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• Page 1
  GSR600 9 9 5 0 0 — 3 6 1 6 0 — 0 1 E…

• Page 2: General Information

  FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSR600 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to…

• Page 3: How To Use This Manual

  HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

• Page 4
  Use engine coolant. wise specified. 99000-99032-11X Apply molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKI 99000-99044-10G MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent grease. Apply or use brake fluid.

• Page 5: Abbreviations Used In This Manual

  ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Engine Control Module : Alternating Current Engine Control Unit (ECU) : Air Cleaner, Air Cleaner Box (FI Control Unit) : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp.

• Page 6
  : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor…
• Page 7
  WIRE COLOR : Black : Green : Pink : Blue : Gray : Red : Brown : Light blue : White : Dark green : Light green : Yellow : Dark gray : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer…

• Page 8: Table Of Contents

  GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ……………..1- 2 GENERAL PRECAUTIONS …………….1- 2 SUZUKI GSR600K6 (’06-MODEL) …………..1- 4 SERIAL NUMBER LOCATION …………..1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION …….1- 5 FUEL …………………..1- 5 ENGINE OIL ……………….1- 5 BRAKE FLUID ………………1- 5 FRONT FORK OIL ……………..1- 5…

• Page 9: Warning/Caution/Note

  GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. …

• Page 10
  GENERAL INFORMATION  * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

• Page 11: Suzuki Gsr600K6 (’06-Model)

  GENERAL INFORMATION SUZUKI GSR600K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.

• Page 12: Fuel, Oil And Engine Coolant Recommendation

  Always select good quality engine oil. Use of API SF/SG or SH/SJ with JASO MA. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative accord- ing to the right chart.

• Page 13: Engine Coolant

  Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

• Page 14: Break-In Procedures

  GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.

• Page 15: Information Labels

  GENERAL INFORMATION INFORMATION LABELS GSR600 GSR600U E-02 E-19 E-24 E-19 1 Noise label 2 Fuel caution label 3 Tire information label 4 General information label 5 General warning label 6 ID plate A: Attached Chain cover…

• Page 16: Specifications

  GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………….2 090 mm Overall width …………….795 mm Overall height …………….1 075 mm Wheelbase …………….1 440 mm Ground clearance…………..130 mm Seat height …………….785 mm Dry mass …………….. 183 kg ENGINE Type ………………

• Page 17
  1-10 GENERAL INFORMATION CHASSIS Front suspension …………..Telescopic, coil spring, oil damped Rear suspension …………..Link type, coil spring, oil damped Front fork stroke…………..130 mm Rear wheel travel …………..134 mm Steering angle…………….. 33° (Right and left) Caster ………………25°15’ Trail ………………
• Page 18
  PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ………… 2- 2 PERIODIC MAINTENANCE CHART…………. 2- 2 LUBRICATION POINTS ……………. 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ……..2- 4 AIR CLEANER………………2- 4 SPARK PLUG………………2- 5 VALVE CLEARANCE…………….2- 7 ENGINE OIL AND OIL FILTER ………….

• Page 19: Periodic Maintenance Schedule

  PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions.

• Page 20: Lubrication Points

  PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. 1 Brake lever holder 2 Brake pedal pivot and footrest pivot 3 Clutch lever holder 4 Side-stand pivot and spring hook 5 Footrest pivot and…

• Page 21: Maintenance And Tune-Up Procedures

  PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (12 months). Replace every 18 000 km (36 months). • Lift and support the fuel tank. (5-3) •…

• Page 22: Spark Plug

  PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (12 months). replace every 12 000 km (24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-13) •…

• Page 23
  PERIODIC MAINTENANCE SPARK PLUG GAP • Measure the spark plug gap with a thickness gauge. • Adjust the spark plug gap if necessary.  Spark plug gap: Standard: 0.7 – 0.8 mm  09900-20803: Thickness gauge ELECTRODE’S CONDITION • Check the condition of the electrode. •…

• Page 24: Valve Clearance

  PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (48 months). • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-13) • Disconnect the CMP sensor coupler 1. • Remove the PAIR control solenoid valve 2. •…

• Page 25
  PERIODIC MAINTENANCE • Remove the valve timing inspection plug 1. • Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches A on the left ends of both camshafts (Ex. and In.) to the positions as shown.
• Page 26
  PERIODIC MAINTENANCE • Turn the crankshaft 360 degrees (one rotation) to bring the “TOP” line on the starter clutch to the index mark of valve tim- ing inspection hole and also to bring the notches A to the position as shown. •…
• Page 27
  2-10 PERIODIC MAINTENANCE NOTE: * Be sure to apply engine oil to tappet shim top and bottom faces. * When seating the tappet shim, be sure the figure printed sur- face faces the tappet. NOTE: Reinstall the camshafts in the specified manner. (  3-97) •…
• Page 28
  PERIODIC MAINTENANCE 2-11 (INTAKE SIDE)
• Page 29
  2-12 PERIODIC MAINTENANCE (EXHAUST SIDE)

• Page 30: Engine Oil And Oil Filter

  PERIODIC MAINTENANCE 2-13 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (2 months) and every 18 000 km (36 months) thereafter. ENGINE OIL REPLACEMENT •…

• Page 31: Fuel Line

  Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle. FUEL LINE Inspect initially 6 000 km (12 months).

• Page 32: Engine Idle Speed

  PERIODIC MAINTENANCE 2-15 ENGINE IDLE SPEED Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter. NOTE: Warm up the engine before adjusting the engine idle speed. • Start the engine, turn the throttle stop screw 1 and set the engine idle speed as follows.

