NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
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............................................
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 ...................
Free Play Inspection ....................
Free Play Adjustment...................
Cable Installation .........................
Cable Lubrication .........................
Throttle Body Assy ............................
3-98
3-100
3-100
3-100
3-101
3-101
3-101
3-102
3-104
3-104
3-105
3-105
3-105
3-107
3-107
3-108
3-108
3-108
3-109
3-109
3-112
3-112
3-112
3-112
3-112
3-112
3-113
3-113
3-114
3-116
3-116
3-117
3-117
3-118
3-119
3-119
3-119
3-121
3-121
3-121
3-121
3-121
3-122
FUEL SYSTEM (DFI) 3-3
Idle Speed Inspection/Adjustment
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......
3-122
3-122
3-122
3-123
3-125
3-126
3-127
3-127
3-127
3-127
3-127
Air Cleaner Housing Installation...
Fuel Tank ...........................................
Fuel Tank Removal ......................
Fuel Tank Installation ...................
Fuel Tank and Cap Inspection .....
Fuel Tank Cleaning ......................
Evaporative Emission Control System
(Equipped Models)..........................
Parts Removal/Installation ...........
Hose Inspection ...........................
Purge Valve Inspection ................
Canister Inspection .....................
3-128
3-129
3-129
3-131
3-132
3-133
3-134
3-134
3-134
3-134
3-134
3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
No.
1
2
3
4
Fastener
Switch Housing Screws
Air Cleaner Housing Assembly Screws
Delivery Pipe Assy Mounting Screws
Air Cleaner Housing Clamp Bolts
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
R: Replacement Parts
N·m
3.5
1.1
3.5
2.0
Torque
kgf·m
0.36
0.11
0.36
0.20
ft·lb
31 in·lb
10 in·lb
31 in·lb
18 in·lb
Remarks
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
No.
1
2
3
4
5
6
7
8
Fastener
Bracket Bolts
Vehicle-down Sensor Mounting Bolts
Spark Plugs
Water Temperature Sensor
Intake Air Temperature Sensor Screw
Gear Position Sensor Bolt
Oxygen Sensor
Crankshaft Sensor Bolts
9. Immobilizer System Equipped Models
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
11
5.9
13
12
1.2
10
44
6.0
Torque
kgf·m
1.1
0.60
1.3
1.2
0.12
1.0
4.5
0.61
ft·lb
97 in·lb
52 in·lb
115 in·lb
106 in·lb
11 in·lb
89 in·lb
32
53 in·lb
Remarks
L
3-8 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-9
Exploded View
No.
1
2
3
4
5
Fastener
Fuel Pump Assembly Screws
Fuel Pump Bolts
Purge Valve Bracket Bolts
Purge Valve Mounting Nut
Canister Holder Bolts
6. Fuel Filter
7. Purge Valve
8. Canister
9. Other than CAL, CN, SEA-B1, TH and WVTA (FULL)
10. CAL, CN, SEA-B1, TH and WVTA (FULL)
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
N·m
0.98
9.8
1.1
6.9
1.1
Torque
kgf·m
0.10
1.0
0.11
0.70
0.11
ft·lb
8.7 in·lb
87 in·lb
10 in·lb
61 in·lb
10 in·lb
Remarks
R
L, S
3-10 FUEL SYSTEM (DFI)
DFI System
DFI System
FUEL SYSTEM (DFI) 3-11
DFI System
1. ECU
2. Battery 12 V 8 Ah
3. Front Wheel Rotation Sensor
4. Rear Wheel Rotation Sensor
5. ABS Hydraulic Unit
6. Vehicle-down Sensor
7. Air Switching Valve
8. Main Throttle Sensor
9. Subthrottle Valve Actuator
10. Subthrottle Sensor
11. Intake Air Temperature Sensor
12. Pressure Regulator
13. Fuel Pump
14. Fuel Filter
15. Delivery Pipe
16. Fuel Injectors
17. Water Temperature Sensor
18. Stick Coils
19. Gear Position Sensor
20. Oxygen Sensor
21. Crankshaft Sensor
22. Purge Valve (Equipped Models)
23. Intake Air Pressure Sensor #1
24. Intake Air Pressure Sensor #2
25. Air Flow
26. 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)
Barometric pressure sensor (Barometric pressure
circuit)
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”)
Wheel 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 4)
Ignition coil primary control circuits (Ignition coil “A
D” 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
Intake air pressure sensor #2
Crankshaft sensor
Water temperature sensor
Gear position sensor
Intake air temperature sensor
Intake air pressure sensor #1
Oxygen sensor
Main throttle sensor
Subthrottle sensor
Rear wheel rotation sensor
Kawasaki Name
Purge valve
Fuel injector
Stick coil
Oxygen sensor heater
Air switching valve
Subthrottle valve actuator
FUEL SYSTEM (DFI) 3-13
DFI System
This page intentionally left blank.
