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TERMS AND DEFINITIONS OF FUEL INJECTION MANAGEMENT SYSTEMS

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Filed Under (Tips and Review) by admin on 19-11-2010

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Throttle Body Assembly (TBA) — The throttle body assembly (also called air valve), controls the airflow to the engine through one, two or four butterfly valves and provides valve position feedback via the throttle position sensor. Rotating the throttle lever to open or close the passage into the intake manifold controls the airflow to the engine. The accelerator pedal controls the throttle lever position. Other functions of the throttle body are idle bypass air control via the idle air control valve, coolant heat for avoiding icing conditions, vacuum signals for the ancillaries and the sensors. FUEL INJECTOR — There are basically three approaches in delivering the fuel to the engine: • Above the throttle plate as in throttle body injection • In the intake port toward the intake valves as in multi-port injection or central multi-port injection. • Directly into the combustion chamber as in gasoline direct injection systems (GDI). The fuel injector is continuously supplied with pressurized fuel from the electric fuel pump. The pressure across the metering orifice of the injector is maintained constant by the fuel pressure regulator. The fuel injector is an electromagnetic valve that when driven by the ECU delivers a metered quantity of fuel into the intake manifold (or combustion chamber in the GDI system). The ECU controls the fuel flow by pulse width modulation. The time the injector is driven into an open condition is determined by the following sensor inputs: • Engine RPM • Throttle position (TPS) • Manifold absolute pressure or mass air flow • Engine coolant temperature • Oxygen sensor feedback voltage • Intake air charge temperature • Battery voltage CENTRAL POINT INJECTION SYSTEM (CPI) — Electronic fuel Injection system consisting on a single fuel injector mounted in the throttle body. DIGITAL FUEL INJECTION (DEFI OR DFI) — Electronic fuel injection system controlled by digital microprocessors as opposed to earlier systems that were of analog design. The analog input signals to the microprocessor are converted from analog to digital before being processed.

Harley-Davidson Electronic Fuel Injection Tuner INSTALLATION Manual

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Filed Under (Harley Davidson) by admin on 14-04-2012

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Harley-Davidson Electronic Sequential Port Fuel Injection System, (ESPFI) This completely new engine management system was released starting with select 2001 model year Softail motorcycles. This system is a speed/density, open loop, sequential port fuel injection design that also controls spark timing and spark intensity. Speed/Density System – When the ECM monitors manifold air pressure, air temperature, throttle position and engine rpm to manage fuel delivery. Open Loop Control – When the ECM monitors sensors positioned on the intake side of the engine and does not monitor the end result of internal combustion at the exhaust. Sequential Port Fuel Injection – When the injector nozzle is positioned in the manifold near the intake valve and is precisely timed to deliver fuel to each cylinder. This ESPFI system is the exclusive design used on 2001 and Later EFI-equipped Softail models, 2002 and Later EFI-equipped Touring models, 2004 and Later Dyna models, and 2004 and later V-Rod models. Current ESPFI Components The following is a list of the major components of Harley-Davidson’s current ESPFI system. It is important to have an understanding of what these components do before learning how the ESPFI system functions. Refer to the appropriate Harley-Davidson Service Manual for the vehicle you are working on for additional information on component design and function and for the physical location and testing procedures for each individual component. ECM – Electronic Control Module – this is the brain of the system that collects input signals from multiple sensors, makes decisions and sends output signals to deliver fuel and spark to the engine. CKP – Crank Position Sensor – this sensor provides input signals to the ECM that indicate engine rpm, (how fast the engine is running in R evolutions P er M inute). The ECM also uses these inputs to determine what stroke the engine is in so it can deliver the fuel and spark at the desired time.

SUZUKI GSX 1300R OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 01-12-2010

