3-18 PREVENTIVE MAINTENANCE Spark Plug Cleaning • Remove LH side spark plug cap. • Remove LH spark plug using spark plug removing special tool. (Part No. 37 25034). • Note : Do not remove spark plug using in engine hot condition. • Remove petrol tank. Central Spark Plug Remove LH Spark Plug Remove • Remove Central spark plug cap.
3-19 PREVENTIVE MAINTENANCE Spark Plug Cleaning • Take out central spark plug using Rubber Tube. (P/N 37 104334). • Remove central spark plug using spark plug removing special tool. (Part No. 37 104333). • Note : Do not remove spark plug using in engine hot condition.
3-20 PREVENTIVE MAINTENANCE Tappet Clearance Setting 1. Remove clutch cable bracket mounting bolts (2 nos.) with 8 mm spanner. 2. Remove clutch cable from clutch release shaft. 3. Remove clutch cover mounting bolts (10 nos.) with 8 mm spanner 4. Take out clutch cover. 5. Ensure the piston it at TDC by aligning primary gear mark with crankcase mark [A] using 24 mm spanner. 6. Ensure horizontal lines mark on cam sprockets should be upwards align with cylinder head face as shown in [B]. • Locking Crankshaft Tool (P/N :37 1044332) • Piston TDC confirmation : Remove dummy bolt from crankcase using 10 mm spanner & fit the crankcase locker tool (P/N : 37 1044332) in dummy hole. If the crankshaft locker tool fits in crankshaft, it means that piston is at TDC. 1 2 B 5 6 3 4
3-21 PREVENTIVE MAINTENANCE Tappet Clearance Setting • Remove air filter element (Refer page 3-2 until 3-5 for complete SOP). • Remove heat insulating rubber sheet from restraining slots 1. Pull out breather pipe clip & take out breather pipe from cover cylinder head. 2. Take out central spark plug cap. 3. Remove cover cylinder head mounting bolts (4 nos.) using 10 mm spanner. 4. By adjusting throttle cable, take out cover cylinder head & it’s gasket. • With the help of feeler gauge, check the tappet clearance. Specifications : Intake : 0.08 - 0.12 mm Exhaust : 0.13 - 0.17 mm 1 3 4 2
3-22 PREVENTIVE MAINTENANCE Tappet Clearance Setting If the tappet clearance is not as per specification :- Measure the tappet clearance : Intake 1 : ___________, Intake 2 : ______________ Exhaust 2 : ___________, Exhaust 2 : ______________ • Remove chain tensioner. • Using cotton cloth & plier, take out sleeve central spark plug. • Remove cam holder & Guide chain top mounting bolts (8 nos.) with 8 mm spanner. Length of bolts : Bolts shown by grey arrow : @ 41 mm. Bolts shown by white arrow : @ 46 mm. Bolts shown by black arrow : @ 51 mm. 1. Take out guide chain top. 2. By adjusting throttle cable, take out cam holder. • Holding the cam chain take out camshaft assembly. • Tie cam chain using copper wire & take out other cam shaft assembly. 1 2
3-23 PREVENTIVE MAINTENANCE Tappet Clearance Setting Intake side 2 1 2 1 Exhaust side Shim calculation for increased tappet clearance : A - Existing Shim Thickness B - Standard Tappet Clearance C - Measured Tappet Clearance D - Increase in Tappet Clearance = C - D E - Shim to be used = A + D Shim A C B D • Lift all four Rocker Arms by hand. • At a one time, take out one shim only using Flexible Wire with Magnetic Tip (P/N : 37104345). Note down shim sizes removed from vehicle as follows :- Intake 1 : ___________, Intake 2 : ______________ Exhaust 2 : ___________, Exhaust 2 : ______________ • Shim thickness to be check with calibrated Micrometer. Shim to be used : For Exhaust valve :- A - 2.40 mm, B - 0.10 mm C - 0.14 mm, D - 0.04 mm E - Shim to be used = A + D = 2.40 + 0.04 = 2.44 mm
3-24 PREVENTIVE MAINTENANCE Tappet Clearance Setting Shim calculation for decreased tappet clearance :- A - Existing Shim thickness B - Standard Tappet Clearance C - Measured Tappet Clearance D - Decrease in Tappet Clearance = B - C E - Shim to be used = A - D Shim to be used :- For Exhaust valve - A - 2.40 mm B - 0.10 mm C - 0.06 mm D - 0.04 mm E - Shim to be used = A - D = 2.40 - 0.04 = 2.36 mm Shim A B C D • Fit new shim. • Fit cam shaft assemblies. Note : Ensure that two horizontal lines on cam sprocket are parallel to cylinder head face as shown in [A] and primary gear mark is align with crankcase mark [B]. • Fit cam holder & chain guide top. • Fit tensioner. • Feeler gauge should have a mild resistance when being slid out after setting valve clearances. • Fit sleeve spark plug. • Fit cover cylinder, gasket cover head & heat resistant cover. • Refit all removed parts. Assembly B A B
