"service manual"
Contents
1. Instruction Manual for Fl Controller gt For Monkey Fl Super Cub FI Little Cub Fl Item No 0 0 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 You are requested to follow the below mentioned instructions in installing this product You are requested to follow the below mentioned instructions in installing this kit Should you have any questions about the products please kindly contact your local dealer Please note that in some cases the illustrations and photos may vary from the actual hardware Features O This is a subcomputer whose wires supplied in this kit can be connected to those of the genuine ECU just by cutting off the ECU s wires Thus this kit is user friendly and can increase the amount of fuel injection O If our S Stage is incorporated into an FI motorcycle the air fuel ratio gets out of order on account of the increase in the engine displacement But with the installation of this kit judging from the engine condition a 16 bit microcomputer inside the FI controller computes in real time based on the signal sent from the genuine computer optimizing the air fuel ratio by correcting the amount of fuel injection to meet our S Stage The amount of increase of fuel injection can be adjusted in 15 steps with a rotary switch so that this kit can meet the changes in2. 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 No PattName T OW Repair Part Remi No Th packs of CT Fi conoterAsserby a e _ 2 FI Controler panel bored swiy 7 i e dT Cs Pug E e Plug receptacle SY 8 7 Plug capt Plug covet E 8 Plug receptacle cap Plug receptacle cover 3 _ __ Po feos E C E x 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 note that in ordering repair parts be sure to quote the Repair Part Item No Otherwise we may not be able to accept your orders There are some parts however for which we are not in a position to accept your order in just the quantity to be used In this case please take them in the quantity packed Product amp Parts Names Fl controller o Samana Red LED Rotary switch Se a Green LED Harness for FI controller f x a8 Feb 18 g f Installation Procedures D We have prepared this Instruction Manua
3. cable from the terminal on the Toe Tie the harnesses of the FI controller and the vehicles in a bundle with How to use the FI controller and about the setting N a suppiiea HSHiaton eck ANA plate ne FI controller i the place O O The setting of the FI controller can be adjusted by turning the yellow where rain or water does not get into it like inside the side cover portion in the middle of the rotary switch T installing the controller as above please use a supplied VETO Please turn the switch carefully so as not to deform the grooves with OU mevicw wheter or not the wiring is correct After confirming that the a flat extra fine tip screwdriver ignition switch is turned off re connect the cables back to the You can change the settings even when the engine is running idle termina B the atey l A WARNING NEVER change the settings when running Otherwise O O While looking at the switch opening on the FI controller turn on the this may cause the consequential accidents 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 Immediately
4. of the FI controller Please never use such ignition devices as an ignition coil or a plug cord which are manufactured outside our factory because the increase in radiation noise caused by the increased ignition voltage may cause this product to malfunction or break down Please never use a generating equipment manufactured outside our factory which is likely to cause the breakdown of this product because of decrease in voltage or unstable control voltage caused by the equipment s insufficient recharging capacity This product is not structurally water or drip proof As this product is not structurally water or drip proof and if it gets wet with rain or water the water may get inside the product causing this product to break down By the same token please take precautions against water in washing your motorcycle Immediately stop using the FI controller once water gets into it When the transparent panel is fit into the opening on the supplied switch and if it is humid or there is a sudden change in the temperatures the transparent panel may absorb moisture and get misted up in some cases The body of this product is made of resin If you are going to keep a motorcycle outside for a long time please put a cover on it to prevent this product from weathering If this product is kept under severe conditions like the scorching sun for a long period there is a possibility that the resin or the rubber parts may deteriorate or deform Never take
5. the pink green wire of the cutoff harness on the vehicle side green wire of the cutoff harness on the ECU side O O From the main harness remove the coupler connected to a genuine ECU And unfasten the screw holding a battery cover On the side of ECU On the side of the e About 50 mm gt vehicle harness p c p Cp G ep O O Referring to the illustration below connect the terminal from the harness on the FI controller to the terminal on the harness on the vehicle side CAUTION Please note beforehand that as a matter of convenience on our side the colors of the wires on the FI controller and those on the harness on the vehicle differ Therefore please carefully connect wires with this in mind battery IMPORTANT Be sure to connect the plug of the brown harness to the harness IMPORTANT Be sure to connect the plug receptacle of the brown harness to the ECU side sm On the vehicle i Installation onto Monkey FI aie aide On the ECU side O O Referring to the genuine service manual remove the left side cover O0 O Demount the seat and detach the battery connector from the battery x The above wiring is based on our verification as of July 1 2008 B OOO BLACK G OOO GREEN L OOO BLUE P OOO PINK R OOO RED Broo ey en Feb 18 09 i O O Disconnect the
6. this product apart Never disassemble or alter this product yourself as it poses a danger to do so And please be informed that in case you yourself have disassembled or altered this product we will not be in a position to comply with your request for the inspection or repair Never make an impact on this product Please refrain from doing such things as off road driving or jumping which may make a severe impact on this product Because of the impact the inner parts may come off or the wires may be disconnected possibly leading to the irreparable damage of the product or breakage of the housing About the maintenance In order to remove the greasy dirt dissolve a small amount of mild detergent in water and rub the dirt slowly and carefully with the liquid Na made of resin may deteriorate or a panel may mist up when they are rubbed with a volatile substance like thinner or alcohol or with an abrasive alla ajs Feb 18 09 x CAUTION The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following cautions O Always try to drive your motorcycle at legal speeds on the public road abiding by the laws Do the following work only when the engine and the muffler are cool Otherwise you will burn yourself Prepare tools suitable for the work Otherwise parts will be damaged or you will suffer injuries Always use a torque wrench
