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. Anyone operating an "unsafe" vehicle can be SERIOUSLY INJURED OR KILLED. We have done our best to identify situations where warnings or cautions are needed and will continue to do so in future publications. But, YOU must always exercise good judgement, and follow safe shop practices when performing service procedures as described in this manual. This manual was accurate at the time of publication. Any supplemental information developed or written after printing may be available on our web site as a "manual supplement." Service bulletins and technical notes are also published as required. These are also posted on the website. You may find that the technical terms and part names in this manual differ from published parts catalogs or microfiche. ABOUT THE MANUAL All the procedures in this manual are organized in a numbered (step-by-step) easy to read format with accompanying photographs, line art, torque values and specifications. The numbered steps of a few procedures are likely to be separate procedures themselves. When this is the case, the numbered step will include a page reference number. COMMENTS? Send your comments to: Cannondale Corporation, Technical Publications, 2 Corporate Drive, Bedford, PA 15522 Or e-mail: technical.publications@cannondale.com 3 8/14/02 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Information important to your safety is distinguished in this manual by the following notations: \ The safety alert symbol means...... "ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED." DANGER WARNING Indicates that DEATH or severe injury WILL result if the instructions are not followed. Indicates a potential hazard that could result in serious injury or death. CAUTION : A CAUTION indicates that special precautions must be taken to avoid damage to the machine. NOTE: A NOTE provides helpful information intended to make maintenance easier or the instructions presented clearer. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved 4 CONTENTS INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - 3 Important Notice - - - - - - - - - - - - - - - - - - 3 About the manual - - - - - - - - - - - - - - - - - 3 Comments? - - - - - - - - - - - - - - - - - - - - 3 Engine Stop Switch (ATV) Clutch Lever Switch (ATV) Key Switch - - - - - - - Starter Solenoid - - - - Starter Motor - - - - - - Fuses - - - - - - - - - - - - - - - - - - - - - - 59 59 59 59 60 60 IMPORTANT MANUAL INFORMATION- - - - - - - - - - - 4 ENGINE MANAGEMENT SYSTEM (EMS) - - - - - - - - - 6 Engine Control Unit (ECU) - - - - - ECU Programming - - - - - - - - - Servicing connectors and couplers - Barometric pressure sensor - - - - Throttle position sensor (TPS) - - - Coolant temperature sensor - - - - Air temperature sensor - - - - - - - Crankshaft position sensor - - - - - Idle Air Control Valve (IACV) - - - - Ignition coil- - - - - - - - - - - - - EMS Power Relay - - - - - - - - - Fuel pump and fuel pressure regulator Cooling Fan (ATV - - - - - - - - - -6 -7 -9 10 10 12 12 13 14 15 15 17 20 CANNONDALE DIAGNOSTIC AND MAINTENANCE TOOL VERSION 2.0 - - - - - - - - - - - - - - - - - - - - - - - 21 General Information - - - - - - - - - - - - - - - 21 Installation - - - - - - - - - - - - - - - - - - - - 21 In the Windows Explorer, double click the SecurityCode application. Or, you can access this application by clicking on Security code.exe through the program group. - - 22 Common Problems- - - - - - - - - - - - - - - - 23 Interpreting Error Messages - - - - - - - - - - - 24 Other Messages - - - - - - - - - - - - - - - - - 25 Communication cable - - - - - - - - - - - - - - 27 Cannondale Diagnostic and Maintenance tool Main Window - - - - - - - - - - - - - - - - - - - - - - - - 28 ECU Operating code - - - - - - - - - - - - - - - 29 Calibrations - - - - - - - - - - - - - - - - - - - 37 ECU Monitor - - - - - - - - - - - - - - - - - - - 39 Reading Fault Codes - - - - - - - - - - - - - - - 40 FAULT TROUBLESHOOTING - - - - - - - - - - - - - - 42 Sensor Supply Voltage - - - System Voltage - - - - - - Fuel Pump - - - - - - - - - Ignition Coil - - - - - - - - Cooling Fan (ATV Only) - - Fuel Injectors - - - - - - - Throttle Position Sensor (TPS) Air temperature Sensor - - - Coolant Sensor - - - - - - Idle Air Control Valve (IACV) Crankshaft Position Sensor- 42 43 44 45 46 47 50 51 53 55 56 57 57 58 58 58 COMPONENT TESTING (NON-EFI)- - - - - - - - - - - - 57 Battery - - - - - - - - - - - - Rectifier /Regulator - - - - - - Flywheel - - - - - - - - - - - Start Button (ATV & Motorcycle) Engine Stop Button- - - - - - - 5 8/14/02 ENGINE MANAGEMENT SYSTEM (EMS) Engine operation is supported by the management system consisting of three main types of electrical components: the ECU, the sensors, and the actuators. · The engine control unit (ECU or ECM) precisely calculates ignition timing and fuel delivery for all engine speeds and loads (based on the currently installed calibration file and its mapping). The ECU is an extremely reliable component and should be the last component checked in the event there is a problem with the fuel injection system. The sensors of the system collect engine operating information and transmit it to the ECU. The actuators are devices like the fuel injectors, fuel pump, fuel pressure regulator, and spark plug coil, and relays. Motorcycle ECUs are located within the subframe. 