uxv500i 500se 500ile service manual

22. FUEL INJECTION SYSTEM

22-0

UXV 500i

13 __________________________________________________________________________________

__________________________________________________________________________________

FUEL INJECTION SYSTEM__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 22- 1SPECIFICATIONS ---------------------------------------------------------- 22- 2INJECTION SYSTEM DIAGRAM --------------------------------------- 22- 3PARTS LOCATION -------------------------------------------------------- 22- 4TROUBLESHOOTING----------------------------------------------------- 22- 8SELF-DIAGNOSTIC PROCEDURES WITHOUTDIAGNOSTIC TOOL------------------------------------------------------- 22- 7EFI SELF-DIAGNOSIS CHECK ENGINE LAMP (CELP) FAILURECODES-------------------------------------------------------------------------22- 9SELF-DIAGNOSIS RESET PROCEDURE ---------------------------- 22-10CELP FAILURE CODES LIST------------------------------------------- 22-11TPS/ISC RESET ----------------------------------------------------------- 22-15FUEL PUMP ---------------------------------------------------------------- 22-16FUEL PUMP RELAY------------------------------------------------------ 22-18TILT SWITCH(ROLL SENSOR) ---------------------------------------- 22-19ELECTRONIC CONTROL UNIT (ECU)------------------------------- 22-20FUEL INJECTOR ---------------------------------------------------------- 22-22WTS SENSOR -------------------------------------------------------------- 22-24THROTTLE BODY/T-MAP SENSOR/ISC/TPS ---------------------- 22-25DIAGNOSTIC TOOL CONNECTOR----------------------------------- 22-28DIAGNOSTIC TOOL OPERATION INSTRUCTIONS-------------- 22-30

22


22-1

UXV500i

SERVICE INFORMATIONGENERAL INSTRUCTIONS

Scooter services can be done with the engine installed in the frame. Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. Bending or twisting the control cables will affect operation and could cause the cables to stick or

bind, resulting in loss of vehicle control. Work in a fully ventilated area. Smoking or allowing flames or sparks in the work area or where

gasoline is stored can cause a fire or explosion. Do not apply the Carburetor Cleaners to the inside of the throttle body, which is coated with

molybdenum. Do not snap the throttle valve from fully open to fully close after the throttle cable has been

removed; it may cause incorrect idle speed. Do not loosen or tighten the painted bolts and screws of the throttle body. Loosening or tighten

them can cause throttle and idle valve synchronization failure. Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from

entering the intake ports after the throttle body has been removed. Do not damage the throttle body. It may cause incorrect throttle and idle valve synchronization. Do not take the fuel pump on the ground downward. Always replace the packing when the fuel pump is removed. The electronic fuel injection system is equipped with the self-diagnostic system. If the Check

Engine Lamp CELP illuminate while riding, follow the self-diagnostic procedures to solve theproblem.

A faulty AFI problem is often related to poorly connected or corroded connectors. Check thoseconnections before proceeding.

When disassembling the fuel injection parts, note the location of the O-rings. Replace them withnew ones upon reassembly.

Do not disconnect the battery negative (-) or positive (+) cable while engine is running, it maycause ECU damage.

Do not disconnect or connect the ECU connector during the ignition switch ON; it maycause the ECU damage.


22-2

UXV 500i

SPECIFICATIONS

ITEM SPECIFICATIONSThrottle body identification number PTA1Idle speed 1400100 rpmThrottle grip free play 26 mm (1/161/4 in)Fuel injector resistance (at 20C/68F) 10.6~15.9

Float at full position About 101 Fuel pump resistance(at 20C/68F) Float at empty position About 3 Fuel pump standard pressure (at 80 L/Hr) 30010 kPa (3 Bar)

At -20C/-4F 28.6 KAt 40C/104F/20C 1.46 K/3.51 K10%Water temperaturesensor resistance At 100C/212F 0.176K

T-MAP sensor resistance(20C) 1613~2544(1.2 pin)

Inductive ignition coil Primary: 0.55~0.75

Throttle position sensor (TPS) resistance (at20C/68F) 3500~6500 (1.2 pin)Crank position sensor resistance 96~144

Standard 0.41.4 VRoll sensor voltage Over 65 (fall down) 3.74.4 V


22-3

UXV500i

INJECTION SYSTEM DIAGRAM

(ECU)

