13MBS5650HGB September, 2009

PART NUMBER 5650

OPERATING MANUAL

®

® 13MBS5650HGB MOTORBIKE SCANNER 5650

Dear Customer,

This product is part of the MOTORSCAN® family of products. It is the result of many years of research and development.

MOTORSCAN® is glad to have you as a customer.

Please contact one of our authorized distributors or our customer service department for any technical questions.

ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

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ENGLISH ® 13MBS5650HGB MOTORBIKE SCANNER 5650

INDEX

INDEX ...... I

INTRODUCTION...... 1 IMPORTANT INFORMATION ABOUT PERSONAL SAFETY...... 2 IMPORTANT INFORMATION ABOUT PRODUCT SAFETY...... 6 GENERAL INFORMATION...... 7 INSTALLATION...... 7 OPERATING INFORMATION ...... 7 CLEANING...... 7 SYMBOLS ...... 8

PRODUCT DESCRIPTION ...... 9 1.1 SPECIFICATIONS ...... 9 1.2 FRONT VIEW...... 10 1.3 DESCRIPTION OF KEYPAD...... 11 1.4 REAR VIEW ...... 12 1.5 STANDARD ACCESSORIES FOR MODEL 5650 ...... 13 1.6 STANDARD ACCESSORIES FOR MODEL 5650/EXP ...... 15 1.7 OPTIONAL...... 19

CONNECTING ...... 25 2.1 CONNECTING THE SCAN TOOL FOR START-UP...... 25 2.2 IDENTIFICATION...... 26 2.3 CONNECTING TO THE MOTORCYCLE USING STANDARD CABLES...... 28 2.3.1 STANDARD CABLES CONNECTION DIAGRAM...... 29 2.4 CONNECTING THE 5603 DATA ROUTER ...... 30 2.5 CONNECTING TO THE MOTORCYCLE USING A MASTER/SLAVE CABLE ...... 31 2.6 CONNECTING TO THE MOTORCYCLE USING BMW SLAVE CABLE...... 32

INDEX i ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

MOTORCYCLE DIAGNOSTICS ...... 33 3.1 DIAGNOSTIC FUNCTIONS ...... 34 3.2 SELECTING THE SEARCH MODE FOR SYSTEMS INSTALLED ...... 35 3.2.1 MANUAL SEARCH...... 35 3.2.1.1 MANUAL SEARCH BY VEHICLE SELECTION...... 36 3.2.1.2 MANUAL SEARCH BY ECU SELECTION...... 39 3.2.2 AUTOMATIC SEARCH CONNECTION...... 41 3.3 ECU MENU ...... 43 3.3.1 ECU DATA ...... 44 3.3.2 PARAMETERS...... 44 3.3.3 READING STORED FAULTS...... 45 3.3.4 ERASING STORED FAULTS...... 47 3.3.5 DIAGNOSTIC PROCEDURES ...... 48 3.3.6 CONFIGURATIONS ...... 49 3.4 SETUP MENU ...... 50 3.5 HELP FUNCTION...... 50

HARLEY-DAVIDSON® QUICK START PROCEDURE...... 51 4.1 STEP 1: USING THE VEHICLES LIST ...... 51 4.2 STEP 2: CONNECTING THE HARLEY DAVIDSON CABLE TO THE SCANNER ...51 4.3 STEP 3: LOCATING THE MOTORCYCLE DIAGNOSTIC PORT ...... 52 4.4 STEP 4: CONNECTING THE SCANNER TO THE MOTORCYCLE ...... 59 4.5 STEP 5: STARTING DIAGNOSTIC WORK ON THE MOTORCYCLE ...... 60

SUZUKI/ INJECTION ADJUSTMENT...... 63 INITIAL STEPS ...... 63 5.2 ADJUSTING THE INJECTION SYSTEM USING THE / CAGIVA CABLE ..66 5.2.1 ORIGINAL VALUES RESET ...... 67 5.2.2 IDLING ADJUSTMENT...... 68 5.2.3 REGULATION AT 10%...... 69 5.2.4 REGULATION AT 25% - 50% - 75%...... 70 5.2.5 REGULATION AT 100%...... 72

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APPENDIX ...... 73 6.1 SCREEN ...... 73 6.1.1 “MENU” SCREEN ...... 73 6.1.2 “PROCEED – EXIT” SCREEN ...... 74 6.1.3 “BINARY SELECTION” SCREEN ...... 74 6.1.4 “MESSAGE” SCREEN ...... 75 6.1.5 “MULTIPLE SELECTION” SCREEN ...... 76 6.1.6 “HELP” SCREEN...... 77 6.1.7 “PARAMETERS TABLE” SCREEN ...... 78 6.2 TYPES OF DIAGNOSTICS ...... 79 6.2.1 SERIAL COMMUNICATION...... 79 6.2.2 BLINKING CODES...... 79 6.2.3 DISPLAY CODES ...... 80 6.2.4 MANUAL PROCEDURE...... 80

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INTRODUCTION

This manual is an integral part of the product. Read these instructions carefully before using the tool and keep them in a safe place. MOTORSCAN S.p.A. apologizes for any errors in the text.

Brand names and products mentioned in the document are registered brands of the relevant owners.

MOTORSCAN S.p.A. is not responsible to third parties for specific, collateral, accidental, direct, or indirect damage related to, or deriving from the product purchase and use.

Copies of this document and technical information are available from an authorized distributor of MOTORSCAN S.p.A..

This document may not be copied or distributed, in part or its entirety, in any form or by any means, without prior written authorisation from MOTORSCAN S.p.A..

MOTORSCAN® S.p.A. Str. Martinella, 28/A 43124 PARMA - Italy Tel. +39 0521 266211 Fax +39 0521 266279 www.motorscan.com E-mail: [email protected] [email protected]

INTRODUCTION 1 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

IMPORTANT INFORMATION ABOUT PERSONAL SAFETY GENERAL SAFETY IN the WORKSHOP.

DANGER OF SUFFOCATION

GASOLINE ENGINES Exhaust gases from gasoline vehicles contain Carbon Monoxide, a colorless and odorless gas which, in case of inhalation, can cause serious physical injury or death. When working under a vehicle, be very careful. Some components of exhaust gases are heavier than air. Be careful also when working on LPG-propelled vehicles.

DIESEL ENGINES The exhaust gas from a diesel engine has a composition that varies according to: type of engine, of induction, conditions of use, and fuel composition. The diesel exhaust includes gas (CO, CO2, NO and HC) and particles (soot, sulphates and PAHs). The small carbon particles forming soot remain suspended in the air and can be breathed in. Small amounts of toxic components are also present.

SAFETY MEASURES: Always ensure good ventilation and breathing protection (especially when working under a vehicle. Always operate the exhaust fan system when working in confined spaces.

DANGER OF CRUSHING

Ensure that the vehicle is locked in place to prevent possible crushing.

SAFETY MEASURES: Make sure that the vehicle is unable to move by engaging the hand brake and locking the wheels.

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DANGER OF INJURY

Whether engines are at a standstill or operating, there are moving parts (belts, etc.) that can injure hands and arms. Pay particular attention to electrically operated fans since these may unexpectedly start up even when the engine itself is off.

SAFETY MEASURES: Never place hands near moving parts when the engine is on. When working near electrically operated fans, let the engine cool first and then unplug the fan.

Keep the test instrument connection wires as far as possible away from moving parts of the engine.

DANGER OF BURNS

Some of the components in engines (exhaust gas manifold, etc.) can become very hot, as can certain sensors. Remember to never touch these parts.

SAFETY MEASURES: Wear protective gloves. Never allow the test instrument connection wires to rest on or near hot parts. Never keep the engine running after the tests.

INTRODUCTION 3 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DANGER OF FIRE OR EXPLOSION

When work is being carried out on the fuel system (fuel pump, injectors and carburetor, etc.) there may be a risk of fire or explosion owing to the fuels used and/or the vapors that these products form.

SAFETY MEASURES: Disconnect the ignition system. Allow the engine to cool.

Do not use open flames or anything liable to produce sparks.

Do not smoke.

Collect any spilled fuel.

Operate exhaust fans in closed rooms.

