CHAPTER 4 ENGINE ELECTRICAL " Ignition and Alternator Data 1985 ............... .. . . ......................................... . ... . . . 4.1 1986 ................................. . . .. ... .. . . . . .. . ..... . . . ...... . .. . 4.2 1987 ........... .. .. . ................................................. . . 4.3 1988 ............................................ . ......... . ........... . 4.4 1989 ................... . .... . .. . ...................................... . 4.5 1990 ..............
Ignition System Troubleshooting Ignition System Testing .................................................. 4.21 o Ignition/Charging System Testing .... .... ...................... ....... 4.22-4.25 Alternator Ignition System Troubleshooting . .. ..................... ............. ... . . 4.26 Alternator Output Test - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.27 Typical Exciter, Pulser or Lighting Coil Replacement ......... .... ..... . ..... 4.
Electronic Control System System III - Electronics Operation ............... . .............. ..... . 4.49-4.50 System 111- Electronics Testing ......... .... . ......................... 4.51-4.56 Select Monitor/RPM Sensor .......... .................. ............. . ... 4.54 Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.55 Intake Air Temperature Sensor ........................................... 4.
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ENGINE ELECTRICAL Ignition Data 1985 Models Spark Plug Engine Model Ignition Type Alternator Output NGK Champion Plug Gap Inches Star EC25PS-06 CDI-100 Watt BR8ES RN-3C .020 SS EC44-2PM-3100 CDI-120 Watt BR9ES RN-2C .020 Indy Trail EC44-2PM-2100 CDI-120 Watt BR9ES RN-2C .020 Indy 400 EC40PL-02 CDI-120 Watt BR9ES RN-2C .020 Indy 600 EC60PL-02 CDI-120 Watt BR9ES RN-2C .020 EC44-2PM-5000 CDI-120 Watt BR9ES RN-2C .
ENGINE ELECTRICAL Ignition Data 1986 Models Spark Plug Engine Model Ignition Type Alternator Output NGK Champion Plug Gap Inches EC25PS-06 CDI-100 Watt SR8ES RN-3C .020 Sprint (ES) EC34-2 PM-O 1102 CDI-120 Watt SR9ES RN-2C .020 SS Machine Model Star EC44-2PM-3100 CDI-120 Watt SR9ES RN-2C .020 Indy Trail EC50PM-01 CDI-120 Watt SR9ES RN-2C .020 Indy 400 EC40PL-02 CDI-120 Watt SR9ES RN-2C .020 Indy 600 (LE) EC60PL-02 CDI-120 Watt SR9ES RN-2C .
ENGINE ELECTRICAL Ignition Data 1987 Models Spark Plug Machine Model Engine Model Ignition Type Alternator Output NGK Champion Plug Gap Inches EC25PS-06 COI-l00 Watt BR8ES RN-3C .025 Sprint (ES) EC34-2PM-Ol /02 COI-120 Watt BR9ES RN-2C .025 Indy Sport EC34-2PM-03 COI-120 Watt BR9ES RN-2C .025 Indy Trail (All) EC50PM-Ol/02 COI-120 Watt BR9ES RN-2C .025 Indy 400 EC40PL-02 COI-120 Watt BR9ES RN-2C .025 Indy 600 EC60PL-02 COI-120 Watt BR9ES RN-2C .
ENGINE ELECTRICAL Ignition Data 1988 Models Spark Plug Machine Model Star, Star Trak Sprint (ES) Engine Model Ignition Type Alternator Output NGK Champion Plug Gap Inches COl Box Identification Number EC25PS-06 CDI-100 Watt BR8ES RN-3C .025 CU6204 EC34-2PM-Q2 CDI-120 Watt BR9ES RN-2C .025 CU6409 Indy Sport EC34-2PM-Q3 CDI-120 Watt BR9ES RN-2C .025 CU6409 Indy Trail (All) EC50PM-Q1/02 CDI-120Watt BR9ES RN-2C .
