Kawasaki Jet Ski ® Watercraft Direct Injection DIAGNOSTIC SOFTWARE
Contents
1. Kawasaki Kawasaki Jet Ski Watercraft Direct Injection Ex A DIAGNOSTIC SOFTWARE MANUAL 2000 Kawasaki Heavy Industries Ltd Table of Contents INtOGUCTION DL ee M 1 Preparation 2 1 Hardware Requirements s disti niece d NEE eege geesde 1 Cable Connections CE 2 Installing and Starting the Program 3 Running software from floppy dek 3 Installing software onto laptop s hard drive 3 Installing a KADIAG shortcut con 3 Settingiup the dee e EE 5 EN ue Uu ER lu Re 5 selecting a Display Mode diced na aapa aine 6 Diagnostic Program EP 7 Running the Diagnostic Program aa aan aa akad akan enne 7 eatem E 9 o Rz 9 Data Base Errore MU 10 SOftware V6ersion a adu dE etd desc ERE ea 11 Communication Problems s escent eet iie e pei ee ves e Pe ud nga cer dre auge ua d 12 gg HEC 13 Main Menu Selections 2 io cree ivi deen ee Ee KEE 13 Menu Option 1 Diagnostic Session nnne 14 Service Code Review Screen uk EEN 14 Service Code SCreens TTT 15 Retest and Static Test Cotton Auen 16 Session Completion Code Clearing 18 M2. 8 Exit Program 44 2 Service Utilities Reports Injectors EMM 3 Exit Program 1 Service Reports 2 Injector Information BEN 3 Service EMM 4 Engine Monitoring Engine Monitoring Screen 5 Adiust Fuel Map 6 Return to Select Menu 3 Print Current EMM Report 4 View Saved Report 5 Print Saved Report 6 Return to Service Utilities Menu The purpose of this screen is to display the serial numbers of the injectors _ Sensors Air Water EMM TPS Cal TPS Act Switches Engine Sync Overheat In S L O W Result Engine Speed H 45 4 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99929 1412 01
3. 31 Menu Option 2 Injector Information eene nene 32 Replacing Blue EC 34 Restoring Previous Injector Ye Nn anan ajag aaa akan 37 Menu Option Service EMMER a anana a a aa gan aa Ng aa E e GEN Ng nnne nnne nenne 38 Menu Option 4 Engine Monttonmg senene anana aana aan 40 Menu Option 5 Adjust Fuel Map 42 Menu Option 6 Return to Program Select Menu 0a asana en aane aan an anane nana anae eene 42 c Tan 43 Service Code Chart iiic atte GE ure EH EU ing Na kag ed eR RA Re ER 43 KADIAG Software Main Menu Chart 44 Introduction Kawasaki s Diagnostic KADIAG Software is intended to be used with a service manual for the Direct Injection D I model to aid a technician in solving D I service problems This software allows a technician to 1 Retrieve and clear stored service codes 2 Actuate individual fuel injectors 3 Check spark on individual cylinders 4 Run the electric fuel pump 5 Perform cylinder drop tests 6 Display accumulated engine hours and EMM information 7 Display recorded engine hours within nine operational rom ranges 8 Display real time sensor values and system voltages 9 Display switch conditions 10 Print and save service report 11 Display Injector serial numbers 12 Install service replacement EMM 13 Adjust fuel map T
4. You can adjust the fuel amount by three PRESS ESC TO RETURN TO MENU conditions 5 0 or 5 e When you are finished with the Fuel Map Adjust Menu press ESC to return to the Service Utilities Menu Menu Option 6 Return to Program Select Menu SERVICE REPORTS INJECTOR INFORMATION SERVICE EMM ENGINE MONITORING ADJUST FUEL MAP RETURN TO PROGRAM SELECT MENU e When you are finished with the Service Utilities press 6 to return to the Program Select Menu SELECT 1 THRU 6 42 Appendix Service Code Chart Service codes are identified as either Priority Level A B or C Solve all Priority Level A problems before going on to those identified as Level B or C In some instances an A level code may set a B or C level codes Fixing an A level code may eliminate a B or C level code thus saving troubleshooting time and effort Number S L O W Warning Light P sensor above expected range 4 Check Eng Check Eng Check Eng Check Eng Check Eng Check Eng rank sensor circuit malfunction gt O D E mm Priority Level A gt aa e NECK pr TOI l1 YES a pe cu YES Check Eng Engine Oil 39 Fuelpumpopenioad CheckEng 59 Fuel pump driver overheat CheckEng aa a ma i Lx pue WEE eege e x PEE YES YES YES 41 WT sensor circuit malfunction Check Eng 42 MT sensor below exp
5. RPM Profile RPM PROFILE SCREEN This is the RPM Profile screen You get to this HOURS 19 Dni screen by pressing 7 at the Main Menu It displays a graph of nine rpm fields in 1000 rpm increments It shows percent of time the engine has been operated in each range and it also shows total engine hours 26 Service Utilities Program Running the Service Utilities Program The Service Utilities functions will use the same configuration e g com port selection color or monoscreen as the FF Diagnostic functions Before attempting to run the Service Utilities function you must install and configure the Kawasaki s FF Diagnostic program Once you have installed and configured the program double click the KADIAG bat icon to PROGRAM SELECT MENU start The Program Select Menu will come up 1 FFI DIAGNOSTICS 2 SERVICE UTILITIES REPORTS INJECTORS EMM 3 EXIT PROGRAM SELECT 1 THRU 3 Service Utilities Menu Press the 2 key to start the service utilities program The Service Utilities Menu will come up This menu offers five choices SERVICE UTILITIES MENU SERVICE REPORTS INJECTOR INFORMATION Option 1 Service Reports SERVICE EMM ENGINE MONITORING This option creates a text file of all information ADJUST FUEL MAP that is unique to a specific engine such as engine RETURN TO PROGRAM SELECT MENU hours RPM profile current service codes and SELECT 1 THRU 6 current se
6. e Type the number of the ignition you want to FIRE IGNITION 1 fire FIRE IGNITION 2 FIRE IGNITION 3 EXIT IGNITION TEST e The next screen tells you which cylinder is firing and how long it will continue to fire The ignition will fire approximately once a second for 5 seconds e Use the spark checker to observe the spark The screen counts down the amount SELECT 1 THRU 3 OR X of time to the end of the test e f you press any key the ignition will stop firing immediately The screen changes back to the previous screen when the ignition stops firing When you are finished testing the ignition press the X or ESC key to return to the S IGNITION FIRING 1 TEST IS Static Test Menu RUNNING TEST WILL STOP IN 4 SECONDS PRESS ANY KEY TO STOP 21 Testing Electric Fuel Pump NOTE Do not start the engine during any static test Doing so will cause erratic operation until you shut off the engine e Type 3 to turn the electric fuel pump on The computer will display a screen telling you the fuel pump is running The fuel pump will run continuously for approximately 7 seconds The screen counts down the amount of time to the end of the test e f you press any key the test will stop immediately and return to the Static Test Menu FUEL PUMP TEST IS RUNNING TEST WILL STOP IN 6 SECONDS PRESS ANY KEY TO STOP The fuel pump motor makes an audible whining sound while running If you hear the fuel
