Inspection

•Liftandsupportthefueltankwithitspropstay.(c:::::t4-52)

llJTurntheignitionswitchOFF.

-

ChecktheTOsensorcouplerforlooseorpoorcontacts.

IfOK,thenmeasuretheTOsensorresistance.DisconnecttheTOsensorcoupler.

MeasuretheresistancebetweenBlackandB/Wwireter•

minals.

DTOsensorresistance:60-64kQ

(Black-B/W)

Irk!09900-25008:Multicircuittester

·m.tTesterknobindication:Resistance(0)

^}_Yes

N~o_..R,_eplacetheTOsensorwithanewone.

WConnecttheTOsensorcoupler.

Insertthecopperwirestothewireleadcoupler.

TurntheignitionswitchON.

Measurethevoltageatthewiresidecouplerbetween

BlackandB/Brwires.

~TOsensorvoltage:Approx.2.5V(Black-B/Br)

Also,measurethevoltagewhenleaningofthemotorcycle.DismounttheTOsensorfromitsbracketandmeasurethevoltagewhenitisleanedmorethan43°,leftandright,fromthehorizontallevel.

~TOsensorvoltage:0V(Black-B/Br)

1Rkib09900-25008:Multicircutitester

^{·WTesterknobindication:Voltage(=-=)}

~----N:....:...=..0-1_L.ooseorpoorcontactsontheECMcoupler.

OpenorshortcircuitintheBlackwireorB/Brwire.ReplacetheTOsensor

_Yes

withanewone.

BlackorB/Brwireopenorshortedtoground,orpoor®or<[$

connection.(c:::::t4-25)

IfwireandconnectionareOK,intermittenttroubleorfaultyECM.Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c:::::t4-4)

ReplacetheECMwithanewone,andinspectitagain.

ECMcouplers

FlSYSTEMANDINTAKEAIRSYSTEM4-45

"C24","C25","C26"or"C27"IGNITIONSYSTEMMALFUNCTION

*RefertotheIGNITIONSYSTEMfordetails.(c:::::T"7-17)

"C28"STVACTUATORCIRCUITMALFUNCTION

^{DETECTEDCONDITIONPO}SSIBLECAUSE^{TheoperationvoltagedoesnotreachtheSTV•}STVactuatormalfunction.

^{actuator.•STVactuatorcircuitopenorshort.}

ECMdoesnotreceivecommunicationsignalfrom•STVAmotormalfunction.

_theSTCunit.

INSPECTION₁

•Liftandsupportthefueltankwithitspropstay.(c:::::T"4-52)

•Removetheaircleanerelement.

L!JTurntheignitionswitchOFF.

ChecktheSTVactuatorleadwirecouplerforlooseorpoor

contacts.

TurntheignitionswitchON.

ChecktheoperationoftheSTVactuatorbytheSTVmove•

ment.

(Operatingorder:Halfopen-?Fullclose-?Fullopen-?

_Halfopen)

_No

t-------;::-~Looseorpoorcontactson

Yes

_,

theSTCunitcoupler.OpenorshortcircuitintheRedorBlackwire.

~TurntheignitionswitchOFF.

DisconnecttheSTVactuatorleadwirecoupler.CheckthecontinuitybetweenRedwireandground.

~STVactuatorcontinuity:ooQ(Infinity)

IfOK,thenmeasuretheSTVactuatorresistance.(between

RedandBlackwires)

_{DSTVactuatorresistance:Approx.5.6o}

^{(©Red-8Black)}

!Mi09900-25008:Multicircuittester

~Testerknobindication:Resistance(0)

1------^N-^o~::-•ReplacetheSTVactuatorwithanewone.

,,Yes

LooseorpoorcontactsontheSTVactuatorcouplerorSTC

unitcoupler.

IfwireandconnectionareOK,intermittenttroubleorfaultySTCunit.Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c:::::r4-4)

'---------1-~ReplacetheSTCunitwithnewone,andinspectitagain.

"C29"STPSENSORCIRCUITMALFUNCTION

DETECTEDCONDITIONPOSSIBLECAUSESignalvoltageloworhigh.•STPsensormaladjusted.

