Suzuki Engine Electrical System User manual
The Suzuki Engine Electrical System user manual provides detailed instructions on how to maintain and repair the electrical components of your engine. It covers various topics including the battery charging system, electric starter system, monitor-tachometer, and electric parts holder.
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ENGINE ELECTRICAL 4-1 ENGINE ELECTRICAL CONTENTS BATTERY CHARGING SYSTEM ....................................................................4- 2 OUTLINE ................................................................................................4- 2 INSPECTION ..........................................................................................4- 4 REMOVAL/INSTALLATION ...................................................................4- 9 ELECTRIC STARTER SYSTEM .....................................................................4-11 OUTLINE ................................................................................................4-11 TROUBLESHOOTING ...........................................................................4-13 INSPECTION ..........................................................................................4-14 STARTER MOTOR .................................................................................4-17 MONITOR-TACHOMETER ..............................................................................4-29 INSPECTION ..........................................................................................4-29 ELECTRIC PARTS HOLDER ..........................................................................4-30 REMOVAL ..............................................................................................4-30 INSTALLATION ......................................................................................4-31 4 1 4-2 ENGINE ELECTRICAL BATTERY CHARGING SYSTEM OUTLINE The battery charging system circuit is illustrated below. It is composed of the BATTERY CHARGE COIL, RECTIFIER & REGULATOR and BATTERY. The three phase AC current generated from the battery charge coil is converted by the rectifier & regulator into regulated DC current which is used to charge the battery. OUTPUT 12 V 44 A (528 W)/3 000 r/min. REGULATED VOLTAGE 14.2 – 15.2 V Fuse box STARTER RELAY MAIN RELAY 30 amp, Fuse [Select, STD] Alternator (Magneto) Rectifier & Regulator 60 amp, Fuse 30 amp. Fuse To PTT switch To IAC, CMP R B 10 amp. Fuse B To PTT relay ! 30 amp. Fuse " 10 amp. Fuse # No.1 output line $ No.2 output line BATTERY (Main) 12 V 100 AH 2 ENGINE ELECTRICAL 4-3 ISOLATOR FUNCTION The battery charging system is equipped with an isolator function. When a sub battery is used in addition to the main battery for engine operation, this function allows both the batteries to be charged at the same time. To modify the charging circuit and distribute the power to the individual batteries, relocate the 30 amp fuse in [STD] position to [OPT x] position in the fuse box. Relocation of the 30 amp fuse to [OPT x] position modifies the charging circuit so the No.2 red output lead of the Rectifier & Regulator can charge the main battery for engine operation and the No.1 red output lead can charge the sub battery. NOTE: For proper charging circuit operation, the negative terminals of both batteries, main and sub batteries, must be connected with a cable of the same size as the existing battery cable. Fuse box STARTER RELAY MAIN RELAY Alternator (Magneto) Rectifier & Regulator 60 amp, Fuse 30 amp. Fuse 10 amp. Fuse BATTERY (Main) 12 V 100 AH B R B To PTT relay R To PTT switch To IAC, CMP : 30 amp, Fuse [Select, OPT ] ! 30 amp. Fuse " 10 amp. Fuse # No.1 output line $ No.2 output line BATTERY (Sub) 12 V 100 AH 3 4-4 ENGINE ELECTRICAL INSPECTION BATTERY CHARGE COIL Measure battery charge coil resistance. ! 09930-99320: Digital tester " Tester range: Ω (Resistance) 1. Disconnect battery charge coil leads from rectifier & regulator. 2. Measure resistance between leads in the combinations shown. Battery charge coil resistance: Terminal for tester probe connection Yellow 1 to Yellow 2 Yellow 2 to Yellow 3 Yellow 3 to Yellow 1 Resistance 0.14 – 0.20 Ω Y3 If measurement exceeds specification, replace battery charge coil. FUSE BOX/FUSE Y2 Fuse Y1 Fuse ! 09930-99320: Digital tester # Tester range: $ (Continuity) Fuse 1. Remove the fuse from fuse box. 2. Inspect continuity between both terminals of fuse. If no continuity is indicated, replace fuse. SPARE 30A select 60A OPT STD MAIN SPARE Main fuse: 60A Isolator select fuse: 30 A Starter motor relay fuse: 30A ECM/Ign. coil/Injector/Fuel pump fuse: 30 A PTT switch fuse: 10 A IAC/VVT/VSV/CMP fuse: 10 A 30A 10A 30A MAIN STARTER 10A RELAY RELAY STARTER MTR PTT SW IAC, CMP, VSV, VVT IGN COIL,INJECTOR,ECM,F/P ISOLATOR SPARE 4 ENGINE ELECTRICAL 4-5 60 amp. main fuse line 1. Disconnect battery cables from battery. 2. Disconnect output lead wire connector from rectifier & regulator. 3. Inspect continuity between the red output lead wire 2 of rectifier & regulator and “B” terminal of starter motor magnetic switch. 4. If no continuity is indicated, replace fuse and/or main harness. 1 1. Starter motor magnetic switch “B” terminal 30 amp. Isolator select fuse line 1. Disconnect battery cables from battery. 2. Install 30 amp. isolator select fuse to “OPT x” position. 1 1. 30 amp. isolator fuse 3. Disconnect output lead wire connector from rectifier & regulator. 4. Inspect continuity between the red output lead wire 1 of rectifier & regulator and charge lead wire connector as shown. 5. If no continuity is indicated, replace fuse and/or main harness. 1 1. Charge lead wire connector 5 4-6 30 1. 2. 