Suzuki electrical system, battery charging system, electric starter system, starter motor, monitor-tachometer, electric parts holder Service manual
The electrical system is responsible for starting the engine, charging the battery, and powering the various electrical components. The battery charging system consists of the battery charge coil, rectifier & regulators, and battery. The three-phase AC current generated from the battery charge coil is converted by the rectifier & regulators into regulated DC current which is used to charge the battery. The electric starter system consists of the battery, starting motor, ignition switch, neutral switch, and related electrical wiring. These components are connected electrically to allow the engine to crank. The starter motor relay will only engage when the ignition switch is turned to the “START” position if the following conditions are satisfied: lock plate is attached to emergency stop switch, neutral switch is in “ON” position and engine is not already operating.
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ELECTRICAL 4-1 ELECTRICAL CONTENTS BATTERY CHARGING SYSTEM ....................................................................4- 2 OUTLINE ................................................................................................4- 2 INSPECTION ..........................................................................................4- 3 REMOVAL/INSTALLATION ...................................................................4- 5 ELECTRIC STARTER SYSTEM .....................................................................4- 7 OUTLINE ................................................................................................4- 7 TROUBLESHOOTING ...........................................................................4- 9 INSPECTION ..........................................................................................4-10 STARTER MOTOR .................................................................................4-13 MONITOR-TACHOMETER ..............................................................................4-25 INSPECTION ..........................................................................................4-25 ELECTRIC PARTS HOLDER ..........................................................................4-26 REMOVAL ..............................................................................................4-26 INSTALLATION ......................................................................................4-26 4 1 4-2 ELECTRICAL BATTERY CHARGING SYSTEM OUTLINE The battery charging system circuit is illustrated below. It is composed of the BATTERY CHARGE COIL, RECTIFIER & REGULATORS and BATTERY. The three phase AC current generated from the battery charge coil is converted by the rectifier & regulators into regulated DC current which is used to charge the battery. OUTPUT 12 V 54 A (648 W)/3 000 r/min. REGULATED VOLTAGE 14.2 – 15.2 V Main relay Alternator (Magneto) W P/B To ignition switch To ECM Sub fuse 30 A W Gr W To High fuel pump To Low fuel pump To ECM To Fuel injector Starting motor To CMP sensor Other M Main fuse 60 A To Starter relay 1 Battery charge coil 2 Battery charge coil 3 Rectifier & Regulator BATTERY 4 Rectifier & Regulator 2 ELECTRICAL 4-3 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 & regulators. 2. Measure resistance between leads in the combinations shown. Terminal for tester probe connection Yellow 1 to Yellow 2 Y4 Y1 Battery charge coil resistance: Y5 Y6 Resistance Y2 Yellow 2 to Yellow 3 Yellow 3 to Yellow 1 Yellow 4 to Yellow 5 0.32 – 0.48 Ω Yellow 5 to Yellow 6 Yellow 6 to Yellow 4 0.32 – 0.48 Ω Y3 If measurement exceeds specification, replace battery charge coil. FUSE CASE/FUSE Main fuse Sub fuse ! 09930-99320: Digital tester # Tester range: $ (Continuity) Fuse 1. Remove the fuse from fuse case (or fuse terminal). 2. Inspect continuity between both terminals of fuse. If no continuity is indicated, replace fuse. Main fuse : 60 A Sub fuse : 30 A Main fuse terminal Inspect continuity between terminal (A) and (B). If no continuity is indicated, replace fuse terminal and/or fuse. B A 3 4-4 ELECTRICAL Sub fuse case 1. Disconnect battery cables from battery. 