2005 suzuki hayabusa fuel injection diagram

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2003 SUZUKI SV 650 FUEL SYSTEM AND THROTTLE BODY SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve . The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM . When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler . This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it . Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port . The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped . Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 -600 kPa (4.5- 6.0 kgf/cm2,64- 85 psi) . Relief valve Brush , ∎ I,’ Check valve Magnet L Armature When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction . This process continuously takes place causing fuel pressure to be built up . The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve . FUEL SYSTEM AND THROTTLE BODY 5- 3 Inlet port I I Impeller 5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve . It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm2,43 psi) to be applied to the injector at all times . When the fuel pressure rises more than 300 kPa (3 .0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank . 90 Spring 02 Valve FUEL INJECTOR The fuel injector consists of the solenoid coil, plunger, needle valve and filter . It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion . As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time)

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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

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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.

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HARLEY DAVIDSON FUEL LEVEL SENDER ADAPTER BRACKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Remove the currently installed fuel tank from the vehicle. Follow the instructions for the correct model vehicle under FUEL TANK: EFI, REMOVAL in the Service Manual. 3. See FUEL PUMP/FUEL GAUGE SENDING UNIT, REMOVAL in the Service Manual for instructions to: a. Unplug the fuel pump module connector. b. Remove and discard the top plate screws. c. Remove the top plate, fuel pump and fuel level sender (fuel gauge sending unit) from the tank. NOTE Take care to avoid bending the fuel level sender float rod. A bent float rod will lead to erroneous gauge readings. 2 6 1 3 4 7 9 8 5 is05284 1. Fuel level sender 2. Electrical grounding tab 3. Fuel level sender lock tab 4. Adapter bracket 5. Slot (2) 6. Terminal strip insert 7. Sender to adapter lock tab 8. Slider 9. Adapter to tank lock tab Figure 1. Fuel Level Sender Assembly to Adapter – 4. See Figure 1. Clean the electrical grounding tab (2) on the back of the fuel level sender if necessary. The tab must make firm contact with the terminal strip insert (6) in the adapter bracket. Slide the original equipment (O.E.) fuel level sender (1) into the slots (5) in the new adapter bracket (4) as shown until the lock tabs (3 and 7) snap into place. Make sure the wire is not pinched between the adapter and sender. 5. See FUEL SUPPLY CHECK VALVE/TUBE in the Service Manual. Remove the check valve/quick-connect fitting assembly from the old fuel tank, and assemble to the new tank, using a new O-ring (purchased separately). 6. Fit the slider (8) on the adapter bracket into the fuel level sender mounting channel inside the tank, and push down until the lock tab (9) snaps into place. Make sure the sender and adapter wires are not pinched between the adapter and the fuel tank tunnel, and remain accessible through the fuel tank top opening. 7. See Figure 2. Obtain the assembly of the top plate (1), regulator (2) and fuel filter (3) removed from the old fuel tank, and the stainless steel screw (8) and nut (9) provided in this kit.

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2007 Softail HARLEY DAVIDSON FUEL PUMP/ FUEL GAUGE SENDING UNIT REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-03-2012

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1. Remove seat. 1 WARNING 1 WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 2. Purge the fuel supply line of high pressure gasoline. a. See Figure 4-36. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for 3 seconds to remove any remaining fuel from the fuel lines. 1 WARNING 1 WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-37. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.26 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. Figure 4-36. Fuel Pump Fuse: View From Top Figure 4-37. Acorn Nut And Washer: All But FXSTD s0660x8xx 7526
4-28 2007 Softail: Fuel System HOME 1 WARNING 1 WARNING Gasoline can drain from the crossover line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00259a) 6. Drain fuel tank. a. Obtain a short section of hose (5/16 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-38. Cut clamp (1) from one end of crossover hose (2). Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gasoline from free end of crossover hose into suitable container. 7. See Figure 4-39. Unplug fuel pump module connector (3) [86]. 8. Remove top plate screws (2) and discard. 9. See Figure 4-40. Pull top plate (2) out of fuel tank enough to expose fuel hose and clamp (1). CAUTION Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure. 10. Cut clamp and remove hose from regulator housing fit- ting.

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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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2001 – '2005 Highlander (V6) FUEL INJECTOR TICKING NOISE

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Filed Under (Toyota Manuals) by admin on 08-10-2011

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Do NOT smoke or work near an open flame when working on the fuel system. Keep gasoline away from rubber or leather parts. Wear safety goggles while working with the fuel system under pressure. Do NOT disconnect any part of the fuel system until you have discharged the fuel system pressure. Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment. 1. Discharge fuel system pressure. A. Remove Circuit Opening Relay from Relay Block No. 1 located to the left of the Instrument Panel Junction Block behind the left lower finish panel If the connector and pipe are stuck, pinch the fuel pipe, push and pull the connector by hand to disconnect them. Do not use any tools. E. Drain the fuel that remains inside Fuel Pipe Sub-assembly No. 1. F. Place a tray under the vehicle or point of disconnection, if needed, to catch any fuel that may spill. G. Protect the disconnected fuel lines from debris by covering with a vinyl or plastic bag. H. Remove the original pulsation damper from the rear fuel rail. I. Remove and discard the remaining bolt holding Fuel Pipe Sub-assembly No. 1 to the front fuel rail

