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CFMoto ATV Terralander CF800-2. Service Manual - part 6

14 FRONT DIFFERENTIAL/REAR GEARCASE

f Adjust item “29” as illustrated, and make sure the

Ring Gear

distance between its end and back of the ring gear is

0.3~0.6. Tighten item “31”.

Apply threadlocker here

14-11

CHARGING SYSTEM

Charging Circuit

4

5

6

3

1

2

1.Magneto 2.Voltage Regulator/Rectifier 3.Voltage Stablizing 4.Fuse 5.Battery 6.Load

Magneto Coil Resistance

Measure 3-phase magneto stator coil resistance;

If the resistance is out of specification,replace with

a new stator;

Check for the insulation between stator coil and

core.

Turn multimeter to 1X10

MAG Coil Resistance 0.5-1.5

(Yellow-Yellow)

Resistance between Stator Coil and Core:

(Yellow-Ground)

MAG Non-loaded Performance

Start the engine and allow it run at 5000r/min;

Use multimeter to measure the voltage

between 3 output lines.

Ifthe reading is below specification,replace with

a new magneto.

Turn Multimeter to V(AC)

Voltage between Output Lines When MAG

Non-loaded:

>200V(AC) at 5000r/min

15-2

15 ELECTRICAL SYSTEM

VOLTAGE REGULATOR/RECTIFIER

1

2

3

After engine running and at the state of battery

Connect multimeter between terminals;

full charged,if the voltage between positive and

Read resistance;

negative terminal exceeds 15v or is lower 12v,

If any reading is out of specification,

replace with a new MAG.

replace with a new regulator.

Turn multimeter to DIODE.

NOTE:

If multimeter reads below 1.4v when

15

probes unconnected,replace its battery.

(+)

1

2

3

(-)

(+)

1

400-500

2

400-500

(-)

3

400-500

(-)

(+)

400-500

400-500

400-501

750-850

15-3

STARTING SYSTEM

Starting Circuit Diagram

1

3

1.Outer Cover

2.Brush Holder

2

5

3.Brush Spring

4.O-ring

4

5.Brush Terminal

6

6.Main Housing(yoke)

4

7.Washer

8.Armature

9.Washer

10.Cover Inner

11.O-ring

9

7

8

11

10

15-4

15 ELECTRICAL SYSTEM

BRUSH

Check brush for damages,cracks.

If any damages,replace with a new brush.

COMMUTATOR

Check for color change,damages,wear;

If any damages,replace with a new commutator;

If the color changes,poslish the commutator sur

face with sand paper and wipe it up with a clean,

dry cloth.

If over wear,cut a part of insulator B and main

tain the distance betwen A nd B as d.

d

1.5mm

ARMATURE

Use a multimeter to check the armature coil continu-

ity and the one between coil and the shaft.If armature

coil has no continuity or there is continuity between

15

the coil and the shaft,replace the armature with a new

one.

OIL SEAL

Check for damages or leaks.

If damages or leaks,replace with a new starter

motor.

15-5

STARTER RELAY

Put 12V between positive and negative

terminal.

Use multimeter to check if there is continuity

between 2 contacts.

If multimeter clicks,there is continuity between

contacts.

If 12V is removed,no continuity remains between

contacts.

If both above 2 items are ok,it indicates the

replay is ok.

Turn mulitimeter to DIODE.

CAUTION:

The voltage loaded between terminals can not

exceed 2 mins,otherwise,starter relay may over-

heat or burn.

Use multimeter to measure starter relay coil

resistance,if the reading is out of specification,

replace a new relay.

Turn multimeter to 1X10

Starter Relay Coil Resistance:3-5

AUXILIARY STARTER RELAY,FUEL

PUMP RELAY

A

Put 12V between auxiliary starter relay positive and

negative terminal;use multimeter to cheack the

continuity between A and B.

Turn multimeter to DIODE.

If multimeter clicks,it indicates there is continuity

between A and B.

If 12V is removed,no continuity remains between

B

contacts.

If both above 2 items are ok,it indicates the

Ground

replay is ok.

Turn multimeter to

1X100

;measure auxiliary

starter relay resistance.

Auxiliary starter relay resistance

90-100

NOTE:At the back of auxiliary starter relay,parallel to

Battery(+)

diode,it’s the relay coil positive terminal.

15-6

15 ELECTRICAL SYSTEM

ENGINE STARTING NOTICE

Poperly route according to starting schematic

diagram.

Before starting,check if all parts are fitted correct;

Regarding EFI components connection,refer to EFI

section.

Check air intake system.

Check fuel supply system;ensure there is no bolck

or leaks.

Test fuel presure with fuel pressure gauge.

Pressure in fuel pump outlet:0.33

0.01Bar.

Place the transmission in Neutral.

Check EFI with PDA for faut;if there is,eliminate

the trouble according to DTC(Diagnostic Trouble

Code).

Fuel Pressure Gauge

Close the throttle and turn the engine stop switch

to “RUN”,then push starter switch to run the engine.

After starting,warm up until idle speed is stable and

check it.

NOTE:

If idle speed is unstable or too high,shut off the

15

engine,and then start it.

Idle Speed:1250

100rpm.

15-7

EFI Structure

Idle Air Control Valve

T-MAP Senor

Air Filter

Ignition Coil

Coolant Temp. Sensor

TPS

O2S(Oxygen

Sensor)

CPS

ECU

Fuel Pump

EFI system is composed of three

subsystems:

Sensors:

A sensor is a device that measures a physical

(3)Actuator:

quantity and converts it into a signal which can be

Execute the EFI instruction.Main actuators include:

read by an observer or by an instrument.Sensors in

Fuel Pump

EFI system include:

Fuel Injector

Throttle Position Sensor(TPS)

Ingnition Coil

Crankshaft Position Sensor(CPS)

Idle Air Control Valve

Coolant Temp. Sensor

Speed Sensor

Gear Positon Sensor and Reverse Gear Sensor

Oxygen Sensor

4WD/LOCK

Over-ride Switch

(2)ECU:

Electronic Control Unit,the brain of EFI system,which

determines the amount of fuel injection, ignition tim-

ing and other parameters a engine needs to keep run-

ning by calculating and analysing values provided by

sensors.