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CLOCK/FUEL INJECTION SYSTEM INDICATOR (D The indicator displays clock under normal condition. The indicator switches from the clock to the fuel injection system indicator if the fuel injection system has any failure. Clock mode The clock indicates 12-hour mode. Follow the procedure below to adjust the clock. 1. Push the button® until the display blinks. 2. Pushing the button will advance one minute at a time. Repeat pushing the button until the display reaches desired time. 3. Keeping the button pushed in will advance ten minutes at a time. Keep the button pushed until the display reaches desired time. Fine- tune the time by pushing the button repeatedly. 4. Wait 5 seconds and push the button to resume to time display. Fuel injection system indicator F I The fuel injection system indicator indicates “Fl” or “CHEC” if the fuel injection system has any trouble. The Fl indicator light (D will also come on if the fuel injection system has failure. No 1 2 3 Fuel injection system indicator Fl Fl/Clock alternately CHEC Fl indicator light Blinks Lights – Engine condition Engine does not start. Engine can start. Engine does not start. 14 If the fuel injection system indicator displays “Fl” and Fl indicator light blinks, the engine will not start due to a serious fuel injection system failure. If the system has serious failure while riding, the engine may stop. When the fuel injection system indicator displays “Fl” and clock alternately and Fl indicator light comes on, the engine can be started and a will keep running with limited engine performance. This shows that the fuel injection system has minor failure. Bring your motorcycle to an anthorized Suzuki dealer or qualified mechanic to inspect the motorcycle. Continuous operation in this condition may seriously damage the motorcycle. 3. When the fuel injection system indicator indicates “CHEC,” the engine will not start. Make sure that the engine stop switch is turned on and the transmission is in neutral position with the side stand fully up. If the indicator still indicates “CHEC,” inspect the ignition fuse next. SPEEDOMETER ® The speedometer indicates the road speed in kilometers per hour and miles per hour. RIGHT TURN SIGNAL INDICATOR LIGHT © When the right turn signals are operated, the indicator light will flash at the same time. NOTE: If the turn signal light is not operating properly due to bulb filament or circuit failure, the indicator light flickers more quickly to notify the rider of the existence of trouble

HARLEY DAVIDSON SCREAMIN' EAGLE ELECTRONIC FUEL INJECTION (EFI) STAGE 1 KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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Installation NOTE The installation procedure is divided into three parts: 1) Replacing ECM (1996 and earlier models ONLY) 2) Calibrating the ECM 3) Replacing stock air cleaner with air cleaner from kit. 1) REPLACING ECM (1996 and earlier models ONLY) 1. Refer to the REMOVAL/REPLACEMENT section 9C in the 1995-1996 FLT Service Manual, Part No. 99483- 96A. 2. Install ECM in accordance with the installation procedure given in the Service Manual. 2) CALIBRATING THE ECM Have dealer recalibrate the ECM prior to starting vehicle. NOTE The product information (EO) label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the information label on the right side of the frame directly beneath the VIN sticker. Do not place the label over other product information labels. Do not place the label on motorcycles other than those specified in the instruction sheet. 3) REPLACING STOCK AIR CLEANER Removing Stock Air Cleaner NOTE Refer to the applicable Service Manual and check the warm- slow idle speed adjustment before removing stock backplate. 1. Remove stock backplate following the instructions given in the appropriate Service Manual. 2. See Service Parts Illustration. Retain stock air cleaner cover and buttonhead screw and washer. Installing High Performance Air Cleaner 1. See Service Parts Illustration. Locate banjo bolts (10) included with kit. Place one washer (11) over each banjo bolt. Insert bolts through holes in mounting bracket (15). Place a second washer over each bolt. Place manifold breather (16) over bolts with hose fitting toward rear of motorcycle. Install remaining washers over the ends of bolts

1990 – 2006 Toyota And Scion Models With Port Electronic Fuel Injection FUEL INJECTOR CLEANING

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Filed Under (Toyota Manuals) by admin on 24-10-2011

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Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): Idle air control device Throttle plate (both sides if possible) Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. D. Start the engine. After the engine has stalled, turn the ignition switch OFF. E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable. NOTE: Do NOT clamp plastic lines. F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose. G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter. H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls. I. Turn the ball valve OFF and remove the empty can. J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system. K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector. L. Before starting the vehicle, pressurize the fuel system and check for leaks. Run the engine for 4 – 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system.

Harley-Davidson Electronic Ignition Module Installation instructions

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Filed Under (Harley Davidson) by admin on 23-04-2012

