Kawasaki Ninja Service Manual: Oxygen Sensor - not activated (Service Code 33, Equipped Models)

Kawasaki Ninja Service Manual / Self-Diagnosis System / Oxygen Sensor - not activated (Service Code 33, Equipped Models)

Oxygen Sensor Removal/Installation

Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter.

Oxygen Sensor Inspection

Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Oxygen Sensor Lead Connector [A]

Oxygen Sensor Inspection

Connect the measuring adapter [A] between the harness connector and oxygen sensor lead connector.

Main Harness [B] Oxygen Sensor [C]

Special Tool - Measuring Adapter: 57001-1700

Connect a digital meter [D] to the measuring adapter leads.

Oxygen Sensor Inspection

Oxygen Sensor Output Voltage Connections to Adapter: Digital Meter (+) → R (sensor BK) lead Digital Meter (–) → BK (sensor GY) lead

Oxygen Sensor Inspection

Remove the air switching valve [A] (see Air Switching Valve Removal in the Engine Top End chapter).

Do not disconnect the air switching valve connector [B].

Remove the hoses [C].

Oxygen Sensor Inspection

Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air.
Install the following parts temporarily.

Air Cleaner Housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter) Fuel Tank (see Fuel Tank Installation in the Fuel System (DFI) chapter)

Oxygen Sensor Inspection

Warm up the engine thoroughly until the radiator fan starts.
Measure the output voltage with the connector joined.

Measuring Adapter [A]

Output Voltage (with Plugs, Rich) Standard: DC 0.8 V or more

Oxygen Sensor Inspection

Turn the ignition switch to OFF.
Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter).
Remove the plugs from the fittings [A].

WARNING

The engine gets extremely hot during normal operation and can cause serious burns. Never touch a hot engine.

Oxygen Sensor Inspection

Install the following parts temporarily.
Air Cleaner Housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter) Fuel Tank (see Fuel Tank Installation in the Fuel System (DFI) chapter)
Start the engine, and let it idle.
Measure the output voltage with the connector joined.
Output Voltage (without Plugs, Lean) Standard: DC 0.24 V or less
Turn the ignition switch to OFF.

If the reading is out of the standard (with plugs: 0.8 V or more, without plugs: 0.24 V or less), remove the ECU and check the wiring for continuity between harness connectors.

Special Tool - Hand Tester: 57001-1394

Oxygen Sensor Inspection

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection ECU Connector [A] ←→ Oxygen Sensor Connector [B] W/BL lead (ECU terminal 35) [C] BR/BK lead (ECU terminal 13) [D]

If the wiring is good, replace the sensor.

If the reading is within the standard (with plugs: 0.8 V or more, without plugs: 0.24 V or less), check the ECU for its ground and power supply (see ECU Power Supply Inspection in the Fuel System (DFI) chapter).

If the ground and power supply are good, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).

Oxygen Sensor Circuit

Oxygen Sensor Circuit

1. ECU

2. Oxygen Sensor

3. Ignition Switch

4. Joint Connector F

5. Joint Connector A

6. Fuse Box 1

7. Ignition Fuse 15 A

8. Relay Box

9. ECU Main Relay

10. Frame Ground 3

11. Starter Relay

12. ECU Fuse 15 A

13. Main Fuse 30 A

14. Battery

15. Engine Ground

Subthrottle Sensor Resistance Inspection

Turn the ignition switch to OFF. Disconnect the subthrottle sensor connector. Connect a digital meter [A] to the subthrottle sensor connector [B]. Measure the subthrottle sensor resistance. ...

Exhaust Butterfly Valve Actuator Sensor (Service Code 34)

Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. ...

Other materials:

Thermostat Installation
Replace the O-rings [A] with new ones, and apply grease to them. Assemble: O-rings Thermostat Housing [B] Thermostat [C] Thermostat Cap [D] Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top. Tighten: Torque - Thermostat Cap Bolts: 5.9 N ...

Fuses
Fuses are arranged in the fuse boxes located under the passenger’s seat and in the left fairing. The main fuse is located under the passenger’s seat. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amp ...

For Primary Fuel Injectors
Remove the air cleaner housing (see Air Cleaner Housing Removal). Disconnect the primary fuel injector connector [A]. Connect a digital meter to the terminals in each primary fuel injector [A]. Measure the primary fuel injector resistance. Primary Fuel Injector Resistance ...