- •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
Inspection
•Liftandsupportthefueltankwithitspropstay.(c:r4-52)
WTurntheignitionswitchOFF.
ChecktheECTsensorcouplerforlooseorpoorcontacts.
IfOK,thenmeasuretheECTsensorvoltageatthewiresidecoupler.
DisconnectthecouplerandturntheignitionswitchON.MeasurethevoltagebetweenBIBIwireterminalandground.
IfOK,thenmeasurethevoltagebetweenBIBIwiretermi•
nalandB/Brwireterminal.
BECTsensorvoltage:4.5-5.5V
(£1B/BI-8Ground)((±)BIBI-c,B/Br
1Root109900-25008:Multicircuittester
·rm.v-'vuTesterknobindication:Voltage(::-:)
1-------'--N'-'o
rYes
.z.TurntheignitionswitchOFF.
LooseorpoorcontactsontheECMcoupler.
Openorshortcircuitinthe
BIBIwireorB/Brwire.
MeasuretheECTsensorresistance.
~ECTsensorresistance:2.3-2.6k.Qat20°C(68°F)2
(Terminal-Terminal)
1Rq109900-25008:Multicircuittester
!WTesterknobindication:Resistance(.Q)
Refertopage5-8fordetails.
I-------No_.
ReplacetheECTsensor
'Yes
connection.(c:=::T4-25)
-withanewone.
-
BIBIorB/Brwireopenorshortedtoground,orpoor~·or·~
IfwireandconnectionareOK,intermittenttroubleorfaultyECM.Recheckeachterminalandwireharnessforopencircuitand
EngineCoolant
Temp.
Resistance
poorconnection.(c:r4-4)
~--~-ReplacetheECMwithanewone.andinspectitagain.
ECMcouplers
20°c(68°F)Approx.2.45k.Q
50°C(122°F)Approx.0.811kQ
80°C(176°F)Approx.0.318kQ
110°C(230°F)Approx.0.142kQ
"C21"IATSENSORCIRCUITMALFUNCTION
DETECTEDCONDITIONPOSSIBLECAUSEHighintakeairtemp.(Lowvoltage-Low•Dgcircuitshortedtoground.
resistance)•B/Brcircuitopen.
Lowintakeairtemp.(Highvoltage-High•IATsensormalfunction.resistance)•ECMmalfunction.
INSPECTION
•Liftandsupportthefueltankwithitspropstay.(c::::T'4-52)
WTurntheignitionswitchOFF.
ChecktheIATsensorcouplerforlooseorpoorcontacts.
IfOK,thenmeasuretheIATsensorvoltageatthewiresidecoupler.
DisconnectthecouplerandturntheignitionswitchON.MeasurethevoltagebetweenDgwireterminalandground.
IfOK,thenmeasurethevoltagebetweenDgwiretermi•
nalandB/Brwireterminal.
~IATsensorvoltage:4.5-5.5V
(±)Dg-9Ground)(@Dg-88/Br
1.:<09900-25008:Multicircuittester
OWtTesterknobindication:Voltage(=)
1-------N'-'--"-o--i_.L.ooseorpoorcontactsontheECMcoupler.
Openorshortcircuitinthe
,,Yes
OgwireorB/Brwire.
TurntheignitionswitchOFF.MeasuretheIATsensorresistance.
WJ1JIATsensorresistance:2.2-2.7kQat20°C(68°F)2(Terminal-Terminal)
irMI09900-25008:Multicircuittester
QW,jTesterknobindication:Resistance(Q)
TYes
No ReplacetheIATsensorwithanewone.
DgorB/Brwireopenorshortedtoground,orpoor'®'or~
connection.(c:::T4-25)
IfwireandconnectionareOK,intermittenttroubleorfaultyECM.Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c:::T4-4)
I ReplacetheECMwithanewone,andinspectitagain.
ECMcouplers
IntakeAirTemp.Resistance
20°c(68°F)Approx.2.45kQ
50°C(122°F)Approx.0.808kQ
80°C(176°F)Approx.0.322kQ
110°C(230°F)Approx.0.148kQ
NOTE:
/ATsensorresistancemeasurementmethodisthesamewayasthatoftheECTsensor.Refertopage5-8fordetails.