3-25 PREVENTIVE MAINTENANCE Coolant Level Check & Adjust • Ensure vehicle position upright on a level surface. • Check the coolant level as shown in photograph & ensure that coolant level in between MIN & MAX level. • If coolant level is below MIN mark, then Top-Up with recommended coolant using funnel. • Remove RH shroud mounting bolts (2nos.) with 4 mm allen key & 2 nos. plastic plugs with screw driver. • Remove expansion tank cap. • Top up with recommended coolant using funnel. Recommended coolant :- Motul Motocool Expert Castrol Radicool
3-26 PREVENTIVE MAINTENANCE Sealed Drive chain Lubrication on Vehicle Sealed Drive Chain on Vehicle • Apply rear wheel stand. Normal dust should be wiped clean using a lint free cloth. • Hold the Chain Lube Spray Can (OKS Spray) vertically upright & shake it vigorously till the noisy of steel ball inside the can is heard uniformly. Fix the extension tube (red pipe provided with the can). • Hold the can at the back of the rear sprocket in line with chain rotation and keep the nose of the extension tube at about 5 - 10 cm away from the chain. • Rotate the wheel in reverse direction & spray the lube on the middle portion of the chain so that lubricant will get spread on roller & bushes and on both sides of the chain. Spray the lube on full length of chain by rotating the wheel to complete rotation. • Rotate the wheel 3 ~ 4 times so that the lubricant spreads & settles. Wipe out any excess lubricant if it has dripped down or sprayes on the wheel / tyre. • If the drive chain is excessively dirty, then clean the drive chain with 50 : 50 diesel & SAE 90 oil by using nylon brush. • Hold the vehicle in such way that bike is perpendicular to surface & both wheels are touched to surface. • Rotate rear wheel slowly in one direction to find out position at which chain is getting tight. At this lowest point of chain slackness, lift & press down the chain to measure chain slackness by steel rule or chain slackness checking tool. (Std. chain slackness 20 - 30 mm). • If chain slackness is not as per specification then - loosen rear axle nut using 22 mm spanner holding rear axle with 17 mm spanner.
3-27 PREVENTIVE MAINTENANCE Sealed Drive Chain on Vehicle • Hold the left side chain adjuster lock nut with 12 mm spanner & adjust the adjuster nut with 13 mm spanner to adjust chain slackness. • Repeat the same procedure for RH chain adjuster. • Ensure that LH & RH chain adjuster marks are equally aligned with marks on adjuster marking line. • Tighten rear axle nut to specified torque (10 Kgf-m). • Check & ensure that rear wheel is rotating freely.
3-28 PREVENTIVE MAINTENANCE Front Caliper Overhaul & Brake Pad Wear / Check / Replace. SkillTip: Before removing caliper assembly from vehicle :- • Clean caliper assembly thoroughly by low pressure water spray before opening caliper bleeder nut. • Remove bleeder nut rubber cap. • Drain the brake fluid from caliper assembly by loosening air bleeder nut using 8 mm spanner using transparent PVC tube which will avoid spillage of brake fluid on caliper body / disc pads & also powder coating peel off / inefficient braking. • Remove front brake hose banjo bolt with copper washers (2 nos.) using 14 mm spanner. • Pull out lock clip fitted on brake pad pin using plier to avoid lock clip bending / breakage issue. • Loosen brake pad pin using star bit T - 30 from force ratchet box
3-29 PREVENTIVE MAINTENANCE Front Caliper Overhaul & Brake Pad Wear / Check / Replace. • Remove caliper mounting bolts (2 nos.) using 12 mm spanner & take out caliper assembly. Note : While removing caliper mounting bolts, hold caliper mounting bolts, hold caliper body to avoid falling of caliper body (Refer photograph - A) • Check brake pads ‘U’ slot for wear, if ‘U’ slot is worn out then remove brake pads as explained in next steps. If ‘U’ slots is ok, clean the brake pads by polish / sandpaper & refit removed parts. Notes :- If ‘U’ slot is not present then check brake pad thickness. As a precautionary measure, it is recommended to apply silicon grease on caliper anchor pin. 1. Remove brake pad pin using star bit T-30 from force rachet box. • Remove bleeder nut using 8 mm spanner from caliper body. 2. Take out brake pad pin, pad spring & brake pads. • Remove caliper pistons (4 nos.) by applying compressed air through banjo bolt hole. Note : Use cotton cloth while removing pistons from caliper body as “piston fly out” may cause damage to it & any one the vicinity. 1 2
Front Caliper Overhaul & Brake Pad Wear / Check / Replace. 3-30 PREVENTIVE MAINTENANCE • Remove dust seals (4 nos.) & oil seals (4 nos.) from caliper body. • Clean the caliper body by diesel / kerosene. • Refit the seals & dust seals in caliper body. • Fit all the pistons in caliper body. • Note : Clean the brake pads by smooth sand paper. • Dry the caliper body by applying low pressure compressed air. • Apply the silicon grease on piston OD & rubber seals.
