52. Fuel Injector #4: BL/G
53. Unused
54. Unused
55. Stick Coil #2: BK/R
56. Unused
57. Engine Stop Switch: R
58. Ground: BK/BL
59. Oxygen Sensor: G
60. External Communication Line (Immobilizer
System (Equipped Models)/*KDS): BR/Y
61. Meter Unit (Tachometer): LB
62. Radiator Fan Relay: Y/BL
63. Air Switching Valve: R/BL
64. Oxygen Sensor Heater: P/BK
65. Ground for Ignition System: BK/Y
66. Stick Coil #3: BK/O
*: KDS (Kawasaki Diagnostic System)

FUEL SYSTEM (DFI) 3-19
DFI Parts Location
Immobilizer Amplifier [A] (Equipped Models)
Vehicle-down Sensor [B]
Air Switching Valve [C]
Stick Coils #1, #2, #3, #4 [D]

Intake Air Pressure Sensor #1 [A]
Subthrottle Valve Actuator [B]
Intake Air Pressure Sensor #2 [C]
Fuel Injectors #1, #2, #3, #4 [D]

Subthrottle Sensor [A]
Main Throttle Sensor [B]

Water Temperature Sensor [A]

Intake Air Temperature Sensor [A]

3-20 FUEL SYSTEM (DFI)
DFI Parts Location
Crankshaft Sensor [A]
Oxygen Sensor [B]

Fuse Box (2) [A]
Main Fuse 30 A [B]
ECU Fuse 15 A [C]
Battery 12 V 8 Ah [D]
Immobilizer (Equipped Models)/Kawasaki Diagnostic
System Connector [E]

Relay Box [A] (ECU Main Relay, Fuel Pump Relay, Radiator Fan Relay)
ECU [B]
Fuse Box (1) [C]

Fuel Pump [A]

Yellow Engine Warning Indicator Light (LED) [A]
Ignition Key [B] (Transponder, Immobilizer System
Equipped Models)
Immobilizer Antenna [C] (Equipped Models)
Ignition Switch [D]

FUEL SYSTEM (DFI) 3-21
DFI Parts Location
Front Wheel Rotation Sensor [A]

Rear Wheel Rotation Sensor [A]

Purge Valve [A] (Equipped Models)

Gear Position Sensor [A]

3-22 FUEL SYSTEM (DFI)
Specifications
Item
Digital Fuel Injection System
Idle Speed
Throttle Body Assy:
Throttle Valve
Bore
Throttle Body Vacuum
Bypass Screws (Turn Out)
ECU:
Make
Type
Fuel Pressure (High Pressure Line)
Fuel Pump:
Type
Discharge
Fuel Injectors:
Type
Nozzle Type
Resistance
Main Throttle Sensor:
Input Voltage
Output Voltage
Resistance
Intake Air Pressure Sensor #1/#2:
Input Voltage
Output Voltage
Intake Air Temperature Sensor:
Output Voltage
Resistance
Water Temperature Sensor:
Output Voltage
Gear Position Sensor:
Input Voltage
Output Voltage
Vehicle-down Sensor:
Input Voltage
Output Voltage

Standard
1 100 ±50 r/min (rpm)
Dual throttle valve
36 mm (1.4 in.)
37.3 ±1.3 kPa (280 ±10 mmHg) at idle speed
–––
DENSO
Digital memory type, with built in IC igniter, sealed
with resin
294 kPa (3.0 kgf/cm², 43 psi) with engine idling
In-tank pump (in fuel tank)
50 mL (1.7 US oz.) or more for 3 seconds
QL7064
Fine atomizing type with 12 holes
About 12.0 Ω @20°C (68°F)
DC 4.75  5.25 V
DC 1.00  1.02 V at idle throttle opening
DC 4.05  4.48 V at full throttle opening (for reference)
4  6 kΩ
DC 4.75  5.25 V
DC 3.80  4.20 V at standard atmospheric pressure
(101.32 kPa, 76 cmHg)
About DC 2.25  2.50 V @20°C (68°F)
5.4  6.6 kΩ @0°C (32°F)
0.29  0.39 kΩ @80°C (176°F)
About DC 2.80  2.97 V @20°C (68°F)
DC 4.75  5.25 V
in the text
DC 4.75  5.25 V
With sensor tilted 60  70° or more right or left: DC
0.65  1.35 V
With sensor arrow mark pointed up: DC 3.55  4.45 V

FUEL SYSTEM (DFI) 3-23
Specifications
Item
Subthrottle Sensor:
Input Voltage
Output Voltage

Resistance
Subthrottle Valve Actuator:
Input Voltage
Resistance
Oxygen Sensor:
Output Voltage (Rich)
Output Voltage (Lean)
Heater Resistance
Immobilizer Antenna (Equipped Models):
Resistance
Purge Valve (Equipped Models):
Resistance
Throttle Grip and Cables
Throttle Grip Free Play
Air Cleaner
Air Cleaner Element

