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

16-68 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This

system provides a theft proof device by means of matching a code between the inbuilt key transponder
and ECU (Electronic Control Unit). If the code does not match, ignition system, injectors and sub
-throttle valve actuator will not operate and the engine will not start.

Abstract

•

Do not keep more than one immobilizer key of any system on a key ring. Jamming of the key code
signal may occur and the operation of the system may be affected.

•

The FI indicator light illuminates for two seconds and then extinguishes when the ignition is first
switched on. This shows the system is operating correctly.

○

If the FI indicator light illuminates when the ignition switch is turned to the ON position and stays
illuminated this shows a fault in the DFI system.

○

If the FI indicator light flashes when the ignition switch is turned to the ON position this shows the
immobilizer system has a fault. Refer to service code to identify the faulty component.

•

The FI indicator light will flash for a period of 24 hours once the ignition switch has been switched
off and the key removed. This flashing can be set to on or off as desired by holding the Mode and
Reset buttons down for two seconds within twenty seconds of switching the ignition off.

•

If all coded keys (master key and user keys) are lost the ECU and ignition switch will have to be
replaced.

•

The immobilizer system can not function until the master key code is registered in the ECU.

•

A total of six keys can be registered in the ECU at any one time (one master key and five user keys).

•

If the master key is lost it is not possible to register new user keys.

Operational Cautions

1. Do not put two keys of any immobilizer system on the same key ring.
2. Do not submerge any key in water.
3. Do not expose any key to excessively high temperature.
4. Do not place any key close to magnet.
5. Do not place a heavy item on any key.
6. Do not grind any key or alter its shape.
7. Do not disassemble the plastic part of any key.
8. Do not drop the key and/or apply any shocks to the key.
9. When a user key is lost, the user should go to his dealer to invalidate the lost key registration in

the electronic control unit (ECU).

10.When the master key is lost, the user should go to his dealer and have a new ECU installed and

NOTE

○

No.9 and 10 are strongly recommended to the customer to ensure security of the motorcycle.

Key Registration

Case 1: When the user key has been lost or additional
spare user key is required.

•

Prepare a new spare user key.

•

Cut the key in accordance with the shape of the current
user key.

•

Remove:

Rear Seat with Cover (see Frame chapter)

•

Disconnect the immobilizer/Kawasaki self-diagnosis sys-
tem connector [A].

ELECTRICAL SYSTEM 16-69

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

•

Connect the key registration unit [A].

Special Tool - Key Registration Unit: 57001-1582

•

Insert the master key to the ignition switch and turn it ON.

Verified

○

The FI indicator light [A] blinks to display the registration
mode (go to the next step).

Not Verified

○

The FI indicator light [A] blinks to display the collation error
(refer to the following failure illustrations).

Immobilizer Amplifier Failure

Master Key Collation Error

•

Turn the master key OFF and remove the master key.

○

The FI indicator light [A] blinks continuously to display that
the ECU is in the registration mode for 15 seconds.

NOTE

○

Insert next key and turn ON within 15 seconds after pre-
vious key is turned off and removed otherwise registra-
tion mode will be ended and the FI indicator light stops
flashing.

○

To return to the registration mode start the master key
verification procedure. This applies to all user key reg-
istration.

16-70 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

•

Insert the user key 1 to the ignition switch and turn it ON.

NOTE

○

Keep the other user key away from the immobilizer an-
tenna.

○

If there is any problem in the registration, the FI indicator
light [A] blinks to display the collation error.

Immobilizer Amplifier Failure

When Registered User Key is Inserted.

User Key Collation Error

•

The user key 1 is successfully registered in the ECU.

○

The FI indicator light [A] blinks 2 times and stops for 1
second and then repeats this cycle.

ELECTRICAL SYSTEM 16-71

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

•

Turn the user key 1 OFF and remove off the user key 1.

○

The FI indicator light [A] blinks to display the registration
mode.

NOTE

○

Turn off the ignition switch and wait for the period of 15
seconds or more. The registration mode automatically
finishes and the FI indicator light will switch off.

○

This procedure registered the master key and one user
key.

○

Continue with the procedure to register the second and
later keys before the 15 seconds period has elapsed.

•

Insert the user key 2 to the ignition switch and turn it ON.

○

If there is any problem in the registration, the FI indicator
light [A] blinks to display the collation error.