3-31 PREVENTIVE MAINTENANCE Front Caliper Overhaul & Brake Pad Wear / Check / Replace. • Fit pad spring, brake pads & prefit brake pad pin. Tighten the brake pad pin to recommended torque (5.0 - 7.0 Kgf-m) by torque wrench. Note : Fit pad spring as shown in photograph - A. • Hold lock clip on groove provided on brake pad pin & press lock clip in the direction of arrow as shown in photograph - B. • Prefit the brake hose mounting bolts & tighten it to recommended torque (2.2 - 2.8 Kgf-m) by torque wrench. Note : Always replace banjo bolt copper washers whenever opened with new one. • Prefit the bleeder nut using 8 mm spanner. • Fit the caliper assembly on LH fork leg. Perfit the caliper mounting bolts & tighten it to recommended torque by torque wrench (2.2 - 2.8 Kgf-m).
3-32 PREVENTIVE MAINTENANCE Brake Fluid Replacement • Clean the surface area of a master cylinder from dust / dirt / oil. • Drain the brake fluid from caliper assembly by loosening air bleeder nut 8 mm and using transparent PVC tube which will avoid spillage of brake fluid on caliper body / disc pads & powder coating peel off / inefficient braking. 1. Remove master cylinder mounting screws (2 nos.) using Phillips head screwdriver. 2. Take out master cylinder cover. 3. Take out PVC Cap. 4. Take out Rubber Diaphragm. • Fill the master cylinder reservoir by recommended brake fluid (DOT3 or DOT4). • Carry out air bleeding. • Tighten the bleeder nut & fit it’s rubber cap. • Fit rubber diaphragm, PVC cap & master cylinder cover. 1 2 3 4
3-33 PREVENTIVE MAINTENANCE Brake Fluid Top Up / Clutch Cable Free Play Check & Adjust Clutch Cable Free Play Check & Adjust • Clean brake fluid level in master cylinder. • Ensure that brake fluid level is between “MIN” and “MAX” mark. • If brake fluid level is below “MIN” mark : - Remove master cylinder cover , PVC cap & rubber diaphragm. - Top up with recommended brake fluid such that brake fluid level is above “MIN” mark. - Refit all removed parts. - Check braking efficiency. If found spongy, do the air bleeding activity. • Press and release the clutch lever to confirm smooth operation. • If clutch operation is jammed or sticky, replace clutch cable. • Slide clutch lever rubber boot & check clutch lever free play by scale or free play gauge. • If free play is not as per specification (2 ~ 3 mm), set it by using adjuster provided at clutch cover end. • Clutch lever free : 2 ~ 3 mm.
3-34 PREVENTIVE MAINTENANCE Throttle Cable Free Play Check & Adjust / Side Stand Pin Clean & Lubrication Side Stand Pin Clean & Lubrication • Check for smooth rotation of throttle grip. • Check throttle free play by scale or free play gauge. Throttle free play : 2 ~ 3 mm. • Adjust throttle free play if not as per specification (2 ~ 3 mm), set if using adjuster provided at throttle grip end. • Apply rear wheel stand. • Remove side stand spring • Remove side stand mounting nut 17 mm spanner and take out side stand.
3-35 PREVENTIVE MAINTENANCE Side Stand Pin Clean & Lubrication / Brake Pedal Pivot Pin Lubrication Brake Pedal Pivot Pin Lubrication • Clean side stand mounting bolt & side stand mounting bracket with diesel / kerosene & apply AP grease. • Refit all the removed parts. • Apply rear wheel stand. • Remove end chamber mounting bolt with 14 mm spanner [A] holding nut with 17 mm spanner [B]. • Remove RH stay mounting bolts (3 nos.) with 6 mm allen key and take out RH stay. • Put cotton cloth as shown in photograph in order to avoid scratches on painted parts. • Remove rear brake switch spring connection from brake pedal.
3-36 PREVENTIVE MAINTENANCE Brake Pedal Pivot Pin Lubrication • Hold RH stay as shown in photograph & remove brake pedal pivot bolt using 17 mm spanner and take out the brake pedal pivot pin. • Clean brake pedal pivot pin by diesel / kerosene / AP grease • Note : Use sand paper (grade 1000) for removing solid grease with dust / rust before grease application. • Apply adequate quantity of AP grease. • Remove excess grease with lint free cotton cloth. • Refit all the parts.
3-37 PREVENTIVE MAINTENANCE Control Switch Contacts Cleaning Steering Play Check & Adjust / Control Switch Contacts Cleaning • Lift the vehicle from front side using overhead structure. • Slightly turn the handle bar to the left hand side & leave the steering handle. Check whether the steering moves by it’s own weight till end stopper position. • Also check the movement of steering turning the handle on the right hand side. This conforms free & smooth operation of steering • Check steering free play by pushing & pulling the fork from bottom side. • If the steering is sticky jam or having play, remove upper bracket. • Tighten steering slotted nut using steering slotted nut tightening special tool to recommended torque (0.5 Kgf-m) • Check & confirm that steering play is zero. Steering Play Check & Adjust • Remove control switch mounting screws (2 nos.) with Philips head screw driver & open control switch. • Use only WD40 electrical contact cleaning spray for control switch contacts cleaning. • Remove excess spray with lint free cotton cloth.
