Suzuki GSX-R1000. Service Manual - part 12

 

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Suzuki GSX-R1000. Service Manual - part 12

 

 

1A-114 Engine General Information and Diagnosis: 

P1658 (Use of SDS)

Step

Action

Yes

No

1

9) Also, check the continuity between R wire and terminal 

“7”.

Special tool

(A):  09900–25008 (Multi circuit tester set)
(B):  09900–25009 (Needle-point probe set)

Tester knob indication
Continuity  (

)

EXCVA lead wire continuity
Continuity (

)

ECM couplers (Harness side)

Is the continuity OK?

Go to Step 2 and go to 
Step 4.

R or Y wire open, or Y 
wire shorted to ground.

(Black)

(Gray)

?

(A)

(B)

“7”

“14”

I947H1110089-01

Step

Action

Yes

No

1

1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the EXCVA coupler (1) for loose or poor contacts.

Is the connection OK?

Go to Step 6.

Loose or poor contacts 
on the EXCVA coupler.

1

I947H1110090-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-115

2

1) Turn the ignition switch OFF.

2) Check the installation of EXCV cables. If it is necessary, 

adjust the EXCV cables. Refer to “EXCV Cable Removal 
and Installation” in Section 1K (Page 1K-6).

3) Disconnect the EXCVA coupler (1).

4) Turn the ignition switch ON.

5) Measure the voltage between the R wire and ground.

6) If OK, then measure the voltage between the R wire and 

B/Br wire.

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Voltage (

)

EXCVA position sensor input voltage
4.5 – 5.5 V
((+) terminal: R – (–) terminal: Ground)
((+) terminal: R – (–) terminal: B/Br)

Is the voltage OK?

Go to Step 3.

• Loose or poor 

contacts on the ECM 
coupler (terminal “7” 
or “35”).

• Open or short circuit 

in the R or B/Br wire.

Step

Action

Yes

No

I947H1110091-01

1

I947H1110092-01

V

(A)

I947H1110093-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1A-116 Engine General Information and Diagnosis: 

3

1) Turn the ignition switch OFF.

2) Check the continuity between Y wire and ground.

Special tool

(A):  09900–25008 (Multi circuit tester set)

EXCVA position sensor continuity

 

 (Infinity)

3) If OK, then measure the EXCVA position sensor 

resistance.

4) Connect the EXCVA coupler and set the EXCVA to 

adjustment position. Refer to “EXCV Cable Removal and 
Installation” in Section 1K (Page 1K-6).

5) Disconnect the EXCVA coupler and measure the 

resistance between Y and W wires.

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Resistance (

)

EXCVA position sensor resistance at adjustment 
position
Approx. 3.1 k

((+) Y – (–) W)

Is the resistance OK?

Go to Step 4.

Replace the EXCVA 
with a new one.

Step

Action

Yes

No

(A)

I947H1110094-01

(A)

I947H1110095-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-117

4

1) Turn the ignition switch OFF.

2) Connect the EXCVA coupler.

3) Set up the SDS tools. Refer to “Self-Diagnostic 

Procedures” (Page 1A-12).

4) Turn the ignition switch ON.

5) Click “Exhaust valve operating control” (1).

6) Click “Full closed” (2).

7) Insert the needle pointed probes into the back side of the 

EXCVA coupler (3). ((+) Y – (–) W)

8) Measure the EXCVA position sensor output voltage at 

EXCV fully closed position.

Special tool

(A):  09900–25008 (Multi circuit tester set) 
(B):  09900–25009 (Needle-point probe set)

Tester knob indication
Voltage (

)

EXCVA position sensor output voltage
EXCV is fully closed: 0.45 – 1.4 V
((+) Y – (–) W)

Replace the ECM with a 
known good one, and 
inspect it again.

Go to Step 5.

Step

Action

Yes

No

1

I947H1110131-01

2

I947H1110132-01

(A)

(B)

3

I947H1110097-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1A-118 Engine General Information and Diagnosis: 

4

9) Click “Full opened” (4).

