AN650/AK7 (’07-MODEL) AN650/AK7 (’07-MODEL) COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO. E-02 U.K. JS1BU111200100524 – E-03 U.S.A. (Except for california) JS1BU111200 100001 – E-19 E.U. JS1BU111100114140 –...
AN650/AK7 (’07-MODEL) SDS CHECK Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
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AN650A/K7 (’07-MODEL) Data at 3 000 r/min under no load Approx. 3 000 r/min Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. XX ˚C Data of manifold absolute pressure operation at the time of cold starting Check the engine r/min.
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AN650/AK7 (’07-MODEL) Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. Approx. 100 ˚C Data of manifold absolute pressure operation at the time of hot starting Check the engine r/min. XXXX r/min Check the manifold absolute pressure.
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AN650A/K7 (’07-MODEL) Example of trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring.
AN650A/K7 (’07-MODEL) FAIL-SAFE FUNCTION FI 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. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY HO2 sensor Feedback compensation is inhibited.
AN650/AK7 (’07-MODEL) MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– ISC valve ISC valve circuit open or shorted Although current is flowing though the to ground C40 (P0505) ISC valve motor, the current detection is not possible.
AN650A/K7 (’07-MODEL) “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Although current is flowing though the • ISC valve circuit open or shorted to ground (P0505) ISC valve motor, the current detection is • Power source circuit open not possible.
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AN650/AK7 (’07-MODEL) 4) Remove the front panel. (#AN650K3 9-8) 5) Disconnect the ISC valve coupler and ECM couplers. 6) Check the continuity between terminals A (B/Lg) and m, ter- minals B (P/W) and t, terminals C (G) and s, terminals D (W/B) and r.
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AN650A/K7 (’07-MODEL) ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Place the motorcycle on the center stand. 2) Pull the parking brake lever and make sure that the rear wheel is locked. 3) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 4) Check that the engine is running.
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AN650/AK7 (’07-MODEL) Check 2 1) Click the button 1 and decrease the “Spec” 2 to 1 050 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. At the same time, check that the number of steps 4 in the ISC valve position decreases NOTE: It takes a few seconds for “Desired idle speed”...
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AN650A/K7 (’07-MODEL) Check 4 1) Increase the “Spec” 1 to 1 500 rpm. 2) Check that the “Desired idle speed” 2 is approx. 1 500 rpm. 3) Check that the “Engine speed” 3 is close to 1 500 rpm. NOTE: Be careful not to increase the “Spec”...
AN650/AK7 (’07-MODEL) “C41” (P2505) ECM/PCM POWER INPUT CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the ECM, • Lead wire/coupler connection of ECM terminal to although the ignition switch is turned (P2505) fuel fuse • Fuel fuse •...
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AN650A/K7 (’07-MODEL) Is the voltage OK? • Fuel pump related circuit malfunction. • R/Bl wire open or shorted or poor terminal W connection. • Battery voltage to ECM (BATT) shorted to ground or open. • If the wire and connection are OK, intermittent trouble or faulty ECM.
AN650/AK7 (’07-MODEL) “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open to ECM during engine operation and (P0130) running condition. (Sensor voltage < 1.0 V) In other than the above value, C44 (P0130) is indicated.
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AN650A/K7 (’07-MODEL) 7) Remove the front panel. (#AN650K3 9-8) 8) Disconnect the ECM coupler. 9) Check the continuity between B/G wire A and terminal e. 10)Also, check the continuity between B/Br wire B and terminal $ HO2S lead wire continuity: Continuity (%) ! 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set ECM coupler (Harness side)
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AN650/AK7 (’07-MODEL) Is the voltage OK? ECM coupler (Harness side) • B/G wire or B/Br wire open or shorted to ground, or poor e or n connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •...
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AN650A/K7 (’07-MODEL) Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probe to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between B (O/W) wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.
AN650/AK7 (’07-MODEL) “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction • ECM malfunction Engine stop Side-stand Ignition...
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AN650A/K7 (’07-MODEL) Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground. $ PAIR control solenoid valve voltage:Battery voltage (+ O/W – - Ground) ! 09900-25008: Multi-circuit tester set ' Tester knob indication: Voltage (() Is the voltage OK? ECM coupler (Harness side) •...
