Engine fuel supply system of motorcycle Suzuki DL1000 V-Strom (2002-2012)

FI system technical features
Injection time (injection volume) The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations....

Fi system parts location
А. Speedometer; B. Secondary throttle position sensor (STPS); C. Throttle position sensor (TPS); D. Secondary throttle valve actuator (STVA); E. Tip over sensor (TOS); F. Fuel pump relay (FP RELAY); G. Atomospheric pressure sensor (APS); H....

FI system wiring diagram
FI system wiring diagram

Self-diagnosis function*
The self-diagnosis function is incorporated in the ECM. The function has two modes, "User mode" and "Dealer mode". The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system...

Fail-safe function
Fl system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. ITEM FAIL-SAFE MODE STARTING ABILITY RUNNING ABILITY Intake air pressure sensor...

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 will facilitate collecting information to the point required for proper analysis and diagnosis....

Self-diagnostic procedures*
Don't disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized information...

Self-diagnosis reset procedure
After repairing the trouble, turn OFF the ignition switch and turn ON again. If the malfunction code indicates (C00), the malfunction is cleared. Disconnect the special tool from the dealer mode coupler.

Malfunction code and defective condition
MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR C00 NO FAULT — C11 Camshaft position sensor The signal does not reach ECM for more than 3 sec. after receiving the starter signal. The camshaft position sensor wiring and mechanical...

“C11” CMP sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE No CMP sensor signal for 3 seconds at engine cranking. Metal particles or foreign material being attached on the CMP sensor and rotor tip. CMP sensor circuit open or short. CMP sensor malfunction. ECM malfunction....

“C12” CKP sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for 3 seconds at engine cranking. Metal particles or foreign material being attached on the CKP sensor and rotor tip. CKP sensor circuit open or short. CKP sensor malfunction. ECM malfunction....

“C13” IAP sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. High pressure and high voltage. (0.10 V Sensor voltage < 4.80 V without the above range.) NOTE: Note that atmospheric pressure caries depending on weather conditions as well as...

“C14” TP sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. Difference between actual throttle opening and opening calculated by ECM in larger than specified value. (0.10 V ≤ Sensor voltage < 4.80 V without the above range.) TP sensor maladjusted....

“C15” ECT sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE High engine coolant temp. (Low voltage - Low resistance) Low engine coolant temp. (High voltage - High resistance) B/BI circuit shorted to ground. B/Br circuit open. ECT sensor malfunction. ECM malfunction....

“C21” IAT sensor circuit malfunction
DETECTED CONDITION POSSIBLE CAUSE High intake air temp. (Low voltage - Low resistance) Low intake air temp. (High voltage - High resistance) Dg circuit shorted to ground. B/Br circuit open. IAT sensor malfunction. ECM malfunction. Inspection Lift...

“C22” AP sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. High pressure and high voltage. (0.10 V ≤ Sensor voltage < 4.80 V without the above range.) Note: Note that atmospheric pressure caries depending on weather conditions as well as...

“C23” TO sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE No TO sensor signal for more than 4 seconds, after ignition switch turns ON. Sensor voltage high. (0.2 V ≤ Sensor voltage < 4.6 V without the above range.) TO sensor circuit open or short. TO sensor malfunction. ECM...

“C28” STV actuator circuit malfunction*
"C24" or "C25" ignition system malfunction Refer to the ignition system for details. (7-19) DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. ECM does not receive communication signal from the STVA. STVA malfunction....

“C29” STP sensor circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. Difference between actual throttle opening and opening calculated by ECM in larger than specified value. (0.10 V ≤ Sensor voltage < 4.80 V without the above range.) STP sensor...

“C31” gear position (GP) switch circuit malfunction*
DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage Switch voltage low. (Switch Voltage > 1.0 V without the above value.) Gear Position switch circuit open or short. Gear Position switch malfunction. ECM malfunction. Inspection Lift...

“C32” or “C33” fuel injection malfunction*
DETECTED CONDITION POSSIBLE CAUSE No injector current. Injector circuit open or short. Injector malfunction. ECM malfunction. Inspection Remove the fuel tank and air cleaner box. (4-52 and -60) 1. Turn the ignition switch OFF. Check the injector...

“C41” FP relay circuit malfunction
DETECTED CONDITION POSSIBLE CAUSE No signal from fuel pump relay. Fuel pump relay circuit open or short. Fuel pump relay malfunction. ECM malfunction. Inspection Remove the seat. (6-4) 1. Turn the ignition switch OFF. Check the FP relay coupler for...

“C42” IG switch circuit malfunction*
Refer to the IGNITION SWITCH INSPECTION for details. Remove the fuel tank and air cleaner box. (4-52 and -60) Inspect the ignition switch. (7-32)

“C44” HO2 sensor (HO2S) circuit malfunction (Except for USA)
DETECTED CONDITION POSSIBLE CAUSE Output voltage of HO2 Sensor higher than the specification or lower than the specification. HO2 sensor or its circuit open or short. Fuel system malfunction. ECM malfunction. Inspection Remove the engine under cover...

Fuel tank lift-up*
Remove the seat. (6-4) Remove the fuel tank side covers, left and right. Remove the cowling fitting bolts, left and right. Remove the fuel tank top cover by removing the bolts and fasteners. Remove the fuel tank mounting bolt. Lift and support the...