"C22"APSENSORCIRCUITMALFUNCTION
DETECTEDCONDITIONPOSSIBLECAUSELowpressureandlowvoltage.•Cloggedairpassagewithdust.
)
Highpressureandhighvoltage.•Redwirecircuitopenorshortedtoground.(0.5V~SensorVoltage<4.5V•B/BrorG/Ywirecircuitshortedtoground.withouttheaboverange.•APsensormalfunction.
NOTE:•ECMmalfunction.
Notethatatmosphericpressurevariesdependingonweatherconditionsaswellasaltitude.
Takethatintoconsiderationwheninspectingvoltage.
INSPECTION
•Removethefrontseat.(c::?6-6)
JJTurntheignitionswitchOFF.
ChecktheAPsensorcouplerforlooseorpoorcontacts.
IfOK,thenmeasuretheAPsensorinputvoltage.TurntheignitionswitchON.
DisconnecttheAPsensorcoupler.
MeasurethevoltagebetweenRedwireandground.
IfOK,thenmeasurethevoltagebetweenRedwireand
B/Brwire.
~APsensorinputvoltage:4.5-5.5V
(±)Red-8Ground)((±)Red-88/Br
1RiOt109900-25008:Multicircuittester
~·mr.v>u"vTesterknobindication:Voltage(::-:)
f--
No--Looseorpoorcontactson
-----
TYes
gJConnecttheAPsensorcoupler.
theECMcoupler.
Openorshortcircuitinthe
RedwireorB/Brwire.
Insertthecopperwirestotheleadwirecoupler.TurntheignitionswitchON.
-
MeasuretheAPsensoroutputvoltageatthewiresidecouplerbetweenG/YandB/Brwires.6APsensoroutputvoltage:Approx.3.6V
at760mmHg(100kPa)
(@GN-8B/Br)
1r1iOL109900-25008:Multicircuittester
=WTesterknobindication:Voltage(::-:)
f-----_...;N...;,.o.".'--C1_hecktheairpassageforclogging.
Openorshortcircuitinthe
G/Ywire.
ReplacetheAPsensorwithanewone.
TYes
WRemovetheAPsensor.
Connectthevacuumpumpgaugetotheairpassageport
oftheAPsensor.
Arrange3new1.5Vbatteriesinseries(checkthattotalvoltageis4.5-5.0V)andconnect8terminaltothegroundterminaland(?terminaltotheVeeterminal.
CheckthevoltagebetweenVoutandground.Also,checkifvoltagereduceswhenvacuumisappliedupto40cmHgbyusingvacuumpumpgauge.(Seetablebelow)
n'OOti09917-47010:Vacuumpumpgauge
09900-25008:Multicircuittester
~~Testerknobindication:Voltage(::-:)
No
Yes
;::. Ifcheckresultisnotsatisfactory,replaceAPsensorwithanewone.
Red,G/YorB/Brwireopenorshortedtoground,orpoor@.@)
or®connection.(CT4-25)
IfwireandconnectionareOK,intermittenttroubleorfaultyECM.Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c:::74-4)
~--;;::.-ReplacetheECMwithanewone,andinspectitagain.
Outputvoltage(Veevoltage4.5-5.0V,ambienttemp.
20-30°C,68-86°F)
ECMcouplers
-
ALTITUDE(Reference)
ATMOSPHERICPRESSURE
OUTPUTVOLTAGE
(ft)
(m)
(mmHg)kPa
(V)
0
0
760100
I
I
I
I
3.1-3.6
2000
610
707
94
2001
I
611
I
707
I
94
I
2.8-3.4
5000
1524
634
85
5001
I
1525
I
634
I
85
I
2.6-3.1
8000
2438
567
76
8001
2439
567
76
I
I
I
I
2.4-2.9
10000
3048
526
70
"C23"TOSENSORCIRCUITMALFUNCTION
DETECTEDCONDITIONPOSSIBLECAUSE
NoTOsensorsignalformorethan2seconds,•TOsensorcircuitopenorshort.afterignitionswitchturnsON.•TOsensormalfunction.
Sensorvoltagehigh.•ECMmalfunction.(0.25V~SensorVoltage<4.85V)
withouttheaboverange.
