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Suzuki GSX-R1000 Service Manual

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Table of Contents
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys
GSX-R1000
SERVICE MANUAL
9 9 5 0 0 - 3 9 3 8 0 - 0 1 E
email: info@motomatrix.co.uk / www.motomatrix.co.uk

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  Summary of Contents for Suzuki GSX-R1000

  • Page 1 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys GSX-R1000 SERVICE MANUAL 9 9 5 0 0 - 3 9 3 8 0 - 0 1 E email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 2 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys FOREWORD This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included.
  • Page 3 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ...
  • Page 4 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 5 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1 email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 6 CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner...
  • Page 7 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Precautions: 00-2 • Never reuse a circlip. When installing a • Inspect each terminal for corrosion and new circlip, take care not to expand the contamination. The terminals must be clean and free end gap larger than required to slip the of any foreign material which could impede proper circlip over the shaft.
  • Page 8 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse is blown, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.
  • Page 9 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged.
  • Page 10 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 00-5 Precautions: 2) Check each connector/coupler at both ends of the Continuity check circuit being checked for loose connection. Also 1) Measure resistance across coupler “B” (between “A” check for condition of the coupler lock if equipped. and “C”...
  • Page 11 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Precautions: 00-6 3) Also, if measured values are as listed following, a Short circuit check (Wire harness to ground) resistance (abnormality) exists which causes the 1) Disconnect the negative (–) cable from the battery. voltage drop in the circuit between terminals “A”...
  • Page 12 : 09900–25008 (Multi circuit tester set) I705H1000009-02 “D”: To other parts Using The Multi-Circuit Testers • Use the Suzuki multi-circuit tester set. • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi circuit tester set)
  • Page 13: General Information

    Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Valve Clearance Inspection and Adjustment ..0B-5 Spark Plug Replacement ........0B-9 General Description ..........0A-1 Spark Plug Inspection and Cleaning ....0B-9 Symbols ..............
  • Page 14 Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.
  • Page 15 ECM: Engine Control Module Engine Control Unit SAE: Society of Automotive Engineers (ECU) (FI Control Unit) SDS: Suzuki Diagnosis System ECT Sensor: Engine Coolant Temperature Sensor SRAD: Suzuki Ram Air Direct (ECTS) STC System: Secondary Throttle Control System Water Temp. Sensor (WTS) (STCS)
  • Page 16 Use of SF/SG or SH/SJ in API with MA in JASO. spare parts. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.
  • Page 17 2) Upon reaching an odometer reading of 1 600 km (1 Suzuki recommends the use of SUZUKI COOLANT anti- 000 miles) you can subject the motorcycle to full freeze/engine coolant. If this is not available, use an throttle operation.
  • Page 18 0A-5 General Information: Country and Area Codes B947H10101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX-R1000 K9 (E-02) U.K. JS1CY111100100001 – GSX-R1000 K9 (E-14) Thailand JS1CY121400100001 – GSX-R1000 K9 (E-19) E.U.
  • Page 19 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-6 Warning, Caution and Information Labels Location B947H10101011 6, 7, 8, 9 6 (E-28) 1 (E-24), 2 1 (E-03, 33) 3, 21, 23 10, 11, 12 16, 17, 18, 19, 20 13, 14, 15 22, 24 I947H1010008-04...
  • Page 20 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0A-7 General Information: Component Location Electrical Components Location B947H10103001 I947H1010006-06 1. Steering damper solenoid valve 9. Fuel level gauge 17. TO sensor 2. PAIR control solenoid valve 10. Fuel pump 18.
  • Page 21 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-8 I947H1010007-02 23. Ignition switch/Immobilizer antenna (E-02, 19, 24, 51) 30. Turn signal/Side-stand relay 37. Horn 24. IAT sensor 31. Cooling fan relay 38. EXCV actuator 25. Secondary fuel injector 32.
