09140-06021 Suzuki NUT

Illustration 1 g01199554
Schematic for the electrical power supply circuit
Illustration 2 g01183529
J1/P1 ECM connectors (typical left side engine view)
Illustration 3 g01112632
P1 connections for the electrical power supply circuit
(P1-48) +Battery
(P1-52) +Battery
(P1-53) +Battery
(P1-61) −Battery
(P1-63) −Battery
(P1-65) −Battery
(P1-70) Keyswitch
Table 1
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Remove electrical power from the engine ECM.
B. Thoroughly inspect the J1/P1 ECM connectors. Inspect all of the connectors that are in the circuit. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
D. Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
E. Check the harness and the wiring for abrasion and for pinch points.
Electrical Connectors and Wiring
Result: The harness and wiring appear to be OK.
Proceed to Test Step 2.
Result: 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.
STOP
2. Check the Battery Voltage at the ECM
A. Remove electrical power from the engine ECM.
B. Disconnect the J1/P1 ECM connector.
C. Restore electrical power to the engine ECM.
D. Measure the voltage between P1-48 (Unswitched +Battery) and P1-61 (−Battery).
E. Measure the voltage between P1-52 (Unswitched +Battery) and P1-63 (−Battery).
F. Measure the voltage between P1-53 (Unswitched +Battery) and P1-65 (−Battery).
G. Measure the voltage between P1-70 (Keyswitch) and P1-63 (−Battery).
Voltage is between 22 VDC and 27 VDC
Result: The ECM is receiving the correct voltage.
Repair: There may be an intermittent electrical problem in a harness or in a connector. If an intermittent condition is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".
STOP
Result: The voltage is not correct for one of the unswitched battery circuits at the ECM.
Proceed to Test Step 3.
Result: The voltage is not correct for the keyswitch circuit at the ECM.
Proceed to Test Step 4.
3. Check the Batteries
A. Measure the no-load battery voltage at the battery posts.
B. Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 Volt and 12 Volt Lead Acid Batteries" and Special Instruction, SEHS7633, "Battery Test Procedure".
Load Test
Result: The batteries pass the load test.
Repair: The batteries are OK. There is an open circuit or excessive resistance in the wiring or connections between the batteries and the ECM. Verify that the 15 Amp circuit breaker for the ECM is not tripped. Verify that the connection at the engine ground stud is clean and tight and that the battery disconnect switch is functioning properly. Repair the connectors or wiring and/or replace the connectors or wiring between the battery and the ECM connector J1/P1.
STOP
Result: The battery voltage is low or the battery did not pass the load test.
Repair: Recharge or replace the faulty batteries. Verify that the repair eliminates the problem.
STOP
4. Check the Voltage from the Keyswitch to the ECM
A. Remove electrical power from the engine ECM.
B. Remove the wire from the terminal R of the keyswitch.
C. Restore electrical power to the engine ECM.
D. Turn the keyswitch to the ON position.
E. Measure the voltage on terminal B of the keyswitch to engine ground.
F. Measure the voltage on terminal R of the keyswitch to engine ground.
G. Remove electrical power from the engine ECM.
Voltage
Result: Voltage is present on terminal B and terminal R at the keyswitch.
Proceed to Test Step 5.
Result: Voltage is not present on terminal B at the keyswitch.
Repair: If voltage is not present on terminal B, repair the circuit between the +Battery and the keyswitch. Check the circuit protection for the circuit. Verify that the problem is eliminated.
STOP
Result: Voltage is not present on terminal R at the keyswitch.
Repair: If voltage is present on terminal B of the keyswitch but not present on terminal R, replace the keyswitch. Return all wiring to the original configuration. Verify that the problem is eliminated.
STOP
5. Check the Voltage from the Main Relay to the "ECM Switch Fuse"
A. Remove the wire from the normally open terminal of the main relay.
B. Turn the keyswitch to the ON position.
C. Measure the voltage between the normally open terminal of the main relay and engine ground.
D. Turn the keyswitch to the OFF position.
E. Reconnect all wires to the original configuration.
24 3.0 VDC
Result: The voltage measures 24 3.0 VDC.
Repair: Verify that the "ECM Switch Fuse" is not blown. Repair the wire between the main relay and the fuse for the engine control or repair the wire between the fuse for the engine control and the ECM connector P1.
STOP
Result: The voltage does not measure 24 3.0 VDC.
Proceed to Test Step 6.
6. Check the Voltage at the Main Relay
A. Remove the wire 308-YL(Yellow)from the coil of the main relay.
B. Remove the wire 101-RD(Red)from the normally open contact of the main relay.
C. Turn the keyswitch to the ON position.
D. Measure the voltage between wire 308-YL(Yellow)and engine ground.
E. Measure the voltage between wire 101-RD(Red)and engine ground.
F. Reconnect all wires to the original configuration.
24 3.0 VDC
Result: The voltage measures 24 3.0 VDC on both wires.
Repair: Verify that the wire 200-BK(Black)has