09117-06032 Suzuki BOLT

Illustration 1 g01142765
Schematic
Illustration 2 g01140772
P1 ECM connector
(P1-5) Digital return
(P1-10) Ether solenoid
(P1-18) Solenoid return
(P1-22) Either switch
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Turn the battery disconnect switch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors for the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" 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.
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, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Status of the Ether Switch
Remove the ether canister from the ether solenoid.
Connect the Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Press the starting aid switch to "MANUAL". Observe the status of "Ether Switch" on Cat ET. Expected Result:When the starting aid switch is pressed, Cat ET displays the status of the switch as "On".When the starting aid switch is not pressed, Cat ET displays the status of the switch as "Off".Results:
OK - The starting aid switch is operating correctly. Proceed to Test Step 5.
Not OK - There may be a problem with the switch circuit. Proceed to Test Step 3.Test Step 3. Short the Switch Wires
Turn the keyswitch to the ON position.
Disconnect the starting aid switch.
Observe the status of "Ether Switch" on Cat ET. Note: The status should be "Off".
Install a jumper wire between terminal 2 and terminal 3 in the plug for the starting aid switch.
Observe the status of "Ether Switch" on Cat ET. Note: The status should be "On".Expected Result:When the terminals are shorted, Cat ET displays the status of the starting aid switch as "On".When the terminals are not shorted, Cat ET displays the status of the starting aid switch as "Off".Results:
OK - The ECM and the harness are OK, but the starting aid switch is not operating correctly.Repair: Replace the starting aid switch.Verify that the repair eliminates the problem.STOP
Not OK - There may be a problem with the harness. Proceed to Test Step 4.Test Step 4. Short the Switch Inputs at the ECM
Turn the keyswitch to the OFF/RESET position.
Remove the wires from P1:22 (Starting Aid Switch) and P1:5 (Digital Return).
Turn the keyswitch to the ON position.
Observe the status of "Ether Switch" on Cat ET. Note: The status should be "Off".
Install a jumper wire with Deutsch sockets on each end between P1:22 (Starting Aid Switch) and P1:5 (Digital Return).
Turn the keyswitch to the ON position.
Observe the status of "Ether Switch" on Cat ET. Note: The status should be "On".
Remove the jumper wire and reinstall the wires in the P1 connector. Expected Result:When the jumper wire is installed, Cat ET displays the status of the switch as "On".When the jumper wire is not installed, Cat ET displays the status of the starting aid switch as "Off".Results:
OK - The ECM is operating correctly. There is a problem in the wiring between the switch and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOP
Not OK - There is a problem with the solenoid circuit or the ECM.Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.Verify that the repair eliminates the problem.STOPTest Step 5. Check for Active Diagnostic CodesNote: The ether canister must be removed prior to activating this test.
Turn the battery disconnect switch to the ON position.
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The diagnostic override will activate for ten seconds.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in