15-8

SERVICE TOOLS

Tool Name:PDA

Function:

Read/clear EFI system trouble codes,observe

datastream.

Tool Name:Digital Multimeter

Function:

measure voltage, current and resistance

and other parameters in EFI system.

Tool Name:Vaccum Gauge

Function:

Check the manifold for air pressure.

15-10

15 ELECTRICAL SYSTEM

Tool name:Timing Light

Function:

This light is used to check engine ignition timing.

Tool name:Compression Tester

Function

This tester is used to check cylinder compression,so

as to determine if the rings or valves are bad and leak-

ing pressure.

Tool Name:Fuel Pressure Gauge

15

Function

This gauge is used to test the fuel pressure,so as to

check fuel pump and fuel pressure regulator working

conditions.

Tool Name:Fuel Injector Analyser

Function:

This analyser is used to clean and analyse fuel

injectors.

15-11

EFI COMPONENTS AND FUNCTION

(1)ECU:

ECU pins and function:

PINOU T CH ART

J1 CONNECTOR

PIN#

Description

PIN#

Description

J1-1

IACVHI/IAV

J1-10

COILB/ESTB

J1-2

MAGNETO

CUT

J1-11

IACALO

RELAY/CLTL/ESTC

J1-3

MIL

J1-12

IACBHI

ECU

J1-4

DEAD

BATT

J1-13

IACBLO

BYPASS/O2BHTR/INJC

J1-5

SPARE ANALOG

J1-14

ROLLOVER

J1-6

TACHOMETER

J1-15

VSS/02B SENSOR

J1-7

CANLO

J1-16

DIAG

J1-8

CANHI

J1-17

FUEL PUMP RE-CIR

J1-9

GND(POWER)

J1-18

PN SW

J2 CONNECTOR

Pin#

Pin#

Description

J2-1

COILA/ESTA

J2-10

5VRTN

J2-2

GND(POWER)

J2-11

MAP

J2-3

KW 2000

J2-12

TPS

J2-4

CRANK VR HI(23XHIFI)

J2-13

C RANK VR LO(23XLOFI)

J2-5

IN JA

J2-14

CLT

J2-6

IN JA

J2-15

IGN

J2-7

O2A HTR

J2-16

5VR EF

J2-8

IAT-MAT

J2-17

O2A SENSOR

J2-9

FUEL PUMP RELAY

J2-18

VBATT

J2

J1

9

1

9

1

18

10

18

10

ECU Pin Locations:

Limit Data:

Value

Item

Unit

Min

Standard

Max

Operation

9.0

14.0±1

16.0

V

Battery Voltage

Normal

Function

6.0-9.0

16.0-18.0

V

Limited

Withstanded

Limited Function Such As

26.0V

5.0

Min

Overvoltage and Time

Diagnosis

Working Temp

-40

+70

Storage Temp

-40

+70

It’s not allowed to apply a heavy load on ECU housing,or it may deform and damage ECU.

Always handle ECU gentlely.Never drop it,especially on a hard surface.

15-12

15 ELECTRICAL SYSTEM

(2)THROTTLE BODY ASSEMBLY:

Idle Air Control Valve

Connected

with Air Filter

Connected between air filter and engine.When throttle

lever is applied,the valve butterfly in throttle body would

spin at a certain angle.Tps can monitor the position of

valve butterfly and send the signal to ECU.

TPS

Pins and function:

Connected with Air

1.Connected to 5V power

Intake Manifold

2.Ground

Throttle Body Assembly

3.Outout voltage signal

1

2

3

TPS

15

TPS Circuit:

9

1

TPS

ECU

J2

18

16

12

10

Idle speed limiter screw is not allowed to adjust.

Idle speed is regulated by ECU.

Idle Speed

Adjuster Screw

15-13

(3)T-MAP SENSOR:

This sensor integrates Inlet Air Temperature Sensor

and Manifold Absolute Sensor.It’s used to detect both

inlet air temperature and maifold absolute pressure,

providing ECU the signal of engien load.

4 3

2 1

Pins and Function:

1.Ground

2.Connected with 5V power

3.Voltage signal output

T-MAP Sensor

T-MAP Sensor Circuit:

9

1

J1

ECU

MAP Sensor

18

16

11

10

1

4

2

9

8

1

J2

18

10

IAT Sensor

1

3

The right figure illustrates the allowed installation angle

to avoid condensated water built up in T-MAP sensor,

causing pressure sensitive elements damage.

15-14

15 ELECTRICAL SYSTEM

The following figure refers to output volatge-pressure relation.

5

4.65

0.4

0

0

10

115

Absolute Pressure in kPa

The following chart explains resistance-temperature relation.

15

60000

50000

40000

30000

20000

10000

0

-40 -30 -20 -10

0

10

20

30

40

50

60

70

80

90

100 110

120 130

-10000

Temp.(

)

Resistance(OHM)

15-15

(4)COOLANT TEMPERATURE SENSOR

(CTS):

This sensor is a negative temperature coefficient(NTC)

thermistance,whose resistance increases with the tem-

perature of coolant decreases.It outputs 2 set of

coefficients,one is for ECU to monitor the tempera-

ture of coolant,the other is for meter dispaly.

A and C consists of one group,which provids signal for

ECU.

Coolant Temperature Sensor

B and threaded portion consists of one group,which

provides sigal for coolant temperature gauge.

Coolant Temperature Sensor Circuit:

9

1

ECU

J2

T

18

14

10

T

B

A C

Connected with Meter

The right chart explains pin B and threaded portion-

Meter Channel Resistance(b-Threaded Portion)

coolant temperature relation.

