HYOSUNG GT250 EI, Service Manual

Page 1: ...SERVICE MANUAL 99000 95620 SERVICE MANUAL...

Page 2: ...rs of your optimum and quick service ELECTRICAL SYSTEM GROUP INDEX GENERAL INFORMATION 1 EI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY 4 2 4 1 5 SERVICING INFORMATION 7 This manual has been prepar...

Page 3: ...Listed in the table below are the symbols indicating instructions and other information necessary for servicing The meaning of each symbol is also included in the table Apply THREAD LOCK 1324 Apply o...

Page 4: ...ne Temperature Sensor ETS F FP Fuel Pump G GP Switch Gear Position Switch I IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air Temperature Sensor IATS IG Ignition ISC Solenoid Idle Speed...

Page 5: ...er GY Green with Yellow tracer GrB Gray with Black tracer GrR Gray with Red tracer GrW Gray with White tracer OB Orange with Black tracer OL Orange with Blue tracer OG Orange with Green tracer OR Oran...

Page 6: ...ENERAL INFORMATION EXTERIOR PHOTOGRAPH 6 1 6 1 EXTERIOR ILLUSTRATION 8 1 6 3 EXTERIOR ILLUSTRATION 9 1 7 1 EXTERIOR ILLUSTRATION 10 1 7 2 FUNCTION OF EI SENSOR 11 1 8 1 SPECIFICATIONS 12 1 8 2 CONTENT...

Page 7: ...6 1 6 1 GENERAL INFORMATION EXTERIOR PHOTOGRAPH...

Page 8: ...7 GENERAL INFORMATION 1 6 2 EXTERIOR PHOTOGRAPH...

Page 9: ...6 3 GENERAL INFORMATION EXTERIOR ILLUSTRATION Rear reflector Brake Tail lamp Rear turn signal lamp License plate lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WID...

Page 10: ...ENERAL INFORMATION 1 7 1 EXTERIOR ILLUSTRATION Rear reflector Brake Tail lamp License plate lamp Rear turn signal lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WID...

Page 11: ...1 7 2 GENERAL INFORMATION EXTERIOR ILLUSTRATION Rear reflector Brake Tail lamp License plate lamp Rear turn signal lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WI...

Page 12: ...provided absolute pressure then analogize the air volume indirectly and help to work the fuel injector properly IAT sensor Intake Air Temperature Sensor IATS IAT sensor perceive the atmospheric tempe...

Page 13: ...air cooled and oil cooled V 2 cylinder 57 0 mm 2 24 in 48 8 mm 1 92 in 249 15 2 in3 Electric fuel Injection Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Fuel syst...

Page 14: ...l Front fork oil capacity One side Oil change Oil and filter change Engine overhaul I T E M CAPACITIES Ignition type Ignition timing Spark plug Battery Fuse Head lamp Turn signal lamp Brake Tail lamp...

Page 15: ...14...

Page 16: ...1 25 C15 ET SENSOR CIRCUIT MALFUNCTION 43 4 1 28 C17 o or r C18 IAP SENSOR CIRCUIT MALFUNCTION 45 4 1 30 C21 IAT SENSOR CIRCUIT MALFUNCTION 47 4 1 32 C22 OXYGEN SENSOR CIRCUIT MALFUNCTION 49 4 1 34 C2...

Page 17: ...e sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The termina...

Page 18: ...ector for bend and female connector for excessive opening Also check the coupler for locking looseness corrosion dust etc FUSE When a fuse blows always investigate the cause to correct it and then rep...

Page 19: ...the components of the EI system instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The moment such removal is made damaging counter elect...

Page 20: ...ate measurements may not be obtained and personal injury may result USING TESTERS Use well charged batteries in the tester Be sure to set the tester to the correct testing range USING THE TESTER Incor...

