Manual of EFI system

Zhejiang Langjie Electronic Co., Ltd.

www.chinaefi.com
 Manual of EFI system
I. Composition and working principle
Fuel pump Ignition Ignition
module wire
Pipe
Spark
plug

Injector Fault warning lamp

P1 P2
Crankshaft
position sensor
Commun
ication
O2 sensor port Fuse
Throttle
ECU(with TPS,THA)
Body
Ignition
switch

Cooler temperature sensor Battery

Fig. 1 Schematic diagram of EFI system
The functions of EFI are fuel injection management and ignition management, which is by the
following parts:
1、ECU(Electronic control unit), attached to the throttle body, there are throttle position sensor (TPS)
and intake air temperature sensor (THA) in it. It is the "brain" of the system, which undertaking the
task of receiving signals from sensors, making control strategies, and outputting the control signals.
2、Fuel supply device, composed of fuel pump, pipe and injector. The fuel pump is installed in the
tank, it pressurizes the fuel to 2.5 bar. The injector is installed in the engine intake pipe, it perform s
fuel injection timing and amount. The pump and injector are both controlled by ECU.
3、Ignition device, composed of ignition module, ignition wire and spark plug. The ignition module
contains DC capacitor igniter and ignition coil, it boosts the 12V battery voltage to more than 15,000
V, and transfers it to the spark plug to produce spark discharge through the ignition wire.
4、Sensors，including:
(1) O2 sensor, mounted on the exhaust pipe, its function is detecting the oxygen concentration in the
exhaust gas and achieves closed-loop regulation of the fuel mixture concentration. It outputs
alternating signal from 0 V to 0.9V when in closed- loop regulation state.
(2) Cylinder temperature sensor, installed on the engine cylinder head, is used to measure the engine
temperature, which is used to calculation start fuel injection amount.
(3) Crankshaft position sensor, integrated in the magnetic motor, is used to measure crank angle signal,
which is the time base for injection and ignition control.
 Manual of EFI system
(3)Intake air temperature sensor, built in the ECU, is used to measure intake air temperature, which is
used to calculate the intake air density.
(4) Throttle position sensor, built in the ECU, is used to measure the throttle valve rotation angle.
5、Others, including:
（1） Throttle body, which controls the intake air amount through the throttle line.
（2） Fault warning light, installed on the dashboard, is used for fault alarm.
（3） Battery, ignition switch and fuse, they undertake the task of power supply to the EFI system.

II. Common troubleshooting methods

1、Startup failed Communication ECU indicator
1) If the fault warning lamp is always on, you can pull the throttle port lamp
twice in one second, and make the system into flashing code mode.
Determine the faults according to Annex 1 " Flash code description
of fault warning light ".
2) You can also determine the faults according to Annex 2 "ECU
indicator light" after turning on the ignition switch, and starting the
engine.
3) If the problem remains, pull out the ignition wire which
connected to the spark plug, keep the end of it about 1 cm to the
engine body or motorcycle frame, then start the motor, if no spark,
or weak spark occurs, please exclude and deal with the following
failures by step till the spark is normal when start the motor: Ignition
module connector failure, ignition module failure, the gap between Idle adjustment screw
the crankshaft position sensor and the magnet motor boss is too Fig. 2 ECU panel
large (normal gap is between 0.3 ~ 0.8mm)
4) If the spark is normal, but startup is still failure, you can remove the injector from the intake pipe
(note: do not remove the pipe and electrical plug connected to it), start the motor, observe if there is
fuel spray from it, and the atomization quality. If there is problem, you can exclude injector failure and
then pump failure by replacement method, you can also measuring pipe pressure by a pressure gauge,
the normal pressure is more than 2.4 bar.

2、 Misfire
1) Exclude the following factors firstly: Whether the spark plug or spark plug cap was replaced by
non-resistive type？ Whether the rectifier was replaced by semi-wave type? Whether the connection
location of the signal ground was changed? If the above factors exist, correct them firstly.
2) If the problem still exists, you can then exclude the possibility that idling intake air is too large.
Do idle intake air adjustment according to Annex 3.
3) If the problem still exists, try replacing the spark plug.
4) If the problem still exists, check the fuel pressure by a pressure gauge(normal pressure is more
than 2.4 bar). You can also try replacing the pump.
5) If the problem still exists, try changing the ignition module.
6) If the problem still exists, try changing the injector.

