

180 mm (7.1 in)

Overall lengthOverall width

Overall height

Wheelbase

Ground clearance

Mass

I T E M

SPECIFICATIONS ( , &

DIMENSIONS AND MASS

Four-stroke, DOHC, air-cooled and oil-cooled

V-2 cylinder

57.0 mm (2.24 in)

48.8 mm (1.92 in)

249 (15.2 in3 )

Fuel Injection

Electric starter

Wet sump

Type

Number of cylinder

Bore

Stroke

Piston displacement

Fuel system

Starter system

Lubrication system

I T E M

ENGINE

Wet multi-plate type Clutch

I T E M

TRANSMISSION


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Telescopic type

Swingarm type

40(right & left)

33

135 mm (5.32 in)

Disk brake

Drum brake

110/90 - 16 59S

150/80 - 15M/C 70S

120 mm (4.72 in)

33(right & left)

25.585 mm (3.35 in)

Disk brake

110/70 - 17 54H

150/70 - 17 69H

Front suspension

Rear suspension

Steering angle

Caster

Trail

Front brake

Rear brake

Front tire size

Rear tire size

Front fork stroke

I T E M

CHASSIS

I T E M

ELECTRICAL

Ignition type

Ignition timing

Spark plug

BatteryFuse

Head lamp

Turn signal lamp

Brake / Tail lamp

License plate lamp

Illumination lampHigh beam indicator lamp

Turn signal indicator lamp(right & left)

Neutral indicator lamp

Fuel meter lamp

FI(Fuel Injection) check lamp

ECU

13B.T.D.C. at 2,000 rpm and

30B.T.D.C. at 6,000 rpm

CR8E

12 V 12 Ah (MF)30 A & 15 A

12 V - H4 : 60 W 1

12 V - H4 : 55 W 1

12 V - W5 W1

12 V - RY10 W 4

12 V - P21/5 W 1

12 V - W5 W 1

12 V - 1.7 W 212 V - 1.7 W 1

12 V - 1.7 W 2

12 V - 1.7 W 1

12 V - 1.7 W 1

LED type

LED typeLED type

LED type

LED type

LED type (Level type)

HI

LO

Position


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PRECAUTIONS IN SERVICING

FI SYSTEM TECHNICAL FEATURESSELF-DIAGNOSIS FUNCTION ( )

SELF-DIAGNOSIS FUNCTION ( )

FI SYSTEM TROUBLESHOOTING

CUSTOMER COMPLAINT ANALYSIS

SELF-DIAGNOSTIC PROCEDURES ( )

SELF-DIAGNOSIS RESET PROCEDURE ( )

MALFUNCTION CODE AND DEFECTIVE CONDITION

C15ET SENSOR CIRCUIT MALFUNCTION

C17orC18IAP SENSOR CIRCUIT MALFUNCTION

C21IAT SENSOR CIRCUIT MALFUNCTION

C22OXYGEN SENSOR CIRCUIT MALFUNCTION

C24orC25IGNITION COIL MALFUNCTION

C27ISC SOLENOID RANGE ABNORMAL

C32orC33FUEL INJECTOR CIRCUIT MALFUNCTION

C37SAV SOLENOID MALFUNCTION

C41FUEL PUMP RELAY CIRCUIT MALFUNCTIONC43OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

SENSORS

FI SYSTEM DIAGNOSIS

CONTENTS


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PRECAUTIONS IN SERVICINGWhen handling the component parts or servicing the

FI system, observe the following points for the safety

of the system.

ELECTRICAL PARTS

CONNECTOR / COUPLER

When connecting a connector, be sure to push itin until a click is felt.

With a lock type coupler, be sure to release thelock when disconnecting, and push it in fully till the

works when connecting it.

When disconnecting the coupler, be sure to holdthe coupler body and do not pull the lead wires.

Inspect each terminal on the connector / coupler

for looseness or bending.

Inspect each terminal for corrosion andcontamination.

The terminals must be clean and free of any

foreign material which could impede proper

terminal contact.

Inspect each lead wire circuit for poor connectionby shaking it by hand lightly. If any abnormal

condition is found, repair or replace.

4-1-1 FI SYSTEM DIAGNOSIS


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When connecting meter probe from the terminalside of the coupler (connection from harness side

not being possible), use extra care not to force

and cause the male terminal to bend or the female

terminal to open.

Connect the probe as shown to avoid opening of

female terminal.

Never push in the probe where male terminal is

supposed to fit.

Check the male connector for bend and femaleconnector for excessive opening. Also check the

coupler for locking (looseness), corrosion, dust,

etc.

FUSE When a fuse blows, always investigate the causeto correct it and then replace the fuse.

Do not use a fuse of a different capacity. Do not use wire or any other substitute for the

fuse.

ECU / VARIOUS SENSORS

Since each component is a high-precision part,great care should be taken not to apply any sharp

impacts during removal and installation.


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Never connect an ohmmeter to the ECU with itscoupler connected. If attempted, damage to ECU

or sensors may result.

Be sure to use a specified voltmeter / ohmmeter.Otherwise, accurate measurements may not be

obtained and personal injury may result.

USING TESTERS Use well-charged batteries in the tester. Be sure to set the tester to the correct testing

range.

USING THE TESTER Incorrectly connecting theandprobes may

cause the inside of the tester to burnout. If the voltage and current are not known, makemeasurements using the highest range.

After using the tester, turn the power off.


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FI SYSTEM TECHNICAL FEATURES

INJECTION TIME (INJECTION VOLUME)

The factors to determine the injection time include the basic fuel injection time, which

intake air pressure, engine speed and throttle opening angle, and various compensatio

These compensations are determined according to the signals from various sensor

driving conditions.

Intake Air Pressure Sensor(IAP Sensor)

Intake air pressure signal

CVarious Sensors

Injectors

Engine speed signal

Various signals

Injection signal

Pick-up coil


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COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensa

(volume).

INJECTION STOP CONTROL

SIGNAL DESCRIPT

ENGINE TEMPERATURE

SENSOR SIGNAL

INTAKE AIR TEMPERATURE SENSOR

SIGNAL

BATTERY VOLTAGE SIGNAL

ENGINE RPM SIGNAL

STARTING SIGNAL

ACCELERATION SIGNAL /

DECELERATION SIGNAL

When engine temperature is low,

increased.

