99924-1515-01 Service Bulletin/Repair Instructions

the tightness of the bolts and nuts listed here. Also,

• Check

check to see that each cotter pin is in place and in good

condition.
NOTE
○For the engine fasteners, check the tightness of them

when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not in the appropriate chapter,

see the Standard Torque Table. For each fastener, first

loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.
2-72 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Bolt Locknut

Engine Mounting Bolts and Nuts

Exhaust Pipe Holder Nuts

Muffler Body Mounting Bolts

Wheels:

Front Axle Clamp Bolt

Front Axle

Rear Axle Nut

Brakes:

Brake Lever Pivot Bolt Locknut

Brake Pedal Bolt

Caliper Mounting Bolts

Front Master Cylinder Clamp Bolts

Rear Master Cylinder Mounting Bolts

Rear Master Cylinder Push Rod Joint Cotter Pin

Suspension:

Front Fork Clamp Bolts

Rear Shock Absorber Bolts and Nuts

Swingarm Pivot Shaft Nut

Steering:

Handlebar Holder Bolts

Steering Stem Head Bolt

Others:

Footpeg Bracket Bolts

Front Fender Mounting Bolts

Side Stand Bolt
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)

Table of Contents

Exploded View........................................................................................................................

DFI System.............................................................................................................................

DFI Components Naming .................................................................................................

DFI Parts Location..................................................................................................................

Specifications .........................................................................................................................

Special Tools and Sealant ......................................................................................................

DFI Servicing Precautions ......................................................................................................

DFI Servicing Precautions ...................................................................................................

Troubleshooting the DFI System ............................................................................................

Outline .................................................................................................................................

Inquiries to Rider..................................................................................................................

DFI System Troubleshooting Guide .......................................................................................

Self-Diagnosis ........................................................................................................................

Self-Diagnosis Outline ......................................................................................................

Self-Diagnosis Procedures ...............................................................................................

Service Code Reading ......................................................................................................

Service Code Erasing .......................................................................................................

Backups ............................................................................................................................

Main Throttle Sensor (Service Code 11) (DTC P0120, P0123)..............................................

Main Throttle Sensor Removal/Adjustment ......................................................................

Main Throttle Sensor Input Voltage Inspection .................................................................

Main Throttle Sensor Resistance Inspection ....................................................................

Main Throttle Sensor Output Voltage Inspection ..............................................................

Intake Air Pressure Sensor (Service Code 12) (DTC P0105, P0106, P0107)........................

Intake Air Pressure Sensor Removal................................................................................

Intake Air Pressure Sensor Installation.............................................................................

Intake Air Pressure Sensor Input Voltage Inspection........................................................

Intake Air Pressure Sensor Output Voltage Inspection.....................................................

Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112)...............................

Intake Air Temperature Sensor Removal/Installation........................................................

Intake Air Temperature Sensor Output Voltage Inspection ...............................................

Intake Air Temperature Sensor Resistance Inspection .....................................................

Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) ....................................

Water Temperature Sensor Removal/Installation .............................................................

Water Temperature Sensor Output Voltage Inspection.....................................................

Water Temperature Sensor Resistance Inspection...........................................................

Crankshaft Sensor (Service Code 21) (DTC P0335)..............................................................

Crankshaft Sensor Removal/Installation...........................................................................

Crankshaft Sensor Resistance Inspection ........................................................................

Crankshaft Sensor Peak Voltage Inspection.....................................................................

Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158)..............................................

Rear Wheel Rotation Sensor Signal Inspection................................................................

Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0917) ................................

Gear Position Sensor Removal/Installation ......................................................................

Gear Position Sensor Input Voltage Inspection ................................................................

Gear Position Sensor Output Voltage Inspection..............................................................

Vehicle-down Sensor (Service Code 31) (DTC C0064) .........................................................

Vehicle-down Sensor Removal .........................................................................................

Vehicle-down Sensor Installation ......................................................................................

