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Table of Contents
Ninja 250R
Motorcycle
Service Manual
http://mototh.com

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Table of Contents

   Also See for Kawasaki Ninja 250R

   Summary of Contents for Kawasaki Ninja 250R

  • Page 1 Ninja 250R Motorcycle Service Manual http://mototh.com...
  • Page 2 http://mototh.com...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 4 http://mototh.com...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2008 Kawasaki Heavy Industries, Ltd. First Edition (1) : Feb. 20, 2008 (K) http://mototh.com...
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. venient operation. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 8 http://mototh.com...
  • Page 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11 http://mototh.com...
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 13 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification EX250K8F Left Side View EX250K8F Right Side View Frame Number Engine Number http://mototh.com...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items EX250K8F Dimensions Overall Length 2 085 mm (82.09 in.) Overall Width 715 mm (28.15 in.) Overall Height 1 115 mm (43.90 in.) Wheelbase 1 400 mm (55.12 in.) Road Clearance 130 mm (5.12 in.) Seat Height 775 mm (30.51 in.) Dry Mass...
  • Page 17 GENERAL INFORMATION 1-9 General Specifications Items EX250K8F Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 1.7 L (1.8 US qt) Drive Train Primary Reduction System: Type Gear...
  • Page 18 1-10 GENERAL INFORMATION General Specifications Items EX250K8F Brake Type: Front Single disc Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W (quartz-halogen) × 2 12 V 55 W (quartz-halogen) Tail/Brake Light 12 V 5/21 W Alternator:...
  • Page 19: Unit Conversion Table

    GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 20 http://mototh.com...
  • Page 21: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Cleaning................... 2-14 Throttle Control System Inspection................... 2-14 Engine Vacuum Synchronization Inspection..............
  • Page 22: Periodic Maintenance

    2-2 PERIODIC MAINTENANCE Steering Stem Bearing Lubrication ................... 2-35 Electrical System ......................... 2-36 Lights and Switches Operation Inspection................ 2-36 Headlight Aiming Inspection ..................... 2-38 Sidestand Switch Operation Inspection ................2-39 Engine Stop Switch Operation Inspection................. 2-40 Others ..........................2-40 Chassis Parts Lubrication ....................2-40 Bolts, Nuts and Fasteners Tightness Inspection...............
  • Page 23: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 24 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Brake fluid level - inspect 2-30 months •...
  • Page 25: Periodic Replacement Parts

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element # - replace 2 years 2-43 •...
  • Page 26: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the "Remarks" column mean: G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide grease oil solution.
  • Page 27 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Air Switching Valve Bracket Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Camshaft Chain Tensioner Cap Bolt 0.51 44 in·lb Camshaft Chain Tensioner Mounting Bolts 87 in·lb Camshaft Sprocket Bolts Coolant Drain Bolt (Cylinder) 0.60...
  • Page 28 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Removal/Installation Engine Mounting Bracket Bolts and Nuts Engine Mounting Nuts Crankshaft/Transmission Connecting Rod Big End Nuts 27.5 Crankcase Bolts (M8, L = 90 mm) MO, S Crankcase Bolts (M8, L = 73 mm) MO, S Crankcase Bolts (M6)
  • Page 29 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut 17.2 Suspension Front Fork Bottom Allen Bolts Lower Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Nut 10.0...
  • Page 30 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Cable Terminal Nut 87 in·lb Starter Motor Clutch Bolts 34.3 Starter Motor Mounting Bolts 87 in·lb Starter Motor Terminal Locknut 0.70 61 in·lb Starter Motor Through Bolts 0.35 30 in·lb Starter Relay Cable Terminal Nuts...
  • Page 31: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 24.0 ±1.33 kPa (180 ±10 mmHg) at idle –...
  • Page 32 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air Pressure (when Cold): Front Up to 170 kg (375 lb) load: – – – 200 kPa (2.00 kgf/cm², 28 psi) Rear – – – Up to 170 kg (375 lb) load: 225 kPa (2.25 kgf/cm², 32 psi) Final Drive 20 ∼...
  • Page 33: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Filler Cap Driver: 57001-143 57001-1454 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Vacuum Gauge: Jack Attachment: 57001-1369 57001-1608 http://mototh.com...
  • Page 34: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately.
  • Page 35: Engine Vacuum Synchronization Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures If the free play is incorrect, adjust the throttle cable as follows. • Loosen the locknut [A]. • Turn the adjuster [B] until the proper amount of free play can be obtained. • Tighten the locknut against the adjuster securely. If the throttle grip free play can not be adjusted with the adjuster, use the adjusters in the lower ends of the throttle cables.
  • Page 36 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull off the air switching valve hose [A] from the air cleaner housing. • Plug the air switching valve hose end and air cleaner housing fitting. • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body.
  • Page 37 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Turn out the bypass screw of the higher vacuum between #1 [A] and #2 [B] to the lower vacuum. • Open and close the throttle valves after each measure- ment and adjust the idle speed as necessary. •...
  • Page 38: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged.
  • Page 39: Cooling System