When intake air temperature is low

increased.

ECU operates on the battery voltag

monitors the voltage signal for compe

time (volume). A longer injection

injection volume in the case of low vo

At high speed, the injection time (volu

When starting engine, additional fue

engine.

During acceleration, the fuel injection

in accordance with the throttle open

During deceleration, the fuel in

decreased.

SIGNAL DESCRIPT

TIP OVER SENSOR SIGNAL

(FUEL CUT-OFF)

OVER-REV. LIMITER SIGNAL

When the motorcycle tips over, th

signal to the ECU. Then, this signal c

the fuel pump, fuel injector and ignitio

The fuel injectors stop operation whe

limit rpm.


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4-1-7 FISYSTEM DIAGNOSIS

FI SYSTEM PARTS LOCATION ( )

Speedometer Ignition coil, NO.1 Ignition coil, NO.2 Pick-up coil

GP switch Fuel injector, N Fuel injector, N ISC solenoid

ECU

3

4

2

6

5

7

8

1


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IAT sensor TO sensor Fuel pump relay IAP sensor, NO.2

IAP sensor, NO ET sensor Oxygen sensor SAV solenoid

ECU

15

10

11 14

1216

13

9


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FI SYSTEM PARTS LOCATION ( )

Speedometer Fuel injector, NO.1 Fuel injector, NO.2 IAT sensor GP switch

Pick-up coil Ignition coil, NO ISC solenoid Fuel pump rela

4-1-9 FISYSTEM DIAGNOSIS

ECU

3

4

2

6 5

7 8

9

1


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TO sensor Ignition coil, NO.2 IAP sensor, NO.1 IAP sensor, NO.2

ET sensor Oxygen sensor SAV solenoid

F

ECU

15

10

11

14

12

16

13


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SELF-DIAGNOSIS FUNCTION ( The self-diagnosis function is incorporated in the ECU.

The function has two modes, USER MODE and DEALER MODE.

The user can only be notified by the FI check lamp .To check the function of the individual FI system devices, the dealer mode is prepared

In this check, the special tool is necessary to read the code of the malfunction items.

USER MODEThe FI check lamp comes on for about three seconds whenever the position with the engine stopped as a test of the injection system operation. The chec

seconds.

If the check lamp comes on during normal engine operation, it means that the fuel inje

correctly.

When this is the case, inspect the fuel injection system to refer to Dealer mode.


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F

Mode select switch : 09900-27000

DEALER MODE

The defective function is memorized in the ECU.

Use the special tools coupler to connect to the dealer mode coupler. (Refer to page 4-

The memorized malfunction code is displayed on LCD (DISPLAY) panel.

Malfunction means that the ECU does not receive signal from the devices. These affe

the code form.


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SELF-DIAGNOSIS FUNCTION ( )The self-diagnosis function is incorporated in the ECU.

The function has a mode, USER MODE. The user and dealer can only be notified by

To check the function of the individual FI system devices, read blinks signal of the FI

The FI check lamp comes on for about three seconds whenever the ignitionwith the engine stopped as a test of the injection system operation. The check l

seconds.

If the check lamp comes on during normal engine operation, it means that the fuel inje

correctly.

When this is the case, inspect the fuel injection system to refer to blinks signal of the

The defective function is memorized in the ECU.

The memorized malfunction code is display with blinks signal of the FI check lamp

Malfunction means that the ECU does not receive signal from the devices. These af

blinks signal of the FI check lamp .


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F

I th FI h k l th lf ti d i di l d f ll bli k i

C15

C17

C18

C21

C22

C24

C25

C27

C32

C33

C37

C41

C43

Engine temperature sensor (ETS)

Intake air pressure sensor (IAPS), N

Intake air pressure sensor (IAPS), N

Intake air temperature sensor (IATS

Oxygen sensor (O2S)

IG coil, NO.1

IG coil, NO.2

Idle speed control solenoid (ISC sole

Fuel injector, NO.1

Fuel injector, NO.2

Secondary air valve solenoid (SAV s

Fuel pump relay

Oxygen sensor heater (O2S heater)

MALFUNCTION PART

[ 1 5 1 5 1 ]

[ 1 7 1 7 ]

[ 1 8 1 8 ]

[ 2 1 2 1 12 2 1]

[ 2 2 222 2 ]

[ 2 4 42 2 ]

[ 2 5 52 2 ]

[ 2 7 72 ]

[ 3 3 32 22 ]

[ 3 3 333 ]

[ 3 37 ]

[ 4 41 1 14 ]

[ 4 3 34 ]

CODE

In the LCD (DISPLAY) panel , the malfunction code is indicated from small code to

CODE


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FI SYSTEM TROUBLESHOOTING

CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as describe

purpose, use of such an inspection form will facilitate collecting information to the poin

and diagnosis.

EXAMPLE : CUSTOMER PROBLEM INSPECTION FORMUser name : Model : VIN :

Date of issue : Date Reg. Date of problem :

FI Check lamp Always ON Sometimes ON Always O

No code Malfunction code ( )

PROBLEM SYMPTOMS

Difficult Starting Poor Driveability

No cranking Hesitation on acceleratio No initial combustion Back fire / After fire

No combustion Lack of power

Poor starting at Surging

( cold warm always) Abnormal knocking

Other Engine rpm jumps briefly

Other

Poor Idling Engine Stall when Poor fast Idle Immediately after start

Abnormal idling speed Throttle valve is opened

( High Low) ( rpm) Throttle valve is closed

Unstable Load is applied

Malfunction display / code

(LCD) or

Blinks signal

( FI check lamp)


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F

MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROB

Environmental condition

Motorcycle condition

NOTE

The above form is a standard sample. If should be modified according to conditmarket.

Fair Cloudy Rain Snow Always

Hot Warm Cool Cold ( F / C)

Always Sometimes ( times / day, month)

Under certain condition

Urban Suburb Highway Mountainous (

Tarmacadam Gravel Other

Cold Warming up phase Warmed up Alw

Immediately after start Racing without load En

During driving : Constant speed Accelerating

Right hand corner Left hand corner At stop

Motorcycle speed when problem occurs ( km/h,

Other

Weather

Temperature

Frequency

Road

Engine condition

Motorcycle condition


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NOTEThe dealer mode coupler is located under the rear

seat.

