Instruction Manual for FI Controller
Contents
1. A CAUTION The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following cautions Please drive safely and follow the local traffic laws O Work only when the engine and the exhaust system are cool to avoid burns Prepare appropriate tools and work properly to avoid the breakage of parts or injuries Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose AS some products and frames have sharp edges or protruding portions work with your hands protected to avoid injuries Before riding always check such parts as screws for loose If you find loose ones screw them securely up to the specified torque to avoid parts coming off The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the WARNING i ae aii following cautions O When you notice something abnormal with your motorcycle stop riding immediately and park your motorcycle in a safe place to avoid an accident Before working place the motorcycle on level ground to stabilize its position for safety to avoid the motorcycle overturning Please conduct checkups and maintenance correctly referring to the instructions and methods described in the instruction or service manual Improper checkups and maintenance could lead to accidents O2. Instruction Manual for FI Controller D For Monkey FI Super Cub FI Little Cub FI Item No 00 00 0000 Fits amp Frame Nos Monkey FI AB27 1900001 Super cub FI AA01 1700001 Little cub Fl AA01 4000001 O Thank you for purchasing one of our TAKEGAWA s products Please strictly follow the instructions to install and use the products O Before installing the products please be sure to check the contents of the kit If you have any questions about the products please kindly contact your local TAKEGAWA dealer Please note Illustrations and photos may vary from actual hardware Features O This is a subcomputer whose wires supplied in this kit can be connected to those of the genuine ECU with minor modification of the ECU s wires Thus this kit is easy to use and can increase the amount of fuel injection O This Fl Controllers 16 bit micro computer allows the air fuel ratio of Fl vehicle equipped with our S Stage to be optimized in real time according to the engine conditions by computing the proper ratio based on the signal of the genuine computer Fuel injection can be adjusted in 15 steps with a rotary switch so that this kit can meet the modifications in the intake and exhaust system O This kit makes possible the fuel injection in larger amount than the maximum amount to be injected by the genuine computer Please read the following instructions before installation We do not take
3. When the FI controller is operating properly the green LED lights up The ignition switch must be ON O O When the ignition switch is turned on the self diagnosis function starts operating and the red LED lights up for one second However if the red LED does not light up at all or on the contrary remains on turn off the ignition switch Please try to turn on the ignition switch again ten seconds later O UMoreover the red LED is designed to light up as a warning light when over burdening on the fuel injector while the engine is running If you open the throttle quickly when the engine is still cool there is a possibility that the fuel injector may keep on injecting fuel This is because the FI controller works to further extend the fuel injection time This kind of symptom may cause the breakdown of the fuel injector Thus the red LED lights up as a warning light Please drive your motorcycle carefully so the red LED does not light up Recommended settings for the specified models or specs O The following table of the settings are all for the vehicles equipped with our S Stage Kit and our Hyper Camshaft Note These recommended settings are only the samples They may vary with external factors such as ambient temperature altitude or rider s weight E Monkey FI Seting tock air cleaner box TAKEGAWA Z style exhaust system AKEGAWA Air Filter Kit TAKEGAWA
4. Before installation Installation This product must be installed with the stock PGM FI system which operates properly If the PGM FI system is in bad condition this controller will not operate correctly or provide the performance as a result it causes damage of this product or other related parts To install and use this controller make sure that your stock PGM FI system operates properly Before you start working stand your vehicle securely on a flat surface such as a maintenance stand placed on a jack E eg eg og ge ge ge gg gg ggg E Installation on Fl Monkey O O Remove the left side cover referring to the original service manual O O Do the following work referring to the original service manual Remove the left side cover and the seat Bolt Side cover Nut Grommet Protruding portion Screw O O Remove the mounting bolt fixing the rear side of fuel pump to attach the ground wire to the frame under the fuel tank If you have a working stand with the same height of the frame you can work without removing the fuel tank When removing the fuel tank be sure to remove the fuel tank after releasing the fuel pressure in the fuel lines referring to the service manual Fueltank Mounting bolt A F x F Collar hi d 4 N ea a Rubber 4 Vapor return hose Fuel hose low pressure Connector Hose clamps WARNING As gasoline is extremely flammable make sure NO FLAME and NEVER leave combustib
5. Z style exhaust system AKEGAWA Air Filter Kit TAKEGAWA Basic exhaust system Nn WwW S E mi Cub FI and Little Cub FI send W tock air cleaner box Stock exhaust system W tock air cleaner box TAKEGAWA Bomber exhaust system AKEGAWA Air Filter Kit Stock exhaust system AKEGAWA Air Filter Kit TAKEGAWA Bomber exhaust system E SPECIAL PARTS UNAI NMA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL dalled eine _5 J ul 20 10
