place.
a non-permanent locking agent to the threads of
• Apply
the fuel pump bolts.
the fuel pump bolts following the specified tight• Tighten
ening sequence [1  6] temporarily.
the fuel pump bolts with the specified torque by
• Tighten
the same sequence.
Torque - Fuel Pump Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

• Tighten the fuel pump bolts again to check the tightness.
• Hold the fuel pump lead [A] to the clamps [B].

FUEL SYSTEM (DFI) 3-51
Fuel Pump
Fuel Pump Operation Inspection
NOTE

○Be sure the battery is fully charged.
the engine stop switch to run position.
• Turn
Turn
ignition switch on and make sure that the fuel
• pumptheoperates
(make light sounds) for 3 seconds, and

•

then stops.
Turn the ignition switch off.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).

Fuel Pump Operating Voltage Inspection
NOTE

○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove:
• Fuel Tank Bolts (see Fuel Tank Removal)
Fuel Tank Bracket Bolts (see Fuel Tank Removal)
the fuel pump lead connector and connect
• Disconnect
the measuring adapter [A] between these connectors as
shown.
Main Harness [B]
Fuel Pump [C]
Special Tool - Measuring Adapter: 57001-1700

a digital meter [D] to the measuring adapter
• Connect
leads.
Fuel Pump Operating Voltage
Connections to Adapter:
Digital Meter (+) → R (pump BK/Y) lead
Digital Meter (–) → BK (pump BK/W) lead

the operating voltage with engine stopped and
• Measure
with the connector joined.
the engine stop switch to run position.
• Turn
• Turn the ignition switch on.
Operating Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V

3-52 FUEL SYSTEM (DFI)
Fuel Pump
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 wiring for continuity (see Fuel Pump 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, but the pump does not operate, replace the fuel pump (see Fuel Pump Removal/Installation).

Pressure Regulator Removal

○The pressure regulator [A] is built into the fuel pump and
can not be removed.

Fuel Pump Relay Removal/Installation

• Remove:
Upper Seat Cover (see Seat Cover Removal in the
•

Frame chapter)
Fuel Pump Relay [A]
Installation is the reverse of removal.

Fuel Pump Relay Inspection

to the Relay Circuit Inspection in the Electrical Sys• Refer
tem chapter.

FUEL SYSTEM (DFI) 3-53
Fuel Pump
Fuel Pump 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. Fuel Pump
9. Ignition Fuse 15 A
10. Fuse Box (1)
11. Fuel Pump Relay
12. Engine Stop Switch
13. Ignition Switch

3-54 FUEL SYSTEM (DFI)
Fuel Injectors
Primary Fuel Injector Removal/Installation

• Refer to the Throttle Body Assy Disassembly/Assembly.
Secondary Fuel Injector Removal/Installation

• Refer to the Nozzle Assy Disassembly/Assembly.
Primary Fuel Injector Audible Inspection

to the Primary Fuel Injector Audible Inspection in
• Refer
the Self-Diagnosis System chapter.

Fuel Injector Resistance Inspection

to the Fuel Injector Resistance Inspection in the
• Refer
Self-Diagnosis System chapter.

Fuel Injector Power Source Voltage Inspection

to the Fuel Injector Power Source Voltage Inspec• Refer
tion in the Self-Diagnosis System chapter.

Fuel Injector Output Voltage Inspection

to the Fuel Injector Output Voltage Inspection in the
• Refer
Self-Diagnosis System chapter.

Fuel Injector Fuel Line Inspection

to the Fuel Injector Fuel Line Inspection in the Self
• Refer
-Diagnosis System chapter.

FUEL SYSTEM (DFI) 3-55
Throttle Grip and Cables
Free Play Inspection

to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.

Free Play Adjustment

to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.

Cable Installation

the throttle cables in accordance with the Cable,
• Install
Wire, and Hose Routing section in the Appendix chapter.
the lower ends of the throttle cables in the throttle
• Install
pulley on the throttle body assy after installing the upper

•

ends of the throttle cables in the grip.
After installation, adjust each cable properly (see Throttle
Control System Inspection in the Periodic Maintenance
chapter).

WARNING
Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition. Be sure the cables are routed correctly and
properly adjusted.

Cable Lubrication

to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.

3-56 FUEL SYSTEM (DFI)
Throttle Body Assy
Idle Speed Inspection/Adjustment

to the Idle Speed Inspection/Adjustment in the Pe• Refer
riodic Maintenance chapter.