SOUND LEVEL

When working near a vehicle, especially at high engine speed, noise levels can reach 90dB. Long term exposure to such noise sources can cause hearing damage.

SAFETY MEASURES:

Wear hearing protection.

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DANGEROUS VOLTAGE

Work safely on vehicle electrical systems. Do not touch electrically “live” parts of engines. Be aware of the risk of shock from damaged connections.

SAFETY MEASURES:

Only use the cables supplied with the test instrument. Make sure that the insulation is not damaged.

Do not touch live parts of the vehicle when testing with the engine running.

Only make test connections with suitable systems (test cables, specific adapter cables).

DANGER OF ASFIXIATION

If subjected to high temperatures (over 250 °C or owing to fire outbreaks), exhaust gas hoses may release highly toxic gases.

SAFETY MEASURES: Immediately contact a physician if such gas is inhaled.

Use neoprene or PVC gloves to eliminate combustion residuals.

Fire residuals can be neutralized with a calcium hydroxide solution. This forms calcium fluoride which can be removed with water.

INTRODUCTION 5 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DANGER OF CORROSION

Acids can harm the skin if not protected.

The residual condensate in gas sampling hoses and the condensate separator unit contains acids. Take great care when replacing the oxygen sensor (O2) and the nitric oxide sensor (NO). They contain highly corrosive substances. Corrosive liquid may be spilled if a liquid crystal indicator is broken. This liquid should never be touched, inhaled or swallowed.

SAFETY MEASURES: In case of contact with the skin, immediately wash the affected area with water and contact a physician.

Immediately contact a physician if such products are inhaled or swallowed.

IMPORTANT INFORMATION ABOUT PRODUCT SAFETY This MOTORSCAN product provides a high level of protection against the risk of electric shock. The installer is responsible for connecting it to a correctly grounded electrical socket. Seek technical assistance before using an adapter or extension cable. These devices could interfere with the grounding circuit. Connection of the appliance to an incorrectly wired electrical outlet could result in electrocution.

Comply with the following rules to protect against the risk of electrocution:

Only connect the instrument to electrical sockets delivering the correct voltage. Contact the electric utility if you are uncertain as to the outlet voltage.

If the instrument has other wires besides the power cable, these must be connected to their respective connectors before connecting the power cables to the electrical outlet. Disconnect the power cables from the sockets before removing other wires.

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Strictly comply with the following instructions when servicing:

Always replace fuses with others of equal value (see indications on the label or in this manual). NEVER open the cover of the instrument: you could risk electrocution. This operation may only be carried out by a qualified technician and not before having disconnected the power supply cable. Deviating from the instructions in this manual or attempting to repair the instrument carries the risk of electric shock.

Pressing too hard on the display may damage the instrument. . Please contact a service technician if the instrument fails to correctly function after following the operating instructions. Check that all installed spare parts have technical characteristics identical to those of the original parts. Other parts may not possess the same safety characteristics.

Always contact qualified technical personnel if repairs are required.

GENERAL INFORMATION INSTALLATION Never allow the instrument to be exposed to the sun for long periods of time or to allow it to stand near hot equipment (stoves, heaters, etc.): the maximum operating temperature is 40 °C/ 105 F. Do not move the instrument from a hot place to a cold place and vice versa. The formation of condensation inside the device may damage the electronic circuits.

Protect the instrument from rain or from excessive moisture.

OPERATING INFORMATION To prevent contamination from toxic gas, it is advisable to use the instrument in a sufficiently ventilated place or to channel exhaust gases outdoors. Never pull on the instrument’s cables. All connections should be made when the vehicle engine in question is off. Check that all cables are far away from hot parts (over 50 °C/ 130F) or moving parts. Disconnect all engine connections before moving the vehicle in question.

CLEANING When necessary, the outer surfaces of the instrument should be cleaned: never use cleaning products containing spirits, ammonia or gasoline. Only use neutral detergents and a soft, slightly moistened cloth.

INTRODUCTION 7 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

SYMBOLS Symbols used in the DEVICE:

ALTERNATING CURRENT

GROUND PROTECTION

CONSULT THE INSTRUCTION MANUAL

RISK OF BURNS

RISK OF ELECTROCUTION

NEVER ATTEMPT TO REMOVE THE COVER (operation only to be carried out by qualified technicians)

CE CONFORMITY MARK It indicates compliance with the relevant European Union Directives.

INFORMATION FOR THE USERS Pursuant to art.13 of the Law Decree 25 July 2005, n.151 “Implementation of directives 2002/95/CE, 2002/96/CE and 2003/108/CE on the reduction of the use of hazardous substances in the electrical and electronic equipment and waste disposal”.

The symbol of the bin with crossed lines on the equipment or on the packaging indicates that the product at the end of its useful life has to be collected separately from other waste.

Disposal of the equipment at the end of its life is organized and managed by the manufacturer. The user wishing to dispose of the equipment should contact the manufacturer and comply with the system the latter has adopted for disposal of the equipment at the end of its life.

Unauthorized disposal of the product by the owner may be penalized under the relevant laws in force in the country in question.

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PRODUCT DESCRIPTION

1.1 SPECIFICATIONS

DIMENSIONS: 225 x 105 x 70 mm (8.8 x 4.1 x 2.75”)

WEIGHT: 475 g (17oz)

POWER SUPPLY: 8-45 V (typically 12 V from battery or vehicle diagnostic socket)

POWER CONSUMPTION: 3.2 W @ 12 V

SHELL: ABS palm unit

DISPLAY: Backlit LCD graphic display (128x64 pixel or 21x8 characters).

KEYPAD: 23 keys (alphanumeric, functions, arrows , ESC, ENTER).

SERIAL INTERFACE: 1 complete RS232 (HOST connection for SW downloading).

PARALLEL INTERFACE: Reserved

DIAGNOSTIC INTERFACE: DB15 proprietary connection (for the connection to diagnostic cables and Data Router mod. 5603).

INTERNAL MEMORY: 12MB internal flash memory, updated via serial link

PROTECTION KEYS: Hardware with chip card to enable software updates.

COMMUNICATION PROTOCOLS: ISO14230-4 (Keyword 2000) ISO9141-2 ISO11519-4 (SAE J1850 41.6 Kbps PWM) (SAE J1850 10.4 Kbps VPW) ISO15765-4 (CAN BUS) PROPRIETARY PROTOCOLS

PRODUCT DESCRIPTION 9 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

1.2 FRONT VIEW

RS232 INTERFACE FOR CONNECTION TO PC (service use).

PARALLEL INTERFACE (reserved)

GRAPHIC DISPLAY

KEYPAD

DB15 INTERFACE FOR DIAGNOSTIC CABLES CONNECTION AND 5603 DATA ROUTER.

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1.3 DESCRIPTION OF KEYPAD

FUNCTION KEYS

ARROW KEYS

ENTER KEY

ESC KEY

ALPHANUMERIC KEYPAD

ESC: Returns scan tool to previous menu or interrupts a function. ENTER: confirms the selected function. Ï Ð Í Î: for selecting lists, navigation or cursor.

F1, F2, F3, F4, F5: Use of function keys is explained in the software text.

ALPHANUMERIC KEYPAD: The alphanumeric keypad is used to enter numbers and letters, in the same way as on cellular phones.

PRODUCT DESCRIPTION 11 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

1.4 REAR VIEW

SMART (CHIP) CARD INPUT. USED TO VALIDATE SOFTWARE UPDATES

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1.5 STANDARD ACCESSORIES for model 5650 Next to each motorcycle model in the “Vehicles List” you can find the part number for the cable required for a particular function.

DESCRIPTION and PART NO. PICTURE

Carrying case

Part number: 22ST5600KP3*A

Carrying case varies by region/ country of sale

Scan tool

Part number: SL5650

CD with: - Operating instructions - Vehicles list

Part number: 13CDISTR

PRODUCT DESCRIPTION 13 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DESCRIPTION and PART NO. PICTURE

Battery power cable

Part number: SL010051

Packard plug cable

Applications: Aprilia1, , Cagiva1, Ducati, Gas Gas, , KVN Motor, , Malaguti1, , , MV Agusta, , Sherco, , Voxan.

