Fuel System DFI

Table of

Exploded View 3-3

DFI Parts Location 3-8

DFI Wiring Diagram 3-10

Specifications 3-12

Special Tools 3-14

DFI Servicing Precautions 3-15

Troubleshooting the DFI System 3-17

Outline 3-17

Inquiries to Rider 3-21

DFI System Troubleshooting Guide .. 3-24

Self-Diagnosis 3-33

Self-diagnosis Outline 3-33

Self-diagnosis Procedures 3-33

Service Code Clearing Procedures 3-34

How to Read Service Codes 3-36

How to Erase Service Codes 3-36

Service Code Table 3-37

Backups 3-38

Main Throttle Sensor (Service Code

Main Throttle Sensor

Removal/Adjustment 3-40

Input Voltage Inspection 3-40

Output Voltage Inspection 3-41

Resistance Inspection 3-42

Inlet Air Pressure Sensor (Service

Removal 3-43

Installation 3-43

Input Voltage Inspection 3-43

Output Voltage Inspection 3-44

Inlet Air Temperature Sensor (Service

Removal/Installation 3-48

Output Voltage Inspection 3-48

Sensor Resistance Inspection 3-49

Water Temperature Sensor (Service

Removal/Installation 3-50

Output Voltage Inspection 3-50

Sensor Resistance Inspection 3-51

Atmospheric Pressure Sensor

(Service Code 15) 3-52

Removal 3-52

Input Voltage Inspection 3-52

Output Voltage Inspection 3-53

Crankshaft Sensor (Service Code

Crankshaft Sensor

Removal/Installation 3-55

Crankshaft Sensor Inspection 3-55

Camshaft Position Sensor (Service

Camshaft Position Sensor

Removal/Installation 3-56

Camshaft Position Sensor

Inspection 3-56

Speed Sensor (Service Code 24, 25) 3-57 Speed Sensor

Removal/Installation 3-57

Speed Sensor Inspection 3-57

Input Voltage Inspection 3-57

Output Voltage Inspection 3-57

Vehicle-down Sensor (Service Code

Removal 3-59

Installation 3-59

Inspection 3-59

Subthrottle Sensor (Service Code

Subthrottle Sensor

Removal/Adjustment 3-62

Input Voltage Inspection 3-62

Output Voltage Inspection 3-63

Resistance Inspection 3-64

Removal/Installation 3-65

Input Voltage Inspection 3-65

Subthrottle Valve Actuator (Service

Subthrottle Valve Actuator

Removal 3-67

Audible Inspection 3-67

Visual Inspection 3-67

Resistance Inspection 3-67

Input Voltage Inspection 3-68

FI Indicator LED Light 3-69

LED Light Inspection 3-70

ECU 3-71

ECU Identification 3-71

ECU Removal 3-71

ECU Installation 3-71

ECU Power Supply Inspection 3-72

DFI Power Source 3-74

ECU Fuse Removal 3-74

ECU Fuse Installation 3-74

ECU Fuse Inspection 3-74

ECU Main Relay Removal 3-74

ECU Main Relay Inspection 3-74

Fuel Line 3-75

Fuel Pressure Inspection 3-75

Fuel Flow Rate Inspection 3-76

Fuel Pump 3-78

Fuel Pump Removal 3-78

Fuel Pump Installation 3-78

Operation Inspection 3-79

Operating Voltage Inspection 3-79

Pressure Regulator Removal 3-80

Pump Screen, Fuel Filter

Cleaning 3-80

Fuel Pump Relay Removal 3-81

Fuel Pump Relay Inspection 3-81

Fuel Injectors 3-82

Removal/Installation 3-82

Audible Inspection 3-82

Power Source Voltage Inspection 3-82

Output Voltage Inspection 3-83

Injector Signal Test 3-84

Injector Resistance Inspection 3-85

Injector Unit Test 3-85

Injector Fuel Line Inspection 3-85

Throttle Grip and Cables 3-88

Throttle Grip Play

Inspection/Adjustment 3-88

Choke Lever Operation 3-88

Choke Lever Play Inspection 3-88

Choke Lever Play Adjustment 3-88

Cable Removal/Installation 3-88

Cable Lubrication and Inspection. 3-88

