0002347: Fix unstable engine run of Suzuki GSR400 (2006 model) - DM

ID	Project	Category	View Status	Date Submitted	Last Update

0002347	vehicle service	Suzuki GSR400	public	2021-04-15 01:39	2021-05-09 13:32

Reporter	DigitalMy
Priority	normal	Severity	minor	Reproducibility	N/A
Status	assigned	Resolution	open

Summary	0002347: Fix unstable engine run of Suzuki GSR400 (2006 model)
Description	GK7DA Suzuki motorcycle repair engine is missing ignition sometimes Check: electric lines fuel lines
Steps To Reproduce	Currently installed ignition coils Denso 129700-4800 JO480 06H02
Tags	No tags attached.

DigitalMy 2021-04-15 01:49 administrator ~0005013 Last edited: 2021-05-06 14:41 View 4 revisions	Ignition coil used in GSR400 K6 /33410-29G00 and K9 /33410-37H00 the same coil as in GSX-R600 and GSR600 /33410-29G00-000 (new version from 2009 may be used /33410-37H00-000 and tested by me Denso 129700-5140 JO5140-4L1009087) Need possible replacement of coil Denso 129700-4800 because of unstable ignition found GSR400 original coils have more or less the same measured R=12.8 kOhm Use 4pcs GSR600 K9 coils > replaced, they have R=8.8 kOhm > same unstable run GSR600_33410-29G00-000_electrical.png (26,957 bytes) GSR600_33410-29G00-000_electrical.png (26,957 bytes)

DigitalMy 2021-04-19 22:02 administrator ~0005015 Last edited: 2021-05-08 16:53 View 8 revisions	Also try replacement of part 15710-44G.. INJECTOR ASSY (4pcs) new version changed from GSR600K9 - same result GSR600 has different injector parts from GSR400 model GSR400 K6 has (violet color) injector part /15710-44G10 EAT259 259065G (with 4 nozzle apertures) and from upgrade GSR400K9 /15710-44GB0 GSR600 K6 /15710-44G00 and from K9 has (orange) deeper injector nozzle (but it works fine) /15710-44G20 -> replaced 4pcs, still have the same unstable run tested with disconnection of each injector one by one: 1 3 4 are more or less the same, but 2 has little affect found dirty input line Tested EAT259 nozzle FI (fuel injector) 5.0V works at 0.5A each 4pcs are of the same resistance 12 Ohm their normal control is made by negative ECM signal , positive terminal is switched on by FPR (fuel pump relay) GSR600K6_E02_012_injector.png (24,699 bytes) GSR600K6_E02_012_injector.png (24,699 bytes)

DigitalMy 2021-05-05 00:57 administrator ~0007016 Last edited: 2021-05-09 13:32 View 2 revisions	Measure Compression ratio, expected 12.5:1 (with tool) cylinder 1 - 10.5 cylinder 2 - 10.0 cylinder 3 - 8.0 cylinder 4 - 11.0

DigitalMy 2021-05-06 00:11 administrator ~0007018 Last edited: 2021-05-08 08:03 View 5 revisions	Measure fuel pump pressure Disassembled fuel tank and found a lot of rust, dirt and filter in awful condition changed filter to no-name model Mitsubishi UC-T30SU23 fuel pump assembly is original for GSR400K6 model /15100-44G00 with pump motor Mitsubishi UC-T30 C6525 (has 2-pin connector) L =115mm D=38mm in d=10.8mm , out d=8.8mm found replacement TC-FEP-YB030 in no-name fuel_pressure_inspection_GSR400.jpg (111,650 bytes) fuel_pressure_inspection_GSR400.jpg (111,650 bytes)

DigitalMy 2021-05-06 00:20 administrator ~0007019	Make self test (ECM) by short cut two side pins in diagnostic port (6-pin) Result is c00 After disconnection of injector, panel showed FI indication self_diag_GSR400.jpg (95,799 bytes) self_diag_GSR400.jpg (95,799 bytes)

DigitalMy 2021-05-06 23:19 administrator	GSR400K6_12.png (372,147 bytes) GSR400K6_16.png (361,102 bytes) GSR400K6_28.png (374,143 bytes)

DigitalMy 2021-05-08 17:05 administrator ~0007024 Last edited: 2021-05-08 23:47 View 2 revisions	Clean FI system with washer stand Original line from pump to fuel rail has diameter 8mm fuel_injection_wiring_GSR600.pdf (131,552 bytes)