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1. ITEM UNIT pane 1 2 3 4 ENGINE SPEED PORT r min L L ENGINE SPEED STBD r min L L ENGINE SPEED CENTER r min L L LPS OUTPUT 1ST P M V L LPS OUTPUT 1ST P S V L LPS OUTPUT 1ST S M V L LPS OUTPUT 1ST S S V L LPS OUTPUT 2ND P M V L LPS OUTPUT 2ND P S V L LPS OUTPUT 2ND S M V L LPS OUTPUT 2ND S S V L ETV TRGT ANGLE PORT V L L ETV TRGT ANGLE STBD V L L ETV TRGT ANGLE CENTER V L L TPS OUTPUT PORT V L L TPS OUTPUT STBD V L L TPS OUTPUT CENTER V L L BATTERY VOLTAGE BCM V L BATTERY VOLTAGE PORT V L L BATTERY VOLTAGE STBD V L L BATTERY VOLTAGE CENTER V L L TRIM ANGLE PORT L L TRIM ANGLE STBD 96 L L TRIM ANGLE CENTER 96 L L BOAT SPEED km h L BOAT SPEED knot L BOAT SPEED mile h L NO OF LPS PORT 1ST times L NO OF LPS STBD 1ST times L NO OF LPS PORT 2ND times L NO OF LPS STBD 2ND times L NO OF LOW VOLTAGE 1ST times L NO OF CAN COMM FAILURE SUB BCM times L NO OF CAN COMM FAILURE PORT times L L NO OF CAN COMM FAILURE STBD times L L 80 ITEM UNIT GROUP No 1 2 3 NO OF CAN COMM FAILURE CENTER times L NO OF SET UP ERROR SUB BCM times L NO OF SET UP ERROR PORT times L L NO OF SET UP ERROR STBD times L L NO OF SET UP ERROR CENTER times L NO OF DBW ETV FAILURE PORT
2. Jepues M4 H 918 OL Jepues IG yue OL im Josues g 5 3 lege H peaj 1ndino 36 sido deo aig H 3 Jojoeuuoo Sas S d I I udzzna r D S d fo Mo lilo elo D HH 92 No PatNme Patno CHOICE 2 MAIN WIRE HARNESS REMOTE CONTROL 6 5 m 36620 98J00 MAIN WIRE HARNESS REMOTE CONTROL 9 5 m 36620 98J10 HARNESS ASSY ACTIVE HUB PWR 2 5 m m HARNESS ASSY ACTIVE HUB PWR 6 0 m WIRE COMP JUMPER UNIT ACTIVE HUB CAP 8 PIN CONNECTOR HARNESS ASSY 3 GAUGE 36664 98J00 HARNESS ASSY 2 GAUGE CAP 6 CONNECTOR CHOICE 1 19 EM 93 5 eui jo 2 3NION 20 ANIDNG 01 20090000 SIU j0euuo2 oJnsseJd 5 8 4 DUAL ENGINE DUAL STATIONS 1ueuudinbe 0002 V3IAN
3. m o o o Jejeuiouoe 1081081 LHOd enel enel Ly 4815 i CD E NOO H Jejeulouoe qns Jejeuiopeeds o o 201805 UL Pm LLL Tr ETES 37 e qeo fueneq qns 9921 vo pug 19987 1 16 15 uoles puc qnu y jo 10 ANIDNG 0 JOJOSUUOD JOSUUOD Goum 1ndino g Jejoulouoe 35nvo ener lege Jepues IJ ue 1914 915 OL Jepues HA yue OL 9 Josues 01619191916
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5. 5 5 Fig 54 2 he Open dialog box Fig 55 appears Select a desired file and click the Open button Keyboard To change the selected button to another button use the Tab key Select a desired file by using the Up or Down arrow key and press the Enter key to have the file accepted jd Look in DataList EJ Look in 3 DataL ist ie D2508071 csv ngine DF250 123456 Boat Type SUZUKI Description XXXXXXXXXXXXXXXXXXXXX File name File name Files of type csvt csv Cancel Files of type Cv csv Cancel 2 E Fig 55 Fig 55 2 NOTE e Entering comments from the Engine No Boat Type and Description fields and selecting the file to be saved displays the information in the subwindow Fig 55 2 e Service data is saved to the DataList folder and logging data to the DataGraph folder 31 4 4 ECM CURRENT SERVICE CODES 1 Clicking the CURRENT SERVICE CODES button from the Main Menu dialog box Fig 48 displays the following CURRENT SERVICE CODES window Fig 56 This window shows failed item names and actions to be taken BET Main Menu F1 File F2 Saye F2 Window F4 Help F9 Exit F10 CURRENT SERVICE CODES Failed item SPEED SENSOR Check sensor connector and harness Check pitot hose
6. reped pudica Mad ane ese ga e qeo qns Co P ok EE III I 7 3 cc c3 c3 3 Sul 10151051 ee au oL CH 5 5 8 5 TRIPLE ENGINES SINGLE STATION 96 N PatNamme OY E MAIN WIRE HARNESS REMOTE CONTROL 6 5 m MAIN WIRE HARNESS REMOTE CONTROL 9 5 m 9 HARNESS ASSY BCM No 1 FOR MULT 6 CONTROL ASSY TOP MOUNT DUAL D CONTROLLER ASSY BOAT ELECTRIC PANEL ASSY TRIPLE 9 BUZZER ASSY WARNING 40 PANEL ASSY MAIN SW HARNESS ASSY INTERFACE UNIT UNIT INTERFACE amp HARNESS ASSY BATTERY 2 m E HARNESS ASSY ACTIVE HUB PWR 2 5 m HARNESS ASSY ACTIVE HUB PWR 6 0 m amp CAP 2 PIN CONNECTOR 9 UNIT HUB b 8 PIN CONNECTOR amp HARNESS ASSY 3 GAUGE 9 HARNESS ASSY 2 GAUGE Q 6 CONNECTOR 4 UNIT PASSIVE HUB 1 WIRE COMP JUMPER 1 HARNESS ASSY 2 HUB 1 m 36662 98J00 O HARNESS ASSY 2 HUB 6 5 m 36662 98J10 6 e eG e 97 5 8 6 TRIPLE ENGINES DUAL STATIONS 15 nss d uoles puc
7. s ww 10 84 3 Click the Main Menu F1 button 1 key on the The following Menu dialog box appears The BCM part number is displayed in the lower left of this dialog box Fig 85 SUZUKI DIAGNOSTIC SYSTEM Main Menu F1 File F2 Save F3 Window F4 9 Exit F10 SYSTEM CALIBRATION SETTING CHANGE SYSTEM CHECK BCM INITIALIZATION Exit Close Esc Click or press Main Menu F1 select item by UP and DN then press Enter press A to exit program 62 SYSTEM CALIBRATION Calibrate the SPC system and registers information of outboard motor and remote control box in the BCM Perform this item when an outboard motor remote control box and meters are first installed on the boat Also perform this item when the BCM is replaced or the ECM or remote control box of the outboard motor is replaced SETTING CHANGE Sets changes or resets the remote control lever and tilt down Perform this item when the remote control box is disassembled or when the tilt position is changed SYSTEM CHECK Enables you to check the system configuration registered in the master BCM BCM INITIALIZATION Deletes the BCM information master or sub registered in the BCM after system calibration and system configuration information Number of engine Number of station Exit Exits the SDS program Close Esc Closes the menu box CAUTION The
8. 5 1 1 APPLICABLE MODELS AND NECESSARY TOOLS 5 1 2 PC HARDWARE REQUIREMENTS 6 1 2 ABBREVIATION ute 7 2 SYSTEM OUTLINE QnH 8 3 INSTALLATION c ee ere 9 3 1 INSTALLING SDS eee 9 3 2 INSTALLING THE SDS USB ADAPTER DRIVER 15 3 3 UPDATING 5 5 2 4 44422211 18 4 OPERATING SDS aoc ese 23 4 1 CONNECTION AND STARTING THE SDS PROGRAM 23 4 2 ECM MAIN MENU 111 LLL re c llll ecran ene n ana nenne aaa aa Run 27 SERVICE DATA 28 SAVING SERVICE DATA 1 LL LL eer rere een nana n nn 29 OPENING SAVED DATA expe rome Res eu 31 4 4 ECM CURRENT SERVICE CODES 32 4 5 ACTUATOR TEST 33 EXPLANATION OF ACTUATOR TEST ITEMS 35 PERFOMING THE 37 4 6 BCM SIMULATOR DEDICATED FOR DF300 41 4 7 DATA LOGGER 43 SAVING LOGGING eee 46 PRINTING A LOGGING DATA GRAPH 48 4 8 OTHER FUNCTIONS eorr ptr opino 49 SERVICE INFORMATION 49 OPERATION MA
9. Erebi _ BBimewmpe 2 Click the Add Remove Programs icon Fig 120 210 xj The Add Remove Program Properties dialog box ponen 3 e appears Fig 121 eds SUZUKI DIAGNOSTIC SYSTEM 5 Select SUZUKI DIAGNOSTIC SYSTEM and click the Change Remove button Add New en CET Programs Suzuki Pass Thru Reprogramming Tool jl visual Authoring Tool 7 3 1 Add Remove Windows Components 3 Set Program Access and Defaults 100 3 SDS program uninstallation is automatically started Fig 122 4 Checkthatthe uninstallation has finished and click the Finish button Fig 123 InstallShield Wizard SUZUKI DIAGNOSTIC SYSTEM Setup 1 preparing the Install Wizard which will quide you through the rest of the setup process Please wall Fig 122 InstallShield Wizard Maintenance Complete InstallShield Wizard has finished performing maintenance operations on SUZUKI DI amp GNOSTIC SYSTEM lt Back Fig 123 101 Prepared by SUZUKI MOTOR CORPORATION Quality Administration Department July 2008 Manual No 99517 03062 01E Printed in Japan SUZUKI MOTOR CORPORATION
10. Esc to close CURRENT SERVICE CODE Click or press Exit F10 to exit program Power 300PS ECM ID 33920 98J71 Spec Engine Type 4028 4 stroke idistar 24 Sos Part suzuer bracwosnic s 10 56 f there is no failed no current service code NO failure is displayed in the CURRENT SERVICE CODES window You can simultaneously display the SERVICE DATA CURRENT SERVICE CODES and ACTUATOH TEST windows To change the active window click the Window F4 button F4 key on the keyboard 32 4 5 ACTUATOR TEST 1 Clicking the ACTUATOR TEST button from the Main Menu dialog box Fig 48 simultaneously displays the following two windows Fig 57 1815 Main Menu F1 File F2 Save F3 Window F4 9 Exit F10 Engine Data Select ENGINE SPEED m FUEL INJECTOR STOP Stop r Description Make sure engine is running with shift in neutral position IGNITION TIMING MANIFOLD ABSOLUTE PRESSURE Are you sure Click Go button for 5 second actuation BAROMETRIC PRESSURE CYLINDER TEMPERATURE INTAKE AIR TEMPERATURE 36 C BATTERY VOLTAGE 1280 Y e UP and DN to select item then press Go FUEL INJ PULSE WIDTH 0 us Use Esc to close ACTUATOR TEST INJECTED FUEL AMOUNT 0 FUEL CONSUMPTION AVE 0 0 HIGH FUEL PUMP DUTY 0 0 IAC VALVE DU
11. 8A deo do 10j2euuoo Sas S uazzna S d fo ike 7 offo deg J0j9euuoo 505 T 9 5 98 No PatNme PartNo AY MAIN WIRE HARNESS REMOTE CONTROL 6 5 m 36620 98J00 CHOICE 2 MAIN WIRE HARNESS REMOTE CONTROL 9 5 m 36620 98J10 HARNESS ASSY DUAL STATION 366229800 1 _ HARNESS ASSY BCM FOR MULT 36623 98311 1 D HARNESS ASSY BCM No 2 FOR MULT 36624 98310 1 amp REMOTE CONTROL ASSY TOP MOUNT DUAL 67200 98311 2 CONTROLLER ASSY BOAT ELECTRIC 3677098001 2 PANEL ASSY TRIPLE __ 371009881 2 BUZZER ASSY WARNING 38500 93390 2 PANELASSY MAINSW 9871009800 1 PANEL ASSY EMERGENCY SW 77 878089800 1 36661 9800 34922 9801 36625 9800 HARNESS ASSY ACTIVE HUB PWR 2 5 m 36663 98J00 HARNESS ASSY ACTIVE HUB PWR 6 0 36663 98J10 CAP 2 PIN CONNECTOR 36667 98J00 UNIT ACTIVE HUB 34921 98J00 HARNESS ASSY 3 GAUGE 36664 98J00 HARNESS ASSY 2 GAUGE 36664 98J10 CAP 6 PIN CONNECTOR 36666 98
12. Use UP and DN to select item group then press Enter 0 select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Window F4 to change active window Click or press Exit F10 to exit program Power 115PS ECM ID 33920 9010 Spec Type 1950cc 4 stroke Fig 60 37 NOTE O feedback requires that the following five items are displayed in the item box of the Service Data window O feedback information Select a display item by using the Select button as required ENGINE SPEED COMPENSATION FACTOR ZONE 1 COMPENSATION FACTOR ZONE 2 COMPENSATION FACTOR ZONE 3 FEEDBACK STAND BY ACTION or FIN NG is displayed in the Data column 4 Shift into forward gear NOTE The feedback operation should be performed under engine load Do not perform feedback operation using the warm up lever or throttle control grip without first shifting into forward gear 5 Adjust the engine speed to ZONE 1 and click the Go button Fig 61 Retain the specified engine speed for at least 20 seconds f the buzzer sounds for about 2 seconds 1 only feedback at this zone finished successfully The Compensation Factor data in the Service Data O feedback information will also be changed Go to the next step f
13. NOTE You can display the SERVICE DATA CURRENT SERVICE CODES and ACTUATOR TEST windows at the same time To change the active window click the Window F4 button or press the F4 key 27 4 3 SERVICE DATA 1 Clicking the SERVICE DATA button from the main menu dialog box Fig 48 displays the following SER VICE DATA window Fig 49 This window displays real time engine data Ea SUZUKI DIAGNOSTIC SYSTEM SERVICE DATA 18 x Main Menu F1 File F2 Save F3 wWindow F4 Help F9 Exit F10 SERVICE DATA Engine Data Select ENGINE SPEED IGNITION TIMING MANIFOLD ABSOLUTE PRESSURE BAROMETRIC PRESSURE CYLINDER TEMPERATURE INTAKE AIR TEMPERATURE BATTERY VOLTAGE FUEL INJ PULSE WIDTH INJECTED FUEL AMOUNT FUEL CONSUMPTION AVE HIGH FUEL PUMP DUTY IAC VALVE DUTY PURGE VALVE DUTY EX MANI TEMPERATURE STBD EX MANI TEMPERATURE PORT ETY TRGT ANGLE Use UP and DN to select item group then press Enter 0 select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Exit F10 to exit program Power 300PS ECMID 3392098J71 Spec Engine Type 4028cc 4stroke 000000000000 d start w 1028 Paint p1aGNosTIC s 6 6 Fig 49 2 In the SERVICE DATA window you can select one of the five data item groups Engine Data Caution Sys info Operation Hour
14. SUZUKI motor SUZUKI DIAGNOSTIC SYSTEM OPERATION MANUAL For Software Version 6 00 99517 03062 01E FOREWORD This manual describes how to operate SDS Suzuki Diagnostic System Ver 6 00 Besides the existing diagnostic functions and the calibration function of the outboard motor DF300 elec tronic control system SDD Ver 6 00 additionally pro vides the automatic installation function of USB adapter driver newly incorporates the operation manual in the form of electronic file and supports Windows Vista For proper SDS operation read this manual care fully to understand its contents so that you can pro vide your customers with accurate and prompt ser vices NOTE e This manual is edited based on the information available at the end of July 2008 e his manual is subject to change without notice e Use this manual with the latest Service Manual of each model SUZUKI MOTOR CORPORATION Quality Administration Department GROUP INDEX GROUP TITLE OVERVIEW SYSTEM OUTLINE INSTALLATION OPERATING SDS SPC SYSTEM CALIBRATION UNINSTALLING SDS N C3 ts 5 6 IMPORTANT A WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the mes sages highlighted by these signal words A WARNING In
15. e Clicking the Stop button when the test is being performed interrupts the test If no response is made from the ECM during the interruption the following dialog box Fig 59 ap pears Turn off the engine key once and then restart the SDS program Turn ignition switch OFF and ON again 1 Actuator test cannot be Finished Fig 59 34 EXPLANATION OF ACTUATOR TEST ITEMS FUEL INJECTOR STOP DF40 to DF300 Fuel injection for the specified cylinder will stop for 5 seconds This test can be performed when the engine is running FUEL INJECTOR ACTUATION DF40 to DF300 Fuel injection for the specified cylinder will be actuated for 5 seconds This test can be performed when the engine is not running X IGNITION MISFIRE DF40 to DF300 Ignition for the specified cylinder will stop for 5 seconds This test can be performed when the engine is running FIXED IGNITION TIMING DF40 to DF300 Ignition timing will be fixed at BTDC 5 till the Stop button is clicked This test can be performed when the engine is running This test can be used for ignition system troubleshooting during engine idling The monitored ignition timing during actuation is a calculated value not an actual value O FEEDBACK DF40 to DF250 2007 year model and early The O feedback operation can be performed Refer to Performing the O Feedback Page 37 in this manual HIGH PRESSURE FUEL PUMP ACTUATION DF40 to DF300 T
16. ACCELERATION VOLTAGE 2 1 TPS MAIN VOLTAGE 1 1 TPS MAIN VOLTAGE 2 1 TPS SUB VOLTAGE 1 1 TPS SUB VOLTAGE 2 1 SHIFT POSITION 1 1 SHIFT POSITION 2 1 SPS VOLTAGE 1 1 SPS VOLTAGE 2 1 BATTERY VOLTAGE 1 1 BATTERY VOLTAGE 2 1 FAILURE TIME 1 1 lt lt lt lt n FAILURE TIME 2 1 ciim FAILURE TIME 1 1 3 5 FAILURE TIME 2 1 3 SPC CAUTION SYSTEM NAME 1 2 SPC CAUTION SYSTEM NAME 2 2 ENGINE SPEED 1 2 ENGINE SPEED 2 2 MANIFOLD ABSOLUTE PRESSURE 1 2 MANIFOLD ABSOLUTE PRESSURE 2 2 MANIFOLD ABSOLUTE PRESSURE 1 2 MANIFOLD ABSOLUTE PRESSURE 2 2 MANIFOLD ABSOLUTE PRESSURE 1 2 MANIFOLD ABSOLUTE PRESSURE 2 2 CYLINDER TEMPERATURE 1 G CYLINDER TEMPERATURE 2 2 CYLINDER TEMPERATURE 2 2 r2 CYLINDER TEMPERATURE 1 2 1 oO om INTAKE AIR TEMPERATURE 2 Om INTAKE AIR TEMPERATURE INTAKE AIR TEMPERATURE 1 EX MANI TEMPERATURE STBD 1 EX MANI TEMPERATURE STBD 2 Om 1 INTAKE AIR TEMPERATURE 2 J 1 Gm EX MANI TEMPERATURE STBD 2 EX MANI TEMPERATURE PORT 2 Om 2 2 2 EX MANI TEMPERATURE STBD 1 2 EX MANI TEMPERATURE PORT 1 2 PORT 1 2 EX MANI TEMPERATURE PORT 1 2 2 2 2 2 2 ACCELERAT
17. to exit program Power 300PS ECM ID 33920 98J71 Specs Engine Type 4028cc 4 stroke Fig 44 25 NOTE first menu window appears after the ECM or BCM is automatically recognized When SDS is connected to ECM ECM main window appears When SDS is connected to the BCM the BCM main window appears Clicking Main Menu F1 when you change the connection from the ECM to BCM or vice versa after you turned off the main switch of the outboard motor with the SDS program started displays the following mes sage Fig 45 COMMUNICATION ERROR B The ECM does nok correspond with the 505 database Exit and restart Ehe program Fig 45 NOTE If there is no reply from the ECM or BCM the following dialog box Fig 46 appears Read the messages in this dialog box follow the instructions and then click the Reset button to communicate again with ECM or BCM Keyboard Select the Reset button by using the Up or Down arrow key and then press the Enter key suzuki DIAGNOSTIC SYSTEM 81 xj Main Menu F1 File F2 Save F3 Window F4 Help F9 Exit F10 COMMUNICATION ERROR No communication between the PC and the ECM or AN BCM Click OK button to Use the functions of Update database Open file and Help Cancel this window To use functions other than the above click Reset button to communicate with the ECM after confirming the following i
