Automotive Manual PDF

The basis of these notes have come from a series of website printouts I obtained over the last couple of years in my effort to understand how the Mikuni BDSR39 carburetors work on my Suzuki SV650. From these printouts, I’ve produced this document aimed at rejetting the SV carburetors yourself rather than taking your bike to a dyno shop and getting it done for you. While a dyno shop will probably produce a more accurate torque/power curve, the DIY wrench monkey will be satisfied in the knowledge that he/she has done it themselves and in doing so, has learned more about their bike as a result. Be aware that rejetting your bike on a dyno normally takes 1 – 2 days, however, doing it yourself is going to take much longer due to the number of times you have to strip down and rebuild your bike for the road tests. To makes things simpler and help you get it right, I’ve divided the rejetting procedure into steps which need to be completed in sequence or you’ll simply compound any problems that you may come across in a later process.
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850 turbo uses a Motronic 4.3 control system, which has a single Electronic Control Module (ECM) to control fuel injection and ignition systems. In addition, Motronic 4.3 control system incorporates an on-board diagnostic function. Signals from various sensors are monitored continuously. If certain signals are lost or become faulty, ECM will adopt fixed substitute values (limp-home mode) to enable vehicle to be driven for certain failures. Substitute values can be adopted for Engine Coolant Temperature (ECT) sensor signal, Throttle Position (TP) sensor signal, Mass Airflow (MAF) sensor signal, and oxygen sensor (HO2S) signal. See Fig. 1.
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Transmission is identified by identification plate attached to transmission case, located on left side, above oil pan. Vehicle Identification Number (VIN) may also be used in identifying transmission. VIN locations are at top left of instrument panel and driver’s-side door post. VIN is used to ensure correct application of component parts and assemblies.
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TECHNICAL INFORMATION
Spark Output: The Enhancer Ignition System for the Honda 400EX produces a high output spark that is approximately double the stock spark output. This increased spark energy allows the use of richer fuel mixtures or even exotic fuel such as alcohol. The MSD Ignition will put out approximately 30,000 volts to the spark plug.
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To get the most from your PowerCard, it is important to recognize the difference between “load,” and throttle position/RPM. For example, put your motorcycle in first gear and hold the throttle wide-open, then do the same thing in fifth. Notice how the rate of RPM change is much faster in first gear than in fifth. This is because the load in fifth gear is much higher. Any given combination of throttle position and RPM can be associated with vastly different loads. PowerCard recognizes this, and uses proprietary algorithms to apply the right amount of additional fuel in the right circumstance. The PowerCard technology is unique because it is load based and does not rely solely on throttle position and RPM; it determines load based on the output from the factory programmed ECU, which has had thousands of hours of development and uses many sensors. Once the PowerCard “knows the load”, you can adjust it to provide the extra fuel needed to get maximum performance from your modifications.
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