7. inside the EMM Voltages measured at the sensor will be substantially different Water Displays engine water temperature in volts degrees Fahrenheit and degrees Celsius Unplug sensor to see this value go to maximum high Jump sensor leads together to see the value go to maximum low When operating correctly voltage and temperature increase or decrease together Use this data to verify S L O W or overheat warnings EMM Displays temperature of injector driver circuits inside the EMM in volts degrees Fahrenheit and degrees Celsius You cannot manually alter this sensor reading Tps Cal Shows sensor value in percent of throttle valve opening Slowly move the throttle lever and watch this value change Value should progressively increase and decrease from 0 idle to 100 WOT without gaps large jumps or plateaus flat spots Tps Act Shows sensor voltage in relation to throttle plate opening Slowly move the throttle lever and watch this value change Value should progressively increase and decrease 41 10 11 12 13 14 15 16 17 Engine Speed Engine RPM when running or cranking Use this data to verify the crankshaft position sensor operation Spark Timing This value is not shown Spark Duration This value is not shown This value is not shown Fuel Command This value is not shown Engine Sync Yes means crank position sensor is detecting the engi
8. 1 99250075990526 order a Replacement Injector DO NOT take CYLINDER 2 99251076445526 an injector from another engine or cylinder CYLINDER 3 99251076435527 Moving an injector to another engine or cylinder will affect air fuel mixture on that cylinder This could affect exhaust emissions cause the engine to run poorly and cause engine damage FOLLOW INSTRUCTIONS SUPPLIED WITH THE REPLACEMENT INJECTOR KIT WHEN REPLACING AN ORIGINAL INJECTOR PRESS ANY KEY FOR MAIN MENU Each Replacement Injector has one floppy disk in which the flow characteristic are stored and one software instruction sheet You can replace an injector following the software instruction sheet independently from the KADIAG software e Follow the instructions in this Diagnostic Software Manual to connect the communication cable to the laptop computer e Insert the Replacement Fuel Injectors floppy disk into the laptop s floppy disk drive after starting the laptop computer Running the Program from Dos e Type the drive letter followed by a semi colon usually A then press the Enter key e Start the program by typing the word GO and pressing the Enter key Follow instructions on the screen 34 Running the Program from Windows e From the Desktop view double click on the My Computer icon e From the My Computer screen double click on the floppy drive e Now double click on the GO icon Follow the instructions on the scr
9. IS ON HAND EMM THE EMM IS POWERED e Before beginning this procedure you must have a service replacement EMM The damaged EMM you are going to replace should still be installed PRESS ANY KEY TO COPY INFORMATION FROM THE DAMAGED EMM lt ESC gt TO CANCEL e When you see this screen press any key to copy the engine specific information from the damaged EMM into your computer When the information is successfully copied into your computer the computer will display INFORMATION COPIED SUCCESSFULLY the next screen DO NOT SHUT OFF YOUR COMPUTER REMOVE POWER FROM DAMAGED EMM INSTALL SERVICE REPLACEMENT EMM e Turn the main switch to the OFF position PROVIDE POWER TO THE NEW EMM e Install the service replacement EMM e Once the service replacement EMM has been installed turn the main switch to the ON position e Press any key to load the engine specific PRESS ANY KEY TO COPY INFORMATION information from your computer into the TENEN EM ener TO TANGE service replacement EMM This will take a few seconds When the program is finished loading into the service replacement EMM the screen will display this message REPLACEMENT EMM HAS BEEN SUCCESSFULLY INITIALIZED e Press any key to return to the Service Utilities Menu PRESS ANY KEY TO RETURN TO MAIN MENU 39 Menu Option 4 Engine Monitoring The following is the Engine Monitoring screen You get to it by pressing 4 at the Main Menu This s
10. RPM on the screen or on the tachometer The RPM drop will be substantially less on a cylinder that is weak If you drop a cylinder and the engine RPM does not change that cylinder has a problem 24 e When you are finished with the Cylinder Drop Testing Menu type X or press the ESC key to return to the Main Menu Menu Option 4 Not Used Menu Option 5 Not Used Menu Option 6 EMM Information This is the EMM Information screen You get EMM INFORMATION SCREEN to this screen by pressing 6 at the Main Menu This screen provides information on ENGINE MODEL 1100STX DI ENGINE SERIAL jtt10ce000047 1 ENGINE MODEL and SERIAL EMM SERIAL 1295 Information in this field should match the SOFTWARE VERSION 3030076 numbers on the engine MAP VERSION CCC ENGINE HOURS 0 2 EMM SERIAL Displays EMM serial number PRESS ANY KEY TO CONTINUE 3 SOFTWARE VERSION Shows part number and version of the EMM software Can be used to confirm engine software compatibility 4 MAP VERSION Indicates the Program Change Number level of change of the present software version 5 ENGINE HOURS This is the total time the engine has been operated Key on Engine off does not accumulate time on this counter This field is not live data Hours will not change while on this screen You must exit the screen return to the Main Menu then select Menu Item 6 again to see new values 25 Menu Option 7
11. Service Manual _ Have the correct manual available before on the Safety Precautions screen continuing e Press any key to advance to the next o screen At this point the computer is still TUS software tobe used ona 2 battery powered laptop computer To minimize not attempting to communicate with the electric shock hazard do not connect A C EMM powered computers to the engine PRESS ANY KEY TO CONTINUE This i i e s is the General Instructions screen GENERA INSTRUCTIONS You get to this screen by pressing any key at the Safety Precautions screen This Remove seat screen provides general instructions on Connect the PC diagnostic cable to the yellow connector on the main harness below the connecting the laptop computer to the Jet seat Ski Watercraft with the communication Connect the PC diagnostic cable 9 pin connector to the laptop serial port cable Make sure you 1 Connect the main harness to the laptop computer with the communication cable PRESS ANY KEY TO CONTINUE 2 Turn the key switch ON 3 Install the lanyard key e When you press any key at this screen the laptop computer will now attempt to communicate with the EMM Error Messages If the program doesn t start an error message will appear explaining the problem If the program doesn t start AND doesn t display an error message the problem is most likely insufficient computer memory COM Port Error This