Part number: SL010421

1 Only Marelli systems

Universal cable

Applications: Aprilia2, BMW, Cagiva2, Harley Davidson3, Honda, Kawasaki, Mondial, Suzuki.

Part number: SL010422

2Except Marelli systems 3Only Marelli systems

Serial cable

Part number: SL010167*A (2 meters)

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1.6 STANDARD ACCESSORIES for model 5650/EXP The part number for the cable required for a particular function is next to each motorcycle model in the “Vehicles List”. Exact cables included vary by kit. Consult distributor.

DESCRIPTION and PART NO. PICTURE

Carrying case

Part number: 22ST5600GR

Carrying case varies by region/ country

Scan tool

Part number: SL5650

CD with: - Operating instructions - Vehicles list

Part number: 13CDISTR

PRODUCT DESCRIPTION 15 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DESCRIPTION and PART NO. PICTURE

Battery power cable

Part number: SL010051

Universal cable

Applications: Aprilia2, BMW, Cagiva2, Harley Davidson3, Honda, Kawasaki, Mondial, Suzuki.

Part number: SL010422

2Except Marelli systems 3Only Marelli systems

Data Router No. 5603

Part number: SL5603

Required for the following cables: MASTER SL010474

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DESCRIPTION and PART NO. PICTURE Master cable

Part number: SL010474

Required for the following cables: KAWASAKI 4 Pin SL010458 KAWASAKI 8 Pin SL010459 HONDA 4 Pin SL010460 HONDA 3 Pin SL010461 HONDA 2 Pin SL010462 SUZUKI 6 Pin SL010463 SUZUKI 4 Pin SL010464 YAMAHA 3 Pin SL010475 CAGIVA 10 Pin SL010476 BMW SL010478 HARLEY-DAVIDSON SL010480 OBDII SL010481 PACKARD (old) SL010482 /DITECH SL010483 KTM SL010489 APRILIA/SAGEM SL010490 PEUGEOT SL010491 KYMCO SL010493 PACKARD (new) SL010499 KAWASAKI 4P/2007 SL010500 BRP SL010501 KAWASAKI REG.INJ. SL010502 6P SL010505 VDO SL010506

BMW slave cable

Part number: SL010478

Harley-Davidson slave cable

Part number: SL010480

PRODUCT DESCRIPTION 17 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DESCRIPTION and PART NO. PICTURE

OBDII slave cable

Part number: SL010481

Packard slave cable (new)

Applications: Aprilia1, Bimota, Cagiva1, Ducati, Gas Gas, Gilera, KVN Motor, Laverda, Malaguti1, Moto Guzzi, Moto Morini, MV Agusta, Piaggio, Sherco, Vespa, Voxan.

Part number: SL010499

1 Only Marelli and Siemens systems

Serial cable

Part number: SL010167*A (2 meters)

Supply cable

Part number: SL010372

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1.7 OPTIONAL The part number for the cable required for a particular function is next to each motorcycle model in the “Vehicles List”. Exact cables included vary by kit. Consult distributor.

DESCRIPTION and PART NO. PICTURE

KAWASAKI 4 Pin SLAVE CABLE

Part number: SL010458

KAWASAKI 8 Pin SLAVE CABLE

Part number: SL010459

HONDA 4 Pin SLAVE CABLE

Part number: SL010460

HONDA 3 Pin SLAVE CABLE Applications: Honda with blinking code systems..

Part number: SL010461

WARNING: do not use on Aprilia/Ditech systems.

PRODUCT DESCRIPTION 19 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DESCRIPTION and PART NO. PICTURE

HONDA 2 Pin SLAVE CABLE

Part number: SL010462

SUZUKI 6 Pin SLAVE CABLE

Part number: SL010463

SUZUKI 4 Pin SLAVE CABLE

Part number: SL010464

YAMAHA 3 Pin SLAVE CABLE

Part number: SL010475

CAGIVA 10 Pin SLAVE CABLE

Part number: SL010476

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DESCRIPTION and PART NO. PICTURE

PACKARD SLAVE CABLE (old)

Part number: SL010482

WARNING: do not use on Aprilia models with SIEMENS VDO system

Replaced by SL010499

APRILIA / DITECH SLAVE CABLE Applications: Aprilia Ditech systems.

Part number: SL010483

WARNING: do not use on Honda systems with blinking code.

KTM SLAVE CABLE

Part number: SL010489

APRILIA/SAGEM SLAVE CABLE Applications: Aprilia Sagem systems.

Part number: SL010490

PRODUCT DESCRIPTION 21 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DESCRIPTION and PART NO. PICTURE

PEUGEOT SLAVE CABLE

Part number: SL010491

KYMCO SLAVE CABLE

Part number: SL010493

KAWASAKI 4 Pin/2007 SLAVE CABLE

Part number: SL010500

BRP SLAVE CABLE

Part number: SL010501

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DESCRIPTION and PART NO. PICTURE

KAWASAKI REG. INJ. SLAVE CABLE

Part number: SL010502

BENELLI 6 Pin SLAVE CABLE

Part number: SL010505 VDO SLAVE CABLE

Part number: SL010506

SUZUKI / CAGIVA CABLE

Part number: SL010477

USB/SERIAL ADAPTER

Part number: 10005

SERIAL CABLE

Part number: SL010092 (8 meters)

PRODUCT DESCRIPTION 23 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

DESCRIPTION and PART NO. PICTURE

AC/DC 15W Power supply

Various according to the destination country.

The picture on the right is only an example.

VIDEO 5605

Part number: 5605/EXP

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CONNECTING

WARNING!

NEVER CONNECT THE TWO CLAMPS OF THE SL010422 CABLE TO THE BATTERY.

WHEN STARTING A DIAGNOSTIC PROCEDURE ON A MOTORCYCLE, THE VCC CLAMPS ON THE SL010051 CABLE MUST BE CONNECTED ONLY TO THE BATTERY OF THE MOTORCYCLE BEING TESTED.

NEVER USE CABLES OTHER THAN THOSE SUPPLIED WITH THE TOOL.

2.1 CONNECTING THE SCAN TOOL FOR START-UP To turn the tool on, follow these instructions: 1) Connect the 15-pole female connector on the SL010421, SL010422 or SL010372 cable to the scan tool; 2) If a 12V power supply unit is available, connect it to the female jack on the cable and go to step 5; 3) If this is not the case, connect the SL010051 cable to the cable jack; 4) Connect the battery clamps to the terminals on a 12V power supply (red clip to the positive terminal and black clip to the negative terminal); 5) Verify that the scan tool switches on automatically. After a few seconds of initialization, the tool displays the following screen.

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CONNECTING 25 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

2.2 MOTORCYCLE IDENTIFICATION To commence the diagnostic procedure, identify in the VEHICLES LIST the correct diagnostic cable for the motorcycle being worked on (see Vehicles List). Please note: there may be several ways (with different cables) to connect to each bike. These are listed in the vehicles list.

