HYOSUNG AQUILA 650 FI Service Manual
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HYOSUNG AQUILA 650 FI Service Manual

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SERVICE MANUAL
99000-51310

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  • Page 1 SERVICE MANUAL 99000-51310...
  • Page 2 WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer.

  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previous page as GROUP INDEX, select the section where you are look- ing for.

  • Page 4: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Liquid Crystal Display : Alternating Current : Light Emitting Diode : American Petroleum Institute : Left Hand ATDC : After Top Dead Center : Maximum BBDC : Before Bottom Dead Center : Minimum : Bettom Dead Center BTDC...
  • Page 5 WIRE COLOR : Black : Gray : Light blue : Blue : Light green : White : Brown : Orange : Yellow : Green : Red : Black with Blue tracer : Black with Brown tracer : Black with Green tracer : Black with Orange tracer : Black with Red tracer : Black with White tracer...

  • Page 6: General Information

    GENERAL INFORMATION CONTENTS SPECIFICATIONS( & ) ………………………… 6 (1-8-1) SPECIFICATIONS( & ) …………………… 8 (1-9-1)
  • Page 7 1-8-1 GENERAL INFORMATION SPECIFICATIONS ( & ◉ ◉ DIMENSIONS AND MASS I T E M 2,430 mm (95.7 in) 2,060 mm (81.1 in) Overall length 840 mm (33.1 in) 740 mm (29.1 in) Overall width 1,155 mm (45.5 in) 1,090 mm (42.9 in) Overall height 1,665 mm (65.6 in) 1,435 mm (56.5 in)
  • Page 8 GENERAL INFORMATION 1-8-2 ◉ ◉ CHASSIS I T E M Front suspension Telescopic type ← Rear suspension Swingarm type ← Steering angle 35°(right & left) 30°(right & left) Caster 35° 25.5° Trail 160 mm (6.3 in) 85 mm (3.35 in) Front brake Double disk brake ←...
  • Page 9 1-9-1 GENERAL INFORMATION SPECIFICATIONS ( & ◉ ◉ DIMENSIONS AND MASS I T E M (Sport type) (Standard type) 2,060 mm (81.1 in) ← ← Overall length 740 mm (29.1 in) ← Overall width 655 mm (25.8 in) 1,125 mm (44.3 in) ←...
  • Page 10 GENERAL INFORMATION 1-9-2 ◉ ◉ CHASSIS I T E M (Standard type) (Sport type) Front suspension Telescopic type ← ← Rear suspension Swingarm type ← ← Steering angle 27°(right & left) ← ← Caster 25.5° ← ← Trail 74 mm (2.91 in) ←...

  • Page 12: Table Of Contents

    FI SYSTEM DIAGNOSIS CONTENTS 4 -1 PRECAUTIONS IN SERVICING ……………………………………… 12 (4-1-1) FI SYSTEM TECHNICAL FEATURES ……………………………… 16 (4-1-5) SELF-DIAGNOSIS FUNCTION ……………………………………… 22 (4-1-11) FI SYSTEM TROUBLESHOOTING ………………………………… 25 (4-1-14) CUSTOMER COMPLAINT ANALYSIS………………………………… 25 (4-1-14) SELF-DIAGNOSTIC PROCEDURES ………………………………… 27 (4-1-16) SELF-DIAGNOSIS RESET PROCEDURE ……………………………...

  • Page 13: Precautions In Servicing

    4-1-1 FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ◉ ◉ ELECTRICAL PARTS ▣ ▣ CONNECTOR / COUPLER ● When connecting a connector, be sure to push it in until a click is felt.
  • Page 14 FI SYSTEM DIAGNOSIS 4-1-2 ● When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female terminal.
  • Page 15 4-1-3 FI SYSTEM DIAGNOSIS ● When disconnecting and connecting the ECU, make sure to turn “OFF” the ignition switch, or electronic parts may get damaged. ● Battery connection in reverse polarity is strictly INCORRECT prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

  • Page 16: Using Testers

    FI SYSTEM DIAGNOSIS 4-1-4 ● Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to ECU or sensors may result. ● Be sure to use a specified voltmeter / ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.