Page 21: ...GRAM ECU IAT Sensor TP Sensor IAP Sensor ISC Solenoid AIR AIR CLEANER THROTTLE BODY FUEL TANK FUEL FUEL PUMP FUEL INJECTOR INTAKE PIPE CYLINDER EXHAUST PIPE O2 Sensor Electrical signal flow Air flow F...

Page 22: ...nd various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air...

Page 23: ...tors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage At high speed the injection time volu...

Page 24: ...23 EI SYSTEM DIAGNOSIS 4 1 8 EI SYSTEM PARTS LOCATION Speedometer Ignition coil NO 1 Ignition coil NO 2 Pick up coil GP switch Fuel injector NO 1 Fuel injector NO 2 TP sensor ECU 3 4 2 6 5 7 8 1...

Page 25: ...24 4 1 9 EI SYSTEM DIAGNOSIS ISC solenoid IAT sensor RO switch Fuel pump relay IAP sensor NO 2 IAP sensor NO 1 ET sensor Oxygen sensor SAV solenoid ECU 15 12 17 16 13 11 1 4 1 0 9...

Page 26: ...I SYSTEM PARTS LOCATION Speedometer Fuel injector NO 1 Fuel injector NO 2 IAT sensor GP switch Pick up coil Ignition coil NO 1 Ignition coil NO 2 TP sensor EI SYSTEM DIAGNOSIS 4 1 10 ECU 3 4 2 6 5 7 8...

Page 27: ...26 4 1 11 EI SYSTEM DIAGNOSIS 26 ISC solenoid Fuel pump relay RO switch IAP sensor NO 2 IAP sensor NO 1 ET sensor Oxygen sensor SAV solenoid 1 0 17 11 12 16 13 14 15 ECU...

Page 28: ...nel indicates CHE letters when no communication signal from the ECU is received for 3 seconds For example The ignition switch is turned ON position and the engine stop switch is turned position In thi...

Page 29: ...27000 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 20 The memorized malfunction code is displayed...

Page 30: ...ecial tool is necessary to read the code of the malfunction items USER MODE The FI check lamp comes on for about three seconds whenever the ignition switch is set to ON position with the engine stoppe...

Page 31: ...h 09900 27000 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 20 The memorized malfunction code is dis...

Page 32: ...O 2 Idle speed control solenoid ISC solenoid Gear position switch GP switch Fuel injector NO 1 Fuel injector NO 2 Secondary air valve solenoid SAV solenoid Fuel pump relay Oxygen sensor heater O2S hea...

Page 33: ...DIAGNOSIS In the FI check lamp the malfunction code is displayed from small numeral blinks signal to large numeral blinks signal In the LCD DISPLAY panel the malfunction code is indicated from small...

Page 34: ...FI Check lamp Always ON Sometimes ON Always OFF Good condition No code Malfunction code PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combusti...

Page 35: ...ld F C Always Always Sometimes times day month Only once Under certain condition Urban Suburb Highway Mountainous Uphill Downhill Tarmacadam Gravel Other Cold Warming up phase Warmed up Always Other a...

Page 36: ...Malfunction code stored in ECU memory can be checked by the special tool To check malfunction code read SELF DIAGNOSIS FUNCTION DEALER MODE Refer to page 4 1 13 15 16 17 carefully to have good underst...

Page 37: ...pairing the trouble turn the ignition switch OFF position and turn ON position again If C LCD INDICATION is indicates the malfunction codes are cleared If not blink FI check lamp the malfunction codes...

Page 38: ...2 The sensor should produce following voltage 0 5 V sensor voltage 4 5 V Without the above range for 6 sec and more C17 or C18 is indicated Intake air pressure sensor lead wire coupler connection C21...

Page 39: ...is interrupted continuous by 31 times or more when ECU confirm ignition surge at each combustion chamber In this case the code C24 or C25 is indicated C27 Idle speed control solenoid ISC solenoid Idl...

Page 40: ...Resistance DETECTED CONDITION POSSIBLE CAUSE The pick up coil signal does not reach ECU for more than 3 sec after ECU receiving the ignition switch signal Metal particles or foreign materiel being att...

