Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013)

3-84 FUEL SYSTEM (DFI)

Yellow Engine Warning Indicator Light (LED)

Inspection

○

In this model, the yellow engine warning indicator light
(LED) goes on or blinks by the data sent from the ECU.

•

Refer to the Meter Unit Inspection in the Electrical System
chapter.

Yellow Engine Warning Indicator Light (LED) Circuit for DFI System

1. ECU
2. Meter Unit
3. Yellow Engine Warning Indicator Light (LED)
4. Frame Ground

FUEL SYSTEM (DFI) 3-85

ECU

ECU Identification

○

Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with
each other and use only the ECU for your model. Other-
wise, the motorcycle cannot clear the regulation.

ECU Identification

Part Number [A]

Specification

21175-0773

WVTA (FULL AB-2), IN

21175-0793

US, CA, CO

21175-0794

21175-0795

21175-0854

CAL

ECU Removal

NOTICE

Never drop the ECU especially on a hard surface.
Such a shock to the ECU can damage it.

•

Remove:

Seat Covers (see Seat Cover Removal in the Frame
chapter)
Bolts [A]
Bracket [B]

•

Disconnect the connector [A] from the turn signal relay.

•

Remove the screw [B].

•

Without disconnecting the connectors, move the bracket
together with connector [C] aside and pull up the ECU [D]
with rubber protector.

•

Make sure that the ignition switch is turned off.

•

Disconnect the ECU connectors [A] from the ECU [B].

NOTICE

To protect the ECU from the electrical surge, dis-
connect the ECU connector while the ignition
switch is turned off.

3-86 FUEL SYSTEM (DFI)

ECU

ECU Installation

•

Install the ECU [A] into the rubber protector [B].

•

Connect the ECU connectors [C].

•

Insert the slits of the rubber protector to the projections
[D] of the rear fender.

•

Install the connector/bracket on the ECU and tighten the
screw.

•

Connect the connector to the turn signal relay.

•

Install the removed parts (see appropriate chapters).

ECU Power Supply Inspection

•

Remove the ECU (see ECU Removal).

•

Visually inspect the ECU connectors.
If the connector is clogged with mud or dust, blow it off
with compressed air.

•

Visually inspect the terminals [A] of the ECU connectors.
If the terminals of the main harness connectors are dam-
aged, replace the main harness.
If the terminals of the ECU connectors are damaged, re-
place the ECU.

•

Turn the ignition switch off.

•

Disconnect the ECU connectors [A].

•

Set the hand tester [B] to the × 1

Ω

range and check the

following wiring for continuity.

Special Tool - Hand Tester: 57001-1394

ECU Grounding Continuity Inspection

Connections:

(I) BK/Y leads (ECU

terminal 42 or 43)

←→

Battery (–) Terminal

(II) BK/BL leads (ECU

terminal 26)

←→

Battery (–) Terminal

(III) Engine Ground

←→

Battery (–) Terminal

Criteria: 0

Ω

If no continuity, check the connectors, the engine ground
lead, or main harness, and repair or replace them if nec-
essary.

FUEL SYSTEM (DFI) 3-87

ECU

If the wiring is good, check the power source voltage of
the ECU.

NOTE

○

Be sure the battery is fully charged.

•

Connect the ECU connectors.

•

Connect a digital meter [A] to the connector [B] with the
needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

ECU Power Supply Inspection

Connections:

(I) Digital Meter (+)

→

Terminal 12 (BR/W)

Digital Meter (–)

→

Battery (–) terminal

(II) Digital Meter (+)

→

Terminal 27 (W/BK)

Digital Meter (–)

→

Battery (–) terminal

Ignition Switch off:

Terminal 12 (BR/W): 0 V
Terminal 27 (W/BK): Battery Voltage

Ignition Switch on:

Both: Battery Voltage

If the reading is out of the specification, check the follow-
ing.

Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
FI Fuse 15 A (see Fuse Inspection in the Electrical Sys-
tem chapter)
ECU Main Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Power Source Wiring (see wiring diagram in this section)

If the fuse, wiring and relay are good, replace the ECU
(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-89

DFI Power Source

FI Fuse Removal

•

Refer to the FI Fuse 15 A Removal in the Electrical Sys-
tem chapter.

FI Fuse Installation

If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.

•

Refer to the Fuse Installation in the Electrical System
chapter.