  • Page 17: Fi System Technical Features

    4-1-5 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES ◉ ◉ INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

  • Page 18: Injection Stop Control

    FI SYSTEM DIAGNOSIS 4-1-6 ◉ ◉ COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION WATER COOLANT TEMPERATURE When engine coolant temperature is low, injection time (volume) SENSOR SIGNAL is increased.
  • Page 19 4-1-7 FISYSTEM DIAGNOSIS ◉ ◉ FI SYSTEM PARTS LOCATION ( E E C C U U ① ⑥ Speedometer Fuel injector, NO.2 ② ⑦ Fuel pump relay GP switch ③ ⑧ Fuel injector, NO.1 Pick-up coil ④ ⑨ TP sensor Ignition coil, NO.1 ⑤...
  • Page 20 FISYSTEM DIAGNOSIS 4-1-8 1 1 2 2 1 1 3 3 E E C C U U 1 1 1 1 1 1 0 0 1 1 4 4 1 1 5 5 ⑩ TO sensor ⑬ IAP sensor, NO.1 ⑪...
  • Page 21 4-1-9 FISYSTEM DIAGNOSIS ◉ ◉ FI SYSTEM PARTS LOCATION ( E E C C U U ① ⑤ Speedometer IAT sensor ② ⑥ Fuel injector, NO.1 GP switch ③ ⑦ TP sensor Pick-up coil ④ ⑧ Fuel injector, NO.2 Ignition coil, NO.1...
  • Page 22 FISYSTEM DIAGNOSIS 4-1-10 E E C C U U 1 1 3 3 1 1 0 0 1 1 2 2 1 1 1 1 1 1 4 4 1 1 5 5 ⑨ ⑬ Fuel pump relay IAP sensor, NO.2 ⑩...

  • Page 23: Self-Diagnosis Function

    4-1-11 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECU. The function has two modes, “USER MODE” and “DEALER MODE”. The user can only be notified by the LCD(DISPLAY) panel ① and the “FI” check lamp “ ”...

  • Page 24: Dealer Mode

    FI SYSTEM DIAGNOSIS 4-1-12 ◉ ◉ DEALER MODE The defective function is memorized in the ECU. Use the special tool’s coupler to connect to the dealer mode coupler. (Refer to page 4-1-16) The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECU does not receive signal from the devices.
  • Page 25 4-1-13 FI SYSTEM DIAGNOSIS CODE MALFUNCTION PART REMARKS None No defective part Pick-up coil Throttle position sensor (TPS) Water temperature sensor (WTS) Intake air pressure sensor (IAPS), NO.1 For NO.1 cylinder Intake air pressure sensor (IAPS), NO.2 For NO.2 cylinder Intake air temperature sensor (IATS) Oxygen sensor (O Tip over sensor (TOS)

  • Page 26: Fi System Troubleshooting

    FI SYSTEM DIAGNOSIS 4-1-14 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 27 4-1-15 FI SYSTEM DIAGNOSIS MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather � � � � � � Fair Cloudy Rain Snow Always Other Temperature � � � � � Warm Cool Cold ( °F / °C) Always Frequency �...

  • Page 28: Self-Diagnostic Procedures

    FI SYSTEM DIAGNOSIS 4-1-16 SELF-DIAGNOSTIC PROCEDURES Don’t disconnect couplers from ECU, battery cable from battery, ECU ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized information in ECU memory.

  • Page 29: Malfunction Code And Defective Condition

    4-1-17 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT The signal does not reach ECU for more than 2 sec. after receiving the IAP signal. Pick-up coil Pick-up coil wiring and mechanical parts. (Pick-up coil, lead wire coupler connection) The sensor should produce following voltage.
  • Page 30 FI SYSTEM DIAGNOSIS 4-1-18 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR Ignition signal is interrupted continuous by 32 times or more when ECU confirm ignition surge at each combustion chamber, Ignition coil (IG coil), C24 or C25 is indicated. C24 / C25 NO.1 / NO.2 Ignition coil, wiring / coupler connection, power supply from the...