  • Page 22 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0A-9 General Information: Specifications Specifications B947H10107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 045 mm (80.5 in) Overall width 720 mm (28.3 in) Overall height...
  • Page 23 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-10 Chassis Item Specification Remark Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 125 mm (4.9 in) Rear wheel travel 130 mm (5.1 in) Caster...
  • Page 24 Small bore gauge (18 0.076 mm) 0.152 mm) – 18 mm) – 35 mm) 09900–25008 09900–25009 09904–41010 09913–50121 09913–70210 Multi circuit tester set Needle-point probe SUZUKI Diagnostic Oil seal remover Bearing installing set (10 – 75 Φ) system set email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 25 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-12 09915–17410 09915–40610 09915–63311 09915–64512 09915–74521 Oil pressure gauge Oil filter wrench Compression gauge Compression gauge Adapter hose adapter attachment 09915–77331 09916–10911 09916–14510 09916–14522 09916–33210 Oil pressure gauge Valve lapper set Valve lifter Valve lifter attachment...
  • Page 26 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0A-13 General Information: 09925–18011 09930–10121 09930–11920 09930–11940 09930–11950 Bearing installer Spark plug wrench set Torx bit (JT40H) Torx bit holder Torx wrench (5 mm) 09930–11960 09930–30104 09930–30460 09930–34970 09930–40113 Torx wrench (4 mm) Rotor remover sliding Rotor remover bolt...
  • Page 27 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-14 09943–74111 09943–88211 09944–28321 99565–01010–020 Front fork oil level Pinion bearing installer Hexagon socket (19 CD-ROM Ver.20 gauge email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 28: Maintenance And Lubrication

    Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B947H10200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy.
  • Page 29: Scheduled Maintenance

    Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-2 Scheduled Maintenance Periodic Maintenance Schedule Chart B947H10205001 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace. T = Tighten. Interval 1 000 6 000...
  • Page 30 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-3 Maintenance and Lubrication: Lubrication Points B947H10205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. NOTE •...
  • Page 31 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-4 3) Drain water from the air cleaner box by removing the Exhaust Control Valve Inspection B947H10206004 drain plug (1). Inspect exhaust control valve Initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter Inspect exhaust control valve as follows: 1) Remove the left side cowling.
  • Page 32 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-5 Maintenance and Lubrication: Valve Clearance Inspection and Adjustment B947H10206005 “A” “A” Inspect valve clearance “B” “B” Initially every 24 000 km (14 500 miles, 48 months) Inspection Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.
  • Page 33 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-6 7) In this condition, read the valve clearance at the Adjustment valves “F” (IN and EX of No. 4 cylinder, EX of No. 3 The clearance is adjusted by replacing the existing and IN of No.
  • Page 34 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-7 Maintenance and Lubrication: (INTAKE SIDE) I837H1020015-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 35 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-8 (EXHAUST SIDE) I837H1020016-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 36 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-9 Maintenance and Lubrication: 6) Install the camshafts and cam chain tension adjuster. 2) Measure the spark plug gap using a wire gauge. If it Refer to “Engine Top Side Assembly” in Section 1D is not within the specification, replace the spark plug.
  • Page 37 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-10 Fuel Line Inspection Engine Oil Replacement B947H10206008 1) Place the motorcycle on the side-stand. Inspect fuel line 2) Place an oil pan below the engine, and drain engine Every 6 000 km (4 000 miles, 12 months) oil by removing the oil drain plug (1) and filler cap (2).
  • Page 38 (thread diameter and pitch), filtering performance and durability I815H1020023-01 which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki Oil Level Inspection automobile oil filter on this motorcycle. 1) Place the motorcycle on the side-stand.
  • Page 39 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-12 Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization B947H10206011 B947H10206013 Inspect throttle cable play Inspect throttle valve synchronization Initially at 1 000 km (600 miles, 2 months) and every Initially at 1 000 km (600 miles, 2 months) (E-33 only) 6 000 km (4 000 miles, 12 months) thereafter and every 12 000 km (7 500 miles, 24 months)
  • Page 40 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-13 Maintenance and Lubrication: Engine Coolant Change Air Bleeding From the Cooling Circuit Refer to “Engine Coolant Description” in Section 1F 1) Remove the side cowlings. Refer to “Exterior Parts (Page 1F-1).