Mode select switch : 09900-27000

SELF-DIAGNOSTIC PROCEDURES( )

Dont disconnect couplers from ECU, battery cable

from battery, ECU ground wire harness from engine

or main fuse before confirming malfunction code

(self-diagnostic trouble code) stored in memory.

Such disconnection will erase memorized information

in ECU memory.Malfunction code stored in ECU memory can be

checked by the special tool.

To check malfunction code, read SELF-DIAGNOSIS

FUNCTION DEALER MODE (Refer to page

4-1-12, 14) carefully to have good understanding as

to what functions are available and how to use it.

Be sure to read PRECAUTIONS for Electrical CircuitService (Refer to page 4-1-1) before inspection and

observe what is written there.

Remove the front and rear seat. Connect the special tool to the dealer mode

coupler at the wiring harness, and the ignition

switch is set to ON position.

Turn the special tools switch ON position and

check the malfunction code to determine themalfunction part.

SELF-DIAGNOSIS RESETPROCEDURE ( )

After repairing the trouble turn the ignition switch


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F

MALFUNCTION CODE AND DEFECTIVE CONDITION

C15

C17 / C18

C21

C22

Engine temperature

sensor (ETS)

Intake air pressure

sensor (IAPS),

NO.1 / NO.2

Intake air temperature

sensor (IATS)

Oxygen sensor (O2S)

Intake air temperature sensor, lead w

Intake air pressure sensor, lead wire

Engine temperature sensor, lead wir

Oxygen sensor, lead wire / coupler c

DETECTED ITEMDETECTED FAILURE

CHECK F

MALFUNCTIONCODE

The sensor voltage should be the fol

0.1 V sensor voltage < 4.6 VWithout the above range for 4 sec. a

The oxygen sensor signal is input in

120 sec. after the engine run.

When this is the case, ECU not

indicated.

The sensor voltage should be the fol


The sensor should produce following

0.1 V sensor voltage 4.8 VWithout the above range for 4 sec

indicated.


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C24 / C25

C27

C32 / C33

C37

C41

C43

Ignition coil (IG coil),

NO.1 / NO.2

Idle speed control

solenoid (ISC solenoid)

Fuel injector, NO.1 / NO.2

Secondary air valve

solenoid (SAV solenoid)

Fuel pump relay

Oxygen sensor heater

(O2S heater)

Ignition coil, wiring / coupler connec

battery.

Idle speed control solenoid, lead wir

Injector, wiring / coupler connec

injector.

Secondary air valve solenoid, lead w

Oxygen sensor heater, lead wire / co

DETECTED ITEMDETECTED FAILUR

CHECK F

MALFUNCTIONCODE

When the IC of the ECU electric cur

or C25 is indicated.

The idle speed control solenoid step

O step solenoid step 100 stepWithout the above range, C27 is ind

The fuel injector not comes in volta

C33 is indicated.

When the secondary air valve sole

ECU, C37 is indicated.

Fuel pump relay, connecting lead wi

pump relay, fuel injector.

The oxygen sensor heater signal is

No voltage is applied to the both incontact of fuel pump relay is turned

applied to the both injectors, when

OFF position.


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F

C15 ET SENSOR CIRCUIT MALFUNCTION

INSPECTION

Step 1

1) Turn the ignition switch OFF position.

2) Check the ET sensor coupler for loose or poorcontacts.

If OK, then measure the ET sensor voltage at the

wire side coupler.

3) Disconnect the coupler and turn the ignition switch

ON position.

DETECTED CONDITION POSSIBL

ET sensor circuit open o ET sensor malfunction.

ECU malfunction.

ET sensor voltage

Is the voltage OK?

Tester knob indication : Voltage ( )

CODE CO

[ 1 5 1 5

C15

Output voltage is out of the specified range.0.1 V Sensor voltage < 4.6 V

4) Measure the voltage between G wire terminal and

ground.

5) If OK, then measure the voltage between G wire

terminal and BW wire terminal.

4.5 ~ 5.5 V

(G-Ground )

(G-

BW )


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Step 21) Turn the ignition switch OFF position.

2) Measure the ET sensor resistance.

Resistance (To ECU)Engine Temp.

ET sensor resistance

Approx. 28.788

Approx. 12.209

Approx. 5.671

Approx. 2.845

Approx. 1.525

0 (32 )

20 (68 )

40 (104 )

60 (140 )

80 (176 )

Is the resistance OK?

Tester knob indication : Resistance ( )

YES

NOReplace the ET sensor with a new

one.

EC

G or BW wire open or shorted toground, or poor or connection.

If wire and connection are OK,intermittent trouble or faulty ECU.

Recheck each terminal and wireharness for open circuit and poor

connection.


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F

C17 or C18 IAP SENSOR CIRCUIT MALFUNCTION

INSPECTION

Step 1

1) Remove the fuel tank.


3) Check the IAP sensor NO.1 coupler and NO.2

coupler for loose or poor contacts.If OK, then measure the IAP sensor input voltage.

DETECTED CONDITION

Clogged vacuum passand IAP sensors.

Air being drawn from throttle body and IAP se

IAP sensor circuit open IAP sensor malfunction ECU malfunction.

POSSIBL

C17

C18

CODE CO

[ 1 7 1

[ 1 8 1

IAP sensor voltage is out of the specified range.

0.1 V Sensor voltage 4.8 VNOTE :

Note that atmospheric pressure varies depending on

weather conditions as well as altitude.

Take that into consideration when inspecting voltage.

4) Disconnect the IAP sensor couplers NO.1 and

NO.2 .5) Turn the ignition switch ON position.

6) Measure the voltage at the OB wire and ground.

If OK, then measure the voltage at the OB wire

and BW wire.


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IAP sensor

output voltage

Approx. 4.0 ~ 4.2 V

when ignition switch ON

([NO.1]BL-BW )([NO.2]BY-BW )

Is the voltage OK?


EC

YES

NO

OB, BL(NO.1), BY(NO,2) or BWwire open or shorted to ground,or poor , (NO.1), (NO.2) or connection.


Recheck each terminal and wireharness for open circuit and poorconnection.

If check result is not satisfactory,replace IAP sensor with a new one.

Step 21) Connect the IAP sensor couplers NO.1 and

NO.2 .2) Insert the needle pointed probes to the lead wire

coupler.