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Check that the hose joints are securely connected. ○ Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked and does not come off.
  • Page 40: Water Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 41: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Using the thickness gauge [A], measure the valve clear- ance between the cam and the valve lifter. Valve Clearance Standard: Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.) 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) Inlet ○...
  • Page 42 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 2.50 92180-1014 2.55 92180-1016 2.60 92180-1018 2.65 92180-1020 2.675 92180-1174 2.70 92180-1022 2.725 92180-1175 2.75 92180-1024 2.775 92180-1176 2.80 92180-1026 2.825 92180-1177 2.85 92180-1028 2.875 92180-1178 2.90 92180-1030 2.925 92180-1179 2.95...
  • Page 43: Air Suction System Damage Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 44: Wheels/tires

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B] of threads are visible. •...
  • Page 45: Wheel/tire Damage Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.
  • Page 46: Wheel Bearing Damage Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). • Turn the handlebar all the way to the right or left. •...
  • Page 47: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 48: Wheel Alignment Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 49: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.
  • Page 50: Brakes

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 51: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and...
  • Page 52: Brake Light Switch Operation Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn on the ignition switch. • The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.).
  • Page 53: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).
  • Page 54: Swingarm Pivot Lubrication

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm Pivot Lubrication • Remove: Swingarm (see Swingarm Removal in the Suspension chapter) Sleeve [A] • Using a high-flash point solvent, clean the old grease out of the needle bearings [B]. • Apply plenty of grease to the inner surface of the needle bearings.
  • Page 55: Steering Play Adjustment

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering Play Adjustment • Loosen: Lower Front Fork Clamp Bolts (Both Sides) Stem Head Bolt [A] • Adjust the steering. Special Tool - Steering Stem Nut Wrench [B]: 57001-1100 If the steering is too tight, loosen the stem nut a fraction of a turn.
  • Page 56: Electrical System

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. Taillight [A] goes on goes on License Plate Light [B] Meter Panel Lights [C] go on Neutral Indicator Light [D]...
  • Page 57 PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Second Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 58: Headlight Aiming Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light [C] should go on. If the high beam headlight and/or high beam indicator light does not go on, inspect or replace the following item.
  • Page 59: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Sidestand Switch Operation Inspection • Inspect the sidestand switch [A] operation accordance to the following table. Sidestand Switch Operation Gear Clutch Engine Engine Sidestand Position Lever Start Continue Neutral Released Starts running Continue Neutral Pulled in Starts running...
  • Page 60: Engine Stop Switch Operation Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Turn on the ignition switch. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. • The engine does not start.
  • Page 61 PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 62: Bolts, Nuts And Fasteners Tightness Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 63: Replacement Parts

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck,...
  • Page 64: Fuel Hose Replacement

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure.
  • Page 65: Coolant Change

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Push and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked and does not come off. WARNING Make sure the fuel hose joint is installed correctly on the fuel supply pipe or the fuel could leak.
  • Page 66 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Place a container under the coolant drain bolts [A], then remove the drain bolts. ○ The coolant will drain from the radiator and engine. • Remove the hose [A]. • Pour the coolant into a suitable container. •...
  • Page 67 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...
  • Page 68: Radiator Hose And O-ring Replacement