Immobilizer Amplifier Failure

When Registered User Key is Inserted.

User Key Collation Error

16-72 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

•

The user key 2 is registered in the ECU.

○

The FI indicator light [A] blinks 3 times and stops for 1
second and then repeats this cycle.

○

This procedure has registered the master key and 2 user
keys.

•

Continue with the procedure to register an additional 3
user keys.

NOTE

○

The ECU can store up the six key codes (master key ×
1 and user key × 5).

User Key Indicator Flashes

FI Indicator

Light Blinks

FI Indicator

Light Stop

Remarks

User Key 3

4 times

1 seconds

Repeat

User Key 4

5 times

1 seconds

Repeat

User Key 5

6 times

1 seconds

Repeat

•

Turn OFF the ignition switch and wait for period of more
than 15 seconds.

•

The registration mode automatically ends.

•

FI indicator light goes off [A].

•

Remove the key registration unit and connect the immo-
bilizer Kawasaki self-diagnostic system connector.

NOTE

○

Turn the ignition switch ON with the registered user key.

○

Check that the engine can be started using all regis-
tered user keys.

16-74 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

Case 2: When the ignition switch is faulty and to be
replaced.

•

Prepare a new ignition switch [A] and two new user keys
[B].

○

These parts are available as a set. Prepare the current
master key [C].

•

Remove:

Ignition Switch and Immobilizer Antenna (see Immobi-
lizer System Parts Replacement)
Rear Seat with Cover (see Frame chapter)

•

Disconnect the immobilizer/Kawasaki self-diagnostic sys-
tem connector.

•

Connect the key registration unit [A].

Special Tool - Key Registration Unit: 57001-1582

•

Connect:

New Ignition Switch Lead Connector [A]
Immobilizer Antenna Lead Connector [B]

NOTE

○

Keep the antenna more than 15 cm from the ignition
switch.

•

Put the current master key [A] at the antenna [B]. Insert
the new user key 1 [C] to the new ignition switch [D] and
turn it ON.

Verified

○

The FI indicator light [A] blinks to display the ECU is in the
registration mode (go to the next step).

ELECTRICAL SYSTEM 16-75

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

Not Verified

○

The FI indicator light [A] blinks to display the collation er-
ror.

Immobilizer Amplifier Failure

Master Key Collation Error

•

Turn off and remove the new user key 1.

•

Temporarily place the antenna [A] on the new ignition
switch [B].

•

Insert the user key 1 [C] again into the new ignition switch
and turn it ON.

NOTE

○

Place the antenna on the ignition switch, insert the next
key and turn ON within 15 seconds after previous key
is turned off and removed otherwise registration mode
will be ended and the FI indicator light stops flashing.

○

To return to the registration mode start the master key
verification procedure. This applies to all user key reg-
istration.

○

Keep other user keys away from the immobilizer an-
tenna.

○

If there is any problem in the registration, the FI indicator
light [A] blinks to display the collation error.

Immobilizer Amplifier Failure

16-76 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

When Registered User Key is Inserted.

User Key Collation Error

•

The user key 1 is successfully registered in the ECU.

○

The FI indicator light [A] blinks 2 times and stops for 1
second and then repeats this cycle to indicate successful
registering of user key 1.

•

Turn off and remove user key 1.

○

The FI indicator light [A] blinks to display the registration
mode.

NOTE

○

Turn off the ignition switch and wait for the period more
than 15 seconds. The registration mode automatically
ends and FI indicator light goes off.

○

This procedure has , registered the master key and one
user key.

○

Continue the procedure to program the second and
later keys.

•

Insert the user key 2 to the ignition switch and turn it ON.

ELECTRICAL SYSTEM 16-77

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

○

If there is any problem in the registration, the FI indicator
light [A] blinks to display the collation error.

Immobilizer Amplifier Failure

When Registered User Key is Inserted.

User Key Collation Error

•

The user key 2 is successfully registered in the ECU.

○

The FI indicator light [A] blinks 3 times and stops for 1
second and then repeat this cycle to indicate successful
programming of user key 2.

•

Turn OFF the ignition switch and wait for period more than
15 seconds.

•

The registration mode automatically ends.

•

FI indicator light goes off [A].

16-78 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

•

Remove the key registration unit and connect the immo-
bilizer/Kawasaki self-diagnostic system connector.