10) Measure the EXCVA position sensor output voltage at 

EXCV fully opened position.

Special tool

(A):  09900–25008 (Multi circuit tester set)
(B):  09900–25009 (Needle-point probe set)

EXCVA position sensor output voltage
EXCV is fully opened: 3.6 – 4.55 V
((+) Y – (–) W)

Is the voltage OK?

Replace the ECM with a 
known good one, and 
inspect it again.

Go to Step 5.

Step

Action

Yes

No

4

I947H1110098-02

(A)

(B)

I947H1110099-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-119

5

1) If the EXCVA position sensor output voltage is 0.45 V 

and less at EXCV fully closed position, adjust the output 
voltage to the specified value by turning the No. 1 cable 
adjuster (1). Refer to “EXCV Cable Removal and 
Installation” in Section 1K (Page 1K-6).

2) Repeat the procedure in Step 4 until the output voltage is 

set within the specified value. (If C46/P1657 code is 
indicated after adjusting the voltage, increase the 
voltage to 0.9 V).

CAUTION

!

 

• Adjusting the cable with the EXCV fully 

opened or fully closed can damage the 
EXCVA. Be sure to adjust the cable with the 
EXCV set in the adjustment position. Refer to 
“EXCV Cable Removal and Installation” in 
Section 1K (Page 1K-6)
.

• Do not turn the EXCVA pulley using a wrench.

 

3) If the EXCVA position sensor output voltage is 4.55 V 

and more at EXCV fully opened position, adjust the 
output voltage to the specified value by turning the No. 2 
cable adjuster (2). Refer to “EXCV Cable Removal and 
Installation” in Section 1K (Page 1K-6). Re
peat the 
procedure in Step 4 until the output voltage is set within 
the specified value.

EXCVA position sensor output voltage
EXCV is fully closed: 0.45 

 Output voltage 

 1.4

EXCV is fully opened: 3.6 

 Output voltage 

 4.55

Is the voltage OK?

Replace the ECM with a 
known good one, and 
inspect it again.

Replace the EXCVA 
with a new one.

Step

Action

Yes

No

2

1

I947H1110100-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1A-120 Engine General Information and Diagnosis: 

6

1) Turn the ignition switch OFF.

2) Disconnect the EXCVA coupler (1).

3) Apply 12 V to the terminals and check the operation of 

EXCVA.

4) Then, switch the wires supplied 12 V and check the 

operation of EXCVA. (Check the operation of EXCVA in 
both way.)

Is the operation OK?

• Loose or poor 

contacts on the 
EXCVA or ECM 
coupler (terminal “13” 
or “1”).

• Open or short circuit 

in the B/R wire or R/B 
wire.

• If wire and 

connection are OK, 
intermittent trouble or 
faulty ECM.

• Recheck each 

terminal and wire 
harness for open 
circuit and poor 
connection.

• Replace the ECM 

with a known good 
one, and inspect it 
again.

• Replace the EXCVA 

with a new one.

• Inspect that the 

EXCV and two cables 
move smoothly. 

Step

Action

Yes

No

1

I947H1110101-01

I947H1110102-01

I947H1110103-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-121

DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction

B947H11104030

Detected Condition and Possible Cause

Wiring Diagram

ECM coupler (Harness side)

Troubleshooting

CAUTION

!

 

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a 
needle pointed tester probe to prevent terminal damage.

 

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset 
Procedures” (Page 1A-14).

 

Detected Condition

Possible Cause

PAIR control solenoid valve voltage is not input to ECM.

• PAIR control solenoid valve circuit open or short.

• PAIR control solenoid valve malfunction.

• ECM malfunction.

ECM

PAIR

W/G

O/W

Engine
stop
switch

Ignition
switch

To side-stand
switch

Side-stand relay

PAIR control
solenoid valve

55

I837H1110103-01

1

2

3

4

5

6

7

8

9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1A-122 Engine General Information and Diagnosis: 

Step

Action

Yes

No

1

1) Turn the ignition switch OFF.