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] (see Thermostat Housing Re- moval in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Cover Removal in the Cooling System chapter) O-rings [C] Hoses [D]...
  • Page 69: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Recommended Engine Oil Type: API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity: SAE 10W-40 Capacity: 1.3 L (1.4 US qt) (when filter is not removed) 1.6 L (1.7 US qt) (when filter is removed) 1.7 L (1.8 US qt) (when engine is completely dry) NOTE...
  • Page 70: Brake Hose And Pipe Replacement

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 71: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 72 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter).
  • Page 73: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Caliper Rubber Parts Replacement NOTE ○ The procedure to assembly/disassembly the front caliper is as follows. Assembling/disassembling the rear caliper is the same as for the front caliper. Caliper Disassembly • Remove: Front/Rear Caliper (see Front/Rear Caliper Removal in the Brakes chapter) Brake Pads (see Brake Pad Removal in the Brakes chapter)
  • Page 74: Spark Plug Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Apply a non-permanent locking agent to the threads of the bleed valve.
  • Page 75 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Replace the spark plug with a new one. Standard Spark Plug Type: NGK CR8E • Insert the new spark plug in the plug hole, and finger -tighten it first. • Using the plug wrench [A] vertically, tighten the plug. CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening.
  • Page 76 http://mototh.com...
  • Page 77 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................DFI Parts Location........................3-14 Specifications ......................... 3-17 Special Tools and Sealant ...................... 3-19 DFI Servicing Precautions ...................... 3-21 DFI Servicing Precautions ....................3-21 Troubleshooting the DFI System .................... 3-23 Outline ..........................
  • Page 78 3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Output Voltage Inspection .............. 3-60 Subthrottle Sensor (Service Code 32)..................3-63 Subthrottle Sensor Removal/Adjustment ................3-63 Subthrottle Sensor Input Voltage Inspection..............3-63 Subthrottle Sensor Output Voltage Inspection ..............3-64 Subthrottle Sensor Resistance Inspection ................ 3-65 Oxygen Sensor - not activated (Service Code 33) ..............
  • Page 79 FUEL SYSTEM (DFI) 3-3 Fuel Injector Removal/Installation..................3-96 Fuel Injector Audible Inspection..................3-96 Fuel Injector Resistance Inspection .................. 3-96 Fuel Injector Power Source Voltage Inspection ..............3-97 Fuel Injector Output Voltage Inspection ................3-98 Fuel Injector Fuel Line Inspection ..................3-99 Throttle Grip and Cables ......................
  • Page 80: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 81 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankshaft Sensor Screws 0.31 27 in·lb Delivery Pipe Assy Mounting Screws 0.35 30 in·lb Inlet Air Temperature Sensor Screw 0.12 11 in·lb Oxygen Sensor 44.1 4.50 32.5 Speed Sensor Bolt 0.80 69 in·lb Throttle Body Assy Holder Clamp Screws...
  • Page 82 3-6 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 83 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Cap Bolts 0.25 22 in·lb Air Cleaner Housing Mounting Bolts 87 in·lb Air Cleaner Housing Screws 1.15 0.12 10 in·lb Air Duct Clamp Screws 0.20 18 in·lb Fuel Pump Bolts 87 in·lb...
  • Page 84: Dfi System

    3-8 FUEL SYSTEM (DFI) DFI System DFI System http://mototh.com...
  • Page 85 FUEL SYSTEM (DFI) 3-9 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Neutral Switch 4. Inlet Air Pressure Sensor 5. Air Switching Valve 6. Water Temperature Sensor 7. Speed Sensor 8. Vehicle-down Sensor 9. Oxygen Sensor 10. Crankshaft Sensor 11.
  • Page 86 3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram http://mototh.com...
  • Page 87 FUEL SYSTEM (DFI) 3-11 DFI System Part Names 1. Oxygen Sensor 2. ECU 3. Joint Connector 2 4. Kawasaki Diagnostic System Connector 5. Self-diagnosis Terminal 6. Fuel Pump 7. Battery 12 V 8 Ah 8. Frame Ground 9. Starter Relay 10.
  • Page 88 3-12 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: W/BL 2. Subthrottle Valve Actuator: P 3. Fuel Level Warning Indicator Light: GY 4. Oxygen Sensor: BL/Y 5. Speed Sensor: LG/R 6. Main Throttle Sensor: Y/W 7.
  • Page 89 FUEL SYSTEM (DFI) 3-13 DFI System 35. Stick Coil #1: BK 36. Sidestand Switch: G/BK 37. Fan Relay: P/W 38. Unused 39. Meter Unit (Tachometer): LB 40. FI Indicator Light: R/Y 41. Unused 42. Ground for Fuel System: BK/Y 43. Ground for Ignition System: BK/Y 44.
  • Page 90: Dfi Parts Location