FI Fuse Inspection

•

Refer to the Fuse Inspection in the Electrical System
chapter.

ECU Main Relay Removal/Installation

○

The ECU main relay is built in the relay box [A].

•

Refer to the Relay Box Removal in the Electrical System
chapter.

ECU Main Relay Inspection

•

Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.

3-90 FUEL SYSTEM (DFI)

Fuel Line

Fuel Pressure Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove:

Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)

○

Be sure to place a piece of cloth around the outlet pipes
of the fuel pump and the throttle body assy.

WARNING

Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.

•

Install the fuel pressure gauge adapter [A] and fuel hoses
(Special Tool: 57001-1607) [B] between the fuel supply
pipes of the fuel pump and throttle body assy.

•

Secure the fuel hoses with the clamps.

•

Connect the pressure gauge [C] to the fuel pressure
gauge adapter.

Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607

WARNING

Fuel is extremely flammable and can be explosive
under certain conditions resulting in serious injury
or death. Do not try to start the engine with the fuel
hoses disconnected.

•

Connect the fuel pump lead connector.

•

Turn the engine stop switch run position.

•

Turn the ignition switch on. The fuel pump will turn 3
seconds, and then stop.

NOTE

○

Turn the ignition switch on and inspect the fuel line leak-
age after installing the special tools.

NOTICE

Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.

•

Start the engine, and let it idle.

•

Measure the fuel pressure with the engine idling.

Fuel Pressure (with Engine Idling)

Standard: 294 kPa (3.0 kgf/cm², 43 psi)

FUEL SYSTEM (DFI) 3-91

Fuel Line

NOTE

○

The gauge needle will fluctuate. Read the pressure at
the average of the maximum and minimum indications.

•

Turn the ignition switch off.
If the fuel pressure is much higher than specified, the fuel
pressure regulator in the fuel pump have been clogged or
stuck. Replace the fuel pump (see Fuel Pump section).
If the fuel pressure is much lower than specified, check
the following.

Fuel Line Leakage (see Fuel Injector Fuel Line Inspec-
tion)
Amount of Fuel Flow (see Fuel Flow Rate Inspection)

•

After above checks, measure the fuel pressure again.

•

Remove the fuel pressure gauge, hoses and adapter.

•

Install:

Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)

•

Start the engine and check for fuel leakage.

Fuel Flow Rate Inspection

WARNING

Gasoline is extremely flammable and can be ex-
plosive under certain conditions, creating the
potential for serious burns. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch off.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch off.

•

Wait until the engine cools down.

•

Prepare a fuel hose (Special Tool: 57001-1607) and a
measuring cylinder.

Special Tool - Fuel Hose: 57001-1607

•

Remove the fuel tank bolts (see Fuel Tank Removal).

3-92 FUEL SYSTEM (DFI)

Fuel Line

•

Open the fuel tank cap [A] to release the pressure in the
tank.

•

Disconnect the fuel hose from the fuel pump (see Fuel
Tank Removal).

○

Be sure to place a piece of cloth around the fuel supply
pipe of the fuel pump.

WARNING

•

Connect the prepared fuel hose [A] to the outlet pipe of
the fuel pump.

•

Secure the fuel hose with a clamp.

•

Insert the fuel hose into the measuring cylinder [B].

WARNING

Wipe off spilled out fuel immediately. Be sure to
hold the measuring cylinder vertical.

•

Close the fuel tank cap.

•

Turn the engine stop switch to run position.

•

Turn the ignition switch on.

○

The fuel pump should operate for 3 seconds, and then
should stop.

NOTICE

Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.

•

Measure the discharge for 3 seconds.

○

Repeat this operation several times.

Amount of Fuel Flow

Standard: 50 mL (1.69 US oz.) or more for 3 seconds

•

Turn the ignition switch off.
If the fuel flow is much less than the specified, replace the
fuel pump (see Fuel Pump Removal/Installation).

•

Install the fuel tank (see Fuel Tank Installation).

•

Start the engine and check for fuel leakage.

FUEL SYSTEM (DFI) 3-93

Fuel Pump

Fuel Pump Removal

WARNING

Gasoline is extremely flammable and can be ex-
plosive under certain conditions, creating the
potential for serious burns. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch off.
Disconnect the battery (–) terminal. To avoid fuel
spills, draw it from the tank when the engine is
cold. Be prepared for fuel spillage; any spilled fuel
must be completely wiped up immediately.