3. ENGINE ELECTRICAL amp. starter motor relay fuse line Disconnect battery cables from battery. Disconnect starter motor relay from fuse box. Disconnect output lead wire connector from rectifier & regulator. 4. Inspect continuity between the lead wire terminal a of starter motor relay and the red output lead wire 2 of rectifier & regulator. 5. If no continuity is indicated, replace fuse and/or main harness. 30 1. 2. 3. amp. ECM/Ign. coil etc. fuse line Disconnect battery cables from battery. Disconnect main relay from fuse box. Disconnect output lead wire connector from rectifier & regulator. 4. Inspect continuity between the lead wire terminal b of main relay and the red output lead wire 2 of rectifier & regulator. 5. If no continuity is indicated, replace fuse and/or main harness. 6 ENGINE ELECTRICAL 10 amp. PTT switch fuse line 1. Disconnect battery cables from battery. 2. Disconnect PTT switch lead wire connector from switch. 4-7 2 1 1. PTT switch lead wire connector 2. White/Red lead wire 3. Inspect continuity between the White/Red lead wire of main harness and “B” terminal of starter motor magnetic switch. 4. If no continuity is indicated, replace fuse and/or main harness. 1 1. Starter motor magnetic switch “B” terminal 10 1. 2. 3. amp. IAC/VVT/VSV/CMP fuse line Disconnect battery cables from battery. Disconnect main relay from fuse box. Disconnect lead wire connector from CMP sensor. 4. Inspect continuity between the Gray/Red lead wire of main harness and lead wire terminal c of main relay. 5. If no continuity is indicated, replace fuse and/or main harness. 1 2 1. CMP sensor 2. Gray/Red lead wire 7 4-8 ENGINE ELECTRICAL RECTIFIER & REGULATOR ! 09900-25002: Pocket tester " Tester range: ×1 kΩ (Resistance) 1. Disconnect all lead wires of rectifier & regulator. 2. Measure resistance between terminals in the combinations shown. NOTE: The values given below are for a SUZUKI pocket tester. As thyristors, diodes, etc. are used inside this rectifier & regulator, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used. Yellow 1 Yellow 2 Yellow 3 Rectifier & regulator resistance: Unit: Approx. kΩ Tester probe + (Red) Tester probe - (Black) Black Black Red 1 Red 2 2 – 25 2 – 25 Red 1 500 – ∞ Red 2 500 – ∞ 500 – ∞ Black Red2 Red1 Yellow 1 Yellow 2 Yellow 3 1–7 1–7 1–7 500 – ∞ 500 – ∞ 500 – ∞ 500 – ∞ 500 – ∞ 500 – ∞ 500 – ∞ Yellow 1 500 – ∞ 1–7 1–7 500 – ∞ 500 – ∞ Yellow 2 500 – ∞ 1–7 1–7 500 – ∞ Yellow 3 500 – ∞ 1–7 1–7 500 – ∞ 500 – ∞ 500 – ∞ ∞: Infinity If measurement exceeds specification, replace rectifier & regulator. 8 ENGINE ELECTRICAL 4-9 REMOVAL/INSTALLATION System construction 118 N.m (11.8 kg-m, 85.5 lb-ft) Bolt Flywheel ! Dowel pin " Screw # Battery charge coil $ Rectifier & regulator % Bolt & Gasket ' Clamp Bolt ) Main harness * Main fuse 60 A + Fuse , ECM relay - Starter motor relay REMOVAL Prior to removing electrical parts: • Disconnect battery cables from battery. Battery charge coil • Remove flywheel magneto. (See page 3-66.) • Remove four (4) screws 1 securing the battery charge coil 2. • Remove the lead wire clamp and battery charge coil. • Disconnect battery charge coil lead wire connector from Rectifier & regulator. 9 4-10 ENGINE ELECTRICAL Rectifier & regulator • Disconnect lead wire connectors 1 from Rectifier & regulator 2. • Remove the six (6) bolts and Rectifier & regulator. INSTALLATION Installation is reverse order of removal with special attention to the following steps. Battery charge coil Apply Suzuki Bond No.1104 to the coil securing screws. % 99000-31030: SUZUKI BOND NO. 1104 Wire routing Secure coil lead wire with lead wire clamps, then check that coil lead wire is routed properly and away from hot or rotating parts. (For wire routing – See page 11-4 to 11-10.) Rectifier & regulator Install gasket and rectifier & regulator, then tighten bolts securely. & Do not reuse gasket, always replace with new one. 10 ENGINE ELECTRICAL 4-11 ELECTRIC STARTER SYSTEM OUTLINE The starting circuit consists of the battery, starting motor, ignition switch, neutral switch, starter relay and related electrical wiring. These components are connected electrically as shown in figure below. STARTING SYSTEM CIRCUIT In the circuit shown in figure below, the magnetic switch coils and starter relay coil are magnetized when the ignition switch is closed (turned to “START”). The resulting plunger and pinion shift lever movement causes the pinion to engage the engine flywheel gear, the magnetic switch main contacts to close, and engine cranking to take place. When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch is opened, at which time the torsion spring causes the pinion to disengage. Starter relay Plunger Hold-in coil Pull-in coil Magnetic switch Shift lever R G Ring gear W Starter motor Pinion & over-running clutch Battery 15 A Fuse 30 A Fuse Main relay 30 A Fuse 60 A Fuse Y/G OFF ON START Neutral switch W Y/G Br B GND Br Br W W BATT Br Br START Neutral switch ECM Ignition switch Bl/R B G B Emergency stop switch 11 4-12 ENGINE ELECTRICAL STARTER MOTOR OPERATION CONDITION The starter motor relay is controlled by the ECM. The starter motor relay will only engage when the ignition switch is turned to the “START” position if the all of the following conditions are satisfied. • Lock plate is attached to emergency stop switch. • Neutral switch is in “ON” position. • Engine is not already operating. NOTE: If a failure exists in the Sub-battery cable or the 15 amp. fuse in its circuit, the starter motor relay circuit will not function. STARTER ENGAGEMENT MECHANISM A solenoid (electromagnetic force) type starter switch, utilizing a torsion spring and shift lever, engages the pinion gear to the flywheel. When