Torque
kgf·m
0.25

ft·lb
22 in·lb

Remarks

3-10 FUEL SYSTEM (DFI)
DFI System
DFI System

FUEL SYSTEM (DFI) 3-11
DFI System
1. Vacuum Chamber
2. Air Intake Solenoid Valve
3. Air Switching Valve
4. ECU
5. Intake Air Temperature Sensor
6. Accelerator Position Sensor
7. ETV Actuator
8. Battery 12 V 8.6 Ah
9. Throttle Position Sensor
10. Water Temperature Sensor
11. Secondary Fuel Injectors
12. Primary Fuel Injectors
13. Delivery Pipe
14. IMU
15. Vehicle-down Sensor
16. Exhaust Butterfly Valve Actuator
17. Fuel Pump
18. Fuel Filter
19. Pressure Regulator
20. Oxygen Sensor
21. Gear Position Sensor
22. Front/Rear Wheel Rotation Sensors
23. Air Intake Valve Actuator
24. Air Intake Valve
25. Purge Valve (Other than US and CA models)
26. Stick Coils
27. Intake Air Pressure Sensor #1
28. Intake Air Pressure Sensor #2
29. Crankshaft Sensor
30. Air Flow
31. 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)
Accelerator (pedal/handle) position sensor
(Throttle/Pedal Position sensor/switch “D”)
Accelerator (pedal/handle) position sensor
(Throttle/Pedal Position sensor/switch “E”)
Barometric pressure sensor (Barometric pressure
circuit)
Crankshaft position sensor (Crankshaft position
sensor “A”)
Engine coolant temperature sensor (Engine
coolant temperature sensor 1)
Exhaust control valve angle sensor (Exhaust
pressure control valve position sensor)
Gear shift position sensor circuit open/low (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 “A”)
Vehicle speed sensor (Vehicle speed sensor “B”)

Kawasaki Name
Accelerator position sensor
Accelerator position sensor
Intake air pressure sensor #2
Crankshaft sensor
Water temperature sensor
Exhaust butterfly valve actuator sensor
Gear position sensor
Intake air temperature sensor
Intake air pressure sensor #1
Oxygen sensor
Throttle position sensor
Throttle position sensor
Front wheel rotation sensor
Rear wheel rotation sensor

Actuators described in R44/2014 (Description
Kawasaki Name
per ISO 15031-6 in the parentheses)
Evaporative emission system purge control valve
Purge valve
(Evaporative emission system purge control valve)
Exhaust control valve actuator (motor driven)
Exhaust butterfly valve actuator
(Exhaust pressure control valve)
Primary fuel injector
Fuel injector (Injector - cylinder 1  8)
Secondary fuel injector
Ignition coil primary control circuits (Ignition coil “A
Stick coil
 D” primary / secondary circuit)
O2 sensor heater (HO2S heater control circuit)
Oxygen sensor heater
Secondary air injection system (Secondary air
Air switching valve
injection system)
Throttle by wire actuator (Throttle actuator control
ETV actuator
motor circuit)

FUEL SYSTEM (DFI) 3-13
DFI System
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3-14 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram (ZX1000S/Z)

FUEL SYSTEM (DFI) 3-15
DFI System
Part Names
1. ECU
2. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
3. Rear Wheel Rotation Sensor
4. Gear Position Sensor
5. Quick Shifter Sensor
6. Joint Connector K
7. Joint Connector J
8. Frame Grounds
9. Fuel Pump
10. Engine Ground
11. Battery 12 V 8.6 Ah
12. Main Fuse 30 A
13. ECU Fuse 15 A
14. Starter Relay
15. ABS Hydraulic Unit
16. Fuse Box (1)
17. Ignition Fuse 15 A
18. Oxygen Sensor Heater Fuse 10 A
19. Fuse Box (2)
20. ETV Actuator Relay Fuse 10 A
21. ETV Actuator Relay
22. Joint Connector E
23. Fuel Pump Relay
24. Immobilizer Antenna (Equipped Models)
25. Immobilizer Amplifier (Equipped Models)
26. IMU
27. Front Wheel Rotation Sensor
28. Air Intake Solenoid Valve
29. Ignition Switch
30. Engine Stop Switch
31. Air Switching Valve
32. Purge Valve (Other than US and CA Models)
33. Spark Plugs and Stick Coils
34. Secondary Fuel Injectors
35. Joint Connector G
36. Intake Air Temperature Sensor
37. Primary Fuel Injectors
38. ETV Actuator
39. Throttle Position Sensor
40. Accelerator Position Sensor
41. Crankshaft Sensor
42. Water Temperature Sensor
43. Intake Air Pressure Sensor #2
44. Intake Air Pressure Sensor #1
45. Vehicle-down Sensor
46. Oxygen Sensor
47. Exhaust Butterfly Valve Actuator

○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 (ZX1000R)

