Injector Resistance Inspection

• Remove the throttle body assy (see Throttle Body Assy Removal).

• Disconnect the connector from the injector [A] (see Throt- tle Body Disassembly/Assembly).

• Measure the injector resistance with the hand tester [Bj. Special Tool - Kawasaki Hand Tester: 57001-1394

Injector Resistance Connections to Injector

Meter (+) Meter (-)

#1: W/R <—> BL/R Terminal #2: W/R <—> BL/G Terminal #3: W/R <—► BL/BK Terminal #4: W/R <—> BL/Y Terminal Standard: about 11.7 ~ 12.3 fl @20°C (68°F)

• If the reading is out of the range, perform the “Injector Unit Test”.

• If the reading is normal, perform the “Injector Unit Test” for confirmation.

Injector Unit Test

• Use two leads [A] and the same test light set [B] as in “Injector Signal Test”.

Rating of Bulb [C]: 12 V • * (3 - 3.4) W 12 V Battery [D]

CAUTION

Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current.

• Connect the test light set to the injector [E] as shown.

• Open and connect [F] the end of the lead to the battery (-) terminal repeatedly. The injector should click.

• If the injector does not click, replace the injector.

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FUEL SYSTEM (DFI) 3-55

Injector Voltage Inspection

• Turn the ignition switch OFF.

• Remove:

Fuel Tank (see Fuel Tank Removal)

• Connect a digital voltmeter [A] to the connector [B], with the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

Injector Power Source Voltage Connector to Injector #1, #2, #3, #4 Meter (+) -> W/R lead Meter (-) Battery (-) Terminal

• Install the fuel tank.

• Turn the ignition switch ON.

Power Source Voltage at Injector Connector Standard: Battery Voltage (12.5 V or more)

• If the power source voltage is less than standard, check the wiring (see wiring diagram in this section), fuel pump relay (Fuel Pump Relay Inspection) and ECU power source (see ECU Power Supply Inspection).

• Turn the ignition switch OFF.

• Remove:

Fuel Tank (see Fuel Tank Removal)

• Connect a digital voltmeter [A] to the connector [B], with the needle adapter set [Cj.

Special Tool - Needle Adapter Set: 57001-1457

Injector Output Voltage Connections to Injector #1 Meter (+) BL/R lead Meter (-) -> Battery (-) Terminal Connections to Injector #2 Meter (+) -> BL/G lead Meter (-) -» Battery (-) Terminal Connections to Injector #3 Meter (+) -» BL/BK lead Meter (-) -» Battery (-) Terminal Connections to Injector #4 Meter (+) -> BL/Y lead Meter (-) -» Battery (-) Terminal

• Install the fuel tank.

• Turn the ignition switch ON.

BL/Y BL/BK BL/G BL/R

Output Voltage at Injector Connector Standard: Battery Voltage (12.5 V or more)

★ If the output voltage is out of the standard, replace the ECU.

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Injector Fuel Line Inspection

• Remove the throttle body assy (see this chapter).

• Check the injector fuel line for leakage as follows:

O Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends connected with the clamps [D]) as shown.

Torque - Fuel Hose Clamp Screws: 1.5 N-m (0.15 kgf-m, 13 in-lb)

O Apply soap and water solution to the areas [E] as shown, o Watching the pressure gauge, squeeze the pump lever [F], and build up the pressure until the pressure reaches the maximum pressure.

Fuel Line Maximum Pressure

Standard: 300 kPa (3.06 kgf/cm^J, 43 psi)

CAUTION

During pressure testing, do not exceed the maxi- mum pressure for which the system is designed.

• Watch the gauge for at least 6 seconds.

• If the pressure holds steady, the system is good.

• If the pressure drops at once, or if bubbles are found in the area, the line is leaking. Replace the delivery pipe, injectors and related parts.

O Repeat the leak test, and check the fuel line for no leak- age.

• Install the throttle body assy (see this chapter).

• Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in Appendix chapter).

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Fuel Injectors

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1. ECU

2. Fuel Injector #4

3. Fuel Injector #3

4. Fuel Injector #2

5. Fuel Injector #1

6. Ignition Switch

7. ECU Main Relay

8. Fuel Pump Relay

9. ECU Fuse 15 A

10. Main Fuse 30 A

11. Starter Relay

12. Battery

13. Engine Stop Switch

14. Ignition Fuse 10 A

15. Junction Box

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Self-diagnosis Outline

The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal [A],

User Mode:

The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles ECU stops the injec- tion/ignition/starter motor operation.

Dealer Mode 1:

The FI indicator LED light emits service code(s) to show the problem(s) which the DFI system and ignition system has at the moment of diagnosis.

Dealer Mode 2:

The FI indicator light LED emits service code(s) to show the problem(s) which the DFI system and ignition system had in the past.