2. Disconnect white lead wire of fuse case from terminal (A). 3. Check continuity between White lead wire with plate terminal and the white lead wire W of ECM main relay connector. If no continuity is indicated, replace main harness and/or fuse. A 2 2. Sub fuse ECM main relay RECTIFIER & REGULATOR ! 09900-25002: Pocket tester " Tester range: ×1 kΩ (Resistance) 1. Disconnect all lead wires of rectifier & regulator. 2. Measure resistance between leads 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. Rectifier & regulator resistance: Unit: Approx. kΩ Tester probe + (Red) Tester probe - (Black) Black Black White 3.0 – 4.6 Yellow 1 Yellow 2 Yellow 3 1.8 – 2.8 1.8 – 2.8 1.8 – 2.8 ∞ ∞ ∞ 4–7 4–7 White ∞ Yellow 1 2 – 3.2 2 – 3.4 Yellow 2 2 – 3.2 2 – 3.4 4–7 Yellow 3 2 – 3.2 2 – 3.4 4–7 4–7 B Y3 W Y2 Y1 4–7 If measurement exceeds specification, replace rectifier & regulator. 4 ELECTRICAL 4-5 REMOVAL/INSTALLATION System construction 118 N.m (11.8 kg-m, 85.3 lb-ft) 1 Bolt 2 Flywheel 3 Dowel pin 4 Screw 5 Battery charge coil 6 Rectifier & regulator 7 Bolt 8 Seal ring 9 Clamp 0 Bolt A Main harness B Main fuse 60 A C Sub fuse 30 A 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. • Disconnect battery charge coil lead wire connectors from Rectifier & regulator. • Remove the lead wire clamps and battery charge coil. 5 4-6 ELECTRICAL Rectifier & regulator • Remove the electric parts holder cover. • Remove the nut 1 and charge output (white) leads 2 from main fuse terminal. • Disconnect battery charge coil lead wire connector from Rectifier & regulator. • Remove the bolt securing ground lead wire of Rectifier & regulator. • Remove the bolts securing the Rectifier & regulator. • Remove the rectifier & regulator 3 and seal ring 4. 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. % 99000-32050: 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 - to .) 6 ELECTRICAL 4-7 ELECTRIC STARTER SYSTEM OUTLINE The starting circuit consists of the battery, starting motor, ignition switch, neutral switch 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 are magnetized when the ignition switch is closed (turn 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 Dg Ring gear W Starter motor Pinion & over-running clutch Battery Main relay 15 A Fuse 30 A Fuse 60 A Fuse Y/G W OFF ON START Neutral switch Y/G Br B GND Br Br W W BATT Br Br START Neutral switch ECM Ignition switch G B G B Emergency stop switch 7 4-8 ELECTRICAL STARTER MOTOR OPERATION CONDITION 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 properly. 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 8 ELECTRICAL 4-9 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 sub (30 A) fuse/case. (See page 4-3.) 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 4-19.) • Check starter magnetic switch. (See page 4-20.) Does the flywheel rotate? • Check ECM-No. 1 terminal voltage. (See page 3-49.) 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 function of neutral switch. (See page 4-11.) • Check emergency stop switch function. (See page 4-12.) • Check ignition switch function. (See page 4-10.) • Check starter relay. (See page 4-10.) • Check wiring system and connections between starter relay and ignition switch. • Check the brush and brush holder. (See page 4-18.) • Check the armature coil. (See page 4-17.) - YES • The magnetic switch and/or connection is faulty. Replace it. 9 4-10 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 ON ! START " FREE # PUSH : Continuity If out of specification, replace ignition switch. Bl B Br Br Gr G Brown White Black White/Red Gray Green Blue STARTER MOTOR RELAY ! 09930-99320: Digital tester # Tester range: $ (Continuity) 1 1. Disconnect starter motor relay from wire. 1. Starter motor relay 2. Electric parts holder 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. 10 ELECTRICAL 4-11 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 Forward Clutch lever Tester indicates Continuity Infinity Infinity Neutral switch If out of specification: • 1st Check switch position adjustment, readjust if necessary. • 2nd Replace neutral switch. NOTE: After installing neutral switch, check for correct function by operating remo-con handle. Y/G Br 11 4-12 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. 