12. error message indicates that the communication port will not open When you see this error message press the ENTER key to try the same port again If the program cannot locate and open the default port the Select Com Port will be displayed This message is usually caused by the following problems The selected com port does not exist on your computer e Make sure you selected the correct com port Most computers have at least two com ports The ports are normally labeled COM1 and COM2 e Consult the documentation for your computer to determine the name of the port you have plugged the diagnostic communication cable into e Make sure the diagnostic program is setup to use the same port e See the section titled Changing a Com Port page 5 in this booklet Some computers have the ability to enable and disable the com ports e Consult the documentation that came with your computer e Make sure the com port is enabled ERROR OPENING PORT NUMBER 4 PRESS ANY KEY TO TRY AGAIN Something is already using the com port This is usually caused by a mouse driver that is loaded in the CONFIG sys file or AUTOEXEC bat file If you are using DOS 6 or newer your can bypass the CONFIG sys and AUTOEXEC bat files by restarting your computer and pressing the F5 key when you see the STARTING MS DOS message If you are using an older version of DOS you will have to remove the command that loads the mouse driv
13. FUEL INJECTOR FIRING TEST 1 IS RUNNING PRESS ANY KEY TO STOP The fuel injector will make an audible clicking sound each time it s activated This sound indicates the injector is being activated by the EMM and that the injector armature is moving You can also use a timing light connected to either but not both injector leads to see if the injector is being triggered by the EMM If the timing light flashes and the injector clicks the injector is most likely functioning as designed If the light flashes but the injector does not click the injector is probably damaged If the timing light does not flash the problem is probably not in the injector but in the fuses wiring or EMM When you are finished testing the injectors type X or press the ESC key to return to the Static Test Menu 20 Testing Ignition System NOTE Do not start the engine during any static test Doing so will cause erratic operation until you shut off the engine e Type 2 and press the ENTER key to test the ignition system The computer will now Remove all spark plug leads and connect them prompt you to install a spark checker onto WASPA NN the high tension leads Set At air gap specified in the service manual e After installing the spark checker press any key to advance to the next screen PRESS ANY KEY TO CONTINUE The computer will next display a screen that allows you to enter the number of the cylinder you want to fire
14. ack to the Main Menu when completed 13 Menu Option 1 Diagnostic Session Service Code Review Screen 1 HARD 13 1 INTERMITTENT 43 This is the Service Code Review screen It appears after pressing 1 at the Main Menu and provides an overview of all the service codes stored in the EMM Two types of service codes are displayed Within each category the codes are displayed in the order they should be PRESS ANY KEY FOR FIRST CODE diagnosed PRESS lt ESC gt TO CANCEL 1 Hard Codes Are displayed first A hard code means the problem that created the code exists now 2 Intermittent Codes Are displayed second An intermittent code means the problem that created the code is not occurring at this time 3 Repaired Codes Are displayed last A repaired code means that a problem that was causing a hard code at the beginning of the session is no longer occurring From this screen you have two options press any key for information on the first service code or press the ESC key to return to the Main Menu 14 Service Code Screens CODE 13 CLASS INTERMITTENT oy S OF EVENTS 1 LAST EVENT AT 13HRS This is a Service Code screen Code screens 4 OF3CODES TOTAL ENGINE HRS are displayed in the same sequence as CODE ANALYSIS Throttle position sensor below presented on the Service Code Review expected range screen You get to them by pressing any key at CODE DESCRIPTION The EMM is detecting a Thro
15. creen is a highly useful diagnostic tool It allows you to see engine conditions as they are occurring In most cases you can artificially change or influence the data readings by manipulating an engine component This will help verify proper operation of a device or circuit and will determine if follow up voltage or resistance tests are necessary to confirm a circuit or component failure This screen displays the following information ENGINE MONITORING EMM On Time 1 51 1 01 2 2 IN Results Engine Speed park Timing park Duration Engine Speed pu VOLTAGES Baro Pressure gt r L lt o D Q Press any key to exit 1 Time This field displays the total time the engine has been operated in hours minutes and seconds Key on Engine off does not accumulate time on this counter 40 2 EMM On Time This field displays a count in hours minutes and seconds It s reset to zero each time the EMM is powered up The EMM powers up when the key is turned ON starting the counter Air Displays intake air temperature at the throttle body in volts degrees Fahrenheit and degrees Celsius Unplug the sensor to see this value go to maximum high Jump the sensor leads together to see the value go to maximum low When operating correctly voltage and temperature increase or decrease together NOTE Voltage values for the sensors reflect the voltage at the analog to digital converter
