Download  Print this page

Kawasaki Ninja ZX-6RR Service Manual

Motorcycle ninja zx-6rr.
Hide thumbs
   
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519

Advertisement

Table of Contents
Ninja ZX-6RR
Motorcycle
Service Manual

Advertisement

Table of Contents

   Summary of Contents for Kawasaki Ninja ZX-6RR

  • Page 1 Ninja ZX-6RR Motorcycle Service Manual...
  • Page 3 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 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. © 2004 Kawasaki Heavy Industries, Ltd. First Edition (1): Jan. 5, 2004 (K)
  • 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: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9: 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 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information – Twin Fuel Injector System ..............1-11 Unit Conversion Table ......................1-12...
  • Page 12: 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 13 Replacement Parts Replacement Parts must be KAWASAKI genuine or rec- ommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
  • Page 15 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 16 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZX600-M1 (Ninja ZX-6RR) Left Side View: ZX600-M1 (Ninja ZX-6RR) Right Side View:...
  • Page 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items ZX600-M1 (Ninja ZX-6RR) Dimensions Overall Length 2 025 mm (79.7 in.) Overall Width 720 mm (28.3 in.) Overall Height 1 110 mm (43.7 in.) Wheelbase 1 400 mm (55.1 in.) Road Clearance 130 mm (5.1 in.) Seat Height 825 mm (32.4 in.)
  • Page 19 GENERAL INFORMATION 1-9 General Specifications Items ZX600-M1 (Ninja ZX-6RR) Duration 272° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt)
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items ZX600-M1 (Ninja ZX-6RR) Tail/brake Light 12 V 0.5/3.8 W (LED) (US), (CAL), (CA) 12 V 0.5/5 W (LED) Alternator: Type Three-phase AC Rated output 22.5 A/14 V @5 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country.
  • Page 21: Technical Information - Twin Fuel Injector System

    GENERAL INFORMATION 1-11 Technical Information – Twin Fuel Injector System This model has a twin fuel injector system to improve engine performance. The secondary injector for each cylinder is installed in the airbox at the mouth of the throttle body. By spraying fuel further upstream in the intake tract, the air is cooled down so the fuel mixture becomes more condensed, allowing more of mixture to be drawn into the combustion chamber to increase power.
  • Page 22: Unit Conversion Table

    1-12 GENERAL INFORMATION 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 milli × 0.001 Units of Torque: micro µ...
  • Page 23: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart (U.S.A. Drive Chain Slack Adjustment ..2-27 and Canada Model) ......Wheel Alignment Inspection ..2-28 Periodic Maintenance Chart (Other Drive Chain Wear Inspection ..2-28 than U.S.A. and Canada Model)..Chain Guide Wear Inspection ..
  • Page 24 2-2 PERIODIC MAINTENANCE Caliper Rubber Parts Oil Filter Replacement ....2-57 Replacement ......2-52 Fuel Hose Replacement ....2-58 Spark Plug Replacement ..... 2-55 Coolant Change ......2-58 Air Cleaner Element Radiator Hose and O-ring Replacement ......2-56 Replacement ......2-60 Engine Oil Change.......
  • Page 25 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart (U.S.A. and Canada Model) 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...
  • Page 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart (U.S.A. and Canada Model) FREQUENCY Whichever * ODOMETER READING comes × 1000 km first (× 1000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Electrical System • • • • • • Spark plug - clean and gap 2-29 •...
  • Page 27 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart (U.S.A. and Canada Model) Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1000 km first (× 1000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (12) (15) (24) (30) • Brake hoses and pipes 4 year 2-48 •...
  • Page 28: Periodic Maintenance Chart (other Than U.s.a. And Canada Model)

