NHTSA ID Number: 10109091
Manufacturer Communication Number: 99924-1509-03
TSB/Document Date: 2017-08-01
Summary
Service Manual
7. Fuse Box (1)
8. Oxygen Sensor Heater Fuse 10 A
9. Ignition Switch
17-68 SELF-DIAGNOSIS SYSTEM
Exhaust Butterfly Valve Actuator Sensor (Service Code 34) (DTC P048B, P048E)
Exhaust Butterfly Valve Actuator Sensor
Removal/Installation
The exhaust butterfly valve actuator sensor is built in the
exhaust butterfly valve actuator. So, the sensor itself can
not be removed. Remove the exhaust butterfly valve actuator (see Exhaust Butterfly Valve Actuator Removal in the
Engine Top End chapter).
Exhaust Butterfly Valve Actuator 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)
Front Seat (see Front Seat Removal in the Frame chapter)
Slide the dust cover [A].
the exhaust butterfly valve actuator sensor
• Disconnect
lead connector (3 pins connector) and connect the setting adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
• Connect a digital meter to the setting adapter leads.
Exhaust Butterfly Valve Actuator Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → Y/W (actuator W) lead
Digital Meter (−) → BK/BL (actuator BK) 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 Exhaust Butterfly Valve Actuator Sensor Output
Voltage Inspection).
SELF-DIAGNOSIS SYSTEM 17-69
Exhaust Butterfly Valve Actuator Sensor (Service Code 34) (DTC P048B, P048E)
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] ←→
Exhaust Butterfly Valve Actuator 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).
Exhaust Butterfly Valve Actuator Sensor Output
Voltage Inspection
NOTE
○Before this inspection, confirm the pulley is original position (see Exhaust Butterfly Valve Cable Installation in
the Engine Top End chapter).
• Disconnect:
3 Pins Connector [A]
2 Pins Connector [B]
the setting adapter [A] between the 3 pins con• Connect
nectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
• Connect a digital meter to the setting adapter leads.
Exhaust Butterfly Valve Actuator Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → BL (actuator Y) lead
Digital Meter (−) → BK/BL (actuator BK) lead
the output voltage at the 3 pins connector of the
• Measure
exhaust butterfly valve actuator when the pulley is original
•
position.
Turn the ignition switch on.
Output Voltage
Standard: DC 3.46 3.76 V at pulley original position
the ignition switch off.
• Turn
If the reading is out of the standard, check the exhaust
butterfly valve actuator sensor resistance (see Exhaust
Butterfly Valve Actuator Sensor Resistance Inspection).
17-70 SELF-DIAGNOSIS SYSTEM
Exhaust Butterfly Valve Actuator Sensor (Service Code 34) (DTC P048B, P048E)
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] ←→
Exhaust Butterfly Valve Actuator Sensor Connector [B]
ECU Terminal 73 [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).
Exhaust Butterfly Valve Actuator Sensor
Resistance Inspection
the ignition switch off.
• Turn
Disconnect
butterfly valve actuator sensor
• connector (3thepinsexhaust
connector) [A] (see Exhaust Butterfly
•
•
Valve Actuator Sensor Input Voltage Inspection).
Connect a digital meter [B] to the exhaust butterfly valve
actuator sensor connector.
Measure the exhaust butterfly valve actuator sensor resistance.
Exhaust Butterfly Valve Actuator Sensor Resistance
Connections: W lead [C] ←→ BK lead [D]
Standard: 4 6 kΩ
If the reading is out of the standard, replace the exhaust
butterfly valve actuator.
If the reading within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation
in the Fuel System (DFI) chapter).
SELF-DIAGNOSIS SYSTEM 17-71
Exhaust Butterfly Valve Actuator Sensor (Service Code 34) (DTC P048B, P048E)
Exhaust Butterfly Valve Actuator Sensor Circuit
1. ECU
2. Exhaust Butterfly Valve Actuator
17-72 SELF-DIAGNOSIS SYSTEM
Immobilizer Amplifier (Service Code 35, Equipped Models)
Antenna Resistance Inspection
the ignition switch off.
• Turn
the left inner cover (see Inner Cover Removal in
• Remove
the Frame chapter).
the antenna lead connector [A].
• Disconnect
• Measure the antenna resistance.
Antenna Resistance
Connections: BK lead ←→ BK/W lead
Standard: About 3.0 4.6 Ω
If the reading is out of the standard, replace the ignition
switch (see Immobilizer System Parts Replacement in the
Electrical System chapter).
If the reading is within the standard, check the wiring to
the amplifier (see Immobilizer System Circuit).