^{Differencebetweenactualthrottleopeningand•STPsensorcircuitopenorshort.}

openingcalculatedbyECMinlargerthanspecified^{•STPsensormalfunction.va}lue.^{•STCunitmalfunction}

_{{0.2V::;;;SensorVoltage<4.8V)}^{•ECMmalfunction.}

withouttheaboverange.

INSPECTION

•Littandsupportthefueltankwithitspropstay.(C74-52)

J.JTurntheignitionswitchOFF.

ChecktheSTPsensorcouplerforlooseorpoorcontacts.

IfOK,thenmeasuretheSTPsensorinputvoltage.DisconnecttheSTPsensorcoupler.

TurntheignitionswitchON.

MeasurethevoltageattheBluewireandground.

IfOK,thenmeasurethevoltageattheBluewireandBlackwire.

~STPsensorinputvoltage:4.5-5.5V

©Blue-8Ground)^(©Blue-8Black

_{1£t109900-25008:Multicircuittester}

·WTesterknobindication:Voltage(::-:::)

_,Yes

^NoLooseorpoorcontactsontheECMcoupler.

Openorshortcircuitinthe

BluewireorBlackwire.

Ground

_{~TurntheignitionswitchOFF.}

_{Removetheaircleanerelement.}¹

DisconnecttheSTPsensorcoupler.

CheckthecontinuitybetweenYellowwireandground.

~STPsensorcontinuity:oo.Q(Infinity)

(Yellowwire-Ground)

IfOK,thenmeasuretheSTPsensorresistanceatthecoupler(betweenYellowandBlackwires).

Closethesecondarythrottlevalvebyfingerandmeasurethevalveclosingresistance.TurntheignitionswitchONandmeasurethevalveopeningresistance.

DSTPsensorresistance

Secondarythrottlevalveisclosed:Approx.0.8k.Q

Secondarythrottlevalveisopened:Approx.3.9k.Q

_{!Tk!09900-25008:Multicircuittester}

·WTesterknobindication:Resistance(.Q)

^No ResettheSTPsensorpositioncorrectly.

([74-71)

ReplacetheSTPsensorwithanewone.

₂

Yes

l1JTurntheignisionswitchOFF.

ConnecttheSTPsensorcoupler.

Insertthecopperwirestotheleadwirecoupler.TurntheignitionswitchON.

MeasuretheSTPsensoroutputvoltageatthecoupler(betweenYellowandBlackwires)byturningthesecond•arythrottlevalve(closeandopen)withafinger.

•STPsensoroutputvoltage

Throttlevalveisclosed:Approx.0.8VThrottlevalveisopened:Approx.4.0V

:w

_{nfill09900-25008:Multicircuittester}

₃

^{Testerknobindication:Voltage(::-:)}

.,^No-';;-Ifcheckresultisnotsatisfactory,replaceSTPsensorwithanewone.

rYes

®connection.(c::::::T"4-25) IfwireandconnectionareOK,intermittenttroubleorSTCunit
faultyorfaultyECM.
Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c::::::T"4-4)	3

_{Blue,YelloworBlackwireopenorshortedtoground,orpoor}

ReplacetheSTCunitorECMwrthanewone,andinspectitagain.

ECMcouplers

"C30"STCUNITCIRCUITMALFUNCTION

^{DETECTEDCONDITIONPOSSIBLE}CAUSEThepowersourcedoesnotreachtheSTCunit.•STCunitmalfunction.

^{ECMdoesnotreceivecommunicationsignalfrom•STCunitcircuitopenorshort.}

theSTCunit.

INSPECTION

•Removetheframecover.(c:::?'6-6)

_{JJTurntheignitionswitchOFF.}

ChecktheSTCunitleadwirecouplerforlooseorpoor

contacts.

IfOK,thenmeasuretheSTCunitinputvoltage.Insertthecopperwirestotheleadwirecoupler.

TurntheignitionswitchON,andmeasurethevoltagebe•

tweentheO/Wwireandground.

IfOK,thenmeasurethevoltagebetweentheO/WwireandB/Wwire.

