ELECTRONIC Kawasaki FUEL INJECTION
Contents
1. ELECTRONIC FUEL INJECTION S G Xa TROUBLESHOOTING MANUAL FOREWORD This manual covers the recommended troubleshooting procedures for Kawasaki Electronic Fuel Injection It contains no disassembly and assembly repair or other maintenance infor mation and is designed to be used in conjunction with the service manual covering the model being worked on Remember that the operation of the Electronic Fuel Injection system is directly related to exhaust emissions and that the system must not be altered in any way READ THE EMISSIONS INFORMATION ON THE FRONT OF THE SERVICE MANUAL FOR THE MODEL BEING WORKED ON Before troubleshooting the Kawasaki Electronic Fuel Injection system check the following and replace add adjust or repair if necessary There is sufficient fuel in the tank Correct amount of specified engine oil is in the engine Fuses are not blown out The engine is cranked normally with the starter motor Cylinder compression spark plugs valve clearance are normal and items other than fuel injection system related items are normal NOTE Measure the cylinder compression in the same way as for a carburetor model with the following exception To stop fuel injector operation during the compression test dis connect the white red lead which connects the battery positive terminal to the fuel injection system harness under the left side cover The oil filler cap breather hose and s2. 72 F 2 1 to 2 9 KQXlat 20 C 72 F Turn page to TEST 13 Replace the Air Flow Meter 29 ENGINE TEMPERATURE SENSOR TEST 3 INSPECTION 78 Remove the fuel tank e Turn off the ignition switch and disconnect the lead of the engine temperature sensor GRAY SENSOR LEAD aa me i e Measure the resistance of the sensor with an ohmeter Make the connections as shown at right 2 1 to 2 9 KQ at 20 C 72 F Less than 2 1 or more than 2 9 Replace Engine Temperature Turn page to TEST 14 Sensor 31 THROTTLE VALVE SWITCH TEST 14 INSPECTION l e Turn off the ignition switch and disconnect the 3 pin f ml connector from the throttle valve switch Er E y T F d a a F y ie l E F eee THROTTLE VALVE SWITCH B dho ai ii e Connect an ohmeter to the throttle valve switch as shown at right STEP 1 Make connections shown at right Move throttle Throttle Released 09 Throttle Released greater than 00 Throttle fully open less thanocof Throttle fully open ell Go to STEP 2 STEP 2 Make connections shown at right Move throttle Replace Throttle Valve Switch Throttle released less than Q STEP 2 Throttle fully open greater than 02 Throttle released coll Throttle fully open 092 Turn page to TEST 15 RX100 m ohms Replace Throttle Valve Switch 3
3. parts and go back to Vacuum Replace pressure Regulator and TEST 7 page 19 Hose go back to TEST 7 page 19 a Tank Check for Obstructions 4 1 aaa f i l LI il 29 Filter ae ahan io for m Pressure too low start here e Check fuel hose from fuel tap to pump inlet for obstructions e Check high pressure fuel lines for leaks No leaks or obstructions Leaks or obstructions Go to top of page 47 Replace problem parts and go back to TEST 7 page 19 46 Pressure too low continued e Plug or clamp return line to fuel tank and repeat TEST 7 Replace regulator Replace fuel pump Pressure okav or too high 47 48 THROTTLE VALVE TEST 22 SVNCHRONIZATION INSPECTION If one of the throttle valves is replaced or if combustion varies from cylinder to cylinder synchronize the throttle valves NOTE These procedures are explained on the assump tion that the intake and exhaust systems of the engine are in good condition Checking engine vacuum e Warm up the engine thoroughly e Remove the fuel tank and put it on the work bench near the motorcycle on the same level as the original posi tion f e Pull off the two vacuum hoses for the pressure regula tor and the two rubber caps from the fittings on the throttle valves e Attach the vacuum gauge special tool to the fittings e Usi