NOTICE

Never drop the fuel pump especially on a hard sur-
face. Such a shock to the pump can damage it.

•

Draw the fuel out from the fuel tank with a commercially
available electric pump.

•

Remove the fuel tank (see Fuel Tank Removal).

○

Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug the outlet
pipe of the fuel pump.

•

Turn the fuel tank upside down.

•

Remove the fuel pump bolts [A] and pull up the fuel pump
[B].

NOTICE

Do not pull the lead of the fuel pump. If they are
pulled, the lead terminals may be damaged.

•

Remove the fuel pump unit [A] from the fuel tank.

NOTICE

Be careful not to bend the float arm [B] during the
fuel pump removal, it may cause incorrect indica-
tion of the fuel level gauge.

○

Do not try to disassemble the fuel pump unit.

3-94 FUEL SYSTEM (DFI)

Fuel Pump

Fuel Pump Installation

•

Remove dirt or dust from the fuel pump [A] by lightly ap-
plying compressed air.

•

Replace the fuel pump gasket [A] with a new one.

•

Install the fuel pump [B] into the fuel tank.

•

Position the fuel pump [A] as shown.

•

Apply a non-permanent locking agent to the threads of
the fuel pump bolts [B].

•

Tighten the fuel pump bolts to a snug fit, tighten them
alternating diagonally.

Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Check the fuel leakage after installation.

Fuel Pump Operation Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the engine stop switch to run position.

•

Turn the ignition switch on and make sure that the fuel
pump operates (make light sounds) for 3 seconds, and
then stops.

•

Turn the ignition switch off.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).

FUEL SYSTEM (DFI) 3-95

Fuel Pump

Fuel Pump Operating Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch off.

•

Remove the fuel tank bolts (see Fuel Tank Removal).

•

Disconnect the fuel pump lead connector and connect the
harness adapter [A] between these connectors as shown.

Main Harness [B]
Fuel Pump [C]

Special Tool - Measuring Adapter: 57001-1700

•

Connect a digital meter [D] to the harness adapter leads.

Fuel Pump Operating Voltage

Connections to Adapter:

Digital Meter (+)

→

R (pump BK/Y) lead

Digital Meter (–)

→

BK (pump BK/W) lead

•

Measure the operating voltage with engine stopped and
with the connector joined.

•

Turn the engine stop switch run position.

•

Turn the ignition switch on.

Operating Voltage

Standard: Battery Voltage for 3 seconds, and then 0 V

•

Turn the ignition switch off.
If the reading stays on battery voltage and never shows 0
V, check the fuel pump relay (see Relay Circuit Inspection
in the Electrical System chapter).
If the pump relay is normal, check the ECU for its ground
and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If there is still no battery voltage, check the ECU main
relay and fuel pump relay (see Relay Circuit Inspection in
the Electrical System chapter).
If the main relay and pump relay are normal, check the
wiring for continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is in specification, but the pump does not op-
erate, replace the fuel pump (see Fuel Pump Removal/In-
stallation).

3-96 FUEL SYSTEM (DFI)

Fuel Pump

Pressure Regulator Removal

○

The pressure regulator [A] is built into the fuel pump unit
[B] and can not be removed.

Fuel Filter Cleaning

○

The fuel filter [A] are built into the fuel pump unit and can
not be cleaned or checked.
If the fuel filter is suspected of clogging or being damaged,
replace it with the fuel pump as a set.

Fuel Pump Relay Removal/Installation

○

The fuel pump relay is built in the relay box [A].

•

Refer to the Relay Box Removal in the Electrical System
chapter.

Fuel Pump Relay Inspection

•

Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.

3-98 FUEL SYSTEM (DFI)

Fuel Injectors

Fuel Injector Removal/Installation

•

Refer to the Throttle Body Assy Disassembly/Assembly.

Fuel Injector Audible Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the left middle fairing (see Middle Fairing Re-
moval in the Frame chapter).

•

Start the engine, and let it idle.

•

Apply the tip of a screwdriver [A] to the fuel injector [B].
Put the grip end onto your ear, and listen whether the fuel
injector is clicking or not.

○

A sound scope can also be used.

○

The click interval becomes shorter as the engine speed
rises.

•

Do the same for the other fuel injector.
If all the fuel injectors click at a regular intervals, the fuel
injectors are normal.

•

Turn the ignition switch off.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).

