User manual CANNONDALE 2003 EFI TROUBLESHOOTING

[. . . ] Electrical/EFI Service Manual ATV and Motorcycle P/N : 5002401 August 14, 2002 INTRODUCTION IMPORTANT NOTICE You must possess significant mechanical knowledge, skills, and tools to perform most of the procedures found in this document. This manual is written for Cannondale Motorsports Dealers and qualified service technicians. This is not a comprehensive shop safety manual and should not be used by anyone who is not familiar with standard safety practices and service techniques. This manual does include warnings and cautions (see descriptions above) that if ignored, could result in SEVERE PERSONAL INJURY to the service technician or significant damage to the vehicle rendering it unsafe to operate. [. . . ] The green LED on the interface cable will light when the engine management circuits are powered up. The "Failed to Unlock System 125" message means that the Cannondale Diagnostic and Maintenance Tool was not able to communicate with the vehicle ECU. There can be several causes: · Check the interface cable at the vehicle harness connector. Make sure the vehicle connector pins are not bent or broken inside the connector. Make sure the cable connector and vehicle coupler are locked together. If the "Failed to Unlock System" message displays repeatedly, the vehicle ECU or · NOTE : On ATVs, after 2 minutes of inactivity (ECU powerdown), the interface cable block green LED will not go out. It will remain lit as long as the ATV ignition is in the "ON" position. · · · · · Electrical_EFI Service Manual. fm © 2002 Cannondale Corporation - All Rights Reserved 24 interface cable may be damaged. I/O Error Message 1. You will see this message if the last engine calibration file opened with the software is no longer available such as: if it was deleted or the CD containing it has been removed from the CD drive. OTHER MESSAGES Progress Indicator Whenever data is being transferred between the vehicle ECU and the PC, a progress indicator displays in the upper right area of the main screen. If the progress indicator freezes for a long time, close the Cannondale Diagnostic and Maintenance Tool software and try again, Make sure the cables are connected properly and that the vehicle battery is fully charged. 25 8/14/02 Retrying Checksum Data is transferred between the vehicle and PC in small "packets" or chunks. During the transfer process, checks are performed by the diagnostic tool (software) to ensure that the data is not damaged during the transfer. If data errors are detected in the packet, the message "Retrying Checksum. . . " will display in the progress indicator: Typically, this is due to electrical "noise" or other interference during the process. The diagnostic tool will keep trying automatically. Electrical_EFI Service Manual. fm © 2002 Cannondale Corporation - All Rights Reserved 26 COMMUNICATION CABLE Connecting the communication cable Motorcycles and ATVs have a "diagnostic" connector integrated into the main wiring harness. The communication cable connects the PC to the vehicle using the connector. CAUTION : Connect the communication cable with the vehicle engine management system OFF. On 2001 and 2002 Motorcycle models, the diagnostic connector is located near the ignition coil at the top of the cylinder head. On 2003 Motorcycles, the diagnostic connector is located near the main fuse under the seat. On 2001 - 2003 ATV, the diagnostic connector is located near the radiator shroud under the front fender on the left side of the ATV. 1 2 3 4 1. 4. Serial connector (PC) LED Cable Connector (vehicle) NOTE : Check the diagnostic connector pins for any bending or damage before connecting to the vehicle. 27 8/14/02 CANNONDALE DIAGNOSTIC AND MAINTENANCE TOOL MAIN WINDOW 1 3 8 9 4 5 6 7 2 1. 9. Numeric Cal ID Description (saved files only - not stored in ECU) Buttons Throttle position sensor min and max values (from vehicle) Throttle Body Leakage (also Throttle Body Offset) (Factory dyno value) Fuel injector flow rate (Factory dyno value) Injector offset (Factory dyno value) Progress indicator Button to access software version information and Cannondale internet files: http://www. cannondale. com/motorsports/tech/maps/ Electrical_EFI Service Manual. fm © 2002 Cannondale Corporation - All Rights Reserved 28 Engine Calibration File ("Map") Identification All Cannondale factory authorized engine calibration files are identified by a Numeric Cal ID code. The Numeric Cal ID number defines the year, model, and issue sequence of any specific engine calibration file. The engine calibration Numeric Cal ID number is displayed in the top left corner of the Cannondale Diagnostic and Maintenance Tool main window whenever a "map" is opened or received from the vehicle ECU. The code number also displays at the Numeric Cal ID field within the main window. Cannondale vehicles (ATVs and motorcycles) are loaded at the factory with a model specific authorized engine calibration file. This file can also be referred to as the vehicle "map. " Engine calibration files have the filename extension ". ccf" YEAR Reset every 10 years (ex. 2002) MODEL CODE 00 - X440s 01 - X440 02 - C440 03 - E440 30 - Cannibal 31 - Speed 32 - Blaze 440 33 - Moto 440 30202. ccf SEQUENCE NUMBER Assigned sequentially. [. . . ] Connect the positive meter lead to solenoid connector harness pin B and the negative meter lead to ground. If an open circuit is detected, consult the vehicle wiring diagram. KEY SWITCH 1. There should be no continuity between the yellow lead and the green or violet. There should be continuity between all leads. Static Test - Resistance 1. [. . . ]