    2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than U.S.A. and Canada Model) 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...
  • Page 29 PERIODIC MAINTENANCE 2-7 Periodic Maintenance Chart (Other than U.S.A. and Canada Model) FREQUENCY Whichever * ODOMETER READING comes × 1000 km first (× 1000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Electrical System • • • Spark plug - clean and gap 2-29 •...
  • Page 30 2-8 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than U.S.A. and Canada Model) Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1000 km first (× 1000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) • Brake hoses and pipes 4 year 2-48 •...
  • Page 31: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-9 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease to the threads.
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cooling System Radiator Hose Clamp Screws 0.20 17 in·lb Coolant Drain Plug (Water Pump) 0.90 78 in·lb Coolant Drain Plug (Cylinder) 87 in·lb Radiator Fan Switch Water Temperature Sensor Water Pump Impeller Bolt 87 in·lb Water Pump Cover Bolts...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Bolt Exhaust Pipe Clamp Bolt Crankshaft Sensor Cover Bolts 87 in·lb L (1) Clutch Clutch Cover Bolts 104 in·lb L (2, Front) Clutch Spring Bolts 0.90 78 in·lb Clutch Hub Nut...
  • Page 34 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb 104 in·lb Shift Drum Cam Holder Bolt Oil Pipe Holder Bolts 113 in·lb Crankshaft Sensor Cover Bolts 87 in·lb L (1) Oil Jet Nozzle Bolts 0.70 61 in·lb Starter Motor Clutch Bolt Upper Crankcase Bolts (7 mm) 14.5...
  • Page 35 PERIODIC MAINTENANCE 2-13 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts (Upper and Lower) Rear Shock Absorber Bracket Nut Swingarm Pivot Shaft Nut Uni-Trak: Rocker Arm Nut Tie-Rod Nuts Swingarm Pivot Shaft Swingarm Pivot Shaft Locknut Steering Steering Stem Head Nut Steering Stem Nut...
  • Page 36 2-14 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Neutral Switch Front Brake Light Switch Screws 0.12 10 in·lb Side Stand Switch Bolt 0.90 78 in·lb Tail/Brake Light Mounting Screws 0.12 10 in·lb...
  • Page 37 PERIODIC MAINTENANCE 2-15 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum: 27 ±1.3 kPa (205 ±10 mmHg) at Idle –...
  • Page 38 2-16 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air Pressure: (When cold) Front Up to 180 kg (397 lb) load: – – – 250 kPa (2.5 kgf/cm², 36 psi) Rear Up to 180 kg (397 lb) load: – – – 290 kPa (2.9 kgf/cm², 42 psi) Final Drive 25 ∼...
  • Page 39 PERIODIC MAINTENANCE 2-17 Special Tools Inside Circlip Pliers: Pilot Screw Adjuster, C: 57001-143 57001-1292 Steering Stem Nut Wrench: Lead Wire-Peak Voltage Adapter: 57001-1100 57001-1449 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Extension Cord: 57001-1249 57001-1595...
  • Page 40: Maintenance Procedure

    2-18 PERIODIC MAINTENANCE Maintenance Procedure Steering System Steering Play Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001-1238 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 41: Lubrication

    PERIODIC MAINTENANCE 2-19 Maintenance Procedure NOTE ○ Turn the stem nut 1/8 turn at a time maximum. • Install the lock washer so that claw of washer fit the notch of steering stem nut. • First tighten the steering stem locknut by hand until the resistance is felt fully, then tighten steering stem nut ad- ditional more than two notches so that align the notch of stem nut and stem locknut.
  • Page 42: Installation Condition Inspection

    2-20 PERIODIC MAINTENANCE Maintenance Procedure Brake Hose Damage and Installation Condition Inspection • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 43 PERIODIC MAINTENANCE 2-21 Maintenance Procedure Brake Pad Wear Inspection • Remove the brake pads (see Brakes chapter). • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
  • Page 44: Wheels/tires

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Wheels/Tires Air Pressure Inspection • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 45: Suspensions

    PERIODIC MAINTENANCE 2-23 Maintenance Procedure WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, in- flated to the standard pressure. NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. ○...
  • Page 46: Front Fork Oil Leak Inspection

