Suzuki GSX-R 1000 Service Manual: DTC “c60” (p0480): cooling fan relay circuit malfunction

Suzuki GSX-R 1000 Service Manual / Engine / Engine general information and diagnosis / Diagnostic information and procedures / DTC “c60” (p0480): cooling fan relay circuit malfunction

Detected condition and possible cause

Detected condition

Possible cause

Cooling fan relay signal is not input to ecm.

Cooling fan relay circuit open or short.
Ecm malfunction.

Wiring diagram

Suzuki GSX-R. Wiring diagram

Troubleshooting

Caution

when using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent terminal damage.

Note

after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures” .

Step

Action

Yes

Turn the ignition switch off.
Remove the frame covers. Refer to “exterior parts removal and installation” in section 9d .
Check the cooling fan relay (1) coupler for loose or poor contacts.

If ok, then inspection the cooling fan relay. Refer to “cooling fan inspection” in section 1f .

Is the cooling fan relay ok?

O/w and g/r wire open or shorted to ground, or poor “42” connection.
If wire and connection are ok, intermittent trouble or faulty ecm.
Recheck each terminal and wire harness for open circuit and poor connection.
Replace the ecm with a known good one, and inspect it again. Refer to “ecm removal and installation” in section 1c .

Replace the cooling fan relay with a new one.

Active control inspection

Set up the sds tool. (Refer to sds operation manual for further details.)
Start the engine and run it in idling condition.
Click “cooling fan relay control” (1).

Suzuki GSX-R. Active control inspection

Click the “operate” (2).
At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal.

Note

the cooling fan relay and cooling fan motor inspection is operational at any engine coolant temperature until reaching 100 °c (212 °f). In a hot engine condition with the intake air temperature exceeding 40 °c (104 °f), however, the engine coolant temperature at which the inspection is operational will be restricted to 95 °c (203 °f).

Suzuki GSX-R. Active control inspection

Click the “stop” (3) to check the operation properly.

Suzuki GSX-R. Active control inspection

Click the “off” (4) to check the cooling fan relay and cooling fan motor operation.

Note

this inspection should be begun from when the engine coolant temperature is below 50 °c (122 °f).

Check that the cooling fan relay operates for a few seconds as the engine coolant temperature reaches each temp. Of 50 °c (122 °f), 70 °c (158 °f), 90 °c (194 °f) and 110 °c (230 °f)/above 4 000 r/ min. It is cooling fan motor malfunction or its circuit failure when the motor would not run even if the relay turns on.
There is a tolerance of operating temperature of cooling fan relay.

Suzuki GSX-R. Active control inspection

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Other materials:

Water hose removal and installation
Removal Remove the side cowlings. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). Drain engine coolant. Refer to “cooling system inspection” in section 0b . Lift and support the fuel tank. Refer to “fuel tank removal and installation” in se ...

Sds check
Using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle function ...

Cylinder inspection
Refer to “engine top side disassembly” . Refer to “engine top side assembly” . Cylinder distortion Check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace t ...