2) Remove the air cleaner box. Refer to “Air Cleaner Box 

Removal and Installation” in Section 1D (Page 1D-7).

3) Check the PAIR control solenoid valve coupler (1) for 

loose or poor contacts.
If OK, then measure the PAIR control solenoid valve 
resistance.

4) Remove the PAIR control solenoid valve. Refer to “PAIR 

Control Solenoid Valve Removal and Installation” in 
Section 1B (Page 1B-9).

5) Measure the resistance between terminals.

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Resistance (

)

PAIR control solenoid valve resistance
20 – 24 

 at 20 – 30 

°

C (68 – 86 

°

F)

(Terminal – Terminal)

Is the resistance OK?

Go to Step 2.

Replace the PAIR 
control solenoid valve 
with a new one. Refer to 
“PAIR Control Solenoid 
Valve Removal and 
Installation” in Section 
1B (Page 1B-9).

1

I947H1110143-01

(A)

I947H1110105-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-123

Active Control Inspection

1) Set up the SDS tool. (Refer to SDS operation manual for further details.)

2) Turn the ignition switch ON.

3) Click “PAIR Sol operating control” (1).

4) Click each button (2). At this time, if an operating sound is heard from the PAIR control solenoid valve, the function 

is normal.

2

1) Turn the ignition switch ON.

2) Measure the voltage between the O/W wire and ground.

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Voltage (

)

PAIR control solenoid valve voltage
Battery voltage
((+) terminal: O/W – (–) terminal: Ground)

Is the voltage OK?

• W/G wire open or 

shorted to ground, or 
poor “55” connection 
failure.

• If wire and 

connection are OK, 
intermittent trouble or 
faulty ECM.

• Recheck each 

terminal and wire 
harness for open 
circuit and poor 
connection.

• Replace the ECM 

with a known good 
one, and inspect it 
again. Refer to “ECM 
Removal and 
Installation” in 
Section 1C 
(Page 1C-1)
.

Open or short circuit in 
the O/W wire.

Step

Action

Yes

No

V

(A)

I947H1110106-02

1

I947H1110133-01

2

I947H1110134-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1A-124 Engine General Information and Diagnosis: 

DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction

B947H11104031

Detected Condition and Possible Cause

Wiring Diagram

ECM coupler (Harness side)

Troubleshooting

CAUTION

!

 

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a 
needle pointed tester probe to prevent terminal damage.

 

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset 
Procedures” (Page 1A-14).

 

Detected Condition

Possible Cause

Cooling fan relay signal is not input to ECM.

• Cooling fan relay circuit open or short.

• ECM malfunction.

42

ECM

Side-stand  
relay

Ignition  
switch

Engine stop  
switch

FAR

G/R

O/W

Cooling fan
motor

Cooling fan
relay

To Side-stand 
switch

I837H1110109-02

1

2

3

4

5

6

7

8

9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-125

Active Control Inspection

1) Set up the SDS tool. (Refer to SDS operation manual for further details.)

2) Start the engine and run it in idling condition.

3) Click “Cooling fan relay control” (1).

Step

Action

Yes

No

1

1) Turn the ignition switch OFF.

2) Remove the frame covers. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the cooling fan relay (1) coupler for loose or poor 

contacts.
If OK, then inspection the cooling fan relay. Refer to 
“Cooling Fan Inspection” in Section 1F (Page 1F-9).

Is the cooling fan relay OK?

• O/W and G/R wire 

open or shorted to 
ground, or poor “42” 
connection.

• If wire and 

connection are OK, 
intermittent trouble or 
faulty ECM.

• Recheck each 

terminal and wire 
harness for open 
circuit and poor 
connection.