SUZUKI VZR1800K6 And VZR1800/ ZK7 FUEL DELIVERY PIPE REPLACEMENT

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Filed Under (Suzuki) by admin on 26-11-2010

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NOTE: The fuel delivery pipe assembly can be removed from the throttle body without removing the throttle body assembly from the motorcycle. 1) Refer to section 6 of the service manual to remove the fuel tank and the air cleaner box. Place shop rags over the bore of each throttle body to prevent anything from falling into the engine through the throttle bodies. 2) Remove the wire harness clamp, disconnect the fuel injector couplers A and move the harness aside. 3) Remove the four fuel delivery pipe assembly mounting screws and remove the fuel delivery pipe assembly. 4) Replace the o-rings and seals with the new parts supplied in the kit (apply a small amount of engine oil to the o-rings and seals to ease the installation of the injector). To prevent damage to the o-rings or seals, don’t turn the injector when pushing it into the fuel delivery pipe and throttle body respectively. Install the new fuel delivery pipe assembly in the reverse order of removal. 5) Connect the fuel injector couplers A and clamp the injector harness to the fuel delivery pipe. DO NOT overtighten the harness clamp. 6) Connect the fuel tank, remove the shop rags from over the bore of each throttle body, and run the engine, checking for fuel leaks. DO NOT reuse the original fuel hose connector retainer. Confirm that the fuel hose connector has completely seated and locked (clicked) into position before turning on the ignition switch. 7) Refer to section 6 of the service manual to install the air cleaner box and the fuel tank. 8) Test ride the motorcycle to confirm proper operation. FUEL DELIVERY PIPE ASSEMBLY REPLACEMENT PROCEDURE

BUELL ACCESSORY GAS CAP KIT INSTALLATION MANUAL

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Filed Under (Buell) by admin on 29-03-2011

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Installation NOTE When performing the following Steps, use the Fuel Tank Vent Valve Installation Kit (Part Number 91432-96Y). This kit consists of: * Fuel Tank Vent Valve Installation Aid * Fuel Tank Vent Valve Fitting Socket To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect battery cables, negative cable first. An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Gasoline is extremely flammable and highly explosive. Do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components. Inadequate safety precautions could result in death or serious injury. 2. Remove gas cap. 3. Carbureted Models: Drain fuel tank. Disconnect hose clamp and fuel supply hose from fuel supply valve and drain fuel into suitable, clean container. See applicable Service Manual, Section 4 for complete, detailed procedure. Fuel Injected Models: Relieve pressure from fuel system. See applicable Service Manual, Section 4 for complete, detailed procedure. Drain fuel tank. a. Using suitable external fuel pump, such as a Gas Caddy, pump fuel from tank and into a suitable, clean container. b. See instructions for external fuel pump for correct use. 4. See Figure 1. Cut cable tie securing vent hose to fitting and remove vent hose from fuel tank. Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed. Thoroughly wipe up any fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury. 5. If the fuel supply valve requires cleaning or repair, refer to applicable Service Manual, Section 4, for complete, detailed procedures. 6. See Figure 1. Remove the fuel filler cap and O-ring. 7. Remove the eight self-tapping screws from fuel clamp flange and remove fuel cap flange

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2005 Honda CRF450X OWNER'S MANUAL AND COMPETITION HANDBOOK

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Filed Under (Honda) by admin on 04-12-2010

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Starting & Stopping the Engine Always follow the proper starting procedure described below. Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the kickstarter or start button. Preparation Make sure that the transmission is in neutral. Turn the fuel valve ON. Fuel Valve Starting Procedure Always follow the proper starting procedure described as follow. 5. Warm up the engine; don’t operate the throttle. 6. About 15 seconds after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. HighAirTemperature 35°C (95°F) or above 1. Turn the fuel valve (1) ON. 2. Do not use the choke. 3. Keep the throttle fully closed. 4. Start the engine following step 4 under “Normal Air Temperature.” LowAirTemperature 10°C (50°) or below 1. If the temperature is below 32°F (0°C), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 2. Follow steps 1-5 under “Normal Air Temperature.” 3. Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. (cont’d) NOTICE NOTICE Basic Operating Instructions 15 (1) fuel valve The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor. ON -Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. OFF -Turning the fuel valve OFF prevents the flow of fuel from the fuel tank to the carburetor. RES -Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor. (1) fuel valve (2) choke knob Check the engine oil, transmission oil and coolant levels before starting the engine (pages 44,47,48). To restart a warm engine, follow the procedure for”High Air Temperature.” NormalAirTemperature 10°C-35°C (50°F-95°F) 1. Turn the fuel valve (1) ON. 2. Pull the choke knob (2) fully ON, if the engine is cold. 3. Keep the throttle fully closed. 4. Pull the clutch lever all the way in, and depress the start button. Or operate the kickstarter to start the engine. Starting from the top of the stroke, kick through to the bottom with a rapid, continuous motion. Do not operate the throttle. Allowing the kickstarter to snap back freely against the pedal stop can damage the engine

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