Temp.(

?

)

Resistance(Ω)

45

265.0-323.0

80

74.6-90.6

115

25.7-31.7

The right chart explains pin A,C-coolant temperature

ECU Channel Resistance(a-c)

relation. The siganl is for ECU.

Temp.(

?

)

Resistance(Ω)

-25

38,583

0

9,399

25

2,795

80

334

115

115.7

15-16

15 ELECTRICAL SYSTEM

(5)OXYGEN SENSOR:

This sensor is used in closed-loop feedback-controlled

fuel injection to improve the air-to-fuel ratio accuracy

and control the emission.

It’s located in the exhaust stream to measure

the amount of oxygen in exhaust and send the signal to

ECU,which can revise the fuel injector output ,so as to

reduce the amounts of both unburnt fuel and oxides of

nitrogen entering the atmosphere.

Pins and Function:

1.Connected with positive terminal,heating power(white)

D C

B

A

2.Connected with negative terminal,heating power(white)

3.Connected with negative terminal,signal output(grey)

4.Connected with positive terminal,signal output(black)

Oxygen Sensor Circuit:

Engine

Stop

D

C

BA

D

C

B

A

Switch

9

7

1

9

5

4

1

1817

10

18

10

15

J2

J1

ECU

O2S

2

O2S 1

The following table explains the oxygen sensor working parameters.

Parameter

New oxygen sensor

After 500 hours bench test

Exhaust temp. at a

350

850

350

850

certain duty ratio

Sensor voltage

(mv)

840±70

710±70

840±70

710±70

when λ=0.97(Co=1%)

Sensor voltage

(mv)

20±50

55±30

20±50

40±40

when λ=1.10

Sensor inner resistance

1.0

0.1

1.5

0.3

Response

150

150

300

200

time(ms)(600mv-300mv)

Response

150

150

300

200

time(ms)(300mv-600mv

15-17

(6)CRANKSHAFT POSITION SENSOR

(CPS):

Detects the rate at which the crankshaft is spinning

and provides the signal for ECU to determine ignition

and fuel injection.

A

B

(+)

(-)

CPS Circuit:

CPS

9

4

1

J2

18

13

10

A

B

ECU

CPS Resistance:

Set multimeter to 1X2K range;

CPS resistance:950

50

(20

)

If the CPS resistance reading is out of specifi

cation above,replace.

Test CPS Peak Voltage

AC Magneto

Connect multimeter and peak voltage adapter as

CPS Resistance

right wiring diagram illustrates;

+Probe: Green Lead

- Probe: Blue Lead

NOTE:

When using peak voltage adapter,refer to some

CPS Peak Voltage Tester

instructions.

Set multimeter to V range;

Place the transmission in N and turn the ignition

switch to ”ON”;

Push starter switch and allow the engine to run for

AC Magneto

seconds,then test CPS peak voltage;

CPS Peak Voltage

Repeat above procedure and get the highest CPS

peak voltage;

CPS peak voltage :

2V (300rpm)

If the CPS peak voltage reading is out of above

specification,replace.

15-18

15 ELECTRICAL SYSTEM

(7)SPEED SENSOR:

This sensor is used to detect the rotating speed of the

engine output shaft and provide the signal for ECU to

determine the vehicle speed. It belongs to Hall effect

sensor,that varies its output voltage in response to a

magnetic field.

Pins and Function:

1

2

1.Ground

3

2.Output voltage signal (>80% input power voltage)

3.Power+DC12V

Speed Sensor

Exterior

+12V Power

The right figure refers to speed sensor wiring:

Ground

1

2

3

ECU

Hall Switch

15

15

Speed Sensor

1

Speed Sensor Test:

2

Ground pin 1and connect pin 3 with +12V power;

3

Fix a gear 2.5mm away from a speed sensor as

the right figure illustrates;

Turn multimeter to DCV range;

Slowly turn the gear and measure the voltage be-

tween pin 2 and pin 3 to determine that if the reading

Gear

2.5mm

varies from 0V-12V;

If the reading doesn’t vary,that indicates the sen-

sor is defective and needs to be

replaced.

15-19

(8)GEAR POSITION SENSOR:

This sensor is used to provide the gear position signal for meter display.

Pins and Function:

Yellow/Blue-L(Low Gear)

Orange/Blue-H(High Gear)

Yellow/Black-P(Park Gear)

White/Yellow-N(Neutral)

Sky Blue/White-R (Reverse Gear)

When each pin at a certain gear position,there is

continuity between this pin and engine.Otherwise,no

continuity.

Gear Position Sensor

(10)CAUTION when driving in reverse

When driving in reverse,gear position sensor sends

the reverse signal to ECU and meter.ECU would limit

the vehicle speed in response to the reverse signal.

15-20

15 ELECTRICAL SYSTEM

(10)FUEL PUMP ASSEMBLY:

This fuel pump assembly includes fuel pump,plastic

12

support,preliminary filter,fine filter and pressure

regulator.It suppies fuel for engine under a certain pres-

sure and flow.

Fuel Outlet

Pins and Function:

1.Blue(Ground)

2.Red(Connected with fuel pump relay output terminal)

Parameters:

Pressure regulator opening pressure:0.33

0.01MPa

Flow:>35L/h

This fuel pump is located in fuel tank;

Don’t operate the fuel pump in dry condition in or-

der to prevent damage.

Always handle the fuel pump gently.Never drop the

fuel pump,especially on a hard surface.Such a shock

to pump can damage it.

Fuel Pump Assembly

Fuel Pump Wiring:

Battery supplies power for fuel pump assembly via

9

1

fuel pump relay,which connects the fuel pump circuit

J2

only with the engine started.