ENGINE ELECTRICAL Ignition Data 1989 Models Spark Plug Engine Model Ignition Type Alternator Output NGK Champion Plug Gap Inches COl Box Identification Number EC25PS-06 CDI-100Watt BR8ES RN-3C .025 CU6204 Sprint (ES) EC34-2PM-02 CDI-120 Watt BR9ES RN-2C .025 CU6409 Indy Sport EC34-2PM-03 CDI-120Watt BR9ES RN-2C .025 CU6409 Indy Trail (All) EC50PM-01/02J03 CDI-120 Watt BR9ES RN-2C .025 CU6410 Indy 400 (All) EC40PL-02 CDI-120 Watt BR9ES RN-2C .
ENGINE ELECTRICAL Ignition Data 1990 Models Spark Plug Machine Model Engine Model Ignition Type Alternator Output NGK Champion Plug Gap Inches CDI Box Identification Number EC25PS-06 CDI-150 Watt BR8ES RN-3C .025 CU2167 Sprint (ES) EC34-2PM-02 CDI-150 Watt BR9ES RN-2C .025 CU6409 Indy Sport EC34-2PM-03 CDI-1 50 Watt BR9ES RN-2C .025 CU6409 EC50PM-01/02 /03 CDI-200 Watt BR9ES RN-2C .025 CU6413 EC40PL-02 CDI-200 Watt BR8ES RN-3C .
ENGINE ELECTRICAL Ignition Data c 1991 Models Spark Plug Champion PIUr. Gap MMI nches CDI Box Identification Number BR8ES RN-3C 0.7/028 CU6204 BR8ES RN-2C 0.7/028 CU6409 CDI-200 Watt BR8ES RN-2C 0.7/028 CU6416 EC50PM-Ol/02l03 CDI-200 Watt BR8ES RN-2C 0.7/028 CU6413 EC40PL-02 EC40PL-04 CDI-200 Watt BR8ES RN-3C 0.7/028 CU6412 CU6415 Indy 500 (All) Incl. WideTrak EC50PL-Ol/02l03 EC50PL-04/05/06 CDI-200 Watt BR8ES RN-3C 0.
ENGINE ELECTRICAL Ignition Data 1992 Models Spark Plug Machine Model Engine Model Ignition Type Alternator Output NGK Champion Plug Gap MMllnches COl Box Identification Number EC25PS-07 CDI-150 Watt BR8ES' RN-3C 0.7/028 CU6204 EC34-2PM-02/03/04 CDI-150 Watt BR8ES' RN-3C 0.7/028 CU6409 Indy Sport'GT EC44-3PM-Ol CDI-200 Watt BR8ES' RN-3C 0.7/028 CU6416 Indy Trail (All) EC50PM-O 1/02/03 CDI-200Watt BR8ES' RN-3C 0.
ENGINE ELECTRICAL Ignition Data 1993 Models Spark Plug Machine Model StarLite/GT Ignition Type Alternator Output NGK Champion PIUPr Gap MMI nches CDI Boxldentification Number EC25PS-07 CDI-150 Watt BR8ES· RN-3C 0.71.028 CU6204 RN-3C 0.7/.028 CU6409 RN~3C 0.71.028 CU6416 EC34-2PM-D2I04 CDI-150 Watt BR8ES· Indy SporVGT EC44-3PM-Ol CDI-200 Watt BR8ES· Indy Trail (All) EC50PM-Dl CDI-200 Watt BR8ES· RN-3C 0.7/.028 CU6413 0.7/.
ENGINE ELECTRICAL Ignition Data 1994 Models Mach ine Mo del Engine Model StarLiteJGT IndyLite/GT/DLX Ig nition Type A lternator Output Spark Plug NGK Champion PI U p, Gap MMI nches COl Box Identification Number Flywheel 10# EC25PS-07 CDI-150Watt BR8ES· RN-3C 0.7/.028 CU6204 FP5355 EC34-2PM-02I04 CDI-150Watt BR8ES· RN-3C 0.7/.028 CU6409 FP5439 EC44-3PM-Ol CDI-200Watt BR8ES· RN-3C 0.7/.028 CU6416 FP5446 EC50PM-Ol/02l03 CDI-200Watt BR8ES· RN-3C 0.7/.
