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FUEL SYSTEM AND THROTTLE BODY 5-1
FUEL SYSTEM AND THROTTLE BODY
CONTENTS
FUEL SYSTEM
5- 2
FUEL DELIVERY SYSTEM
5- 2
FUEL PUMP
5- 3
FUEL PRESSURE REGULATOR
5- 4
FUEL INJECTOR
5- 4
FUEL PUMP CONTROL SYSTEM
5- 5
FUEL TANK LIFT-UP
5- 6
FUEL TANK REMOVAL
5- 6
FUEL TANK INSTALLATION
5- 7
FUEL PRESSURE INSPECTION
5- 8
5
FUEL PUMP INSPECTION
5- 9
FUEL PUMP RELAY INSPECTION
5-10
FUEL PUMP AND FUEL FILTER REMOVAL
5-10
FUEL MESH FILTER INSPECTION AND CLEANING
5-12
FUEL PUMP CASE BUSHING INSPECTION
5-12
FUEL LEVEL SWITCH
5-12
I
FUEL PUMP AND FUEL MESH FILTER INSTALLATION
5-13
THROTTLE BODY AND STV ACTUATOR
5-15
CONSTRUCTION
5-15
AIR CLEANER AND THROTTLE BODY REMOVAL
5-16
THROTTLE BODY DISASSEMBLY
5-19
THROTTLE BODY CLEANING
5-23
THROTTLE BODY INSPECTION
5-24
THROTTLE BODY REASSEMBLY
5-24
STV SYNCHRONIZATION
5-28
THROTTLE BODY INSTALLATION
5-29
STP SENSOR ADJUSTMENT
5-29
AIR CLEANER BOX INSTALLATION
5-30
TP SENSOR ADJUSTMENT
5-30
FAST IDLE INSPECTION
5-31
FAST IDLE ADJUSTMENT
5-32
THROTTLE VALVE SYNCHRONIZATION
5-33
5-2 FUEL SYSTEM AND THROTTLE BODY
FUEL SYSTEM
FUEL DELIVERY SYSTEM
The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe
(including fuel injectors) and fuel pressure regulator . There is no fuel return hose
. The fuel in the fuel tank is
pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe
.
Fuel pressure is regulated by the fuel pressure regulator
. As the fuel pressure applied to the fuel injector (the
fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of 300 kPa (3
.0 kgf/cm2,
43 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the
injection signal from the ECM .
The fuel relieved by the fuel pressure regulator flows back to the fuel tank
.
Fuel pressure
regulator
Fuel mesh filter
(For low pressure)
BEFORE-PRESSURIZED
FUEL
PRESSURIZED FUEL
< ____ RELIEVED FUEL
J
vo
Fuel injector
FUEL SYSTEM AND THROTTLE BODY 5-3
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 pressur-
ized 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)
.
4r
Relief valve
Brush
Magnet
Impeller
,
I
∎
I,'
L
I
Check valve
Armature
Inlet port
r
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
.
r
I
V
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 regu-
lator 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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Y
O
O
OO
10 Needle valve
O2
Plunger
® solenoid coil
40
Filter
FUEL SYSTEM AND THROTTLE
BODY
5-5
FUEL PUMP CONTROL SYSTEM
When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the side-
stand relay and the fuel pump relay causing the motor to turn .
Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has
been turned on .
Thereafter, when the crankshaft is turned by the starter motor or the engine has been started, the engine
revolving signal is input to the ECM . Then, current flows to the fuel pump motor from the battery through the
side-stand relay and the fuel pump relay so that the pump continues to function .
A tip over sensor is provided in the fuel pump control circuit . By this provision, anytime the motorcycle tips
over, the tip over sensor sends a signal to the ECM to turn off power to the fuel pump relay, causing the fuel
pump motor to stop . At the same time, current to the fuel injectors as well as the ignition coil is interrupted,
which then stops the engine .
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