FUEL SYSTEM (DFI) 3-17
DFI System
Part Names
1. ECU
2. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
3. Rear Wheel Rotation Sensor
4. Gear Position Sensor
5. Quick Shifter Sensor
6. Joint Connector K
7. Joint Connector J
8. Frame Grounds
9. Fuel Pump
10. Engine Ground
11. Battery 12 V 8.6 Ah
12. Main Fuse 30 A
13. ECU Fuse 15 A
14. Starter Relay
15. Fuse Box (1)
16. Ignition Fuse 15 A
17. Oxygen Sensor Heater Fuse 10 A
18. Fuse Box (2)
19. ETV Actuator Relay Fuse 10 A
20. ETV Actuator Relay
21. Joint Connector E
22. Fuel Pump Relay
23. Immobilizer Antenna (Equipped Models)
24. Immobilizer Amplifier (Equipped Models)
25. IMU
26. Front Wheel Rotation Sensor
27. Air Intake Solenoid Valve
28. Ignition Switch
29. Engine Stop Switch
30. Air Switching Valve
31. Purge Valve (Other than US and CA Models)
32. Spark Plugs and Stick Coils
33. Secondary Fuel Injectors
34. Joint Connector G
35. Intake Air Temperature Sensor
36. Primary Fuel Injectors
37. ETV Actuator
38. Throttle Position Sensor
39. Accelerator Position Sensor
40. Crankshaft Sensor
41. Water Temperature Sensor
42. Intake Air Pressure Sensor #2
43. Intake Air Pressure Sensor #1
44. Vehicle-down Sensor
45. Oxygen Sensor
46. Exhaust Butterfly Valve Actuator

○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. Secondary Fuel Injector #2: O/G
2. Primary Fuel Injector #3: BL/O
3. Secondary Fuel Injector #3: O/BK
4. Primary Fuel Injector #4: BL/G
5. Secondary Fuel Injector #4: O/Y
6. Ignition Coil #2: BK/R
7. Ignition Coil #1: BK
8. Primary Fuel Injector #2: BL/R
9. ETV Actuator Relay: Y/BL
10. Air Intake Solenoid Valve: R/W
11. Air Switching Valve: R/BL
12. Unused
13. Immobilizer Amplifier (Equipped Models): P/BK
14. Secondary Fuel Injector #1: O/R
15. Fuel Pump Relay: BR/Y
16. Purge Valve (Other than US and CA Models): G/R
17. Brake Light Switches: BL
18. Radiator Fan Relay: P/BL
19. Immobilizer Amplifier (Equipped Models): Y
20. Primary Fuel Injector #1: BL/BK
21. Green Neutral Indicator Light (LED): LG
22. Engine Ground: BK/Y
23. Engine Ground: BK/Y
24. Unused
25. Ignition Coil #3: BK/O
26. Ignition Coil #4: BK/G
27. Unused
28. Unused
29. Unused
30. Unused
31. Power Supply to Wheel Rotation Sensors (ZX1000R): W/G
32. Ignition Switch: BR/W
33. Power Supply to ECU (from Battery): W/BK
34. Unused

FUEL SYSTEM (DFI) 3-19
DFI System
35. Unused
36. Crankshaft Sensor (+): Y
37. Crankshaft Sensor (–): Y/BK
38. Ground for Sensors: G
39. Power Supply to ECU (from Battery): W/BK
40. Side Stand Switch: G/BK
41. Starter Lockout Switch: R/G
42. Starter Button: BK/R
43. Dongle (ZX1000S/Z): Y/G
44. Power Supply to Sensors: BL
45. Battery Monitor Voltage Line: W/R
46. Quick Shifter Sensor: G/W
47. Unused
48. Unused
49. Power Supply to Sensors: BL/Y
50. Unused
51. External Communication Line (Immobilizer System (Equipped Models)/*KDS): LG
52. Ground for Control System: BK/BL
53. ETV Actuator (+): G/BL
54. Exhaust Butterfly Valve Actuator (+): W/R
55. Exhaust Butterfly Valve Actuator (–): W/BL
56. Oxygen Sensor Heater: R/Y
57. Accelerator Position Sensor 1 (–): G
58. Front Wheel Rotation Sensor (ZX1000R): G/Y
59. Front Wheel Rotation Sensor Signal (from ABS Hydraulic Unit, ZX1000S/Z): GY/Y
60. CAN Communication Line (Low): LB
61. CAN Communication Line (High): GY/BL
62. ETV Actuator (–): BK/Y
63. Accelerator Position Sensor 1 (+): BL
64. Accelerator Position Sensor 2 (+): BL
65. Accelerator Position Sensor 2: Y
66. Accelerator Position Sensor 2 (–): G
67. Rear Wheel Rotation Sensor (ZX1000R): BK/O
68. Rear Wheel Rotation Sensor Signal (from ABS Hydraulic Unit, ZX1000S/Z): W/Y
69. External Communication Line (Immobilizer System (Equipped Models)/*KDS): LG/BK
70. ETV Actuator (–): BK/O
71. Power Supply to Throttle Position Sensor: W
72. Throttle Position Sensor 1: V
73. Exhaust Butterfly Valve Actuator Sensor: GY
74. Gear Position Sensor: G/R
75. Vehicle-down Sensor: Y/G
76. Accelerator Position Sensor 1: Y/BK
77. Intake Air Temperature Sensor: GY/R
78. ETV Actuator (+): W/G
79. Throttle Position Sensor 2: V/W
80. Ground for Throttle Position Sensor: BK
81. Intake Air Pressure Sensor #2: R/W
82. Water Temperature Sensor: O
83. Unused
84. Oxygen Sensor: W/BK
85. Ground for Oxygen Sensor: G/BK
86. Intake Air Pressure Sensor #1: R/BK
*: KDS (Kawasaki Diagnostic System)