421 = SL0100421 Packard cable 051 = SL010051 battery power supply cable

Follow the connection procedures below:

VEHICLE CABLES SECTION LIST PART NUMBER CODE Connecting to the motorcycle 421 + 051 SL010421 + SL010051 using standard cables (section 2.3) 422 + 051 SL010422 + SL010051

480 + M + R SL010480 + SL010474 + 5603 Connecting to the motorcycle using a MASTER/SLAVE 481 + M + R SL010481 + SL010474 + 5603 cable combination (section 2.5) SL010499 + SL010051 + 499 + 051 + M + R SL010474 + 5603 Connecting to the motorcycle 478 + M + R SL010478 + SL010474 + 5603 using BMW slave cable SL010478 + SL010051 + (section 2.6) 478 + 051 + M + R SL010474 + 5603 Injection adjustment cable SUZUKI / CAGIVA (section. 477 + 051 + R SL010477 + SL010051 + 5603 5) 372 + 051 SL010372 + SL010051 Powering the tool (section. 2.1) 372 + AC/DC SL010372 + Power supply

ENGLISH 26 CONNECTING ® 13MBS5650HGB MOTORBIKE SCANNER 5650

VEHICLE CABLES SECTION LIST PART NUMBER CODE 458 + M + R SL010458 + SL010474 + 5603

459 + M + R SL010459 + SL010474 + 5603 SL010460 + SL010051 + 460 + 051 + M + R SL010474 + 5603 SL010461 + SL010051 + 461 + 051 + M + R SL010474 + 5603 SL010462 + SL010051 + 462 + 051 + M + R SL010474 + 5603 463 + M + R SL010463 + SL010474 + 5603 SL010464 + SL010051 + 464 + 051 + M + R SL010474 + 5603 475 + M + R SL010475 + SL010474 + 5603

476 + M + R SL010476 + SL010474 + 5603 Connecting to the motorcycle SL010499 + SL010051 + 499 + 051 + M + R using a MASTER/SLAVE SL010474 + 5603 cable combination (section. SL010483 + SL010051 + 483 + 051 + M + R 2.5) SL010474 + 5603 SL010489 + SL010051 + 489 + 051 + M + R SL010474 + 5603 SL010490 + SL010051 + 490 + 051 + M + R SL010474 + 5603 SL010491 + SL010051 + 491 + 051 + M + R SL010474 + 5603 SL010493 + SL010051 + 493 + 051 + M + R SL010474 + 5603 500 + M + R SL010500 + SL010474 + 5603

501 + M + R SL010501 + SL010474 + 5603

502 + M + R SL010502 + SL010474 + 5603

505 + M + R SL010505 + SL010474 + 5603

506 + M + R SL010506 + SL010474 + 5603

CONNECTING 27 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

2.3 CONNECTING TO THE MOTORCYCLE USING STANDARD CABLES 1) Connect the 15-pole female connector, on the diagnostics cable being used, to the scan tool (see section "STANDARD CABLES CONNECTION DIAGRAM"); 2) Connect the cable SL010051 (with battery clamps) to the diagnostic cable jack (see section "STANDARD CABLES CONNECTION DIAGRAM"); 3) Connect the battery clamps to the battery terminals on the vehicle being tested (red clamp on the positive terminal and black clamp on the negative terminal, see section "STANDARD CABLES CONNECTION DIAGRAM"); 4) Verify that the scan tool switches on automatically. After a few seconds of initialization, the tool displays the following STAND-BY screen.

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WARNING!

WHEN USING STANDARD CABLES SL010421 AND SL010422, CONNECT THE DIAGNOSTIC SOCKET ONLY WHEN THE SOFTWARE TELLS YOU TO DO SO.

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2.3.1 STANDARD CABLES CONNECTION DIAGRAM

1

2

33

CONNECTING 29 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

2.4 CONNECTING THE 5603 DATA ROUTER The 5603 DATA ROUTER is a signal router. It automatically selects the correct connection on the vehicle diagnostic socket.

To use the BMW, Harley Davidson, OBDII, and MASTER cables, connect the 5603 Data Router between the tool and one of the cables.

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2.5 CONNECTING TO THE MOTORCYCLE USING A MASTER/SLAVE CABLE 1. Connect the 15-pole female connector on the 5603 Data Router to the scan tool; 2. Connect the 25-pole connector on the 5603 Data Router to the SL010474 MASTER cable indicated in the vehicles list by the letter “M”; 3. Connect the 14-pole connector on the MASTER cable to the SLAVE cable indicated in the vehicles list; 4. If the SLAVE cable has a jack, connect the SL010051 cable also; 5. Connect the clamps to the battery terminals on the vehicle being tested (red clamp on the positive terminal and black clamp on the negative terminal); 6. Connect the other end of the cable to the diagnostic socket on the motorcycle; 7. If the motorcycle is a SUZUKI, KAWASAKI or HARLEY-DAVIDSON, switch on the board; 8. Verify that the scan tool switches on automatically. After a few seconds of initialization, the tool displays the following screen.

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CONNECTING 31 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

2.6 CONNECTING TO THE MOTORCYCLE USING BMW SLAVE CABLE 1. Connect the 15-pole female connector on the 5603 Data Router to the scan tool; 2. Connect the 25-pole connector on the 5603 Data Router to the SL010474 MASTER cable indicated in the vehicles list by the letter “M”; 3. Connect the 14-pole connector on the MASTER cable to the SLAVE cable SL010478; 4. If the SL010051 cable is indicated in the vehicle list, connect it to the jack on the SLAVE cable and to the battery terminals on the vehicle being tested (red clamp on the positive terminal and black clamp on the negative terminal). 5. In case you have to connect the SL010051 cable, connect the 3-pin end of the SL010478 cable to the diagnostic socket of the vehicle; in case the SL010051 cable is not required, connect the BMW SLAVE 10-pin end. 6. Verify that the scan tool switches on automatically. After a few seconds of initialization, the tool displays the following screen.

®

12/01/2006 12:03:45

WARNING!

WHEN USING THE BMW CABLE SL010478 TOGETHER WITH THE SL010051 CABLE, CONNECT TO THE DIAGNOSTIC SOCKET ONLY WHEN INSTRUCTED TO DO SO.

ENGLISH 32 CONNECTING ® 13MBS5650HGB MOTORBIKE SCANNER 5650

MOTORCYCLE DIAGNOSTICS Once the scan tool is powered up, as defined in the section "CONNECTING FOR MOTORCYCLE DIAGNOSTICS", the following screen appears.

®

12/01/2006 12:03:45

The menu shown below appears after pressing any key on the scan tool.

- MAIN MENU - Î ADIVA APRILIA ARTIC CAT BENELLI BIMOTA BMW Ð

This menu includes the list of all makes of supported by the software version.

Scroll down to find "SETUP MENU". See description in the relevant section.

MOTORCYCLE DIAGNOSTICS 33 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

3.1 DIAGNOSTIC FUNCTIONS After selecting the make of the motorcycle to be tested, the diagnostic function selection menu appears.

- APRILIA - Î Ignition Inj., display codes Injection Immobilizer ABS SERVICE Ð

The menu being displayed is not always the same. It varies by the manufacturer selected in the "MAIN MENU".

The following is a comprehensive list of diagnostic modules:

- IGNITION: Diagnosing faults in the ECU controlling the ignition. - INJECTION, display codes: Diagnosing faults in the electronic injection ECU, display codes mode. - INJECTION, blinking codes: Diagnosing faults in the electronic injection ECU, blinking codes mode. - INJECTION: Diagnosing faults in the electronic injection ECU. - IMMOBILIZER/ ANTI-THEFT: Diagnosing faults in the immobilizer system. - ABS: Diagnosing faults in the ABS system management ECU. - SERVICE: Resetting the service light. - DASHBOARD: Diagnosing faults in the ECU controlling the dashboard. - BODY COMPUTER: Diagnosing faults in the body computer module. - INJECTION REGUL.: Adjustment function of injection times of the ECU electronic injection. - TRANSMISSION: Diagnostics of the ECU controlling the automatic transmission. - EPT: Diagnosing faults in the electronic accelerator (drive-by-wire) module

ENGLISH 34 MOTORCYCLE DIAGNOSTICS ® 13MBS5650HGB MOTORBIKE SCANNER 5650

3.2 SELECTING THE SEARCH MODE FOR SYSTEMS INSTALLED After selecting the diagnostic function, select the mode for searching for systems installed on the motorcycle and for connecting to the motorcycle:

- INJECTION - Î Manual search Automatic search EXIT

Ð

MANUAL SEARCH: search for systems and connect by motorcycle module or ECU selection.

AUTOMATIC SEARCH: only for systems equipped with serial communication. If no system with serial communication is available for the selected make, the "automatic search" will be negative and connection using the Manual Search mode will be required.

3.2.1 MANUAL SEARCH The manual search by vehicle selection is the easiest operation for users lacking a thorough knowledge of the motorcycle being tested.

The manual search by ECU selection is the quickest operation but the user should know beforehand which systems are installed on the vehicle, where the diagnostic connector is located, and what type it is.

- MANUAL SEARCH- Î Vehicle selection ECU Selection EXIT

Ð

MOTORCYCLE DIAGNOSTICS 35 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

3.2.1.1 MANUAL SEARCH BY VEHICLE SELECTION This function lists the models covered for the manufacturer selected, and supported by the current software version.