3) Start the engine at idle speed.

4) Measure the IAP sensor output voltage at the wire

side coupler (between BL(NO.1) or BY(NO.2) and

BW wires).

Output voltage

(Input voltage 5 V, ambient temp. 25 C, 77 F)

ALTITUDE(Reference)

(ft) (m) (mmHg) kPa (V)

0 0 760 100

ATMOSPHERICPRESSURE

OUTPUTVOLTAGE

Approx.


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F

INSPECTION

Step 11) Remove the fuel tank.


3) Check the IAT sensor coupler for loose or poor

contacts.

If OK, then measure the IAT sensor voltage at the

wire side coupler.

4) Disconnect the coupler and turn the ignition switch

ON position.

C21 IAT SENSOR CIRCUIT MALFUNCTION


IAT sensor circuit open IAT sensor malfunction.

ECU malfunction.

IAT sensor voltage4.5 ~ 5.5 V

(Lg-Ground )(Lg

-

BW )

Is the voltage OK?


C21

CODE CO

[ 2 1 2 1 2

Output voltage is out of the specified range.

0.1 V Sensor voltage < 4.6 V

5) Measure the voltage between Lg wire terminal and

ground.

6) If OK, then measure the voltage between Lg wire

terminal and BW wire terminal.


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Step 21) Turn the ignition switch OFF position.

2) Measure the IAT sensor resistance.

Is the resistance OK?

YES

NO

EC

ResistanceIntake Air Temp.

IAT sensor resistance

Approx. 53.30

Approx. 31.52

Approx. 12.33

Approx. 5.19

Approx. 2.42

-10 (14 )

0 (32 )

20 (68 )

40 (104 )

60 (140 )

Tester knob indication : Resistance ( )

Lg or BW wire open or shorted toground, or poor or connection.



connection.Replace the IAT sensor with a new

one.


36/90

F

INSPECTION1) Remove the front seat and frame cover.

2) Turn the ignition switch OFF position.3) Check the Oxygen sensor coupler for loose or

poor contacts.

C22 OXYGEN SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION

Oxygen sensor, Oxygeor short.

Oxygen sensor, Oxygen ECU malfunction.

POSSIBL

Is OK?

YES

C22

CODE CO

[ 2 2 22

Oxygen sensor signal is not input in ECU since thenmore than 120 sec. after the engine run.

BR or BW wire open or shortedto ground, or poor orconnection.


Recheck each terminal and wire


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INSPECTION1) Remove the front seat.


3) Check the ISC solenoid coupler for loose or poor

contacts.4) Turn the ignition switch ON position to check the

ISC solenoid operation.

C27 ISC SOLENOID RANGE ABNORMAL

[ When Ignition switch OFF ]

C27

CODE CO

[ 2 7 2


ISC solenoids step is out of the specified range.

O step Solenoid step 100 step

ISC solenoid malfunctio

ISC solenoids step is o

ECU malfunction.


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F

INSPECTION

Step 11) Remove the fuel tank and frame cover.


3) Check the injector couplers NO.1 and NO.2for loose or poor contacts.

If OK, then measure the injector resistance.

: Fuel injector NO.1

: Fuel injector NO.2

4) Disconnect the injector couplers NO.1 andNO.2 and measure the resistance betweenterminals.

C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTI


Fuel injector not comes in voltage from battery. Injector circuit open or s

Injector malfunction.

ECU malfunction.

Injector resistance 11.5 ~ 13.5 at 20 (68)

C32

C33

CODE CO

[ 3 3 22

[ 3 33


39/90


Injector voltage

NOTEInjector voltage can be detected only 3

seconds after ignition switch is turned ON

position.

YES

NO

Is the voltage OK?


EC

Step 21) Turn the ignition switch ON position.

2) Measure the injector voltage between YG(NO.1),

YR(NO.2) wire and ground.

YG(NO.1) or YR(NO.2) wire open orshorted to ground, or poor (NO.1)or (NO.2) connection.



connection.

Inspect the fuel pump or fuelpump relay. (Refer to page 4-2-6)

: Fuel injector c : Fuel injector c

Battery voltage

([NO.1]YG-Ground )([NO.2]YR-Ground )


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F

SAV solenoid voltageBattery voltage

(GL-Ground )

Is the voltage OK?

NO

YES

Replace the SAV solenoid with a new

one.

C37 SAV SOLENOID MALFUNCTION


SAV solenoid voltage is not input in ECU. SAV solenoid circuit ope

SAV solenoid malfunctio

ECU malfunction.


C37

CODE CO

[ 3 7

INSPECTION1) Remove the front seat.


3) Check the SAV solenoid coupler for loose or poorcontacts.

4) Connect the SAV solenoid coupler.

5) Turn the ignition switch ON position.

6) Measure the voltage at the wire side coupler

between GL wire and ground.

GL wire open or shorted to ground, orconnection.


Recheck each terminal and wire harnessfor open circuit and poor connection.


41/90


C41 FUEL PUMP RELAY CIRCUIT MALFUNCTION


No voltage is applied to the both injectors for 3 sec.

after the contact of fuel pump relay is turned ONposition.

Or voltage is applied to the both injectors, when the

contact of fuel pump is OFF position.

Fuel pump relay circuit o

Fuel pump relay malfun

ECU malfunction.

CODE COD

C41

CODE CO

[ 4 1 14

: Head lamp relay : Fuel pump relay : Main relay : Turn signal relay

INSPECTION

Step 1

1) Remove the frame cover.2) Turn the ignition switch OFF position.

3) Check the fuel pump relay coupler for loose or

poor contacts.

If OK, then check the insulation and continuity.

Refer to page 4-2-6 for details.


42/90

F

C43 OXYGEN SENSOR HEATER CIRCUIT MALFUNT

Oxygen sensorheater voltage

Battery voltage(OB-B )

(OB-Ground )

Is the voltage OK?

YES


Oxygen sensor heater signal is not input in ECU. Oxygen sensor, Oxygen

or short. Oxygen sensor, Oxygen ECU malfunction.


CODE CODCODE COD

C43

CODE CO

[ 4 3 4

OB or B wire open or shorted to ground,or poor or connection.


Recheck each terminal and wire harnessf

INSPECTION1) Remove the frame cover.


3) Check the Oxygen sensor heater coupler for loose

or poor contacts.

