Suzuki SV1000 2003-2005 Service Manual 7 Electrical System

ELECTRICAL SYSTEM

CONTENTS

ELECTRICAL SYSTEM

7-1

CAUTIONS IN SERVICING

COUPLER CLAMP FUSE

SEMI-CONDUCTOR EQUIPPED PART BATTERY

CONNECTING THE BATTERY WIRING PROCEDURE

USING THE MULTI CIRCUIT TESTER

LOCATION OF ELECTRICAL COMPONENTS

CHARGING SYSTEM

TROUBLE SHOOTING

INSPECTION STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM

TROUBLE SHOOTING

STARTER MOTOR REMOVAL AND DISASSEMBLY STARTER MOTOR INSPECTION STARTER MOTOR REASSEMBLY STARTER RELAY INSPECTION

SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS

INSPECTION

IGNITION SYSTEM

TROUBLESHOOTING INSPECTION

COMBINATION METER

REMOVAL PARTS NAME

OPERATING PROCEDURE ENGINE COOLANT TEMPERATURE METER AND INDICATOR

LAMPS

RELAYS

~ HEADLIGHT AND POSITION LIGHT BRAKE LIGHT/TAILLIGHT, TURN SIGNAL LIGHT AND

LICENCE PLATE LIGHT

TURN SIGNAL/SIDE-STAND RELAY STARTER RELAY FUEL PUMP RELA Y SWITCHES

~

7- 3 7- 3 7- 3 7- 3 7- 3 7- 4 7- 4 7- 4 7- 4

7- 5

7- 7 7- 7 7- 9

7-12 7-12 7-13 7-14 7-15 7-16

7-17 7-20 7-20 7-22

7-25 7-25 7-26

7-26

~

7-28

7-31

7-32

7-33

7--33

7-34

7

7-2

ELECTRICAL

SYSTEM

ELECTRICAL SYSTEM

CONTENTS

BATTERY

SPECIFICATIONS INITIAL CHARGING

SERVICING RECHARGING OPERATION

~

7-36

~

7-36 7-36 7-37 7-38

~

CAUTIONS IN SERVICING

COUPLER

•

With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it

•

When disconnecting the coupler, be sure to hold the coupler

itself and do not pull the lead wires

•

Inspect each terminal on the coupler for being loose or bent

•

Inspect each terminal for corrosion and contamination

CLAMP

•

Clamp the wire harness at such positions as indicated in "WIRE HARNESS ROUTING"

•

Bend the clamp properly so that the wire harness is clamped securely

•

In clamping the wire harness, use care not to allow it to hang

down

.

•

Do not use wire or any other substitute for the band type

clamp

.

-

78-14)

(C"

.

ELECTRICAL SYSTEM 7-

3

FUSE

•

When a fuse blows, always investigate the cause, correct it and then replace the fuse

•

Do not use a fuse of a different capacity

•

Do not use wire or any other substitute for the fuse

.

SEMI-CONDUCTOR EQUIPPED PART

•

Be careful not to drop the part with a semi-conductor built in

such as a ECM

•

When inspecting this part, follow inspection instruction strictly Neglecting proper procedure may cause damage to this part

.

~

7-4 ELECTRICAL SYSTEM

BATTERY

•

The MF battery used in this motorcycle does not require maintenance (e.g.,

replenishment)

•

During normal charging, no hydrogen gas is produced

ever, if the battery is overcharged, hydrogen gas may be produced

. Therefore, be sure there are no fire or spark sources

(e.g., short circuit) nearby when charging the battery

•

Be sure to recharge the battery in a well-ventilated and open

area

.

•

Note that the charging system for the MF battery is different

from that of a conventional battery battery with a conventional battery

electrolyte level inspection, distilled water

.

. How-

.

. Do not replace the MF

.

CONNECTING THE BATTERY

•

When disconnecting terminals from the battery for disassem-

bly or servicing, be sure to disconnect the

wire, first

•

When connecting the battery lead wires, be sure to connect theOObattery lead wire first

•

If the terminal is corroded, remove the battery, pour warm

water over it and clean it with a wire brush

•

After connecting the battery, apply a light coat of grease to the

battery terminals

•

Install the cover over the

.

battery terminal

O

battery lead

O

.

WIRING PROCEDURE

•

Properly route the wire harness according to the "WIRE HARNESS ROUTING" section

. (CJ8-14)

USING THE MULTI CIRCUIT TESTER

•

Properly use the multi circuit testerOand Improper use can cause damage to the motorcycle and

tester

.

•

If the voltage and current values are not known, begin mea-

suring in the highest range

•

When measuring the resistance, make sure that no voltage is applied

•

After using the tester, be sure to turn the switch to the OFF position

CAUTION

Before using the multi circuit tester, read its instruc-

tion manual

. If voltage is applied, the tester will be damaged

.

e

probes

.

~

ELECTRICAL SYSTEM 7-5

LOCATION OF ELECTRICAL COMPONENTS

~ 40

•

Fuel pump (C14-68)

02 CMP sensor (C'4-92) ~3 IAP sensor (=4-91)

Ignition coil (No

•

05 Horn

. 1)

® TO sensor (=4-93) 07 Gear position switch

Starter motor

•

Oil pressure switch

•

1o ECT sensor(f-

4-93)

~

7-6 ELECTRICAL SYSTEM

90 Cooling fan thermo-switch

Cooling fan

•

Cooling fan motor switch coupler (=5-8)

•

Fuel injector

~5 TP sensor (=4-91)

STP sensor

•

Secondary throttle valve actuator (=4-51)

•

IAT sensor

•

(r

-

75-8)

(r

--

74-86)

(f"74-91)

(r

--

74-92)

(

F-75-9)

O

10 ECM (Engine Control Module)

5-8)

0

13 Starter relay 14 Side-stand/turn signal relay

4-51) 15 Fuse box

16 Mode selection switch coupler

Battery

11 Fuel pump relay

AP sensor (=4-93)

4-93)

17 Ignition coil (No

18 Regulator/rectifier

19 Generator

20 Speedometer sensor 21 CKP sensor 22 Side stand switch

. 2)

~

j CHARGING SYSTEM

ELECTRICAL SYSTEM 7-7

4)

Regulator/rectifier

Generator

I

TROUBLE SHOOTING

Battery runs down quickly

.

I I

I

.,

~

SCR

I I

is

Step 1

1) Check accessories which use excessive amounts of electricity

.

Are accessories being installed?

Ig

l

.switch

I N

m

a

m

0

J

40

YES

NO

Remove accessories

Go to Step 2

.

Step 2

1) Check the battery for current leaks

. (=7-9)

Is the battery for current leaks OK?

YES

NO

Go to Step 3

Short circuit of wire harness

•

Faulty electrical equipment

.

Step 3

1) Measure the charging voltage between the battery terminals

. (11r7-9)

Is the battery charging of voltage OK?

Faulty battery

YES

NO

•

Abnormal driving condition

Go to Step 4

.

~

7-8 ELECTRICAL SYSTEM

Step 4

1) Measure the resistance of the generator coil Is the resistance of generator coil OK?

. (=7-1 0)

YES

NO

Step 5

1) Measure the generator no-load voltage Is the generator no-load voltage OK?

YES

NO

Step 6

1) Inspect the regulator/rectifier Is the regulator/rectifier OK?

YES NO

Step 7

1) Inspect the wirings Are the wirings OK?

YES

NO

Go to Step 5 Faulty

Go to Step 6 Faulty

Go to Step 7

Faulty regulator/rectifier

.

Faulty battery

Short circuit of wire harness

•

Poor contact of couplers

.

generator

.

generator

.(I"

77-11)

.

coilordisconnected

. (C_r7-10)

lead~^.iros

Battery overcharge

•

Faulty regulator/rectifier

•

Faulty battery

•

Poor contact of generator lead wire coupler

~

ELECTRICAL SYSTEM

INSPECTION

j

BATTERY CURRENT LEAKAGE

Remove the front seat

•

Turn the ignition switch to the OFF position

•

Disconnect theObattery lead wire

Measure the current between the battery lead wire using the multi circuit tester exceeds the specified value, leakage is evident

Battery current (leak)

09900-25008

~j Tester knob indication

CAUTION

* Because the current leak might be large, turn the

tester to high range first to avoid tester damage

* Do not turn the ignition switch to the "ON" position

when measuring current

: Multi circuit tester set

. (=6-7)

: Under 3 mA

: Current

.

battery terminal and the

O

. If the reading

.