    3-14 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Fuel Injectors #1, #2 [A] Crankshaft Sensor [A] Oxygen Sensor [A] Ignition Switch [A] FI Indicator Light [B] http://mototh.com...
  • Page 91 FUEL SYSTEM (DFI) 3-15 DFI Parts Location Stick Coils #1, #2 [A] Air Switching Valve [B] Inlet Air Pressure Sensor [C] Subthrottle Valve Actuator [A] Speed Sensor [A] Water Temperature Sensor [A] Vehicle-down Sensor [B] Inlet Air Temperature Sensor [A] http://mototh.com...
  • Page 92 15 A, Ignition Fuse 10 A, Fan Fuse 10 A ) [A] Battery 12 V 8 Ah [B] Relay Box (ECU Main Relay, Fan Relay, Fuel Pump Re- lay) [C] ECU [D] Kawasaki Diagnostic System Connector [E] Self-diagnosis Terminal [F] Fuel Pump [A] http://mototh.com...
  • Page 93: Specifications

    FUEL SYSTEM (DFI) 3-17 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Type Two barrel type Bore 28 mm (1.10 in.) Throttle Body Vacuum 24.0 ±1.33 kPa (180 ±10 mmHg) 0 ∼ 2 1/2 (for reference) Bypass Screws (Turn Out) ECU: Make...
  • Page 94 3-18 FUEL SYSTEM (DFI) Specifications Item Standard Subthrottle Sensor: DC 4.75 ∼ 5.25 V Input Voltage DC 0.78 ∼ 0.82 V at subthrottle valve full close Output Voltage position DC 3.9 ∼ 4.1 V at subthrottle valve full open position (for reference) 4 ∼...
  • Page 95: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1:...
  • Page 96 3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Hose: Measuring Adapter: 57001-1607 57001-1700 Oxygen Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant): 57001-1682 56019-120 http://mototh.com...
  • Page 97: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 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.
  • Page 98 3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A].
  • Page 99: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indi- cator light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the mem- ory of the ECU (Electronic Control Unit).
  • Page 100 After measurement, 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.
  • Page 101 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System • 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. •...
  • Page 102: Inquiries To Rider

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 103 FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 104 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ Poor running spark plug loose (tighten it). □ or no power at spark plug dirty, broken, or gap maladjusted (remedy it). high speed □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect). □...
  • Page 105: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 106 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 107 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Stick coil trouble Inspect (see chapter 16).
  • Page 108 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions Firing incorrect: Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 109 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in crankshaft sensor or speed sensor trouble chapter 17) Air switching valve trouble Inspect and replace (see chapter 16). Air suction valve trouble Inspect and replace (see chapter 5).
  • Page 110: Self-diagnosis

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator light when DFI system and ignition system parts are faulty, and initiates fail-safe function.
  • Page 111: Service Code Clearing Procedures

    FUEL SYSTEM (DFI) 3-35 Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [A] and ground [B] the lead more than five times [C] within 2 sec- onds [D] after the lead is first grounded, and then keep it grounded continuously [E] for more than 2 seconds.
  • Page 112 3-36 FUEL SYSTEM (DFI) Self-Diagnosis http://mototh.com...
  • Page 113: How To Read Service Codes

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator light as shown below. ○ Read 10th digit and unit digit as the FI indicator light blinks. ○...
  • Page 114: Service Code Table

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service FI Indicator Light Problems Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring...
  • Page 115: Backups

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle...
  • Page 116 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The stick coil primary If the stick coil #2 primary winding has failures winding must send (no signal, wiring short or open), the ECU Stick Coil #2* signals continuously to shuts off the injector #2 to stop fuel to the...
  • Page 117: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) 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 throttle body assy especially on a hard surface.
  • Page 118: Main Throttle Sensor Output Voltage Inspection

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, note the follow- ing. ○ Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
  • Page 119: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 120: Inlet Air Pressure Sensor (service Code 12)