18. 800 700 600 500 400 300 200 100 0 10 20 30 40 50 60 70 80 90 100 Logging data is not saved Click press Save F3 to save data Click Monitor button to start monitoring Click Setup button to input logging condition Use Esc to close DATA LOGGER Use Tab to select button Click or press Exit F10 to exit program Power 300 5 ECM ID 33920 9871 Spec Type 4028 4 stroke Fi 0 67 If you open the DATA LOGGER window when the SERVICE DATA CURRENT SERVICE CODES AC TUATOH TEST windows are open other windows are automatically closed and only the DATA LOGGEH window is displayed 43 2 Selecting the Setup button displays the LOG GING CONDITION SETUP dialog box Fig 68 In the Condition field enter a sampling cycle and data logger time and select up to three display items Items are displayed when their check boxes are selected check boxes with W mark Items are not displayed when their check boxes are cleared check boxes without V mark You select whether to display or hide an item by clicking the check box Keyboard To display or hide an item select it by using the Up or Down arrow key and press the Space key To have the selected item accepted move to the OK button by using the Tab key and press the Enter key NOTE If the input status is incorrect or no item is selected the INPUT ERROR dialog box
19. August 2 First file recorded on the above date Keyboard Move to the Save button and press the Enter key to have the saved data accepted or move to the Cancel button and press the Enter key to cancel the selected data NOTE When opening the saved logging data refer to Opening Saved Data Page 31 in this manual 47 PRINTING A LOGGING DATA GRAPH When the DATA LOGGER window is displayed you can print a graph of up to 100 points same as the range display in the window 1 In the DATA LOGGER window Fig 72 click the File F2 button 2 key on the keyboard 2 The Print dialog box Fig 75 appears Canon 130 Properties Select a printer print range and the number of Status Ready C opi es Bubble Jet BJ 130 To start printing click the OK button To cancel pen printing click the Cancel button Keyboard Move to the OK button by using the Tab key and press the Enter key to have the printing accepted or move to the Cancel button by using the Tab key and press the Enter key to have the cancellation accepted Copies Number af copies Print range C Pages mm tcf Selection p Collate Fig 75 48 4 8 OTHER FUNCTIONS SERVICE INFORMATION Currently the corresponding electronic file is unavailable fro Suzuki Motor Corporation You can add PDF versions of electronic file service manuals
20. DATA Engine Data window Read Description and Message in the BCM SIMULATOR NOTICE window and follow the instructions To change the active window click the Window F4 button F4 key on the keyboard Inthe BCM SIMULATOR window check that Neu tral is selected in the SHIFT POSITION and the slide bar in the throttle opening is set to the mini mum position Fig 66 Clicking the START button in the Engine menu of the BCM SIMULATOR window starts the en gine Keyboard Move to the START button by using the Tab key and press the Enter key In the SHIFT POSITION menu click the FOR WARD NEUTRAL or REVERSE button as required to switch shift operation You can adjust the engine speed by dragging the slide bar in the Throttle position menu Keyboard Move to an item you want to select by using the Tab key and press the Enter key Operate the slide bar by using the Left or Right arrow key Operate the shift position by using the Up or Down key To stop the engine click the STOP button in the Engine menu or press the Esc key on the key board Keyboard Move to the STOP button by using the Tab key and press the Enter key NOTE You can click the START button only when is selected in the SHIFT POSITION menu and throttle opening is set to Minimum Inthe SHIFT POSITION menu you can select FORWARD and REVERS
21. PRESSURE 3 L L MANIFOLD ABSOLUTE PRESSURE 1 kPa L L MANIFOLD ABSOLUTE PRESSURE 3 L L MANIFOLD ABSOLUTE PRESSURE 1 inHg L L MANIFOLD ABSOLUTE PRESSURE 3 L L CYLINDER TEMPERATURE 1 L L CYLINDER TEMPERATURE 3 L L CYLINDER TEMPERATURE 1 F L L CYLINDER TEMPERATURE 3 L L INTAKE AIR TEMPERATURE 1 L L INTAKE AIR TEMPERATURE 3 L L INTAKE AIR TEMPERATURE 1 F L L INTAKE AIR TEMPERATURE 3 L L EX MANI TEMPERATURE STBD 1 L L EX MANI TEMPERATURE STBD 3 L L EX MANI TEMPERATURE PORT 1 L L EX MANI TEMPERATURE PORT 3 L L EX MANI TEMPERATURE STBD 1 iz L L EX MANI TEMPERATURE STBD 3 L L EX MANI TEMPERATURE PORT 1 F L L EX MANI TEMPERATURE PORT 3 L L ACCELERATION VOLTAGE 1 V L L ACCELERATION VOLTAGE 3 L L TPS MAIN VOLTAGE 1 V L L TPS MAIN VOLTAGE 3 L L TPS SUB VOLTAGE 1 V L L TPS SUB VOLTAGE 3 L L SHIFT POSITON 1 V L L SHIFT POSITON 3 L L SPS VOLTAGE 1 V L L SPS VOLTAGE 3 L L BATTERY VOLTAGE 1 V L L BATTERY VOLTAGE 3 L L FAILURE TIME 1 h L L FAILURE TIME 3 L L FAILURE TIME 1 min L L FAILURE TIME 3 L L ELAPSE OF TIME 1 min L L ELAPSE OF TIME 3 L L CAUTION SYSTEM NAME 2 L L ENGINE SPEED 2 r min L L MANIFOLD ABSOLUTE PRESSURE 2 mmHg L L MANIFOLD ABSOLUTE PRESSURE 2 kPa L L MANIFOLD ABSOLUTE PRESSURE 2 inHg L L CYLINDER TEMPERATURE 2 L L CYLINDER TEMPERATURE 2 L L INTAKE AIR TEMPERATURE 2 L L INTAKE AIR TEMPERATURE 2 iF L L EX MANI TEM
22. SPC CAUTION SYSTEM NAME 3 2 ENGINE SPEED 3 2 MANIFOLD ABSOLUTE PRESSURE 3 2 MANIFOLD ABSOLUTE PRESSURE 3 MANIFOLD ABSOLUTE PRESSURE 3 2 CYLINDER TEMPERATURE CYLINDER TEMPERATURE INTAKE AIR TEMPERATURE 3 3 2 INTAKE AIR TEMPERATURE 3 2 V V V V V V h 3 5 2 G 3 2 3 2 EX MANI TEMPERATURE STBD 3 EX MANI TEMPERATURE STBD 3 EX MANI TEMPERATURE PORT 3 EX MANI TEMPERATURE PORT 3 ACCELERATION VOLTAGE 3 2 TPS MAIN VOLTAGE 3 2 TPS SUB VOLTAGE 3 2 SHIFT POSITION 3 2 SPS VOLTAGE 3 2 BATTERY VOLTAGE 3 2 2 2 2 2 CIEC E W CI ECT CT IEC o E lt lt lt lt lt Il 56 EXPLANATION OF DATA ITEMS ENGINE SPEED R MIN Indicates the engine speed within a range from O r min to 8 000 r min IGNITION TIMING 9 Indicates the ignition timing in the range from ATDC 10 to BTDC 40 MANIFOLD ABSOLUTE PRESSURE mmHg kpa inHg Indicates intake manifold pressure within a range from 0 mmHg to 800 mmHg BAROMETRIC PRESSURE mmHG inHg Indicates barometric pressure within a range from 700 mmHg to 780 mmHg Atmospheric pressure is 760 0 to 120 kpa 0 inHg to 30 inHg CYLINDER TEMPERATURE Indicates the cylinder wall temperature in the range
23. Vista Installing device driver software is displayed on the lower right corner and the installation of driver auto matically starts Fig 23 After the installation of driver is completed Device driver software installed successfully is displayed on the lower right corner Fig 24 NOTE Registration of driver With SDS USB Adapter and its cable connected to USB port of computer register this device informa tion into the computer Found New Hardware Wizard Welcome to the Found New Hardware Wizard Windows will search for current and updated software by looking on your computer on the hardware installation CD or on the Windows Update Web site with your permission Can Windows connect to Windows Update to search for software O Yes this time only Yes now and every time connect a device O No not this time Click Next to continue Fig 22 3 i X 1 Installing device driver software Click here for status 158 Fig 23 _ 505 USB Adapter X 2 Device driver software installed successfully Fig 24 15 3 4 5 16 When another new hardware detection wizard Fig 25 appears check that Install software au tomatically recommended is selected and then click the Next button The Driver Installation window Fig 26 appears and driver installation begins The Hardware Installation window Fig 27 ap pears To
24. calibration SYSTEM CALIBRATION System Formation Number of stations 2 Dual Station Number of engines 1 Single Engine 1 Specify the number of stations and the number of engines 2 Click OK button to go next OK Cancel Press Tab to select item Press UP and DN to select the number of stations then press Enter Press UP and DN to select the number of engines then press Enter Click OK button Use Esc or Cancel button to return to the previous screen Fig 91 NOTE e If you make a selection different from the actual configuration the error screen is displayed x Fig 91 1 Ifthe number of engines actually connected is larger j The specified composition differs From real composition than that previously selected it cannot be detected as an error and the error screen Fig 91 1 is not displayed Fig 91 1 66 5 The following window Fig 92 appears Check that the calibration are correct click the OK button and proceed to the next step Enter key on the keyboard Clicking the Cancel button brings you back to the previous window SYSTEM CALIBRATION System Formation Number of stations 2 Number of engines 1 1 Confirm the above setup information is correct 2 The current BCM data will be erased and the new setup data will be retained by the BCM when clicking OK button Use Esc or Cancel button to return to the previous scr
25. continue the driver installation click the Continue Anyway button Clicking the STOP Installation button stops the driver installation Found New Hardware Wizard This wizard helps you install software for USB Device gt If your hardware came with an installation CD lt 6 or floppy disk insert it now What do you want the wizard to do Install from list or specific location Advanced Click Next to continue Found New Hardware Wizard Please wait while the wizard installs the software 505 USB Adapter Fig 26 Hardware Installation The software you are installing for this hardware e 505 USB Adapter has not passed Windows Logo testing to verify its compatibility with Windows Tell me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing Continue amp nyway Fig 27 6 The Driver Installation Completion window Fig 28 s 5 Completing the Found New Click the Finish button Hardware Wizard The wizard has finished installing the software for 505 USB Adapter Click Finish to close the wizard 7 To make sure that the SDS USB Adapter driver is 5 Device Manager 5 File
26. if mismatch between the actual shift position and the target shift position due to a reason other than engine failure continues longer than specified SELECT SWITCH 1ST 2ND ON OFF Indicates the select switch status by ON or OFF Select switch 1st ON means that the 1st station is effective START amp STOP SWITCH 1ST 2ND PORT STBD CENTER ON OFF Indicates the start amp stop switch status by ON or OFF By pressing the switch to start or stop the engine the switch is turned ON and when you leave your hand it is turned OFF EMERGENCY STOP SWITCH ON OFF Indicates the emergency stop switch status by ON or OFF When the lock plate is inserted into the emergency stop switch the switch is turned OFF THROTTLE ONLY SWITCH 1ST 2ND ON OFF Indicates the throttle only switch status by ON or OFF By shifting the remote control lever to forward or reverse with the throttle only switch ON racing the engine becomes possible with the gear in the neutral position 83 SYNC SWITCH 1ST 2ND ON OFF Indicates the synchronization switch status by ON or OFF When starting 2 or more engines turn on the synchronization switch ON and then match the r min of each engine to the PORT side outboard motor In the initialization the switch is at ON CENTER CTRL SWITCH 1ST 2ND ON OFF Indicates the center control switch status by ON or OFF When starting engines the PORT side outboard motor and CENTER side outboard motor
27. lt lt lt 7 6 6 peq 105589007 9 epp U GOQQ esnj E 5 3 19987 e qeo giqeo qng peaj 9 8A JOjeJos L LR CI 5 3 t 19981 esn4 1012euuoo SAS ene 2 uoles 151 pug Q uoles puc 90 N QIY 0 RESISTOR TERMINAL 33926 98J00 EXT WIRE HARNESS REMOTE CONTROL 2 0 m 36620 08 20 CHOICE 1 MAIN WIRE HARNESS REMOTE CONTROL 6 5 m 36620 98J00 MAIN WIRE HARNESS REMOTE CONTROL 9 5 m 36620 98J10 b HARNESS ASSY DUAL STATION 36622930 1 HARNESS ASSY BCM FOR SNGL 36623 9801 1 6 HARNESS ASSY BCM No 2 FOR SNGL 36624 98301 1 b REMOTE CONTROL ASSY TOP MOUNT 672009801 1 amp CONTROLLER ASSY BOAT ELECTRI
28. open it Far you Open C Program Browse Fig 19 Windows Media Center gt Windows Media Player Windows Meeting Space x Windows Movie Maker Windows Photo Gallery d Windows Update Administrator Accessories Docurnents ES Calculator cM Pictures EN Command Prompt iz Connect to Network Projector Music Notepad M Paint Games Remote Desktop Connection Run Search Se Snipping Too t Sound Recorder Recent Items a Sync Center d Welcome Center Computer Windows Explorer E Windows Mobility Center Windows Sidebar m WordPad Ease of Access Metwork Connect Control Panel System Tools Tablet PC Default Programs Help and Support Fig 20 Run as ypethe of a program folder document or Internet resource and Windows will open it for you pen C Program Files SDS Driver DPInst exe ae This task will be created with administrative privileges OK __ Browse Fig 21 3 2 INSTALLING THE SDS USB ADAPTER DRIVER 1 Connect the diagnostic harness and USB cable with a USB adapter to the USB port of your PC and communication connector 4 connector 2 Turn on the Main switch After a while a new hard ware detection wizard appears Check that No not this time is selected and then click the Next button Fig 22 For Windows
29. switch main Fig 118 switch and turn it ON again e f the initialization of BCM information fails an er ror message is indicated Click the OK button Fig 119 and start from the internation RENTUR step 1 again Again please perform BCM INITIALIZATION Fig 119 86 MEMO 87 5 8 WIRING With Teleflex Gauge 5 8 1 SINGLE ENGINE SINGLE STATION sale OA 22 Jejeuiopeedg qns OQ re TN c gt qnu 94110 0 40 b ANIDNA 0 101990009 JOOUUOD Jepues M8 YUE Jen qns OL Jepues yue n OL 259062006209 QOOOOcQ 25952069209 QOOOOcQ 8JIM peaj 1ndino Bojeuy dey 8 8A OO j p sas o r OO dO OO uazzng OO lege 88 N 9 Parto QY amp HARNESS AS
30. the Main Menu dialog box Fig 85 displays the following NOTICE window Fig 86 SYSTEM CALIBRATION is essential to calibrate the electronic remote control system components and set up the system Keyboard Select a desired item by using the instruction on the screen Up or Down arrow key and press the Enter 1 System formation registration 2 Engine location registration key to have the selected item accepted 3 Lever position calibration 4 Full tilt down position calibration Click the OK button and proceed to the next step Use Tab to select items then press Enter Click OK button to continue Fig 86 64 2 The following window Fig 87 appears Click the OK button and proceed to the next step Enter key on the keyboard SYSTEM CALIBRATION BCM System Connection 1 Make sure that all parts are properly connected Engine Remote Control Harness amp BCM Harness Remote Control Box Switch Panel Boat Control Module BCM Battery Main amp Sub Battery Cable 2 Tilt the engine to full down 3 Click OK button to accept Use Tab to select items then press Enter Click OK button to go next Fig 87 NOTE If the has already been calibrated the Confir mation window appears Fig 88 Has this BCM been set up vet Do vou want to re set up this BEM Fig 88 The following window appea