Page 41: ...he OB wire and ground 6 If OK then measure the voltage at the OB wire and GR wire DETECTED CONDITION POSSIBLE CAUSE TP sensor circuit open or short TP sensor malfunction ECU malfunction YES NO Go to S...

Page 42: ...the ignition switch OFF position 3 Disconnect the TP sensor coupler 4 Check the continuity between LY and ground TP sensor continuity Infinity Ground YES NO Replace the TP sensor with a new one Go to...

Page 43: ...voltage OK YES NO OB LY or GR wire open or shorted to ground or poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harne...

Page 44: ...3 Disconnect the ET sensor coupler 4 Measure the resistance between the terminals and DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range for 2 sec and more 0 08 V Sensor v...

Page 45: ...32 20 68 40 104 60 140 80 176 120 248 140 284 160 320 180 356 Is the resistance OK YES NO Br or GR wire open or shorted to ground or poor or connection of ECU coupler If wire and connection are OK int...

Page 46: ...lfunction POSSIBLE CAUSE YES NO IAP sensor input voltage 4 5 5 5 V OB Ground OB GR Is the input voltage OK Tester knob indication Voltage IAP sensor voltage is out of the specified range for 6 sec and...

Page 47: ...satisfactory replace IAP sensor with a new one Step 2 1 Connect the IAP sensor couplers NO 1 and NO 2 2 Insert the needle pointed probes to the lead wire coupler 3 Start the engine at idle speed 4 Me...

Page 48: ...pler C21 IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAT sensor circuit open or short IAT sensor malfunction ECU malfunction IAT sensor resistance 0 081 48 352 When Intake air tem...

Page 49: ...ection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the IAT sensor with a new one ECU Coupler Resistance Intake Air Tem...

Page 50: ...since then 600 sec after the engine run INSPECTION 1 Remove the front seat and frame cover 2 Turn the ignition switch OFF position 3 Check the Oxygen sensor coupler for loose or poor contacts BR or GR...

Page 51: ...tically and ignition switch turns ON position Switch resistance Infinity RO switch circuit short or leaned more than 60 RO switch malfunction ECU malfunction RO switch 5 Measure the resistance at the...

Page 52: ...or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Loose or poor contacts on the...

Page 53: ...When Ignition switch ON DETECTED CONDITION POSSIBLE CAUSE ISC solenoid s step is out of the specified range O step Solenoid step 250 step ISC solenoid malfunction ISC solenoid s step is out of the sp...

Page 54: ...cally 5 Turn the side stand to up right position 6 Make sure the engine stop switch is in the position 7 Insert the needle pointed probes to the GP switch coupler 8 Turn the ignition switch ON positio...

Page 55: ...OR CIRCUIT MALFUNCTION 5 If OK then check the continuity between injector terminals and ground DETECTED CONDITION POSSIBLE CAUSE Injector signal is interrupted continuous for more than 1 sec when ECU...

Page 56: ...Measure the injector voltage between YR NO 1 RB NO 2 wire and ground YR NO 1 or RB NO 2 wire open or shorted to ground or poor NO 1 or NO 2 connection of ECU coupler If wire and connection are OK inte...

Page 57: ...indication Voltage INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the SAV solenoid coupler for loose or poor contacts 4 Connect the SAV solenoid coupler 5 Turn the...

Page 58: ...ay with a new one Head lamp relay Fuel pump relay Main relay Turn signal relay INSPECTION 1 Remove the frame cover 2 Turn the ignition switch OFF position 3 Check the fuel pump relay coupler for loose...

Page 59: ...or B wire open or shorted to ground or poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and po...

Page 60: ...TION The intake air pressure IAP sensor NO 1 and NO 2 are installed at each intake pipe Refer to page 4 1 30 IAP SENSOR REMOVAL AND INSTALLATION Remove the fuel tank Remove the IAP sensor NO 1 NO 2 fr...

