NHTSA ID Number: 10109091
Manufacturer Communication Number: 99924-1509-03
TSB/Document Date: 2017-08-01
Summary
Service Manual
• Remove
Temperature Sensor Removal).
the sensor [A] in a container of machine oil so
• Suspend
that the heat-sensitive portion is submerged.
a thermometer [B] with the heat-sensitive por• Suspend
tion [C] located in almost the same depth with the sensor.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradually
• Place
raise the temperature of the oil while stirring the oil gently
•
for even temperature.
Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown below.
Intake Air Temperature Sensor Resistance
Standard: 5.4 6.6 kΩ @0°C (32°F)
0.29 0.39 kΩ @80°C (176°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation in
the Fuel System (DFI) chapter).
Intake Air Temperature Sensor Circuit
1. ECU
2. Intake Air Temperature Sensor
SELF-DIAGNOSIS SYSTEM 17-35
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117)
Water Temperature Sensor Removal/Installation
NOTICE
Never drop the water temperature sensor especially
on a hard surface. Such a shock to the sensor can
damage it.
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
• Disconnect:
Water Temperature Sensor Connector [A]
• Remove:
Water Temperature Sensor [B] with O-ring
Replace
• Tighten: the O-ring with a new one.
•
Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106
in·lb)
the engine with coolant and bleed the air from the cool• Fill
ing system (see Coolant Change in the Periodic Maintenance chapter).
Water Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal in
•
the Fuel System (DFI) chapter)
Disconnect the water temperature sensor connector and
connect the measuring adapter [A] between these connectors as shown.
Subharness [B]
Water Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Water Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor O) lead
Digital Meter (–) → BK (sensor G) lead
17-36 SELF-DIAGNOSIS SYSTEM
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117)
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Output Voltage
Standard: About DC 2.80 2.97 V @20°C (68°F)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.
the ignition switch off.
• Turn
If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply Inspection in the Fuel System (DFI) chapter).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main and sub
harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Water Temperature Sensor Connector [B]
ECU Terminal 82 [C] ←→ Sensor Terminal [D]
ECU Terminal 38 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).
Water Temperature Sensor Resistance Inspection
to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation in
the Fuel System (DFI) chapter).
SELF-DIAGNOSIS SYSTEM 17-37
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117)
Water Temperature Sensor Circuit
1. ECU
2. Water Temperature Sensor
17-38 SELF-DIAGNOSIS SYSTEM
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)
Intake Air Pressure Sensor #2 Removal
NOTICE
Never drop the intake air pressure sensor #2 especially on a hard surface. Such a shock to the sensor
can damage it.
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
•
•
in the Fuel System (DFI) chapter)
Disconnect:
Intake Air Pressure Sensor #2 Connector [A]
Take the intake air pressure sensor #2 [B] off the bracket.
the vacuum hose [A].
• Disconnect
Remove
the
• sensor #2. rubber damper from the intake air pressure
Intake Air Pressure Sensor #2 Installation
the intake air pressure sensor #2 [A] between the
• Position
projections [B] on the rubber damper.
the vacuum hose.
• Connect
Install
the
damper [A] on the bracket [B].
• Connect therubber
connector.
• Install the removed
parts (see appropriate chapters).
•
Intake Air Pressure Sensor #2 Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
SELF-DIAGNOSIS SYSTEM 17-39
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)
the ignition switch off.
• Turn
Remove
the intake air pressure sensor #2 from the
• bracket (see
Intake Air Pressure Sensor #2 Removal).
Disconnect
the
air pressure sensor #2 connector
• and connect theintake
measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #2 [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Intake Air Pressure Sensor #2 Input Voltage
Connections to Adapter:
Digital Meter (+) → R (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 output voltage (see Intake Air Pressure Sensor #2 Output Voltage
Inspection).
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] ←→
Intake Air Pressure Sensor #2 Connector [B]
ECU Terminal 44 [C] ←→ Sensor Terminal [D]
ECU Terminal 38 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection in the
Fuel System (DFI) chapter).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).
17-40 SELF-DIAGNOSIS SYSTEM
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)
Intake Air Pressure Sensor #2 Output Voltage
Inspection
the output voltage at the intake air pressure sen• Measure
sor #2 in the same way as input voltage inspection, note
the following.
○Disconnect the intake air pressure sensor #2 connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #2 [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #2 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor R/W) lead
Digital Meter (–) → BK (sensor G) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Output Voltage
Usable Range: DC 3.80 4.20 V at standard
atmospheric pressure (101.32 kPa, 76
cmHg absolute)
NOTE
○The output voltage changes according to the local atmospheric pressure.
the ignition switch off.