  • Page 41 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-14 Clutch Cable Play Inspection and Adjustment 7) From this position, turn out the clutch release B947H10206015 adjusting screw (6) 1 rotation, and tighten the lock- nut (5) while holding the screw (6).
  • Page 42 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-15 Maintenance and Lubrication: 2) Visually check the drive chain for the possible defects listed as follows. If any defects are found, the 1 2 3 19 20 21 drive chain must be replaced.
  • Page 43 “drive chain oil”. Such oil can damage the meets the following specification. O-rings. BF: Brake fluid (DOT 4) • The standard drive chain is a DID 50VAZ. SUZUKI recommends to use this standard drive chain as a replacement. “A” I947H1020023-01 I947H1020022-01...
  • Page 44 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-17 Maintenance and Lubrication: Brake Pads Check The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones.
  • Page 45 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-18 Air Bleeding from Brake Fluid Circuit CAUTION Refer to “Air Bleeding from Brake Fluid Circuit” in The standard tire fitted on this motorcycle is Section 4A (Page 4A-4). 120/70 ZR17 M/C (58W) for front and 190/50 ZR17 M/C (73W) for rear.
  • Page 46: Front Fork Inspection

    Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-19 Maintenance and Lubrication: Front Fork Inspection Chassis Bolt and Nut Inspection B947H10206021 B947H10206023 Inspect front fork Tighten chassis bolt and nut Every 12 000 km (7 500 miles, 24 months) Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect the front forks for oil leakage, scoring or...
  • Page 47 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-20 I947H1020043-02 I947H1020046-02 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Rear shock absorber bracket nut 115 N⋅m (11.5 kgf-m, 83.0 lbf-ft) Front axle bolt 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) Front axle pinch bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Front brake disc bolt 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) Front brake caliper mounting bolt 39 N⋅m (3.9 kgf-m, 28.0 lbf-ft)
  • Page 48 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-21 Maintenance and Lubrication: Compression Pressure Check B947H10206024 Refer to “Compression Pressure Check” in Section 1D (Page 1D-3). Oil Pressure Check B947H10206025 Refer to “Oil Pressure Check” in Section 1E (Page 1E- SDS Check B947H10206026 Refer to “SDS Check”...
  • Page 49 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-22 Special Tools and Equipment Recommended Service Material B947H10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-16) NOTE Required service material is also described in the following.
  • Page 50: Service Data

    Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-1 Service Data: Service Data General Information Specifications Service Data B947H10307001 Valve + Guide Unit: mm (in) Item Standard Limit 31.0 (1.22) — Valve diam. 25.0 (0.98) — 0.08 – 0.18 (0.003 – 0.007) —...
  • Page 51 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-2 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 –...
  • Page 52 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-3 Service Data: Balancer Unit: mm (in) Item Standard Limit Balancer shaft journal oil clearance 0.028 – 0.052 (0.0011 – 0.0020) 0.080 (0.0031) Balancer shaft journal O.D. 19.992 – 20.000 (0.7871 – 0.7874) —...
  • Page 53 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-4 Thermostat + Radiator + Cooling Fan + Coolant Item Standard/Specification Note Thermostat valve opening Approx. 82 °C (180 °F) — temperature Over 8 mm (0.31 in) and at 95 °C (203 °F) Thermostat valve lift —...
  • Page 54 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-5 Service Data: FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage 4.5 –...
  • Page 55 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-6 Throttle Body Item Specification Bore size 44 mm (1.73 in) I.D. No. 47H1 (For E-33), 47H0 (For others) 1 150 ± 100 r/min Idle r/min Throttle cable play 2.0 –...