15

18

10

Fuel Pressure Test:

Connect the fuel pressure gauge with fuel outlet

and tighten the joint with a clamp to prevent fuel leaks;

Route according to the right circuit;

Turn both ignition switch engine stop switch on;

At this moment,fuel pump will operate for 5

seconds.After the fuel pump stops running,fuel pres-

Fuel Pump Relay

sure should be in specification,otherwise replace it;

After the engine stops running,0.25MPa fuel

pressue should be kept for more than 5minutes,other-

wise replace the fuel pump;

Power

Pressure Relief in Fuel System:

In an EFI model,the pressure in fuel system is very

Engine

high,so all the line is high pressure resistant.Even

Stop

though the engine is not started,the pressure in fuel

Switch

system remains high.Therefore,it’s not recommended

Ignition Switch

to remove fuel lines before pressure relief.

M

Follow the procedure below to perform pressure relief:

Remove fuel pump relay.Start the engine and allow it

to idle until the engine stops automatically

15-21

(11)FUEL INJECTOR:

Connected with Injector Cap

One end of fuel injector mounts into fuel injector seat,

and the other end attaches to the injector cap,which

connects with a fuel line.Fuel injector is controlled by

ECU to inject fuel at stated time into the engine.

This injector nozzle is a 4-hole style.Don’t turn injec-

tor after the joint between injector and injector cap is

installed.

Pins and Function:

Mark”+”

Connector with the mark”+”:connected with fuel

pump relay output terminal.

Connector without mark:connected with ECU pin 14.

Connected with Injector

Seat

Fuel Injector Resistance:12

1

(20

)

Fuel Injector Exterior

9

65

1

18

10

ECU

Fuel Injector Circuit:

Engine

Stop

Switch

Ignition

Switch

1

2

1

2

Fuel Injector Installation:

Install fuel injector manually.Never knock fuel in-

jector with a hammer.

When removing and installing fuel injector,the o-

Injector 1

Injector 2

rings on both ends must be replaced;

Perform pressure relief before fuel injector removal

if necessary;

Test the fuel injector sealing after installation to

ensure no leaks.

15-22

15 ELECTRICAL SYSTEM

(12)IDLE AIR CONTROL VALVE:

IACV is used to control the air flow of by-pass.ECU

Idle Air Control Valve

calculates the engine load and controLs IACV through

Connected with Air Filter

electrical pulse durationand frequency(commonly

known as duty ratio).IACV allows diffrent air flows

passed through under different pressure diffrences.

Therefore,it should be connected properly,otherwise,

idle speed may be incorrect.When there is no electri-

cal pulse,IACV would be closed.

TPS

Pins and Function:

1.Pin A:IACBLO-ECU J1-13;

2.Pin B:IACBHI-ECU J1-12;

Connected with Manifold

3.Pin C:IACALO-ECU J1-11;

4.Pin D:IACAHI/IAV-ECU J1-1;

9

1

ECU

J1

18

10

Idle Air Control Valve Circuit:

1

2

3

4

15

Idle Air Control Valve

Idle Air Control Valve Parameters:

Value

Unit

Item

Min

Standard

Max

Rated Voltage

13.5

V

Resistance(+20?

)

16

Ω

Rated Current

0.85

A

Control Pulse Frequency

30

Hz

Standard Control Pulse Width

≈8

ms

Air Flow(When Pressure

Difference=700mbr,

5.0

m3/h

Duty Ratio=100%)

15-23

(13)IGNITION COIL

Ignition coil transforms the low voltage of primary coil

to high voltage of secondary coil needed to spark the

spark plug and ignite the mixture of air and fuel in

cylinder.

Pins and Function:

1.Ignition coil (-) of cylinder 1 connected with pin 1,ECU J2;

1.Ignition coil (+) of cylinder 1 connected with battery(+);

3.Ignition coil (-) of cylinder 2 connected with pin 10,ECU J1;

4.Ignition coil (+) of cylinder 2 connected with battery(+);

Connected with High Tnesion Lead

J2

9

11

18

10

ECU

Ignition Coil 1

Ignition Coil Circuit:

9

1

18

10

Engine

Stop

J1

Switch

Ignition Coil 2

Secondary Ignition Voltage Test:

Connect the engine according to EFI wiring diagram;

Peak Voltage Tester

V

Connect the peak voltage tester according to the

right diagram;

Start the engine;

Secondary ignition voltage should be >15000V.

Battery

ECU

Spark Plug

Ignition Coil Parameters:

Item

Value

Unit

Min

Standard

Max

Stated Voltage

14

V

Operating Voltage

6

16.5

V

Resistance

Primary Winding Resistance

0.74

0.76

0.78

Ω

（ 20-25℃

）

Secondary Winding Resistance

10.1

10.6

11.1

KΩ

Primary Current

7

A

15-24

15 ELECTRICAL SYSTEM

(14)EFI SELF-DIAGNOSIS:

ECU constantly monitors sensors,actuators,circuits,MIL and battery voltage,etc,even itself.It also tests sen-

sors output signal,actuator drive signal and inner signal(such as closed-loop control,coolant temp. signal,idle

speed control and battery voltage control,etc for reliability ).If any malfunction or suspectable signal found,

ECU would record the fault information in RAM.

Fault information comes in form of fault codes,which are then displayed on PDA, in sequence of which fault

comes first.

Fualt can be divided into “steady fault” and “occasional fault” (such as a fault caused by harness short or loose

connection.)

PDA or MIL can be used to locate the part in trouble immediately after fault happens.

(1)MIL(or FI Indicator):

MIL is a light-emitting diode and located on instrument panel.

It indicates different fault codes through the flashes in differ

ent frequency.

Resistance

MIL Circuit:The current in pin 3,ECU J1 should be

J1-3

less than0.1A.

+12V Power

LED

MIL Flash Principles:

J1-9

(1):Turn ignition switch on and depress kill

J2-2

switch.Don’t run the engine.If no malfunc-

tion happens.

ECU

MIL turns on for 5 seconds,then turns off.

(2):Turn ignition switch on and depress kill

switch.Don’t run the engine.If malfunction

happens.

