Мануал на кавасаки z1000

Z1000 Motorcycle Service Manual

Quick Reference Guide This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact

Z1000 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s)

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper

NOTE ○This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done. ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a

GENERAL INFORMATION 1-1 General Information 1 Table of Contents Before Servicing ……………………………………………………………………………………………………… Model

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions

GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including

1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating

GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed

1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is

GENERAL INFORMATION 1-7 Model Identification ZR1000–A1 Left Side View: ZR1000–A1 Right Side View:

1-8 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 770 mm (30.3 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 420 mm (55.9 in.) Road clearance 145 mm (5.7 in.) Seat height 820 mm (32.3 in.) Dry mass 198 kg (410.1 lb)

GENERAL INFORMATION 1-9 General Specifications ZR1000–A1 ∼ Items Lubrication system Engine oil: Type Viscosity Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th 6th Final drive system: Type Reduction ratio Overall

1-10 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Tail/brake light 12 V 0.5/3.8 W (LED) (US, CA, Cal) 12 V 0.5/5W (LED) Alternator: Type Three-phase AC Rated output 24 A/ 14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Subthrottle Control System The ZR1000–A1 ∼ employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a

1-12 GENERAL INFORMATION Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body. The

GENERAL INFORMATION 1-13 Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs

1-14 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5

GENERAL INFORMATION 1-15 Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor GaAsP, GaAlAs Emitting Color Red GaP Green GaN Blue Ga: Gallium As:

1-16 GENERAL INFORMATION Technical Information — KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst protection system, according to each regulation of different countries. The

GENERAL INFORMATION 1-17 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro Symbol M k c m µ Units of Length: × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Mass: kg g × × 2.205 0.03527 = = lb oz = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US)

PERIODIC MAINTENANCE 2-1 Periodic Maintenance 2 Table of Contents Periodic Maintenance Chart ………….. Torque and Locking Agent…………….. Specifications ……………………………… Special Tools ………………………………. Periodic Maintenance Procedures….. Fuel

2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever comes first → ↓ OPERATION Spark plug

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first → ↓ OPERATION Clutch-adjust † Every Radiator hoses, connections — inspect † Brake fluid — change Brake master cylinder cup and dust seal — replace 2 years Coolant — change 2 years Caliper piston seal and dust seal

2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non -permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. G: Apply

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Water pump drain bolt Water pipe bolts Thermostat housing ground bolt Thermostat bracket bolt Radiator upper bolts Radiator lower bolts Radiator screen bolt Coolant reserve tank screws Radiator fan switch Water temperature sensor Engine Top

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Engine Lubrication: Oil filler plug Engine drain plug Oil filter (cartridge type, P/No.16097–1070) Oil filter (cartridge type, P/No.16097–0002) Oil cooler mounting bolt Oil pan bolts Oil pipe holder bolts Oil pressure relief valve Oil

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Wheels/Tires: Front axle clamp bolt Front axle Rear axle nut Final Drive: Engine sprocket nut Engine sprocket cover bolts Engine sprocket cover damper bolt Rear sprocket nuts Speed sensor bolt Brakes: Bleed valves Front brake hose joint

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Handlebar lower clamp nuts Handlebar switch housing screws Frame: Footpeg holder bolts Muffler mounting bolts Side stand bolt Side stand switch bolt Windshield screws Front fender bolts Electrical System: Spark plugs Alternator rotor bolt

PERIODIC MAINTENANCE 2-9 Specifications Item Fuel System: Throttle grip free play Idle speed Bypass screws (turn out) Engine vacuum Air cleaner element Cooling System: Coolant: Type (recommended) Color Mixed ratio Freezing point Total amount Engine Top End: Valve clearance Inlet Exhaust Clutch:

2-10 PERIODIC MAINTENANCE Specifications Item Air pressure: (when cold) Front Rear Final Drive: Drive chain slack Drive chain (20-link length) Brakes: Brake fluid: Grade Brake pad lining thickness: Front Rear Brake light timing: Front Rear Electrical System: Spark plug gap AT: Republic of Austria

PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench: 57001–1100 Pilot Screw Adjuster, C: 57001–1292 Jack: 57001–1238 Hand Tester: 57001–1394 Oil Filter Wrench: 57001–1249 Spark Plug Wrench (Owner’s Tool): 92110–1132

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable (see below). • Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) that

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Bore Cleaning Check the throttle bore for cleanliness as follows: ○Remove the throttle body assy (see Fuel System (DFI) chapter). ○Check the main throttle valves and throttle bores [A] for carbon deposits by opening the main valves.