the ignition key is turned to “START”, current flows through the switch winding creating an electromagnet pulling the plunger in. The shift lever, attached to the plunger, then pushes the pinion up into engagement with the flywheel. Plunger and shift lever movement also compresses the torsion spring, which applies pressure against the shift lever and pinion gear to maintain positive engagement. Final plunger movement closes the starter switch contacts, which allows current to flow through the starter motor windings, rotating the starter motor armature, pinion gear and flywheel. When the ignition key is released from start, current flow to the switch is shut off and electromagnetic force ceases. The torsion spring then pulls the plunger out, disengaging the pinion gear from the flywheel through the shift lever. Movement of the plunger also opens the switch contacts, stopping current flow to the starter motor windings, shutting off the starter motor. 11 9 12 7 8 10 4 5 6 3 1 13 2 1. Pinion 2. Armature 3. Magnet 4. Torsion spring 5. Shift lever 6. Stationary contact 7. Movable contact 8. Hold-in coil 9. Pull-in coil 10. Plunger 11. Ignition switch 12. Battery 13. Ring gear 12 ENGINE ELECTRICAL 4-13 TROUBLESHOOTING NOTE: Before troubleshooting the electric starter system, make sure of the following: • Battery is fully charged. • All cables/wires are securely connected. • Shift is in “NEUTRAL” position. • Emergency stop switch lock plate is set in place. & If any abnormality is found, immediately disconnect battery cables from battery. Engine does not start. Does engine turn over with continued cranking? NO Does starter motor rotate? NO • Check battery for charging condition. • Check battery terminals for connections and corrosion. • Check main (60 A) and/or starter relay (30 A) fuse. (See page 4-4 to 4-6.) YES YES No (or turns slowly) • Check battery for charging condition. • Check battery terminals for connections and corrosion. YES YES Check for starter relay “Click” sound when turning ignition switch to “START”. Is there “Click” sound? • Check pinion and overrunning clutch. (See page 4-23.) • Check starter magnetic switch. (See page 4-24.) Does the flywheel rotate? • Check ECM-No. 1 terminal voltage. (See page 3-48.) NO YES • Remove starter motor from engine. • Does starter motor turn under no-load conditions by connecting battery terminal to “M” terminal of starter motor and battery terminal to the starter motor body. + NO • Check sub-battery cable circuit. • Check function of neutral switch. (See page 4-15.) • Check emergency stop switch function. (See page 4-16.) • Check ignition switch function. (See page 4-14.) • Check starter relay. (See page 4-14.) • Check wiring system and connections between starter relay and ignition switch. • Check the brush and brush holder. (See page 4-22.) • Check the armature coil. (See page 4-21.) - YES • The magnetic switch and/or connection is faulty. Replace it. 13 4-14 ENGINE ELECTRICAL INSPECTION IGNITION SWITCH ! 09930-99320: Digital tester 4 FREE # Tester range: $ (Continuity) 1 (OFF) 2 (ON) 3 (START) 1. Disconnect the ignition switch from remo-con box wiring harness. 2. Check continuity between wiring leads at the key positions shown in the chart. 5 PUSH Switch Lead Wires Black Green White Gray Brown Orange Key Position OFF Orange Brown White Black White/Red Gray Green Blue ON ! START " FREE # PUSH : Continuity If out of specification, replace ignition switch. Bl B Br Br Gr G STARTER MOTOR RELAY ! 09930-99320: Digital tester # Tester range: $ (Continuity) 1. Disconnect starter motor relay from fuse box. 1 1. Starter motor relay 2. ECM main relay 2 2. Check continuity between terminal 1 and 2 each time 12 V is applied. Connect positive + side to terminal 4, and negative - side to terminal 3. Starter motor relay function: 12 V power Applied Not applied 12 V Continuity Yes No CONT & Be careful not to touch 12 V power supply wires to each other or with other terminals. 3. Measure resistance between relay terminals 3 and 4. " Tester range: Ω (Resistance) Starter motor relay solenoid coil resistance: 145 – 190 Ω If out of specification, replace starter motor relay. 14 ENGINE ELECTRICAL 4-15 NEUTRAL SWITCH Check for continuity/infinity of the neutral switch. ! 09930-99320: Digital tester # Tester range: $ (Continuity) Neutral switch in remo-con box 1. Disconnect neutral switch lead wire connector from ignition switch. 2. Check continuity/infinity between switch brown wire leads while operating remo-con handle. Shift position Neutral Forward Reverse Tester indicates Continuity Infinity Infinity REVERSE FORWARD Brown Brown If out of specification, replace neutral switch. Neutral switch on engine side 1. Disconnect neutral switch lead wire connector. 2. Check continuity/infinity between Yellow/Green and Brown lead wires while operating remo-con handle. Shift position Neutral Forward Reverse Neutral Reverse Tester indicates Continuity Infinity Infinity If out of specification: • 1st Check remo-con cable adjustment, readjust if necessary. • 2nd Check wire harnesses for open and short. If wire harnesses are in good condition, replace neutral switch and recheck. NOTE: After installing neutral switch, check for correct function by operating remo-con handle. Forward Clutch lever Neutral switch Y/G Br 15 4-16 ENGINE ELECTRICAL EMERGENCY STOP SWITCH ! 09930-99320: Digital tester # Tester range: $ (Continuity) B 1. Disconnect the emergency stop switch lead wire. G 2. Check continuity/infinity between the wiring leads under the condition shown below. Tester probe connection Red (+) Black (–) Lock plate installed Lock plate removed Tester indicates B Infinity Green Black Continuity G 3. If out of specification, replace switch. 