  • Page 31: C12" Pick-Up Coil Circuit Malfunction

    4-1-19 FI SYSTEM DIAGNOSIS “C12” PICK-UP COIL CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECU for more than 2 sec. ● Metal particles or foreign materiel being attached after receiving the IAP signal. on the pick-up coil and rotor tip. ●...

  • Page 32: C14" Tp Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-20 “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. ● TP sensor circuit open or short. 0.2 V � Sensor voltage � 4.8 V ● TP sensor malfunction. ●...
  • Page 33 4-1-21 FI SYSTEM DIAGNOSIS ◈ Step 2 1) Remove the frame cover. 2) Turn the ignition switch “OFF” position. 3) Disconnect the TP sensor coupler. 4) Check the continuity between � and ground. ∞ Ϊ (Infinity) TP sensor continuity (� - Ground) Ground 5) If OK, then measure the TP sensor resistance (between �...
  • Page 34 FI SYSTEM DIAGNOSIS 4-1-22 ◈ Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch “ON” position. Measure the TP sensor output voltage at the coupler (between � LY and �...

  • Page 35: C15" Wt Sensor Circuit Malfunction

    4-1-23 FI SYSTEM DIAGNOSIS “C15” WT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. ● WT sensor circuit open or short. 0.2 V � Sensor voltage � 4.6 V ● WT sensor malfunction. ●...
  • Page 36 FI SYSTEM DIAGNOSIS 4-1-24 ◈ Step 2 1) Turn the ignition switch “OFF” position. 2) Measure the WT sensor resistance. ☞ Refer to the service manual 『 』 page 5-7 (99000-51210) ☞ Refer to the service manual 『 』 page 5-7 (99000-94810) WT sensor resistance Engine Coolant Temp.

  • Page 37: C17 " " O O R R " " C18 " " Iap Sensor Circuit Malfunction

    4-1-25 FI SYSTEM DIAGNOSIS “C17” or “C18” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is out of the specified range. ● Clogged vacuum passage between throttle body 0.2 V � Sensor voltage � 4.8 V and IAP sensor. NOTE : ●...
  • Page 38 FI SYSTEM DIAGNOSIS 4-1-26 ◈ Step 2 ② 1) Connect the IAP sensor coupler NO.1 ① NO.2 ② . ① 2) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed. 4) Measure the IAP sensor output voltage at the wire side coupler (between BL and GR wires).

  • Page 39: C21" Iat Sensor Circuit Malfunction

    4-1-27 FI SYSTEM DIAGNOSIS “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. ● IAT sensor circuit open or short. 0.2 V � Sensor voltage � 4.6 V ● IAT sensor malfunction. ●...
  • Page 40 FI SYSTEM DIAGNOSIS 4-1-28 ◈ Step 2 1) Turn the ignition switch “OFF” position. 2) Measure the IAT sensor resistance. IAT sensor resistance Intake Air Temp. Resistance ㏀ 0 ℃ (32 ℉ ) Approx. 5.4 ~ 6.6 ㏀ 80 ℃ (176 ℉ ) Approx.

  • Page 41: C22" Oxygen Sensor Circuit Malfunction

    4-1-29 FI SYSTEM DIAGNOSIS “C22” OXYGEN SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Oxygen sensor signal is not input in ECU since then ● Oxygen sensor, Oxygen sensor heater circuit open more than 180 sec. after the engine run. or short. ●...

  • Page 42: C23" To Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-30 “C23” TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. ● TO sensor circuit short or leaned more than 60。 . 0.2 V � Sensor voltage � 4.6 V ●...

  • Page 43: C24 " " O O R R " " C25 " " Ignition Coil Malfunction

    4-1-31 FI SYSTEM DIAGNOSIS ◈ Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probe to the lead wire coupler. 3) Turn the ignition switch “ON” position. 4) Measure the voltage at the wire side coupler between OB and GR wires of the TO sensor at horizontal.