    2-24 PERIODIC MAINTENANCE Maintenance Procedure • 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) or shock absorber clamps (see Sus- pension chapter).
  • Page 47: Clutch And Drive Train

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure Swingarm Pivot Lubrication • The grease nipple [A] is equipped for the lubrication of swingarm bearing. Force grease into the nipple until the grease comes out from the swingarm pivot, and wipe off any excess of it. Rocker Arm and Tie-rod Lubrication In order for the tie-rod and rocker arm to function safely and wear slowly, it should be lubricated in accordance with...
  • Page 48 2-26 PERIODIC MAINTENANCE Maintenance Procedure WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. • Slide the dust cover [A] at the clutch cable lower end out of place. • Loosen both adjusting nuts [B] at the clutch cover as far as they will go.
  • Page 49 PERIODIC MAINTENANCE 2-27 Maintenance Procedure • 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. • Wipe off any excess oil.
  • Page 50: Wheel Alignment Inspection

    2-28 PERIODIC MAINTENANCE Maintenance Procedure • 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 51: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure WARNING If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.
  • Page 52 2-30 PERIODIC MAINTENANCE Maintenance Procedure Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. goes on City Light [A] (Europe Model) Taillight [B] goes on goes on License Plate Light [C] Meter Panel LED [D]...
  • Page 53 PERIODIC MAINTENANCE 2-31 Maintenance Procedure Third 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. • The turn signal indicator LED [C] in the meter unit should flash.
  • Page 54: Headlight Aiming Inspection

    2-32 PERIODIC MAINTENANCE Maintenance Procedure • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator LED [C] should go on. If the high beam headlight and/or high beam indicator LED does not go on, inspect or replace the following item.
  • Page 55 PERIODIC MAINTENANCE 2-33 Maintenance Procedure NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○...
  • Page 56: Engine Top End

    2-34 PERIODIC MAINTENANCE Maintenance Procedure If the side stand switch operation does not work, inspect or replace the following item. Battery (see Electrical System chapter) Main Fuse 30 A (see Electrical System chapter) Ignition Fuse 10 A (see Electrical System chapter) Ignition Switch (see Electrical System chapter) Side Stand Switch (see Electrical System chapter) Engine Stop Switch (see Electrical System chapter)
  • Page 57 PERIODIC MAINTENANCE 2-35 Maintenance Procedure • Position the crankshaft at 1, 4 piston TDC. TDC Mark [A] for #1, 4 Pistons Timing Mark [B] (crankcase halves mating surface) • Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter. Valve Clearance Standard: 0.11 ∼...
  • Page 58 2-36 PERIODIC MAINTENANCE Maintenance Procedure Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.
  • Page 59 PERIODIC MAINTENANCE 2-37 Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1.300 92180-0108 1.325 92180-0109 1.350 92180-0110 1.375 92180-0111 1.400 92180-0112 1.425 92180-0113 1.450 92180-0114 1.475 92180-0115 1.500 92180-0116 1.525 92180-0117 1.550 92180-0118 1.575 92180-0119 1.600 92180-0120 1.625 92180-0121 1.650 92180-0122 1.675 92180-0123...
  • Page 60: Fuel System (dfi)

    2-38 PERIODIC MAINTENANCE Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 61: Choke Operation Inspection

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure If necessary, adjust the throttle cable as follows: ○ Loosen the locknuts [A] [B]. ○ Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play. ○ Turn out the decelerator cable adjuster [C] until there is no play when the throttle grip is completely closed.
  • Page 62 2-40 PERIODIC MAINTENANCE Maintenance Procedure Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. • Situate the motorcycle so that it is vertical. •...
  • Page 63 PERIODIC MAINTENANCE 2-41 Maintenance Procedure • Install: Air Cleaner Housing [A] Tachometer [B] Vacuum Gauge [C] • Connect: Extension Cord [D] Extension Tube [E] Special Tool - Extension Tube: 57001-1578 Extension Cord: 57001-1595 • Start the engine and warm it up thoroughly. •...
  • Page 64 2-42 PERIODIC MAINTENANCE Maintenance Procedure If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, C: 57001-1292 • Adjust the lowest vacuum between #1 and #2 to the high- est of 1 and 2.
  • Page 65 PERIODIC MAINTENANCE 2-43 Maintenance Procedure • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 66: Cooling System

