NHTSA ID Number: 10109091
Manufacturer Communication Number: 99924-1509-03
TSB/Document Date: 2017-08-01
Summary
Service Manual
ESD Actuator Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Disconnect
the ESD actuator connector and connect a
• suitable measuring
leads [A] between these connectors
•
as shown.
Main Harness [B]
ESD Actuator [C]
Connect the peak voltage adapter [D] and a digital meter
[E] to the measuring adapter leads.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
ESD Actuator Input Voltage
Connections to Adapter:
(I) Digital Meter (+) → Actuator BK lead
Digital Meter (–) → Battery (–) Terminal
(II) Digital Meter (+) → Actuator R lead
Digital Meter (–) → Battery (–) Terminal
(III) Digital Meter (+) → Actuator O lead
Digital Meter (–) → Battery (–) Terminal
(IV) Digital Meter (+) → Actuator Y lead
Digital Meter (–) → Battery (–) Terminal
SELF-DIAGNOSIS SYSTEM 17-113
ESD Actuator Error (Service Code E2E)
the actuator input voltage with
• Measure
stopped and with the connector joined.
• Turn the ignition switch on.
the engine
Input Voltage
Standard: About DC 9 11 V and then 0.1 V or
About DC 9 11 V
• Turn the ignition switch off.
If the reading is out of the specification, remove the ESD
ECU and check the wiring for continuity between main
harness connectors.
○Disconnect the ESD ECU and actuator connectors.
Wiring Continuity Inspection
ESD ECU Connector [A] ←→
ESD Actuator Connector [B]
ESD ECU Terminal 3 [C] ←→ Actuator Terminal [D]
ESD ECU Terminal 4 [E] ←→ Actuator Terminal [F]
ESD ECU Terminal 12 [G] ←→ Actuator Terminal [H]
ESD ECU Terminal 13 [I] ←→ Actuator Terminal [J]
If the wiring is good, check the ESD ECU for its ground
and power supply (see ESD ECU Power Supply Inspection).
If the ground and power supply are good, replace the ESD
ECU (see ESD ECU Removal/Installation in the Steering
chapter).
ESD Actuator Circuit
1. ESD ECU
2. ESD Actuator
17-114 SELF-DIAGNOSIS SYSTEM
ESD ECU Error (Service Code E3B)
If this service code appears, check that the following parts
are correctly.
Crankshaft Sensor
Gear Position Sensor
Starter Lockout Switch
Throttle Position Sensor
Rear Wheel Rotation Sensor
If these parts are normal, check the ESD ECU for its
ground and power supply (see ESD ECU Power Supply
Inspection).
ESD ECU Removal
• Refer to the ESD ECU Removal in the Steering chapter.
ESD ECU Installation
• Refer to the ESD ECU Installation in the Steering chapter.
ESD ECU Power Supply Inspection
• Remove:
Upper Fuel Tank Cover (see Fuel Tank Cover Removal
•
in the Frame chapter)
Visually inspect the ESD ECU connectors.
If the connector is clogged with mud or dust, blow it off
with compressed air.
the ESD ECU connector.
• Disconnect
Visually
inspect
the terminals [A] of the ESD ECU and
• main harness connectors.
If the terminals of the main harness connector are damaged, replace the main harness.
If the terminals of the ESD ECU connector are damaged,
replace the ESD ECU.
the ignition switch off.
• Turn
Disconnect
ESD ECU connector [A].
• Set a testerthe
[B] and check the following wiring for conti• nuity.
ESD ECU Grounding Inspection
Connections:
(I) BK/Y lead (ESD ECU
terminal 9)
(II) Engine Ground
Criteria:
Both: 0 Ω
If no continuity, check the connector, 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 ESD ECU.
NOTE
○Be sure the battery is fully charged.
SELF-DIAGNOSIS SYSTEM 17-115
ESD ECU Error (Service Code E3B)
the ESD ECU connector.
• Connect
Connect
a digital meter [A] to the connector [B] with the
• needle adapter
set.