4. 3 HARNESS TEST 15 INSPECTION lf each component checks out good upon individual inspection but the system does not work well when they are connected together inspect the harness for the Electronic Fuel Injection system as follows oe e Remove the harness k e Make sure all connectors are clean and tight Examine wires for signs of burning fraying etc e Check conductivity of the wires in the harness Both ends of the same color wire should conduct e Check the O ring in the multi pin connectors for damage and check the retaining clip ot the connector for deformation Harness is in good condition Harness is in poor condition Turn page to TEST 16 Replace the Fuel Injection Wiring Harness 35 THROTTLE VALVES LINK MECHANISM INSPECTION e Check the throttle valve and the fast idle link mechan ism for smooth operation Throttle valves and fast idle mechanism work smoothly Throttle valves or link mechanism bind or do not operate properly Turn page to TEST 17 Replace the problem parts and go to TEST 22 page 37 AIR LEAK INSPECTION e Inspect the connections between the parts shown for air leaks No air leaks Replace Control Unit Air Leak Inspection 1 Air Cleaner Element 8 Pressure Regulator 15 Breather Hose 2 Rubber Fitting 9 Vacuum Hoses 16 Air Cleaner Housing 3 Air Flow Meter 10 Rubber Caps on hose fittings 17 Dr
5. EST 2 page 9 No battery voltage Go to TEST 4 page 13 and TEST 3 page 11 43 FUEL INJECTER SIGNAL TEST 20 INSPECTION WARNING fi Do not attempt to start the engine while the fuel hoses are disconnected fuel will spout from the fuel line if vou attempt to start the engine with the fuel hoses disconnected Remove the fuel tank and disconnect all of the 2 pin connectors from all the injectors Yellow Red White To By Harness I ES 2 PIN CONNECTOR E Injector Connector e install the fuel tank and connect the fuel hoses to the tank e Make the connections shown at right The white red leads in the 2 pin connec i tors are connected directiv to the bat terv i iettive terminal even when the ignition siwtch 10 is off so take care not to short the test leads to the ii VDC chassis ground oe e Crank the engine with the starter motor and watch meter needle Meter needie flickers at regular Meter needle does not flicker at intervals regular intervals Replace injector Check wiring and connectors REPEAT TEST FOR ALL INJECTORS 45 PRESSURE REGULATOR TEST 21 INSPECTION Pressure too high start here e Check the fuel return line for obstructions Fuel e Check the vacuum hose for air leaks Returii Line Fuel Return Line open and no air Fuel Return Line clogged or Vacuum Hose leaking leaks Regulator Replace bad
6. ain Plug 4 Rubber Seal 11 Fuel Injectors 18 Breather Cover 5 Surge Tank 12 Cylinder Head 19 Oil Filler Cap 6 Ait Ducts 13 Throttle Valve Holders 20 Oil Seal on crankshaft 7 3 Way Joint 14 Throttle Valves right end 21 Others mating surfaces etc 39 OUT OF CIRCUIT FUEL PUMP TEST 8 INSPECTION i e Disconnect the 2 pin connector of the fuel pump under the left side cover Orange Black k I Black Yellow qa a i a To Fuel Pump z 6 D 2 PIN i sa CONNECTOR MT son HA e Connect a 12 volt battery to the 2 pin connector pump side and check whether the pump operates Pump runs Pump does not run Turn page to TEST 19 Check pump leads and rep lace problem parts Repeat TEST 18 41 FUEL PUMPCIRCUIT TEST 19 INSPECTION 9 Remove the air cleaner element Connect a voltmeter to the 2 pin connector harness side as shown at right Black Yellow Orange Black To Harness E Ae h at i i S aa jaqa KT Al i 7 mai ese F 2 PINI jag 4 Fuel A CONNECTOR g f Pump ee ee Connector STEP 1 e Ignition switch ON et Starter Button Pushed S ae Clutch lever Pulled it Battery voltage 12 to 14 volts No battery voltage Wa sA Go to TEST 2 page 9 and TEST 3 page 11 STEP 2 e Ignition Switch ON e Air Flow Meter Flap Pushed ZO Battery voltage 12 to 14 volts Go to T
7. ctors click regularly One or more injectors does not click regularly Go to TEST 20 page 45 4 Turn page to TEST 7 NOTE 1 The interval between clicking sounds becomes shorter as the engine speed rises 2 If the engine does not start perform this inspection while cranking the engine with the starter motor 17 FUEL PRESSURE INSPECTION e Pull the right side cover off and disconnect the high pressure fuel hose from the fuel pump outlet WARNING When the fuel hose is pulled off a small amount of fuel may spout out because of residual pressure in the fuel line Cover the hose con nection with a clean cloth to prevent the fuel from flving about e Install the pressure gauge special tool between the fuel pump and the hose disconnected using the Re adapter special tool and high pressure fuel hose AVERAGE READING Tighten the hose clamps in the correct position PRESSURE GAUGE PRESSURE GAUGE P N 57001 1089 is 3 je ar iFUEL HOSE l mAn D mra i ates St Se Install the fuel tank WARNING e Start the engine and read the gauge TO INJECTORS Do not attempt to start the engine while the fuel hoses are disconnected Engine idling gauge reads 2 2 to 2 4 kg em 31 to 34 psi Pressure is too low or too high The moment the throttle is fully opened the gauge reads 2 4 to 2 6 kg cm 34 to 37 psi If engine will not star