31. the buzzer does not sound within 2 minutes feedback at this zone is unsuccessful Ignore this zone and go to the next step f the buzzer sounds with a series of long about 2 seconds beep and FIN NG appears in the Service Data O feedback information feedback at this zone is unsuccessful Fig 63 Click the Stop button to return to STAND BY mode DIAGNOSTIC SYSTEM ACTUATOR TEST Bav Windawie ESSERE D SERVICE DATA E xi m ACTUATOR TEST X 02 Feedback Info 4 Select orepBack 1H FEEDBACK E r Description ENGINE SPEED Read Operation Manual before doing 02 feedback MANIFOLD ABSOLUTE PRESSURE CYLINDER TEMPERATURE Message Feedback is in operation Maintain engine speed at the specified RPM Pay attention when operating outboad motor under load Close throttle after finished at all RPM zones TOTAL OPERATION TIME MIN COMPENSATION FACTOR ZONE 1 COMPENSATION FACTOR ZONE 2 Use UP and DN to select item then press Go Use Esc to close ACTUATOR TEST COMPENSATION FACTOR ZONE 3 TIME OF LAST O2 FEEDBACK O2 FEEDBACK ACTION A Use UP and DN to select item group then press Enter select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Window F4 to chang
32. times L L NO OF DBW ETV FAILURE STBD times L L NO OF DBW ETV FAILURE CENTER times L NO OF DBW ESA FAILURE PORT times L L NO OF DBW ESA FAILURE STBD times L L NO OF DBW ESA FAILURE CENTER times L SELECT SWITCH 1ST ON OFF L SELECT SWITCH 2ND ON OFF L START amp STOP SW 1ST PORT ON OFF L L START amp STOP SW 1ST STBD ON OFF L L START amp STOP SW 1ST CENTER ON OFF L START amp STOP SW 2ND PORT ON OFF L L START amp STOP SW 2ND STBD ON OFF L L START amp STOP SW 2ND CENTER ON OFF L EMERGENCY STOP SWITCH ON OFF L THROTTLE ONLY SWITCH 1ST ON OFF L THROTTLE ONLY SWITCH 2ND ON OFF L SYNC SWITCH 1ST ON OFF L SYNC SWITCH 2ND ON OFF L CENTER CTRL SWITCH 1ST ON OFF L CENTER CTRL SWITCH 2ND ON OFF L BUZZER RESET SWITCH ON OFF L FORWARD SHIFT TRGT POSITION PORT NEUTRAL L L REVERSE FORWARD SHIFT TRGT POSITION STBD NEUTRAL L L REVERSE FORWARD SHIFT TRGT POSITION CENTER NEUTRAL L REVERSE FORWARD SHIFT POSITION PORT NEUTRAL L L REVERSE FORWAR SHIFT POSITION STBD NEUTRAL L L REVERSE FORWARD SHIFT POSITION CENTER NEUTRAL L REVERSE EXPLANATION OF DATA ITEMS ENGINE SPEED PORT STBD CENTER r min Indicates the engine speed of the outboard motor in the range from O to 8 000 r min LPS OUTPUT 1ST P M V Indicates the voltage of the PORT side lever position sensor main in the remote control box of the 1st station in the range from O to 5 V LPS OUTPUT 1ST P S V Indicates the vo
33. 3000 R MIN NO OF INTAKE FAILURE 3000 4000 R MIN NO OF MAP SENSOR FAILURE 4000 5000 R MIN NO OF CKP SENSOR FAILURE 5000 6000 R MIN NO OF IAC VALVE FAILURE ABOVE 6000 R MIN NO OF CMP SENSOR FAILURE ELAPSE TIME FROM REMINDER CANCEL NO OF CYL TEMP SNSR FAILURE NO OF OIL CHANGE REMINDER NO OF IAT SENSOR FAILURE COMPENSATION FACTOR ZONE 1 NO OF FUEL INJECTOR FAILURE COMPENSATION FACTOR ZONE 2 NO OF OVER REVOLUTION COMPENSATION FACTOR ZONE 3 NO OF LOW BATTERY VOLTAGE TIME OF LAST FEEDBACK NO OF LOW OIL PRESSURE O FEEDBACK h NO OF OVERHEAT GRADIENT EMERGENCY STOP SWITCH ON OFF NO OF OVERHEAT TEMP CTP SWITCH ON OFF NO OF ETV FAILURE ECM NEUTRAL SWITCH ON OFF NO OF ETV FAILURE MTR START SW ON OFF NO OF ETV FAILURE MOV VSV MI ON OFF LOW FUEL PUMP ON OFF SHIFT POSITION TRGT FOREWARD NEUTRAL REVERSE SHIFT POSITION FOREWARD NEUTRAL REVERSE 53 GROUP No GROUP No ITEM UNIT ITEM 34 5 34 5 CAUTION SYSTEM NAME 1 L L CAUTION SYSTEM NAME 3 L L ENGINE SPEED 1 r min L L ENGINE SPEED 3 L L MANIFOLD ABSOLUTE PRESSURE 1 mmHg L L MANIFOLD ABSOLUTE
34. 914 79410 Test wheel for DF40 DF50 09914 79010 Test wheel for DF90 DF115 DF140 NOTE e Refer to Periodic Maintenance FUEL MIXTURE CHECK section in the Service Manual of the associated outboard motor DF70A 80A 90A DF300 does not have the feedback function 2 Start the engine and warm it up for at least 5 minutes at around 2 000 r min Select FEEDBACK by clicking the W button of the Actuator Test text box Fig 58 The Service Data window O feedback information automatically appears Confirm that STAND BY is displayed to the right of O FEEDBACK in the lower part of the item box Fig 60 5 DIAGNOSTIC SYSTEM ACTUATOR TEST Main Menu F1 File F2 3 Window F4 Help F9 Exit F10 SERVICE oix o2 Feedback Info 4 Select o FEEDBACK Go Sing Description ENGINE SPEED 2000 rpm Read Operation Manual before doing 02 feedback MANIFOLD ABSOLUTE PRESSURE 315 mmHg CYLINDER TEMPERATURE 64 9C Message US zen Keep O2 sensor dry at all times Perform O2 TOTAL OPERATION TIME MIN 8 min feedback under a stable engine speed Click Go button to perform it COMPENSATION FACTOR ZONE 1 1 000 COMPENSATION FACTOR ZONE 2 1 000 Use UP and DN to select item then press Go Use Esc to close ACTUATOR TEST COMPENSATION FACTOR ZONE 3 1 000 TIME OF LAST O2 FEEDBACK 0 02 FEEDBACK STAND BY 4
35. ATA SHIFT POSITION FORWARD REVERSE THROTTLE POSITION Use RIGHT or LEFT to operate the throttle Use UP or DN to change the shift position Use Tab to select items then press Enter Use Esc to close BCM SIMULATOR 0 r min ENGINE SPEED BTDC5 IGNITION TIMING MANIFOLD ABSOLUTE PRESSURE 757 mmHg MANIFOLD ABSOLUTE PRESSURE 100 9 kPa MANIFOLD ABSOLUTE PRESSURE 29 83 inHg BAROMETRIC PRESSURE 757 mmHg BAROMETRIC PRESSURE kPa BAROMETRIC PRESSURE 29 89 inHg CYLINDER TEMPERATURE CYLINDER TEMPERATURE INTAKE AIR TEMPERATURE INTAKE AIR TEMPERATURE BATTERY VOLTAGE FUEL INJ PULSE WIDTH 0 INJECTED FUEL AMOUNT 0 FUEL CONSUMPTION AVE 0 0 zi UP and DN to select item group then press Enter select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Window F4 to change the active window Click or press Exit F10 to exit program Power 300PS ECM ID 33920 98J00 Spec Engine Type 4028cc 4 stroke Pstart 4 suzuki Dracvosric s Sf 3u7PM Fig 65 41 NOTE e Opening the BCM SIMULATOR window automatically opens the SERVICE
36. Action View correctly installed from the menu opened by right clicking My Computer select Property Hard 2 2 DVD CD ROM drives 3 4 Floppy disk controllers ware Device Manager to open the Device Man Floppy disk drive i 3 IDE ATA ATAPI controllers ager window Fig 29 iy Keyboards _ Mice and other pointing devices Check that USB Universal Serial Bus and SDS Pm USB Adapter are created under Device Manager 4 Sound video and game controllers in the window 2 System devices Universal Serial Bus controllers Standard Universal PCI to USB Host Controller NO TE Standard Universal PCI to USB Host Controller Standard Universal PCI to USB Host Controller Standard Universal PCI to USB Host Controller For confirming SDS USB adapter driver in Device USB Root Hub USB Root Hub Manager turn ON the main switch with the outboard motor and PC connected Fig 29 17 3 3 UPDATING DATABASES 1 Exitall the applications being executed other than Windows 2 Click the Start button point to Programs and click SUZUKI DIAGNOSTIC SYSTEM from the displayed menu Fig 30 3 The SDS program is started Fig 31 NOTE Set Program Access and Defaults 1 Accessories 3 Suzuki Pass Thru Reprogramming Tool Internet Explorer Outlook Express 7
37. C 367709800 1 33 1 1 _ PANEL ASSY SINGLE 7 37100984 1 BUZZER ASSY WARNING 83850093990 1 PANELASSY MAINSW 9871009800 1 PANEL ASSY EMERGENCY SW 3780893000 1 HARNESS ASSY INTERFACE UNT 8366019800 1 HARNESS ASSY ACTIVE HUB PWR 2 5 m 36663 98J00 CHOICE 1 2 69 9519 9 3 3666398000 CHOICE 1 HARNESS ASSY ACTIVE HUB PWR 6 0 m 36663 98J10 HARNESS ASSY 2 HUB 1 m CHOICE 1 HARNESS ASSY 2 HUB 6 5 m 9 h 5 8 3 TWIN ENGINES SINGLE STATION d Aieneg qns d eui 1016106 EES 15 leqe CI n NOO H 57 leqe e qeo Aueneg 1018081 Jejeujouoe o Cnn qnu 94110 0 10 3NION 01 10290009 JOSUUOD a5nv5 enel 19987 OF
38. CE 1 CHOICE 1 9 Jojeuiouoe Jejeujopeedg any eui 10 2 3NION3 20 ANIDNG 1012euu00 8970 ener Jepues yug qns OL Jepues Josues como peq au ug qns Jo1eJos 1ndino dO d Joyowoyoe Bojeuy qns A 8A deo 7 T j Sn grs S Ld CJ HH H31N39 aie M i 9T OE Lb NOO H leqe1 3 D iH ajqeo j 2 S Ld Lesen
39. E only when the throttle opening is set to Minimum When the throttle opening is Maximum the maximum engine speed is 2 500 r min If you stop the engine by clicking the STOP button or pressing the Esc key the shift position and throttle opening automatically enter the initial status Shift position Neutral throttle opening Minimum ENGINE 7 BCM SIMULATOR x SHIFT POSITION FORWARD NEUTRAL REVERSE THROTTLE POSITION Use RIGHT or LEFT to operate the throttle Use UP or DN to change the shift position Use Tab to select items then press Enter Use Esc to close BCM SIMULATOR Fig 66 File F2 Save F3 and Help F9 keys are invalid when performing BCM simulator 42 4 7 DATA LOGGER 1 Clicking the DATA LOGGER button from the Main Menu dialog box Fig 48 displays the following window Fig 67 This window can display up to three primary service data in the graph form To change or select a display item click the Setup button Keyboard To change the Monitor menu select it by using the Up or Down arrow key and press the Enter key S suzuki DIAGNOSTIC SYSTEM DATA LOGGER 1 x 1 x 7 Main Menu F1 File F2 Save F3 Window F4 Help F9 Exit F10 End 00 10 0 00 10 Setup ENGINE SPEED 1656 rpm IGNITION TIMING BTDC 11 3 MANIFOLD ABSOLUTE PRESSURE 401 mmHg
40. ECM or BCM calibrated in one boat cannot be reused in another boat To reuse the ECM or BCM be sure to calibrate the system after deleting the BCM information by using the BCM INITIALIZATION menu The BCM INITIALIZATION menu cannot be used to delete the diagnostic information registered in the BCM Use the BCM INITIALIZATION menu to delete information for the connected BCM To delete information for the master BCM connect the diagnostic harness to the master BCM To delete information for the sub BCM connect the diagnostic harness to the sub 63 5 3 SYSTEM CALIBRATION Calibrate the system and register information in the BCM e SYSTEM FORMATION REGISTRATION Sets the number of stations and the number of engines and registers information in the BCM If two stations are available also registers information in both the master BCM and sub BCM ENGINE LOCATION REGISTRATION Hegisters the positions PORT CENTER STBD of engines in the BCM e LEVER POSITION CALIBRATION Registers the position Forward full opening full closing neutral Reverse full opening full closing of the remote control lever in the BCM CAUTION To change the system configuration after system calibration be sure to initialize the system by using the BCM INITIALIZATION menu Example The system is calibrated as a single engine and then the single engine is changed to the dual engine 1 Clicking the SYSTEM CALIBRATION button from
41. ELECTRIC CORPORATION Details VERSION INFORMATION DETAILS PROGRAM SUZUKI P N 09933 19862 MELCO P N F007T90682 9312 203 Ver 1 07 0 0 1 07 0 0 DATABASE SUZUKI P N 09933 19862 MELCO P N F007T90682 9312 203 Ver 1 12 0 0 1 12 0 0 x e Exif program Fig 82 Fig 81 51 4 10 DATA ITEM GROUPS DATA ITEM GROUP TABLE The following table shows the groups to which each data item belongs Items with mark be freely selected and displayed Group No 1 Engine data items that can be selected in SERVICE DATA Group No 2 Caution Sys Info items that can be selected in SERVICE DATA Group No 3 Operation Hours items that can be selected in SERVICE DATA Group No 4 O Feedback Info items that can be selected in SERVICE DATA Group No 5 Service Data items that can be selected in SERVICE DATA Group No 6 Data Logger items that can be selected in DATA LOGGER GROUP No GROUP No ENGINE SPEED ETV TRGT ANGLE IGNITION TIMING TPS MAIN MANIFOLD ABSOLUTE PRESSURE TPS MAIN OUTPUT MANIFOLD ABSOLUTE PRESSURE TPS SUB MANIFOLD ABSOLUTE PRESSURE TPS SUB OUTPUT PRESSURE ESA TRGT POSITION PRESSURE SHIFT POSITION SNSR OUTPUT PRESSURE TRIM ANGLE CYLINDER TEMPERATURE TRIM ANGLE SNSR OUTPUT CYLINDER TEMPERATURE TILT LIMIT VOLTAGE INTAKE AIR TEMPERATU
42. Fig 69 appears Click the button and repeat Step 2 LOGGING CONDITION SETUP Condition Sampling cycle sec 0 2 3 9sec 0 10 SEC Tsec T min Logging time Item Selectable item 0 WENGINE SPEED rpm LIINTAKE AIR TEMPERATURE C OK Cancel nput Condition and press Tab se UP and to select items and press Space Bar to change from isplayed to not displayed then click OK button Max 3 items se Esc or Cancel button to cancel Fig 68 INPUT ERROR x Incorrect input data Check Sampling cycle and Logging time Fig 69 3 To monitor data click the Monitor button To stop monitoring click the Stop button Fig 67 Keyboard Move to the Monitor button by using the Tab key and press the Enter key to have monitor ing accepted NOTE The Stop button is available only when data is being monitored or logged On the graphs for the following 33 items the numbers on the vertical axis show the number of times counted after the current DATA LOGGER window has opened not the total number of items The number of times is returned to zero 0 when logging or monitoring is started Refer to DATA ITEM GROUPS page 52 of this manual for items which can be selected NO OF CHECK CODE WIRE FAILURE NO OF EX TEMP SNSR FAILURE S NO OF EX TEMP SNSR FAILURE P NO OF SP SENSOR FAILURE NO OF TPS FAIL
43. File has been updated Fig 37 NOTE DATABASE UPDATE ERROR xj If you select a directory file location where the da tabase file does not exist a database update error 69 message appears Fig 38 Click the OK button and restart database update from Step 8 ig 22 4 OPERATING SDS 4 1 CONNECTION AND STARTING THE SDS PROGRAM NOTE Make sure that your is off before connecting the diagnostic harness Make sure that the battery connected to the outboard motor is properly fully charged 1 Connect the diagnostic harness and USB cable with a USB adapter to the USB port of your PC and communication connector 4 pin connector Fig 39 USB port USB1 1 or USB2 0 Diagnostic USB cable harness ECM of outboard motor SDS Ver 6 00 USB adapter 4 pin connector Fig 39 2 Turn on the main switch of the outboard motor 45 E MEN 3 Turn on your PC to start Windows 4 From the task bar of the computer window click the Start button and point to Programs FE Provans 5 start the SDS program click SUZUKI DIAG NOSTIC SYSTEM Fig 40 The SDS program will start Fig 41 Suzuki Pass Thru Reprogramming Tool amp amp Internet Explorer al Outlook Express 7 Fig 40 23 SUZUKI Suzuki Diagnostic System PROGRAM Ver 6 00 DATABASE 6 00 SUZUKI MOTOR CORPORATION Copyright 2000 MITSUB
44. ION VOLTAGE 1 2 EX MANI TEMPERATURE PORT 2 ACCELERATION VOLTAGE 2 2 TPS MAIN VOLTAGE 1 2 TPS MAIN VOLTAGE 2 2 TPS SUB VOLTAGE 1 2 TPS SUB VOLTAGE 2 2 SHIFT POSITION 1 2 SHIFT POSITION 2 2 SPS VOLTAGE 1 2 SPS VOLTAGE 2 2 BATTERY VOLTAGE 1 2 lt lt lt lt lt lt IS S IN IN SS N31 BATTERY VOLTAGE 2 2 jim CSS IN UN INS INK UIN OS NK I IS UNS NUN UNIS IN INS UIN N VC NV 55 GROUP No ITEM 3 4 SPC CAUTION SYSTEM NAME 3 1 ENGINE SPEED 3 1 MANIFOLD ABSOLUTE PRESSURE 3 1 MANIFOLD ABSOLUTE PRESSURE 3 1 MANIFOLD ABSOLUTE PRESSURE 3 1 CYLINDER TEMPERATURE 3 1 CYLINDER TEMPERATURE 3 1 INTAKE AIR TEMPERATURE 3 INTAKE AIR TEMPERATURE 3 1 3 3 1 Gm EX MANI TEMPERATURE STBD 3 1 3 1 EX MANI TEMPERATURE STBD STBD STBD EX MANI TEMPERATURE PORT 3 1 EX MANI TEMPERATURE PORT 3 1 ACCELERATION VOLTAGE 3 1 TPS MAIN VOLTAGE 3 1 TPS SUB VOLTAGE 3 1 SHIFT POSITION 3 1 SPS VOLTAGE 3 1 BATTERY VOLTAGE 3 1 FAILURE TIME 3 1 FAILURE TIME 3 1
45. ISHI ELECTRIC CORPORATION Press Enter Fig 41 6 To proceed to the next window press the Enter key The IMPORTANT NOTICE window Fig 42 ap pears Head the messages in this window and follow the instructions IMPORTANT NOTICE Read the Operation Manual carefully before proceeding Refer to safety precautions shown in the Operation Manual This software is designed for use with battery powered laptop PC Do not use AC powered PC This software may not operate with the operating environment required on some PC Press Enter Fig 42 24 7 To proceed to the next window press the Enter key The GENERAL INSTRUCTION window Fig 43 appears Head the messages on this window and follow the instructions Then press the Enter key GENERAL INSTRUCTIONS 1 Place remote control lever in NEUTRAL position 2 Remove engine cover 3 Connect the diagnostic harness 4 pin connector to the engine harness 4 Connect the adapter to the diagnostic harness 5 Connect the USB cable connector small one to the adapter 6 Connect the USB cable connector large one to the PC 7 Turn the main switch ON Press Enter Fig 43 8 The first menu window Fig 44 appears a SUZUKI DIAGNOSTIC SYSTEM 18 xl Main Menu F1 File F2 Save F2 W ndowiF4 Help F9 Exit F10 ECM or BCM information or press Main Menu F1 select item by UP and DN then press Enter Click or press Exit F10