ENGINE ELECTRICAL Ignition Data 1995 Models Machine Model StarLite IndyLite Models Engine Model Spark Plug Alternator Wattage NGK Champion Plue Gap MMI nches COl Box Identification Number Flywheel 10# EC25PS07 150 BR8ES RN-3C 0.71.028 CU6204 FP5355 EC34-2PM02lE02 150 BR8ES RN-3C 0.71.028 CU6409 FP5439 FP5446 EC44-3PM01/02 200 BR8ES RN-3C 0.7/.028 CU6416 EC50PM04/E04 200 BR8ES RN-3C 0.71.028 CU6413 FP5441 EC50PM03 200 BR8ES RN-3C 0.7/.
ENGINE ELECTRICAL Typical 1985 - Current Timing Advance Curves Ignition Timing MAXIMUM ADVANCE OPERATING RPM (DEPENDING ON ENGINE) SEE DATA 1000 2000 3000 4000 5000 6000 7000 8000 RPM NOTE: Always verify timing of engine at room temperature only (68 0 F/20° C). The ignition maximum advance is at or near 3000 RPM on all current style ignition systems. Verify the ignition position at maximum advance when checking the timing.
'-, . ENGINE ELECTRICAL Conversion Chart - Degrees to Piston Position - B.T.D.C. ( If the ignition timing specification is listed in degrees only, convert to either inches or mm BlOC and use a dial indicator to verify timing marks. NOTE: Due to differing rod lengths and engine strokes, consult the engine model list for correct engine. Engine Model DEG.
ENGINE ELECTRICAL Single Cylinder COl Ignition - Exploded View - Timing Timing Procedure - Single Cylinder Models ) Single Cylinder Capacitor Ignition System STATOR PLATE RFI SPARK PLUG CAP LIGHTING CO IL FLYWHEEL o CO l CONTROL VIBRATION OAMPNER 1 EXCITER COIL UNIT~STATOR PLUGS QUICK COUPLERS 1·/ . ~@. ~- ~~ TORQUE TO 8 TO 10 IN. LBS. NOTE: Always verify timing of engine at room temperature only (68 0 F/20° C). 7.
10 , ENGINE ELECTRICAL Twin Cylinder Fan COl Ignition (Fixed) - Exploded View - Timing Timing Procedure NON ADJUSTABLE SYSTEM LI GHTING COIL STAT IONARY CO I LS CO l PLUG - I NOTE: Always verify timing of engine at room temperature only (68 0 F/20° C). 12. Verify and mark which flywheel timing line corresponds with the listed ignition timing from the chart at the beginning of this unit. Refer to the method of using a dial indicator for verifying timing marks described on page 4.12. 13.
ENGINE ELECTRICA L Twin Cylinder Fan COl Ignition (Adjustable) - Exploded View - Timing Timing Procedure ~ RFICAP 00 FAN 120 Watt Pulse Type 150 and 200 Watt Pulseless NOTE: Always verify timing of engine at room temperature only (68 0 F/20° C). 19. Verify and mark which blower housing timing line corresponds with the listed ignition timing from the charts at the beginning of this unit. Refer to the method of using a dial indicator for verifying timing marks described on page 4. 12. 20.
ENGINE ELECTRICAL Twin Cylinder Liquid COl Ignition (Pulse, Pulseless) - Exploded View - Timing c Timing Procedure STATOR PLATE EXCITER COIL PULSER COIL LIGHTING COIL c ~ RFICAP o~ 120 Watt Pulse Type COl 200 Watt Pulseless COl NOTE: Always verify timing of engine at room temperature only (68 0 F/20° C). 24. Verify and mark which flywheel timing line corresponds with the listed ignition timing from the chart at the beginning of this unit.
ENGINE ELECTRICAL Three Cylinder COl Ignition (Pulse, Trigger) Timing - Exploded View Stator Plate Exciter Coil Lighting Coil Lighting Coil Flywheel Charging Coil (RXL) Lighting Coil (650, Storm) 1985 - 1990 3 Cylinders (Except RXL) All RXL's, 1991 and Later 650's, 1993 to Current Storms 180 Watt Timing Procedure: Three Cylinder Models NOTE: Always verify timing of engine at room temperature only (20°C/68°F). 1.
