- •Generalinformation
- •Informationlabels
- •Periodicmaintenance
- •Valveclearance...................................................................2-8
- •Valveclearance
- •Inspectevery24000km(15000miles,24months).
- •IrWtl09900-20803:Thicknessgauge
- •09913-10750:Adaptor
- •Ventitsshortoropencircuit.
- •Iacautioni
- •09900-22302:Plastigauge
- •09900-22403:Smallboregauge{18-35mm)
- •09916-34542:Reamerhandle
- •09916-43220:Attachment(2)
- •Initialseatcut
- •15Mm(0.6in)fromthepistonskirtend.
- •Installation
- •1Root109913-70210:Bearinginstallerset
- •Inspectionandcleaning
- •09900-20701:Magneticstand
- •09900-21304:V-block(100mm)
- •09900-22401:Smallboregauge(1o-18mm)
- •Inspection
- •Iacautioni
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Becareful!nottodamagethecylinderwallbytheconrod.
- •1L1molybdenumoilsolution
- •Iacautioni
- •Initial:15n·m(1.5kgf·m,11.0lb-ft)Final:90°(1/.Iturn)
- •Inglightly.
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Usethenewgaskettopreventoilleakage.
- •FlSystemandintakeairsystem
- •Voltagecheck
- •VoltageBetween:
- •VoltageBetween:
- •Injectiontime(injectionvolume)
- •Various
- •ISensors
- •IUltimate
- •Injectionstopcontrol
- •Injectiontiming
- •Intakeairsystem
- •Injection"yes""'yes"
- •Inspection
- •1Root109900-25008:Multicircuittester
- •1Rq109900-25008:Multicircuittester
- •Inspection
- •Irk!09900-25008:Multicircuittester
- •1Rkib09900-25008:Multicircutitester
- •Construction
- •Inspection
- •1Root109930-11960:Torxwrench
- •Inspection
- •Iapsensorinspection
- •Iapsensorremoval/installation
- •28ForTPsensorsettingprocedure.
- •Iatsensorinspection
- •Iatsensorremoval/installation
- •Inspection
- •Installation
- •Inspection
- •..Takespecialcarewhenhandlingthetemperature-sen• sor.Itmaycausedamageifitgetsasharpimpact.
- •Installation
- •Inspection
- •Installation
- •Inspection
- •Usethenew0-ringstopreventenginecoolantleakage.
- •Icamdrivechaini
- •Istarterclutchi
- •Chassis
- •Installation
- •Installation
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Itemn·mkgf·mlb-ft
- •Inspection
- •09940-14960:Steeringstemnutwrenchsocket
- •Inspectionanddisassembly
- •09940-14960:Steeringstemnutwrenchsocket
- •09940-14960:Steeringstemnutwrenchsocket
- •Itemn·mkgf-mlb-ft
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Inspectionanddisassembly
- •Ingsolventsuchasgasoline,kerosineortheothers.
- •Iw)lllllu.D
- •Inspection
- •Valveinspection
- •Valveinstallation
- •Electricalsystem
- •IIncorrectt
- •Ignitioncoil
- •Ignitionsystem
- •0 Sensor
- •ICorrectIncorrect
- •Inspection
- •Ventanelectricshockwhiletesting.
- •Ignitioncoiuplugcapresistance
- •1Riot109900-25008:Multicircuittesterset
- •Inspection
- •09930-11940:Bitholder
- •Initialcharging
- •Iacautioni
- •Iacautioni
- •Insideofthebodycowling
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Note
- •Itemstd/spec.Note
- •11IiiIu
- •Iatsensor
- •Suzukimotorcorporation
Injectiontime(injectionvolume)
Thefactorstodeterminetheinjectiontimeincludethebasicfuelinjectiontimewhichiscalculatedonthebasisoftheintakeairpressure,enginespeedandthrottleopeningangle,andvariouscompensationswhicharedeterminedaccordingtothesignalsfromvarioussensorsthatdetecttheengineanddrivingconditions.
