SYM 4.

Fuel Injection System

EFi System Diagram ························· 4-1 Crankshaft Position Sensor··············· 4-17

EFi System Introduction···················· 4-2 Engine Temperature Sensor / T-Map Sensor
······················································ 4-18
EFi System Components ··················· 4-3
Air By-pass Valve ···························· 4-19
EFi System Location························· 4-4
Fuel Injector ···································· 4-19
EFi System Component Description ··· 4-5
Fuel Pump ······································ 4-19
EFi System Circuit···························· 4-8
Fuel Unit ········································· 4-20
Precautions in Operation ·················· 4-9
Fuel Tank ········································ 4-23
Troubleshooting ······························ 4-10
Air Cleaner ······································ 4-24
Throttle Body & By-pass Valve Clean
Procedure ······································· 4-14 EFi Troubleshooting & Solution ········· 4-25
5
Fuel Lines ······································· 4-15 EFi Components Malfunction Check &
Replacement Procedure···················· 4-53
Ignition System ································ 4-16

EFi System Diagram

4-1
5. Fuel Injection System SYM
EFi System Introduction
Based on 4-stroke SOHC engine, displacement 125/180 c.c. electronically controlled fuel
injection. The O2 sensor enhances the efficiency of the catalytic converter, by dynamically
controlling the Fuel/Air ratio.

Electronic Fuel Injection Device

Fuel supply devices: fuel tank, fuel pump, fuel filter, and fuel pressure regulator.
Fuel control devices: fuel injector, and ECU.
The fuel is pumped from electrical fuel pump in the fuel tank, to the injector on the inlet pipe.
The fuel pressure regulator keeps the pressure around 2.5 Bar. The signals from ECU enable the
injector to spray fuel into the combustion chamber once each two crankshaft-revolutions. The
excessive fuel flows back to the fuel tank through the fuel pressure regulator. Fuel pump is
placed inside the fuel tank to reduce the working noise, and the complicity of fuel pipes.
Electrically controlled ignition and injection system effectively reduce fuel consumption rate and
pollution.

In traditional gasoline engine, carburetor supplies the fuel. The process is done by the engine
vacuum, and the negative pressure in the carburetor mixes fuel with air. Under this condition,
three major processes are done simultaneously in the carburetor: 1. air quantity measurement,
the determination of fuel quantity, the mix of fuel and air.

Electronic fuel injection system separates the three major processes into three different devices:
1. T-MAP sensor measures the air quantity and temperature and sends the signal to ECU as a
reference. 2. ECU determines the amount of fuel to be injected, according to the default A/F rate.
3. ECU enables the injector to spray appropriate fuel amount. The independence of these three
functions will raise the accuracy of the whole process.

EFi engine uses computer-programmed fuel injection, the main features are:
1. The quantity of fuel injected is determined according to the condition of the engine. The engine
RPM, and throttle position determines the fuel quantity and injection time-length.
2. The quantity of fuel injection, and the determination of injection time length, are all controlled
by 16-bit microcomputer.
3. The fuel pressure regulator maintains a 2.5 Bar pressure difference between inlet pipe and fuel
pipe, raising the accuracy of fuel injection.
4. By measuring the air pressure of inlet pipe, this system gives the vehicle better
accommodation to the environment.
5. Air by-pass system supplies fuel and air to stabilize the idle running, and cold starting.

4-2
SYM 4. Fuel Injection System
EFi System Components

Battery
Main Switch

5V 12V

Fuel Pump
ECT Sensor

ECU
Integrated with T-MAP Sensor,
TPS, ABV, and Throttle Body

Ignition Coil

CPS Fuel Injector

4-3
5. Fuel Injection System SYM
EFi System Component Description
Integrated ECU Module
Engine Control Unit (ECU)
• Powered by DC 8~16V, and has 32 terminals connector on the unit.
• The hardware component consists of an 16-bit computer that is its
control center. It contains the functional circuit interface of engine
condition sensing and the driving actuator for the air by-pass valve,
fuel injector, and fuel pump, as well as transistor ignition coil.
• Its major software is a monitor strategy operation program that
includes with controlling strategy, microarray profile and
self-diagnosis programs.

Air Bypass Valve (ABV)

• Its major component is the solenoid valve of high resistance driven
by electric current.
• By means of signals from all sensors, ECU outputs a signal to
control the opening angle of the valve so that can adjust air flowing
to the inlet manifold through the air by-pass valve, and then correct
the idle speed to have engine in normal operation.

T-MAP Sensor
• The major component of the T-MAP sensor is a variable transistor IC.
Its reference voltage is DC 5V, and output voltage range is DC 0~5V.
• It is a sensor of combination by both sensing pressure and
temperature, and can measure the absolute pressure and
temperature in intake process. It also conducts the fuel injection
quantity correction based on environmental temperature and position
level.