- VEHICLE SELECTION - Î Arrecife 250 i.e. Arrecife 500 [01-05] Arrecife 500 [06-..] Atlantic 250 i.e. Atlantic 400 Sprint Atlantic 500 Ð

Selecting the model of the motorcycle to work on brings up the following screens:

- VEHICLE DATA - - VEHICLE DATA - Model: Connector position: Atlantic 500 Under the rh side casing Diagnostic mode: Connector image: Serial communication Press Cable type: 421 + 051 Ð 1/2 2/2

ENGLISH 36 MOTORCYCLE DIAGNOSTICS ® 13MBS5650HGB MOTORBIKE SCANNER 5650

MODEL: Name of the selected motorcycle

TYPE OF DIAGNOSTICS: Type of diagnostics supported by the system on the model selected.

The types of diagnostics supported7 by the tool are the following: - Serial communication; - Blinking codes; - Display codes; - Manual procedure.

TYPE OF CABLE: required diagnostic cable.

CONNECTOR POSITION: indication of the position of the diagnostic connector.

CONNECTOR IMAGE: picture of the connector (push F5)

Screens for the selected system are displayed, indicating the status and connections, if any, of the diagnostic cable and of the key.

- SEARCHING ECU - - SEARCHING ECU -

Start with key off Connect scanner cable And antitheft OFF, if to diagnostic port on present motorcycle

1/3

- SEARCHING ECU - - SEARCHING ECU -

Set engine switch to “RUN” Turn key on

2/3 3/3

WARNING!

WRONG CONNECTIONS CAN IRREPARABLY DAMAGE THE TOOL.

7 For further information, please refer to the APPENDIX.

MOTORCYCLE DIAGNOSTICS 37 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

If the ECU is equipped with serial communication, a connection is attempted.

Connecting …

If the ECU search is successfully, a screen appears similar to the one below.

- SEARCHING ECU - Connected ID received ECU recognized: Marelli IAW 15P

If the search fails, screens appear similar to the ones below.

- SEARCHING ECU - - SEARCHING ECU -

Cannot connect to ECU Turn key off.

1/2 2/2

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3.2.1.2 MANUAL SEARCH BY ECU SELECTION This function lists the ECUs for the manufacturer selected and supported by the current software version installed on the scanner.

- ECU SELECTION - Î Marelli IAW 5AM Marelli IAW 15P Sagem MC1000 Marelli MIU Synerject Ditech Siemens VDO Ð

After selecting the ECU for the motorcycle being tested, the selection is confirmed.

- ECU SELECTION -

ECU selected: Marelli IAW 15P

PROCEED EXIT

After selecting PROCEED, further instructions are displayed (see examples).

- SEARCHING ECU - - SEARCHING ECU -

Start with key off Connect scanner cable And antitheft OFF, if to diagnostic port on present motorcycle

1/3

- SEARCHING ECU - - SEARCHING ECU -

Set engine switch to “RUN” Turn key on

2/3 3/3

MOTORCYCLE DIAGNOSTICS 39 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

WARNING!

WRONG CONNECTIONS CAN IRREPARABLY DAMAGE THE TOOL.

If the ECU is equipped with serial communication, a connection is attempted.

Connecting …

If the ECU search is successful, a screen appears similar to the one below.

- SEARCHING ECU - Connected

ID received xxxxxxxxxxxxx

If the search is negative, error messages are displayed.

- SEARCHING ECU - - SEARCHING ECU -

Cannot connect to ECU Turn key off.

1/2 2/2

ENGLISH 40 MOTORCYCLE DIAGNOSTICS ® 13MBS5650HGB MOTORBIKE SCANNER 5650

3.2.2 AUTOMATIC SEARCH CONNECTION Use this function to connect automatically to the selected manufacturer if that manufacturer supports automatic connection. The user should be familiar with the position, type of diagnostic socket and connection instructions beforehand.

WARNING!

WRONG CONNECTIONS CAN IRREPARABLY DAMAGE THE TOOL.

The following instructions are displayed, .

- SEARCHING ECU - - SEARCHING ECU -

Start with key off Connect scanner cable And antitheft OFF, if to diagnostic port on present motorcycle

1/3

- SEARCHING ECU - - SEARCHING ECU -

Set engine switch to “RUN” Turn key on

2/3 3/3

After completing the above steps, connection to the ECU is attempted.

Connecting …

MOTORCYCLE DIAGNOSTICS 41 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

If the automatic search is successful, a screen appears similar to the one:

- SEARCHING ECU - Connected ID received ECU recognised: Marelli IAW 15P

If the automatic search fails, error messages are displayed.

- SEARCHING ECU - - SEARCHING ECU -

Cannot connect to ECU Turn key off.

1/2 2/2

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3.3 ECU MENU If the system search is successful, a menu appears similar to the one below.

- MARELLI IAW 15P - Î ECU data Parameters Reading stored faults Erasing stored faults Diagnostic procedure Configurations Ï Ð

NOTE:

Some items of the ECU menu might be not be shown. Not all manufacturers support all functions.

ECU DATA: select to display the ECU data.

PARAMETERS: select to display the parameters and live data supported by the ECU.

READING STORED FAULTS: indicates the number of faults, the fault codes and relevant descriptions (if available). Will also indicate possible causes, if available.

ERASING STORED FAULTS: resets all stored faults.

DIAGNOSTIC PROCEDURE: test the components controlled by the ECU.

CONFIGURATIONS: change the settings of some of the components controlled by the ECU.

EXIT: press to stop communication.

MOTORCYCLE DIAGNOSTICS 43 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

3.3.1 ECU DATA By selecting "ECU data" from the "ECU MENU", a screen appears similar to the one below.

- ECU DATA - HW Number: xxxxxxxxxxxxx SW Number: xxxxxxxxxxxxx SW version: xxxxxxxxxxxxx

3.3.2 PARAMETERS By selecting “Parameters” from the "ECU MENU", the list of parameters supported is displayed.

- PARAMETERS - Î Engine rpm Injection time Spark advance Atmospheric pressure Air temperature Water temperature Ð

Using the key select a list of parameters (6 max. simultaneously.) Push F5 to display the selected parameters.

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After confirming the selection, a table (see below) displays the data in real time.

- PARAMETERS – Engine rpm 0RPM Spark advance 0° CO Trimmer 2 Air Tempera... 22°C Water Tempe.. 23°C Throttle po.. 150 mV ------

Use the arrows (Ï Ð Í Î) to move the cursor to scroll long texts. Push the F5 key to display live data on further parameters supported by the ECU.

3.3.3 READING STORED FAULTS Select “Reading stored faults” from the "ECU MENU", to read faults stored in the ECU.

If no faults are stored, the following screen (or something similar) appears.

- STORED FAULTS -

No fault stored

Press to return to the ECU menu.

MOTORCYCLE DIAGNOSTICS 45 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

If faults are present in the ECU, a screen appears similar to the one below, indicating the number of saved DTCs.

- STORED FAULTS -

Stored Diagnostic Fault Codes: 5

Press to display the list including code and description of faults stored.

- STORED FAULTS - Î01 – Throttle valve .. 02 – Atmospheric pre.. 03 – Lambda probe 04 – Engine temperat.. 05 – Air temperature..

Selecting an item from the above list brings up a screen for the specific fault, with additional information, as outlined in the following image.

- DTC: 01- DESCRIPTION: Throttle valve sen.. CONDITION: Present DETAIL: Circuit open/Short..

ENGLISH 46 MOTORCYCLE DIAGNOSTICS ® 13MBS5650HGB MOTORBIKE SCANNER 5650

3.3.4 ERASING STORED FAULTS Selecting "Erasing stored faults" in the "ECU MENU" deletes faults stored in the ECU.

Before deleting fault codes, confirm by pressing PROCEED.

- DELETING FAULTS -

This deletes faults from ECU memory

PROCEED EXIT

Once the procedure has been completed, the status is displayed.

- DELETING FAULTS -

Faults deleted!

MOTORCYCLE DIAGNOSTICS 47 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

3.3.5 DIAGNOSTIC PROCEDURES Select "Diagnostic procedures" in the "ECU MENU", to display the list of tests of components controlled by the ECU and supported by the scan tool.