ENGINE ELECTRICAL Three Cylinder CDl lgnition (Storm/XLT) Timing - Exploded View Pulser Coil l::I--~-- Stator Plate *Lighting/Exciter ~--- Flywheel COl Control Box \-------r-,."---- RFI Spark Plug Cap Secondary Cable 170 Watt 1993 to current XLT Secondary Coils * The Exciter Coil can be identified by wire color, and smaller windings. Timing Procedure: Three Cylinder Models NOTE: Always verify timing of engine at room temperature only (20°C/68 °F). 1.
ENGINE ELECTRICAL Operating RPM Timing Check - All Models Due to the high RPM necessary and the possible danger involved, special care must be observed whenever performing an operating RPM timing check to avoid serious personal injury. This check need not be performed unless symptoms leading to poor performance and possible engine damage are present. • Never operate the engine with the clutch guard open or removed. • Do not stand over or around the clutch while performing this test.
ENGINE ELECTRICAL Ignition System Testing Ignition system components can be individually tested by measuring their internal resistance and insulation to ground. These checks must be done with a digital volt/ohm meter. Compare the readings obtained to the values listed on the chart. Actual values may vary up to ± 10% between like components. Any readings outside the span should be considered questionable. NOTE: The stator coils can be checked without removing them from the engine.
ENGINE ELECTRICAL Ignition I Charging System Testing Stator Schematics Single C~linders STATOR YEL EC-25-PS Exciter Coil: Lighting Coil: Wire Color Value BrnIW to BlklR 123 ohms Vel to W or Brn Twin Wire Color Value .3 to .6 ohms C~linders Lighting Coil: Exciter Coil: Wire Color ~ BrnIW to BlklR 164 ohms Vel to W or Brn Wire Color ~ .3 to .
ENGINE ELECTRICAL Ignition I Charging System Testing Stator Schematics Lighting Y to Brn 199211993 2 Cylinder EC50PL-07 All 500 EFI Pulseless 200 Watt Battery Charge Coil: Exciter Coil: / / / Battery Charge Gry to Gry/W Wire Color ~ Wire Color ~ Brn/W to BlklR 164 ohms Gry to Gry/W .2 to .4 ohms Lighting Coil: Wire Color Value Y to Brn .2 to .
ENGINE ELECTRICAL Ignition I Charging System Testing Stator Schematics Stator Control 1983-1992 Grn------~~~~~~ ~-4-Y Blu --GoL--------J 3 Cylinder Exciter Coil: Wire Color Blk to W Lighting Coil: Wire Color Y to Brn or Ground EC60PL and EC65PL-01/02 Value 261 ohms Pulser Coil: Wire Color RtoW Control Coil: Value Wire Color .3 to .5 ohms Grn to Blu ~ 20 ohms Value 29.4 ohms NOTE: All Values are ± 10% 1990-1991 Stator 3 Cylinder .
ENGINE ELECTRICAL Ignition I Charging System Testing Stator Schematics 1993 to Current y B 3 Cylinder EC75PL-01 Storm 180 Watt EC80PL-01 Storm Exciter Coil: Wire CQIQr BlklR to Grn Pulser Coil: ~ Wire CQIQr ~ 248 ohms Grn to Blk 20 ohms Lighting Coil: Blk Trigger Coil: Wire ColQr ~ Wire CQlor Value Y to Brn .2 to .4 ohms Wto W/R 96 ohms Brn 4.
ENGINE ELECTRICAL Ignition System Troubleshooting Condition: No Spark Disconnect the single black (black/white) wire from the COl Module to the ignition kill circuit. Does it have a spark? Yes-+ Not Check the ignition switch, wire harness, throttle safety switches and kill switch for proper adjustment or short to ground. Repair or replace as necessary. Disconnect the stator to COl module wires. Test the resistance values of the flywheel coils as per the charts on page 4.21 .
ENGINE ELECTRICAL Alternator Output Test - Open Circuit CAUTION: Perform this test with a digital volt/ohm meter such as the Fluke 73 (PN 2870659), or equivalent. Set meter to AC volts (V..-v) when performing the test. 1. Disconnect alternator connector from engine. 2. Insert red test lead into yellow wire coming from engine alternator. 3. Black tester lead must be grounded to either the engine, a brown wire at the connector, or the yellow/red wire at the plug.
