NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
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).
3-82 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32) (DTC P0220, P0223)
Subthrottle Sensor Resistance Inspection
the ignition switch off.
• Turn
the subthrottle sensor connector.
• Disconnect
Connect
the
setting adapter [A] to the sensor connector
• only.
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
• Measure the subthrottle sensor resistance.
Subthrottle 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, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Subthrottle Sensor Circuit
1. Main Throttle Sensor
2. Subthrottle Sensor
3. ECU
FUEL SYSTEM (DFI) 3-83
Oxygen Sensor - not activated (Service Code 33) (DTC P0130, P0132)
Oxygen Sensor Removal/Installation
to the Oxygen Sensor Removal/Installation in the
• Refer
Electrical System chapter.
Oxygen Sensor Inspection
the ignition switch off.
• Turn
• Remove:
Fuel Tank (see Fuel Tank Removal)
Disconnect
the oxygen sensor lead connector [A].
•
the measuring adapter [A] between these con• Connect
nectors.
Main Harness [B]
Oxygen Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (−) → BK (sensor W) lead
the air switching valve [A] (see Air Switching
• Remove
Valve Removal in the Engine Top End chapter).
○Do not disconnect the air switching valve connector [B].
3-84 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33) (DTC P0130, P0132)
the suitable plugs [A] on the fitting of the air suction
• Install
valve covers, and shut off the secondary air.
the fuel hose (see Fuel Hose Replacement in the
• Remove
Periodic Maintenance chapter).
the following parts temporarily.
• Connect
Fuel Pump Lead Connector [A]
Extension Tube [B]
Air Cleaner Housing (see Air Cleaner Housing Installation)
Special Tool - Extension Tube: 57001-1578
up the engine thoroughly until the radiator fan
• Warm
starts.
• Measure the output voltage with the connector joined.
Output Voltage (with Plugs, Rich)
Standard: DC 0.7 V or more
the ignition switch off.
• Turn
Remove
• Removal).the air cleaner housing (see Air Cleaner Housing
• 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.
the air cleaner housing temporarily (see Air Cleaner
• Install
Housing Installation).
the engine, and let it idle.
• Start
Measure
the output voltage with the connector joined.
•
Output Voltage (without Plugs, Lean)
Standard: DC 0.2 V or less
• Turn the ignition switch off.
FUEL SYSTEM (DFI) 3-85
Oxygen Sensor - not activated (Service Code 33) (DTC P0130, P0132)
If the reading is out of the standard (with plugs: DC 0.7
V or more, without plugs: DC 0.2 V or less), remove the
ECU and check the wiring for continuity between main
harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connectors [A] ←→
Oxygen Sensor Connector [B]
ECU Terminal 8 [C] ←→ Sensor Terminal [D]
ECU Terminal 59 [E] ←→ Sensor Terminal [F]
If the wiring is good, replace the sensor.
If the reading is within the standard (with plugs: DC 0.7 V
or more, without plugs: DC 0.2 V or less), 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).
Oxygen Sensor Circuit
1. Ignition Switch
2. Fuse Box (1)
3. Ignition Fuse 15 A
4. Oxygen Sensor
5. ECU
6. Joint Connector B
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. ECU Main Relay
14. Frame Ground (6)
3-86 FUEL SYSTEM (DFI)
Immobilizer Amplifier (Service Code 35, Equipped Models)
Antenna Resistance Inspection
the ignition switch off.
• Turn
the air cleaner housing (see Air Cleaner Housing
• Remove
Removal).
the antenna lead connector [A].
• Disconnect
Measure
the
antenna resistance.
•
Antenna Resistance
Connections: BK lead ←→ BK/W lead
Standard: About 3.0 4.6 Ω
If the reading is out of the standard, replace the ignition
switch (see Immobilizer System Parts Replacement in the
Electrical System chapter).
If the reading is within the standard, check the wiring to
the amplifier (see Immobilizer System Circuit).
If the wiring is good, check the input voltage of the amplifier (see Amplifier Input Voltage Inspection).
Amplifier Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove:
• Air Cleaner Housing (see Air Cleaner Housing Removal)
Bracket Bolts [A]
a digital meter to the amplifier connector [A] with
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Amplifier Input Voltage
Connections to Amplifier Connector:
Digital Meter (+) → BR/W lead
Digital Meter (–) → BK/BL lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Input Voltage
Standard: Battery Voltage
the ignition switch off.
• Turn
If the reading is out of the standard, check the wiring (see
Immobilizer System Circuit).
If the reading is within the standard, check the wiring to
ECU (see Immobilizer System Circuit).
If the wiring is good, replace the amplifier (see Immobilizer System Parts Replacement in the Electrical System
chapter).