- DIAGNOSTIC PROCEDURES - Î Fuel pump relay A.T. coil Stepper Revolution counter Injector Fan relay Ð

Selecting a diagnostic procedure in the manu starts the test in question.

- DIAGNOSTIC PROCEDURES - Stepper

Test in progress..

Press to stop the test.

When the diagnostic procedure is complete, the result of the test is displayed.

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3.3.6 CONFIGURATIONS Select "Configurations" in the "ECU MENU" to display the list of setup and adjustment operations controlled by the ECU and supported by the scan tool.

- CONFIGURATIONS - Î Setting TPS to zero CO calibration EXIT

Ð

Selecting an item from the list starts the process. For some setup operations, confirm using CONTINUE. The following screen shows an example of a supported setup function.

- CONFIGURATIONS - TRIMMER value: 2

Ï or Ð to vary. to confirm to cancel

When the setup or adjustment procedure is complete, the result is displayed.

MOTORCYCLE DIAGNOSTICS 49 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

3.4 SETUP MENU Select the SETUP function to bring up the following menu.

- SETUP MENU - Î Language selection System of units Display SW release Update ME0149 Set time & date Display Barcode Ð

LANGUAGE SELECTION: Function used to select language. SYSTEM OF UNITS: Function switches between the English/ AF measurement system (°F, mi, mph, in Hg) and the standard international system (°C, km, km/h, mmHg). DISPLAY SW RELEASE: Function used to view software release. UPDATE ME0149: Optimization of ME0149 board functionality. SET TIME & DATE: Set time and date display. DISPLAY BARCODE: View the scanner’s barcode. MAIN MENU: Return to main menu.

3.5 HELP FUNCTION Help screens (similar to that below) can be accessed by pushing the F1 key at any point in the software with the following exceptions: Images display. Graphic animations display.

- HELP - : confirm item indicated : Exits the list Ï: Moves item indicator up 1 line

Press any key…

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Harley-Davidson® Quick Start Procedure Follow these instructions to use the scan tool on a Harley-Davidson motorcycle.

4.1 STEP 1: USING THE VEHICLES LIST 1. In the Harley-Davidson section, search for the motorcycle in the MODEL column. 2. Verify the model year and the systems covered by the scanner. Note: Some systems are optional and might not be installed on some motorcycles (such as an IMMOBILIZER/ anti-theft system, or ABS). 3. Select the applicable diagnostic cable (CABLES column). All Harley-Davidson motorcycles have the same cable SL010480 (480+M+R). The "R" suffix indicates that the Data Router 5603 is also required; the "M" suffix indicates that the cable Master SL010474 is also required together with the other one. 2 Harley Davidson

Section

3 1

4.2 STEP 2: CONNECTING THE HARLEY DAVIDSON CABLE TO THE SCANNER

1. Connect the 5603 Data Router's 15 pin female connector to the diagnostic port on the scan tool.

2. Connect the 25 pin connector on the 5603 Data Router to the SL010474 MASTER cable, or the Harley-Davidson cable, if the kit includes no Master Cable.

3. Connect the 14 pin connector on the MASTER cable to the SLAVE cable Harley- Davidson SL010480.

4. Check that the scan tool, the Data Router and the Harley Davidson cable are firmly connected.

Harley-Davidson® Quick Start Procedure 51 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

4.3 STEP 3: LOCATING THE MOTORCYCLE DIAGNOSTIC PORT 1. Identify the Harley Davidson motorcycle series: Sportster, Dyna, Softail, VRSC or Touring.

2. With the Sportster series, remove the seat and the left side panel, use the pictures below to identify the 4-pin diagnostic connector, remove the cap, and go to STEP 4.

ENGLISH 52 Harley-Davidson® Quick Start Procedure ® 13MBS5650HGB MOTORBIKE SCANNER 5650

3. With the Dyna series, remove the left side panel and use the pictures below to identify the 4-pin diagnostic connector. Remove the cap and go to STEP 4.

Harley-Davidson® Quick Start Procedure 53 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

ENGLISH 54 Harley-Davidson® Quick Start Procedure ® 13MBS5650HGB MOTORBIKE SCANNER 5650

4. With the Softail series, remove the seat, using the pictures below to identify the 4-pin diagnostic connector. Remove the cap and go to STEP 4.

Harley-Davidson® Quick Start Procedure 55 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

5. For VRSC series motorcycles, remove the left side panel of the steering column. Use the pictures below to identify the 4-pin diagnostic connector, remove the cap and jump to STEP 4.

ENGLISH 56 Harley-Davidson® Quick Start Procedure ® 13MBS5650HGB MOTORBIKE SCANNER 5650

6. With the Touring series, remove the right hand case and the right hand panel. Use the diagrams below to identify the 4-pin diagnostic connector, and remove the cap.

Harley-Davidson® Quick Start Procedure 57 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

ENGLISH 58 Harley-Davidson® Quick Start Procedure ® 13MBS5650HGB MOTORBIKE SCANNER 5650

4.4 STEP 4: CONNECTING THE SCANNER TO THE MOTORCYCLE 1. Connect the SL010480 Harley-Davidson cable to the motorcycle diagnostic socket.

2. If the motorcycle has an immobilizer security system, turn it off.

3. If the lock-set is not installed, turn the key into "IGN" (or IGNITION) position and go to step 5.

4. If the lock-set is installed, turn the key to the "UNLOCK" position and then turn the lock-set to "IGN" (or IGNITION) position.

5. Set the RUN/OFF (engine) switch to "RUN" position.

LOCK SET (TYPE 1)

LOCK SET (TYPE 2) SWITCH RUN/OFF

Harley-Davidson® Quick Start Procedure 59 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

4.5 STEP 5: STARTING DIAGNOSTIC WORK ON THE MOTORCYCLE 1. Check that the Scanner is turned on.

2. Press a key and select "Harley-Davidson" in the MAIN MENU.

3. Select the applicable system for the motorcycle, as defined in the SYSTEM column in the VEHICLES LIST(STEP 1).

4. Select "Automatic search" and wait for connection to the motorcycle ECU.

5. Press the ENTER key ( ) and select the applicable diagnostic function.

1 - MAIN MENU - 2

® DUCATI GAS GAS GILERA Î HARLEY DAVIDSON 12/01/2006 HONDA 12:03:45 HYOSUNG Ï Ð

3 - HARLEY DAVIDSON - - INJECTION - 4.1 Ignition Manual search Î Injection Î Automatic search Immobilizer EXIT ABS Dashboard Radio Ð Ï Ð

- SEARCHING ECU - - SEARCHING ECU -

Start with key off Connect scanner cable and antitheft off, if to diagnostic port on installed motorcycle

1/4 2/4

- SEARCHING ECU - - SEARCHING ECU -

Set engine switch to Turn key on “RUN

3/4 4/4

ENGLISH 60 Harley-Davidson® Quick Start Procedure ® 13MBS5650HGB MOTORBIKE SCANNER 5650

4.2 - SEARCHING ECU - 4.3 Connected ID received ECU recognised: DELPHI ECM

Connecting...

5 - DELPHI ECM - Î ECU data Parameters Reading stored faults Erasing stored faults Diagnostic procedure Configurations Ð

Harley-Davidson® Quick Start Procedure 61 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

Blank Page

ENGLISH 62 Harley-Davidson® Quick Start Procedure ® 13MBS5650HGB MOTORBIKE SCANNER 5650

SUZUKI/CAGIVA INJECTION ADJUSTMENT Follow these instructions to use the optional cable SL010477 to adjust the injection system on SUZUKI and CAGIVA motorcycles, where the ECU has this capability. For additional information about the use of the vehicles list and the connection mode, refer to the following sections in this manual: “MOTORCYCLE IDENTIFICATION”, “CONNECTING THE 5603 DATA ROUTER” and “CONNECTING TO THE MOTORCYCLE USING PROPRIETARY (OEM) CABLES”.

