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Cannondale 5002401 Service Manual

Manual is about: Electrical EFI

Summary of 5002401

  • Page 1

    Electrical/efi service manual atv and motorcycle p/n : 5002401 august 14, 2002.

  • Page 2

    3 8/14/02 3 introduction about the manual all the procedures in this manual are organized in a numbered (step-by-step) easy to read format with accompa- nying photographs, line art, torque values and specifications. The numbered steps of a few procedures are likely to be separate procedures themselv...

  • Page 3

    © 2002 cannondale corporation - all rights reserved 4 electrical_efi service manual.Fm 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 not...

  • Page 4

    5 8/14/02 5 contents introduction - - - - - - - - - - - - - - - - - - - - - - 3 important notice - - - - - - - - - - - - - - - - - - 3 about the manual - - - - - - - - - - - - - - - - - 3 comments? - - - - - - - - - - - - - - - - - - - - 3 important manual information- - - - - - - - - - - 4 engine m...

  • Page 5

    © 2002 cannondale corporation - all rights reserved 6 electrical_efi service manual.Fm 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 actu- ators. • the engine control unit (...

  • Page 6

    7 8/14/02 7 ecu programming the ecu is “programmed” with three types of infor- mation. 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...

  • Page 7

    © 2002 cannondale corporation - all rights reserved 8 electrical_efi service manual.Fm 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 di...

  • Page 8

    9 8/14/02 9 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 oper- ate freely with your fingers; do not force it. Servicing connectors and couplers many electrical problems could be caused by faulty ...

  • Page 9

    © 2002 cannondale corporation - all rights reserved 10 electrical_efi service manual.Fm barometric pressure sensor the barometric pressure sensor is housed within the ecu. Air pressure within the airbox is transferred to the ecu by a narrow hose. Air pressure infor- mation is used to adjust the amou...

  • Page 10

    11 8/14/02 11 required on a “perfect” throttle body to match the air flow of the vehicle's throttle body at the closed position. Typical values are from 0.0 to 1.0%" starting on page 37. The tps sensor signal informs the ecu of not only the relative position of the throttle plate, but also the speed...

  • Page 11

    © 2002 cannondale corporation - all rights reserved 12 electrical_efi service manual.Fm coolant temperature sensor the coolant temperature sensor is brown in color and located on the front of the engine cylinder head. It is an ntc thermistor. The ecu measures the current flow through this thermistor...

  • Page 12

    13 8/14/02 13 2. Compare the value with a reading taken manually in the vicinity of the air temperature tip. If the two values do not correspond closely, the sensor may be damaged. Static test - resistance 1. Remove the sensor from the airbox by placing an open-end wrench on the sensor body and turn...

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    © 2002 cannondale corporation - all rights reserved 14 electrical_efi service manual.Fm static test - resistance 1. Disconnect the sensor harness connector. 2. Use an ohmmeter to measure the sensor resis- tance between terminals 1 and 2. Service: crankshaft position sensor resistance range - 532 to ...

  • Page 14

    15 8/14/02 15 caution : do not remove the valve from the housing when performing this test. 3. Disconnect the engine coolant sensor. 4. Reconnect the idle air control valve to the har- ness. 5. Press the engine start button quickly without turn- ing over the engine. The valve should extend fully. 6....

  • Page 15

    © 2002 cannondale corporation - all rights reserved 16 electrical_efi service manual.Fm on motorcycles, if this relay is damaged, the engine can start but will shut down when the start button is released. On atvs, if this relay is damaged or removed, the engine will run, but damage to a harness diod...

  • Page 16

    17 8/14/02 17 note : when the ignition switch is turned “on,” the installed relay will make an audible “click.” fuel pump and fuel pressure regulator the fuel pump and regulator maintain fuel supply and pressure to the injectors. When the engine man- agement system is first “powered-up,” this pump a...

  • Page 17

    © 2002 cannondale corporation - all rights reserved 18 electrical_efi service manual.Fm and the wiring is in good condition. Make sure the boots are in place. Check for voltage at the pump when the start button is pressed. Check for any open or short circuit conditions in the fuel pump circuit. Cons...