• Page 33: Clutch

  2-16 PERIODIC MAINTENANCE CLUTCH Inspect every 6 000 km (12 months). • Loosen the lock-nut 1 and turn in the adjuster 2 all the way into the clutch lever assembly. • From that position, turn out the adjuster screw 3 rotations. •…

• Page 34: Engine Coolant Level Check

  PERIODIC MAINTENANCE 2-17 COOLING SYSTEM Inspect every 6 000 km (12 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the engine cool- ant reservoir. A Full line B Lower line •…

• Page 35
  2-18 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •…

• Page 36: Drive Chain

  PERIODIC MAINTENANCE 2-19 DRIVE CHAIN Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter. Clean and lubricate every 1 000 km. Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.) * Loose pins…

• Page 37: Drive Chain Slack

  2-20 PERIODIC MAINTENANCE • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the 1 2 3 19 20 21 service limit, the chain must be replaced.  Drive chain 20-pitch length: Service limit: 336.5 mm ADJUSTING •…

• Page 38
  • After washing and drying the chain, oil it with a heavyweight motor oil.  * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is RK525SMOZ7Y. Suzuki recommends to use this standard drive chain as a replacement.

• Page 39: Brake

  2-22 PERIODIC MAINTENANCE BRAKE (BRAKE) Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (12 months). Replace hoses every 4 years. Replace fluid every 2 years.

• Page 40
  PERIODIC MAINTENANCE 2-23 BRAKE PADS Front brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (8-54) …
• Page 41
  2-24 PERIODIC MAINTENANCE BRAKE LIGHT SWITCH • Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
• Page 42
  PERIODIC MAINTENANCE 2-25 FRONT BRAKE • Fill the reservoir with brake fluid to the top of the inspection window. Place the reservoir cap to prevent dirt from entering. • Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle.

• Page 43: Tires

  2-26 PERIODIC MAINTENANCE TIRES Inspect every 6 000 km (12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.

• Page 44: Front Fork

  PERIODIC MAINTENANCE 2-27 FRONT FORK Inspect every 12 000 km (24 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (8-14) REAR SUSPENSION Inspect every 12 000 km (24 months). Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm.

• Page 45: Exhaust Pipe Bolt And Nut

  2-28 PERIODIC MAINTENANCE EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (2 months) and every 12 000 km (24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolts and muffler connecting bolts to the specified torque. Muffler Apply PERMATEX 1372.

• Page 46: Chassis Bolts And Nuts

  PERIODIC MAINTENANCE 2-29 CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-30 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m…

• Page 47
  2-30 PERIODIC MAINTENANCE…

• Page 48: Compression Pressure Check

  PERIODIC MAINTENANCE 2-31 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit…

• Page 49: Oil Pressure Check

  2-32 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 200 – 500 kPa (2.0 – 5.0 kgf/cm ) at 3 000 r/min, Oil temp. at 60 °C If the oil pressure is lower or higher than the specification, the following causes may be considered.

• Page 50: Sds Check

  PERIODIC MAINTENANCE 2-33 SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.

• Page 51: Data At The Time Of Racing

  2-34 PERIODIC MAINTENANCE Data at 3 000 r/min under no load 3 000 r/min Check the manifold absolute pressure. XXX mmHg Data at the time of racing Throttle: Slowly open Throttle: Quick wide open Secondary throttle valve opens closes in according with the engine r/min.

• Page 52
  PERIODIC MAINTENANCE 2-35 Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. Approx. XXX mmHg Data of secondary throttle valve operation at the time of starting Closes fully in approx. XX sec.
• Page 53
  ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ….3- 2 ENGINE REMOVAL AND INSTALLATION………..3- 3 ENGINE REMOVAL …………….3- 3 ENGINE INSTALLATION…………….3- 9 ENGINE DISASSEMBLY…………….3-14 ENGINE COMPONENTS INSPECTION AND SERVICE ………………..3-27 CYLINDER HEAD COVER…………..3-27 CMP SENSOR ………………3-27 PAIR REED VALVE …………….3-27 PCV HOSE ………………..3-28 CAMSHAFT…………………3-28 CAM CHAIN TENSION ADJUSTER …………3-30…

• Page 54: Engine Components Removable With Engine In Place

  ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION REINSTALLATION 3-14…

• Page 55: Engine Removal And Installation

  ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Remove the under covers. (8-5) •…

• Page 56
  ENGINE RADIATOR • Disconnect the radiator inlet hoses 1 and 2. • Disconnect the oil cooler water hose 3. • Open the hose clamp 4. • Remove the radiator mounting bolts. • Move the radiator forward.  Be careful not to bent the radiator fins. •…
• Page 57
  ENGINE • Remove the front engine cover 8. EXHAUST PIPE AND MUFFLER JOINT • Remove the exhaust pipe and muffler joint. (6-3) • Remove the O2 sensor. (6-3) • Remove the radiator mounting bracket 1. ELECTRIC PARTS AND PAIR HOSE •…
• Page 58
  ENGINE • Disconnect the starter motor lead wire 3. • Disconnect the engine ground lead wire 4. • Disconnect the respective lead wire couplers. CKP sensor 5 Generator 6 Side-stand 7 GP switch 8 ECT sensor 9 • Disconnect the ignition coil/plug cap lead wire couplers 0 and CMP sensor lead wire coupler A.
• Page 59
  ENGINE ENGINE SPROCKET AND GEAR SHIFT LEVER • Disengage the gearshift lever 1. • Remove the engine sprocket cover 2. • Remove the clamp 3. • Remove the clutch push rod 4. • Remove the speed sensor rotor 5. • Remove the engine sprocket nut 6 and its washer. NOTE: When loosening the engine sprocket nut 6 , depress the brake pedal.
• Page 60
  ENGINE • Remove the engine sprocket 9. ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolts 1. • Remove the engine mounting bolt 2. • Remove the engine mounting bolt/nut 3.