46. J10 CAP 8 PIN CONNECTOR 36666 98J00 WIRE COMP JUMPER 36665 98J00 HARNESS ASSY 2 HUB 1 m 36662 98J00 HARNESS ASSY 2 HUB 6 5 m 36662 98J10 UNIT PASSIVE HUB 34921 98010 C H gt MIM om oO CHOICE 1 2 9 6 UNINSTALLING THE SDS PROGRAM Uninstall delete the SDS program from your PC NOTE Check that all other programs have exited before uninstalling the SDS program 1 From the task bar of your PC click the Start button and select Control Panel The following dialog box appears Fig 120 EJ Control Panel Fille Edit View Favorites Tools Help 4 Back p C Felders x Address B Control Panel Go Eo x Li M 19 Accessibility Add Remove Add Remove Administrative Automatic Control Panel Options Hardware Programs Tools Updates 11 e Lise Ehe settings in Control Panel to i A LA personalize your computer BDE Date Time Display Fax Folder Options Select an item to view its Administrator description Windows Update 44 A Windows 2000 Support Fonts Game InterBase Internet Keyboard Controllers Manager Options a Network and Phone and Power Options Printers Dial up Co Modem 7 icm my QE Regional Scanners and Scheduled Sounds and System Options Cameras Tasks Multimedia ET E
47. NUAL tror 50 VERSION 51 4 9 EXITING THE SDS PROGRAM 51 4 10 DATA ITEM GROUPS DATA ITEM GROUP TABLE 52 EXPLANATION OF DATA ITEMS c oerre en 57 5 SPC cece eccentrics 61 5 1 CONNECTING PC AND BCM 61 5 2 BCM MAIN MENU 62 5 3 2 64 5 4 SETTING CHANGE 70 5 5 SYSTEM CHECK 74 5 6 DATA GROUPS BCM DATA ITEM GROUP TABLE 80 EXPLANATION OF DATA ITEMS ee eren nnn 82 5 7 BCM INITIALIZATION 11 nana aun a aun 85 5 8 WIRING With Teleflex Gauge 88 6 UNINSTALLING THE SDS PROGRAMM rrr 100 1 OVERVIEW 1 1 APPLICABLE MODELS AND NECESSARY TOOLS The table below lists application models and necessary tools The numbers in the Necessary Tool column correspond to the tool numbers in the figure shown below NECESSARY TOOL MODEL NAME MODEL YEAR O FEEDBACK DF40 50 999 and later DF60 70 998 and later DF70A 80A 90A 009 DF90 115 001 and later DF100 009 DF140 DF150 175 006 and
48. PERATURE STBD 2 B L L EX MANI TEMPERATURE PORT 2 C L L EX MANI TEMPERATURE STBD 2 L L EX MANI TEMPERATURE PORT 2 T L L ACCELERATION VOLTAGE 2 V L L TPS MAIN VOLTAGE 2 V L L TPS SUB VOLTAGE 2 V L L SHIFT POSITON 2 V L L SPS VOLTAGE 2 V L L BATTERY VOLTAGE 2 V L L FAILURE TIME 2 h L L FAILURE TIME 2 min L L ELAPSE OF TIME 2 min L L 54 ITEM GROUP No 3 4 ITEM GROUP No 3 4 SPC CAUTION SYSTEM NAME 1 1 SPC CAUTION SYSTEM NAME 2 1 ENGINE SPEED 1 1 ENGINE SPEED 2 1 MANIFOLD ABSOLUTE PRESSURE 1 1 MANIFOLD ABSOLUTE PRESSURE 2 1 MANIFOLD ABSOLUTE PRESSURE 1 1 MANIFOLD ABSOLUTE PRESSURE 2 1 MANIFOLD ABSOLUTE PRESSURE 1 1 MANIFOLD ABSOLUTE PRESSURE 2 1 CYLINDER TEMPERATURE 1 1 CYLINDER TEMPERATURE 2 1 CYLINDER TEMPERATURE 1 CYLINDER TEMPERATURE 2 1 INTAKE AIR TEMPERATURE om INTAKE AIR TEMPERATURE 2 1 INTAKE AIR TEMPERATURE EX MANI TEMPERATURE STBD GT EX MANI TEMPERATURE STBD 2 1 o o EX MANI TEMPERATURE STBD INTAKE AIR TEMPERATURE 2 1 EX MANI TEMPERATURE PORT Om EX MANI TEMPERATURE STBD 2 1 EX MANI TEMPERATURE PORT 2 1 EX MANI TEMPERATURE PORT ACCELERATION VOLTAGE 1 1 EX MANI TEMPERATURE PORT 2 1
49. RE Are you sure Click Go button 5 actuation UP and DN to select item then press Go Esc to close ACTUATOR TEST IGNITION TIMING MANIFOLD ABSOLUTE PRESSURE BAROMETRIC PRESSURE CYLINDER TEMPERATURE INTAKE AIR TEMPERATURE Actuator test item BATTERY VOLTAGE FUEL INJ PULSE WIDTH INJECTED FUEL AMOUNT FUEL CONSUMPTION AVE HIGH FUEL PUMP DUTY IAC VALVE DUTY PURGE VALVE DUTY EX MANI TEMPERATURE STBD EX MANI TEMPERATURE PORT ETY TRGT ANGLE Use UP and DN to select item group then press Enter 0 select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Window F4 to change the active window Click or press Exit F10 to exit program Power 300PS ECM ID 33920 9871 Spec Engine Type 4028cc 4 stroke Astarte ci amp r 036 Paint suzuki DIAGNOSTIC S i 10 30 am Fig i 58 NOTE When selecting O Feedback refer to Performing the O Feedback Page 37 3 To perform the selected actuator test click the Go button The test is performed for 5 seconds and then stops automatically Keyboard Move to the Go button by using the Tab key and then press the Enter key NOTE ACTUATOR TEST ERROR Fixed Ignition Timing continues till the Stop but ton is pressed
50. RE 353 mmHg 800 700 600 500 400 300 200 100 i 0 10 20 30 40 50 60 70 80 90 100 Click Go button to start logging Click Stop button to stop monitoring Use Tab to select button Click or press Exit F10 to exit program Power 300PS ID 33920 98 771 Spec Type 4028 4 stroke PAstart 4 8039 Paint suzuki pracnosti s 10 34 am Fig 70 Ea suzuki DIAGNOSTIC SYSTEM DATA LOGGER 4 8 x Bl Main 1 File F2 Save E3 window F4 Help F9 8j f Stop Logging 00 04 6 00 10 setup 1313 rpm 0 10 20 30 40 50 60 70 80 90 100 IGNITION TIMING BTDC7 _ 0 10 20 30 40 50 60 70 80 90 100 MANIFOLD ABSOLUTE PRESSURE 349 mmHg 800 700 600 500 400 300 200 100 1 0 10 20 30 40 50 60 70 80 90 100 Click Stop button to stop logging Use Tab to select button Click or press Exit F10 to exit program Power 300PS ID 33920 9871 Spec Type 4028 4 stroke 22 Sr os0 Paint suzuki pracnosti s ge 103a Fi g 71 button is available only when data is being monitored Up to 100 points be displayed in the window The horizontal axis is automatically scrolled to the left if the number of logged monitored horizontal axis data exceeds 100 points A point on the
51. RE BOAT SPEED OVER WATER INTAKE AIR TEMPERATURE BOAT SPEED OVER WATER BATTERY VOLTAGE BOAT SPEED OVER WATER FUEL INJ PULSE WIDTH SPEED SNSR OUTPUT INJECTED FUEL AMOUNT WATER PRESSURE FUEL CONSUMPTION AVE WATER PRESSURE HIGH FUEL PUMP DUTY WATER PRESSURE SNSR OUTPUT IAC VALVE DUTY TPS PURGE VALVE DUTY TPS OUTPUT EX MANI TEMPERATURE STBD NO OF CMP FAILURE VVT_STBD EX MANI TEMPERATURE PORT NO OF CMP FAILURE VVT_PORT EX MANI TEMPERATURE STBD VVT ADVANCE ANGLE STBD EX MANI TEMPERATURE PORT VVT ADVANCE ANGLE PORT 52 GROUP No 3 4 GROUP No 3 4 NO OF VVT ADVANCE FAILURE S NO OF DBW SYSTEM FAILURE times NO OF VVT ADVANCE FAILURE P NO OF ESA FAILURE ECM times NO OF OCV FAILURE VVT STBD NO OF ESA FAILURE MTR times NO OF OCV FAILURE VVT PORT NO OF ESA FAILURE MOV times NO OF CHECK CODE WIRE FAILURE SYSTEM FORMATION STA Station NO OF EX TEMP SNSR FAILURE S SYSTEM FORMATION ENG Engine NO OF EX TEMP SNSR FAILURE P SYSTEM FORMATION ENG POSITION NO OF SPS FAILURE TOTAL OPERATION TIME HRS NO OF TPS FAILURE TOTAL OPERATION TIME MIN NO OF TRIM SENSOR FAILURE 0 1000 NO OF SPEED SENSOR FAILURE 1000 2000 R MIN NO OF NEUTRAL SW FAILURE 2000
52. SUZUKI DIAGNOSTIC SYSTEM Fig 30 Do not update the database when your PC is connected to the ECM or BCM of the outboard motor SUZUKI Suzuki Diagnostic System PROGRAM Ver 6 00 DATABASE Ver 6 00 SUZUKI MOTOR CORPORATION Copyright 2000 MIT SUBISHI ELECTRIC CORPORATION Press Enter 18 Fig 31 4 Press the Enter key to display the next window Fig 32 IMPORTANT NOTICE Read the Operation Manual carefully before proceeding Refer to safety precautions shown in the Operation Manual This software is designed for use with battery powered laptop PC Do not use AC powered PC This software may not operate with the operating environment required on some PC Press Enter Fig 32 5 Press the Enter key to display the next window Fig 33 GENERAL INSTRUCTIONS 1 Place remote control lever in NEUTRAL position 2 Remove engine cover 3 Connect the diagnostic harness 4 pin connector to the engine harness 4 Connect the adapter to the diagnostic harness 5 Connect the USB cable connector small one to the adapter 6 Connect the USB cable connector large one to PC 7 Turn the main switch ON Press Enter Fig 33 19 6 Pressing the Enter key displays the Communication Error dialog box Fig 34 Click the OK button to proceed to the next 50 DIAGNOSTIC SYSTEM 18 x Menu F1 File F2 Save F3 Wind
53. SY BCM No 1 FOR SNGL 36623 98101 1 REMOTE CONTROL ASSY TOP MOUNT 672009801 1 CONTROLLER ASSY BOAT ELECTRIC 367709800 1 CARBCMCONNECTOR 33911 88BL0 1 _ 6 PANELASSY SINGLE 3700989031 _ 1 9 BUZZER ASSY WARNING 7 385009890 1 0 PANELASSY MAINSW 370009800 1 6 HARNESS ASSY INTERFACE UNIT 36661980 1 UNIT INTERFACE 8 HARNESS ASSY BATTERY 2m 366259800 E HARNESS ASSY ACTIVE HUB PWR 2 5 m HARNESS ASSY ACTIVE HUB PWR 6 0 m WIRE COMP JUMPER UNIT ACTIVE b 6 CONNECTOR amp HARNESS ASSY 3 GAUGE HARNESS ASSY 2 GAUGE G m e 89 5 8 2 SINGLE ENGINE DUAL STATIONS uOnels 15 qnu eui jo 40 OA 1 Jejeuopeeds 01 1099 000 SIU 9 009 89 0 ener puc Jepues yue jen qns OL 8 yug jan d 9 13 or Josues jueudinbe 000ZV3INN
54. TY 338 PURGE VALVE DUTY 0 0 EX MANI TEMPERATURE STBD EX MANI TEMPERATURE PORT C ETY TRGT ANGLE 205 Use UP and DN to select item group then press Enter 0 select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Window F4 to change the active window Click or press Exit F10 to exit program Power 300PS ECM ID 33920 9871 Spec Enqine Type 4028cc 4 stroke 4 805 Paint suzuki pracnosti s 10 29 am Fig 57 NOTE Opening the ACTUATOR TEST window automatically opens the SERVICE DATA Engine Data window Head Description and Message in the ACTUATOR TEST window and follow the instructions To change the active window click the Window F4 button F4 key on the keyboard 33 2 In the ACTUATOR TEST window click the W button to select an actuator test item Fig 58 Keyboard To select a displayed item move to the Select button by using the Tab key Select an item by using the Up or Down arrow key and press the Enter key to have the item accepted 5 DIAGNOSTIC SYSTEM ACTUATOR TEST 81 x Main Menu F1 File F2 Save F3 Window F4 Help F9 Exit F10 ES o ml x OR 2122 Engine Data Select ENGINE SPEED 85 IGNITION MISFIRE 6 IGNITION MISFI
55. TY TRGT ANGLE CENTER TPS OUTPUT PORT lt lt lt lt lt lt lt lt lt lt lt lt TPS OUTPUT STBD Use UP and DN to select item group then press Enter 0 select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Exit F10 to exit program Ti 8070 Paint suzuki pracnosti s Eg 11 02 AM Fig 1 1 0 Refer to DATA ITEM GROUP TABLE page 80 of this manual for items which be called out respectively from the service data of the outboard motor ECM connected with the master BCM 76 5 You can select whether to display or hide the win dows of service data for the outboard motor ECM with SDS connected to the master BCM To se lect an item whose window you want to display click the Select button Keyboard Move to the Select button by using the Tab key and press the Enter key 6 The ITEM SELECTION SERVICE DATA dialog box appears Fig 111 Items are displayed when their check boxes are selected check boxes with V mark Items not displayed when their check boxes are cleared check boxes without V mark You select whether to display or hide an item by clicking the check box Keyboard To display or hide an item select it by using the Up or Down arrow key and press the Space key To have the selected item acce
56. URE NO OF NEUTRAL SWITCH FAILURE NO OF INTAKE FAILURE NO OF MAP SENSOR FAILURE NO OF CKP SENSOR FAILURE NO OF CMP FAILURE VVT STBD NO OF CMP FAILURE VVT PORT 44 NO OF VVT ADVANCE FAILURE S NO OF VVT ADVANCE FAILURE P NO OF OCV FAILURE VVT STBD NO OF OCV FAILURE VVT PORT NO OF IAC VALVE FAILURE NO OF CMP SENSOR FAILURE NO OF CYL TEMP SENSOR FAILURE NO OF IAT SENSOR FAILURE NO OF FUEL INJECTOR FAILURE NO OF OVER REVOLUTION NO OF LOW BATTERY VOLTAGE NO OF LOW OIL PRESSURE NO OF OVERHEAT GRADIENT NO OF OVERHEAT TEMP NO OF ETV FAILURE ECM NO OF ETV FAILURE MTR NO OF ETV FAILURE MOV NO OF DBW SYSTEM FAILURE NO OF ESA FAILURE ECM NO OF ESA FAILURE NO OF ESA FAILURE MOV NO OF TRIM SENSOR FAILURE 4 To start data logging click the Go button Fig 70 Data logging automatically stops at the entered time To stop data logging click the Stop button Fig 71 Keyboard Move to the Go or Stop button by using the Tab key and press the Enter key to have it accepted EJ SUZUKI DIAGNOSTIC SYSTEM DATA LOGGER E 1 x E Main Menu File F2 Save F3 Windaw F4 9 Exit F10 18 xl Monitoring 00 00 0 00 10 Setup NGINE SPEED 1188 rpm 10 20 30 40 50 60 70 80 90 100 IGNITION TIMING BTDC 7 4 0 10 20 30 40 50 60 70 80 90 100 MANIFOLD ABSOLUTE PRESSU
57. UT SERVICE DATA Description Fig 112 NOTE When opening the saved service data refer to Opening Saved Data Page 31 in this manual Service data is saved when you click the Save F3 button F3 key on the keyboard 2 The dialog box appears Fig 113 Saveas The file save destination DataList folder is au tomatically selected and the file name is also au tomatically displayed 0009191 File name 8000921 1 Save as type Cancel 2 Fig 113 Default initial save destination directory Windows 2000 XP C Documents and Settings All Users Documents SDS DataList BXXXXXXX csv Windows Vista C Users Public Documents SDS DataList BXXXXXXX csv NOTE You can change the file name and file save destination as required 78 BXXXXXXX A D Engine type Example B3007251 2 Month 1 2 3 4 5 6 7 8 9 X Y Z 300 horsepower O Date 01 31 July 25 4 Number 1 9 A Z First file recorded on the above date 3 Click the 5 button to save data To cancel data save click the Cancel button Keyboard Move to the save button and press the Enter key to have the saved data accepted or move to the Cancel button and press the Enter key to cancel the selected data BCM CURRENT SERVICE CODE 1 Clicking the CURRENT SERVICE CODE button from the menu window Fig 107 displa
58. UU UU H 10 8 OS 5 pug leqe1 e CY b D 165 19987 5 puc 94 No PatNme PartNo MAIN WIRE HARNESS REMOTE CONTROL 6 5 m 36620 98J00 CHOICE 2 MAIN WIRE HARNESS REMOTE CONTROL 9 5 m 36620 98J10 HARNESS ASSY DUAL STATION 366229800 1 _ HARNESS ASSY BCM FOR MULT 36623 98311 1 D HARNESS ASSY BCM No 2 FOR MULT 36624 98310 1 amp REMOTE CONTROL ASSY TOP MOUNT DUAL 67200 98311 2 CONTROLLER ASSY BOAT ELECTRIC 3677098001 2 9 PANEL ASSY DUAL 371009881 2 BUZZER ASSY WARNING 38500 93390 2 PANELASSYMANSW 9871009800 1 PANEL ASSY EMERGENCY SW 3878089800 1 36661 9800 34922 9801 36625 9800 HARNESS ASSY ACTIVE HUB PWR 2 5 m 36663 98J00 HARNESS ASSY ACTIVE HUB PWR 6 0 36663 98J10 CAP 2 PIN CONNECTOR 36667 98J00 UNIT ACTIVE HUB 34921 98J00 HARNESS ASSY 3 GAUGE 36664 98J00 HARNESS ASSY 2 GAUGE 36664 98J10 CAP 6 PIN CONNECTOR 36666 98J10 CAP 8 PIN CONNECTOR 36666 98J00 WIRE COMP JUMPER 36665 98J00 HARNESS ASSY 2 HUB 1 m 36662 98J00 HARNESS ASSY 2 HUB 6 5 m 36662 98J10 UNIT PASSIVE HUB 34921 98010 C H MIM ms oO CHOI
59. ailable from Suzuki Motor Corporation 49 OPERATION MANUAL Operation Manual in the form of electronic file can be called out 1 On the main menu Fig 44 click Help F9 but ton On the keyboard press F9 key 2 Dialog box is shown Fig 76 Click Operation Manual On Keyboard Select an item by pressing Up or Down arrow key and press Enter key to con firm the entry 3 Applicable application start up to display the op eration manual Fig 78 Default initial save destination directory C Program Files SDS Manual XXXXXXX NOTE e Adobe Acrobat or Adobe Reader is required to dis play the SDS operation manual f the applicable application has not been installed not the manual but the open error screen Fig 79 is shown e The operation manual is automatically incorporated when installing SDS Ver 6 00 50 Operation Manual 99517 03061 01E pdf Adobe Reader ca Jen File Edit View Document Tools Window Help x e 1 6 amp xix E E ra E RATION MANUAL COVER FOREWORD GROU P INDEX CONTENTS 1 OVERVIEW 2 SYSTEM OUTLINE 3 INSTALLATION E 4 OPERATING SUZUKI motor 5 SPC SYSTEM SUZUKI DIAGNOSTIC SYSTEM CALIBRATION 6 UNINSTALLING THE SDS PROGRAM For Software Version 6 00 e Sree 5 24PM Fig 78 IS SUZUKI DIAGNOSTT Operation Manual OPEN ERROR The correspo
60. and parts catalogs 1 In the Main Menu window Fig 44 click the Help F9 button F9 key on the keyboard 2 The following dialog box appears Fig 76 Click the Service data manual button Keyboard Move to the Service data manual button by using the Up or Down arrow key and press the Enter key to have the selected item accepted 3 The Open dialog box appears Fig 77 Click a desired file and click the Open button Keyboard To change the selected button to an other button use the Tab key Select a desired file by using the Up or Down arrow key and press the Enter key to have the file accepted Default initial save destination directory C Program Files SDS Manual XXXXXXX NOTE SUZUKI DIAGNOSTIC SYSTEM ee Main Menu Ft File F2 Save F3 Window F4 Help F9 Exit F10 Service data manual Operation manual Version information Close Esc r press Main Menu F1 select item by UP and DN then press Enter ress Exit F10 to exit program x ECM ID Sinom Engine Type cc Look in Info e E 3 File name Files of type PbF pdf 2 Fig 77 The following directory automatically opens Change this directory if necessary Save necessary files to the default initial save directory Currently electronic file service manuals parts catalogs are unav