  • Page 56 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-7 Service Data: Wattage Unit: W Specification Item E-02, 19, 24, 51 E-03, 14, 28, 33 ← Headlight ← ← Position light 5 x 2 ← Brake light/Taillight ← Turn signal light 21 x 4 ←...
  • Page 57 75 (2.95) — outer tube fully compressed) 70 (2.76) 10 min. after adjustment Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 476 ml (16.1/16.8 US/lmp oz) — Front fork inner tube O.D.
  • Page 58 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-9 Service Data: Tightening Torque List B947H10307002 Engine Item N⋅m kgf-m lbf-ft Exhaust pipe bolt 16.5 Muffler chamber connecting bolt 21.5 Muffler chamber bracket bolt 18.0 Muffler chamber mounting bolt 16.5 Muffler connecting bolt 16.5...
  • Page 59 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-10 Item N⋅m kgf-m lbf-ft 37 N⋅m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/6 Conrod cap bolt (60°) turn Breather cover bolt Oil pan bolt Oil cooler mounting bolt Driveshaft bearing case bolt (LH and RH) Driveshaft oil seal retainer screw Gearshift arm stopper...
  • Page 60 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-11 Service Data: Chassis Item N⋅m kgf-m lbf-ft Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt 16.5 Steering damper nut 16.5 Front fork clamp bolt (Upper and Lower) 16.5 Front fork cap 25.5...
  • Page 61 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-12 Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a”...
  • Page 62 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-13 Service Data: email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 63 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Precautions............. 1-1 Malfunction............1A-75 Precautions for Engine.......... 1-1 DTC “C28”...
  • Page 64 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1-ii Table of Contents Emission Control Devices ...... 1B-1 ECT Sensor Inspection ........1C-4 IAT Sensor Removal and Installation....1C-5 Precautions............1B-1 IAT Sensor Inspection.........1C-5 Precautions for Emission Control Devices ..1B-1 AP Sensor Inspection..........1C-5 General Description ..........1B-1 AP Sensor Removal and Installation....1C-5...
  • Page 65 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 1-iii Camshaft Inspection .........1D-36 Oil Pressure Switch Inspection ......1E-10 Camshaft Sprocket ...........1D-38 Oil Jet Removal and Installation......1E-10 Cam Chain Tension Adjuster Inspection...1D-38 Oil Jet Inspection..........1E-12 Cam Chain Guide / Cam Chain Tensioner Oil Pump Removal and Installation ....1E-12 Removal and Installation.........1D-39 Oil Pump Inspection ..........1E-14...
  • Page 66 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1-iv Table of Contents Schematic and Routing Diagram....... 1G-3 Component Location ..........1I-1 Fuel Tank Drain Hose and Breather Hose Starting System Components Location ....1I-1 Routing Diagram ..........1G-3 Diagnostic Information and Procedures .....
  • Page 67 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 1-v Exhaust System........1K-1 EXCVA Pulley Inspection........1K-9 EXCVA Adjustment ..........1K-9 Precautions............1K-1 Muffler / Muffler Chamber / Exhaust Pipe Precautions for Exhaust System ......1K-1 Removal and Installation.........1K-11 General Description ..........1K-1 Exhaust System Inspection.......1K-13 Exhaust Control System Description....
  • Page 68 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1-1 Precautions: Precautions Engine Precautions Precautions for Engine B947H11000001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2). email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 69: Engine General Information And Diagnosis

    Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine General Description Injection Timing Description B947H11101001 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.
  • Page 70 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-2 Engine General Information and Diagnosis: Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions When atmospheric pressure is low, the sensor sends the signal to...
  • Page 71 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-3 Self-Diagnosis Function B947H11101002 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 indicator light). To check the function of the individual FI system devices, the dealer mode is provided.
  • Page 72 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-4 Engine General Information and Diagnosis: Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices.
