Kawasaki Ninja Service Manual: Fuel Injector Fuel Line Inspection

Kawasaki Ninja Service Manual / Fuel System (DFI) / Fuel Injectors / Fuel Injector Fuel Line Inspection

Remove: Fuel Tank (see Fuel Tank Removal) Air Cleaner Housing (see Air Cleaner Housing Removal)
Disconnect: Primary and Secondary Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter)

Fuel Injector Fuel Line Inspection

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.

Check the injector fuel line for leakage as follows.

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]

Fuel Injector Fuel Line Inspection

Connect the fuel hose [F] (both ends with the clamps [G]) between the delivery pipes [H] of the throttle body assy and nozzle assy [I] as shown in the figure.

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.

Repeat the leak test, and check the fuel line for no leakage.

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

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

NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the ECU (see ECU Removal). Do not disconnect the ECU connector Connect a digital meter [A] to the c ...

Throttle Grip and Cables

Free Play Inspection Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Free Play Adjustment Refer to the Throttle Control System Inspection in the Periodic Mai ...

Other materials:

Fuel Pressure Inspection
NOTE Be sure the battery is fully charged. Remove: Fuel Tank Covers (see Fuel Tank Removal) Fuel Tank Bolts (see Fuel Tank Removal) Primary Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Be sure to place a piece of cloth around the fuel outlet pipe of the ...

Clutch
Due to friction plate wear and clutch cable stretch over a long period of use, the clutch operation should be checked each day before riding the motorcycle, and must be adjusted in accordance with the Periodic Maintenance Chart. Inspection Check that the clutch lever operates properly an ...

Meter Unit Inspection
Remove the meter unit (see Meter Unit Removal). [1] Battery (+) [2] Fuel Reserve Switch [3] Ground (–) [4] Unused [5] Right Turn Signal Indicator Light (LED) (+) [6] Left Turn Signal Indicator Light (LED) (+) [7] High Beam Indicator Light (LED) (+) [8] Neutral Indicator Light (LED) (� ...