Stick coil trouble
Inspect (see chapter 16).
ECU trouble
Inspect (see chapter 3).
Engine vacuum not synchronizing
Inspect (see chapter 2).
Intake air pressure sensor #1 or #2 trouble
Inspect (see chapter 17).
Water temperature sensor trouble
Inspect (see chapter 17).
Intake air temperature sensor trouble
Inspect (see chapter 17).
Miscellaneous:
Throttle valves will not fully open
Inspect throttle cables (see chapter 3).
Inspect ETV system (see chapter 17).
Engine overheating - Water temperature sensor (see Overheating of Troubleshooting Guide in
chapter 18)
or crankshaft sensor trouble
Air switching valve trouble
Inspect and replace (see chapter 16).
Air suction valve trouble
Inspect and replace (see chapter 5).

3-38 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Exhaust Smokes Excessively:
(Black smokes)
Air cleaner element clogged
Fuel pressure too high
Fuel injector trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
(Brown smoke)
Air intake duct loose
Fuel pressure too low
Water temperature sensor trouble
Intake air temperature sensor trouble

Actions (chapter)

Clean element (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 17).
Inspect (see chapter 17).
Inspect (see chapter 17).
Reinstall (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 17).
Inspect (see chapter 17).

FUEL SYSTEM (DFI) 3-39
Warning Indicator Light (LED)
Yellow Engine Warning/Red Warning Indicator
Light (LED) Inspection
Yellow Engine Warning Indicator Light (LED) [A]
Red Warning Indicator Light (LED) [B]
○In this model, the above mentioned warning indicator
lights (LED) go on or blink by the data sent from the ECU.
Refer to the Meter Unit Inspection in the Electrical System
chapter.

•

Warning Indicator Light (LED) Circuit

1. ECU
2. Joint Connector K
3. Joint Connector J
4. Meter Unit

3-40 FUEL SYSTEM (DFI)
ECU
ECU Identification

○Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with
each other and use only the ECU for your model. Otherwise, the motorcycle can not clear the regulation.
ECU Identification (ZX1000R/S)
Part Number [A]

Specification

without immobilizer
21175-1128

CAL

21175-1129

US, CA

with immobilizer
21175-1118

WVTA (FULL), AU

21175-1152

ID, PH, SEA-B3

21175-1153

SEA-B1

21175-1154

TH

21175-1156

MY

ECU Identification (ZX1000Z)
Part Number [A]

Specification

without immobilizer
21175-1270

US, CA

21175-1271

CAL

with immobilizer
21175-1268

WVTA (FULL), AU, SEA-B3

21175-1274

TH

21175-1275

MY

ECU Removal
NOTICE
Never drop the ECU especially on a hard surface.
Such a shock to the ECU can damage it.

NOTE

○When replace the ECU with a new one or reused one
from another motorcycle, you must register the accelerator position and throttle position data of the throttle
body to the ECU.
1. In the new ECU, wait the 10 seconds at the idle speed
and the coolant temperature 40°C (104°F) or more to
register the sensor position to the ECU.
2. In the reused ECU, erase the stored service code memory using Kawasaki Diagnostic System (KDS Ver.3), and
wait the 10 seconds at the idle speed and the coolant
temperature 40°C (104°F) or more to register the sensor position to the ECU.

NOTE

○For immobilizer equipped models, register the ignition
key correctly before doing the following procedure (see
Key Registration in the Electrical System chapter).

FUEL SYSTEM (DFI) 3-41
ECU

• Remove:
Rear Seat (ZX1000R/S, see Rear Seat Removal in the

•
•
•

Frame chapter)
Single Seat Cover (ZX1000Z, see Single Seat Cover Removal in the Frame chapter)
Upper Seat Cover (see Seat Cover Removal in the
Frame chapter)
Disconnect the vehicle-down sensor connector [A].
Remove the relays [B] from the bracket.
Remove:
ECU Cover Bolts [C]
ECU Cover [D]

○For WVTA (FULL) model, remove the ECU guards as be-

•

low.
Remove the screws [A] to free the seat latch [B].