8. elease air flap Less than oo RX10 ohms Replace the air flow meter Replace the air flow meter Go to Step 2 13 IGNITION SIGNAL INSPECTION Remove the fuel tank Fae Turn off the ignition switch DE Disconnect the Electronic Control Unit Les Ball i Hi Mi ji STEP 1 ki e GREEN COILS e Attach a voltmeter to the green coil primary lead and ie A Fi f BLACK then to the black Boece EA Turn on the ignition and activate the starter ATT AI starr ma TO IC Meter shows battery voltage and Meter shows zero volts on one or IGNITER flickers regulariv on both wires both wires Troubleshoot Ignition Svstem according to the Service Manual STEP 2 e Attacha voltmeter to the green wire and then the black in the ECU connector 0 Turn on the ignition and activate the starter TO FRAME Meter shows zero volts on one or both wires Meter shows battery voltage and flickers regularly on both wires Check the wiring to the IC Igniter from the ECU and troubleshoot the Ignition System according to the Service Manual Turn page to TEST 6 FUEL INJECTOR SOUND INSPECTION Start the engine Place the tip of a screwdriver against one of the injec tors Put your ear on the grip end and listen to check whether the injector is clicking or not Do the same for the other injectors Sound Inspection inje
9. er Installation 1 Good 2 Wrong To Fuel l Pump RAE Sp 23 AIR FLOW METER FLAP INSPECTION Remove the air flow meter e Check the air flamp movement by pushing it from the air cleaner side BAIR FLOW METER _ Flap swings smoothly without Flap does not move smoothly or binding returns to rest position does not return to the closed by itself position by itself Turn page to TEST 11 Replace Air Flow Meter 25 AIR FLOW METER POTENTIOMETER INSPECTION TEST 11 Turn off the ignition switch e Disconnect the 7 pin connector from the air flow meter STEP 1 Air Flow Meter Terminals Top Lf Et ta H 39 36 6 9 HB 7 27 Da Ge Se ee ee Bottom Less than 350 or more than 4000 Replace air flow meter 350 to 4000 Top Ba 39 36 6 9 8 E 27 w a Bottom STEP 2 Air Flow Meter Terminals STEP 2 Make the connections shown at right Oor o flap in any position Replace air flow meter Any values other than O or co Q with flap in any position Turn page to TEST 12 27 AIR TEMPERATURE SENSOR INSPECTION lt Turn off the ignition switch and disconnect the 7 pin connector from the air flow meter Connect an ohmeter to the air flow meter terminals as shown at right Less than 2 1 or greater than 2 9 Kat 20 C
10. ng suitable hoses connect the fuel tap to the fuel filter and the check valve to the pressure regulator e Start the engine and let it idle Adjust the idle speed Note the gauge readings All cylinders are within 3 cm Hg of One or more cvlinders are more each other than 3 cm Hg away from the F others Throttles are synchronized Synchronize throttles page 49 THROTTLE VALVE SYNCHRONIZATION PROCEDURE Stop the engine 7 To change the vacuum open the throttle loosen the locknut and turn the balance adjusting screw NOTE 1 Loosen the locknut with the throttle valves opened NOTE 2 First synchronize the left two or ew I cylin ders by means of the adjusting screw or between No 1 and No 2 cylinders or No 3 and No 4 cylinders Then synchronize the left two cylinders and the right two_cylinders using the center adjusting screw 3 Adjust the idle speed as necessary e Tighten the locknuts e Open and close the throttle a few times to make sure that the throttle valves are synchronized Readjust if necessary e Install all parts previously removed and adjust the idle speed F ik LI Adjusting Screw for Svnchronization 1 Left Adjusting Screw 3 Center Adjusting Screw 2 Right Adjusting Screw Turn this screw clock Turn this screw clock Turn this screw clock wise to lower No 1 wise to lower No 1 and wise to lower No 4 cylinder vacuum No 2 cylinder vacuum cylinde
