_ $ SUZUKI SV650/AIXA © SERVICE MANUALIMPORTANT NOTICE WARNING / CAUTION / NOTICE / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words EMIMEMIG,, 4 CAUTION , NOTICE and NOTE have spacial meanings. Pay special attention to the messages highlighted by these signal words. ACAUTION Indicates a potential hazard that could result Inminor or moderate injury. NOTICE Tndicates a potential hazard that could result in motorcycle or equipment damage. NOTE Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all poten- tial nazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS, CAU- TIONS and NOTICES stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. FOREWORD This manual contains an introductory description on the SUZUKI SVB5Q/A/XA and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manuol wili help you know the motoreycle better so that you can assure your customers of fast and reliable service. * This manual has been prepared on the basis of the Iatest specifications at the time of publication. If modi- cations have been made since then, differences may exist between the content of this manual and the actual motoreycle. * ustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycies. If you do not have the proper knowledge and tools, ask your authorized ‘SUZUKI motoraycle dealer fo help you. waApplicable Model / VIN Applicable model SV65O/A L7 — L9 (2017 — 2019) SVG5OXA L9 (2019) Applicable VIN NOTE + "¥# indicates any check digit from 0 to Sand X. + “@” indicates the year of manufacture or the month and year of manufacture. ‘Applicable Model VIN Number County or Area ‘evesou7 JSIVPS5ARH2100001 — USA. except for California State JSIVPSSAaF2700007 — California State [SVG5DALT JSIVPSSB#H2 100001 — California State ‘evesoue [JSIVPS5ARJ2100001_— U.S.A. except for California State [JSIVP55AaI2100001_— California State [SVESOALS [JS1VPSSBAN2100001_— California State ‘svesoL9 [ISIVPSSARK7 100001 — USA, except for California State [JSIVPSSA#KT100001_ — Califomia State (SVESOALO [JSIVPESB#K7i00001 — [California State 'SVB5OXALS [JSIVPSSB8K7100001_— [Calltomia StateTABLE OF CONTENTS General Information Maintenance and Lubrication Service Data... Engine... Precautions Engine General information and Diagnosis Emission Control Devices... Engine Electrical Devices. Engine Mechanical Engine Lubrication Engine Cooling System.. Fuel System... Ignition System. Starting System. ‘Charging System. sesnanoneae CD PreCAULIONS ve nnnnonnnnnnve Brake Control System and Diagnosis Front Brakes.. Rear Brakes. ABS... . ‘Transmission / Transaxle. Precautions... Manual Transmission Clutch Steering Precautions. : Steering General Diagnosis ....Section 00 Precautions CONTENTS Precautions. Precautions. General Precautions .. Precautions for Electrical Circuit Service Precautions for Circuit Tester. 00-1 Precautions for SDS-I.Precautions Precautions ' General Precautions ‘BeNsianeco00o01 + Proper service and repair procedures are ‘+ When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative (-} cable from the battery. ‘When tightening the cylinder head or case important for the safety of the service bolts and nuts, tighten the larger sizes mochanie and the safety and rllbily of fret Always tighten the bolts and nuts + When 2 or more persons work together, pay attention to the safety of each other. + When it is necessary to run the engine indoors, make sure that exhaust gas is, forced outdoors. ‘+ When working with toxic or flammable ‘materials, make sure that the area you ‘work in is well ventilated and that you follow atl of the material manufacturer's instructions. * To avoid gotting burned, do not touch the engine, engine oil and exhaust system diagonally from the inside toward outside and to the specified tightening torque. Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self- locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. Never reuse a citclip. When installing a ‘now circtip, take care not to expand the ‘end gap larger than required to slip the untit they have cooled. Circlip over the shatt, After installing a LS Circlip, always ensure that itis completely NOTICE seated in its groove and securely fitted, + Never use gasoline as a cleaning solvent. + After servicing the fust, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks. «+ If parts replacement is necessary, replace ‘the parts with Suzuki Genuine Parts or Use a torque wrench to tighten fasteners: to the specified torque. Wipe off grease and oil if a thread is smeared with them. Aftor reassembling, check parts for tightness and proper operation. To protect the environment, do not unlawfully dispose of used motor oil and their equivalent. ‘other fluids: batteries, and tires. ‘+ When removing parts that are fo be reused, To protect Earth's natural resources, keep them arranged in an orderly mann ; 80 that they may be reinstalled in the Property dispose of used motorcycle and proper order and orientation, a ‘+ Make sure that all parts used in reassembly are clean, Lubricate them As this motorcycle equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter, when specified. or it can be damaged. + Use the specified lubricant, bond, or + Conduct a spark jump test only when necessary to the seatant. shortest possible time without opening the throttle. ‘+ When removing the battery, disconnect the + Conduct engine compression checks within the nagative (-) cable first and then the shortest possible time. positive (+) cable. . Avoid anv eituations which can reauit in encine misfireeee OS OF cape ee penta ‘BERL LeKe00c0002 ‘When handling the electrical parts or servicing the electric system, observe the following points for the safety of the system. Electrical Parts ‘Connector / Coupler + Faulty electrical system is offen related to poor electrical contact of connector/coupler. Before servicing individual electrical part, check electrical contact of the connector/coupler. “+ When connecting a connector, be sure to push it in until a click is felt lek “+ With a lock type coupler, be sure to release the lock when disconnecting, and push itn fully to engage the lock when connecting. + When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires. + Inspect each terminal on the connectorfeoupler for looseness or bending, + Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed, possibly resulting in poor electrical contact. + Inspect each terminal for corrosion and contamination. The terminals must be clean and free ‘of any foreign material which could impede proper terminal contact, + Bofors refting the sealed coupler, make sure its seal rubber is positioned properly. The seal rubber may possibly come of the position during disconnecting ‘work and ifthe coupler is refited with the seal rubber propery positioned, it may resuttin poor water sealing, ‘shaking it by hand lightly. If any abnormal condition Is. found, repair oF replace. + When taking measurements at elecitical coupler (1) using a fester probe (2), be sure to insert the probe from the wire hamess side (rear) of the coupler. researc + When connecting meter probe (2) from the terminal side of the coupler (1) because it cannot be connected from hamess side, use extra care not to bend the male terminal of couplet of force its female terminal ‘open for connection. In case of such coupler as shown connect probe a6 shown to avoid opening female terminal Never connect probe where male terminal is ‘supposed to fit, es eeeaee ar other similar material to* Clamp the wire harness at such positions as indicated in "Wiring Hamess Routing Diagram’ in Section 9A (Page 98-15), + Bend the clamp property so thatthe wire harness fe clamped securely. + In clamping the wire hamess, use care not to allow it tohang down. * Donnot use wire or any other substitute for the band type clamp. ee. Fuse + When a fuse is blown, always investigate the cause to correct it and then replace the fuse. + Donot use a fuse of different capacily. + Donot use wire or any other substitute for the fuse, ‘Switch Never apply grease material to switch contact points to prevent damage. See EEE NOES sensors, + Since each component is a high-precision part, great =~ ‘care should be taken not to apply any severe impacts, during removal and instalation, rotearoncuer + Be careful not to touch the electrical terminals of the electrical parts (ECM / CDI UNIT, elc.). The static. electricity from your body may damage them. Be‘When disconnecting and connecting the couples, make sure to tum OFF the ignition switch (1), or electrical parts may get damaged. Ge 86 + Never allow dust or water to contact the ABS control univU. + The ABS control univHU cannot be disassembled. Replace the whole unit with a new one. + Never connect any tester (voltmeter, ohmmeter, of whatever) to the electronic unit when its coupler is disconnected. Otherwise, damage to electronic unit may result + Never connect an ohmmeterto the electronic unit with its coupler connected. If attempted, damage to ECM / CDI UNIT / ABS contro! uniVHU or sensor may result e Be mre tn vee a specified volmeterahmmeter Battery + Select the same type MF battery when replacing the battery. + Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the ‘components of the Fl system and ABS instantly when reverse power is applied. + Removing eny battery terminal of a running engine is strictly prohibited, The moment such removallis made, damaging counter electromotive force will be applied to the electronic unit which may result in serious damage. + Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low battery voltage will Jead to erroneous diagnosis.Electrical Circuit inspection Procedur While there are various methods for electrical circuit inspection, described here is a ganeral method to check for open and short cirouit using an ohmmeter and a voltmeter. Open circuit check Possible causes for the open circuit are as follows. AS the cause can exist in the connector/coupler or terminal, they need to be checked carefully + Loose connection of connectoricoupler *+ Poor contact of terminal (due to dirt, corrosion or rust, oor contact tension, entry of foreign object etc.) + Wire hamess being open. * Poor terminal-to-wire connection. When checking system circuits including an electronic Control unit such 8s ECM, ete, its important to perform Careful check, starting with items which are easier to check. 1) Disconnect the negative (-) cable from the battery. 2} Check each connectoricoupler at both ends of the circuit being checked for loose connection. Also ‘check for condition of the coupler lack if equipped. Thi” Cheaxoriosce comnecon “Sener 2 Eetica pa 3) Using a test male terminal, check the female terminals ofthe circuit being checked for contact tension, ‘Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, atc.) At the same time, check to make sure that each terminalis fully inserted in the ‘coupler and locked Hf contact tension is not enough, rectify the contact to increase tension or replace. The terminals must be ‘lean and free of any foreign material which could impede proper terminal contact. ey wy A (a (_ Cheek coiae erain by ig a ein [BE chock each tenn er bend and prone ganar 4) Using continuity inspect or voltage check procedure: as described below. inspect the wire hamess ‘erminals for open circuit and poor connection. Locate abnormality, if any. t a) 4 er 8 TF Lssceness of ene Ter Oe [eh ite eran‘Continuity check 1) Measure resistance across coupler [B] (between [A] and [C] in the figure). no continuity is indicated {infinity or over limit), the circuit is open between terminals [A] and [C}. l & (8) S (e] 1. Bectiical part _— 2) Disconnect the coupler [B] and measure resistance between couplers [A] and [8-1]. ifn continuity is indicated, the circu is open between couplers [A] and [8-1] If continuity is indicated, there is an open circuit between couplers [8-2] and [C] or an abnormality in coupler [B-2] or coupler [C]. AL @ (2-21 ‘ay (1 e ge cr tf voltage is supalied to the circuit being checked, voltage ‘check can be used as circuit check. 