  • Page 18

    19 8/14/02 19 fuel injectors atvs and motorcycles utilize a pair of fuel injectors that operate (inject) simultaneously. Pressurized fuel flows into the injectors from the fuel pump. The fuel is delivered into the intake port when the ecu sends voltage to the injector internal solenoid. When the sol...

  • Page 19

    © 2002 cannondale corporation - all rights reserved 20 electrical_efi service manual.Fm each injector harness connector. Crank the engine over. If the light flashes evenly on each connector, voltage is available at the injectors. 3. If the light fails to flash for either injector, check the fuel inj...

  • Page 20

    21 8/14/02 21 cannondale diagnostic and maintenance tool version 2.0 this section of the manual describes how to use t he ca nn on da le d ia gn ost ic an d m a in te na nce software tool. General information the cannondale diagnostic and maintenance tool, version 2.0 is a windows-based software app...

  • Page 21

    © 2002 cannondale corporation - all rights reserved 22 electrical_efi service manual.Fm 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. When the dealercal window displays (see next ill...

  • Page 22

    23 8/14/02 23 enter the serial provided by the service rep in the dealercal window. Click next. Verifying com port setup under windows 95/98/2000/nt/me: 1. Click ’start’ button and select ’settings->control panel’. 2. From ’control panel’, double-click ’system’. 3. From ’system panel’, click ’device...

  • Page 23

    © 2002 cannondale corporation - all rights reserved 24 electrical_efi service manual.Fm the vehicle’s lighting or starting electrical systems are isolated from the ems power relay supplying the ecu. Lighting can remain on if the ecu is powered- down. Or, if insufficient battery voltage is present to...

  • Page 24

    25 8/14/02 25 interface cable may be damaged. I/o error message 1. You will see this message if the last engine calibration file opened with the software is no longer available such as: if it was deleted or the cd containing it has been removed from the cd drive. Other messages progress indicator wh...

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    © 2002 cannondale corporation - all rights reserved 26 electrical_efi service manual.Fm retrying checksum data is transferred between the vehicle and pc in small “packets” or chunks. During the transfer process, checks are performed by the diagnostic tool (software) to ensure that the data is not da...

  • Page 26

    27 8/14/02 27 communication cable connecting the communication cable motorcycles and atvs have a “diagnostic” con- nector integrated into the main wiring harness. The communication cable connects the pc to the vehicle using the connector. Caution : connect the communication cable with the vehicle en...

  • Page 27

    © 2002 cannondale corporation - all rights reserved 28 electrical_efi service manual.Fm cannondale diagnostic and maintenance tool main window 1. Numeric cal id 2. Description (saved files only - not stored in ecu) 3. Buttons 4. Throttle position sensor min and max values (from vehicle) 5. Throttle ...

  • Page 28: 30202.Ccf

    29 8/14/02 29 engine calibration file (“map”) identification all cannondale factory authorized engine cali- bration files are identified by a numeric cal id code. The numeric cal id number defines the year, model, and issue sequence of any specific engine calibration file. The engine calibration num...

  • Page 29

    © 2002 cannondale corporation - all rights reserved 30 electrical_efi service manual.Fm atv and motorcycle operating codes are not interchangeable. The software tool can load operating code version updates to the ecu. The software does not read back the installed oper- ating code currently in the ec...

  • Page 30

    31 8/14/02 31 3. In the ecu reprogramming tool window, select the operating code file to send. Have an assistant press and continue to hold the start button. Click download. The progress indicator will display while the trans- fer take place. When the transfer is complete release the start button. C...

  • Page 31

    © 2002 cannondale corporation - all rights reserved 32 electrical_efi service manual.Fm opening a saved calibration file note : a saved calibration file might be one that you have received via e-mail, downloaded from the our website, or one that is stored on a diskette or cd. This button functions t...

  • Page 32

    33 8/14/02 33 receiving a calibration file from the ecu “reading a map and variables” by receiving the engine calibration file or the vehicle variables from the ecu, the technical can determine which specific engine calibration file is in use by the vehicle and what the vehicle specific variable are...

  • Page 33

    © 2002 cannondale corporation - all rights reserved 34 electrical_efi service manual.Fm sending a calibration file or “map” to the ecu - “changing a map” note : “sending” a calibration file transfers the engine calibration file and vehicle variables currently open in the cannondale diagnostic and ma...