Throttle Body Assy 3-89

Idle Speed Inspection/Adjustment 3-89

Throttle Bore Cleaning 3-89

Engine Vacuum Synchronization

Inspection/Adjustment 3-89

High Altitude Performance

Adjustment 3-89

Throttle Body Assy Removal 3-89

Throttle Body Assy Installation 3-91

Throttle Body Assy Disassembly . 3-92

Throttle Body Assy Assembly 3-93

Air Cleaner 3-94

Element Removal/Installation 3-94

Air Cleaner Oil Draining 3-94

Air Cleaner Housing Removal 3-94

Fuel Tank 3-95

Fuel Tank Removal 3-95

Fuel Tank Installation 3-97

Fuel Tank and Cap Inspection 3-98

Fuel Tank Cleaning 3-98

Evaporative Emission Control

System 3-99

Parts Removal/Installation 3-99

Canister Installation 3-99

Hose Inspection 3-99

Separator Inspection 3-99

Separator Operation Test 3-100

Clifornia Evaporative Emission Control System

Clifornia Evaporative Emission Control System

How Disassemble The Body Cbr 1000

1. Canister

2. Separator

3. Right fitting of throttle body #2

4. Right fitting of throttle body #3

5. Canister purge hose (green)

6. Fuel return hose (left, red)

7. Fuel tank breather hose (right, blue)

8. Separator breather hose (blue)

9. Separator vacuum hose (white)

Exploded View

Exploded View Yamaha 350

No.

Fastener

Torque

Remarks

Nm

kgfm

ftlb

1

Throttle cable plate bolt

6

0.6

52 inlb

2

Throttle body cover bolts

7

0.7

61 inlb

3

Throttle assy holder clamp bolts

2

0.2

17 in lb

4

Choke link holder screws

2.1

0.21

18 in lb

5

Delivery pipe screws

3.4

0.35

30 in lb

6

Bypass screws

0.2

0.02

1.7 in lb

7

Fuel pump bolts

9.8

1.0

87 in lb

S, L

8

Fuel level sensor bolts

6.9

0.7

62 in lb

9. FI indicator LED light

10. Meter unit

11. Throttle cable (accelerator)

12. Throttle cable (decelerator)

13. Choke cable

14. Injector connectors

15. Main throttle sensor connector (grey)

16. Subthrottle sensor connector (black)

17. Subthrottle valve actuator connector

18. Throttle body assy connector

19. Main throttle sensor

20. Subthrottle sensor

21. Injectors

22. Center adjusting screw CL: Apply cable lubricant.

EO: Apply engine oil to the seals and O-rings. G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts.

S: Follow the specified tightening sequence.

Exploded View

Yamaha Warrior Expanded View

No.

Fastener

Torque

Remarks

Nm

kgfm

ftlb

1

Inlet air pressure sensor bolt

12

1.2

104 inlb

2

Water temperature sensor

25

2.5

18

3

Vehicle downsensor bolts

2

0.2

17 in lb

4

Camshaft position sensor bolt

12

1.2

104 in lb

5

Camshaft position sensor rotor bolt

12

1.2

104 in lb

L

6

Air cleaner duct holder screws

3.8

0.39

34 in lb

7

Air cleaner housing mounting bolts

9.8

1.0

87 in lb

8

Air cleaner duct clamp bolts

2

0.2

17 in lb

9

Air cleaner housing screws

1.2

0.12

10 in lb

10

Air cleaner housing tapping screws

1.2

0.12

10 in lb

11

Speed sensor bolt

6.9

0.7

62 in lb

L

12. Inlet air pressure sensor

13. Stick coils (see Electrical System chapter)

14. ECU

15. Fuel pump relay

16. ECU main relay

17. Atmospheric pressure sensor

18. Crankshaft sensor (see Electrical System chapter)

19. Inlet air temperature sensor

20. Vacuum switch valve (see Engine Top End chapter)

21. Air suction valves

22. Grommet

L: Apply a non-permanent locking agent.