Vehicle-down Sensor Input Voltage Inspection.................................................................
3-4

3-10

3-12

3-19

3-22

3-24

3-26

3-26

3-28

3-28

3-32

3-35

3-40

3-40

3-40

3-43

3-43

3-44

3-47

3-47

3-47

3-48

3-48

3-51

3-51

3-51

3-52

3-53

3-57

3-57

3-57

3-58

3-60

3-60

3-60

3-61

3-62

3-62

3-62

3-62

3-63

3-63

3-66

3-66

3-66

3-67

3-69

3-69

3-70

3-70
3
3-2 FUEL SYSTEM (DFI)

Vehicle-down Sensor Output Voltage Inspection ..............................................................

Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) .................................................

Subthrottle Sensor Removal/Adjustment ..........................................................................

Subthrottle Sensor Input Voltage Inspection.....................................................................

Subthrottle Sensor Output Voltage Inspection ..................................................................

Subthrottle Sensor Resistance Inspection ........................................................................

Oxygen Sensor - not activated (Service Code 33) (DTC P0130, P0132)...............................

Oxygen Sensor Removal/Installation................................................................................

Oxygen Sensor Inspection................................................................................................

ECU Communication Error (Service Code 39) .......................................................................

ECU Communication Line Inspection ...............................................................................

Fuel Injectors (Service Code 41, 42) (DTC P0201, P0202) ...................................................

Fuel Injector Removal/Installation.....................................................................................

Fuel Injector Audible Inspection........................................................................................

Fuel Injector Resistance Inspection ..................................................................................

Fuel Injector Power Source Voltage Inspection ................................................................

Fuel Injector Output Voltage Inspection ............................................................................

Fuel Injector Fuel Line Inspection .....................................................................................

Stick Coils #1, #2 (Service Code 51, 52) (DTC P0351, P0352) .............................................

Stick Coil Removal/Installation..........................................................................................

Stick Coil Primary Winding Resistance Inspection ...........................................................

Stick Coil Input Voltage Inspection....................................................................................

Radiator Fan Relay (Service Code 56) (DTC P0480) ............................................................

Radiator Fan Relay Removal/Installation..........................................................................

Radiator Fan Relay Inspection..........................................................................................

Subthrottle Valve Actuator (Service Code 62) (DTC P2100)..................................................

Subthrottle Valve Actuator Removal .................................................................................

Subthrottle Valve Actuator Inspection ...............................................................................

Subthrottle Valve Actuator Resistance Inspection ............................................................

Subthrottle Valve Actuator Input Voltage Inspection .........................................................

Air Switching Valve (Service Code 64) (DTC P0410).............................................................

Air Switching Valve Removal/Installation ..........................................................................

Air Switching Valve Inspection ..........................................................................................

Oxygen Sensor Heater (Service Code 67) (DTC P0030).......................................................

Oxygen Sensor Heater Removal/Installation ....................................................................

Oxygen Sensor Heater Resistance Inspection .................................................................

Oxygen Sensor Heater Power Source Voltage Inspection ...............................................

Fuel Supply System (Service Code 94) (DTC P0170) ...........................................................

Fuel Supply System Inspection.........................................................................................

Purge Valve (Service Code 3A) (DTC P0443) (CAL, CN, SEA-B1, SEA-B3, TH and WVTA

(FULL) Models)....................................................................................................................

Purge Valve Removal/Installation .....................................................................................

Purge Valve Inspection .....................................................................................................

Warning Indicator Light (LED) ................................................................................................

Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection ............................

ECU ........................................................................................................................................

ECU Identification .............................................................................................................

ECU Removal ...................................................................................................................

ECU Installation ................................................................................................................

ECU Power Supply Inspection..........................................................................................

DFI Power Source ..................................................................................................................

ECU Fuse Removal ..........................................................................................................

ECU Fuse Installation .......................................................................................................

ECU Fuse Inspection ........................................................................................................

ECU Main Relay Removal/Installation ..............................................................................

ECU Main Relay Inspection ..............................................................................................