IntakeAirPressureIntakeairpressure
r------ECM-------,
I
I
Sensor(IAPSensor)signalI-
IBasic
I
CrankshaftPositionEnginespeedIfuelSensor(CKPSensor)signalIinjection
Itime
I-
ThrottlePositionThrottleooenlnoII
Sensor(TPSensor)signalI
I
I
Various
ISensors
r
InjectorsI
VarioussignalsI~Compensation-
II
I
I
IUltimate
Ifuel~InjectionsignalIinjection
Itime-
I
L_J
COMPENSATIONOFINJECTIONTIME(VOLUME)
Thefollowingdifferentsignalsareoutputfromtherespectivesensorsforcompensationofthefuelinjectiontime(volume).
SIGNALDESCRIPTION
ATMOSPHERICPRESSURESENSORSIG-Whenatmosphericpressureislow,thesensorsendsthe
NALsignaltotheECMandreducetheinjectiontime(volume).ENGINECOOLANTTEMPERATURESEN-Whenenginecoolanttemperatureislow,injectiontime(vol-
SORSIGNALume)isincreased.
INTAKEAIRTEMPERATURESENSORSIG-Whenintakeairtemperatureislow,injectiontime(volume)NALisincreased.
BATTERYVOLTAGESIGNALECMoperatesonthebatteryvoltageandatthesametime,itmonitorsthevoltagesignalforcompensationofthefuelinjectiontime(volume).Alongerinjectiontimeisneededtoadjustinjectionvolumeinthecaseoflowvoltage.
ENGINERPMSIGNALAthighspeed,theinjectiontime(volume)isincreased.ThisisthecompensationoftheSAAD.
STARTINGSIGNALWhenstartingengine,additionalfuelisinjectedduringcrank-ingengine.
ACCELERATIONSIGNAUDuringacceleration,thefuelinjectiontime(volume)isin-DECELERATIONSIGNALcreased,inaccordancewiththethrottleopeningspeedandenginerpm.Duringdeceleration,thefuelinjectiontime(vol-
ume)isdecreased.
Injectionstopcontrol
SIGNALDESCRIPTION
TIPOVERSENSORSIGNALWhenthemotorcycletipsover,thetipoversensorsendsa
(FUELSHUT-OFF)signaltotheECM.Then,thissignalcutsOFFcurrentsup-pliedtothefuelpump,fuelinjectorsandignitioncoils.
OVER-REV.LIMITERSIGNALThefuelinjectorsstopoperationwhenenginerpmreachesrev.limitrpm.
FUELDELIVERYSYSTEM
Thefueldeliverysystemconsistsofthefueltank,fuelpump,fuelfilters,fuelfeedhose,fueldeliverypipe(includingfuelinjectors)andfuelpressureregulator.Thereisnofuelreturnhose.Thefuelinthefueltankispumpedupbythefuelpumpandpressurizedfueltoflowintotheinjectorinstalledinthefueldeliverypipe.Fuelpressureisregulatedbythefuelpressureregulator.Asthefuelpressureappliedtothefuelinjector(thefuelpressureinthefueldeliverypipe)isalwayskeptabsolutefuelpressureof3.0kgf/cm2(300kPa,43psi),thefuelisinjectedintothethrottlebodyinconicdispersionwhentheinjectoropensaccordingtotheinjectionsignalfromtheECM.
Thefuelrelievedbythefuelpressureregulatorflowsouttothefueltank.
Fueltank
-
/
<--
I
\
!----~.,Fuelmeshfilterr
---(\orlo~pressure)
\~-,Fuelpump
.>\
~Beforepressurizedfuel
•Pressurizedfuel
<~::_·_-_-_;Relievedfuel
FUELPUMP
Theelectricfuelpumpismountedatthebottomofthefueltank,whichconsistsofthearmature,magnet,impeller,brush,checkvalveandreliefvalve.TheECMcontrolsitsON/OFFoperationascontrolledundertheFUELPUMPCONTROLSYSTEM.
Whenelectricalenergyissuppliedtothefuelpump,themotorinthepumprunsandsodoestheimpeller.Thiscausesapressuredifferencetooccurbetweenbothsidesoftheimpellerastherearemanygroovesaroundit.Thenthefuelisdrawnthroughtheinletport,andwithitspressureincreased,itisdischargedthroughtheoutletport.Thefuelpumphasacheckvalvetokeepsomepressureinthefuelfeedhoseevenwhenthefuelpumpisstopped.Also,thereliefvalveisequippedinthefuelpump,whichreleasespressurizedfueltothefueltankwhentheoutletofthefuelpressurehasincreasedupto4.5-6.0kgf/cm2(450-600kPa,64-85
psi).