7. l on the assumption that our S Stage had already been installed Please install this FI Controller in reference to this Instruction Manual but only after the installation of S Stage Kit Introduction Installation of Fl Controller Make sure your motorcycle is secure on a maintenance O O Cut off a total of 3 pieces of a pink green a black blue and a green wires at about stand or the like on level and safe ground 50 mm from the root of the coupler of the ECU You may choose whichever green wire out of three in the bundled green harness Referring to the fig below attach and process the supplied terminal being careful of the kinds of the terminal whether a plug or a receptacle plug SCAUTION If you cut the harness too close to the ECU coupler you will find it impossible to install the terminal because the plug receptacle cover is long Therefore please be careful about where to cut the harness A CAUTION Install the terminal securely using a proper tool like a plier J CAUTION In this Instruction Manual the wire colors are shown in the order of whole wire color and the line color on the wire The description of pink green wire indicates a pink wire with a green line on it mi Installation onto Cub FI and Little Cub FI O O Referring to the genuine service manual remove the right side cover i IMPORTANT Connect the plug receptacle to IMPORTANT Connect the plug to the pink
8. njection 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 intended settings because of the individual part difference or such foreign elements as temperatures height above sea level or rider s physical constitution This product is a subcomputer which makes the general driving possible by increasing the amount of fuel injection in a simple way when our S Stage is installed Since this product is just a subcomputer we do not warrant that this subcomputer 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 It is hoped that you will use this kit with all above in your mind Precautions in using this kit About those parts which cannot be used together with this kit Please never use any HID kits manufactured outside our factory whose ballast and inverter voltage converter in most cases produce high voltage noise giving adverse effect to the digital circuit and causing the breakdown
9. or let the dust or water get into the FI controller through the opening which may ultimately lead to the breakdown of the FI controller controller does not work properly O When the green LED is on this indicates that FI controller is powered Usually when the ignition switch is turned on and the FI controller is operating properly the green LED lights up 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 And about ten seconds later turn on the ignition switch again O O Moreover the red LED is designed to light up as a warning light when too much load is placed on the fuel injector at the time the engine is running If you open the throttle at a rapid rate 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 which is originally long 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 when the engine is running About the rubber cap and panel In setting the FI controller remove the rubber cap only when you are going to turn the rotary switch A CAUTION If you dri
10. 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 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 shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the installation and use of this product You are kindly requested not to contact us about the combination of our products with other manufacturers Please note that this product is designed for exclusive use in 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 Should you have any questions about the repair parts please contact your local motorcycle 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 function to cancel the rotation limiter The data described in this Manual on the increase in the fuel i
11. to screw bolts and nuts tight and securely to the specified torque Improper torque could cause these parts to get damaged or fall off AS some products and frames have sharp pointed or protruding portions please work with your hands protected Otherwise you will suffer injuries Before riding always check every hardware for slack in parts like screws If you find slack ones screw them securely up to the specified torque Or improper torque may cause parts to come off The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the J N WARNING i ey i es following cautions When you notice something unusual with your motorcycle while riding stop riding immediately and park your motorcycle in a safe place Otherwise the continued ride could lead to accidents Before starting the work secure your motorcycle firmly on level ground for safety s sake Otherwise your motorcycle could overturn and injure you while you are working 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 If you find damaged parts when checking or performing maintenance of your motorcycle do not use these parts any longer and replace them with new ones The continued use of these damaged parts as they are could lead to accidents
12. turn off the ignition switch and check if there is no wrong wiring O0 O And reinstall back the removed battery cover and side cover in the reverse order of removal N CAUTION Please check at this point whether or not an FI controller harness is stuck by the battery cover or side cover O O Referring to the List of Settings by Engine Specifications at the end of this Manual on the last page set the FI controller switch at the designated setting No which matches your engine specifications Then fit the supplied rubber cap onto the opening on the switch A CAUTION Fit the rubber cap securely If the rubber is wrongly fit onto O O The arrowed figure or letter shows the setting value If the arrowed figure is at 0 this means that the amount of fuel to be injected is the same as the genuine ECU in other words there is no change in the amount of injected fuel As you turn the rotary switch from 1 to F clockwise the fuel is to be injected in all the larger amount than the genuine ECU The adjustment is not an infinitely variable type but a 16 step adjustment type starting from 0 Be sure to set at a figure or letter i the switch as well there will be an opening between the precisely until it clicks into place If the setting is set halfway the U rubber cap and the panel of the FI controller This may cause the rubber cap to fall off
13. ve your motorcycle without the rubber cap on the dust or water may get into FI controller causing it to break Both of the settings in the list below are subject to installation of our down S Stage Kit and hyper camshaft When driving never fail to either put on the rubber cap or the ginstallation onto Cub FI and Little Cub Fl panel to be described at a later stage When no more setting is needed 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 change of panels increases the dust proof and drip proof quality of the product leading to the prevention of the needless troubles installation onto Monkey FI A CAUTION When attaching the panel please paste it right on the octagonal recessed surface on the FI controller If the panel is fit onto the edge not on the recessed surface Genuine air cleaner box stock muffler 8 or the groove then the dust or water will get into the List of Settings by Engine Specifications Genuine air cleaner box Our Z Style Muffler 9 controller through the opening leading to the breakdown of Genuine air cleaner box Our Basic Muffler 8 the Fl controller SPECIAL PARTS WNSeV WA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL oes Va 4 Feb 18 09
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