ENGINE ELECTRICAL Typical Exciter, Pulser or Lighting Coil Replacement 1. Remove coil retaining screws and spacers. 2. Using a pliers, remove epoxy from solder jOints (A) on the coil to be replaced. 3. Unsolder connection from coil. 4. Clean solder terminals (8) on the replacement coil and re-solder to their proper wires. NOTE: Always position with numbers towards the outside. 5. Reinstall retaining screws and spacers. 6. Using a moisture-proof sealant, seal solder joints as shown.
ENGINE ELECTRICAL Battery Service Preparing a New Battery for Service ( To assure maximum service life and performance from a battery, it must have proper initial servicing. To service a new battery, the following steps must be taken. NOTE: Do not service the battery unless it will be put into regular service within 30 days. 1. Remove vent plug from vent fitting. 2. Fill battery with electrolyte to the upper level marks on the case. c 3.
ENGINE ELECTRICAL Battery Service Load Test NOTE: This test can only be performed on machines equipped with electric start. This test cannot be performed if the engine or starting system is not working properly. A battery may indicate a fully charge condition on the OCV test and the specific gravity test, but still not have the storage capacity necessary to properly function in the electrical system.
ENGINE ELECTRICAL Dynamic Testing of Electric Starter System Condition: Starter fails to turn motor or motor turns slowly. NOTE: Assure that engine crankshaft is free to turn before proceeding. For this test a digital multitester must be used. With tester on VDC, place tester black lead on battery negative (-) terminal and tester red lead on battery positive (+) terminal. Reading should be 12.6V or greater. Is it? No-+ Remove battery, test and/or service.
ENGIN E ELECTRICAL Electric Starter System Testing (Static) Starter Motor Static Testing IGNIT ION SW ITCH I GN IT JON SWITCH SYSTEM BRN-GROUND IGNIT ION WIRE COLORS G TERMINAL - BROWN - GROUND B TERMINAL - RED - BATTERY M TERMINAL - BLACK - IGNIT ION S TERMINAL - RED/WHITE - STARTER OFF RUN ALTERNATOR OUTPUT ~: R '--- - - R' W- -- - RECT IF IER START :: ~ : R B R/W S R C I RCU IT BREAKER (8 AMP ) ,/ ",," IGNIT I ON SW ITCH COLOR CODE R 0 RED BRN 0 BROWN BLK 0 BLACK Y 0 YELLOW R/W 0 RED
ENGINE ELECTRICAL Electric Starter Reassembly and Reinstallation c Starter Reassembly 25 1 - Field Coil Housing 2 - Armature Assembly 3 - Washer Kit 4 - Field Coil 5 - Pole Core Set Screw 6 - Brush (+) 7 - Brush Holder 8 - Brush H 9 - Brush Spring 10 - Brush End Frame 11 - Brush End Bushing 12 - Pinion Assembly 13 - Pinion Stopper Set 14 - Through Bolt 15 - Dust Cover 16 - Drive End Frame 17 - Drive End Bushing 18 - Screw 19 - Spring Washer 20 - Engine Mounting Bracket 21 - Stud 22 - Nut 23 - Spring Wa
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Electrical Fuel Injection Section 4 4.
ENGINE ELECTRICAL EFI Introduction and Operation ROM Identification I Charge Coil Test Specifications Model System Type ROM 10 ROMPN Battery Charge Coil Test Position/Resistance 1990 RXL I 1990 V2 G to G/W .3 to .5 ohms 1991 RXL 1991 500 I II FSM 582 FSM 752 Contact Service Dept.
ENGINE ELECTRICAL Electronic Fuel Injection Data EFI models have two separate alternators or charging systems. One is used for lighting and accessories, the other for battery charging and EFI operation. The battery size and alternator size have been designed to provide adequate output for the EFI system. If your sled is equipped with electric start, a larger battery will be required to provide adequate cold cranking amperage.
ENGINE ELECTRICAL Battery Maintenance and Testing Battery Maintenance And Testing Battery maintenance is of the utmost importance to ensure satisfactory EFI operation. Partially shorted batteries can cause an additional load on the charging system and in turn leave the EFI system with too little to supply the relays, ECU, fuel pump, injectors, etc. When this type of machine enters your service area, be sure to thoroughly clean, inspect and test the battery.