FUEL PUMP

T-MAP SENSORCPS WTS VOLTAGETPS

Fuel Injector ISCInductive

Ignition Coil

END

KEY OFF?No

YES

InputSignalToECU

Key Switch OnOutputSignalByECU


UXV 500i

PARTS LOCATION

ECU ECUConnector

T-MAPSensor

T

Fuel Injector

InThrottle Body

PS

let Pipe22-4

ISC


22-5

UXV500i

Air/C

Fuel Pump

Fuel Pump CouplerConnector

Fuel Pump

Inductive ignition coil

WTSFuel HoseFuel Hose


UXV 500i

WTS

InductiveIgnitionCoil

Start Relay

Battery

Lo BeamRelayHi Beam Relay22-6


22-7

UXV500i

Winker Relay

Hazard ControlFuel Pump Relay

Roll Sensor

REG/RECSwitch PowerRelay


22-8

UXV 500i

TROUBLESHOOTINGEngine wont start Backfiring or misfiring during acceleration Battery voltage too low Ignition system malfunction Fuel level too low Pinched or clogged fuel hose Poor performance (drive ability) and poor Faulty fuel pump operating system fuel economy

Pinched or clogged fuel hose Clogged fuel injector Faulty fuel injector Faulty spark plug or wrong type Clogged Airflow Bypass Valve Wet spark plug

Engine stall, hard to start, rough idling Intake air leak Fuel contaminated/deteriorated Pinched or clogged fuel hose Idle speed miss adjusted Wet spark plug


22-9

UXV500i

CHECK ENGINE LAMP (CELP)z When turning on the switch, the lamp will

be lighted for 2 seconds then off. Letuser to know the lamp is available andconnect to ECU.

z But after then or during riding, if theCELP start to blink or keep lighting, itmeans something wrong with thisvehicle, you better do the further checkto find out the failure code to knowwhich part get trouble

z There are 3 kinds of priority grade letuser to know what kind of trouble washappened.

z Priority grade 1: CELP blinkscontinuously. This is the most emergentsituation like engine over heat. Userbetter slow down the riding and go todealer for checking.

z Priority grade 2: CELP lights all thetime. It means components get troubleor circuit something wrong. Do thefurther check to find out the failure codeto know which part get trouble.

z Priority grade 3: CELP just blinks oncesuddenly and then disappear. Itsometimes just warning like the RPMwas too high in a short term.

CELP (Check Engine Lamp)


22-10

UXV 500i

How To Show Failure Codez You can read the failure code by as

below :z Turn switch on. The CELP will be

lighted for 2 seconds then off. TheCELP start to blink to show the failurecodes

z (The number of blinks from 1 to 22).z If vehicle got more than one failure

code, the CELP will be shown fromlower number failure code and thenshow the other higher number one afterfour seconds. All the failure codeswould be shown repeatedly.

How To Reset Failure Codez After repairing the trouble, you should

clear the failure code or it will still exist inthe ECU memory. When you maintainthis vehicle next time, it will show againand you get confuse.

z Turn switch on. The CELP will be lightedfor two seconds then off.

z The CELP begins to blink to show thefailure codes.

z The self-diagnosis memory data will beerased when all the failure codes hasshowed for 4 cycles.

Example (failure codes 1 and 2):


22-11

UXV500i

CELP FAILURE CODES LIST

Blinks Failure Codes Fault description Priority Fault management

1 P0217

Engine temperatureoverheat

1

1.Slow down the vehicle and go to workshop forchecking immediately.2.Confirm if the engine temperature sensor or electriccircuit is abnormality.

2 P0335Crankshaft positionsensor or circuitmalfunction

2 1.Check if the connector of crankshaft position sensoris loosen.2.Check if the Rotor is align with Crankshaftposition sensor during the crankshaft running.

3 P1120

Throttle position sensorsetting value problem 2

1.Make sure if the connector of Throttle positionsensor is connected correctly.2.Check if the Throttle position sensor is adjusted.

4 P1121 Throttle position sensoroutput range problem

2


22. FUEL INJECTION SYSTEMUXV 500i


5 P1122

Throttle position sensormovement speedproblem 2


6 P0560 Battery voltagemalfunction

1 1. Check if the battery voltage is lower or higher.2.Check if the charge system is malfunction.

7 P0110 Intake air temperaturecircuit malfunction

2Inlet air temperature sensor or electric circuitmalfunction

1. Check if the connector of Idle air valve loosen.8 P0410 Idle air valve circuitmalfunction

2

2.Check if the resistance of valve is normal.

9 P0505

Idle speed volumecontrol range problem

3

1.Check if the ISC steps range over 65 steps .

10 P0251 Injector or electriccircuit problem

21.Check if the connector of Injector is loosen.2.Check if the ECU send signal to Injector.3.Check if the power source and resistance of Injectorare malfunction. 22-12


22-13

UXV500i


11 P0350

Ignition coil or electriccircuit malfunction

2

1. Check if the connector of ignition coil is loosen.2. Check if the ECU send signal to Ignition coil.3. Check if the power source and resistance ismalfunction

12 P0230Fuel pump relay orelectric circuitmalfunction

21. Check if the connector of relay is loosen.2. Check if the ECU send signal to relay.3. Check the fuel pump relay resistance

13 P0219 Engine speed is overthan top speed

2

Check if the belt of CVT is broken.