16 ENGINE ELECTRICAL 4-17 STARTER MOTOR REMOVAL Prior to removing starter motor: • Disconnect battery cables from battery. 1. Remove bolts and ring gear cover with air intake silencer case 1. (See page 6-2.) 2. Remove nut 2, positive + battery cable 3 and positive + battery charge cable 4 from the starter motor magnetic switch. 3. Remove the two (2) bolts 5, negative - battery cable 6, harness GND lead wire 7 and starter motor band 8. 4. Remove the two bolts 9 securing starter motor. 5. Remove the starter motor 0, then disconnect the red lead wire A from “S” terminal of starter magnetic switch. 17 4-18 ENGINE ELECTRICAL INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Install starter motor and tighten starter motor mounting bolts securely. ' Starter motor mounting bolt: 23 N·m (2.3 kg-m, 16.5 lb-ft) DISASSEMBLY When overhauling starting motor, it is recommended that component parts be cleaned thoroughly. However, the yoke assembly, armature coil, over-running clutch assembly, magnetic switch assembly and rubber or plastic parts should not be washed in a degreasing tank or with a grease dissolving solvent. These parts should be cleaned with compressed air or wiped with clean cloth. NOTE: Before disassembling starting motor, be sure to put match marks at three locations (A, B and C) as shown in figure at right to avoid any possible component alignment mistakes. A C B 1. Remove nut 1 from magnetic switch, then disconnect the connecting wire 2. 2. Remove two bolts 3 securing magnetic switch. 3. Remove the magnetic switch 4. 18 ENGINE ELECTRICAL 4-19 4. Remove screws 5, long through bolts 6 and rear cover 7. 5. Remove thrust washer 8 with screwdriver. 6. Pull the brush spring 9 up to separate the brush from the surface of the commutator, then remove the brush holder 0. 7. Remove the yoke A and armature B. 8. Remove the center cover plate C. 9. Remove the planetary gears D and internal gear E. 19 4-20 ENGINE ELECTRICAL 10. Remove the center bracket F (with shift lever H, pinion I and pinion shaft J) from front housing G. 11. Remove the shift lever H. 12. Push the pinion stopper K down, then remove stopper ring L. Remove the pinion stopper and pinion I. ( Wear safety glasses when disassembling and assembling stopper ring. NOTE: Using a screw-driver, pry off the stopper ring. 13. Remove the E-ring M. 14. Remove the pinion shaft J, washers N and rubber ring O from center bracket. 20 ENGINE ELECTRICAL 4-21 INSPECTION AND SERVICING Armature and Commutator • Inspect the commutator surface. If surface is gummy or dirty, clean with #500 grit emery paper A. • Measure commutator outside diameter. ! 09900-20101: Vernier calipers Commutator outside diameter: Standard: 29.0 mm (1.14 in) Service limit: 28.0 mm (1.10 in) If measurement exceeds service limit, replace armature. • Check that mica (insulator) between the segments is undercut to specified depth. SEGMENT Commutator undercut 1: Standard: 0.5 – 0.8 mm (0.02 – 0.03 in) Service limit: 0.2 mm (0.01 in) If measurement exceeds service limit, cut to specified depth. MICA NOTE: Remove all particles of mica and metal using compressed air. 1 undercut ( Wear safety glasses when using compressed air. • Check for continuity between the commutator and the armature core/shaft. Replace armature if continuity is indicated. Commutator Shaft ! 09930-99320: Digital tester # Tester range: $ (Continuity) Armature core 21 4-22 ENGINE ELECTRICAL • Check for continuity between adjacent commutator segments. Replace armature if no continuity is indicated. ! 09930-99320: Digital tester # Tester range: $ (Continuity) BRUSHES Check the length of each brush. ! 09900-20101: Vernier calipers Brush length: Standard: 16.0 mm (0.63 in) Service limit: 12.0 mm (0.47 in) Brush If brushes are worn down to the service limit, they must be replaced. BRUSH HOLDER • Check brush holder continuity. ! 09930-99320: Digital tester # Tester range: $ (Continuity) Brush holder continuity: Tester probe connection Brush holder positive + to Brush holder negative Brush holder positive + to Base plate (ground) Continuity Base plate No No Replace brush holder if the tester doesn’t show the above. BRUSH SPRING Inspect brush spring for wear, damage or other abnormal conditions. Check the brush spring tension. Replace if necessary. Brush spring tension Standard: 15 – 18 N (1.5 – 1.8 kg, 3.3 – 4.0 lbs) 22 ENGINE ELECTRICAL 4-23 SHIFT LEVER Inspect shift lever for wear. Replace if necessary. PINION AND OVER-RUNNING CLUTCH • Inspect pinion for wear, damage or other abnormal conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction. Replace if necessary. • Inspect spline teeth for wear or other damage. Inspect pinion for smooth movement. Replace if necessary. GEAR • Inspect planetary gears and internal gear for wear, damage or other abnormal conditions. Replace if necessary. PINION SHAFT/PINION SHAFT BUSH • Inspect pinion shaft for wear, damage or other abnormal conditions. Replace if necessary. • Inspect pinion shaft bush for wear or other damage. Replace if necessary. 23 4-24 ENGINE ELECTRICAL FRONT HOUSING • Inspect front housing for wear, damage or other abnormal conditions. Replace if necessary. • Inspect bush for wear or other damage. Replace if necessary. ARMATURE SHAFT BUSH Inspect bush for wear or other damage. Replace if necessary. PLUNGER Inspect plunger for wear or other damage. Replace if necessary. MAGNETIC SWITCH Push in plunger and release. The plunger should return quickly to its original position. Replace if necessary. 1 1. Plunger Pull-in coil Open circuit Test 3 ! 