FUEL SYSTEM (DFI) 3-87
Blank Key Detection (Service Code 36, Equipped Models)
code appears in the following conditions.
•○This
The transponder [A] in the ignition key is malfunction.
○When the spare key of unregistration is used.
○When the ignition key is registered in the registered ECU.
the service code 36 will disappear when the
• Therefore,
above issue is solved.
Ignition Key Inspection
the ignition key correctly (see Key Registration
• Register
in the Electrical System chapter).
If the service code 36 appears again, the transponder in
the key is malfunction, replace it.
Immobilizer System Circuit
1. Ignition Switch
2. Fuse Box (1)
3. Ignition Fuse 15 A
4. ECU
5. Joint Connector B
6. Immobilizer/Kawasaki
Diagnostic System Connector
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. ECU Main Relay
14. Frame Ground (7)
15. Frame Ground (6)
16. Meter Unit
17. Immobilizer Antenna
18. Immobilizer Amplifier
3-88 FUEL SYSTEM (DFI)
ECU Communication Error (Service Code 39)
ECU Communication Line Inspection
○When the data is not sent from the ECU to the meter unit
for more than about 10 seconds, the service code 39 is
displayed.
○The service code 39 is detected with meter unit.
Remove the ECU and meter unit, check the wiring for
continuity between main harness connectors.
○Disconnect the ECU and meter unit connectors.
•
Wiring Continuity Inspection
ECU Connector [A] ←→ Meter Unit Connector [B]
ECU Terminal 26 [C] ←→ Meter Terminal [D]
If the wiring is good, check the meter unit (see Meter Unit
Inspection in the Electrical System chapter).
If the meter unit is normal, replace the ECU (see ECU
Removal/Installation).
ECU Communication Line Circuit
1. Meter Unit
2. ECU
3. Frame Ground (10)
FUEL SYSTEM (DFI) 3-89
Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204)
Inspect the eligible fuel injector according to the following
service code or DTC.
Service Code 41/DTC P0201 → Fuel Injector #1
Service Code 42/DTC P0202 → Fuel Injector #2
Service Code 43/DTC P0203 → Fuel Injector #3
Service Code 44/DTC P0204 → Fuel Injector #4
Fuel Injector Removal/Installation
• Refer to the Throttle Body Assy Disassembly/Assembly.
Fuel Injector Audible Inspection
NOTE
○Be sure the battery is fully charged.
the engine, and let it idle.
• Start
Apply
screwdriver [A] to the fuel injector [B].
• Put thethegripflatendtiponto
your ear, and listen whether the fuel
injector is clicking or not.
○A sound scope can also be used.
○The click interval becomes shorter as the engine speed
•
•
rises.
Do the same for the other fuel injectors.
If all the fuel injectors click at a regular intervals, the fuel
injectors are normal.
Turn the ignition switch off.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).
Fuel Injector Resistance Inspection
the throttle body assy with the connectors in• Remove
stalled (see Throttle Body Assy Removal).
the fuel injector connector.
• Disconnect
Connect
a
digital
meter to the terminals [A] in each fuel
• injector.
• Measure the fuel injector resistance.
Fuel Injector Resistance
Standard:
About 12.0 Ω @20°C (68°F)
If the reading is out of the standard, replace the fuel injector.
If the reading is within the standard, check the power
source voltage (see Fuel Injector Power Source Voltage
Inspection).
3-90 FUEL SYSTEM (DFI)
Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204)
Fuel Injector Power Source Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
the throttle body assy with the connectors in• stalled (see
Throttle Body Assy Removal).
the injector connector and connect the mea• Disconnect
suring adapter [A] between these connectors as shown.
Main Harness [B]
Fuel Injector #1 [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the measuring adapter lead.
Fuel Injector Power Source Voltage
Connections to Adapter:
For Fuel Injector #1, #2, #3, #4
Digital Meter (+) → R (injector W/R) lead
Digital Meter (–) → Battery (–) Terminal
the power source voltage with
• Measure
stopped.
the engine stop switch to run position.
• Turn
Turn
• the ignition switch on.
the engine
Power Source Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch off.
• Turn
If the reading stays on battery voltage and never shows 0
V, check the fuel pump relay (see Relay Circuit Inspection
in the Electrical System chapter).
If the fuel pump relay is normal, 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).
If there is still no battery voltage, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System
chapter).
If the fuel pump relay is normal, check the power source
wiring (see Fuel Injector Circuit).
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).
If the reading is in specification, check the output voltage
(see Fuel Injector Output Voltage Inspection).
FUEL SYSTEM (DFI) 3-91
Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204)
Fuel Injector Output Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
the ECU (see ECU Removal).