1) With all connectors/couplers connected and vottage applied to the circu being checked, measure voltage between each terminal and body ground, 2) ff measurements were taken as shown in the figure ‘and resulis wore fisted in the following, Rt means that the circuit is opan between terminals [A] and (8). Voltage between ~ TA and body ground: 0 V IB] and body ground: Approx. 5 V IC] and body ground: Approx. 5 V 3) Also, if measured values are as listed following, a resistance (abnormality) exists which causes the voltage drop in the circuit botween terminals [A and 6). Voltage betwoon TA and body ground: 3 V - 2 V voltage drop IB] and body ground: Approx. 5 V [C] and body ground: Approx. §V le w aSMIOES GATGUE CTR (ww lhe Narness to ground) 1) Disconnect the negative (-) cable from the battery. 2) Disconnect the connectors/couplers at both ends of the circult to be checked, NoTE ifthe circuit to be checked branches to other parts as shown, disconnect all connectors! couplers of those parts. Otherwise, diagnosis will be wrong. 3) Measure resistance between terminal at one end of ireuit((A] terminal in the figure) and body ground. If Continuity is indicated, there is @ short crcut to ‘ground between terminals [A] and [C). wl ] tl 4] we a/t A te (Beeeeme [orem 4) Disconnect the connectoricoupler included in ciroult (coupler [8)) and measure resistance between terminal [A] and body ground. If continuity is indicated, the circuit is shorted to the ground between terminals [A] and [B} O97 pL Precauuons for Vircuit lester ssenrexecooonns + Use the Suzuki mull circuit tester set, ‘Special tool {A}: 09900-25008 a + Read the instruction manual to use the tester correctly, + Be sure to setthe tester to the correct testing range. + Ifthe voltage and current are not known, make: ‘measurements using the highest range. Symbols ‘Symbor Definition = DG = AG. a Resistanos = Continuity ae Diods Using Needle Pointed Prove NOTICE + When using the multi circuit tester, do not ‘strongly touch the terminal of the olectrical part couplers with a needle pointed tester probe to prevent the terminal damage or terminal bend. + When connecting the multi circuit tester, Use the needle pointed probe to the back coupter and connect the probes of tester to them. + Use the needle pointed probe to prevent ‘the rubber of the water proof coupler from damage. Special too!Precautions for SUS Benstenecco00ak + In some models of the SUZUKI motorcycles, the DTC can be confirmed by using SOS-I. + Read the instruction manual when using SDSl and operate it propery, ‘Special too! {A): 09904-41030 ‘09904-41040 imesonscnetSection 0 General Information CONTENTS General Information ....... General Description snus ‘Abbreviations SAE-to-Former SUZUKI Term Symbols... - . Wire Color Symbols Vehicle Side View Vehicle Identification Number County and Area Codes, Electrical Components Location Maintenance and Lubrication. fecautions. se Precautions for Maintenance .. Scheduled Maintenance -nmmnn Periodic Maintenance Schedule Chart. Repair Instructions .. ‘Air Cleaner Element inspection Air Cleaner Element Replacement. Exhaust Pipe Bolt and Muffler Bot Inspection Vale Clearance Inspecton and Agustment Spark Plug Inspection... . ‘Spark Plug Replacement .. Fuel Hose Inspection... Fuel Hose Replacement Evaporative Emission Control System Inspection (if Equipped)... Engine Oil Replacement Engine Oil Filter Replacement. Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization. PAIR System Inspection (if Equipped). Engine Coolant Replacement Radiator Hose Inspection...... ‘Clutch Cable Play Inspection and Adjustment Drive Chain Inspection and Adjustment. Drive Chain Cleaning and Lubricating... Brake System Inspection . Brake Fluid Inspection Brake Fluid Replacement. Brake Hose Inspection . Brake Hose Replacement Tire inspection, Steering System inspection Front Fork Inspection . Rear Suspension Inspection. Chassis Bolt and Nut Inspect Lubrication Points. 7 Special Tools and Equipment. ‘Special Tools and Equipment... Fuel / Oil Fluid / Coolant Recommendation .. Spactal TOO! aresnesv 00-13 0C-15General Intormation General Description Abbreviations A AAT: Ambient Air Temperature ‘ABDC: After Bottom Dead Center ABS: Anti-lock Brake System AC: Alternating Current ACL: Air Cleaner AK: Anti-knock Index ‘AP: Atmospheric Pressure ‘API: American Petroleum institute ATDG: After Top Dead Center AIF: Air Fuel Ratio B: BEDC: Before Bottom Dead Center BTDC: Before Top Dead Centar B+: Battery Positive Vohtage c ‘CDI: Capacitive Discharge Ignition KP: Crankshaft Position OKT: Circuit CLP: Clutch Lever Position ‘CMP: Camshaft Position ‘CO; Carbon Monoxide CPU: Central Processing Unit (CVT: Continuously Variable Transmission D: DC: Direct Current DOHC: Double Over Head Camshaft ORL: Daytime Running Light DTC: Diagnostic Trouble Code E ECM: Engine Control Module ECT: Engine Coolant Temperature ET: Engine Temperature VAP: Evaporative Emission EX: Exhaust EXCV: Exhaust Control Valve EXGVA: Exhaust Control Valve Actuator FE FF: Fuel Injection, Fuel Injector FP: Fuel Pump FPR: Fuel Pressure Regulator FTPC: Fuel Tank Pressure Control FWD: Forward c GEN: Generator Intake Air Temperature Inside Diameter 1G: Ignition IN. Intake Idle Speed Control JASO: Japanese Automobile Standards Organization u LOD: Liquié Crystal Display LED: Light Emiting Diode LH: Lett Hand to: Low Max: Maximum MIL: Malfunction indicator Light Min: Minimum MTBE: Methyl Tertiary Butyl Ether N NOx: Nitrogen Oxides o 02: Oxygen OBD: On-Board Diagnostic System ‘OHC: Over Head Camstiaft 0.D.: Outside Diameter PAIR: Pulsed Secondary Air injection PCV: Positive Crankcase Ventilation PP: Pulley Position R RH: Right Hand ROM: Read Only Memory RON: Research Octane Number RPM: Engine Speed SAE: Society of Automotive Engineers SDS: Suzuki Diagnosis System STCS: Secondary Throttie Control System STD: Standard STP: Secondary Throttle Position STV: Secondary Throttle Valve STVA: Secondary Throttle Valve Actuator ho. TC: Traction Control ‘TDC: Top Dead CenterSAE-to-Frormer SUZUKI term BesteKso101008 This list shows SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. Ex. SAE term (Abbreviation): Former SUZUKI term Air Cleaner, Air Cleaner Box Barometric Pressure (BARO): Barometric Pressure, ‘Atmospheric Pressure (APS, AP Sensor) Battery Positive Voltage (B+): Battery Voltage, +B c: Camshaft Position Sensor (CMP Sensor): Camshaft Position Sensor (CMPS) Crankshaft Position Sensor (CKP Sensor): ‘Crankshaft Position Sensor (CKPS), Crank Angle Do Data Link Connector (DLC): Deeter Mode Coupler Diagnostic Test Mode (DTM): — Diagnostic Trouble Code (DTC): Diagnostic Code, Matfunction Code E Electronic Ignition (El): — Engine Control Module (ECM): Engine Control ‘Module (ECM), FI Control Unit, Engine Control Unit (ECU) Engine Coolant Level (ECL): Coolant Level Engine Goolant Temperature (ECT): Coolant “Temperature, Engine Coolant Temperature, Water Temperature Engine Speed (RPM): Engine Speed (RPM) Evaporative Emission (EVAP}: Evaporative Emission Evaporative Emission Canistor (EVAP Canister): — (Canister) Exhaust Control System: EXC System (EXCS) Exhaust Control Valve: EXC Valve (EXCV) Exhaust Control Valve Actuator: EXCV Actuator (EXCVA) FB Fan Control (FC}: — Fuel Level Sensor: Fuel Level Sensor, Fuel Level, Gauge Fuel Pump (FP); Fuel Pump (FP) G Generator (GEN): Generator Ground (GND): Ground (GND. GRD) mn Hydrocarbons (HC): Hydrocarbons Heated Oxygen Sensor (HO28): Heated Oxygen ‘Sensor (HO2S), 02 sensor & Intake Air Temperature (IAT): Intake Air Temperature (AT), Air Temperature Idle Spood Control {1SC); — Ignition Control (IC): Electronic Spark Advance (ESA) Ignition Control Module (ICM): — M: Malfunction Indicator Lamp (MIL): LED Light, Malfunction Indicator Light (MIL) Manifold Absolute Pressure (MAP): Intake Air Pressure (IAP), Intake Vacuum ‘Mass Air Flow (MAF): Ait Flow oO On-Board Diagnostic (BD): Self-Diagnosis Function, Diagnostic Open Loop (OL): — P Power Control Module (PCM): — Programmable Read Only Memory (PROM): — Pulsed Secondary Air Injection (PAIR): Pulse Air ‘Control (PAIR) Purge Valve (Puri R Random Access Memory (RAM): — Road Only Memory (ROM): ROM Ss ‘Secondary Air Injection (AIR): — Secondary Throttle Control System (STC: System (STCS) Secondary Throttle Valve (STV): ST Valve (STV) Secondary Throttle Valve Actuator (STVA): STV ‘Actuator (STVA) Valve}: Purge Valve (SP Valve) tr Throttle Body (TB): Throttle Body (TB) Throttle Body Fuel Injection (TBI): Throtle Body Fusl Injection (TEI) Throttle Position Sensor (TP Sensor): TP Sensor (TPS) Tank Pressure Control Valve: TPC Valve (TPCV) Traction Control (TC): Traction Control Voltage Regulator (VR): Vollage Regulator Volume Air Flow (VAF): Air Flowyes eensieKsototoo2 Listed in the table below are the symbols indicating instructions and other information necessary for servicing, The ‘meaning of each symbol fs also inciuded in the table. NOTE ‘The table below shows generally used symbols, and Includes some symbols not used in this manual, ‘Symbor Definition Torque control required. [Data beside it indicate specified torque. [Apply ol. |Use engine oil unless otherwise specified. JApply molybdenum oil solution. |(wixture of engine oil and SUZUKI MOLY PASTE in a ratio of 4:1). [Apply SUZUKI SUPER GREASE A, lo9000-25011 "Apply SUZUKI SUPER GREASE C. 99000-25030 "Apply SUZUKI MOLYBDENUM GREASE L. '99000-25280 "Apply SUZUKI MOLY PASTE, '99000-25140 "Apply SUZUKI SILICONE GREASE, '99000-25100 ‘Apply SUZUKI WATER RESISTANT GREASE EP2. '99000-25350 "Apply SUZUKT BOND 12078, |99000-31140 (Apply SUZUKI BOND 1278, [98000-31110 (Apply SUZUKI BOND 12168, leso00-31230 [Apply THREAD LOCK CEMENT 13038, |298000-32030 [Apply THREAD LOCK CEMENT 13220. |98000-32150 \Apply THREAD LOCK CEMENT 13421, !98000-32180 AB BIB/AlA/Ala elaleleje lays (Apply THREAD LOCK CEMENT 1360. 