DFI Parts Location

Air Suction Valve

DFI

: DFI Parts (this chapter)

8.

ECU Fuse 15A

19.

Turn Signal Relay

F:

Front

9.

ECU (DFI)

20.

Subthrottle Sensor (DFI)

1.

Water temperature

10.

Stick Coils

21.

Main Throttle Sensor (DFI)

Sensor (DFI)

11.

Throttle Body Assy

22.

Ignition Switch

2.

Inlet Air Pressure

12.

Self-diagnosis Terminal

23.

FI Indicator LED Light (DFI)

Sensor (DFI)

13.

Neutral Switch

24.

Crankshaft Sensor

3.

Injectors (DFI)

14.

Vehicle Down Sensor (DFI)

25

Camshaft Position Sensor

4.

Fuel Pump (DFI)

15.

Atmospheric Pressure

26

Fuel Pump Screen

5.

Inlet Air Temperature

Sensor (DFI)

27

Return Fuel Check Valve

Sensor (DFI)

16.

Delivery Pipe

28

Pressure Regulator

6.

Sealed Battery

17.

ECU Main Relay

29

Fuel Filter

7.

Junction Box

18.

Fuel Pump Relay (DFI)

Dfi Kawasaki System
[1], [2], [10], [13], [22] and [24] are not included.

DFI Wiring Diagram

Harley Davidson Softail Wire Diagram

Terminal Names

1. Power Supply to Sensors (inlet air pressure, atmospheric pressure, and throttle sensors) from ECU.

2. Main Throttle Sensor Signal

3. Subthrottle Sensor Signal for ECU

4. Atmospheric Pressure Sensor Signal

5. Water Temperature Sensor Signal (+) 6.7.8.9. Camshaft Position Sensor Signal (+)

11. Crankshaft Sensor Signal (+)

13. Power Supply to ECU, Injectors, and Fuel Pump

14. Sensor Ground (inlet air temperature, water temperature, inlet air pressure, atmospheric pressure, vehicle-down, and throttle sensors)

16. Vehicle-down Sensor Signal

17. Inlet Air Pressure Sensor Signal

18. Inlet Air Temperature Sensor Signal (+)

20. Speed Sensor Signal

22. Camshaft Position Sensor Signal (-)

24. Crankshaft Sensor (-)

Part Name

A. ECU (Electronic Control Unit)

B. Crankshaft Sensor

C. Inlet Air Pressure Sensor

D. Water Temperature Sensor

E. Atmospheric Pressure Sensor

F. Inlet Air Temperature Sensor

G. Camshaft Position Sensor

H. Speed Sensor

I. Main Throttle Sensor J. Subthrottle Sensor K. Injectors #1, #2, #3, #4 L. Subthrottle Valve Actuator M. Stick Coils #1, #2, #3, #4 N. Engine Stop Switch O. Joint Connector D P. see Electrical System chapter Q. Ground Terminal R. Ground Terminal S. ECU Main Relay

26. ECU Power Source Circuit Ground to Battery (-) Terminal

27. Engine Stop Switch Signal

28. Starter Lockout Switch Signal

29. Electric Starter Button Signal

30. Signal For Fuel Pump Relay

31. Subthrottle Valve Actuator Drive Signal

32. Subthrottle Valve Actuator Drive Signal

34. Tachometer Signal

35. Injector #2 Signal

36. Injector #1 Signal

37. Stick Coil #3 Signal

38. Stick Coil #2 Signal

39. Stick Coil #1 Signal

40. Interlock Circuit Signal

41. Self-diagnosis Signal (generated by grounding this terminal and shown by FI indicator LED light)

43. Battery Power ON-OFF Signal

44. Subthrottle Valve Actuator Drive Signal

45. Subthrottle Valve Actuator Drive Signal

47. FI Indicator LED Light Signal

48. Injector #4 Signal

49. Injector #3 Signal

50. DFI System Ground

51. Ignition System Ground

52. Stick Coil #4 Signal

T. Ignition Switch U. FI Indicator LED Light V. Tachometer W. Speedometer X. Ignition Fuse 10A Y. Junction Box

Z. Fuel Pump Relay (for fuel pump and injectors)

a. ECU Fuse 15A

b. Vehicle-down Sensor d. Starter Relay e. Joint Connector D

f. Sealed Battery g. Fuel Pump h. Self-diagnosis Terminal j. Joint Connector B

k. Main Fuse 30A m. Throttle Body Assy Connector n: Connector Locks p: ECU Connector

