User manual CANNONDALE 2003 EFI TROUBLESHOOTING

[. . . ] Electrical/EFI Service Manual ATV and Motorcycle P/N : 5002401 August 14, 2002 INTRODUCTION IMPORTANT NOTICE You must possess significant mechanical knowledge, skills, and tools to perform most of the procedures found in this document. This manual is written for Cannondale Motorsports Dealers and qualified service technicians. This is not a comprehensive shop safety manual and should not be used by anyone who is not familiar with standard safety practices and service techniques. This manual does include warnings and cautions (see descriptions above) that if ignored, could result in SEVERE PERSONAL INJURY to the service technician or significant damage to the vehicle rendering it unsafe to operate. [. . . ] As long as nothing goes wrong with the PC and the information is retained by the software tool, the information can be sent to the ECU right after the operating code update is finished. WRITE down the engine calibration file ID number (Numeric Cal ID), the throttle body leakage, fuel injector flow rate, and injector offset before continuing. 1. On Motorcycles, disconnect the starter solenoid so that the engine will not turn over when the start button is held down in a later step. Electrical_EFI Service Manual. fm © 2002 Cannondale Corporation - All Rights Reserved 30 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 transfer take place. When the transfer is complete release the start button. Reinstall the correct engine calibration file. Be sure to update the vehicle variables before sending the file to the ECU. On Motorcycles, be sure to reconnect the starter solenoid. 31 8/14/02 Opening a SAVED Calibration file CAUTION : 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 the same way as if you click File - Open in the top right corner of the main window. Once "opened, " the file is ready for installation into the vehicle ECU. Check the Numeric Cal ID field in the main window to make sure the filename selected is displayed. If not, go back to step 2 and repeat. CAUTION : Before the saved file is sent to the ECU, be sure to receive the vehicle variable or they will be lost. Refer to "Receiving a calibration file FROM THE ECU "Reading a map and variables"" starting on page 33. To open a saved calibration file, NOTE : In version 2. 0 of the software, when the program is launched, the last engine calibration file that was opened is automatically open in the main window. This feature is useful for servicing many unit at once, however, be sure to check the engine calibration file Numeric Cal ID code in the main window to make sure that the right file is being used. In the main window, click on the "OPEN Calibration File (saved) button. Use the Windows explorer to locate (browse for) the saved engine calibration file. The file is now "loaded" to the main window. Electrical_EFI Service Manual. fm © 2002 Cannondale Corporation - All Rights Reserved 32 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 included in the data file: throttle min/ max, Throttle body leakage (also known as offset, fuel injector flow rate, and injector offset). NOTE : When you "receive" an engine calibration file, a copy of the file stored in the vehicle ECU is loaded in the software tool main window. The vehicle specific variables or "calibration" are also loaded. No information is removed or deleted from the vehicle ECU. You can select to receive all the calibration file from the vehicle ECU or just the throttle body and injector variables or "calibrations. " In case of PC failure, it is a good idea, whenever a file is received from the vehicle ECU to write down the throttle body and injector variables or "calibrations. " complete" message. 5. The vehicle calibration file has now been copied to the Cannondale Diagnostic Tool program. 4-SEND Calibration File (to ECU). To receive 1. Connect the interface cable to the PC and vehicle. [. . . ] Disconnect the solenoid from the main wiring harness. Connect the positive lead of a 12V battery power source to the solenoid coil positive lead or terminal (pin A) and the negative lead of the 12V battery power source to the solenoid coil negative lead or terminal (pin B). There should be continuity between the large terminals while the battery source is connected, and no continuity when the battery source is disconnected. harness starting circuits for short or open circuits. If the starter motor does not turn, confirm that the engine can be turned over manually. [. . . ]