Outletport
CheckvalveArmature
Whentheimpellerisdrivenbythemotor,pressuredifferentialoccursbetweenthefrontpartandtherearpartofthebladegrooveasviewedinangulardirectionduetofluidfriction.Thisprocesscontinuouslytakesplacecausingfuelpressuretobebuiltup.Thepressurizedfuelisthenletoutfromthepumpchamberanddischargedthroughthemotorsectionandthecheckvalve.
©
Impeller
Motorshaft
Vortexflow
FUELPRESSUREREGULATOR
Thefuelpressureregulatorconsistsofthespringandvalve.Itkeepsabsolutefuelpressureof3.0kgf/cm2
(300kPa,43psi)appliedtotheinjectoratalltimes.
Whenthefuelpressurerisesmorethan3.0kgf/cm2(300kPa,43psi),thefuelpushesthevalveintheregulatoropenandexcessfuelreturnstothefueltank.
Fuelfrom--""=""'·
fuelpump
Fuelfrom.-.E:O:::~~~~'N
fuelpump
Fuelreturnstothefueltank
Valve
-
FUELINJECTOR
Thefuelinjectorconsistsofthesolenoidcoil,plunger,needlevalveandfilter.
ItisanelectromagnetictypeinjectionnozzlewhichinjectsfuelinthethrottlebodyaccordingtothesignalfromtheECM.
WhenthesolenoidcoiloftheinjectorisenergizedbytheECM,itbecomesanelectromagnetandattractstheplunger.Atthesametime,theneedlevalveincorporatedwiththeplungeropensandtheinjectorwhichisunderthefuelpressureinjectsfuelinconicdispersion.Astheliftstrokeoftheneedlevalveoftheinjectorissetconstant,thevolumeofthefuelinjectedatonetimeisdeterminedbythelengthoftimeduringwhichthe
solenoidcoilisenergized(injectiontime).
-
NeedlevalveFilter
FUELPUMPCONTROLSYSTEM
Whentheignitionswitchisturnedon,currentfromthebatteryflowstothefuelpumpmotorthroughtheside-standrelayandthefuelpumprelaycausingthemotortoturn.
SincetheECMhasatimerfunction,thefuelpumpmotorstopsturninginthreesecondsaftertheswitchhasbeenturnedon.
Thereafter,whenthecrankshaftisturnedbythestartermotorortheenginehasbeenstarted,theenginerevolvingsignalisinputtotheECM.Then,currentflowstothefuelpumpmotorfromthebatterythroughtheside-standrelayandthefuelpumprelaysothatthepumpcontinuestofunction.
Atipoversensorisprovidedinthefuelpumpcontrolcircuit.Bythisprovision,anytimethemotorcycletipsover,thetipoversensorsendsasignaltotheECMtoturnoffpowertothefuelpumprelay,causingthefuelpumpmotortostop.Atthesametime,currenttothefuelinjectorsaswellastheignitioncoilisinterrupted,
whichthenstopstheengine.
e(±)
BATTERY
30A
IGSWITCH
l
ENGINESTOPSWITCH
ToStarterbutton
~ow
SIDE-STANDSWITCH
TOS
ECM(FlCONTROLUNIT)
TheECMislocatedundertheseat.
TheECMconsistsofCPU(CentralProcessingUnit),memory(ROM)and1/0(Input/Output)sections.ThesignalfromeachsensorissenttotheinputsectionandthensenttoCPU.Onthebasisofsignalinformationreceived,CPUcalculatesthevolumeoffuelnecessaryforinjectionusingmapsprogrammedforvaryingengineconditions.Then,theoperationsignalofthefuelinjectionissentfromtheoutputsectiontothefuelinjector.
TheeightkindsofindependentprogrammapsareprogrammedintheROM.
Theseeightkindsofmapsaredesignedtocompensatefordifferencesoftheintake/exhaustsystemsandcoolingperformance.
LIGHTLOAD:Whentheengineisrunninginalightload,thefuelinjectedvolume(time)isdeterminedthebasisoftheintakeairpressureandenginespeed.
HEAVYLOAD:Whentheengineisrunninginaheavyload,thefuelinjectedvolume(time)isdeterminedthe
basisofthethrottlevalveopeningandenginespeed.
FlSYSTEMANDINTAKEAIRSYSTEM4-15
