31100-95240 Suzuki Motor Assembly, starting

Illustration 1 g03836628
Schematic for the start relay
Illustration 2 g03836694Note: When investigating a 677-4 code, disconnect the wires from the starting motor and insulate the wire terminals.Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Inspect the terminals on the start relay. Refer to Troubleshooting, "Electrical Connector - Inspect" for details.
B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the start relay.
C. Check the harness for abrasion and pinch points from the start relay back to the ECMs.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all of the seals are properly in place and ensure that the connectors are correctly coupled.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points. The fuses are not blown.
Proceed to Test Step 2.
2. Check for Active Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector.
B. Turn the keyswitch to the ON position.
Note: Do not start the engine.
C. Use the electronic service tool to check for active diagnostic codes.
D. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: Diagnostic code 677-3 is active or recently logged.
Proceed to Test Step 3.
Result: Diagnostic code 677-4 is active or recently logged.
Proceed to Test Step 6.
3. Check the Supply Voltage at the Start Relay Connector
A. Remove the start relay.
B. Turn the keyswitch to the START position.
C. Measure the voltage between Test Point 1 on the relay socket and a suitable ground.
D. Turn the keyswitch to the OFF position.
E. Install the start relay.
At least 11 VDC
Result: The voltage is not within the expected range.
Repair: Repair or replace the supply wiring to the start relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The voltage is within the expected range.
Proceed to Test Step 4.
4. Check the Return Wire from the Start Relay to the Engine ECM
A. Turn the keyswitch to the OFF position.
B. Remove the start relay.
C. Disconnect the P2 connector from the engine ECM.
D. Measure the resistance between Test Point 2 on the start relay socket and P2:92.
E. Connect the P2 connector to the engine ECM.
F. Install the start relay.
Less than 2.0 Ohms
Result: The measured resistance is more than 2.0 Ohms.
Repair: Repair or replace the return wiring from the start relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured resistance is less than 2.0 Ohms.
Proceed to Test Step 5.
5. Check the Start Relay Solenoid for an Open Circuit
A. Verify that the keyswitch is in the OFF position.
B. Remove the start relay.
C. Measure the resistance between Test Points 1 and 2 on the start relay. Refer to Illustration 2.
D. Install the start relay.
81 to 113 Ohms
Result: The measured resistance is more than 81 to 133 Ohms.
Repair: Install a replacement start relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured resistance is within 81 to 133 Ohms.
Contact the Dealer Solutions Network (DSN).
6. Check the Wiring for a Short Circuit
A. Turn the keyswitch to the OFF position.
B. Remove the start relay.
C. Disconnect the P2 connector from the engine ECM.
D. Disconnect the P1 connector from the engine ECM.
F. Check the resistance between P2:92 and all other pins on the P2 connector for the engine ECM.
G. Check the resistance between P1:54 and all other pins on the P1 connector for the engine ECM.
H. Reconnect the P1 connector to the machine ECM.
I. Reconnect the P1 connector to the engine ECM.
J. Reconnect the P2 connector to the engine ECM.
More than 1k Ohm
Result: One or more resistance measurements are less than 1k Ohm.
Repair: Repair or replace the wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All resistance measurements are more than 1k Ohm.
Proceed to Test Step 7.
7. Check the Start Relay Solenoid for a Short Circuit
A. Verify that the keyswitch is in the OFF position.
B. Remove the start relay.
C. Measure the resistance between Test Points 1 and 2 on the start relay. Refer to Illustration 2.
D. Install the start relay.
81 to 113 Ohms
Result: The measured resistance is less than 81 to 133 Ohms.
Repair: Install a replacement start relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured resistance is within 81 to 133 Ohms.
Proceed to Test Step 8.
8. Perform a Start Relay Override Test
A. Verify that the keyswitch is in the OFF position.
B. Disconnect the wire from the starting motor solenoid.
C. Turn the keyswitch to the ON position.
D. Use the electronic service tool to perform the Start Relay Override Service Test.
E. Measure the voltage between the starting motor solenoid wire and a suitable ground.
F. Stop the Start Relay Override Service Test.
G. Turn the keyswitch to the OFF position.
H. Reconnect the wire to the starting motor solenoid.
81 to 113 Ohms
Result: The measured voltage is equal to battery voltage.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured voltage is not battery voltage.
Contact the Dealer Solutions Network (DSN).