09491-91002 Suzuki JET, MAIN (91.3)

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Schematic
Test Step 1. Inspect the Electrical Connectors and the Wiring
Remove electrical power from the ECM.
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(1) J1/P1
Thoroughly inspect the J1/P1 ECM connectors and the J700/P700 engine shutdown switch connector. Also inspect each of the machine connectors that are in the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
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Terminal locations at the P1 ECM connector
(P1-5) Digital sensor return
(P1-40) Engine shutdown switch (N/C)
(P1-23) Engine shutdown switch (N/O)
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Harness connector for the engine shutdown switch
(Terminal A) Engine shutdown switch (N/C)
(Terminal B) Digital return
(Terminal C) Engine shutdown switch (N/O)
Perform a 45 N (10 lb) pull test on each of the wires for the engine shutdown switch.
Check the torque of the allen head screw on the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the switch back to the ECM. Expected Result:All of the connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and the connectors appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. 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 Shutdown Switch on Cat ET
Connect Cat ET to the service tool connector.
Restore electrical power to the ECM.
Monitor the status screen on Cat ET while you operate the shutdown switch. Observe the status for the shutdown switch. Note: Wait at least 30 seconds for the status of the switch to change.Expected Result:The status of the shutdown switch reads "ON" with the shutdown switch in the STOP position. The status of the shutdown switch reads "OFF" when the shutdown switch is in the RUN position.Results:
OK - The status of the shutdown switch reads "ON" with the shutdown switch in the STOP position. The status of the shutdown switch reads "OFF" when the shutdown switch is in the RUN position. The shutdown switch is operating normally.Repair: The circuit for the shutdown switch appears to be operating correctly. There may be an intermittent problem in the harness or in a connector. If an intermittent problem is suspected, refer to Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - The status of the switch does not read "ON" with the shutdown switch in the STOP position. The status of the shutdown switch does not read "OFF" when the shutdown switch is in the RUN position. There is a problem with the circuit for the shutdown switch. There may be a problem with the ECM. Proceed to Test Step 3.Test Step 3. Short the Terminals at the Harness Connector for the Shutdown Switch
Remove electrical power from the ECM.
Fabricate a jumper wire that is long enough to short circuit two terminals at the harness connector for the shutdown switch. Crimp connector pins to each end of the jumper wire.
Disconnect the harness connector for the shutdown switch.
Check the status of the shutdown switch while the circuit is shorted to the RUN position.
Install the jumper wire between terminals B (digital return) and A (engine shutdown switch (N/C)) at the harness connector for the switch.
Restore electrical power to the ECM.
Observe the status of the shutdown switch on Cat ET. Note: Wait at least 30 seconds for the status of the switch to change.The correct status for the shutdown switch is "OFF".
Remove electrical power from the ECM.
Check the status of the shutdown switch while the circuit is shorted to the STOP position.
Install the jumper wire between terminals C (engine shutdown switch (N/O)) and B (digital return) at the harness connector for the switch.
Restore electrical power to the ECM.
Observe the status of the shutdown switch on Cat ET. Note: Wait at least 30 seconds for the status of the switch to change.The correct status for the shutdown switch is "ON".
Remove electrical power from the ECM.
Remove the jumper wire from the harness connector. Expected Result:The switch status on Cat ET agrees with the test results that are stated above.Results:
OK - The switch status on Cat ET agrees with the test results.Repair: There is a problem with the shutdown switch. Replace the shutdown switch. Verify that the new shutdown switch solves the problem.STOP
Not OK - The switch status on Cat ET does not agree with the test results that are stated above. The problem is in the harness between the ECM and the harness connector for the switch. There may be a problem with the ECM. Proceed to Test Step 4.Test Step 4. Short the Terminals for the Shutdown Switch at the ECM
Disconnect the J1/P1 ECM connectors.
Fabricate three jumper wires that are long enough to short circuit terminals at the P1 ECM connector. Crimp connector sockets to one end of each of the jumper wires.
Remove the wires from terminal locations P1-5, P1-23, and P1-40 at the ECM connector. Install a jumper wire into each of these terminal locations.
Check the status of the shutdown switch while the circuit is shorted to the RUN position.
Short circuit the ends of the jumper wires that are