  • Page 73 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-5 Combination meter Cooling fan Cooling fan relay motor 15 A Br/Y Y/Bl R/Bl *1 Immobilizer *2 Ignition switch 23 11 42 Fuel 64*1 Lg/W pump 64*2...
  • Page 74 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-6 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B947H11102002 I837H1110004-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT EXCVA power (MO+) ISC valve signal (ISC, 2A) Speed sensor signal ISC valve signal (ISC, 1B) STVA signal (STVA, 2A) ISC valve signal (ISC, 1A)
  • Page 75 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-7 Component Location FI System Parts Location B947H11103001 “I” “C” “J” “A” “D” “F” “B” “K” “H” “G” I947H1110005-01 “A”: ECM “E”: Intake air pressure sensor (IAPS) “I”: Fuel pump relay (FP relay) “B”: Throttle position sensor (TPS) “F”: EVAP system purge control solenoid valve (E-33 only)
  • Page 76 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-8 Engine General Information and Diagnosis: “Y” “M” “O” “S” “P” “A” “T” “Q” “R” “W” “U” “N” “L” “X” “V” I947H1110006-01 “A”: ECM “Q”: Camshaft position sensor (CMPS) “W”: Atmospheric pressure sensor (APS) “L”: Exhaust control valve actuator (EXCVA) “R”: Ignition coil (IG coil)
  • Page 77 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-9 Condition Possible cause Correction / Reference Item Engine will not start or is TP sensor out of adjustment. Adjust. hard to start (Incorrect Defective fuel pump.
  • Page 78 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-10 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Noisy engine (Noise Worn down piston or cylinder. Replace. seems to come from Combustion chamber fouled with Clean.
  • Page 79 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-11 Condition Possible cause Correction / Reference Item Engine runs poorly in Low fuel pressure. Repair or replace. high speed range Defective TP sensor. Replace.
  • Page 80 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-12 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Dirty or heavy exhaust Too much engine oil. Check with inspection window, drain out smoke excess oil. Worn piston ring or cylinder.
  • Page 81 Removal and Installation” in Section 9D (Page 9D- 2) Set up the SDS tools. (Refer to the SDS operation manual for further details.) Special tool (A): 09904–41010 (SUZUKI Diagnostic I705H1110116-03 system set) 3) Click the DTC inspection button (1). (B): 99565–01010–020 (CD-ROM Ver.20)
  • Page 82 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-14 Engine General Information and Diagnosis: 4) Start the engine or crank the engine for more than 4 3) Check the DTC. seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part.
  • Page 83 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-15 Show Data When Trouble (Displaying Data at the Time of DTC) B947H11104004 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory.
  • Page 84 1) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6). 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) Special tool : 09904–41010 (SUZUKI Diagnostic system set) : 99565–01010–020 (CD-ROM Ver.20) NOTE •...
  • Page 85 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-17 Sample Data sampled from cold starting through warm-up Check the engine r/min. XXX r/min Check the engine coolant temperature. XX ˚C Check the manifold absolute pressure. XXX kPa I947H1110146-01 Data at 3 000 r/min under no load...
  • Page 86 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-18 Engine General Information and Diagnosis: Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens closes in according with the throttle valve opening PAIR control solenoid valve OFF in according with the throttle valve opens...
  • Page 87 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-19 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XXX kPa I947H1110150-01 email: info@motomatrix.co.uk / www.motomatrix.co.uk...
  • Page 88 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-20 Engine General Information and Diagnosis: Example of Trouble Three data; value 3 (current data 3), value 1 (past data 1) and value 2 (past data 2); can be made in comparison by showing them in the graph.
  • Page 89 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-21 Code Malfunction Part Remarks C25 (P0352) Ignition signal #2 (IG coil #2) For #2 cylinder (Page 1A-75) C26 (P0353) Ignition signal #3 (IG coil #3) For #3 cylinder (Page 1A-75) C27 (P0354)
  • Page 90 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-22 Engine General Information and Diagnosis: Fail-Safe Function Table B947H11104007 FI 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.