• Replace the ECM 

with a known good 
one, and inspect it 
again. Refer to “ECM 
Removal and 
Installation” in 
Section 1C 
(Page 1C-1)
.

Replace the cooling fan 
relay with a new one.

1

I947H1110107-01

1

I947H1110135-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1A-126 Engine General Information and Diagnosis: 

4) Click the “Operate” (2).

At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the 
function is normal.

NOTE

The cooling fan relay and cooling fan motor inspection is operational at any engine coolant 
temperature until reaching 100 

°

C (212 

°

F). In a hot engine condition with the intake air temperature 

exceeding 40 

°

C (104 

°

F), however, the engine coolant temperature at which the inspection is 

operational will be restricted to 95 

°

C (203 

°

F).

 

5) Click the “Stop” (3) to check the operation properly.

6) Click the “Off” (4) to check the cooling fan relay and cooling fan motor operation.

NOTE

• This inspection should be begun from when the engine coolant temperature is below 50 

°

C (122 

°

F). 

Check that the cooling fan relay operates for a few seconds as the engine coolant temperature 
reaches each temp. of 50 

°

C (122 

°

F), 70 

°

C (158 

°

F), 90 

°

C (194 

°

F) and 110 

°

C (230 

°

F)/above 4 000 r/

min. It is cooling fan motor malfunction or its circuit failure when the motor would not run even if the 
relay turns ON.

• There is a tolerance of operating temperature of cooling fan relay.

 

2

I947H1110136-03

3

I947H1110137-03

4

I947H1110138-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-127

DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only)

B947H11104032

Detected Condition and Possible Cause

Wiring Diagram

ECM coupler (Harness side)

Troubleshooting

CAUTION

!

 

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a 
needle pointed tester probe to prevent terminal damage.

 

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset 
Procedures” (Page 1A-14).

 

Detected Condition

Possible Cause

EVAP system purge control valve voltage is not input to 
ECM.

• EVAP system purge control valve circuit open or short.

• EVAP system purge control valve malfunction.

• ECM malfunction.

ECM

EVAP

Dbr

O/W

Engine
stop
switch

Ignition
switch

To side-stand
switch

Side-stand relay

EVAP purge control valve

61

I837H1110113-01

1

2

3

4

5

6

7

8

9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1A-128 Engine General Information and Diagnosis: 

Step

Action

Yes

No

1

1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank 

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the EVAP system purge control valve coupler (1) 

for loose or poor contacts.
If OK, then measure the EVAP system purge control 
valve resistance.

4) Disconnect the EVAP system purge control valve 

coupler.

5) Measure the resistance between terminals.

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Resistance (

)

EVAP system purge control valve resistance
Approx. 32 

 at 20 

°

C (68 

°

F)

(Terminal – Terminal)

Is the resistance OK?

Go to Step 2.

Replace the EVAP 
system purge control 
with a new one. Refer to 
“Evaporative Emission 
Control System 
Removal and 
Installation (Only for E-
33)” in Section 1B 
(Page 1B-12)
.

1

I947H1110108-01

(A)

I947H1110109-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-129

2

1) Turn the ignition switch ON.

2) Measure the voltage between the O/W wire and ground.

Special tool

(A):  09900–25008 (Multi circuit tester set)

Tester knob indication
Voltage (

)

EVAP system purge control valve voltage
Battery voltage
((+) terminal: O/W – (–) terminal: Ground)

Is the voltage OK?

• Dbr wire open or 

shorted to ground, or 
poor “61” connection 
failure.

• If wire and 

connection are OK, 
intermittent trouble or 
faulty ECM.

• Recheck each 

terminal and wire 
harness for open 
circuit and poor 
connection.

• Replace the ECM 

with a known good 
one, and inspect it 
again. Refer to “ECM 
Removal and 
Installation” in 
Section 1C 
(Page 1C-1)
.

Open or short circuit in 
the O/W wire.

Step

Action

Yes

No

V

(A)

I718H2110003-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

 

 

 

 

 

 

 

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