15

MIL turns on for 5 seconds and turns off.Then MIL

flashes to indicate a fault code:

The interval between fault codes is 3.5s,between dig-

its is 1.2s,and a flash lasts for 0.4s as well as the

interval between 2 flashes.

MIL fashes 10 times to indicate 0.From 1-9,how much

it counts,how many times MIL flashes.

Take fault codes P0117 and P0232 for example:

MIL lights up for 5 seconds turns off and lasts for 3.

5s flashes for 10 times(the frequency is 0.4s)

turns off and lasts for 1.2s flashes once turns off

and lasts for 1.2s flashes once turns off and lasts

for 1.2s flashes for 7 times turns off and lasts for

3.5s flashes for 10 times turns off and lasts for

1.2s flashes for 2 times turns off and lasts for 1.

2s flashes for 3 times turns off and lasts for 1.2s

flashes for 2 times.

(3):Turn ignition switch on and run the

engine.Malfunction happens.

MIL lights up until malfunction disappears.

15-25

(2)PDA:PDA has 3 pins-power,ground wire and data

cable K.Thses pins are connected with related ECU

pins.

The right photoe refers to operation panel of PDA.When

it comes to detailed keys function,refer to PDA in-

struction book.

Pins and Function:

1.Connected with pin 3,ECU J2;

2.Ground

UP

1 2 3

3.Connected with +12V power

RH Selection

LH Selection

DOWN Key

Keys and Function:

EXIT

OK Key

LH Key:Page up

Power Switch

UP Key:Scroll Up

RH Key:Page Down

9

21

J2

Down Key:Scroll Down

18

10

OK Key:Entrance

EXIT Key:Exit

Connected with

Battery(+)

PDA Function:

(1)Version Infomation Display

RED

GRN

PPL

PDA can display engine,ECU hardware and soft ware infomation.

(2)Fault Display

PDA monitors IAP sensor,IAT sensor,coolant temperature sensor,TPS,O2S,O2S heater circuit,air-to-fuel

ratio revision,fuel injector,fuel pump relay,CPS,speed signal,idle speed,idle air control valve,system voltage,

ECU,FI indicator and displays the fault code.

(3)Engine Data stream Display

PDA can display battery voltage,RPM,desired idle speed,vehicle speed,coolant temperature,coolant tem-

perature sensor signal voltage,inlet air temperature,IAT sensor signal voltage,inlet air pressure,inlet air flow,

IACV target position,TPS signal voltage,throttle body position,throttle body relative position,canister duty,

charging time,FI pulse width,park

advance angle,O2S voltage,engine relative load,cansiter load,IACV position,atmospheric pressure,altitude

multiplier,engine operation time.

(4)EFI Status Display

Starter switch,main relay,fuel pump relay,idle speed,idle speed,full load status,deceleration activation,

acceleration activation,FI close loop activation,lambda control activation,canister control valve activation,

MIL status.

(5)Actuator Test Function

MIL,fuel pump,IACV,canister control valve,ignition,fuel injection.

15-26

16 LIGHTS,INSTRUMENT,SWITCHES

Maintenance Info

16-1

Handlebar Switches

16-7

Troubleshooting

16-2

Brake Light Switch-Horn

16-8

Bulb replacement

16-3

Fuel Sensor

16-9

Dashboard- Headlight

16-5

Fuel pump

16-10

16

16

Ignition Switch

16-6

Maintenance Information

Operation Cautions

WARNING

z Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off.

Operation should be done when the bulb is cooled down.

z The temperature of headlight is quite high when turned on. Replacing with bare hand or stained glove will

leave oil residue on the glass face which may form hot spot and cause deformation of glass face and

damage to bulb.

z Pay attention to the following when replacing the bulb.

Do not replace the bulb when it is turned on. Keep ignition switch in the OFF position, and replace after the

bulb is cooled down.

-Replace the bulb with hands in clean gloves to avoid oil rsidue on the glass surface.

-Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil residue on the glass

surface.

z If the inspection has to be done with battery, check if the battery is normal.

Inspection of switch continuity can be done without removing switches from the vehicle.

z After the inspecting and maintenance of each part, cables and wires should be routed properly (chapter 1).

Refer to Chapter 2 for removal and installation of taillight and rear turning lights.

Maintenance Specifications

Item

S ta n da rd

Main

20A

Fuse

Auxiliary

10A×1

15A×5

Headlight（ Hi／ Lo）

12V-35/35W×2

Brake light／ Taillight

12V-21/5W×2

Turn Light

12V-10W×4

Panel Light

LED

Light

Coolant

temp.,Fuel

LCD

level,2WD/4WD

indicator

light

MIL

LED

16-1

16 LIGHTS,INSTRUMENT,SWITCHES

Bulb Replacement

Headlight Bulb

Cautions

Headlight bulb will be very hot when it is turned on.

Do not touch it after it is just turned off.

Operation should be done when the bulb is cooled

down.

Remove left headlight protector (

2-11);

Remove headlight(

16-5);

Remove left position light(front) no.1;

Remove headlight bulb (left) no.2;

Remove left turn light no.3;

Unplug headlight connector;

Remove dust-proof cap, headlight connector,

circlip and replace with a new bulb.

WARNING:

Wear clean gloves when replacing bulb.

Oil residue on the glass surface may cause

the bulb break.Clean the stained surface with

alcohol or isoamyl acetate.

9

Align the three pins of the bulb with the three

7

positioning holes in the

6

socket when replacing the bulb.

4

2

5

Bulb no.7 specification:12V-35/35W

3

3

Bulb no.6 specification:12V-5W

1

2

Bulb no.5 specification :12V-10W

8

2

Reverse the removal procedure for installation

After replacing the bulb, adjust headlight beam

(

3-14).

Headlight Inspection

Turn the ignition switch to ON position,

turn light switch to the illumination

position and check if the headlight is on.

