MOTORCYCLE DIVISION

4-STROKE SERVICE BULLETIN GS/GSX/GSX-R/GSF NO. 157A DATE: 3/26/2010

SUBJECT: MODEL:

C46 TROUBLESHOOTING AN INTERMITTENT FI CODE DISPLAY GSX-R600K6, GSX-R750K6, GSX-R1000K3 K8

REFERENCE: GSX-R600 SERVICE MANUAL (P/N 99500-35100-03E) PAGE 6-8 TO 6-10 GSX-R750 SERVICE MANUAL (P/N 99500-37130-03E) PAGE 6-8 TO 6-10 GSX-R1000 SERVICE MANUAL (P/N 99500-39241-03E) PAGE 6-9 TO 6-11 GSX-R1000 SERVICE MANUAL (P/N 99500-39271-03E) PAGE 6-10 TO 6-13 GSX-R1000 SERVICE MANUAL (P/N 99500-39310-03E) PAGE 6-9 TO 6-12 SUBJECT: It has been reported that some GSX-R600/750K6 and GSX-R1000K3K8 models may experience an intermittent "FI" code during normal operation. The engine control module (ECM) on these models continuously monitors the function of the fuel injection system and ignition systems for proper operations, and will display an "FI" warning indicator to the rider if the system detects a malfunction. Field experience has shown that in many cases an intermittent "FI" display on the GSX-R600/ 750K6 and GSX-R1000K3K8 models can often be traced to incorrect adjustment of the Suzuki Exhaust Tuning (SET) cables. This problem can be corrected by readjustment of the cables using the outlined procedure. Problem Verification If an "FI" code is displayed continuously on the LCD panel, place the system in dealer mode using the mode selector switch. This will cause any currently active diagnostic code(s) to be displayed on the LCD panel. Incorrect adjustment of the SET cables typically will result in a C-46 code being displayed.

Mode Selector Switch: 09930-82720

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Inspection Inspect the open and close cables to verify that neither cable is pinched or bent and that both cables are properly routed before performing an adjustment. Re-route improperly routed cables and replace cables that are bent or damaged. Make sure to minimize the cable bend at the indicated point 3 . Overtightening the cable clamp will increase cable bend and interfere with smooth cable operation. 1 Close cable 2 Open cable

Figure 1 1 2 3

1 2

Adjustment SET Precautions Always use a mode selector switch to set the drive pulley on the Exhaust Control Valve Actuator (EXCVA) in the ADJUST position before making any adjustments or replacing components. Adjusting cable tension when not in the ADJUST position will damage the actuator gears. Use a wrench to hold the EXCVA drive pulley when loosening or tightening the retaining bolt or the nylon gears inside the EXCVA will be damaged. Do not apply voltage to the EXCVA motor any longer than required when setting the drive pulley to the fully open or closed position. 1) Turn the ignition switch off. Disconnect the EXCVA motor lead wire coupler (P/Gr leads) 1 (Figure 2). Use a 12V battery and harness to set the EXCVA drive pulley to the FULLY OPEN position (Figure 3) by connecting the wires to the terminals as described below. (A harness can be built from connectors in the standard terminal kit.)

Figure 2 valve open position

Figure 3 - 2/4 -

2) Turn the ignition switch ON. Measure the EXCVA position sensor voltage at the Y- B/ Br. The specification for the FULLY OPEN position is 3.7 to 4.5 V. It is normal for the open cable to stretch with use and then the voltage will read high. EXCVA position sensor coupler 2 (Figure 4)

Figure 4 3) If the voltage measurement is out of specification, reconnect the EXCVA motor lead wire coupler and use the mode selector switch to set the drive pulley to the ADJUST position (Figure 5) before adjusting the open cable.

cable adjust position

Figure 5 4) Loosen the lock-nut 3 on the open cable and turn the cable adjuster 4 out approximately one turn. Tighten the lock-nut against the cable adjuster. The EXCVA position sensor voltage will not change in the ADJUST position and must be retested in the FULLY OPEN position. Repeat Steps 1 and 2 to test the voltage after making the adjustment. Make further adjustments following steps 3 and 4 as necessary until the correct voltage specification for the FULLY OPEN position is acheived. 5) Disconnect the EXCVA motor lead wire coupler and use the battery and harness (used in Step 1) to set the EXCVA drive pulley to the FULLY CLOSED position (Fig ure 7) by connecting the wires to the terminals as described below.

Figure 6 valve closed position

Figure 7 - 3/4 -

6) Turn the ignition switch ON. Measure the EXCVA position sensor voltage at the Y- B/ Br. The specification for the FULLY CLOSED position is 0.5 to 1.3 V. It is normal for the close cable to stretch with use and then the voltage will read low.

Figure 8 7) If the voltage measurement is out of specification, set the EXCVA drive pulley in the ADJUST position per the instructions in Step 3. Loosen the lock-nut 3 on the close cable and turn the cable adjuster 4 out approximately one turn. Tighten the lock-nut against the adjuster. The EXCVA position sensor voltage will not change in the ADJUST position and must be retested in the FULLY CLOSED position. Repeat Steps 5 and 6 to test the voltage after making the adjustment. Make further adjustments (following step 7) as necessary until the correct voltage specification for the FULLY CLOSED position is acheived.

Figure 9

8) Test ride the unit thoroughly and verify that the C-46 code does not reappear. If a C-46 code reappears, re-check adjustment. If EXCVA position sensor voltage is still within specification at the FULLY OPEN and FULLY CLOSED positions, inspect the following items (start engine and raise engine speed briefly as necessary): Smooth movement of the SET cables. EXCVA drive pulley reaches fully open and closed positions (see Figure 3 and Figure 7). The EXCVA motor does not make any abnormal noise. The Exhaust Control Valve (EXCV) moves freely.

AFFECTED DEPARTMENTS: The following departments in your dealership should be notified of this information: Management Service Warranty Sales Parts Accessories

American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV / Scooter - 4/4 -