14 P1560 Sensor dont receivepower source from ECU

2

.Check if ECU output DC5V to sensor.2. Check if the power source of all sensor is DC5V.3. Replace a new ECU if the CELP still blinks even theoutput power source of ECU is normal.

15 P0700 Engine starting speedexceed CVT speedlimited

2

Dont use it at present.

16 P0115

Engine temperaturesensor or electric circuitmalfunction 2

1. Check if the connector of sensor is loosen.2. Check if ECU pin is broken.3.Check if the resistance of sensor is malfunction.

17 P1561 Temperature gaugeelectric circuitmalfunction

2

Dont use it at present.


22-14

UXV 500i


18 P0650 CELP electric circuitmalfunction 3

1. Check if the lamp of CELP is broken.2. Check if wires of CELP is broken.

21 P0105 Atmospheric PressureSensor/CircuitMalfunction

2

1. Check if the connector of sensor is loosen.2. Check if ECU pin is broken.3. Check if voltage of sensor is fit in specification.

P0110

Roll sensor or electriccircuit malfunction

2

1. Check if the sensor installation direction is correct.2. Check if voltage of sensor is fit in specification.3. Check if ECU pin is broken.22


22-15

UXV500i

TPS/ISC RESET If close or open the throttle grip randomly,

the ECU may record the incorrect TPSwhen the ECU or the throttle body hasbeen reinstalled. It can cause hard to startengine or idling speed is not smooth whenengine installation.

ISC has a motor inside, which controlsISC valve to obtain smooth idling speed.The ECU may record the incorrect ISCposition during the engine speed isntworking when the ECU or the throttlebody has been reinstalled. It can causeengine stop, hard to start engine or roughidling speed.

The throttle position sensor (TPS) and idleair bypass valve (ISC) have to be reset whenthrottle body, T-MAP, TPS, ISC or ECU hasbeen reinstalled.

TPS/ISC RESET PROCEDURE

Start the engine till engine temperature to

85C over on idle condition.

ECU will automatic learn engine newcondition.


22-16

UXV 500i

FUEL PUMP

INSPECTIION

Put the side stand up and the engine stopswitch is at RUN

Disconnect the fuel pump/fuel unitconnector.Connect the multimeter (+) probe to the Redterminal and the multi-meter (-) probe to theGray terminal.Turn the ignition switch to ON andmeasure the voltage between the terminals.It should be shown the current batteryvoltage for a few seconds.

If there is still battery voltage, replace thefuel pump.If there is not any battery voltage, inspectthe following: Fuse Fuel pump relay ECU

Measure the resistance between the Red(+)and Black(-) terminals of the fuel pump sideconnector.Standard (at 20C/68F): About 10.7

Fuel level sensor inspection

Measure the resistance between the redand blue terminals of the fuel pump sideconnector.

Standard (at 20C/68F):Float at full position About101Float at empty position About 3

F

E


22-17

UXV500i

REMOVALDisconnect the connector and fuel band fromthe fuel pump.Remove the six screws onto the fuel pump.Remove the fuel pump and O-ring.

INSTALLATIONReplace a new O-ring on the fuel tank.Dont damage the fuel pump wire andensure the connector rearward carefully.

Torque: 0.35 kgf-m (3.5 N-m, 2.5 lbf-ft)

FUEL OUTPUT PRESSUREINSPECTIIONTurn the key to the OFF position.Use the fuel hose clamp.Disconnect the fuel hose from the fuelinjector.Connect the fuel pressure gauge.Turn the key to the ON position.Check the fuel pressure.

Standard:3.0 Bar

Fuel Pump Connector

Hose quick bandScrew

O-ring

If the fuel output pressure is less than 3.0bar, may fail to start the engine or introuble in case of riding.


22-18

UXV 500i

FUEL PUMP RELAY

INSPECTION

Remove the fuel pump relay.Connect the ohmmeter to the fuel pumprelay connector terminals.

Connection: R/L-B/R

Connect 12 V battery with the fuel pumprelay connector.

Connection: R/Y-O/R

There should be continuity only when 12 Vbattery connected.If there is not continuity when the 12 Vbattery is connected, replace a fuel pumprelay.

REMOVALDisconnect the fuel pump relay connectorand remove it from frame.

Battery

Fuel Pump Relay

Fuel Pump Relay


22-19

UXV500i

TILT SWITCH(ROLL SENSOR)INSPECTIONSupport the ATV level surface.

Turn the ignition switch to OFFRemove the screws, washers and tilt switch.

Place the tilt switch vertical as shown, andturn the ignition switch to ON.Measure the voltage between the followingterminals of the tilt switch connector withthe connector connected.

Terminal Normal

V/R (+) -G(-) 5 V (ECUvoltage)B/W (+) G(-) 0.41.4 V

Incline the tilt switch 6510 degrees to theleft or right with the ignition switch turnedto ON.Measure the voltage between the followingterminals of the tilt switch connector withthe connector connected.