• Turn
If the reading is out of the usable range, replace the sensor.
If the reading is within the usable range, 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] ←→
Intake Air Pressure Sensor #2 Connector [B]
ECU Terminal 81 [C] ←→ Sensor Terminal [D]
ECU Terminal 38 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the sensor for various vacuum (see Intake Air Pressure Sensor #1 Output Voltage
Inspection).
SELF-DIAGNOSIS SYSTEM 17-41
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)
Intake Air Pressure Sensor #2 Circuit
1. ECU
2. Intake Air Pressure Sensor #2
17-42 SELF-DIAGNOSIS SYSTEM
Accelerator Position Sensor (Service Code 18) (DTC P2120, P2121, P2123,
P2125, P2128)
Accelerator Position Sensor Removal
NOTICE
Do not remove the accelerator position 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
throttle sensor can damage it.
Accelerator Position Sensor Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove:
• Fuel Tank (see Fuel Tank Removal in the Fuel System
•
(DFI) chapter)
Disconnect:
Accelerator Position Sensor Connector [A]
the measuring adapters [A] between the main
• Connect
harness connector and accelerator position sensor connector.
Main Harness [B]
Accelerator Position Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Accelerator Position Sensor Input Voltage
Connections to Adapters:
(1) Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
(2) Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
SELF-DIAGNOSIS SYSTEM 17-43
Accelerator Position Sensor (Service Code 18) (DTC P2120, P2121, P2123,
P2125, P2128)
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 output voltage (see Accelerator Position Sensor Output Voltage Inspection).
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] ←→
Accelerator Position Sensor Connector [B]
(1) ECU Terminal 63 [C] ←→ Sensor Terminal [D]
ECU Terminal 57 [E] ←→ Sensor Terminal [F]
(2) ECU Terminal 64 [G] ←→ Sensor Terminal [H]
ECU Terminal 66 [I] ←→ Sensor Terminal [J]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection in the
Fuel System (DFI) chapter).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).
Accelerator Position Sensor Output Voltage
Inspection
the output voltage at the accelerator position
• Measure
sensor in the same way as input voltage inspection, note
the following.
○Disconnect the accelerator position sensor connector and
connect the measuring adapters [A] between these connectors.
Main Harness [B]
Accelerator Position Sensor [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Accelerator Position Sensor Output Voltage
Connections to Adapters:
(1) Digital Meter (+) → Y (sensor Y/BK) lead
Digital Meter (–) → BK (sensor G) lead
(2) Digital Meter (+) → Y (sensor Y) lead
Digital Meter (–) → BK (sensor G) lead
17-44 SELF-DIAGNOSIS SYSTEM
Accelerator Position Sensor (Service Code 18) (DTC P2120, P2121, P2123,
P2125, P2128)
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Output Voltage
Standard: (1) DC 0.50 0.90 V at ordinary throttle
position
(2) DC 0.35 1.00 V at ordinary throttle
position
○Open
NOTE
the throttle, confirm the output voltage will be
raise.
the ignition switch off.
• Turn
If the reading is out of the standard, check the accelerator position sensor resistance (see Accelerator Position
Sensor Resistance Inspection).
If the reading is within 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] ←→
Accelerator Position Sensor Connector [B]
(1) ECU Terminal 76 [C] ←→ Sensor Terminal [D]
ECU Terminal 57 [E] ←→ Sensor Terminal [F]
(2) ECU Terminal 65 [G] ←→ Sensor Terminal [H]
ECU Terminal 66 [I] ←→ Sensor Terminal [J]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection in the
Fuel System (DFI) chapter).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).
Accelerator Position Sensor Resistance
Inspection
the ignition switch off.
• Turn
Disconnect:
• Accelerator Position Sensor Connector (see Accelerator
•
Position Sensor Input Voltage Inspection)
Connect a digital meter [A] to the terminals of the accelerator position sensor connector [B].
Accelerator Position Sensor Input Voltage
Connection:
(1) BL lead terminal ←→ G lead terminal
(2) BL lead terminal ←→ G lead terminal
• Measure the accelerator position sensor resistance.
Accelerator Position Sensor Resistance
Standard: 4.5 6.5 kΩ
If the reading is out of the standard, replace the throttle
body assy (see Throttle Body Assy Removal/Installation
in the Fuel System (DFI) chapter).