16. ctions TEST FUEL PUMP EXIT STATIC TESTING NOTE O Before selecting a static test make sure the engine is not running SELECT 1 THRU 3 OR X If the engine is running a warning screen will be displayed and the software will not advance to the Static Test Menu If this happens you must press the ESC key to return to the Main Menu or shut the engine off using the engine stop switch When the engine stops the Static Test Menu will be displayed NOTE CANNOT RUN TEST WITH ENGINE RUNNING PRESS ESC TO CANCEL OR ANY OTHER KEY TO TRY AGAIN Testing Fuel Injectors NOTE Do not start the engine during any static test Doing so will cause erratic operation until you shut off the engine v Type Toto TESTINE computer will display a screen prompting you to enter the number of the injector you want to fire FIRE FUEL INJECTOR 1 FIRE FUEL INJECTOR 2 e Type the number of the injector you want to FIRE FUEL INJECTOR 3 fire EXIT FUEL INJECTOR TEST SELECT 1 THRU 3 OR X 19 The computer will display a screen telling you which injector is firing and how long it will continue to fire The injector will fire approximately once a second for 5 seconds The screen counts down the amount of time to TEST WILL STOP IN 4 SECONDS the end of the test If you press any key the injector will stop firing immediately The screen changes back to the previous screen when the injector stops firing
17. ected range Check Eng EX sensor above expected range YES Water Temp Check Engine P sensor circuit malfunction Check Eng Check Eng Check Eng B F A A A Check Eng Check Eng Check Eng Check Eng Check Eng T sensor above expected range Check Eng uel Injector 3 open load T sensor circuit malfunction T sensor below expected range i gnition coil 1 primary open load ka Check Eng gnition coil 2 primary open load Check Eng gnition coil 3 primary open load Check Eng Abbreviation TP Throttle Position WT Water Temperature BP Barometric Pressure AT Air Temperature Note When NO STORED CODE is displayed the D I System has no fault 43 KADIAG Software Main Menu Chart Service Code Review 1 Diagnostic Session R Retest Service Code Review Screen Return Main Menu 1 Test Fuel Injectors Fire 1 2 3 2 Test Ignition Firing Fire 1 2 3 2 Statistic Test 3 Test Fuel Pump Turn Fuel Pump ON X Exit Static Testing Ge 1 Cylinder Drop Test 1 2 Cylinder Drop Test 2 1 FFI Diagnostics 3 Cylinder Drop Test E 3 Cylinder Drop Test 3 4 Not Used 5 Not Used 6 EMM Information Screen fe iThis screen provides information on 1 Engine Model Engine Serial i i EMM Serial Software Version Map Version t Engine Hours CIREM Es Nata IG the REM Broke screen W displays a gra 77 tof nine RPM fields in 1000 RPM increments
18. een e This screen displays the serial numbers of Iniector Serial Number and Compensation Type Ggs Cylinder 1 the injector installed on the engine Compensated 99250075990526 e Type the cylinder number for injector you Cylinder 2 want to replace Compensated 99251076445526 Cylinder 3 Compensated 99251076435527 Type cylinder number for injector you want to replace Enter to continue ESC to cancel Injector Serial Number and Compensation This screen appears after typing a number and Cylinder 1 pressing the Enter key In this case 1 is Compensated typed 00168093905524 Cylinder 2 Compensated e Verify that serial number on the screen 9951076445596 matches the replacement injector serial Cylinder 3 number y Compensated 99251076435527 Please verity that serial number on the screen matches the replacement injector serial number press any key to continue 35 This screen appears after pressina the Enter Iniector Serial Number and Compensation Type pp p 9 Cylinder 1 Compensated 00168093905524 Cylinder 2 Compensated 99251076445526 Cylinder 3 Compensated 99251076435527 Install the replacement injector on cylinder 1 press any key to continue Installing Injector e Turn off the main switch e Disconnect the battery e Follow instructions in Service Manual to replace fuel injector e Reconnect battery e Turn on the main
19. enu Option 2 Static Tests errare eee ebrei ore necat a erence 19 Testing Fuel Injectors ter reet dei ier tee eae e dpt 19 Testing Ignition System descents hehe dct ceris da aga NG o e denar STE ve b eve a ae Lua 21 Testing Electric Fuel PUMP eet e RR TT es 22 Menu Option Cylinder Drop nennen nennen nennen nennen 23 DidQnOsing a WIL 3T HARE 24 Diagnosing Low Performance or Rough Running eeeeeeeneenn 24 Menu Option 4 Not Used aee aee eed Ss EE ee ee a aa a Ei e dee 25 Menu Option S Not Used tret rere eter Sides ee adea tabi re ee a E De ce efe owes 25 Menu Option 6 EMM Information mene nnne nnne nennen 25 Menu Option 7 RPM Profile Aren 26 ee CRU EE 27 Running the Service Utilities Program 27 Service Utilities Menu ceti trie Enn ML decepti d den anake 27 Menu Option 1 Service Hepont Anke esent nennen nnne nennen nennen nennen 29 View Current EMM eene ene nennen ENEE 29 Save Current Reportase an a na REENEN 30 Print Current EMM Report iioii prope aana 30 View Saved 31 Print Saved cdc aes dite ate Ra ap na daga Ka a aa aa anaa aa a 31 Return to Service Utilities
20. er When you exit the Select Com Port the Title screen appears Selecting a Display Mode By default the program starts with a monochrome display This ensures compatibility with the widest array of available laptop computers e f you are using a color display press F2 key to switch to the color mode NOTE O The com port and screen mode color or monochrome that is being used when the program is shut down will automatically be used the next time you start the program Diagnostic Program Running the Diagnostic Program Once you have installed and configured the program start the program PROGRAM SELECT MENU Se FFI DIAGNOSTICS e Double clicking KADIAG bat icon on the SERVICE UTILITIES Windows desktop The Program Select REPORTS INJECTORS EMM s lt EXIT PROGRAM Menu will immediately display SELECT 1 THRU 3 e Press the 1 key to start the Diagnostic Program The Diagnostic Title screen will KAWASAKI immediately display FFI WATERCRAFT DIAGNOSTICS SUPPORT e Press any key to change to the next screen VERSION 1 20 FOR FFI WATERCRAFTS 2000 COPYRIGHT 1999 2000 OUTBOARD MARINE CORPORATION ALL RIGHTS RESERVED PRESS ANY KEY TO CONTINUE e The next screen is the Safety Precautions SAFETY PRECAUTIONS screen You get to this screen by pressing any key at the Title screen This software is designed to be used in conjuction e Read understand and follow the directions With the appropriate Kawasaki
21. er by editing the CONFIG sys or AUTOEXEC bat file Data Base Error If the laptop displays this error screen there are three possible causes Not enough DOS memory available e Tocorrect this press the ESC key to end the program e Check computer memory by typing MEM and pressing the ENTER key at the DOS prompt The largest executable program size must be more than 400KB If not reconfigure the computer to make more memory available Attempting to start the program outside of the KADIAG directory e Change to the KADIAG directory before starting the program Damaged or erased program file e Reinstall the program e Seethe section titled Installing and Starting the Program in this booklet 10 C KADIAG gt KADIAG 40 DATABASE ERROR RESTART PROGRAM IF ERROR OCCURS AGAIN REINSTALL PROGRAM FROM THE DISKETTE Software Version If the laptop displays this error screen the EMM program part number is not being recognized by the diagnostic software program This is most likely caused by using old diagnostic software DIAGNOSTIC SOFTWARE UPDATE REQUIRED TO ACCESS THIS EMM on a new engine Always use the newest diagnostic software PRESS ANY KEY TO EXIT 11 Communication Problems The EMM must be powered up for communication to occur This means the battery must be charged and connected The key switch must be ON The Main Menu screen will be displayed when the laptop and EMM establish commun