Special Tool - Needle Adapter Set: 57001-1457
ESD ECU Power Supply Inspection
Connections:
Digital Meter (+) → Terminal 18 (BR/BK)
Digital Meter (–) → Battery (–) Terminal
Ignition Switch OFF: 0 V
Ignition Switch ON: 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)
Electronic Steering Damper Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Power Source Wiring (see ESD ECU Power Source Circuit)
If the fuse and wiring are good, replace the ESD ECU (see
ESD ECU Removal/Installation in the Steering chapter).
ESD ECU Power Source Circuit
1. Engine Ground
2. Battery 12 V 8.6 Ah
3. Starter Relay
4. Main Fuse 30 A
5. Frame Ground
6. Fuse Box (1)
7. ESD Fuse 10 A
8. Ignition Switch
9. ESD ECU
17-116 SELF-DIAGNOSIS SYSTEM
ESD Calibration Error (Service Code E3F)
The ESD ECU operates the ESD actuator for initial calibration when the ignition switch is turned on. When the
ignition switch is turned on while moving the vehicle, the
ESD ECU stops the initial calibration. At this time, the ESD
indicator blinks and the yellow warning indicator light (LED)
goes on.
If this service code appears, first turn the ignition switch
off, and then back on while completely stopping the motorcycle. The ESD indicator and the yellow warning indicator light (LED) should then go off.
If they do not go off, check the ESD ECU for its ground and
power supply (see ESD ECU Power Supply Inspection in
the ESD ECU Error (Service Code E3B) section).
If the ESD ECU is normal, check the ECU for its ground
and power supply (see ECU Power Supply Inspection in
the Fuel System (DFI) chapter).
If the ECU is normal, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).
SELF-DIAGNOSIS SYSTEM 17-117
IMU (Inertial Measurement Unit) (Service Code E8E)
IMU Removal
NOTICE
Never drop the IMU especially on a hard surface.
Such a shock to the IMU can damage it.
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the IMU connector [A].
• Disconnect
Remove:
• IMU Mounting Bolts [B] and Washers
IMU [C]
IMU Installation
the IMU.
• Install
a non-permanent locking agent to the threads of
• Apply
the IMU mounting bolts, and tighten them.
Torque - IMU Mounting Bolts: 6.5 N·m (0.66 kgf·m, 58 in·lb)
the IMU connector.
• Connect
Install
the
fuel tank (see Fuel Tank Installation in the Fuel
• System (DFI)
chapter).
IMU Power Supply Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
the IMU (see IMU Removal).
•○Remove
Do not disconnect the IMU connector [A].
a digital meter [B] to the IMU connector with nee• Connect
dle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
IMU Power Supply Voltage
Connections to IMU Connector:
Digital Meter (+) → BR/W [C] lead
Digital Meter (–) → BK/Y [D] lead
the power supply voltage with
• Measure
stopped and with the connector joined.
• Turn the ignition switch on.
Power Supply Voltage
Standard: Battery Voltage
• Turn the ignition switch off.
the engine
17-118 SELF-DIAGNOSIS SYSTEM
IMU (Inertial Measurement Unit) (Service Code E8E)
If the reading is out of the specification, check the following.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
Power Source and Ground Wirings (see IMU Circuit)
If the fuses and wirings are good, replace the IMU (see
IMU Installation).
If the IMU is normal, 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).
IMU Circuit
1. ECU
2. Frame Ground
3. Main Fuse 30 A
4. Engine Ground
5. Battery 12 V 8.6 Ah
6. Starter Relay
7. Ignition Fuse 15 A
8. Fuse Box (1)
9. Ignition Switch
10. IMU
11. Joint Connector J
12. Joint Connector K
SELF-DIAGNOSIS SYSTEM 17-119
IMU (Inertial Measurement Unit) Communication Error (Service Code E8F)
IMU Communication Line Inspection
○When the data (for status of IMU) is not sent from the IMU
to the ECU, the service code E8F is displayed.
○The data is sent through the CAN communication line.
○The service code E8F is detected with the ECU.
○When the service code E8F is detected, the IMU indicator
[A] blinks, yellow warning indicator light (LED) [B] goes on
and code of E8F [C] displayed on the LCD.
the ECU and IMU connectors, and check the
• Disconnect
wiring for continuity between main harness connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→ IMU Connector [B]
ECU Terminal 60 [C] ←→ IMU Terminal [D]
ECU Terminal 61 [E] ←→ IMU Terminal [F]
If the wiring is good, replace the IMU (see IMU Installation).