•○Do not disconnect
the ECU connector.
a digital meter [A] to the connector [B] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Fuel Injector Output Voltage
Connections to ECU Connector:
For Fuel Injector #1
Digital Meter (+) → BL/BK lead (ECU terminal 42)
Digital Meter (–) → Battery (–) Terminal
For Fuel Injector #2
Digital Meter (+) → BL/R lead (ECU terminal 41)
Digital Meter (–) → Battery (–) Terminal
For Fuel Injector #3
Digital Meter (+) → BL/O lead (ECU terminal 40)
Digital Meter (–) → Battery (–) Terminal
For Fuel Injector #4
Digital Meter (+) → BL/G lead (ECU terminal 52)
Digital Meter (–) → Battery (–) Terminal
the output voltage with the engine stopped and
• Measure
with the connector joined.
the engine stop switch to run position.
• Turn
Turn
• the ignition switch on.
Output Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch off.
• Turn
If the reading is in specification, 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).
3-92 FUEL SYSTEM (DFI)
Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204)
If the reading is out of the specification, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and injector connector.
Wiring Continuity Inspection
ECU Connector (Gray)
Fuel Injector Connector
←→
[A]
[B]
For Fuel Injector #1 [C]
ECU Terminal 42 [D] ←→ Fuel Injector Terminal [E]
For Fuel Injector #2
ECU Terminal 41 ←→ Fuel Injector Terminal
For Fuel Injector #3
ECU Terminal 40 ←→ Fuel Injector Terminal
For Fuel Injector #4
ECU Terminal 52 ←→ Fuel Injector Terminal
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).
Fuel Injector Fuel Line Inspection
the throttle body assy (see Throttle Body Assy
• Remove
Removal).
the fuel injector fuel line for leakage as follows.
•○Check
Connect a commercially available vacuum/pressure
pump [A] to the nipple of the delivery pipe [B] with the
fuel hose [C] (both ends with the clamps [D]) as shown.
Rear Side View [E]
Apply
soap and water solution to the areas [F] as shown.
○
○Watching the pressure gauge, squeeze the pump lever
[G], and build up the pressure until the pressure reaches
the maximum pressure.
Fuel Injector Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm², 43 psi)
NOTICE
During pressure testing, do not exceed the maximum pressure for which the system is designed.
○Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once or if bubbles are found in the
area, the fuel line is leaking. Replace the delivery pipe,
fuel injectors and related parts.
○Repeat the leak test, and check the fuel line for no leakage.
Install the throttle body assy (see Throttle Body Assy Installation).
Start the engine and check for fuel leakage.
•
•
FUEL SYSTEM (DFI) 3-93
Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204)
Fuel Injector Circuit
1. Ignition Switch
2. Fuse Box (1)
3. Ignition Fuse 15 A
4. Engine Stop Switch
5. Fuel Injector #1
6. Fuel Injector #2
7. Fuel Injector #3
8. Fuel Injector #4
9. ECU
10. Engine Ground
11. Battery 12 V 8 Ah
12. Starter Relay
13. Main Fuse 30 A
14. ECU Fuse 15 A
15. Relay Box
16. Fuel Pump Relay
17. Frame Ground (9)
3-94 FUEL SYSTEM (DFI)
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353,
P0354)
Inspect the eligible stick coil according to the following
service code or DTC.
Service Code 51/DTC P0351 → Stick Coil #1
Service Code 52/DTC P0352 → Stick Coil #2
Service Code 53/DTC P0353 → Stick Coil #3
Service Code 54/DTC P0354 → Stick Coil #4
Stick Coil Removal/Installation
to the Stick Coil Removal/Installation in the Electri• Refer
cal System chapter.
Stick Coil Primary Winding Resistance Inspection
to the Stick Coil Inspection in the Electrical System
• Refer
chapter.
If the reading is within the standard, check the input voltage (see Stick Coil Input Voltage Inspection).
Stick Coil Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
the ECU (see ECU Removal).
•○Do not disconnect
the ECU connectors.
Connect
a
digital
meter
• needle adapter set. [A] to the connector [B] with the
Special Tool - Needle Adapter Set: 57001-1457
Stick Coil Input Voltage
Connections to ECU Connector:
For Stick Coil #1
Digital Meter (+) → BK lead (terminal 44)
Digital Meter (–) → Battery (–) Terminal
For Stick Coil #2
Digital Meter (+) → BK/R lead (terminal 55)
Digital Meter (–) → Battery (–) Terminal
For Stick Coil #3
Digital Meter (+) → BK/O lead (terminal 66)
Digital Meter (–) → Battery (–) Terminal
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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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