Outline

When an abnormality in the system occurs, the FI indica­tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit). With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator LED light blinks.

When due to a malfunction, the FI indicator LED light re­mains lit, ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C], Don’t rely solely on the DFI self-diagnosis function, use common sense; first conduct a pre-diagnosis inspection, check the ECU for ground and power supply, the fuel line for no fuel leaks, and for correct pressure. The pre-diagnosis items are not indicated by the FI indicator LED light.

Even when the DFI system is operating normally, the FI indicator LED light [A] may light up under strong electri­cal interference. No remedy needed. Turn the ignition SW (switch) OFF to stop the indicator light.

When the FI indicator LED light goes on and the motor­cycle is brought in for repair, check the service codes.

When the repair has been done, the LED light doesn’t go on. But the service codes stored in memory are not erased to preserve the problem history, and the LED light can dis­play the codes in the self-diagnosis mode. The problem history is referred when solving unstable problems.

Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them. ^•

• When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance.

Special Tool - Needle Adapter Set: 57001-1457

CAUTION

Tape the leads to prevent short circuit of the leads.

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FUEL SYSTEM (DFI) 3-23

O After measurement, remove the needle adapters and ap­ply silicone sealant to the seals [A] of the connector [B] for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120)

Seals of Connector

• Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.

• Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem. If the problem was caused by some other item or items, they too must be repaired or replaced, or the new replacement part will soon fail again

• Measure coil winding resistance when the DFI part is cold (at room temperature)

• Do not adjust or remove the throttle sensor.

• Do not directly connect a 12 V battery to a fuel injector. Insert a resistor (5 ~ 7 Cl ) or a bulb (12 V x 3 ~ 3.4 W) in series between the battery and the injector.

• The DFI parts have been adjusted and set with precision. Therefore, they should be handled carefully, never strike sharply, as with a hammer, or allowed to drop on a hard surface. Such a shock to the parts can damage them.

• Check wiring and connections from the ECU connector to the suspected faulty DFI parts, using the hand tester (special tool, analog tester) rather than a digital tester. Special Tool - Hand Tester: 57001-1394

• Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Dete­riorated leads and bad connections can cause reappear­ance of problems and unstable operation of the DFI sys­tem.

• If any wiring is deteriorated, replace the wiring.

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• Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.

• If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely.

• Check the wiring for continuity.

O Use the wiring diagram to find the ends of the lead which is suspected of being a problem.

o Connect the hand tester between the ends of the leads.

oSet the tester to the * 1 ft range, and read the tester.

• If the tester does not read 0 Q, the lead is defective. Re­place the lead or the main harness or the sub harness.

O If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con­tinuity between the end [E] and the ground [F], This en­ables to check a long harness for continuity. If the harness is open, repair or replace the harness.

★ Narrow down suspicious locations by repeating the con­tinuity tests from the ECU connectors.

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FUEL SYSTEM (DFI) 3-25

O Lead Color Codes:

BK: Black G: Green P: Pink

BL: Blue GY: Gray PU: Purple

BR: Brown LB: Light blue R: Red

CH: Chocolate LG: Light green W: White

DG: Dark green O: Orange Y: Yellow

o Electrical Connectors: Female Connectors [A]

Male Connectors [B]

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NG

Check operation [6],

t OK

End of inspection

Self-diagnosis Fault code table

Problem chart

DFI parts location

Diagnosis sheet Fault inspection 11 — 62 DFI wiring diagram

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Troubleshooting the DFI System

FUEL SYSTEM (DFI) 3-27

Notes:

OK: No problem.

NG: Problem exists.

1. Inspection starts.

• An abnormality occurs in the DFI system, and the FI indicator LED light goes on to alert the rider.

• Bring the motorcycle into the shop.

2. Confirm problems.

• Reproduce the problems if possible.

3. Conduct pre-diagnosis inspection.

• The pre-diagnosis inspection items are not handled by self-diagnosis. Check the problem before self-diagnosis, considering the symptoms of the problem.

• Pre-diagnosis Inspection Items

ECU Power Supply Inspection

ECU Fuse Inspection

ECU Main Relay Inspection

FI Indicator LED Light Operation Inspection

Fuel Pressure Inspection

Fuel Flow Rate Inspection

Fuel Line Leakage Inspection

Fuel Injectors and Fuel Pump Leakage Inspection

4. Conduct self-diagnosis.

• Enter the self-diagnosis mode and count the blinks of the FI indicator LED light to read the service code.

5. Check items.

• Decide the faulty part, referring to the problem chart.

• Decide the check procedure for each faulty part, referring to each section (Fault Inspection 11 ~ 62).

6. Operation check.

• Make sure the FI indicator LED light goes off.

• If the problem is related to startability or idle stability, idle the engine to confirm that the DFI system and the ignition system are operating correctly.

• If the problem is related to driveability, ride the motorcycle at 30 km/h (18 mph) or above to confirm that the DFI system and the ignition system are operating correctly.

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