Synchronization Inspection

to the Engine Vacuum Synchronization Inspection
• Refer
in the Periodic Maintenance chapter.

Throttle Body Assy 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. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.

NOTICE
Never drop the throttle body assy especially on a
hard surface. Such a shock to the body assy can
damage it.

NOTE

○When replace the throttle body assy 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. 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.

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Primary and Secondary Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter)

• Disconnect:
Accelerator Position Sensor Connector [A]
ETV Actuator Connector [B]
Intake Air Pressure Sensor #1 Connector [C]
Intake Air Pressure Sensor #2 Connector [D]
Throttle Position Sensor Connector [E]

FUEL SYSTEM (DFI) 3-57
Throttle Body Assy
than US and CA models, disconnect the purge
• Other
valve hose [A].
• Disconnect:
Primary Fuel Injector Connectors [B]

• Remove the cap [A] on both sides.

• Loosen the throttle body assy holder clamp bolts [A].

the throttle body assy from the throttle body assy
• Remove
holders.
the clamp [A] from the cable holder [B].
• Clear
Disconnect:
• Throttle Cable Lower Ends [C]

•

Hose [D]
After removing the throttle body assy, stuff pieces of lint
-free, clean cloth into the throttle body assy holders.

NOTICE
If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.

3-58 FUEL SYSTEM (DFI)
Throttle Body Assy
Throttle Body Assy Installation

the throttle body assy holder clamps [A] so that their
• Install
bolt heads [B] face outward.

a thin coat of grease to the throttle cable lower ends
• Apply
[A].
• Install:
Accelerator Cable [B]
Decelerator Cable [C]
Clamp [D]

the throttle body assy.
• Install
Tighten:
•
Torque - Throttle Body Assy Holder Clamp Bolts: 2.0 N·m
(0.20 kgf·m, 18 in·lb)

the throttle grip and make sure that the throttle pulley
• Turn
moves smoothly and return by spring force.
the leads and hoses correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
the removed parts (see appropriate chapters).
• Install
Adjust:
• Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter)

FUEL SYSTEM (DFI) 3-59
Throttle Body Assy
Throttle Body Assy Disassembly

1. Intake Air Pressure Sensor #1
2. Intake Air Pressure Sensor #2
3. Primary Fuel Injectors
4. Throttle Position Sensor
5. ETV Actuator
6. Accelerator Position Sensor
7. Throttle Body Assy
8. Delivery Pipe Assy
9. US and CA Models

NOTICE
Do not remove, disassemble or adjust the throttle
position sensor, ETV actuator, accelerator position
sensor, throttle link mechanism and throttle body
assy, because they are adjust or set surely at the
manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of
the throttle body assy.
the throttle body assy (see Throttle Body Assy
• Remove
Removal).
the delivery pipe mounting screws [A] and wash• Remove
ers.
out the primary fuel injectors [B] from the throttle body
• Pull
assy together with the delivery pipe assembly [C].

NOTE

○Do not damage the insertion portions of the injectors
when they are pulled out from the throttle body assy.

3-60 FUEL SYSTEM (DFI)
Throttle Body Assy

• Disassemble:
Primary Fuel Injectors [A]
Delivery Pipes [B]
Joint Pipe [C]

NOTE

○Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.

NOTICE
Never drop the primary fuel injector especially on
a hard surface. Such a shock to the injector can
damage it.

Throttle Body Assy Assembly

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.
assembling, blow away dirt or dust from the throttle
• Before
body and delivery pipe [A] by applying compressed air [B].

the O-rings [A] of the joint pipe [B] with new ones.
• Replace
Apply
engine
• delivery pipes oil[C].to the new O-rings, and insert it to the

○Left and right delivery pipes are identical.

FUEL SYSTEM (DFI) 3-61
Throttle Body Assy

• Fit the flat portions [A].

the O-ring [A] of each primary fuel injector [B]
• Replace
with new ones.

the dust seals [A] with new ones.
• Replace
Install
the
primary fuel injectors [B].
•

the delivery pipe assembly [A] onto the primary fuel
• Install
injectors.

○Press the fuel injector portions [B] to connect securely.
the washers with new ones.
• Replace
Tighten:
•

Torque - Delivery Pipe Assy Mounting Screws: 3.5 N·m
(0.36 kgf·m, 31 in·lb)

the throttle body assy (see Throttle Body Assy In• Install
stallation).