Standard
DC 4.75  5.25 V
DC 0.48  0.52 V at subthrottle valve full close
position
DC 3.66  4.38 V at subthrottle valve full open
position (for reference)
4  6 kΩ
About DC 8.5  10.5 V and then 0 V or About DC
8.5  10.5 V
About 5.2  7.8 Ω
DC 0.7 V or more
DC 0.2 V or less
11.7  15.5 Ω @20°C (68°F)
About 3.0  4.6 Ω
30  34 Ω @20°C (68°F)
2  3 mm (0.08  0.12 in.)
Viscous paper element

3-24 FUEL SYSTEM (DFI)
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²:
57001-125

Needle Adapter Set:
57001-1457

Carburetor Drain Plug Wrench, Hex 3:
57001-1269

Throttle Sensor Setting Adapter:
57001-1538

Fork Oil Level Gauge:
57001-1290

Extension Tube:
57001-1578

Vacuum Gauge:
57001-1369

Fuel Pressure Gauge Adapter:
57001-1593

Peak Voltage Adapter:
57001-1415

Fuel Hose:
57001-1607

FUEL SYSTEM (DFI) 3-25
Special Tools and Sealant
Measuring Adapter:
57001-1700

Liquid Gasket, TB1211:
56019-120

3-26 FUEL SYSTEM (DFI)
DFI Servicing Precautions
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.

○This DFI system is designed to be used with a 12 V sealed
battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
○Do not reverse the battery cable connections. This will
damage the ECU.
○To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is on, or while the engine is running.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.

○Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the engine.
○Connect these connectors until they click [A].

○Do not turn the ignition switch on while any of the DFI
electrical connectors are disconnected. The ECU memorizes service codes.
○Do not spray water on the electrical parts, DFI parts, connectors, leads and wiring.
○If a transceiver is installed on the motorcycle, make sure
that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.
○When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
○Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.
○When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
○When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and run the fuel hoses with a
minimum of bending so that the fuel flow will not be obstructed.
○Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
○To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.

FUEL SYSTEM (DFI) 3-27
DFI Servicing Precautions

○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose
to burst. Remove the fuel tank (see Fuel Tank Removal)
and check the fuel hose [A].
Replace the fuel hose if any fraying, cracks or bulges are
noticed.

○To maintain the correct fuel/air mixture (F/A), there must
be no intake air leaks in the DFI system. Be sure to install
the oil filler plug [A] after filling the engine oil.
Torque - Oil Filler Plug: Hand-tighten

3-28 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Outline
When a problem occurs with DFI system, the yellow engine warning indicator light (LED) [A] stays on after starting
the engine to alert the rider.

For models equipped with an immobilizer system, the red
warning indicator light (LED) [A] and immobilizer warning
indicator [B] blink, when a problem occurs in the system.

With the engine stopped and turned in the self-diagnosis
mode, the service code [A] is displayed on the LCD by the
number of two digits.
If the problem is with the following parts, the ECU can
not recognize these problem. Therefore, the yellow engine
warning indicator light (LED) does not go on, and service
code is not displayed.
Fuel Pump
Fuel Pump Relay
ECU Main Relay

FUEL SYSTEM (DFI) 3-29
Troubleshooting the DFI System
When the service code [A] is displayed, for first ask the
rider about the conditions [B] of trouble, and then start to
determine the cause [C] of problem.
As a pre-diagnosis inspection, check the ECU for ground
and power supply, the fuel line for no fuel leaks, and for
correct pressure. The pre-diagnosis items are not indicated
by the yellow engine warning indicator light (LED).
Don’t rely solely on the DFI self-diagnosis function, use
common sense.
Even when the DFI system is operating normally, the yellow engine warning indicator light (LED) goes on may be
displayed under strong electrical interference. Additional
measures are not required. Turn the ignition switch off to
stop the indicator light.
If the yellow engine warning indicator light (LED) of the
motorcycle brought in for repair still goes on, check the service code.
When the repair has been done, the yellow engine warning indicator light (LED) goes off after the service code erasing procedure (see Service Code Erasing) is done.
When the motorcycle is down, the vehicle-down sensor
operates and the ECU shuts off the fuel pump relay, fuel
injectors and ignition system. The ignition switch is left on.
If the starter button is pushed, the electric starter turns but
the engine does not start. To start the engine again, raise
the motorcycle, turn the ignition switch off, and then on.
Much of the DFI system troubleshooting work consists
of confirming continuity of the wiring. The DFI parts are
assembled and adjusted with precision, and it is impossible
to disassemble or repair them.

3-30 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
checking the DFI parts, use a digital meter which
• When
can be read two decimal place voltage or resistance.

○The DFI part connectors [A] have seals [B], including the

ECU. When measuring the input or output voltage with the
connector joined, use the needle adapter set [C]. Insert
the needle adapter inside the seal until the needle adapter
reaches the terminal.
Special Tool - Needle Adapter Set: 57001-1457

NOTICE
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
sure that measuring points are correct in the con• Make
nector, noting the position of the lock [D] and the lead

•
•

color before measurement. Do not reverse connections
of a digital meter.
Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters.
Turn the ignition switch on and measure the voltage with
the connector joined.

