Kawasaki Ninja Service Manual: 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.
• Do not reverse the battery cable connections. This will damage the ECU.
• To prevent damage to the DFI parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running.
• Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground.
• When charging, remove the battery from the motorcycle.

  This is to prevent ECU damage by excessive voltage.

• Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect the battery (–) terminal. Do not pull the lead, only the connector.

  Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine.

• Connect these connectors until they click [A].


• Do not turn the ignition switch to ON while any of the DFI electrical connectors are disconnected. The ECU memorizes service codes.
• Do not spray water on the electrical parts, DFI parts, connectors, leads and wiring.
• If a transceiver is installed on the motorcycle, make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU.
• When any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose.
• Do not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure.
• Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.
• When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage.
• When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and run the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.
• Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter
• To prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals.
• If the motorcycle is not properly handled, the high pressure 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.

  Primary Fuel Hose [A] Secondary Fuel Hose [B]

Replace the fuel hose if any fraying, cracks or bulges are noticed.

• To maintain the correct fuel/air mixture (F/A), there must be no intake air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil.

Torque - Oil Filler Plug: Hand-tighten