NHTSA ID Number: 10109091
Manufacturer Communication Number: 99924-1509-03
TSB/Document Date: 2017-08-01
Summary
Service Manual
•
Wiring Continuity Inspection
ECU Connector [A] ← →
ABS Hydraulic Unit Connector [B]
ECU Terminal 68 [C] ← →ABS Hydraulic Unit
Terminal 16 [D]
17-50 SELF-DIAGNOSIS SYSTEM
Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158)
Wiring Continuity Inspection
ABS Hydraulic Unit Connector [A] ← →
Rear Wheel Rotation Sensor Connector [B]
ABS Hydraulic Unit Connector Terminal 14 [C] ←
→ Sensor Terminal [D]
ABS Hydraulic Unit Connector Terminal 13 [E] ←
→ Sensor Terminal [F]
If the resistance is out of the standard, replace the main
harness.
If the wiring and resistance are 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).
Wheel Rotation Sensor Circuit (ZX1000R)
1. ECU
2. Rear Wheel Rotation Sensor
3. Front Wheel Rotation Sensor
SELF-DIAGNOSIS SYSTEM 17-51
Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158)
Wheel Rotation Sensor Circuit (ZX1000S/Z)
1. ECU
2. Rear Wheel Rotation Sensor
3. ABS Hydraulic Unit
4. Front Wheel Rotation Sensor
17-52 SELF-DIAGNOSIS SYSTEM
Gear Position Sensor (Service Code 25) (DTC P0914, P0917)
Gear Position Sensor Removal/Installation
to the Gear Position Sensor Removal/Installation in
• Refer
the Electrical System chapter.
Gear Position Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
the left lower fairing (see Lower Fairing Removal
• in the Frame
chapter).
• Disconnect the gear position sensor connector [A].
the measuring adapter [A] between the main har• Connect
ness connector and gear position sensor connector.
Main Harness [B]
Gear Position Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Gear Position Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL/Y) 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 Gear Position Sensor Output Voltage Inspection).
SELF-DIAGNOSIS SYSTEM 17-53
Gear Position Sensor (Service Code 25) (DTC P0914, P0917)
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] ← →
Gear Position Sensor Connector [B]
ECU Terminal 49 [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).
Gear Position Sensor Output Voltage Inspection
the gear position sensor (see Gear Position Sen• Remove
sor Removal in the Electrical System chapter).
the output voltage at the gear position sensor in
• Measure
the same way as input voltage inspection, note the following.
○Connect the measuring adapter [A] between these connectors.
Main Harness [B]
Gear Position Sensor [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Gear Position Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor G/R) lead
Digital Meter (–) → BK (sensor G) lead
17-54 SELF-DIAGNOSIS SYSTEM
Gear Position Sensor (Service Code 25) (DTC P0914, P0917)
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Output Voltage
Angle
Output Voltage (V)
–240°
0.40 0.60
–185°
1.03 1.23
+55°
3.82 3.92
+110°
4.40 4.60
NOTE
○The figure shows 55°.
○Rotate the gear position sensor, confirm the output voltage will be raise or lower.
the ignition switch off.
• Turn
If the reading is out of the standard, replace the gear position sensor.
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] ← →
Gear Position Sensor Connector [B]
ECU Terminal 74 [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).
SELF-DIAGNOSIS SYSTEM 17-55
Gear Position Sensor (Service Code 25) (DTC P0914, P0917)
Gear Position Sensor Circuit
1. ECU
2. Gear Position Sensor
17-56 SELF-DIAGNOSIS SYSTEM
Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500)
Front Wheel Rotation Sensor Signal Inspection
○For ZX1000R, the front wheel rotation sensor sends the
signal to the ECU directly.
○For ZX1000S/Z, the front wheel rotation sensor sends the
signal to the ECU through the ABS hydraulic unit.
○The ECU uses the front wheel rotation sensor signal for
S-KTRC control.
○The service code 27 is detected with the ECU.
When the service code 27 and following ABS service
codes are displayed at the same time, inspect the front
wheel rotation sensor.
Service Code B42 (see Front Wheel Rotation Sensor
Signal Abnormal)
Service Code B43 (see Front Wheel Rotation Sensor
Wiring Inspection)
•
only service code 27 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.