09930-99320: Digital tester # Tester range: $ (Continuity) Check for continuity across magnetic switch “S” terminal and “M” terminal. If no continuity exists, the coil is open and should be replaced. 2 1 1. Terminal “S” 2. Terminal “M” 3. Terminal “B” 24 ENGINE ELECTRICAL 4-25 Hold-in coil Open circuit Test ! 09930-99320: Digital tester # Tester range: $ (Continuity) Check for continuity across magnetic switch “S” terminal and coil case. If no continuity exists, the coil is open and should be replaced. Contact points Test ! 09930-99320: Digital tester # Tester range: $ (Continuity) Put the plunger on the under side and then push the magnetic switch down. At this time, check for continuity between terminal “B” and terminal “M”. Continuity indicates proper condition. If no continuity exists, replace the magnetic switch and/or plunger. 25 4-26 ENGINE ELECTRICAL ASSEMBLY Assembly is reverse order of disassembly with special attention to the following steps. & When installing armature, use care to avoid breaking brushes. When installing pinion shift lever, refer to figure in construction diagram for installation direction. Construction diagram 7 N.m (0.7 kg-m, 5.1 lb-ft) 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 1 Nut 2 Bolt 3 Magnetic switch 4 Gasket 5 Spring 6 Plunger 7 Torsion spring 8 Rubber packing 9 Shift lever 0 Front housing A Screw B Through bolt C Rear cover D Thrust washer E Brush holder F Yoke G Armature H Center cover plate I Internal gear J Planetary gear K Pinion shaft L Pinion M E-ring N Washer O Center bracket P Rubber ring Q Stopper ring R Pinion stopper 26 ENGINE ELECTRICAL 4-27 PERFORMANCE TEST & Each test must be performed within 3 – 5 seconds to avoid coil damage from overheating. ( When performing the following test, be sure to connect the battery and the starting motor with a lead wire of the same size as original equipment. PULL-IN/HOLD-IN TEST Connect battery to magnetic switch as shown in figure. • Check that plunger and pinion (over-running clutch) move outward. If plunger and pinion don’t move, replace magnetic switch. NOTE: Before testing, disconnect brush lead from terminal “M”. 1 3 4 2 1. Terminal “S” 3. Terminal “B” 2. Terminal “M” 4. Brush lead • While connected as above with plunger out, disconnect negative lead from terminal “M”. Check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch. PLUNGER AND PINION RETURN TEST Disconnect negative lead from switch/motor body. Check that plunger and pinion return inward. If plunger and pinion don’t return inward, replace magnetic switch. 27 4-28 ENGINE ELECTRICAL NO-LOAD PERFORMANCE TEST & Before performing following test, secure the starter motor to the test bench. 1. Connect battery and ammeter to starter motor as shown. 2. Check that starter rotates smoothly and steadily with pinion moving out. Check that ammeter indicates specified current. No load current: Within 90 A at 11 V 28 ENGINE ELECTRICAL 4-29 MONITOR-TACHOMETER 1 “CHECK ENGINE” 2 TEMP “ ” 3 OIL “ ” 4 REV “LIMIT” INSPECTION MONITOR LAMP CHECK 1. Connect test cord as shown in figure. ! 09930-89240: 4-pin test cord NOTE: This check can be performed without test cord (P/no. 09930-89240). If it is not available, directly connect battery to terminal of meter. B 2. Apply 12 V power to meter. Connect Gray wire to positive + terminal, and Black wire to negative - terminal of battery. Gr 12 V Battery P BI/B G/W G/Y 3. Check if lamp lights when connecting battery to test cord terminal as shown. Monitor lamp check: Battery terminal Negative Negative Negative Positive + Terminal for battery connection Test cord Meter Bl G/W W G/Y Y BI/B R P Lighting lamp Lamp Lamp Lamp Lamp BI W Y 12 V Battery 1 2 3 4 If out of specification, replace monitor-tachometer. R 12 V Battery 29 4-30 ENGINE ELECTRICAL ELECTRIC PARTS HOLDER REMOVAL Before removing electric parts holder: • Disconnect battery cables from battery. 1. Disconnect lead wire connectors from ECM 1, then remove ECM. 2. Remove nut 2, positive + battery cable 3 and positive lead wire 4 from magnetic switch 5 of starter motor. Remove bolt 6, negative - battery cable 7 and GND lead wire 8. Disconnect red lead wire 9 from magnetic switch “S” terminal. Pull battery cables out of electric parts holder. 3. Disconnect PTT relay connector 0 from PTT motor cable wire. 4. Remove communication connector A from electric parts holder. Remove cable clamp B from electric parts holder by releasing clamps’ lock. 30 ENGINE ELECTRICAL 4-31 5. Remove the two (2) bolts C securing electric parts holder D. Slide the electric parts holder upward, then remove it from cylinder block. 6. Remove PTT motor relay E and joint connectors F from electric parts holder. 7. Pull and remove fuse box G from electric parts holder. 8. Remove cable clamp H from electric parts holder by releasing clamps’ lock. 9. To free the electric parts holder, unfasten the cable tie I securing main harness. INSTALLATION Installation is reverse order of removal. Final check: • All parts removed have been returned to their original position. • Check wire routing. (See page 11-4 to 11-10.) 31 FUEL SYSTEM 5-1 FUEL SYSTEM CONTENTS PRECAUTIONS WHEN SERVICING FUEL SYSTEM ................................... 5- 2 GENERAL PRECAUTION ..................................................................... 5- 2 FUEL PRESSURE RELIEF PROCEDURE ........................................... 5- 3 FUEL LINE ...................................................................................................... 5- 4 REMOVAL/INSTALLATION .................................................................. 5- 4 FUEL LEAKAGE CHECK PROCEDURE ............................................. 5- 4 FUEL HOSE CONNECTION ................................................................. 