    2-44 PERIODIC MAINTENANCE Maintenance Procedure • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.
  • Page 67: System Inspection

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure Cooling Hose and Connection Inspection ○ 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. Visually inspect the hoses for signs of deterioration.
  • Page 68: Air Suction System

    2-46 PERIODIC MAINTENANCE Maintenance Procedure Air Suction System Air Suction Valve Inspection • Remove the air suction valve (see Engine Top End chap- ter). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly.
  • Page 69: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-47 Maintenance Procedure Cables: Lubricate with Rust Inhibitor Throttle Cables Clutch Cable • 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 70: Replacement Parts

    2-48 PERIODIC MAINTENANCE Maintenance Procedure Bolt, Nut and Fastener to be checked Wheels: Front Axle Nut Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin...
  • Page 71 PERIODIC MAINTENANCE 2-49 Maintenance Procedure • When installing the hoses [A], avoid sharp bending, kink- ing, flatting or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in Appendix chap- ter. • Fill the brake line after installing the brake hose (see Brake Fluid Change).
  • Page 72 2-50 PERIODIC MAINTENANCE Maintenance Procedure • 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 73: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-51 Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Brakes chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D]. Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 74 2-52 PERIODIC MAINTENANCE Maintenance Procedure • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. CAUTION Do not remove the secondary cup from the piston since removal will damage it.
  • Page 75 PERIODIC MAINTENANCE 2-53 Maintenance Procedure NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○...
  • Page 76 2-54 PERIODIC MAINTENANCE Maintenance Procedure Rear Caliper Disassembly • Remove the rear caliper. • Remove the pads and anti-rattle spring (see Brakes chap- ter). • Using compressed air, remove the piston. ○ Cover the caliper opening with a clean, heavy cloth [A]. ○...
  • Page 77 PERIODIC MAINTENANCE 2-55 Maintenance Procedure • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the shaft rubber friction boot [A] and dust boot [B]. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high temperature, water-resistance grease).
  • Page 78 Install a new element [A] with the mesh side facing up- ward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013–1301). Using other air cleaner element will wear the engine prema- turely or lower the engine performance. Engine Oil Change •...
  • Page 79 PERIODIC MAINTENANCE 2-57 Maintenance Procedure Recommended Engine Oil Type: API SE, SF or SG API SH or SJ with JASO MA Viscosity: SAE 10W-40 Capacity: 3.4 L (3.6 US qt) (when filter is not removed) 3.6 L (3.8 US qt) (when filter is removed) 4.0 L (4.2 US qt) (when engine is completely dry) NOTE...
  • Page 80 2-58 PERIODIC MAINTENANCE Maintenance Procedure Fuel Hose Replacement • Remove the fuel tank (see Fuel System (DFI) chapter). • Be sure to place a piece of cloth [A] around the fuel hose joint [B]. • While pinching the hose joint locks [C] with fingers, pull the joint out along the delivery pipe.
  • Page 81 PERIODIC MAINTENANCE 2-59 Maintenance Procedure • Remove: Right Inner Cover (see Frame chapter) Radiator Cap [A] ○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. •...
  • Page 82 2-60 PERIODIC MAINTENANCE Maintenance Procedure Water and Coolant Mixture Ratio (Recommended) Soft Water: Coolant: Freezing Point: –35°C (–31°F) Total Amount: 2.4 L (2.5 US qt) NOTE ○ Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. • Bleed the air from the cooling system as follows.
  • Page 83 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Backups .......... 3-65 Specifications ........3-10 Main Throttle Sensor (Service Code DFI System........3-12 11)........... 3-67 Special Tools and Sealant ....3-18 Main Throttle Sensor DFI Servicing Precautions ....3-19 Removal/Adjustment ....
  • Page 84 3-2 FUEL SYSTEM (DFI) Output Voltage Inspection.... 3-88 Throttle Body Assy ......3-103 Vehicle-down Sensor (Service Code Idle Speed Inspection ....3-103 31)........... 3-90 Throttle Bore Cleaning ....3-103 Removal........3-90 Synchronization Inspection ..3-103 Installation........3-90 Synchronization Adjustment ..3-103 Inspection........
  • Page 86: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 87 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Mounting Bolt 0.70 61 in·lb Air Inlet Duct Mounting Bolts 0.70 61 in·lb Air Cleaner Housing Holder Clamp Bolts 0.20 17 in·lb Air Cleaner Housing Screws 0.12 10 in·lb Nozzle Assy Mounting Bolts...
  • Page 88 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 89 15. Primary Fuel Injectors 16. Dust Seals 17. Bypass Screw 18. ECU (Electric Control Unit) CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 90 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S 2. Fuel Pump 3. Canister 4. Separator 5. Red 6. Blue 7. Green 8. White L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specific tightening sequence.
  • Page 92: Specifications

