Black Widow Security BW 2800 Servisní příručka Strana 1

Electrical/EFI Service Manual ATV and MotorcycleP/N : 5002401August 14, 2002

11 8/14/0211required on a “perfect” throttle body to match theair flow of the vehicle's throttle body at the closedposition. Typical values are

© 2002 Cannondale Corporation - All Rights Reserved12Electrical_EFI Service Manual.fmCOOLANT TEMPERATURE SENSOR The coolant temperature sensor is brow

13 8/14/02132. Compare the value with a reading taken manuallyin the vicinity of the air temperature tip. If the twovalues do not correspond closely,

© 2002 Cannondale Corporation - All Rights Reserved14Electrical_EFI Service Manual.fmStatic Test - Resistance1. Disconnect the sensor harness connecto

15 8/14/0215CAUTION:Do not remove the valve from the housing whenperforming this test.3. Disconnect the engine coolant sensor.4. Reconnect the idle

© 2002 Cannondale Corporation - All Rights Reserved16Electrical_EFI Service Manual.fmOn motorcycles, if this relay is damaged, theengine can start but

17 8/14/0217NOTE :When the ignition switch is turned “ON,” theinstalled relay will make an audible “click.”FUEL PUMP AND FUEL PRESSURE REGULATORThe f

© 2002 Cannondale Corporation - All Rights Reserved18Electrical_EFI Service Manual.fmand the wiring is in good condition. Make sure theboots are in pl

19 8/14/0219FUEL INJECTORSATVs and motorcycles utilize a pair of fuel injectorsthat operate (inject) simultaneously. Pressurized fuel flows into the

© 2002 Cannondale Corporation - All Rights Reserved20Electrical_EFI Service Manual.fmeach injector harness connector. Crank theengine over. If the lig

3 8/14/023INTRODUCTIONABOUT THE MANUALAll the procedures in this manual are organized in a numbered (step-by-step) easy to read format with accompa-n

21 8/14/0221CANNONDALE DIAGNOSTIC AND MAINTENANCE TOOL VERSION 2.0This section of the manual describes how to usethe Cannondale Diagnostic and Mainte

© 2002 Cannondale Corporation - All Rights Reserved22Electrical_EFI Service Manual.fmIn the Windows Explorer, double click the SecurityCode applicatio

23 8/14/0223Enter the Serial provided by the service rep in theDealerCal window. Click Next. Verifying COM port setupUnder Windows 95/98/2000/NT/ME:

© 2002 Cannondale Corporation - All Rights Reserved24Electrical_EFI Service Manual.fmThe vehicle’s lighting or starting electrical systemsare isolated

25 8/14/0225interface cable may be damaged.I/O Error Message1. You will see this message if the last engine calibration file opened with the software

© 2002 Cannondale Corporation - All Rights Reserved26Electrical_EFI Service Manual.fmRetrying ChecksumData is transferred between the vehicle and PC i

27 8/14/0227COMMUNICATION CABLEConnecting the communication cableMotorcycles and ATVs have a “diagnostic” con-nector integrated into the main wiring

© 2002 Cannondale Corporation - All Rights Reserved28Electrical_EFI Service Manual.fmCANNONDALE DIAGNOSTIC AND MAINTENANCE TOOL MAIN WINDOW 1. Numeric

29 8/14/0229Engine Calibration File (“Map”) IdentificationAll Cannondale factory authorized engine cali-bration files are identified by a Numeric Cal

© 2002 Cannondale Corporation - All Rights Reserved30Electrical_EFI Service Manual.fmATV and Motorcycle operating codes are NOTinterchangeable. The so

© 2002 Cannondale Corporation - All Rights Reserved4Electrical_EFI Service Manual.fmIMPORTANT MANUAL INFORMATIONFAILURE TO FOLLOW THE WARNINGS CONTAIN

31 8/14/02313. In the ECU Reprogramming Tool window, selectthe operating code file to send.Have an assistant press and continue to hold thestart butt

© 2002 Cannondale Corporation - All Rights Reserved32Electrical_EFI Service Manual.fmOpening a SAVED Calibration fileNOTE :A saved calibration file mi

33 8/14/0233Receiving a calibration file FROM THE ECU“Reading a map and variables”By receiving the engine calibration file or thevehicle variables fr

© 2002 Cannondale Corporation - All Rights Reserved34Electrical_EFI Service Manual.fmSending a calibration file or “map” to the ECU - “Changing a map”

35 8/14/0235The throttle position sensor minimum andmaximum values must be set using the CDMTanytime the throttle body is serviced (removed,replaced,

© 2002 Cannondale Corporation - All Rights Reserved36Electrical_EFI Service Manual.fmto the next step to learn more. 7. If you click the Accept Value

37 8/14/0237the progress indicator. When the send is com-plete, the Send complete prompt will display, clickOK.Click Cancel and the “From File” value

© 2002 Cannondale Corporation - All Rights Reserved38Electrical_EFI Service Manual.fmat the closed position. Typical values are from 0.0 to 1.0%•“Inje