Fuel Line.................................................................................................................................
3-71

3-74

3-74

3-74

3-75

3-77

3-78

3-78

3-78

3-81

3-81

3-82

3-82

3-82

3-82

3-83

3-84

3-85

3-87

3-87

3-87

3-87

3-89

3-89

3-89

3-90

3-90

3-90

3-90

3-91

3-93

3-93

3-93

3-94

3-94

3-94

3-95

3-97

3-97

3-98

3-98

3-98

3-100

3-100

3-101

3-101

3-101

3-101

3-102

3-105

3-105

3-105

3-105

3-105

3-105

3-106
FUEL SYSTEM (DFI) 3-3

Fuel Pressure Inspection ..................................................................................................

Fuel Flow Rate Inspection ................................................................................................

Fuel Pump ..............................................................................................................................

Fuel Pump Removal .........................................................................................................

Fuel Pump Installation ......................................................................................................

Fuel Pump Operation Inspection ......................................................................................

Fuel Pump Operating Voltage Inspection .........................................................................

Pressure Regulator Removal............................................................................................

Fuel Pump Relay Removal/Installation .............................................................................

Fuel Pump Relay Inspection .............................................................................................

Throttle Grip and Cables ........................................................................................................

Throttle Grip Free Play Inspection ....................................................................................

Throttle Grip Free Play Adjustment...................................................................................

Throttle Cable Installation .................................................................................................

Throttle Cable Lubrication.................................................................................................

Throttle Body Assy .................................................................................................................

Idle Speed Inspection/Adjustment ....................................................................................

Throttle Bore Cleaning ......................................................................................................

Synchronization Inspection/Adjustment ............................................................................

Throttle Body Assy Removal.............................................................................................

Throttle Body Assy Installation..........................................................................................

Throttle Body Assy Disassembly ......................................................................................

Throttle Body Assy Assembly ...........................................................................................

Air Cleaner..............................................................................................................................

Air Cleaner Element Removal/Installation ........................................................................

Air Cleaner Element Inspection ........................................................................................

Air Cleaner Oil Draining ....................................................................................................

Air Cleaner Housing Removal...........................................................................................

Air Cleaner Housing Installation........................................................................................

Fuel Tank ................................................................................................................................

Fuel Tank Removal ...........................................................................................................

Fuel Tank Installation ........................................................................................................

Fuel Tank and Cap Inspection ..........................................................................................

Fuel Tank Cleaning ...........................................................................................................

Evaporative Emission Control System (CAL, CN, SEA-B1, SEA-B3, TH and WVTA (FULL)

Models) ................................................................................................................................

Parts Removal/Installation ................................................................................................

Hose Inspection ................................................................................................................

Purge Valve Inspection .....................................................................................................

Canister Inspection ..........................................................................................................
3-106

3-107

3-109

3-109

3-110

3-110

3-110

3-111

3-112

3-112

3-113

3-113

3-113

3-113

3-113

3-114

3-114

3-114

3-114

3-114

3-116

3-117

3-118

3-120

3-120

3-120

3-120

3-120

3-121

3-122

3-122

3-125

3-126

3-126

3-127

3-127

3-127

3-127

3-127
3-4 FUEL SYSTEM (DFI)

Exploded View
FUEL SYSTEM (DFI) 3-5

Exploded View

No.

1

2

3

4

5

6

7

8

9
Fastener

Spark Plugs

Water Temperature Sensor

Crankshaft Sensor Bolts

Air Cleaner Housing Assembly Screws

Intake Air Temperature Sensor Screw

Air Cleaner Element Screw

Air Cleaner Housing Clamp Bolt

Gear Position Sensor Bolt

Oxygen Sensor
G: Apply grease.

R: Replacement Parts
N·m

15

12

6.0

1.2

1.2

1.2

2.0

9.8

25
Torque

kgf·m

1.5

1.2

0.61

0.12

0.12

0.12

0.20

1.0

2.5
ft·lb

11

106 in·lb

53 in·lb

11 in·lb

11 in·lb

11 in·lb

18 in·lb

87 in·lb

18
Remarks
3-6 FUEL SYSTEM (DFI)

Exploded View
FUEL SYSTEM (DFI) 3-7

Exploded View

No.