• Page 61: Engine Installation

  ENGINE • Remove the engine mounting nut 4. • Loosen the engine mounting thrust adjuster lock-nut 5 with the special tool. • Loosen the engine mounting thrust adjuster 6.  09940-14980: Engine mounting thrust adjuster socket wrench NOTE: Do not remove the engine mounting bolt 7 at this stage. •…

• Page 62
  3-10 ENGINE • Tighten the engine mounting thrust adjuster 2 to the speci- fied torque.  Engine mounting thrust adjuster: 23 N·m (2.3 kgf-m) • Tighten the engine mounting thrust adjuster lock-nut 3 to the specified torque with the special tool. …
• Page 63
  ENGINE 3-11 • Tighten all engine mounting bolts and nuts to the specified torque. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. A Left B Right  LENGTH ITEM N·m kgf-m…
• Page 64
  • Install the speed sensor rotor 2. • Tighten the speed sensor rotor bolt 3 to the specified torque.  Speed sensor rotor bolt: 23 N·m (2.3 kgf-m) • Apply SUZUKI SUPER GREASE “A” to the clutch push rod end.  99000-25010: SUZUKI SUPER GREASE “A”…
• Page 65
  ENGINE 3-13 • Replace the exhaust pipe gaskets and muffler connectors with new ones. NOTE: Be sure to face the tabs A on the exhaust pipe gaskets 1 to the engine side when installing them. • Tighten the exhaust pipe bolts, muffler mounting bolts and muffler connecting bolts to the specified torque.

• Page 66: Engine Disassembly

  3-14 ENGINE ENGINE DISASSEMBLY  Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the spark plugs. (2-5) STARTER MOTOR •…

• Page 67
  ENGINE 3-15 CAMSHAFTS • Remove the valve timing inspection cap 1. • Turn the crankshaft to bring the line A on the starter clutch to the index mark B of the valve timing inspection hole and also to bring the cams to the position as shown. •…
• Page 68
  3-16 ENGINE • Remove the intake camshaft 6. • Remove the exhaust camshaft 7. • Remove the dowel pins. CYLINDER HEAD • Remove the water hose 1. • Remove the thermostat cover 2 and thermostat. THERMOSTAT INSPECTION (7-9) • Remove the ECT sensor 3. ECT SENSOR INSPECTION (7-7) •…
• Page 69
  ENGINE 3-17 CLUTCH • Remove the clutch cover 1. • Remove the dowel pins and gasket. • Hold the clutch housing with the special tool.  Do not damage the clutch plates by the special tool.  09920-53740: Clutch sleeve hub holder •…
• Page 70
  3-18 ENGINE • Remove the clutch push rod 8. NOTE: If it is difficult to pull out the push rod 8 , use a magnetic hand or a wire. • Unlock the clutch sleeve hub nut. • Hold the clutch sleeve hub with the special tool. …
• Page 71
  ENGINE 3-19 • Remove the thrust washer F. • Remove the oil pump drive gear G from the primary driven gear assembly H. OIL PUMP • Remove the snap ring 1. • Remove the oil pump driven gear 2. NOTE: Do not drop the snap ring 1 into the crankcase.
• Page 72
  3-20 ENGINE • Remove the gearshift shaft assembly 3 and washer 4. NOTE: Do not drop the washer 4 into the crankcase. • Remove the gearshift cam plate bolt 5 and gearshift cam plate 6. • Remove the gearshift cam stopper 7. STARTER IDLE GEAR •…
• Page 73
  ENGINE 3-21 • Remove the starter clutch cover 8. • Remove the dowel pins and gasket. • Remove the concaved washer 9, starter idle gear No.2 0 and shaft A. STARTER CLUTCH • Hold the starter clutch with the special tool. …
• Page 74
  3-22 ENGINE GENERATOR COVER • Remove the generator cover 1. • Remove the dowel pins and gasket. GENERATOR ROTOR • Hold the generator rotor with the special tool.  09930-44520: Rotor holder • Remove the generator rotor bolt. • Install a bolt A of suitable size to the left end of crankshaft. SUITABLE BOLT A [M12, length: 28 –…
• Page 75
  ENGINE 3-23 GEAR POSITION SWITCH • Remove the gear position switch 1. CRANKCASE BREATHER (PCV) COVER • Remove the crankcase breather cover 1. OIL FILTER • Remove the oil filter with the special tool.  09915-40610: Oil filter wrench OIL COOLER •…
• Page 76
  3-24 ENGINE OIL PRESSURE REGULATOR • Remove the oil pressure regulator case 1. • Remove the oil pressure regulator 2. OIL PRESSURE SWITCH • Remove the oil pressure switch 1. • Remove the oil pipe 2. OIL STRAINER • Remove the oil strainer 3 and its O-ring. LOWER CRANK CASE •…
• Page 77
  ENGINE 3-25 MIDDLE CRANKCASE • Remove the crankcase bolts (M6). • Remove the crankcase bolts (M6), clamp 1 and regula- tor/rectifier backet 2. • Remove the crankshaft journal bolts (M9). NOTE: Loosen the crankcase bolts diagonally with the smaller sizes first.
• Page 78
  3-26 ENGINE • Remove the piston pin circlip 1. • Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the piston head.

• Page 79: Engine Components Inspection And Service

  ENGINE 3-27 ENGINE COMPONENTS INSPECTION AND SERVICE  Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER •…

• Page 80: Pcv Hose

  3-28 ENGINE INSPECTION • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. INSTALLATION • Set new gasket to the PAIR reed valve as shown. PCV HOSE •…

• Page 81
  ENGINE 3-29 CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge 1 to read the clearance at the widest portion, which is specified as follows: …

• Page 82: Cam Chain Tension Adjuster

  3-30 ENGINE • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. …

• Page 83: Cam Chain Tensioner

  ENGINE 3-31 CAM CHAIN TENSIONER INSPECTION • Check the contacting surface of the cam chain tensioner. • If it is worn or damaged, replace it with a new one. CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guides. •…