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. the motorcycle so that it is vertical. • Situate Remove fuel tank (see

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures the fuel tank (see Fuel System (DFI) chapter). • Install Start the and warm it up thoroughly. • Check theengine idle speed. • Tachometer [A] If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Special Tool — Pilot Screw Adjuster, C: 57001-1292 the lowest vacuum between #1 and #2 to the high• Adjust est of

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures out the same number of turns counted when first • Back turned in. This is to set the screw to its original position. NOTE ○A throttle body has different “turns out” of the bypass screw for each individual unit. When setting the bypass screw,

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○In dusty areas, the element should be cleaned more frequently than the recommended interval. ○After riding through rain or on muddily roads, the element should be cleaned immediately. WARNING If dirt or

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures the element by tapping it lightly to loosen dust. • Clean Blow away the remaining dust by applying compressed • air [A] from the outside to the inside (from the clean side • to the dirty side). Visually inspect the element for no tears or no

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures ○Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. Front [B] ○Visually inspect the separator for cracks and other damage. If the separator has any cracks or damage, replace it with a new

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures the fuel tank (see Fuel System (DFI) chapter). • Remove Remove the radiator cap [A] in two steps. First turn the • cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○The coolant

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures the air bleeder bolt [A] on the thermostat housing. • Loosen Front [B] the coolant into the radiator until the coolant • Replenish begins to flow out the air bleeder bolt hole (that is, all the • remaining air is forced out). Tap the

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Removal)

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Valve Clearance Adjustment change the valve clearance, remove the camshaft • To chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○Mark and record the valve lifter and shim locations so

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Adjust Inspection the clutch lever just enough to take up the free play • Pull [A]. the gap between the lever and the lever holder. • Measure If the gap is too wide, the clutch may not release fully. If the gap is too narrow,

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change the motorcycle so that it is vertical after warming • Situate up the engine. the engine drain plug [A] to drain the oil. •○Remove The oil in the oil filter can be drained by removing the filter •

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Tire Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90 % of all tire failures occur during the last 10 % of tread life (90 % worn). So it is false

PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Air Pressure Inspection/Adjustment the air valve cap. • Remove the tire air pressure with an air pressure gauge • Measure [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures both chain adjuster locknuts securely. • Tighten Tighten the axle nut. • Torque — Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) the wheel, measure the chain slack again at the tight• Turn est position, and readjust if necessary. • Insert a new

PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures the rear wheel to inspect the drive chain for dam• Rotate aged rollers, and loose pins and links. • • If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. Stretch the chain taut by hanging a 98

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures oil to the sides of the rollers so that oil will penetrate • Apply to the rollers and bushings. Apply the oil to the O-rings so • that the O-rings will be coated with oil. Wipe off any excess oil. Oil Applied Areas [A] O-ring [B] Brakes

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • If it does not, adjust and inspect the brake light switch. While holding the switch body, turn the adjusting nut [A] to adjust the switch. CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) the front and rear master cylinders. • Disassemble there are no scratches, rust or pitting on the that • Check inner wall [A] of each master cylinder and on the outside • of each piston [B]. If

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Level Inspection that the brake fluid level in the front brake reservoir • Check [A] is above the lower level line [B]. NOTE ○Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures the brake fluid reservoir. • Level Remove reservoir cap and diaphragm. • Remove the the • caliper. rubber cap from the bleed valve [A] on the a clear plastic hose [B] to the bleed valve, and run • Attach the other end of the hose into a

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures the brake line and the caliper: •○Bleed Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B]

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures WARNING When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types

2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check inspect the front forks [A] for oil leakage, scoring • Visually or scratches on the outer surface of the inner tubes. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak

PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Steering Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool — Jack: 57001–1238 the front wheel pointing straight ahead, alternately • With tap each end of the handlebar. The front wheel should • swing

2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool — Steering Stem Nut Wrench: 57001–1100 [B] If the steering is too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn. NOTE ○Turn

PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures the thermostat bracket bolt [A]. •○Unscrew If removing the spark plug #2 or #3. • Disconnect: Stick Coil Connectors [A] Pull the stick coil #1 [B]. • Takeout out the camshaft position sensor connector [C] from • the bracket. • Pull out the