WARNING ! PLEASE READ THE NEXT SET OF INSTRUCTIONS IN DETAIL. THESE DESCRIBE HOW TO USE THE SUZUKI/CAGIVA CABLE PROPERLY. ANY IMPROPER USE OF THIS CABLE CAN CAUSE IRREPARABLE DAMAGE TO THE SCAN TOOL.

INITIAL STEPS 1. Connect the SL010477 cable to the 5603 Data Router. Connect the Data Router to the scan tool. 2. Connect the SL010051 cable to the SL010477 cable. 3. Connect the battery clamps to the battery terminals on the motorcycle being tested (red clamp on the positive terminal and black clamp on the negative terminal). 4. Verify that the scan tool is switched on . 5. Wait for the initial screen to appear and press any key. 6. In the MAIN MENU select “CAGIVA” or “SUZUKI. 7. When the systems selection menu appears, select “Injection Adjustment,” “Manual search” and afterwards “Vehicle selection”. 8. Select the vehicle model and connect the scan tool to the injection system adjustment socket on the motorcycle as described in screens 7.1, 7.2 e 7.3 below. 9. Push the ENTER key ( ) and only now connect the SL010477 cable to the diagnostic socket on the motorcycle, as described in the screen of point 8. 10. At this point you can access the main ECU menu. Select “Configurations” to view the supported adjustments, as described in the next sections.

4 - MAIN MENU - 5

® PEUGEOT PIAGGIO SHERCO Î SUZUKI 12/01/2006 TRIUMPH 12:03:45 VESPA Ï Ð

SUZUKI/CAGIVA INJECTION ADJUSTMENT63 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

6 - SUZUKI - - INJECTION ADJUST. - 6.1 Inj., display codes Î Manual search Injection EXIT Î Injection adjustment Transmission EXIT

Ð Ï Ð

6.2 - MANUAL SEARCH - - VEHICLE SELECTION - 7 Î Vehicle selection Boulevard M50 Black.. ECU selection GSX-R1000 [01-02] EXIT GSX-R1000 [03-07] Î GSX-R1000 Black L.E. GSX-R1000 Limited.. GSX-R1000 Matt Black Ð Ï Ð

7.1 - VEHICLE DATA - - VEHICLE DATA - 7.2 Model: Connector position: GSX-R1000 Black L.E. Under the seat Diagnostic mode : Connector image: Serial communication Press Cable type : 477+051+5603 ½ 2/2

7.3

8 - SEARCHING ECU - - SEARCHING ECU -

Start with key off For the system and antitheft off, if selected, connect the installed Data Router 5603 and the cable SL010477

ENGLISH 64 SUZUKI/CAGIVA INJECTION ADJUSTMENT ® 13MBS5650HGB MOTORBIKE SCANNER 5650

9 - DENSO (S) - - CONFIGURATIONS - 9.1 Î Configurations Î Original values reset EXIT Idling adjustment Regulation at 10% Regulation at 25% Regulation at 50% Regulation at 75% Ð Ð

SUZUKI/CAGIVA INJECTION ADJUSTMENT65 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

5.2 ADJUSTING THE INJECTION SYSTEM USING THE SUZUKI / CAGIVA CABLE The operations described in this section must be carried out only by a qualified technician. This function adjusts the motorcycle injection timing.

The smaller openings of the throttle valve should be adjusted first, as the idling and 10% affect the bigger openings (50%, 75%, 100%).

The adjustments are in real time. If you use the arrow keys to enrich or reduce the fuel, the fuel values, as well as the injection times, are adjusted while the engine is on.

The only exception is the idling adjustment, with all cylinders selected. Here you operate in real time only on one single cylinder. After confirming the adjustment value by pressing the ENTER key, all cylinders are adjusted in sequence to the same value as the first cylinder.

The motorcycle ECU does not provide the current injection time adjustment values. To make adjustments easier, the unit stores the most recent values set using the adjustment cable.

When working on a new motorcycle, where the current injection time configuration is unknown, go to “Original values reset”.

If you intend to work on more than one motorcycle, it is a good idea to create a personal data base of the last values set on each motorcycle.

The following sections show the screens displayed during injection adjustments. These screens indicate which key has which function in the injection adjustment process. Use these keys in sequence to adjust the injection system:

Ï increase the value by 1% Î increase the value by 10% Í decrease the value by 10% Ð decrease the value by 1% to store the set value. to restore the original setting.

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5.2.1 ORIGINAL VALUES RESET This function resets the ECU to its original factory settings. This is necessary when working on a particular motorcycle for the first time.

After selecting “Original values reset” the following screens appear in sequence.

1 - CONFIGURATIONS - - CONFIGURATIONS - 1.1

This function resets Turn key on and set the original ECU engine switch to settings “RUN”.

PROCEED EXIT

1.2 - CONFIGURATIONS - - CONFIGURATIONS - 1.3

Data storage in Turn key off process….

SUZUKI/CAGIVA INJECTION ADJUSTMENT67 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

5.2.2 IDLING ADJUSTMENT This function adjusts the idling injection. It is possible to adjust the idling on each cylinder, and on all cylinders at the same time. Setting a value between +10% - +40% is preferable.

During the storage phase the change in cylinder noise can be heard, depending on the adjustment value percentage.

After selecting “Idling adjustment” the following screens appear in sequence.

1 - CONFIGURATIONS - - CONFIGURATIONS - 1.1

This function regulates the idling Turn key on and start injection engine

PROCEED EXIT 1/3

1.2 - CONFIGURATIONS - - CONFIGURATIONS - 1.3 With engine running, Warm up engine and select in next screen regulate idling to one single cylinder lowest possible value or all cylinder for regulation

2/3 Ð 3/3

2 - SELECT CYLINDERS - - CONFIGURATIONS - 2.1 Î Cylinder 1 In the next screen Cylinder 2 modify the regulation Cylinder 3 value using the arrow Cylinder 4 key. to confirm All entry

Ð

2.2 - CONFIGURATIONS - - CONFIGURATIONS - 2.3 Adjustment value 0% Ï or Î to increase Data storage in Ð or Í to reduce process…. to confirm. to cancel.

After making the adjustments “Stop engine and turn key off”.

ENGLISH 68 SUZUKI/CAGIVA INJECTION ADJUSTMENT ® 13MBS5650HGB MOTORBIKE SCANNER 5650

5.2.3 REGULATION AT 10% This function adjusts the injection opening to 10% of the throttle valve. This function requires the engine to be warmed up. Make sure 93° C (200 °F) is not reached, as this will cause the ECU will try to compensate the overheating and the set adjustments will be incorrect.

After selecting “Regulation at 10%” the following screens appear in sequence.

1 - CONFIGURATIONS - - CONFIGURATIONS - 1.1

This function regulates opening Turn key on and start injection to 10% of engine the throttle valve

PROCEED EXIT 1/3

1.2 - CONFIGURATIONS - - CONFIGURATIONS - 1.3 Warm engine to temperature of Without motorcycle in 82°C(180°F) - gear set target rpm 87°C(190°F). Not value to increase and higher than keep constant 93°C(200°F). 2/3 3/3

1.4 - CONFIGURATIONS - - CONFIGURATIONS - 1.5 In the next screen Adjustment value modify the regulation 0% value using the arrow Ï or Î to increase key. to confirm Ð or Í to reduce entry to confirm. to cancel.

1.6 - CONFIGURATIONS -

Data storage in process….

After making the adjustments “Stop engine and turn key off”. Verify that the idling adjustment has not been negatively affected. If so repeat the idling “Idling adjustment”.

SUZUKI/CAGIVA INJECTION ADJUSTMENT69 ENGLISH 13MBS5650HGB ® MOTORBIKE SCANNER 5650

5.2.4 REGULATION AT 25% - 50% - 75% These functions adjust the injection opening to 25%, 50%, or 75% of the throttle valve.

Warm up the engine. Make sure 93° C (200 °F) is not reached, as this will cause the ECU will try to compensate the overheating and whatever adjustments made will not be saved. After selecting “Regulation at 10%” the following screens appear in sequence.

Once you reach the values which achieve the best engine response at a quick opening of the throttle valve to 25% (see screens 1.3 and 1.4 ), use the same procedure for the points (50% and 75%).

