- •LIST OF ABBREVIATIONS
- •New Ignition Interlock Sidestand System
- •Current Ignition Interlock Sidestand System
- •Materials of Semi-Conductor and Emitting Color
- •Units of Mass:
- •Units of Volume:
- •Units of Force:
- •Units of Length:
- •Units of Torque:
- •Units of Pressure:
- •Units of Speed:
- •Units of Power:
- •Periodic Inspection:
- •Periodic Replacement Parts:
- •Basic Torque for General Fasteners
- •Throttle Grip Free Play
- •Idle Speed
- •Engine Vacuum
- •Water and Coolant Mixture Ratio (when shipping)
- •Valve Clearance
- •Clutch Lever Free Play
- •Engine Oil
- •Tread Depth
- •Air Pressure (when cold)
- •Chain Slack
- •Drive Chain 20-link Length
- •Standard Chain
- •Pad Lining Thickness
- •Sample Diagnosis Sheet
- •Poor Running at Low Speed
- •Poor Running or No Power at High Speed:
- •Wiring Connection
- •Idle Speed
- •Wiring Connection
- •Main Throttle Sensor Resistance
- •Inlet Air Pressure Sensor Output Voltage
- •Inlet Air Temperature Sensor Output Voltage
- •Water Temperature Sensor Output Voltage
- •Atmospheric Pressure Sensor Input Voltage
- •Output Voltage at Sensor
- •Wiring Connection
- •Wiring Connection
- •Throttle Sensor Resistance
- •Stick Coil Input Voltage at ECU
- •Input Voltage at ECU
- •Subthrottle Valve Actuator Resistance
- •Subthrottle Valve Actuator Input Voltage
- •Input Voltage at Actuator
- •FI Indicator LED Light Check
- •ECU Grounding Inspection
- •ECU Power Source Inspection
- •Testing Relay
- •Fuel Pressure
- •Fuel Pressure (idling)
- •Amount of Fuel Flow
- •Testing Relay
- •Injector Power Source Voltage at ECU
- •Output Voltage at Injector Connector
- •Injector Wiring Inspection
- •Choke Lever Free Play
- •Radiator Cap Relief Pressure
- •Thermostat Valve Opening Temperature
- •Camshaft Journal, Camshaft Cap Clearance
- •Camshaft Journal Diameter
- •Camshaft Runout
- •Cylinder Compression
- •Cylinder Head Warp
- •Valve/Valve Guide Clearance (Wobble Method)
- •Valve Seating Surface Outside Diameter
- •Valve Seating Surface Width
- •Cylinder Inside Diameter
- •Piston Diameter
- •Piston Ring/Groove Clearance
- •Piston Ring Groove Width
- •Piston Ring Thickness
- •Piston Ring End Gap
- •Clutch Plate Assembly
- •Friction Plate Thickness
- •Friction and Steel Plate Warp
- •Clutch Spring Free Length
- •Oil Pressure
- •Connecting Rod Bend
- •Connecting Rod Twist
- •Connecting Rod Big End Side Clearance
- •Crankpin Diameter
- •Crankpin Diameter Marks
- •Connecting Rod Big End Inside Diameter Marks
- •Crankshaft Side Clearance
- •Crankshaft Runout
- •Crankshaft Main Journal Diameter
- •Crankshaft Main Journal Diameter Marks
- •Crankcase Main Bearing Inside Diameter Marks
- •Shift Fork Ear Thickness
- •Gear Groove Width
- •Shift Fork Guide Pin Diameter
- •Shift Drum Groove Width
- •Rim Runout
- •Axle Runout/100 mm (3.94 in.)
- •Balance Weight
- •Link Pin Outside Diameter
- •Link Plates Outside Width
- •Rear Sprocket Warp
- •Pedal Position
- •Front Disc Thickness
- •Rear Disc Thickness
- •Disc Runout
- •Oil Level (fully compressed, without spring)
- •Fork Spring Free Length
- •Rebound Damping Adjustment
- •Spring Preload Setting
- •Spring Preload Adjustment
- •Table 1 Alternator Output Voltage
- •Table 2 Stator Coil Resistance
- •Rectifier Circuit Inspection
- •Charging Voltage
- •Crankshaft Sensor Peak Voltage
- •Connections:
- •Camshaft Position Sensor Peak Voltage
- •Ignition Coil Winding Resistance
- •Primary Lead Connection
- •Connection:
- •Condition:
- •Starter Motor Brush Length
- •Commutator Diameter
- •Testing Relay
- •Testing Turn Signal Relay
- •Water Temperature Sensor
- •Fuel Level Sensor Resistance
- •Connections:
- •Fuse Circuit Inspection
- •Relay Circuit Inspection (with the battery disconnected)
- •Relay Circuit Inspection (with the battery connected)
- •Diode Circuit Inspection
- •Foreword
- •General Information
- •Battery Ground
- •Edges of Parts
- •Solvent
- •Cleaning vehicle before disassembly
- •Arrangement and Cleaning of Removed Parts
- •Storage of Removed Parts
- •Inspection
- •Replacement Parts
- •Assembly Order
- •Tightening Sequence
- •Tightening Torque
- •Force
- •Gasket, O-ring
- •Liquid Gasket, Locking Agent
- •Press
- •Ball Bearing and Needle Bearing
- •Oil Seal, Grease Seal
- •Circlips, Cotter Pins
- •Lubrication
- •Direction of Engine Rotation
- •Electrical Wires
- •ZR750–J1 Left Side View:
- •ZR750–J1 Right Side View:
- •Subthrottle Control System
- •Outline
- •Outline
- •Due Position of LED Installation
- •Honeycomb Type Catalytic Converter
- •Prefixes for Units:
- •Units of Temperature:
- •Periodic Maintenance
- •Steering Stem Nut Wrench:
- •Fuel System (DFI)
- •Fuel Hose and Connection Inspection
- •Throttle Control System Inspection
- •Engine Vacuum Synchronization Inspection
- •Air Cleaner Element Cleaning
- •Cooling System
- •Radiator Hose and Connection Inspection
- •Coolant Change
- •Engine Top End
- •Valve Clearance Inspection
- •Clutch
- •Engine Lubrication System
- •Engine Oil Change
- •Wheels/Tires
- •Tire Wear Inspection
- •Air Pressure Inspection
- •Final Drive
- •Drive Chain Slack Inspection
- •Brakes
- •Rear Brake Light Switch Connections:
- •Caliper Fluid Seal Damage
- •Brake Line Bleeding
- •Suspension
- •Steering
- •Steering Adjustment
- •Electrical System
- •General Lubrication
- •Lubrication
- •Nut, Bolt, and Fastener Tightness
- •Fuel System (DFI)
- •Terminal Names
- •Part Name
- •Oil Pressure Gauge:
- •DFI Servicing Precautions
- •Outline
- •Outline
- •DFI Diagnosis Flow Chart
- •Inquiries to Rider
- •Inquiries to Rider
- •DFI System Troubleshooting Guide
- •Self-diagnosis Outline
- •Self-diagnosis Outline
- •Self-diagnosis Procedures
- •Self-diagnosis Procedures
- •Service Code Clearing Procedures
- •How to Read Service Codes
- •How to Read Service Codes
- •How to Erase Service Codes
- •How to Erase Service Codes
- •Service Code Table
- •Service Code Table
- •Notes:
- •Backups
- •Backups
- •Main Throttle Sensor Removal/Adjustment
- •Input Voltage Inspection
- •Resistance Inspection
- •CAUTION
- •Removal
- •Installation
- •Input Voltage Inspection
- •Output Voltage Inspection
- •Removal/Installation
- •Output Voltage Inspection
- •Removal/Installation
- •Output Voltage Inspection
- •CAUTION
- •Removal
- •Input Voltage Inspection
- •Crankshaft Sensor Inspection
- •Camshaft Position Sensor Removal/Installation
- •Camshaft Position Sensor Inspection
- •Input Voltage Inspection
- •Removal
- •Installation
- •Inspection
- •Subthrottle Sensor Removal/Adjustment
- •Input Voltage Inspection
- •Removal/Installation
- •Input Voltage Inspection
- •Subthrottle Valve Actuator Removal
- •Audible Inspection
- •Input Voltage Inspection
- •Inspection Flow Chart
- •CAUTION
- •ECU Power Source Circuit
- •ECU Fuse Installation
- •ECU Main Relay Removal
- •Fuel Pressure Inspection
- •Fuel Flow Rate Inspection
- •Fuel Pump Removal
- •Operation Inspection
- •Operating Voltage Inspection
- •Pressure Regulator Removal
- •Pump Screen, Fuel Filter Cleaning
- •Fuel Pump Relay Removal
- •Removal/Installation
- •Choke Lever Operation
- •Throttle Body Assy Removal
- •Throttle Body Assy Disassembly
- •Throttle Body Assy Assembly
- •Air Cleaner Oil Draining
- •Fuel Tank Removal
- •Fuel Tank Cleaning
- •Cooling System
- •Bearing Driver:
- •Coolant Level Inspection
- •Cooling System Flushing
- •Water Pump Housing Disassembly
- •Water Pump Housing Assembly
- •Radiator and Radiator Fan Removal
- •CAUTION
- •Engine Top End
- •Exhaust System
- •Compression Gauge:
- •Camshaft Chain Tensioner Removal
- •Cylinder Compression Measurement
- •Cylinder Head Installation
- •Valve Guide Installation
- •Seat Cutter Operation Care:
- •Cylinder Installation
- •WARNING
- •Clutch
- •Clutch Holder:
- •Clutch Lever Adjustment
- •Release Shaft Removal
- •Engine Lubrication System
- •WARNING
- •Oil Pressure Measurement
- •Engine Removal/Installation
- •Crankshaft/Transmission
- •Bearing Puller:
- •Crankcase Splitting
- •Crankcase Assembly
- •Crankshaft Installation
- •Connecting Rod Installation
- •Wheels/Tires
- •Bearing Driver Set:
- •Front Wheel Installation
- •Axle Inspection
- •Tire Installation
- •Tire Repair
- •Hub Bearing Inspection
- •Final Drive
- •Bearing Driver Set:
- •Coupling Bearing Inspection
- •Brakes
- •Jack:
- •Brake Lever Position Adjustment
- •Brake Pedal Position Adjustment
- •Caliper Holder Shaft Wear
- •Rear Master Cylinder Disassembly
- •Brake Hose Removal/Installation
- •Suspension
- •Fork Cylinder Holder Handle:
- •Swingarm Installation
- •Swingarm Bearing, Sleeve Inspection
- •Steering
- •Steering Stem Nut Wrench:
- •Frame
- •Electrical System
- •Rotor Puller, M16/M18/M20/M22 × 1.5 :
- •Battery Removal
- •Initial Charge
- •Precautions
- •Alternator Inspection
- •Charging System Circuit
- •WARNING
- •Special Tool -
- •Crankshaft Sensor Peak Voltage Inspection
- •Stick Coil (Ignition Coil together with Spark Plug Cap) Removal
- •Stick Coil Primary Peak Voltage
- •IC Igniter Inspection
- •Ignition System Circuit
- •Starter Motor Removal
- •Starter Motor Installation
- •Electric Starter Circuit
- •Headlight/Tail Light Circuit (CA, AS)
- •Headlight/Tail Light Circuit (Other than CA, AS)
- •Turn Signal Light Circuit
- •Turn Signal Light Bulb Replacement
- •Radiator Fan Circuit
- •Electronic Combination Meter Unit Inspection
- •Meter Circuit
- •Rear Brake Light Switch Connections
- •Side Stand Switch Connections
- •Neutral Switch Connections
- •Oil Pressure Switch Connections*
- •Special Tool -
- •Junction Box Internal Circuit
- •30 A Main Fuse Removal
- •15 A ECU Fuse Removal
- •Appendix
- •NOTE
- •Starter motor not rotating:
- •No fuel flow:
- •Engine flooded:
- •No spark; spark weak:
- •Fuel/air mixture incorrect:
- •Compression Low:
- •Poor Running at Low Speed:
- •Spark weak:
- •Fuel/air mixture incorrect:
- •Compression low:
- •Other:
- •Poor Running or No Power at High Speed:
- •Firing incorrect:
- •Fuel/air mixture incorrect:
- •Compression low:
- •Knocking:
- •Miscellaneous:
- •Overheating:
- •Firing incorrect:
- •Muffler overheating:
- •Fuel/air mixture incorrect:
- •Compression high:
- •Engine load faulty:
- •Lubrication inadequate:
- •Gauge incorrect:
- •Coolant incorrect:
- •Cooling system component incorrect:
- •Over Cooling:
- •Gauge incorrect:
- •Cooling system component incorrect:
- •Clutch Operation Faulty:
- •Clutch slipping:
- •Clutch not disengaging properly:
- •Gear Shifting Faulty:
- •Jumps out of gear:
- •Overshifts:
- •Abnormal Engine Noise:
- •Knocking:
- •Piston slap:
- •Valve noise:
- •Other noise:
- •Abnormal Drive Train Noise:
- •Clutch noise:
- •Transmission noise:
- •Drive line noise:
- •Abnormal Frame Noise:
- •Front fork noise:
- •Rear shock absorber noise:
- •Disc brake noise:
- •Other noise:
- •Oil Pressure Warning Light Goes On:
- •Exhaust Smokes Excessively:
- •White smoke:
- •Black smoke:
- •Brown smoke:
- •Handlebar hard to turn:
- •Handlebar shakes or excessively vibrates:
- •Handlebar pulls to one side:
- •Shock absorption unsatisfactory:
- •Battery Trouble:
- •Battery discharged:
- •Battery overcharged:
3-38 FUEL SYSTEM (DFI)
Self-Diagnosis
Backups
Backups
○The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles.
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Service |
Parts |
Output Signal Usable |
Backups by ECU |
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Codes |
Range or Criteria |
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If the main throttle sensor system fails (the signal |
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is out of the usable range, wiring short or open), |
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the ECU locks ignition timing into the ignition |
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11 |
Main |
Main Throttle Sensor |
timing at closed throttle position and sets the DFI |
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Throttle |
Output Voltage |
in the D-J method. |
