EMISSION CONTROL INFORMATION

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1 EMISSION CONTROL INFORMATION 9-1 EMISSION CONTROL INFORMATION 1 CONTENTS EMISSION CONTROL SYSTEMS 9-2 FUEL INJECTION SYSTEM 9-2 CRANKCASE EMISSION CONTROL SYSTEM 9-3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) 9-4 NOISE EMISSION CONTROL SYSTEM 9-5 EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33) 9-5 PAIR (AIR SUPPLY) SYSTEM INSPECTION 9-6 HOSES 9-6 PAIR REED VALVE 9-6 PAIR CONTROL SOLENOID VALVE 9-6 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 9-8 HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-2,19) 9-9 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (FOR E-33) 9-1 HOSES 9-1 EVAP CANISTER 9-1 TANK PRESSURE CONTROL VALVE 9-1 EVAP CANISTER HOSE ROUTING (FOR E-33) It

2 9-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM SV1S motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. ~%~~~ BEFORE-PRESSURIZED FUEL Ift PRESSURIZED FUEL I' RELIEVED FUEL

3 EMISSION CONTROL INFORMATION 9-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body. 9 C FRESH AIR FUEL/AIR MIXTURE BLOW-BY GAS

4 9-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, ZAPS and CKPS. I H2 sensor (Except for USA)

5 EMISSION CONTROL INFORMATION 9-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED : Federal law prohibits the following acts or the causing thereof : 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW : Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases. Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air. Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label. EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33) #1 Throttle body EVAP canister 1~ FUEL <- HC VAPOR ---- FRESH AIR < f VACUUM

6 9-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES Inspect the hoses for wear or damage. Inspect that the hoses are securely connected. PAIR REED VALVE Remove the PAIR reed valve cover. (=3-34) Inspect the reed valve for the carbon deposit. If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. PAIR CONTROL SOLENOID VALVE Remove the air cleaner box. ( f-74-75) Disconnect the PAIR control solenoid valve lead wire coupler 1. Remove the PAIR control solenoid valve (Z. Check that air flows through the air inlet port to the air outlet ports. If air does not flow out, replace the PAIR control solenoid valve with a new one. Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow. If air does not flow out, the solenoid valve is in normal condition. No I

7 EMISSION CONTROL INFORMATION Check the resistance between the terminals of the PAIR control solenoid valve. Resistance : 2-24 S (at 2 C/68 F) : Multi circuit tester set ~gy Tester knob indication : Resistance (S2) If the resistance is not within the standard range, replace the PAIR control solenoid valve with a new one.

8 9-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Matching mark (White) 1% 4 4V ' MI I II 11 4.Mm Matching mark (Yellow) 1 N m 1. kgf-m, 7. lb-ft) 4 PAIR read valve qu 4

9 EMISSION CONTROL INFORMATION 9-9 J I H EATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-2, 19) Disconnect the H2 sensor lead wire coupler. (=4-61) Inspect the H2 sensor and its circuit referring to flow table of the malfunction code (C44). Check the resistance between the terminals of the H2 sensor. Resistance : 4-5 S2 (at 23 C/73.4 F) : Multi circuit tester set Tester knob indication : Resistance () If the resistance is not within the standard range, replace the H2 sensor with a new one. NOTE: * Temperature of the sensor affects resistance value largely. * Make sure that the sensor heater is at correct temperature. A WARNING Do not remove the H2 sensor while it is hot. CAUTION Be careful not to expose it to excessive shock. Do not use an impact wrench while removing or installing the H2 sensor unit. Be careful not to twist or damage the sensor lead wire.

10 9-1 EMISSION CONTROL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (FOR E-33) Remove the air cleaner box. ((- r4-75) HOSES Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. VA I EVAP CANISTER Inspect the canister for damage to the body. TANK PRESSURE CONTROL VALVE Inspect the tank pressure contorol valve body for damage. Inspect the tank pressure control valve operation in the following procedure. Vol,' Remove the tank pressure control valve. When air pressure is applied to the tank pressure control valve from the side OO, air should flow out through the purge control valve. When air pressure is applied to the tank pressure control valve from the side, air should not flow through the purge valve. If the tank pressure control valve operates otherwise, it must 1% 4 be replaced. A WARNING Gasoline and gasoline vapor is toxic. A small amount of fuel remains in the tank pressure control valve when checking it. Do not swallow the fuel when blowing the tank pressure control valve. NOTE: When connecting the tank pressure control valve to the hose, the side should face toward the fuel shut-off valve side, and the side AO should face toward the canister side. 14,

11 EMISSION CONTROL INFORMATION 9-11 EVAP CANISTER HOSE ROUTING (FOR E-33) EVAP canister Fuel shut-off valve Clamp ends should face top side. Clamp ends should face outside. Tank pressure ~~ control valve i