Terminal Normal

V/R (+) G (-) 5 V (ECUvoltage)B/W (+) G(-) 3.74.4 V

If repeat this test, first turn the ignitionswitch to OFF, then turn the ignitionswitch to ON.

REMOVAL/INSTALLATIONDisconnect the connector and remove twoscrews.Remove the Tilt switch.Installation is in the reverse order ofremoval.

Tighten the mounting screws securely.

Do not disconnect the tilt switchconnector during inspection.

Install the tilt switch with its UP markfacing up.

Roll Sensor


22-20

UXV 500i

ELECTRIC CONTROL UNIT(ECU)REMOVAL/INSTALLATION

Disconnect the ECU connector and removethe ECU from the frame.Installation is in the reverse order of theremoval.

ECU connector remove procedure (Same as DOWNTOWN 125i)

ECU connector install procedure (Same as DOWNTOWN 125i)

Do not disconnect or connect the ECUconnector during the ignition switchON; it may cause the ECU damaged.

The throttle position sensor (TPS) andidle air bypass valve (ISC) have to bereset when throttle body, MAP, TPS,ISC or ECU has been reinstalled.

ECU Connector


22-21

UXV500i

INSPECTIONOutlook checkingChecking for ECU pin(1-48) if has damage.

Checking for ECU part number if is correct.3920A-LKC3-E00 is correct

Voltage inspectionConnect the meter (+) probe to theB4(R/W)wire and themeter (-) probe to the M3(G/B) wire tomeasure the voltageMAP content (edition issue no.)

Performance confirmed


22-22

UXV 500i

FUEL INJECTOR

INSPECTIONDisconnect the fuel injector connector.Measure the resistance between 2 pins of thefuel injector connector.

Standard: 10.6~15.9 (at 20C/68F)

REMOVALDisconnect the connector from the fuelinjector.Remove the bolts of the fuel injector.Take out of the fuel pipe and fuel injectorfrom the Inlet pipe.Remove the fuel injector from the fuel pipe.

Connector

Bolt

Ensure the fuel pipe without anypressure, then remove the fuel injector.STEP 1: Disconnect the fuel pump relayor fuel pump connector.STEP 2: Turn the key to the ONposition. Starting the engine till theengine stop working.


22-23

UXV500i

INSTALLATIONApply the engine oil to a new O-ring.Install the fuel injector into the fuel pipe.Ensure the clip of the fuel injector insertedinto the groove of the fuel pipe.

Install the fuel pipe into the intake manifold

Be careful not to damage the O-ring.Tighten the fuel pipe mounting bolts.

FUEL INJECTOR CLEANING

PROBLEM1. Fuel Injector cannot output the fuel.2. The Injector injection time (ms) is shorter

or longer.Standard: See the KYMCO Diagnosticreport

ANALYSISInjector block (With some carbons).

TROUBLESHOOTING1. Use the specified injector cleaner.2. Pouring the liquid of injector cleaner until

half container.3. Connect the battery as picture.4. The injector cleaner with the flash relay.5. Keeping the fuel Injector operation.6. Waiting for 20~30 minutes.7. Cleaning the carbons completely.

clip

GrooveO-ring

Battery

Flash Relay

Container

FuelInjector

Injectorcleaner


22-24

UXV 500i

WTS SENSOR (WaterTemperature Sensor)

REMOVAL / INSTALLATIONDrain the coolant from the cooling system.Disconnect the WTS sensor connector fromthe sensor.Remove the WTS sensor and O-ring.

Install a new O-ring and WTS sensor.

Tighten the WTS sensor to the specifiedtorque.

Torque: 1.2 kgf-m (12 N-m, 8.6 lbf-ft)

Connect the WTS sensor connector.

Fill the cooling system with therecommended coolant.

INSPECTIONMeasure the resistance at the WTS sensorterminals.

STANDARDC -20 40 100

K 28.6 1.46 0.176

Standard: 3.5110% K (at 20C/68F)

Always replace an O-ring with a new one.

O-ring


22-25

UXV500i

THROTTLE BODY/T-MAP SENSOR/ISC/TPS

Turn off the ignition switch whilereplacement.

Check and confirm if the voltage is over12V by a voltmeter after replacement.

Check and confirm if the other connectorsare installed correctly after replacement.

Do not damage the throttle body, it maycause the throttle and idle valve isntsynchronization.

The throttle body is preset in KYMCOfactory, do not disassemble it by a wrongway.

Do not loosen or tighten the painted boltsand screws for the throttle body. Loosen ortighten them can cause the throttle and idlevalve to synchronization failure.

TPS and ISC have to be reset after thethrottle body T-MAP, TPS, ISC or ECUhas been reinstalled.