12 ELECTRICAL 4-13 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 the two (2) bolts 3, negative - battery cable 4 and starter motor band 2. 3. Remove nut 5 and positive + battery cable 6, positive + battery charge cable 7 from the magnetic switch of starter motor. 4. Remove the bolt 8 securing the remote control cable connector holder. 5. Remove the two bolts 9 securing starter motor. 6. Remove the starter motor 0, then disconnect the red lead wire A from “S” terminal of starter magnetic switch. 13 4-14 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. 14 ELECTRICAL 4-15 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. 15 4-16 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 grasses 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. 16 ELECTRICAL 4-17 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 grasses 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 17 4-18 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 lb) 18 ELECTRICAL 4-19 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. 19 4-20 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” 20 ELECTRICAL 4-21 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. 21 4-22 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 22 ELECTRICAL 4-23 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 used there. 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. 23 4-24 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 24 ELECTRICAL 4-25 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 25 4-26 ELECTRICAL ELECTRIC PARTS HOLDER REMOVAL Before removing electric parts holder: • Disconnect battery cables from battery. • Remove bolt 2, then remove remo-con cable holder 1 by sliding it upward. • Remove electric parts holder cover. • Disconnect lead wire connectors from ECM 3, then remove ECM. • Disconnect following lead wires in electric parts holder. • Two (2) White Rectifier & Regulator lead wires and White 30 A fuse lead on 60 A main fuse lower terminal. • Red battery charge lead and Red lead of PTT relay unit on 60 A main fuse upper terminal. • Harness connector at CKP sensor. • Remove starter motor relay 4, ECM main relay 5, PTT relay unit 6, 30 A fuse case from electric parts holder. • Remove four (4) bolts securing electric parts holder, then remove electric parts holder. INSTALLATION Installation is reverse order of removal. Final check: • All parts removed have been returned to their original position. • Check wire routing. (See page x-xx to x-xx.) 26 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 LOW PRESSURE FUEL PUMP/FUEL VAPOR SEPARATOR SET ............. 5- 7 REMOVAL ............................................................................................. 5- 7 FUEL SYSTEM DIAGRAM .................................................................... 5- 9 INSPECTION ......................................................................................... 5-10 INSTALLATION ..................................................................................... 5-10 FUEL VAPOR SEPARATOR/HIGH PRESSURE FUEL PUMP ..................... 5-11 REMOVAL AND DISASSEMBLY ......................................................... 5-11 INSPECTION ......................................................................................... 5-13 ASSEMBLY ........................................................................................... 5-14 EVAPORATION PURGE SYSTEM ................................................................ 5-17 SYSTEM INSPECTION ......................................................................... 5-17 PURGE VALVE ..................................................................................... 5-17 FUEL INJECTOR ............................................................................................ 5-19 REMOVAL ............................................................................................. 5-19 INSTALLATION ..................................................................................... 5-20 LOW PRESSURE FUEL PUMP ..................................................................... 5-22 INSPECTION ......................................................................................... 5-22 LOW PRESSURE FUEL FILTER/FUEL HOSE ............................................. 