5- 5 FUEL PRESSURE INSPECTION .......................................................... 5- 5 FUEL VAPOR SEPARATOR SET/HIGH PRESSURE FUEL PUMP ............. 5- 7 REMOVAL ............................................................................................. 5- 7 INSTALLATION ..................................................................................... 5- 8 DISASSEMBLY ..................................................................................... 5- 9 INSPECTION ......................................................................................... 5-10 ASSEMBLY ........................................................................................... 5-12 FUEL INJECTOR ............................................................................................ 5-14 INSPECTION ......................................................................................... 5-14 REMOVAL ............................................................................................. 5-14 INSTALLATION ..................................................................................... 5-15 LOW PRESSURE FUEL PUMP ..................................................................... 5-17 REMOVAL/INSTALLATION .................................................................. 5-17 INSPECTION ......................................................................................... 5-18 LOW PRESSURE FUEL FILTER/FUEL HOSE ............................................. 5-19 INSPECTION ......................................................................................... 5-19 OPERATION ................................................................................................... 5-20 FUEL PUMP .......................................................................................... 5-20 5 32 5-2 FUEL SYSTEM PRECAUTIONS WHEN SERVICING FUEL SYSTEM GENERAL PRECAUTION ! Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except when battery power is required for servicing/inspection. • Keep the working area well ventilated and away from open flame (such as gas heater) or sparks. • Do not smoke or allow anyone else to smoke near the working areas. Post a “NO SMOKING” sign. • Keep a fully charged CO2 fire extinguisher and readily available for use. • Always use appropriate safety equipment and wear safety glasses when working around pressurized fuel system. • To avoid potential fire hazards, do not allow fuel to spill on hot engine parts or on operating electrical components. • Wipe up fuel spills immediately. ! Fuel components and fuel hoses after the high pressure fuel pump remain pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components. 33 FUEL SYSTEM 5-3 FUEL PRESSURE RELIEF PROCEDURE After making sure that engine is cold, relieve fuel pressure as follows. 1. Turn OFF ignition switch. 2. Remove the three (3) bolts and fuel hose guard 1. 3. Disconnect high pressure fuel pump lead wire connector at high pressure fuel pump. 1 1. High pressure fuel pump 4. Disconnect the ignition coil primary lead wire connector from all ignition coils. 5. Crank the engine 5 – 10 times (3 seconds each time) to dissipate fuel pressure in lines. 6. Make sure fuel pressure has been removed by pinching high pressure fuel hose between finger tips (line should feel soft without pressure). 7. Upon completion of servicing, connect ignition coil primary lead wire and high pressure fuel pump lead wire. 2 2. High pressure fuel hose 34 5-4 FUEL SYSTEM FUEL LINE REMOVAL/INSTALLATION Pay special attention to the following steps when removing or installing fuel hoses. ! Fuel components and fuel hoses after the high pressure fuel pump remain pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components. " • Do not over bend (kink) or twist hoses when installing. • When installing hose clamps, position tabs to avoid contact with other parts. • Be sure hoses do not contact rods, levers or other components with engine either operating or at rest. • Extreme care should be taken not to cut, abrade or cause any other damage to hoses. • Use care not to excessively compress hoses when tightening clamps. NOTE: • Check fuel hose routing. (See page 11-11 and 11-17.) • Check for fuel leakage. FUEL LEAKAGE CHECK PROCEDURE After performing any fuel system service, always be sure there is no fuel leakage by checking as follows. 1. 2. 3. 4. Squeeze fuel primer bulb until you feel resistance. Shift into “NEUTRAL” position. Ensure emergency stop switch lock plate is in place. Turn ignition switch “ON” for 6 seconds (to operate fuel pump), then turn it “OFF”. Repeat this (ON and OFF) procedure 3 or 4 times to pressurize the fuel system. 5. Once pressurized, check all connections and components for any signs of leakage. OFF ON 35 FUEL SYSTEM 5-5 FUEL HOSE CONNECTION Clamp (Clip) “A” Hose Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly by referring to the figure. Joint pipe 3 – 7 mm (0.1 – 0.3 in) • For type “A” (short barbed end) pipe, hose must completely cover pipe. • For type “B” (bent end) pipe, hose must cover straight part of pipe by 20 – 30 mm (0.8 – 1.2 in). “B” 20 – 30 mm (0.8 – 1.2 in) 3 – 7 mm (0.1 – 0.3 in) • For type “C” pipe, hose must fit up against flanged part of pipe. “C” 3 – 7 mm (0.1 – 0.3 in) • For type “D” pipe, hose must cover pipe by 20 – 30 mm (0.8 – 1.2 in). “D” 20 – 30 mm (0.8 – 1.2 in) 3 – 7 mm (0.1 – 0.3 in) FUEL PRESSURE INSPECTION 1 1. Relieve fuel pressure in fuel feed line. (See page 5-3.) 2. Disconnect high pressure fuel feed hose from fuel delivery pipe upper union. 