2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures the spark plug, preferably in a sandblasting device, • Clean and then clean off any abrasive particles. The plug may • also be cleaned using a high-flash point solvent and a wire brush or other tool. If the spark plug center electrode [A]

PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures General Lubrication Lubrication lubricating each part, clean off any rusty spots with • Before rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. ○Whenever NOTE the

2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection the tightness of the bolts and nuts listed here. Also, • Check check to see that each cotter pin is in place and in good condition. NOTE ○For the engine fasteners, check the tightness of

FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View…………………………….. DFI Parts Location……………………….. DFI Wiring Diagram ……………………… Specifications ……………………………… Special Tools

3-2 FUEL SYSTEM (DFI) ECU Installation ……………………… ECU Power Supply Inspection….. DFI Power Source ……………………….. ECU Fuse Removal ………………… ECU Fuse Installation ……………… ECU Fuse Inspection ………………. ECU Main Relay Removal

FUEL SYSTEM (DFI) 3-3 Exploded View Clifornia Evaporative Emission Control System 1. Canister 2. Separator 3. Right fitting of throttle body #2 4. Right fitting of throttle body #3 5. Canister purge hose (green) 6. Fuel return hose (left, red) 7. Fuel tank breather hose (right, blue) 8. Separator

3-4 FUEL SYSTEM (DFI) Exploded View

FUEL SYSTEM (DFI) 3-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Throttle cable plate bolt 6 0.6 52 in·lb 2 Throttle body cover bolts 7 0.7 61 in·lb 3 Throttle assy holder clamp bolts 2 0.2 17 in·lb 4 Choke link holder screws 2.1 0.21 18 in·lb 5 Delivery pipe screws 3.4 0.35 30 in·lb 6

3-6 FUEL SYSTEM (DFI) Exploded View

FUEL SYSTEM (DFI) 3-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Inlet air pressure sensor bolt 12 1.2 104 in·lb 2 Water temperature sensor 25 2.5 18 3 Vehicle downsensor bolts 2 0.2 17 in·lb 4 Camshaft position sensor bolt 12 1.2 104 in·lb 5 Camshaft position sensor rotor bolt 12 1.2 104

3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) F: Front 1. Water temperature Sensor (DFI) 2. Inlet Air Pressure Sensor (DFI) 3. Injectors (DFI) 4. Fuel Pump (DFI) 5. Inlet Air Temperature Sensor (DFI) 6. Sealed Battery 7. Junction Box 8. 9. 10. 11. 12. 13. 14. 15. ECU Fuse

FUEL SYSTEM (DFI) 3-9 DFI Parts Location [1], [2], [10], [13], [22] and [24] are not included.

3-10 FUEL SYSTEM (DFI) DFI Wiring Diagram

FUEL SYSTEM (DFI) 3-11 DFI Wiring Diagram Terminal Names 1. Power Supply to Sensors (inlet air pressure, atmospheric pressure, and throttle sensors) from ECU. 2. Main Throttle Sensor Signal 3. Subthrottle Sensor Signal for ECU 4. Atmospheric Pressure Sensor Signal 5. Water Temperature Sensor Signal

3-12 FUEL SYSTEM (DFI) Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Usable engine speed Fuel Pressure (high pressure line): Right after Ignition switch ON After 3 sec from Ignition switch ON With engine idling Fuel

FUEL SYSTEM (DFI) 3-13 Specifications Item Detection time Output voltage Subthrottle Sensor: Input Voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Subthrottle Valve Actuator: Resistance Input voltage Throttle Grip and Cables Throttle grip free play

3-14 FUEL SYSTEM (DFI) Special Tools Oil Pressure Gauge: 57001–125 Fuel Pressure Gauge Adapter: 57001–1417 Carburetor Drain Plug Wrench, Hex 3: 57001–1269 Needle Adapter Set: 57001–1457 Fork Oil Level Gauge: 57001–1290 Throttle Sensor Setting Adapter: 57001–1538 Hand Tester: 57001–1394 Sensor

FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a

3-16 FUEL SYSTEM (DFI) DFI Servicing Precautions ○To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Clutch Cover [B] Front [C] Torque — Oil Filler Plug: 1.5 N·m (0.15 kgf·m, 13

FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indicator LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control

3-18 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○The DFI part connectors [A] have seals [B], including the • ECU. Join the connector and insert the needle adapters (special tool) [C] inside the seal [B] from behind the connector until the adapter reaches the terminal. Special Tool — Needle

FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System each connector [A] apart and inspect it for corrosion, • Pull dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. Check the wiring for continuity. ○Use the

3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output

FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○Try to find out exactly what problem occurred under exactly what

3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Model: Registration No. (license plate No.): Year of initial registration: Engine No.: Date problem occurred: Frame No.: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □

FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Poor running at low speed □ choke lever pulled out fully (push it in fully) □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idle speed □ battery voltage is low (charge the battery) □ spark plug

3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant as a rough guide to assist the troubleshooting for some of the more common difficulties. simply ○The ECU may be involved in the DFI

FUEL SYSTEM (DFI) 3-25 DFI System Troubleshooting Guide Symptoms or possible Causes Ignition and engine stop switches not ON Clutch lever not pulled in and gear not in neutral whether sidestand up or not Though clutch lever pulled in, sidestand up and gear not in neutral Vehicle-down sensor coming

3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Piston ring /groove clearance excessive Cylinder head gasket damaged Cylinder head warped No valve clearance Valve guide worn Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon

FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes Atmospheric pressure sensor trouble Fuel pressure too low or too high Battery voltage low Incorrect idle speed : Water temperature sensor trouble Main throttle sensor trouble Engine stalls easily : Fuel pump trouble

3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Subthrottle sensor trouble Subthrottle valve actuator trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor

FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Spark plug dirty, broken or gap maladjusted Too low fuel pressure Fuel pump trouble Main throttle sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor

3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Firing incorrect : Spark plug dirty, broken or maladjusted Spark plug cap trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble

FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil

3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Too low fuel pressure Water temperature sensor trouble Inlet air temperature sensor trouble Actions (chapter) Inspect fuel line and fuel pump (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace

FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode: The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when

3-34 FUEL SYSTEM (DFI) Self-Diagnosis enter the self-diagnosis dealer mode 2, open [B] and • To ground [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds. ○Count the blinks of the LED light

FUEL SYSTEM (DFI) 3-35 Self-Diagnosis

3-36 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○Read 10th digit and unit digit as the FI indicator LED light blinks. ○When there are a number of problems, all the service

FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table Service Code FI Indicator LED Light 11 Problems Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water

3-38 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Codes Parts 11 Main Throttle Sensor 12 Inlet Air Pressure Sensor 13 14 15 21 23 24 and 25 31 32 Inlet Air Temperature Sensor

FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Codes 51 52 53 54 62 Output Signal Usable Range or Criteria The stick coil primary Stick Coil winding must send #1 (Ignition signals (output voltage) Coil)* continuously to the ECU. The stick coil primary Stick Coil winding must send #2 (Ignition

3-40 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to

FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection the output voltage at the main throttle sensor • Measure in the same way as input voltage inspection, Note the • following. Disconnect the main throttle sensor (gray) [A] and connect the harness adapter [B]

3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection the ignition switch OFF. • Turn the main throttle sensor connector. • Disconnect a digital meter [A] to the main throttle sensor • Connect connector [B]. • Measure the main throttle sensor resistance. Main Throttle

FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel Tank (see Fuel System chapter) • Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B]

3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○The output voltage changes according to the local atmospheric pressure. the output voltage at the ECU in the same way • Measure as input voltage inspection. Note the following. Inlet Air Pressure

FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) ○Turn the ignition switch ON. ○Measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. ○Check the inlet air pressure sensor output voltage, using the

3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 24 ∼ 55 cmHg

FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (absolute) Ps: Standard Atmospheric Pressure (absolute) A. ECU C. Inlet Air Pressure Sensor ID: Idling TO:

3-48 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal). • Remove the connector [A] from the inlet air tempera• Disconnect

FUEL SYSTEM (DFI) 3-49 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection the inlet air temperature sensor (see this sec• Remove tion). the sensor [A] in a container of machine oil so • Suspend that the heat-sensitive portion is submerged. a thermometer [B] with the

3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal). • Remove the coolant about 200 mL (6.76 US oz). • Drain the sensor

FUEL SYSTEM (DFI) 3-51 Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection the water temperature sensor (see this section). • Remove Refer to the System chapter for water temper• ature sensorElectrical

3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○The atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure

FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection the output voltage at the ECU in the same way • Measure as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU

3-54 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) H: Altitude (m or feet) A. ECU E. Atmospheric Pressure Sensor ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)

FUEL SYSTEM (DFI) 3-55 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of

3-56 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic