Precautions in servicing electrical parts When handling the component parts or servicing the Fl system, observe the following points for the safety of the system. Connector/coupler When connecting a connector, be sure to push it in until a click is felt. With a lock type coupler, be sure to...
Electrical circuit inspection procedure While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check Possible causes for the open circuits are as follows. As...
Precautions in using testers Use the Suzuki multi-circuit tester set (09990-25008). Use well-charged batteries in the tester. Be sure to set the tester to the correct testing range. Using the tester Incorrectly connecting the (+) and @ probes may cause the inside of the tester...
Fuel injection 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 intake air pressure, engine speed and throttle opening angle, and various compensations. These...
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 (Fl light). To check the function of the individual Fl 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 mini mum performance necessary even under malfunction condition. ITEM FAIL-SAFE MODE STARTING ABILITY RUNNING ABILITY Intake air pressure...
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 COO is indicates, the malfunction codes are 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 — C12 Crankshaft position sensor The signal does not reach ECM for 3 sec. and more, after receiving the IAP signal. The crankshaft position sensor wiring and mechanical...
«C12» CKP sensor circuit malfunction DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. and more, after receiving the IAP signal. • Metal particles or foreign materiel being attached on the CKP sensor and rotor tip. • CKP sensor circuit open or short. • CKP...
«C13» IAP sensor circuit malfunction DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is out of the specified range. 0.1 V ≤ Sensor voltage ≤ 4.8 V NOTE: Note that atmospheric pressure varies depending on weather conditions as well as altitude. Take that into consideration when...
«C14» TP sensor circuit malfunction DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. 0.1 V ≤ Sensor voltage ≤ 4.8 V • TP sensor maladjusted. • TP sensor circuit open or short. • TP sensor malfunction. • ECM malfunction. Inspection Step 1 1) Remove the...
«C15» ECT sensor circuit malfunction DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. 0.1 V ≤ Sensor voltage ≤ 4.6 V • ECT sensor circuit open or short. • ECT sensor malfunction. • ECM malfunction. Inspection Step 1 1) Turn the ignition switch OFF. 2)...
«C21» IAT sensor circuit malfunction DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. 0.1 V ≤ Sensor voltage ≤ 4.6 V • IAT sensor circuit open or short. • IAT sensor malfunction. • ECM malfunction. Inspection Step 1 1) Lift and support the fuel tank. (...
«C23» TO sensor circuit malfunction DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the following for 2 sec. and more after ignition switch turns ON. 0.2 V ≤ Sensor voltage ≤ 4.6 V • TO sensor circuit open or short. • TO sensor malfunction. • ECM malfunction. Inspection...
«C28» STV actuator circuit malfunction DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. ECM does not receive communication signal from the STVA. • STVA malfunction. • STVA circuit open or short. • STVA motor malfunction. Inspection Step 1 1) Remove the...
«C29» STP sensor circuit malfunction DETECTED CONDITION POSSIBLE CAUSE Signal voltage is out of the specified range. Difference between actual throttle opening and opening calculated by ECM in larger than specified value. 0.1 V ≤ Sensor voltage ≤ 4.8 V • STP sensor maladjusted. • STP...
«C31» Gear position (GP) switch circuit malfunction DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage Switch voltage is out of the specified range. Switch Voltage ≤ 0.2 V • Gear Position switch circuit open or short. • Gear Position switch malfunction. • ECM malfunction. Inspection...
«C32» or «C33» Fuel injector circuit malfunction DETECTED CONDITION POSSIBLE CAUSE Fuel injector voltage is 1.3 V and less. • Injector circuit open or short. • Injector malfunction. • ECM malfunction. Inspection Step 1 1) Remove the air cleaner box. ( 5-15 ) 2) Turn the ignition switch OFF. 3)...
«C41» FP relay circuit malfunction DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the both injectors for 3 sec. after the contact of fuel pump relay is turned ON. Or voltage is applied to the both injectors, when the contact of fuel pump is OFF. • Fuel pump relay circuit...
«C42» IG switch circuit malfunction DETECTED CONDITION POSSIBLE CAUSE Ignition switch signal is not input in the ECM. • Ignition system circuit open or short. • ECM malfunction. Inspection Refer to the IGNITION SWITCH INSPECTION for details. ( 8-39 )
«C49» PAIR control solenoid valve circuit malfunction DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input in ECM. • PAIR control solenoid valve circuit open or short. • PAIR control solenoid valve malfunction. • ECM malfunction. Inspection Step 1 1) Remove the fuel tank....
«C44» HO2 sensor (HO2S) circuit malfunction (E-02, 19) DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the following and less after warming up condition. (Sensor Voltage ≤ 0.4 V) • HO2 sensor or its circuit open or short. • Fuel system malfunction. • ECM malfunction. Inspection Step 1 1)...
Sensors — removal and installation CKP sensor Inspection The crankshaft position sensor is installed in the generator cover. ( 4-23 ) Removal and installation Remove the generator cover. ( 3-26 ) Install the generator cover in the reverse order of removal. IAP sensor Inspection The...
Emission control systems Fuel injection system DL650 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. 1. Fuel filter...
PAIR (air supply) system inspection Hoses Inspect the hoses for wear or damage. Inspect that the hoses are securely connected. Pair reed valve Remove the PAIR reed valve cover. ( 3-36 ) Inspect the reed valve for the carbon deposit. If the carbon deposit is found in the reed valve,...
Evaporative emission control system inspection (Only for E-33) Remove the frame cover. ( 7-5 ) Lift and support the fuel tank with its prop stay. ( 5-7 ) Hoses Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. EVAP canister Inspect the canister for damage to the body....
EVAP canister hose routing (Only for E-33) 1. Purge hose; 2. Wiring harness; 3. EVAP canister; 4. Frame *1 Clamp ends should face inside. *2 Clamp ends should face outside. *3 White paint mark should face top side. *4 Pass through the purge hose between the frame and wiring harness. *5 To...