ENGINE ELECTRICAL Power Up Testing - Type I RXLs Reference correct wiring diagram in chapter 3. 1. Check battery voltage. Must be 12.2 or higher. Use digital fluke meter. Does it read correctly? No-+ Yes! Charge, service, test and/or replace battery. 2. Check EFI brown relay. Y/BK wire should read 12.2 volts or more with switches turned on. Does it read correctly? No-+ Yes! Check circu it breaker, key switch, kill switch, connections and wires. Check relay ground black wire. 3. Check brown relay.
ENGINE ELECTRICAL Power Up Testing - Early Type II, 1991-1992 500's c o 1. Check battery voltage. Must be 12.2 or higher. Use a digital fluke meter. Is voltage OK? No-+ Yes! Charge, service and test battery; or replace battery. 2. Check voltage between ECU Orange wire and ground, and between Y/Blk and ground. With key switch in the spring loaded position, voltage shou ld read 12.2 or higher.
ENGINE ELECTRICAL Power Up Testing - Late Type II, 1993 to Current 500's 1. Check battery voltage using digital fluke meter. Must read 12.2 Qr higher. It voltage OK? No-+ Vest Charge, service, and test battery; or replace battery. Continue testing if needed. See battery service. 2. Check voltage to ECU R1GN Pin #106. Should be 12.2 or higher. Is voltage OK? No-+ Vest Check circuit from battery through circuit breaker and to ECU. Repair and/or replace faulty wiring or components. Continue to step 3. 3.
ENGINE ELECTRICAL Power Up Component Testing Fuse Link The fuse link is the circuit protection device in Type I and 1991-1992 Type II electrical system. Should a system overload such as a dead short occur, the fuse wire will open the circuit preventing further damage. If this link should open, find and correct the problem and then replace the fuse link. Never attempt to replace the fuse link with a conventional fuse. Use only an OEM fuse link.
ENGINE ELECTRICAL Alternator Controlled Switch "ACS" Shown is the (ACS) for the 1993 to current 500 EFI systems. The ACS controls voltage from the alternator by rectifying from AC to DC voltage current to charge the battery. It also supplies the ECU with a 12vDC battery voltage signal to indicate that the engine's crankshaft is turning. The ACS eliminates the need for the "Ready" light system reset as used on previous 500 EFI models.
ENGINE ELECTRICAL Basic Operation - System II c The fuel system consists of all the parts responsible for storing, cleaning, delivering, pressurizing and injecting fuel into the engine. They are: fuel tank, fuel pick-up, fuel hose, primary filter, fuel pump, secondary filter, fuel rail, injectors, throttle bodies, pressure regulator and fuel return hose. Tracing the path of fuel through the system, fuel is picked up from the bottom of the fuel tank by the fuel pick-up hose and filter.
ENGINE ELECTRICAL EFI Fuel System Maintenance and Testing Tank, Hose And Filters STANDARD FUEL HOSE The fuel tank is the reservoir for the fuel. It contains a flexible hose with a weighted pickup and a course screen which drops to the lowest part of the tank regardless of machine attitude. Fuel trav~ls through the urethane fuel hose to the primary 75 micron filter located under the airbox and then to the fuel pump.
ENGINE ELECTRICAL Fuel System Maintenance and Testing c Output Pressure Test: Install EFI fuel System pressure tester (PN 2870982) in fuel line on PTa end of rail. NOTE: Use caution when removing hose. The rail may contain pressurized gas if engine has been recently run. Activate dealer mode using select monitor service harness plug, by connecting gray and black test loads together or by jumping gray and black wire terminals at diagnostic plug, then turning on ignition switch.
ENGINE ELECTRICAL EFI Fuel System Maintenance and Testing The regulator can also vary pressure consistent with engine load, atmospheric pressure, etc. A manifold pressure tube runs between the mag end throttle body and the top of the diaphragm. As the throttle is opened, the pressure in the throttle bore rises.
ENGINE ELECTRICAL EFI Fuel System Maintenance and Testing \ 1. Check battery voltage. Must be 12.2 or Charge, service, test and/or replace battery. See battery service section. higher and be capable of handling pump load. If not, the fuel rail pressure test will below. No -+ • Yes~ Connect fuel pressure gauge and test as earlier outlined. Must read 35 to 37 psi. Pressure reading high-+ Pressure reading low ~ Check for pinched or kinked pressure regulator return line.