  • Page 34

    35 8/14/02 35 t h e t h r o t t l e p o s i t i o n s e n s o r m i n i m u m a n d maximum values must be set using the cdmt anytime the throttle body is serviced (removed, replaced, installed). It also must be set if the ecu operating code is updated. Set the throttle position with the engine off....

  • Page 35

    © 2002 cannondale corporation - all rights reserved 36 electrical_efi service manual.Fm to the next step to learn more. 7. If you click the accept values button, the values of the engine calibration file currently stored in the cdmt will change to the new ones and immedi- ately the send calibrations...

  • Page 36

    37 8/14/02 37 the progress indicator. When the send is com- plete, the send complete prompt will display, click ok. Click cancel and the “from file” values will not be sent. They will remain in the currently open engine calibration file. 10. Power-up the vehicle ecu and click on the monitor ecu para...

  • Page 37

    © 2002 cannondale corporation - all rights reserved 38 electrical_efi service manual.Fm at the closed position. Typical values are from 0.0 to 1.0% • “injector flow rate” (input range 1500 - 3000) typical values are from 2300-2800 the fuel injectors’ flow rate, used by the ecu to convert fuel mass i...

  • Page 38

    39 8/14/02 39 ecu monitor monitor selected ecu parameters with the vehicle engine running or with the vehicle engine off and the ecu powered-up. It can be operated in “continuous” (live) or “hold” (snap shot) mode. You can start and run the vehicle engine with the ecu monitor active. While the monit...

  • Page 39

    © 2002 cannondale corporation - all rights reserved 40 electrical_efi service manual.Fm reading fault codes to read fault codes when a fault is reported, consult the fault diagnostic tables in this manual. Refer to "fault troubleshooting" starting on page 42. Caution : obtain the vehicle’s wiring di...

  • Page 40

    41 8/14/02 41 ton was pressed. The fault report window does not constantly update fault conditions. The fault report window sample above was taken while the cannondale diagnostic tool was connected to an 2002 x440s motorcycle. This vehicle does not have a cooling fan. The “cooling fan open fault” wi...

  • Page 41

    © 2002 cannondale corporation - all rights reserved 42 electrical_efi service manual.Fm fault troubleshooting consult the following troubleshooting tables when diagnosing a fault reported by the cannondale diag- nostic and maintenance tool fault report window function. Refer to "reading fault codes"...

  • Page 42

    43 8/14/02 43 system voltage fault reported possible cause action battery voltage low fault wiring/ stator/ regulator/ battery c h e c k b a t t e r y v o l t a g e a t b a t t e r y ; minimum voltage 12.8v. Disconnect ecu and go to test 1. Battery voltage high fault regulator ensure regulator outpu...

  • Page 43

    © 2002 cannondale corporation - all rights reserved 44 electrical_efi service manual.Fm fuel pump reported fault possible cause action fuel pump short d a m a g e d f u e l p u m p (internal short circuit), harness short circuit, damaged ecu component test fuel pump. Refer to "fuel pump" starting on...

  • Page 44

    45 8/14/02 45 ignition coil fault possible cause action coil short fault damaged ignition coil or ecu, harness short circuit, coil connector disconnected or damaged component test ignition coil. Refer to "ignition coil" starting on page 45. Check ignition coil harness connector is secure. Disconnect...

  • Page 45

    © 2002 cannondale corporation - all rights reserved 46 electrical_efi service manual.Fm cooling fan (atv only) fault possible cause action cooling fan short fault, cooling fan open fault damaged cooling fan or ecu, harness short circuit, fan connector disconnected or damaged component test the cooli...

  • Page 46

    47 8/14/02 47 fuel injectors fault possible cause action injector a short fault (left) injector b short fault (right) damaged injector or ecu, harness short circuit - flooding indicates short circuit component test the injector. Refer to "fuel injectors" starting on page 19. Check that injector harn...

  • Page 47

    © 2002 cannondale corporation - all rights reserved 48 electrical_efi service manual.Fm 3. Check wire for short circuit - p1 h2 to ground - p1 h3 to ground ok go to test 7. Short circuit locate and correct wire fault and go to test 7. 4. Check wire continuity: motorcycle disconnect diagnostic connec...