•
Wiring Continuity Inspection
ECU Connector [A] ← →
Front Wheel Rotation Sensor Connector [B]
ECU Terminal 31 [C] ←→ Sensor Terminal [D]
ECU Terminal 58 [E] ←→ Sensor Terminal [F]
ZX1000S/Z
Check the wiring for continuity between harness connectors.
•
Wiring Continuity Inspection
ECU Connector [A] ← →
ABS Hydraulic Unit Connector [B]
ECU Terminal 59 [C] ← → ABS Hydraulic Unit
Terminal 8 [D]
SELF-DIAGNOSIS SYSTEM 17-57
Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500)
Wiring Continuity Inspection
ABS Hydraulic Unit Connector [A] ← →
Front Wheel Rotation Sensor Connector [B]
ABS Hydraulic Unit Connector Terminal 12 [C] ←→
Sensor Terminal [D]
ABS Hydraulic Unit Connector Terminal 3 [E] ←→
Sensor Terminal [F]
If the resistance is out of the standard, replace the main
harness.
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).
Wheel Rotation Sensor Circuit (ZX1000R)
1. ECU
2. Rear Wheel Rotation Sensor
3. Front Wheel Rotation Sensor
17-58 SELF-DIAGNOSIS SYSTEM
Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500)
Wheel Rotation Sensor Circuit (ZX1000S/Z)
1. ECU
2. Rear Wheel Rotation Sensor
3. ABS Hydraulic Unit
4. Front Wheel Rotation Sensor
SELF-DIAGNOSIS SYSTEM 17-59
Air Intake Solenoid Valve (Service Code 2D) (DTC P0660)
Air Intake Solenoid Valve Removal/Installation
to the Air Intake Solenoid Valve Removal/Installa• Refer
tion in the Fuel System (DFI) chapter.
Air Intake Solenoid Valve Inspection
to the Air Intake Solenoid Valve Unit Test in the
• Refer
Electrical System chapter.
If the air intake solenoid valve is normal, check the wiring
for continuity (see Air Intake Solenoid Valve Circuit).
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).
Air Intake Solenoid Valve Circuit
1. ECU
2. Engine Ground
3. Battery 12 V 8.6 Ah
4. Main Fuse 30 A
5. Starter Relay
6. Fuse Box (1)
7. Oxygen Sensor Heater Fuse 10 A
8. Ignition Switch
9. Air Intake Solenoid Valve
17-60 SELF-DIAGNOSIS SYSTEM
Vehicle-down Sensor (Service Code 31) (DTC C0064)
This sensor has a weight [A] with two magnets inside,
and sends a signal to the ECU. But when the motorcycle
banks 60 70° or more to either side (in fact falls down),
the weight turns and the signal changes. The ECU senses
this change, and stops the fuel pump relay, the fuel injectors
and the ignition system.
Hall IC [B]
When the motorcycle is down, the ignition switch is left on.
If the engine starter button is pushed, the electric starter
turns but the engine does not start. To start the engine
again, raise the motorcycle, turn the ignition switch off, and
then turn it on.
Vehicle-down Sensor [A]
Ground Terminal [B]: G
Output Terminal [C]: Y/G
Power Source Terminal [D]: BL
Vehicle-down Sensor Removal
NOTICE
Never drop the vehicle-down sensor especially on
a hard surface. Such a shock to the sensor can
damage it.
• Remove:
Upper Seat Cover (see Seat Cover Removal in the
•
•
Frame chapter)
Disconnect:
Vehicle-down Sensor Connector [A]
Remove:
Vehicle-down Sensor Mounting Bolts [B] and Nuts
Vehicle-down Sensor [C]
Vehicle-down Sensor Installation
sure to install the rubber dampers [A] and collars [B]
• Be
on the bracket.
SELF-DIAGNOSIS SYSTEM 17-61
Vehicle-down Sensor (Service Code 31) (DTC C0064)
• The UP mark [A] of the sensor should face upward.
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situations for an accident resulting in injury or death.
Ensure that the vehicle-down sensor is held in
place by the sensor bracket.