3-20 FUEL SYSTEM (DFI)
DFI Parts Location
Ignition Switch [A]
Immobilizer Antenna (Equipped Models) [B]
Ignition Key (Transponder, Immobilizer System
Equipped Models) [C]
Red Warning/Immobilizer Indicator Light (LED) [D]

Air Intake Solenoid Valve [A]
Immobilizer Amplifier (Equipped Models) [B]

Crankshaft Sensor [A]
Oxygen Sensor [B]
Rear Wheel Rotation Sensor [C]

Gear Position Sensor [A]
Quick Shifter Sensor [B]

Fuse Box (1) [A]
- Ignition Fuse 15 A

Front Wheel Rotation Sensor [B]

FUEL SYSTEM (DFI) 3-21
DFI Parts Location
Fuel Pump [A]

Intake Air Temperature Sensor [A]
IMU (Inertial Measurement Unit) [B]
Secondary Fuel Injectors [C]

Air Switching Valve [A]
Stick Coils [B]
Accelerator Position Sensor [C]
ETV Actuator [D]

Intake Air Pressure Sensor #1 [A]
Intake Air Pressure Sensor #2 [B]
Throttle Position Sensor [C]
Primary Fuel Injectors [D]
Water Temperature Sensor [E]

Exhaust Butterfly Valve Actuator [A]
Starter Relay [B]
- Main Fuse 30 A
- ECU Fuse 15 A

Fuse Box (2) [C]
- ETV Actuator Relay Fuse 10 A

Battery 12 V 8.6 Ah [D]

3-22 FUEL SYSTEM (DFI)
DFI Parts Location
Fuel Pump Relay [A]
Immobilizer (Equipped Models)/Kawasaki Diagnostic
System Connector [B]
Vehicle-down Sensor [C]
ETV Actuator Relay [D]
ECU [E]

FUEL SYSTEM (DFI) 3-23
Specifications
Item
Digital Fuel Injection System
Idle Speed
Throttle Body Assy:
Throttle Valve
Bore
Throttle Body Vacuum
ECU:
Make
Type
Fuel Pressure (High Pressure Line)
Fuel Pump:
Type
Discharge
Primary/Secondary Fuel Injectors:
Type
Nozzle Type
Resistance
CAN Communication Line:
Resistance
Throttle Grip and Cables
Throttle Grip Free Play
Air Cleaner
Element

Standard
1 100 ±50 r/min (rpm)
Single throttle valve
47 mm (1.9 in.)
29.3 ±1.3 kPa (220 ±10 mmHg) at idle speed
MITSUBISHI
Digital memory type, with built in IC igniter, sealed
with resin
294 kPa (3.0 kgf/cm², 43 psi) with engine idling
In-tank friction pump
67 mL (2.3 US oz.) or more for 3 seconds
EAT803
Fine atomizing type with 12 holes
About 11.7  12.3 Ω @20°C (68°F)
123  125 Ω at ECU connector
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

Fuel Hose:
57001-1607

Needle Adapter Set:
57001-1457

Measuring Adapter:
57001-1700

Fuel Pressure Gauge Adapter:
57001-1593

Liquid Gasket, TB1211:
56019-120

FUEL SYSTEM (DFI) 3-25
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.

3-26 FUEL SYSTEM (DFI)
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.
Primary Fuel Hose [A]
Secondary Fuel Hose [B]
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

FUEL SYSTEM (DFI) 3-27
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) [B] and immobilizer warning
indicator [C] blink, when a problem occurs in the system.

○When a problem occurs with the KLCM system, the yellow
warning indicator light (LED) [A] goes on and the KLCM
indicator [B] blinks.
○When a problem occurs with the power mode system,
the yellow warning indicator light (LED) goes on and the
power mode indicator [C] blinks.
○When a problem occurs with KEBC system, the yellow
warning indicator light (LED) goes on and the KEBC mode
indicator [D] blinks.
○When a problem occurs with S-KTRC system, the yellow
warning indicator light (LED) goes on and the S-KTRC
mode indicator [E] blinks.
○When a problem occurs with KQS system, the yellow
warning indicator light (LED) goes on and the KQS indicator [F] blinks.
○When a problem occurs with ESD system, the yellow
warning indicator light (LED) goes on and the ESD indicator [G] blinks.
○When a problem occurs with CAN communication line between the ABS hydraulic unit and the meter unit, the yellow ABS indicator light (LED) goes on and the KIBS indicator [H] blinks.
○When a problem occurs with IMU, the yellow warning indicator light (LED) goes on and the IMU indicator [I] blinks.
With the engine stopped and turned in the self-diagnosis
mode, the service code [A] is displayed on the LCD.
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

3-28 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
When the service code [A] is displayed, for first ask the