Fuel System (dfi) Table of Contents

Exploded View........................................................................................................................ 3-4

DFI System............................................................................................................................. 3-10

DFI System............................................................................................................................. 3-12

DFI Parts Location.................................................................................................................. 3-15 3

Specifications ......................................................................................................................... 3-16

Special Tools and Sealant ...................................................................................................... 3-18

DFI Servicing Precautions...................................................................................................... 3-20

DFI Servicing Precautions ................................................................................................ 3-20

Troubleshooting the DFI System ............................................................................................ 3-22

Outline ................................................................................................................................. 3-22

Outline............................................................................................................................... 3-22

Inquiries to Rider.................................................................................................................. 3-26

Inquiries to Rider............................................................................................................... 3-26

DFI System Troubleshooting Guide ....................................................................................... 3-29

Self-Diagnosis ........................................................................................................................ 3-37

Self-diagnosis Outline.......................................................................................................... 3-37

Self-diagnosis Outline ....................................................................................................... 3-37

Self-diagnosis Procedures................................................................................................... 3-37

Self-diagnosis Procedures ................................................................................................ 3-37

Service Code Clearing Procedures ..................................................................................... 3-38

Service Code Clearing Procedures................................................................................... 3-38

How to Read Service Codes................................................................................................ 3-40

How to Read Service Codes............................................................................................. 3-40

How to Erase Service Codes............................................................................................... 3-40

How to Erase Service Codes ............................................................................................ 3-40

Service Code Table.............................................................................................................. 3-41

Service Code Table........................................................................................................... 3-41

Backups ............................................................................................................................... 3-42

Backups ............................................................................................................................ 3-42

Main Throttle Sensor (Service Code 11) ................................................................................ 3-44

Main Throttle Sensor Removal/Adjustment ...................................................................... 3-44

Main Throttle Sensor Input Voltage Inspection ................................................................. 3-44

Main Throttle Sensor Output Voltage Inspection .............................................................. 3-45

Main Throttle Sensor Resistance Inspection .................................................................... 3-46

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-47

Inlet Air Pressure Sensor Removal................................................................................... 3-47

Inlet Air Pressure Sensor Installation................................................................................ 3-47

Inlet Air Pressure Sensor Input Voltage Inspection........................................................... 3-47

Inlet Air Pressure Sensor Output Voltage Inspection........................................................ 3-48

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-52

Inlet Air Temperature Sensor Removal/Installation........................................................... 3-52

Inlet Air Temperature Sensor Output Voltage Inspection .................................................. 3-52

Inlet Air Temperature Sensor Resistance Inspection ........................................................ 3-53

Water Temperature Sensor (Service Code 14) ...................................................................... 3-54

Water Temperature Sensor Removal/Installation ............................................................. 3-54

Water Temperature Sensor Output Voltage Inspection..................................................... 3-54

Water Temperature Sensor Resistance Inspection........................................................... 3-55

Crankshaft Sensor (Service Code 21).................................................................................... 3-56

Crankshaft Sensor Removal/Installation........................................................................... 3-56

Crankshaft Sensor Inspection........................................................................................... 3-56

Speed Sensor (Service Code 24, 25)..................................................................................... 3-57

Speed Sensor Removal/Installation.................................................................................. 3-57

Speed Sensor Inspection.................................................................................................. 3-57

Speed Sensor Input Voltage Inspection............................................................................ 3-57

Speed Sensor Output Voltage Inspection ......................................................................... 3-57

Vehicle-down Sensor (Service Code 31)................................................................................ 3-59

Vehicle-down Sensor Removal ......................................................................................... 3-59

Vehicle-down Sensor Installation ...................................................................................... 3-59

Vehicle-down Sensor Inspection....................................................................................... 3-59

Subthrottle Sensor (Service Code 32).................................................................................... 3-62

Subthrottle Sensor Removal/Adjustment .......................................................................... 3-62

Subthrottle Sensor Input Voltage Inspection..................................................................... 3-62

Subthrottle Sensor Output Voltage Inspection.................................................................. 3-63