    3-10 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Assy: Type Four barrel type Bore 38 mm (1.5 in.) Throttle Body Vacuum: 27 ±1.3 kPa (205 ±10 mmHg) Bypass Screws –...
  • Page 93 FUEL SYSTEM (DFI) 3-11 Specifications Item Standard about 0.05 ∼ 0.07 V DC at Ignition SW ON and 0 km/h Output Voltage at Sensor Vehicle-down Sensor: Detection Method Magnetic flux detection method More than 60 ∼ 70° for each bank Detection Angle Within 0.5 ∼...
  • Page 94: Dfi System

    3-12 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 95 FUEL SYSTEM (DFI) 3-13 DFI System 1. ECU (Electric Control Unit) 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. Water Temperature Sensor 10.
  • Page 96 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 97 FUEL SYSTEM (DFI) 3-15 DFI System Part Name 1. Subthrottle Valve Actuator 2. Primary Fuel Injector #1 3. Primary Fuel Injector #2 4. Primary Fuel Injector #3 5. Primary Fuel Injector #4 6. Secondary Fuel Injectors #1 7. Secondary Fuel Injectors #2 8.
  • Page 98 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors...
  • Page 99 FUEL SYSTEM (DFI) 3-17 DFI System Terminal Names 1. Power Supply to Sensors 2. Main Throttle Sensor Output Signal 3. Subthrottle Sensor Output Signal 4. Atmospheric Pressure Sensor Output Signal 5. Water Temperature Sensor Output Signal 6. Unused 7. Ignition Switch Output Signal 8.
  • Page 100: Special Tools And Sealant

    57001-125 57001-1417 Carburetor Drain Plug Wrench, Hex 3: Needle Adapter Set: 57001-1269 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter: Kawasaki Bond (Silicone Sealant): 57001-1400 56019-120...
  • Page 101: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-19 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 102 3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ The fuel hose [A] is designed to be used through out the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak or the hose to burst.
  • Page 103: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light 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).
  • Page 104 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) Seals of Connector • 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 105 FUEL SYSTEM (DFI) 3-23 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 106 3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ Electrical Connectors: Female Connectors [A] Male Connectors [B]...
  • Page 107 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System DFI Diagnosis Flow Chart...
  • Page 108 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System Notes: OK: No problem. NG: Problem exists. 1. Inspection starts. • An abnormality occurs in the DFI system, and the FI indicator LED light goes on to alert the rider. • Bring the motorcycle into the shop. 2.
  • Page 109: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System 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 110 3-28 FUEL SYSTEM (DFI) 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 111 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System □ Poor running at low choke lever pulled out fully (push it in fully). □ speed very low choke speed. □ □ □ very low idle speed, very high idle speed, rough idle speed. □...
  • Page 112: Dfi System Troubleshooting Guide