3-38 PREVENTIVE MAINTENANCE Ignition Switch Contacts Cleaning EVAP Drain Tube Cleaning / Ignition Switch Contacts Cleaning • Remove EVAP drain tube & remove it’s clamp using coolant clamp plier. Evap Drain Tube Cleaning • Take out plug from EVAP drain tube & drain accumulated petrol if any. • Clean the top surface of ignition switch by clean lint / fiber free cotton cloth. • Use only WD40 electrical contact spray for ignition switch contact cleaning. • Note : Do not lubricate ignition switch by oil.
1 Chapter 4 Fuel System & EMS Table of Contents Exploded View .................................................... 4-2 Wiring Harness Routing : Reference Part .......... 4-9 Evap Routing ………........................................... 4-10 Working Of Systems ........................................... 4-13 Fuel Injection System .........................................4-23 EMS Sensors & Actuators .................................. 4-24 Diagnosis & Trouble Shooting Of Error Codes .. 4-28 4
4-2 FUEL SYSTEM & EMS Exploded View Fuel Injector Injector & Throttle Body Throttle Body Cap Tank Tank Fuel Pump Fuel Filter Fuel Tank & Gauge Fuel HT Coil & Regulator
4-3 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts
4-4 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts : Cable ties are shown in BLACK color : Cable ties are shown in BLACK color
4-5 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts : Cable ties are shown in BLACK color : Cable ties are shown in BLACK color
4-6 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts : Cable ties are shown in BLACK color : Cable ties are shown in BLACK color
4-7 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts
4-8 FUEL SYSTEM & EMS Exploded View Location of Parts : Cable ties are shown in BLACK color
4-9 FUEL SYSTEM & EMS Wiring Harness Routing : Reference Part Photo Part Name Remark Fuel injector To inject the fuel into the intake manifold until the electric signal from solenoid is cut off by ECU. Oil pressure sensor It measures the pressure of the engine oil flowing thru the internal oil galleries and communicates the signal to the speedometer. TMAP It is a micromechanical sensor that measures the absolute pressure in the intake manifold and compares it with a reference vacuum, not with the ambient pressure. TPS To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU. Stepper motor Stepper motor is a brushless DC electric motor that divides a full rotation into a number of equal steps. The motor's position can then be commanded to move and hold at one of these steps without any feedback sensor. Photo Part Name Remark ECU To collect information from various sensors & insure that correct quantity of fuel is injected into the intake manifold at precise timing at various engine load & speed condition Main relay A relay is an electrically operated switch. Most relays use an electromagnetic to mechanically operate a switch. Relays are used where it is necessary to control a circuit by a lowpower signal Fuel pump relay Radiator fan relay Photo Part Name Remark H.T. Coil 1 For Central spark plug H.T. Coil 2 For LH spark plug Roll Over Sensor Sends ignition cut of signal to ECU when bike inclination angle > 60°
4-10 FUEL SYSTEM & EMS Electrical Parts Inspection Parameter Components Standard Value Starter Relay Coil 3.9 Ohms ± 10% Battery Charging Coil 0.4 to 0.6 Ohms Pick Up Coil 390 ± 10 Ohms DC Charging Voltage 14.5 ± 0.2 V Horn 2.5A Max @12V Engine Temperature Sensor Temperature in Degree Centigrade Resistance in K Ohms 0 5.30 ~ 6.11 10 3.44 ~ 3.92 20 2.28 ~ 2.58 25 1.88 ~ 2.12 30 1.55 ~ 1.75 40 1.06 ~ 1.21 50 0.75 ~ 0.86 Low oil pressure warning Warning comes : If Active low ; RPM > 4000 ; t > 20 sec Roll Over Sensor Input voltage : 5V Output voltage - Normal (Vehicle mounted condition) 3.51 ~ 3.71 V Output voltage - Tilted (More than 60 degree on either side) 0.14 ~ 0.54 V Crank Angle Sensor resistance 390 ± 10 Ohms Neutral switch Contact type TMAP sensor Resistance 2 ± 0.5 K Ohms @ 250C Input voltage 5 V Output voltage 0.4 ~ 4.65 V TPS sensor Input voltage 5V Coil Resistance 2000 ± 600 W Side Stand Switch Input voltage (Side stand position - any) 5 V Output voltage (Side stand position - OFF) 0.14 ~ 0.54 V Side stand 3.51 ~ 3.71 V Fuel Injector resistance 12 ± 0.6 Ohms @ 200C Central H.T. Coil resistance : Primary 2.3 ± 10% Ohms Secondary 13 ± 20% K Ohms LH HT coil resistance : Primary 2.3 ± 10% Ohms Secondary 13 ± 20% K Ohms Stepper Motor resistance : w.r.t each pair 51 W ± 10% Radiator Fan Fan motor START 95.30C Fan motor OFF 900C Intermediate Relay resistance 110 ± 10%
4-11 FUEL SYSTEM & EMS EVAP Routing Location of Parts JF171623
4-12 FUEL SYSTEM & EMS EVAP Routing Location of Parts