-ON: Normal

-Still off: short circuit of main cable or

broken main cable

16-3

Front Turn Light Bulbs

Remove LH headlight protector(

2-11);

Remove headlight(

16-5);

Remove front turn llight no.1;

Rmove front turn light bulbs.

Bulb Specification:12V-10W

Rear Turn Light Bulbs

Remove rear turn light cover;

Remove rear turn light bulbs;

Replace rear turn light bulbs no.4;

Bulb Specification:12V-10W

Reverse the removal procedure for installation.

Remove tail light cover;

Remove brake light/tail light bulb no.5;

Replace brake light/tail light bulb;

Bulb Specification:12V-21/5W

Reverse the removal procedure for installation.

NOTE:

Main cable,wiring and tube should

be routed properly( Chapter 1).

16-4

16 LIGHTS,INSTRUMENT,SWITCHES

Dashboard

Remove cover of dashboard(

2-5);

Remove nuts no.1;

Remove dashboard connectors no.2;

Remove dashboard.

NOTE: If dashboard has something wrong,

it’s recommended to replace the whole dashboard.

Reverse the removal procedure for installation.

Headlight

Remove cover of headlight (-2-11);

Remove screw no.3;

Remove screw o.4;

Disconnect headlight connector;

Disassemble headlight comp.

Reverse the removal procedure for installation

NOTE:

Be careful not to damage main cable when

assembling.

After replacment, adjust the headlight beam(

3-14);

NOTE:

Main cables and wires should be routed

properly.(

1-20)

16-5

Ignition Switch

Inspection

Remove dashboard cover(

2-5);

Disconnect 4P connector of ignition switch;

Check according to the following table if

the connector terminals are in continuity.

z

:Continuityz

ON

z

z

OFF

z

z

P

z

z

R B G B/W

Removal

Remove dashboard cover(

2-5);

Disconnect 4P connector of ignition switch;

Remove bolt and remove ignition switch;

Installation

Reverse the removal procedure for installation.

16-6

16 LIGHTS,INSTRUMENT,SWITCHES

Handlebar Switches

Remove dashboard cover(

2-5);

Disconnect left handlebar switch connectors;

Check according to the following table if

the connector terminals are in continuity.

zz

Continuity

Light Switch no.1

B/Br

Br

Br/W

L

W/L

W

z

z

z

z

z

z

z

z

z

z

OFF

z

z z

B=Black Br=Brown W=White L=Blue G=Green

Gr=Grey R=Red O=Orange Sb=Sky Blue

Lg=Light Green

Kill Switch no.3

Starter Switch no.2

B/W

G

B/Br

Y

Y

Gr/R

z

z

z

z

z

z

16-7

Turn Switch no.1

O

Gr

Sb

L

z

z

PUSH

R

z

z

Horn switch no.3 Over-ride Switch no.4

OFF

OFF

ON

z

z

ON

z

z

Right Handlbar Switch no.5

Br/B

L/G

L/B

Br/G

Gr/W

L/G

Br/R

Br/G

Lg/Br

G

2WD

z

z

z

z

4WD

z

z

z

z

LOCK

z

z

z

z

z

z

If something above wrong, replace

handlebar switches(

12-12).

Hazard Light Switch no.2

Gr/B

B/Br

!

z

z

Brake Light Switch no.6

Disconnect brake light switch connector and

check terminals for continuity.

Brake lever applied:continuity

Brake lever released. no continuity

No continuity: Replace brake light switch

Horn no.7

Inspection

Remove front vent grille (

2-13);

Disconnect horn;

Connect with a fully charged 12V battery

and check if the horn sounds.

Defective Horn: Replace

16-8

16 LIGHTS,INSTRUMENT,SWITCHES

Fuel Sensor

Remove:

Remove passenger seat (

2-4);

Remove driver seat (

2-4);

Remove fuel sensor;

Disconnect 2P connector.

Inspection

Remove fuel sensor (refer to above steps);

Connect 2P connector;

Turn ignition switch to ON;

Shake fuel sensor float with hand, locate the float

position and check if it conforms to the fuel gauge

reading.

Non-conformity: -check main cable for damage or

short circuit

-Check fuel sensor and fuelgauge.

Remove fuel sensor 2P connector;

Connect multimeter between 2P connector

terminals;

Shake float with hand and measure the resistance

of float at different positions.

Connection Terminal:

Upper: Blue/White-Green:

4-10

(20

)

Lower: Blue /White-Green:

Fuel Sensor 2P Connector

90-100

(20

)

Faulty fuel sensor: Replace

Installation

Put fuel sensor into installation hole of fuel tank.

Fuel sensor should be fitted properly.

No fuel leakage is allowed.

Inspection of Fuel Gauge

Switch on power supply and check if fuel

Fuel Sensor

level gauge functions normally.

If fuel gauge works normally,

Reverse the removal procedure for

installation of plastic parts and seat.

16-9

Fuel Pump

Removal

Remove rear seat(

2-4);

Remove front seat(

2-4);

Remove related plastics(see Chapter 2);

Drain fuel in fuel tank ;

Remove the 5 bolts no. 2;

Remove fuel pump no.3 from fuel tank no.1;

Disconnect fuel pump connector.

Fuel Pump Specifications

Voltage:DC13.5

0.3V,

Pressure:0.2

0.01MPa,

Rate of flow

45L/h,

Current

2A,

Regulator working pressure: 0.25

0.01MPa,

Current

2.2A.

Inspection of Fuel Pump

Turn ignition switch to ON and check if fuel

pump functions normally.

If fuel fuel works abnormally,please check if circuit

is open circuit or if EFI system has any problem.

NOTE:

If any probelm of electrical equipment and electrical

system in this chapter ,please refer to chapter of elec-

trical equipment .