  • Page 48

    49 8/14/02 49 5. Check short circuit: motorcycle disconnect diagnostic connector cn10, lighting connector cn26, r e m o v e e m s p o w e r r e l a y. Measure between relay socket terminal 30 and: - p1 h3 - p1 h2 atv disconnect the ignition coil, diagnostic co nnector cn10, switch engine stop button...

  • Page 49

    © 2002 cannondale corporation - all rights reserved 50 electrical_efi service manual.Fm throttle position sensor (tps) fault possible cause action throttle position sensor high fault throttle position sensor low fault d a m a g e d t p s s e n s o r, ecu, harness short or open circuit, tps sensor co...

  • Page 50

    51 8/14/02 51 air temperature sensor fault possible cause action air temp sensor high fault air temp sensor low fault damaged air temperature sensor, ecu, harness short or o p e n c i r c u i t , s e n s o r c o n - n e c t o r d i s c o n n e c t e d o r damaged component test the air temperature s...

  • Page 51

    © 2002 cannondale corporation - all rights reserved 52 electrical_efi service manual.Fm circuit diagram air temperature sensor resistance range resistance (ohms) temp. (deg. C) temp. (deg. F) resistance (ohms) temp. (deg. C) temp. (deg. F) resistance (ohms) temp. (deg. C) temp. (deg. F) 15071 -20 -4...

  • Page 52

    53 8/14/02 53 coolant sensor fault reported possible cause action engine temp sensor high fault engine temp sensor hi fault damaged coolant temper- ature sensor, ecu, harness short or open circuit, sensor connector disconnected or damaged component test the coolant temperature sensor. Refer to "cool...

  • Page 53

    © 2002 cannondale corporation - all rights reserved 54 electrical_efi service manual.Fm coolant sensor resistance range resistance (ohms) temp. (deg. C) temp. (deg. F) resistance (ohms) temp. (deg. C) temp. (deg. F) resistance (ohms) temp. (deg. C) temp. (deg. F) 45313 -40 -40 2500 20 68 322 80 176 ...

  • Page 54

    55 8/14/02 55 idle air control valve (iacv) fault reported possible cause action stepper motor fault damaged idle air control valve, ecu, harness short or open circuit, iacv connector disconnected or damaged component test the iacv. Refer to "idle air co nt ro l valve (iacv)" starting on page 55. Ch...

  • Page 55

    © 2002 cannondale corporation - all rights reserved 56 electrical_efi service manual.Fm crankshaft position sensor fault reported possible cause action crank tooth sync fault damaged or contaminated crankshaft position sensor, damaged ecu, harness short or op en circu it, iac v con - n e c t o r d i...

  • Page 56

    57 8/14/02 57 component testing (non-efi) battery 1. Filling electrolyte properly, charging (times and rates). 2. Load testing using a commercially available load tester. 3. Installation washers? Loctite torque rectifier /regulator note : if vehicle is equipped with single phase rectifier/ regulator...

  • Page 57

    © 2002 cannondale corporation - all rights reserved 58 electrical_efi service manual.Fm if an ol (no continuity) is obtained on any one of the three tests, replace the rectifier/regulator. Stator note : if vehicle is equipped with a single phase stator, complete the steps described, but omit the ref...

  • Page 58

    59 8/14/02 59 engine stop switch (atv) 1. Disconnect the engine stop switch from the main harness. 2. Slide the switch to the run position. There should be continuity between the two switch leads. 3. Slide the switch to the off position. There should be no continuity. Clutch lever switch (atv) 1. Di...

  • Page 59

    © 2002 cannondale corporation - all rights reserved 60 electrical_efi service manual.Fm operation test 1. Disconnect the solenoid from the main wiring harness. 2. Connect the positive lead of a 12v battery power source to the solenoid coil positive lead or termi- nal (pin a) and the negative lead of...

  • Page 60

    1 printed : 8/14/02 1 5002066 introduction - - - - - - - - - - - - - - - - - - - - - - 3 important notice - - - - - - - - - - - - - - - - - - 3 about the manual - - - - - - - - - - - - - - - - - 3 comments? - - - - - - - - - - - - - - - - - - - - 3 important manual information- - - - - - - - - - - 4...