4-13 FUEL SYSTEM & EMS EVAP Routing Location of Parts
Function To draw the fuel from the fuel tank and push it along the fuel lines to the injector rail and keeping a constant pressure in the system. Also the fuel pump needs to ensure a high level of fuel flowing through the fuel line thus maintaining constant fuel delivery pressure. Part No : JF1718 02 (Fuel Pump) 4-14 FUEL SYSTEM & EMS Working of Systems Fuel Pump Construction Fuel pumpmodule assembly Working The fuel is pumped from the fuel tank by a roller cell pump through a fuel filter into a fuel rail at the end of which is a fuel pressure regulator In order to keep the injector pressure differential constant despite variations of inlet manifold depression with load, the fuel pressure regulator senses the difference between pumping pressure and that of the inlet manifold. Excess fuel is returned to the fuel tank, the continuous flushing keeps the fuel cool and avoids formation of pockets of fuel vapor. The fuel pump is lubricated and cooled by the fuel flowing through the motor, including the brushes and across the armature hence it is important that never run the pump without adequate fuel inside the fuel tank. The fuel filter strains impurities out of the fuel. This is an important measure in preventing the fuel pump, fuel injector nozzles from clogging. Fuel Pump Resistance = 2.7 + 0.1 Ohms ( Refer page 7-13 )
4-15 FUEL SYSTEM & EMS Working of Systems Fuel Injector Construction Fuel Supply Rail 'O' Ring Seal Integral Filter Coil Washer Pintle Protection Cap Pintle Valve Needle Manifold 'O' Ring Armature ReturnSpring Electric Connection Working The fuel injector supplies the fuel in the form of a spray from the injector pintle which is located on intake manifold. The injector have the nozzles which are opened and closed by solenoid wound (coil) in the injector body. When the windings are energized the armature is attracted due to magnetism and compresses the spring which lifts the needle valve. Thus pintle automizes the fuel into a fine spray form with a pressure about 2.5 bars (36 lbf / in2) until the electric signal in the solenoid is cut off by the ECU. The injector internal movement is restricted just to < 0.1 mm. Also period that an injector remains open is very low (between 1.5 and 10 milliseconds). Thus the opening and closing time is critical for accurate fuel metering. The fuel spray mixes with the incoming air as both move towards the inlet valve giving a precisely metered combustion mixture. To inject the fuel into intake manifold until the electric signal from solenoids is cut off by ECU.
4-16 FUEL SYSTEM & EMS Working of Systems Engine Control Unit (ECU) Introduction The automotive engine has two power generation systems named as ‘Carburetor System’ & ‘Ignition System’ respectively. The carburetor supplies atomized / vaporizes air fuel mixture to the engine maintaining the desired air fuel ratio per engine requirement. The ignition system supplies igniting spark at the spark plug tip as per percise engine demand ( timing ) to burn the compressed air fuel miture inside the combustion chamber. However these 2 systems like carburetor and ignition has been dealt separately. In digital ignition circuits a microprosessor is used in the CDI unit. This microprocessor is capable of controlling various tasks. Hence it was logical to use this capacity for controlling fueling also. Thus then developed a digital electronic control system for fuel injection and combined it with the digital ignition control to form a single unit controller. This unit is named as “Electronic Control Unit” Function It collects information from various sensors and ensure that a correct quantity fuel is injected into the intake manifold at precise time considering various engine load and speed conditions. It is the brain of the engine and controls various devices. Also it controls / supports on vehicle diagnostic instrument for diagnosing the problem in fuel injection system Construction It consists of a micro computer A-D Converter ( Analog to Digital ) and I-O Unit ( Input-Output ) Sensors Signal Processing (SP) Vehicle Speed Sensor Side Stand Sensor Clutch Switch Engine Oil Pressure Sensor Roll Over Sensor Lambda Sensor Crank Angle Sensor and Neutral Switch T Map Sensor Throttle Position Sensor Coolant Temperature Sensor Analogue to Digital - (A-D) Input signals are received from various set of Sensors Signals given to operate following Actuators Please pull or slot in the ECU in paralel from or to the ECU socket. NOTE Actuators MPRD (Relay) Steeper Motor Motor Injector Fuel Pump H.T. Coil (Center & LH) Engine Malfunction Speedo Icon Radiator Fan It also supports in Diagnostic trouble codes assessment.