Throttle Position Sensor (TPS)

• Its major component is a highly variable resistor. The input voltage
range: 5V DC.
• Located on the side of throttle body. By means of the throttle valve
rotation to cause voltage change in linear, it provides ECU with
current throttle valve openness information. And also, the ECU
determines the most properly fuel injection and ignition timing.

Idle Speed Control Valve (stepper motor)：

• If it’s mainly low-power DC motors, drives idle speed control valve
(ISC) of the movement to adjust the idle air flow channel size, control
of idle speed of the engine in the cold or hot.

4-4
SYM 4. Fuel Injection System

Fuel Injector
• Powered by DC 8~16V, and has 2 terminals connector on the
injector.
• Its major component is the solenoid valve of high resistance driven
by electronic current.
• The two terminals are connected to power source and ground
respective. It is controlled by ECU to determine the injection timing,
and the injector pulse width. Working with 2-valve engine, the unique
2-hole designed injector can provide each intake valve with suitable
fuel quantity to reduce HC emission.

Fuel Pump
• Powered by DC 8~16V, and has 2 terminals connector on the pump.
• The two terminals are connected to power source and ground
respective. The ECU is to control and manage the operation of fuel
pump through electrical power.
• Its major component is a driving fan pump that equipped with a low
electrical consuming DC motor. Powered by 12V voltage and keep
fuel pressure inside the fuel pump in 2.5 bars, which can offer 14
liters of fuel per hour.
• The fuel pump is located inside of the fuel tank, and installed a filter
in front of its inlet so that can prevent from foreign materials sucking
into the fuel pump to damage it and the fuel injector.

Ignition Coil
• Powered by DC 8~16V, and has 2 terminals connector on the coil.
• The two terminals are connected to power source and ground
respective. Its major component is the high transferring rate
transformer.
• Its ignition timing is controlled by computer program. From the
signals of crankshaft position sensor, throttle position sensor, and
engine temperature sensor as well as intake air temperature sensor,
and correspondence with engine speed, then the ECU determines
the ignition timing properly by means of controlling primary current in
ON & OFF operation to create the secondary voltage of
25000~30000V. And then, the voltage triggers the spark plug ignition.
Such kind of ignition system not only can enhance engine
performance to maximum, but also increases fuel consumption
efficiency and improves emission quality.

4-5
5. Fuel Injection System SYM

ECT Sensor
• Powered by 5V DC from ECU, and has 2 terminals connector on the
sensor. One terminal is for voltage output and the other one for
ground.
• Its major component is the thermo-resistance of negative
temperature coefficient (temperature rises up while resistance falls
down).
• Located on the cylinder head. Correspondence with engine coolant
temperature change, it transferred to voltage signal and sent to ECU
to calculate current temperature. Then, the ECU will correct fuel
injection time and ignition timing according to engine warm up
condition.

CPS
• It does not need power supply, and has 2-signal terminals connector
on the sensor.
• Its major component is the magnetic pickup coil, and its output
voltage range is ±0.8~100V.
• The air gap between the sensor and flywheel must have .07~0.9mm.
• By cutting the magnetic field, the magnetic sensor sends an
inductive voltage that is created with the rotation gear (24-1 tooth) on
the flywheel, and the pulse will be sent to the ECU. Then, the ECU
calculates current engine speed and crank position based on the
voltage so that controls fuel injection quantity and ignition timing
properly.

O2 Sensor
• Powered by DC 8~16V, and has 1 terminals connector on the sensor.
the one is for signal output.
• The O2 sensor feeds signal to ECU, and the ECU can control the
air/fuel rate around 14.6. It’s a close –loop control system.
• The catalytic converter reaches the best converting rate when this
14.6 A/F ratio is maintained.
• The heating coil resistance <200kohm (30—45kohm)

4-6
SYM 4. Fuel Injection System
EFi System Circuit

4-7
5. Fuel Injection System SYM

Precautions in Operation
General information
Warning
● Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated
place and strictly prohibit flame when working with gasoline.
● Release the fuel pressure before removing the fuel pipe to prevent splashing the fuel.

Caution
● Do not bend or twist throttle cable. Damaged cable will make unstable drive ability.
● When disassembling the fuel system parts, pay attention to O-ring position, replace with new
one as re-assembly.

Fuel pressure release procedure:

Disconnect the fuel pump relay, switch on and press the start switch for a few seconds to crank
the engine.

Specification
Item
Idle speed 1700±100 rpm
Throttle grip free play 2~6 mm
Fuel pressure 2.5 bar

Torque value
Engine temperature sensor：0.74~0.88 kgf-m
O2 sensor：3.6~4.6 kgf-m

Special tools
Injection system diagnostic tool

4-8
SYM 4. Fuel Injection System
Troubleshooting
EFi circuit inspection Switch on 1. Burnt Bulb?
2. Blown fuse?
3. Battery voltage too low?
Does the warning lamp goes on for 2 seconds and
NG 4. Poor wire contact on ECU
circuit?
then off?
5. Poor contact on the master
switch?
OK 6. Malfunction of ECU?