Subthrottle Sensor Resistance Inspection ........................................................................ 3-64

Oxygen Sensor-not activated (Service Code 33) (Europe Models)........................................ 3-66 Oxygen Sensor Removal/Installation................................................................................ 3-66

Oxygen Sensor Inspection................................................................................................ 3-66

Stick Coils #1, #2: (Service Code 51, 52) .............................................................................. 3-68

Stick Coil Removal/Installation.......................................................................................... 3-68

Stick Coil Input Voltage Inspection.................................................................................... 3-68

Radiator Fan Relay (Service Code 56)................................................................................... 3-70

Radiator Fan Relay Removal/Installation.......................................................................... 3-70

Radiator Fan Relay Inspection.......................................................................................... 3-70

Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-71

Subthrottle Valve Actuator Removal ................................................................................. 3-71

Subthrottle Valve Actuator Audible Inspection .................................................................. 3-71

Subthrottle Valve Actuator Inspection ............................................................................... 3-71

Subthrottle Valve Actuator Resistance Inspection ............................................................ 3-71

Subthrottle Valve Actuator Input Voltage Inspection ......................................................... 3-72 Air Switching Valve (Service Code 64) ................................................................................... 3-73

Air Switching Valve Removal/Installation .......................................................................... 3-73

Air Switching Valve Inspection .......................................................................................... 3-73

Oxygen Sensor Heater (Service Code 67) (Europe Models) ................................................. 3-74

Oxygen Sensor Heater Removal/Installation .................................................................... 3-74

Oxygen Sensor Heater Inspection ................................................................................... 3-74

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models) ..................... 3-76 Oxygen Sensor Removal/Installation................................................................................ 3-76

Oxygen Sensor Inspection................................................................................................ 3-76

FI Indicator Light (LED) .......................................................................................................... 3-78

FI Indicator Light (LED) Inspection ................................................................................... 3-79 ECU ........................................................................................................................................ 3-80

ECU Removal ................................................................................................................... 3-80

ECU Installation ................................................................................................................ 3-80

ECU Power Supply Inspection.......................................................................................... 3-81 Fuel Line................................................................................................................................. 3-83

Fuel Pressure Inspection .................................................................................................. 3-83

Fuel Flow Rate Inspection ................................................................................................ 3-85

Fuel Pump .............................................................................................................................. 3-87

Fuel Pump Removal ......................................................................................................... 3-87

Fuel Pump Installation ...................................................................................................... 3-87

Fuel Pump Operation Inspection ...................................................................................... 3-88

Fuel Pump Operating Voltage Inspection ......................................................................... 3-88

Pressure Regulator Removal............................................................................................ 3-89

Pump Screen, Fuel Filter Cleaning ................................................................................... 3-89 Fuel Injectors .......................................................................................................................... 3-91

Removal/Installation.......................................................................................................... 3-91

Audible Inspection............................................................................................................. 3-91

Fuel Injector Power Source Voltage Inspection ................................................................ 3-91

Fuel Injector Output Voltage Inspection ............................................................................ 3-92

Injector Signal Test............................................................................................................ 3-92

Injector Resistance Inspection .......................................................................................... 3-93

Injector Unit Test ............................................................................................................... 3-94

Injector Fuel Line Inspection ............................................................................................. 3-94

Throttle Grip and Cables ........................................................................................................ 3-96

Throttle Grip Free Play Inspection .................................................................................... 3-96

Throttle Grip Free Play Adjustment................................................................................... 3-96

Throttle Cable Installation ................................................................................................. 3-96

Throttle Cable Lubrication................................................................................................. 3-96

Throttle Body Assy ................................................................................................................. 3-97

Idle Speed Inspection ....................................................................................................... 3-97

Engine Vacuum Synchronization Inspection/Adjustment.................................................. 3-97 High Altitude Performance Adjustment ............................................................................. 3-97

Throttle Body Assy Removal............................................................................................. 3-97

Throttle Body Assy Installation.......................................................................................... 3-98

Throttle Body Assy Disassembly ...................................................................................... 3-99