19000-32130 (Use SUZUKI SUPER LONG LIFE COOLANT (BLUE). '99000-99032-20x ‘Use SUZUKI LONG LIFE COOLANT (GREEN). '99000-98032-12X ‘Apply or use fork of ‘Apply or use brake fluid. [Use special tool [Do not reuse. KeoB ae A INole on reassembly.Mire Volor symbols: BensreKeororone ‘Symbol Wire Color ‘Simbar Wire Color B Black ta [Light green BI Blue oO Orange 6 [Brown P Pink ‘Dbr [Dark brown: R id Bg [Dark green Vv iolet C iGreen Ww. ite G—|Gray Y allow? Lot flight is ‘There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. ‘The single-colored wire uses only one color symbol (i.e. G). The dual-colored wire uses twa color symbols (Le. G/Y). ‘The frst symbol represents the base color of the wire and the second symbol represents the color of the stipe. a ie cao 5 Giwane cay 2 (Se eer)‘BENIEKeDIOT004 ‘SUZUKI SV650XA Country and Area Codes The following codes stand for the applicable country(-ies) and area(-s). ‘Vehicle Identincation Number BEN, 800101008 ‘The frame serial number or V.LN. (Vehicle Identification Number) (1) is stariped on the steering head tube. The ‘engine serial number (2) located on the crankcase ‘BenteRs0101006 Code Country of Area E03 USA. except for California State E33 California State:EN eKeD101007 ‘Warning, Caution and Information Labels LocationFudd tank A: 1. General waming label if ecisppe) 9. _intoernation label or Nose label (if equipped) 18; Framer 7 Werciobc or Gussie abel (Fequpeay | 10. Warman label or Vacuum hose roig label (ieauboed) Teh Fane ‘Feel aon abl i auped) Brae ti iforraton aba eauipedt To)_Wareetrs SEBAT Brake aproval ak abe if eupsed) 12_CES Canedaiabe i equbpe) TEL Rasitr cap 5 maton bel equiped) "Raat cap be peed) F)_ Sungai) ‘SUN re lbel Hepa) “<_Tre information bet TS} Rear fender Fone 71 pate Mintaro Faw [IE Moa ice SAP cau Ty fern Fon (EAP caer) | 6 EPA nose iabal eaupped)Component Location Electrical Components Location "Tew od apood sneer NAB) = cocina ney 7 anaen o ee 2. Mode scsi over 6P) 18 Bate 18, onrerare ih ._Moge sla soup 2P) ith ABE) 1 Ect 18 Sart mob Sar elayBian ss 2_To sensor 20 Regusiedtor 5 Tun cis okay 3 Funl paoEieilevel gauge” Hom1. BR core stoned va eatipoed)_[__7_Wrwaniar 1a Gener 2. Fuslinpcor #1 _StP ansot 1a GRP sraor 3. Fuelinjcor 2 0 STVacuser 15 HOP saraor 7 EVAE syste purge cone soaraaie | 10 TP eenscr 16. GP eee eniDpes) AP senor TABS catol ra TARR ABS) T7 Skenend sath (bod 5 AP ser 12. Front wel spo sensor (Wh ABS) 6 Speed versa 'a26)Maintenance and Lubrication Precautions Precautions for Maintenance cenvvecean ‘The “Periodic Maintenance Schedule Chart’ lists the recommended intervals forall the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in ferms of kiometers, miles and months for your convenience. IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and It will also ensure the reliability and performance of the motorcycle. NOTE More frequent servicing may be required on motorcycles that are used under savere conditions. Scheduled Maintenance Periodic Maintenance Schedule Chart senuioxscanecot NOTE + 1=Inspect and clean, adjust, replace or lubricate as necessary. R= Replace. T= Tighten. + (CA. only) means that the item or the maintenance interval is to be applied only for the California model. Interval Item months | 2 7: ES 36 48 km 4000 6000 12000 18000, 24000 miles 600 4000, 7500 14000 14500" [Air cleaner element (I “(Page 08-2), R’ “(Page 0B-)| _ — T R T Exhaust pipe bolts and mufler bolts (= (Page 08-2) | Tr = T = T ‘Valve clearance (I. (Page 08-2) Trapec every 27000 km (15000 Tiles) ‘Spark plugs (I: = (Page 0B-2), R: = (Page 08-2)) = T R T R Lo = 2 = T T T T Fue! hose (|: © (Page 0B-2), R: «(Page 08-2)) pees [Evaporative emission control system (if equipped) (FE a ~ 1 _ i (Page 08-2) [Engine ofl (R: = (Page 06-2)) R R R R Rg [Engine oii fiter (R: + (Page 0B-2)) R = = R = [Throttle cable play (iE + (Page OB-2)) i T t T T Po T | Throttle valve synchronization (I: #- (Page 0B-2)) (CA. only) _ t - 1 [PAIR (air supply) system (equipped) (: (Page 0B-2))[ — = 1 = ! |"SUZUKI SUPER LONG LIFE COOLANT") Replace every 4 years or 48000 km (29000 miles) (Blue) lEnaine coolant (R: @(Page 0B-| SUZUKI LONG LIFE______eiitervae tem months |—_2~ 72 2 36 km__| 7000 —| — 6000 | —72000_| —ta000 miles_| 600 | 4000__| 70047000 Brakes (i > (Page 08-3) T 7 T T i x = T T i Brake fluid (1: "(Page 08-3), R: (Page 0B-3)) Sasa a om = 1 T 7 i Brake hose (|: + (Page 08-3), R: = (Page 0B-3)) RT Tears = T T T T T = r = T = = T = i Rear suspension = = T = i (Chassis bots and nuts (7: (Page 08-4) T T T T T Lubscation (¢ = (Page 08-6) Lubricate at every 1000 kin (G00 miles) Repair Instructions Air Cleaner Elomontinepoction | Evaporative Emission Control System Refer to “Air Cleaner Element inspection and Cleaning" | Inspection (If Equipped) enstensoznsnne in Section 1D (Page 10-7). Air Cleaner ElementReplacement enstexsna0e002 Refer to “Air Cleaner Element Removal and Installation" in Section 10 (Page 10-7). Exhaust Pipe Bolt and Muffler Bolt Inspection ttexeaz0¢e0s| Refer fo “Exhaust System Inspection’ in Section 1K (Page 1K-5).. Valve Clearance Inspection and Adjustment IBENITEK0206c04 Refer to "Valve Clearance Inspection and Adjustment’ in Section 10 (Page 10-32). ‘Spark Plug Inspection Benstenoo209006 Refer to “Spark Plug Inspection” in Section 1H (Page 1H8). Spark Plug Replacement Refer to “Spark Plug Removal and Installatior ‘Section 1H (Page 14-7), Fuel Hose Inspection enstexsoz0e007 Refer to "Fuel Hose Inspection" in Section 1G (Page 1G- 1). Refer to "EVAP Control System Inspection (If Equipped)" in Section 18 (Page 18-15), e ingine Oil Replacement cxnoroeczoono Refer to “Engine Oil Replacement” in Section 1 (Page 15). Engine Oil Filter Rept gine Ol Filter Replacement sew isaoztsn Refer fo "Oil Fitter Replacement” in Section 16 (Page 16.8) Throttle Cable Play Inspection and Adjustment ‘dlvemment Refer to "Throttle Cable Play On-Vehicle Inspection and Adjustment" in Section 1D (Page 1D-10). Throttle Valve Synchronization seus Refer to “Throttle Valve Synchronization" in Section 1D (Page 1D-15). PAIR System I tion (IF yatem Inspection Hf ESUIPP ED aca Refer to"PAIR System Inspection (t Eaupped os ‘Section 1B (Page 1B-12). 5 ingine Coolant Replacement scunscoorteors Refer to “Engine Coolant Replacement’ in Section 1FMauten Vale ray Inspecuon and Adiustnent NOTORDD20017 Refer to "Clutch Cable Play On-Vehicle Inspection and Adjustment” in Section 5C (Page 5C-2). Drive Chain Inspection and Adjustment EI Te & 09930-40113 (09930-44530 }99930-82720 |09930-82760 09940-14914 Rotor holder. Rotor holder |Mode selection switch |Mode selection switch | Steering stem nut sockst ’ is |p & “Oe, Go 09940-34520 (09940-34531 09940-40241 }09940-40220 }09940-52861 Than (Long shank: [Font fork assembling /Puel pressure gauge [Fuel pressure gauge_|Front ok ol seal 8 sq.) lattachment (A) adapter |attachment installer set 09940-63110 09941-34513 }09941-54911 09941-74911 09943-74111 “Torx® bit (E8) ‘Bearing installer set Bearing outer race __| Steering stem bearing |Front fork oil levelSection 1 Engine CONTENTS Precautions Precautions for Idetiicaon Engine General Information and gnosis . Precautions. Precautions for DTC Trouble Shooting... General Description wove Injection Timing Descriptio Seff-Diagnosis Function. ‘Schematic and Routing Diagram. FI System Wiring Diagram Component Locatio . FI System Component Location. Diagnostic Information and Procedures. Engine Symptom Diagnosis... .nn DIC Check... DTC Clearance. DTC Table... Fall-Safe Function Table. FI System Troubleshooting DTC P0030 / P0032 (C44), DIC P0105 / PO106 / P0107 (C17)... DTC PO110 / POT12 (C21). DTC POI15 / PO117 (C18). DTC PO120/ PO123 (C14)... DTC P0130 / PO131 / P0132 (C44) . DTC P0170 (C45) DTC P0201 (C32) DTC P0202 (C33) DTC Pa220/ P0222 (C29), DTC Po230 / Po231 (C41) DTC P0336 (C12) DTC P0351 (C24) 7 183 DTG P1100/ P1101 / P1102 (o19) DTC P1610 (C42)... DTC P1700 / P1701 (C23). DTC P2100 (C28)... Emission Control Devices Procautions... General Description Fuel injection System Crankcase Emission Control System Description. Exhaust Emission Control System Description Noise Emission Control System Description. Evaporative Emission Control System Diagram (If Equipped)... ‘Schematic and Routing Diagram... PAIR System Hose Routing Diagram (i Equipped)... oe ABB PCV Hose Routing Diagram... 187 EVAP Carister Hose Routing Diegram Equipped)... Repair Instructions PAIR Reed Valve Removal and Installation (If Equipped). ~ PAIR Conirol Solenoid Vaive Removal and Installation (tt Equipped) PAIR System Inspection (If Equipped) FAIR Hose Removal and Inston (i Equipped). 1843 PCV Hose Inspection on 1843 PCV Hose Remeval and Installation “B43 EVAP Control System Removal andISC Valve System Schematic and Routing Diagram. HO2 Sensor Lead Wire Routing Diagram Component Location Engine Electrical Comp: Diagnostic Information and Procedures... Engine Symptom Diagnosis. Repair Instructions ... ISC Valve (Secondary Throtte Valve Interinked) Inspection ISC Aperture Learned Value Reset ECM Removal and Installation. IAP Sensor Inspection... IAP Sensor Removal and Installation... IAT Sensor inspection... IAT Sensor Removal and Inetallstion.. ECT Sensor inspection ECT Sensor Removal TP Sensor Inspection. TP Sensor Adjustment - ‘TP Sensor Removal and Installation HO2 Sensor inspection... HO2 Sensor Removal and Installation. ‘CKP Sensor Inspection CKP Sensor Removal a TO Sensor Inspection : TO Sensor Removal and Installation STP Sensor Inspection and Adjustment STP Sensor Removal and Installation ‘STV Actuator Inspection... Specifications nna CAS Tightening Torque Specifications... Special Tools and Equipment.. Special Tool... Engine Mechanical Precautions. Precautions for Engine Mechanical. Schematic and Routing Diagram, Throttle Cable Routing Diagram. Diagnostic Information and Procodures, Engine Mechanical Symptom Diagnosis. Compression Pressure Check Repair Instructions... Intake System Construction... Ai Cleaner Element Removal and Installation ..1D-7 Air Cleaner Element Inspection and Cleaning ...1D-7 intake Cylinder Head Cover Removal and Installation Cylinder Head Cover inspection. Cam Chain Tension Adjuster / Camshaft Removal ‘Cam Chain Tension Auster Camahat Installation ‘Camshaft inspection ‘Cam Chain Tension ee fDB1 Valve Clearance Inspection and Adjustment ...1D-32 Engine Assembly Removal Engine Assembly Installation Cylinder Head Assembiy / Cam Chain Guide Cylinder Removal... ss Cylinder Head Assembly / Gam Chain Guide 1 Cylinder Installation... ‘Gam Chain Guide inspection Cylinder inspection... Vale / Valve Spring Removal and installation . 1D-49 Vale Inspection... son DBL Valve Seat Repair. Valve Spring Inspection... Cylinder Head Disassembly and Cylinder Head Inspection Valve Guide Replacement... Piston Removal and Installation Piston Ring Removal and Installation Piston and Piston Ring Inspection ‘Cam Chain Tensioner / Cam Chain / Gam ‘Chain Drive Sprocket Removal and Installation... ‘Cam Chain Tensioner Inspection. Crankcase Assembly Disassembly... Grankcase Assembly Reassembly... Crankshaft Assembly Removal and Installation... Crankshaft Journal Bearing Removal and instalation... Left Crankcase Disassembly and Reassembly Right Crankcase Disassembly and Reassembly Crankcase Beating / Oii Seal inspection CConrod Removal and Installation Gonrod / Crankshaft Inspection ‘Conrod Crank Pin Bearing Inspection and Selection. Crankshaft Journal Bearing Insgection and Selection Specifications.Schematic and Kouting Viagram.... Engine Lubrication System Chart Diagram... 1E-2 Diagnostic Information and Procedures verwnn IES Engine Lubrication Symptom Diagnosis «nnn 1E-3 ll Pressure Check. Repair Instructions Engine Oil Inspection . Engine Oil Replacement Oil Filter Replacement : 166 Oil Strainer / Oil Pressure Regulator Removal and Installation ...mnmnnnnnnnninnesne 1B ll Strainer inspection and Cleaning... ll Pressure Regulator Inspection Oil Gooler / Oil Cooler Hose Inspection Oil Cooler Removal and Installatior Oil Pressure Switch Removal and Oil Pressure Switch Inspection... Oil Jet Piston Cooling Jet Removal and Installation... il Jet / Piston Cooling Jet inspection... il Pump Removal and Installation. Oil Pump Inspection. (Oil Separator Removal and Installation. ‘Transmission Oil Guide Removal and Installation.. Transmission Oil Guide Inspection E14 Specifications... re E45 Tightening Torque Specifications. E48, Special Tools and Equipment. Recommended Service Material Special TOOL nnn Engine Cooli Precautions for Engine Coolant - ‘General Description... Engine Coolant Description ‘Schematic and Routing Diagram ..r0. Cooling Circuit Diagram ‘Water Hose Routing Diagram... Diagnostic Information and Procedures.. Engine Cooling Symptom Diagnosis... Repair Instructions Engine Coolant Level Inspection Engine Coolant Replacement... Engine Cooling System inspection . Radiator Cap inspection... ‘Cooling Fan On-Vehiale Inspection Radiator Hose Inspection.. ee eee ane. Thermostat Removal and Instalanon. ‘Thermostat inspection. Water Pump Assembly Components. . Water Pump Removal and Installation... Water Pump Disassembly and Reassembly..... Water Pump Related Parts Inspection ‘Specifications. Tightening Torque Specification Special Tools and Equipment. Recommended Service Material ‘Special Too! Precautions for Fuel System. General Description. Fuel Sysiem Description ‘Schematic and Routing Diagram... Fuel Tank Water Orain Hose and Fuel Tank Breather Hose Routing Diagram 163 Diagnostic Information and Procedures... 