1

2

3

4

5
Fastener

Switch Housing Screws

Fuel Pump Assembly Screws

Fuel Pump Bolts

Throttle Body Assy Clamp Mounting Screw

Delivery Pipe Assy Mounting Screws
N·m

3.5

0.98

9.8

2.1

3.4
Torque

kgf·m

0.36

0.10

1.0

0.21

0.35
6. Other than CAL, CN, SEA-B1, SEA-B3, TH and WVTA (FULL) Models

CL: Apply cable lubricant.

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.
ft·lb

31 in·lb

8.7 in·lb

87 in·lb

19 in·lb

30 in·lb
Remarks
R

L, S
3-8 FUEL SYSTEM (DFI)

Exploded View

CAL, CN, SEA-B1, SEA-B3, TH and WVTA (FULL) Models
FUEL SYSTEM (DFI) 3-9

Exploded View

No.

1

2
Fastener

Canister Bracket Bolts

Purge Valve Mounting Nut
3. Purge Valve

4. Canister
N·m

9.8

7.0
Torque

Remarks

kgf·m

ft·lb

1.0

87 in·lb

0.71

62 in·lb
3-10 FUEL SYSTEM (DFI)

DFI System

DFI System
FUEL SYSTEM (DFI) 3-11

DFI System

1. ECU

2. Battery

3. Pressure Regulator

4. Fuel Pump

5. Fuel Injectors

6. Intake Air Temperature Sensor

7. Subthrottle Sensor

8. Subthrottle Valve Actuator

9. Air Switching Valve

10. Gear Position Sensor

11. Purge Valve (CAL, CN, SEA-B1, SEA-B3, TH and WVTA (FULL) Models)

12. Main Throttle Sensor

13. Water Temperature Sensor

14. Intake Air Pressure Sensor

15. Oxygen Sensor

16. Crankshaft Sensor

17. Wheel Rotation Sensors

18. Vehicle-down Sensor

19. Air Flow

20. Fuel Flow
3-12 FUEL SYSTEM (DFI)

DFI System

DFI Components Naming

The terms used in the European regulation for DFI components are sometimes different from those

used by Kawasaki. Use this table to cross reference terms which may appear in a generic scan tool

when diagnosing the DFI system.

Sensors described in R44/2014

(Description per ISO 15031-6 in the parentheses)

Crankshaft position sensor (Crankshaft position sensor

“A”)

Engine coolant temperature sensor (Engine coolant

temperature sensor 1)

Gear shift position sensor (Gear shift position circuit)

Intake air temperature sensor (Intake air temperature

sensor 1)

Manifold absolute pressure sensor (Manifold absolute

pressure/barometric pressure circuit)

O2 sensor (binary/linear) signals (O2 sensor)

Throttle position sensor (Throttle/Pedal position

sensor/switch “A”)

Throttle position sensor (Throttle/Pedal position

sensor/switch “B”)

Vehicle speed sensor (Vehicle speed sensor “B”)

Actuators described in R44/2014

(Description per ISO 15031-6 in the parentheses)

Evaporative emission system purge control valve

(Evaporative emission system purge control valve)

Fuel injector (Injector - cylinder 1  2)

Ignition coil primary control circuits (Ignition coil “A  B”

primary/secondary circuit)

O2 sensor heater (HO2S heater control circuit)

Secondary air injection system (Secondary air injection

system)

Throttle by wire actuator (Throttle actuator control motor

circuit)
Kawasaki Name

Crankshaft sensor

Water (Engine) temperature sensor

Gear position sensor

Intake air temperature sensor

Intake air pressure sensor

Oxygen sensor

Main throttle sensor

Subthrottle sensor

Rear wheel rotation sensor

Kawasaki Name

Purge valve

Fuel injector

Ignition coil (Stick coil)

Oxygen sensor heater

Air switching valve

Subthrottle valve actuator (ETV actuator)
FUEL SYSTEM (DFI) 3-13

DFI System

This page intentionally left blank.
3-14 FUEL SYSTEM (DFI)

1...9 101112 13...52

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