3-14 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram (ZR900A)
FUEL SYSTEM (DFI) 3-15
DFI System
Part Names
1. ECU
2. Joint Connector B
3. Rear Wheel Rotation Sensor
4. Immobilizer (Equipped Models)/Kawasaki
Diagnostic System Connector
5. Fuel Pump
6. Frame Ground (2)
7. Engine Ground
8. Battery 12 V 8 Ah
9. Starter Relay
10. Main Fuse 30 A
11. ECU Fuse 15 A
12. Relay Box
13. Fuel Pump Relay
14. ECU Main Relay
15. Radiator Fan Relay
16. Frame Ground (10)
17. Frame Ground (9)
18. Frame Ground (8)
19. Frame Ground (7)
20. Frame Ground (6)
21. Meter Unit
22. Immobilizer Antenna (Equipped Models)
23. Immobilizer Amplifier (Equipped Models)
24. Fan Fuse 15 A
25. Ignition Fuse 15 A
26. Fuse Box (1)
27. Ignition Switch
28. Engine Stop Switch
29. Fan Motor
30. Air Switching Valve
31. Spark Plugs
32. Stick Coil #1, #2, #3, #4
33. Purge Valve
34. Crankshaft Sensor
35. Fuel Injectors
36. Subthrottle Valve Actuator
37. Main Throttle Sensor
38. Subthrottle Sensor
39. Intake Air Pressure Sensor #2
40. Intake Air Pressure Sensor #1
41. Vehicle-down Sensor
42. Intake Air Temperature Sensor
43. Water Temperature Sensor
44. Gear Position Sensor
45. Oxygen Sensor
○Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green
G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
3-16 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram (ZR900B)
FUEL SYSTEM (DFI) 3-17
DFI System
Part Names
1. ECU
2. Joint Connector B
3. Rear Wheel Rotation Sensor
4. Immobilizer (Equipped Models)/Kawasaki
Diagnostic System Connector
5. Fuel Pump
6. ABS Hydraulic Unit
7. Frame Ground (2)
8. Engine Ground
9. Battery 12 V 8 Ah
10. Starter Relay
11. Main Fuse 30 A
12. ECU Fuse 15 A
13. Relay Box
14. Fuel Pump Relay
15. ECU Main Relay
16. Radiator Fan Relay
17. Frame Ground (10)
18. Frame Ground (9)
19. Frame Ground (8)
20. Frame Ground (7)
21. Frame Ground (6)
22. Meter Unit
23. Immobilizer Antenna (Equipped Models)
24. Immobilizer Amplifier (Equipped Models)
25. Fan Fuse 15 A
26. Ignition Fuse 15 A
27. Fuse Box (1)
28. Ignition Switch
29. Engine Stop Switch
30. Fan Motor
31. Air Switching Valve
32. Spark Plugs
33. Stick Coil #1, #2, #3, #4
34. Purge Valve (Equipped Models)
35. Crankshaft Sensor
36. Fuel Injectors
37. Subthrottle Valve Actuator
38. Main Throttle Sensor
39. Subthrottle Sensor
40. Intake Air Pressure Sensor #2
41. Intake Air Pressure Sensor #1
42. Vehicle-down Sensor
43. Intake Air Temperature Sensor
44. Water Temperature Sensor
45. Gear Position Sensor
46. Oxygen Sensor
○Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green
G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
3-18 FUEL SYSTEM (DFI)
DFI System
Terminal Numbers of ECU Connectors
Terminal Names
1. Subthrottle Valve Actuator: P/BL
2. Unused
3. Water Temperature Sensor: W/G
4. Power Supply to Sensors: BL
5. Fuel Pump Relay: BR/Y
6. Power Supply to ECU (from Battery): BR/W
7. Power Supply to ECU (from Battery): W/BK
8. Oxygen Sensor: BL/Y
9. CAN Communication Line (High): GY/BL
10. CAN Communication Line (Low): LB
11. Immobilizer Amplifier (Equipped Models): V
12. Subthrottle Valve Actuator: Y/BK
13. Unused
14. Unused
15. Unused
16. Intake Air Temperature Sensor: R/BK
17. Intake Air Pressure Sensor #2: G/W
18. Intake Air Pressure Sensor #1: Y/BL
19. Vehicle-down Sensor: Y/G
20. Rear Wheel Rotation Sensor Output: P
21. Rear Wheel Rotation Sensor Signal: R/Y
22. Immobilizer Amplifier (Equipped Models):
P/BK
23. Subthrottle Valve Actuator: BK/O
24. Subthrottle Valve Actuator: G
25. Unused
26. Meter Communication Line: BL/O
27. Main Throttle Sensor: Y/W
28. Subthrottle Sensor: BL/W
29. Unused
30. Unused
31. Unused
32. Power Supply to Rear Wheel Rotation Sensor (ZR900A): W/G
33. Side Stand Switch: G/BK
34. Unused
35. Starter Button: R/BK
36. Gear Position Sensor: G/R
37. Crankshaft Sensor (–): Y/BK
38. Ground for Control System: BK/BL
39. Ground for Fuel System: BK/Y
40. Fuel Injector #3: BL/O
41. Fuel Injector #2: BL/R
42. Fuel Injector #1: BL/BK
43. Stick Coil #4: BK/G
44. Stick Coil #1: BK
45. Unused
46. Starter Lockout Switch: R/G
47. External Communication Line (Immobilizer
System (Equipped Models)/*KDS): BL/R
48. Crankshaft Sensor (+): Y
49. Ground for Sensors: G
50. Purge Valve (Equipped Models): R/Y
51. Green Neutral Indicator Light (LED): LG
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TSB/Document ID: 99924-1525-01
Replacement Service Bulletin Number:
MFR Communication Date: 2017-01-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
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