If OK, then measure the Oxygen sensor heater

voltage.

4) Disconnect the coupler and then the ignition

switch ON position.

5) Measure the voltage between OB wire terminal

and B (or ground) wire terminal.


43/90


ET sensor : 18 Nm (1.8 kgfm)

ET SENSOR INSPECTION

The engine temperature (ET) sensor is installed atthe engine case. (Refer to page 4-1-20)

ET SENSOR REMOVAL ANDINSTALLATION

Remove the ET sensor. Install the ET sensor in the reverse order of

removal.

SENSORS IAP SENSOR INSPECTION

The intake air pressure (IAP) sensors NO.1 andNO.2 are installed at the upside of each intakepipe. (Refer to page 4-1-22)

IAP SENSOR REMOVAL AND

INSTALLATION Remove the fuel tank. Remove the IAP sensor from the intake pipe. Install the IAP sensor in the reverse order of

removal.


44/90

F

IAT SENSOR INSPECTIONThe intake air temperature (IAT) sensor isinstalled at the air cleaner case.

(Refer to page 4-1-24)

IAT SENSOR REMOVAL ANDINSTALLATION

Remove the fuel tank. Remove the IAT sensor from the air cleaner case. Install the IAT sensor in the reverse order of

removal.

TO SENSOR INSPECTION,

REMOVAL AND INSTALLATIONThe tip over (TO) sensor is located in the frame. Romove the seat. Remove the TO sensor from the frame. Install the TO sensor in the reverse order of

removal.


45/90


46/90

FUEL SYSTEM

REMOVAL AND DISASSEMBLY ( )

REASSEMBLY AND INSTALLATION ( )

REMOVAL AND DISASSEMBLY ( )

REASSEMBLY AND INSTALLATION ( )

FUEL PRESSURE INSPECTION

FUEL PUMP RELAY INSPECTION

FUEL MESH FILTER INSPECTION AND CLEANING( )

FUEL GAUGE INSPECTION

THROTTLE BODY

REMOVAL

CLEANING

INSPECTION

INSTALLATION

CONTENTS

FUEL SYSTEM AND THROTTLE B

S S O BO


47/90

4-2-1 FUEL SYSTEM AND THROTTLE BODY

FUEL SYSTEM

FUEL SYSTEM


48/90

FUEL SYSTEM

REMOVAL AND DISASSEMBLY ( ) Remove the front seat.

Disconnect the fuel gauge coupler .

Remove the fuel tank mounting bolt and take offthe hooks.

4 2 3 FUEL SYSTEM AND THROTTLE BODY


49/90


Remove the fuel tank rearward.

Remove the fuel pump assembly by removingits mounting bolts diagonally.

Remove the fuel gauge .

REASSEMBLY AND INSTALLATION

( )

CAUTION

As gasoline leakage may occur in this operation,

keep away from fire and sparks.

WARNING

Gasoline is highly flammable and explosive.Keep heat, spark and flame away.

FUEL SYSTEM


50/90

FUEL SYSTEM

REMOVAL AND DISASSEMBLY( )

Remove the front seat. Remove the fuel tank mounting bolts and take off

the hooks.

Disconnect the fuel gauge coupler .

Remove the fuel pump coupler .


51/90

FUEL SYSTEM


52/90

FUEL SYSTEM

FUEL PRESSURE INSPECTION Remove the front seat. Place a rag under the fuel injector hose. Disconnect the fuel injector hose from the fuel

delivery pipe.

Install the special tool between the fuel tank andfuel delivery pipe.

Fuel pump pressure gauge: 09915-54510

Turn the ignition switch ON position and check the

fuel pressure.

Fuel pressureApprox. 3.4 ~ 3.7 kgf/cm2

(333 ~ 363 kPa, 48.4 ~ 52.6 psi)

WARNING

Before removing the special tool, turn theignition switch to OFF position and release

the fuel pressure slowly.

Gasoline is highly flammable and explosive.Keep heat, sparks and flame away.

If the fuel pressure is lower than the specification,

inspect the following items :

* Fuel hose leakage

* Clogged fuel filter

* Pressure regulator

* Fuel pump

If the fuel pressure is higher than the specification,

inspect the following items :* Fuel pump check valve

* Pressure regulator

FUEL PUMP RELAY INSPECTION

Fuel pump relay is located the left side of the frame



53/90

FUEL MESH FILTER INSPECTIONAND CLEANING( )

If the fuel mesh filter is clogged with sediment orrust, fuel will not flow smoothly and loss in engine

power may result.

Blow the fuel mesh filter with compressed air.

NOTEIf the fuel mesh filter is clogged with many

sediment or rust, replace the fuel filter cartridgewith a new one.

FUEL GAUGE INSPECTION

Measure resistance between the terminals whenfloat is at the position instead below.

Fuel float position Resistance between terminals

F

1/2

E

Approx. 90 ~ 105

Approx. 38

First, check the insulation between andterminals with pocket tester. Then apply 12 volts to and terminals,to andto , and checkthe continuity between and .If there is no continuity, replace it with a new one.


54/90



55/90

REMOVAL Remove the fuel tank. Remove the air cleaner box. Disconnect the fuel hose. Remove the all coupler to related the throttle

body.

Loosen the throttle body clamp screws.

FUEL SYSTEM A


56/90

Clean all passageways with a spray-type throttlebody cleaner and blow dry with compressed air.

CLEANING

WARNING

Some throttle body cleaning chemicals,

especially dip-type soaking solutions, are very

corrosive and must be handled carefully. Always

follow the chemical manufacturers instructions

on proper use, handling and storage.

CAUTION

Do not use wire to clean passageways. Wire can

damage passageways. If the components cannot

be cleaned with a spray cleaner it may benecessary to use a dip-type cleaning solution and

allow them to soak. Always follow the chemical

manufacturers instructions for proper use and

cleaning of the throttle body components. Do not

apply throttle body cleaning chemicals to the

rubber and plastic materials.

CAUTIONNever operate the idle screws (NO 1) and

INSPECTION

Check following items for any damage or clogging.

* O-ring * Secondary throttle valve

* Throttle shaft bushing and seal

* Injector cushion seal

* Throttle valve * Vacuum hose

Check fuel injector filter for evidence of dirt and

contamination. If present, clean and check for

presence of dirt in the fuel lines and fuel tank.