NOTICE
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.

○After measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B]
for waterproofing.
Sealant - Liquid Gasket, TB1211: 56019-120

check battery condition before replacing the DFI
• Always
parts. A fully charged battery is a must for conducting

•
•
•

accurate tests of the DFI system.
Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
Measure the coil winding resistance when the DFI part is
cold (at room temperature).
Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, short,
etc. Deteriorated leads and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.

FUEL SYSTEM (DFI) 3-31
Troubleshooting the DFI System
each connector [A] apart and inspect it for corrosion,
• Pull
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect the connectors securely.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect a tester between the ends of the leads.
If the tester does not read about 0 Ω, the lead is defective.
Replace the lead or the main harness or the subharness.

•

○If both ends of a harness [A] are far apart, ground [B] the
one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness
is open, repair or replace the harness.

○When checking a harness [A] for short circuit, open one
end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or replaced.

down suspicious locations by repeating the con• Narrow
tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.

3-32 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
DFI Diagnosis Flow Chart

Inquiries to Rider

○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.

○Try to find out exactly what problem occurred under exactly what conditions by asking the rider;
knowing this information may help you reproduce the problem.
○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.

FUEL SYSTEM (DFI) 3-33
Troubleshooting the DFI System
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.):
Year of initial registration:
Model:
Engine No.:
Frame No.:
Date problem occurred:
Mileage:
Environment when problem occurred.
Weather
□ fine, □ cloudy, □ rain, □ snow, □ always, □ other:
Temperature □ hot, □ warm, □ cold, □ very cold, □ always, □ other:
Problem
□ chronic, □ often, □once
frequency
Road
□ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble
Altitude
□ normal, □ high (about 1 000 m or more)
Motorcycle conditions when problem occurred.
Yellow engine □ goes on immediately after turning the ignition switch on, and goes off after
warning
starting the engine (normal)
indicator light □ goes on immediately after turning the ignition switch on, and stays on after
(LED)
starting the engine (DFI problem)
□ does not go on after turning the ignition switch on (indicator light (LED), meter
unit fault)
Red warning □ Starts blinking about 3 seconds after ignition switch on, and the immobilizer
warning indicator on the LCD starts blinking (immobilizer system problem).
indicator light
(LED)
□ Does not go on about 1 seconds after ignition switch on (ECU or meter unit fault).
□ light up (battery, oil pressure, water temperature, immobilizer or meter unit
problem)
Starting
□ starter motor not rotating.
difficulty
□ starter motor rotating but engine do not turn over.
□ starter motor and engine do not turn over.
□ no fuel flow (□ no fuel in tank, □ no fuel pump sound).
□ no spark.
□ other:
Engine stalls □ right after starting.
□ when opening throttle grip.
□ when closing throttle grip.
□ when moving off.
□ when stopping the motorcycle.
□ when cruising.
□ other:

3-34 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Poor running
at low speed

Poor running
or no power at
high speed

□ very low idle speed, □ very high idle speed, □ rough idle speed.
□ battery voltage is low (charge the battery).
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ backfiring.
□ afterfiring.
□ hesitation when acceleration.
□ engine oil viscosity too high.
□ brake dragging.
□ engine overheating.
□ clutch slipping.
□ other:
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ spark plug incorrect (replace it).
□ knocking (fuel poor quality or incorrect, → use high-octane gasoline).
□ brake dragging.
□ clutch slipping.
□ engine overheating.
□ engine oil level too high.
□ engine oil viscosity too high.
□ other:

FUEL SYSTEM (DFI) 3-35
DFI System Troubleshooting Guide
NOTE

○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties in
DFI system.
○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits are checked out good, be sure to check the ECU for ground and power supply. If the
ground and power supply are checked good, replace the ECU.
Engine Won’t Turn Over
Symptoms or Possible Causes
Gear position sensor, starter lockout or side
stand switch trouble
Immobilizer system trouble
Vehicle-down sensor operated
Vehicle-down sensor trouble
Crankshaft sensor trouble
Stick coil shorted or not in good contact
Stick coil trouble
Spark plug dirty, broken or gap maladjusted
Spark plug incorrect
ECU ground and power supply trouble
ECU trouble
No or little fuel in tank
Fuel injector trouble
Fuel pump not operating
Fuel pump relay trouble
Fuel filter clogged
Fuel pressure regulator trouble
Fuel line clogged

Actions (chapter)
Inspect each sensor or switch (see chapter 3 or
16).
Inspect (see chapter 3).
Turn ignition switch off (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 16).
Inspect or reinstall (see chapter 16).
Inspect (see chapter 16).
Inspect and replace (see chapter 16).
Replace it with the correct plug (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Supply fuel (see Owner’s Manual).
Inspect and replace (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 3).
Replace fuel filter (see chapter 2).
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Inspect and repair (see chapter 3).

Poor Running at Low Speed
Symptoms or Possible Causes
Spark weak:
Stick coil shorted or not in good contact
Stick coil trouble
Spark plug dirty, broken or gap maladjusted