9_Servicing_Information.pdf

SERVICING INFORMATION 9-1

SERVICING INFORMATION

CONTENTS

TROUBLESHOOTING

9- 2

MALFUNCTION CODE AND DEFECTIVE CONDITION

9- 2

ENGINE

9- 4

RADIATOR (COOLING SYSTEM)

9- 9

CHASSIS

9-10

BRAKES

9-11

ELECTRICAL

9-12

BATTERY

9-13

WIRE HARNESS, CABLE AND HOSE ROUTING

9-14

CABLE ROUTING (SV650)

9-14

CABLE ROUTING (SV650S)

9-15

WIRE HARNESS ROUTING

9-16

WIRE HARNESS ROUTING (SV650S only)

9-17

SPEED SENSOR LEAD WIRE ROUTING

9-18

THROTTLE BODY INSTALLATION/HOSE ROUTING

9-19

FUEL SYSTEM HOSE ROUTING

9-20

BATTERY CUSHION INSTALLATION

9-21

COOLING SYSTEM HOSE ROUTING

9-22

PAIR SYSTEM HOSE ROUTING

9-24

FUEL TANK INSTALLATION

9-25

BRAKE PEDAL/FOOTREST SET-UP For SV650

9-26

For SV650S

9-27

SIDE-STAND SET-UP

9-28

ENGINE ELECTRICAL PARTS SET-UP

9-29

SEAT LOCK CABLE ROUTING

9-30

HEAT SHIELD INSTALLATION

9-31

FRONT BRAKE HOSE ROUTING For SV650

9-32

FRONT BRAKE HOSE ROUTING For SV650S

9-33

REAR BRAKE HOSE ROUTING For SV650

9-34

REAR BRAKE HOSE ROUTING For SV650S

9-35

SPECIAL TOOLS

9-36

TIGHTENING TORQUE

9-40

ENGINE

9-40

Fl SYSTEM PARTS

9-41

CHASSIS

9-42

TIGHTENING TORQUE CHART

9-43

SERVICE DATA

9-44

9-2 SERVICING INFORMATION

TROUBLESHOOTING

MALFUNCTION CODE AND DEFECTIVE CONDITION

MALFUNCTION

CODE

DETECTED ITEM

DETECTED FAILURE CONDITION

CHECK FOR

COO

NO FAULT

C12

Crankshaft position

sensor

The signal does not reach ECM for more than 3 sec . after

receiving the IAP signal .

The crankshaft position sensor wiring and mechanical parts .

(Crankshaft position sensor, lead wire/coupler connection)

C13

Intake air pressure

sensor

The sensor should produce following voltage .

0 .10 V < sensor voltage < 4.80 V

Without the above range for 4 sec . and more, C13 is indicated.

Intake air pressure sensor, lead wire/coupler connection .

C14

Throttle position sen-

sor

The sensor should produce following voltage .

0.1 V <_ sensor voltage < 4.8 V

Without the above range for 4 sec . and more, C14 is indicated.

Throttle position sensor, lead wire/coupler connection .

Engine coolant tem-

perature sensor

The sensor voltage should be the following .

0.1 V <_ sensor voltage < 4.6 V

Without the above range for 4 sec . and more, C15 is indicated.

Engine coolant temperature sensor, lead wire/coupler connec-

tion.

C15

C21

Intake air temperature

sensor

The sensor voltage should be the following .

0.1 V < sensor voltage < 4.6 V

Without the above range for 4 sec. and more, C21 is indicated.

Intake air temperature sensor, lead wire/coupler connection .

Tip over sensor

The sensor voltage should be the following for more than 2 sec.

after ignition switch turns ON .

0 .2 V <_ sensor voltage < 4 .6 V

Without the above value for 2 sec . and more, C23 is indicated .

Tip over sensor, lead wire/coupler connection .

C23

SERVICING INFORMATION 9-3

MALFUNCTION

CODE

DETECTED ITEM

DETECTED FAILURE CONDITION

CHECK FOR

C24/C25

Ignition signal #1/#2 Crankshaft position sensor (pick-up coil) signal is produced, but

signal from ignition coil is interrupted continuous by 4 times or

more. In this case, the code C24 or C25 is indicated .

Ignition coil, wiring/coupler connection, power supply from the

battery.

Secondary throttle

valve actuator

When no actuator control signal is supplied from the ECM or

communication signal does not reach ECM or operation voltage

does not reach STVA motor, C28 is indicated . STVA can not

operate .

STVA lead wire/coupler.

C28

Secondary throttle

position sensor

The sensor should produce following voltage .

0.1 V <_ sensor voltage <_ 4 .8 V

Without the above range for 4 sec. and more, C29 is indicated .