ENGINE ELECTRICAL EFI Fuel System Testing Injectors cannot be disassembled for service or cleaning. If a cylinder is not functioning properly and fuel supply is suspected as the cause, determine if an injector problem exists and whether it is mechanical or electrical. Switch the harness leads from the injector in question with an adjacent injector. If the problem moves to the adjacent injector, then it is electrical (see injector electrical service).
ENGINE ELECTRICAL System III - Electronics Operation c The Electronic Control System is the mixture control part of the system. It uses sensor inputs to control the fuel/air ratio. The illustration shows the components of the basic Electronic Control System. Sensors (Inputs) (Three Cylinder System Shown) Twins have 2 injectors Injectors (Outputs) ECU Drop Resistor In From Battery L......,,.....
ENGINE ELECTRICAL System III - Electronics Operation Input from the other sensors either adds to or subtracts a percentage from the pulse width to tailor the fuel/air ratio for the specific altitude, air temperature and engine temperature. See illustration. Richer for low altitude, cold engine, cold inlet air, etc. [J . ] Leaner for warm air temps, high altitude etc. ./ ./ " " ) ....... Pulse Width Z ) ........ ./ ........
ENGINE ELECTRICAL System III - Electronics Testing Select Monitor The select monitor (PN 2870969) is designed to provide easy, accurate diagnostic and service information to the technician. When installed on the machine it will provide both dynamic and static displays of the function of critical fuel system control components. It also has the ability to display the contents of the ECU memory. With this tool, electrical service of the EFI system should be quick and easy.
ENGINE ELECTRICAL System III - Electronics Testing ROM Chip Removal and Installation The chip can be removed and replaced with the appropriate chip puller and installation tool. You will need to supply ROM Removal Tool (Digi-Key PN K158-ND; Call 1-800-344-4539); and Nyogel (Polaris PN 2871 044). Note the location of the indicator notch when replacing the chip (see photo). The system will .not function with the chip in backwards or with the chip pins not properly in their sockets.
ENGINE ELECTRICAL System III - Electronics Testing C Troubleshooting EFI System When key switch is turned to the on position, voltage is supplied to ECU and the select monitor. NOTE: Some models will require the engine to be turned over. As explained on page 4.36, after the ECU is powered up, it will run the fuel pump for five seconds, read the sensors and do a self diagnosis of the complete system. The ECU does not check the Air Temperature Sensor (ATS) until the engine RPM is above 1000.
ENGINE ELECTRICAL System III - Electronics Testing The ECU determines the amount of fuel to be injected by accurately calculating the engine's needs for fuel delivery. In order to do this, the ECU is loaded with a memory chip for the read out of the three dimensional map which reads the throttle sensor and engine speed.
• r. ENGINE ELECTRICAL System III - Electronics Testing Throttle Position Sensor (TPS) c Throttle position is one of the two main inputs used to calculate fuel/air ratio. The throttle position sensor is a rheostat type variable resistor which is mounted on the end of the throttle shaft. The resistance value of the sensor is relatively low at idle. As the throttle is opened, the resistance goes up proportionately to the butterfly angle.
ENGINE ELECTRICAL System 111- Electronics Testing Intake Air Temperature Sensor (ATS) The air temperature sensor is mounted in the air box. Its function is similar to the crankcase temperature sensor in that its temperature will vary the resistance across the sensor. It has a reduced thermal capacity for quicker response. Cold air will cause high resistance and warmer air will lower the resistance.
ENGINE ELECTRICAL System III - Electronics c Barometric Pressure Sensor (BPS) The barometric pressure sensor is located inside the ECU. Its function is to read atmospheric pressure. This information is then used by the ECU to determine fuel/air ratio, depending on pressure changes during a given day, or for any altitude change. The barometric pressure sensor is an integral part of the ECU and cannot be replaced separately.