AN650/AK7 (’07-MODEL) ISC VALVE REMOVAL • Remove the front box. (#AN650K3 9-18) • Disconnect the ISC valve coupler 1. " Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned OFF. If the ECM coupler or ISC valve coupler is discon- nected within 5 seconds after ignition switch is turned OFF, there is a possibility of an unusual valve position being written in ECM and causing an error of ISC valve...
AN650A/K7 (’07-MODEL) ISC VALVE PRE-SET When removing or replacing the ISC valve, set the ISC valve in the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Click “Active control”.
AN650/AK7 (’07-MODEL) THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization between two cylinders. Step 1 • Remove the front box. (#AN650K3 9-18) • Disconnect the respective vacuum hoses 1 from vacuum nip- ples. • Disconnect the IAP sensor coupler 2. •...
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AN650A/K7 (’07-MODEL) • Click “Active control”. • Click “ISC air volume control” 1. • Click “ON” 2 to fix the ISC air volume of two cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 80 – 100 °C (176 – 212 °F). A Engine speed: Approx.
AN650/AK7 (’07-MODEL) WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp CVT control unit Wiring harness Position light (LH) Throttle cable Position light (RH) Headlight (LH) Wiring harness To ECM/PCM Pass the headlight harness inside the wiring harness. Headlight (RH) To headlights Front turn signal light (LH) Front turn signal light (RH)
AN650/AK7 (’07-MODEL) SPECIAL TOOLS 09900-25008 09900-25009 Multi-circuit tester Needle pointed 09904-41010 09930-82720 99565-01010-010 probe set SDS set tool Mode select switch CD-ROM Ver. 10 NOTE: When order the special tool, please confirm whether it is available or not. TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4”...
AN650A/K7 (’07-MODEL) ITEM SPECIFICATION NOTE TO sensor resistance 19.1 – 19.7 kΩ +: Gr/R TO sensor output voltage Normal 0.4 – 1.4 V -: B/Br +: Gr/R Leaning 3.7 – 4.4 V -: B/Br #1 +: W/Bl Ignition coil primary peak voltage -: Ground More than 80 V (When cranking) #2 +: B/Y...
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AN650/AK7 (’07-MODEL) ITEM STANDARD/SPECIFICATION LIMIT Engine coolant type Use an anti-freeze/coolant compatible with alumi- num radiator, mixed with distilled water only, at the — ratio of 50:50. Engine coolant including reserve Reverse Approx. 250 ml — tank side (0.264/0.220 US/Imp qt) Approx.
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Front fork stroke — (4.3) Front fork spring free length — (13.4) Front fork oil type SUZUKI FORK OIL G-10 (#10) or — an equivalent fork oil Front fork oil capacity (each leg) 458 ml — Front fork oil level —...
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AN650A/K7 (’07-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
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AN650/AK7 (’07-MODEL) ITEM SPECIFICATION NOTE TO sensor resistance 19.1 – 19.7 kΩ +: Gr/R TO sensor output voltage Normal 0.4 – 1.4 V -: B/Br +: Gr/R Leaning 3.7 – 4.4 V -: B/Br #1 +: W/Bl Ignition coil primary peak voltage -: Ground More than 80 V (When cranking) #2 +: B/Y...
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AN650A/K7 (’07-MODEL) ITEM STANDARD/SPECIFICATION LIMIT Engine coolant type Use an anti-freeze/coolant compatible with alumi- num radiator, mixed with distilled water only, at the — ratio of 50:50. Engine coolant including reserve Reverse Approx. 250 ml — tank side (0.264/0.220 US/Imp qt) Approx.
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Front fork stroke — (4.3) Front fork spring free length — (13.4) Front fork oil type SUZUKI FORK OIL G-10 (#10) or — an equivalent fork oil Front fork oil capacity (each leg) 458 ml — Front fork oil level —...
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AN650/AK7 (’07-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal) reserve Fuel meter mark Approx. 3.0 L (0.79/0.66 US/lmp gal) flickering Fuel meter mark and...