SELF-DIAGNOSIS SYSTEM 17-45
Accelerator Position Sensor (Service Code 18) (DTC P2120, P2121, P2123,
P2125, P2128)
Accelerator Position Sensor Circuit
1. ECU
2. Accelerator Position Sensor
17-46 SELF-DIAGNOSIS SYSTEM
ABS Hydraulic Unit Communication Error (Service Code 1B, ZX1000S/Z)
ABS Hydraulic Unit Communication Line
Inspection
○When the data (for status of ABS hydraulic unit) is not sent
from the ABS hydraulic unit to the meter unit and ECU, the
service code 1B is displayed.
○The data is sent through the CAN communication line.
○The service code 1B is detected with the meter unit.
○When the service code 1B is detected, the yellow ABS
indicator light (LED) [A] goes on, KIBS indicator [B] blinks
and the code of 1B [C] displayed on the LCD.
the wiring for continuity between main harness
• Check
connectors.
• Disconnect:
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal in the Brakes chapter)
Meter Unit Connector (see Meter Unit Removal in the
Electrical System chapter)
Wiring Continuity Inspection
ABS Hydraulic Unit Connector [A] ←→
Meter Unit Connector [B]
ABS Hydraulic Unit Terminal 2 [C] ←→ Meter Unit
Terminal 13 [D]
ABS Hydraulic Unit Terminal 11 [E] ←→ Meter Unit
Terminal 12 [F]
If the wiring is good, replace the ABS hydraulic unit (see
ABS Hydraulic Unit Removal/Installation in the Brakes
chapter).
SELF-DIAGNOSIS SYSTEM 17-47
ABS Hydraulic Unit Communication Error (Service Code 1B, ZX1000S/Z)
ABS Hydraulic Unit Communication Line Circuit
1. ECU
2. ABS Hydraulic Unit
3. Meter Unit
4. Joint Connector J
5. Joint Connector K
17-48 SELF-DIAGNOSIS SYSTEM
Crankshaft Sensor (Service Code 21) (DTC P0335)
When the engine stops, the crankshaft sensor generates
no signals.
Crankshaft Sensor Removal/Installation
to the Crankshaft Sensor Removal/Installation in
• Refer
the Electrical System chapter.
Crankshaft Sensor Resistance Inspection
to the Crankshaft Sensor Inspection in the Electrical
• Refer
System chapter.
If the reading is within the standard, check the peak voltage (see Crankshaft Sensor Peak Voltage Inspection).
Crankshaft Sensor Peak Voltage Inspection
to the Crankshaft Sensor Peak Voltage Inspection
• Refer
in the Electrical System chapter.
If the reading is within 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] ←→
Crankshaft Sensor Connector [B]
ECU Terminal 36 [C] ←→ Sensor Terminal [D]
ECU Terminal 37 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection in the
Fuel System (DFI) chapter).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).
Crankshaft Sensor Circuit
1. ECU
2. Crankshaft Sensor
SELF-DIAGNOSIS SYSTEM 17-49
Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158)
Rear Wheel Rotation Sensor Signal Inspection
○For ZX1000R, the rear wheel rotation sensor sends the
signal to the ECU directly.
○For ZX1000S/Z, the rear wheel rotation sensor sends the
signal to the ECU through the ABS hydraulic unit.
○The ECU uses the rear wheel rotation sensor signal for
motorcycle speed and S-KTRC control.
○The service code 24 is detected with the ECU.
When the service code 24 and following ABS service
codes are displayed at the same time, inspect the rear
wheel rotation sensor.
Service Code B44 (see Rear Wheel Rotation Sensor
Signal Abnormal)
Service Code B45 (see Rear Wheel Rotation Sensor
Wiring Inspection)
•
only service code 24 is displayed, do the following
• When
inspection procedures.
• Disconnect:
ECU Connectors (see ECU Removal in the Fuel System
(DFI) chapter)
Front and Rear Wheel Rotation Sensor Lead Connectors
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal in the Brakes chapter)
ZX1000R
Check the wiring for continuity between harness connectors and resistance.
•
Wiring Continuity Inspection
ECU Connector [A] ← →
Rear Wheel Rotation Sensor Connector [B]
ECU Terminal 31 [C] ←→ Sensor Terminal [D]
ECU Terminal 67 [E] ←→ Sensor Terminal [F]
ZX1000S/Z
Check the wiring for continuity between harness connectors.
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TSB/Document ID: 99924-1509-03
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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