Is battery voltage over 12.5V?

NG 1. Abnormal charging circuit?
2. Battery cannot be charged?
3. Short wire circuit?
The voltage difference between battery and ECU is
less than 0.2V.
1. Turn off the main switch. OK
2. Disconnect the ECU connector.
3. Turn on the main switch.
4. With a multi-meter to measure the voltage
between the F4 pin(+) and the H4 pin (-).
NG 1. Abnormal wire connection?
Make sure the voltage difference between
battery and ECU is less than 0.2V.

The voltage difference between battery and active

components is less than 0.2V. OK
1. Turn off the ignition switch.
2. Disconnect the connectors of the fuel injector,
by-pass valve, and ignition coil.
3. Measure the voltage between battery negative NG
side and the each connector (1). 1. Abnormal wire connection?
4. Make sure the voltage difference between
battery and those active components is less
than 0.2V.
OK
The voltage difference between 5V-sensors is less
than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the connectors of throttle valve
position sensor and intake manifold NG 1. Abnormal wire connection?
temperature/pressure sensors. 2. Malfunction of ECU?
3. Turn on the ignition switch.
4. Measure the voltage between the pins(1)(4) of
throttle valve position, and the pins of intake
manifold temperature/pressure sensors (1) (3) is OK
within 5V±0.2V.

The voltage difference between battery and fuel

pump is less than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the fuel pump connector. 1. Abnormal wire connection?
3. With the probes of multi-meter to touch the NG
2. Malfunction of relay?
positive & negative sides of the fuel pump. 3. Malfunction of ECU?
4. Turn on the ignition switch.
5. Record the voltage difference of the fuel pump OK
within 3 seconds.
6. Make sure the voltage difference between
battery and fuel pump is less than 0.2V. END

4-9
 5. Fuel Injection System SYM

Engine cannot be started or difficult to start.

Cannot be started or difficult to start

Does the warning lamp goes 1. Check electrical circuit according to

on for 2 seconds and then off? NG procedure.

OK
1. Connect the diagnostic tool and check
Is the warning lamp out of NG trouble content.
order? 2. Trouble shooting according to the
troubleshooting procedure.

OK

1. No spark on the spark plug?

2. Wet spark plug?
3. Loosen spark plug cap?
Is the electrical circuit abnormal? NG 4. Short in RPM sensor?
5. Loosen high voltage cable?
6. No connection for the by-pass valve?
7. Abnormal ECU?
OK 8. Clean the throttle valve body and ECU
does not be set-up?

1. Low fuel in fuel tank.

2. The fuel pressure of the injector is lower
than 2.5bar.
Is the fuel system abnormal? NG 3. Fuel leaking in pipe?
4. Abnormal regulator?
5. Fuel pump pipe leaking?
6. Abnormal fuel pump?
OK 7. Abnormal fuel injector?

1. No valve clearance?
2. Incorrect ignition timing?
3. Stuck valve?
Is the engine abnormal? NG
4. Worn out cylinder and piston ring?
5. Improperly adjustment of the air
adjustment screw onto the throttle valve
OK body?

END

4-10
SYM 4. Fuel Injection System
Diagnosis of Idle Speed Misfire

Idle speed misfire Does the throttle cable

stuck so could not be
set-up?

1. Connect the Data Scan

and check trouble content Connect the Data Scan
2. Troubleshooting and enter into CO
according to the adjustment at idle menu.
troubleshooting Positive value is for
procedure. enrichment, and negative
value is for lean.

Is the CO value in idle

speed out of set up range?
(0.5%~3.0%)
Is fuel enough?

Does the carbon

Are the battery wires deposited onto the throttle
loose? body?

Replace with
new one for
Is the vacuum pipe Does the by-pass valve confirmation
leaking? operate or out of order?

If the idle speed misfire

problem still can not be solved
after check above related EFI
components item by item,
then check if the other
traditional components on the
engine is in abnormal.

4-11
5. Fuel Injection System SYM

Abnormal CO value
If the system has O2 sensor, the CO value doesn’t have to be adjusted. If the CO value still goes
abnormal, please check O2 sensor first, to see if any malfunction occurred.

Idle speed misfire.

Does the throttle valve cable
stuck so could not be set-up?

Connect the Data Scan

and check trouble content Connect the Data Scan
if there is an abnormal and enter into the data
CO correct value in idle analysis menu.
speed.

Start the engine and warm it

up to 115℃~125℃. Make
sure whether the engine
Is fuel enough? RPM, the openness (75º~90º)
of the by-pass valve, and the
fuel injection time are in
normal.