1G-5 Fuel System Diagnosis 165 Repair Instructions so 16 Fuel Pressure Inspection 166 Fuel Discharge Amount Inspection . 166 Fuel Feed Hose Disconnection and. Reconnection 167 Fuel Feed Hose Removal and Installation ..... 1G-7 Fuel Hose Inspection... Fuel Tank Construction Fuel Tank Cap Removal and Installation . Fual Tank Removal and Installation. Fuel Pump Components... Fuel Pump On-Vehicle Inspection. Fuel Pump Assembly Removal and Installation... Fuel Pump Disassembly and Reassembi Fuel Mesh Fitter Inspection. Fuel Level Gauge Inspection Fuel Pump Relay Inspection Fuel Injector On-Vehicle Inspection . Fuel Injector / Fuel Delivery Pipe Removal and Installation. Fuel Injector Inspection and Cleaning. Specifications. Tightening Torque Speci Special Tools and Equipment. Recommended Service Material... Special Tod! a. lanition System.RG Palr INSTFUCHIONS «.-..- Ignition Coll Construction Spark Plug Removal and Installation - ‘Spark Plug Inspection eB Ignition Coil Removal and instalation Ignition Coll Inspection Engine Stop Switch Inspection. Ignition Switch Inspection. Tightening Torque Specification Special Tools and Equipment, Recommended Service Material Special Tool. Starting System. ‘Schematic and Routing Diagram. ‘Starting System Diagram Component Location aM Starting System Components Locatior a Diagnostic Information and Procedures somnnmne tle4 ‘Starting System Symptom Diagnosis... Alt ‘Starter Motor Will Not Run... Starter Motor Runs But Does Not Crank the Engine Repair Instructions Starter Motor Comp: Starter Motor Assembly Removal and Installation. Starter Motor Disassembly and Reassembly ‘Starter Motor Inspection. Starter Relay Removal and installatio: Starter Relay Inspection. Side-stand Relay Remov: Starter Interlock System Parts Inspection . ‘Starter Clutch Removal and Installation... 118 ‘Starter Clutch Inspection, W410 Starter Switch Inspection 1 Specifications. Tightening Torque Sp ‘Special Tools and Equipment. Recommended Service Material ‘Special Todt. Charging System Schematic and Routing Diagram. Charging System Diagram... Component Location Charging System Comp Diagnostic Information and Procedures .o..4J-2 Charging System Symptom Diagnosis. 12 Battery Runs Down Quickly... Repair Instructions Batlery Current Leakage Inspe Regulated Voltage Inspection Generator Inspection... Gonerator Remove Generator Instalato Regulator / Rectifier Inspection Regulator / Rectifier Construction... 8 Regulator / Rectifier Removal and Installation . 11-10 Battery Charging . 1410 Battery Protector Construction... Battery Removal and Installation Battery Visual Inspection. oe Specifications sn. so Tightening Torque Spectfications. Special Tools and Equipment nnn ‘Special Too! w42 4613 113 15-44 14 1014 Weld Precautions for Exhaust System Repair Instructions Exhaust System Components, Exhaust System Inspection none Exhaust Pipe / Muffler Removel and Installation... ‘Specifications. Tightening Torque SpecticationPrecautions Precautions Precautions for Engine exurennoo001 Refer to "General Precautions" in Section 00 (Page 00-1), "Precautions for Electrical Circuit Service in Section 00 (Page 00.2) and "Precautions for Circuit Tester” in Section 00 (Page 00-7). Precautions for Identification Benstsxeroo002 When viewed from the state in siting on the seat, the front cylinder (1) is distinguished as No. 1 cylinder, and the rear cylinder (2) is as No. 2 cylinder. ‘The sensor, actuator or the like for the front cylinder are distinguished as #1, and the ones for the rear ylinder are as #2,My Names and the lerms hat Are Used in rhe service Manu Refer to "Electrical Components Location’ in Section OA (Page 0A-8). ‘The comparison with the terms used in DTC name and this service manual are shown in the table below. DTC name. "Term in the service maniial |CKP Sensor “A Circuit |CKP Sensor JECT Sensor Circuit JECT Sensor Gireuit Low ECT Sensor [EVAR System Purge Contr Vale Chou EVAP System Purge Control Solenoid Valve Fan 1 Contra Great Ceaing Fa FP Primary Creu IFP Secondary Circ Low Fuel Pump [SP Sensor Circuit (SP Sula IHO2 Sensor Healer Cont Cro Bank 1 Sensor 1 [OZ Sensor Heater Control Cru nor HO2 Sensor TAP Senor Creuit TAP Sensor Crcuit Low AP Sensor #1 IAP Sensor Circuit Range / Pavfommance [AP Sensor? Greut TAP Sensor 2 Grout Low IAP Sensor #2 IAP Sensor 2 Gircuit Range / Parfommanos TAT Sensor 1 Circuit IAT Seneor t Circuit LOW AT Sensor ignition Coll"A" Primary / Secondary Circuit Igaiton Carat Ighlion Coll"B" Primary / Secondary Chul ignition Cone ignition Switeh Sighal Cireuk ignition Switch injector Circuit Open = Cylinder’ Fuel injector #1 Injector Circuit / Open — Cylinder 2 Fuel Injector #2 SC System RPM Higher Then Expedted ISC Valve [SC Syetem RPM Lower Than Expected [02 Sensor Circuit Bank 7 Sensor 1 [02 Sensor Greuil High Vollage Bank 7 Sensor 102 Sensor [O2 Sensor Circuit Low Voltage Bank 1 Sensor 1 PAIR System Control “A* Circuit PAIR System Control "A" Circuit High PAIR Control Solenoid Valve Thrsttie Actuator "A Control Motor Circuit TWA HO Sensor Gircut [TO Sensor Cireur Caw [TO Sensor HTP Sensor? Switch "A" Circuit TPs ITP Sensor / Switch “A” vensor [TP Sensor / Switch °B" Circuit ISTP sa [TP Sensor / Switch "B Circuit Low nsor Vehicle Speed Sensor “Av |" Speed Sensor (Without ABS) |+_ Front Wheel Speed Sensor (With ABS)Engine General Information and Diagnosis Precautions Precautions for DTC Trouble Shooting jpenstsKs 100001 Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service" in Section 00 (Page 00-2) and "Precautions for Circuit Tester” in Section 00 (Page 00-7}, NOTE After repairing the trouble, clear the DTC using the special tool, = (Page 1A-15) General Description Injection Timing Description Injection Time {Injection Volume) ‘The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the 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. Benstexstiotoot .----- Eom -———— | | Intake Air Pressure Intake air pressure | Sensor (IAP Sensor) ‘signal i | | Basic | Crankshaft Position Engine fuel | ‘Sensor (CKP Sensor) sgn +>] injection I “Throtle Position Throttle opening time | Sensor (TP Sensor) signal I | | Various Various signals L | Corrective : Sensors { variables ' | oo | Definitive | Injectors [< Injection signal ___| fuel I injection | time | |Compens: n of Injection Time (Volume) “The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). ‘Signal Descriptions ECT sensor signal ieh engine coolant temperature is low, injection time (volume) is increased] [IAT sensor signal Intake air temperature is Tow, injection time (volume) Is increased. Airfluel ratio is compensated to the theoretical ratio from density of oxygen in HO2 sensor signal ‘exhaust gasses. The compensation cours in such a way that more fuel is ‘supplied if detected aifuel ratio is lean and less fuel is supplied if tis rich. ECM operates on the battery voltage and at the same time, it monitors the Battery voltage signal voltage signal for compensation of the fuel injection time (volume). A longer Injection time is needed to adjust injection volume in the case of low voltage. |Efigine rpm signal [At high speed, the injection time (volume} is increased. [Starting signal [When starting engine, additional fuels injected during cranking engine /Acceleration signal / deceleration signal [During acceleration, the fuel injection time (volume) is increased, in accordance with the throttle opening speed and engine rpm. During deceleration, the fuel injection time (volume) is decreased. Injection Stop Controt ‘Signal Descriptions ‘When the motorcycle tips over, the tip-over sensor sends a signal fo the ‘1 sensor signal ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors and ignition coil lOver-rev. limiter signal 1en actual engine speed reaches a programmed maximum, tha fuél injection pulses are suppressed.‘Sell-Diagnosis Function enuieKerro1002 The setf-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 (MIL). To check the function of the individual FI system devices, the dealer made is provided. In this check, the special tool is necessary to read the code of the ‘matfunction items. Warning Function ‘The ECM wams riders to turn the MIL (1) on or blink it depending on the failure place or its content. ‘And the ECM tums the MIL off when detecting 3 DiC-correct continuously after detecting the first abnormality, ‘The ECM erases the registered failure data when not detecting the same one during 40 times of warm up cycle after turning MIL on. ‘Supplementation + The driving cycle (D/C) means the cycle beginning from turning the ignition switch ON through starting the engine until turning the ignition switch OFF. The 3 driving cycles are the term repeating 3 times of the above mentioned coyote. + The warm up cycle means the cycle of engine warm up operation that the engine coolant temperature reaches ‘more than 74 *C (159.8 °F) and also rises more than 22.5 °C (72.5 °F) from the one at engine starting. Diagnostic coupler location ‘Mode select coupler (6P) (1) is located under the seat. This coupler can use SDS tool and OBD conversion cable. ‘Special too! (09904-41051User Mode TOD (display) Malfunction indication (1) MIL indication (2) Indication mode "NO" [Odometer *7 = z = (Odometer *T and "FT" Fach 2 sec. Odometer *1 and "FT “ves* |Engine can start letters *2 ‘MIL. turns ON. indi alternately. Engine can aan eter “3 RAs ON a fas nate contrac. 4 ‘Current leer displayed any one of the odometer, tripmeter A or tripmeter B. 2 ‘When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case, “FI" and odometer *1 are indicated in the LCD panel and motorcycle can run. 3 The injection signal is stopped, when the crankshaft position sensor signal, tip-over sensor signal, #1 and #2 ignition signals, #1 and #2 fue! injector signals, fuel pump relay signal or ignition switch signal is not sent to ECM. In this case, “FP is i The LCD panel indicates “HEC” when no communication signal rom the ECM is received for 3 seconds or more. For Example: ‘The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the combination meter does ‘not receive any signal from the ECM, and the panel indicates “CHEC*. ICHEC is indicated, the LCD does not indicate the trouble code. Itis necessary to check the wiring harness between ECM and combination meter couplers. ‘The possible cause of this indication is as follows: Engine stop switch is in OFF position. Starter interlock system is not working. Ignition fuse is burt. NOTE ‘The NIL (2) turns ON about 3 seconds after turning the ignition switch ON.Vealer Mode ‘The defective function is memorized in the computer. Use the spacial toots coupler to connect to the mode select witch. 