    3-30 FUEL SYSTEM (DFI) 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. ○...
  • Page 113 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) No spark or spark weak: Ignition and engine stop switches not ON Turn both switches ON . Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral.
  • Page 114: Poor Running At Low Speed

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5). Cylinder head gasket damaged Replace (see chapter 5).
  • Page 115 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3). Battery voltage low Inspect and charge (see chapter 16).
  • Page 116 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).
  • Page 117 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Clean spark plugs and adjust plug gap (see Spark plug dirty, broken or gap maladjusted chapter 2). Too low fuel pressure Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3).
  • Page 118: Poor Running Or No Power At High Speed

    3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Actions (chapter) Firing incorrect: Clean spark plug and adjust plug gap (see Spark plug dirty, broken or maladjusted chapter 2). Spark plug cap trouble Inspect stick coil (see chapter 16).
  • Page 119 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 120 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect fuel line and fuel pump (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
  • Page 121: Ecu

    FUEL SYSTEM (DFI) 3-39 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seats (see Frame chapter) Seat Cover (see Frame chapter) Battery Leads Bolts [A] Storage Compartments [B] ○...
  • Page 122: Ecu Power Supply Inspection

    3-40 FUEL SYSTEM (DFI) • Insert the projections [A] of the rear fender front into the slits [B] of the rubber protector. ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 123 FUEL SYSTEM (DFI) 3-41 • Check the ECU power source voltage with a tester [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors [B] in this chapter figure. Battery [C] ECU Power Source Inspection Tester Connections: between 13 (W/Y) Terminal and Battery (–) Terminal between 43 (W/BK) Terminal and...
  • Page 124: Dfi Power Source

    3-42 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 125: Fi Indicator Led Light

    FUEL SYSTEM (DFI) 3-43 FI Indicator LED Light Inspection Flow Chart...
  • Page 126: Led Light Inspection

    3-44 FUEL SYSTEM (DFI) FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection:...
  • Page 127: Fuel Line

    FUEL SYSTEM (DFI) 3-45 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Seats (see Frame chapter) Fuel Tank Bolts (see Fuel Tank Removal) • Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assembly and fuel pump.
  • Page 128: Fuel Flow Rate Inspection

    3-46 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. If the fuel pressure is much higher than the specified, re- place the fuel pump.
  • Page 129 FUEL SYSTEM (DFI) 3-47 Fuel Line • Connect the prepared fuel hose [A] to the fuel supply pipe of the fuel pump. • Secure the fuel hose with a clamp. • Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately.
  • Page 130: Fuel Pump

    3-48 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 131: Operation Inspection

    FUEL SYSTEM (DFI) 3-49 Fuel Pump • Check that the fuel pump terminal [A] and band [B] are in place. [C] Front • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts to a snug fit following the tight- ening sequence shown.
  • Page 132 3-50 FUEL SYSTEM (DFI) Fuel Pump 1. ECU 7. Starter Relay 2. Ignition Switch 8. Battery 3. ECU Main Relay 9. Fuel Pump 4. Fuel Pump Relay 10. Engine Stop Switch 5. ECU Fuse 15 A 11. Junction Box 6. Main Fuse 30 A 12.
  • Page 133: Fuel Pump Relay

    FUEL SYSTEM (DFI) 3-51 Fuel Pump Relay Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • Remove: Seats (see Frame chapter) • Remove the fuel pump relay [A] from the bracket and dis- connect the connector.
  • Page 134 3-52 FUEL SYSTEM (DFI) Fuel Pump Relay 1. ECU 7. Main Fuse 30 A 2. Fuel Pump 8. Starter Relay 3. Ignition Switch 9. Battery 4. ECU Main Relay 10. Engine Stop Switch 5. Fuel Pump Relay 11. Ignition Fuse 10 A 6.
  • Page 135: Fuel Injectors

    FUEL SYSTEM (DFI) 3-53 Fuel Injectors CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Audible Inspection Primary Fuel Injector • Start the engine. • Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 136: Injector Resistance Inspection