• Page 84
  3-32 ENGINE • Install the special tool 3 between the valve spring and cylin- der head. • Using the special tools, compress the valve spring and remove the two cotter halves from the valve stem.  09916-14510: Valve lifter 09916-14530: Valve lifter attachment 09916-84511: Tweezers 09919-28610: Sleeve protector …
• Page 85
  ENGINE 3-33 VALVE STEM RUNOUT • Support the valve using V-blocks and check its runout using the dial gauge as shown. • If the runout exceeds the service limit, replace the valve.  Valve stem runout: Service Limit: 0.05 mm …
• Page 86
  3-34 ENGINE VALVE STEM DEFLECTION • Lift the valve about 10 mm from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.
• Page 87
  ENGINE 3-35 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 °C – 150 °C with a hot plate.  Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
• Page 88
  3-36 ENGINE • If the seat width W measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter.  Valve seat width W: Standard: 0.9 – 1.1 mm If the valve seat is out of specification, re-cut the seat. VALVE SEAT SERVICING •…
• Page 89
  ENGINE 3-37 • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. …
• Page 90
  3-38 ENGINE • Install the valve spring with the small-pitch portion A facing cylinder head. B Large-pitch portion C UPWARD D Paint • Put on the valve spring retainer 2, and using the special tool 3, press down the spring, fit the cotter halves 4 to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.
• Page 91
  • Install the intake pipes. WATER BYPASS UNION • Remove the water bypass union 1. • Apply SUZUKI BOND to the thread part of water bypass union and tighten it to the specified torque.  99000-31140: SUZUKI BOND “1207B”  Water bypass union: 12 N·m (1.2 kgf-m)

• Page 92: Clutch

  3-40 ENGINE CLUTCH CLUTCH DRIVE PLATES INSPECTION NOTE: * Wipe off engine oil from the clutch drive plates with a clean rag. * Clutch drive plate No.1: 40 friction pieces * Clutch drive plate No.2 and No.3: 48 friction pieces A Friction piece •…

• Page 93: Oil Pump

  ENGINE 3-41 CLUTCH BEARING INSPECTION • Inspect the clutch release bearing for any abnormality, partic- ularly cracks, to decide whether it can be reused or should be replaced. • Smooth engagement and disengagement of the clutch depends on the condition of this bearing. CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY •…

• Page 94: Generator

  3-42 ENGINE • If a large resistance is felt for rotation, inspect the starter clutch bearing or the starter clutch contacting surface on the starter driven gear for wear and damage. • If they are found to be damaged, replace them with the new ones.

• Page 95: Water Pump

  ENGINE 3-43 WATER PUMP DISASSEMBLY/INSPECTION (7-12) GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. 1 Washer 4 Gearshift cam drive plate 2 Snap ring 5 Plate return spring 3 Gearshift shaft return spring GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION •…

• Page 96: Oil Pressure Regulator

  3-44 ENGINE OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regula- tor with a new one. OIL STRAINER •…

• Page 97: Transmission

  ENGINE 3-45 TRANSMISSION DISASSEMBLY Disassemble the countershaft and driveshaft. Pay attention to the following points: • Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2. • Slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, then remove the 2nd drive gear circlip 5.

• Page 98
  Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE “ A” to it.  99000-25010: SUZUKI SUPER GREASE “A”…
• Page 99
  ENGINE 3-47 TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft…

• Page 100: Cylinder

  3-48 ENGINE CYLINDER CRANKCASE SERVICING (3-51) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set.

• Page 101: Piston And Piston Ring

  ENGINE 3-49 PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm A from the piston skirt end. • If the measurement is less than the limit, replace the piston.  Piston diameter: Service Limit: 66.845 mm at 15 mm from the skirt end …

• Page 102: Piston Ring Groove Width

  3-50 ENGINE PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston rings.  09900-20803: Thickness gauge 09900-20205: Micrometer (0 –…

• Page 103: Crankcase

  ENGINE 3-51 CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer screws 1 and gearshift fork shaft retainer 2 from the lower crankcase. • Remove the gearshift fork shafts 3 and gearshift 4 forks from the lower crankcase. •…

• Page 104
  3-52 ENGINE GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers.  Shift fork thickness: Standard: 4.8 – 4.9 mm  09900-20102: Vernier calipers GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT BEARING Inspection • Inspect the gearshift cam bearing for abnormal noise and smooth rotation.
• Page 105
  • Install the oil seal with the special tool.  09913-70210: Bearing installer set (22) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the gearshift cam 4 with the bearing 5.
• Page 106
  3-54 ENGINE • Install the gearshift forks and their shafts as shown. 6 For 3rd/4th drive gears (17E-3W) 7 For 6th driven gear (17E-1E) 8 For 5th driven gear (17E-1F) • Apply a small quantity of THREAD LOCK to the bearing retainer screws 9.
• Page 107
  ENGINE 3-55 OIL JET Removal • Remove the piston cooling oil jets 1 from the upper crank- case. • Remove the oil jet 2 (for transmission) from the lower crank- case. • Remove the oil jet 3 (for cam chain tension adjuster) from the cylinder head.
• Page 108
  3-56 ENGINE Installation • Fit new O-ring 1 to each piston cooling oil jet as shown and apply engine oil to them.  Use new O-rings to prevent oil pressure leakage. • Install each piston cooling oil jet with the bolt. NOTE: Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque.
• Page 109
  • Remove the oil gallery plugs 4 (for lower crankcase side). Installation • Apply engine coolant to the O-rings of the water jacket plugs  99000-99032-11X: SUZUKI COOLANT • Apply THREAD LOCK to the oil gallery plug 2.  99000-32050: THREAD LOCK “1342”…

• Page 110: Crankshaft And Conrod

  3-58 ENGINE CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with “V” blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. •…

• Page 111
  ENGINE 3-59 CONROD BIG END SIDE CLEARANCE • Inspect the conrod side clearance by using a thickness gauge. • If the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width. •…
• Page 112
  3-60 ENGINE • Remove the bearing caps and measure the width of the com- pressed plastigauge using the envelope scale. This measure- ment should be taken at the widest part of the compressed plastigauge.  Conrod big end oil clearance: Standard: 0.032 –…
• Page 113
  ENGINE 3-61  Crank pin O.D. Code O.D. specification 30.992 – 31.000 mm 30.984 – 30.992 mm 30.976 – 30.984 mm  09900-20202: Micrometer (25 – 50 mm)  Bearing thickness Color C (Part No.) Thickness Yellow 1.492 – 1.496 mm (12164-29G00-0D0) Brown 1.488 –…

• Page 114: Crankshaft Journal Bearing

  3-62 ENGINE CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and middle crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown.  09900-22301: Plastigauge  Never rotate the crankshaft when a piece of plasti- gauge is installed.