• Remove:
Bolts [A]
ECU Guards [B]

NOTE

○Use a small chisel or other suitable tool to remove the
bolts.

the ECU connectors.
• Disconnect
Remove
the
ECU.
•

ECU Installation

the ECU [A] to the rubber protector [B].
• Install
the ECU under the rear frame rear.
• Put
Connect
the ECU connectors.
•

3-42 FUEL SYSTEM (DFI)
ECU
WVTA (FULL) model, replace the bolts [A] with new
• For
ones.

○Using the Kawasaki genuine bolts of which threads are

•

coated with locking agent.
Install the ECU guards [B] and tighten the bolts.

a non-permanent locking agent to the ECU cover
• Apply
bolts.
the ECU cover.
• Install
Tighten:
•
Torque - ECU Cover Bolts: 3.0 N·m (0.31 kgf·m, 27 in·lb)

• Install the removed parts (see appropriate chapters).
ECU Power Supply Inspection

the ECU cover (see ECU Removal).
• Remove
inspect the ECU connectors.
• Visually
If the connector is clogged with mud or dust, blow it off
with compressed air.
Remove the ECU (see ECU Removal).

•
inspect the terminals [A] of the ECU and main
• Visually
harness connectors.
If the terminals of the main harness connectors are damaged, replace the main harness.
If the terminals of the ECU connectors are damaged, replace the ECU.

the ignition switch off.
• Turn
Disconnect
ECU connector [A] (see ECU Removal).
• Set a testerthe
[B]
and check the following wiring for conti• nuity.
ECU Grounding Inspection
Connections:
(I) BK/Y leads (ECU
terminal 22 or 23)

←→ Battery (–) Terminal

(II) Engine Ground

←→ Battery (–) Terminal

Criteria:
Both: 0 Ω

If no continuity, check the connectors, the engine ground
lead, or main harness, and repair or replace them if necessary.
If the wiring is good, check the power source voltage of
the ECU.

NOTE

○Be sure the battery is fully charged.

• Connect the ECU connectors.

FUEL SYSTEM (DFI) 3-43
ECU
a digital meter [A] to the connector [B] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
ECU Power Supply Inspection
Connections:
(I) Digital Meter (+) → Terminal 32 (BR/W)
Digital Meter (–) → Battery (–) Terminal
(II) Digital Meter (+) → Terminal 33 (W/BK)
Digital Meter (–) → Battery (–) Terminal
(III) Digital Meter (+) → Terminal 39 (W/BK)
Digital Meter (–) → Battery (–) Terminal
Ignition Switch Off:
(I) Terminal 32 (BR/W): 0 V
(II, III)Terminal 33, 39 (W/BK): Battery Voltage
Ignition Switch On:
All: Battery Voltage

If the reading is out of the specification, check the following.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
ECU Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
Power Source Wiring (see ECU Power Source Circuit)
If the fuse, wiring and relay are good, replace the ECU
(see ECU Removal/Installation).

3-44 FUEL SYSTEM (DFI)
ECU
ECU Power Source Circuit

1. ECU
2. Frame Ground
3. Engine Ground
4. Battery 12 V 8.6 Ah
5. Main Fuse 30 A
6. ECU Fuse 15 A
7. Starter Relay
8. Ignition Fuse 15 A
9. Fuse Box (1)
10. Joint Connector E
11. Ignition Switch

FUEL SYSTEM (DFI) 3-45
DFI Power Source
ECU Fuse Removal

to the 30 A Main/15 A ECU Fuse Removal in the
• Refer
Electrical System chapter.

ECU Fuse Installation

•

If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.
Refer to the Fuse Installation in the Electrical System
chapter.

ECU Fuse Inspection

to the Fuse Inspection in the Electrical System
• Refer
chapter.

3-46 FUEL SYSTEM (DFI)
Fuel Line
Fuel Pressure Inspection
NOTE

○Be sure the battery is fully charged.

• Remove:
Fuel Tank Covers (see Fuel Tank Cover Removal in the
Frame chapter)
Fuel Tank Bolts (see Fuel Tank Removal)
Primary Fuel Hose (see Fuel Hose Replacement in the
Periodic Maintenance chapter)
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.

WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
the fuel pressure gauge adapter [A] and fuel hoses
• Install
(Special Tool: 57001-1607) [B] between the fuel outlet

•
•

pipe and delivery pipe.
Secure the fuel hoses with the clamps.
Connect the pressure gauge [C] to the fuel pressure
gauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607

WARNING
Fuel is extremely flammable and can be explosive
under certain conditions resulting in serious injury
or death. Do not try to start the engine with the fuel
hoses disconnected.
the fuel pump lead connector.
• Connect
the engine stop switch to run position.
• Turn
Turn
the ignition switch on.
•○The fuel
pump should operate for 3 seconds, and then
should stop.

○After

NOTE

turning on the engine stop switch and ignition
switch, inspect the fuel leakage from the connected
portion of the special tools.

NOTICE
Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.

FUEL SYSTEM (DFI) 3-47
Fuel Line
the engine, and let it idle.
• Start
Measure
the fuel pressure with the engine idling.
•
Fuel Pressure (with Engine Idling)
Standard: 294 kPa (3.0 kgf/cm², 43 psi)

NOTE

○The gauge needle will fluctuate. Read the pressure at
the average of the maximum and minimum indications.
the ignition switch off.
• Turn
If the fuel pressure is much higher than specified, replace

•
•
•
•

the fuel pump because the fuel pressure regulator in the
fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check
the following.
Primary Fuel Injector Fuel Line Leakage (see Primary
Fuel Injector Fuel Line Inspection in the Self-Diagnosis
System chapter)
Secondary Fuel Injector Fuel Line Leakage (see
Secondary Fuel Injector Fuel Line Inspection in the
Self-Diagnosis System chapter)
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
After above checks, measure the fuel pressure again.
Remove the fuel pressure gauge, hoses and adapter.
Install the removed parts (see appropriate chapters).
Start the engine and check for fuel leakage.

Fuel Flow Rate Inspection

WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.

NOTE

○Be sure the battery is fully charged.
the ignition switch off.
• Turn
until the engine cools down.
• Wait
Prepare
hose (Special Tool:
• measuringa fuel
cylinder.

57001-1607) and a

Special Tool - Fuel Hose: 57001-1607

3-48 FUEL SYSTEM (DFI)
Fuel Line
the fuel tank cap [A] to lower the pressure in the
• Open
tank.
the primary fuel hose from the fuel pump (see
• Disconnect
Fuel Tank Removal).

○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump.

the prepared fuel hose [A] to the fuel outlet pipe.
• Connect
Secure
the
hose with a clamp.
• Insert the fuelfuelhose
into the measuring cylinder [B].
•

WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
the fuel tank cap.
• Close
Turn
the
stop switch to run position.
• Turn the engine
switch on.
•○The fuel ignition
pump should operate for 3 seconds, and then
should stop.

NOTICE
Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
the discharge for 3 seconds.
•○Measure
Repeat this operation several times.
Amount of Fuel Flow
Standard: 67 mL (2.3 US oz.) or more for 3 seconds

the ignition switch off.
• Turn
If the fuel flow is much less than the specified, replace the

•
•

fuel pump (see Fuel Pump Removal/Installation).
Install the fuel tank (see Fuel Tank Installation).
Start the engine and check for fuel leakage.

FUEL SYSTEM (DFI) 3-49
Fuel Pump
Fuel Pump Removal

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential
for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.

NOTICE
Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it.
the fuel out from the fuel tank with a commercially
• Draw
available electric pump.
the fuel tank (see Fuel Tank Removal).
•○Remove
Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
the fuel tank upside down.
• Turn
Unscrew
• pump [B].the fuel pump bolts [A], and take out the fuel

NOTICE
Do not pull the leads of the fuel pump. If they are
pulled, the lead terminals may be damaged.

• Discard the fuel pump O-ring [A].

3-50 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Installation

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential
for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
dirt or dust from the fuel pump [A] by lightly ap• Remove
plying compressed air.
• Replace the fuel pump O-ring with a new one.

that the fuel pump terminal [A] and band [B] are in
• Check