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. NOTE Before checking the malfunction code, do not disconnect the ECM couplers. Ifthe couplers from the ECM is disconnected, the matfunction code memory is erased and the malfunction code can not be checked. ‘Special tool (A): 09930-82720 Malfunction Flight indication Indication mode NO" TED (display) indication COO "yes" IC™ codes indicated om small [numeral to large one. ‘MIL turns OFF. For each 2 sec., code is indicated,schematic and Routing Diagram FI System Wiring Diagram ‘BEN eKst102005 24 TSH Ta 38JA} _To made select coupler (OP) 10._Front. whee! speed sensor 26 Fuel pane 18}_Wi ABS: 1 ABS corer ant Fr Sdeetane ey ~ [eh Wink ABS 72. Speed sensor 728. Sanarans wach Pal 18. Fualiecor 2 Neubaldcatr 1g Te} Toby "a Fusnecorez 30 Sarer ay Fl For UR_EU and ala 18._tten est 31 Stare molt [6] Eseepttor UK, EU ana Ansale 1 epee Sire ach “OFF sano 1 Bie yen aceciaieY | 88 Gehironeh Tesoro Ta_ PAIR conte elena valve Weare) Eng Sp ach 3._TP enon? 32. GP ower 35. pater ow SAP eens ‘ai S1Vecuat 38. Feo (5A) 5 WP aenaor¥2 Bi Combination ler 37. Fuel tse (10) ECT semar Zeon 35ers (5 A) T_T conor 23._Gooing an way 33. Sorat we ISA) TO anes [Bi Casing fn motor ata foe SOA) ‘8. HO sensor 2. Feet pmo ai_ samy ‘Terminal Arrangement of ECM Connector “T" eegaseras PSSHIHOGHSODODIOBO OO9ESOEOS PHOIRGSVSSSLIIIST rca. TERMINAL NO, CIRCUIT TERMINAL NO. SIRCUT Tt [SP switch signal T27____[OKP sensor Signal (CKP+) T2___AT sensor signal 128 = 3____ IAP sensor #1 signal 129 (Mode select switch T4_~ [STP sensor signal 730 = TS___ [Power source for Sensors T31___ [Sele data for combination meter TS [Sela data for self-diagnosis T3Z__|HO2 sensor signal Tr_~ [Clutch iever position switch = Te [OKP sensor signal (KP) 38 = Ta___[Power source for batiory mavitr ‘T35_ | STWA signal (STVA, 16) 10 |Power source for backup 36 |STVA signal (STVA, 2B) Tit [Power source T37___|HO? sensor heater Tiz___|Sensor ground (E2) T38 = EVAP system purge control solenoid valve 113 [ECM ground (1) 738 reautppod) Tia = T40 “Tachometer 15 = T4i____[General power ground (E01) THe = T4z___[Fuel injector #2 TI = T43____ [ignition col #2 TIs____ Tgniion Siaich signa ac ‘TVA signal (STVA, 1A) “119” [ECT sensor signal T45_~|STVA signal (STVA, 2A) 720___|TO sensor signal ‘146 |Fuel pump relay. 121 _~~“]TP sensor signal ‘Ta? [Starter motor relay TED —“]TAP sensor #2 signal ““Ta8-——PAIR control solenokd valve (W equipped)Component Location FI System Component Location en18x61/00001EAS contol ume TA ABS) Tea rearDiagnostic Information and Procedures ji Diagnosi Engine Symptom Diagnosis sens eerioon Condition Possible cause Coiréction /Reference Hem Engine will not start or [Valve clearance out of adjustment | Adjust. (Page 1D-32) lhard to start ‘Wom valve guides or poor sealing of [Repair or replace. =(Page 1D-B) (Compression too low) _ | valves. (Mistimed valves. Adjust. “(Page 1D-33) [Excessively wom piston ings. [Replace (Page 10-57) 'Worn-down cylinder bores. (Replace. *(Page 10-42) (Page 10-44) ‘Too slow starter motor cranking. Repair or replace. {Page ira) (Page 15) Poor Seating 6f spark plugs [Retighten. + (Page TT) [Engine will not start or is [Defective spark plugs. (Replace. *(Page TH-7) ‘hard to start (Plug not Too wide spark plug gap |Adiust orreplace. (Page 1-8) sparking) Fouled spark plugs. (Giean or replace. “(Pago 17-8) ‘Wet spark plugs. [Diy or replace. *{Page TH-8) Defective spark plug caps. [Replace. {Page 1H-7} [Defective Ignition coils. Replace. +(Page 11-3) ‘sensor. |Replace. = (Page 1-5) (Page 14-6) [Defective ECM |Replace. "(Page 10-4 'Open-circulted wiring connections. Repair or replace. + SVE5OIA: » (Page 94-5) ‘(Page 94-9) -_SVE50XA: @(Page 94-13) ‘Open or short in Figh-tenision Cords. |Replace. (Page 111-5) [Engine will not start or Is |Clogged fuel fiter or fuel hose. [Clean orreptace. hard to start (No fuel + Fuotfiter: (Page 16-15) reaching the intake port }-_ Fuet hose: {Page 16-7) Defective fuel pump. Replace. (Page 16-13) Defective fuel pressuré regulator. Replace. “(Page 16-19) Defective fue injectors. Replace. (Page 16-16) Defective fuel pump relay. Repiece. (Page 16-16) Defective ECM. Replace. =(Page 10-4) ‘Open-circuited wiring connéetions. [Repair and replace. + SVO50/A: = (Page 9A-5) {Page 94-9) s_SVB5OXA: «(Page 94-13) Engine will not start or is [TP sensor out of adjustment. [Adjust (Page 70-7) \hard to start (Incorrect [Defective fuel pump. Replace. «(Page 16-73) fueValr mixture) Defective fuel pressure regulator, Replace. = (Page 16-73) Defective TP sensor. (Replace. “(Page 10-7) Defective CKP sensor. Replace. *(Page 15) (Page 14-6) Defective TAP sensor. Defective ECM. Replace. (Page 1C-5) RepiacCondition Possible cause Correction / Reference item Engine idles poorly |Valve clearance out of adjustment. [Adjust {Page 10-32) [Poor Seating of valves. Repair = (Page 10-53) Defective valve guides. Replace. “(Page 10-68) |Worn down camshafts and/or camshafts |Replace. (Page 70-18) leurtace. (Page 10-21) Too wide Spark plug Gaps. (Adjust or replacé. > (Page TH-8) Defective ignition cols. ‘Replece. © (Page 19) [Defective CKP sensor. ‘Replace. = (Page 1-5) (Page 1-6) Defective ECM \Roplace, (Page 10-4) [Defective TP sensor. [Replace =(Page 7C-7) [Defective fuel pump. Replace. *(Page 16-73) imbalanced throtle valve. “Adust_>(Page 10-15) [Damaged or cracked vacuum hose. | Replace. ‘Damaged or clogged ISC valve. (Clean or replace. (Page 1D-14) Dirly throttle body. (Giean. (Page 10-14) ISC incoréct leaning. Reset learned value >{Page 10-3) ‘Engine stalls offer [Defective IAP sensor or cru. (Repair Or replace. ={Page 10-4) (incorrect fueVair mixture)|Clogged fuel ier. (lean or replace. >{Page 16-15) (Defective fuel pur. ‘Replace. + (Page 16-13) (Defective fuel pressure regulator ‘Replace. = (Page 16-13) [Defective ECT sensor. Replace. “(Page 1C-6) Defective thermostat Replace. =(Page 1-12) Defective IAT sensor. Replace. (Page 10-5) Damaged or Cracked vabuumi ROSS. ~~ |Replace. Damaged or clogged (SC valve. [Giean or reptace. (Page 10-74) Engine stalls Gen (Fuel |Defective fuel injectors Replace. (Page 16-16) injector improperly No injection signal from ECM. Repair or replace. [Page TA-34) operating) (Page 14-36) [Open or shor circuited wiring Repair or replace. jconnection. + SVE5Q/A; > (Page 9A-5) ‘7 (Page 94-8) |-_SV650xA: «(Page 94-12) Defective battery or low battery volage. [Replace or rechaige. “(Page TJ-10) [Engine stale often Defective ECM. (Replace. {Page 10-4) |{Controt circuit or sensor [Defective fuel pressure regulator ___|Replace. (Page 16-13) limproperly operating) [Defective TP sensor. Replace. (Page 1C-2) Defective TAT sensor Replace. Page 16-8) Defective CKP sensor Replace. “(Page 155) {Page 1-6) Defestive ECT sénscr. Replace. {Page 10-6) [Defective fuel pump relay. (Replace. =(Page 16-16) [Defective ISC valve. (Replace. (Page 10-10) [TSC incorrect fearing, [Reset learned value. =(Page 10-3) Engine stalls offen [Fouled spark plugs. [Clean or replace. (Page 1H-8) (Engine internal parts Defective CKP sensor. \Replace, (Page 1.55) |improperly operating) (Page 1-6) [Defective ECM. ‘Replace. “(Page 10-4) ‘Clogged fuel hose. (Clean or replace. (Pega 16-7) Valve clearance out of adjustment. ‘Adjust. >(Page 1D-32)Condition Possible cause Correction / Reference Item INaisy engine (Noise [seems to come from piston) lWorn down pistons. (Replace. (Page 1D-56) Worn down cylinders. [Replace. (Page 1D-42) ‘(Page 10-44) [Combustion chamber fouled with |Clean. + {Page 1D-55) carbon [Worn piston pins or piston pin bores. [Replace ~{Page 10-66) ]Worn piston rings or ring grooves. | Replace. (Page 10-87) INoisy engine (Noise __|Streiched cam chain. (Replace. “Page 1D-60) |seems to come from cam |iWorn sprockels. [Replace. =(Page 1D-19) chain) ‘(Page 1-21) (Page 1D-60) (Page 10-73) [Cam chain tension adjuster not workiig,|Repair or replace, =(Page 1-37) |Noisy engine (Noise [Railing bearing due fo wear. [Replace. {Page 1D-70) seems fo come from ‘= (Page 1D-71) crankshaft) [Wor or burnt conrod crank pin [Replace. =(Page 1-73) bearings. [Wom or burt journal Bearings. (Replace. =(Page 10-67) 'Nolsy éngine (Noise [Too much play on pump shaft bearings. |Replace. >{Page 1F-15) ‘seems to come from | Worn or damaged impeller shat (Replace. “Page 1-15) water pump) lWom or damaged mechanical seal. Replace. = (Page 1F-15) [Contact between pump case and ‘Replace. (Page 1F-15) impeller. Engine runs poorly im _|Weakendd valve springs. (Replace. *{Page 10-49) high speed range [Worn camshaft. ‘Replace. “(Page 1D-19) (Detective engine intern (Page 10-21) ‘electrical parts) Valve timing out of agjustimént \Agjust_ (Page 10-22) Too narrow spark plug gaps. [Adjust or replace. «(Page TH-8) ignition not advanced sufficiently dua te lpootty working timing advance circuit. [Replace ECM. (Page 10-4) [Defective ignition coils. [Replace. =(Page 1H-9) [Defective CKP sensor. Replace. (Page 14-5) = (Page 14-6) [Defective ECM (Replace. (Page 10-4) [Clogged air cleaner element. [Repiace. “(Page 1D-7) [Clogged fuel hose, resulling [Clean and prime. inadequate fuel supply to injector. [Defective fuel pump. (Replace. (Page 16-13) [Defective TP sensor. [Replace > (Page 1C-7) [Defective STP sensor. [Replace. *(Page 1C-13)_ [Defective STVA. [Replace. (Page 10-12) [Enigite runs poorly in [Clogged air cleaner element. [Replace. (Page 1D-7) high speed range [Defective throtle valve. [Adjust and repiace. (Page 10-10) (Defective air flow [Defective secondary throtile valve. [Adjust and replace. (Page 1D-10) system) [Sucking air from throttle body joint or |Retighton or replace. (Page 1D-B) intake pipe joint. ‘=(Page 10-16) [Defective ECM. [Replace. *(Page 10-4) [Tnbatancing throtie vane (Adjust. “(Page 10-78) |synchronization. [Defective STP sensor. (Replace. (Page 10-13)Condition Possible cause. Gorrection 7 em [Engine runs poorly in [Low Tuel pressure. [Repair or replace. >{Page 16-7) lnigh speed range (Page 16-13) |(Detective control circuit (Defective TP sensor. [Replace (Page 10-7) lor sensor) [Deteciive IAT sensor. (Replace. (Page 10-5) Defective CKP sensor. (Replace. (Page 1/-5) ‘(Page 14-6) [Defective IAP sensor. Replace. *(Page 10-5) [Detective ECM Roplace. (Page 1C-4) ITP senor out of adjustment. \Adjust. "(Page 1C-7) Defective STP sensor. [Replace =(Page 10-73) Defective STVA. Replace. (Page 1D-12) lEngine lacks power |Loss of valve clearance. (Aduust. *{Page 1D-32) (Defective engine ened vaive springs. ‘Replace. (Page 10-48) electrical parts) ve Uming out of adjustment. (Adust. “(Page 10-32) piston rings or cylinders, iRoplace. (Page TD-07] ‘(Page 10-42) (Page 1-44) [Poor Seating of valves. [Repair #(Page 1-53) [Fouled spark plugs. (Clean or replace. +(Pagé THB) incorrect spark plugs. (Replece. + (Page 11-7) [Cloagéd fuel injectors. (Glean or féplace. {Page 16-18) [Clogged air cleaner olement Replace, + (Page 10-7) "Sucking air rom throttle body joint or | Refighten or replace. «(Page 10-8) intake pipe joint Page 10-16) foo much engine Oi rain out excess oil Defective fuel pump. Replace. =(Page 16-13) Defective ECM. (Replace. »(Page 1C-4) Defective CKP sensor Replace. > (Page 15-3) (Page 1-8) ‘Defective ignition cons. (Replace. =(Page 11-9) Defective STP sensor. Replace. =(Page 1C-13) Defective STVA. (Replace. (Page 1D-12) 'Eagine Tacks power |Low fuel pressure. [Repair or replace. {Pago 1-7) (Defective contro! circuit (Page 16-13) Jor sensor} Defective TP sensor Replace. {Page 1C-7) [Defective IAT sensor Replace. (Page TC-5) Defective CKP sensot Replace. = (Page 15) (Page 11-6) Defective IAP sensor. Replace. (Page 10-5) TP sensor out of adjusiment. (Adiust. ={Page 1C-7) Defective ECM. Replece. (Page 10-4) [Defective STP serisor (Replace. = (Page 10-73) Defective STVA. (Replace. “= {Page 10-12) Engine overheats [Heavy carton deposit on piston erown. |Cleen: (Defective engine internat |Not enough oifin the engine. [Ade of. (Page TE-3) parts) [Defective oil pump oF clogged oil circuit [Replace or clean. {Page 16-12) [Sucking air from throttle body joint or intake pipe joint. [Retighten or replace. =(Page 10-8) (Page 1D-16) Jse of incorrect engine of (Replace, (Page 16-5) Defective cooling system. |Reier to “Engine Cooling Symptom Diegnosis™ fee te eee tmCondition Possible cause Correction | Reference Item [Engine overheats (Other factors} Tgnition timing is too advanced due to \defective timing advance syste (ECT sensor, CKP sensor or ECM). Replace. Dirty or heavy exhaust [Too much engine oll Drain: OUT OXGESS OT smoke [Worn pis ton ee or cylinders. Replace. (Page 1-57) (Page 10-42) (Page 10-44) n valve guides. Replace (Page 1A-20) [os Shor Grea gh VoTagS pots2 Bank 1 Sensor ‘The sensor output voltage is higher than 3.13 V. = (Page 14-30) Por7o | cas ee “The fuel rim correction is out of is threshold value. po2ot | cae [oper out Open = Fue! injector #1 signal is interrupted by 8 times or more y ‘continuity although CKP signal is detected. (Page 1-34) pezoe | 33 (mnlera OPS" | Fuel injector #2 signal i interupted by 6 times oF more ctpage 1A-38) [continuity although CKP signal is detected. TP Sensor / Switch & Po220 Sense Sich BGTEN Ine eraor ups votage snigherthan 483 29 | TP Sensor/ Swifch"B° Clicut P0222 Low The sensor output voltage is lower than 0.10 V. '7(Page 14-38)BTS name LTS detecting conden 20361) 62k eae 7 ignition coi #1 signal is interrupted by 8 times or more [mpage Thad) [continuity although CKP signal is detected. ignition Goit"=* Primary ae Ignition col #2 signal is interrupted by 8 times or more 2 no poste! caer amc Conter"A” | No voltage is input to ECM even though the FAIR control Stave 1-44) solenoid valve is OFF poss "1 EXAP gysiem Purge Control” To vonage is input to ECM even though the EVAP system Meee a6) purge control solenoid valve is OFF. 801 ERP System VaR VEReT posag “1 Solenoid Creu?) [Voltage is input to ECM even though the EVAP system purge [= (Page 18-46) control solenoid valve is ON. Poasa | C60 tpageiaag) [Cooling fan relay signal is not input to ECM. Vehicle Speed Sensor "A" + Without ABS posoo | C16 | (Page 1A-50) ‘The speed sensor signal is not input for more than 2.8 sec. > With ABS (Page 14-52) 0506 ISC System RPM Lower Tan Tia speed dropped lower than desied idle speed by more ar age 14-53) than specified range. 