• Page 115
  ENGINE 3-63 • Check the corresponding crankcase journal I.D. code number A, “A” or “B” which is stamped on the rear of upper crank- case. • Check the corresponding crankshaft journal O.D. code num- ber B, “A”, “B” or “C” which is stamped on the crankshaft. …
• Page 116
  3-64 ENGINE  Crankshaft journal O.D. specification Code O.D. specification 29.992 – 30.000 mm 29.984 – 29.992 mm 29.976 – 29.984 mm  09900-20202: Micrometer (25 – 50 mm)  Bearing thickness specification Color (Part No.) Thickness Yellow 1.500 – 1.504 mm (12229-29G00-0D0) Brown 1.496 –…

• Page 117: Crankshaft Thrust Bearing

  ENGINE 3-65 CRANKSHAFT THRUST BEARING • With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. L: Left-side thrust bearing R: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.

• Page 118
  3-66 ENGINE  Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing White 2.560 – 2.585 mm 2.475 – 2.500 mm 0.060 – 0.110 mm (12228-17E00-0F0) Yellow 2.535 – 2.560 mm 2.450 –…

• Page 119: Engine Reassembly

  ENGINE 3-67 ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. •…

• Page 120
  3-68 ENGINE • 1st ring 5 and 2nd ring 6 have letters “IT” and “T” marked on the side. Be sure to bring the marked side to the top when fit- ting them to the piston. • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
• Page 121
  ENGINE 3-69 • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent C of each piston head must be brought to the exhaust side.  Be careful not to damage the cylinder wall and piston jet by the conrod.
• Page 122
  3-70 ENGINE • Set the crankshaft to the conrods and upper crankcase. • Apply MOLYBDENUM OIL SOLUTION to the crank pin and bearing surface.  MOLYBDENUM OIL SOLUTION  Be sure to clean the conrod big end. • When fitting the conrod cap, make sure that I.D. code A on each conrod faces intake side.
• Page 123
  ENGINE 3-71 • Insert the right and left thrust bearings with oil groove B fac- ing the crank web. NOTE: Right thrust bearing has green painting. CRANKCASE • Clean the mating surfaces of the crankcases. • Install the dowel pins 1 and O-ring 2 to the upper crank- case.
• Page 124
  3-72 ENGINE • Apply SUZUKI BOND to the mating surface of the middle crankcase.  99000-31140: SUZUKI BOND “1207B” NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.
• Page 125
  ENGINE 3-73 • Install the regulator/rectifier bracket 3 and tighten the other crankcase bolts a little at a time to equalize the pressure.  Crankcase bolt: (M6) Initial: 6 N·m (0.6 kgf-m) Final : 11 N·m (1.1 kgf-m) NOTE: Fit the clamp to the crankcase bolt A . NOTE: Fit a new gasket to the crankcase bolt B .
• Page 126
  3-74 ENGINE TRANSMISSION • Install the bearing pins 1 and the C-rings 2 on the middle crankcase. • Install the countershaft assembly on the middle crankcase. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. •…
• Page 127
  ENGINE 3-75 • Apply SUZUKI BOND to the mating surface.  99000-31140: SUZUKI BOND “1207B” NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.
• Page 128
  3-76 ENGINE • Tighten the crankcase bolts a little at a time to equalize the pressure.  Crankcase bolt: (M6) Initial: 6 N·m (0.6 kgf-m) Final : 11 N·m (1.1 kgf-m) (M8) Initial : 15 N·m (1.5 kgf-m) Final : 26 N·m (2.6 kgf-m) NOTE: * Fit new copper washer to the crankcase bolts A .
• Page 129
  • Apply SUZUKI BOND to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque.  99000-31140: SUZUKI BOND “1207B”  Oil pressure switch: 14 N·m (1.4 kgf-m) NOTE: Be careful not to apply SUZUKI BOND to the hole of thread end.
• Page 130
  3-78 ENGINE OIL PAN • Apply SUZUKI BOND to the mating surface. (3-75)  99000-31140: SUZUKI BOND “1207B” • Install the oil pan. NOTE: Fit the gasket washer to the oil pan bolt A . • Tighten the oil pan bolts diagonally to the specified torque.
• Page 131
   99000-31140: SUZUKI BOND “1207B” • Install the crankcase breather cover 1.  Crankcase breather cover bolt: 10 N·m (1.0 kgf-m) • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the gear position switch as shown.
• Page 132
  3-80 ENGINE • Tighten the water pump mounting bolts to the specified torque.  Water pump mounting bolt: 10 N·m (1.0 kgf-m) NOTE: Pass the gear position switch lead wire 1 under the water pump lib. • Apply engine coolant to the O-ring. •…
• Page 133
  ENGINE 3-81 • Apply SUZUKI BOND to the mating surfaces.  99000-31140: SUZUKI BOND “1207B” NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the covers within few minutes.
• Page 134
  NOTE: Fit the gasket washer to the bolts A . • Install the CKP sensor 3. • Apply SUZUKI BOND lightly to the groove of CKP sensor lead wire gromet.  99000-31140: SUZUKI BOND “1207B”…
• Page 135
  ENGINE 3-83 CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft. NOTE: When installing the cam chain drive sprocket, align the wide spline teeth A and B . CAM CHAIN TENSIONER AND CAM CHAIN GUIDE •…
• Page 136
  • Install the starter idle gear No.2 1, its shaft 2 and concaved washer 3. • Apply SUZUKI BOND lightly to the mating surfaces A at the parting line between the upper and middle crankcases and surface B as shown.
• Page 137
  ENGINE 3-85 • Install the starter clutch cover and tighten its bolt as shown. NOTE: Fit a new gasket washer to the starter clutch cover bolt C as shown.  Use new gasket washer to prevent oil leakage.  Starter clutch cover bolt: 10 N·m (1.0 kgf-m) •…
• Page 138
  3-86 ENGINE NOTE: Hook the return spring end A to the stopper 5 . • Check the gearshift cam stopper moves smoothly. • Locate the gearshift cam in the neutral position. • Install the gearshift cam stopper plate 6. NOTE: Align the gearshift cam pin B with the gearshift cam stopper plate hole C .
• Page 139
  ENGINE 3-87 OIL PUMP • Install the O-ring to the oil pump and apply SUZUKI SUPER GREASE “A” to it.  Use new O-ring to prevent oil leakage. NOTE: Set the oil pump shaft end A to the water pump shaft.
• Page 140