3 1 2 · 1. ECU 2. Air pressure sensor hose (from airbox and fuel pressure regulator) 3. Internal barometric (air) pressure sensor. · ATV ECUs are located on the electronics tray under the cowl. ENGINE CONTROL UNIT (ECU) 4 3 The engine control unit or "ECU" is a kind of computer that calculates ignition timing and fuel delivery for all engine speeds and loads based on its programming. It is sometimes referred to as the "brain" of the fuel injection system. This brain calculates fuel delivery and ignition timing based on information gathered from vehicle sensors (inputs) and the calibration file loaded at the factory. The ECU inputs are the air temperature, coolant, crankshaft position, throttle position, and barometric pressure sensors. Information from these sensors together with the ECU operating code (hex file) and engine calibration file (map) are used to control the system actuators (e.g. fuel pump, ignition coil, injectors, relays, idle air control valve). NOTE : In this manual, the engine control unit is referred to as the "ECU." It is also sometimes called an "ECM" or engine control module. Either reference is OK. 1 2 3 1. 2. 3. 4. ECU Air pressure sensor hose (from airbox) Accessories connector EMS power relay Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved 6 ECU PROGRAMMING of the ATV. The tool is a combination of a specially developed Windows- based software program and a data cable used to connect your PC or pocket PC computer to your vehicle. With the tool, you can read fault codes, install engine calibration files, set vehicle rpm, and monitor engine operating parameters. The ECU is "programmed" with three types of information. the operating code (also known as the "hex" file, the engine calibration file (also known as the "map"), and the vehicle variables or "calibrations." Calibrations are stored in the map file but are specific to the throttle body and injectors installed on the vehicle. Any programmed information can be changed. using the Cannondale Diagnostic and Maintenance Tool. Refer to "Cannondale Diagnostic and Maintenance Tool Version 2.0" starting on page 21. 2 1 3 ECU diagnostic connectors ATVs and motorcycles have a diagnostic connector to connect the software tool PC to the vehicle. · On 2001 and 2002 Motorcycles, the diagnostic connector is located near the ignition coil on 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 on the left side 1. Diagnostic connector 2. EMS power relay 3. Main fuse · · Reporting system faults The ECU is capable of reporting system hardware malfunctions during operation. It reports current problems and does not store problem "faults" in memory. System faults are read from the ECU using the Cannondale Diagnostic and Maintenance Tool, a Windows-based PC program enabling communication between a PC and the vehicle ECU. The ECU does not store intermittent faults; the faults reported are occurring at the moment when the ECU Fault Report window is selected in the software tool. A special communication cable is needed to connect the vehicle to a PC. Refer to "Cannondale Diagnostic and Maintenance Tool Version 2.0" starting on page 21. This manual provides step-by-step fault diagnostic testing based on the actual fault reported by the software tool. Refer to "Fault Troubleshooting" starting on page 42. 7 8/14/02 P1 and P2 Connectors MC1000 ECUs have two main harness connector sockets. Remove both main harness connectors from the ECU when performing pin point tests described in this manual. Also, if required, be sure to disconnect any other devices; see the specific pin point tests. · Connector P1 color is black. It connects to the black ECU socket. Connector P2 color is grey. It connects to the grey ECU socket. Pin identification (P1 or P2) Use the following illustration for P1 and P2 pin identification. H G FEDCBA 2 4 1 3 · H G FEDCBA CAUTION : Allow connector rotating latch to draw the connector into the ECU socket (coupler). Do not press or force the connector; it should slide into the socket easily. Check for contamination and pin condition before reconnecting. Lubricate the connector seals with a highquality dielectric grease before reinstalling. Use a commercially available pin gauge when performing pin point tests. Ordinary tester probes can spread pins resulting in loose connections. This photo shows how to identify individual pins in the ECU harness connectors. Each row is identified by a number 1-4. Each column is identified by a letter A - H. Disconnecting the ECU 1. Disconnect the battery. 2. Press in the latch locking tab and rotate the latch in direction (a) until it stops. Pull the connector from the ECU socket. 1 1 a 1. Latch 2. Locking tab Reconnecting the ECU 1. Make sure the battery is disconnected. 2. Make sure the main fuse is removed. Electrical_EFI Service Manual.fm © 2002 Cannondale Corporation - All Rights Reserved 8 3. Align the latch groove and tab on the ECU socket. Rotate the latch in direction (b) until the latch is locked by the locking tab. The latch should operate freely with your fingers; do not force it. Cleaning 1. Wipe the connector or coupler with a clean, lintfree rag and blow off any moisture using compressed air. 2. Remove corrosion, rust, stains or other foreign material by using contact cleaner on the terminals. 3. Apply a water-displacement chemical on connector seals. 2 1 4. Apply a light coat of dielectric grease onto the terminals/pins, and properly connect the halves. Disconnecting · · 1. Latch 2. Tab Release any locking device first. Do not pull the leads. Connecting SERVICING CONNECTORS AND COUPLERS · Inspect for bent terminals/pins, damaged cable terminal/pin joints, water, dirt, or corrosion, and secure wiring. If a terminal or pin is bent, carefully straighten it with a thin-blade screwdriver. Before joining or connecting, check for dirt or corrosion Push male and female ends together squarely to avoid incorrectly locating or bending the terminal pins. Whenever a connector or coupler is disconnected or checked, be sure to clean it and apply some dielectric grease before reconnecting. Make sure the two halves connect positively. Many electrical problems could be caused by faulty electrical connectors or couplers. Check for the following conditions before beginning any diagnostics: · · · wet terminals/pins dirty or corroded terminals/pins broken bent couplers cable pins within multi-plug · · · · terminal pins backing out of the connector or coupler · Connector - a single male lead that connects into a single fe ...