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Step 1: Switch main dashboard switch to “off” position (Ignition& light switch) Step 2: Disconnect negative (ground) cable from the Battery Step 3: Remove the Condenser and Breaker points from the circuit breaker timing base. Step 4: Disconnect advance/ retard cable from timing base Step 5: Remove timing base from timer shaft and housing (see your manual for instructions) Step 6: Remove circuit breaker wire stud or circuit breaker to coil wire assembly from timing base Step 7: Remove circuit breaker wire from Ignition coil, and mark terminal on coil with piece of tape. Step 8: Install the Electronic Ignition Module on the timing base. Mount this short black wire to one on the timer base screws by keeping some slack in this wire so the timing base can turn free. Solder the flag terminal to this short black wire and mount it under the timer to motor bolt. This way of mounting provides a much better grounding. Do NOT use the screws (number 1 or 2 screws from picture below) from the timing base!!!! Step 9: Now three wires pass this hole via the rubber grommet. Figure 1 Figure 2 Step 10: Reinstall the timer base on the timer shaft housing, and keep some slack in the wires before protruding the hole in the timer shaft housing, and secure with ground spring and cover retainer. Reconnect the advance/retard cable to the timer base. Step 11: Route the two long wires to the ignition coil. Check in the HD service manual for a proper route to the ignition coil. (Keep away from hot surfaces like exhaust systems). Cut the wires to the exact length necessary for mounting. Step 12: Determine the exact length of the wire loom. Keep in mind that one end of the loom enters the timer shaft housing by 1cm. Cut the loom to the proper length. Step 13: Insert both wires in the loom. Strip both wire ends and solder the two flag terminals on the wires. Step 14: Connect the red wire to the ignition coil, on the terminal where the 6 or 12 volt is supplied to. This terminal has at minimum one wire connected which runs to the main switch. Step 15: Connect the black wire to the ignition coil on the terminal which is empty, and has piece of tape on it. (Old place where the circuit breaker wire was connected to) Step 16: Install the trigger rotor on the timer shaft cam, and tighten the hex screw by using the hex key tool. Do not over tighten the screw! Step 17: Check for clearance between trigger rotor and Electronic Ignition Module. Appropriate clearance is between 0,5mm and 1,5mm . Minor adjustments can be made by unlocking the two screws and slightly shift/move the Electronic Ignition Module. Check if the rotor moves free. Timing instructions: Remove the spark plugs from the engine, but keep them connected to the spark coil cables and engine ground. This enables normal operation of the spark, and prevents unwanted engine firing on compression stroke. See service manual or handbook for timing instructions of your model Step 18: Reconnect the negative (ground) cable to the battery. Step 19: Switch main power to “on” position. The red light in the Electronic Ignition Module might already light up. If not, turn the kick starter slowly. The red light is on while charging (closed points)the Ignition coil, facing solid metal of the trigger rotor. The light goes off (open points) when the end of the solid surface of the trigger rotor passes the centre of the Electronic Ignition Module. At that point a spark is generated by the coil

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Kawasaki KX250F Factory Tuning And Fuel Injection to keep expert riders at the front of the pack

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Filed Under (Kawasaki) by admin on 08-02-2011

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Battery-less fuel injection system Designed specifically for motocrossers, the fuel injection system incorporates a small lightweight ECU and operates without a battery to further eliminate unnecessary weight. And of course, fuel injection eliminates the need to adjust engine settings to suit track and climate conditions. Ensuring quick starting without a battery was a prime directive when developing this fuel injection system. Using only electricity generated by the kick starter, the engine can be started with only three rotations of the crankshaft. The system delivers electricity in the following order:1) ECU, 2) fuel pump, 3) injector. With a warm engine, starting can be accomplished in a single kick. The compact, lightweight ECU, located just in front of the steering head (behind the number plate), was designed specifically for motocross use. To help cope with the shocks and vibrations of motocross riding, the fuel pump relay is built into the ECU. A 43 mm throttle body makes use of a progressive throttle link to deliver airflow in much the same way as would a FCR carburettor. Using two linked shafts, the throttle body opens more quickly after the 3/8 open position, delivering sharp response and excellent power. Lightweight throttle body is approximately half the weight of a FCR carburettor – a weight savings of about 600 g. To ensure the high-rpm engine’s demand for a high flow of fuel in a short period is met, the KX250F’s injector features larger holes than that used on the KX450F. A fine atomising injector with 4 holes disperses spray particles with a droplet size of 120 µm. Fuel flow is about 20% greater than on the KX450F. The newly designed fuel pump, located in the fuel tank, is a lightweight aluminium construction. (Fuel tank capacity is now 7.2 litres.)

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Toyota Electronic Throttle Control Investigation

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Filed Under (Toyota Manuals) by admin on 14-06-2011

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The purpose of this research study was to contribute to a better understanding of electronic throttle control system malfunctions and the fail-safe detection capabilities of selected vehicles equipped with electronic throttle controls. More specifically, this research primarily examined the fail-safe detection capabilities of electrical circuitry
designed to prevent sudden or unintended acceleration of electronic throttle controlled vehicles manufactured by Toyota Motor Co. The Accelerator Pedal Position

HARLEY DAVIDSON V-ROD Fi2000 Fuel Injection Module Installation Manual

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Filed Under (Harley Davidson) by admin on 15-11-2010