  • Page 44: C31" Gp Switch Circuit Malfunction

    FI SYSTEM DIAGNOSIS 4-1-32 “C31” GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage ● GP switch circuit open or short. Switch voltage is out of the specified range. ● GP switch malfunction. Switch Voltage � 0.1 V ●...

  • Page 45: C32 " " O O R R " " C33 " " Fuel Injector Circuit Malfunction

    4-1-33 FISYSTEM DIAGNOSIS “C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Injector circuit open or short. Injector signal is interrupted continuous by 16 times or more when ECU confirm injector running surge at ● Injector malfunction. each combustion chamber.
  • Page 46 FISYSTEM DIAGNOSIS 4-1-34 ◈ Step 2 1) Turn the ignition switch “ON” position. 2) Measure the injector voltage between YR(NO.1), RB(NO.2) wire and ground. Battery voltage Injector voltage ( � YR[NO.1] - � Ground ) ( � RB[NO.2] - � Ground ) Tester knob indication : Voltage ( NOTE...

  • Page 47: C41" Fuel Pump Relay Circuit Malfunction

    4-1-35 FISYSTEM DIAGNOSIS “C41” FUEL PUMP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Fuel pump relay circuit open or short. Voltage is applied continuous over 5 sec., battery voltage � 5 V when fuel pump relay is “OFF” position ●...

  • Page 48: Sensors

    FISYSTEM DIAGNOSIS 4-1-36 SENSORS ① ◉ ◉ PICK-UP COIL INSPECTION The pick-up coil ① is installed in the magneto cover. ◉ ◉ PICK-UP COIL REMOVAL AND INSTALLATION ● Remove the magneto cover. ● Install the magneto cover in the reverse order of removal.

  • Page 49: Iat Sensor Inspection

    4-1-37 FISYSTEM DIAGNOSIS ◉ ◉ IAT SENSOR INSPECTION ① The intake air temperature (IAT) sensor ① installed at the downside of the air cleaner case. (Refer to page 4-1-27) ◉ ◉ IAT SENSOR REMOVAL AND INSTALLATION ● Remove the fuel tank. ●...
  • Page 50 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM …………………………………………………………… 50 (4-2-1) REMOVAL AND DISASSEMBLY ………………………………………… 52 (4-2-3) REASSEMBLY AND INSTALLATION …………………………………… 53 (4-2-4) 4 -2 FUEL PRESSURE INSPECTION ………………………………………… 54 (4-2-5) FUEL PUMP RELAY INSPECTION ……………………………………… 54 (4-2-5) FUEL MESH FILTER INSPECTION AND CLEANING ………………… 55 (4-2-6) FUEL LEVEL GAUGE INSPECTION ……………………………………...

  • Page 51: Fuel System

    4-2-1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM...
  • Page 52 FUEL SYSTEM AND THROTTLE BODY 4-2-2...

  • Page 53: Removal And Disassembly

    4-2-3 FUEL SYSTEM AND THROTTLE BODY REMOVAL AND DISASSEMBLY ● Remove the seat. ( ● Remove the front seat. ( ● Remove the fuel tank mounting bolts and fuel tank bracket mounting bolt. ( ● Remove the fuel tank mounting bolts and take off the hooks.

  • Page 54: Reassembly And Installation

    FUEL SYSTEM AND THROTTLE BODY 4-2-4 ● Remove the fuel tank rearward. CAUTION As gasoline leakage may occur in this operation, keep away from fire and sparks. ● Remove the fuel pump assembly ① by removing its mounting bolts diagonally. WARNING �...

  • Page 55: Fuel Pressure Inspection

    4-2-5 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION ● Remove the seat. ● Place a rag under the fuel injector hose. ● Disconnect the fuel injector hose from the fuel delivery pipe. ● Install the special tool between the fuel tank and fuel delivery pipe.