5-23 INSPECTION ......................................................................................... 5-23 5 27 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. 28 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. Disconnect high pressure fuel pump lead wire connector at high pressure fuel pump. High pressure fuel pump 3. Disconnect the ignition coil primary lead wire connector from all ignition coils. 4. Crank the engine 5 – 10 times (3 seconds each time) to dissipate fuel pressure in lines. 5. Make sure fuel pressure has been removed by pinching high pressure fuel hose between finger tips (line should feel soft without pressure). 6. Upon completion of servicing, connect ignition coil primary lead wire and high pressure fuel pump lead wire. High pressure fuel hose 29 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 xx-xx and xx-xx.) • 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. Squeeze fuel primer bulb until you feel resistance. 2. Ensure emergency stop switch lock plate is in place. 3. 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. 4. Once pressurized, check all connections and components for any signs of leakage. OFF ON 30 FUEL SYSTEM 5-5 FUEL HOSE CONNECTION “A” Clamp (Clip) 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. Relieve fuel pressure in fuel feed line. (See page 5-3.) 2. Remove the ring gear cover and air intake silencer case. (See page 6-xx.) 3. Disconnect high pressure fuel feed hose from 3-way joint pipe. 4. Connect special tools (pressure gauge, pressure hose & pressure joint) between fuel feed hose and 3-way joint pipe 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 1 3 1. High pressure fuel filter 2. Fuel delivery pipe 3. 3-way joint pipe 2 31 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 3-way joint pipe with a shop cloth so that released fuel is caught in container or absorbed in cloth. Place fuel soaked cloth in an approved container. 5. Ensure emergency stop switch lock plate is in place. 6. Squeeze fuel primer bulb until you feel resistance. 7. Turn ignition switch “ON” for 6 seconds (to operate fuel pump), then turn it “OFF”. 8. Repeat this (“ON” and “OFF”) procedure 3 or 4 times to pressurize the fuel system and then check fuel pressure. 9. Check for any signs of fuel leakage, then reinstall the ring gear cover and air intake silencer case. 10. 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) 11. 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 following procedures. • Place container under joint to catch fuel. • Cover joint with rag and loosen joint nut slowly to gradually release fuel pressure. 1 1. Joint nut 12. After checking fuel pressure, remove fuel pressure gauge. 13. Reconnect fuel line. 14. With engine not running and ignition switch “ON”, check fuel system for leaks . 15. Reinstall the ring gear cover and air intake silencer case. 32 FUEL SYSTEM 5-7 LOW PRESSURE FUEL PUMP/FUEL VAPOR SEPARATOR SET REMOVAL ! 1 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 ring gear cover and air intake silencer case. (See page 6-2.) 1. Ring gear cover and air intake silencer case 3. Disconnect low pressure fuel pump lead wire connector 1. Disconnect high pressure fuel pump lead wire connector 2 at fuel pump. 4. Disconnect purge valve hose 3 from fuel vapor separator. 5. Disconnect water outlet hose 4 from crankcase water jacket cover. 6. Disconnect fuel inlet hose 5 from low pressure fuel filter. 33 5-8 FUEL SYSTEM 7. Disconnect water inlet hose 6 from fuel cooler. 8. Disconnect high pressure fuel feed hose 7 from 3-way joint pipe. Disconnect purge valve lead wire connector 8 at purge valve. 3-way Joint 9. Remove the two (2) bolts securing fuel vapor separator 9 to crankcase. 10. Remove the two (2) bolts securing high pressure fuel filter 0 to crankcase. 