Item

Standard

Digital Fuel Injection System

Idle Speed

1 100 ± 50 r/min (rpm)

Throttle Assy:

Type

Four barrel type

Bore

</>38 mm (1.5 in.)

ECU (Electronic Control Unit):

Make

Denso

Type

Digital memory type, with built in IC igniter, sealed with resin

Usable engine speed

100 ~ 11 160 r/min (rpm)

Fuel Pressure (high pressure line):

Right after Ignition switch ON

310 kPa (3.2 kgf/cm2, 46 psi) with fuel pump running

After 3 sec from Ignition switch

290 kPa (2.9 kgf/cm2, 43 psi) with fuel pump stopped

With engine idling

310 kPa (3.2 kgf/cm2, 46 psi) with fuel pump running

Fuel Pump:

Type

In-tank friction pump

Discharge

67 mL (2.3 US oz) or more for 3 seconds

Fuel Injectors:

Type

INP-250

Nozzle type

One spray type with 4 holes

Resistance

about 11.7 ~ 12.3 Q at 20°C (68°F)

Main Throttle Sensor:

Non-adjustable and non-removable

Input voltage

4.75 ~ 5.25 V DC between BL and BR/BK leads

Output voltage at idle throttle

0.99 ~ 1.03 V DC between Y/Wand BR/BK leads

opening

Output voltage at full throttle

4.19 ~ 4.39 V DC between Y/Wand BR/BK leads

opening

Resistance

4 ~ 6 kQ

Inlet Air Pressure Sensor or

Atmospheric Pressure Sensor:

Input voltage

4.75 ~ 5.25 V DC between BL and BR/BK leads

Output voltage

3.74 ~ 4.26 V DC at standard atmospheric pressure (see

this text for details)

Inlet Air Temperature Sensor:

Resistance

1.6 ~ 3.7 kQ at 20°C (68°F)

0.24 ~ 0.43 kQ at 80°C (176°F)

Output voltage at ECU

about 2.25 ~ 2.50 V @20°C (68°F)

Water Temperature Sensor:

Resistance

see Electrical System chapter

Output voltage at ECU

about 2.80 ~ 2.97 V @20°C (68°F)

Speed Sensor:

Input voltage at sensor

about 9 ~ 11 V DC at Ignition Switch ON

Output voltage at sensor

about 0.05 ~ 0.07 V DC at Ignition Switch ON and 0 km/h

Vehicle-down Sensor:

Detection method

Magnetic flux detection method

Detection angle

More than 60 ~ 70° for each bank

Item

Standard

Detection time

Within 0.5 ~ 1.0 sec.

Output voltage

with the sensor tilted 60 ~ 70° or more: 3.7 ~ 4.4 V with sensor arrow mark pointed up: 0.4 ~ 1.4 V

Subthrottle Sensor:

Non-adjustable and non-removal

Input Voltage

4.75 ~ 5.25 V DC between BR and BR/BK leads

Output voltage at idle throttle

0.48 ~ 0.52 V DC between BR and BR/BK leads

opening

Output voltage at full throttle

3.6 ~ 3.8 V DC between BR and BR/BK leads

opening

Resistance

4 ~ 6 kQ

Subthrottle Valve Actuator:

Resistance

about 5 ~ 7 kQ

Input voltage

about 8.5 ~ 10.5 V DC

Throttle Grip and Cables

Throttle grip free play

2 ~ 3 mm (0.08 ~ 0.12 in.)

Choke Cable

Choke cable free play

0 ~ 0.5 mm (0 ~ 0.02 in.)

0 0

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