Suzuki kq500 User Manual

Table of Contents 1- i
1
Section 1
CONTENTS
Engine
Precautions.................................................1-1
Precautions............................................................. 1-1
Precautions for Engine.......................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
General Description.............................................1A-1
Injection Timing Description................................1A-1
Schematic and Routing Diagram........................1A-4
FI System Wiring Diagram ..................................1A-4
Terminal Alignment of ECM Coupler...................1A-5
Component Location ...........................................1A-6
FI System Parts Location....................................1A-6
Diagnostic Information and Procedures............1A-7
Engine Symptom Diagnosis................................1A-7
Self-Diagnostic Procedures ..............................1A-10
Use of SDS Diagnosis Reset Procedures.........1A-12
Show Data When Trouble (Displaying Data at
the Time of DTC) ............................................1A-13
SDS Check .......................................................1A-15
DTC Table.........................................................1A-18
Fail-Safe Function Table...................................1A-18
FI System Troubleshooting...............................1A-19
Malfunction Code and Defective Condition
Table...............................................................1A-21
DTC “C12” (P0335): CKP Sensor Circuit
Malfunction......................................................1A-23
DTC “C13” (P0105-H/L): IAP Sensor Circuit
Malfunction......................................................1A-26
DTC “C14” (P0120-H/L): TP Sensor Circuit
Malfunction......................................................1A-33
DTC “C15” (P0115-H/L): ECT Sensor Circuit
Malfunction......................................................1A-40
DTC “C20” (P1752): Diff-lock Relay Circuit
Malfunction......................................................1A-45
DTC “C21” (P0110-H/L): IAT Sensor Circuit
Malfunction......................................................1A-47
DTC “C23” (P1651-H/L): TO Sensor Circuit
Malfunction......................................................1A-52
DTC “C24” (P0351): Ignition Coil Circuit
Malfunction......................................................1A-59
DTC “C32” (P0201): Fuel Injector Circuit
Malfunction......................................................1A-59
DTC “C40” (P0505-H/L): ISC Valve Circuit
Malfunction......................................................1A-62
DTC “C41” (P230-H/L): FP Relay Circuit
Malfunction......................................................1A-68
Specifications.....................................................1A-70
Service Data......................................................1A-70
Special Tools and Equipment...........................1A-71
Special Tool ......................................................1A-71
Emission Control Devices ...................... 1B-1
Precautions...........................................................1B-1
Precautions for Emission Control Devices..........1B-1
Repair Instructions ..............................................1B-1
Crankcase Breather (PCV) Hose Inspection.......1B-1
Crankcase Breather (PCV) Hose Removal
and Installation..................................................1B-1
Engine Electrical Devices.......................1C-1
Precautions...........................................................1C-1
Precautions for Engine Electrical Device ............1C-1
Component Location ...........................................1C-1
Engine Electrical Components Location .............1C-1
Diagnostic Information and Procedures............1C-1
Engine Symptom Diagnosis................................1C-1
Repair Instructions ..............................................1C-1
ECM Removal and Installation............................1C-1
CKP Sensor Inspection.......................................1C-1
CKP Sensor Removal and Installation................1C-2
IAP / TP / IAT Sensor Inspection ........................1C-2
IAP / TP / IAT Sensor Removal and
Installation.........................................................1C-2
ECT Sensor Removal and Installation ................1C-2
ECT Sensor Inspection .......................................1C-3
TO Sensor Inspection .........................................1C-3
TO Sensor Removal and Installation ..................1C-3
ISC Valve Inspection...........................................1C-3
ISC Valve Removal and Installation....................1C-4
GP Switch Inspection..........................................1C-4
GP Switch Removal and Installation...................1C-4
Specifications.......................................................1C-5
Service Data........................................................1C-5
Tightening Torque Specifications........................1C-5
Special Tools and Equipment.............................1C-5
Special Tool ........................................................1C-5

Suzuki kq500 Specifications

General

Brand	Suzuki
Model	kq500
Category	Offroad Vehicle
Language	English