57/90

INSTALLATIONInstallation is in the reverse order of removal.

Pay attention to the following points :

Connect the throttle cable to the throttle cabledrum.

Ad just the th ro tt le cable play wi th the cableadjusters.

ELECTRICAL SYSTEM


58/90

LOCATION OF ELECTRICAL COMPONENTS

IGNITION SYSTEM

CHARGING SYSTEM

CONTENTS

ELECTRICAL SYSTEM

5-1 ELECTRICAL SYSTEM


59/90

LOCATION OF ELECTRICAL COMPONENTS

Ignition coil NO.1 Ignition coil NO.2

Main relay Fuel pump relay Head lamp relay

Main ECU Head Batte


60/90

SAV s IAP sensor NO.1 ET sensor IAP sensor NO.2

ISC solenoid



61/90

REAR

IGNITION

COIL

FRONT

IGNITION

COIL

RELAY

ENGINE STO

MAGECU

IGNITION SYSTEM

INSPECTION IGNITION COIL RESISTANCE

INSPECTION

Disconnect the ignition coil read wire.Measure the ignition coil resistance in bolt the

primary and secondary windings. If the resistance is

not within the standard range, replace the ignition coil

with a new one.

IGNITION COIL / PLUG CAP RESISTANCE

3.5 ~ 5.5 (Terminal -Terminal)

20 ~ 31 (Plug cap -Terminal)SecondaryPrimary


62/90

Standard

G - L Approx. 85 ~ 105

Y - Y Approx. 0.2 ~ 1.0

MAGNETOUsing the pocket tester, measure the resistancebetween the lead wires in the following table.

If the resistance is not within the specified value,

replace the magneto coil, with a new one.

CAUTIONWhen mounting the stator on the magneto cover,

apply a small quantity of THREAD LOCK1324to the threaded parts of screws.

WIRE COLOR

L : Blue

G : GreenY : Yellow

BY : Black with Yellow tracer

OB : Orange with Black tracer

Br : Brown

BW : Black with White tracer

WL : White with Blue tracer

YG : Yellow with Green tracer

Tester knob indication : Resistance ()

MAGNETO NO-LOAD PERFORMANCEDisconnect the three lead wires from the magneto

terminal.

Start the engine and keep it running at 5 000 rpm

Magneto coil resistance

Pick-up coil

Charging coil

THREAD LOCK1324



63/90

CHARGING SYSTEM

INSPECTION CHARGING OUTPUT CHECKStart the engine and keep it running at 5,000 rpm.

Using the pocket tester, measure the DC voltage

between the battery terminaland.If the voltage is not within the specified value, check

the magneto no-load performance and regulator /

rectifier.

CAUTION

When making this test, be sure that the battery is

full charged condition

Regulator

Rectifier

Ba

A. C generator

Regulator / Rectifier

IC


64/90

REGULATOR / RECTIFIER Disconnect the regulator / rectifier couplers. Using the pocket tester, measure the resistance

between the terminals in the following table.

If the resistance checked is incorrect, replace the

regulator / rectifier.

Tester knob indication : Resistance (M)

34

34

12

12

34

34

12

12

34

34

12

12

12

12

12

32

12

12

12

32

Tester probe

Testerprobe

Unit :M


65/90

SERVICING INFORMATION


66/90

TROUBLESHOOTING

SPECIAL TOOLS

TIGHTENING TORQUE

SERVICE DATA

WIRING DIAGRAM ( )

WIRING DIAGRAM ( )

WIRING DIAGRAM ( )

CONTENTS

7-1-1 SERVICING INFORMATION


67/90

TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVE CONDITION

C15

C17 / C18

C21

C22

Engine temperature

sensor (ETS)

Intake air pressure

sensor (IAPS),

NO.1 / NO.2

Intake air temperature

sensor (IATS)

Oxygen sensor (O2S)

Intake air temperature sensor, lead w

Intake air pressure sensor, lead wire

Engine temperature sensor, lead wir

Oxygen sensor, lead wire / coupler c

DETECTED ITEMDETECTED FAILUR

CHECK F

MALFUNCTIONCODE

The sensor voltage should be the fo

0.1 V sensor voltage < 4.6 V

Without the above range for 4 sec. a

The oxygen sensor signal is input in

120 sec. after the engine run.

When this is the case, ECU not indicated.

The sensor voltage should be the fo


The sensor should produce following

0.1 V sensor voltage 4.8 VWithout the above range for 4 sec

indicated.

SER


68/90

C24 / C25

C27

C32 / C33

C37

C41

C43

Ignition coil (IG coil),

NO.1 / NO.2

Idle speed control

solenoid (ISC solenoid)

Fuel injector, NO.1 / NO.2

Secondary air valve

solenoid (SAV solenoid)

Fuel pump relay

Oxygen sensor heater(O2S heater)

Ignition coil, wiring / coupler connectbattery.

Idle speed control solenoid, lead wir

Injector, wiring / coupler connec

injector.

Secondary air valve solenoid, lead w

Oxygen sensor heater, lead wire / co

DETECTED ITEMDETECTED FAILURE

CHECK F

MALFUNCTIONCODE

When the IC of the ECU electric cur

or C25 is indicated.

The idle speed control solenoid step

O step solenoid step 100 stepWithout the above range, C27 is ind

The fuel injector not comes in voltaC33 is indicated.

When the secondary air valve sole

ECU, C37 is indicated.

Fuel pump relay, connecting lead wi

pump relay, fuel injector.

The oxygen sensor heater signal is n

No voltage is applied to the both inj

contact of fuel pump relay is turned

applied to the both injectors, when

OFF position.



69/90

ENGINEComplaint Symptom and possible causes

Engine will not

start or is hard to

start.

Compression too low1. Tappet clearance out of adjustment.

2. Worn valve guides or poor seating of valves.

3. Mistimed valves.

4. Excessively worn piston rings.

5. Worn-down cylinder bore.

6. Starter motor cranks too slowly.

7. Poor seating of spark plugs.

Plug not sparking1. Fouled spark plugs.

2. Wet spark plugs.

3. Defective ignition coils.

4. Open or short in high-tension cord.

5. Defective pick-up coil.

6. Defective ECU.

7. Open-circuited wiring connections.

No fuel reaching the intake manifold1. Clogged fuel filter or fuel hose.