T-MAP SENSOR INSPECTIONSupport the scooter on a level surface.Put the side stand up and engine stop switchis at RUN.

Turn the ignition switch to ON position.

Measure if the ECU voltage outputs to theT-MAP sensor between the followingterminals of the MAP connector.

Terminal NormalV/R (+) -V/G (-) 5 V

TPS Sensor T-MAP Sensor

ISC


22-26

UXV 500iTPS INSPECTIONSupport the ATV on a level surface.

Turn the ignition switch to ON.Measure if the ECU voltage outputs to TPSbetween the following terminals of the TPSconnector.

Terminal NormalV/R (+) -V/G(-) 5 V

Throttle position sensor (TPS) resistance(at 20C/68F) 3500~6500

REMOVALLoosen the throttle cables with the adjustingnuts.Disconnect the throttle cable ends fromthrottle seat.

Disconnect the TPS, ISC and T- MAPsensor connectors.Loosen the air cleaner connecting hose bandscrew.Loosen the intake manifold band screw.Remove the throttle body, T-MAP sensor,TPS sensor and ISC sensor as a set.

Cable Ends

Adjusting Nuts

TPS Sensor T-MAP Sensor

ISC


22-27

UXV500i

DISASSEMBLY

Remove the screws and then remove theISC .Remove the screw..Remove the T-MAP sensor.Remove the screw and then remove the TPS.

ASSEMBLY

Apply oil onto a new O-ring.

When install the TPS onto the throttle body,being careful not to damage the O-ring.Install and tighten the screw securely.

TPS

Screw

ISC TPS

T-MAP sensor

The throttle position sensor (TPS) and idleair bypass valve (ISC) have to reset whenthe throttle body T-MAP sensor, TPS, ISCor ECU has been reinstalled.

Screws ISC

Screw T-MAP sensor


UXV 500i

Apply oil onto a new O-ring.

When install the T-MAP sensor onto thethrottle body, being careful not to damagethe O-ring.

Install the set plate and tighten the screwsecurely.

Apply oil onto a new O-ring.When install the ISC and T-MAP sensoronto the throttle body, being careful not todamage the O-ring.

DIAGNOSTIC TOOLCONNECTOR

INSPECTIONUnhook the hood and then slowly tilthood up until it .Make sure moving the shift lever into theN or P position .Remove diagnostic tool connector protectsheath.Turn the ignition switch to ONMeasure the voltage between the followingterminals of the diagnostic tool connector .

Terminal NormalBR/L (+) G/B (-) Battery voltage

B/L (+) W/L (-)Battery voltage1 V

T-MAP sensor

O-ring

Always replace an O-ring with a new one.

Screws ISC

Screw T-MAP se22-28

nsor

Diagnostic Connector

Diagnostic ConnectorProtect sheath.

Hood


22-29

UXV 500i

SF : Customer : Eng. No:ServiceDate : Mileage :

Reason of repair: maintenance breakdown

Date ReferenceECU No LKC3Hardware VerSoftware VerCalibration Ver QK111010Model Name A4LKC3QKAAActiveOccurredHistoryAir Temp.(C) environ.temp 2 CEngine Temp.(Coiling) environ.temp 2 C

Atom. Pressure(Kpa) 101.3 3 kPaThrottle Position(%) 0% / 90% over Idle/Throttle fullyThrottle Position (V) 0.67V 0.05 / >3.6VIdle/Throttle fullyTPIIdleMean (V) 0.67 0.05Battery Volt (V) >12 VIdle speed setpoint (rpm) ---ISCAdapMean () ---Roll Sensor volt (V) ---Accumulated ECU. run time(M) ---EngineSpeed IDLE(rpm) 1400 100 rpmMAPSample (kPa) 30 ~ 40kpaInjection duration (ms) 2.6 ~ 3.8msIgn. Advance () 12 ~ 16 BTDCIgn.Dwell duration (ms) ---Air Temp.(C) >45 CEngine Temp. (C) >80 CO2 sensor voltage (V) ---O2 sensor heater (Yes/no) ---O2 sensor correct ---IDLE CO(% ) 1.5 ~ 4.5 %ISC Step < 65

2 5%EngineSpeed IDLE(rpm) 1400 100 rpmMAPSample (kPa) 30 ~ 40kpaInjection duration (ms) 2.6 ~ 3.8msIgn. Advance () 12 ~ 16 BTDCIgn.Dwell duration (ms) ---Air Temp.(C) >45 CEngine Temp. (C) >80 CO2 sensor voltage (V) ---O2 sensor heater (Yes/no) ---O2 sensor correct ---IDLE CO(% ) 1.5 ~ 4.5 %ISC Step < 65

2 5%Repair description Repair Process

Report Version : JAN/29/2010

The ambient pressure drop about 12 kpa at the altitudeevery 1000m raised

UXV 500i

Report ID=

ProductionDate :