3-62 FUEL SYSTEM (DFI)
Nozzle Assy
Nozzle Assy Removal

the fuel tank (see Fuel Tank Removal).
• Remove
the secondary fuel hose [A] from the delivery
• Disconnect
pipe of the nozzle assy [B] (see Fuel Hose Replacement

•
•

in the Periodic Maintenance chapter).
Disconnect the secondary fuel injector connectors [C].
Remove:
Nozzle Assy Mounting Bolts [D]
Nozzle Assy

Nozzle Assy Installation

the insulators [A] with new ones.
• Replace
• Install the secondary fuel injectors [B] onto the insulators.

the nozzle assy [A] onto the secondary fuel injec• Install
tors.

○Press the fuel injector portions [B] to connect securely.
○Set the joint pipe [C] so as to be parallel to the air cleaner
housing.

NOTICE
When installing the nozzle assy, apply force equally
to the both sides of the delivery pipes. If the resin
made delivery pipe is pushed strongly, it could be
damaged.

• Tighten the nozzle assy mounting bolts [D].
Torque - Nozzle Assy Mounting Bolts: 5.0 N·m (0.51 kgf·m,
44 in·lb)

○Tighten the inside bolts firstly.

Then tighten the outside

bolts.
the leads correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
the secondary fuel hose to the delivery pipe of
• Connect
the nozzle assy (see Fuel Hose Replacement in the Periodic Maintenance chapter).

FUEL SYSTEM (DFI) 3-63
Nozzle Assy
Nozzle Assy Disassembly

the nozzle assy (see Nozzle Assy Removal).
• Remove
• Disassemble:
Secondary Fuel Injectors [A]
Delivery Pipes [B]
Joint Pipe [C]

NOTE

○Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.
NOTICE
Never drop the secondary fuel injector especially
on a hard surface. Such a shock to the injector can
damage it.

Nozzle Assy Assembly

assembling, blow away dirt or dust from the deliv• Before
ery pipes [A] by applying compressed air [B].

the O-rings [A] of the joint pipe [B] with new ones.
• Replace
the joint pipe to the delivery pipes [C].
•○Insert
The direction of the joint pipe does not matter.

○Left and right delivery pipes are identical.
○Insert the joint pipe so as to be parallel to the air cleaner
housing surface.

the O-rings [A] of each secondary fuel injector
• Replace
[B] with new ones.
• Install the nozzle assy (see Nozzle Assy Installation).

3-64 FUEL SYSTEM (DFI)
Air Cleaner
Air Cleaner Element Removal/Installation

to the Air Cleaner Element Replacement in the Pe• Refer
riodic Maintenance chapter.

Air Cleaner Element Inspection

the air cleaner element (see Air Cleaner Element
• Remove
Replacement in the Periodic Maintenance chapter).
check the element [A] for tears or breaks.
• Visually
If the element has any tears or breaks, replace the element.

Air Cleaner Oil Draining
A drain hose is connected to the bottom of the air cleaner
to drain water or oil accumulated in the cleaner part.
Visually check the drain hose [A] if the water or oil accumulates.
If any water or oil accumulates in the hose, remove the
plug [B] from the drain hose and drain it.

•

WARNING
Oil on tires will make them slippery and can cause
an accident and injury. Be sure to reinstall the plug
in the drain hose after draining.

Air Cleaner Housing Removal

the fuel tank (see Fuel Tank Removal).
• Remove
Disconnect:
• Secondary Fuel Hose (see Fuel Hose Replacement in
the Periodic Maintenance chapter)
Intake Air Temperature Sensor Connector [A]
IMU Connector [B]
Secondary Fuel Injector Connectors [C]
Remove the turn signal relay [D], radiator fan relay [E] and
ESD ECU [F] from the air cleaner housing.
Free the clamps [G] from the air cleaner housing.

•
•
• Remove:
Connector Bracket [A]
the clamps.
• Slide
Disconnect:
• Air Cleaner Drain Hose [B]
•

Breather Hose [C]
Loosen the air cleaner housing clamp bolts [D].

FUEL SYSTEM (DFI) 3-65
Air Cleaner
the bolts [A].
• Remove
Free
the
bracket [B].
• Remove the
bolt [C] and washer.
•

the air switching valve hose [A].
• Disconnect
Remove
the
air cleaner housing.
•

Air Cleaner Housing Installation

• Be sure to install the pad [A].

the air cleaner housing clamps [A] so that their bolt
• Install
heads [B] face inward.
the air cleaner housing [C] to the throttle body assy.