• Tighten:
Torque - Vehicle-down Sensor Bolts: 6.0 N·m (0.61 kgf·m,
53 in·lb)
• Install the removed parts (see appropriate chapters).
Vehicle-down Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove:
• Upper Seat Cover (see Seat Cover Removal in the
•
Frame chapter)
Disconnect the vehicle-down sensor connector and connect the measuring adapter [A] between these connectors
as shown.
Main Harness [B]
Vehicle-down Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Vehicle-down Sensor 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 Vehicle-down Sensor Output Voltage Inspection).
17-62 SELF-DIAGNOSIS SYSTEM
Vehicle-down Sensor (Service Code 31) (DTC C0064)
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] ←→
Vehicle-down Sensor 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).
Vehicle-down Sensor Output Voltage Inspection
the vehicle-down sensor (see Vehicle-down
• Remove
Sensor Removal).
the measuring adapter [A] to the vehicle-down
• Connect
sensor connectors as shown.
Main Harness [B]
Vehicle-down Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Vehicle-down Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor Y/G) lead
Digital Meter (–) → BK (sensor G) lead
SELF-DIAGNOSIS SYSTEM 17-63
Vehicle-down Sensor (Service Code 31) (DTC C0064)
the sensor vertically.
• Hold
Measure
the output voltage with the engine stopped and
• with the connector
joined.
Turn
the
ignition
switch
• Tilt the sensor 60 70° oron.more [A] right or left, then hold
• the sensor almost vertical with the arrow mark pointed up
[B], and measure the output voltage.
Output Voltage
Standard: With sensor tilted 60 70° or more right or
left: DC 0.65 1.35 V
With sensor arrow mark pointed up: DC
3.55 4.45 V
the ignition switch off.
• Turn
If the reading is out of the standard, replace the sensor.
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] ←→
Vehicle-down Sensor Connector [B]
ECU Terminal 75 [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).
17-64 SELF-DIAGNOSIS SYSTEM
Vehicle-down Sensor (Service Code 31) (DTC C0064)
Vehicle-down Sensor Circuit
1. ECU
2. Vehicle-down Sensor
SELF-DIAGNOSIS SYSTEM 17-65
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 fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
• Disconnect the oxygen sensor lead connector [A].
the measuring adapter [A] between the harness
• Connect
connector and oxygen sensor lead connector.
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 BK) lead
Digital Meter (–) → BK (sensor GY) 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].
17-66 SELF-DIAGNOSIS SYSTEM
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 following parts temporarily.
• Install
Air Cleaner Housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter)
Fuel Tank (see Fuel Tank Installation in the Fuel System
(DFI) chapter)
up the engine thoroughly until the radiator fan
• Warm
starts.
the output voltage with the connector joined.
• Measure
Measuring Adapter [A]
Output Voltage (with Plugs, Rich)
Standard: DC 0.8 V or more
the ignition switch off.
• Turn
Remove
air cleaner housing (see Air Cleaner Housing
• Removalthe
in the Fuel System (DFI) chapter).
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 following parts temporarily.
• Install
Air Cleaner Housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter)
Fuel Tank (see Fuel Tank Installation in the Fuel System
(DFI) chapter)
Start the engine, and let it idle.
•
• Measure the output voltage with the connector joined.
Output Voltage (without Plugs, Lean)
Standard: DC 0.24 V or less
• Turn the ignition switch off.
SELF-DIAGNOSIS SYSTEM 17-67
Oxygen Sensor - not activated (Service Code 33) (DTC P0130, P0132)
If the reading is out of the standard (with plugs: 0.8 V or
more, without plugs: 0.24 V or less), remove the ECU and
check the wiring for continuity between harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Oxygen Sensor Connector [B]
ECU Terminal 84 [C] ←→ Sensor Terminal [D]
ECU Terminal 85 [E] ←→ Sensor Terminal [F]
If the wiring is good, replace the sensor.
If the reading is within the standard (with plugs: 0.8 V
or more, without plugs: 0.24 V or less), 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).
Oxygen Sensor Circuit
1. ECU
2. Oxygen Sensor
3. Engine Ground
4. Battery 12 V 8.6 Ah
5. Main Fuse 30 A
6. Starter Relay
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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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