Kawasaki Ninja Service Manual: Engine Vacuum Synchronization Inspection

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Fuel System (DFI) / Engine Vacuum Synchronization Inspection

NOTE

These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition.

Engine Vacuum Synchronization Inspection


Engine Vacuum Synchronization Inspection


NOTE

When the engine is running, the ECU detects the service code 16. But the engine synchronization can be inspected correctly.

Special Tool - Vacuum Gauge: 57001-1369

Special Tool - Vacuum Gauge: 57001-1369


Special Tool - Extension Tube: 57001-1578

Engine Vacuum Synchronization Inspection


Engine Vacuum Synchronization Inspection


NOTE

Engine Vacuum Synchronization Inspection


1. The engine speed is more than 6 000 r/min (rpm).

2. The throttle opening is more than 12°.

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, especially when atomized by the fuel injector nozzle. To prevent a fire or explosion, be sure the secondary fuel injector connectors are disconnected before starting the engine so that fuel cannot be sprayed by the injectors.

Idle Speed Standard: 1 100 ±50 r/min (rpm)

If the idle speed is out of the specified range, inspect the idle speed control valve (see Idle Speed Control Valve Inspection in the Self-Diagnosis System chapter).

Engine Vacuum Synchronization Inspection


NOTICE

Do not measure the idle speed by the meter unit.

Throttle Body Vacuum Standard: 30.7 ±1.33 kPa (230 ±10 mmHg) at idle speed

Special Tool - Pilot Screw Adjuster, D [C]: 57001-1588

Engine Vacuum Synchronization Inspection


NOTE

View from Rear [E]

Engine Vacuum Synchronization Inspection


If all vacuums are within the specification range, finish the engine vacuum synchronization.

If any vacuum can not be adjusted within the specification, remove the bypass screws #1 ∼ #4 and replace them with new ones.

Engine Vacuum Synchronization Inspection


Bypass Screw

Spring [B]

Washer [C]

O-ring [D]

Engine Vacuum Synchronization Inspection


If any carbons accumulate, wipe the carbons off from the hole, using a cotton pad penetrated with a high flash-point solvent.

NOTICE

Do not over-tighten the bypass screw. The tapered portion [E] of the bypass screw could be damaged.

NOTE

A throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, use the “turns out” determined during disassembly.

If the vacuums are correct, check the output voltage of the main throttle sensor (see Main Throttle Sensor Output Voltage Inspection in the Self-Diagnosis System chapter).

Special Tool - Throttle Sensor Setting Adapter: 57001 -1538

Main Throttle Sensor Output Voltage

Connections to Adapter: Degital Meter (+) → R (sensor L) lead

Degital Meter (–) → BK (sensor V/W) lead

Standard: DC 0.64 ∼ 0.68 V at idle throttle opening

If the output voltage is out of the standard, check the input voltage of themain throttle sensor (see Main Throttle Sensor Input Voltage Inspection in the Self-Diagnosis System chapter).

Run the vacuum hose according to Cable, Wire, and Hose Routing section in the Appendix chapter.

Throttle Control System Inspection
Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2 3 mm (0.08 0.12 in.) Check that the throttle grip [ ...

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 ...

Other materials:

Wheel Bearing Damage Inspection
Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by moving [A] ...

Self-Diagnosis Procedures
NOTE Use a fully charged battery when conducting self-diagnosis. Otherwise, the light (LED) and symbol do not light or blink. Turn the ignition switch to ON. When a problem occurs with DFI system and ignition system, the warning indicator light (LED) [A] goes on and FI warning symbol ...

Upper Fairing Assembly Removal
Remove: Lower Fairings (see Lower Fairing Removal) Center Inner Fairing (see Center Inner Fairing Removal) Upper Inner Fairings (see Upper Inner Fairing Removal) Windshield (see Windshield Removal) Disconnect the front turn signal light lead connector [A] (both sides). Remove the bo ...