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1. Flip up seat, to gain access to radiator reservoir area. 2. Remove Dzus fastener to remove simulated fuel tank cover, over airbox housing. Depending on which model V-Rod is being worked on, the front shrouds covering the upper front frame section may also need to be removed. 3. Place Fi2000 in under-seat area, run fuel injector connector harness up right side frame rail between top right frame rail, and radiator overflow tank, see Figure 1. At the rear of the airbox, route the harness below the airbox, and downward next to the inner radiator hose. Unplug both stock fuel injector connectors, on the front and rear injectors between the engine cylinders, see Figure 2. These are disconnected, by depressing the metal springs that are on the end of each female connector. The stock female connectors are marked “F” and “R”, noting which connector goes to the front and rear injector, be sure to pay attention to this. Now connect the longer male Fi2000 connector to the front female H.D. connector. Plug shorter Fi2000 male connector into the stock rear female H.D. connector. Then plug the longer female Cobra connector onto the front stock H.D. injector. Plug the shorter Fi2000 female connector onto the rear injector. Each injector connector pair should rest underneath each respective injector. 4. It is now time to install the oxygen sensor eliminator modules. This product is designed to eliminate the “check engine” light from coming on when the stock oxygen sensors are disconnected on Harley Davidson Motorcycles utilizing fuel injection. The motorcycle has a full “open loop” fuel injection map written in its ECU and the motorcycle reverts to this default map after the oxygen sensors have been removed or just disconnected. 5. Locate the rear oxygen sensor and follow the harness up to the under-seat area behind the radiator overflow tank. Pull the stock connectors up from below the overflow tank and disconnect, see Figure 1. Plug one of the supplied Oxygen sensor eliminators on to the stock male connector. Tuck the connectors back underneath the bracket behind the radiator overflow tank. 6. Now locate the front oxygen sensor on the front headpipe, and trace the oxygen sensor harness back to the connectors tucked between the left front frame rail and plastic radiator shroud, see Figure 3. Pull these connectors out, and disconnect them. Plug the remaining supplied oxygen sensor eliminator on to the stock male connector. Tuck the connectors back in between the frame rail and plastic shroud

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APRILIA SR 50R / DITECH FACTORY Technical Specifications

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Filed Under (Aprilia) by admin on 06-11-2010

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APRILIA SR 50R / DITECH FACTORY Uncompromising racing design, the most advanced engine technology of any scooter, plus unrivalled performance and handling. That is what the Aprilia SR 50 has always been about. Now the world’s only real racing replica scooter has pushed the frontiers of performance and technology even further forward. The completely new SR 50 is further ahead that ever before. Technical Specifications Engine Liquid cooled horizontal single cylinder two stroke. Electronic direct fuel injection Bore and stroke 40 x 39.3 mm Displacement 49 cc Compression ratio 11.5:1 Intake Reed valve Fuel injection Electronically controlled, air assisted, direct injection into the combustion chamber Fuel injector EFI low flow injector Direct injector External opening, SMD 8 micron medium spray Pressure regulator Pressure differential maintained at 2.5 bar Throttle body 18 mm throttle body with integrated TPS (Throttle Position Sensor) Air compressor Driven off crankshaft, lubricated by air-oil mix in crank chamber Fuel pump 6.5 – 8 bar, high pressure pump with low electrical power absorption, < 0.5 A Electronic control unit Clock Speed 8 Hz, 22 pin Ignition High power inductive ignition Starter Electric Alternator Flywheel-magneto, 165W – 12 V Lubrication Oil injection by electronic oil pump Oil tank capacity 1.2 liters (0.317 gal.) including 0.2 liter (0.053 gal.) reserve Gear box Continuous automatic converter Primary transmission “V” belt Final transmission Adapter with gears in oil bath Clutch Automatic centrifugal dry clutch Frame Split single cradle frame in high tensile strength steel Front suspension Hydraulic fork mounted on offset steering sleeve, 3.5 inches (90 mm) of travel Rear suspension Engine unit acting as swingarm; frame linkages on two radial silent block mountings, 2.8 inches (72 mm) of travel Brakes front: stainless steel 190 mm diameter disk, “racing” calliper with two opposing pistons, diameter 32 mm rear: stainless steel 190 mm diameter disk, “racing” calliper with two opposing pistons, diameter 30 mm Rims light alloy, 5 spokes front and rear: 3.50 x 13″ Tires (tubeless) front and rear: 130/60 x 13” Dimensions max. length: 73.2 inches (1860 mm) max. width: 27.8 inches (705 mm) max. height: 44.1 inches (1120 mm) saddle height: 32.0 inches (820 mm) wheelbase: 50.8 inches (1290 mm) Dry weight 198 lbs. (90 kg) Tank capacity 1.85 gallons (7 liters)

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