NOTE

○

Turn the ignition switch ON with the registered user key.

○

Check that the engine can be started using all regis-
tered user keys.

•

Install the new ignition switch and antenna.

Case 3: When the electric control unit (ECU) is faulty
and has to be replaced.

•

Prepare a new ECU [A], current master key [B] and cur-
rent user keys [C].

NOTE

○

The key registration unit is not required.

•

Replace:

ECU [A] (see Immobilizer System Parts Replacement)

•

Insert the current master key into the ignition switch and
turn it ON.

○

If there is any problem in the registration, the FI indicator
light [A] blinks to display the collation error.

Immobilizer Amplifier Failure

Master Key Collation Error

ELECTRICAL SYSTEM 16-79

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

•

The master key is registered in the ECU.

○

The FI indicator light [A] blinks 1 time and stops for 1
second and the repeats this cycle to indicate successful
registration of the master key.

•

Turn of the master key and remove it.

○

The FI indicator light [A] blinks to display the registration
mode.

NOTE

○

Insert next key and turn ON within 15 seconds after pre-
vious key is turned off and removed otherwise registra-
tion mode will be ended and the FI indicator light goes
off.

○

To return to the registration mode start the master key
verification procedure. This applies to all user key reg-
istration.

•

Insert the user key 1 to the ignition switch and turn it ON.

NOTE

○

Keep the other user keys away from the immobilizer
antenna.

○

If there is any problem in the registration, the FI indicator
light [A] blinks to display the collation error.

Immobilizer Amplifier Failure

When Registered User Key is Inserted.

16-80 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

User Key Collation Error

•

The user key 1 is registered in the ECU.

○

The FI indicator light [A] blinks 2 times and stops for 1
second and then repeats this cycle to indicate successful
registration of user key.

•

Turn off and remove the user key 1.

○

The FI indicator light [A] blinks to display the registration
mode codes.

NOTE

○

Insert next key and turn ON within 15 seconds after pre-
vious key is turned off and removed otherwise registra-
tion mode will be ended and the FI indicator light goes
off.

○

To return to the registration mode start the master key
verification procedure. This applies to all user key reg-
istration.

•

Insert the user key 2 to the ignition switch and turn it ON.

○

If there is any problem in the registration, the FI indicator
light [A] blinks to display the collation error code.

Immobilizer Amplifier Failure

ELECTRICAL SYSTEM 16-81

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

When Registered User Key is Inserted.

User Key Collation Error

•

The user key 2 is registered in the ECU.

○

The FI indicator light [A] blinks 3 times and stops for 1
second and then repeats this cycle to indicate successful
registration of user key 2.

•

Turn OFF the ignition switch and wait for period more than
15 seconds.

•

The registration mode automatically ends.

•

FI indicator light goes off [A].

NOTE

○

Turn the ignition switch ON with the registered user key.

○

Check that the engine can be started using all regis-
tered user keys.

Case 4: When master key is faulty or lost.

The master key replacement is considered very rare case.

However if it is required, the following is necessary.

NOTE

○

The ECU must be replaced with a new one because the
master key code that is registered in the current ECU
can not be rewritten.

16-82 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

•

Prepare a new ECU [A], new master key [B] and current
user keys [C].

NOTE

○

The key registration unit is not required.

○

The key registration process is same as the electric con-
trol unit replacement.

Case 5: When replacing the antenna.

•

Prepare a new antenna.

•

Refer to the Immobilizer System Parts Replacement.

NOTE

○

No key registration is required.

16-84 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

Immobilizer System Parts Replacement

Immobilizer Antenna

•

Remove:

Left Lower Inner Cover (see Frame chapter)

•

Disconnect the lead connectors [A].

•

Remove:

Steering Stem Head (see Steering chapter)
Handlebar (see Steering chapter)

•

Using a small chisel [A] or punch, turn out the Torx bolts.

•

Cut the band [A].

•

Remove the screw [B].

•

Remove the antenna [C] with the cover [D].

○

Pull the lower parts [E] of the cover outside to clear the
projection [F] of the ignition switch.

•

Tighten a new Torx bolt [A] until the bolt head [B] is broken
[C].

•

Run the leads correctly (see General Information chap-
ter).

Immobilizer Amplifier Replacement

•

Remove:

Upper Fairing (see Frame chapter)

•

Disconnect the connector [A].