_{•STCunitinputvoltage:Batteryvoltage}

(±)O/W-8Ground)⁽⁽⁺⁾O/W-8B/W

1.footi09900-25008:Multicircuittester

-~Testerknobindication:Voltage(==)

1------N-0--1-O~penorshortcircuitinthe

_{O!WwireorB/Wwire.}

,Yes

O!W,B/WorDbrwireopenorshortedtoground,orpoor®

connection.(C:::?'4-25)

MeasuretheSTCunitvoltagewiththemulticircuittester.(C:::77-

22)

IfwireandconnectionareOK,intermittenttroubleorSTCunitfaultyorfaultyECM.

Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(C:::?'4-4)

_{'~-~~-ReplacetheSTCunitwithanew}^-

_{one,andinspectitagain.}

ECMcouplers

"C31"GEARPOSITION(GP)SWITCHCIRCUITMALFUNCTION

DETECTEDCONDITION_{POSSIBLECAUSE}

^{NoGearPositionswitchvoltage•}GearPositionswitchcircuitopenorshort.^{Switchvoltagelow.•}GearPositionswitchmalfunction.

^{(SensorVoltage>0.6V)•}ECMmalfunction.withouttheaboverange.

INSPECTION

•Liftandsupportthefueltankwithitspropstay.(c:::::t4-52)

WTurntheignitionswitchOFF.

ChecktheGPswitchcouplerforlooseorpoorcontacts.

IfOK,thenmeasuretheGPswitchvoltage.Supportthemotorcyclewithajack.

Turntheside-standtoup-rightposition.TurntheenginestopswitchON.

Insertthecopperwiretotheleadwirecoupler.TurntheignitionswitchON.

MeasurethevoltageatthewiresidecouplerbetweenPinkwireandground,whenshiftingthegearshiftleverfrom1sttoTop.

~ GPswitchvoltage:Morethan0.6V(Pink-Ground)

_{1Rioh09900-25008:Multicircuittester}

^{~-WTesterknobindication:Voltage(::-:)}

1-------^N-^o....,::-•Openorshortcircuitinthe

Pinkwire.

ReplacetheGPswitchwithanewone.

^·irYes

Pinkwireopenorshortedtoground,orpoor®connection.

(c:::::t4-25)

IfwireandconnectionareOK,intermittenttroubleorfaultyECM.Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c:::?4-4)

_{~-.....;..-ReplacetheECMwithanewone,}

_{andinspectitagain.}^ECMcouplers

"C32","C33","C34"or"C35"FUELINJECTIONMALFUNCTION

DETECTEDCONDITION^{POSSIBLECAUSE}_{Noinjectorcurrent.•}Injectorcircuitopenorshort.

•Injectormalfunction.

•ECMmalfunction.

INSPECTION

•Liftandsupportthefueltankwithitspropstay.(c::::::r4-52)

JJTurntheignitionswitchOFF.

Checktheinjectorcouplerforlooseorpoorcontacts.

IfOK,thenmeasuretheinjectorresistance.

Disconnectthecouplerandmeasuretheresistancebe•

tweenterminals.

BInjectorresistance:11-16nat20°c(68°F)

(Terminal-Terminal)

IfOK,thencheckthecontinuitybetweeneachterminalandground.

^{g1njectorcontinuity:oo.Q(Infinity)}

(Terminal-Ground)

_{1rooti09900-25008:Multicircuittester}

^{,WTesterknobindication:Resistance(Q)}

_{No_}

^{1----------'1R7'•eplacetheinjectorwith}

_{anewone.(c::::::r4-64)}

Yes

l.£JTurntheignitionswitchON.

MeasuretheinjectorvoltagebetweenY/Rwireand

ground.

~Injectorvoltage:Batteryvoltage

_(Y/R-Ground)

NOTE:

Injectorvoltagecanbedetectedonly3secondsafterig•

nitionswitchisturnedON.

_{1Ri0t!09900-25008:Multicircuittester}

tWTesterknobindication:Voltage(::7:)

,

_,Yes

N_;:o,~O-pencircuitintheYellow/Redwire.

Gr/W,Gr/B,Gr/Y,Gr/RorY/Rwireopenorshortedtoground,orpoorA),·~'.·ID,(J)or©connection.(c::::::r4-25)

IfwireandconnectionareOK,intermittenttroubleorfaultyECM.Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c::::::r4-4)

^I ReplacetheECMwithanewone,andinspectitagain.

ECMcouplers

^{Nosignalfromfuelpumprelay.•}Fuelpumprelaycircuitopenorshort.

•Fuelpumprelaymalfunction.

•ECMmalfunction.

INSPECTION

•Removethefrontseat.

•Liftandsupportthefueltankwithitspropstay.(CT4-52)

_{JJTurntheignitionswitchOFF.}

ChecktheFPrelaycouplerforlooseorpoorcontacts.

IfOK,thenchecktheinsulationandcontinuity.Refertopage4-55fordetails.

^i._Yes

_No

^~;.ReplacetheFPrelaywith

anewone.

-

_{Y/BorO/Wwireopenorshortedtoground,orpoor".IDor}

^{®connection.(c:::::T'4-25)}

IfwireandconnectionareOK,intermittenttroubleorfaulty

ECM.

Recheckeachterminalandwireharnessforopencircuitandpoorconnection.(c::::::T4-4)

^I -^{ReplacetheECMwithanewonea}ndinspectitagain.

_ECMcouplers

"C42"IGSWITCHCIRCUITMALFUNCTION

*RefertotheIGNITIONSWITCHINSPECTIONtordetails.

•Removetherightundercowling.(CT6-3)

•Inspecttheignitionswitch.(c:::77-31)

FUELSYSTEM

FUELTANKLIFT-UP

•Removethefrontseat.

•Removethefueltankmountingbolts.

•Liftandsupportthefueltankwiththefueltankpropstay(i\

FUELTANKREMOVAL

•Liftandsupportthefueltankwiththefueltankpropstay.(Seeabove)

^{•DisconnectthefuelpumpleadwirecouplerCD.}

•Placearagunderthefuelfeedhoseandremovethefuelfeedhose(2).

/ACAUTIONI

Whenremovingthefueltank,donotremainthefuelfeedhose'2)atthefueltankside.

AWARNING

Gasolineishighlyflammableandexplosive.Keepheat,sparkandflameaway.

•Removethefueltankbracketmountingbolts.

•Removethefueltank.

FUELTANKINSTALLATION

•Installationisinthereverseorderofremoval.

...

FUELPRESSUREINSPECTION

•Liftandsupportthefueltankwithitspropstay.(c::::?'4-52)

•Placearagunderthefuelfeedhose.(c::::?'4-52)

•Removethefuelfeedhoseandinstallthespecialtoolsbe•

tweenthefueltankandfueldeliverypipe.

n'OOti09940-40211:Fuelpressuregaugeadaptor

09940-40220:Fuelpressuregaugehoseattachment

09915-77330:Oilpressuregauge

09915-74520:Oilpressuregaugehose

TurntheignitionswitchONandcheckthefuelpressure.

BFuelpressure:Approx.300kPa(3.0kgf/cm2,43psi)

Ifthefuelpressureislowerthanthespecified,inspectthefol•

lowingitems:

·Fuelhoseleakage

•Cloggedfuelfilter

..Pressureregulator

*Fuelpump

Ifthefuelpressureishigherthanthespecified,inspectthefol•

lowingitems:

*Fuelpumpcheckvalve

*Pressureregulator

AWARNING

*Beforeremovingthespecialtools,turntheignitionswitchOFFpositionandreleasethefuelpressureslowly.

*Gasolineishighlyflammableandexplosive.Keepheat,

_{sparksandflameaway.}

Tofueltank

_!

^{Tofueldeliverypipe}

FUELPUMPINSPECTION

TurntheignitionswitchONandcheckthatthefuelpumpoper•

atesforfewseconds.

Ifthefuelpumpmotordoesnotmakeoperatingsound,replacethefuelpumpassemblyorinspectthefuelpumprelayandtipoversensor.

FUELDISCHARGEAMOUNTINSPECTION

AWARNING

Gasolineishighlyflammableandexplosive.Keepheat,sparkandflameaway.