ENGINE ELECTRICAL System 111- Electronics MR Adjustments Fuel/air ratio at engine RPMs below 3500 can be adjusted Slightly richer or leaner from the standard program mixture by adjusting the MR control. This adjustment is to compensate for individual engine differences on Type I and 1991 and 1992 Type II systems. This adjustment affects the same area as an air screw on a carbo To adjust the MR control, remove the rubber plug. Install the select monitor, power up the system and press buttons F-21 .
ENGINE ELECTRICAL EFI Electronics Type II System - 1991 To Current EFls Type II EFI systems incorporate an engine coolant temperature sensor. This sensor is positioned in the engine water jacket where it is able to receive and relay reliable engine top end temperature to the ECU. This sensor also controls the temperature light and a fail safe mode. The "TEMP" dash light will come on and begin to blink slowly when the coolant reaches an unsafe temperature.
ENGINE ELECTRICAL EFI Electronics Fuel Injectors Variation in the amount of fuel delivered per stroke to suit varying load and speed conditions can be obtained by controlling the discharge duration of the injector. The injector is a solenoid-actuated constant stroke plunger consisting of a solenoid, plunger, needle valve and housing. The ECU will determine the duration time the injector is energized to deliver fuel. The resistance between the two pins on the injector (isolated) should be 2 to 2.5 ohms.
!£Wit ENGINE ELECTRICAL EFI Electronics ECU Diagnostics If any of the main sensors should malfunction while the machine is being driven, the ECU will sense a problem and proceed to an over-rich "fail-safe" mode. An open or shorted circuit in any of the sensor circuits will show the ECU a reading outside of what it normally sees and the ECU will determine that a problem exists.
ENGINE ELECTRICAL EFI Electronics The FA modes are for testing the input and output functions from the ignition switch and the relays. Type I System With the select monitor on mode FAD, the display should show KY. Whenever the ignition switch and the handlebar kill switch are in the run position, the number 3 LED should also light. Cycle the switches a few times and observe that the LED goes off when the switches are turned off and re-lights when the switches are returned to the run position.
() ST A TOR RES I STANCES BLK/R-GRN 1~~8_?~~S R-GRN W-W/R 96 OHMS Y-BRN .2-.4 OHMS GRY-GRY/W .4-. 8 OHMS BRN/W- GRY I W .3-. S OHMS HANDWARMER RES I ST ANCES BLU/ R-BRN 9. B OHMS BLU - BRN 19. 8 ~S REGULATOR HASSIS GN -:- HANDWARMER SWITCH ~~I &;It · "'I :~·' 2.10 , I! ~ 0'> W COl MOOlA..E CU 2178 II !~~~ f ~l . AEGlA... ...
I ~ +>- GRY~~ BRN/ W i GAY / W r I ( 7"F r 11 I '\ GRNffi LOW STATOR RESISTANCES 1'10%1 BRN/ W-BLK/R 16 4 OHMS BRN-W-GRNO 0 OHMS Y-Y/R . 2- . 5 OHMS GRY-GRY/W . 4- . 8 OHMS BRN/ W-GRY/ W .2-.4 OHMS STATOR ,~ Y HIGH ~m CDZ CDG) . Y/R . ~~Z HI/LOW SWITCn y------, REGULATOR CDm CD BLU ·· 6RN 19. 6 OHMS Bl U/A- BRN 9 . B Ot-NS :::!.o CHASSIS GND Y/R (0:::0 BAN HIOH r- :::J-I LOWeENolLIOtfT BAN I 8C;:\.~ BAN BAN ' j, Y~/A r.::-:..
1~1~ 1~ 11 1 EC U * PIN WIRE COLOR 1 P/BLU & 3 W 4 BLU/ W BLU/G RN GRN/R BLK OR/BLK Y/BLU Y/GRN GRN/Y BLK / Y 5 8 ~ (J) (}l 10 11 14 15 16 17 * PIN & WIRE 101 _ 102 105 106 111 »2 "5 ' " "6 1 13 COLOR LG L G/ BLK GRN / W R/GRN BRN BRN/y P BRN/y BRN / R ~~L~CEL" fI SEE PO LAR I S WI R I N G HARN : ® ,' 5ELF _ ____ _ _ ,- ---- R/ BL K BRN 123 BRN/R BLK / R : BLK / W I 0 = 125 0 SEE POL AR I S 126 WI R = r NG / BLK '5 H HARNESS .
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