Kawasaki Ninja Service Manual: Outline

Kawasaki Ninja Service Manual / Fuel System (DFI) / Troubleshooting the DFI System / Outline

When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] goes on to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU. For models equipped with an immobilizer system, the warning indicator light (LED) and immobilizer warning symbol [C] blinks, when a problem occurs in the system.

Outline


With the engine stopped and turned in the self-diagnosis mode, the service code [A] is displayed on the LCD (Liquid Crystal Display) by the number of two digits (see Self -Diagnosis Procedures in the Self-Diagnosis System chapter).

If the problem is with the following parts, the ECU can not recognize these problem. Therefore, the warning indicator light (LED), FI and/or immobilizer warning symbols do not goes on and/or blinks, and service code is not displayed.

Outline


LCD for Meter Unit

Fuel Pump

Primary and Secondary Fuel Injectors

Stick Coil Secondary Wiring and Ground Wiring

ECU Power Source Wiring and Ground Wiring

When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the cause [C] of problem.

As a pre-diagnosis inspection, check the ECU for ground and power supply, the fuel line for no fuel leaks, and for correct pressure. The pre-diagnosis items are not indicated by the warning indicator light (LED) and FI warning symbol.

Don’t rely solely on the DFI self-diagnosis function, use common sense.

Troubleshooting the DFI System


Troubleshooting the DFI System


Even when the DFI system is operating normally, the warning indicator light (LED) and FI warning symbol may goes on under strong electrical interference. Additional measures are not required. Turn the ignition switch to OFF to stop the indicator light and symbol.

If the warning indicator light (LED) and FI warning symbol of the motorcycle brought in for repair still goes on, check the service code.

When the repair has been done, the warning indicator light (LED) and FI warning symbol goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems.

When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel injectors (primary and secondary) and ignition system. The ignition switch is left ON. If the starter button is pushed, the electric starter turns but the engine does not start. When the starter button is pushed, the warning indicator light (LED) and FI warning symbol blink but the service code is not displayed. To start the engine again, raise the motorcycle, turn the ignition switch to OFF, and then ON.

Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them.

Troubleshooting the DFI System


Special Tool - Needle Adapter Set: 57001-1457

NOTICE

Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals.

NOTICE

Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts.

Troubleshooting the DFI System


Sealant - Liquid Gasket, TB1211: 56019-120

If any wiring is deteriorated, replace the wiring.

If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely.

Use the wiring diagram to find the ends of the lead which is suspected of being a problem.

Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

If the tester does not read 0 Ω, the lead is defective. Replace the lead or the main harness.

Troubleshooting the DFI System


Troubleshooting the DFI System


Troubleshooting the DFI System


If no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages. However, there is no way to check the ECU itself.

If an abnormality is found, replace the affected DFI part.

If no abnormality is found in the wiring, connectors, and DFI parts, replace the ECU.

Troubleshooting the DFI System
The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer equipped models), water temperature warning indicator and oil pressure warning indicator. ...

Inquiries to Rider
DFI Diagnosis Flow Chart 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 pro ...

Other materials:

Valve-to-Guide Clearance Measurement (Wobble Method)
If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cy ...

Exploded View
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