Secondary throttle position sensor, lead wire/coupler connec-

tion.

C29

C31

Gear position signal It judges from gear position voltage, engine speed and throttle

position by ECM, when the gear position voltage is 0 V .

Gear position sensor, wiring/coupler connection . Gearshift cam

etc .

C32/C33

Fuel injector #1/#2 When fuel injector voltage gets 1 .3 V and less, C32 or C33 is

indicated .

Injector, wiring/coupler connection, power supply to the injector .

Fuel pump relay

No voltage is applied to the both injectors #1/#2 for 3 sec . after

the contact of fuel pump relay is turned ON . Or voltage is

applied to the both injectors #1/#2, when the contact of fuel

pump is OFF.

Fuel pump relay, connecting lead wire, power source to fuel

pump relay, fuel injectors .

C41

C42

Ignition switch

Ignition switch signal is not input in ECM.

Ignition switch, lead wire/coupler.

C49

PAIR control solenoid

valve

PAIR control solenoid valve voltage is not input in ECM .

PAIR control solenoid valve, lead wire/coupler .

9-4 SERVICING INFORMATION

ENGINE

Complaint

Symptom and possible causes

Remedy

Engine will not start

or is hard to start.

Compression too low

1 . Tappet clearance out of adjustment.

Adjust .

2 . Worn valve guides or poor seating of valves .

3. Mistimed valves.

4. Excessively worn piston rings .

5. Worn-down cylinder bores .

6. Starter motor cranks too slowly .

7. Poor seating of spark plugs .

Plug not sparking

1 . Fouled spark plugs .

2. Wet spark plugs.

3. Defective ignition coils.

4. Open or short in high-tension cord .

5. Defective CKP sensor .

6 . Defective ECM .

7. Open-circuited wiring connections .

No fuel reaching the intake manifold

1 . Clogged fuel filter or fuel hose .

2. Defective fuel pump .

3. Defective fuel pressure regulator .

4. Defective fuel injector .

5. Defective fuel pump relay.

6. Defective ECM.

7. Open-circuited wiring connections .

Incorrect fuel/air mixture

1 . TP sensor out of adjustment .

2 . Defective fuel pump.

3. Defective fuel pressure regulator .

4 . Defective TP sensor.

5 . Defective CKP sensor.

6 . Defective IAP sensor.

7 . Defective ECM.

8 . Defective ECT sensor.

9 . Defective IAT sensor.

Repair or replace .

Adjust .

Replace .

See electrical section .

Retighten .

Clean .

Clean and dry.

Replace .

Repair or replace .

Clean or replace.

Replace .

Replace.

Check and repair.

Adjust.

Replace.

Replace .

SERVICING INFORMATION 9-5

Complaint

Symptom and possible causes

Remedy

Engine idles poorly. 1 . Tappet clearance out of adjustment.

2. Poor seating of valves .

3 . Defective valve guides .

4 . Worn down camshafts .

5. Too wide spark plug gaps.

6 . Defective ignition coils .

7. Defective CKP sensor.

8. Defective ECM.

9. Defective TP sensor.

10 . Defective fuel pump.

11 . Imbalanced throttle valve or STV .

12 . Damaged or cracked vacuum hose .

Adjust.

Replace or repair.

Replace .

Adjust or replace.

Replace .

Replace.

Adjust.

Replace.

Engine stalls often Incorrect fuel/air mixture

1 . Defective IAP sensor or circuit.

2 . Clogged fuel filter.

3 . Defective fuel pump.

4 . Defective fuel pressure regulator.

5 . Defective ECT sensor.

6 . Defective thermostat .

7 . Defective IAT sensor.

8 . Damaged or cracked vacuum hose.

Fuel injector improperly operating

1 . Defective fuel injectors.

2 . No injection signal from ECM .

3. Open or short circuited wiring connection .

4 . Defective battery or low battery voltage .

Control circuit or sensor improperly operating

1 . Defective ECM .

2. Defective fuel pressure regulator .

3. Defective TP sensor.

4. Defective IAT sensor.

5. Defective CKP sensor .

6. Defective ECT sensor.

7. Defective fuel pump relay.

Engine internal parts improperly operating

1 . Fouled spark plugs .

2 . Defective CKP sensor or ECM .

3. Clogged fuel hose.

4. Tappet clearance out of adjustment .

Repair or replace .

Clean or replace.

Replace .

Replace.

Replace .

Replace.

Repair or replace .

Repair or replace.

Replace or recharge.

Replace .

Replace.

Replace .

Replace.

Clean .

Replace.

Clean.

Adjust .

Plik z chomika:

Inne pliki z tego folderu:

Inne foldery tego chomika: