Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year)

3-54 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions (chapter)

Spark plug dirty, broken or gap maladjusted

Clean spark plugs and adjust plug gap (see
chapter 2).

Too low fuel pressure

Inspect (see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Atmospheric pressure sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Vacuum switch valve broken

Inspect and replace (see chapter 5).

Air suction valve trouble

Inspect and replace (see chapter 5).

After fire:

Crankshaft sensor trouble

Inspect (see chapter 16).

Spark plug burned or gap maladjusted

Adjust plug gap or replace plug (see chapter 2).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Atmospheric pressure sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Run-on (dieseling):

Ignition switch trouble

Inspect and replace (see chapter 16).

Engine stop switch trouble

Inspect and repair or replace (see chapter 16).

Fuel injector trouble

Inspect (see chapter 3).

Loose terminal of battery (–) lead or ECU
ground lead

Inspect and repair (see chapter 16).

Carbon accumulating on valve seating surface Repair (see chapter 5).

Engine overheating

(see Overheating of Troubleshooting Guide, see
chapter 17)

Other:

Engine oil viscosity too high

Change (see chapter 2).

Drive train trouble

Inspect drive chain (see chapter 2) and sprocket
(see chapter 11).

Brake dragging

Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (see
chapter 12).

Clutch slipping

Inspect friction plates for wear (see chapter 6).

Engine overheating

(see Overheating of Troubleshooting Guide, see
chapter 17)

Vacuum switch valve trouble

Inspect and replace (see chapter 5).

Air suction valve trouble

Inspect and replace (see chapter 5).

Intermittent any DFI fault and its recovery

Check that DFI connectors are clean and tight,
and examine wires for signs of burning or fraying
(see chapter 3).

FUEL SYSTEM (DFI) 3-55

DFI System Troubleshooting Guide

Poor Running or No Power at High Speed

Symptoms or Possible Causes

Actions (chapter)

Firing incorrect:

Spark plug dirty, broken or maladjusted

Clean spark plug and adjust plug gap (see chapter
2).

Spark plug cap trouble

Inspect stick coil (see chapter 16).

Spark plug cap 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).

Crankshaft sensor trouble

Inspect (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Fuel/air mixture incorrect:

Choke lever pulled

Push it (see chapter 3).

Air cleaner clogged, poorly sealed or missing

Clean element or inspect sealing (see chapter 3).

Air cleaner duct loose

Reinstall (see chapter 3).

Air cleaner O-ring damaged

Replace (see chapter 3).

Water or foreign matter in fuel

Change fuel. Inspect and clean fuel system (see
chapter 3).

Throttle body assy loose

Reinstall (see chapter 3).

Throttle body assy O-ring damaged

Replace (see chapter 3).

Fuel tank air vent obstructed

Inspect and repair (see chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Fuel pump operates intermittently and often
ECU fuse blows.

Pump bearings may wear. Replace the pump (see
chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Atmospheric pressure sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Cracked or obstructed inlet air pressure sensor
hose

Inspect and repair or replace (see chapter 3).

Injector clogged

Visually inspect and replace (see chapter 3).

Compression low:

Spark plug loose

Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down

Tighten (see chapter 5).

No valve clearance

Adjust (see chapter 2).

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).

Cylinder head warped

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 the seating surface)

Inspect and repair or replace (see chapter 5).

Knocking:

Carbon built up in combustion chamber

Repair (see chapter 5).

3-56 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions (chapter)

Fuel poor quality or incorrect (Use the gasoline
recommended in the Owner’s Manual)

Change fuel (see chapter 3).

Spark plug incorrect

Replace it with the correct plug (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

IC igniter in ECU trouble

Inspect (see chapter 16).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Atmospheric pressure sensor trouble

Inspect (see chapter 3).

Miscellaneous:

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Speed sensor trouble

Inspect (see chapter 3).

Throttle valves won’t fully open

Inspect throttle cable and lever linkage (see
chapter 3).

Brake dragging

Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (see
chapter 12).

Clutch slipping

Inspect friction plates for wear (see chapter 6).

Engine overheating - water temperature sensor,
crankshaft sensor or speed sensor trouble

(see Overheating of Troubleshooting Guide in
chapter 17)

Engine oil level too high

Repair (see chapter 7).

Engine oil viscosity too high

Change (see chapter 3).

Drive train trouble

Inspect drive chain (see chapter 2) and sprockets
(see chapter 11).

Camshaft cam worn

Inspect and replace (see chapter 5).

Vacuum switch valve trouble

Inspect and replace (see chapter 5).

Air suction valve trouble

Inspect and replace (see chapter 5).

Catalytic converters melt down due to muffler
overheating (KLEEN)

Replace muffler (see chapter 5).

Exhaust Smokes Excessively:
(White smokes)

Piston oil ring worn

Inspect and replace (see chapter 5).

Cylinder worn

Inspect and replace (see chapter 5).

Valve oil seal damaged

Replace (see chapter 5).

Valve guide worn

Replace the guide (see chapter 5).

Engine oil level too high

Repair (see chapter 7).

(Black smoke)

Air cleaner clogged

Clean (see chapter 3).

Choke lever pulled

Push it (see chapter 3).

Too high fuel pressure

Inspect (see chapter 3).

Injector stuck open

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect and replace (see chapter 3).

Inlet air temperature sensor trouble

Inspect and replace (see chapter 3).

(Brown smoke)

Air cleaner duct loose

Reinstall (see chapter 3).

Air cleaner O-ring damaged

Replace (see chapter 3).

3-58 FUEL SYSTEM (DFI)

Self-Diagnosis

Self-diagnosis Outline

The self-diagnosis system has three modes and can be

switched to another mode by grounding the self-diagnosis
indicate terminal [A].

User Mode

The ECU notifies the rider of troubles in DFI system and

ignition system by lighting the FI indicator when DFI sys-
tem and ignition system parts a faulty, and initiates fail-safe
function. In case of serious troubles ECU stops the injec-
tion/ignition/starter motor operation to prevent battery dis-
charge, and notifies the rider that the engine will no start.

Dealer Mode 1

The FI indicator LED light emits service code(s) to show

the problem(s) which the DFI system and ignition system
has at the moment of diagnosis.

Dealer Mode 2

The FI indicator light LED emits service code(s) to show

the problem(s) which the DFI system and ignition system
had in the past.

Self-diagnosis Function

The self-diagnosis indicates problems with the parts,

wiring, and ECU in the DFI system and ignition system.

The ECU [C] always monitors each DFI circuit [A] for

problems by measuring the voltage [B]. This circuit includes
parts [D], and wiring [E].

When the circuit is open (problem), the following are pos-

sible problems.

Disconnection [F] in the Parts
Disconnection [G] in the Wiring
Disconnection [H] in the ECU

When the FI indicator indicates a problem, the ECU has

the possibility of the problem as well as the parts and the
wiring outside the ECU.

FUEL SYSTEM (DFI) 3-59

Self-Diagnosis

Self-diagnosis Procedures

○

When a problem occurs with the DFI system and ignition
system, the DFI indicator LED light [A] goes on.

NOTE

○

Use a fully charged battery when conducting
self-diagnosis. Otherwise, the LED light blinks very
slowly or doesn’t blink.

○

Keep the display switch grounded during self-diagnosis,
with a auxiliary lead.

•

Remove the strage box (see Frame chapter) and pull the
self-diagnosis indicator terminal [G].

•

Turn on the ignition switch.

•

Connect an auxiliary a lead [E] for grounding to the self-
diagnosis indicator terminals.

•

Enter the self-diagnosis dealer mode 1 by grounding
[A] the self-diagnosis indicator terminal to the ground
for more than 2 seconds [C], and then keep it grounded
continuously [D].

○

Count the blinks of the LED light to read the service code.

•

Enter the self-diagnosis dealer mode 2 by repeat opening
[B] and grounding [A] the lead more than five times [F]
within 2 seconds [C] after the lead is first grounded, and
then keep it grounded continuously [D] for more than 2
seconds.

○

Count the blinks of the LED light to read the service code.

NOTE

○

If the self-diagnosis mode is in user mode or dealer
mode 1 then you need to enter the dealer mode 2, turn
off the ignition switch once.

FUEL SYSTEM (DFI) 3-61

Self-Diagnosis

How to Read Service Codes

○

Service codes are shown by a series of long or short blinks of the FI indicator LED light as shown
below.

○

Read 10th digit and unit digit as the FI indicator LED light blinks.

○

When there are a number of problems, all the service codes can be stored and the display will
begin starting from the lowest number service code in the numerical order. Then after completing
all codes, the display is repeated until the self-diagnosis indicator terminal is open.

○

If there is no problem, no code is shown.

○

Repeat blinks [C] or light [B], unlight [A].

○

For example, if four problems occurred in the order of 12, 21, the service codes are displayed from
the lowest number in the order listed.

(12

→

21)

→

(12

→

21)

→

· · · (repeated)

○

If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator
LED light doesn’t go on, and no service codes can be displayed.

FI Indicator LED Light
Fuel Pump
Pressure Regulator (Fuel Pressure, Fuel Flow Rate)
DFI Main Relay
Ignition Coil Secondary Wiring (see Electrical System chapter)
ECU Power Source Wiring and Ground Wiring (see ECU Inspection in this chapter)

3-62 FUEL SYSTEM (DFI)

Self-Diagnosis

How to Erase Service Codes

○

Even if the ignition SW is turned OFF, or the problem is solved, all service codes remain in the ECU.
If the battery or the ECU are disconnected, all service codes will disappear in the ECU.

Service Code Table

Service

Code

FI Indicator LED Light

Problems (1)

Throttle sensor (ZX1200-B1/B2), main throttle sensor
(ZX1200-B3

∼

), malfunction, wiring open or short

Inlet air pressure sensor malfunction, wiring open or
short

Inlet air temperature sensor malfunction, wiring open
or short

Water temperature sensor malfunction, wiring open or
short

Atmospheric pressure sensor malfunction, wiring open
or short

Crankshaft sensor malfunction, wiring open or short

Camshaft position sensor malfunction, wiring open or
short

Speed sensor malfunction, wiring open or short

Gear position switch malfunction, wiring open or short

Vehicle-down sensor, malfunction, wiring open or short

Subthrottle sensor malfunction, wiring open or short

Immobilizer amplifier malfunction

Blank key detection

Injector #1 malfunction, wiring open or short

Injector #2 malfunction, wiring open or short

Injector #3 malfunction, wiring open or short

Injector #4 malfunction, wiring open or short

FUEL SYSTEM (DFI) 3-63

Self-Diagnosis

Service

Code

FI Indicator LED Light

Problems (1)

Fuel pump relay wiring open

Fuel pump relay stuck ON

Ignition coil #1 malfunction, wiring open or short

Ignition coil #2 malfunction, wiring open or short

Ignition coil #3 malfunction, wiring open or short

Ignition coil #4 malfunction, wiring open or short

Subthrottle valve actuator malfunction, wiring open or
short

Footnotes

(1) The ECU may be involved in these problems. If all the parts and circuits checked out good, be

sure to check the ECU for ground and power supply. If the ground and power supply are checked
good, replace the ECU.

3-64 FUEL SYSTEM (DFI)

Self-Diagnosis

Backups

○

The ECU takes the following measures to prevent engine damage when the DFI or the ignition
system parts have troubles.

Service

Codes

Parts

Output Signal Usable

Range or Criteria

Backups by ECU

Throttle

Sensor

(ZX1200

-B1/B2),

Main

Throttle

Sensor

(ZX1200-B3

∼

)

ZX1200-B1/B2:
Throttle Valve Opening
Angle

= 6.5°

∼

+ 86.5°

ZX1200-B3

∼

Main Throttle Sensor Output
Voltage
0.2

∼

4.8 V

If the throttle sensor system fails (the signal
is out of the usable range, wiring short or
open), the ECU locks ignition timing into the
ignition timing at closed throttle position and
sets the DFI in the D-J method.
Also, the throttle sensor system and inlet air
pressure fails, the ECU locks ignition timing
into the ignition timing at closed throttle
position and sets the DFI in the

-N method.

Inlet Air

Pressure

Sensor

Inlet Air Pressure (absolute)
Pv = 100 mmHg

∼

900 mmHg

If the inlet air pressure sensor system fails
(the signal Pv is out of the usable range,
wiring short or open), the ECU sets the DFI
in the

- N method (1).

Inlet Air

Temperature

Sensor

Inlet Air Temperature
Ta = –47°C

∼

+ 178°C

If the inlet air temperature sensor fails (the
signal is out of the usable range, wiring
short or open), the ECU sets Ta at 45°C.

Water

Temperature

Sensor

Water Temperature
Tw = –30C°

∼

+ 120°C

If the water temperature sensor system fails
(the signal is out of the usable range, wiring
short or open), the ECU sets Tw at 86°C.

Atmospheric

Pressure

Sensor

Absolute Atmospheric
Pressure
Pa = 100 mmHg

∼

900 mmHg

If the atmospheric pressure sensor system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets Pa
at 760 mmHg (the standard atmospheric
pressure).

Crankshaft

Sensor

Crankshaft sensor must send
signals (output voltage) 8
continuously to the ECU.

If crankshaft sensor generates less than 8
or more signals, the engine stops by itself.

Camshaft

Position

Sensor

Camshaft position sensor
must send one signal (output
signal) to the ECU at the two
cranking

If the camshaft position sensor system fails
(the signal is missing, wiring short or open),
the ECU continues to ignite cylinders in
the same sequence following the last good
signal.

Speed

Sensor

The output voltage of the
rectangular wave:
Low Level: 1 V to 0
High Level: 4 V to 5 V

If the speed sensor system fails (no
conductivity, wiring short or open),
revolution limiter begin to start before
getting to the specified speed.

Gear

Position

Switch

Gear Position Switch
ON = Ground
OFF = 5 V or more (neutral),
5 V or less

If the gear position switch system fails (the
signal is out of the usable range, wiring
short or open), the ECU locks in 6th gear
position.

Vehicle

-down

Sensor

Vehicle-down Sensor Output
Voltage (signal)
Vd = 0.4 V

∼

4.4 V

If the vehicle-down sensor system has
failures (the output voltage Vd is out of
the usable range, wiring short or open),
the ECU shuts off the fuel pump, the fuel
injectors and the ignition system.

FUEL SYSTEM (DFI) 3-65

Self-Diagnosis

Service

Codes

Parts

Output Signal Usable

Range or Criteria

Backups by ECU

Subthrottle

Sensor

Subthrottle Sensor Output
Voltage
0.15

∼

4.85 V

If the subthrottle sensor system fails (the
signal is out of the usable range, wiring
short or open), the actuator locks subthrottle
valve at full open position.

Immobilizer

Amplifier

—

If the immobilizer system fails (no signal,
wiring short or open), the vehicle is no start
and run.

Master or

User Key

The user or master key must
use register key.

If the blank key or broken key is used, the
vehicle is no start and run.

Fuel Injector

#1*

The injector must send
signals (output voltage)
continuously to the ECU.

If the injector #1 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#1, though the engine keeps running.

Fuel Injector

#2*

The injector must send
signals (output voltage)
continuously to the ECU.

If the injector #2 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#2, though the engine keeps running.

Fuel Injector

#3*

The injector must send
signals (output voltage)
continuously to the ECU.

If the injector #3 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#3, though the engine keeps running.

Fuel Injector

#4*

The injector must send
signals (output voltage)
continuously to the ECU.

If the injector #4 fails (no signal, wiring short
or open), the ECU shuts off the signal to the
injector. Fuel is not supplied to the cylinder
#4, though the engine keeps running.

Stick Coil

#1 (Ignition

Coil)*

The ignition coil primary
winding must send signals
(output voltage) continuously
to the ECU.

If the ignition primary winding #1 has
failures (no signal, wiring short or open),
the ECU shuts off the injector #1 to stop
fuel to the cylinder #1, though the engine
keeps running.

Stick Coil

#2 (Ignition

Coil)*

The ignition coil primary
winding must send signals
(output voltage) continuously
to the ECU.

If the ignition primary winding #2 has
failures (no signal, wiring short or open),
the ECU shuts off the injector #2 to stop
fuel to the cylinder #2, though the engine
keeps running.

Stick Coil

#3 (Ignition

Coil)*

The ignition coil primary
winding must send signals
(output voltage) continuously
to the ECU.

If the ignition primary winding #3 has
failures (no signal, wiring short or open),
the ECU shuts off the injector #3 to stop
fuel to the cylinder #3, though the engine
keeps running.

Stick Coil

#4 (Ignition

Coil)*

The ignition coil primary
winding must send signals
(output voltage) continuously
to the ECU.

If the ignition primary winding #4 has
failures (no signal, wiring short or open),
the ECU shuts off the injector #4 to stop
fuel to the cylinder #4, though the engine
keeps running.

Subthrottle

Valve

Actuator

The actuator operates open
and close of the subthrottle
valve by the pulse signal from
the ECU.

If the sub throttle actuator fails (the signal
is out to the usable range, wiring short or
open), the ECU stops the current to the
actuator.

FUEL SYSTEM (DFI) 3-67

Throttle Sensor (Service Code 11) (ZX1200-B1/B2)

The throttle sensor is a rotating variable resistor that

change output voltage according to throttle operating.
The ECU senses this voltage change and determines fuel
injection quantity, and ignition timing according to engine
rpm, and throttle opening.

Input Terminal [A]
Output Terminal [B]
Ground Terminal [C]
Front [D]

Throttle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the throttle sensor [A]
since it has been adjusted and set with precision
at the factory.
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.
Do not connect the throttle sensor connector to the
inlet air pressure sensor, because the inlet air pres-
sure sensor is broken by opposite electrical con-
nection.

Throttle Sensor Connector [B]

Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

○

The inspection is the same as “Input Voltage Inspection”
of the vacuum sensor and the atmospheric pressure
sensor.

•

Turn the ignition switch OFF.

•

Remove the ECU (see this chapter). Do not disconnect
the ECU connectors.

•

Connect a digital voltmeter [A] to the connector [B], using
the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

•

Measure the input voltage with the engine stopped, and
with the connectors joined.

Turn the ignition switch ON.

Throttle Sensor Input Voltage

Connections to ECU Connector

Meter (+)

→

BL/W lead (terminal 41)

Meter (–)

→

BR/BK lead (terminal 54)

Input Voltage at ECU Connector

Standard: 4.75

∼

5.25 V DC

•

Turn the ignition switch OFF.
If the reading of input voltage is less than the standard,
check the ECU for its ground, power supply and wiring
shorted.
If the input voltage is within the standard range, check the
input voltage at the throttle sensor connector.

•

Remove the left lower inner cover (see Frame chapter).

3-68 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code 11) (ZX1200-B1/B2)

•

Disconnect the throttle sensor connector and connect the
harness adapter between the sub harness connector and
throttle sensor connector.

•

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

Special Tool - Throttle Sensor Setting Adapter:

57001

-1521

•

Measure the sensor input voltage with the engine
stopped, and with the connector joined.

•

Turn the ignition switch ON.

Throttle Sensor Input Voltage

Connections to Sensor

Meter (+)

→

BL/W lead [C]

Meter (–)

→

BR/BK lead [D]

Input Voltage at Sensor

Standard: 4.75

∼

5.25 V DC

•

Turn the ignition switch OFF.
If the reading is out of the range, check the wiring (see
wiring diagram in this section).
If the reading is good, check the output voltage of the
sensor.

Output Voltage Inspection

•

Measure the output voltage at the ECU in the same way
as input voltage inspection. Note the following.

Digital Voltmeter [A]
Connector [B]

Special Tool - Needle Adapter Set: 57001-1457

•

Start the engine and warm it up thoroughly.

•

Check idle speed to ensure throttle opening is correct.

Idle Speed

Standard:

1 000 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust the
idle speed (see Idle Speed Inspection in the Periodic
Maintenance chapter).

•

Turn the ignition switch OFF.

•

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

•

Turn the ignition switch ON.

•

Measure the output voltage when the throttle is fully
opened or completely closed.

Throttle Sensor Output Voltage

Connections to ECU

Meter (+)

→

Y/W lead (terminal 56)

Meter (–)

→

BR/BK lead (terminal 54)

Output Voltage at ECU

Standard:

1.07

∼

4.61 V DC (at idle throttle opening

to full throttle opening)

FUEL SYSTEM (DFI) 3-69

Throttle Sensor (Service Code 11) (ZX1200-B1/B2)

NOTE

○

The throttle sensor is operating correctly if the following
voltages are obtained:
• 1.07 VDC (or slightly higher) with the throttle at the idle
position.
• 4.61 VDC (or slightly lower) with the throttle at the fully
open position.

CAUTION

Do not remove or adjust the throttle sensor. It has
been adjusted and set with precision at the factory.
Never drop the sensor can especially on a hard sur-
face. A shock to the sensor can damage it.

If the output voltage is within the standard range, check
the ECU for a good ground, and power supply (see this
chapter). If the ground and power supply are good, re-
place the ECU.
If the output voltage is far out of the standard range (e.g.
when the wiring is open, the reading is 0 V), check the
output voltage again at the sensor connector.

•

Disconnect the throttle sensor connector and connect the
harness adapter between the sub harness connector and
throttle sensor connector.

•

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

Special Tool - Throttle Sensor Setting Adapter:

57001

-1521

•

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

•

Turn the ignition switch ON.

•

Measure the output voltage when the throttle is fully
opened or completely closed.

Throttle Sensor Output Voltage

Connections to Sensor

Meter (+)

→

Y/W lead [C]

Meter (–)

→

BR/BK lead [D]

Output Voltage at Sensor

Standard:

1.07

∼

4.61 V DC (at idle throttle opening

to full throttle opening)

3-70 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code 11) (ZX1200-B1/B2)

NOTE

○

CAUTION

Do not remove or adjust the throttle sensor. It has
been adjusted and set with precision at the factory.
Never drop the sensor, especially on a hard surface.
A shock to the sensor can damage it.

NOTE

○

The standard voltage marked with an asterisk refers to
the value when the voltage reading at the Input Voltafe
Inspection shows 5V exactly.

○

When the input voltage reading shows other than 5V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.07 × 4.75 ÷ 5.00 = 1.02 V
4.61 × 4.75 ÷ 5.00 = 4.38 V
Thus, the valid range is 1.02

∼

4.38 V

•

After throttle sensor voltage inspection, remove the har-
ness adapter.
If the reading is out of the standard range, inspect the
throttle sensor resistance.
If the output voltage is normal, check the wiring for conti-
nuity (see next diagram).

Resistance Inspection

•

Turn the ignition switch OFF.

•

Disconnect the throttle sensor connector.

•

Connect a digital meter [A] to the throttle sensor connector
[B].

•

Measure the throttle sensor resistance.

Throttle Sensor Resistance

Connections:

BL/W lead [C]

←→

BR/BK lead [D]

Standard:

∼

6 k

Ω

If the reading is out of the range, replace the throttle body
assy.
If the reading is within the range, but the problem still
exists, replace the ECU (see this chapter).

3-72 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11) (ZX1200-B3

∼

)

Main Throttle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the main throttle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.

Main Throttle Sensor Connector (gray) [B]

Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Disconnect the main throttle sensor connector (gray) [A]
and connect the harness adapter [B] between these con-
nectors.

•

Connect a digital meter to the harness adapter lead.

Special Tool - Throttle Sensor Harness Adapter: 57001

-1538

•

Measure the sensor input voltage with the engine stopped
and with the connector joined.

•

Turn the ignition switch ON.

Main Throttle Sensor Input Voltage

Connections to Adapter

Meter (+)

→

BK (sensor BL/W) lead

Meter (–)

→

W (sensor BR/BK) lead

Standard:

4.75

∼

5.25 V DC

•

Turn the ignition switch OFF.
If the input voltage is normal, check the sensor output
voltage.
If the input voltage is less than the standard, remove the
ECU and check the wiring between these connectors.

○

Disconnect the ECU and sensor connectors.

Wiring Connection

ECU Connector [A]

←→

Throttle Sensor Connector [B]

BL/W lead (ECU terminal 10)
BR/BK lead (ECU terminal 28)

If the wiring is good, check the ECU for its ground and
power supply (see ECU section).

FUEL SYSTEM (DFI) 3-73

Main Throttle Sensor (Service Code 11) (ZX1200-B3

∼

)

Output Voltage Inspection

•

Measure the output voltage at the main throttle sensor
in the same way as input voltage inspection, Note the
following.

•

Disconnect the main throttle sensor connector (gray) [A]
and connect the harness adapter [B] between these con-
nectors.

Special Tool - Throttle Sensor Harness Adapter: 57001

-1538

•

Start the engine and warm it up thoroughly.

•

Check idle speed to ensure the throttle opening is correct.

Idle Speed

Standard:

1 000 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it
(see Idle Speed Inspection in the Periodic Maintenance
chapter).

•

Turn off the ignition switch.

•

Measure the output voltage of the sensor with the engine
stopped, and with the connector joined.

•

Turn the ignition switch ON.

Main Throttle Sensor Output Voltage

Connections to Adapter

Meter (+)

→

R (sensor Y/W) lead

Meter (–)

→

W (sensor BR/BK) lead

Standard:

1.06

∼

1.10 V DC (at idle throttle opening)

4.26

∼

4.86 V DC (at full throttle opening)

If the output voltage is out of the standard, inspect the
main throttle sensor resistance.
If the output voltage is normal, check the wiring for conti-
nuity.

Wiring Connection

ECU Connector [A]

←→

Throttle Sensor Connector [B]

Y/W lead (ECU terminal 7)
BR/BK lead (ECU terminal 28)

If the wiring is good, check the ECU for its ground and
power supply (see ECU section).

3-74 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11) (ZX1200-B3

∼

)

Resistance Inspection

•

Turn the ignition switch OFF.

•

Disconnect the main throttle sensor connector.

•

Connect a digital meter [A] to the main throttle sensor
connector [B].

•

Measure the main throttle sensor resistance.

Main Throttle Sensor Resistance

Connections:

BL/W lead [C]

←→

BR/BK lead [D]

Standard:

∼

6 k

Ω

If the reading is out of the range, replace the throttle body
assy.
If the reading is within the range, but the problem still
exists, replace the ECU (see this chapter).

1. ECU

12. Main Throttle Sensor

A. Throttle Body Assy Connector

FUEL SYSTEM (DFI) 3-75

Inlet Air Pressure Sensor (Service Code 12)

CAUTION

Never drop the sensor, especially on a hard surface.
Such a shock to the part can damage it.

Inlet Air Pressure Sensor Removal

•

Remove the left lower inner cover (see Frame chapter).

•

Unscrew the inlet air pressure sensor bracket nut [A] to
remove the air pressure sensor [B].

•

For ZX1200-B3 model

∼

; as shown in the figure.

•

Disconnect the inlet air pressure sensor connector [A].

•

Disconnect the vacuum hose [B] from the joint.

•

Remove the inlet air pressure sensor [C].

•

For ZX1200-B3 model

∼

; as shown in the figure.

3-76 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

Inlet Air Pressure Sensor Installation

CAUTION

Do not connect the throttle sensor connector to the
inlet air pressure sensor, because the pressure sen-
sor is broken by the opposite electrical connection.

NOTE

○

The inlet air pressure sensor is the same part as the at-
mospheric sensor except that the sensor has a vacuum
hose and different wiring.

•

Route the vacuum hose correctly (see Cable, Wire, and
Hose Routing section in General Information chapter).
Make sure they do not get pinched or kinked.

•

Install:

Inlet Air Pressure Sensor [A]
Frame Ground [B]

○

Hit the stopper [C] of the inlet air pressure sensor bracket
onto the frame [D].

Torque - Inlet Air Pressure Sensor Bolts: 12 N·m (1.2 kgf·m,

106 in·lb)

Inlet Air Pressure Sensor Bracket Nut: 12 N·m (1.2

kgf·m, 106 in·lb)

Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

○

The inspection is the same as “Input Voltage Inspection”
of the throttle sensor and the atmospheric pressure sen-
sor.

•

Turn the ignition switch OFF.

•

Remove the ECU (see this chapter). Do not disconnect
the ECU connectors.

•

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

○

Measure the input voltage with the engine stopped, and
with the connectors joined.

Special Tool - Needle Adapter Set: 57001-1457

•

Turn the ignition switch ON.

Inlet Air Pressure Sensor Input Voltage

Connections to ECU

ZX1200-B1/B2:

Meter (+)

→

BL/W lead (terminal 41)

ZX1200-B3

∼

Meter (+)

→

BL/W lead (terminal 10)

Meter (–)

→

BR/BK lead (terminal 28)

Input Voltage at ECU

Standard:

4.75

∼

5.25 V DC

Meter (–)

→

BR/BK lead (terminal 54)

If the reading is less than the standard range, check the
ECU for its ground, and power supply (see this chapter). If
the ground and power supply are good, replace the ECU.

FUEL SYSTEM (DFI) 3-77

Inlet Air Pressure Sensor (Service Code 12)

If the reading is within the standard range, and check the
input voltage again at the sensor connector.

•

Disconnect the inlet air pressure sensor connector and
connect the harness adapter between the sub harness
connector and inlet air pressure sensor connector.

•

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

Special Tool - Throttle Sensor Setting Adapter:

57001

-1521

•

Measure the input voltage with the engine stopped.

•

Turn the ignition switch ON.

Inlet Air Pressure Sensor Input Voltage

Connections to Sensor

Meter (+)

→

BL/W lead [C]

Meter (–)

→

BR/BK lead [D]

Input Voltage at Sensor Connector

Standard:

4.75

∼

5.25 V DC

If the reading is out of the standard range, check the
wiring (see wiring diagram in this section).
If the reading is good, the input voltage is normal. Check
the output voltage.

Output Voltage Inspection

•

Measure the output voltage at the ECU in the same way
as input voltage inspection. Note the following.

Inlet Air Pressure Sensor Output Voltage

Connections to ECU

ZX1200-B1/B2:

Meter (+)

→

Y/BL lead (terminal 51)

Meter (–)

→

BR/BK lead (terminal 54)

ZX1200-B3

∼

Meter (+)

→

Y/BL lead (terminal 8)

Meter (–)

→

BR/BK lead (terminal 28)

Output Voltage at ECU

Usable Range:

3.46

∼

3.82 V DC at the standard

atmospheric pressure (101.32 kPa,
76 cmHg abs.)

NOTE

○

The output voltage changes according to the local at-
mospheric pressure.

○

The vacuum sensor output voltage is based on a nearly
perfect vacuum in the small chamber of the sensor. So,
the sensor indicates absolute vacuum pressure.

If the output voltage is within the usable range, check the
ECU for its ground, and power supply (see this chapter). If
the ground and power supply are good, replace the ECU.

3-78 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

If the output voltage is far out of the usable range, check
the output voltage again at the sensor connector (when
the lead is open, the output voltage is about 1.8 V).

•

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

Special Tool - Throttle Sensor Setting Adapter:

57001

-1521

Inlet Air Pressure Sensor Output Voltage

Connections to Sensor

Meter (+)

→

Y/BL lead [C]

Meter (–)

→

BR/BK lead [D]

Output Voltage at Sensor Connector

Usable Range:

3.46

∼

3.82 V DC at the standard

atmospheric pressure (101.32 kPa
or 76 cmHg absolute)

If the output voltage is normal, check the wiring for conti-
nuity (see next diagram).
If the output voltage is out of the usable range, replace
the sensor.

•

Turn the ignition switch OFF.

•

Remove the throttle sensor harness adapter.

ZX1200-B1/B2

→

: Signal

ECU [1]

Inlet Air Pressure Sensor [3]

FUEL SYSTEM (DFI) 3-79

Inlet Air Pressure Sensor (Service Code 12)

ZX1200-B3

∼

→

: Signal

ECU [1]

Inlet Air Pressure Sensor [3]

If you need to check the inlet air pressure sensor for vac-
uum other than 76 cmHg (abs), check the output voltage
as follows:

•

Remove the inlet air pressure sensor [A] and disconnect
the vacuum hose from the sensor.

○

Do not disconnect the sensor connector.

•

Connect an auxiliary hose [B] to the inlet air pressure sen-
sor.

•

Temporarily install the inlet air pressure sensor.

○

Connect a commercially available digital meter [C], vac-
uum gauge [D], and the fork oil level gauge [E] to the inlet
air pressure sensor.

Special Tool - Fork Oil Level Gauge: 57001-1290

Digital Volt Meter Connections

Meter (+)

→

BL/W lead of Inlet Air Pressure Sensor

Meter (–)

→

BR/BK lead of Inlet Air Pressure Sensor

○

Turn the ignition switch ON.

○

Measure the inlet air pressure sensor output voltage from
various vacuum readings, while pulling the handle of the
fork oil level gauge.

○

Check the inlet air pressure sensor output voltage, using
the following formula and chart.

Suppose:

Pg: Vacuum Pressure (gauge) of Throttle Assy

Pl: Local Atmospheric Pressure (absolute) measured by

a barometer

Pv: Vacuum Pressure (absolute) of Throttle Assy
Vv: Sensor Output Voltage (v)

then

Pv = Pl – Pg

3-80 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

For example, suppose the following data is obtained:

Pg = 8 cmHg (vacuum gauge reading)

Pl = 70 cmHg (barometer reading)

Vv = 3.0 V (digital volt meter reading)

then

Pv = 70 – 8 = 62 cmHg (abs)

Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.

Usable range = 2.92

∼

3.28 V

Plot Vv (3.0 V) on the vertical line.

→

Point [3].

Results: In the chart, Vv is within the usable range and
the sensor is normal.