    • Disconnect the connector from the injector [A] (see Throt- tle Body Disassembly/Assembly). • Measure the injector resistance with the hand tester [B]. Special Tool - Kawasaki Hand Tester: 57001-1394 Primary Injector Resistance Connections to Injector Meter (+) Meter (–) #1: W/R ←→...
  • Page 137: Injector Unit Test

    Removal). • Disconnect the connector from the injector [A]. • Measure the injector resistance with the hand tester [B]. Special Tool - Kawasaki Hand Tester: 57001-1394 Secondary Injector Resistance Connections to Injectors Meter (+) Meter (–) #1: W/R ←→ O/R Terminal #2: W/R ←→...
  • Page 138: Injector Voltage Inspection

    3-56 FUEL SYSTEM (DFI) Fuel Injectors Injector Voltage Inspection • Turn the ignition switch OFF. • Remove: Fuel Tank (see Fuel Tank Removal) • Connect a digital voltmeter [A] to the connector [B], with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Primary Injector Power Source Voltage Connector to Injector #1, #2, #3, #4 Meter (+) →...
  • Page 139 FUEL SYSTEM (DFI) 3-57 Fuel Injectors • Turn the ignition switch OFF. • Remove: Fuel Tank (see Fuel Tank Removal) • Connect a digital voltmeter [A] to the connector [B], with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Primary Injector Output Voltage Connections to Injector #1 Meter (+) →...
  • Page 140: Injector Fuel Line Inspection

    3-58 FUEL SYSTEM (DFI) Fuel Injectors Injector Fuel Line Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). • Remove the nozzle assy (see Nozzle Assy Removal). • Check the injector fuel line for leakage as follows: ○...
  • Page 141 FUEL SYSTEM (DFI) 3-59 Fuel Injectors 1. ECU 11. ECU Main Relay 2. Secondary Fuel Injector #4 12. Fuel Pump Relay 3. Secondary Fuel Injector #3 13. ECU Fuse 15 A 4. Secondary Fuel Injector #2 14. Main Fuse 30 A 5.
  • Page 142: Self-diagnosis

    3-60 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 [A]. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.
  • Page 143: Service Code Clearing Procedures

    FUEL SYSTEM (DFI) 3-61 Self-Diagnosis • To enter the self-diagnosis dealer mode 2 repeat opening [B] and grounding [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 144 3-62 FUEL SYSTEM (DFI) Self-Diagnosis...
  • Page 145: How To Read Service Codes

    FUEL SYSTEM (DFI) 3-63 Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long or short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
  • Page 146: Service Code Table

    3-64 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service FI Indicator LED Light Problems (1) 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...
  • Page 147: Backups

    FUEL SYSTEM (DFI) 3-65 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 signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition Main...
  • Page 148 3-66 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The ignition coil primary If the ignition primary winding #1 has failures (no Stick Coil winding must send signal, wiring short or open), the ECU shuts off #1 (Ignition signals (output voltage) the injector #1 to stop fuel to the cylinder #1,...
  • Page 149: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-67 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 150 3-68 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector [A] and connect the harness adapter [B] between the harness connector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Harness Adapter: 57001 -1538 Main Throttle Sensor Input Voltage...
  • Page 151: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Voltmeter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 152 3-70 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector [A] and connect the harness adapter [B] between the harness connector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Harness Adapter: 57001 -1538 Throttle Sensor Output Voltage...
  • Page 153: Resistance Inspection

    FUEL SYSTEM (DFI) 3-71 Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 154: Inlet Air Pressure Sensor (service Code 12)