16-10

17 TROUBLESHOOTING

1.Engine troubleshooting

Trouble

Possible causes

Countermeasures

Engine cannot be started

1.Check electrical system

1) Fuse defective

Check or replace

2) Battery low voltage

Check or recharge

3)Bad wiring connection

Check or replace

2.Check spark plug

1) Ignition coil bad connection or defective

Check or replace

2) High-tension cable bad connection or defective

Check or replace

3) Speed sensor defective

Check or replace

4) Flywheel defective

Check or replace

5) Gap of spark plug incorrect

Adjust or replace

6) Spark plug dirty

Clean or replace

7) Spark plug wet

Dry it or replace

3. Check fuel supply system

1) Canister

2) Fuel pump leakage or defective

Repair or replace

3) Fuel hose leakage

Tighten

4) Fuel insufficient

Check fuel tank

5) Injector blocked or defective

Replace

4.Check cylinder pressure

1) Cylinder worn

Replace

2) Piston ring worn

Replace

3) Cylinder gasket broken

Replace

4) Valve stem worn

Replace

5) Valve seat seal unsuitable

Repair or replace

6) Valve worn

Replace

7) Spark plug loose

Tighten

8) Starting RPM too low

Check or replace

9) Valve timing incorrect

Adjust

10) Valve clearance incorrect

Adjust

5. Air bypass valve blocked or defective

Clean or replace

6. Not shift to “N” gear

Shift to “N” gear

7. Check trouble code

Check

Difficult to start engine

1. Air bypass valve adjustment failure

See engine control system

2. TPS not reset

See engine control system

3. Adjust throttle cable

4. Cylinder pressure insufficient

5. Check spark plug

Check or replace

1) Spark plug defective

2) Spark plug improper installation

Replace defective part

3) Spark plug damaged

4) Spark plug dirty

6. Fuel insufficient or fuel pressure not enough

17-2

17 TROUBLESHOOTING

Trouble

Possible causes

Countermeasures

Engine

1. Coolant insufficient (lower than LOWER line)

Refill coolant

overheating

2. Air bubbles inside cooling system

Remove air bubbles and refill

3. Water temp. sensor defective

Replace sensor

4. Thermostat defective(cannot open when coolant is very

Replace thermostat

hot)

a. Check and replace water

5. Coolant leakage

pump seal

b. Check and replace water hose

● Water hose broken or aging

and clamp

● Clamp loosen

Replace

6. Water impeller damaged

Tighten

7. Water pump cover leaking

Replace

8. Cylinder head cover/Cylinder gasket leakage

Tighten or replace

9. Water pump cover washer leakage

Replace

10. Water pump gear wear or damaged

Replace

11. Water pump shaft defective

Troubles

Possible causes

Countermeasures

Engine oil

1. Check oil level and if any leakage of crankcase or oil seal

Replace and reassembly

consumption

● Crankcase damaged

Replace

too high or

● Tightening bolt loosen

Tighten

oil pressure

● Seal ring or O-ring/washer damaged or broken

Replace

too low

● Piston ring wear (blue spark can be seen)

● Piston ring damaged (compression ratio too low)

Replace

● Oil seal of valve damaged or aging

Replace

2. Oil filter blocked

3. Check oil drain plug screw of crankcase

Replace all oil seal of valves

● Oil drain plug screw loosen

Replace and change oil

● Oil drain plug screw of left crankcase loosen or washer is

missing

Tighten

4. Oil seal of indicator hole is leaking

Tighten or install washer

5. Oil strainer blocked

Replace oil seal

6. Check oil pump

Clean or replace

● Oil pump rotor over-worn

Replace

● Oil pump leakage or damaged by air into oil pump

Replace

● Oil pump gear damaged

Replace

● Engine oil is unsuitable

Use recommended oil

Engine

oil

1. Coolant and oil leaking from leakage indicator hole

Replace oil seal and water

whitening

2. Cylinder head cover and cylinder gasket damaged

seal

3. Bolt of cylinder head cover loosen

Tighten or replace

4. Engine oil impure

Tighten and change oil

Replace damaged parts

(including oil filter and oil)

17-3

17 TROUBLESHOOTING

Abnormal

1.

CVT belt getting narrow

Replace

acceleration

2.

Check drive pulley

●

Rollers wear

Replace

●

Drive pulley track wear

Replace

3.

Drive/driven pulley shaft move not flexibly

Clean or replace

4.

Spring of driven pulley too strong

Replace

5.

Sliders of driven pulley wear

Replace

6.

Groove of drive/driven pulley damaged

Replace

7.

Intake&exhaust valve clearance incorrect

Replace

8.

Compression ratio too low

Adjust

9.

Ignition of spark plug abnormal

Replace

Max. speed too low

1.

Check point 1,2 and 3 of “abnormal acceleration”

2.

CVT system polluted by water, oil and dust

3.

Drive pulley blocked

Clean and replace

4.

Spring of driven pulley weak or damaged

Clean or replace

Replace

Transmission

not

1.

Check bush of drive pulley

good

2.

Check point 1and 2 of “abnormal acceleration”

●

Bush blocked on shaft

Clean and Replace

3.

Check driven pulley

●

Spring of driven pulley weak or damaged

Replace

●

Sliders wear or damaged

Replace

CVT belt over-worn or

1.

Check CVT inlet&outlet air pipe

burned

●

CVT overheating

Clean

●

Drive fixing sheave impeller blocked

Clean

2.

Check pulley groove

●

Dirty oil inside groove

Clean and replace belt

●

Water into CVT case

Clean and replace belt

CVT belt not good

1.

Belt over-worn and getting narrow

Replace

2.

Wrong belt

Replace

3.

Part of belt wear

Replace

4.

Belt broken or over-used

Clean CVT system and

5.

Dirty oil inside groove

replace belt

6.

Drive/driven pulley groove damaged by stone or other

Clean

foreign objects

Clean or replace

7.

Belt aging and getting fragile

Replace

17-4

17 TROUBLESHOOTING

Noise from cylinder head

1.