065, oso? Coad” FPMFTGRET TSN Ite speed ose higher than desired ile speed by mere than fe Tpose 14-82) speciied range. poos | car |S (Page 1a So [Gear position signal voltage is lower than the specified value. P1100 Nrewmao The sensor output voltage is higher than 4.80 V. hia Seraor Creu Range Piiot | 13. [Performance “The IAP sensor #2 vacuum hose has come off. (Page 14-56) Pree IRE Senter 2 CTEUTTSH Fre ers ety vale ove thn 0.10 pasio | az [armen sich Sanat CFU ignition switch signals nt input tothe ECM. P1700 eco The sensor output voltage is higher than 4.60 V. 23 P1701 een “The sensor output voliage Is lower than 0.20 V. Throltie Actuator "A" Convo! —|STVA cantrel agnalls nat supplied Fom he ECM, P2100 | 28 |aotor Cireuit JECM does not receive communication signal rom the STVA or| [7(Page 1460) __loperation voltage does not reach STVA. pozsest| caact [reat tig [Voltage is inputto ECM even though the PAIR control solenoid > (Page 18-44) valve is ON.muse Pee bane Fl system is provided with performance necessary even under malfunction condition, ewstexs 0005 afe function to allow the engine to start and the motorcycle to run in a minimum Tem Fail-Sate Mode Starting ABI Running ABI When TAP sensor #1 i falbsafe, pressure tne atmospheric pressure from the JAP "ves" "ves" sensor #2 value. JAP sensor |When TAP senor #21 al cafe, lake ar pressure value i fixed to 101.3 kPa (760, "Yes" "ves" Imm). The teal opening ie fied To Tal open TP sensor postion ves" “ves: Ignition timing is also fixed. Engine coolant temperalure value fixed To ECT sensor 70° (58°F). Yes" "ves" Costing fan is fixed on postion iaveoneor isc operate vate edt 25 VES" YES" ES! "YES" [ft fuetcut Rear oylinder can run. lonition signal FE Ee ey 2 fuetout Fron S7ider ean run, YES YES" [ft feetout Rear finder can rin. Injection signal TE es #2 fuebout Froal gylinder can fun. ecandary Wvotle valve W fred ofall cose STV actuator positon. When motor disconnection or lock | “YES* "ves" occurs, power from ECM is shut of. isp censor Sec reo avo Tro Teer ES" (Gear positon signal [Sear postion signal Thad t Gh géat. YE YES" Feedback compensaiion is ihbiled. ES" HO2 sensor (sive ratio is fixed to normal) ves" ves PAIR control solenold valve i ]ECM stops controlling PAIR: contol SOTeROTS - PAIR corr ECM "YES" "ves EVAP system purge conta ECM siops cntating EVAP aysieni Ge | a,cqr ES eolenoid valve ( equipped) _|eontol solenoid valve. ‘The engine can start and can run even ifthe signal inthe table is not received from each sensor. But, the engine ‘unning condition is not complete, providing only emergency netp (by fal-safe circuit). In this case, itis necessary to bring the motorcycle to the workshop for complete repair. When two ignition signals or two injector signals are not received by ECM, the fail-safe circuit can not work and ignition ‘or injection is stopped. 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 following will facitats collecting information to the point required for proper analysis and diagnosis. enssexer101008TOONS 4) Tum the ignition switch OFF. 2) Disconnect the HO2 sensor coupler. (Page 1C- 9) 3) Check for proper terminal connection to the HO2 sensor coupler. 4) Ifeonnections are OK, tum igrition switch ON. 5) Measure the voltage between WIR wite and Is check result OK? Yes Goto Step2. No Repair or replace the WIR wire. ‘Step 2 - : ~ HO2 sonsor heater déive circuit check 1) Tum the ignition switch OFF. 2) Disconnect the ECM couplers. «(Page 1C-4) 3) Check for proper terminal connection to the ECM couplers. 4) eonnections are OK, check the following points. + Resistance — WIB wire: less than 1.0 — RGIWEET Verb WATE ANG QlOUNG. Hine - Between WIB wire terminal and other terminal at HO2 sensor coupler: infinity * Voltage = Tum the ignition switch ON. — WIB wire: approx. 0 V rarnioneos Is check result OK? Yes Goto Step 3. No Repair or replace the Wi wire, Step 3 HO2 sensor heater resistance check 1) Tum the ignition switch OFF. 2) Measure the HO2 sensor resistance, Refer to “HO2 Sensor Heater Resistance” under "HO2 Sensor Inspection’ in Section 1C (Page 1C-8), ts chock rosult OK? ‘Yes Replace the ECM with a known good one, and inspect it again, (Page 1-4) No Replace the HO2 sensor with a new one. (Page 10-9)BES POTIO F PUTOG LF PUTUE (OTe) DTC Detecting Condition and Trouble Area ensteneniocone POt06 (C17): IAP Sensor Circuit Range 7 Performance [The IAP sensor #1 vacuum hose PO" iru “The sensor output voltage is lower than 0.10 V. 18 come off DTC detecting condition Trouble area P0105 (C17): IAP Sensor Circuit Vacuum passage between throttle body and IAP sensor #1 [The sensor output vokage ishigher than 4.80V. |. iAP sensor#t IAP sensor #1 circuit ECM Wiring Diagram Refer to "F! System Wiring Diagram" (Page 18-6). 2 4 eer te oe a R % Troubleshooting Is check result OK? NOTE Yes Goto Step 3, When DTG P0106 (617) and P1101 (C13) are No Goto Step 2. dotocted together, check that each IAP sensor vacuum hose is connected correctly. Step 2 Step 1 IAP sensor power supply circuit check 1) Tum the ignition switch OFF, 2) Disconnect the IAP sensor #1 coupler. (Page 1C-5) 3) Check for proper terminal connection to the IAP ‘sensor #1 coupler, 4) Ifeonnections are OK, turn the ignition switeh ON. 5} Measure the voltage between the R wire and B/Br wire. JAP sensor #1 ‘supply voltage [Standard]: 4.75 - 5.25V IAP sensor ground circuit check 1) Measure the voltage between the R wire and ‘ground, Is voltage same as Step 17 Yes Repair or replace the BYBr wire. No Repair or replace the R wire,=—_—_ This form is a standaré characteristic of each -d sample. The form should be modified according to conditions and market. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Mod VINE [Dale of iseuer [Date Reg: Date of problem: [Mifeage: (MIC condition (CED) 1 AWays ON J a Sometimes ON / « Always OFF / « Good condition Malfancttan displaylcode [User mode: o No display a Malfunction display ( [Dealer mad a Na code a Malfunction code (~——)—_ | = Abnormal iding speed (oHigh /n Low)( lo Unatable ic Hunting( r/min to lc Other (uc) PROBLEM SYMPTOMS a Difficult Starting io Poor Driveabiity 12.No cranking 12 Hesitation on acceleration 12 No initial combustion fo Back fire /c After fire J: No combustion |b Lack of power > Poor starting at J Surging (c:cold Js warm / 5 always) [p Abnormat knocking lo Other jo Engine rpm jumps brietly 0 Other fa Poor Idling Is Engine Stall when In Poor fast Idle > Immediately after start |o Throtto vaive is opened tmin) 2 Throttle valve is closed rn Load is applied min) > Other la OTHERS: [___-WOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS: Environmental condition feather Fair To Cloudy 70 Rein Snow fu Always 70 Other [Temperature 2 Hot/ 0 Warm / > Cool 0 Cold (°C /*F) fc Always Frequency ja Always / 0 Sometimes (times / day, month)/ 0 Only once [a Under certain condition [Road io Urban 7n Suburb [a Highway 7 Mounlainous (o Uphill Downhilly Jc Tarmacadam / 3 Gravel / c Other Motorayéle condition Engine condition ia Cold 7 o Waning up phase /o Warmed up 7a Always /c Other at starting 1c Immediately after start / c Racing without lad / a Engine speed (_r/min) Motorcycle condition [During driving: o Constant speed / a Accelerating /c Decelerating > Richt hand comer /n Left hand comera sree Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections, The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS. Taspection lier Referring section Engine oi ie (Page 16-5) Level Page 18) [Engine coolant Leakage = (Page 1-7) Lever = rust Leakage: (Page 16-5) ir cleaner element Pe = (Page 10-7) [Battery otha or arainal [Page 75-73) Throtile Cable Pay [= (Page 10-10) [Disconnection = [Vacuum hoses of sir intake system |Looseness = [Beng = Fuses Eunng = ta [Operat PAGS TAS] [Esch indicator ight (Operation (Page 9C-6) [Combination meter ‘Operation (Page 9-10) lexnaust system peakae of exaust gas sr (Page 1K-5) Homess counter Dacoieaton Page 002) DTC Po030 / Po032 (C44) seurexeso4or DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area 4 Sensor 1 HO2 sensor heater drive circuit is shorted to ground or P0030 (C44): HO2 Sensor Heater Control Circuit Bank |» HO2 sensor heater ‘+ HO2 sensor heater circuit \° ECM em P0032 (C44): HOZ Sensor Heater Control Circuit High Bank 1 Sensor t |HO2 sensor heater drive circuit is shorted to power supply. vrng Dagam Motos Sym Weng gran (Page 148), ‘ a | we, alee = + Tit 7Stop 3... IAP sensor signal circuit chock 0 2) 3 4) ‘Tum the ignition switch OFF. Disconnect the ECM couplers. (Page 1C-4) ‘Check for proper terminal connection to the ECM couplers, connections are OK, check the following points. + Resistance ~ GIB wire: less than 1.9 — Between G/B wire and ground: infinity — GIB wire terminal and other terminal at |AP sensor #1 coupler: infinity + Voltage — Tum the ignition switch ON. — G/B wire: approx. 0V Step4 TAP sensor output voltage at idle e speed ‘check 1) Tun the ignition switch OFF. 2) Connect the ECM couplers and IAP sensor #1 coupler. 3) Measure the IAP sensor #1 output voltage at idle ‘speed. Refer to “IAP Sensor Output Voltage at Idle Speed” under “IAP Sensor Inspection” in Section 16 (Page 16-4). Is check result OK? Yes Goto Step §. No Check the vacuum hose for crack or damage. I vacuum hose is OK, replace the JAP sensor #1 with a new one. *(Page 1C-5) Steps IAP sensor output voltage check 1) Tum the ignition switch OFF. 2) Remove the IAP sensor #1. (Page 1C-5) 3) Measure the IAP sensor #1 output voltage. Refer io “IAP Sensor Output Voltage" under “IAP Sensor Inspection” In Section 1C (Page 1C-4). Is check result OK? ‘Yes Replace the ECM with a known good one, ‘and inspect it again. (Page 10-4) No Replace the AP sensor #1 with anew ‘one, «(Page 1C-5)MN Te ie he Waly BensteKortor008 DTC Detecting Condition and Trouble Area DTC detecting condition ‘Trouble area OHO (C21) IAT Sonsor 4 Circuit STAT senor ‘The sensor output voltage is higher than 4.60 1+ IAT sensor circuit ota (C2iy TAT Sensor Circuit tow —) 7 Circuit Low The sensor output voltage is ower than o.t0v, _—_|* ECM Wiring Diagram Refer to "FI System Wiring Diagram’ (Page 14-8). \ o os ey)bibenateietale E IAT sensor input voltage check 1) Tum the ignition switch OFF, 2) Disconnect the IAT sensor coupler. (Page 1C-5) 3), Check for proper terminal connection to the IAT sensor coupler. 