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Sensor |
0.2 4.8 V |
Also, the main throttle sensor system and inlet air |
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pressure fails, the ECU locks ignition timing into |
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the ignition timing at closed throttle position and |
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sets the DFI in the α-N method. |
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Inlet Air |
Inlet Air Pressure |
If the inlet air pressure sensor system fails (the |
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12 |
(absolute) |
signal Pv is out of the usable range, wiring short |
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Pressure |
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Pv = 100 mmHg ~ 900 |
or open), the ECU sets the DFI in the α - N |
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Sensor |
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mmHg |
method. |
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13 |
Inlet Air |
Inlet Air Temperature |
If the inlet air temperature sensor fails (the signal |
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Tempera- |
is out of the usable range, wiring short or open), |
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Ta = –47°C +178°C |
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ture Sensor |
the ECU sets Ta at 40°C. |
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14 |
Water Tem- |
Water Temperature |
If the water temperature sensor system fails (the |
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perature |
Tw = –30C° +120°C |
signal is out of the usable range, wiring short or |
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Sensor |
open), the ECU sets Tw at 80°C. |
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Atmo- |
Absolute Atmospheric |
If the atmospheric pressure sensor system fails |
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15 |
spheric |
Pressure |
(the signal is out of the usable range, wiring short |
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Pressure |
Pa = 100 mmHg 900 |
or open), the ECU sets Pa at 760 mmHg (the |
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Sensor |
mmHg |
standard atmospheric pressure). |
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Crankshaft sensor must |
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21 |
Crankshaft |
send 23 signals (output |
If crankshaft sensor generates other than 23 |
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Sensor |
signal) to the ECU at the |
signals, the engine stops by itself. |
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one cranking. |
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Camshaft |
Cam sensor must send |
If the camshaft position sensor system fails |
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23 |
one signal (output signal) |
(the signal is missing, wiring short or open), the |
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Position |
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to the ECU at the two |
ECU continues to ignite cylinders in the same |
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Sensor |
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cranking |
sequence following the last good signal. |
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Speed sensor must send |
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4 signals (output signal) |
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24 |
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to the ECU at the one |
If the speed sensor system fails (no signal, wiring |
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Speed |
rotation of the engine |
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and |
short or open), the speedometer shows 0, and |
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Sensor |
sprocket. |
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25 |
the ECU sets the top (6) gear position. |
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The gear position is |
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decided by the signal of |
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the speed sensor. |
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Vehicle |
Vehicle-down Sensor |
If the vehicle-down sensor system has failures |
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31 |
(the output voltage Vd is more than usable range, |