4-17 FUEL SYSTEM & EMS Working of Systems Engine Control Unit ( ECU ) Working The ignition and fuel injection is controlled by a single control unit named as 'ECU'. In ECU the inputs from various sensors are fed into a signal processor circuits to ensure that all outputs to the computer are in the form of digital pulses. These inputs received may be steady or slowly varying voltages. These are said to be in analogue from and which are converted into equivalent digital valves by an analogue to digital ( AD ) converter. The digital output are fed to the input I output rail for transporting to the main heart of the computer. Thus the ECU collects all signals, calculates them and process them to actuators to delivery precise ignition advance timing and fuel injection requirement for the engine at various load and speed conditions. Set of Various Sensors A sensor is a device which detects or measure a quantity, usually in electrical form so that it may be used in measurement or control. The analogue signal processing is added to the sensor, this improves the resistance to interference. Set of Various Actuators Actuators is a general term used to describe a control mechanism i.e. a device that converts electrical signals into mechanical movement e.g. : • Fuel injector. • Fuel pump. • Solenoid starter relay.
4-18 FUEL SYSTEM & EMS Working of Systems Throttle Position Sensor Function To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU. Construction The throttle body has a throttle valve mounted on the intake manifold. The throttle valve is connected by accelerator cable and its opening and closing is controlled by accelerator twist grip mounted on RH side of handle bar. The throttle position sensor mounted on the throttle valve continuously reports the throttle position to the ECU. This is a rotary throttle position sensor having a variable resistor also called as a potentiometer. Internally it has a coil resistance wire in the form of a half circle. One end connects to the ground and other end is connected to a 5 volt source from ECU. The wiper blade has a contact that rides on the coil and connects to the throttle valve shaft. Also the position of the throttle valve is important in controlling the idling rpm. Working Upon acceleration the throttle valve position changes. The wiper type blade moves over the coil winding as it is pivoted directly on the throttle valve shaft. Throttle position at zero (closed) position : When the throttle valve is closed, the blade is at the grounded end of the coil. A small voltage signal is send to ECU at this position which senses that the throttle position is at zero. Further movement of throttle position : Wide Open Throttle Resistance Coil Closed Throttle Wiper Pivot Blade Output Voltage to ECU 5 Volts from ECU
4-19 FUEL SYSTEM & EMS Working of Systems Engine Temperature Sensor (ETS) Function To measure the engine / engine oil temperature up to 2000 C. Construction The principal methods of temperature measurement is done by the thermistor. The thermistor is made from semi conductor material such as cobalt or nickel oxides and is encapsulated in a brass sleeve for mechanical protection. Working The thermistors are semi conductor resistors which change their resistance valve with temperature. The resistance decreases with an increase in engine temperature as it has a negative temperature coefficient (NTC) and vice versa. The characteristic of engine temperature is represented graphically (The values do not match exactly, it is just a representation for understanding). This NTC type thermistor is used to measure the engine temperature in engine management system. 200 180 160 140 120 100 80 60 40 20 0 0 10 20 30 40 50 60 70 80 90 100 NTC Thermistor Characteristic Temp. 0C Thermistor Resistance (Ohm) NTC Thermistor
4-20 FUEL SYSTEM & EMS Working of Systems Roll Over Sensor Function To send the ignition cut off signal to ECU for shutting down the engine if the bike exceeds the inclination angle beyond 60° on either of the side. Construction The roll over sensor is a sealed sensor unit and that contains moving weight which is suspended freely on a shaft. This is mounted below the air filter box onto the chassis. Working The moving weights are suspended freely. When the vehicle leans down on either of the LH and RH side of the position of this weights changes. The change of position of the weights is sensed by the sensor. If the inclination angle exceeds beyond 60º to the vertical the sensor will give signal to ECU to cut off the ignition system. This is a useful safety feature because inclination angle exceeding 60º indicates that the rider has dropped the bike or is involved in an accident. Thus, safety of the bike and rider is ensured. Please note, even if over sensor is not connected (coupler open) the vehicle does not start (to ensure safety) and the malfunction will be shown on speedometer. Main Switch Sensor Magnet y x 0
4-21 FUEL SYSTEM & EMS Working of Systems Crank Angle Sensor Function To communicate the ECU how fast the crankshaft is rotating per minute and help ECU in delivering precise fuel metering and ignition spark advance. Construction A magnetic sensor located in magneto cover facing towards square notched I square block on the rotor periphery. Working As the rotor rotates the notched square blocks on the rotor periphery causes voltage pulses in the sensor. These pulses are sent to the ECU. The ECU counts the number of pulses per second and understands at what RPM the engine is operating and accordingly precise fuel metering and ignition spark advance is controlled. These are 23 square notches I square blockes on the rotor outer periphery and are placed equidistance. At a particular location these is wide gap seen between 2 square noches I square blocks. This can also be determined as square notch missing. The missing square notch area represents the BTDC position. At this BTDC position voltage pulse is sensed by the crank angle sensor and communicated to ECU. ECU use this information to control ignition spark plug advance.
