User manual DAELIM SQ125 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. [. . . ] 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. 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. 7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10). 8. TPS(THROTTLE POSITION SENSOR) It is Located on the right side of throttle body ! CAUTION Before disassembly, the key is off. Remove Lh. side cover Air cleaner TPS connector TPS screw Replace the TPS 5-17 EMS(Engine Management System) CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number displayed by MIL Checking circuit TPS ECU 4 : SENSOR GROUND 18 : 5V SUPPLY VOLTAGE 19 : TPS The coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off ignition key . Input voltage : 4. 5 ~ 5. 5[V] Measuring terminal : ECU NO. 18(Gr/B : GRAY/BLACK) ~ ECU NO. 4 (W/R : WHITE/RED) Measure the terminal voltage of TPS's coupler. Measuring voltage : 4. 5[V] ~ 5. 5[V] Remarks : Measuring unit of voltage : voltage [V] If voltage value is not normal, Check to see if the ECU coupler is loose if there is bad contact. Check the `GR/B'' electric wire, `W/R' electric wire, `GR /L' electric wire to see if they have been broken or have short- circuited. 5) If the value of voltage is normal, turn off the ignition key. 5-18 EMS(Engine Management System) Checking Procedure 6) Check continuty between the Sensor Ground Terminal of TPS and Earth. 4 (W/R : WHITE/RED) ~ EARTH Remarks : Measuring unit for resistance : Resistance ` R ` [ ] 7) If not problem, measure the resistance of TPS. The resistance of TPS If the throttle is totally closed : 1. 38~1. 6[k ], 20±1 If the throttle is totally opened : About 2. 4[k ], 20±1 Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No. 4 (W/R : WHITE/RED) Remarks : Measuring value of resistance : Resistance[k ] 8) If resistance and the continuty are not abnormal. Adjust correctly the position of TPS Replace the TPS with the new one and re-check. Rotate the throttle lever, measure the voltage Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No. 4 (W/R : WHITE/RED) Output voltage of TPS -If the throttle is totally closed : 0. 1~0. 6[V] -If the throttle is totally opened : 4. 0~5. 5 [V] Remarks : Measuring unit for voltage : Voltage [V] 12) If the measured voltage is abnormal, Replace the TPS with the new one, and re-check. If the measured voltage is normal, Check the `GR/B' electric wire, `GR/L' electric wire, `W/R' electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10). 5-19 EMS(Engine Management System) 9. ETS(ENGINE TEMPERATURE SENSOR) Situated on the Right-hand side of cylinder head ! CAUTION Before disassembly, the key is off. Remove Rh. shroud comp Connector by hand ETS Replace the ETS PUSH PUSH Install in reverse order of removal ! CAUTION PULL PULL ETS torque:3±0. 3[kgf m] 5-20 EMS(Engine Management System) 1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor) Fault code number is displayed by MIL CHECKING CIRCUIT ETS ECU 4 : SENSOR GROUND 20 : ETS Coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off the ignition key . 20 (Gr/L: GREEN/BLUE) ~ ECU No. 4 (W/R : WHITE/RED) Measure the terminal voltage of ETS's coupler. Measuring voltage : 4. 5[V] ~ 5. 5[V] Remarks : Measuring unit for voltage : voltage [V] If the voltage value is not normal, Check to see if the ECU coupler is loose if there is bad contact. Check the `G/L'' electric wire, `W/R' electric wire, `W/R' electric wire to see if they have been broken or have short- circuited. Resistance of ETS :1. 6[k ]~10. 6[k ], 20 ~80 Measuring terminal : Each terminal of ETS Remarks : Measuring unit for resistance : Resistance ` R ` [k ] 5-21 EMS(Engine Management System) 6-1) If the measured value is not normal, Replace the ETS with the new one, recheck. If the measured value is normal, Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if the ECU coupler is a bad contact ( No. 4, No. 6-2) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10). Checking Procedure 1) Disassembly Disassemble the ETS(Engine Temperature Sensor) : (Refer to 4-20) 2) Check the ETS(Engine Temperature Sensor) Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil. Read the temperature of thermometer depending upon oil temperature's change and tester's value. [. . . ] Torque : 1. 2 kgf m ADJUSTMENT OF THROTTLE CABLE Assemble the throttle cable Adjust the free play of the throttle grip ( -4) INSPECTION OF SENSOR AND ACTUATOR Connect each sensor and the actuator's coupler. Check the ISA (Idle speed actuator) ( -23) Check the TPS (Throttle position sensor ( -17) ! CAUTION Be sure to the value of TPS is whether the standard value after it became assembly. Check the MAPAT sensor ( -14) 5-39 EMS(Engine Management System) SUPPLEMENT ADJUSTMENT OF THROTTLE ADJUST SCREW A vehicle is assembled in the state which engine operation is possible. Loosen the maintenance cover and the adjust-screw is makes possible to adjust. [. . . ]