22. f operating hours on the engine Compare this number to the LAST EVENT AT HRS number to determine how long since the code was last set Retest and Static Test Options Some hard codes have a Retest and or an associated Static Test option If these tests are available Press S for Static Test and or Pres R to Retest is displayed at the bottom of the Service Code screen Service codes that have a static test option are the fuel injector and the ignition system The static test allows you to instruct the EMM to S momentarily activate a component that is causing the code so you can verify its operation In the retest mode the computer constantly scans the EMM to see if the present service code is still being set You can use Retest to diagnose and verify some repairs For example Service Code 43 will be set if an open connection occurs in the water temperature sensor circuit NOTE O When service code 39 appears perform the static test and inspect the fuel pump according to the service manual 16 CODE 43 CLASS INTERMITTENT OF EVENTS 1 LAST EVENT AT 13 HRS 2 OF 3 CODES TOTAL ENGINE HRS 13 CODE ANALYSIS Water temperature sensor above expected range CODE DESCRIPTION If this is a hard fault STOP THE ENGINE to prevent serious damage Check engine temperature if overheating troubleshoot cooling system Check cooling fittings and hoses for blockage If engine is not overheating check for dama
23. ge up and Page down keys or the Up Down arrow keys to view the report e Use ESC key to return to Service Report Menu for other options SERVICE REPORT MENU VIEW CURRENT EMM REPORT SAVE CURRENT EMM REPORT PRINT CURRENT EMM REPORT VIEW SAVED REPORT PRINT SAVED REPORT RETURN TO SERVICE UTILITIES MENU SELECT 1 THRU 6 Engine Model No Engine Serial number EMM Serial Software Version EMM On Time Engine Run Time Hard Service Codes Intermittent Codes Engine Speed TPS Calibrated Fuel Timing Fuel Command Spark Timing Spark Duration Engine Sync Overheat Active S L O W Active TPS Actual PDS Voltage Air Temp Engine Temp EMM Temp Baro Pressure Max EMM Temp Max Engine Temp Max Engine Speed 0 1000 RPM 1000 2000 RPM 2000 3000 RPM 3000 4000 RPM 4000 5000 RPM 5000 6000 RPM 6000 7000 RPM 7000 8000 RPM 8000 RPM Injector 1 S N Injector 2 S N Injector 3 S N 1100STX DI jtt10ce000047 1295 3030076 0 31 0 0 51 52 53 39 0 0 XXXXX XXXXX XXXXX XXXXX No No No 0 22 V 12 20 V 21C 20C 21C 29 61 in HG 23 22C 100 0 0 0 0 0 0 0 0 99250075990526 99251076445526 99251076435527 Save Current EMM Report FILE NAME e Type 2 from the Service Report Menu to save a report about the engine you are connected to You will be asked to enter a Sen file name or select a file name from a list 1150FLEE e To use an existing fi
24. ged temperature sensor or sensor leads in wiring harness See Diagnostic Manual PRESS R TO RETEST THIS FAILURE PRESS ANY KEY FOR NEXT CODE The Service Code screen for Service Code 43 has the Retest feature If you press The problem causing this service code is still detected Conduct a visual inspection test and clean key the Retest screen will be displayed If you connections and test components The computer wiggle the water temperature sensor connector will beep and the screen will change when the problem is repaired and it momentarily improves contact the computer will beep when the connection is good The computer will then display a message that the code appears to be repaired PRESS ANY KEY TO STOP NOTE O You need set the computer to beep when the signal directs REPAIRED PRESS ANY KEY TO EXIT If the connection breaks the computer will beep again and display the Retest screen When you exit the Retest feature you will automatically return to the Service Code screen The CLASS field will reflect the status of the service code either Hard or Repaired When you are finished with a Service Code screen you have two options press any key to see the next Service Code screen or press the ESC key to return to the Main Menu 17 Session Completion Code Clearing The Session Completion screen is displayed after you have seen the last Service Code screen The Session Completion scree
25. he following pages cover these features and functions in more detail Preparation Hardware Requirements WARNING This software is intended to be used a battery powered laptop computer To minimize electric shock hazard DO NOT connect an A C powered computer to the Jet Ski watercraft Kawasaki s Diagnostic Software will operate on a wide range of laptop computers It has been tested on laptops using 286 386 486 and Pentium processors At least 400 kilobytes K of DOS memory must be available for the program to run The screen fonts and colors will display well on monochromatic or color displays The program is provided on a single 1 44 Meg 3 inch floppy disk This disk can be accessed by most newer IBM compatible laptop computers Cable Connections e Locate the diagnostic port on the engine wiring harness It is positioned at the mid right side under the seat The port has a cover to keep the connections clean e Remove the cover to access the port e Connect the yellow end of the communication cable A to the diagnostic port B on the wiring harness A Communication cable B Diagnostic port of wiring harness NOTE O When you are finished with all testing make sure you protect the diagnostic port by reinstalling the cover Do not disconnect or cut off the wire of the cover e Connect the other end of the communication cable A to the serial port B on the laptop computer A Communicat