20 mA)

(-,

O

.

7-9

When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part

REGULATED VOLTAGE

Remove the front seat.(r'6-7)

•

Start the engine and keep it running at 5 000 r/min with the

•

dimmer switch turned HI position

Measure the DC voltage between the nals using the multi circuit tester

specified value, inspect the generator and regulator/rectifier (r--r7-1

NOTE

When

charged condition

.

1)

:

making

Charging output (Regulated voltage)

.

09900-25008

Tester knob indication

this

test,besure

.

: Multi circuit tester set

.

and

O

. If the voltage is not within the

that

the

14.0- 15

: Voltage

(-)

battery termi-

O

battery is in fully-

:

.5 V at 5 000 r/m i n

.

~

7

.10 ELECTRICAL SYSTEM

GENERATOR COIL RESISTANCE

•

Remove the front seat

•

Disconnect the generator coupler

Measure the resistance among the three lead wires If the resistance is not specified value, replace the stator with a new one

['~Generator coil resistance

. Also, check that the generator core is insulated

. (F-

76-7)

: 0.2- 0

D

.

(Yellow-Yellow)

.7 S2

-

S (Yellow-Ground)

.

09900-25008 Tester knob indication

ZJ

NOTE

: When making above test, it is not necessary to remove the generator

.

GENERATOR NO-LOAD PERFORMANCE

•

Disconnect the generator coupler

•

Don't disconnect the crankshaft position sensor coupler

•

Start the engine and keep it running at 5 000 r/min

Using the multi circuit tester, measure the voltage among the three lead wires

If the tester reads under the specified value, replace the generator with a new one

: Multi circuit tester set

: Resistance (S2)

. (Crabove)

.

A

Generator no-load performance

75 V and more at 5 000 r/min (When engine is cold) 09900-25008 Tester knob indication

: Multi circuit tester set

: Voltage

:

(-)

~

I

4)

REGULATOR/RECTIFIER

•

Disconnect the couplers and remove the regulator/rectifier

Measure the voltage among the terminals using the multi circuit tester as indicated in the table below the specified value, replace the regulator/rectifier with a new one

.

09900-25008

~$

Tester knob indication

g

~'

B/R

131

0

B2 B3

a

B/W

OI

B

: Black, B/R

* More than 1

: Black with Red trancer

.4 V (tester's battery voltage)

: Multi circuit tester set

: Diode test

Probe of tester to

O

B/R

* *

131

0.4-0.70.4-0.70.4-0.70.5-1

*

. If the voltage is not within

(-W)

:

B2 B3

*

* *

.

Unit

: V

B/W

.2

0

.4-0

.7

0

.4-0

.7

0.4-0.7

ELECTRICAL SYSTEM

7-11

NOTE

: If the tester reads under 1 connected, replace the battery of multi circuit tester

.4 V when the tester probes are not

.

~

7-12 ELECTRICAL SYSTEM

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM

Engine stop switch

0

Starter motor

Starter relay

To ECM and

0

ignition coil

B/Y

Clutch lever position switch

B/W

I

Y/G

Starter button

W

TROUBLE SHOOTING

Starter motor will not run Step 1

1) The transmission is in neutral switch in the "RUN" position

2) Listen for a click from the starter relay when the starter button is pushed Is a click sound heard?

.

. Grasp the clutch lever, turn on the

ignition switch with the engine stop

.

Ignition switch

Fuse (30 A)

.

ro m

A

rr

In

J

YES

NO

Step 2

1) Check if the starter motor runs when its terminal is connected to the "wire" because a large amount of current flows

Go to Step 2 Go to Step 3

. .

.)

battery terminal

O

. (Do not use thin

Does the starter motor run?

Faulty starter relay

YES

NO

•

Loose or disconnected starter motor lead wire

Faulty starter motor