2. Defective fuel pump.

3. Defective fuel pressure regulator.

4. Defective fuel injector.

5. Defective fuel pump relay.

6. Defective ECU.


Incorrect fuel / air mixture1. Defective fuel pump.



4. Defective IAP sensor.

5. Defective ECU.

6. Defective ET sensor.

7. Defective IAT sensor.

SER


70/90

Complaint Symptom and possible causes

Engine idles poorly. 1. Tappet clearance out of adjustment.2. Poor seating of valves.

3. Defective valve guides.

4. Worn down camshafts.

5. Too wide spark plug gaps.



8. Defective ECU.


10. Imbalanced throttle valve or SAV solenoid.

11. Damaged or cracked vacuum hose.

Incorrect fuel / air mixture1. Defective IAP sensor or circuit.

2. Clogged fuel filter.


4. Defective fuel pressure regulator.5. Defective ET sensor.


7. Damaged or cracked vacuum hose.

Fuel injector improperly operating1. Defective fuel injectors.

2. No injection signal from ECU.

3. Open or short circuited wiring connection.

4. Defective battery or low battery voltage.

Control circuit or sensor improperly operating1. Defective ECU.





6. Defective fuel pump relay.

Engine internal parts improperly operating1. Fouled spark plugs.

2. Defective pick-up coil or ECU.

3. Clogged fuel hose.

Engine stalls often



71/90


Noisy engine. Excessive valve chatter1. Too large tappet clearance.

2. Weakened or broken valve springs.

3. Worn tappet or cam surface.

4. Worn and burnt camshaft journal.

Noise seems to come from piston1. Worn down pistons or cylinders.

2. Combustion chambers fouled with carbon.

3. Worn piston pins or piston pin bore.

4. Worn piston rings or ring grooves.

Noise seems to come from cam chain1. Stretched chain.

2. Worn sprockets.

3. Tension adjuster not working.

Noise seems to come from clutch1. Worn splines of countershaft or hub.

2. Worn teeth of clutch plates.

3. Distorted clutch plates, driven and drive.

4. Worn clutch release bearing.

5. Weakened clutch dampers.

Noise seems to come from crankshaft1. Rattling bearings due to wear.

2. Worn and burnt big-end bearings.

3. Worn and burnt journal bearings.

Noise seems to come from transmission1. Worn or rubbing gears.

2. Worn splines.

3. Worn bearings.

4. Worn or rubbing primary gears.

SER


72/90


Engine runs poorly

in high speed range.

Defective engine internal / electrical parts1. Weakened valve springs.

2. Worn camshafts.

3. Valve timing out of adjustment.

4. Too narrow spark plug gaps.

5. Ignition not advanced sufficiently due to poorly working timing

advance circuit.



8. Defective ECU.

9. Clogged fuel hose, resulting in inadequate fuel supply to injector.


11. Defective SAV solenoid.

12. Clogged air cleaner element.

Defective air flow system1. Clogged air cleaner element.

2. Defective throttle valve.

3. Sucking air from throttle body joint.

4. Defective ECU.

Defective control circuit or sensor1. Low fuel pressure.



4. Defective IAP sensor.5. Defective ECU.




73/90


Engine lacks

power.

Defective engine internal / electrical parts1. Loss of tappet clearance.

2. Weakened valve springs.

3. Valve timing out of adjustment.

4. Worn piston rings or cylinders.

5. Poor seating of valves.

6. Fouled spark plugs.

7. Incorrect spark plugs.

8. Clogged injectors.

9. Clogged air cleaner element.

10. Sucking air from throttle valve or vacuum hose.

11. Too much engine oil.

12. Defective fuel pump or ECU.

13. Defective pick-up coil and ignition coils.

Defective control circuit or sensor1. Low fuel pressure.2. Defective IAT sensor.


4. Defective IAP sensor.

5. Defective ECU.


8. Defective GP switch.

Defective engine internal parts

1. Heavy carbon deposit on piston crowns.2. Not enough oil in the engine.

3. Defective oil pump or clogged oil circuit.

4. Sucking air from intake pipes.

5. Use incorrect engine oil.

6. Defective oil cooler.

Lean fuel / air mixture1. Short-circuited IAP sensor / lead wire.

2. Short-circuited IAT sensor / lead wire.3. Sucking air from intake pipe joint.

4. Defective fuel injectors.


Engine overheats.

SER


74/90


Dirty or heavy

exhaust smoke.

Slipping clutch.

1. Too much engine oil in the engine.

2. Worn piston rings or cylinders.

3. Worn valve guides.

4. Cylinder wall scored or scuffed.

5. Worn valves stems.

6. Defective stem seals.

7. Worn side rails.

1. Weakened clutch springs.

2. Worn or distorted pressure plates.

3. Distorted clutch plates or pressure plates.

1. Some clutch springs weakened while others are not.

2. Distorted pressure plates or clutch plates.

1. Broken gearshift cam.2. Distorted gearshift forks.

3. Worn gearshift pawl.

1. Broken return spring on shift shaft.

2. Rubbing or sticky shift shaft.

3. Distorted or worn gearshift forks.

1. Worn shifting gears on driveshaft or countershaft.

2. Distorted or worn gearshift forks.3. Weakened stopper spring on gearshift stopper.

Dragging clutch.

Transmission willnot shift.

Transmission will

not shift back.

Transmission

jumps out ofgear.

7-4 SERVICING INFORMATION

ELECTRICAL


75/90

ELECTRICAL


No sparking or

poor sparking.

1. Defective ignition coils or spark plug caps.

2. Defective spark plugs.


4. Defective ECU.

5. Defective TO sensor.


1. Mixture too rich.

2. Idling speed set too high.

3. Incorrect gasoline.

4. Dirty element in air cleaner.

5. Spark plugs too cold.

1. Worn piston rings.2. Pistons or cylinders worn.

3. Excessive clearance of valve stems in valve guides.

4. Worn stem oil seal.

1. Spark plugs too hot.

2. The engine overheats.

3. Spark plugs loose.

4. Mixture too lean.

1. Lead wires tend to get shorted or open-circuited or loosely

connected at terminals.