4-22 FUEL SYSTEM & EMS Working of Systems Crank Angle Sensor Working When certain troubles develop on the electronic control system, the ECU stores in its memory or number or trouble code for each fault. This turns a Malfunction Red Indicator Light (circle) on the secondary speedometer (next to Low Battery Indicator & Coolant Temperature Indicator). This alerts the driver that there is some problem and repair / service in needed. If a single sensor or its harness part falls the ECU may subtitute a value for failed sensor. This allows the engine to appear to run normal. A fault that turns on the malfunction indicator light may also put the engine into its limp-in mode. This means that limited operation strategy (LOS) chip in the ECU has taken over. It provides basic instructions to the microprocessor if a part of the electronic system fails. The engine runs but with fixed ignition timing and air fuel ratio. The injector pulse width does not change. This allows the vehicle to be driven but with greatly reduced performance. The benefit of this is the vehicle can be limp-in for service instead of being towed or transported into cargo. The technician can retrieve the stored trouble code from ECU memory using the diagnostic tool. To use the code the technician can refer the Diagnostic Chart or the Flash Code. This chart explains where lies the problem and its probable cause.
4-23 FUEL SYSTEM & EMS Working of Systems FUEL INJECTION - ADVANTAGES OVER CARBURATOR Advantages of Fuel Injection Increased power output per unit of displacement. Higher torque at low engine rpm. Improved cold start, warm up and sudden acceleration (No chance of wetting intake manifold). Lower fuel consumption. Overall superb drive-ability. Lower maintenance cost Communicates malfunctioning of fuel injection system, if any. Low emission level. Limitations of Carburetor Restricted air flow due to venture design causes power loss (volumetric effeciency is limited). As intake manifold contains combustible mixture, danger of back fire from the cylinder into the manifold is always there. At high altitude or in warm weather, possibility of vapour lock. After burning noise in silencer on sudden deceleration. Does not support sudden acceleration. Difficult cold starting and required choke for starting. In cold conditions, fuel wets the wall of the induction manifold causing running difficulties. Maintenance cost is reasonably more. High emission level. Inconsistence in fuel efficiency.
4-24 FUEL SYSTEM & EMS Fuel Injection System Measure the Coolant Temperature and assist ECU to adjust the fuel injection volume. It detects the side stand position and gives signal to ECU. Detect the tilt angle of motorcycle & if it is more than 60 degree ECU disable the ignition and fuel supply. Measure the oxygen proportioning exhaust & assist ECU to adjust the amount of fuel to be injected. Measure the rotational speed of crankshaft & assist ECU to determine injection & ignition timing. Measures the intake air temperature & pressure and assist the ECU to adjust the fuel injection volume. Detect the throttle position COOLANT TEMP SENSOR SIDE STAND SWITCH TEMPERATURE / MANIFOLD PRESSURE SENSOR CRANK ANGLE SENSOR THROTTLE POSITION SENSOR ROLLOVER SENSOR OXYGEN SENSOR Input toECU Output fromECU ECU calculates & determines the volume of fuel to be injected and the injection & ignition timing. For connecting the diagnostic tool. Start when coolant temp reach 98 degree & stop at 88 degree RADIATOR FAN DIAGNOSTIC TOOL COUPLER Blinks if there is any malfunctioning in FI system. MALFUNCTION INDICATOR H.T COIL Adjust the idle speed of engine base on input from ECU. Supply pressurized to injector. Injects the precise amount of fuel based on the ECU data. Injects appropriately based on the ECU data. STEPPER MOTOR FUEL INJECTOR FUEL PUMP
4-25 FUEL SYSTEM & EMS EMS Sensors & Actuators Purpose To control precisely air fuel mixture as per the engine RPM and to get optimum engine performance. Advantages over Carburetor System Increased power output per unit of displacement. Higher torque at low engine rpm. Improved cold start ability, roll over & sudden acceleration. Lower fuel consumption - better mileage. Overall superb drive ability. Low maintenance cost. Communicates malfunctioning of fuel injection system, if any. Low emission level. Sensors & Actuators
4-26 FUEL SYSTEM & EMS EMS Sensors & Actuators 1 - MPRD (Relay) 2 - Steeper Motor 3 - Injector 5 - TPS 7 - H. T. Coils (LH) 8 - H. T. Coils (CENTER) 9 - Engine Malfunction Indicator (MIL) 11 - Radiator Fan 10 - Diagnostic Coupler 6 - Fuel Pump 4 - T MAP Sensor P4 P3P2 P1 4 2 3 5 6 7 8 10 9 9 11 1 Sensors & Actuators