Item MemoECU

Version

DT

C(C

ool Engine) E

ngineStop(H

ot Engine) B

eforeRepair

(Hot E

ngine) AfterR

epair


22-30

UXV 500i

UXV500 i FI DIAGNOSTIC TOOLOPERATION INSTRUCTIONS

3620A-LEB2-E00(ENGLISH VERSION)version:V1.0.7

22. FUEL INJECTION SYSTEM31

22-31

UXV 500i

1. FI DIAGNOSTIC TOOL

z This tool is developed by KYMCO and for KYMCO vehicle only.z Please refer to the specification when serving this vehicle.z This tool is without battery inside. The power is provided from vehicle.z This software can be updated with computer for new model through the

USB cable. The power required of tool is connected with 12V battery.z For connection, please connect this tool with the connector of ECU. Its

available when turning on the ignition switch.

z The function includes ECU version, model name, data analysis .- ECU version: includes model name, ECU number, identifications

number and software version.- Failure codes: DTC reading, DTC clearing and troubleshooting.- Data analysis: For ECUs software inspection.- Adjust : The adjust function setting is not allowed

DATA Analyze

ECU Version

DTC Inspect

Adjust

UP Button Down Button

Enter or ExitPower indicator DTC indicator(Failure codes)

Model No.LKC3


22-32

UXV 500i

2. DTC INSPECTION PROCEDURE

Showing four functions on the screen when switching onpower.

A). ECU version: Including of model name, ECU number, identificationsnumber and software version. Press the Enter button

Press the " Enter " button

LKC3 is forUXV500i

LKC3 is forUXV 500i

22. FUEL INJECTION SYSTEM33

22-33

UXV 500i

B). Press the " Down " button and then turn to the first page.

C). Press the " Enter " button to check the DTC failure code


22-34

UXV 500i

D). Press the " Enter " button

E). Press the " Enter " button

F). Display what's DTC number on this DTC-List. Press the " Enter " button and then turn to the previous page


22-35

UXV 500i

G). Press the " UP " button

H). Press the " Enter " button and then turn to the previous page .

I). Press the " UP " button


22-36

UXV 500i

J). Press the " Enter " button and then turn to the first page.


22-37

UXV 500i

3. DTC CLEAR PROCEDURE

A). Check the DTC

B). Press the " Enter " button

C). Choose " DTC Load " Press the " Down " button


22-38

UXV 500i

D). Press the " Enter " button and the indicator is lighting.

E). Clearing DTC completed if the indicator is off.


22-39

UXV 500i

4. DATA ANALYSIS PROCEDURE

A). Press the " Down " twice

B). Choose Data Analyze Press the " Enter " button to enter page 01

C). Down-page 01 The measure figures including of Engine speed, Battery voltage

and Engine speed. Press the " Down " button to enter page 02.


22-41

UXV 500i

D). Down-page 02 The measure figures including of TPS position, TPI idle adapted

and ISC step . Press the Down button to enter page 03.

E). Down-page 03 The measure figures including of engine temperature ,air

temperature and intake pressure .Press the Down button to enterpage 04.

F). Down-page 04 The measure figures including of atmosphere pressure, fuel

injector interval and ignition advance . Press the Down button toenter page 05.


22-42

UXV 500i

G). Down-page 05 The measure figures including of gear position and gear ratio.

Press the Down button to enter page 06.

H). Down-page 06 The measure figures including of rollover voltage(The function

setting is not allowed). Press the Down button to enter page 07.

I). Down-page 07

The measure figures including of ECU counter.

J). Press the " UP " to the previous page.

STARTER MOTORSTARTER MOTOR

BATTERY

12V 18AH

START MAGSTART MAG

WINKERRELAYWINKERRELAY

GEARCHANGE SWGEARCHANGE SW REAR

STOP SWREARSTOP SW

HAZARDHAZARD

SB

RH FR WINKER12V 10W

RH FR WINKER12V 10W

FR POSITION12V 5W

FR POSITION12V 5W

HEAD LIGHT12V 35W/35WHEAD LIGHT12V 35W/35W

W

L

G G

BR/L

HORN

RH FR WINKER12V 10W

RH FR WINKER12V 10W

BR

G

L/B

W/B(1)W/B(1)

G

L

W

HEAD LIGHT12V 35W/35WHEAD LIGHT12V 35W/35WFR POSITION12V 5W

FR POSITION12V 5W

BR

BR

BR

G

G

RRSTOP SW

RRSTOP SW

L1

C

L2

MOTORFAN

M

FANTHERMO SW

FANTHERMO SW

IGN.

COIL

IGN.