4) If connections are OK, tum the ignition switch ON. 5) Measure the voltage between the Dg wire and, ground, 6) IF OK, measure the voltage between the Dg wire and B/Br wire, or power [Standard]: 45-55 V voltas ls check result OK? Yes Goto Stop 3. No Goto Step 2 Step 2 IAT sensor circuit chook 1) Tum the ignition switch OFF. 2) Disconnect the ECM couplers. (Page 1C-4) 3) Check for proper terminal connection to the ECM couplers. 4) Ifeonnections are OK, check the following points. + Resistance = Dg wire and B/Br wire: less than 12 eee ae ee Between BY/Br wire and ground: infinity = Between Dg wire terminal and B/Br wire {terminal at IAT sensor coupler: infinity + Voltage = Tum the ignition switch ON = Dg wire and B/Br wire: approx. OV Is check result OK? ‘Yes Replace the ECM with a known good one, ‘and inspect it again, “(Page 1C-4) No Repair or replace the defective wire hamess, Step 3 IAT sensor resistance check 1) Tum the ignition switch OFF. 2) Measure the IAT sensor resistance. “(Page 1C- 5) ls check result OK? Yes Replace the ECM with a known good one, and inspect it again. “(Page 1C-4) en Renlane‘the IAT senacr with a new one.BINS PONS ESTEE RSS) BensiexoHo4o19 DTC Detecting Condition and Trouble Area [_____ Df@ detecting condition Trouble area POTTS (C15): ECT Sensor Circuit > ECT sensor [The sensor output voltage is higher than 4.85 V. PO11? (C18): ECT Sensor Circuit Low . ECM [The sensor output voltage is lower than 0.10 V. Wiring Diagram Refer to “Fl System Wiring Diagram” (Page 146). + ECT sensor circuit 2 1 AW “re eer 112— Between BIBI wire and ground: intinity: = Between B/Br wire and graund: infinity 4) Tum the ignition switch OFF. 2) Disconnect the ECT sensor coupler. «(Page 10- 8) 3) Check for proper terminal connection to the ECT sensor couple. 4) tfconnections are OK, tum the ignition switch ON, 5) Me the voltag ind besvensees Menage te volege teen he Ble ~ bawoen 0 ie toma ans Bre 8) IF OK, measure the voltage between the B/BI wire ferminal at ECT sensor coupler: infinity and B/Br wire, ‘voll reauroisee + Voltage = Tum the ignition switch ON, ~ BIBI wire and B/Br wire: approx. OV Is check result OK? Yes Goto Step 3. No Goto Step 2. step 2 Tomatoes ECT sensor circuit check Is check result OK? 1) Tum the Ignition switch OFF. Yes — Replace the ECM with a known good one, 2) Disconnect the ECM couplers. "(Page 1C-4) ‘and inspect it again, (Page 10-4) 3) Check for proper terminal connection to the ECM couplers. No Repair or replace the defective wire 4) If connections are OK, check the following points. hamess, + Resistance Step 3 ~ BIBI wire and BIBr wire: less than 1.0 ECT sensor resistance check 1) Turn the ignition switch OFF. 2) Measure the ECT sensor resistance, «(Page 1C- 8) Is check result OK?BES PUTEU s PUtes (C14) DTC Detecting Condition and Trouble Area ReNeKesto4O1 Trouble area ‘The sensor output voltage is higher than 4.80 V. DIC detecting condition (POvaH (TAF TP Sonsor Swich "A" Coat > TP sensor The sensor output voltage is lower than 0.10 V. «TP sensor circuit FBOia5 (Gta) TP Sense 7 Switch "A" Circa GA] . OM Wiring Diagram Refer to “Fl System Wiring Diagram" (Page 14-6). R 15 tt Pw ma L aier 12 a Troubleshooting stop 2 Step 4 TP sensor power supply circuit check 1) Tum the ignition switen OFF, 2) Disconnect the TP sensor coupler. °-(Page 1C-7) 2) Check for proper terminal connection to the TP ‘sensor coupler, 4) If connections are OK, turn the ignition switch ON, 5) Measure the voltage between the R wire and B/Er wire, ‘TP sensor power supply voltage ‘TP sensor ground circuit check 1) Measure the voltage between the R wire and ground. Is voltage samo as Step 1? Yes Repair or replace the B/Br wire. No Repair or replace the R wire. reser:‘Step. ‘TP sensor signs Vv 2) 3) 4 I circuit check ‘Tum the ignition switch OFF. Disconnect the ECM couplers. * (Page 1C-4) ‘Check for proper terminal connection to the ECM ‘couplers. If connections are OK, check the following points, + Resistance = PAW wire: less than 1.0 Between PAY wire and ground: infinity — Between PW wire terminal and other terminal at TP sensor coupler: infinity ventana: eee = Turn the ignition switch ON. = PIW wire: approx. OV resuwnoniae Is check result OK? Yes Goto Step 4. No Repair or replace the P/W wire. Sten 4. ‘TP serisor output voltage check 4). Turnthe ignition switch OFF. 2) Connect the ECM couplers. 3) Measure the TP sensor output voltage. (Page 17) Is cheek result OK? Yes Replace the ECM with a known good one, and inspect i again. =(Page 1C-4) No Replace the TP sensor with a new one. (Page 1C-7}EE IE I NON DTC Detecting Condition and Trouble Area enstoxetiacor2 “DIG detecting condition Trouble Area [P0130 (C44): 02 Sensor Circuit Bank 1 Sensor 1 [> }HO2 sensor output: 1s within 2.4 V- 1 (Cady: O2 Sensor Circult \s0r 1 ‘The sensor cutput voltage is lower than 0.10 V. P0132 (C4a}: O2 Sensor Circult High Voltage Bank 1 Sensor 1 The sensor output voltage is higher than 3.13 V. HOZ sensor HO2 sensor circuit ECM ‘Wiring Diagram Refer to "Fl System Wiring Diagram" (Page 14-6). 1 12 Br 132 wis. fd zads at etttead | 2 uenssca00% Ti Teaeaant a HO senior 4 Seana oay 1 EM 3. Engins wap ove lien ova 4) Turn the ignition switch OFF. Disconnect the HO2 sensor coupler and ECM ‘couplers. + HO2 sensor: © (Page 1C-9) + ECM: = (Page 1-4) Check for proper terminal connection to the HOZ ‘sensor coupler and ECM couplers. lf connections are OK, check the following points. + Resistance — WIG wire and B/Br wire: less than 1.0 = Between WIG wire and ground: infinity — Between B/Br wite and ground: infinity eos nce = Between WIG wire terminal and other terminal at HO2 sensor coupler: infinity ronstrcaoer eee ee terminal at HO2 sensor coupler: infinity i) + Voltage — Tum the ignition switch ON. ~ WIG wire and B/Br wire: approx. 0V Is check result OK? Yes Goto Step2, No Repair or replace the defective wire hamess. Stop 2 HO2 sensor output voltage check 1) Turn the ignition switch OFF. 2) Connect the ECM couplers and HO2 sensor ‘coupler. 3) Measure the HO2 sensor output voltage. Refer to "HO? Sensor Output Voltage” under “HO2 Sensor Inspection” in Section 1¢ (Page 1C-8). Is check result OK? Replace the ECM with a known good one, ‘and inspect it again. (Page 1C-4) Yes No Replace the HO2 sensor with a new one. (Page 1C-9)Mie eee DTC Detecting Condition and Trouble Area Benstoxeniovo13 DTC detecting coriditfon. Trouble Area P0170 (C45): Fuel Trim Bank 1 The fuel trim correction is out of its threshold value. > Fuel ayatern * Air intake system * Exhaust system *+ Emission contro! system + HO2 sensor 1+ HO2 sensor circuit ECM Wiring Diagram Refer to "Fl System Wiring Diagram’ (Page 1A-6). 13 Br A estes ith Pao 4 Steararear "5 nln sichTroubleshooting step 4 Fuel system ‘and emission control system ‘check | 1) Check the folowing points related to fuel and emission contol systems. + Fuel pressure: »(Page 16-6) + Fuel injector circuit: Refer to "Wiring Diagram" under “DTC P0201 (C32)" (Page 14-34) and “DTC P0202 (C33 (Page 14-36). + Fuel injector: * (Page 16-18) + IAP sensor: (Page 1C-4) + PAIR system (If equipped): (Page 1B-12) + EVAP control system (If equipped): "(Page 18-15) + PCV hose: «(Page 18-13) Is check result OK? Yes Goto Step 2. No Repair or replace defective parts. Step 2 ‘ BPE Exhaust system and air intake system check 1). Check exhaust system and air intake system for logging and leakage. + Exhaust system: (Page 1«-5) + Airintake system: Refer to "Step 3° under ‘DTC P0506 f POSO7 (C65)" (Page 14-53) Is check result OK? Yes Goto Step 3. No Repair or replace defective part. Step 30 HO2 sensor cirout chock 1) Check HO2 sensor citcuil, Refer to “Step 1" under “DTC PO130/ PO131 / PO132 (C44) (Page 1A- 30). Is chock result OK? Yes Goto Step 4. No Repair or replace defective wire harness. Step 4 DTC recheck 1) Replace the HO2 sensor. (Page 1C-9) 2) Perform “OTC Check” (Page 14-15) and check ore. fs DTC PO170 (C45) still detected? Yes Replace the ECM with a known good one, and inspect it again. 7(Page 1C-4) No End.Ne eh DTC Detecting Condition and Trouble Area BowsreKeri04014 Trouble area interrupted by 8 times or more continuity although CKP signal is detected, > Fuel injector #7 + Fuel injector #4 circuit J; ECM Wiring Diagram Refer to "Fl System Wiring Diagram" (Page 14-6). 1 3 ror v 1d Tet Git 2 TA Toone nop en Pac echt Fray“Tum the ignition switch OFF. 2) Disconnect the fue! injector #1 coupler. Refer to “Fuel Injector On-Vehicle Inspection” in Section 1G (Page 16-16). 3) Check for proper terminal connection to the fuel injector #1 coupler. 4) if connections are OK, turn the ignition switch ON. 5) Measure the voltage between YIR wire and ‘ground. NOTE Fuel injector power supply voltage can be detected only for 3 seconds after ignition ‘switch is turned ON. Fuel injector #4 supply volt [Standard]: Battery voltage Is check result OK? Yes Goto Step 2 No Repair or replace the Y/R wire, Stop 2 Fuol injector drive circuit check 1) Tum the ignition switch OFF. 2) Disconnect the ECM couplers. ="(Page 1C-4) 3) Check for proper terminal connection to the ECM couplers. 4) If connections are OK, check the following points. + Resistance ~ GrAW wite: less than 1. ~ Between GW wire terminal and Y/R wire {terminal at fuel injector #1 coupler: infinity = Tum the ignition switch ON. — GrfW wire: approx. 0V roan Is check result OK? Yes Goto Step 3. No Repair or replace the Gr/W wire. Step 3 Fuel injector restetance check 1). Turn the ignition switch OFF. 2) Measure the fuel injector resistance. “(Page 1G- 13) Is check result OK? ‘Yes Replace the ECM with a known good one, ‘and inspect it again. (Page 1C-4) No Replace the fuel injector #1 with a new: one. (Page 16-16)ON EEE We} DTG Detecting Condition and Trouble Area DTC datéating condition Trouble area P0202 (633): Injector Circuit / Open - Cylinder 2 |" Fuelinjector #2 Fuel injector #2 signals interrupted by 8 times ormore|. Fuel injector #2 circuit continuity although CKP signal is detected. BeNLrEKE HOOKS |. ECM Wiring Diagram Refer to “Fl System Wiring Diagram’ (Page 1A-6) 1 3 vk i ne Ta oe T ; I Tat Teargre poe 2 Foal paar FC 3 Peay‘Turn the ignition switch OFF. 2) Disconnect the fuel injector #2 coupler. Refer to “Fuel Injector On-Vehicle Inspection” in Section 1G (Page 16-16). 3) Check for proper terminal connection to the fuel injector 42 coupler. 4) connections are OK, turn the ignition switch ON. 5) Measure the voitage between Y/R wire and ground. NOTE Fuel injector power supply voltage can bo detected only for 3 seconds after ignition switch fs turned ON. Fuel inj on #2. ‘supply voltage {Standard}: Battery vollage ope Is check result OK? Yes Golo Step2. No Repair or replace the Y/R wire. ‘Stop 2 Fuel injector drive circuit check 41) Turn the ignition switch OFF. 2) Disconnect the ECM couplers, «(Page 1C-4) 3) Check for proper terminal connection to the ECM couplers. 4) Ifconnections are OK, check the following points. + Resistance ~ GiB wire: less than 1.0 — Between GriB wire terminal and YR wire terminal at fuel injector #2 coupler: infinity = Turn the ignition switch ON. ~~ GrfB wire: approx. OV ee Is check result OK? Yes Goto Step 3. No Repair or replace the GriB wire. step3 | Fuol injector resistance check 1). Turn the ignition switch OFF. 2) Measure the fuel injector resistance. (Page 16- 16) Is check result OK? Yes Replace the ECM with a known good one, and inspect it again. = (Page 1C-4) No Replace the fuel injector #2 with a new one. + (Page 16-16)EES Wo DTC Detecting Condition and Trouble Area enstexstiocore ‘The sensor output voltage is higher than 4.83 V. [P0222 (C29): TP Sensor / Switch "B” Circult Low [The sensor output voltage is lower than 0,10 V. DTC detecting condition OREO TEES. TP Sensor Switch" Circuit > STP sensor Trouble area + STP sensor circuit |. ECM Wiring Diagram Refer to ‘Fl System Wiring Diagram" (Page 14-6). Troubleshooting 5 4 112 sero. Step 1 STP sensor power supply circuit check 1» 2) 3) 4) 5) ‘Tum the ignition switch OFF. Disconnect the STP sensor coupler. © (Page 1C- 13) ‘Check for proper terminal connection to the STP sensor coupler. W connections are OK, tur the ignition switch ON, Measure the voltage between the R wire and B/Br wire. STP sensor ground circuit check 1) Measure the voltage between the R wire and ground. 