6. any responsibility for any accident or damage whatsoever arising from the use of this product not in conformity with the instructions in this Manual We do not have any information or service data on the combination of our products and other manufacturer s products Please note that this product is designed for exclusive use with the above mentioned fitting models and that it cannot be mounted on any other models When ordering repair parts please quote above Item No or reference Nos in the figures in this Manual If you have any questions about the repair parts please contact your local TAKEGAWA dealer This product is designed to extend the fuel injection time through the incorporation of this product to the injection power from the genuine ECU In the case of a technical trouble like the breakdown of this product or faulty wiring it is structurally likely that the fuel injection may stop There is no rev limiter release function The data described in this Manual on the increase in the fuel injection is based upon the test on the motorcycles owned by us and equipped with our products However when this product is installed on altered motorcycles other than those motorcycles tested by us or on motorcycles using other manufacturers parts as well you may not be able to get the optimum settings for the air fuel ratio However even if your motorcycle is equipped with our products in some cases you cannot get the intende
7. the prevention of the needless troubles A CAUTION When attaching the panel please paste it right on the octagonal recessed surface on the FI controller If the panel is fit on the edge not on the recessed surface or the groove then the dust or water will get into the controller through the gap Please place panel properly How to use the FI controller and about the setting O O The setting of the FI controller can be adjusted by turning the yellow rotary switch Please turn the switch carefully with a flat extra fine tip crewdriver DO NOT deform the grooves You can adjust the settings even when the engine is running idle JA WARNING NEVER adjust the settings while riding Otherwise this may cause the consequential accidents O O Arrow of the switch indicates a setting shown by numbers or letter N When it shows 0 the amount of fuel injection is almost the same as the amount injected by the genuine ECU No fuel increase The amount of fuel injection increases more than the amount injected by the genuine ECU following to the numbers and letters of the dial from 1 to F by turning it clockwise O The adjustment is a 16 step adjustment type starting from 0 Be sure to set at a figure or letter precisely until it clicks into place If the clicks are incomplete the controller does not work properly O O When the green LED is on this indicates that FI controller is powered
8. Black G Green R Red Br Brown BI Blue P Pink Wires of FI controller Green Female bullet terminal DO NOT connect Greeni Male bullet termina Brown Male bullet terminal Sub wire hamess 1COMP Pink Green Female bullet terminal Red Female bullet terminal Sub wire hamess LCOMP Black Blue Male bullet terminal Brown Female bullet terminal Sub wire hamess 2COMP Pink Green Male bullet terminal Red Male bullet terminal Sub wire hamess 2COMP Black Blue Female bullet terminal O0 O Connect the coupler of sub wire harness 1COMP to the injector Then connect the coupler of sub wire harness 2COMP to the 2P coupler of the stock wire harness O O Route the wire harness of FI controller with the wire harness of the vehicle and fasten them with the included insulation lock Zip Tie Note Install Fl controller where it does not get rain or water directly such as inside the side cover or under the seat Use the Velcro set included in the kit to install O Double check to make sure if the wiring connection is correct O While looking at the switch opening on the FI controller turn on the ignition switch Please check that after turning on the switch the green and red LEDs on the switch opening light up and that the red LED goes out in about one second A CAUTION As we switch on all the controllers before shipment from our factory in case the LEDs do not light up as mentioned above the wrong wiring can be the cause Immedi
9. If you find damaged parts when inspecting or performing maintenance of your motorcycle do not use these parts and replace them with new ones The continued use of these damaged parts could lead to accidents Keep plastic bags for packing the products out of children s reach or discard them If children get them on there will be a danger of their suffocating Please be informed that mainly because of improvement in performance design changes or cost increase the product specifications and prices are subject to change without prior notice This manual should be retained for future reference Kit includes Mo Pme Oy Repar Part ern No In packs of Ta F Contoter Asserby a Reer OOOO OO O a o a 5 Sub wre hamess 1 COMP O 1 ooon f o 6 Sub wre hamess 2 comp 1 ooo f r jomme Y t oe a e ews O a oo a o nsun Tock omm 2 ooo f o The FI Controller panel of Item No 2 above with a bored switch is factory installed onto the Fl Controller assembly of Item No 1 Please order repair parts with the Repair Part Item No Without the repair part item No we may not be able to provide the correct parts Some parts are only available as a set Please order them with the set number Product amp Parts Names Fl controller Red LED Rotary switch mc En tata Green LED ie Harness for FI controller 2D Jul 20 10 Ve lia
10. age if this controller gets wet with rain or water or water enters the controller body Be careful when washing as well Stop using the controller immediately when the controller body gets wet Also be careful if you use the transparent switch panel in the kit When it is humid or the temperature changed suddenly the controller body may get the moisture inside and the transparent panel fogs up The housing of controller is plastic Cover the vehicle to avoid deterioration when parking the vehicle outside for a long time If the controller is left in the severe conditions such as hot climates for a long time the plastic or rubber may deteriorate or deform NEVER disassemble the controller Ite fs VERY DANGEROUS NEVER disassemble or modify this controller NOTE If it is disassembled we do not accept any maintenance or repair DO NOT give an excessive impact DO NOT give an excessive impact to this product with riding on off road or jumping By the impact malfunctions may occur including the breakage of the inner parts unrepairable failure due to the disconnection or damage of the controller housing How to clean If the dirt is stubborn wipe the dirt with a soft cloth slightly moistened with a mild detergent solution and clean gently and carefully To prevent adversely affecting the plastic material or fogging up the panel DO NOT use a rubbing compound or volatile solvents such as alcohol or paint thinner J zie J ul 20 10