  • Page 91 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-23 Item Fail-Safe Mode Starting Ability Running Ability EVAP system purge control ECM stops controlling EVAP system purge “YES” “YES” solenoid valve (E-33 only) control solenoid valve.
  • Page 92 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-24 Engine General Information and Diagnosis: MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair / Cloudy / Rain / Snow / Always / Other Cold ( °C / °F) / Temperature Hot / Warm /...
  • Page 93 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-25 Malfunction Code and Defective Condition Table B947H11104009 Malfunction Detected Item Detected Failure Condition Check For Code NO FAULT — — CMP sensor wiring and The signal does not reach ECM for 3 sec.
  • Page 94 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-26 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned TO sensor, lead wire/coupler 0.2 V ≤...
  • Page 95 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-27 Malfunction Detected Item Detected Failure Condition Check For Code No voltage is applied to the fuel pump, Fuel pump relay, lead wire/ although fuel pump relay is turned ON, or coupler connection, power voltage is applied to fuel pump although fuel source to fuel pump relay and...
  • Page 96 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-28 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code Speedometer does not receive signal from the vehicle speed sensor for more than 6 sec. when the motorcycle is running.
  • Page 97 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-29 DTC “C11” (P0340): CMP Sensor Circuit Malfunction B947H11104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after •...
  • Page 98 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-30 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Y, R or B/Br wire • Inspect that metal open or shorted to particles or foreign 2) Lift and support the fuel tank.
  • Page 99 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-31 Step Action 6) Under this condition, if a suitable screwdriver touching • B/Y, R or B/Br wire • Inspect that metal the pick-up surface of the CMP sensor is moved, the open or shorted to particles or foreign tester reading voltage changes (0.8 V and less ↔...
  • Page 100 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-32 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B947H11104011 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after •...
  • Page 101 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-33 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation”...
  • Page 102 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-34 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi circuit tester set) CKP sensor continuity...
  • Page 103 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-35 DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B947H11104012 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the •...
  • Page 104 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-36 Engine General Information and Diagnosis: C13 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank.
  • Page 105 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-37 P0105-H for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open.
  • Page 106 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-38 Engine General Information and Diagnosis: Step Action 8) Check the continuity between the G/B wire and terminal Go to Step 3. G/B wire shorted to “19”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire and terminal “35”.
  • Page 107 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-39 P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/B wire open, G/ B wire shorted to 2) Lift and support the fuel tank.
  • Page 108 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-40 Engine General Information and Diagnosis: Step Action 8) Check the continuity between the R wire and terminal Go to Step 2. R and G/B wire open, G/ “7”. Also, check the continuity between the G/B wire and B wire shorted to terminal “19”.
  • Page 109 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-41 Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum hose for crack or 2) Connect the ECM couplers and IAP sensor coupler. damage.
  • Page 110 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-42 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor.
  • Page 111 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-43 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B947H11104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following •...
  • Page 112 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-44 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank.
  • Page 113 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-45 P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. P/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank.
  • Page 114 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-46 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 3. P/B wire shorted to “6”. Also, check the continuity between the B/Br wire and VCC, or B/Br wire open.
  • Page 115 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-47 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or P/B wire open, or Y/W wire shorted to 2) Lift and support the fuel tank.
  • Page 116 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-48 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 2. R or P/B wire open, or “6”. Also, check the continuity between the R wire and Y/W wire shorted to terminal “7”.
  • Page 117 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-49 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the ECM couplers and TP sensor couplers.
  • Page 118 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-50 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B947H11104014 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following •...
  • Page 119 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-51 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the left side cowling.
  • Page 120 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-52 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation”...
  • Page 121 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-53 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation”...
  • Page 122 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-54 Engine General Information and Diagnosis: Step Action 9) Measure the output voltage between the B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. ground. •...
  • Page 123 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-55 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B947H11104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following •...
  • Page 124 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-56 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank.
  • Page 125 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-57 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Lift and support the fuel tank.