  • Page 56: Fuel Mesh Filter Inspection And Cleaning

    FUEL SYSTEM AND THROTTLE BODY 4-2-6 First, check the insulation between ① and ② ① terminals with pocket tester. Then apply 12 volts to ③ ③ and ④ terminals, � to ③ and � to ④ , and check the continuity between ① and ②...

  • Page 57: Throttle Body

    4-2-7 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY...

  • Page 58: Removal

    FUEL SYSTEM AND THROTTLE BODY 4-2-8 REMOVAL ● Remove the fuel tank. ● Remove the air cleaner box. ● Disconnect the fuel hose. ● Remove the all coupler to related the throttle body. ● Loosen the throttle body clamp screws. ●...

  • Page 59: Cleaning

    4-2-9 FUEL SYSTEM AND THROTTLE BODY CLEANING WARNING Some throttle body cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. ● Clean all passageways with a spray-type throttle body cleaner and blow dry with compressed air.

  • Page 60: Electrical System

    ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS ………………… 60 (6-1) IGNITION SYSTEM ……………………………………………………… 62 (6-3) CHARGING SYSTEM …………………………………………………… 63 (6-7)

  • Page 61: Location Of Electrical Components

    6-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS ④ ⑥ ⑧ ⑦ ⑩ ① ⑤ ⑨ ⑬ ⑫ ⑪ ③ ② ① ④ ⑨ ⑪ Ignition coil NO.1 Cooling fan motor relay Fuel pump relay Battery ② Main fuse (30A) ⑤ Head lamp relay ⑩...
  • Page 62 ELECTRICAL SYSTEM 6-2 � � � � � � � SAV solenoid IAP sensor NO.2 ISC solenoid � Ignition coil NO.2 � � � � Oxygen sensor � Fuel injector NO.1 � Fuel injector NO.2...

  • Page 63: Ignition System

    6-3 ELECTRICAL SYSTEM IGNITION SYSTEM IG. S/W ENGINE STOP S/W FUSE BATTERY 12V 12Ah...

  • Page 64: Charging System

    ELECTRICAL SYSTEM 6-7 CHARGING SYSTEM Regulator / Rectifier IG. switch A. C generator ◉ ◉ INSPECTION ▣ ▣ MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. If the resistance is not within the specified value, replace the stator coil, with a new one.
  • Page 65 6-10 ELECTRICAL SYSTEM ▣ ▣ REGULATOR / RECTIFIER ● Disconnect the regulator / rectifier couplers. ● Using the pocket tester, measure the resistance between the terminals in the following table. If the resistance checked is incorrect, replace the regulator / rectifier. Unit : MΪ...

  • Page 66: Servicing Information

    SERVICING INFORMATION CONTENTS TROUBLESHOOTING ………………………………………………… 66 (8-1-1) SPECIAL TOOLS ……………………………………………………… 75 (8-9) TIGHTENING TORQUE ……………………………………………… 76 (8-12) SERVICE DATA ………………………………………………………… 77 (8-18) WIRING DIAGRAM …………………………………………………… 80 (8-30-1) WIRING DIAGRAM …………………………………………………… 82 (8-30-3) & WIRING DIAGRAM …………………………………………………… 84 (8-30-5)