  3-88 ENGINE • Install the oil pump drive gear 1 to the primary driven gear assembly. • Install the primary driven gear assembly. NOTE: Be sure to engage the oil pump driven gear with drive gear and primary driven gear with drive gear. •…
• Page 141
  ENGINE 3-89 • Lock the clutch sleeve hub nut with a center punch. • Install the spring washer seat 9 and spring washer 0 onto the clutch sleeve hub correctly. • Install the clutch push rod A into the countershaft. •…
• Page 142
  3-90 ENGINE • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. NOTE: Insert the outermost drive plate claws B to the other slits C of clutch housing as shown. *1: Direction of outside DRIVE PLATE: a No.2 Drive plate…1 pc [48 friction pieces/I.D.
• Page 143
   Clutch spring set bolt: 10 N·m (1.0 kgf-m) NOTE: Tighten the clutch spring set bolts diagonally. CLUTCH COVER • Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper, middle and lower crankcases as shown.  99000-31140: SUZUKI BOND “1207B”…
• Page 144
  3-92 ENGINE CYLINDER HEAD • Fit the dowel pins 1 and new cylinder head gasket 2 to the cylinder.  Use new gasket to prevent gas leakage. • Place the cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. •…
• Page 145
  ENGINE 3-93 • Apply SUZUKI SUPER GREASE “A” to the O-rings and install them into the cylinder head.  Replace the O-rings with new ones.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Fit the gasket 2 and tighten the ECT sensor.
• Page 146
  3-94 ENGINE  Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.  To adjust the camshaft timing correctly, be sure to align the line A with the index mark B and hold this position when installing the camshafts.
• Page 147
  ENGINE 3-95 • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked “1” C. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. •…
• Page 148
  3-96 ENGINE • Install the dowel pins 3. • Install the O-rings 4 to the camshaft journal holders.  Replace the O-rings with new ones. • Install the camshaft journal holders. “B” NOTE: * Each camshaft journal holder is identified with an embossed letter.
• Page 149
  ENGINE 3-97 • Tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque.  Camshaft journal holder bolt: 10 N·m (1.0 kgf-m)  The camshaft journal holder bolts are made of a spe- cial material and much superior in strength, compared with other types of high strength bolts.
• Page 150
  3-98 ENGINE • Install the gasket 4 and cam chain tension adjuster cap bolt NOTE: Click sound is heard when the cam chain tension adjuster cap bolt is installed. • Tighten the cam chain tension adjuster cap bolt to the speci- fied torque.
• Page 151
  ENGINE 3-99  A Cam chain tension adjuster mounting bolt B Cam chain tension adjuster cap bolt ITEM N·m kgf-m…
• Page 152
  • Install the PAIR reed valves 1 along with the gaskets.  Replace the gaskets with new ones. • Install new gasket 2 to the cylinder head cover. • Apply SUZUKI BOND to the cam end caps of the gasket as shown.  99000-31140: SUZUKI BOND “1207B” …
• Page 153
  • Install the new O-ring 1 to the starter motor.  Use new O-ring to prevent oil leakage. • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the starter motor 2.
• Page 154
  FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING …………..4- 3 ELECTRICAL PARTS …………….4- 3 FUSE…………………. 4- 4 ECM/VARIOUS SENSORS …………..4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE ……4- 6 USING THE MULTI-CIRCUIT TESTER……….4- 9 FI SYSTEM TECHNICAL FEATURES…………4-10 INJECTION TIME (INJECTION VOLUME) ………..
• Page 155
  FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION……. 4-72 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) FUEL INJECTOR CIRCUIT MALFUNCTION……..4-74 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION ….4-76 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION (Only for Immobilizer) …………….

• Page 156: Precautions In Servicing

  FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.

• Page 157: Fuse

  FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.

• Page 158
  FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

• Page 159: Electrical Circuit Inspection Procedure

  FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

• Page 160
  FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
• Page 161
  FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.

• Page 162: Using The Multi-Circuit Tester

  FI SYSTEM DIAGNOSIS USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and — probes may cause the inside of the tester to burnout.

• Page 163: Fi System Technical Features

  4-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

• Page 164: Compensation Of Injection Time (Volume)

  FI SYSTEM DIAGNOSIS 4-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (volume).

• Page 165: Fi System Parts Location

  4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A Speedometer F Intake air pressure sensor (IAPS) B Engine coolant temperature sensor (ECTS) G Intake air temperature sensor (IATS) C Ignition coil H Fuel injector D Speed sensor I HO2 sensor E Cam shaft position sensor (CMPS)

• Page 166
  FI SYSTEM DIAGNOSIS 4-13 J Secondary throttle valve actuator (STVA) N Fuel pump (FP) K Secondary throttle position sensor (STPS) O Fuel pump relay (FP relay) L Throttle position sensor (TPS) P Atmospheric pressure sensor (APS) M Crankshaft position sensor (CKP) Q Tip-over sensor (TOS)

• Page 167: Fi System Wiring Diagram

  4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM…

• Page 168: Ecm Terminal

  FI SYSTEM DIAGNOSIS 4-15 ECM TERMINAL ECM couplers TERMINAL TERMINAL CIRCUIT CIRCUIT STVA signal (STVA. 2A) CKP sensor signal (CKP–) STVA signal (STVA. 1A) Serial data for self-diagnosis Immobilizer indicator light Power source for fuel injector (VM) Immobilizer communication ECM ground (E1) Immobilizer communication —…

• Page 169: Self-Diagnosis Function

  4-16 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is provided.