  • Page 126 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-58 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation”...
  • Page 127 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-59 Step Action 10) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. ground. •...
  • Page 128 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-60 Engine General Information and Diagnosis: DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction B947H11104016 Detected Condition and Possible Cause Detected Condition Possible Cause AP sensor voltage is not within the •...
  • Page 129 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-61 C22 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the front seat.
  • Page 130 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-62 Engine General Information and Diagnosis: P1450-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/Y wire shorted to VCC, or B/Br wire open. 2) Remove the front seat.
  • Page 131 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-63 Step Action 9) Check the continuity between the G/Y wire and terminal Go to Step 3. G/Y wire shorted to “20”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire and terminal “35”.
  • Page 132 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-64 Engine General Information and Diagnosis: P1450-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/Y wire open, G/ Y wire shorted to 2) Remove the front seat.
  • Page 133 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-65 Step Action 9) Check the continuity between the R wire and terminal Go to Step 2. R and G/Y wire open, G/ “7”. Also, check the continuity between the G/Y wire and Y wire shorted to terminal “20”.
  • Page 134 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-66 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum port for crack or 2) Connect the ECM couplers and AP sensor coupler. damage.
  • Page 135 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-67 Step Action 1) Turn the ignition switch OFF. • G/Y, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the AP sensor.
  • Page 136 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-68 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B947H11104017 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the •...
  • Page 137 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-69 C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the front seat.
  • Page 138 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-70 Engine General Information and Diagnosis: P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to VCC, or B/Br wire open. 2) Remove the front seat.
  • Page 139 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-71 Step Action 8) Check the continuity between the B wire and terminal Go to Step 2. B wire shorted to VCC, “31”. Also, check the continuity between B/Br wire and or B/Br wire open.
  • Page 140 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-72 Engine General Information and Diagnosis: P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or B wire open, or B wire shorted to ground.
  • Page 141 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-73 Step Action 8) Check the continuity between the R wire and terminal Go to Step 2. R or B wire open, or B “7”.
  • Page 142 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-74 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Insert the needle pointed probes to the lead wire coupler.
  • Page 143 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-75 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B947H11104018 NOTE Refer to “No Spark or Poor Spark” in Section 1H (Page 1H-5) for details. DTC “C28”...
  • Page 144 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-76 Engine General Information and Diagnosis: Step Action 1) Lift and support the fuel tank. Refer to “Fuel Tank Go to Step 2. • Loose or poor Removal and Installation” in Section 1G (Page 1G-9). contacts on the STVA coupler.
  • Page 145 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-77 Step Action 1) Turn the ignition switch OFF. • B/Lg, P/W, G and W/ • Loose or poor B wire open or contacts on the ECM 2) Disconnect the STVA lead wire coupler.
  • Page 146 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-78 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control”...
  • Page 147 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-79 DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B947H11104020 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following •...
  • Page 148 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-80 Engine General Information and Diagnosis: C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank.
  • Page 149 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-81 P1654-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. Y/W wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank.
  • Page 150 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-82 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 3. Y/W wire shorted to “18”. Also, check the continuity between the B/Br wire VCC, or B/Br wire open.
  • Page 151 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-83 P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Y/W wire open, or Y/W wire shorted to 2) Lift and support the fuel tank.
  • Page 152 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-84 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 2. R or Y/W wire open, or “18”. Also, check the continuity between the R wire and Y/W wire shorted to terminal “7”.
  • Page 153 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-85 Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM couplers and STP sensor couplers.
  • Page 154 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-86 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B947H11104021 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range.
  • Page 155 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-87 Step Action 1) Turn the ignition switch OFF. • P wire open or • P or B/W wire open, shorted to ground. or P wire shorted to 2) Lift and support the fuel tank.
  • Page 156 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-88 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction B947H11104022 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is •...
  • Page 157 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-89 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation”...
  • Page 158 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-90 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and...
  • Page 159 Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-91 DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39