Suzuki GF60A - Section 1 Power Head; Power Head; Table of Contents

Table of Contents 1- i
1
Section 1
CONTENTS
Power Head
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Powerhead................................... 1-1
Engine Control......................................... 1A-1
Precautions...........................................................1A-1
Precautions on Engine Diagnosis ....................... 1A-1
General Description .............................................1A-2
Engine Control System Description ....................1A-2
Engine Control Module (ECM) ............................1A-4
Caution System Description................................ 1A-7
Self-Diagnostic System Description.................. 1A-10
Fail-Safe System Description............................ 1A-12
Operating Hour Indication System
Description ......................................................1A-12
Oil Change Reminder System Description........ 1A-14
Component Location .........................................1A-15
Engine Control System Components / Engine
Electrical Device Location............................... 1A-15
Diagnostic Information and Procedures..........1A-15
ECM Power and Ground Circuit Check............. 1A-15
Troubleshooting with Self-Diagnostic Code ......1A-16
Self-Diagnostic Code “3 – 4” MAP Sensor........1A-17
Self-Diagnostic Code “1 – 4” Cylinder Temp.
Sensor.............................................................1A-19
Self-Diagnostic Code “2 – 3” IAT Sensor.......... 1A-20
Self-Diagnostic Code “4 – 2” CKP Sensor ........1A-21
Self-Diagnostic Code “2 – 4” CMP Sensor........ 1A-22
Self-Diagnostic Code “2 – 2” Air Intake
System ............................................................1A-23
Self-Diagnostic Code “3 – 2” MAP Sensor 2.....1A-24
Self-Diagnostic Code “4 – 3” Fuel Injector ........1A-25
Self-Diagnostic Code “2 – 1” TPS (Throttle
Position Sensor).............................................. 1A-26
Self-Diagnostic Code “1 – 1” Rectifier/
Regulator (Over Charging).............................. 1A-28
Self-Diagnostic Code “5 – 3” Oil Pressure
Switch ............................................................. 1A-28
Self-Diagnostic Code “3 – 7” Trim Sensor ........ 1A-29
Troubleshooting Without Self-Diagnostic
Code ............................................................... 1A-30
IAC System Troubleshooting ............................ 1A-31
Service Instructions...........................................1A-32
How to Use the 36 Pin Test Cord Set ............... 1A-32
Inspection of the ECM and Its Circuit................1A-32
ECM Main Relay Inspection..............................1A-35
Engine Electrical Devices ....................... 1C-1
Precautions...........................................................1C-1
Precaution for Engine Electrical Device ..............1C-1
General Description .............................................1C-1
Sensor and Switch Description ...........................1C-1
ECM Power Source Line.....................................1C-6
Component Location ...........................................1C-7
Location of Sensor and Switch............................1C-7
Service Instructions.............................................1C-7
Resistance Check ...............................................1C-7
Cylinder Temp. Sensor Removal and
Installation .........................................................1C-8
Cylinder Temp. Sensor Inspection ......................1C-8
MAP Sensor / TPS / IAT sensor Removal and
Installation .........................................................1C-9
Throttle Position Sensor Calibration....................1C-9
CKP Sensor Removal and Installation ................1C-9
CKP Sensor Inspection .....................................1C-10
IAT Sensor Inspection.......................................1C-10
CMP Sensor Removal and Installation .............1C-11
CMP Sensor Inspection ....................................1C-11
MAP Sensor Output Voltage Inspection............1C-12
IAC Valve Removal and Installation..................1C-12
IAC Valve Inspection.........................................1C-13
TPS Inspection..................................................1C-13
Trim Sensor Inspection .....................................1C-14
Emergency Stop Switch Inspection...................1C-15
Power Unit Mechanical ........................... 1D-1
General Description .............................................1D-1
Power Unit Construction Description ..................1D-1
Diagnostic Information and Procedures............1D-1
Cylinder Compression Check..............................1D-1
Oil Pressure Check .............................................1D-1
Service Instructions.............................................1D-2
Tappet Clearance Inspection ..............................1D-2
Ring Gear Cover Removal and Installation.........1D-2
Cylinder Head Cover Removal and
Installation .........................................................1D-2
Air Intake Silencer Case Removal and
Installation .........................................................1D-4
Electric Parts Holder Removal and Installation ....1D-4