Throttle Body Assy Assembly 3-100

Air Cleaner. 3-101

Air Cleaner Element Removal/Installation 3-101

Air Cleaner Element Inspection 3-101

Air Cleaner Oil Draining 3-101

Air Cleaner Housing Removal 3-101

Air Cleaner Housing Installation 3-102

Fuel Tank 3-103

Fuel Tank Removal 3-103

Fuel Tank Installation 3-105

Fuel Tank and Cap Inspection 3-106

Fuel Tank Cleaning 3-107

Evaporative Emission Control System (California Model) 3-108

Parts Removal/Installation 3-108

Hose Inspection 3-108

Separator Inspection 3-108

Separator Operation Test 3-109

Canister Inspection 3-109

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Fuel Pump Bolts	9.8	1.0	87 in·lb		L, S

2. FI Indicator Light (LED)

3. Throttle Cable (Accelerator)

4. Throttle Cable (Decelerator)

5. Throttle Body Assy

6. Injectors

7. Meter Unit (EX650B Models) CL: Apply cable lubricant.

EO: Apply engine oil. G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

S: Follow the specified tightening sequence.

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Water Temperature Sensor	12	1.2	106 in·lb
2	Speed Sensor Bolt	7.8	0.80	69 in·lb	L
3	Oxygen Sensor (Europe Models)	44.1	4.50	32.5

4. Inlet Air Pressure Sensor

5. Air Switching Valve

6. Inlet Air Temperature Sensor

7. Crankshaft Sensor

8. Battery

9. Relay Box

10. Stick Coil

11. Vehicle-down Sensor

12. ECU (Electronic Control Unit)

13. California Model G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

SS: Apply silicone sealant.

California Model

1. Tube (Green)

2. Tube (Blue)

3. Tube (White)

4. Tube (Blue)

5. Tube (Red)

DFI System

1. Ignition Switch

2. Starter Lockout Switch

3. Starter Relay

4. Tachometer

5. FI Indicator Light (LED)

6. Inlet Air Pressure Sensor

7. Spark Plug

8. Crankshaft Sensor

9. Injector

10. Main Throttle Sensor

11. Delivery Pipe

12. Subthrottle Sensor

13. Subthrottle Valve

14. Main Throttle Valve

15. Subthrottle Valve Actuator

16. Fuel Pump

17. Pressure Regulator

18. Fuel Tank

19. Air Cleaner Element

20. Air Switching Valve

21. Inlet Air Temperature Sensor

22. Air Cleaner Housing

23. Neutral Switch

24. Speed Sensor

25. Vehicle-down Sensor

26. Oxygen Sensor (Europe Models)

27. ECU (Electronic Control Unit)

28. Battery

29. Air Flow

30. Fuel Flow

31. Water Temperature Sensor

DFI System Wiring Diagram

Part Name

1. Oxygen Sensor (Europe Models)

2. Crankshaft Sensor

3. Inlet Air Temperature Sensor

4. Water Temperature Sensor

5. Water-proof Joint E

6. Injectors

7. Vehicle-down Sensor

8. Water-proof Joint D

9. Inlet Air Pressure Sensor

10. Main Throttle Sensor

11. Subthrottle Sensor

12. Subthrottle Valve Actuator

13. Speed Sensor

14. Air Switching Valve

15. Water-proof Joint C

16. Stick Coils

17. Fan Motor

18. Engine Stop Switch

19. Ignition Switch

20. FI Indicator Light (LED)

21. Water Temperature Gauge

22. Tachometer

23. Speedometer

24. Water-proof Joint A

25. Water-proof Joint B

26. Oxygen Sensor Heater Fuse 10 A

27. Radiator Fan Fuse 15 A

28. ECU Fuse 15 A

29. Ignition Fuse 10 A

30. Radiator Fan Relay

31. ECU Main Relay

32. Fuel Pump Relay

33. Relay Box

34. Main Fuse 30 A

35. Battery

36. Frame Ground

37. Fuel Pump

38. Diagnosis Connector

39. Self-diagnosis Terminal

40. Joint Connector

41. ECU