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05 Fuel System and Throttle Body

sv650 03 up over

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Chris Liddle
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63 views

05 Fuel System and Throttle Body

sv650 03 up over

Uploaded by

Chris Liddle
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS ——— - FUEL SYSTEM. FUEL DELIVERY SYSTEM.. FUEL PUMP... FUEL PRESSURE REGULATOR. FUEL INJECTOR FUEL PUMP CONTROL SYSTEM. FUEL TANK LIFT-UP. FUEL TANK REMOVAL. FUEL TANK INSTALLATION... FUEL PRESSURE INSPECTION. FUEL PUMP INSPECTION o.oo FUEL PUMP RELAY INSPECTION. FUEL PUMP AND FUEL FILTER REMOVAL FUEL MESH FILTER INSPECTION AND CLEANING. FUEL PUMP CASE BUSHING INSPECTION. FUEL LEVEL SWITCH.. FUEL PUMP AND FUEL MESH FILTER INSTALLATION.. THROTTLE BODY AND STV ACTUATOR. CONSTRUCTION... AIF CLEANER AND THROTTLE BODY REMOVAL... THROTTLE BODY DISASSEMBLY .. THROTTLE BODY CLEANING........ THROTTLE BODY INSPECTION .. THROTTLE BODY REASSEMBLY ‘STV SYNCHRONIZATION. THROTTLE BODY INSTALLATION. STP SENSOR ADJUSTMENT. AIR CLEANER BOX INSTALLATION TP SENSOR ADJUSTMENT. FAST IDLE INSPECTION FAST IDLE ADJUSTMENT. THROTTLE VALVE SYNCHRONIZATION. 52 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe. Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector (the fuel pressure in the fuel delivery pipe) is always Kept at absolute fuel pressure of 300 kPa (3.0 kgl/om®, 43 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM The fuel relieved by the fuel pressure regulator flows back to the fuel tank. Fuel pressure regulator sap (fot hich pressure) — fis an Fuel pump Fuel mesh fitor (For iow pressure) BEFORE-PRESSURIZED FUEL Que Pressunizeo uct 1) RELIEVED FUEL Ful injector w ¢ w * w FUEL SYSTEM AND THROTTLE BODY 53 FUEL PUMP ‘The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM. ‘When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler. This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it. Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port. The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped. Also, the relief valve is equipped in the fuel pump, which releases pressur- ized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 ~ 600 kPa (4.5 - 6.0 kgl/om®, 64 — 85 psi). Impaler Check valve ‘Armature Inlet port ‘When the impeller is driven by the motor, pressure differential ocours between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction. This process continuously takes place causing fuel pressure to be built up. The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve. Blade groove Outlet x __-Fow clearance Turning diction ‘Motor shat Impetir ¢ \ 5-4 _ FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kPa (3.0 kgt/om, 43 psi) to be applied to the injector at all times. ‘When the fuel pressure rises more than 300 kPa (3.0 kgf/cm’, 43 psi), the fuel pushes the valve in the regu- lator open and excess fuel retums to the fuel tank. @ ~@ Fusl rom fearon = ) {vol pump Fuslrtuns tothe fuoltale D Spring 2 Valve FUEL INJECTOR ‘The fuel injector consists of the solenoid coil, plunger, needle valve and filter. It is an electromagnetic type injection nozzie which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion. As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time). 1) Needle valve 2 Plunger ® solenoid coil @ Filter FUEL SYSTEM AND THROTTLE BODY 5-5 FUEL PUMP CONTROL SYSTEM When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the side- stand relay and the fuel pump relay causing the motor to turn. Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has been turned on. Thereafter, when the crankshaft is turned by the starter motor or the engine has been started, the engine revolving signal is input to the ECM. Then, current flows to the fuel pump motor from the battery through the side-stand relay and the fuel pump relay so that the pump continues to function, A tip over sensor is provided in the fue! pump control circuit. By this provision, anytime the motorcycle tips over, the tip over sensor sends a signal to the ECM to turn off power to the fuel pump relay, causing the fuel pump motor to stop. At the same time, current to the fuel injectors as well as the ignition coil is interrupted, which then stops the engine. [a9] 5-6 FUEL SYSTEM AND THROTTLE BODY FUEL TANK LIFT-UP + Remove the front seat. ((7°7-4) ‘+ Remove the fuel tank mounting