Kawasaki Ninja Service Manual: Fuel Pressure Inspection

Kawasaki Ninja Service Manual / Fuel System (DFI) / Fuel Line / 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 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.

Install the fuel pressure gauge adapter [A] and fuel hoses (Special Tool: 57001-1607) [B] between the fuel outlet pipe and delivery pipe.
Secure the fuel hoses with the clamps.
Connect the pressure gauge [C] to the fuel pressure gauge adapter.

Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Fuel Pressure Gauge Adapter: 57001-1593

Fuel Hose: 57001-1607

Fuel Pressure Inspection

WARNING

Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death. Do not try to start the engine with the fuel hoses disconnected.

Turn the engine stop switch to run position.
Turn the ignition switch to ON.

The fuel pump should operate for 3 seconds, and then should stop.

NOTE

After turning on the engine stop switch and ignition switch, inspect the fuel leakage from the connected portion of the special tools.

NOTICE

Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.

Start the engine, and let it idle.
Measure the fuel pressure with the engine idling.

Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi)

NOTE

The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.

Turn the ignition switch to OFF.

If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check the following.

Fuel Line Leakage (see Fuel Injector Fuel Line Inspection) Amount of Fuel Flow (see Fuel Flow Rate Inspection)

After above checks, measure the fuel pressure again.

Remove the fuel pressure gauge, hoses and adapter.

Install the removed parts (see appropriate chapters).

Start the engine and check for fuel leakage.

Fuel Line

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Fuel Flow Rate Inspection

WARNINGGasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from ...

Other materials:

Fuel Tank and Cap Inspection
Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it ...

Water Temperature Sensor Output Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). Disconnect the water temperature sensor connector and connect the measuring adapter [A] between these connectors ...

Engine Installation
Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. Install the adjusting collars to crankcase backside until end of the threads. Install the adjusting collar [A] to the frame until end of the threads. Replace the engine mounting nuts with ne ...