Fuel Injector Resistance Inspection

•

Remove the fuel tank (see Fuel Tank Removal).

•

Disconnect the injector connector [A].

•

Connect a digital meter to the terminals of the injector [B].

•

Measure the fuel injector resistance.

Fuel Injector Resistance

Connections:

For Fuel Injector #1

W/R

←→

BL/BK terminal

For Fuel Injector #2

W/R

←→

BL/R terminal

Standard: About 11.7

∼

12.3

Ω

at 20°C (68°F)

If the reading is out of the standard, replace the injector.
If the reading is within the standard, check the power
source voltage (see Fuel Injector Power Source Voltage
Inspection).

FUEL SYSTEM (DFI) 3-99

Fuel Injectors

Fuel Injector Power Source Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the fuel tank (see Fuel Tank Removal).

•

Turn the ignition switch off.

•

Disconnect the injector connector and connect the har-
ness adapter [A] between these connectors as shown.

Main Harness [B]
Fuel Injector #1 [C]

Special Tool - Measuring Adapter: 57001-1700

•

Connect a digital meter [D] to the harness adapter leads.

Fuel Injector Power Source Voltage

Connections to Adapter:

For Fuel Injector #1, #2

Digital Meter (+)

→

R (injector W/R) lead

Digital Meter (–)

→

Battery (–) terminal

•

Measure the power source voltage with the engine
stopped.

•

Turn the engine stop switch to run position.

•

Turn the ignition switch on.

Power Source Voltage

Standard: Battery Voltage for 3 seconds, and then 0 V

•

Turn the ignition switch off.
If the reading stays on battery voltage and never shows 0
V, check the fuel pump relay (see Relay Circuit Inspection
in the Electrical System chapter).
If the pump relay is normal, check the ECU for its ground
and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If there is still no battery voltage, check the ECU main
relay and pump relay (see Relay Circuit Inspection in the
Electrical System chapter).
If the main relay and pump relay are normal, check the
power source wiring (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is in specification, check the output voltage
(see Fuel Injector Output Voltage Inspection).

3-100 FUEL SYSTEM (DFI)

Fuel Injectors

Fuel Injector Output Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch off.

•

Remove the ECU (see ECU Removal).

○

Do not disconnect the ECU connector.

•

Connect a digital meter [A] to the connector [B] with the
needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

Fuel Injector Output Voltage

Connections to ECU Connector:

For Fuel Injector #1

Digital Meter (+)

→

BL/BK lead (ECU terminal 34)

Digital Meter (–)

→

Battery (–) terminal

For Fuel Injector #2

Digital Meter (+)

→

BL/R lead (ECU terminal 33)

Digital Meter (–)

→

Battery (–) terminal

•

Measure the output voltage with the engine stopped and
with the connector joined.

•

Turn the engine stop switch to run position.

•

Turn the ignition switch on.

Output Voltage

Standard: Battery Voltage for 3 seconds, and then 0 V

•

Turn the ignition switch off.
If the reading is in specification, check the ECU for its
ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).

If the reading is out of the specification, remove the ECU
and check the wiring for continuity between main harness
connectors.

Special Tool - Hand Tster: 57001-1394

○

Disconnect the ECU and injector connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Fuel Injector Connector [B]

For Fuel Injector #1 [C]

BL/BK lead (ECU terminal 34) [D]

For Fuel Injector #2

BL/R lead (ECU terminal 33)

If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-101

Fuel Injectors

Fuel Injector Fuel Line Inspection

•

Remove:

Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)

○

Be sure to place a piece of cloth around the delivery pipes
of the fuel pump and the throttle body assy.

WARNING

Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.

•

Check the injector fuel line for leakage as follows.

○

Connect a commercially available vacuum/pressure
pump [A] to the nipple of the delivery pipe [B] with the
fuel hose [C] (both ends with the clamps [D]) as shown.

Right Side View [E]

○

Apply soap and water solution to the areas [F] as shown.

○

Watching the pressure gauge, squeeze the pump lever
[G], and build up the pressure until the pressure reaches
the maximum pressure.

Injector Fuel Line Maximum Pressure

Standard: 294 kPa (3.0 kgf/cm², 43 psi)

NOTICE

During pressure testing, do not exceed the maxi-
mum pressure for which the system is designed.

○

Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once or if bubbles are found in the
area, the fuel line is leaking. Replace the delivery pipe
assy, injectors and related parts.