Switch the Data Scan to

CO adjustment at idle
Are the battery wires menu. Positive value is for
loose? enrichment, and negative
Is the voltage enough? value is for lean.

Is the CO value in idle speed

out of set up range?
(0.5%~3.0%)
Is the vacuum pipe
leaking?

Keep the engine run for 3~5

minutes and then turn off the
engine after confirmed
engine operation in normal.
Conduct Error code erasing
operation.

If the abnormal co correct

value problem still cannot be
solved after check above
related EFI components item
by item, then check if the
other traditional components
on the engine are in
abnormal.

4-12
SYM 4. Fuel Injection System
Throttle Body & By-pass Valve Clean Procedure

● It’s suggested that clean the air by-pass valve before cleaning the throttle body.
● Recommended cleaning frequency: every 6000 km.

Clean procedure:
1. Air by-pass valve：
1. Switch off; disconnect the air tube between the air by-pass valve and connecting pipe.
2. Turn on the engine and keep the idle speed.
3. Spray a little carburetor cleaner into the air by-pass vale for 3~5 minutes. Do not shut
down the engine during cleaning.
4. Connect the air tube.

2. Throttle body:
1. Switch off; remove the throttle body.
2. Spray a little carburetor cleaner into the throttle body.
3. Wipe off the dirty oil with clean cloth or tissue.
4. Dry the throttle body with compressed air and install the throttle body. Connect the
diagnostic tool and switch on.

Idle speed learning:

After performing air by-pass valve or throttle body cleaning, idle speed learning should be carried
out to let ECU know the engine condition well.
When performing the idle speed learning, run the engine at idle speed over 10 minutes after the
engine temperature reaches the working temperature (around 70℃~95℃), and then ECU will get
the parameters from sensors.

4-13
 To this chapter contents

5. Fuel Injection System SYM

Fuel Lines
Regulator

Fuel filter
Fuel
Injector
tank

Fuel

Vacuum
pipe

ECU

Battery

System description:
1. After key-on, all sensors’ signals sent to the ECU first. The electrical fuel pump will be
activated by ECU signal. If the engine did not start for 2~3 seconds, then the fuel pump will
be turned off to save electricity. The pressure regulator maintains the fuel pressure around
2.5 Bar, and the fuel injector spray proper fuel quantity according to the conditions and
environmental coefficient. When key-off or engine stopped, the fuel pumps stop operating.
2. The fuel filter is to filter alien materials so it has to be replaced regularly.
3. Do not let the starting motor keep running when the engine cannot start. It will cause battery
voltage to decrease. If the voltage drops under 8V, the pump will not operate. The
countermeasure will be starting the engine by connecting a new battery or with kick-starter.

4-14
 SYM 4. Fuel Injection System
Ignition System
Transistor
ignition coil
TPS
T-MAP
ECU
ET Sensor Spark
AC Generator CPS plug
Flywheel (24-1 teeth)

Battery

Regulator
rectifier

Principle of operation
The engine is equipped with a computerized ignition control system that collects signals from
CPS, TPS, ET Sensor, and T-MAP Sensor. Then, correspondence with engine RPM, this
8-bit microcomputer in the system controls ignition timing properly. The secondary coil
creates 25000~30000V high voltage to ignite the spark plug by means of the transistor
operation of the primary current entry from the ECU. This can maximize engine performance
and also decrease fuel consumption.

Specification
1. Ignition timing: BTDC 10°/ 1700RPM

2. Spark plug: DPR8EA-9

Gap: 0.8mm

3. CPS pulse generator coil: 80~160Ω / 20ºC (G/W-LY)

4. Ignition coil
Primary circuit：0.63±0.03Ω(23ºC)

5. Battery:
Capacity: 12V 6Ah

4-15
5. Fuel Injection System SYM
Crankshaft Position Sensor

No tooth

ECU signal Closed

Secondary TDC TDC

voltage Ignition

Sensor signal Time

Description:
The magnetic field type sensor generates a
voltage signal to calculate engine speed with
ACG gear ring (24-1 tooth).

There is one tooth every 15 degree on the gear

ring. But, one of the teeth is blank for the TDC
calculating base.

4-16
SYM 4. Fuel Injection System
Engine Temperature Sensor / T-Map Sensor

Engine temperature sensor:

According to the semiconductor’s characteristic, the sensor detects the temperature of engine oil
and metal parts and then sends a voltage signal to the ECU. On this base, the ECU can correct
fuel injection and ignition timing.

NTC- Negative Temperature

Coefficient Resistor

T-MAP Sensor：
Sensor combined both pressure and NTC can detect the absolute pressure and temperature in
the intake manifold, and then provides the ECU with signal for adjustment fuel injection quantity
based on environmental temperature and air pressure difference from elevation level change.

mv

-40ºC 140ºC

4-17
5. Fuel Injection System SYM

Air By-pass Valve

Description:
ECU receives all sensors’ signals to control the throttle valve openness with PWM, and adjust
airflow through the by-pass valve of the intake manifold. It can adjust idle speed for a stably
running engine.