•Liftandsupportthefueltankwithitspropstay.(c::r4-52)

•DisconnectthefuelfeedhoseG)fromthefuelpump.

•Connectaproperfuelhose!%}tothefuelpump.

•DisconnecttheECMleadwirecoupler@.

•Pushthelock®topulloutthepowersourceleadwire(Yellowwithredtracer@).

ECMcouplers

•Placethemeasuringcylinderandinsertthefuelhoseendintothemeasuringcylinder.

•Apply;2voltstothefuelpumpfor30secondsandmeasuretheamountoffueldischarged.

Battery'±)terminal--PowersourceleadwireG)

(Yellowwithredtracer)

Ifthedischargeamountisnotspecifieditmeansthatthefuelpumpisdefectiveorthatthefuelfilterisclogged.

~ Fueldischargeamount:Approx.1200ml/30sec.(1.311.1US/Impoz)/30sec.

NOTE:

Thebatterymustbeinfullychargedcondition.

FUELPUMPRELAYINSPECTION

Fuelpumprelayislocatedinaheadofthebattery.

•Removethefrontandrearseats.

•Liftandsupportthefueltankwithitspropstay.(CT4-52)

•Removethefuelpumprelay.

First,checktheinsulationbetweenCDand%terminalswithpockettester.Thenapply12voltsto@and@terminals,±)to~and8to@,andcheckthecontinuitybetween0)and(2).

Ifthereisnocontinuity,replaceitwithanewone.

FUELPUMPANDFUELFILTERREMOVAL

N·m	kgf·m	lb-tt
10	1.0	7.0

_CONSTRUCTION

(I:Fuelpressureregulator

@Fuelpumpcase/Fuelfiltercartridge

(Forhighpressure)

'~Fuelpump

~Fuelmeshfilter

_{(Forlowpressure)}

'2,Thermistor

wO-ring

REMOVAL

•Removethefueltank.(c:::?4-52)

•Removethefuelpumpassemblybyremovingitsmountingboltsdiagonally.

AWARNING

Gasolineishighlyflammableandexplosive.Keepheat,sparkandflameaway.

•Removethenuts.

•Removethescrews.

•Removethefuelpumpassyfromthefuelpumpplate.

•Removethefuelpumpholder(D.

•Removethefuelmeshfilter.

•RemovethefuelpressureregulatorholderG)andthefuelpressureregulator~.

FUELMESHFILTERINSPECTIONANDCLEANING

Ifthefuelmeshfilteriscloggedwithsedimentorrust,fuelwillnotflowsmoothlyandlossinenginepowermayresult.

Blowthefuelmeshfilterwithcompressedair.

NOTE:

Ifthefuelmeshfilteriscloggedwithmanysedimentorrust,replacethefuelfiltercartridgewithanewone.

FUELPUMPANDFUELMESHFILTERINSTALLATION

Installthefuelpumpandfuelmeshfilterinthereverseorderofremoval,andpayattentiontothefollowingpoints:

•Installthenew0-ringstothefuelpressureregulatorandfuelpipe.

•Applythincoatoftheengineoiltothe0-rings.

IACAUTIONI

Usethenew0-ringstopreventfuelleakage.

•Passthroughthewiresbehindthethermistors.

•Besuretoconnectthewirestotheproperterminals.

'8'±:'terminalforfuelpump

§,Thermistorforlowlevel

·~Thermistorforhighlevel

•Installthe0-ringandapplygreasetoit.

,099000-25010:SUZUKISUPERGREASE"A"

AWARNING

The0-ringmustbereplacedwithanewonetopreventfuelleakage.

•Wheninstallingthefuelpumpassembly,lightlytightenallthefuelpumpassemblymountingboltsintheascendingorderofnumbers,andthentightenthemtothespecifiedtorqueintheabovemanner.

(!)Fuelpumpmountingbolt:10N·m(1.0kgf·m,7.0lb-ft)

NOTE:

ApplyasmallquantityoftheTHREADLOCK"1342"tothethreadportionofthefuelpumpmountingbolt.

~99000-32050:THREADLOCK"1342"

THROTTLEBODYANDSTVACTUATOR