○

Repeat the leak test, and check the fuel line for no leak-
age.

•

Install:

Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)

•

Start the engine and check for fuel leakage.

FUEL SYSTEM (DFI) 3-103

Throttle Grip and Cables

Free Play Inspection

•

Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.

Free Play Adjustment

•

Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.

Cable Installation

•

Install the throttle cables in accordance with the Cable,
Wire, and Hose Routing section in the Appendix chapter.

•

Install the lower ends of the throttle cables in the throttle
pulley on the throttle body assy after installing the upper
ends of the throttle cables in the grip.

•

After installation, adjust each cable properly (see Throttle
Control System Inspection in the Periodic Maintenance
chapter).

WARNING

Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition. Be sure the cables are routed correctly and
properly adjusted.

Cable Lubrication

•

Refer to the Chassis Parts Lubrication in the Periodic
Maintenance chapter.

3-104 FUEL SYSTEM (DFI)

Throttle Body Assy

Idle Speed Inspection/Adjustment

•

Refer to the Idle Speed Inspection/Adjustment in the Pe-
riodic Maintenance chapter.

Synchronization Inspection/Adjustment

•

Refer to the Engine Vacuum Synchronization Inspection
in the Periodic Maintenance chapter.

Throttle Body Assy Removal

WARNING

NOTICE

If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.

NOTICE

Never drop the throttle body assy especially on a
hard surface. Such a shock to the body assy can
damage it.

•

Remove:

Middle Fairings (see Middle Fairing Removal in the
Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)

•

Clean around the throttle body assy thoroughly.

•

Disconnect:

Main Throttle Sensor Connector [A]
Subthrottle Sensor Connector [B]

•

Remove the fuel hose [C] (see Fuel Hose Replacement
in the Periodic Maintenance chapter).

•

Disconnect:

Fuel Injector Connectors [A]
Subthrottle Valve Actuator Connector [B]

FUEL SYSTEM (DFI) 3-105

Throttle Body Assy

•

Loosen the nuts [A], and remove the throttle cable lower
ends [B].

•

Disconnect the vacuum hose [C].

•

Remove:

Bracket Bolts [A]
Upper Air Cleaner Housing Mounting Bolt [B]

•

Disconnect the air switching valve hose and intake air
temperature sensor connector [C] from the air cleaner
housing.

•

Remove the lower air cleaner housing mounting bolt [A].

•

Loosen the air duct clamp screw [B] (both sides).

•

Remove:

Battery (see Battery Removal in the Electrical System
chapter)
Air Cleaner Housing Cap (see Air Cleaner Element Re-
placement in the Periodic Maintenance chapter)
Screw [A]
Left Inner Cover [B]

•

Move the air cleaner housing [A] backward to pull out the
air ducts [B] from the throttle body assy [C].

3-106 FUEL SYSTEM (DFI)

Throttle Body Assy

•

Loosen the throttle body assy holder clamp screws [A],
and pull the throttle body assy [B] backward.

•

Remove the throttle body assy to left side of motorcycle.

•

After removing the throttle body assy, stuff pieces of lint-
free, clean cloth into the throttle body assy holders.

Throttle Body Assy Installation

•

Install the throttle body assy holder clamps [A] in the di-
rection as shown.

Screw Heads [B]

•

Install the throttle body assy to the throttle body assy hold-
ers.

•

Tighten:

Torque - Throttle Body Assy Holder Clamp Screws: 2.0

N·m (0.20 kgf·m, 18 in·lb)

•

Install the air duct clamps [A] in the direction as shown.

Screw Heads [B]

•

Move the air cleaner housing forward to connect the air
ducts to the throttle body assy.

•

Tighten:

Torque - Air Duct Clamp Screws: 2.0 N·m (0.20 kgf·m, 18

in·lb)

Air Cleaner Housing Mounting Bolts: 4.0 N·m

(0.41 kgf·m, 35 in·lb)

•

Tighten the air cleaner mounting bolts (see Air Cleaner
Housing Installation).

•

Apply a thin coating of grease to the throttle cable lower
ends.

•

Fit the accelerator cable end and the decelerator cable
end into the throttle pulley.

•

Turn the throttle grip and make sure that the throttle valves
move smoothly and return by spring force.

•

Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).