39 8/14/0239ECU MONITORMonitor selected ECU parameters with the vehicleengine running or with the vehicle engine off and theECU powered-up. It can be

© 2002 Cannondale Corporation - All Rights Reserved40Electrical_EFI Service Manual.fmREADING FAULT CODESTo read fault codesWhen a fault is reported, c

5 8/14/025CONTENTSINTRODUCTION - - - - - - - - - - - - - - - - - - - - - - 3Important Notice - - - - - - - - - - - -

41 8/14/0241ton was pressed. The Fault Report window doesnot constantly update fault conditions.The Fault Report window sample above wastaken while t

© 2002 Cannondale Corporation - All Rights Reserved42Electrical_EFI Service Manual.fmFAULT TROUBLESHOOTINGConsult the following troubleshooting tables

43 8/14/0243 SYSTEM VOLTAGEFault Reported Possible Cause ActionBattery voltage low fault Wiring/ Stator/ Regulator/BatteryCheck battery voltage at ba

© 2002 Cannondale Corporation - All Rights Reserved44Electrical_EFI Service Manual.fm FUEL PUMPReported Fault Possible Cause ActionFuel pump short Dam

45 8/14/0245 IGNITION COILFault Possible Cause Action Coil short fault Damaged ignition coil orECU, harness short circuit,coil connector disconnected

© 2002 Cannondale Corporation - All Rights Reserved46Electrical_EFI Service Manual.fm COOLING FAN (ATV ONLY)Fault Possible Cause Action Cooling fan sh

47 8/14/0247 FUEL INJECTORSFault Possible Cause Action Injector A short fault (left) Injector B short fault (right) Damaged injector or ECU,harness s

© 2002 Cannondale Corporation - All Rights Reserved48Electrical_EFI Service Manual.fm3. Check wire for short circuit- P1 H2 to ground- P1 H3 to ground

49 8/14/02495. Check short circuit: MotorcycleDisconnect diagnostic connectorCN10, lighting connector CN26,remove EMS power relay.Measure between rel

© 2002 Cannondale Corporation - All Rights Reserved50Electrical_EFI Service Manual.fm THROTTLE POSITION SENSOR (TPS)Fault Possible Cause ActionThrottl

© 2002 Cannondale Corporation - All Rights Reserved6Electrical_EFI Service Manual.fmENGINE MANAGEMENT SYSTEM (EMS) Engine operation is supported by th

51 8/14/0251 AIR TEMPERATURE SENSORFault Possible Cause Action Air temp sensor high faultAir temp sensor low fault Damaged air temperaturesensor, ECU

© 2002 Cannondale Corporation - All Rights Reserved52Electrical_EFI Service Manual.fmCircuit DiagramAir Temperature Sensor Resistance RangeResistance(

53 8/14/0253 COOLANT SENSORFault Reported Possible Cause Action Engine temp sensor high faultEngine temp sensor hi fault Damaged coolant temper-atur

© 2002 Cannondale Corporation - All Rights Reserved54Electrical_EFI Service Manual.fm Coolant Sensor Resistance RangeResistance(ohms)Temp. (deg. C)Te

55 8/14/0255 IDLE AIR CONTROL VALVE (IACV)Fault Reported Possible Cause Action Stepper motor fault Damaged idle air controlvalve, ECU, harness short

© 2002 Cannondale Corporation - All Rights Reserved56Electrical_EFI Service Manual.fm CRANKSHAFT POSITION SENSORFault Reported Possible Cause Action C

57 8/14/0257COMPONENT TESTING (NON-EFI)BATTERY1. Filling electrolyte properly, Charging (times andrates).2. Load testing using a commercially availab

© 2002 Cannondale Corporation - All Rights Reserved58Electrical_EFI Service Manual.fmIf an OL (no continuity) is obtained on any one ofthe three tests

59 8/14/0259ENGINE STOP SWITCH (ATV)1. Disconnect the engine stop switch from the mainharness.2. Slide the switch to the RUN position. Thereshould be

© 2002 Cannondale Corporation - All Rights Reserved60Electrical_EFI Service Manual.fmOperation Test1. Disconnect the solenoid from the main wiringharn

7 8/14/027ECU PROGRAMMINGThe ECU is “programmed” with three types of infor-mation. the operating code (also known as the “hex”file, the engine calibr

1 Printed : 8/14/0215002066INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - 3Important Notice - - - - - - - - -

© 2002 Cannondale Corporation - All Rights Reserved8Electrical_EFI Service Manual.fmP1 and P2 ConnectorsMC1000 ECUs have two main harness connectorsoc

9 8/14/0293. Align the latch groove and tab on the ECU socket.Rotate the latch in direction (b) until the latch islocked by the locking tab. The la

© 2002 Cannondale Corporation - All Rights Reserved10Electrical_EFI Service Manual.fmBAROMETRIC PRESSURE SENSOR The barometric pressure sensor is hous