11. r vacuum simultaneously a 49 50 RELAV TEST 23 INSPECTION The relay is divided into two parts the main relay and the fuel pump relay The two parts are tested in eight sep arate steps Before starting the inspection procedure pre pare a twelve volt battery with auxiliary leads and remove the relay STEP 1 Make the connections shown at right Meter shows continuity Go to STEP 2 STEP 2 Make the connections shown at right Meter shows continuity Meter shows no continuity Go to STEP 3 Replace relay 52 Slee 6 Make the connections shown at right Meter shows continuity Go to STEP 7 Replace relay Meter shows no continuity STEP 7 Make the connections shown at right Goto STEP 8 Replace relay 12V 3 4W STEP 8 E Botton Make the connection shown at right Black Connecror Side Meter shows continuitv Replace relay Meter shows no continuity Relay is okay Check all connec tions and wiring
12. ring this inspection L Jee ne ba a tg a 3 E JE a ri i ki g ee am i 3 ik SSR i si i ka z e Turn ON the ignition switch e Push the starter button e Pull in the clutch lever and listen to the fuel pump Pump runs Turn page to TEST 2 Pump does not run Go to TEST 18 page 41 a ee START SIGNAL INSPECTION e Turn off the ignition switch Il Disconnect the black and white 9 pin connectors from the relay under the left side cover and connect a voltmeter to the connector to check the Start signal dm BLACK YELLOW i Less than 7 or more than 10 volts 7 to 10 volts Turn page to TEST 3 Inspect all leads and connectors and repeat TEST 2 page to TEST 4 RELAY INSPECTION To save time substitute a good relay for the suspected problem relay If a good relay is not available use TEST 23 page 50 to troubleshoot the suspect relay New relay does not cure problem New relay cures problems eplace original relay and turn Discard original relay FUELPUMPCONTACT INSPECTION Remove the air cleaner element or l Pull off the right side cover cet e Turn off the ignition switch and disconnect the 7 pin i connector from the air flow meter 2 b gt h da Air Flow Meter Terminals A AT PIN e Connectan ohmmeter to the air flow meter terminals as shown Step 1 i Step 2 Push air flap R
13. t remove air cleaner and push air flap Pressure gauge reads 2 4 to 2 6 kg cm 34 to 37 psi Turn page to TEST 8 Go to TEST 21 page 47 19 FUEL SVSTEMLEAK INSPECTION inspect the connections between the parts shown below for leaks Turn page to TEST 9 Repair leaks NOTE Use genuine Kawasaki parts or equivalent MI eS TIFEL EEG FUEL FILTER INSPECTION AND FUEL SYSTEM CLEANING 1 Clean the fuel system in a well ventilated area WARNING j and take ample care there are no sparks or flame anvwhere near the working area 2 Never clean out the fuel system when the engine is still warm 3 Wipe any fuel off the engine before starting it nspect the fuel filter for proper installation water debris and damage Water or debris in filter or filter damaged No water debris or damage Pro perly installed Remove the fuel tank and drain it e Remove the fuel tap from the tank and clean the fuel tap filter with a high flash point solvent e Flush out the fuel tank with a high flash point solvent e Clear the air vent in the tank cap with compressed air Remove the fuel pump fuel injectors fuel distributing pipe and pressure regulator and clean them using a high flash point solvent e Replace the fuel filter and hoses with new ones Install the parts on the motor cycle Use new hose clamps _ Turn page to TEST 10 Fuel Filt
14. urge tank drain plug are installed correctly e All electrical connectors are clean and tight The ignition system is normal e There is no external damage These are the special tools and instruments needed for troubleshooting the Kawasaki Electronic Fuel Injection system WEAN means starter button is pushed a 7 ARE ANN means ignition switch ON l 7 means multimeter is connected N p as shown and switched to setting means clutch lever pulled Pte printed in mater ayrib to activate starter switch NOTE For best results start with TEST 1 and follow the instructions to the letter This manual was designed to guide vou through the Kawasaki Electronic Fuel Injection svstem in a careful and thorough examination of all its component parts ELECTRONIC FUEL INJECTION TROUBLESHOOTING MANUAL All information contained in this Supplement is based on the latest product information available at the time of publication The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously Published by Pro duct Services KMC Copyright Kawasaki Motors Corp USA 1980 Printed in USA First Issue May1980 a FUEL PUMP IN CIRCUIT INSPECTION e Turn ignition switch OFF e Disconnect the yellow red lead of the starter motor relay under the left side cover This is to prevent the starter motor from working du
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