User manual DAELIM S1 125 SERVICE MANUAL

[. . . ] How to use this manual General This manual explains how to maintain procedure for the S2-125 manufactured by DAELIM MOTOR CO. , LTD. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule(Section 2). Sections 1 through 2 provide information on overall vehicle; section 3, assembly and disassembly procedures for external components, and section 4 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. [. . . ] The resistance between each terminal and ground : [ ] If resistance value is not normal, replace injector with the new one. 5)If the resistance is normal, turns on the ignition key - If the fuel pump operated for 3 seconds, the power supply relay of injector is normal. Measuring terminal : BLACK/RED electric wire ~ ground Measuring voltage : battery voltage ­ 1. 0[V]over Remarks : Measuring unit of voltage : voltage [V] 5-12 EMS(Engine Management System) 7) If the measured voltage is normal, Check the `Blue/Yellow' electric wire to see if they have been broken or have short-circuited or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40) If there is no problem in the electric wires, ECU is broken Replace the ECU with new one, it rechecks 8) If the measured voltage is not normal, Check the Black/Red electric wire to see if they have been broken or have short-circuited. 9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10). 5-13 EMS(Engine Management System) ISA ISA 7. MAPAT(Manifold Air pressure sensor, Temperature sensor) Located on the left- side of the throttle body ! CAUTION MAPAT MAPAT TPS TPS Before disassembly, the key is off. Remove MAPAT connector (Push by hand and pull to the front-side) Loosen the flange bolt 2EA. ! CAUTION Be sure to check the coupler is toward to insulator. 5-14 EMS(Engine Management System) Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))'s circuit Fault code number is displayed by MIL The Fault code of intake pressure sensor The Fault code of intake temperature sensor Checking circuit MAPAT ECU 3 : Intake pressure sensorpressure ground 3 : Inhalation 26 : sensor GROUND 5V voltage 27 : 26 : 5V voltage IMP 28 : TBA 27 : IMP 28 : TBA Coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off the ignition key . 2) Check to see if the MAPAT coupler has come loose or the wire is peeling off. If there is normal, measured the input voltage of MAPAT's coupler. 3) Disassemble the coupler of MAPAT and turn on the ignition key 4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)'s coupler. Input voltage : 4. 5 ~ 5. 5[V] Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal Remarks : Measuring unit of voltage : voltage [V] If voltage value is not normal, Check to see if the ECU coupler is loose or if there is a bad contact. Check the `P' electric wire, `P/G' electric wire, `P/L' to see if they have been broken short-circuited Remark : refer to (5-16) if the intake pressure sensor is broken refer to (5-16) if the intake temperature sensor is broken 5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10). 5-15 EMS(Engine Management System) Checking of the intake pressure sensor 1) If voltage value is normal, turn off the ignition key. Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler 2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-32 ) 3) Turn on the ignition key. 27(P/L:PINK/BLUE) ~ ECU No. 3(P/G : PINK/GREEN) Measuring voltage : 0. 1[V] ~ 4. 8[V] Remarks : Measuring unit of voltage : Voltage [V] The voltage of air pressure; 20[kPa]: 0. 719 ~ 0. 859[V] 107[kPa]: 4. 154 ~ 4. 294[V] 5) If the measured voltage is not normal, Check the `P' electric wire, `P/G' electric wire, `P /L' electric wire to see if they have been broken or have short- circuited. If measuring voltage is normal, Check the `P' electric wire, `P/G' electric wire, `P/L' electric wire to see if they have been broken or have short- circuited if there is a bad contact. 6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU. Checking of the intake temperature sensor 1) If voltage value is normal, turn off ignition key. 2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor. Resistance of intake pressure sensor : 2000±100[], 25±1 Measuring terminal : ECU No. 3(P/G : PINK/GROUND) Remarks : Measuring value for resistance : Resistance[ ] The Voltage of air pressure; 24 ~ 26[ ] : 1800~2200[ ] 99 ~ 101[ ] : 161~206[ ] 3) If measuring resistance is not normal, Replace the MAPAT sensor with new one and it rechecks. If the measured voltage is normal, Check the `P' electric wire, `P/G' electric wire, `P/L' electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. Replace the ECU with the new one, it rechecks. 5-16 EMS(Engine Management System) Checking of intake temperature sensor 4) Turn on the ignition key. Measuring the voltage of intake pressure sensor - Measuring terminal: ECU No. 28(TBA) ~ ECU No. 3(IMP GROUND) - Measuring voltage: 0. 1[V] ~ 4. 9[V] Remarks : Measuring unit of voltage : Voltage [V] 6) If the measured voltage is not normal, Check the `P' electric wire, `P/G' electric wire, `P /L' electric wire to see if they have been broken or have short- circuited. [. . . ] Press the power-button of diagnostic tool. ! CAUTION The ECU is always initialized, before the engine is starting. The vehicle is warms up enough to adjust the idling speed. ! CAUTION If the ETS temperature is 90 degrees, adjust the` throttle adjust screw'. By adjusting the throttle adjust screw. Adjust the value of ISA PWM to standard value, among the service data of diagnostic tool. ISA PWM : 12 2%, 1600 100RPM After the ISA PWM became adjusted, fix the throttle adjust screw with adjusting nut. 5-40 EMS(Engine Management System) 18. HOW TO USE THE SCAN WHEN ECU IS INITIALIZED The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. [. . . ]