If the wiring is good, check the input voltage of the amplifier (see Amplifier Input Voltage Inspection).
Amplifier Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
immobilizer amplifier (see Immobilizer Sys• tem Partsthe
Replacement in the Electrical System chapter).
○Need not disconnect the amplifier connector [A].
a digital meter [B] to the amplifier connector with
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Amplifier Input Voltage
Connections to Amplifier Connector:
Digital Meter (+) → BR/W [C] lead
Digital Meter (–) → BK/Y [D] lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Input Voltage
Standard: Battery Voltage
the ignition switch off.
• Turn
If the reading is out of the standard, check the wiring (see
Immobilizer System Circuit).
If the reading is within the standard, check the wiring to
ECU (see Immobilizer System Circuit).
If the wiring is good, replace the immobilizer amplifier (see
Immobilizer System Parts Replacement in the Electrical
System chapter).
SELF-DIAGNOSIS SYSTEM 17-73
Blank Key Detection (Service Code 36, Equipped Models)
code appears in the following conditions.
•○This
The transponder [A] in the ignition key is malfunction.
○When the spare key of unregistration is used.
○When inserting the registered key during the key registra-
•
tion.
Therefore, the service code 36 will disappear when the
above issue is solved.
Ignition Key Inspection
the ignition key correctly (see Key Registration
• Register
in the Electrical System chapter).
If the service code 36 appears again, the transponder in
the key is malfunction, replace it.
Immobilizer System Circuit
1. ECU
2. Immobilizer/Kawasaki
Diagnostic System Connector
3. Engine Ground
4. Battery 12 V 8.6 Ah
5. Frame Grounds
6. Main Fuse 30 A
7. Starter Relay
8. Fuse Box (1)
9. Ignition Fuse 15 A
10. Joint Connector E
11. Meter Unit
12. Immobilizer Antenna
13. Immobilizer Amplifier
14. Ignition Switch
15. Joint Connector J
16. Joint Connector K
17-74 SELF-DIAGNOSIS SYSTEM
ECU Communication Error (Service Code 39) (DTC U0001)
ECU Communication Line Inspection
○When the data is not sent from the ECU to the meter unit
for more than about 5 seconds, the service code 39 is
displayed.
○The data is sent through the CAN communication line.
○The service code 39 is detected with the meter unit.
○When the user mode, this communication error go on or
blink the following items.
Yellow Engine Warning Indicator Light (LED) [A]
Yellow Warning Indicator Light (LED) [B]
KLCM Indicator [C]
Gear Position Indicator [D]
Power Mode Indicator [E]
KEBC Mode Indicator [F]
S-KTRC Mode Indicator [G]
KQS Indicator [H]
Coolant and Intake Air Temperature Meter [I]
the CAN communication line resistance (see CAN
• Inspect
Communication Line Resistance Inspection in the Fuel
System (DFI) chapter).
If the CAN communication line resistance is normal,
check the wiring according following procedure.
the ECU and meter unit, check the wiring for
• Remove
continuity between main harness connectors.
○Disconnect the ECU and meter unit connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→ Meter Unit Connector [B]
ECU Terminal 60 [C] ←→ Meter Unit Terminal 13 [D]
ECU Terminal 61 [E] ←→ Meter Unit Terminal 12 [F]
If the wiring is good, check the meter unit (see Meter Unit
Inspection in the Electrical System chapter).
If the meter unit is normal, replace the ECU (see ECU
Removal/Installation in the Fuel System (DFI) chapter).
SELF-DIAGNOSIS SYSTEM 17-75
ECU Communication Error (Service Code 39) (DTC U0001)
ECU Communication Line Circuit
1. ECU
2. Meter Unit
3. Joint Connector J
4. Joint Connector K
17-76 SELF-DIAGNOSIS SYSTEM
Purge Valve (Service Code 3A, Other than US and CA Models) (DTC P0443)
Purge Valve Removal/Installation
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
•
•
•
•
•
chapter)
Nut [A]
Remove the purge valve [B] from the bracket.
Slide the clamp [C].
Disconnect:
Hose [D]
Installation is the reverse of removal.
Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Purge Valve Inspection
the purge valve (see Purge Valve Removal/In• Remove
stallation).
a digital meter [A] to the purge valve terminals
• Connect
as shown.
Purge Valve Resistance
Standard: 30 34 Ω @20°C (68°F)
If the resistance reading is out of the specified value, replace it with a new one.
the 12 V battery [A] to the purge valve terminals
• Connect
as shown.
the air to the intake air duct [A], and make sure that
• Blow
the air flows from the outlet air duct [B].
