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kawasaki njinja ZX-10R TROUBLESHOOTING GUIDE

1. Troubleshooting the DFI System

The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator.

Outline

When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU. For models eqquipped with an immobilizer system, the warning indicator light (LED) and immobilizer warning symbol [C] blinks, when a problem occurs in the system.

With the engine stopped and turned in the self-diagnosis mode, the service code [A] is displayed on the LCD (Liquid Crystal Display) by the number of two digits.

When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the cause of problem. As a pre-diagnosis inspection, check the ECU for ground and power supply, the fuel line for no fuel leaks, and for correct pressure. The pre-diagnosis items are not indicated by the warning indicator light (LED) and FI warning symbol. Don’t rely solely on the DFI self-diagnosis function, use common sense.

Even when the DFI system is operating normally, the warning indicator light (LED) and FI warning symbol may blink under strong electrical interference. Additional mea-sures are not required. Turn the ignition switch OFF to stop the indicator light and symbol.

If the warning indicator light (LED) and FI warning symbol of the motorcycle brought in for repair still blinks, check the service code.When the repair has been done, the FI warning symbol goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems

Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them. •When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. ○The DFI part connectors have seals, including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set. Insert the needle adapter inside the seal until the needle adapter reaches the terminal. Special Tool – Needle Adapter Set: 57001-1457

After measurement, remove the needle adapters and ap-ply silicone sealant to the seals [A] of the connector [B] for waterproofing.

Sealant – Kawasaki Bond (Silicone Sealant): 56019-120 -Seals of Connector

Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.

Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem. If the problem was caused by some other item or items, they too must be repaired or replaced, or the new replacement part will soon fail again •Measure coil winding resistance when the DFI part is cold (at room temperature)

•Do not adjust or remove the throttle sensor.
•Do not directly connect a 12 V battery to a fuel injector. Insert a resistor (5 ∼ 7 Ω ) or a bulb (12 V × 3 ∼ 3.4 W) in series between the battery and the injector.

The DFI parts have been adjusted and set with precision. Therefore, they should be handled carefully, never strike sharply, as with a hammer, or allowed to drop on a hard surface. Such a shock to the parts can damage them.
•Check wiring and connections from the ECU connector to the suspected faulty DFI parts, using the hand tester (special tool, analog tester) rather than a digital tester. Special Tool – Hand Tester: 57001-1394

Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Deteriorated leads and bad connections can cause reappearance of problems and unstable operation of the DFI sytems.

If any wiring is deteriorated, replace the wiring.
•Pull each connector [A] apart and inspect it for corrosion, 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 wiring diagram to find the ends of the lead which is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
○Set the tester to the × 1 Ω range, and read the tester.If the tester does not read 0 Ω, the lead is defective. Replace the lead or the main harness or the sub harness.

○If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness is open, repair or replace the harness.

When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or replaced.

•Narrow down suspicious locations by repeating the continuity tests from the ECU connectors. If no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages. However, there is no way to check the ECU itself. If an abnormality is found, replace the affected DFI part. If no abnormality is found in the wiring, connectors, and DFI parts, replace the ECU. ○The diagnosis flow chart illustrates the above procedures. ○After inspection, be sure to connect all the DFI electrical connectors. Do not turn the ignition switch ON while the DFI electrical connectors and ignition system connectors are disconnected. Otherwise, the ECU memorizes service codes as open circuit.

○Lead Color Codes:
BK: Black G: Green P: Pink
BL: Blue GY: Gray PU: Purple
BR: Brown LB: Light Blue R: Red
CH: Chocolate LG: Light Green W: White
DG: Dark Green O: Orange Y: Yellow

Electrical Connectors:
Female Connectors [A]
Male Connectors [B]

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 conditions by asking the rider; knowing this information may help you reproduce the problem.
○The diagnosis sheet will help prevent you from overlooking any areas, and will help you decide if it is a DFI system problem, or a general engine problem.

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