Valve clearance incorrect

Adjust or replace

2.

Tensioner failure

Replace

3.

Chain guide wear

Replace

4.

Chain extended or chain sprocket wear

Replace

5.

Bolt of sprocket loosen

Tighten

6.

Valve rocker arm or camshaft wear

Adjust or replace

7.

Camshaft timing incorrect

Adjust or replace

Noise from crankshaft and

1.

Bearing damaged

Replace

connecting rod

2.

Plain bearing damaged

Replace

3.

Flywheel rotor loosen

Tighten or replace

4.

Bearing of left crankcase cover wear

Replace

Noise from crankcase

1.

Engine oil leaking

Replace, tighten and add oil

2.

Gear damaged or wear

Replace

Noise from CVT when at idle

1.

Bush of driven pulley blocked or wear

Replace driven pulley

speed

2.

Check drive pulley

3.

Rollers wear

Replace at the same times

4.

Drive pulley track wear

Replace

5.

Drive moving sheave wear

Replace

6.

Nylon sliders wear

Replace

7.

Axial move blocked

Clean or replace

8.

Nut of drive pulley loosen

Tighten

Noise from CVT when at

1.

Check point 1~3 of idle abnormal noise

transmission

2.

Drive pulley dirty and wet

Clean and dry

3.

Nut of drive/driven loosen

Tighten

4.

Driven sliders over-worn

Replace

5.

Belt and cone surface damaged by outside

Clean or replace

materials

CVT drive pulley vibration

1.

Nut of drive pulley loosen

Tighten

2.

Gap of bush of drive pulley too big

Replace

3.

Rollers missing or over-worn

Replace at the same times

CVT driven pulley vibration

Gap of bush of driven pulley too big

Replace

17-5

17 TROUBLESHOOTING

2.Trouble code table

Trouble Code

Trouble Description

Remarks

P0107

MAP Circuit Low Voltage or Open

MAP-Manifold Absolute Pressure

P0108

MAP Circuit High Voltage

P0112

IAT Circuit Low Voltage

IAT-Inlet Air Temperature

P0113

IAT Circuit High Voltage or Open

P0117

Coolant/Oil Temperature Sensor Circuit Low Voltage

P0118

Coolant/Oil Temperature Sensor Circuit High Voltage or Open

P0122

TPS Circuit Low Voltage or Open

TPS-Throttle Body Position

P0123

TPS Circuit High Voltage

P0131

O2S 1 Circuit Low Voltage

O2S-Oxygen Sensor

P0132

O2S 1 Circuit High Voltage

P0032

O2S 1 Heater Circuit High Voltage

P0031

O2S 1 Heater Circuit Low Voltage

P0201

Injector 1 Circuit Malfunction

P0202

Injector 2 Circuit Malfunction

P0230

FPR Coil Circuit Low Voltage or Open

FPR-Fuel Pump Relay

P0231

FPR Coil Circuit Low Voltage or Open

P0232

FPR Coil Circuit High Voltage

P0336

CKP Sensor Noisy Signal

CKP-Crankshaft Position

P0337

CKP Sensor No Signal

P0351

Cylinder 1 Ignition Coil Malfunction

P0352

Cylinder 2 Ignition Coil Malfunction

P0505

Idle Speed Control Error

P0562

System Voltage Low

P0563

System Voltage High

P0650

MIL Circuit Malfunction

MIL-Malfunction Indicator Light

P1693

Tachometer Circuit Low Voltage

P1694

Tachometer Circuit High Voltage

P0137

O2S 2 Circuit Low Voltage

P0138

O2S 2 Circuit High Voltage

P0038

O2S Heater 2 Circuit High Voltage

P0037

O2S Heater 2 Circuit Low Voltage

P0500

VSS No Signal

VSS-Vehicle Speed Sensor

17-6

17 TROUBLESHOOTING

Trouble code:P0032/P0038：Heater coil high voltage of Cylinder 1 and 2 oxygen sensor

Possible causes

Checking procedures

1）Open circuit between ECU and oxygen sensor C

1）Measure resistance between ECU pins and oxygen

pin

sensor C pin, check if it’s ok.

2）Open circuit between main relay and oxygen

2）Measure resistance between main relay and oxygen

sensor C pin.

sensor D pin, check if it’s ok.

3) Open circuit between oxygen sensor C and D pin

3) Measure resistance (9.6KΩ) between oxygen sensor C

pin and D pin.

Trouble code P0031/P0037：Heater coil low voltage of Cylinder 1 and 2 oxygen sensor

Possible causes

Checking procedures

1）Short circuit between ECU and ground.

1)Measure resistance between ECU and ground

2）Short circuit between ECU and oxygen sensor D pin

2）Measure ECU voltage and check if it's ok.

3）Short circuit between ECU and other circuits.

3）Measure resistance (9.6KΩ) between oxygen sensor D

pin and ECU

Trouble code :P0131/P0137：Oxygen sensor low voltage of cylinder 1 and 2

Tips: EFI system can judge output signal if it’s ok by measuring voltage between oxygen sensor A pin and B pin.

Oxygen sensor sometimes will be broken during cold starting.

Possible causes

Checking procedures

1）Short circuit between ECU and ground

1） Measure resistance between ECU and ground and

2）Short circuit between ECU and oxygen sensor D

check if it’s ok.

pin.

2）Measure ECU voltage and check if it’s ok.

3）Short circuit between ECU and other circuits.

3) Measure resistance (9.6KΩ) between oxygen sensor D

4）Oxygen sensor defective, replace it.

pin and ECU

Trouble code : P0132/P0138：Oxygen sensor high voltage of cylinder 1 and 2

Possible causes:

Checking procedures

1）Open circuit between ECU and oxygen sensor A

1)

Replace oxygen sensor

and B pins.

2)

Replace ECU

2) Open circuit between oxygen sensor A pin and B

3)

Wiring checking.

pin

17-8

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