Needle Adapter Set: 57001-1457

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Fork Oil Level Gauge: 57001-1290

Throttle Sensor Setting Adapter: 57001-1538

Hand Tester: 57001-1394

Sensor Harness Adapter: 57001-1561

Throttle Sensor Setting Adapter #1: 57001-1400

Fuel Pressure Gauge Adapter: 57001-1593

Peak Voltage Adapter: 57001-1415

Fuel Hose: 57001-1607

Special Tools and Sealant

Kawasaki Bond (Silicone Sealant): 56019-120

DFI Servicing Precautions

DFI Servicing Precautions

There are a number of important precautions that should be followed servicing the DFI system.

○This DFI system is designed to be used with a 12 V sealed

battery as its power source. Do not use any other battery

except for a 12 V sealed battery as a power source.

○Do not reverse the battery cable connections. This will

damage the ECU.

○To prevent damage to the DFI parts, do not disconnect the

battery cables or any other electrical connections when

the ignition switch is on or while the engine is running.

○Take care not to short the leads that are directly con-

nected to the battery positive (+) terminal to the chassis

ground.

○When charging, remove the battery from the motorcycle.

This is to prevent ECU damage by excessive voltage.

○Do not turn the ignition switch ON while any of the DFI

electrical connectors are disconnected. The ECU memo-

rizes service codes.

○Do not spray water on the electrical parts, DFI parts, con-

nectors, leads, and wiring.

○Whenever the DFI electrical connections are to be dis- connected, first turn off the ignition switch, and disconnect the battery (–) terminal. Do not pull the lead, only the con- nector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the en- gine.

○Connect these connectors until they click [A]

○If a transceiver is installed on the motorcycle, make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU.

○When any fuel hose is disconnected, fuel may spout out

by residual pressure in the fuel line. Cover the hose joint

with a piece of clean cloth to prevent fuel spillage.

○When any fuel hose is disconnected, do not turn on the

ignition switch. Otherwise, the fuel pump will operate and

fuel will spout from the fuel hose.

○Do not operate the fuel pump if the pump is completely

dry. This is to prevent pump seizure.

○Before removing the fuel system parts, blow the outer sur-

faces of these parts clean with compressed air.

○To prevent corrosion and deposits in the fuel system, do

not add to fuel any fuel antifreeze chemicals.

DFI Servicing Precautions

○To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil.

Clutch Cover [B]

Torque - Oil Filler Plug: Hand-tighten

Outline

Outline

When an abnormality in the system occurs, the FI indi- cator light (LED) 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 light (LED) blinks.

When due to a malfunction, the FI indicator light (LED) re- mains lit, ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C].

• First, conduct a self-diagnosis inspection and then a non

-self-diagnosis inspection. The non-self-diagnosis items

are not indicated by the FI indicator light (LED). Don’t rely solely on the DFI self-diagnosis function, use common sense.

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

When the FI indicator light (LED) goes on and the motor- cycle is brought in for repair, check the service codes.

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

When the motorcycle is down, the vehicle-down sensor is turned OFF and the ECU shuts off the fuel injectors and ignition system. The FI indicator light (LED) blinks but the service code cannot be displayed. The ignition switch is left ON. If the starter button is pushed, the electric starter turns but the engine doesn’t start. To start the engine again, raise the motorcycle, turn the ignition switch OFF, and then ON. The vehicle-down sensor is turned ON and the light (LED) goes OFF.

○The DFI part connectors [A] have seals [B], including the ECU.

• Join the connector and insert the needle adapters [C]

inside the seals [B] from behind the connector until the

adapter reaches the terminal.

CAUTION

Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals.

Special Tool - Needle Adapter Set: 57001-1457

• Make sure that measuring points are correct in the con-

nector, noting the position of the lock [D] and the lead

color before measurement. Do not reverse connections of the hand tester or a digital meter.

• Be careful not to short-circuit the leads of the DFI or elec-

trical system parts by contact between adapters.

CAUTION

Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts.

• Turn the ignition switch ON and measure the voltage with the connector joined.

○Aftermeasurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

• 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).

• Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, short,

etc. Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system.

If any wiring is deteriorated, replace the wiring.

• 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.

○Use the wiring diagram to find the ends of the lead which

is suspected of being a problem.

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

○Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Re-

place the lead or the main harness or the sub harness.

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

○When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed.

• Narrow down suspicious locations by repeating the con- tinuity tests from the ECU connectors.

If no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages. However, there is no way to check the ECU itself.

If an abnormality is found, replace the affected DFI part. If no abnormality is found in the wiring, connectors, and DFI parts, replace the ECU.

○Lead Color Codes:

BK: Black BL: Blue BR: Brown

CH: Chocolate DG: Dark Green

G: Green GY: Gray

LB: Light Blue LG: Light Green O: Orange

P: Pink PU: Purple R: Red

W: White Y: Yellow

○There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method.

(Voltage Check Method)

○This method is conducted by measuring the input voltage

[B] to a sensor [A] first, and then the output voltage [C]

from the sensor.

○Sometimes this method can detect a fault of the ECU.

• Refer to each sensor inspection section for detail in this chapter.

• Use a fully charged battery and a digital meter [D] which

can be read two decimal places voltage or resistance.

(Resistance Check Method)

○This method is simple. No need for a fully charged battery

and the needle adapter. Just do the following especially

when a sensor [A] is suspect.

• Turn the ignition switch OFF and disconnect the connec- tors.

• Inspect the sensor resistance, using a digital meter (see

each sensor inspection).

• Inspect the wiring and connectors [B] for continuity, using the hand tester [C] (analog tester) rather than a digital

meter.

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