61. are operated at mutual linkage Those engines are linked by turning the switch ON and unlinked by turning it OFF In the initialization the switch is at ON BUZZER RESET SWITCH ON OFF Indicates the buzzer reset switch status by ON or OFF When ECM monitors the engine status and a caution buzzer sounds the caution buzzer can be stopped by pushing the main switch key SHIFT TRGT POSITION PORT STBD CENTOR FORWARD NEUTRAL REVERSE Information entered to BCM is transmitted as the control command from the LPS sensor to ECM of the outboard motor and the target shift position at this position is indicated SHIFT POSITION PORT STBD CENTER ECM controls the actuator by the control command transmitted from BCM to ECM of the outboard motor and the shift position at this time is indicated 84 5 7 BCM INITIALIZATION Initialize the information registered in the BCM 1 Clicking the BCM INITIALIZATION button from the Main Menu dialog box Fig 85 displays the menu window Fig 115 BCM INITIALIZATION INFORMATION The information on BCM is initialized The item initialized is the following two Master BCM Sub BCM composition information System configuration information Number of stations Number of engines Use Tab to select items then press Enter Click OK button to go next Fig 115 2 Delete the master or sub BCM information registered in the BCM after system calibration and system configuration inform
62. atabase Database Database Database DF40 50 OQ DF60 70 NE EN DF70A 80A 90A x DF90 115 DF100 DF140 RECEN DF150 175 DF200 225 250 2505 DF300 x X 1 2 PC HARDWARE REQUIREMENTS Running the SDS program requires the following environments Personal computer PC DOS V PCs PC AT compatible machines where Windows 2000 or Windows XP operates as OS and that come with the following CPUs Windows 2000 Pentium 133 MHz or higher Pentium 233 or higher MHz recommended Windows XP Pentium 300 MHz or higher Pentium 500 MHz or higher recommended Windows Vista Intel Core Solo Core2 Duo etc 1 6 GHz or higher 2 0 GHz or higher recommended Memory Windows 2000 64 MB or more 128 MB or more recommended Windows XP 128 MB or more 256 MB or more recommended Windows Vista 1 GB more Hard disk 20 MB or more of free space 40 MB or more of free space recommended Display SVGA 800 x 600 pixels 65 000 colors or more Drive CD ROM drive Interface port USB x 1CH or more required f two or more communication ports exist they may be able to be used for infrared communication Check that these communication ports are usable by referring to individual personal computer manuals Recommended environment Environment in which you can run the SDS program without feeling uncomfortable with the file processing speed and screen display 6 NOTE Depending on your PC environme
63. ation Number of engine Number of station Click the OK button and proceed to the next step Keyboard Move to the OK button using the Tab key and press the Enter key 85 3 The following BCM INITIALIZATION CAUTION window appears Fig 116 Read the messages and follow the instruction Then click the OK button and proceed to the next step To cancel information deletion click the Cancel button or press the Esc key on the keyboard Keyboard To delete BCM information move to the OK button by using the key and press the Enter key to have the deletion accepted To cancel BCM information deletion move to the Cancel button by using the Tab key and press the Enter key to have the cancellation accepted BCM INITIALIZATION CAUTION When BCM information is initialized with this menu please be sure to carry out SYSTEM CALIBRATION Use Tab to select items then press Enter Click OK button to go next Use Esc or Cancel button to cancel Fig 116 4 The following window appears Fig 1 17 Clicking the Yes button deletes BCM informa tion Clicking the button cancels information deletion 7 Is the information on BCM initialized Fig 117 NOTE By clicking the OK button the initialization of BCM i information is completed Click the OK button C Pasar turn the mam OFF and ON aea Fig 118 turn OFF the engine
64. b to select items then press Enter Press OK button to return to the main menu Fig 98 69 5 4 SETTING CHANGE Change or reset the remote control lever characteristics and full tilt down position NOTE Change system settings when disassembling or replacing the remote control lever its related parts or tilt related parts 5 4 1 LEVER CHARACTERISTICS 1 Clicking the SETTING CHANGE button from the Main Menu dialog box Fig 85 displays the fol lowing window Fig 99 Fig 100 of boat station configuration registered in the BCM during sys tem calibration Full Tilt Down Position Fig 99 is the SETTING CHANGE initial win Ful Up Position dow registered as the single station Close Esc Fig 100 is the SETTING CHANGE initial win dow registered as the dual station ick or press Main Menu F1 select item by UP and then press Enter ick or press Ex to exit program BCM ID 36770 98J00 21 suzuct oracvosric s Wh soem Fig 99 Lever Position Second Station Lever Position First amp Second Station Full Tilt Down Position Full Tilt Up Position Close Esc ick or press Main Menu F1 select item by UP and DN then press Enter or press Exit F10 to exit program BCM ID 36770 9800 Fig 100 70 2 Clicking LEVER POSITION XXXXXX button from the Setup Change dialog box Fig 99 Fig 100 dis
65. dicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in motor damage NOTE Indicates special information to make maintenance easier or instructions clearer Please note however that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the outboard motor In addition to the WARNING and CAUTION stated you must use good judgement and basic mechanical safety principles Precautions for use e This software is only used for outboard motor with DC 12V battery Do not use for outboard motors with other than DC 12V battery This software is specially designed for SUZUKI outboard motors Please apply this software to the outboard motors only Do not wet the diagnosis harness USB adapter personal computer etc e Do not disassemble modify the diagnosis harness USB adapter etc Do not connect the diagnosis harness USB adapter etc to the outboard motor or personal computer unless SDS is in use e Use SUZUKI genuine special tools for outboard motor when handling the diagnosis harness USB adapter USB cable etc Always hold the coupler with both hands when disconnecting the diagnosis harness from the connector on the outboard motor Broken wire may occur if the cable is pulled Do not connect disconnect the interface cable with a wet hand or electrical shock or inj
66. dow Fig 44 click Main Menu F1 or press the F1 key from the keyboard The following main menu dialog box Fig 48 appears 5 DIAGNOSTIC SYSTEM Main Menu F1 File F2 Save F3 Window F4 Help F9 Exit F10 CURRENT SERVICE CODES ACTUATOR TEST BCM SIMULATOR DATA LOGGER Exit Close Esc Click or press Main Menu F1 select item by UP and DN then press Enter ECM ID 33920 98 771 Spec Engine Type 4028 4 stroke Fig 48 SERVICE DATA Enables you to monitor real time data related to the engine control system The monitored service data can be selected at will and can be saved as csv file format CURRENT SERVICE CODES Enables you to display self diagnosis code current failure location name ACTUATOR TEST Enables you to start and stop the actuator by using the monitored real time data Also O feedback operation can be performed BCM SIMULATOR dedicated for DF300 Enables you to control engine start stop gear settings Forward Neutral Reverse and throttle opening from idling engine speed to max 2 500 r min in place of the BCM This simulator is used when the engine is operated in a test tank without a remote control box connected DATA LOGGER Enables you to display major service data in a graph form A maximum of three items can be logged at one time and can be saved as csv file format Exit Exits the SDS program Close Esc Closes the menu box
67. e active window Click or press Exit F10 to exit program Power 115PS ECM ID 33920 90J10 Spec Type 1950cc 4 stroke Fig 61 38 NOTE Do not close the throttle fully for more than 10 seconds while the feedback operation is being performed This will cause the O feedback operation to finish with incomplete data Do not allow the engine to be stable at an unnecessary speed range other than the zone r min for more than 10 seconas Thie will cause the O feedback operation to be done with an incorrect data for that speed range As the zirconia element in the O sensor is not conductive below 250 C the O sensor will not function properly until the engine is at normal operating temperature Zone r min chart a DF40 50 DF60 70 DF90 115 140 DF150 175 DF200 225 250 ZONE 1 2 500 100 r min 2000 100r min 3000 100r min 3000 100 r min 3000 100 r min ZONE 2 500 100 r min 3000 100 r min 4000 100 r min 4000 100r min 4000 100 r min ZONE 3 4 500 100 r min 4000 100 r min 5 000 100 r min 5000 100 r min 5 000 100 r min 6 Repeat Step 5 at r min of ZONE 2 7 Repeat Step 5 at r min of ZONE 3 8 If there is a zone at which feedback failed rerun feedback at that zone 9 When O feedback at all zones has successfully finished return the throttle to the fully closed position 10 After about 10 seconds the throttle is set to the fully closed position the buzzer sound
68. een cancel Use Tab to select items then press Enter Click OK button to continue Use Esc or Cancel button to return to the previous screen Fig 92 6 The following window Fig 93 appears This window is used to register the outboard motor position in the BCM Operate the PTT switch of the outboard motor to perform full tilt down Click the OK button to have the outboard motor position accepted and proceed to the next step Fig 93 is an example of registering the PORT outboard motor Clicking the Cancel button cancels system calibration system __ _ 1815 Main 1 File F2 Save F3 Window F4 Help F9 Exit F10 SYSTEM CALIBRATION Engine Location Registration PORT Press the engine side PTT Switch Down Button and bring the engine to Full Down trim When the PTT switch is released listen for the High Pressure Fuel Pump operating sound If the pump sound is heard and the engine is at full down trim click OK button se Tab to select items then press Enter lick OK button to continue se Esc or Cancel button to return to the previous screen Click or press Main Menu F1 select item by UP and DN then press Enter Click or press Exit F10 to exit program BCM ID 36770 98J00 if start w 2059 Paint DIAGNOSTIC 5 10 53 am Fig 93 NOTE For dual engines register the PORT and STBD positions For t
69. elp F9 Exit F10 SERVICE DATA Master BCM X Select ENGINE SPEED PORT ENGINE SPEED STBD ENGINE SPEED CENTER LPS OUTPUT 1ST P M LPS OUTPUT 1ST P S LPS OUTPUT 1ST S M LPS OUTPUT 1ST S S LPS OUTPUT 2ND P M LPS OUTPUT 2ND P S LPS OUTPUT 2ND S M LPS OUTPUT 2ND S S TRGT ANGLE PORT ETY TRGT ANGLE STBD ETY TRGT ANGLE CENTER TPS OUTPUT PORT Cow lt lt lt lt lt lt lt lt TPS OUTPUT STBD Use UP and DN to select item group then press Enter 0 select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Exit F10 to exit program if stat w 87069 Paint 1 s p 11 01 AM Fig 1 09 4 You can select service data for the connected outboard motor ECM by clicking the W button Fig 110 Keyboard Select a desired menu by using the Up or Down arrow key and press the Enter key Ea SUZUKI DIAGNOSTIC SYSTEM SERVICE DATA 18 x Main Menu F1 File F2 Save F3 Window F4 Help F9 Exit F10 E SERVICE DATA Master BCM Select Master BCM ENGINE SPEED PORT ENGINE SPEED STBD ENGINE SPEED CENTER LPS OUTPUT 1ST P M LPS OUTPUT 1ST P S LPS OUTPUT 1ST S M LPS OUTPUT 1ST S S LPS OUTPUT 2ND P M LPS OUTPUT 2ND P S LPS OUTPUT 2ND S M LPS OUTPUT 2ND S S ETY TRGT ANGLE PORT ETY TRGT ANGLE STBD E
70. equired DXXXXXXX A D Engine type Example D3007251 2 Month 1 2 3 4 5 6 7 8 9 X Y Z 300 horsepower 0 0920 01 31 July 25 4 Number 1 9 A Z First file recorded on the above date 3 Click the Save button to save data To cancel data save click the Cancel button Keyboard Move to the Save button and press the Enter key to have the saved data accepted or move to the Cancel button and press the Enter key to cancel the selected data NOTE When opening the saved service data refer to OPENING SAVED DATA Page 31 in this manual Service data is saved when you click the Save F3 button F3 key on the keyboard 30 OPENING SAVED DATA 1 In the Initial Menu window Fig 44 click the File F2 button F2 key on the keyboard The following File Menu dialog box Fig 54 appears Click the Open button Keyboard Move to the Open button by using the Up or Down arrow key and press the Enter key to have the button accepted 35 1 DIAGNOSTIC SYSTEM l amp l x Main Menu F1 File F2 Save F3 Window F4 Exit F10 File menu Print Update database Close Esc Click or press Main Menu F1 select item by UP and DN then press Enter Click or press Exit F10 to exit program Power 77 ECM ID zm Spec Engine Type cc stroke 4 5 022 Paint
71. er Click or press Exit F10 to exit program BCMID 3677098 0 Fig 107 74 2 Clicking the SYSTEM FORMATION button from the menu window Fig 107 displays the window Fig 108 The upper part of this window illustrates the system configuration registered in the BCM The following figure shows a dual station of triple outboard motor type The lower part of this window shows the master BCM ID sub BCM ID PORT ECM ID CENTER ID and STBD ID Click the button to terminate system check SYSTEM FORMATION Station Dual Station Master Boat Control Module ID 36770 98J00 Sub Boat Control Module ID 36770 98J00 Engine Control Module ID PORT 33920 98J00 Engine Control Module ID CENTER 33920 9800 ENGINE Control Module ID STBD 33920 98J00 Use Tab to select button then press Enter If the OK button is pushed it will progress to the next Fig 108 NOTE If the illustration and description of the displayed system configuration differ from the registered configuration and the configuration of actual boat it means that the system is not correctly calibrate In this case be sure to calibrate the system 75 3 Clicking the SERVICE DATA button from the menu window Fig 107 displays the window Fig 109 This window displays master BCM service data in real time 5 DIAGNOSTIC SYSTEM SERYICE DATA B 15 x Main Menu F1 File F2 Save F3 Window F4 H
72. from 20 to 180 OF to 360 F INTAKE AIR TEMPERATURE C Indicates intake air temperature within a range from 20 to 100 OF to 200 F BATTERY VOLTAGE V Indicates battery voltage within a range from 6 V to 16 V FUEL INJ PULSE WIDTH us Injection time duration for each cylinder per 1 time INJECTED FUEL AMOUNT mcc Injected fuel amount for each cylinder per 1 time 1 mcc is 0 001 L FUEL CONSUMPTION AVE Indicates the fuel flow rate per hour and the average fuel flow rate in the range from 0 to 150 L HIGH PRESSURE FUEL PUMP DUTY Indicates the high pressure pump actuation rate within a range from 096 to 100 indicates the actuation of the high pressure fuel pump that pressure feeds high pressure fuel to the injector at a rate of ON time to one cycle 1 ms IAC VALVE DUT Y 96 Indicates the IAC valve actuation rate within a range from 0 to 100 indicates the actuation of the IAC valve that controls the amount of air flowing from the IAC path at a rate of ON time to one cycle 1 ms PURGE VALVE DUTY 96 Indicates the purge control valve actuation rate within a range from 0 to 100 EX MANI TEMPERATURE C F Indicates the exhaust manifold temperature within a range from 20 to 180 C to 360 57 ETV TRGT ANGLE Indicates the target throttle opening in the range from 0 to approx 90 based on data transmitted from master BCM to ECM of the outboard motor TPS MAIN Ind