• Page 170: Dealer Mode

  FI SYSTEM DIAGNOSIS 4-17 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

• Page 171
  4-18 FI SYSTEM DIAGNOSIS CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air temperature sensor (IATS) Atmospheric pressure sensor (APS) Tip-over sensor (TOS) Ignition signal #1 (IG coil #1)

• Page 172: Tps Adjustment

  FI SYSTEM DIAGNOSIS 4-19 TPS ADJUSTMENT 1. Adjust the engine rpm to 1 300 r/min. (2-15) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, remove the air cleaner box (5-13) and follow the procedure below.

• Page 173: Fail-Safe Function

  4-20 FI SYSTEM DIAGNOSIS FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY CMP sensor When camshaft position signal has…

• Page 174
  FI SYSTEM DIAGNOSIS 4-21 STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY Secondary throttle valve Secondary throttle valve is fixed to actuator full close position. When motor dis- “YES” “YES” connection or lock occurs, power from ECM is shut off. STP sensor Secondary throttle valve is fixed to “YES”…

• Page 175: Fi System Troubleshooting

  4-22 FI SYSTEM DIAGNOSIS FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

• Page 176: Visual Inspection

  FI SYSTEM DIAGNOSIS 4-23 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill…

• Page 177: Self-Diagnostic Procedures

  4-24 FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

• Page 178: Use Of Sds Diagnostic Procedures

  FI SYSTEM DIAGNOSIS 4-25 USE OF SDS DIAGNOSTIC PROCEDURES * Do not disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

• Page 179: Use Of Sds Diagnosis Reset Procedure

  4-26 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.

• Page 180: Show Data When Trouble (Displaing Data At The Time Of Dtc)

  FI SYSTEM DIAGNOSIS 4-27 SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.

• Page 181: Malfunction Code And Defective Condition

  4-28 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

• Page 182
  FI SYSTEM DIAGNOSIS 4-29 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated.
• Page 183
  4-30 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated.
• Page 184
  FI SYSTEM DIAGNOSIS 4-31 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM HO2 sensor HO2 sensor output voltage is not input HO2 sensor circuit open or to ECM during engine operation and shorted to ground running condition. (Sensor voltage 0.1 V) P0130 In other than the above value, C44…

• Page 185: C11″ (P0340) Cmp Sensor Circuit Malfunction

  4-32 FI SYSTEM DIAGNOSIS “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CMP sensor and rotor tip •…

• Page 186
  FI SYSTEM DIAGNOSIS 4-33 Step 2 1) Crank the engine a few seconds with the starter motor, and measure the CMP sensor peak voltage at the coupler. 2) Repeat the above test procedure a few times and measure the highest peak voltage. …

• Page 187: C12″ (P0335) Ckp Sensor Circuit Malfunction

  4-34 FI SYSTEM DIAGNOSIS “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip •…

• Page 188
  FI SYSTEM DIAGNOSIS 4-35 5) If OK, then check the continuity between each terminal and ground.  CKP sensor continuity: ∞ Ω (Infinity) (Black – Ground) (Green – Ground) Are the resistance and continuity OK? Go to step 2. Replace the CKP sensor with a new one. 6) After repairing the trouble, clear the DTC using SDS tool.

• Page 189: C13″ (P0105-H/L) Iap Sensor Circuit Malfunction

  4-36 FI SYSTEM DIAGNOSIS “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage < 4.85 V •…

• Page 190
  FI SYSTEM DIAGNOSIS 4-37 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch to ON. 6) Insert the needle pointed probes to the lead wire coupler. 7) Measure the voltage at the Red wire and ground. If OK, then measure the voltage at the Red wire and B/Br wire.
• Page 191
  4-38 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between G/B wire B and terminal 9. If OK, then check the continuity between B/Br wire C and ter- minal S.  IAPS lead wire continuity: Continuity () …
• Page 192
  FI SYSTEM DIAGNOSIS 4-39 7) Disconnect the ECM coupler. Check the continuity between Red wire A and terminal A. 9) Also, check the continuity between G/B wire B and terminal  IAPS lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set …
• Page 193
  4-40 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch to OFF. 2) Remove the IAP sensor. 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total — voltage is 4.5 –…
• Page 194
  FI SYSTEM DIAGNOSIS 4-41 Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (mmHg) 3.1 – 3.6 2.8 – 3.4 1 524 1 525 2.6 – 3.1 2 438 2 439 2.4 –…

• Page 195: C14″ (P0120-H/L) Tp Sensor Circuit Malfunction

  4-42 FI SYSTEM DIAGNOSIS “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •…

• Page 196
  FI SYSTEM DIAGNOSIS 4-43  TP sensor input voltage: 4.5 – 5.5 V (+ Red – — Ground) (+ Red – — B/Br)  09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. •…
• Page 197
  4-44 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0120-L:) 1) Turn the ignition switch to OFF. 2) Lift and support the fuel tank. (5-3) 3) Remove the air cleaner box and lift up the throttle body. (5-13) 4) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity.
• Page 198
  FI SYSTEM DIAGNOSIS 4-45 Step 2 1) Turn the ignition switch to OFF. 2) Disconnect the TP sensor coupler. 3) Install the test harness to the TP sensor. 4) Check the continuity between terminal A and ground.  TP sensor continuity: ∞ Ω (Infinity) (Terminal A –…
• Page 199
  4-46 FI SYSTEM DIAGNOSIS Are the continuity and resistance OK? Go to Step 3. • Reset the TP sensor position correctly. • Replace the TP sensor with a new one. After repairing the trouble, clear the DTC using SDS tool. B/Br (4-26) Step 3…