    3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air pressure sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Pressure Sensor Connector [A] (Disconnect) •...
  • Page 121: Inlet Air Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 122 3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 123 FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Barometer Reading) Vv = 3.2 V (Digital Meter Reading) then Pv = 70 –...
  • Page 124 3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) http://mototh.com...
  • Page 125 FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Inlet Air Pressure Sensor 4. Water-proof Joint 1 http://mototh.com...
  • Page 126: Inlet Air Temperature Sensor (service Code 13)

    3-50 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the inlet air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Temperature Sensor Connector [A] (Disconnect)
  • Page 127: Inlet Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-51 Inlet Air Temperature Sensor (Service Code 13) • Turn the ignition switch OFF. If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 128 3-52 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Water-proof Joint 1 3. Inlet Air Temperature Sensor http://mototh.com...
  • Page 129: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-53 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Connector [A] (Disconnect) Water Temperature Sensor [B]...
  • Page 130: Water Temperature Sensor Resistance Inspection

    3-54 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 131: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-55 Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 132: Speed Sensor (service Code 24, 25)

    3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 133: Speed Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection • Raise the rear wheel off the ground with the stand. • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○...
  • Page 134 3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Circuit 1. ECU 2. Speed Sensor 3. Water-proof Joint 2 4. Water-proof Joint 1 http://mototh.com...
  • Page 135: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal CAUTION Never drop the vehicle-down sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Connector [A] (Disconnect) Vehicle-down Sensor [B] Vehicle-down Sensor Installation...
  • Page 136: Vehicle-down Sensor Output Voltage Inspection

    3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 137 FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) • Hold the sensor vertically. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch ON. • Tilt the sensor 55 ∼ 75° or more [A] right or left, then hold the sensor almost vertical with the arrow mark pointed up [B], and measure the output voltage.
  • Page 138 3-62 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Vehicle-down Sensor 4. Water-proof Joint 1 http://mototh.com...
  • Page 139: Subthrottle Sensor (service Code 32)

    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 140: Subthrottle Sensor Output Voltage Inspection

    3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Output Voltage Inspection • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection, note the fol- lowing. ○ Disconnect the subthrottle sensor connector and connect the harness adapter [A] between these connectors.
  • Page 141: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-65 Subthrottle Sensor (Service Code 32) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 142: Oxygen Sensor - Not Activated (service Code 33)

    3-66 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 143 FUEL SYSTEM (DFI) 3-67 Oxygen Sensor - not activated (Service Code 33) • Install the suitable plug [A] on the fitting of the air suction valve cover, and shut off the secondary air. • Install the fuel tank (see Fuel Tank Installation). •...
  • Page 144: Oxygen Sensor Inspection

    3-68 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Circuit 1. Ignition Switch 2. Water-proof Joint 3 3. Water-proof Joint 1 4. Oxygen Sensor 5. ECU 6. Joint Connector 2 7. Battery 12 V 8 Ah 8.
  • Page 145: Stick Coils #1, #2 (service Code 51, 52)

    FUEL SYSTEM (DFI) 3-69 Stick Coils #1, #2 (Service Code 51, 52) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil Removal/Installation • Refer to the Stick Coil Removal/Installation in the Electri- cal System chapter. Stick Coil Primary Winding Resistance Inspection •...
  • Page 146 3-70 FUEL SYSTEM (DFI) Stick Coils #1, #2 (Service Code 51, 52) Stick Coil Circuit 1. Engine Stop Switch 2. Stick Coil #1, #2 3. Water-proof Joint 3 4. ECU 5. Joint Connector 2 6. Battery 12 V 8 Ah 7.
  • Page 147: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-71 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 148 3-72 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit 1. ECU 2. Joint Connector 2 3. Battery 12 V 8 Ah 4. Frame Ground 5. Main Fuse 30 A 6. Joint Connector 1 7. Relay Box 8.
  • Page 149: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-73 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 150: Subthrottle Valve Actuator Input Voltage Inspection

    3-74 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the subthrottle valve actuator connector and connect the harness adapter [A] between these connec- tors as shown in the figure.
  • Page 151 FUEL SYSTEM (DFI) 3-75 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator http://mototh.com...
  • Page 152: Air Switching Valve (service Code 64)