1s voltage same as Stop 1? Yes Repair or replace the B/Br wire. No Repair or replace the R wire‘STP sensor signal circult check ! 1) Turn the ignition switch OFF. 2) Disconnect the ECM couplers. # (Page 10-4) 3). Check for proper terminal connection to the ECM couplers. 4) connections are OK, check the following points. + Resistance ~ Yowire: less than 40 = Between ¥ wire and ground: infinity — Between Y wire terminal and other terminal at STP sensor coupler: infinity “vonage = Tum the ignition switch ON. = Ywire: approx, 0V ts check result OK? Yes Goto Step 4. No Repair or replace the ¥ wire. ‘STP sensor output voltage check 1) Tum the ignition switch OFF. 2) Connect the ECM couplers, 3) Measure the STP sensor output voltage. “(Page 10-12) Is check result OK? Yes Replace the ECM with a known good one, ‘and inspect it again. (Page 10-4) No Replace the STP sensor with a new one. (Page 10-13)NE NE ON DTC Detecting Condition and Trouble Area BeNJioKsTIOHOTT DTC detecting condition ‘Trouble area (CA): FP Primary Circuit letected, although the FP rel Voltage is applied to fuel pump even though the Fe relay is OFF. > Fuel pump relay hthe + Fuel pump relay circuit lary Cirouit Low SECM Wiring Diagram Refer to *F System Wiring Diagram’ (Page 1A-6). 19] 146 TAR Woe wand ch 3 Fray Ei ach +o 4 Enghe sop sane 7 Fost te 2 Ful pare & Sdesare lay_TFOUDIESHOON Step.1 FP relay power supply voltage check — 1) Tum the ignition switch OFF. 2) Remove the FP relay. «(Page 16-16) 3) Cheek for proper terminal connection to the FP relay terminal. 4) Ieonnections are OK, tum the ignition switch ON. 5} Measure the voltage between WIR wire and ground. 8) IFOK, measure the voltage between RW wire and, ground. NOTE FP relay powor supply voltage can be detected only for 3 seconds after ignition switch Is turned ON. FP retay power supply voltage [Standard]; Battery voltage Teas? Ey ape ae Is check result OK? Yes Goto Step 2. No Repair or replace the defective wire hamess. Stop 2 FP relay check ‘Check the FP relay. (Page 16-16) Is check result OK? Yes Goto Step 3. No Replace the FP retay with anew one. = (Page 16-16) FP relay drive circuit check — 1) Tumnthe ignition switch OFF, 2) Disconnect the fue! purnp coupler and ECM couplers. + Fuel pump: (Page 16-9) + ECM: (Page 10-4) 3) Check for proper terminal connection to the ECM couplers. 4). If connections are OK, check the fllowing points. + Resistance = YiRwire and YIB wire: less than 1 — Between Y/R wire and ground: infinity — Between Y/B wire and ground: infinity * Voltage — Tum the ignition switch ON. — Y/R wire and YiB wire: approx. 0V i Is check result OK? Yes Replace the ECM with a known good one, and inepect it again. (Page 1C~4) No Repair or replace the defective wireNO We NE DTC Detecting Condition and Trouble Area eNsioesso4018 Trouble area ~ DYE detecting condition |Pos3s {eTa}rcKP Sensor "A" Gheulk The signal does not reach ECM for 2 sec. or more, after receiving the starter signal, Metal particles or foreign material being stuck on tha CKP sensor and rotor t CKP sensor CKP sensor circuit ECM Wiring Diagram Refer to “Fl System Wiring Diagram" (Page 14-8). w BS are i st eer Te 2 } a T_T pulteasior 2 Saran 5 ERE aesor Eo4) Tum the ignition switch OFF. 2) Disconnect the CKP sensor coupler and ECM ‘couplers. + KP sensor: = (Page 16-11) + EOM: (Page 1C-4) 3) Check for proper terminal connection to the CKP sensor coupler and ECM couplers. 4) If connections are OK, check the following points, + Resistance ~ B/Br wire and BIG wire: less than 1.0. — Between B/Br wire and ground: infinity = Betwoen B/G wire and ground: infinity = Between the B/Br wire terminal and B/G wire terminal at CKP sensor coupler: infinity rom r0er 9) + Voltage = Tum the ignition switch ON. = BBr wire and BYG wire: approx. 0 V (a _ age. ‘Step 20s CKP sensor 1) Tum the ignition switch OFF. 2) Measure the CKP sensor resistance. Refer to “CKP Sensor Resistance” under "CKP Sensor Inspection” in Section 1C (Page 1C-10). Is check result OK? Yes Goto Step 3. No Replace the CKP sensor with a new one, (Page 10-11) Step 3 . KP sensor peak voltage check 1) Connect the ECM couplers. 2) Measure the CKP sensor peak voltage with the peak volt adapter. Refer to “CKP Sensor Peak \Vottage” under "CKP Sensor Inspection’ in Section 1C (Page 1C-10). Is chock result OK? Yes Replace the ECM with a known good one, and ingpect it again. «(Page 1C-4) No Goto Step 4. step 4 KP sensor and generator rotor check 41) Turn the ignition switch OFF. 2) Remove the generator cover, «(Page 14-5) 3) Check that end face of the CKP sensor (1) and signal generator rotor teeth (2) are free from any metal particles ond damage. Is check result OK?EE NOS DTC Detecting Condition and Trouble Area ENIeKSt YON DTC detecting condition Trouble area P035% (C24): Ignition Coll “A” Primary / Secondary Circuit Ignition coil #4 signal is interrupted by & times or more [continuity although CKP signal is detected Refer fo "No Spark or Poor Spark” in Section 1H (Page 44-3), DTC P0382 (C25) DTC Detecting Condition and Trouble Area eNueKst 08220 DTC detecting condition ‘Trouble area |PG352 (C25): Tgnition Coil *B” Primary /Secondary Cirouit Ignition coll #2 signal is interrupted by 8 times or more ‘continuity although CKP signal is detected. [Refer to "No Spark or Poor Spark” in Section 1H (Page 1H3). DTC P0418 / P2258 (C49) [If Equipped] DTC Detecting Condition and Trouble Area eNUeKer 0421 DiC ‘condition P0418 (Cay: PAIR Syaueer asta "A" Circuit ‘Trouble area 'No voltage is input to ECM even though the PAIR control solenoid valve is OFF. > PAIR control solenoid valve + PAIR control solenoid valve circuit P2258 (C49): PAIR System Control “A” Cireut High | E°M Voltage Is input to ECM even though the PAIR control solenoid valve is ON. Wiring Diagram Refer to Fl System Wiring Diagranr (Page 1A-6). 1 3 4 5 ve wc wr. >} wfonp —T | o i || 1 TA eabeand arch ‘2 Bar camel soercid ale Saray = Engine sp oh lien chNS Step te ue PAIR control soténoid valve power stu check 1) Tum the ignition switch OFF. 2) Disconnect the PAIR control solenoid valve coupler. (Page 1B-12) 3) Check for proper terminal connection to the PAIR control solenoid valve coupler. 4) Heonnections are OK, turn the ignition switch ON. 5) Measure the voltage between the WIR wire and ‘ground. PAIR control solenoid v. ly voltage Is chock result OK? Yes Goto Step 2 No Repair or replace the WIR wire. Step2 PAIR control solenoid vaive driver circuit check 1) Tum the ignition switch OFF. 2) Disconnect the ECM couplers. «(Page 1C-4) 3) Check for proper terminal connection to the ECM couplers. 4) If connections are OK, check the following points. + Resistance = WIG wire: fess than 1.0 — Between WIG wire terminal and WIR wire terminal at PAIR control solenoid valve + Voltage ~ Turn the ignition switch ON. = WIG wire: approx. 0V ape. Is check result OK? Yes Goto Step 3, No Repair or replace the WIG wire. 3 PAIR control solencid valve resistance check 1) Tum the ignition switch OFF. 2) Measure the PAIR control solenoid valve resistance. Refer to “PAIR Control Solenoid Valve" under “PAIR System Inspection (If Equipped)" in Section 1B (Page 18-12) Is check result OK? Yes Replace the ECM with a known good one, land inspect it again. «(Page 1C-4) No Replace the PAIR control solenoid valve with a new one. © (Page 18-12)ON EE NEST WE) UN EGEIP POG) BeNest0«022 DTC Detecting Condition and Trouble Area DTC datecting condition Trouble area [poaa5 (CRD) EVAP System Purge Conta Valve + EVAP system purge control solenoid valve Circuit + EVAP system purge control solenoid valve circuit No voltage is input to ECM even though the EVAP | ey, system purge control solenoid valve is OFF. P0449 (C82): EVAP System Vent Valve / Solenoid circuit Voltage is input to ECM even though the EVAP system [purge control solenoid valve is ON. Wiring Diagram Refer to "F! System Wiring Diagram’ (Page 14-6). 1 34 5 80 ow a a w-por] 1 co it all: I gcrser Te sae SRIAP cymom pug cool acaraiavane_[ 4 Gav sand chy 3. Eng sop swt 3 ignton gute EomONS Steg 1 EVAP system purge control solenoid valve power ‘supply voltage check 1) 2 3) 4) ) Turn the ignition switch OFF, Disconnect the EVAP system purge control solenoid valve coupler. (Page 18-13) Check for proper terminal connection to the EVAP system purge control solenoid valve coupler Ifconnections are OK, turn the ignition switch ON. Measure the voltage between the WR wire and ground. EVAP system purge control solenoid val power supply voltage [Standard]: Battery voltage Is check result OK? Yes Goto Step 2. No Repair or replace the WIR wire. Stop 2 EVAP system purge control solenoid valve driver circuit check 1) 2) 3) 4) ‘Tum the ignition switch OFF. Disconnect the ECM couplers. (Page 10-4) Check for proper terminal connection to the ECM couplers. If connections are OK, check the following points, + Resistance — Dbr wire: less than 1 eee manent = Between Dbr wire terminal and WIR wire terminal at EVAP system purge control solenoid valve coupler: infinity BAe ts check result OK? Yes Goto Step 3. No Repair or replace the Dbr wire. Step 3 EVAP system purge control solenoid valve resistance check 41) Tum the ignition switch OFF. 2) Measure the EVAP system purge control solenoid valve resistance. Refer to “EVAP System Purge Control Solenoid Valve" under “EVAP Control System Inspection (If Equipped)" in Section 18 (Page 18-15}. Is check result OK? Yes Replace the ECM with a known good one, and inspect it again. «(Page 10-4) No Replace the EVAP system purge control solenoid valve with anew one. (Page 18-13)ae eee Benstenortonees DTC Detecting Condition and Trouble Area DTC detecting condition: Trouble area [P0880 (C60): Fait 7 Control Circuit JF Coaling fat relay [Cooling fan relay signal is not input to ECM, |- Cooling fan relay circuit |. ECM Wiring Diagram Refer io "FI System Wiring Diagram” (Page 14-6). 1 2 4 5 6 rat |} orf} wre 4 aH) al RY 3 = Twice Sasi nny Erg spa ee i “ee a Gesirg mer & Sesh ayoe ‘Cooling fan relay power supply voltage check 1) Tum the ignition switch OFF. 2) Disconnect the cooling fan relay. «(Page 1F-12) 3) Check for proper terminal connection to the ‘cooling fan relay terminal. 4) Mf eonnections are Ox, turn the ignition switch ON. 5) Measure the voltage between WIR wire and ‘ground. Cooling fan relay power supply voltage 1). Turn the ignition switch OFF. 2) Disconnect the ECM couplers. “(Page 1C-4) 3) Check for proper terminal connection to the ECM couplers. 4) If connections are OX, check the following points, + Resistance = GIR wire: less than 1. [Standard]: Battery voltage Is check result OK? Yes Goto Step2 No Repair or replace the WIR wire. Step2 Cooling fan retay check Check the cooling fan relay. + (Page 1F-12) Is check result OK? Yes Goto Step 3. No Replace the cooling fan relay with a new ‘one. (Page 1F-12) mntkatonson ~ Between G/R wire and ground: infinity fon) @ + Voltage Turn the ignition switch ON. GIR wire: approx. OV Is check result OK? Replace the ECM with a known good one, and inspect it again, *(Page 1C-4) Yes Repair or replace the G/R wite.