Vv: Inlet Air Pressure Sensor Output Voltage (V)(Digital Meter Reading)
Pv: Throttle Vacuum Pressure (absolute)
Ps: Standard Atmospheric Pressure (absolute)

ID: Idling

TO: Throttle Full Open

ST: Standard of Sensor Output Voltage (v)

UR: Usable Range of Sensor Output Voltage (v)

FUEL SYSTEM (DFI) 3-81

Inlet Air Temperature Sensor (Service Code 13)

Inlet Air Temperature Sensor Removal/Installation

CAUTION

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

•

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

•

Set up the fuel tank (see this chapter).

•

Disconnect the connector [A] from the inlet air tempera-
ture sensor.

•

Remove:

Bolts [B]
Damper [C]

•

Remove the inlet air temperature sensor [A].

Torque - Inlet Air Temperature Sensor Nut: 7.8 N·m (0.80

kgf·m, 69 in·lb)

Output Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the ECU (see this chapter). Do not disconnect
the ECU connectors.

•

Connect a digital voltmeter [A] to the ECU connector [B],
using needle adapter set [C].

Special Tool - Needle Adapter Set: 57001-1457

•

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

•

Turn the ignition switch ON.

Inlet Air Temperature Sensor Output Voltage

Connections to ECU Connector

ZX1200-B1/B2:

Meter (+)

→

P lead (terminal 57)

ZX1200-B3

∼

Meter (+)

→

P lead (terminal 26)

Meter (–)

→

BR/BK lead (terminal 28)

Output Voltage at ECU

Standard:

about 2.26

∼

2.50 V at inlet air

temperature 20°C (68°F)

Meter (–)

→

BR/BK lead (terminal 54)

NOTE

○

The output voltage changes according to the inlet air
temperature.

•

Turn the ignition switch OFF.

3-82 FUEL SYSTEM (DFI)

Inlet Air Temperature Sensor (Service Code 13)

If the output voltage is out of the specified, check the ECU
for its ground, and power supply (see ECU section in this
chapter). If the ground and power supply are good, re-
place the ECU.
If the output voltage is far out of the specified (e.g. when
the wiring is open, the voltage is about 4.6 V), remove the
fuel tank cover, and check the wiring (see next diagram).

•

Remove the needle adapter set, and apply silicone
sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of ECU Connectors

If the wiring is good, check the sensor resistance.

Sensor Resistance Inspection

•

Remove the inlet air temperature sensor (see this sec-
tion).

•

Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion and threaded portion are
submerged.

•

Suspend a thermometer [B] with the heat-sensitive por-
tion [C] located in almost the same depth with the sensor.

NOTE

○

The sensor and thermometer must not touch the con-
tainer side or bottom.

•

Place the container over a source of heat and gradually
raise the temperature of the oil while stirring the oil gently
for even temperature.

•

Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the table.

Inlet Air Temperature Sensor Resistance

Standard:

657

∼

1 003 k

Ω

at 0°C (32°F)

∼

89 k

Ω

at 50°C (122°F)

11.95

∼

14.37 k

Ω

at 100°C (212°F)

If the measurement is out of the range, replace the sensor.
If the measurement is within the specified, replace the
ECU.

3-84 FUEL SYSTEM (DFI)

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Removal/Installation

CAUTION

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

•

Disconnect the sensor connector [A], and unscrew the
water temperature sensor [B].

Silicone Sealant (Kawasaki Bond: 56019-120)

- Threads of Water Temperature Sensor

Torque - Water Temperature Sensor: 18 N·m (1.8 kgf·m, 13

ft·lb)

•

Fill the engine with coolant and bleed the air from the
cooling system (see Coolant Filling in the Cooling System
chapter).

Output Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the ECU (see this chapter). Do not disconnect
the connectors.

•

Connect a digital voltmeter [A] to the ECU connector [B],
with the needle adapter set [C].

Special Tool - Needle Adapter Set: 57001-1457

•

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

•

Turn the ignition switch ON.

FUEL SYSTEM (DFI) 3-85

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Output Voltage

Connections to ECU

ZX1200-B1/B2:

Meter (+)

→

O lead (terminal 58)

Meter (–)

→

BR/BK lead (terminal 54)

ZX1200-B3

∼

Meter (+)

→

O lead (terminal 9)

Meter (–)

→

BR/BK lead (terminal 28)

Output Voltage at ECU

Standard:

about 1.95

∼

2.29 V at 20°C (68°F)

NOTE

○

The output voltage changes according to the coolant
temperature in the engine.

•

Turn the ignition switch OFF.
If the output voltage is out of the specified, check the ECU
for its ground, and power supply (see this chapter). If the
ground and power supply are good, replace the ECU.
If the output voltage is far out of the specified (e.g. when
the wiring is open, the voltage is about 5V), check the
wiring (see next diagram).
If the wiring is good, check the water temperature sensor
resistance.

•

Remove the needle adapter set, and apply silicone
sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of ECU Connectors

ZX1200-B1/B2

→

: Signal

ECU [1]

Water Temperature Sensor [5]

Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year) - page 6