26. ication If the program locates and opens the selected com port but cannot communicate with the EMM for any reason it will display this screen The software will not advance beyond this screen until communication can be established between the laptop computer and the EMM If you see this screen make sure the 1 Key switch is on 2 Main battery selector switch is on There is not main battery selector switch on JT1100 C1 Battery cable connections are clean and tight Battery is charged All fuses and relays are good EMM electrical connections are clean and tight Communication cable connections are clean and tight 8 Communication cable is attached to the laptop and to the diagnostic connector on the engine wiring harness 9 Com port with the number you entered when starting or configuring the program is connected to the communication cable 10 Engine stop lanyard is attached to the stop button NO or P ro This screen will also be displayed if the laptop momentarily loses communication with the EMM If this happens allow a few seconds for the communication to reestablish 12 The computer is having trouble communicating with the engine EMM Please check the following e Key switch is on Main battery selector switch is on Battery cable connections are clean and tight Battery is charged All fuses and relays are good EMM electrical connections are clean and tight Communication cable connec
27. ion cable B Serial port of laptop computer Special Tool 57001 1460 Communication Cable A To diagnostic port of wiring harness B To serial port of laptop computer Special Tool 57001 1461 KADIAG Software Installing and Starting the Program Running software from floppy disk e With the computer off insert the floppy disk into the laptop s floppy disk drive and turn on the computer e After boot up the program will be at the program select menu Installing software onto laptop s hard drive The installation program will create a directory on your drive called KADIAG and place the Kawasaki Diagnostic Software in that directory It will also place a file called KADIAG bat in the root directory of your C drive e Insert the floppy disk into the laptop s floppy disk drive e Open the drive from EXPLORER screen e Click INSTALL bat then press the ENTER key e f the program will not run from the C drive restart the computer with the disk in drive A Installing a KADIAG shortcut icon Install a KADIAG shortcut icon on the windows desktop e With the cursor not pointing to an icon click the right mouse button e Select NEW then SHORTCUT e Choose BROWSE on the Create Shortcut Screen Choose the KADIAG folder Click on KADIAG bat file O Choose open O Choose NEXT then NEXT then FINISH The KADIAG bat icon will then appear on the desktop scree
28. le name use the JOE SMIT arrow keys to move through the list of files e When you have the desired file highlighted press the ENTER key to save the file using the highlighted name e f you want to create a new file enter the name you want the report file saved as Remember to use the standard DOS file naming conventions no more than eight characters and no special characters e After typing the file name press the ENTER key e The file can also be saved to the A drive by typing A and the file name You will be asked to enter a customer name ENTER CUSTOMER NAME This name will print at the top of the service John Doe report You can use any name you wish as long as the total number of characters will fit in the area provided You can also press the ENTER key to leave this field blank After typing the customer name press the ENTER key The file will be saved in the C KADIAGDATA directory on your computer hard drive or floppy drive Print Current EMM Report e Type 3 from the Service Report Menu to print a report about the engine you are connected to You will be asked to enter a customer name e After typing the customer name press the ENTER key This will copy the report to the computer parallel port Some printers daisy wheel and dot matrix will begin printing right away Other printers will require you to push the form feed button 30 View Saved Report FILE NAME e Type 4 from
29. n e Start the program by clicking KADIAG bat icon then press the ENTER key or by double clicking it When the program starts you Will see the Program Select Menu 2 E S S CoiDRAW 8 SN PROGRAM SELECT MENU FFI DIAGNOSTICS SERVICE UTILITIES REPORTS INJECTORS EMM EXIT PROGRAM SELECT 1 THRU 3 Setting up the Program The first time you run the program it may need PROGRAM SELECT MENU to be configured FFI DIAGNOSTICS SERVICE UTILITIES e Press 1 to start the Diagnostic Program REPORTS INJECTORS EMM EXIT PROGRAM e When the Title screen appears press the F3 key to display the Select Com Port screen SELECT 1 THRU 3 KAWASAKI FFI WATERCRAFT DIAGNOSTICS SUPPORT VERSION 1 20 FOR FFI WATERCRAFTS 2000 COPYRIGHT 1999 2000 OUTBOARD MARINE CORPORATION ALL RIGHTS RESERVED PRESS ANY KEY TO CONTINUE Changing a Com Port The program can be configured to use any com port The initial default is com 1 Consult the Soe documentation for your computer to determine COM 3 which port you have plugged the diagnostic EE 4 communication cable into Set the diagnostic program to use the same port Current Configuration uses Com Port 1 e To change the default com port press the key from the Title screen or the Main Menu to display the Select Com Port screen The Select Com Port screen displays a numbered list of com ports SELECT 1 THRU 3 OR X e Type the com port numb
30. n provides three options e f you type 1 the computer will display a message asking if you are sure you want t clear the codes e Press ESC key if you do not want to clear the service codes Pressing any other key will clear the codes A screen will then appear telling you service codes were successfully cleared e f you type 2 the computer will display th Service Code Review screen then page through the Service Code screens again e You can end the session and return to the Main Menu without clearing the service codes by typing X NOTE Itis important to recheck for codes after clearing codes If hard codes are still present they will reappear Clearing codes only removes intermittent codes e 18 SESSION COMPLETION Please choose one of the following options to complete this diagnostics session before testing engine Clear all service codes Review current service codes without clearing codes End Session return to main menu without clearing service codes SELECT 1 2 or X DO YOU REALLY WANT TO CLEAR SERVICE CODES PRESS lt ESC gt TO CANCEL OR ANY OTHER KEY TO CLEAR CODES SERVICE CODES SUCCESSFULLY CLEARED PRESS ANY KEY FOR MAIN MENU Menu Option 2 Static Tests This is the Static Testing Menu You get to this screen by pressing 2 key at the Main TEST EUEE INJECTORS Menu It allows you to select and test one of TEST IGNITION FIRING three engine fun