2. Grounded or open-circuited stator coils of magneto.

3. Defective regulator / rectifier.

4. Defective cell plates in the battery.

1. Internal short - circuit in the battery.

2. Resistor element in the regulator / rectifier damaged or defective.

3. Regulator / rectifier poorly grounded.

1 Open or short circuited lead wirse or loose lead connections

Spark plug soon

become fouled

with carbon.

Spark plugbecome fouled

too soon.

Magneto charge,

but charging

rate is below the

specification.

Magneto

overcharges.

Magneto does not

Spark plug

electrodes

overheat or burn.

S


76/90

Special tools Part NumberPart NameDescription

09915-54510

Fuel pump pressure gauge

Measure fuel pressure of fuel pump.

SPECIAL TOOLS

09900-27000

Mode select switch

Inspect FI system sensor.

(Only for )


77/90

SER

SERVICE DATA


78/90

FI SENSORS

ITEM

IAP sensor input voltage

IAP sensor output voltage

IAT sensor voltage

IAT sensor resistance

TO sensor voltage

SAV solenoid voltage

Oxygen sensor heater voltage

ET sensor voltage

ET sensor resistance (To ECU)

4.5 ~ 5.5 V

Approx. 4.0 ~ 4.2 V when ignition switc

4.5 ~ 5.5 V

Refer to page 34 (4-1-25)

4.5 ~ 5.5 V at normal condition(To sensor switch - ON at leaned more

Battery voltage

Battery voltage

4.5 ~ 5.5 V

SPECIFICATION

0 (32)

20 (68)

40 (104)

60 (140)

80 (176)

Approx. 28.788

Approx. 12.209Approx. 5.671

Approx. 2.845

Approx. 1.525


79/90


80/90


WIRING DIAGRAM ( )


81/90

WIRING DIAGRAM ( )

TACHOSPEED

FUEL

SPEEDOMETER

O O YBW B YB

WLYLg L

LO O YBW B YB

WLYLg

HANDLESWITCHR

ENGINESTOP

STOP

RUN

LIGHTING

OFF

ON

STARTER

PUSH

OOB O G

rOB

YR

OOB

Gr

YR

OOB

Gr

YR

Ft.TURNSIGNALL

BW

B

BW

B

POSITION

HEADLAMP

W

BW

W

BW

Y

W

BW

Y

O

BW

Ft.TURNSIGNALR

Lg

BW

Lg

BW

SER


82/90

YR

BW

YR

GR

DIODE#3 FUELGAUGE

BW

YB

BW

YB

02SENSOR DIODE#2

O RB

O RB

OBBB

WBR

RRBRAKES/W

OFF

ON

OWB

OWB

FUELPUMP

BBr

BW

MAINRELAY

R B RRB

FUELPUMP

RELAY

HEADLAMP

RELAY

OBW OY

WOB

GW OB

Br

BGW

BBr

BWL

YBW G R

BYRG L Y

B L BY

W OB

YG

OB

BL

Br

Lg

1 2 4 5 6 7 8 9 10 11 1 2 13 1 4 15 1 6 17 1 8 19 2 0 21 22 2

ENGINECONTROLUNIT


WIRING DIAGRAM ( )


83/90

( )

TACHO

DISPLAY

HANDLESWITCHR

ENGINESTOP

STOP

RUN

LIGHT

OFF

ON

Ft.BRA

OFF

ON

STARTER

PUSH

OOB

OOB

Gr

YR

WB

BW G OYB

WW

YBWW R

R BY L Y

B B W Lg

YW O L

WL

LYYB B W L

g O O L BW G O

OOB

Gr

YR

WB

O Gr

OB

YR O

Ft.TURNSIGNALL

POSITION

HEADLAMP

FtTURNSIGNALR

BW

B

W

BW

Lg

BW

Lg

BW

W

BW

Y

W

BW

Y

O

BW

BW

B

SER


84/90

UELGAUGE02SENSOR

DIODE#2

RRBRAKES/W

FUELPUMP MAINRELAYFUELPUMP

RELAY

HEADLAMP

RELAY

OFF

ON

BW

YB O R

B

OWB

BBr

BW R B RR

BGr

BW OY

WBG

WBBr

BW

BW G R

BYRG LY

B L BYW O

BYG

OB

BL

Br

Lg

YL

BYW G

L B GL

BY

BR

WL

GRY G

r

1 2 4 5 7 8 9 10 11 12 1 3 14 1 5 16 1 7 18 1 9 20 2 1 22 2 3 24 2 5 26 2 7 28 2 9 30 3 1 32 3 3 34

ENGINECONTROLUNIT

34P

OB

GW O B

Br

OWB

OBBB

WBR

BW

YB


WIRING DIAGRAM ( )


85/90

TACHO

DISPLAY

HANDLESWITCHR

ENGINESTOP

STOP

RUN

LIGHT

OFF

ON

Ft.BRA

OFF

ON

STARTER

PUSH

OOB O G

rOB

YR O

BW G OYB

WW

YBWW R

R BY L Y

B B W Lg

YW O L

WL

LYYB B W L

g O O LBW G O

OOB

Gr

YR

WB

OOB

Gr

YR

WB

Ft.TURNSIGNALL

BW

B

BW

B

POSITION

HIGHBEAM

LOWBEAM

HEADLAMP

W

BW

W

BW

Y

BW

W

BW

Y

O

BW

FtTURNSIGNALR

Lg

BW

Lg

BW

SER


86/90

UELGAUGE02SENSOR

DIODE#2

BW

YB O R

BOBBB

WBR

BW

YB

RRBRAKES/W

FUELPUMP MAINRELAYFUELPUMP

RELAY

HEADLAMP

RELAY

OFF

ON

OWB

BBr

BW R B RR

BGr

BW OY

WOB

GW OB

Br

OWB

BGW

BBr

BW

BW G R

BYRG L Y

B L BY

W OB

YG

OB

BL

Br

Lg

YL

BY

W GL B G

LBY

BR

WL

GRY G

r

1 2 4 5 7 8 9 10 11 1 2 13 1 4 15 1 6 17 1 8 19 2 0 21 2 2 23 2 4 25 2 6 27 2 8 29 3 0 31 3 2 33 3 4

ENGINECONTROLUNIT

34P

MEMO


87/90

MEMO


88/90


89/90

Prepared by

1st Ed. OCT. 2008.

Manual No. 99000-95610

Printed in Korea


90/90

S&T Motors Co., Ltd.

gv250 gt250 efi service manual

Documents