If the IMU is normal, 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).
17-120 SELF-DIAGNOSIS SYSTEM
IMU (Inertial Measurement Unit) Communication Error (Service Code E8F)
IMU Circuit
1. ECU
2. Frame Ground
3. Main Fuse 30 A
4. Engine Ground
5. Battery 12 V 8.6 Ah
6. Starter Relay
7. Ignition Fuse 15 A
8. Fuse Box (1)
9. Ignition Switch
10. IMU
11. Joint Connector J
12. Joint Connector K
SELF-DIAGNOSIS SYSTEM 17-121
ABS Service Codes (ZX1000S/Z)
Solenoid Valve Inspection (Service Code B13,
B14, B17, B18)
○The solenoid valve is built in the ABS hydraulic unit [A].
•
Therefore the solenoid valve cannot be checked directly.
Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider in the Brakes chapter).
If any of these service codes appears even if all checks
are ended, replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
ABS Solenoid Valve Relay Inspection (Service
Code B19)
○The ABS solenoid valve relay is built in the ABS hydraulic
•
unit. Therefore the relay cannot be checked directly.
Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider in the Brakes chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
Front, Rear Wheel Rotation Difference Abnormal
Inspection (Service Code B25)
the following and correct the faulty part.
• Check
Incorrect Tire Pressure
Tires not recommended for the motorcycle were installed
(incorrect tire size).
Deformation of Wheel or Tire
Missing Teeth or Clogging with Foreign Matter of Sensor
Rotor (see Wheel Rotation Sensor Rotor Inspection in
the Brakes chapter)
If the all parts corrected, go to next step.
the Pre-Diagnosis Inspection 1 and 2 (see In• Perform
quiries to Rider in the Brakes chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
ABS Motor Relay Inspection (Service Code B35)
the ABS motor relay fuse (25 A) [A] (see Fuse
• Check
Inspection in the Electrical System chapter).
If the fuse is good, check the wiring continuity as follows.
○Disconnect:
Battery Positive Cable (see Battery Removal in the Electrical System chapter)
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal in the Brakes chapter)
17-122 SELF-DIAGNOSIS SYSTEM
ABS Service Codes (ZX1000S/Z)
○Check the wiring continuity between the positive cable
terminal [A] of the battery and R/W lead terminal [B] in
the ABS hydraulic unit connector [C].
If the wiring is open, replace or repair the harness (see
ABS System Circuit in the Brakes chapter).
If the wiring is good, go to next step.
○The ABS motor relay is built in the ABS hydraulic unit.
•
Therefore the relay cannot be checked directly.
Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider in the Brakes chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
Front Wheel Rotation Sensor Signal Abnormal
(Service Code B42)
the air gap between the front wheel rotation sen• Measure
sor and sensor rotor.
Thickness Gauge [A]
Air Gap
Standard:
0.4 1.6 mm (0.02 0.06 in.)
If the measurement is not the standard, check each part
for deformation and looseness and correct accordingly.
If the measurement is the standard, go to next step.
that there is iron or other magnetic deposits be• Check
tween the sensor and sensor rotor, and the sensor rotor
•
•
•
slots for obstructions.
Check the installation condition of the sensor for looseness.
Check the sensor and sensor rotor tip for deformation or
damage (e.g., chipped sensor rotor teeth).
If the sensor and sensor rotor in bad condition, remove
the any deposits. Install the proper part or replace faulty
part.
If the all items are good, go to next step.
Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider in the Brakes chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
SELF-DIAGNOSIS SYSTEM 17-123
ABS Service Codes (ZX1000S/Z)
Front Wheel Rotation Sensor Wiring Inspection
(Service Code B43)
the front wheel rotation sensor lead connec• Disconnect
tor [A] (see Front Wheel Rotation Sensor Removal in the
Brakes chapter).
the ABS hydraulic unit connector (see ABS
• Disconnect
Hydraulic Unit Removal in the Brakes chapter).
the wiring continuity of the W/BK lead and BK/W
• Check
lead.