COIL

SPARK

PLUG

SPARK

PLUG

REG RECT ASSYREG RECT ASSY

IC

PULSER

ACG

12V 5W12V 5WLICENCE LIGHTLICENCE LIGHT

G G

SB

RH RR WINKER12V 10W

RH RR WINKER12V 10W

TAIL/STOP LIGHT12V 5/21W


G/Y

G

BR

G/Y

G

G

G/Y

G

G/Y



RH RR WINKER12V 10W

RH RR WINKER12V 10W

O

SB

O

BR

BRBR

BR BR

FUSE A:10A(FAN MOTOR)FUSE A:10A(FAN MOTOR)

FUSE D:15A(DC 12V POWER)FUSE D:15A(DC 12V POWER)

FUSE B:15A(IGN)FUSE B:15A(IGN)

FUSE C:15A(LIGHT)FUSE C:15A(LIGHT){

10A 15A

A B

15A

C

FUSE BOX ASS'YFUSE BOX ASS'Y

W/B(1)W/B(1)

L/B

L/W

Y/WMETER FUELMETER FUEL

W/R

L/R

LG/R

METER

N

R

L

L/R(2)

G/B

L(1)

O

SB

BR

BR/L

R/W

FREE

PUSH

START SWSTART SW

COLOR

ST C

COLOR

PO

OFFON

LIGHT SWLIGHT SW

HI

COLOR

LO HAZARD SWHAZARD SW

BAT

COLOR

HACOMB SWCOMB SW

B/W

IG

B R RED

G GREEN GR

ORANGE

WHITE

YELLOW

W

Y

BLUE

O

L

SB

LG

BLACKB BR

GRAY

LIGHT GREENLIGHT GREEN

SKY BLUESKY BLUE

BROWN

BATHO

HORN SWHORN SW

PUSH

FREE

BLG Y/R Y/BR BR/B W L R/W Y/BGROSB

LR

COLOR

WR

L

R

WINKER SWWINKER SW

R

PO

E BAT1 POBAT2

G BR

GND(-)

H.B

TURN(L,R)

BACKLIGHT

IGN

BAT+

METER

LO-

RELAYBEAM

LO-

RELAYBEAM

W/B(2)D

CAN(+)

15A

D

POWERDC12VPOWERDC12V

2WD/4WD SW2WD/4WD SW

W/O

2WD

COLOR

4WD

2WD

2WD/4WD SW2WD/4WD SW

4WD

W/L

4WDLOCK4WDLOCK

4WDLOCK4WDLOCK

G

W/L(2)

R/W

R/W

Y/R

STARTRELAYSTARTRELAY

Y/G

G

G/Y

G

CLUTCHDIODECLUTCHDIODE

Y/G

LG/R

Y/G

GGR

BR/L

G/Y

BR/L

G/Y

BR/L

BR/L

B(1)

B(2)

RR/W

Y/B

GSB

O

Y/B

GSB

O

WGR/W

W/B(1)

LGR/W

L/BG

LG

O

G G

O

G

SB

BR/L

G/Y

W/L(1)

B(2)

L/B(2)

B(2)

L(2)

B L

B L

L(2)

G

GR

G

B(1)

R/W

B R

G

Y Y Y

Y Y Y Y Y Y

L/Y

G/W(1)

L/Y

G/W

G

G/B

ENG TEMPENG TEMP

t

(ETC)

4P

TMAPSENSORTMAPSENSOR

(T-MAP)

3P

THROTTLEPOSITIONSENSOR

THROTTLEPOSITIONSENSOR

(TPS)

4P

IDLESPEEDCONTROL

IDLESPEEDCONTROL

(ISC)

V/R

V/B

V/G(1)

V/R

V/G(2)

O/B

BR/W(2)

G/O

BR/W(1)

G/B(2)

GR/L

A B C D

G/L

1 2 3 4

4P

FUELRELAYFUELRELAY

B/R

R/L

O/R

R/Y

V/G(1)

4P

FANRELAYFANRELAY

B(2)

L(2)

GL/B(2)

4P

SWITCHEDPOWERRELAY

SWITCHEDPOWERRELAY

B/O

R/W

R/Y

1 2 3 4 1 2 3 4

48PEFI ECU (M3 C)EFI ECU (M3 C)

SENSORPOWER

SENSOR

POWER

(A1)

(A2)

(A3)

+12VSWITCHPOWER

+12VSWITCH

POWER

(A4)

CAN-HIGH(+)

CAN-HIGH

(+)

(B1)

+12VMEMORY

+12VMEMORY

CAN-LOW(-)

CAN-LOW

(-)

(C1)

SENSORGROUND(1)

SENSOR

GROUND

(1)

ISC(STEPB2)

ISC(STEPB2)

CRANKANGLE(+)

CRANK

ANGLE

(+)

(D1)

TILTSENSOR

TILTSENSOR

ISC(STEPA1)

ISC(STEPA1)

ISC(STEPA2)

ISC(STEPA2)

CRANKANGLE(-)

CRANK

ANGLE

(-)

(E1)

ISC(STEPB1)