12 WIRING DIAGRAM FI SYSTEM WIRING DIAGRAM IGNITION COIL 3 A IG2 IG1 MAIN 15A 1A NEUTRAL LAMP SI RE ECM BATT FP 41 TOS 33 AT a +B 18 CLT IG1 IG2 VM 36 THW -R/W - Y/B -Br/W O/R - O/G - B/Y -B -W/BI- -Y/R -B/BI 6'`p 1A TIP OVER SENSOR FUE SOL 5 FI #1 Fl #2 21 STA MO+ MO- 14 THA 1 VCC 19 TPS 34 E2 STPS H2 (OXH) 24 H2 (OX) (2 G+ -Br -Gr/W - Gr/B -Y/G - B/R - R/B - Dg --R -P/W -B/Br -y- - W/B - W/G - Y/W is 31 GP N+ 3 N- 3s TS 16 PM PA TACO TECH 4 NT - G/BI - G -W/R -G/B -G/Y - Br/B - B/G - BI -B/W- -B/W- -B/W - MODE SELECTION L ATMOSPHERIC PRESSURE SENSOR 4) SPEEDOMETER PAIR SOLENOID INTAKE AIR CONTROL VALVE PRESSURE SENSOR SIDE- STAND

RELAY I ENGINE STOP FUEL PUMP RELAY 1 E- GEAR CLUTCH ND POSITION LEVER ITCH POSITION HO2SENSOR (Except for USA) Fl FUEL INJECTOR STPS SECONDARY THROTTLE POSITION SENSOR ECTS

13 RELAY I ENGINE STOP FUEL PUMP RELAY 1 E- GEAR CLUTCH ND POSITION LEVER ITCH POSITION HO2SENSOR (Except for USA) Fl FUEL INJECTOR STPS SECONDARY THROTTLE POSITION SENSOR ECTS ENGINE COOLANT TEMP SENSOR TPS THROTTLE POSITION SENSOR TATS INTAKE AIR TEMP SENSOR CMPS CAMSHAFT POSITION SENSOR CKPS CRANKSHAFT POSITION SENSOR STVA SECONDARY THROTTLE VALVE ACTUATOR

14 R( WIRING DIAGRAM E-3, 24, 28, 33 HANDLEBAR (R) R : TURN SIGNAL INDICATOR LIGHT (R) L : TURN SIGNAL INDICATOR LIGHT (L) B : HI-BEAM INDICATOR LIGHT N : NEUTRAL INDICATOR LIGHT F : FUEL WARNNING LIGHT O : OIL PRESSURE, FI INDICATOR LIGHT N vi' SPEEDOMETER IIL' B IGNITION ~onom mmmo mu // MESON HAZARD ENGINE STOP STARTER FRONT BRAKE Ell ICoT mcl J O IL PRE,' swit m m m ~m m OmOammm~ m ~~ooo3> m m 3 u POSITION LIGHT (R) B Br-,1-Br Bnv env FRONT TURN SIGNAL LIGHT (R) Lg Lg B/W B/W HEADLIGHT (R) Y B/W W HEADLIGHT (L) Y B/W W B/W B B B/W FRONT TURN SIGNAL LIGHT (L) Lg - Y - B/W- W - B - Br - - Lg Y BIW - W a-/w 13111W, POSITION LIGHT (L) mjjmom 3 mmm m o'o mm m mmi/j m` mm 5o L~~ Ofm mm` mm HORN O mcn O// i~~ El// ~C J IIIIIIIIII HORN PASSING DIMMER BUTTON TURN SIGNAL LIGHT LEVER POSITION HANDLEBAR (L) mm mam B/R I m m STP m i ~y CTid// SENSOR FAN MOTOR FAN OCR MOTOR O IAP SENSOR CENSOR ECT SENS( ACTUATOR MOTOR #2 #1 INJECTOR

15 IRE FUEL PUMP gym : i2 REAR BRAKE MEN M// mm of FUEL PUMP SENSOR AP RELAY SENSOR ffm m=> m mm m ECM ~IIIIIII IIIillllllllll IIIIIIIIIIIIIIIIIIII ( III II ~~ mm ~m~m m ~ m~~>o~b?z5 C3 B ~>mms?oam m`>lmq~ m~~ > m~mr~ Z ~ ;mmo m>m Oc~mmam>3 mi3m>r >ommmmm3 mmm mmmmmm 3 Cm 1 Br B/W LIC ENSE LIGHT B B REAR TURN SIG NAL LIGHT (R) Lg B B/W B/W1 Br B/W W/B BRAKE LIG HTITAILLIGHT Gr B/W W/B B Iji B B/W REAR TURN SIGNAL LIGHT (L) V- OO O mm m - > om m Z- S2 Q~ q~ m >mm m m R-1 F GEAR POSITION FUSE BOX SENSOR PAIR SORENOID SPEEDOMETER SENSOR GENERATOR -RECTIFIER STARTER 1 : MAIN 3 A BATTERY MOTOR STARTER RELAY 1. HEAD HI 15 A 2. HEAD LO 15 A 3. FUEL 1 A 4. IGNITION 15 A 5. SIGNAL 1A 6. FAN 15A SIDE STAND

16 Prepared by SUZUKI MOTOR CORPORATION February, 23 Part No E Printed in Japan 476

17 SUZUKI MOTOR CORPORATION Printed in Japan ~TK; K3

ECU Pinout Chart 2002 WRX Engine Control Module (ECM) I/O Signals. Wire Ignition SW Color ON Engine ON (Idling)

ECU Connector Diagram ECU Pinout Chart 2002 WRX Engine Control Module (ECM) I/O Signals Signal (V) Content Pin Wire Ignition SW Color ON Engine ON (Idling) Note (Engine OFF) Crankshaft Signal (+) B2 W