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kawasaki versys DFI System Troubleshooting REPAIR TROUBLESHOOTING GUIDE

Outline

When an abnormality in the DFI system occurs, the FI indicator light (LED) 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 unit). With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator light (LED) blinks.

When due to a malfunction, the FI indicator light (LED) remains lit, ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C].

First, conduct a self-diagnosis inspection and then a non-self-diagnosis inspection. The non-self-diagnosis items are not indicated by the FI indicator light (LED). Don’t rely solely on the DFI self-diagnosis function, use common sense.

Even when the DFI system is operating normally, the FI indicator light (LED) [A] may light up under strong electrical interference. No repair needed. Turn the ignition switch OFF to stop the indicator light.

When the FI indicator light (LED) goes on and the motorcycle is brought in for repair, check the service codes. When the repair has been done, the light (LED) doesn’t go on. But the service codes stored in memory are not erased to preserve the problem history, and the light (LED) can display the codes in the self-diagnosis mode. The problem history is referred when solving unstable problems. When the motorcycle is down, the vehicle-down sensor is turned OFF and the ECU shuts off the fuel injectors and ignition system. The FI indicator light (LED) blinks but the service code cannot be displayed. The ignition switch is left ON. If the starter button is pushed, the electric starter turns but the engine doesn’t start. To start the engine again, raise the motorcycle, turn the ignition switch OFF, and then ON. The vehicle-down sensor is turned ON and the light (LED) goes OFF.

○The DFI part connectors [A] have seals [B], including the ECU.

•Join the connector and insert the needle adapters [C] inside the seals [B] from behind the connector until the adapter reaches the terminal.
Special Tool – Needle Adapter Set: 57001-1457

•Make sure that measuring points are correct in the connector, noting the position of the lock [D] and the lead color before measurement. Do not reverse connections of the hand tester or a digital meter.

•Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters.

•Turn the ignition switch ON and measure the voltage with the connector joined.

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

Sealant – Kawasaki Bond (Silicone Sealant): 56019-120

•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).

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

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.

○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

○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 voltage [C] from the sensor.

○Sometimes this method can detect a fault of the ECU.

•Refer to each sensor inspection section for detail in this chapter.

•Use a fully charged battery and a digital meter [D] which can be read two decimal places voltage or resistance.

(Resistance Check Method)

○Thismethod is simple. No need for a fully charged battery and the needle adapter. Just do the following especially when a sensor [A] is suspect.

•Turn the ignition switch OFF and disconnect the connectors.

•Inspect the sensor resistance, using a digital meter (see each sensor inspection).

•Inspect the wiring and connectors [B] for continuity, using the hand tester [C] (analog tester) rather than a digital meter.

Special Tool – Hand Tester: 57001-1394

If the sensor, the wiring and connections are good, inspect the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, the ECU is suspect. Replace the ECU.

DFI System Troubleshooting Guide

Engine Doesn’t Start, Starting Difficulty

 

Symptoms or possible Causes Actions (chapter)
Clutch lever not pulled in and gear not in neutral whether sidestand up or not Pull the lever in and shift the gear in neutral.
Though clutch lever pulled in, sidestand up and gear not in neutral Sidestand down and clutch lever pulled in whether gear in neutral or not
Vehicle-down-sensor coming off Reinstall (see chapter 3).
Vehicle-down-sensor trouble Inspect (see chapter 3)
ECU ground or power supply trouble Inspect (see chapter 3).
Battery voltage low Inspect and charge (see chapter 16).
Spark plug dirty, broken or gap maladjusted Replace (see chapter 2).
Stick coil trouble Inspect stick coil (see chapter 16).
Stick coil shorted or not in good contact Reinstall or inspect stick coil (see chapter 16).
Spark plug incorrect Replace it with the correct plug (see chapter 16).
IC igniter in ECU trouble Inspect (see chapter 16).
Neutral, starter lockout or sidestand switch trouble Inspect each switch (see chapter 16).
Crankshaft sensor trouble Inspect (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Ignition switch shorted Inspect and replace (see chapter 16).
Engine stop switch shorted Inspect and repair or replace (see chapter 2).
Starter system wiring shorted or open Inspect and repair or replace (see chapter 16).
Main 30A or ignition fuse blown Inspect and replace (see chapter 16).
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed or missing Clean or reinstall (see chapter 3).
Leak from oil filler cap, crankcase breather hose or air cleaner drain hose Inspect and repair or replace (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see chapter 3).
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Fuel pressure may be low Inspect (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Crankshaft sensor trouble Inspect (see chapter 3).
Compression low: Reinstall (see chapter 16).
Spark plug loose Tighten (see chapter 5).
Cylinder head not sufficiently tightened down Inspect and replace (see chapter 5).
Cylinder, piston worn Inspect and replace (see chapter 5).
Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).
Piston ring/groove clearance excessive Inspect and replace (see chapter 5).
Cylinder head gasket damaged Replace (see chapter 5).
No valve clearance Adjust (see chapter 2).
CValve guide worn Inspect and replace (see chapter 5).
Valve spring broken or weak Inspect and replace (see chapter 5).
Valve not seating properly (valve bent, worn or carbon accumulating on seating surface) Inspect and repair or replace (see chapter 5).

For more information, please download the relevant fault kawasaki  repiar service manual pdf

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