User manual SUZUKI GSX-R600

[. . . ] GSX-R600 99500-35100-01E FOREWORD This manual contains an introductory description on the SUZUKI GSX-R600 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. [. . . ] POSSIBLE CAUSE · HO2 sensor circuit open or shorted to ground. · Battery voltage supply to the HO2 sensor. C44 (P0135) ECM E2 OX OXH B/Br W/G W/B O/W To GP switch W B Gr W Engine stop Side-stand relay switch Ignition switch INSPECTION Step 1 (When indicating C44/P0130:) 1) Turn the ignition switch OFF. (5-3) 3) Check the HO2 sensor for loose or poor contacts. If OK, then check the HO2 sensor lead wire continuity. A S P M HO2 sensor E L 1 1 ! 4) Disconnect the HO2 sensor coupler 5) Check the continuity between W/G wire A and ground. 6) Also, check the continuity between W/G wire A and B/Br wire B. If the sound is not heard from the tester, the circuit condition is OK. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test () 4-88 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. 8) Check the continuity between W/G wire A and terminal B. 9) Also, check the continuity between B/Br wire B and terminal S. HO2S lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Continuity test () When using the multi-circuit tester, do not storongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. (When indicating C44/P0130:) W/G wire shorted to ground, or W/G or B/Br wire open. 1 ! ECM couplers (Harness side) 10)After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 2 (When indicating C44/P0130:) 1) Connect the ECM couplers and HO2 sensor coupler. 3) Measure the HO2 sensor output voltage between W/G wire and B/Br wire, when idling condition. HO2 sensor output voltage at idle speed: 0. 4 V and less (+ W/G ­ - B/Br) A S P M 2 E L V 4) If OK, then remove the air cleaner box (5-14) and pinch the PAIR hoses 1 with proper hose clamps. 5) Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r/min. HO2 sensor output voltage at 5 000 r/min: 0. 6 V and more (+ W/G ­ - B/Br) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Voltage () FI SYSTEM DIAGNOSIS 4-89 Is the voltage OK?· W/G wire or B/Br wire open or shorted to ground, or poor B or S 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. Replace the HO2 sensor with a new one. 2 ECM couplers (Harness side) YES NO When using the multi-circuit tester, do not storongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. 6) After repairing the trouble, clear the DTC using SDS tool. [. . . ] · If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. · Set new gasket to the PAIR reed valve. · Install the PAIR reed valve assembly on the cam shaft journal holder with facing the projection A exhaust side. · Install the cylinder head cover. (3-97) A S P M E L PCV HOSE · Remove the PCV hose between air cleaner box and crankcase breather cover. [. . . ]