•

Adjust:

Throttle Grip Free Play (see Throttle Control System In-
spection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)

FUEL SYSTEM (DFI) 3-107

Throttle Body Assy

Throttle Body Assy Disassembly

1. Delivery Pipe Assy
2. Fuel Injectors
3. Throttle Body Assy
4. Main Throttle Sensor
5. Subthrottle Sensor
6. Subthrottle Valve Actuator
7. For CAL Model

NOTICE

Do not remove, disassemble or adjust the main
throttle sensor, subthrottle sensor, subthrottle
valve actuator, throttle link mechanism and throttle
body assy, because they are adjust or set surely at
the manufacturer. Adjustment of these parts could
result in poor performance, requiring replacement
of the throttle body assy.

•

Remove the throttle body assy (see Throttle Body Assy
Removal).

•

Cut the band [A].

•

Remove the screws [B] and pull out the injectors from the
throttle body assy together with the delivery pipe assy [C].

NOTE

○

Do not damage the insertion portions of the injectors
when they are pulled out from the throttle body.

3-108 FUEL SYSTEM (DFI)

Throttle Body Assy

•

Pull out the injectors [A] from the delivery pipe assy [B].

NOTE

○

Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.

NOTICE

Never drop the fuel injector especially on a hard
surface. Such a shock to the injector can damage
it.

Throttle Body Assy Assembly

•

Before assembling, blow away dirt or dust from the throttle
body and delivery pipe by applying compressed air.

•

Replace the O-rings [A] of each injector [B] with new ones.

•

Apply engine oil to the new O-rings, insert them to the
delivery pipe assy [C] and confirm whether the injectors
turn smoothly or not.

•

Replace the dust seals [A] with new ones.

•

Apply engine oil to the new dust seals.

•

Install the injectors along with the delivery pipe assy to
the throttle body.

•

Tighten:

Torque - Delivery Pipe Assy Mounting Screws: 3.4 N·m

(0.35 kgf·m, 30 in·lb)

•

Bind the lead with band.

•

Install the throttle body assy (see Throttle Body Assy In-
stallation).

FUEL SYSTEM (DFI) 3-109

Air Cleaner

Air Cleaner Element Removal/Installation

•

Refer to the Air Cleaner Element Replacement in the Pe-
riodic Maintenance chapter.

Air Cleaner Element Inspection

•

Remove the air cleaner element (see Air Cleaner Element
Replacement in the Periodic Maintenance chapter).

•

Visually check the element [A] for tears or breaks.
If the element has any tears or breaks, replace the ele-
ment.

Air Cleaner Oil Draining

•

Visually check the drain cap [A] if the water or oil accu-
mulates.
If any water or oil accumulates in the cap, remove the cap
and drain it.

WARNING

Oil on tires will make them slippery and can cause
an accident and injury. Be sure to reinstall the cap
in the drain hose after draining.

Air Cleaner Housing Removal

•

Remove:

Middle Fairings (see Middle Fairing Removal in the
Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Bracket Bolts [A]
Upper Air Cleaner Housing Mounting Bolt [B]
Chain Cover (see Driver Chain Removal in the Final
Drive chapter)
Rear Fender (see Flap and Rear Fender Removal in the
Frame chapter)

•

Disconnect the air switching valve hose and intake air
temperature sensor connector [C] from the air cleaner
housing.

•

Clean around the throttle body assy thoroughly.

•

Remove:

Lower Air Cleaner Housing Mounting Bolt [A]

•

Disconnect the breather hose [B] from the air cleaner
housing.

•

Loosen the air duct clamp screw [C] (both sides).

3-110 FUEL SYSTEM (DFI)

Air Cleaner

•

Move the air cleaner housing [A] backward to pull out the
air ducts [B] from the throttle body assy [C].

•

Remove the air cleaner housing [A] from the frame as
shown.

•

After removing the air cleaner housing, stuff pieces of lint-
free, clean cloth into the throttle body assy.

NOTICE

If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.

Air Cleaner Housing Installation

•

Installation is the reverse of removal.

○

Install the air duct clamps [A] in the direction as shown.

Screw Heads [B]

•

Push the air cleaner housing [A] forward to insert the pro-
jection [B] into the grommet [C].

•

Insert the air ducts [D] to the throttle body [E].

•

Tighten:

Torque - Air Duct Clamp Screws: 2.0 N·m (0.20 kgf·m, 18

in·lb)

Air Cleaner Housing Mounting Bolts: 4.0 N·m

(0.41 kgf·m, 35 in·lb)

•

Install the removed parts (see appropriate chapters).