1. When engine cold starting---the by-pass valve open for a while to increase airflow and to
stabilize engine idle speed within initial starting
2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts airflow
according to engine temperature (engine oil temperature), and raises idle speed.
3. Speed decreasing--- ECU controls the by-pass valve in correspondence with throttle
operation, to provide inlet pipe with proper airflow quantity. Such operation will smooth the
engine rpm reduction process, preventing the engine from stalling, excessive negative
pressure, and also reduce HC emission.

Fuel Injector
The injector provides intake valve a fuel jet. This can reduce the pollution of HC. The shortened
version of fuel pump plate makes its size more compact, and sturdier against shocks. ECU
signal controls the regulator to maintain 2.5 bars between the fuel pressure and the air pressure
of inlet pipe. Through controlling the time length of injection under steady fuel pressure, the
system can optimize the fuel injection quantity according to different engine workloads.

Fuel Pump
Electrical fuel pump is mounted inside the fuel tank. The power source is DC current provided
and controlled by ECU; the pump can provide 14L/hour under the pressure of 2.5 bars.

4-18
SYM 4. Fuel Injection System
Inspection：
Disconnect the fuel pipe from the fuel injector. Fuel pressure gauge
Connect the fuel pressure gauge to check the
fuel pressure.
Caution
● Make sure the fuel pressure is normal
(2.5 bar).
● Always release the fuel pressure before
removing the fuel pipe to prevent the fuel
from splashing.

Fuel pipe
Special tool：
Fuel pressure gauge SYM-HT07010
Replace the fuel pump with new one if
malfunction is confirmed.

Fuel Tank
Removal
Disconnect the fuel pump and the fuel unit
coupler.
Remove fuel pipe.
Remove the fuel cut valve pipe.
Remove the fuel tank
Installation
Install in the reverse order of removal.
Caution
● Make sure the fuel in the tank is not too
much before removing the fuel tank.
● Replace the fuel tank if there is any
damage or leakage.

4-19
5. Fuel Injection System SYM
EFi Troubleshooting and Solution
y Electronic fuel injection（EFi）system fault warning light
After the main switch is on, the EFI indicator will be light. If the vehicle existing problems, the
EFI indicator will light up all the time after the electrical starter button is on. When the problem
is eliminated, restart the electrical starter button, the EFI indicator will light out automatically.

Error Code Message and Solution Operation

DTC Service
Message Solution operation
code priority
Stop the vehicle immediately, and solve it with priority.
Check the lubricant system for malfunction.
Engine
Check if the ignition or fuel supply system is in normal.
P0217 1 temperature
Check if the engine is burnt.
overheat
Make sure if the engine temperature sensor is in normal.
Make sure if the connector is in normal.

Check if the connection of the crank position sensor is open-circuit.

Abnormal Check if the gap between the sensor and gear tooth is within specification.
P0335 2 crankshaft Check if the crank rotation is run-out.
position sensor Check if the sensor is in normal according to the new component
replacement procedure.

Connect the diagnostic and reset the throttle valve position. Make sure if
the idle speed position is within standard range.
Make sure if the wire circuit of the throttle valve position sensor is loosen or
Abnormal short.
throttle position Check if the openness of idle speed by-pass valve is within specification.
P0120 2 sensor learning (40~100%)
value Adjust the idle speed CO value to specified range. (0.5%~2.0%)
If this problem symptom still existing, check if the throttle position sensor
(TPS) is in normal according to the new component replacement
procedure.
Make sure if the wire circuit of the throttle valve position sensor is loosen or
Abnormal
short.
throttle position
P0121 2 If this problem symptom still existing, check if the throttle position sensor
sensor output
(TPS) is in normal according to the new component replacement
voltage
procedure.

Abnormal Make sure if the wire circuit of the throttle valve position sensor is loosen or
throttle position short.
P0124 2 sensor turning If this problem still existing, check if the throttle position sensor (TPS) is in
speed normal according to the new component replacement procedure.

Make sure if the battery voltage is too low or high (below 10V or exceed
16V)
Make sure if the ACG generator charging system circuit is short or
Abnormal
P0560 1 abnormal.
battery voltage
Check if the G4 terminal on the ECU to battery positive post is short.
Make sure if the battery is in normal. Replace it with new if the battery is out
or order.

Abnormal intake Make sure if the sensor’s wire is in open-circuit.

P0110 2 air temperature Make sure if the sensor is normal according to the new component
sensor replacement procedure.

