User manual SUZUKI GSX-R600

[. . . ] GSX-R600 99500-35100-01E FOREWORD This manual contains an introductory description on the SUZUKI GSX-R600 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. [. . . ] · If wire and connection are OK, intermittent trouble or faulty ECM. · Recheck each terminal and wire harness for open circuit and poor connection. Replace the HO2 sensor with a new one. 2 ECM couplers (Harness side) YES NO When using the multi-circuit tester, do not storongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. (4-27) Step 1 (When indicating C44/P0135:) 1) Turn the ignition switch OFF. If OK, then measure the HO2 sensor resistance. A S P M E L 1 1 4) Disconnect the HO2 sensor coupler and measure the resistance between terminals. HO2 heater resistance: 4. 0 ­ 5. 0 at 23 °C (W ­ W) NOTE: * Temperature of the sensor affects resistance value largely. * Make sure that the sensor heater is at correct temperature. 09900-25008: Multi-circuit tester set Tester knob indication: Resistance () Is the voltage OK?Replace the HO2 sensor with a new one. 5) After repairing the trouble, clear the DTC using SDS tool. (4-27) 4-90 FI SYSTEM DIAGNOSIS Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W (O/W) wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition. Heater voltage: Battery voltage (+ W ­ - Ground) 2 V NOTE: Battery voltage can be detected only before starting the engine. 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Voltage () Is the voltage OK?· O/W or W wire open or shorted to ground, or poor `a connection. · Recheck each terminal and wire harness for open circuit and poor connection. · If wire and connection are OK, intermittent trouble or faulty ECM. · Loose or poor contacts on the ECM coupler (Terminal a) or HO2 sensor coupler. 2 YES NO A S P M E L ECM couplers (Harness side) When using the multi-circuit tester, do not storongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. (4-27) FI SYSTEM DIAGNOSIS 4-91 "C46" (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION C46 The operation signal does not reach the EXCV actuator. EXCVA position sensor voltage low or high 0. 1 V Sensor voltage < 4. 9 V (without the above range) P1657 Sensor voltage is higher than specified H value. · · · · POSSIBLE CAUSE EXCVA maladjusted EXCVA circuit open or short EXCVA motor malfunction EXCVA position sensor malfunction · EXCVA position sensor circuit shorted to VCC or ground circuit open · EXCVA position sensor circuit open or shorted to ground or VCC circuit open · EXCVA motor circuit open or short · EXCVA motor malfunction EXCVA Gr P B Y W A S P M B/R R R/B Y B/Br E L 1 ECM MO MO VCC MPS E2 INSPECTION Step 1 (When indicating C46:) 1) Turn the ignition switch OFF. (5-8) 3) Check the EXCVA lead wire couplers for loose or poor contacts. 4) Turn the ignition switch ON. (EXCVA operating order: Full close Full open 30% open) Is the operation OK?Go to Step 6. 1 4-92 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-H:) 1) Turn the ignition switch OFF. [. . . ] · Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air. · Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label. A S P M E L 11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES · Inspect the PAIR hoses for wear or damage. · Inspect the PAIR hoses is securely connected. PAIR REED VALVE · Remove the cylinder head cover. (3-14) · Remove the PAIR reed valve 1 with the gasket. · Inspect the reed valve for the carbon deposit. [. . . ]