When looking for the optimal value, it is advisable to adjust to +/- 20% of the desired value. After selecting “Regulation at 25%”, “Regulation at 50%”, “Regulation at 75%” the following screens appear in sequence. Only the percentage value of the throttle valve will change.

1 - CONFIGURATIONS - - CONFIGURATIONS - 1.1

This function regulates opening Turn key on and start injection to 25% of engine the throttle valve

PROCEED EXIT 1/4

1.2 - CONFIGURATIONS - - CONFIGURATIONS - 1.3 Warm engine to temperature of Set gear to 1st 82°C(180°F) - speed, set the engine 87°C(190°F). Not rpm at 5000RPM and higher than hold constant 93°C(200°F). Ð 2/4 3/4

1.4 - CONFIGURATIONS - - CONFIGURATIONS - 1.5 In the next screen Open throttle quickly modify the regulation to 25% and check value using the arrow engine response key. to confirm entry

4/4

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1.6 - CONFIGURATIONS - - CONFIGURATIONS - 1.7 Adjustment value 0% Ï or Î to increase Data storage in Ð or Í to reduce process…. to confirm. to cancel.

After making the adjustments “Stop engine and turn key off”.

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5.2.5 REGULATION AT 100% This function adjusts the injection opening to 100% of the throttle valve. To find the optimal value it is advisable make adjustments of +/- 20% of the desired value. Road tests with a complete opening of the throttle valve are required. It is possible that the ideal value is negative.

After selecting “Regulation at 100%” the following screens will appear in sequence.

- CONFIGURATIONS - - CONFIGURATIONS - 1 Regulation at 25% Regulation at 50% This function Regulation at 75% regulates opening Î Regulation at 100% injection to 100% of EXIT the throttle valve

Ï Ð PROCEED EXIT

1.1 - CONFIGURATIONS - - CONFIGURATIONS - 1.2 In the next screen Turn key on and set modify the regulation engine switch to value using the arrow “RUN”. key. to confirm entry

1.3 - CONFIGURATIONS - - CONFIGURATIONS - 1.4 Adjustment value 0% Ï or Î to increase Data storage in Ð or Í to reduce process…. to confirm. to cancel.

After having executed the adjustments “Stop engine and turn key off”.

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APPENDIX

6.1 SCREEN This section describes the main types of screens displayed when using the diagnostic software. The screens shown in the following sections are examples and may be subject to modification.

6.1.1 “MENU” SCREEN

- MAIN MENU - Î ADIVA Selection arrow APRILIA ARTIC CAT BENELLI BIMOTA BMW Ð

Selection arrow direction

The “MENU” screen is for selection of an item from a list.

The functions of the various navigation keys are described below: : return to the previous screen. : select the item indicated. Ï : move the selection arrow up 1 item. Ð : move the selection arrow down 1 item. Í : move the selection arrow up 6 items (only if the menu has more than 6 items). Î : move the selection arrow down 6 items (only if the menu has more 6 items).

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6.1.2 “PROCEED – EXIT” SCREEN

- CONFIGURATIONS -

This function regulates the TPS sensor angle. Highlighted item

PROCEED EXIT

Use the “PROCEED – EXIT” commands to continue by selecting PROCEED or to stop by selecting EXIT.

The functions of navigation keys are described below: : confirm the highlighted item. Í : move the selection to the left. Î : move the selection to the right.

6.1.3 “BINARY SELECTION” SCREEN

- SEARCHING ECU - Select the correct motorcycle diagnostic socket. Î 6 PINS 4 PINS

In the “BINARY SELECTION” screen select one of two options.

The functions of navigation keys are: : return to the previous screen. : confirm the option that has been selected. Ï : move the selection arrow up. Ð : move the selection arrow down.

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6.1.4 “MESSAGE” SCREEN

- CONFIGURATIONS - Refer to the next Indicates the presence of picture. Read on the additional invisible text motorcycle display lines the position of the dash located to the left of the "c00" Ð 4/10

The “MESSAGE” screen displays a message. The current page/total pages indicator is displayed only if there are several “MESSAGE” screens in sequence.

The functions of the various navigation keys are described below: : return to the previous screen or the previous sequence of messages. : display the next message or screen. Ï : move the message screen up one line (only if the message has more than 6 lines). Ð : move the message screen down one line (only if the message contains more than 6 lines). Í : return to the previous message (only in case of messages in sequence).

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6.1.5 “MULTIPLE SELECTION” SCREEN

- PARAMETERS - Selected item Î Throttle valve posi… Selection arrow . Atmospheric pressure . Pressure differene.. Intake air temperat.. Water temperature Speed sensor pulses Ð

Selection arrow direction

The “MULTIPLE SELECTION” screen allows one or more options to be selected from a list.

The functions of the various navigation keys are described below: : return to the previous screen. : add an item to the multiple selection. Ï : move the selection arrow up 1 item. Ð : move the selection arrow down 1 item. Í : move the selection arrow up 6 items (only if the menu has more than 6 items). Î : move the selection arrow down 6 items (only if the menu has more than 6 items). F5 : confirm the multiple selection

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6.1.6 “HELP” SCREEN

- HELP - - HELP - : Confirms item indicated Ð : Moves item : Exits the list indicator down 1 line Ï : Moves item Í : Moves item indicator up 1 line indicator up 6 lines

Press any key… Press any key…

- HELP -

Î : Moves item indicator down 6 lines

Press any key…

The “HELP” screen provides information on the functions of keys displayed in the lower right hand part of the screen.

Push any key to go to the following help screen (if any) or to return to the screen where help was requested.

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6.1.7 “PARAMETERS TABLE” SCREEN

- PARAMETERS – Enabling cursor Engine rpm 0RPM Spark advance 0° CO Trimmer 2 Air Tempera... 22°C Water Tempe.. 23°C Throttle po.. 150 mV ------

The "PARAMETERS TABLE" screen displays live data from the ECU.

To scroll the long texts, press the arrow key (Ð) once.

The functions of the various navigation keys are described below: : return to the parameters selection menu. Ï : move the enabling cursor up 1 line. Ð : move the enabling cursor down 1 line. Í : move the enabling cursor from the right column to the left column. Î : move the enabling cursor from the left column to the right column. F5 : display the table of the following parameters supported by the ECU (6 simultaneously).

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6.2 TYPES OF DIAGNOSTICS 6.2.1 SERIAL COMMUNICATION Serial communication is the most advanced diagnostics mode. A communication handshake is established automatically between the scan tool and the ECU. This type of diagnostic capability also allows the display of live data from the ECU and may support the adjustment of certain functions.

6.2.2 BLINKING CODES Blinking codes are a simple diagnostic mode for identifying fault codes stored in the ECU. Fault codes are indicated by a series of long and short blinks from the malfunction indicator lamp (LED), as described below.

When the malfunction indicator lamp blinks, long blinks denote tens. Short blinks denote units. For instance, in case of error 15, the malfunction indicator gives one long blink (1 ten) and 5 short blinks (5 units).

In the event of more than one fault code, the ECU stores all fault codes. These are then displayed in sequence. The code sequence is repeated until the autodiagnostics mode is activated.

If no fault is present, the malfunction indication lamp does not light up.

For instance, if two faults occur, 12 and then 15, maintenance codes are displayed as follows.

The autodiagnostics function activation mode is explained by messages displayed on the instrument panel of the motorcycle being tested.

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6.2.3 DISPLAY CODES Display codes identify fault codes stored in the ECU. Fault codes are indicated by a number or by an alphanumeric code shown on the display of the motorcycle dashboard.

If more than one fault is present, the ECU stores all fault codes, which are then displayed in sequence. Codes are repeated in sequence until the autodiagnostics mode is activated.

The autodiagnostics function activation mode is explained by messages displayed on the instrument panel of the motorcycle being tested.

6.2.4 MANUAL PROCEDURE Some diagnostic functions can be activated with manual procedures and are described by the scanner on a case-by-case basis.

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FOR TECHNICAL HELP IN NORTH AMERICA, PLEASE CONTACT:

STRATEGIC TOOLS & EQUIPMENT COMPANY TEL: +1.847.356.3220 FAX: +1.213.402.6687 E-MAIL: [email protected]

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