Fuel tank removal and installation*
Lift and support the fuel tank with the fuel tank prop stay. (4-51) Disconnect the fuel pump lead wire coupler (1). Place a rag under the fuel feed hose and disconnect the feed hose (2) from the fuel tank. Caution: When removing the fuel tank, do...

Fuel pressure inspection*
Lift and support the fuel tank with the fuel tank prop stay. (4-51) Place a rag under the fuel feed hose. (4-52) Remove the fuel feed hose and install the special tools between the fuel tank and fuel delivery pipe. 09940-40211: Fuel pressure gauge...

Fuel pump inspection*
Turn the ignition switch ON and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor. Fuel discharge amount...

Fuel pump relay inspection
Fuel pump relay is located behind the ECM. Remove the seat. Remove the fuel pump relay. First, check the insulation between (1) and (2) terminals with pocket tester. Then apply 12 volts to (3) and (4) terminals, (+) to (3) and (−) to (4), and check...

Fuel pump and fuel filter removal*
Remove the fuel tank. (4-52) Remove the fuel pump assembly by removing its mounting bolts diagonally. Warning: Gasoline is highly flammable and explosive. Keep heat, spark and flame away. Remove the fuel level gauge. Remove the nuts. Remove the...

Fuel mesh filter inspection and cleaning
If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. Note: If the fuel mesh filter is clogged with many sediment or rust, replace...

Fuel pump and fuel mesh filter installation
Install the fuel pump and fuel mesh filter in the reverse order of removal, and pay attention to the following points: Install the new О-rings to the fuel pressure regulator and fuel Pipe. Apply thin coat of the engine oil to the O-rings. Caution:...

Throttle body and STV actuator — construction
1. TP sensor; 2. STP sensor; 3. STV actuator; 4. STV actuator lead wire connector; 5. Fuel delivery pipe; 6. O-ring; 7. Dust seal; 8. Injector; 9. Cushion seal

Throttle body removal*
Remove the fuel tank. (4-52) Loosen the respective throttle body clamp screws (air cleaner side). Disconnect the PAIR solenoid valve lead wire coupler, IAP senor coupler and IAT sensor coupler. Disconnect the PAIR hoses from the PAIR solenoid valve....

Throttle body disassembly
Remove the IAP sensor vacuum damper and its hose. Remove the throttle link rod (1) and secondary throttle link rod (2). Note: The throttle link rod (1) is longer than the secondary throttle link rod (2). Remove the fuel delivery pipe. Remove the...

Throttle body cleaning
Warning: Some carburetor cleaning chemicals, especially dip­ type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man­ ufacturer's instructions on proper use, handling and storage. Clean all...

Throttle body inspection
Inspection Check following items for any damage or clogging. O-ring Fuel injector filter Throttle shaft bushing and seal Injector cushion seal Throttle valve Injector dust seal Secondary throttle valve Vacuum hose

Throttle body reassembly
Reassemble the throttle body in the reverse order of disassem­bly. Pay attention to the following points: Be careful not to apply grease to the other parts when apply­ ing the grease to the shaft. 99000-25030: SUZUKI SUPER GREASE "A" (USA)...

STP sensor adjustment*
If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor positioning as follows: Disconnect the STP sensor coupler. Set the ST valve to fully close position by finger and measure the resistance Т 3 and Т 4...

Throttle body installation*
Installation is in the reverse order of removal. Pay attention to the following points: Connect the throttle pulling cable and throttle returning cable to the throttle cable drum. Adjust the throttle cable play with the cable adjusters. Refer to...

TP sensor adjustment*
After checking or adjusting the throttle valve synchronization, adjust the TP sensor positioning as follows: After warming up engine, adjust the idling speed to 1200±100 rpm. Stop the warmed-up engine and connect the special tool to the dealer mode...

Fuel injector inspection*
The fuel injector can be checked without removing it from the throttle body. Refer to page 4-47 for details.

Fuel injector removal*
Remove the fuel tank and air cleaner box. (4-52 and -60) Remove the fuel delivery pipe assembly. (4-61) Disconnect the injector couplers. Remove the fuel injectors No.1 and No.2. (4-62) Inspection Check fuel injector filter for evidence of dirt and...

Fuel injector installation*
Apply thin coat of the engine oil to new injector cushion seals and O-rings. Install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. (4-67)

Fast idle inspection
The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine...

Fast idle adjutment*
Remove the fuel tank and air cleaner box. (4-52 and -60) Disconnect the STVA lead wire coupler and turn the ignition switch ON. Open the STV gradually with the finger and just when the STP sensor output voltage has become 3.0 V. With the STV held at...

Throttle valve synchronization*
Check and adjust the throttle valve synchronization between two cylinders. 09913-13121: Vacuum balancer gauge Note: Before balancing the throttle valves, calibrate each vacuum balancer gauge. Remove the fuel tank and air cleaner box. (4-52 and -60)...

Sensor — inspection, removal and installation*
IAP sensor inspection The intake air pressure sensor is located at the rear side of the air cleaner box. (4-34) IAP sensor removal/installation Lift and support the fuel tank. (4-51) Remove the IAP sensor (1) by removing the screw and disconnect the...