2 1. High pressure fuel feed hose 2. Fuel delivery pipe 3. Connect special tools (pressure gauge, pressure hose & pressure joint) between fuel feed hose and fuel delivery pipe upper union as shown in figure. Clamp hose securely to ensure no leaks occur during checking. # 09912-58442: Pressure gauge – a 09912-58432: Fuel pressure hose – b 09912-58490: Fuel pressure joint – c 3 1 2 1. High pressure fuel filter 2. Fuel delivery pipe 3. Delivery pipe upper plug 5-6 FUEL SYSTEM " A small amount of fuel may be released when the fuel feed hose is disconnected. Place container under the fuel feed hose or fuel delivery pipe upper union with a shop cloth so that released fuel is caught in container or absorbed in cloth. Place fuel soaked cloth in an approved container. 4. Ensure emergency stop switch lock plate is in place. Shift into “NEUTRAL” position. 5. Squeeze fuel primer bulb until you feel resistance. 6. Turn ignition switch “ON” for 6 seconds (to operate fuel pump), then turn it “OFF”. 7. Repeat this (“ON” and “OFF”) procedure 3 or 4 times to pressurize the fuel system and then check fuel pressure. 8. Check for any signs of fuel leakage. 9. Measure fuel pressure in line at cranking or idle speed operation. OFF ON Fuel pressure: Approx. 255 kPa (2.55 kg/cm2 , 36.3 psi) 10. Stop engine and wait 5 minutes. Check residual fuel pressure in line. Residual fuel pressure: 200 kPa (2.0 kg/cm2, 28.4 psi) or more " As fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to fuel pressure relief procedures mentioned earlier. Use the following procedures to remove fuel pressure gauge. • Place container under joint to catch fuel. • Cover joint with rag and loosen joint nut slowly to gradually release any residual fuel pressure. 11. After checking fuel pressure, remove fuel pressure gauge. 12. Reconnect fuel line. 13. With engine not running and ignition switch “ON”, check fuel system for leaks . 1 1. Joint nut FUEL SYSTEM 5-7 FUEL VAPOR SEPARATOR SET/HIGH PRESSURE FUEL PUMP REMOVAL ! Fuel components and fuel hoses after the high pressure fuel pump remain pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components. 1. Relieve fuel pressure in fuel feed line. (See page 5-3.) 2. Remove the engine side lower cover. (See page 7-2.) 1 1. Fuel vapor separator 3. Remove the two bolts securing front panel. 2 2. Front panel 4. Disconnect high pressure fuel pump lead wire connector 1 at fuel pump. 5. Disconnect fuel inlet hose 2 from vapor separator 3. 5-8 FUEL SYSTEM 6. Remove the three (3) bolts securing fuel vapor separator to crankcase. 7. Disconnect fuel return hose 4 from fuel vapor separator. 8. Disconnect fuel outlet hose 5 from high pressure fuel filter, then remove evaporation hose 6 from fuel vapor separator. INSTALLATION Installation is reverse order of removal with special attention to the following steps. Final Check • Check to ensure that all removed parts are back in place. • Check fuel hose routing. (See page 11-11 to 11-17.) • Check for fuel leakage. (See page 5-4.) FUEL SYSTEM 5-9 DISASSEMBLY 1. Remove five (5) screws 1. Remove separator cover 2 with high pressure fuel pump from separator case 3. 2. Remove the screw 4 securing float pin 5. Remove the float 6, float pin 5 and needle valve 7. 3. Remove screw 8 and valve seat 9. 4. Remove screw and fuel pressure regulator 0 from separator case. 5-10 FUEL SYSTEM 5. Remove suction filter A. 6. Remove high pressure fuel pump B and grommet C from separator cover and then disconnect pump lead wire connector. INSPECTION NOTE: If cracks, excessive wear or other damage is found on any component, replace component. Needle valve/Valve seat Inspect needle valve and valve seat for groove, other damage or dirt. Replace or clean if necessary. Float Inspect float for cracks or other damage. Replace if necessary. FUEL SYSTEM 5-11 Filter Inspect pump suction filter for clog or other damage. Replace or clean if necessary. Fuel pressure regulator Inspect fuel pressure regulator for damage or corrosion. Check fuel pressure regulator operation. # 09952-99310: Hand air pump 1 09940-44121: Air pressure gauge 2 09940-44130: Attachment 3 09912-58490: Hose 4 1. Connect special tools to inlet side of regulator as shown in figure. 2. Pump air into regulator using pump 1 until air is released through outlet side. 3. Read pressure on gauge when air is released. Regulator operating pressure: 240 – 270 kPa (2.4 – 2.7 kg/cm2, 34.1 – 38.4 psi) If out of specification, replace regulator. 5-12 FUEL SYSTEM ASSEMBLY Assembly is reverse order of disassembly with special attention to the following steps. High pressure fuel pump Connect pump lead wire connector, then install grommet 1 and fuel pump 2. NOTE: Apply fuel to grommet before installing. Float/Float pin Install float 1 and float pin 2, then secure float pin with screw 3. NOTE: After assembling, check for smooth and free float movement. Checking float height Measure float height. # 09900-20101: Vernier calipers Float height H: 43 ± 1 mm NOTE: Make sure that float weight is not applied to needle valve. Setting float height To correct specification, bend only adjustment tab 1. " When adjusting tab, do not bend to the point that it applies pressure to the needle and seat. FUEL SYSTEM 5-13 Fuel pressure regulator Install fuel pressure regulator and tighten screw securely. NOTE: Apply fuel to O-ring before installing regulator. Apply fuel to O-ring Separator cover/Separator case 1. Install seal ring 1, then apply SUZUKI BOND evenly to only the outside mating surface of separator case as shown in figure. $ 99000-31140: SUZUKI BOND “1207B” NOTE: • Clean mating surfaces before applying bond. • Do not apply bond to seal ring , groove and inside mating surface. 