73. from O to 5 V THROTTLE POSITION ANGLE Indicates the throttle position opening within a range from 0 to 100 58 THROTTLE POSITION SENSOR OUTPUT V Indicates the throttle position sensor output voltage within a range from O V to 5 V VVT ADVANCE ANGLE STBD PORT Indicates the VVT advance angle within a range from 0 to 50 NO OF CHECK CODE WIRE FAILURE times DF150 DF175 DF200 DF225 DF250 Indicated when the model discrimination terminal is disconnected XXXXXX FAILURE times Indicates the total number of abnormal signals sent from sensors and switches NO OF XXXXXX times Indicates the total number of over revolution oil pressure battery voltage and overheat cautions that oc curred overheat cautions are displayed gradient and temperature CAUTION SYSTEM NAME 1 2 and 3 Indicates caution names indication of past three cautions If no cautions occurred in the past No code is displayed XXXXXXXXXXXX AT CAUTION OCCURRENCE 1 2 3 Indicates the numeric value of each caution If no caution occurred for the cylinder intake and EX MANI STBD PORT temperatures in the past 50 is displayed for them SPC CAUTION SYSTEM NAME XXXXXX SPC Abbreviation of SUZUKI PRECISION CONTROL Indicates the data of the electronic throttle electronic shift and communication system in the event of a trouble 9 1 Indicates data of the electronic throttle electronic shift and communicat
74. he high pressure fuel pump will be actuated at 100 duty for 5 seconds This test can be performed when the engine is not running LOW PRESSURE FUEL PUMP ACTUATION DF200 to DF300 The low pressure fuel pump will be actuated at 100 duty for 5 seconds This test can be performed when the engine is not running IAC ACTUATION DF40 to DF140 The IAC valve will be actuated at 1 Hz once in one minute for 5 seconds This test can be performed when the engine is not running DF70A 80A 90A 2009 year model DF150 DF250 The IAC valve will be actuated so that the target engine speed becomes 1 000 r min This test can be performed when the engine is running and the fully close throttle signal of throttle position sensor to be input to ECM ETV ACTUATION DF300 The ETV valve will be actuated so that the target engine speed becomes 1 000 r min This test can be performed when the engine is running and the fully close throttle signal of throttle position sensor to be input to ECM VSV ACTUATION VARIABLE INDUCTION MODELS DF150 DF175 DF225 DF250 The vacuum switching valve will be actuated at 50 duty for 5 seconds This test can be performed when the engine is not running 35 OCV STBD ACTUATION DF250 DF300 The oil control valve STBD will be actuated for 5 seconds This test can be performed when the engine is not running OCV PORT ACTUATION DF250 DF300 The oil control valve PORT will be actuated for 5 seconds This
75. horizontal axis means the elapsed time for data logging or monitoring For example if 0 5 sec is entered as the sampling cycle in the Condition Setting window Fig 68 100 points serve as 50 seconds 45 SAVING LOGGING DATA You can save logging data in the csv file format after logging has finished executed Fig 72 S ETZTISI DIAGNOSTIC SYSTEM DATA LOGGER 7 Main Menu F1 File F2 Save F3 Window F4 Help F9 Exit F10 1858 rpm ENGINE SPEED 1 x 1 x 0 10 20 30 40 50 80 70 IGNITION TIMING BTDC 11 B50 B40 B30 B20 B10 10 20 30 40 50 60 70 MANIFOLD ABSOLUTE PRESSURE 401 mmHg 800 700 B00 500 400 300 200 100 04 10 20 30 40 50 80 70 Logging data is not saved Click or press Save F3 to save data Click Monitor button to start monitoring Click Setup button to input logging condition Use Esc to close DATA LOGGER Use Tab to select button Click or press Exit F10 to exit program Power 300PS ECM ID 33920 9871 Spec Type 4028 4 stroke 22 801 Paint suzuki pracnosti s 1 In the DATA LOGGER window Fig 72 click the Save F3 button key on the keyboard The COMMENT INPUT DATA LOGGER dialog box Fig 73 appears From this dialog box type a com ment into the Engine No Boat Type and Descrip tion fields and then click the OK button To can cel logging data saving click
76. i Precision Control system Improper electronic calibration of the system will make this product and or the system inoperable or unsafe for use 5 1 CONNECTING PC AND BCM 1 Connect your PC to the BCM of the outboard motor by using the following special tools Fig 83 Connect the SDS diagnostic harness to the SDS 4 pin communication connector of or Fig 83 NOTE Check that your PC and the main switch of the outboard motor are off before connecting the diagnostic harness If two stations are available a master BCM and sub BCM are installed To calibrate the system connect the diagnostic harness to the master BCM main switch side If only one station is available only the master BCM is installed 61 5 2 BCM MAIN MENU 1 Start the SDS program See page 23 2 he SDS program window Fig 84 appears SETZT DIAGNOSTIC SYSTEM E xl Main Menu F1 File F2 3 Window F4 MHelp F9 Exit F10 Click or press Main Menu F1 select item by UP and DN then press Enter Click or press Exit F10 to exit program BCM ID 36770 9800 BCMID 38 709840 24 Sr oso Part S suzuki
77. icates the input voltage of BCM in the range from 6 to 16 V 82 BATTERY VOLTAGE PORT STBD CENTER V Indicates the ECM input voltage transmitted from the ECM of the outboard motor to the master BCM in the range from 6 to16 V TRIM ANGLE PORT STBD CENTER Indicates the trim sensor angle transmitted from ECM of the outboard motor to the master BCM in the range from 0 to 100 0 indicates the full trim down and 100 the full trim up BOAT SPEED through water km h knot mile h Indicates the log speed transmitted from ECM of outboard motor to master BCM in the range from O to 160 km h O to 100 knot O to 100 mile h NO OF LPS PORT STBD 1ST 2ND times Counts if the value of the main and sub lever position sensor control voltage in the remote control box is out of the specified range of the upper and lower limits NO OF LOW VOLTAGE 1ST times Counts if the dropped voltage continues for longer time than specified NO OF CAN COMM FAILURE SUB BCM PORT STBD CENTER times Counts if data is not periodically received NO OF SET UP ERROR SUB BCM PORT STBD CENTER times Counts if no validation is demanded from the sub BCM or ECM of the outboard motor to master BCM NO OF DBW ETV FAILURE PORT STBD CENTER times Counts if mismatch between the actual throttle opening of the outboard motor and the target opening contin ues longer than specified NO OF DBW ESA FAILURE PORT STBD CENTER times Counts
78. icates the throttle opening in the range from 0 to approx 90 TPS MAIN OUTPUT V Indicates the throttle position sensor main output voltage within a range from O V to 5 V TPS SUB 9 Indicates the throttle opening in the range from to 45 TPS SUB OUTPUT V Indicates the throttle position sensor sub output voltage within a range from 0 V to 5 V ESA TRGT POSITION V Indicates the target shift position in the range from to 5 V based on the data transmitted from the master BCM to ECM of the outboard motor SHIFT POSITION SENSOR OUTPUT V Indicates the output voltage of the shift position sensor in the range from O to 5 V TRIM ANGLE Indicates the trim sensor angle within a range from 0 to 100 For full trim down this angle is 0 For full trim up this angle is 10096 TRIM ANGLE SNSR OUTPUT V Indicates the trim sensor output voltage within a range from O V to 5 V TILT LIMIT VOLTAGE V Indicates the tilt up limit set in the range O to 5 V maximum BOAT SPEED OVER WATER km h KNOT mph Indicates the speed to water within a range from 0 km h to 160 km h 0 KNOT to 86 KNOT 0 mph to 100 mph SPEED SENSOR OUTPUT V Indicates the output voltage of the speed sensor in the range from O to 5 V WATER PRESSURE kpa psi Indicates the cooling water pressure in the range from O to 150 kpa 0 to 20 psi WATER PRESSURE SNSR OUTPUT V Indicates the output voltage of water pressure sensor in the range
79. ig 102 a FomadMm g Forward Max Move the remote control lever to the positions listed in their numerical order Click Set button to fix the position and confirm checkmark appears After fixing all lever positions in order click OK button to accept Note When using a Dual Remote Control Box both levers should be moved simultaneously to the same position Use Tab to select items then press Enter Click OK button to continue Use Esc or Cancel button to return to the previous screen Fig 102 71 NOTE If the lever is not set to a correct position the error message Fig 103 is displayed Click the OK button set the lever to the correct position and click the Set button To change the dual station settings select First Station Second Station and Both First and Second Stations e After all the lever positions have been registered the following confirmation message Fig 104 is displayed x N Set Ehe lever to Ehe correct position Fig 103 4 Clicking the OK button after all the lever posi tions have been registered displays the following window Fig 105 Click the OK button to terminate setting change 72 Lonfirmation Fig 104 SETTING CHANGE Completed SYSTEM CALIBRATION has been completed OK button to return to the main menu Use Tab to select button then press Enter If the OK butt
80. ion system at the time of trouble 2 Indicates data of the electronic throttle electronic shift or communication system 5 seconds after the occurrence of the trouble FAILURE TIME 1 2 3 hour Indicates the total operation time when a caution occurred ELAPSE OF TIME 1 2 3 minute Indicates the elapsed time from caution occurrence ELAPSE TIME FROM REMINDER CANCEL hour Elapsed time from the latest cancellation of the OIL CHANGE REMINDER system activation NO OF OIL CHANGE REMINDER times Indicates the total number of times display of the OIL CHANGE REMINDER system was cancelled O FEEDBACK Indicates the O feedback status ISTAND BY ACTION FIN OK or FIN NG 59 COMPENSATION FACTOR ZONE X Indicates the compensation factor of fuel injection time The initial status is 1 000 TIME OF LAST O FEEDBACK Indicates the total operation time when the latest O feedback was perform XXXXXX SWITCH AND OTHERS Indicates the status ON or OFF of the emergency stop switch idle switch neutral switch vacuum switching valve and low pressure fuel pump SHIFT POSITION Indicates the shift position FORWARD NEUTRAL REVERSE 60 5 SPC SYSTEM CALIBRATION Electronic calibration is required bofore use After installation of this product Suzuki sion Control system requires electronic calibration only by a person who has been specifically trained in the Suzuk
81. l 4 unidentified program wants access to your computer Don t run the program unless you know where it s from or you ve used it before Setup exe Unidentified Publisher gt Cancel I don t know where this program is from or what it s Allow Itrust this program I know where it s from or I ve used it before Details User Account Control helps stop unauthorized changes to your computer Fig 3 InstallShield Wizard SUZUKI DIAGNOSTIC SYSTEM Setup is preparing the Installs Wizard which will guide vou through the rest of the setup process Please wait Cancel Fig 4 5 To continue the installation click the Next but ton to proceed to the next step Fig 5 NOTE If SDS is already installed on your PC the window shown in Fig 6 appears Clicking the Yes button in this window Fig 6 con tinues the setup and the Wizard proceeds to the next step Clicking the No button quits the installation NOTE Clicking the Cancel button displays the Exit Setup dialog box shown in Fig 7 To quit the installation click the Yes button 10 SUZUKI DIAGNOSTIC SYSTEM Setup Welcome to the InstallShield Wizard for SUZUKI DIAGNOSTIC SYSTEH The InstallShield Wizard will install SUZUKI DIAGNOSTIC SYSTEM on your computer To continue click Next This program has already existed Da you wank to update gt Setup is not complete IF you quit the se
82. later DF200 225 250 004 and later 2505 2008 and later DF300 2007 and later NOTE No conversion adapter 09933 19880 is required for 2008 year model and later ee eee amp NO N no 5 DF40 50 2 DF6070 2 DF7OA 80A 90A 2 DF90 115 2 00 9090 DF100 Q DF140 2 1501 0 2 DF200 225 250 0625056 DF300 0 SUZUKI DIAGNOSTIC SYSTEM SOFTWARE DATA BASE Ver X XX lI rights reserved This may not be reproduced or copied without the i TOKYO JAPAN ission of SUZUKI MOTOI 09933 XXXXX Suzuki Diagnostic System Software Ver 6 00 Diagnostic harness USB cable Conversion adapter 09933 19862 09933 19840 09933 19850 09933 19880 Test wheel A 09914 79410 DF40 50 USB adapter O sensor 18213 74 00 09914 79511 DF60 70 Laptop computer supporting 09933 19830 Protector 18498 90J20 C 09914 79010 DF90 115 140 USB ports SDS Set 09933 19812 Suzuki Diagnostic System Software Ver 6 00 Diagnostic harness USB cable USB adapter Conversion adapter BCM Simulator harness 09930 89860 Relationship between SDS software databases and models Ver 5 00 Ver 6 00 Database Database D
83. li cubic centimeter Minute Motor Number Oil Control Valve Personal computer Port side Revolution Per Minute Suzuki Diagnostic System Sensor Suzuki Precision Control Starboard Temperature Throttle Position Sensor Target Micro second Move 2 SYSTEM OUTLINE Connect your PC to the ECM or of the outboard motor by using the following special tools Fig 1 USB port USB1 1 or USB2 0 Diagnostic USB cable harness SDS Ver 6 00 USB adapter 4 pin connector Fig 1 SDS performs communication between a PC and the ECM Engine Control Module or BCM Boat Control Module of the outboard motor via the diagnostic harness and USB adapter to provide the following informa tion through ECM and BCM storage data and sensor data Engine information display Current service self diagnostic codes Service data display and save Actuator test forced start and stop of actuator BCM simulator Data logger save and graph printing SPC system calibration SPC system initialization BCM service data display and save SPC system check NOTE Head the Operation Manual before starting SDS Observe IMPORTANT NOTICE and GENERAL INSTRUCTIONS written in the Operation Manual e This software is designed for use with a battery powered DC type lap top personal computer Do not use an AC type personal computer e This softwa
84. ltage of the PORT side lever position sensor sub in the remote control box of the 1st station in the range from O to 5 V LPS OUTPUT 1ST S M V Indicates the voltage of the STBD side lever position sensor main in the remote control box of the 1st station in the range from O to 5 V LPS OUTPUT 1ST S S V Indicates the voltage of the STBD side lever position sensor sub in the remote control box of the 1st station in the range from O to 5 V LPS OUTPUT 2ND P M V Indicates the voltage of the PORT side lever position sensor main in the remote control box of the 2nd station in the range from O to 5 V LPS OUTPUT 2ND P S V Indicates the PORT side lever position sensor sub in the remote control box of the 2nd station in the range from O to 5 V LPS OUTPUT 2ND 5 V Indicates the voltage of the STBD side lever position sensor main in the remote control box of the 2nd station in the range from O to 5 V LPS OUTPUT 2ND 5 5 V Indicates the voltage of the STBD side lever position sensor sub in the remote control box of the 2nd station in the range from O to 5 V ETV TRGT ANGLE PORT STBD CENTER V Indicates the target opening voltage transmitted from the master BCM to PORT outboard motor ECM in the range from O to 5 V TPS OUTPUT PORT STBD CENTER V Indicates the throttle opening voltage transmitted from ECM of the outboard motor to the master in the range from O to 5 V BATTERY VOLTAGE BCM V Ind
85. makes the previous selection valid Pressing the Esc key ignores the selected item and makes the previous selection valid SAVING SERVICE DATA You can save all the displayed service data 1 In the SERVICE DATA window Fig 49 click the Save F3 button key on the keyboard The COMMENT INPUT SERVICE DATA dialog box Fig 52 appears From this dialog box type a com ment into the Engine No Boat Type and Descrip tion fields and then click the button Keyboard Move the cursor to the field in which to type a comment by using the Tab key After typing the comment move to the OK button by using the Tab key and press the Enter key to have the comment accepted Fig 51 Engine Ho Boat Type Description OH Cancel Input Comment and press Tab Click OK button Use Esc ar Cancel button to cancel Fig 52 29 2 The Save As dialog box Fig 53 appears Save As The save destination DataList folder is au Save in selected and the file name is also au tomatically displayed File name Save as csv Cancel Default initial save destination directory Windows 2000 XP C Documents and Settings All Users Documents SDS DataList Dxxxxxxx csv Windows Vista C Users Public Documents SDS DataList Dxxxxxxx csv NOTE You can change the file name and file save destination as r