31. ne revolution correctly Overheat YES or NO YES means water temperature sensor is indicating an overheat The temperature sensor reading can verify this condition Ground the water temperature sensor lead and watch this value change In S L O W YES or NO Yes means engine is in S L O W mode The water temperature sensor reading can verify this condition Ground the water temperature sensor lead and watch this value change when engine goes into S L O W Alt Voltage Indicates battery voltage when engine is not running Indicates voltage available to power the ignition and injectors when engine is running Use these readings to verify regulator and charging system operation Barometric Pressure Indicated in Inches of Hg This data allows EMM altitude compensation NOTE Most sensors switches and voltages will have associated service codes Refer to the Service Code Chart attached this service manual for a description of the failure Menu Option 5 Adjust Fuel Map This is the Fuel Map Adjust Menu screen FUEL MAP ADJUST MENU You get to this screen by typing 5 at the Service Utilities Menu The purpose of this CURRENT ADJUSTMENT IS 0 screen is to adjust the fuel amount OF CALIBRATED FUEL AMOUNT e To adjust the fuel amount you can increase PRESS THE KEY TO INCREASE E OR THE KEY TO DECREASE 5 by pressing the key or decrease Tae FURL ADJUSTMENT 5 by pressing the key
32. nsor values The file can be printed immediately or saved to the hard drive for printing or viewing later Option 2 Injector Information This option displays the original fuel injector serial numbers and identifies their cylinder locations on the engine 27 Option 3 Service EMM This option allows you to copy the engine model number serial number operating hours RPM profile and other engine specific information from the original EMM into a service replacement EMM Option 4 Engine Monitoring This option displays the following live data from the EMM 1 Sensor values throttle position sensor water temperature sensor etc 2 System voltages battery voltage or alternator voltage 3 Engine speed Option 5 Adjust Fuel Map This option allows you to increase or decrease the calibrated fuel amount by 5 or 5 Option 6 Return to Program Select Menu This option displays the Program Select Menu 28 Menu Option 1 Service Report This is the Service Report Menu You get to this screen by typing 1 at the Service Utilities Menu The purpose of the Service Report Menu is to provide a method of creating and printing a service report View Current EMM Report Type 1 from the Service Report Menu to view a report about the engine you are connected to The figure right shows page one of a typical report file The figure right lower shows the second page e Use the Pa
33. pump running the pump is probably okay You can also use this procedure to turn the fuel pump on to perform the pressure and volume test outlined in the service manual When you are finished with the Static Test Menu press the ESC key to return to the Main Menu 22 Menu Option 3 Cylinder Drop Test The cylinder drop test is a highly useful diagnostic tool It allows you to momentarily shut off fuel to any one cylinder while the engine is running To use the cylinder drop test you must run the engine with the laptop attached e To start the cylinder drop test type 3 at the Main Menu The computer will display e Extract all EMM service codes and make the the Cylinder Drop Test information indicated before using the Cylinder Drop est screen e This test will help you diagnose an engine problem e Read and understand the screen before when the systems or cylinders are not known Is e This test allows you to drop any cylinder as you run continuing the engine at the RPM where the problem exists e f the problem is power loss engine RPM will not change when the cylinder is dropped If the Press any key to advance to the next problem is a misfire the misfire will stop when the screen cylinder is dropped PRESS ANY KEY TO CONTINUE The engine must be running above 500 rpm If NOTE the engine is not running or is below 500 rpm a warning screen will be displayed and the RPM SHOULD BE ABOVE 500 soft
34. switch This screen appears after pressina the Enter Iniector Serial Number and Compensation Type pp p 9 Cylinder 1 Compensated 00168093905524 EE Cylinder 2 The program is finished loading the Compensated replacement injector information into the EMM 99251076445526 Cylinder 3 e Press any key to exit Write the engine serial number and the original injector serial number on the floppy disk label press any key to exit When the program is finished remove the floppy disk and write the engine serial number and the original injector serial number on the floppy disk label 36 Restoring Previous Injector Iniector Serial Number and Compensation Cylinder 1 me Compensated in r If you accidentally type the wrong injecto GE number restart the Program Cylinder 2 Compensated 99251076445526 This screen appears after starting the Program E Cylinder 3 If you wani to KO the previous injector Compensated press the Enter key 99251076435527 THE INJECTOR HAS REPLACED ON CYLINDER 1 Tue Jun 27 10 57 43 2000 Do you want to restore the previous injector 1 Entar ta rantarna Ennn ta nanan Iniector Serial Number and Compensation This screen appears next Cylinder 1 Compensated e 99250075990526 e Verify that the serial number on the screen matches the original injector serial number Cylinder 2 Compensated 99251076445526 Cylinder 3 Compensa
35. ted 99251076435527 matches the original injector serial number press any key to continue Iniector Serial Number and Compensation Type Cylinder 1 Compensated 99250075990526 Cylinder 2 Compensated 99251076445526 e Install the original injector on the cylinder Cylinder 3 Compensated 99251076435527 NOTE O Store the replacement injector and floppy On cylinder 1 press any key to continue This screen appears after pressing the Enter key e Press any key to exit disk You can use this injector as a replacement injector 37 Menu Option 3 Service EMM Important Each fuel injector s serial number and flow characteristics are loaded into the EMM during production This means that there is a unique relationship between the engine s EMM and its fuel injectors The result is optimum fuel delivery to each cylinder based on the flow characteristics of that cylinder s fuel injector You must use Kawasaki s FFI Diagnostic Software Version 1 20 when you perform either of the following service procedures on an engine that has this capability 1 Replacing an EMM 38 This is the Service EMM screen You get to BEFORE STARTING THIS PROCEDURE this screen by typing 3 at the Service MAKE SURE THAT Utilities Menu The purpose of this screen is to provide a simple method of loading engine THE DAMAGED EMM IS ON THE ENGINE specific information into a service replacement THE SERVICE REPLACEMENT EMM