2. Install separator case, then tighten screws securely. NOTE: When installing separator case, align suction hole A with hole B of separator case. NOTE: Separator cover and case are a set. Make sure paint marks on both items are matched when assembling. Final Assembly Check • Check to ensure that all removed part are back in place. • Check fuel hose routing. (See page 11-11 to 11-17.) • Check for fuel leakage. (See page 5-4.) Paint mark 5-14 FUEL SYSTEM FUEL INJECTOR INSPECTION Injector body 1. Using sound scope or equivalent, check operating sound of fuel injector when engine is running or cranking. Injector operating sound cycle should vary according to engine speed. If no sound or an unusual sound is heard, check injector circuit (wire or connector) or injector. Click 2. Disconnect lead wire connector from fuel injector. 3. Connect digital tester between terminals of injector and measure resistance. # 09930-99320: Digital tester % Tester range: Ω (Resistance ) Fuel injector resistance: 10.0 – 14.0 Ω If out of specification, replace fuel injector. 4. Connect lead wire connector to fuel injector securely. REMOVAL 1. Relieve fuel pressure according to procedure described on page 5-3. 2. Loosen clamp and place a large cloth over end of fuel feed hose. Slowly pull fuel feed hose from fuel delivery pipe. Drain any excess fuel in hose into a small container. 1 1. Fuel feed hose 3. Disconnect the inlet hose 1 and outlet hose 2 from low pressure fuel filter. 4. Remove bolts and fuel filter bracket 3. FUEL SYSTEM 5-15 5. Disconnect four fuel injector connectors. 6. Remove two bolts and fuel delivery pipe (with fuel injectors). " A small amount of fuel may be released when the fuel injector is removed from delivery pipe. Place a shop cloth under fuel injector before removal to absorb any fuel released. Dispose of fuel soaked cloth in appropriate container. 7. Remove each injector from delivery pipe. INSTALLATION Installation is reverse order of removal with special attention to the following steps. " Do not reuse O-ring and cushion once removed. Always use new parts. 1. Replace injector O-ring 1 with new one using care to avoid nicks or cuts during installation. Apply fuel to O-ring 5-16 FUEL SYSTEM 2. Replace injector cushion 2 with new one and install to cylinder head. 3. Apply thin coat of fuel to injector O-rings, then install injectors into delivery pipe 3 and cylinder head. Make sure that injectors rotate smoothly. 4. Tighten delivery pipe bolts and make sure that injectors rotate smoothly. & Fuel delivery pipe bolt: 23 N·m (2.3 kg-m, 16.5 lb-ft) 5. Install fuel filter bracket and tighten bolts securely. 6. Reconnect fuel feed hose and fuel line securely. 7. Connect lead wire connector to injectors securely. 8. Make sure the emergency stop switch lock plate is in place. Shift into “NEUTRAL” position. 9. Squeeze fuel primer bulb until you feel resistance. Turn ignition switch “ON” for 6 seconds (to operate fuel pump), then turn it “OFF”. Repeat this (ON and OFF) procedure 3 or 4 times to pressurize fuel system. Check for fuel leaks around fuel injector. FUEL SYSTEM 5-17 LOW PRESSURE FUEL PUMP The low pressure fuel pump is a non-repairable component. Do not attempt to disassemble the low pressure pump. It must be replaced as a complete unit if it is defective. REMOVAL/INSTALLATION REMOVAL 1. Disconnect inlet hose 1 and outlet hose 2 from low pressure fuel pump. 2. Remove two bolts 3. 3. Remove fuel pump 4. Note position before removing O-ring 5. INSTALLATION Installation is reverse order of removal with special attention to the following steps. " • Before installing fuel pump, rotate the crankshaft to bring No.1 (top cylinder) piston to Top Dead center on compression stroke. • Do not reuse O-ring once removed. Always use a new O-ring. & Low pressure fuel pump bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft) 5-18 FUEL SYSTEM INSPECTION Fuel pump assembly Inspect fuel pump. If leakage, cracks, damage or other abnormal condition is found, replace fuel pump assembly. FUEL SYSTEM 5-19 LOW PRESSURE FUEL FILTER/FUEL HOSE When disassembling or reassembling fuel line, refer to the construction diagram below. 4 5 1 5 5 5 2 7 5 6 4 4 5 3 5 4 1. Low pressure fuel filter 2. Fuel connector 3. Fuel primer bulb 4. Fuel hose 5. Clip INSPECTION FUEL CONNECTOR Inspect fuel connector for leakage, deterioration or other damage. Replace if necessary. FUEL HOSE Inspect fuel hose for cuts, cracks, leakage, tears or deterioration. Replace if necessary. FUEL PRIMER BULB Inspect fuel primer bulb for cracks, leakage, deterioration or check valve function. Replace if necessary. LOW PRESSURE FUEL FILTER To perform fuel filter inspection, refer to “PERIODIC MAINTENANCE/LOW PRESSURE FUEL FILTER” section on page 2-19. 6. Clip 7. Cap 5-20 FUEL SYSTEM OPERATION FUEL PUMP The fuel pump is operated by the plunger contacting the cam. Cam Plunger IN Cam Plunger OUT ">

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Key features
- Battery Charging System
- Electric Starter System
- Monitor-Tachometer
- Electric Parts Holder
- Troubleshooting
Frequently asked questions
The manual provides step-by-step instructions on how to measure the resistance of the battery charge coil, inspect the fuse box, and check the rectifier and regulator. These checks will help determine if there are any issues with the battery charging system.
Common symptoms include the engine not turning over, the starter motor not rotating, or the starter relay not clicking. The manual provides troubleshooting information and step-by-step instructions to diagnose and repair any problems with the electric starter system.
The manual explains how to check the monitor lamp for proper operation. It also provides specific instructions on how to connect the test cord and apply power to the meter.