  • Page 67: Troubleshooting

    8-1-1 SERVICING INFORMATION TROUBLESHOOTING ◉ ◉ MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT The signal does not reach ECU for more than 2 sec. after receiving the IAP signal. Pick-up coil Pick-up coil wiring and mechanical parts.
  • Page 68 SERVICING INFORMATION 8-1-2 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR Ignition signal is interrupted continuous by 32 times or more when ECU confirm ignition surge at each combustion chamber, Ignition coil (IG coil), C24 or C25 is indicated. C24 / C25 NO.1 / NO.2 Ignition coil, wiring / coupler connection, power supply from the...
  • Page 69 8-1-3 SERVICING INFORMATION ◉ ◉ ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low Adjust. start or is hard to 1. Tappet clearance out of adjustment. Repair or replace. 2. Worn valve guides or poor seating of valves. start.
  • Page 70 SERVICING INFORMATION 8-1-4 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn down camshafts. Replace. 5. Too wide spark plug gaps. Adjust or replace.
  • Page 71 8-1-5 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter 1. Too large tappet clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace.
  • Page 72 SERVICING INFORMATION 8-1-6 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal / electrical parts in high speed range. 1. Weakened valve springs. Replace. Replace. 2. Worn camshafts. Adjust. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gaps. Replace ECU.
  • Page 73 8-1-7 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks Defective engine internal / electrical parts Adjust. power. 1. Loss of tappet clearance. Replace. 2. Weakened valve springs. Adjust. 3. Valve timing out of adjustment. Replace. 4. Worn piston rings or cylinders. Repair.
  • Page 74 SERVICING INFORMATION 8-1-8 Complaint Symptom and possible causes Remedy Dirty or heavy 1. Too much engine oil in the engine. Check with inspection win- dow, drain out excess oil. exhaust smoke. 2. Worn piston rings or cylinders. Replace. 3. Worn valve guides. Replace.
  • Page 75 8-5 SERVICING INFORMATION ◉ ◉ ELECTRICAL Complaint Symptom and possible causes Remedy 1. Defective ignition coils or spark plug caps. Replace. No sparking or 2. Defective spark plugs. Replace. poor sparking. 3. Defective pick-up coil. Replace. 4. Defective ECU. Replace. 5.

  • Page 76: Special Tools

    SERVICING INFORMATION 8-9 SPECIAL TOOLS Special tools Part Number∙ ∙ Part Name∙ ∙ Description 09900-27000 Mode select switch Inspect FI system sensor. 09915-54510 Fuel pump pressure gauge Measure fuel pressure of fuel pump.

  • Page 77: Tightening Torque

    8-12 SERVICING INFORMATION TIGHTENING TORQUE ◉ ◉ FI SYSTEM PARTS N∙ ∙ m kg∙ ∙ m ITEM Water sensor (WT sensor) 6 ~ 8 0.6 ~ 0.8 Fuel injector bolt...

  • Page 78: Service Data

    SERVICING INFORMATION 8-18 SERVICE DATA ◉ ◉ FI SENSORS ITEM SPECIFICATION NOTE Ϊ Pick-up coil resistance 110 ~ 140 IAP sensor input voltage 4.5 ~ 5.5 V IAP sensor output voltage Approx. 2.7 V at idle speed TP sensor input voltage 4.5 ~ 5.5 V ㏀...
  • Page 79 8-19 SERVICING INFORMATION ◉ ◉ THERMOSTAT + COOLING FAN + COOLANT ITEM STANDARD LIMIT 88 ℃ (190 ℉ ) Valve opening 100 ℃ (212 ℉ ) Thermostat valve operating temperature Valve full open Valve closing 83 ℃ (181 ℉ ) Thermostat valve lift Over 8mm (0.32 in) / 100 ℃...
  • Page 80 SERVICING INFORMATION 8-20 ◉ ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE BTDC 5� / 1,500 rpm Ignition timing Type CR8E 0.7 ~ 0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E Over 8mm (0.32) Spark performance 150 V and more Ignition coil primary peak voltage...

  • Page 81: Wiring Diagram

    8-30-1 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 82 SERVICING INFORMATION 8-30-2...

  • Page 83: Wiring Diagram

    8-30-3 SERVICING INFORMATION WIRING DIAGRAM (...
  • Page 84 SERVICING INFORMATION 8-30-4...
  • Page 85 8-30-5 SERVICING INFORMATION WIRING DIAGRAM ( &...
  • Page 86 SERVICING INFORMATION 8-30-6...
  • Page 87 MEMO...
  • Page 88 MEMO...
  • Page 89 Prepared by 1st Ed. JUN. 2008. Manual No. 99000-51310 Printed in Korea...
  • Page 90 S&T Motors Co., Ltd.

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