4-20
SYM 4. Fuel Injection System
DTC Service
Message Solution operation
code priority

Abnormal air
Check if the air bypass valve openness is in normal.
P0505 2 bypass valve
Check if the intake manifold is leaking.
learning value

Make sure if the fuel injector resistance is within specification. (12 Ω, 20℃)
Abnormal fuel
P0200 2 injector Check if the connector or wire is in open-circuit. (The G1 terminal of ECU)
Make sure if the fuel injector power supplied is normal. (12~15V)

Make sure if the ignition coil resistor is within specification. (0.63 Ω, 23℃)
Abnormal Make sure if the connector or wire is in open-circuit. (The 12th terminal of
P0350 2 ignition circuit ECU)
Make sure if the ignition coil’s power supplied is in normal. (12~15V)

Abnormal fuel Make sure if the connector or wire is in open-circuit.

P0230 2 pump relay Replace with new relay to make sure if this abnormal is disappeared.

Engine speed exceed safety limit. Decrease the speed and then the DTC
Engine
P0219 2 code disappeared.
over-RPM
Check if the CVT belt is broken.

If the engine RPM exceeds 3000rpm as starting, in order to prevent

Too high RPM run-away accident, the ECU will decrease engine speed or stop the engine.
P0700 2 when starting Rider should avoid to starting engine with WOT suddenly.
engine Check if acceleration cable is stuck. Re-set the idle speed adjustment
position.
Abnormal Make sure if the sensor’s resistor is within specification. (60℃, 703.8±40.9
engine
P0115 2 Ω)
temperature
sensor Make sure if the sensor’s wire is in open-circuit. (9th terminal of ECU)

Abnormal check Check if the check lamp is burnt.

P0650 2 lamp Check if the check lamp circuit is open. (C2 terminal of ECU)

Abnormal O2 Check O2 sensor coupler.

P0136 2 sensor wiring Check O2 sensor wiring (D2, D1 terminal of ECU).

Abnormal O2 Check O2 sensor coupler.

P0141 2 sensor heater Check O2 sensor wiring (H1 terminal of ECU).
wiring Check O2 sensor white cable voltage (12V).

Abnormal MAP Clean the sensor.

P0105 2 sensor Replace the ECU.

4-21
5. Fuel Injection System SYM

DTC Service
Message Solution operation
code priority

Check the fuel tank.

Fuel supply too
P0170 2 Check and clean the air cleaner.
thick or too thin
Check the fuel injector, O2 sensor and fuel pump.

Abnormal reset
P1001 2 Check the coupler wiring.
coupler

ECU coupler terminal layout：

EFi System Diagnosis Methods

When the motorcycle injection system in the wrong signal, causing abnormal functioning of the engine or can not
start engine, warning light at the meter will be lighting, to inform drivers to carry out maintenance.
Overhaul, the diagnosis tool can be used for troubleshooting (refer to diagnosis tool use guide), or manually by the
meter warning light inspection revealed that the fault codes (refer to checking signal fault codes discriminant
method), the two methods for maintenance.
If the fault has been ruled out or repair after the inspection light will be extinguished, but ECU fault code will be
recorded, so the need to get rid of fault codes. If a fault exists, this system has two kinds of methods to eliminate
fault codes respectively in the diagnosis tool removal and manual removal.

4-22
SYM 4. Fuel Injection System
Injection System for Use diagnosis - V70
Cable connector

LCD
monitor

Link cable

Information
transmission indicator
Function
set Button Button to turn the
pages, and numerical
adjustment
Leave Executive
button Function button

Digital
button

Software cartridge
Soft cartridge slots

Note:
● When problems arise, can be used for diagnosis tool of the fault is detected, and exclusion.
● In addition to testing, troubleshooting, another of the operation can be carried out data
analysis-type monitor.

Method of Use:
1. Maintain engine flameout state, do not open main switch.
2. Opened the luggage box lighting light cover (screw x2), connected to the diagnostic
connector for diagnosis tool.
3. Then open the main switch and the diagnosis tool power switch after diagnosis display screen
appeared the words connection.
4. Press the "ENTER" button into the main screen (there are 6 major functions: ECU ID, DATA
STREAM, FREEZED DATA, TROUBLE CODE, ERASE TB CODE and CO ADAPTION)
5. Use ▲, ▼ select button under the function, press the "ENTER" button access into various
functions.
Example: select "DATA STREAM," by the "ENTER" button, the screen showed that the
existing fault codes; indicates no fault "system is OK."
6. Press "EXIT" buttom to leave of the various functions.
7. Must to close the main switch or power switch of the diagnosis tool after, and then can
removal of diagnosis tool coupler.

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5. Fuel Injection System SYM

Diagnostic tool illustration

Connect the diagnostic tool wire connector
and turn on the main switch.
Press <Enter> button to proceed.

Press <Enter> button to enter function-options

page.

Press <Enter> button to enter ECU ID version

page.

System Information
Press <Enter> button to get back to the
function-options page.