11. Remove the two (2) bolts securing fuel vapor separator bracket A. 34 FUEL SYSTEM 5-9 12. Remove the low pressure fuel pump/fuel vapor separator set B, then disconnect cooling water outlet hose C from fuel cooler. FUEL SYSTEM DIAGRAM FUEL VAPOR SEPARATOR SET SECTION OF LOW PRESSURE FUEL LINE SECTION OF HIGH PRESSURE FUEL LINE Needle valve Float Fuel tank FUEL VAPOR SEPARATOR ASSEMBLY 1 2 3 4 5 Low pressure fuel filter Low pressure fuel pump Fuel filter Relief valve Fuel filter 6 7 8 9 0 High pressure fuel pump Pressure regulator Fuel cooler High pressure fuel filter Fuel delivery pipe 35 5-10 FUEL SYSTEM INSPECTION FUEL FILTER • Remove the fuel filter. • Inspect filter for clog or other damage. Replace or clean if necessary. • Reinstall fuel filter, then secure the hose with hose clamp (clip). Fuel filter RELIEF VALVE Check the relief valve operation. # 09952-99310 : Hand air pump 09940-44121 : Air pressure gauge 09940-44130 : Attachment 1. Remove the relief valve 1. 2. Connect special tool to inlet side of relief valve as shown in figure. 3. Plug the outlet hose 2. 4. Pump air into the relief valve using hand air pump until air is released through fitting a·b. 5. Read pressure on gauge when air is released. Relief valve operating pressure: 70 – 80 kPa (0.7 – 0.8 kg/cm2, 10 – 11.4 psi) If out of specification, replace relief valve. 6. Reinstall relief valve, then secure the hose with hose clamp (clip). 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 and water hose routing. (See page x-xx.) • Check wire routing. (See page x-xx to x-xx.) • Check for fuel leakage. (See page 5-4.) • Check for water leakage. Fuel vapor separator FUEL SYSTEM 5-11 FUEL VAPOR SEPARATOR/HIGH PRESSURE FUEL PUMP REMOVAL AND DISASSEMBLY ! 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. Remove the low pressure fuel pump/fuel vapor separator set. (See page 5-7.) 2. Remove the two (2) bolts securing low pressure fuel pump 2 to fuel vapor separator 1. 3. Remove the three (3) bolts securing fuel cooler bracket 3 to fuel vapor separator 1. 4. Disconnect fuel inlet hose 4 and fuel outlet hose 5 from fuel vapor separator. 5-12 FUEL SYSTEM 5. Disconnect fuel return hose 6 from fuel vapor separator. 6. Remove seven (7) screws 1. Remove separator cover 2 with high pressure fuel pump from separator case 3. 7. Remove float pin 4 and float 5. 8. Remove needle valve 6, screw 7 and valve seat 8. 9. Remove screw and fuel pressure regulator 9 from separator case. FUEL SYSTEM 5-13 10. Remove suction filter 0. 11. Remove high pressure fuel pump A and grommet B 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 crack or other damage. Replace if necessary. 5-14 FUEL SYSTEM Filter Inspect pump suction filter for clog or other damage. Replace or clean if necessary. Fuel pressure regulator Check fuel pressure regulator operation. # 09952-99310 09940-44121 09940-44130 09912-58490 : Hand air pump 1 : Air pressure gauge 2 : Attachment 3 : 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. 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 and float pin. NOTE: After assembling, check for smooth and free float movement. FUEL SYSTEM 5-15 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 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. 5-16 FUEL SYSTEM NOTE: Separator cover and case are a set. Make sure paint marks on both items are matched when assembling. Paint mark Final check • Check to ensure that all removed part are back in place. • Check fuel and water hose routing. (See page x-xx.) • Check for fuel leakage. (See page 5-4.) FUEL SYSTEM 5-17 EVAPORATION PURGE SYSTEM SYSTEM INSPECTION 1. Warm up engine to normal operating temperature. 2. Disconnect purge hose A from fuel vapor separator 1. Purge valve ! Do not suck air through valve. Fuel vapor inside valve is harmful. 3. Blow into hose A, air should come out of hose B. 4. Stop engine, blow into hose A. Air should not come out of hose B. 5. If check results are not satisfactory, check vacuum passage, hose, purge valve, wire harness and ECM. (See page 3-xx.) Hose B Hose A PURGE VALVE INSPECTION 1. With ignition switch OFF, disconnect connector from purge valve 2. 2. Check resistance between two terminals of purge valve. Resistance of purge valve: 28 – 35 Ω at 20 °C If resistance is as specified, proceed to next operation check. 3. Remove the ring gear cover and air intake silencer case. (See page x-xx.) Disconnect purge hose A from fuel vapor separator. Ω 5-18 FUEL SYSTEM 4. With connector disconnected, blow into hose A. Air should not come out of hose B. 5. Remove two (2) bolts 3, purge valve 2 and purge valve bracket. 