3、 The power output is not continuous, or exhaust pipe blasting

 Manual of EFI system
1) Referring to Annex 2, if the NO.4 ECU lamp is always off even if the engine has warmed up, it
indicates that open circle or sensor failure occurred in O2 sensor. Re-insert the O2 sensor's
connector, if the problem isn’t solved, replace the sensor. Temporary approach: Separate the
connector of the O2 sensor, do a fast self-learning according to Annex 4.
2) If the problem still exists，check the supply pressure of the fuel pump by pressure gauge or try
replacing it.
3) If the problem still exists，try replacing the injector.

4、 Idle speed is too high

1) According to Annex 2, judge if there is throttle opening calibration error by No. 4 ECU lamp. If
the error exits, re-calibration the throttle opening according to Annex 3.
2) If the problem still exists，try reducing the idle intake air according to Annex 4.

III. Precautions in maintain

1) Don’t add excessive lubricating oil in engine, or blue smoke will appear, and damage the O2
sensor.
2) Every 5,000 km running, you should take out of the fuel pump from the tank and replace the fuel
filter on it, otherwise injector plug or the pump stuck might occur.
3) Don’t arbitrarily change the connection location of the signal ground, or the EFI system will
works abnormally.
4) All the electrical plug should be combined firmly, or they will separated in using.
5) Wire harness and pipes should be bundled by standard, or it will break in use, and resulting in
short circuit or oil spills.
6) When the spark plug cap or spark plug is replaced, the replacement must be resistance type, the
resistance value is between 4KΩ ~ 8KΩ.
7) When the rectifier is replaced, the replacement must be qualified full-wave rectifier, otherwise it
will make the EFI system working unsteadily. Simple judgment method: when the engine is
running, move away the fuse above the battery, if the engine can still working normally , it is
qualified.
8) When the motorcycle is out of the run-in period , it is recommended to reduce the idle intake air
(under the premise without affecting the cold start performance), according to Annex 4.
 Manual of EFI system
Annex 1 Description of the flashing code
If the fault warning lamp light, you can pull the throttle twice in one second to make the system into
flashing code mode. The code is described in the following table
flashing Fault source Fault information Troubleshooting
code
2 Idle valve(Note: Open or short circuit Check the connector, Measure the
Applies only to resistance between the idle valve
types with idle electrodes, If a short circuit or an open
valves installed) circuit fault occurs, replace the valve.
3 Electromagnetic The ECU is reset by Check in this turn: Is the spark plug and
interference interference spark plug cap with resistance? Was the
connection location of signal ground
changed? Is the rectifier failed and the
charge voltage is more than 15.6V?
4 Open circuit error, or the Is the connector reliable? Is the
Crankshaft signal is disturbed distance between the wiring harness and
position sensor the ignition wire is more than 2 cm? Is
the spark plug and spark plug cap with
resistance?
5 Battery voltage Voltage is more than 15.6V Replace the rectifier (Note: It must be
full wave type)
6 O2 Sensor Oxygen heating circuit is Check the O2 sensor connector. If the
open or short; Oxygen problem cannot be resolved, try
signal is abnormal replacing the oxygen sensor
7 Cooler The signal is over Check the connector, or replace the
temperature reasonable range sensor
sensor
8 Injector Open or short circuit Check the connector, try replacing the
injector
9 Pump Open or short circuit Check the connector, try replacing the
fuel pump
10 Ignition output Open circuit Check the connector, try replacing the
ignition module
11 Throttle Calibration error, or over Re-calibration throttle opening
position sensor reasonable range according to Annex 3. If the problem is
not resolved, try replacing the throttle
body.
12 ECU Software failure Eliminate interference factors as the
flashing code 3 before replace the ECU
13 Intake air The signal is over Replace ECU
temperature reasonable range
 Manual of EFI system
Annex 2 Description of the ECU indicator lamp
ECU indicator lamp, located on the ECU panel, as shown in Figure 2

