Do not remove the nozzle assy from the air cleaner housing.
Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
| WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. 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. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. |
Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends with the clamps [D]) as shown in the figure.
Rear View [E]
Apply soap and water solution to the areas [J] as shown in the figure.
Watching the pressure gauge, squeeze the pump lever, and build up the pressure until the pressure reaches the maximum pressure.
Injector Fuel Line Maximum Pressure Standard: 300 kPa (3.06 kgf/cm², 43 psi)
NOTICE
During pressure testing, do not exceed the maximum pressure for which the system is designed.
Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe assy, injectors and related parts.
Install: Primary and Secondary Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter) Air Cleaner Housing (see Air Cleaner Housing Removal) Fuel Tank (see Fuel Tank Removal)
Start the engine and check for fuel leakage.
Fuel Injector Circuit
1. Ignition Switch
2. Engine Stop Switch
3. Secondary Fuel Injector #1
4. Secondary Fuel Injector #2
5. Secondary Fuel Injector #3
6. Secondary Fuel Injector #4
7. Primary Fuel Injector #1
8. Primary Fuel Injector #2
9. Primary Fuel Injector #3
10. Primary Fuel Injector #4
11. Joint Connector E
12. ECU
13. Engine Ground
14. Battery
15. Starter Relay
16. Main Fuse 30 A
17. ECU Fuse 15 A
18. Frame Ground 2
19. Frame Ground 1
20. Fuel Pump Relay
21. Relay Box
22. Fuse Box 1
23. Ignition Fuse 15 A
24. Joint Connector F
Fuel Injector Output Voltage Inspection
Throttle Grip and CablesIntake Air Pressure Sensor #1 Output Voltage Inspection
Measure the output voltage at the intake air pressure sensor
#1 in the same way as input voltage inspection, note
the following.
Disconnect the intake air pressure sensor #1 connector
and connect the measuring adapter [A] between these
connectors.
[B] Main Harness
[C] Intake Air Pressu ...
Vehicle-down Sensor Installation
Be sure to install the rubber dampers [A] and collars [B]
on the bracket.
The UP mark [A] of the sensor should face upward.
WARNINGIncorrect installation of the vehicle-down
sensor
could cause sudden loss of engine power. The
rider could lose balance during certain ...
Steering Damper Oil Leak Inspection
Visually inspect the steering damper [A] for oil leakage.
If the oil leakage is found on it, replace the steering
damper with a new one (see Steering Damper Removal/
Installation in the Steering chapter).
ZX1000JD/KD [B]
...