Gear position sensor malfunction, wiring open or short

FI

Vehicle-down sensor malfunction, wiring open or short

FI

Subthrottle sensor malfunction, wiring open or short

FI

Oxygen sensor malfunction or inactivate, wiring open or
short

Immobilizer
Immobilizer
FI
FI
FI
FI
FI
FI
FI
FI
FI
FI
FI
FI
FI
FI
FI

Immobilizer amplifier malfunction (Equipped Models)
Blank key detection (Equipped Models)
ECU communication error
Fuel injector #1 malfunction, wiring open or short
Fuel injector #2 malfunction, wiring open or short
Fuel injector #3 malfunction, wiring open or short
Fuel injector #4 malfunction, wiring open or short
Stick coil #1 malfunction, wiring open or short
Stick coil #2 malfunction, wiring open or short
Stick coil #3 malfunction, wiring open or short
Stick coil #4 malfunction, wiring open or short
Radiator fan relay malfunction, wiring open or short
Subthrottle valve actuator malfunction, wiring open or short
Air switching valve malfunction, wiring open or short
Oxygen sensor heater malfunction, wiring open or short
Fuel supply system malfunction
Purge valve malfunction, wiring open or short (Equipped
Models)

Notes:
○The ECU may be involved in these problems. If all the parts and circuits 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.
○When no service code is displayed, the electrical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.
○DTC (Diagnostic Trouble Code) is displayed on the Kawasaki Diagnostic System (KDS Ver.3) and
the Generic Scan Tool (GST).

FUEL SYSTEM (DFI) 3-45
Self-Diagnosis
Backups

○The ECU takes the following measures to prevent engine damage when the DFI, ignition or immobilizer system parts have troubles.
Service
Codes

11

12

Parts or
Function

Output Signal Usable
Range or Criteria

Main Throttle Output Voltage
Sensor
0.2  4.8 V

Intake Air
Pressure
Sensor #1

Intake Air Pressure
(Absolute)
Pv = 60  900 mmHg

13

Intake Air
Intake Air Temperature
Temperature
Ta = –30  +120°C
Sensor

14

Water
Water Temperature
Temperature
Tw = –30  +120°C
Sensor

16

21

24

25

31

32

Intake Air
Pressure
Sensor #2

Intake Air Pressure
(Absolute)
Pv = 60  900 mmHg

Backups by ECU
If the main throttle sensor system fails (the
output voltage is out of the usable range,
wiring short or open), the ECU locks ignition
timing into the ignition timing at closed throttle
position and sets the DFI in the D-J method
(1). The ECU stops the feedback mode of the
oxygen sensor.
If the intake air pressure sensor #1 system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets the DFI
in the α-N method (2). The ECU stops the
feedback mode of the oxygen sensor.
If the intake air temperature sensor system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets Ta at 40°C.
The ECU stops the feedback mode of the
oxygen sensor.
If the water temperature sensor system fails
(the signal is out of the usable range, wiring
short or open), the ECU sets Tw at 80°C and
the radiator fan operates. The ECU stops the
feedback mode of the oxygen sensor.
If the intake air pressure sensor #2 system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets Pa at 760
mmHg (the standard atmospheric pressure).
The ECU stops the feedback mode of the
oxygen sensor.

Crankshaft sensor must
If the crankshaft sensor fails, the engine stops
send 22 signals to the ECU
by itself.
at the one cranking.
Rear wheel rotation sensor
Rear Wheel
must send 45 signals to
–
Rotation
the ECU at the 1 rotation of
Sensor
the wheel.
Gear
If the gear position sensor system fails (no
Output Voltage
Position
signal, wiring short or open), the ECU set the
0.2  4.8 V
Sensor
top (6th) gear position.
If the vehicle-down sensor system has failures
Vehicle
(the output voltage is out of the usable range,
Output Voltage
-down
wiring short or open), the ECU shuts off the
Vd = 0.10  4.84 V
Sensor
fuel pump relay, the fuel injectors and the
ignition system.
If the subthrottle sensor system fails (the
output voltage is out of the usable range, wiring
Subthrottle Output Voltage
short or open), the ECU drive the subthrottle
Sensor
0.15  4.85 V
valve to the full closed position, and it stops
the current to the subthrottle valve actuator.
Crankshaft
Sensor

3-46 FUEL SYSTEM (DFI)
Self-Diagnosis
Service
Codes

Parts or
Function

33

Oxygen
Sensor

35

Immobilizer
Amplifier
(Equipped
Models)

36

Ignition Key

39

ECU

Output Signal Usable
Range or Criteria
The oxygen sensor is
active and sensor must
send signals (output
voltage) continuously to
the ECU.
–
The ignition key must use
register key.
The communication error
between the ECU and
meter unit

41

The injector must send
Fuel Injector
signals continuously to the
#1*
ECU.

42

The injector must send
Fuel Injector
signals continuously to the
#2*
ECU.

43

The injector must send
Fuel Injector
signals continuously to the
#3*
ECU.

44

The injector must send
Fuel Injector
signals continuously to the
#4*
ECU.

51

The ECU sends
signals (output voltage)
Stick Coil #1*
continuously to the stick
coil.

52

The ECU sends
signals (output voltage)
Stick Coil #2*
continuously to the stick
coil.

Backups by ECU

If the oxygen sensor is not activated, the ECU
stops the feedback mode of the oxygen sensor.

