Use and Care Manual

EN – 64
Code 28: High Battery Voltage
This trouble code will activate if ECU detects a higher
voltage from the stator.
1. Start the engine. Refer to Operator’s Manual.
2. Set a multi-meter to volts AC and probe the red and
black stator connector wire. The output should be
11.5 – 14 volts AC at full throttle (3600 RPM).
If stator output measures over 14 volts, replace stator. If
output is within range, advance to step 3. See Figure 157.
IMPORTANT: If the engine is cold, it is normal for the
engine speed to be 100 – 200 RPM higher until operating
temperature is reached.
3. Set a multi-meter to volts DC and probe the battery
connector at the battery terminals. With the engine
running at full throttle (3600 RPM), the output should
be 7.2 – 8.4 volts DC.
If DC output is higher than 8.4 volts, replace ECU. See
Figure 156.
If DC output is within range and red trouble code persists,
replace ECU.
DIAGNOSTICS FOR NON-TROUBLE
CODES
Engine Starts and Loses Power
If the engine starts and loses power immediately, this is
usually an indication that the ECU does not detect an RPM
signal. The RPM signal is generated by the stator, which
also powers the hand warmers, headlight and charges the
ECU battery.
A common cause for RPM signal failure may be a ground
short in the AC output wire coming from the stator to the
ECU. Another possible cause may be a defect in the
engine-charging system.
Engine No-Start Condition
If the engine does not start, check for system power.
1. Check spark plug.
a. Stop engine, remove key and wait for all moving parts
to stop and for hot parts to cool.
b. Disconnect the spark plug cap and remove debris
from the spark plug area.
c. Remove spark plug.
d. Inspect the spark plug. Spark plug gap MUST be
0.7 – 0.8 mm (0.027 – 0.030”). Replace if the
electrodes are worn or if the insulator is cracked or
chipped.
e. Position spark plug against engine block and pull
recoil starter handle to check for spark. If no spark is
present, replace spark plug.
f. Reinstall spark plug and finger tighten. Turn an
additional 1/4 turn after spark plug is seated.
g. Reinstall spark plug cap and make sure it is correctly
positioned onto the spark plug.
2. Check the battery. Battery should have 7.2 – 8.4 volts
DC, depending on when the battery was most recently
charged. Extremely low voltage could cause a no-start
condition without triggering a trouble code. If battery
has low voltage, connect battery charger to battery.
Also check the inline fuse on the battery cable.
If battery measures below specification after charging,
replace battery.
3. Check the ECU status. With battery voltage between
7.2 – 8.4 volts DC, check if the green ECU status light
is blinking at a consistent rate.
IMPORTANT:
If battery measures below 7.0 volts, ECU
LEDs may appear dim or will not illuminate red or
green LEDs.
If green LED is constant, (not-blinking) see
EFI Trouble Code Identification on page 60.
4. Check fuel pump output.
a. Remove the heater box.
b. Check voltage at fuel pump. See Code 27: Low Fuel
Pressure on page 63 for voltage readings.
c. Remove fuel hose from fuel pump outlet and attach a
suitable length of fuel hose to the fuel pump outlet
that can safely reach a clearly marked fuel container.
Engine Temperature
Potentiometer
Servo -
Servo +
B-
Injector-
1
2
3
4
5
6
Ext-ANA- (Potentiometer)
Fuel Pressure Input
Servo-Signal
Ext-ANA+ (Potentiometer)
ECU+
Pump-
7
8
9
10
11
12
Pink
Blue
Yellow
Yellow
Red
Green
Red
Figure 162