SELF-DIAGNOSIS SYSTEM 17-77
Purge Valve (Service Code 3A, Other than US and CA Models) (DTC P0443)
the 12 V battery.
• Disconnect
Blow
the
air
to the intake air duct [A] again, and make sure
• that the air does
not flow from the outlet air duct [B].
If the purge valve does not operate as described, replace
it with a new one.
If the purge valve is good, check the wiring for continuity
(see Purge 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).
Purge 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. Purge Valve
17-78 SELF-DIAGNOSIS SYSTEM
ESD ECU Communication Error (Service Code 3C)
ESD ECU Communication Line Inspection
○When the data (for status of ESD system) is not sent from
the ESD ECU to the meter unit and ECU, the service code
3C is displayed.
○The data is sent through the CAN communication line.
○The service code 3C is detected with the meter unit.
○When the service code 3C is detected, the ESD indicator
[A] blinks, yellow warning indicator light (LED) [B] goes on
and code of 3C [C] displayed on the LCD.
the wiring for continuity between main harness
• Check
connectors.
• Disconnect:
ESD ECU Connector (see ESD (Electronic Steering
Damper) ECU Removal in the Steering chapter)
Meter Unit Connector (see Meter Unit Removal in the
Electrical System chapter)
Wiring Continuity Inspection
ESD ECU Connector [A] ←→ Meter Unit Connector
[B]
ESD ECU Terminal 10 [C] ←→ Meter Unit Terminal
13 [D]
ESD ECU Terminal 1 [E] ←→ Meter Unit Terminal
12 [F]
If the wiring is good, replace the ESD ECU (see ESD
(Electronic Steering Damper) ECU Removal/Installation
in the Steering chapter).
SELF-DIAGNOSIS SYSTEM 17-79
ESD ECU Communication Error (Service Code 3C)
ESD ECU Communication Line Circuit
1. ECU
2. Meter Unit
3. ESD ECU
4. Joint Connector J
5. Joint Connector K
17-80 SELF-DIAGNOSIS SYSTEM
Quick Shifter Sensor (Service Code 3E) (DTC P0826)
Quick Shifter Sensor Removal/Installation
to the Quick Shifter Sensor Removal/Installation in
• Refer
the Crankshaft/Transmission chapter.
Quick Shifter 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 quick shifter sensor lead connector [A].
the measuring adapter [A] between the main har• Connect
ness connector and quick shifter sensor connector.
Main Harness [B]
Quick Shifter Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Quick Shifter 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 standard, check the output voltage
(see Quick Shifter Sensor Output Voltage Inspection).
SELF-DIAGNOSIS SYSTEM 17-81
Quick Shifter Sensor (Service Code 3E) (DTC P0826)
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] ←→
Quick Shifter 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).
Quick Shifter Sensor Output Voltage Inspection
the output voltage at the quick shifter sensor in
• Measure
the same way as input voltage inspection, note the following.
○Disconnect the quick shifter sensor lead connector and
connect the measuring adapter [A] between these connectors.
Main Harness [B]
Quick Shifter Sensor [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Quick Shifter Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor G/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
Standard: DC 0.35 4.65 V
NOTE
○By shifting up (down) the gear, confirm the output voltage will be raise (drop).
the ignition switch off.
• Turn
If the reading is out of the standard, check the quick shifter
sensor resistance (see Quick Shifter Sensor Resistance
Inspection).
17-82 SELF-DIAGNOSIS SYSTEM
Quick Shifter Sensor (Service Code 3E) (DTC P0826)
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] ←→
Quick Shifter Sensor Connector [B]
ECU Terminal 46 [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).
Quick Shifter Sensor Resistance Inspection
the quick shifter sensor lead connector.
• Disconnect
Connect
a
digital
• connector [B]. meter [A] to the quick shifter sensor lead
• Measure the quick shifter sensor resistance.
Quick Shifter Sensor Resistance
Connections: BL/Y lead [C] ←→ G lead [D]
Standard:
209 231 kΩ
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).
Quick Shifter Sensor Circuit
1. ECU
2. Quick Shifter Sensor
SELF-DIAGNOSIS SYSTEM 17-83
Primary Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201,
P0202, P0203, P0204)
Primary Fuel Injector #1:
Primary Fuel Injector #2:
Primary Fuel Injector #3:
Primary Fuel Injector #4:
Service Code 41
Service Code 42
Service Code 43
Service Code 44
Primary Fuel Injector Removal/Installation
to the Throttle Body Assy Disassembly/Assembly
• Refer
in the Fuel System (DFI) chapter.
Primary Fuel Injector Audible Inspection
NOTE
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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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