    3-72 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Turn the ignition switch off. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Pressure Sensor Connector [A] Inlet Air Pressure Sensor Screw [B] Inlet Air Pressure Sensor [C]...
  • Page 155: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector. Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the sub harness connector and inlet air pressure sensor connector.
  • Page 156 3-74 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the output voltage is far out of the usable range, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 •...
  • Page 157 FUEL SYSTEM (DFI) 3-75 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 158 3-76 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Vv: Inlet Air Pressure Sensor Output Voltage (V) TO: Throttle Full Open (Digital Meter Reading) ST: Standard of Sensor Output Pv: Throttle Vacuum Pressure (absolute) Voltage (v) Ps: Standard Atmospheric Pressure (absolute) UR: Usable Range of Sensor Output ID: Idling Voltage (v)
  • Page 159: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-77 Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 160: Sensor Resistance Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors If the wiring is good, check the sensor resistance. Sensor Resistance Inspection •...
  • Page 161 FUEL SYSTEM (DFI) 3-79 Inlet Air Temperature Sensor (Service Code 13) 1. ECU 2. Inlet Air Temperature Sensor...
  • Page 162: Water Temperature Sensor (service Code 14)

    Such a shock to the sensor can damage it. • Disconnect the sensor connector [A], and unscrew the water temperature sensor [B]. Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 163: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-81 Water Temperature Sensor (Service Code 14) 1. ECU 2. Meter 3. Water Temperature Sen- Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to Electrical System chapter for water temperature sensor inspection.
  • Page 164: Atmospheric Pressure Sensor (service Code 15)

    3-82 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Turn the ignition switch off. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Atmospheric Pressure Sensor Connector [A] Atmospheric Pressure Sensor Screw [B] Atmospheric Pressure Sensor [C]...
  • Page 165: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-83 Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, remove the seat cover, and check the input voltage again at the sen- sor connector. Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 166 3-84 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, remove the fuel tank, and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V).
  • Page 167 FUEL SYSTEM (DFI) 3-85 Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see intake Air Pressure Sensor section in this chapter). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output...
  • Page 168: Crankshaft Sensor (service Code 21)

    3-86 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 169: Camshaft Position Sensor (service Code 23)

    FUEL SYSTEM (DFI) 3-87 Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the camshaft position sensor.
  • Page 170: Speed Sensor (service Code 24, 25)

    3-88 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • Refer to the Switches and Sensors section in the Electri- cal System chapter. Speed Sensor Inspection • Refer to the Switches and Sensors section in the Electri- cal System chapter.
  • Page 171 FUEL SYSTEM (DFI) 3-89 Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and speed sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1400...
  • Page 172: Vehicle-down Sensor (service Code 31)

    3-90 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 173 FUEL SYSTEM (DFI) 3-91 Vehicle-down Sensor (Service Code 31) • Connect a digital volt meter [A] to the connector of the vehicle-down sensor [B], with the needle adapter set [C]. Vehicle-down Sensor Power Source Voltage Connections to Sensor Meter (+) → W/Y lead [D] Meter (–) →...
  • Page 174 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring.
  • Page 175: Subthrottle Sensor (service Code 32)

    FUEL SYSTEM (DFI) 3-93 Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 176: Output Voltage Inspection

    3-94 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and sub throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538...
  • Page 177 FUEL SYSTEM (DFI) 3-95 Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for a good ground, and power supply (see this chapter). If the ground and power supply are good, re- place the ECU.
  • Page 178: Resistance Inspection

    3-96 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • After subthrottle sensor voltage inspection, remove the harness adapter. If the reading is out of the standard range, inspect the throttle sensor resistance. If the output voltage is normal, check the wiring for conti- nuity (see next diagram).
  • Page 179: Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-97 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil #3: Ignition Coil (Service Code 53) Stick Coil #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION...
  • Page 180 3-98 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) 1. ECU 5. Stick Coil #4 9. Ignition Fuse 10 A 2. Stick Coil #1 6. Ignition Switch 10. Main Fuse 30 A 3. Stick Coil #2 7.
  • Page 181: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-99 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 actuator , especially on a hard sur- face.
  • Page 182: Input Voltage Inspection

    3-100 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D]. Recommended Tool - Peak Voltage Adapter Type: KEK-54-9-B Brand: KOWA SEIKI...
  • Page 183: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-101 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...