86. nding application is not installed Please install an appropriate application Fig 79 VERSION INFORMATION You can check the SDS program version In the Main Menu window Fig 44 click the Help F9 button F9 key on the keyboard The dialog box Fig 76 appears Click the Version Information button Keyboard Move to the Version Information but ton by using the Up or Down arrow key and press the Enter key to have the selected item accepted The VERSION INFORMATION dialog box ap pears From this dialog box you can check the current program version and database version Fig 80 Clicking the Details button displays the VERSION INFORMATION DETAILS dialog box from which you can check the details of version information Fig 81 4 9 EXITING THE SDS PROGRAM 1 To exit the SDS program click the Exit F10 but ton in the main menu window F10 on the keyboard The EXIT dialog box Fig 82 appears To exit the program click the Yes button To can cel program existing click the No button Keyboard Move to the Yes button by using the Tab key and press the Enter key to have pro gram exiting accepted Or move to the No but ton and press the Enter key to have exiting can cellation accepted VERSION INFORMATION Suzuki Diagnostic System gt PROGRAM Ver 6 00 DATABASE Ver 6 00 SUZUKI MOTOR CORPORATION Copyright 2000 MITSUBISHI
87. ngine Type stroke 871022 Paint pracosric s Fig 35 20 9 The DIRECTORY SELECTION dialog box file location in Fig 36 appears In this dialog box select a file necessary for database update In the following case the database file to be updated is in the CD ROM drive d drive into which the SDS database disk compact disk was inserted NOTE Depending on the PC to be used the driver letter of the CD ROM drive may be e or g Fig 36 Refer to the manual of your PC To cancel database update click the Cancel button DIRECTORY SELECTION E Directory Indicates the contents of the disk inserted into the Dh d drive The database file to be updated is Db Drive Cancel Database file will be updated Select database drive and directory Use Esc to cancel Fig 36 10 Check that Db exists in the selected directory file location and then click the OK button Fig 36 2 DIRECTORY SELECTION Indicates the contents of Directory the disk inserted into the d drive In this case the database to be updated is stored in Db Cancel Database file will updated Select database drive and directory Use Esc to cancel Fig 36 2 21 11 When the database has been successfully up dated the COMPLETED UPDATE dialog box Fig 37 appears e Database
88. ngine Type 1950cc 4 stroke 39 ESSUZUKI DIAGNOSTIC SYSTEM ACTUATOR TEST x Main Menu F1 File F2 Save F3 Window F4 Help F9 Exit F10 SERVICE DATA mix 02 Feedback info o2 FEEDBACK r Description ENGINE SPEED 656 rpm Read Operation Manual before doing 02 feedback MANIFOLD ABSOLUTE PRESSURE 271 mmHg CYLINDER TEMPERATURE 64 9C Message 4 TOTAL OPERATION TIME HRS 200 h Feedback unsuccessful Consult Operation Manual Click Go button to retry O2 feedback TOTAL OPERATION TIME MIN 32 min COMPENSATION FACTOR ZONE 1 0 954 COMPENSATION FACTOR ZONE 2 0 940 Use UP and DN to select item then press Go Use Esc to close ACTUATOR TEST COMPENSATION FACTOR ZONE 3 0 926 TIME OF LAST O2 FEEDBACK 02 FEEDBACK UP and DN to select item group then press Enter 0 select items displayed move to Select button by Tab then ress Enter Click or press Save F3 to save data Esc to close SERVICE DATA Click or press Window F4 to change active window Click or press Exit F10 to exit program Power 115PS ECM ID 33920 90J10 Spec Fig 63 Engine Type 1950cc 4 stroke 11 If retrying feedback operation repeat procedure used in the Step 5 t
89. nstallation Wizard The drivers are now installing ay Ly LJ Please wait while the drivers install This may take some time to complete lt Back Next Cancel Fig 14 NOTE Hardware Installation For Windows XP the confirmation screen of installa tion Fig 15 is displayed The software you are installing for this hardware Kk 3 Clicking Continue button continues the installation SDS USB Adapter while clicking Stop button abort the installation For Windows Vista the security confirmation screen has not passed Windows Logo testing to verify its compatibility d uid with Windows Tell me why this testing is important Fig 16 IS disp lay ed Clicking Install this Gnver soft Continuing your installation of this software may impair ware button continues the installation while clicking or destabilize the correct operation of your system T either immediately or in the future Microsoft strongly Don t install this driver software button abort the recommends that you stop this installation now and installati contact the hardware vendor for software that has instalation passed Windows Logo testing Fig 15 4 Windows Security amp Windows can t verify the publisher of this driver software gt Dont install this driver software You should check your manufacturer s website for updated driver software for your device gt Install this driver software anyway Only ins
90. nt settings you may feel uncomfortable with the operation speed e The necessary memory capacity and hard disk capacity may depend on the system environment Also running an SDS program when there is not enough space on the hard disk may cause your PC to run out of memory or encounter other problems during operation e Some PC models may not operate or may be unable to display data correctly depending on their operating environments Use a small system font Do not start 505 program when another application is running Do not use the screen saver Do not use energy saving mode When replacing the ECM or BCM exit the system program For Windows Vista use the existing scale 96 dpi 1 3 ABBREVIATION Abbreviations used in this operation manual are as follows ABBREVIATION FULL TERM BCM Boat control Module CKP sensor Cranckshaft position sensor CMP sensor Camshaft position sensor CPU Central Processing unit CTP switch Close Throttle Position switch Cyl Cylinder DBW Drive By Wire ECM Engine control Module ESA Electronic Shift Actuator Electronic Throttle Valve Ex Exhaust Hour S IAC valve Idle Air Control Valve IAT sensor Intake Air Temperature sensor Info Information INJ Injection MAP sensor Manifold Absolute Pressur sensor MANI Manifold Mega Byte Mi
91. o 10 12 Click the Stop button before closing the ACTUATOR TEST O FEEDBACK window NOTE Repeat the O feedback operation with a new O sensor if The total feedback operation finishes without returning he throttle to a full closed position The total feedback operation failed repeatedly 40 4 6 BCM SIMULATOR DEDICATED FOR DF300 1 Clicking the BCM SIMULATOR button from the Main Menu dialog box Fig 48 displays the following NOTICE window Click the button to proceed to the next step Fig 64 BCM SIMULATOR NOTICE BCM SIMULATOR can perform the following functions in place of the remote control system Start and stop the engine Change shift position Forward Neutral Reverse Open and close the throttle Initial Condition Engine Stop Shift Position Neutral Throttle Position Full Closed Pressing ESC when the engine is running will cause the engine to stop and resetto the initial condition Use Tab to select 5 press Enter Click OK button to continue Fig 64 Engine main harness Battery cable BCM simulator harness 09930 89860 Main switch 37110 98J00 NOTE Before commencing simulation connect special tools as shown in the right 2 The following window Fig 65 appears 5020 DIAGNOSTIC SYSTEM BCM SIMULATOR 81 xj MainMenu F1 File F2 Save F3 Window F4 Help F9 10 imi SERVICE D
92. on NOTE 3 For a dual control box you must simultaneously LeverPosition status erate both levers 1 Reverse Max v 2 Reversemin 8 When all the lever positions have been registered ni a return the lever to the neutral position Fig 95 a Forward min Move the remote control lever to the positions listed in their numerical order Click Set button to fix the position and confirm checkmark v appears After fixing all lever positions in order click OK button to accept Note When using a Dual Remote Control Box both levers should be moved simultaneously to the same position Use Tab to select items then press Enter Click OK button to continue Use Esc or Cancel button to return to the previous screen Fig 95 68 NOTE the lever is not set to a correct position the error message Fig 96 is displayed Click the OK button set the lever to the correct position and click the Set button After all the lever positions have been registered the following confirmation message Fig 97 is displayed Set Ehe lever to Ehe position Fig 96 9 Clicking the OK button displays the following window Fig 98 Click the button to terminate system calibration SYSTEM CALIBRATION Completed SYSTEM CALIBRATION has been completed OK button to return to the main menu Use Ta
93. on is pushed it will return to main menu Fig 105 5 4 2 Full Tilt Down Position 1 Clicking the Full Tilt Down Position button from the SETTING CHANGE dialog box Fig 99 dis plays the window Fig 106 2 Operate the PTT switch of the outboard motor to perform full tilt down Clicking the OK button registers the full tilt down position and redisplays the SETTING CHANGE completed window Fig 105 Click the OK button to complete setup change Click oi 1 pre um select it RENS and DN then press Ent Click or pr it progra B EJ SUZUKI DIAGNOSTIC SYSTEM Press the engine side PTT Switch Down Button and bring the engine to its ideal full au ap After adjusting the engine full tilt down pos click Note uw Muerge ations set y engines dep ies al ful down position before click OK butt Use Tab to select button then press Bur n crab progress ud the next BCM ID 33920 98J00 Fig 106 73 5 5 SYSTEM CHECK Check system settings SYSTEM CONFIGURATION 1 Clicking the SYSTEM CHECK button from the Main Menu dialog box Fig 85 displays the following menu window Fig 107 5 DIAGNOSTIC SYSTEM Main Menu F1 File F2 Save F3 Wwindow F4 Help F9 Exit F10 SYSTEM FORMATION SERVICE DATA CURRENT SERVICE CODES Close Esc Click or press Main Menu F1 select item by UP and DN then press Ent
94. ow F4 Help F9 Exit F10 COMMUNICATION ERROR communication between the PC and the ECM or BCM Click OK button to Use the functions of Update database Open file and Help Cancel this window use functions other than the above click Reset button to communicate with the ECM after confirming the following items 5 the main switch ON 15 the boat main switch Is the diagnostic harness connected with the ECM correctly s the diagnostic harness connected with the BCM correctly 15 the diagnostic harness connected with the PC correctly 15 the diagnostic harness connected with the diagnostic adapter correctly Are the battery cable and the sub battery cable connected with the battery correctly Is the battery fully charged Are the fuses and the main relay in good condition _ PPP 299 4 suzuki pracosric s Be Fig 34 7 Insert the SDS database disk compact disk into the CD ROM drive of your PC NOTE A new database overwrites the old database 8 Click the File F2 button in the upper left of the dialog box From the submenu select and click Update database Fig 35 sE DIAGNOSTIC SYSTEM 8 2121 x Main Menu F1 File F2 Save F3 Window F4 9 Exit F10 Print Update database Close Esc Click or press Main Menu F1 panne item by UP and DN then press Enter ECM Due MK Spec E
95. plays the following window Fig 101 Set the lever to each position Forward Neutral Reverse and click the Set button If the set lever positions are correctly registered V mark is displayed in the Status column in the right side of the window Repeat the same operation to register all the lever positions Clicking the Cancel button cancels system setting change SYSTEM CALIBRATION Lever Position Calibration First Station Forward Lever Position Status 1 Reverse Max 2 Reverse Min 5 Forward Max Move the remote control lever to the positions listed in their numerical order Click Set button to fix the position and confirm checkmark v appears After fixing all lever positions in order click button to accept Note When using a Dual Remote Control both levers should be moved simultaneously to the same position sane Use Tab to select items then press Enter Click OK button to continue Use Esc or Cancel button to return to the previous screen Fig 101 NO TE SYSTEM CALIBRATION Lever Position Calibration First Station For a dual control box you must simultaneously op LeverPositon status erate both levers a Reversemax aye V 2 Reverse Min 3 When all the lever positions have been registered v a return the lever to the neutral position F
96. pted move to the OK button by using the Tab key and press the Enter key NOTE ITEM SELECTION SERVICE DATA WLPS OUTPUT 2 0 5 5 Aa nn Cancel Use LP and DN to select items and press Space Bar to change rom displayed not displayed then click button Use Esc to cancel Fig 111 e Clicking the Cancel button ignores the selected item and makes the previous selection valid Pressing the Esc key ignores the selected item and makes the previous selection valid 77 SAVING BCM SERVICE DATA You can save all the displayed service data for the outboard motor ECM with SDS connected to the master BCM 1 In SERVICE DATA window Fig 93 of the out board motor ECM connected to the master BCM click the Save F3 button F3 key on the Engine No board The COMMENT INPUT SERVICE DATA dialog box appears From this dialog box type a comment into the Engine No Boat Type and De scription fields and then click the OK button Fig 112 Keyboard Move the cursor to the field in which to type a comment by using the Tab key After typing the comment move to the OK button by OK Cancel using the Tab key and press the Enter key to have the comment accepted Input Comment and press Tab Click button Use Esc or Cancel button to cancel COMMENT INP
97. re cannot operate on some PCs depending on their operating environments e Always follow the instruction displayed in windows 3 INSTALLATION 3 1 INSTALLING SDS BEFORE INSTALLING SDS Check that the PC on which to install SDS software meets the operating environments of SDS before installing SDS 1 Exitall the applications being executed other than Windows 2 Insert the install disk for SDS Ver 6 00 into your CD ROM drive 3 Double click the My Computer icon and then the CD ROM Drive icon 4 Double click the Setup icon in the setup disk This will copy files required for application instal lation to prepare for the SDS installation Fig 2 Fig 4 NOTE For Windows Vista when executing Setup the user account control screen Fig 3 is displayed Clicking Allow continues the setup while clicking Cancel aborts the setup laj xl File Edit Favorites Tools Help Back QQsearch Folders History Re Or Address 8 Compact Disc D P gt x ZA 5 d Uu 4 lt Db Driver datal datal hdr data2 ikernel layout Setup Setup Setup Compact Disc D Select an item to view its d description setup Capacity 1 75 MB used 1 75 MB 0 Free 0 bytes 11 object s 1 45 B My Computer start 4 3505 stet 1009 Paint compact pisc 0 5 4 9 53am Fig 2 User Account Contro