bolts, * Lift and support the fuel tank with its prop stay. FUEL TANK REMOVAL * Lift and support the fuel tank with its prop stay. (C7-above) * Disconnect the fuel pump lead wire coupler * Place a rag under the fuel feed hose and disconnect the feed hose () from the fuel tank. [CAUTION] When removing the fuel tank, do not leave the fuel feed hose 2 on the fuel tank side. CZTENI highly flammable and explosive. | Keep heat, spark and flame away. + Remove the air vent hose and fuel drain hose. « FUEL SYSTEM AND THROTTLE BODY 57 + Remove the fuel tank mounting bol. ‘+ Remove the fuel tank. ‘+ Remove the fuel tank bracket. + Remove the fuel tank stay and its rubber cushion. FUEL TANK INSTALLATION * Installation is in the reverse order of removal. 5.8 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION * Lift and support the fuel tank with the fuel tank prop stay. (77-4) + Place a rag under the fuel feed hose. + Disconnect the fuel feed hose from the fuel delivery pipe. * Install the special tools between the fuel tank and fuel delivery pipe. 09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77331: Oil pressure gauge 09915-74521: Oil pressure gauge hose ‘Tun the ignition switch ON and check the fuel pressure. Fuel pressure: Approx. 300 kPa (3.0 kgf/cm’, 43 psi) Hf the fuel pressure is lower than the specification, inspect the following items: * Fuel hose leakage * Clogged fuel filter * Pressure regulator * Fuel pump If the fuel pressure is higher than the specification, inspect the following items: * Fuel pump check valve * Pressure regulator POON * Before removing the special tools, turn the ignition switch to OFF position and release the fuel pressure slowly. * Gasoline is highly flammable and explosive. Keep heat, sparks and flame away. e- ota ; rou Jl delivery pipe LU FUEL SYSTEM AND THROTTLE BODY 5-9 FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds, If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor. FUEL DISCHARGE AMOUNT INSPECTION Gasoline is highly flammable and explosive. | Keep heat, spark and flame away. * Lift and support the fuel tank with the fuel tank prop stay. (7-4) * Disconnect the fuel feed hose from the fuel delivery pipe. * Place the measuring cylinder and insert the fuel teed hose end into the measuring cylinder. + Disconnect the ECM lead wire coupler. + Push the lock A) to pull out the power source lead wire (Yel- low with black tracer) * Apply 12 volts to the fuel pump for 10 seconds and measure the amount of fuel discharged. Battery @ terminal — Power source lead wire (Yellow with black tracer) If the pump does not discharge the amount specified, it means that the fuel pump is defective or that the fuel fier is clogged. Fuel discharge amount: MIN. 168 mi/10 sec. (6.7/5.9 US/Imp 02) NOTE: The battery must be in fully charged condition. 5-10 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP RELAY INSPECTION Fuel pump relay is located behind the ECM. + Remove the seat. + Remove the fuel pump relay. First, check the insulation between @ and @) terminals with pocket tester. Then apply 12 volts to @) and @ terminals, ® to | and © to @, and check the continuity between (and 2) If there is no continuity, replace it with a new one. FUEL PUMP AND FUEL FILTER REMOVAL + Remove the fuel tank. ((7°5-6) + Remove the heat shield. ‘+ Remove the fuel pump assembly by removing its mounting bolts ee EQ Gasoline is highly flammable and explosive. |_Keop heat, spark and flame away. * Disconnect the lead wires. FUEL SYSTEM AND THROTTLE BODY 5-11 ‘+ Remove the screws and fuel level switch gs y ‘+ Remove the fuel pump assembly from the fuel pump plate. g + Remove the fuel pump holder (7 + Remove the rubber cap 2. yg ad + Remove the fuel mesh filter @ bd | i; Ay 5:12_ FUEL SYSTEM AND THROTTLE BODY + Remove the fuel pressure regulator holder @ and the fuel pressure regulator 5). + Remove the fuel pump. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will nt flow smoothly and loss in engine power may result * Blow the fuel mesh fiter with compressed air. NOTE: If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one. FUEL PUMP CASE BUSHING INSPECTION * Inspect the fuel pump case rubber bushing for damage. FUEL LEVEL SWITCH (838) @® w 4 w « w « 7 by + FUEL SYSTEM AND THROTTLE BODY 543 FUEL PUMP AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh filter in the reverse order of removal, and pay attention to the following points: * Install the new O-rings to the fuel pressure regulator and fuel Pipe * Apply thin coat of the engine oll to the O-rings, CAUTION, Use the new O-rings to prevent fuel leakage. + Tighten the screws together with the lead wire terminals and fuel level switch, + Connect the lead wires as below. Benne @ terminal for fuel pump B...... Fuel level switch * Install the new O-ring and apply grease to it. PONS The O-ring must be replaced with a new one to prevent fuel leakage. AGH 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) 5-14__ FUEL SYSTEM AND THROTTLE BODY ‘+ When installing the fuel pump assembly, first tighten all the fuel pump assembly mounting bolts lightly in the ascending order of numbers, and then tighten them to the specified torque in the above tightening order (©) Fuel pump mounting bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-ft) NOTE: Apply a small quantity of the THREAD LOCK to the thread por- tion of the fuel pump mounting bott. sf) 99000-32050: THREAD LOCK “1342” oi Mion © (Lokgtm, 7316) Fuel pressure regulator (2 Fuel pump case/Fuel filter cartridge (For high pressure) @ Fuel pump @ Fuel mesh fer (For low pressure) © Fuel level switch © Bushing FUEL SYSTEM AND THROTTLE BODY 5-15 THROTTLE BODY AND STV ACTUATOR g CONSTRUCTION J eva: a Dar senor aor YY ‘eh 7 8] 2.0Nm a (0.2 kgf-m, 1.5 lb-ft) -——O asm er (0.35 kgf-m, 2.5 Ib-ft) Ons nia Dee cae oS ‘Do not turn this screw. JL ® ON“ @ o Por 516 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER AND THROTTLE BODY REMOVAL AIR CLEANER BOX * Lift and support the fuel tank with its prop stay. (C7"5-6) ‘+ Disconnect the IAT sensor coupler 1 * Disconnect the crankcase breather hoses. + Remove the IAP sensor vacuum hose 2). * Disconnect the IAP sensor coupler. + Loosen the throttle body clamp screws. FUEL SYSTEM AND THROTTLE BODY 5-17 * Disconnect the PAIR hose. * Disconnect the PAIR coupler. + Remove the air cleaner box. THROTTLE BODY * Lift and support the fuel tank with its prop stay. ((7°5-6) ‘+ Remove the air cleaner box. (("5-16) * Disconnect the fuel feed hose * Disconnect the various lead wire couplers. @ TP sensor. STP sensor. 4 STVA motoriinjector coupler. * Disconnect the idle stop screw. 5-18 FUEL SYSTEM AND THROTTLE BODY * Loosen the throttle body clamp screws. * Disconnect the throttle cables from their drum. * Dismount the throttle body assembly. ‘CAUTION | * Be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly. * After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body. FUEL SYSTEM AND THROTTLE BODY _ 5-19 THROTTLE BODY DISASSEMBLY [CAUTION * Be careful not to damage the throttle lever when dis- assembling the throttle body. * The throttle body is assembled precisely in factory. Do not disassemble it other than shown in this man- ual. ee ‘+ Remove the IAP sensor vacuum damper and its hose. + Disconnect the STVA and injector couplers. * Remove the throttle link rod @ and secondary throttle link rod 2. NOTE: The throttle link rod @ is longer than the secondary throttle link rod @ + Remove the fuel delivery pipe 3) 5.20 _ FUEL SYSTEM AND THROTTLE BODY ‘+ Remove the fuel injectors. + Remove the TPS @) and STPS ‘6) with the special tool ) 09930-11950: Torx wrench 09930-11960: Torx wrench NOTE: Prior to disassembly, mark each sensor's original position with a paint or scribe for accurate reinstallation. + Remove the seal 6). ‘CAUTION) Donotturnthe screw. é FS ud FUEL SYSTEM AND THROTTLE BODY 5-21 CAUTION, Y Never remove the STVA. g ‘* Remove the throttle stop screw ®). g NOTE: ‘Measure the length ‘) for accurate reinstallation. 7 CAUTION v v v 5.22 FUEL SYSTEM AND THROTTLE BODY [CAUTION [CAUTION] [Never remove the throttle body link plates. ‘+ Remove the fast idle link lever @) we . = + Remove the spring ©. + Remove the bushing (f) and plastic washer @ THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions on proper use, handling and storage. | * Clean all passageways with a spray type carburetor cleaner and blow dry with compressed air. CAUTION Do not use wire to clean passageways. Wire can dam- ‘age passageways. if the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer's instructions for proper use and cleaning of the throttle body components. Do not apply carburetor cleaning chemicals to the rubber and plastic materials. FUEL SYSTEM AND THROTTLE BODY 5-23 & & Ss ay

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