36620-93J01 Suzuki WIRE ASSY, REMOTE CONTROL

Illustration 1 g00755287
Schematic
Test Step 1. Inspect Electrical Connectors and Wiring
Illustration 2 g01089706
Terminal locations for ECM
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the harness connector J1/P1 and the machine connector J3/P3. Also inspect the connections for the battery to the ECM. Inspect the connections from the keyswitch to the ECM. Refer to the diagnostic functional test 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 following connections:
P1:04 (+Battery (unswitched))
P1:05 (−Battery)
P1:06 (+Battery (switched))
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Also, check the harness and wiring for abrasions and for pinch points from the keyswitch to the ECM. 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 connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with the connectors 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.STOPTest Step 2. Check the Battery Voltage at the ECM
Disconnect engine harness connector P1 from ECM connector J1.
Turn the battery disconnect switch to the ON position.
Turn the keyswitch to the ON position.
Measure the voltage between terminal P1:04 (+Battery (unswitched)) and engine ground.
Measure the voltage between terminal P1:06 (+Battery (switched)) and engine ground. Expected Result:The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system.Results:
OK - The ECM is receiving the correct battery voltage.Repair: Verify that the negative battery wires from the ECM have continuity to the negative terminal of the battery. If necessary, repair the negative battery wires. If an intermittent condition is suspected, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The battery voltage at the ECM is out of normal range. Proceed to Test Step 3.
Not OK - The voltage at terminal P1:06 is out of normal range. Proceed to Test Step 5.Test Step 3. Check the Batteries
Measure no-load battery voltage at the battery posts.
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 and 12 Volt Lead Acid Batteries" and Special Instruction, SEHS7633, "Battery Test Procedure". Expected Result:The batteries pass the load test. The measured voltage is the minimum specification for a 12V or 24V system.Results:
OK - The battery voltage meets minimum specifications. Proceed to Test Step 4.
Not OK - The battery voltage does not meet minimum specifications.Repair: Recharge or replace the faulty batteries. Verify that the repair eliminates the problem.STOPTest Step 4. Check the Voltage from the 15 amp Circuit Breaker to the ECM
Measure the voltage from the 15 amp circuit breaker that is between the battery disconnect switch and the ECM. Measure the voltage between the 15 amp circuit breaker and engine ground. Expected Result:The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system.Results:
OK - The correct voltage is present at the 15 amp circuit breaker.Repair: Repair the wiring between the 15 amp circuit breaker and the ECM connector P1. Refer to Illustration 1.STOP
Not OK - The correct voltage is not present at the 15 amp circuit breaker.Repair: Verify that the battery disconnect switch is in the ON position. Verify that the 15 amp circuit breaker is operating correctly. Repair the wiring between the battery and the 15 amp circuit breaker. Refer to Illustration 1.STOPTest Step 5. Check the Voltage from the Keyswitch to the ECM
Turn the keyswitch to the OFF/RESET position.
Remove the wire from terminal R of the keyswitch.
Turn the keyswitch to the ON position.
Measure the voltage on terminal B of the keyswitch to engine ground.
Measure the voltage on terminal R of the keyswitch to engine ground.
Turn the keyswitch to the OFF/RESET position. Expected Result:Voltage is present on terminal B and terminal R at the keyswitch.Results:
OK - Voltage is present on terminal B and terminal R at the keyswitch.Repair: If voltage is present on terminal R, repair the wire between the keyswitch and the ECM. Verify that the 15A breaker is not tripped. Return all wiring to the original configuration. Verify that the problem is eliminated.STOP
Not OK - Voltage is not present on terminal B at the keyswitch.Repair: If voltage is not present on terminal B, repair the wire between the +Battery and the keyswitch. Verify that the breaker is not tripped. Check the battery's no-load voltage. Return all wiring to the original configuration. Verify that the problem is eliminated.STOP
Not OK - 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