Self-diagnosis Procedures

O When a problem occurs with the DFI system and ignition system, the DFI indicator LED light [A] goes on.

NOTE

O Use a fully charged battery when conducting self-diagnosis. Otherwise, the LED light blinks very slowly or doesn’t blink.

O Keep the self-diagnosis terminal grounded during self -diagnosis, with a auxiliary lead. ^•

• Remove the seats (see Frame chapter) and pull the self -diagnosis terminal [G].

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FUEL SYSTEM (DFI) 3-59

• To enter the self-diagnosis dealer mode 2 repeat opening [B] and grounding [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.

NOTE

o If the self-diagnosis mode is in dealer mode 1 then you need to enter the dealer mode 2, turn off the ignition switch once.

Service Code Clearing Procedures

• Enter the self-diagnosis dealer mode 2 (see Self- diagno­sis Procedures).

NOTE

O Make sure to keep the grounding until the following opening and grounding starts.

• Pull the clutch lever in more than 5 seconds, and then release it.

• Repeat opening [B] and grounding [A] the lead (self-diagnosis terminal) more than five times [F] within 2 seconds [C] after the lead is grounded, and then keep it grounded continuously [D] for more than 2 seconds.

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Dealer Mode 2.

Repeat opening and grounding the self-diagnosis indicator terminal more than five times within 2 seconds after the terminal is first grounded and then keep it grounded.

FI indicator LED light blinks to dispaly the fault code for more than 2 seconds.

Locate the problem with the fault code table and check and repair DFI or ignition system according to inspection procedure on all fault code.

Remove the auxiliary lead, ending the self-diagnosis mode.

Make sure the FI indicator LED light doesn't go ON.

NG

OK

Run the engine for several minutes at idling and run the motorcycle at 30 km/h (18 mph) or above in order to confirm no problem.

NG

L

OK _S__ _

END

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FUEL SYSTEM (DFI) 3-61

Self-Diagnosis

How to Read Service Codes

O Service codes are shown by a series of long or short blinks of the FI indicator LED light as shown below.

o Read 10th digit and unit digit as the FI indicator LED light blinks.

oWhen there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open.

Olf there is no problem, no code and unlight.

O For example, if two problems occurred in the order of 21, 12. the service codes are displayed from the lowest number in the order listed.

(12 -> 21) -> (12 -» 21) -» • • • (repeated)

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Self-Diagnosis indicator terminal Groundedp

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FI Indicator LEO Light ON OFF

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O If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator LED light doesn’t go on, and no service codes can be displayed.

FI Indicator LED Light Fuel Pump Fuel Pump Relay DFI Main Relay

ECU Power Source Wiring and Ground Wiring (see ECU Inspection in this chapter)

Fuel Injectors

How to Erase Service Codes

O Even if the ignition SW is turned OFF, the battery or the ECU are disconnected, or the problem is solved, all service codes remain in the ECU.

O Refer to Service Code Clearing Procedure for the service code erasure.

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Main Throttle Sensor (Service Code 11)

FUEL SYSTEM (DFI) 3-65

The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.

Input Terminal [A]

Output Terminal [B]

Ground Terminal [C]

Main Throttle Sensor Removal/Adjustment

CAUTION ~

Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory.

Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. ^{* ★}

Main Throttle Sensor Connector [B]

Input Voltage Inspection

NOTE

O Be sure the battery is fully charged.

• Turn the ignition switch OFF.

• Remove the ECU (see this chapter). Do not disconnect the ECU connectors.

• Connect a digital voltmeter [A] to the connector [B], using the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

Main Throttle Sensor Input Voltage Connections to ECU Connector Meter (+)-> BL lead (terminal 1)

Meter (-)-> BR/BK lead (terminal 4)

• Measure the input voltage with the engine stopped, and with the connectors joined.

• Turn the ignition switch ON.

Input Voltage at ECU Connector Standard: 4.75 ~ 5.25 V DC

• Turn the ignition switch OFF.

★ If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted.

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Main Throttle Sensor (Service Code 11)

• Disconnect the main throttle sensor connector [A] and connect the harness adapter [B] between the harness connector and main throttle sensor connector.

• Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Harness Adapter : 57001

-1538

Main Throttle Sensor Input Voltage Connections to Sensor Meter (+)-> BL lead Meter (-)-* BR/BK lead

• Install the throttle body assembly.

• Measure the sensor input voltage with the engine stopped, and with the connector joined.

• Turn the ignition switch ON.

Input Voltage at Sensor Standard: 4.75 ~ 5.25 V DC

• Turn the ignition switch OFF.

• If the reading is out of the range, check the wiring (see wiring diagram in this section).

• If the reading is good, check the output voltage of the sensor.

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