C annondale D iagnostic Tool M anual For vehicles (ATV & Motorcycles) equipped with the MC1000 Engine Management System Software CD P/N 971-5001983 Data Cable P/N 971-5001984 DANGER POTENTIAL HAZARD Running the engine indoors. Breathing exhaust gases. WHAT CAN HAPPEN Running the engine indoors will expose you to dangerous exhaust gases. Breathing carbon monoxide gas leads to poisoning, asphyxiation, and death. This will happen rapidly and without notice.
S afety A lerts • • FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Keep this Assembly manual in a safe place. Messages with the Safety Alert Symbol • Pay special attention to all messages preceded by the Safety Alert Symbol. The Safety Alerts symbols means: ATTENTION! BECOME ALERT! YOUR and YOUR CUSTOMER’S SAFETY IS INVOLVED. DANGER Indicates that severe personal injury or death WILL result if instructions are not followed.
Basics WHAT IS THE CANNONDALE DIAGNOSTIC TOOL? The Cannondale Diagnostic Tool is a Windows-based software program and special data cable that enables you to connect and communicate with vehicles using the MC1000 Engine Management System. The software is installed on a PC or Pocket PC, then the PC (or Pocket PC) is connected to the vehicle wiring harness via the special data cable.
POWERING-UP ATV ECU’S To power-up the ECU on ATVs you have to switch the ignition switch to the “ON” position, then switch the engine switch to the RUN position. Then, press the green start button and release it without starting the engine. When the system is powered-up the green LED on the data cable “block” will light. After 2 minutes of inactivity, the ECU will power-down automatically except with the ATV the data cable block green LED will not go out.
“FAILED TO UNLOCK SYSTEM 125”. This message means that the Cannondale Diagnostic Tool was not able to communicate with the vehicle ECU. If you see this message check one or more of the following: • Make sure that both the vehicle harness connector and data cable are undamaged (pins not bent or broken) and the connectors are properly locked together. • Make sure the vehicle battery is fully charged. • Make sure the vehicle ECU is powered-up. See page 3.
MAIN SCREEN (1) (2) (3) (4) (5) (6) (7) (8) (9) 00200 (5) (8) 00200 00200,X440s,082801 (1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Calibration file identification Opens a saved calibration file Receives a calibration file from the vehicle’s ECU Sends the current calibration file to the vehicle ECU Used to set the vehicle’s throttle body (min./max.
1 - CALIBRATION FILE ID On the top left corner of the Cannondale Diagnostic Tool main screen there will be a Numeric Cal ID number for the calibration file that is open. If “Untitled” is displayed in this area of the screen, no calibration file has been opened (from a saved file) or received from the vehicle ECU. In addition to the ID number, each calibration file is assigned a 128-character description.
NUMERIC CAL ID CODING MODEL CODE (2 DIGIT) 0 0 YEAR SEQ (2 DIGIT) 0 00 thru 99 MODEL CODES Code Model 0 0 X440s 0 1 X440 0 2 C440 0 3 E440 3 0 Cannibal 3 1 Speed 3 2 Blaze 3 3 Moto 440 YEAR Year Code 2002 2 2003 3 2004 4 2005 5 2006 6 2007 7 2008 8 2009 9 2010 0 2011 1 NOTE : Reset every 10 years SEQ 00 thru 99 NOTE : The two digit SEQ number is assigned sequentially. When a calibration file is updated the SEQ number increases.
2 - OPENING A CALIBRATION FILE The OPEN Calibration File (saved) button opens the Windows explorer so that you can look for and open a calibration file that is saved on your PC or Pocket PC. A saved calibration file might be one that you have received via e-mail, downloaded from the Cannondale website, or one that is stored on a diskette or CD. This button functions the same way as if you click File - Open.
4-SEND CALIBRATION FILE (TO ECU) The SEND Calibration File (to ECU) button “sends” the calibration file open (in the Cannondale Diagnostic Tool software) to the vehicle ECU. Whenever you send a calibration file to the vehicle ECU you have to keep the following points in mind: • The software will automatically retrieve the vehicle specific variables (throttle positions (min.
5- SET THE THROTTLE POSITION CAUTION Set the throttle position with the vehicle off. This SET Throttle Position button enables you to “teach” the ECU the fully closed and fully open throttle body plate positions. Teaching the ECU these positions assures that the ECU is calculating fuel and timing on the information arriving from the Throttle Position Sensor (TPS) mounted on the throttle body. Slight variations in different vehicles necessitate this teaching step.
6. Since you already made sure the throttle plate was completely closed click OK to continue. Next, the following prompt will display: 7. When the prompt above displays, have an assistant fully open the throttle and hold it. While the throttle is held in the fully open position click OK. Immediately after you click OK, you will see the following prompt: 8. Tell your assistant to release the throttle.
6 - ECU MONITOR The MONITOR ECU Parameters button enables you to monitor selected ECU parameters with the vehicle engine running or with the vehicle engine off. It can be operated in “Continuous” (live) or “Hold” (snap shot) mode. You can start the vehicle with the monitor running. 1. Connect the data cable to the computer and vehicle. 2. Open the Cannondale Diagnostic Tool software on your PC. 3. Power-up the vehicle ECU. 4. Click the MONITOR ECU Parameters button. The ECU monitor window will be displayed.
7 - RECEIVE FAULTS (FROM ECU) The vehicle ECU will record and maintain faults that it encounters during operation. The “RECEIVE Fault(s) (From ECU)” button enables you to read the codes the ECU is currently encountering. Most faults reported by the system can be corrected by examining the connector attached to the device or by tracing the continuity between the ECU connectors and the device connector. NOTE : Obtain the vehicle’s wiring diagram before attempting any testing. 1.
8 - UPDATING CALIBRATIONS The UPDATE Calibrations button enables you to calibrate the Throttle Body Leakage (also called Throttle Body Offset), the Injector Flow Rate, and Injector Offset. The current values for an open or received calibration file are displayed in the main screen: These calibrations compensate or correct for slight manufacturing variations in the vehicle’s throttle body and/or fuel injectors. Anytime these components are serviced or changed, these values must be calibrated.
4. Type in the values in the corresponding fields and click “OK.” The new values will display in the main screen. 5. Now, you have to send these values to the ECU for them to take effect. Click the “SEND Calibration File (to ECU)” button. 9 - PROGRESS INDICATOR Whenever data is being transferred between the vehicle ECU and PC a progress indicator displays in the upper right area of the main screen. Data transfers should take no more than 1 minute.