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-down |
Output Voltage (signal) |
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wiring open), the ECU shuts off the fuel pump, |
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Sensor |
Vd = 0.4 V 4.4 V |
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the fuel injectors and the ignition system. |
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FUEL SYSTEM (DFI) 3-39 |
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Self-Diagnosis |
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Service |
Parts |
Output Signal Usable |
Backups by ECU |
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Codes |
Range or Criteria |
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Subthrottle Sensor |
If the subthrottle sensor system fails (the signal |
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32 |
Subthrottle |
is out of the usable range, wiring short or open), |
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Output Voltage |
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sensor |
0.15 4.85 V |
the actuator locks sub throttle valve at full open |
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position. |
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Stick Coil |
The stick coil primary |
If the ignition primary winding #1 has failures (no |
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51 |
winding must send |
signal, wiring short or open), the ECU shuts off |
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#1 (Ignition |
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signals (output voltage) |
the injector #1 to stop fuel to the cylinder #1, |
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Coil)* |
continuously to the ECU. |
though the engine keeps running. |
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Stick Coil |
The stick coil primary |
If the ignition primary winding #2 has failures (no |
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52 |
winding must send |
signal, wiring short or open), the ECU shuts off |
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#2 (Ignition |
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signals (output voltage) |
the injector #2 to stop fuel to the cylinder #2, |
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Coil)* |
continuously to the ECU. |
though the engine keeps running. |
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Stick Coil |
The stick coil primary |
If the ignition primary winding #3 has failures (no |
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53 |
winding must send |
signal, wiring short or open), the ECU shuts off |
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#3 (Ignition |
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signals (output voltage) |
the injector #3 to stop fuel to the cylinder #3, |
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Coil)* |
continuously to the ECU. |
though the engine keeps running. |
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Stick Coil |
The stick coil primary |
If the ignition primary winding #4 has failures (no |
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54 |
winding must send |
signal, wiring short or open), the ECU shuts off |
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#4 (Ignition |
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signals (output voltage) |
the injector #4 to stop fuel to the cylinder #4, |
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Coil) * |
continuously to the ECU. |
though the engine keeps running. |
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The actuator operates |
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62 |
Subthrottle |
open and close of the |
If the subthrottle valve actuator fails (the signal is |
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Valve |
subthrottle valve by the |
out of the usable range, wiring short or open), the |
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Actuator |
pulse signal from the |
ECU stops the current to the actuator. |
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ECU. |
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Note:
(1) D-J Method and α – N Method: When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method (low-speed mode). As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle sensor output voltage) and the engine speed. This method is called α – N method (high-speed mode).
(*) This depends on the number of stopped cylinders.