If the immobilizer system fails (no signal, wiring
short or open), the vehicle does not start, and
does not run.
If the blank key or broken key is used, the
vehicle does not start the engine.
–
If the injector #1 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#1, though the engine keeps running. The
ECU stops the feedback mode of the oxygen
sensor.
If the injector #2 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#2, though the engine keeps running. The
ECU stops the feedback mode of the oxygen
sensor.
If the injector #3 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#3, though the engine keeps running. The
ECU stops the feedback mode of the oxygen
sensor.
If the injector #4 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#4, though the engine keeps running. The
ECU stops the feedback mode of the oxygen
sensor.
If the stick coil #1 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #1 to stop fuel to the
cylinder #1, though the engine keeps running.
The ECU stops the feedback mode of the
oxygen sensor.
If the stick coil #2 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #2 to stop fuel to the
cylinder #2, though the engine keeps running.
The ECU stops the feedback mode of the
oxygen sensor.

FUEL SYSTEM (DFI) 3-47
Self-Diagnosis
Service
Codes

Parts or
Function

Output Signal Usable
Range or Criteria

53

The ECU sends
signals (output voltage)
Stick Coil #3*
continuously to the stick
coil.

54

The ECU sends
signals (output voltage)
Stick Coil #4*
continuously to the stick
coil.

56

62

64

67

94

3A

Radiator Fan When the radiator fan relay
is OFF, the relay is opened.
Relay
The actuator operates
Subthrottle
open and close of the
Valve
subthrottle valve by the
Actuator
pulse signal from the ECU.
The air switching valve
controls the flow of the
Air Switching
secondary air by opening
Valve
and shutting the solenoid
valve.
The oxygen sensor heater
Oxygen
raise temperature of
Sensor
the sensor for its earlier
Heater
activation.
Fuel Supply Fuel correction value
System
exceeds a threshold.
The purge valve controls
Purge Valve
the flow of the purge air for
(Equipped
the canister and shutting
Models)
the solenoid valve.

Backups by ECU
If the stick coil #3 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #3 to stop fuel to the
cylinder #3, though the engine keeps running.
The ECU stops the feedback mode of the
oxygen sensor.
If the stick coil #4 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #4 to stop fuel to the
cylinder #4, though the engine keeps running.
The ECU stops the feedback mode of the
oxygen sensor.
–
If the subthrottle valve actuator fails (the
signal is out to the usable range, wiring short
or open), the ECU stops the current to the
actuator.

–

If the oxygen sensor heater fails (wiring short
or open), the ECU stops the current to the
heater.
–
If the purge valve fails (wiring short or open),
the ECU stops operating purge valve.

Note:
(1): D-J Method: When the engine load is light like at idling or low speed, the ECU determines the
injection quantity by calculating from the throttle vacuum (intake air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method.
(2): α-N Method: As the engine speed increases, and the engine load turns middle to heavy, the
ECU determines the injection quantity by calculating from the throttle opening (throttle sensor
output voltage) and the engine speed. This method is called α-N method.
*: This depends on the number of stopped cylinders.

3-48 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11) (DTC P0120, P0123)
The main throttle sensor is a rotating variable resistor that
change output voltage according to throttle operating. The
ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm,
and throttle opening.
Input Terminal [A]: BL
Output Terminal [B]: Y/W
Ground Terminal [C]: G

Main Throttle Sensor Removal/Adjustment
NOTICE
Do not remove or adjust the main throttle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the main throttle sensor can damage it.

Main Throttle Sensor Input Voltage Inspection
NOTE

○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Disconnect
the main throttle sensor connector and con• nect the setting
adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter:
-1538

57001

• Connect a digital meter to the setting adapter leads.
Main Throttle Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead

the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Input Voltage
Standard: DC 4.75  5.25 V

the ignition switch off.
• Turn
If the reading is within the standard, check the main throttle sensor resistance (see Main Throttle Sensor Resistance Inspection).

FUEL SYSTEM (DFI) 3-49
Main Throttle Sensor (Service Code 11) (DTC P0120, P0123)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
ECU Terminal 4 [C] ←→ Sensor Terminal [D]
ECU Terminal 49 [E] ←→ Sensor Terminal [F]

If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).

Main Throttle Sensor Resistance Inspection

the ignition switch off.
• Turn
the main throttle sensor connector.
• Disconnect
Connect
the
setting adapter [A] to the sensor connector
• only.
Special Tool - Throttle Sensor Setting Adapter:
-1538

57001

• Measure the main throttle sensor resistance.
Main Throttle Sensor Resistance
Connections to Adapter:
W (sensor BL) lead ←→ BK (sensor G) lead
Standard:

4  6 kΩ

If the reading is out of the standard, replace the throttle
body assy (see Throttle Body Assy Removal/Installation).
If the reading is within the standard, check the output voltage (see Main Throttle Sensor Output Voltage Inspection).

Main Throttle Sensor Output Voltage Inspection

the output voltage at the main throttle sensor in
• Measure
the same way as input voltage inspection, note the following.

○Disconnect the main throttle sensor connector and connect the setting adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter:
-1538

57001

Main Throttle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor Y/W) lead
Digital Meter (–) → BK (sensor G) lead

the engine and warm it up thoroughly.
• Start
Check
speed to ensure the throttle opening is correct
• (see IdleidleSpeed
Inspection in the Periodic Maintenance
chapter).
Idle Speed
Standard:

1 100 ±50 r/min (rpm)

3-50 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11) (DTC P0120, P0123)
the ignition switch off.
• Turn
Measure
the output voltage with the engine stopped and
• with the connector
joined.
Turn
the
ignition
switch
on.
•
Output Voltage
Standard: DC 1.00  1.02 V at idle throttle opening
DC 4.05  4.48 V at full throttle opening (for
reference)

○Open

NOTE