98. riple engines register the PORT and STBD positions e After full tilt down the high pressure fuel pump of the outboard motor is actuated for 3 seconds Listen for the actuation sound 67 7 The following window Fig 94 appears This window is used to register the position of the remote control lever in the BCM Set the lever to each position Forward Neutral Reverse and click the Set button If the set lever positions are correctly registered mark is displayed in the Status column in the right side of the window Hepeat the same operation to register all the lever positions Clicking the Cancel button cancels system calibration SYSTEM CALIBRATION Lever Position Calibration First Station Lever Position Status Reverse 2 Reverse Min 3 Neutral 5 Forward Move the remote control lever to the positions listed in their numerical order Click Set button to fix the position and confirm checkmark v appears After fixing all lever positions in order click button to accept Note When using a Dual Remote Control Box both levers should be moved simultaneously to the same position Use Tab to select items then press Enter Click OK button to continue Use Esc or Cancel button to return to the previous screen Fig 94 SYSTEM CALIBRATION Lever Position Calibration First Stati
99. rs Fig 89 Click the OK button and proceed to the next step Enter key on the keyboard SYSTEM CALIBRATION Master BCM Registration 1 Make sure that SDS is connected to the First Station BCM 2 Click OK button to accept Note This BCM is registered as Master BCM Use Tab to select items then press Enter Click OK button to go next Use Esc or Cancel button to return to the previous screen Fig 89 65 NOTE station to which SDS was connected is regis tered as the master BCM If SDS is connected to the BCM of the second station and the system is calibrated the BCM of the second station serves as the master BCM If the Cancel button is clicked or the Esc key is pressed during system calibration the window 2 xp sd shown at right Fig 90 appears Click the OK but ton to calibrate the system To continue system Cancel calibration click the Cancel button Fig 90 4 The following window Fig 91 appears This window is used to register the system configuration In this window select the number of stations and the number of engines by clicking the W button click the OK button and proceed to the next step Keyboard Move to a desired item by using the Tab key Select a desired item by using the Up or Down arrow key and press the Enter key to have the selected item accepted Clicking the Cancel button cancels system
100. s Feedback info and All Service Data Fig 50 Select a data item group you want to use by clicking the W button Keyboard To select a data item group from the keyboard select a menu by using the Up or Down key and then press the Enter key SUZUKI DIAGNOSTIC SYSTEM SERVICE DATA Main Menu F1 Save F3 wWindow F Help F9 Exit F10 JELE N DATA Select e S Data ccc ine Data Caution Sys Info Operation Hours 02 Feedback Info Secundi Service Data ABsoLUTE se ABSOLUT SSURE BAROMETRIC PRESSURE 753 mmHg CYLINDER TEMPERATURE INTAKE AIR TEMPERATURE 36 Data item group BATTERY VOLTAGE 1260 V FUEL INJ PULSE WIDTH 0 ys INJECTED FUEL AMOUNT 0 FUEL CONSUMPTION AVE 0 0 HIGH FUEL PUMP DUTY 00 IAC VALVE DUTY 338 PURGE VALVE DUTY 00 EX MANI TEMPERATURE STBD EX MANI TEMPERATURE PORT ETV TRGT ANGLE 2 05 UP and DN to select item group then press Enter 0 select items move to Select button by Tab then press Enter Click or press ave F3 to save Esc to close SERVICE DATA ick or press Exit F10 to exit program Power 300PS ECM ID 33920 98J71 Spec Engine Type 4028cc 4 stroke istae E02 Pant suzucr oracwosric s BE Fig 50 28 NOTE To check the items you can select from these five data groups refer to the data item gro
101. s as follows When feedback finishes normally the buzzer sounds for about 0 5 second 1 only is also displayed Fig 62 When feedback does not normally finish the buzzer sounds with a series of long 2 seconds beep FIN NG is also displayed Fig 63 DIAGNOSTIC SYSTEM ACTUATOR TEST Main 1 2 Save F3 Window F4 Help F9 Exit F10 SERVICE DATA a 10 5 02 Feedback Info Select 02 FEEDBACK 3 5 Description ENGINE SPEED Read Operation Manual before doing 02 feedback MANIFOLD ABSOLUTE PRESSURE CYLINDER TEMPERATURE Message a Feedback completed successfully Disconnect 02 sensor connector Remove 02 sensor and TIE install plug Then check and adjust engine idle COMPENSATION FACTOR ZONE 1 speed COMPENSATION FACTOR ZONE 2 Use UP and DN to select item then press Go Use Esc to close ACTUATOR TEST COMPENSATION FACTOR ZONE 3 TIME OF LAST O2 FEEDBACK 02 FEEDBACK 4 Use UP and DN to select group then press Enter 0 select items displayed move to Select button by Tab then press Enter Click or press Save F3 to save data Use Esc to close SERVICE DATA Click or press Window F4 to change active window Click or press Exit F10 to exit program Power 115PS ECM ID 33920 90J10 Spec Fig 62 E
102. tall driver software obtained from your manufacturer s website or disc Unsigned software from other sources may harm your computer or steal information See details Fig 16 9 When the installation is correctly performed the Completing the Device Driver screen as shown in Fig 17 is displayed Installation Wizard Clicking Finish button completes the installation The drivers were successfully installed on this computer You can now connect your device to this computer your device came with instructions please read them first Driver Name Status 505 USB Adapter Ready to use Fig 17 NOTE Warni farming If an error occurs during installation of USB Adapter Driver the warning screen Fig 18 is dis Installation of the device driver Failed played e Please execute the installation of the device driver again In this case re install the device driver as follows Fig 18 13 For Windows 2000 XP 1 Start Button click Run 2 Enter C Program Files SDS Driver DPInst exe into Open column Fig 19 3 Clicking OK button to execute For Windows Vista 1 Start Button Program Files Accessories Click Run Fig 20 2 Enter C Program Files SDS Driver DPInst exe into Open column Fig 21 3 Clicking OK button to execute 14 Run the name of a program Folder document 2 x Internet resource and Windows will
103. tems Is the main switch ON 15 the boat main switch ON 15 the diagnostic harness connected with the ECM correctly s the diagnostic harness connected with the BCM correctly 15 the diagnostic harness connected with the PC correctly Is the diagnostic harness connected with the diagnostic adapter correctly Are the battery cable and the sub battery cable connected with the battery correctly 15 the battery fully charged Are the fuses and the main relay in good condition gt gt Pstart 4 suzuki 5 MEET Fig 46 NOTE x If the ECM or BCM makes no reply after the first 63 tno ord she ESM ex Bo menu window Fig 44 has appeared once the fol Is the switch Ist t mai itch ON lowing dialog box Fig 47 appears Is the diagnostic harness connected with the BCM correctly Is the diagnostic harness connected with the ECM correctly Read the messages in this dialog box follow the in reer edis NN S tru ctio ns an d th th e n 0 sd pus and mn sub battery cable connected with the battery correctly J Ist tt n i ca t e wit h t h e E or B C M um the pud eiie ras relay in good condition Press Enter after checking the above items Keyboard Press the Enter key Fig 47 26 4 2 ECM MAIN MENU 1 From the first menu win
104. test can be performed when the engine is not running OCV ACTUATION DF175 The oil control valve will be actuated for 5 seconds This test can be performed when the engine is not running PURGE VALVE ACTUATION DF200 to DF300 The purge valve will be actuated at 5096 duty This test can be performed when the engine is not running VVT ACTUATOR DF175 DF250 DF300 The actuator will be actuated so that the advance quantity becomes 10 This test can be performed when the engine is running 2 000 engine speed or faster 36 PERFORMING THE FEEDBACK DF40 to DF250 2007 year model and early After extended usage the engine components may become deteriorated or worn out This might make the air fuel mixture raito incorrect which could affect the exhaust emission of the engine To correct the air fuel mix ture raito the O sensor should be used to measure oxygen in the exhaust gas The ECM uses the O sensor data to correct the compensation coefficient of the fuel injection duration map PROCEDURE 1 Install the O sensor and protector tube on the outboard motor Connect the O sensor connector to the conversion adapter then connect the diagnostic harness with the adapter to the communication connector of the outboard motor Fit the test wheel 09933 19840 Diagnostic harness 09933 19830 USB adapter 09933 19880 Conversion adapter 18213 74F00 O sensor 18498 90J20 Protector tube 09914 79511 Test wheel for DF60 DF70 09
105. the Cancel button Keyboard Move the cursor to the field in which to type a comment by using the Tab key After typing the comment move to the OK button by using the Tab key and press the Enter key to have the comment accepted 46 Se osm 19 72 COMMENT INPUT LOGGER E E DF250 123456 Engine Boat Type SUZUKI Description XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXX Cancel Input Comment and press Tab Click OK button Use Esc ar Cancel button cancel Fig 73 2 The Save As dialog box Fig 74 appears The file save destination DataGraph folder is automatically selected and the file name is also automatically displayed Default initial save destination directory Windows 2000 XP 21 xi Save atal3raph dm Ex Es 12508071 54 File name Save as type csvr csv Cancel Fig 74 2 C Documents and Settings All Users Documents SDS DataGraph Lxxxxxxx csv Windows Vista C Users Public Documents SDS DataGraph Lxxxxxxx csv NOTE You can change the file name and file save destination as required LXXXXXXX D Engine type Example L2508021 2 Month 1 2 3 4 5 6 7 8 9 2 250 horsepower TIT 0 09 3 Date 01 31 4 Number 1 9 2 3 Click the Save button to save data To cancel data save click the Cancel button
106. tup program now the components you requested to add remove will not be installedjuninstalled You may run the setup program at a later time to complete operations Are you sure you want to quit the setup Fig 7 6 The confirmation window for the installation des tination folder and program folder appears Fig 8 To continue the installation click the Next but ton File copy is started Fig 9 NOTE To go back to the previous window click the Back button To quit the installation click the Cancel button 7 The installation of SDS Ver 6 00 software is com plete Fig 10 Click Finish button to install USB Adapter Driver SUZUKI DIAGNOSTIC SYSTEM Setup Start Copying Files Review settings before copying files Setup has enough information to start copying the program files If you want to review or change any settings click Back If you are satisfied with the settings click Next to begin copying files Current Settings Target directory C Program Files SDS Program group SUZUKI DIAGNOSTIC SYSTEM E InstallShield TN SUZUKI DIAGNOSTIC SYSTEM Setup L Setup Status SUZUKI DIAGNOSTIC SYSTEM Setup is performing the requested operations Installing C Program Files SDS SD5 exe InstallShield Fig 9 SUZUKI DIAGNOSTIC SYSTEM Setup InstallShield Wizard Complete Setup has finished installing SUZUKI DIAGNOSTIC SYSTEM on your comp
107. up tables in Section 4 10 DATA ITEM GROUPS Page 52 in this manual 3 You can select whether to display or hide the win dows of these five data groups To select an item whose window you want to display click the 5 lect button Keyboard Move to the Select button by using the Tab key and press the Enter key 4 The ITEM SELECTION Engine Data dialog box Fig 51 appears Items are displayed when their check boxes are selected check boxes with V mark Items are not displayed when their check boxes are cleared check boxes without V mark You select whether to display or hide an item by clicking the check box Keyboard To display or hide an item select it by using the Up or Down arrow key and press the Space key To have the selected item accepted move to the OK button by using the Tab key and press the Enter key NOTE ITEM SELECTION Engine Data ABSOLUTE PRESSURE mmHg LIMANIFOLD ABSOLUTE PRESSURE kPa LIMANIFOLD ABSOLUTE PRESSURE inHg PRESSURE mmHg BAROMETRIC PRESSURE kPa BAROMETRIC PRESSURE inHg TEMPERATURE CIRIT AKC TCRANCNATIINC OK Cancel Use and to select items and press Space Bar to change rom displayed not displayed then click OK button Use Esc to cancel e Clicking the Cancel button ignores the selected item and
108. ury may happen Do not leave USB connector in direct sunlight or high temperature circumstance Do not drop or apply strong shock to USB adapter Do not stick engine oil gasoline battery electrolyte to USB adapter cable etc Do not wipe them with solvent such as thinner f there is an abnormal condition such as smoke or smell from USB adapter or diagnosis harness please immediately stop the usage Do not use the diagnosis harness USB adapter etc which has broken sheathing Make sure that the main switch of outboard motor and the power of personal computer are OFF before connecting the diagnosis harness USB adapter USB cable etc Do not operate 505 with driving the boat or collision accident may occur BCM simulator harness is connected to the battery an incorrect sequence or at incorrect poles equip ments may be damaged The harness must be connected to the battery in the correct manner e engine switch must be turned OFF before connecting disconnecting BCM simulator harness Trademark Microsoft and Windows are registered trademarks of Microsoft Corporation in the United States and other countries Adobe Adobe Acrobat and Adobe Reader are the trademarks of Adobe Systems Inc or registered trade marks of Adobe Systems Inc in particular areas Pentium Core Solo and Core2 Duo are trademarks of Intel US CONTENTS T OVERVIEW cm
109. uter Installation of the 505 USB Adapter driver begins continuously Finish 11 NOTE If SDS Ver 5 00 has been already installed the per sonal computer displays the completion screen Fig 11 and the installation of USB Adapter Driver is not required NOTE If an error occurs during SDS software installation the warning screen Fig 12 is displayed In this case re execute the installation from step 1 8 Install wizard screen of device driver is displayed Fig 13 At this stage the temporary registration of driver is performed When continue the installation click NEXT but ton The installation of driver starts Fig 14 NOTE This installation is for temporary registering the de vice driver Connection between outboard motor and personal computer is not required for the temporary registration of the driver Temporary registration of driver With SDS USB Adapter and its cable disconnected from USB port of computer copy USB driver into the computer 12 InstallShield Wizard Complete Setup has finished installing SUZUKI DIAGNOSTIC SYSTEM on your computer Finish Fig 11 Warning Program File is not installed properly _ Please install again Fig 12 Welcome to the Device Driver Installation Wizard This wizard helps you install the software drivers that some computers devices need in order to work To continue click Next ee Snel Fig 13 Device Driver I
110. ys the window Fig 114 This window shows failed item names and actions to be taken S suzuki DIAGNOSTIC SYSTEM CURRENT SER ICE CODES 1 xl Main Menu F1 File F2 5sve F3 wWindow F4 Help F9 Exit F10 CURRENT SERVICE CODES Failed item LEVER POSITION SENSOR PORT 1ST Check sensor connector and harness Esc to close CURRENT SERVICE CODE Click or press Exit F10 to exit program BCMID 367709800 Pstart 4 E072 Paint suzuki vracwosric s Ed num Fig 114 NOTE f there is no failed item the message No failure appears in the CURRENT SERVICE CODES window You can simultaneously display the service data window of the outboard motor ECM connected to the master BCM and CURRENT SERVICE CODES window To change the active window click the Window F4 button F4 key on the keyboard 79 5 6 DATA GROUPS BCM DATA ITEM GROUP TABLE The following table shows the groups to which each data item belongs Items with mark can be freely selected and displayed Group No 1 Items that can be selected in master BCM service data Group No 2 ECM on the PORT side items that can be selected in the information sent the master BCM Group No 3 ECM on the STBD side items that can be selected in the information sent via the master BCM Group No 4 ECM on the CENTER side items that can be selected in the information sent via the master BCM

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