Page 61: ...f removal RO SWITCH INSPECTION REMOVAL AND INSTALLATION The roll over RO switch is located in the downside of the front seat lock Refer to page 4 1 35 Romove the front seat Remove the RO switch from t...

Page 62: ...INSPECTION 65 4 2 4 FUEL MESH FILTER INSPECTION AND CLEANING 66 4 2 5 FUEL GAUGE INSPECTION 66 4 2 5 THROTTLE BODY 67 4 2 6 REMOVAL 68 4 2 7 CLEANING 69 4 2 8 INSPECTION 69 4 2 8 INSTALLATION 70 4 2...

Page 63: ...62 4 2 1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM...

Page 64: ...he front seat Disconnect the fuel gauge coupler Remove the fuel tank mounting bolts and take off the hooks CAUTION After disconnecting the fuel injector hose insert a blind plug into the end to stop f...

Page 65: ...ssembly When installing the fuel pump assembly first tighten all the fuel pump assembly mounting bolts lightly in diagonal stages and then tighten them in the above tightening order CAUTION As gasolin...

Page 66: ...ecial tool turn the ignition switch to OFF position and release the fuel pressure slowly Gasoline is highly flammable and explosive Keep heat sparks and flame away If the fuel pressure is lower than t...

Page 67: ...ridge with a new one FUEL GAUGE INSPECTION Measure resistance between the terminals when float is at the position instead below If the resistance measured is out of the specification replace the gauge...

Page 68: ...67 FUEL SYSTEM AND THROTTLE BODY 4 2 6 THROTTLE BODY...

Page 69: ...Remove the air cleaner box Disconnect the throttle cables from their drum Dismount the throttle body assembly CAUTION Be careful not to damage the throttle cable bracket when dismounting or remounting...

Page 70: ...nts cannot be cleaned with a spray cleaner it may be necessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and clea...

Page 71: ...he reverse order of removal Pay attention to the following points Connect the throttle cable to the throttle cable drum Adjust the throttle cable play with the cable adjuster CAUTION Never operate the...

Page 72: ...71 LOCATION OF ELECTRICAL COMPONENTS 72 5 1 IGNITION SYSTEM 74 5 3 CHARGING SYSTEM 76 5 7 CONTENTS ELECTRICAL SYSTEM 5...

Page 73: ...SYSTEM Main relay Fuel pump relay Head lamp relay LOCATION OF ELECTRICAL COMPONENTS Ignition coil NO 1 Ignition coil NO 2 Main fuse 30A ECU Head lamp fuse 15A Battery IAT sensor RO switch Magneto Pick...

Page 74: ...73 ELECTRICAL SYSTEM 5 2 ISC solenoid IAP sensor NO 1 ET sensor IAP sensor NO 2 SAV solenoid 21 Fuel injector NO 2 22 Fuel injector NO 1 Oxygen sensor 22 21...

Page 75: ...th a new one CAUTION When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws Tester knob indication Resistance Stator coil resistance P...

Page 76: ...ure the ignition coil resistance in bolt the primary and secondary windings If the resistance is not within the standard range replace the ignition coil with a new one Tester knob indication Resistanc...

Page 77: ...and If the voltage is not within the specified value check the magneto no load performance and regulator rectifier 13 5 15 0 V at 5 000 rpm Charging output Regulated voltage CAUTION When making this t...

Page 78: ...0 0 0 0 4 0 7 0 0 0 0 0 0 4 0 7 0 4 0 7 0 4 0 7 0 5 1 2 Tester probe Tester probe Unit V Tester knob indication Voltage MAGNETO NO LOAD PERFORMANCE Disconnect the three lead wires from the magneto te...

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Page 80: ...TROUBLESHOOTING 80 7 1 1 SPECIAL TOOLS 89 7 8 TIGHTENING TORQUE 90 7 11 SERVICE DATA 91 7 19 1 WIRING DIAGRAM 94 7 31 1 WIRING DIAGRAM 96 7 32 1 WIRING DIAGRAM 98 7 32 3 CONTENTS SERVICING INFORMATION...