36. the Service Report Menu to view a previously saved report 586430 e You will be asked to enter a file name or 99175EV select a file name from a list Use the 1150FLEE arrow keys to move through the list of JOE SMIT files e When you have the desired file highlighted press the ENTER key to view that file e Ifthe file was saved to the floppy drive type A and the Enter e Use this option to review information on an engine that is not connected to your computer e Use ESC key to return to Service Report Menu for other options Print Saved Report Use this option to print information on an engine that is not connected to your computer e Type 5 from the Service Report Menu to print a previously saved report e You will be asked to enter a file name or select a file name from a list Return to Service Utilities Menu e Type 6 from the Service Report Menu to return to the Service Utilities Menu 31 Menu Option 2 Injector Information This is the Injector Information screen You get to this screen by typing 2 at the Service Utilities Menu The purpose of this screen is to display the serial numbers of the injectors that were originally installed on the engine during production Important Each fuel injector s serial number and flow characteristics are loaded into the EMM during production This means that there is a unique relationship between the engine s EMM and its fuel injec
37. tions are clean and tight COMPUTER WILL CONTINUE COMMUNICATING WHEN CONNECTION IS CORRECTED FFI Diagnostics Main Menu Selections This screen is the Main Menu It s displayed as soon as the laptop computer establishes communication with the EMM and it offers a number of choices Option 1 Diagnostic Session DIAGNOSTIC SESSION STATIC TESTS CYLINDER DROP TEST NOT USED NOT USED EMM INFORMATION SCREEN RPM PROFILE EXIT PROGRAM 4 Allows you retrieve stored service codes from the EMM Helps you diagnose the problems generating the service codes Allows you to clear stored service codes SELECT 1 THRU 7 OR X 26 Option 2 Static Tests For testing purposes allows you to 1 activate any fuel injector 2 fire any ignition coil 3 turn the fuel pump on Option 3 Cylinder Drop Test Helps isolate a cylinder that s not operating properly by allowing you to momentarily shut off fuel to any cylinder while the engine is running Option 4 Not Used Option 5 Not Used Option 6 EMM Information Provides information on engine model and serial number EMM serial number software version program change number and total engine hours Option 7 RPM Profile Displays a graph of nine rpm fields in 1 000 rpm increments Shows percent of time engine has been operated in each range Also shows total engine hours All menu selections will return b
38. tors The result is optimum fuel delivery to each cylinder based on the flow characteristics of that cylinder s fuel injector You must use Kawasaki s FF Diagnostic Software Version 1 20 when you perform either of the following service procedures on an engine that has this capability e Replacing an EMM 32 INJECTOR INFORMATION CYLINDER 1 99250075990526 CYLINDER 2 99251076445526 CYLINDER 8 99251076435527 FOLLOW INSTRUCTION SUPPLIED WITH THE REPLACEMENT INJECTOR KIT WHEN REPLACING AN ORIGINAL INJECTOR PRESS ANY KEY FOR MAIN MENU Each injector has a white label A with the injector s unique serial number Each EMM has a unique serial number A The Injector Information screen displays the INJECTOR INFORMATION serial numbers of the original injectors The screen indicates which injector serial number belongs in each cylinder When servicing a D I engine you should verify that each injector is in the correct cylinder Compare the serial number tag on each original fuel injector to the serial number shown on the Injector CYLINDER 1 99250075990526 CYLINDER 2 99251076445526 CYLINDER 8 99251076435527 FOLLOW INSTRUCTION SUPPLIED WITH THE REPLACEMENT INJECTOR KIT WHEN Information screen REPLACING AN ORIGINAL INJECTOR PRESS ANY KEY FOR MAIN MENU 33 Replacing Inj rs epraeing Injectors INJECTOR INFORMATION CAUTION If you need to replace an injector you must CYLINDER
39. ttle position sensor value that is lower than expected This the Service Code Review screen They can be caused by mechanical damage to the sensor or display the following information linkage that increases the sensor travel toward the idle position Damage to the sensor leads or sensor electrical connectors that are loose corroded or Code unplugged can also cause this code See Diagnostic Manual An identifying number given to each code PRESS ANY KEY FOR FIRST CODE 1 Class Hard intermittent or repaired 2 of Events Indicates how many times this code has been stored This field can only increase by one each time the engine is run This means that if a code occurs several times during a run it will only increase this counter by one 3 Last Event at Hrs Indicates the number of operating hours on the engine when this code was last present This field will update during a run during a single power up cycle For instance if a code occurs at 50 hours and is still occurring at 51 52 and 53 hours the counter will advance to 53 hours This however is not a live data screen The counter is read only when you begin a diagnostic session NOTE O Youmust exit the diagnostic session return to the Main Menu then begin a new diagnostic session to see the counter change value 15 4 t of Codes How many codes are present and which code you are presently viewing 5 Total Engine Hours Current number o
40. ware will not advance to the Cylinder Drop FOR TEST TO BE EFFECTIVE Testing Menu If this happens start the engine or press ESC key to return to the Main Menu PRESS ANY KEY TO TRY AGAIN 23 When the engine is running above 500 rpm CYLINDER DROP TESTING MENU the Cylinder Drop Testing Menu will be displayed The screen will also show engine rpm so it can be noted before conducting a CYLINDER DROP TEST CYL 1 CYLINDER DROP TEST CYL 2 drop test CYLINDER DROP TEST CYL 3 EXIT CYLINDER DROP TEST RPM 550 SELECT 1 THRU 3 OR X e Type the number of the cylinder you want to CYLINDER 1 DROP TEST drop The computer will display a screen IS RUNNING telling you which cylinder is dropped and how long it will continue Engine RPM will TEST WILL STOP IN 19 SECONDS again be displayed so you can note if a change occurs The screen counts down CURRENT RPM IS 800 the amount of time to the end of the test e f you press any key the test will end immediately When the test ends the screen changes back to the Cylinder Drop Testing Menu PRESS ANY KEY TO STOP Diagnosing a Misfire e Run the engine under the conditions that cause the misfire to occur and drop each cylinder e When you drop the cylinder that is misfiring the misfire will stop You can focus on that cylinder Diagnosing Low Performance or Rough Running e Run the engine under a load in a test tank and drop each cylinder e Watch the
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