01550-08857 Suzuki BOLT

Illustration 1 g00932971
Test Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connector J1/P1. Inspect the machine connector J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the machine connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the Sensor Supply Voltage at the Sensor Connector.
Turn the keyswitch to the OFF position.
Disconnect the brake oil temperature sensor at the sensor connector.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin A and pin B for the suspect sensor.
Turn the keyswitch to the OFF position.
Reconnect the brake oil temperature sensor.Expected Result:The supply voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. Proceed to Test Step 4.
Not OK - The voltage is not 24 3 VDC. Proceed to Test Step 3.Test Step 3. Check the Sensor Supply Voltage at the ECM.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Check the supply voltage by removing wires P1-57 (150-OR) and P1-9 (998-BR) from ECM connector P1. Install a wire jumper into the sockets for P1-57 and for P1-9.Note: If you remove the sensor common from the ECM, an open circuit diagnostic code will be generated for all sensors that use the sensor common. Troubleshoot the original code. Delete the logged diagnostic codes when you are finished.
Reconnect ECM connector J1/P1.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage between the wire jumper in P1-57 and the wire jumper in P1-9.
Turn the keyswitch to the OFF position.
Remove the wire jumpers and replace all wires. Reconnect ECM connector J1/P1.Expected Result:The supply voltage is 24 3 VDC.Results:
OK - The supply voltage is 24 3 VDC. The supply voltage at the ECM is correct. There is a problem in the wiring between the ECM and the suspect sensor. Proceed to Test Step 6.
Not OK - The supply voltage is not 24 3 VDC. The voltage at the ECM is not correct.Repair: Perform the diagnostic functional test Troubleshooting, "Electrical Power Supply". Stop.Test Step 4. Check the Sensor's Signal Frequency and the Duty Cycle at the Sensor Connector.
Turn the keyswitch to the OFF position.
Remove the sensor's signal wire from pin C of the sensor connector.
Turn the keyswitch to the ON position. The engine should be off.
Use a digital multimeter to measure the frequency and the duty cycle between the sensor's signal wire and pin B of the suspect sensor at the sensor connector.
Turn the keyswitch to the OFF position.
Replace the sensor's signal wire and reconnect the sensor.Expected Result:The frequency reading is between 4000 Hz and 5700 Hz.When the temperature is below -40 °C (-40 °F), the duty cycle is between 0 percent to 10 percent.When the temperature is between 0 °C (32 °F) and 120 °C (248 °F), the duty cycle is between 22 percent to 88 percent.Results:
OK - The frequency and the duty cycle are correct. Proceed to Test Step 5.
Not OK - The frequency and the duty cycle are not correct.Repair: Replace the sensor. Stop.Test Step 5. Check the Digital Sensor's Signal Frequency and the Duty Cycle at the ECM.
Turn the keyswitch to the ON position. The engine should be off.
Use a digital multimeter to measure the frequency and the duty cycle between P1-5 and P1-9 at the ECM connector P1.
Turn the keyswitch to the OFF position.Expected Result:The frequency reading is between 4000 Hz and 5700 Hz.When the temperature is below -40 °C (-40 °F), the duty cycle should be between 0% to 10%.When the temperature is between 0 °C (32 °F) and 120 °C (248 °F), the duty cycle is between 22 percent to 88 percent.Results:
OK - The frequency and the duty cycle at the ECM are correct.Repair: There may be an intermittent problem. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - The frequency and the duty cycle at the ECM are NOT correct. Proceed to Test Step 6.
ABNORMAL SIGNAL - The frequency and the duty cycle at the ECM is correct. The status screen on the Cat ET displays "ABNORMAL SIGNAL". The signal is out of normal range.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM". Stop.Test Step 6. Check for Shorts in the Wiring Harness.
Disconnect the ECM connector J1/P1. Disconnect the suspect sensor.
Measure the resistance between the sensor signal wire and engine ground.
Measure the resistance between the sensor common and engine ground.
Measure the resistance between the supply wire for the sensor and the engine ground.
Reconnect all connectors and all sensors.Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 7.
Not OK - The resistance is less than 20,000 Ohms.Repair: There is a short in the wiring harness. Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 7. Check the Resistance through the Harness.
Disconnect the suspect sensor connector.
Use a suitable piece of wire to connect pin A