Front Wheel Rotation Sensor Lead Connector [A]
ABS Hydraulic Unit Connector [B]
W/BK Lead Terminals [C]
BK/W Lead terminals [D]
If the wiring is open, replace or repair the harness (see
ABS System Circuit in the Brakes chapter).
If the wiring is good, go to next step.
the Pre-Diagnosis Inspection 1 and 2 (see In• Perform
quiries to Rider in the Brakes chapter).
•
If this service code appears even if all checks are ended,
replace the front wheel rotation sensor (see Front Wheel
Rotation Sensor Removal in the Brakes chapter).
Still, when it is not good, replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
Rear Wheel Rotation Sensor Signal Abnormal
(Service Code B44)
the air gap between the rear wheel rotation sen• Measure
sor and sensor rotor.
Thickness Gauge [A]
Air Gap
Standard:
0.4 1.6 mm (0.02 0.06 in.)
If the measurement is not the standard, check each part
for deformation and looseness and correct accordingly.
If the measurement is the standard, go to next step.
that there is iron or other magnetic deposits be• Check
tween the sensor and sensor rotor, and the sensor rotor
•
•
slots for obstructions.
Check the installation condition of the sensor for looseness.
Check the sensor and sensor rotor tip for deformation or
damage (e.g., chipped sensor rotor teeth).
If the sensor and sensor rotor in bad condition, remove
the any deposits. Install the proper part or replace faulty
part.
If the all items are good, go to next step.
17-124 SELF-DIAGNOSIS SYSTEM
ABS Service Codes (ZX1000S/Z)
the Pre-Diagnosis Inspection 1 and 2 (see In• Perform
quiries to Rider in the Brakes chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
Rear Wheel Rotation Sensor Wiring Inspection
(Service Code B45)
the rear wheel rotation sensor lead connec• Disconnect
tor [A] (see Rear Wheel Rotation Sensor Removal in the
Brakes chapter).
the ABS hydraulic unit connector (see ABS
• Disconnect
Hydraulic Unit Removal in the Brakes chapter).
the wiring continuity of the BK/O lead and W/G
• Check
lead.
Rear Wheel Rotation Sensor Lead Connector [A]
ABS Hydraulic Unit Connector [B]
BK/O Lead Terminals [C]
W/G Lead terminals [D]
If the wiring is open, replace or repair the harness (see
ABS System Circuit in the Brakes chapter).
If the wiring is good, go to next step.
the Pre-Diagnosis Inspection 1 and 2 (see In• Perform
quiries to Rider in the Brakes chapter).
•
If this service code appears even if all checks are ended,
replace the rear wheel rotation sensor (see Rear Wheel
Rotation Sensor Removal in the Brakes chapter).
Still, when it is not good, replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
Power Supply Voltage Inspection (Low-Voltage)
(Service Code B52)
the battery condition (see Charging Condition In• Check
spection in the Electrical System chapter).
If the battery is good condition, perform the Pre-Diagnosis
Inspection 1 and 2 (see Inquiries to Rider in the Brakes
chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
SELF-DIAGNOSIS SYSTEM 17-125
ABS Service Codes (ZX1000S/Z)
Power Supply Voltage Inspection (Over-Voltage)
(Service Code B53)
the charging voltage (see Charging Voltage In• Check
spection in the Electrical System chapter).
If the charging voltage is good, perform the Pre-Diagnosis
Inspection 1 and 2 (see Inquiries to Rider in the Brakes
chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
ECU Inspection (Service Code B55)
○This ECU is built in the ABS hydraulic unit. Therefore the
•
ECU cannot be checked directly.
Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider in the Brakes chapter).
If this service code appears even if all checks are ended,
replace the ABS hydraulic unit.
If the service code does not appear, the ABS system normal (temporary failure).
CAN Communication (Transmission)/CAN
Bus OFF Monitor Inspection
(Service Code B57)
CAN Communication (Reception)
Monitor Inspection (Service Code B58)
• 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)
Immobilizer (Equipped Models)/Kawasaki
Diagnostic
System Connector Cap [A]
the CAN communication line resistance.
• Measure
Immobilizer (Equipped Models)/Kawasaki Diagnostic
System Connector [A]
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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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