ISC(STEPB1)

BRAKESWITCH

BRAKE

SWITCH

(F1)

MANIFOLDPRESSVRE

MANIFOLD

PRESSVRE

AIRINTAKETEMP

AIRINTAKE

TEMP

ENGINECOOLANTTEMP

ENGINE

COOLANT

TEMP

LHCA-ENGINESTOPSW

(G1)

SENSORGROUND(2)

SENSOR

GROUND

(2)

THROLLERPOSITION

THROLLER

POSITION

K-LINE

(H1)

GEAR-B(H)

GEAR-B

(H)

SPEEDSIGNAL

SPEED

SIGNAL

GEAR-C(N)

GEAR-C

(N)

FUELRELAY

FUELRELAY

(J1)

DIFF-LOCKINPUT

DIFF-LOCK

INPUT

GEAR-A(R)

GEAR-A

(R)

OVERRIDE

IGNITIONRELAY

IGNITION

RELAY

(K1)

FANRELAY

FANRELAY

4WDINPUT

4WDINPUT

+12VSWITCHEDPOWER

+12VSWITCHED

POWER

(L1)

STARTERSOLENOID

STARTER

SOLENOID

INJECTOR

IGNITIONCOIL

IGNITION

COIL

(M1)

(M2)

GROUND(1)

GROUND

(1)

(M3)

GROUND(2)

GROUND

(2)

(M4)

(B2)

(B3)

(B4)

(C2)

(C3)

(C4)

(D2)

(D3)

(D4)

(E2)

(E3)

(E4)

(F2)

(F3)

(F4)

(G2)

(G3)

(G4)

(H2)

(H3)

(H4)

(J2)

(J3)

(J4)

(K2)

(K3)

(K4)

(L2)

(L3)

(L4)

B/Y

W/R(2)

B/W

V/R

G/O

BR/W(1)

GR/L

V/G(1)

G/W(1)

V/B

L/Y

V/G(2)

G/L

BR/L

O/B

BR/W(2)

G/B(1)

G/B(2)

L/R

B/R

W/L(2)

B/L

G/L(2)

R/W

FUEL PUMPLEVEL SENSORFUEL PUMPLEVEL SENSOR

4P

L/W

G ENGCHECK

ENGCHECK

B/O

R/Y

V

Y/W

O/R

GEAR-D(L)

GEAR-D

(L)

W/R

W/B(2)

LG/R

FRSTOP SW

FRSTOP SW

BR/L

G/Y

EMIFILTER

EMIFILTER

W/BR

L/R

LG/R

W/B

W/R(1)

L/R

LG/R

W/B(2)

W/R

RDN

PL

10A 10A

SPEEDSENSORSPEEDSENSOR

IC

V G BR/L

E F

R/L

B(1)

SENSOR,

ANGLE

DETECT FUEL INJFUEL INJ

W/R(2)

V/R

B/W

G

R/Y

B/Y

R/Y

CANDIAGNOSTICSCANDIAGNOSTICS

B/LW/L(2)BR/LG/B

CAN-H(+)CAN-L(-)BAT(+)BAT(-)

2WD/4WDACTUATOR(4WD&LOCK)

2WD/4WDACTUATOR(4WD&LOCK)

W/L(1)BR/L

G W/O

LIGHTINGSWLIGHTINGSW

BR

W L(1)

BR/B

BR

W L(1)

BR/B

STARTERSWSTARTERSW

Y/R

R/W

B

OFFOFF

PO LO

HI OFF

ON START

Y/R

R/W

B(1)

WINKER/HORNSW

WINKER/HORNSW

G GR

SB

RL

W/O

HAZARDSWHAZARDSW

R/W

Y/B

R/W

Y/B

O

LG

GR

SB

O

BR/B

Y/G

G/B(1)

L/R(2)

W/L(1)

L(2)

W/BR

W/BR

ENG CHECKENG CHECK

P

4WD & LOCK4WD & LOCK W/O

CAN(-)

B/L

R/W

G

HAND BRAKEHAND BRAKE GR/W

HANDBRAKE SWHANDBRAKE SW

GGR/W

GGR/W

FUSE A G10A (FAN MOTOR)FUSE B G15A (IGNITION)FUSE C G15A (LIGHT)FUSE D G15A (DC 12V POWER)FUSE E G10A (FUEL)FUSE F G10A (SPARE)

FUSE A G10A (FAN MOTOR)FUSE B G15A (IGNITION)FUSE C G15A (LIGHT)FUSE D G15A (DC 12V POWER)FUSE E G10A (FUEL)FUSE F G10A (SPARE)

KYMCO UXV500 i

ON ROAD

KYMCO UXV500 i

ON ROAD

0030Z-LKC3-E003(2010.02)

HI

BEAM

-

RELAY

HI

BEAM

-

RELAY

uxv500i 500se 500ile service manual

Documents