Page 81: ...PS NO 1 NO 2 The sensor should produce following voltage 0 5 V sensor voltage 4 5 V Without the above range for 6 sec and more C17 or C18 is indicated Intake air pressure sensor lead wire coupler conn...

Page 82: ...l is interrupted continuous by 31 times or more when ECU confirm ignition surge at each combustion chamber In this case the code C24 or C25 is indicated C27 Idle speed control solenoid ISC solenoid Id...

Page 83: ...ircuited wiring connections No fuel reaching the intake manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel...

Page 84: ...operating 1 Defective fuel injectors 2 No injection signal from ECU 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operatin...

Page 85: ...n adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of clutch plates 3 Distorted clutch plates driven and drive 4 Worn clutch release bearing 5 We...

Page 86: ...inadequate fuel supply to injector 10 Defective fuel pump 11 Defective SAV solenoid 12 Clogged air cleaner element Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3...

Page 87: ...rnal parts 1 Heavy carbon deposit on piston crowns 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit 4 Sucking air from intake pipes 5 Use incorrect engine oil 6 Defective oil...

Page 88: ...pressure plates or clutch plates 1 Broken gearshift cam 2 Distorted gearshift forks 3 Worn gearshift pawl 1 Broken return spring on shift shaft 2 Rubbing or sticky shift shaft 3 Distorted or worn gear...

Page 89: ...lead connections 2 Short circuited grounded or open stator coil 3 Short circuited or punctured regulator rectifier 1 Lead wire insulation frayed due to vibration resulting in intermittent shorting 2...

Page 90: ...CING INFORMATION 7 8 Special tools PartNumber PartName Description 09915 54510 Fuel pump pressure gauge Measure fuel pressure of fuel pump SPECIAL TOOLS 09900 27000 Mode select switch Inspect EI syste...

Page 91: ...gine temperature sensor ET sensor Fuel injector mounting bolt Intake air temperature sensor IAT sensor 0 5 0 8 0 5 0 8 0 5 0 8 kgf m 5 8 5 8 5 8 N m TIGHTENING TORQUE EI SYSTEM PARTS 7 11 SERVICING IN...

Page 92: ...To ECU each temperature 4 5 5 5 V Approx 3 7 3 9 V when ignition switch ON 4 5 5 5 V 0 081 48 352 When Intake air temperature is 40 130 40 266 Refer to page 48 4 1 33 Infinity at normal condition 0 at...

Page 93: ...able play 13400H88 28 1 400 1 600 rpm 0 5 1 0 mm 0 02 0 04 in SPECIFICATION NOTE FUEL INJECTOR FUEL PUMP ITEM Fuel injector resistance Fuel injector voltage Fuel pressure of fuel pump 11 4 12 6 at 20...

Page 94: ...STANDARD BTDC 13 2 000 rpm 30 6 000 rpm More than 60 V 5 000 rpm 13 5 15 0 V 5 000 rpm More than 8 mm 0 32 in 150 V and more NOTE 1 320 at 20 68 Unit mm in Ignition timing Spark plug Spark performanc...

Page 95: ...94 7 31 1 SERVICING INFORMATION WIRING DIAGRAM...

Page 96: ...95 SERVICING INFORMATION 7 31 2...

Page 97: ...96 7 32 1 SERVICING INFORMATION WIRING DIAGRAM...

Page 98: ...97 SERVICING INFORMATION 7 32 2...

Page 99: ...98 7 32 3 SERVICING INFORMATION WIRING DIAGRAM...

Page 100: ...99 SERVICING INFORMATION 7 32 4...

Page 101: ...Prepared by 1st Ed APR 2009 Manual No 99000 95620 Printed in Korea...

Page 102: ...SERVICE MANUAL S T Motors Co Ltd...