4-27 FUEL SYSTEM & EMS EMS Sensors & Actuators Fuel Injection System Sensors - Working & Malfunction Effect S.N . Input to ECU Input Details How ECU Uses Input Effect incase of abnormability 1 Coolant Temperature Sensor Temperature of coolant. Radiator fan relay gets ON. Adjusts temperature based Ignition timing. 1.Radiator fan will not work & coolant temperature may shoot up affecting engine performance. 2.High coolant temperature icon may not blink. 3.Start ability, fuel consumption & power-pickup will be affected. 2 Engine Oil Pressure Sensor Engine oil pressure. Glowing of Engine oil pressure icon. Running of engine on low oil level may result in early wear of engine parts. 3 Roll Over Sensor Voltage of 2 VDC in vehicle tilted condition. ECU cuts off main relay & ignition is cut off. Engine will keep running in case of accident or vehicle slips & may result in serious injury to rider and damage to vehicle. 4 Side Stand Switch Voltage of 5 VDC in case when vehicle is parked on side stand. ECU will switch ON side stand indication in speedo console & will cut off ignition system. No indication of side stand ON inspeedo console. Vehicle will not run in gear. 5 Oxygen Sensor Voltage signal depending on amount of oxygen in exhaust. ECU determines air fuel mixture & adjusts accordingly. Malfunctioning of Oxygen sensor will result in either rich mixture causing black smoke or lean mixture resulting in vehicle drive ability. 6 Crank Angle Sensor It senses rotation of crank shaft & gives pulse input to ECU. ECU calculates no. of pulses revolution & indicates engine RPM on Tachometer dial. Gives input to ECU for ignition circuit. Wrong indication of Engine RPM in speedo. Malfunction Ignition system. No start situation in case of open circuit. 7 Throttle Position Sensor Monitors position of throttle & gives voltage input to ECU in POT to WOT modes ECU increases or reduces fuel rate to Engine suitably. Fuel consumption & power - pickup will be affected. 8 TMAP Sensor Monitors temperature & pressure of air entering manifold & gives SVDC signal to ECU. ECU increases or reduces. Air supply rate to Engine suitably. Start ability, Fuel consumption & power - pickupwill be affected.
4-28 FUEL SYSTEM & EMS EMS Sensors & Actuators Fuel Injection System - Actuators S.N. Output from ECU Input Details Effect incase of abnormability 1 Fuel Pump Fuel pump relay gets ON through ECU Malfunctioning of fuel pump will result in intermittent fuel supply causing hesitation / misfiring, no start. 2 Fuel Injector Earthing signal from ECU Malfunctioning of fuel injector will result in either rich or lean mixture causing smokey exhaust / misfiring problems. Knocking / Combustion noise. 3 HT Coils Earthing signal from ECU Misfiring or hesitation problems. No spark resulting in no start. 4 Radiator Fan Radiator fan motor relay gets ON Radiator fan will not work & coolant temperature may increase excessively affecting engine components. Icon glows in speedometer at 115 degree Centigrade & vehicle can not be accelerated above 4000 rpm. At 120 Degree Centigrade engine will get-OFF. 5 Malfunction Indicator Malfunction in FI system signal from ECU Malfunctioning in F1 system will go unnoticed. 6 Stepper Motor Signal from ECU Unstable idling RPM. Start ability wil be affected. 7 Diagnostic tool port CAN high / Low input from ECU No communication with BOSCH Diagnostic tool -show link error. Important : Do not disturb the position of throttle adjuster screw. If done it will affect the vehicle performance and claim will not be accepted under warranty.
4-29 FUEL SYSTEM & EMS Diagnosis & Trouble Shooting of Error Codes D&T Codes No. P-Code DTC meaning DTC cause Symptoms To Check 1 P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit High Short circuit to battery voltage, short to sensor supply +5V - Idle control is affected. - No overrun fuel cut-off happens. - Drivability is affected. -Load on engine(In tool, group1,entry5 is engine load which is equivalent to volumetric efficiency) is calculated based on Manifold. Air Pressure sensor. Throttle Position Sensor connections, wiring harness. Replace Throttle body and check. 2 P0122 Throttle/Pedal Position Sensor/Switch “A” Circuit Low Short circuit to Ground ; Open Circuit - Idle control is affected. - No overrun fuel cut-off happens. - Drivability is affected. -Load on engine(In tool, group1,entry5 is engine load which is equivalent to volumetric efficiency) is calculated based on Manifold Air Pressure sensor. Throttle Position Sensor connections, wiring harness. Replace Throttle body and check. 3 P0507 Idle Air Control System RPM Higher Than Expected Intake manifold leakage Limited engine speed Check for intake manifold leakage. 4 P0506 Idle Air Control System RPM Lower Than Expected Torque loss of engine is too high Check for any damage to engine (Damage inside engine - valve, piston, crank shaft etc.). 5 P0108 Manifold Absolute Pressure/ Barometric Pressure Circuit High Short Circuit to battery voltage; Short Circuit to sensor Supply ; Open Circuit Deactivation of manifold pressure diagnosis -Cold Start and after start is affected. - Altitude adaptation doesn’t happen. - Secondary Load sensor i.e. Throttle Position Sensor is used for sensing load. - Drivability is affected - Vehicle running in group injection mode (In ok case 1 injection happens in one cycle, but in case of this error 2 injections happen in one cycle and that is called group injection). Temperature Manifold Air Pressure connections, wiring harness. Replace Throttle body and check. 6 P0107 Manifold Absolute Pressure/ Barometric Pressure Circuit Low Short Circuit to Ground