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 connected to the battery positive (+) terminal to the
When charging, remove the battery from the motorcycle. This is to prevent ECU damage by exces-
Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch.
Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting
Do not turn the ignition switch ON while any of the DFI electrical connectors are disconnected. The
ECU memorizes service codes.
Do not spray water on the electrical parts, DFI parts, connectors, leads, and wiring.
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, 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 surfaces of these parts clean with compressed
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 installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the
fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.
Route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
Replace the fuel hose if it has been sharply bent or kinked.
The motorcycle is not properly handled, the high pressure
inside the fuel line can cause fuel to leak or the hose [A]
to burst. Bend and twist the fuel hose while examining it.
Replace the hose if any cracks or bulges are noticed.
To maintain the correct fuel/air mixture, 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: 1.5 N·m (0.15 kgf·m, 13 in·lb)
FUEL SYSTEM (DFI) 3-21