Air Cleaner Housing Disassembly

•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)
Air Cleaner Element (see Air Cleaner Element Replace-
ment in the Periodic Maintenance chapter)
Screws [A]
Right Cover [B]
Flame Arrester

FUEL SYSTEM (DFI) 3-111

Air Cleaner

Air Cleaner Housing Assembly

•

Install the flame arrester [A].

•

Be sure the seal ring [B] is in position.

•

Apply a adhesive cement to the slash portions [A] of the
air cleaner housing.

•

Install the right cover.

•

Tighten:

Torque - Air Cleaner Housing Screws: 1.15 N·m (0.117

kgf·m, 10 in·lb)

3-112 FUEL SYSTEM (DFI)

Fuel Tank

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be ex-
plosive under certain conditions, creating the
potential for serious burns. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch off.
Disconnect the battery (–) terminal. To avoid fuel
spills, draw it from the tank when the engine is
cold. Be prepared for fuel spillage; any spilled fuel
must be completely wiped up immediately.

•

Turn the ignition switch off.

•

Wait until the engine cools down.

•

Disconnect the battery (–) terminal (see Battery Removal
in the Electrical System chapter).

•

Remove:

Front Seat (see Front Seat Removal in the Frame chap-
ter)
Tank Side Cover (see Tank Side Cover Removal in the
Frame chapter)
Fuel Tank Bolts [A]

•

Disconnect the fuel tank drain hose [A] from the tank [B].

○

In this photo, the left middle fairing has been removed for
clearity.

•

For models equipped with the evapratice emission con-
trol system, disconnect the fuel tank drain hose [A] and
breather hose [B] from the fuel tank.

FUEL SYSTEM (DFI) 3-113

Fuel Tank

•

Open the fuel tank cap [A] to release the pressure in the
tank.

•

Draw the fuel out from the fuel tank with a commercially
available pump [A].

○

Use a soft plastic hose [B] as a pump intake hose in order
to insert the hose smoothly.

○

Put the hose through the fill opening [C] into the tank and
draw the fuel out.

Front [D]

WARNING

Spilled fuel is flammable and can be explosive un-
der certain conditions. The fuel can not be removed
completely from the fuel tank. Be careful for re-
mained fuel spillage.

•

Lift the rear of the fuel tank slightly and disconnect the fuel
pump lead connector [A].

•

Be sure to place a piece of cloth around the fuel hose joint
[B].

•

Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.

3-114 FUEL SYSTEM (DFI)

Fuel Tank

When removing with standard tip screwdriver

•

Insert the standard tip screwdriver [A] into slit on the joint
lock [B].

•

Turn the driver to disconnect the joint lock.

When removing with fingers

•

Open and push up [C] the joint lock with your fingers.

NOTICE

Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.

•

Pull the fuel hose joint [A] out of the outlet pipe [B].

WARNING

Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.

•

Remove the fuel tank, and place a it on a flat surface.

•

Clean the pipe [A].

•

Cover the pipe and the hose joint [B] with the vinyl bags
[C] to keep it clean.

•

Close the fuel tank cap.

FUEL SYSTEM (DFI) 3-115

Fuel Tank

Fuel Tank Installation

•

Note the above WARNING (see Fuel Tank Removal).

•

Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).

•

Check that the dampers [A] are in place on the frame and
the fuel tank.
If the dampers are damaged or deteriorated, replace
them.

•

Remove the vinyl bag on the pipe and fuel hose joint.

•

Check the joint lock for deformation and wear.
If the joint lock is deformed, replace the fuel hose with a
new one.

•

Check that there are no flaws, burrs, and adhesion of
foreign materials on the outlet pipe [A].

•

Apply engine oil to the pipe.

•

Insert the fuel hose joint [A] straight onto the outlet pipe
until the hose joint clicks.

•

Push the joint lock [B] until the hose joint clicks.

•

Push and pull [A] the hose joint [B] more than two times
to make sure it is locked and does not come off.

WARNING

Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe by sliding the
joint.

If it comes off, reinstall the hose joint.

•

Connect the fuel pump lead connector [C] and the battery
(–) terminal (see Battery Installation in the Electrical Sys-
tem chapter).

•

Install the removed parts (see appropriate chapters).

Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013) - page 6