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SYM 4. Fuel Injection System

DATA STREAM
Press <Enter> button to enter Data Stream
page.

Press <UP> or <DOWN> button to choose

Fault No. item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

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5. Fuel Injection System SYM

Press <UP> or <DOWN> button to choose

Intake Air item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
Engine Temp item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <UP> or <DOWN> button to choose

BARO item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
BATT. VOLT item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <UP> or <DOWN> button to choose

Engine SPD item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
TPS position item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <UP> or <DOWN> button to choose

IDLE LEARN item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
IDLE SET item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <RIGHT> button to get to next page to

choose MAP item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
INJECT TIME item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <UP> or <DOWN> button to choose

IGN. ANGLE item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
IGN. CHARGE item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <UP> or <DOWN> button to choose

RUN TIME item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <UP> or <DOWN> button to choose

FUEL PUMP item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
BYPASS ADAPT item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <UP> or <DOWN> button to choose

BYPASS LEARN item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose
BYPASS OPEN item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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5. Fuel Injection System SYM

Press <RIGHT> button to get to next page to

choose O2 SENSOR item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <F4> button to enter waveform page.

Press <EXIT> button to get back to Data
Stream page.

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SYM 4. Fuel Injection System
Press <UP> or <DOWN> button to choose O2
HEATER item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

Press <UP> or <DOWN> button to choose O2

ADAPT item.

Press <F1> button to enter description page.

Press any key to get back to Data Stream
page.

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5. Fuel Injection System SYM
Read Trouble Code
Press <UP> or <DOWN> button to choose
Trouble Code item.
Press <Enter> button read trouble code.

If there is no malfunction in the EFi system,

“System is OK” will be shown.

If there is malfunction happen to the EFi

system, Trouble Code will be shown.

Press <Enter> button to enter Trouble Code

and troubleshooting description page.

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SYM 4. Fuel Injection System
Erase Trouble Code
Press <UP> or <DOWN> button to choose
Erase TB Code item.
Press <Enter> button erase Trouble Code.

Key on but do not start the engine.

Press any key to erase Trouble Code.

Trouble Code is erased successfully.

Press <Enter> button to leave.

Get back to function-options page.

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5. Fuel Injection System SYM
Reset ABV
Press <UP> or <DOWN> button to choose
ABV reset item.
Press <Enter> button to reset ABV.

ABV reset is completed.

Press any key to continue.

Get back to function-options page.

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SYM 4. Fuel Injection System
EFi Component Malfunction Check& Replacement Procedure
Parts
Item Service schedule Inspection Method Adjustment & replacement procedure
Name
1 Ignition coil At least 20000km Use diagnostic tool to check if the If the ignition coil has to be changed,
life-expectancy ignition coil has malfunction. erase the DTC codes with the
Check it every Erase the DTC codes and replace diagnostic tool.
3000km with new coil and confirm again. If Turn off ignition switch, and replace
the DTC codes disappear, then the the coil with new one.
ignition coil is abnormal. Replace it Turn on ignition switch and make sure
with new one. the DTC codes disappear.
If the DTC codes still exist, replace
the ECU for confirm. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new one
Before the ignition coil is verified for
malfunction, check the coil
resistance and connector wire for
short-circuit.
2 Air by-pass At least 20000km Check if the by-pass valve DTC code If the by-pass valve has to be
valve life-expectancy appears on the diagnostic. changed, erase the DTC codes with
Check it every Erase the DTC codes and replace the diagnostic tool first.
3000km with new one & confirm again. If the Turn off the ignition switch, and then
DTC codes disappear, then the replace the valve with new one.
by-pass valve is abnormal. Replace Turn on ignition switch and make sure
it with new one. the DTC codes disappear.
If the DTC codes still exist, check if Check idle speed CO value and adjust
the wire connector and by-pass valve if necessary.
resistance are normal.
If the DTC codes still exist, replace
the ECU for confirmation. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new one.
3 fuel pump At least 20000km Connect a pressure gauge between The oil seal has to be replaced along
and fuel life-expectancy the regulator and fuel injector. with replacement of the fuel-regulating
regulating Check it every Make sure fuel pressure is within valve.
valve 6000km 2.5bar. The pressure should reach Oil seal has to be installed into the
2.5 bars within 3 seconds after outer cover before assembling.
turning on ignition switch.
If the fuel pressure is out of the
range, check if the fuel pipe is
leaking. And check if the fuel pump
voltage is over 12V?
Replace the fuel-regulating valve and
confirm again.
4 Engine At least 20000km Is there any DTC code on the Data If the sensor has to be changed, erase
temperatur life-expectancy Scan diagnostic? the DTC codes with the diagnostic
e sensor Check it every Engine temperature has to reach to tool.
3000km. environmental temperature after Turn off ignition switch, and remove
engine stopped for a while. connector.
Erase the DTC codes and replace Remove the sensor with tools.
with new one and confirm again. If Engine temp. Sensor tighten torque is
the DTC codes disappear, then the 0.74~0.88kg-m.
sensor is abnormal. Replace it with Connect the coupler, and the
new one. diagnostic tool. Then, turn on ignition
If the DTC codes still exist, check if switch.
wire connector and sensor’s Check if the DTC codes disappear.
resistance are in normal range The value of stopped engine
temperature should approximate the
environmental temperature.