Nu Name Normal Performance Abnormal Performance Troubleshooting method

mbe and Notice
r
Fuel Pump light 2-3 seconds after Always off, meaning the Check fuel pump connections and
1 Indicator turning on the ignition pump circuit is open wires, If the fault still exists, try
Lamp switch. replacing the pump
Always off, Check injector connection and
Injector flashing when the meaning the injector Wiring harness , If the fault still
2
Indicator engine is starting or circuit is open exists, try replacing the injector
Lamp running
Always off, Check the crankshaft position
meaning no ignition sensor, wiring harness ,
Ignition
signal output. If 2,3 connector, and The gap
3 Indicator
lamp are all off, it means between the sensor and the
Lamp
no crankshaft position magnet motor boss(reasonable
signal input value is 0.3 ~ 0.8mm)
Indicates throttle If the lamp can’t light Re-calibrate the throttle
position when the in the two limit according to the procedure in
engine is stop, the position, throttle Annex 3 "Throttle Calibration"
lamp lights when calibration error
the throttle is in the occurs
maximum or
O2 sensor
minimum position
4 indicator
Indicates the O2 Check the sensor connector,
lamp
sensor voltage Always off, wiring harness , if the fault still
when the engine is indicating no O2 exists, try replacing the O2
running, it lights 1- signal received sensor
3 times per second
after the engine is
warming up.
If it is always on, pull Refer to Annex 1 " Description
The lamp lights for the throttle twice in of the flashing code "
Fault alarm
2-3 seconds after one second, the
lamp( same
the ignition switch system will then enter
as the
is turn on, and then into flashing mode.
5 fault alarm
off. If unstable light and Eliminate the interference
lamp on
dark during engine factors referring to flashing code
the
operation, ECU is 3 in the Annex 1
dashboard)
likely to get
interfered
 Manual of EFI system
Annex 3 Throttle calibration
If the idle speed is too high, throttle opening calibration error should be firstly ruled out by this
method: turn on the ignition switch, keep the engine stop, pull the throttle to the minimum and
maximum opening, if the No. 4 ECU indicator lamp can all lights, it means the throttle opening
calibration is correct, otherwise is wrong, and need to be re-calibration by the following steps:
(1) Pull the throttle to the maximum opening;
(2) Turn on the ignition switch, keep in maximum opening till the fault warning lamp (on dash board
or ECU panel)is off.
(3) Relax throttle to minimum opening , turn off the ignition switch to finish the calibrating process.
(4) Check: Turn on the ignition switch again, check the throttle opening by NO. 4 ECU indicator
lamp, if correct, the process is end.
Note: This is also the process to restore self-learning value to the factory settings. If the acceleration
performance deteriorates after this process, do a fast self-learning according to Annex 5.

Annex 4 Adjustment of idle intake air

If the idle air intake is too low, cold start will be difficult, and easy to flameout at cold engine
condition. If the idle air intake is too large, the engine idling will be high and is easy to flameout at
hot engine condition. After the run-in period, the individual motorcycles will appear the problem that
idling intake air is too large. The adjustment steps are as the following:
(1) Pull the throttle to the maximum opening;
(2) turn on the ignition switch, loose throttle in 1 seconds, then the EFI will work in "fast self-
learning " mode.
(3)Start the engine, pull the throttle to fast warm the engine, stay the throttle in idle position, look the
fault light, under normal circumstances it will go off after self-study process is over in idle position.
If rapid flash occurs, it indicating that the idle intake air is too small, you should adjust the “Idle
adjustment screw "(Figure 2) counterclockwise, if slow flashing occurs, it indicating that the intake
air is too large, you should adjust the “Idle adjustment screw " clockwise.
(4) Simpler method: If the engine idling speed is too high, or easy to misfire when the engine is
warm up, try adjusting the idle adjustment screw 1 to 2 turns clockwise, if the engine is difficult to
start, or is easy to misfire , when the engine is cold, try adjusting the idle adjustment screw 1 to 2
turns counterclockwise. Maintain if improvement, restore if deterioration.

Annex 5 fast self-learning

Referring to annex 4, make the engine into "fast self-learning" mode. You can also do it after
completing the " Adjustment of idle intake air"(don't stop the engine) , the step is as follows:
(1) There are 5 self-learning nodes, the corresponding throttle opening are: 0% (idle opening), 8%,
25%, 50%, 100%;
(2) When the throttle close to the above nodes, the fault alarm lamp will light, stay in the node until
the self-learning process of this node finishes and the lamp is turn to off, pull the throttle to the next
self-learning node;
(3) The optimal self-learning order is: 2 ------3 ------ 4 ------ 1 ----- 5;
 Manual of EFI system
(4) When all the nodes have completed self-learning, the engine will automatically stop running. If
the engine is still running, it means there is still uncomplete node, pull the throttle to find the node
where the lamp lights, stay until the lamp is off.
(5) after the engine stop running automatically, turn off the ignition switch to finish the self-learning
process.

Annex 6 Description of the wiring harness

The diagram of wiring harness A and B is shown in Figure 3. Their corresponding relationship with
the ECU socket is shown in Figure 1.

Pump Wiring harness P2

Ignition module

Injector BU + GN1+GN2
Wiring harness P1 Ground

O2 sensor
Composite connector of
Battery& fault light&
Crankshaft signal
Cooler temperature sensor

Fig. 3 Wiring harness diagram

 Manual of EFI system

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