11. ately turn off the ignition switch and check if there is no XK wrong wiring p _4 Jul 20 10 Tos Install the removed exteriors in the reverse order of removal Ve A CAUTION Be careful NOT to pinch the wire harness in FI controller O O Referring to the Recommended settings for the specified models or specs in this page adjust the FI controller switch at the designated setting No which matches your engine specifications Then attach the supplied rubber cap onto the switch panel CAUTION Attach the rubber cap securely If the rubber is wrongly fit on the switch there will be a gap between the rubber cap and the panel of the FI controller This may cause the rubber cap to fall off or let the dust or water get into the FI controller through the gap which may ultimately lead to the breakdown of the FI controller About the rubber cap and panel O Remove the rubber cap ONLY when you adjust the rotary switch A CAUTION If you drive your motorcycle without the rubber cap on the dust or water may get into FI controller causing it to break down When riding be sure to cover the top with the rubber cap or the transparent panel in the kit When the setting is finished peel off the panel stuck on the switch at the time of shipment from factory and replace the panel with the transparent one And this increases the dust proof and drip proof quality of the product leading to
12. colors of wires from the 2P coupler of the removed stock wire harness If the colors of the wires and the included sub wire harness 1COMP are opposite in color do the following procedure to counterchange the places of the wires CAUTION If the wires are opposite in color you cannot turn on the FI controller therefore the engine will not Start For 2P copular on FI Cub a Remove the retainer grey plastic part from the stock coupler with a small slotted driver A CAUTION Modify on chassis side copular only Do not modify other copular b Pull out the wires individually from the coupler with a pick while pulling up the inner hook fixing the terminal of the stock coupler At this time you do not have to remove the retainer on wire side and rubber seal O 0O Insert colored wire Same as sub harness to the 2P copular N B BI NCAUTION Make sure that the terminal should be pushed in with facing up or the terminal will not insert into the coupler Be careful not to insert upside down 0 0 Go to the section The wire connection of FI Controller M N M a a a a a a a a a a a a a a a a a a a a The wire connection of FI Controller O O Connect the FI controller and the bullet terminal of sub wire harness referring to the following diagram Do Not connect et Ground wire e i O To the stock wire harness Sub wire harness 1COMP Sub wire harness 2COMP B
13. d settings because of the individual part difference or such foreign elements as temperatures height above sea level or riders physical constitution This product can make the general driving possible by increasing the amount of fuel injection for the vehicles with our S Stage installed Since this product is a subcomputer we do not guarantee this kit that always produces perfect settings with engines of any specifications Moreover we shall not be liable for the breakdown of the engine Before driving be sure to always check whether the air fuel ratio or the setting meets your engine Precautions to use this kit DO NOT USE the following parts with this FI controller DO NOT USE H I D kits in aftermarket because many of H I D kits in aftermarket emit noise of high voltage from the ballast inverter a device to convert the voltage and adversely affect the digital circuit It causes failure or malfunction DO NOT USE ignition systems in aftermarket such as ignition coil or plug wire because many of ignition systems in aftermarket increase the radiation noise due to increase the ignition voltage It causes malfunction or product failure DO NOT USE generating systems in aftermarket because many of them cannot charge enough electricity and battery voltage lowers Also they cannot control voltage Those cause malfunctions This product is NOT waterproof or drip proof Since this product is not waterproof or drip proof it may dam
14. le materials around the work area As gasoline vapors are explosive work in a well ventilated area and release the vapors If you work without removing the fuel tank be careful NOT to work the fuel hose by force N CAUTION N Procedures O0 O Tie up the included ground wire with other stock wire harnesses including the ground wire gathering and connecting at one section on the frame under the fuel tank and route the wire with the main wire harness close to the injector O O Disconnect the 2P coupler of stock wire harness connecting the injector 0 0 Goto section The wire connection of FI Controller ee a a g Installation on FI Cub FI Little Cub O O Remove the leg shield referring to the original service manual Bolt washer Bolt hook Nut washer Set plate Set plate gt Set bolt washer s Forward O HGround wire included in the kit is tied up at the place to ground safely with other wires and route the wire close to the injector Ne S 3 Jul 20 10 fan Remove the drum cover unfastening the two fixing screws of the throttle drum cover on the throttle body Screws 7 Drumcover lh j O0 O Remove the rubber coupler cover and 2P couplers of the stock wire harness connecting injector m a De E 2P coupler zi L i i O O Check to see the
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