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5. Fuel Injection System SYM
Parts
Item Service schedule Inspection Method Adjustment & replacement procedure
Name
5 Intake At least 20000km Connect the diagnostic tool for Replacement procedure for T-MAP
temperatur life-expectancy inspection. The engine intake (intake temperature/pressure sensor)
e/pressure Check every temperature and pressure should Turn off the ignition switch.
sensor 3000km approximate environmental Disconnect the connector of intake
temperature and atmosphere temperature/pressure sensor. Replace
pressure. (Execute this task after the sensor with new one.
engine is stopped for a while) Connect the connector with diagnostic
If the DTC codes of intake tool.
temperature or pressure shown on Turn on the ignition switch, and check
the diagnostic tool, replace the if the intake temperature/ pressure
pressure sensor with new one. readings close to environmental
Check if the DTC codes are temperature and atmosphere
disappearing. If not, check the pressure.
connector wires for short-circuit. Erase the DTC codes, and make sure
Replace the connector if necessary. the problem is solved.
If the DTC codes still exist, replace
the ECU. But if the DTC codes
disappear, install the original
pressure sensor and check it again.
If the original sensor doesn’t trigger
the DTC error code, replace the ECU
with new one.
6 Throttle At least 20000km Please refer to idle speed adjustment The throttle body replacement
body life-expectancy section for the idle speed CO procedure:
Check every adjustment. Install a new throttle body
3000km Connect the diagnostic tool and Make sure there is no leaking.
check if the throttle position DTC Connect the diagnostic tool and read
code appears. the carbon-accumulated time.
If the code appears, replace the Reset the time with the diagnostic tool.
throttle body to make sure the code Reset the throttle position data with
can be erased. the diagnostic tool.
If the code disappears, replace the Throttle valve WOT set up. Turn off
throttle body. ignition switch, and WOT the throttle
If the code still exists, replace the valve and hold. Turn on the ignition
ECU with new one. switch and hold WOT position for 2
seconds. Then release the throttle
valve.
Please refer to the idle speed
adjustment section for the idle speed
CO if necessary.
7 Fuel At least 20000km Check if the fuel injector DTC code Confirmation or replacement
injector life-expectancy appears. procedure for the fuel injector:
Check every If the code appears, replace a new Erase the DTC code with the Data
3000km fuel injector for confirmation. If the Scan.
code can be erased, then, replace Turn off ignition switch and disconnect
the fuel injector. the fuel injector coupler.
If the code still is there after Connect to a new fuel injector.
changing a new injector, check if Connect the diagnostic tool, and turn
connector wire is short. on the ignition switch.
If the code still exists, replace the Make sure the DTC code had been
ECU with new one. If the code can cleared.
be erased after changing the ECU, Please refer to idle speed adjustment
this ECU has to be replaced. section for idle speed CO value
confirmation.
(Firstly, make sure if the fuel injector
DTC code had been clear, and then
install a new fuel injector.)

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SYM 4. Fuel Injection System

Parts
Item Service schedule Inspection Method Adjustment & replacement procedure
Name

8 ECU At least 20000km Connect the diagnostic tool. ECU replacement procedure:
life-expectancy Record the ECU service time. Connect the Diagnostic tool onto the
Check every original ECU.
3000km Record the ECU service time.
Turn off the ignition switch.
Replace the ECU with new one.
Re-set the ECU service time.
Clean the carbon deposition around
the throttle body.
Please refer to idle speed adjustment
section for idle speed CO value
confirmation.
9 Idle speed Check for new Warm up the motorcycle by running Warm up the motorcycle by running it
CO motorcycle and it in 50km/hr for 5 minutes. in 50km/hr for 5 minutes.
Adjustment every 3000km. Connect the diagnostic tool. Connect the Diagnostic tool.
Record the idle speed CO value, and Record the idle speed CO value, rpm.
engine rpm Use the Data Scan to adjust the idle
In O2 sensor closed-loop system, the speed CO value to be 0.5%~2.0%.
CO value should be kept in normal Record the idle speed CO value, rpm
range. If the CO value goes wild, and CO variant value.
please check the O2 sensor, engine, (The engine temperature has to be in
injector, and the fuel system for 115℃~140℃, and intake temperature
malfunction. to be in 25℃~40℃ as adjusting.)
Perform ECU learning

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5. Fuel Injection System SYM
NOTE:

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