6. Connect 12-V battery to purge valve terminals. With voltage applied, blow into hose A. Air should come out of hose B. If check result is not as described, replace purge valve. ! Do not suck air through valve. Fuel vapor inside valve is harmful. 7. Install purge valve and purge valve bracket, then connect purge hose. Install the ring gear cover and air intake silencer case. Hose A: Vapor separator to purge valve. Hose B: Purge valve to air intake silencer case. 8. Connect purge valve connector securely. Hose A Hose B FUEL SYSTEM 5-19 FUEL INJECTOR REMOVAL 1. Relieve fuel pressure according to procedure described on page 5-3. 2. Remove the collector assembly. (See page x-xx.) 3. Loosen clamp and place a large cloth over end of fuel feed hose. Slowly pull fuel feed hose from PORT side fuel delivery pipe. Drain any excess fuel in hose into a small container. 4. Disconnect six (6) fuel injector connectors. 5. For PORT side bank: Loosen the two (2) bolts securing fuel delivery pipe. 6. For STBD side bank: Loosen the two (2) bolts securing fuel delivery pipe. 7. Remove PORT/STBD fuel delivery pipes (with fuel injectors), delivery pipe bolts and collars. " 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. 8. Remove each injector from delivery pipe. 1 1. Fuel feed hose 5-20 FUEL SYSTEM INSTALLATION Installation is reverse order of removal with special attention to the following steps. " Do not re-use O-ring and cushion once removed. Always use new parts. 1. Replace injector O-ring 1 with new one using care not to damage it. Install grommet 2 to injector. 2. Place delivery pipe bolts 3 and four (4) insulators (collars) 4 in position. Apply fuel to O-ring 3. Replace injector cushion 5 with new one and install it to intake manifold. 4. Apply thin coat of fuel to injector O-rings, then install injectors into delivery pipes 6 and intake manifold. Make sure that injectors rotate smoothly. 5. 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) FUEL SYSTEM 5-21 6. Reconnect fuel feed hose securely. 7. Connect lead wire connector to injectors securely. 8. Make sure the emergency stop switch lock plate is in place. NOTE: Because some sensor leads are disconnected when removing the collector assembly, a diagnosis code will temporarily be displayed during inspection. 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. 10. Install collector assembly. (See page x-xx.) 5-22 FUEL SYSTEM LOW PRESSURE FUEL PUMP The low pressure fuel pump is a non-serviceable component. If it is defective, it must be replaced as a complete unit. The following procedure will determine whether or not the pump is defective. 1 INSPECTION NOTE: To prevent damage to the low pressure fuel pump, fill the fuel feed lines with fuel prior to operating the pump. 1. Install the emergency stop switch lock plate in position. 2. When the ignition key is turned to ON from OFF, check that a pump operating sound is heard for six (6) seconds. 3. If no pump operating sound is heard: (a) Turn the ignition key to OFF and disconnect the pump lead connector. (b) Check for contact failure in the lead connector. (c) Measure resistance between the two terminals of pump lead connector. # 09930-99320: Digital tester & Tester range: Ω (Resistance) Pump resistance: Standard 1 – 5 Ω If the measurement is out of specification, replace the pump. (d) Check that pump drive voltage is output from ECM and no abnormal condition exists in the engine main wiring harness. (See page 3-xx.) 4. If the pump operating sound is heard: (1) Remove the fuel feed hose from the vapor separator. (2) Operate the pump by turning the ignition key from OFF to ON and discharge fuel into a suitable container. (3) If no fuel is discharged, check for clogging or other failure in the fuel feed line. If no failure is found, replace the pump. 1. Low pressure fuel pump 2. Fuel vapor separator 2 FUEL SYSTEM 5-23 LOW PRESSURE FUEL FILTER/FUEL HOSE When disassembling or reassembling fuel line, refer to the construction diagram below. 5 1. Low pressure fuel filter 2. Fuel connector 3. Fuel primer bulb 4. Fuel hose 5. Clip 4 4 1 5 2 5 4 5 3 5 4 5 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. 1 1. Low pressure fuel filter ">

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Key features
- Battery charging system
- Electric starter system
- Starter motor
- Monitor-tachometer
- Electric parts holder