• Page 200: C15″ (P0115-H/L) Ect Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-47 “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction 0.15 V Sensor voltage < 4.85 V •…

• Page 201
  4-48 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-H:) 1) Turn the ignition switch to OFF. 2) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 3) Disconnect the ECT sensor coupler and ECM coupler. 4) Check the continuity between B/Bl wire A and terminal 0.
• Page 202
  FI SYSTEM DIAGNOSIS 4-49 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch to OFF. 2) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 3) Disconnect the ECT sensor coupler. 4) Check the continuity between B/Bl wire A and ground.
• Page 203
  4-50 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch to OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance.  ECT sensor resistance: Approx. 2.3 – 2.6 kΩ at 20 °C (Terminal – Terminal) …

• Page 204: C21″ (P0110-H/L) Iat Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-51 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction 0.15 V Sensor voltage < 4.85 V •…

• Page 205
  4-52 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-H:) 1) Turn the ignition switch to OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
• Page 206
  FI SYSTEM DIAGNOSIS 4-53 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch to OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
• Page 207
  4-54 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch to OFF. 2) Measure the IAT sensor resistance.  IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (Terminal – Terminal)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Is the resistance OK? ECM couplers (Harness side) •…

• Page 208: C22″ (P1450-H/L) Ap Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-55 “C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE AP sensor voltage is not within the fol- • Clogged air passage with dust lowing range. • AP sensor circuit open or shorted to ground 0.5 V Sensor voltage <…

• Page 209
  4-56 FI SYSTEM DIAGNOSIS 4) Disconnect the AP sensor coupler. 5) Turn the ignition switch to ON. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the Red wire A and B/Br wire B.
• Page 210
  FI SYSTEM DIAGNOSIS 4-57 6) Disconnect the ECM coupler. 7) Check the continuity between G/Y wire C and terminal P. If OK, then check the continuity between B/Br wire B and ter- minal S.  APS lead wire continuity: Continuity () …
• Page 211
  4-58 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. Check the continuity between R wire A and terminal A. 9) If OK, then check the continuity between G/Y wire C and ter- minal P.  APS lead wire continuity: Continuity () …
• Page 212
  FI SYSTEM DIAGNOSIS 4-59 Step 3 1) Remove the AP sensor. 2) Connect the vacuum pump gauge to the vacuum port of the AP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 – 5.0 V) and connect — terminal to the ground terminal 2 and + terminal to the VCC terminal 3.

• Page 213: C23″ (P1651-H/L) To Sensor Circuit Malfunction

  4-60 FI SYSTEM DIAGNOSIS “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON.

• Page 214
  FI SYSTEM DIAGNOSIS 4-61 Step 1 (When indicating P1651-H:) 1) Turn the ignition switch to OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
• Page 215
  4-62 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-L:) 1) Turn the ignition switch to OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.

• Page 216: C24″ (P0351), «C25» (P0352), «C26» (P0353) Or «C27» (P0354) Ignition System Malfunction

  FI SYSTEM DIAGNOSIS 4-63 Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch to ON. 4) Measure the voltage at the wire side coupler between B and B/Br wires.

• Page 217: C28″ (P1655) Stv Actuator Circuit Malfunction

  4-64 FI SYSTEM DIAGNOSIS “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. •…

• Page 218
  FI SYSTEM DIAGNOSIS 4-65 Step 2 1) Turn the ignition switch to OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground.  STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between terminal A and terminal B) and (between terminal C and terminal …
• Page 219
  4-66 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch to ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.

• Page 220: C29″ (P1654-H/L) Stp Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-67 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is •…

• Page 221
  4-68 FI SYSTEM DIAGNOSIS  STP sensor input voltage: 4.5 – 5.5 V (+ R – — Ground) (+ R – — B/Br)  09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. •…
• Page 222
  FI SYSTEM DIAGNOSIS 4-69 Step 1 (When indicating P1654-L:) 1) Turn the ignition switch to OFF. 2) Lift and support the fuel tank. (5-3) 3) Remove the air cleaner box and lift up the throttle body. (5-13) 4) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity.
• Page 223
  4-70 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch to OFF. 2) Remove the air cleaner box and lift up the throttle body. (5-13) 3) Disconnect the STP sensor coupler. 4) Install the test harness to the STP sensor. 5) Check the continuity between each terminal and ground.
• Page 224
  FI SYSTEM DIAGNOSIS 4-71 If OK, then measure the STP sensor resistance at the wire terminals (between terminal A and terminal C).  STP sensor resistance: Approx. 4.69 kΩ  09900-25008: Multi-circuit tester set 09900-28630: TPS test wire harness …
• Page 225
  4-72 FI SYSTEM DIAGNOSIS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short Switch voltage is not within the following range. • Gear Position switch malfunction Switch voltage >…
• Page 226
  FI SYSTEM DIAGNOSIS 4-73 Is the voltage OK? ECM couplers (Harness side) • P wire open or shorted to ground • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
• Page 227
  4-74 FI SYSTEM DIAGNOSIS “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short interrupted by 4 times or more continuously. •…
• Page 228
  FI SYSTEM DIAGNOSIS 4-75 5) If OK, then check the continuity between each terminal and ground.  Injector resistance: ∞ Ω (Infinity) Are the resistance and continuity OK? Go to Step 2. Replace the injector with a new one. (5-14) 6) After repairing the trouble, clear the DTC using SDS tool.
• Page 229
  4-76 FI SYSTEM DIAGNOSIS “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump • Fuel pump relay circuit open or short although fuel pump relay is turned ON, • Fuel pump relay malfunction or voltage is applied to fuel pump, •…
• Page 230
  FI SYSTEM DIAGNOSIS 4-77 Step 1 (When indicating P0230-H:) 1) Turn the ignition switch to OFF. 2) Remove the seat tail cover. (8-4) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (5-6) Is the FP relay OK? ECM couplers (Harness side) •…

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