User manual SUZUKI AN400 SERVICE MANUAL

[. . . ] FOREWORD This manual contains an introductory description on the SUZUKI AN400 and procedures for its inspection/service and overhaul of its main components. 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 manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service. [. . . ] (#8-23) FI SYSTEM 4-37 "C32" FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION CKP signals produced but fuel injector signal is interrupted continuous by 2 times or more. · ECM malfunction. INSPECTION Step 1 1) Remove the frame cover. If OK, then measure the injector resistance. 4) Disconnect the injector coupler and measure the resistance between terminals. $ Injector resistance: 10 ­ 18 at 20 °C (68 °F) (Terminal ­ Terminal) 5) If OK, then check the continuity between each terminal and ground. 09900-25008: Multi circuit tester set % Tester knob indication: Resistance () Is the resistance OK?(#5-16) 4-38 FI SYSTEM Step 2 1) Turn the ignition switch ON. $ Injector voltage: Battery voltage (+ Y/R ­ - Ground) NOTE: Injector voltage can be detected only 3 seconds after ignition switch is turned ON. 09900-25008: Multi circuit tester set & Tester knob indication: Voltage (') Is the voltage OK?· Gr/W wire open or shorted to ground, or poor N or W connection. · If wire and connection are OK, intermittent trouble or faulty ECM. · Recheck each terminal and wire harness for open circuit and poor connection. Open circuit in the Y/R wire. YES ECM Coupler NO FI SYSTEM 4-39 "C40" IAC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION No IAC valve voltage is supplied after starting the engine. · ECM malfunction. INSPECTION Step 1 1) Remove the frame cover. 09900-25008: Multi circuit tester set % Tester knob indication: Resistance () Is the resistance OK?YES NO Go to Step 2 Replace the IAC valve with a new one. Step 2 1) Remove the IAC valve cover 1. 2) Connect the 12 V battery to the IAC valve terminals for more than 3 minutes and check for change of the IAC valve temperature from the cold condition. YES NO GO to Step 3 Replace the IAC valve with a new one. 4-40 FI SYSTEM Step 3 1) Turn the ignition switch ON. 09900-25008: Multi circuit tester set & Tester knob indication: Voltage (') Is the voltage OK?· O/W or B/Y wire open or shorted to ground, or poor P or V connection. · If wire and connection are OK, intermittent trouble or faulty ECM. · Recheck each terminal and wire harness for open circuit and poor connection. ECM Coupler NO FI SYSTEM 4-41 "C41" FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE · Fuel pump relay circuit open or short. No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel · Fuel pump relay malfunction. [. . . ] Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV(breather) hose, air cleaner and throttle body. PAIR control solenoid valve FUEL/AIR MIXTURE EXHAUST GAS PCV hose BLOW-BY GAS FRESH AIR PAIR reed valve 10-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, IAPS and CKPS. PAIR control solenoid valve FUEL/AIR MIXTURE Three-way catalyst PAIR reed valve ECM HO2 sensor (Except for E-28) EXHAUST GAS FRESH AIR EMISSION CONTROL INFORMATION 10-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2. [. . . ]