•

Remove the amplifier [B] from the bracket [C].

ELECTRICAL SYSTEM 16-85

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

ECU (Electric Control Unit) Replacement (for European
Model)

•

Remove:

Rear Seat with Cover (see Frame chapter)

•

Remove the screws [A] and upper guard bracket [B].

•

Remove:

ECU [A]

•

Disconnect the connectors [B] and remove the under
guard bracket.

•

Set the connectors [A] to the under guard bracket.

•

Install the under guard bracket to the ECU.

•

Connect the connectors.

•

Install:

Upper Guard Bracket [A]

CAUTION

Do not pinch the leads.

•

Apply a non-permanent locking agent to the threads and
tighten the screws [B].

16-86 ELECTRICAL SYSTEM

Immobilizer System (ZX1200-B3

∼

) (Equipped Models)

Immobilizer Relational Parts Replacement Chart

Failed or Lost Part

Master

Key

(Red)

User

Key

(Black)

Ignition

Switch

An-

tenna

Ampli-

fier

ECU

Master

Key

(Red)

•

User

Key

(Black)

•

○

Ignition

Switch

•

An-

tenna

•

Ampli-

fier

•

ECU

○

•

Replacement Part

•

Main Replacement Part

○

Additional Replacement Part

Immobilizer System Inspection

•

Refer to the Immobilizer Amplifier and Blank Key Detec-
tion section in the Fuel System (DFI) chapter.

Immobilizer System Circuit

1. Immobilizer Amplifier
2. Immobilizer Antenna
3. Ignition Switch
4. Meter Unit
5. FI Indicator Light
6. Ignition Fuse 10 A

7. ECU Fuse 15 A
8. Junction Box
9. ECU Main Relay

10. Starter Relay

11. Main Fuse 30 A

12. Battery 12 V 12 Ah

13. Immobilizer/Kawasaki Di-

agnostic System Connec-
tor

14. Electronic

Control

Unit

(ECU)

ELECTRICAL SYSTEM 16-87

Switches and Sensors

Front Brake Light Switch Inspection

•

Refer to the Front Brake Light Switch Inspection in the
Periodic Maintenance chapter.

Rear Brake Light Switch Check/Adjustment

•

Refer to the Rear Brake Light Switch Inspection/Adjust-
ment in the Periodic Maintenance chapter.

Switch Inspection

•

Using a hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).

○

For the switch housing and the ignition switch, refer to the
tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.

Special Tool - Hand Tester: 57001-1394

Rear Brake Light Switch Connections

Side Stand Switch Connections

Gear Position Switch Connections

Engine Oil Pressure Switch Connections*

*: Engine lubrication system is in good condition

16-88 ELECTRICAL SYSTEM

Switches and Sensors

Radiator Fan Switch Inspection

•

Remove the fan switch (see Cooling System chapter).

•

Suspend the switch [A] in a container of coolant so that the
temperature-sensing projection [C] and threaded portion
[C] are submerged.

•

Suspend an accurate thermometer [B] in the coolant.

NOTE

○

The switch and thermometer must not touch the con-
tainer sides or bottom.

•

Place the container over a source of heat and gradu-
ally raise the temperature of the coolant while stirring the
coolant gently.

•

Using the hand tester, measure the internal resistance
of the switch across the terminals at the temperatures
shown in the table.
If the hand tester does not show the specified values, re-
place the switch.

Fan Switch Resistance

Rising temperature:

From OFF to ON at 95

∼

101°C (203

∼

214°F)

Falling temperature:

Fan stops with the temperature 3

∼

8°C (37

∼

46°F)

lower than the operation temperature range.

ON: Less than 0.5

Ω

OFF: More than 10 M

Ω

ELECTRICAL SYSTEM 16-89

Switches and Sensors

Water Temperature Sensor Inspection

•

Remove the water temperature sensor (see Fuel System
(DFI) chapter).

•

Suspend the sensor [A] in a container of coolant so that
the temperature-sensing projection [E] and threaded por-
tion [E] are submerged.

•

Suspend an accurate thermometer [B] in the coolant.

NOTE

○

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

•

Place the container over a source of heat and gradu-
ally raise the temperature of the coolant while stirring the
coolant gently.

•

Using the hand tester, measure the internal resistance of
the sensor.

○

The sensor sends electric signals to the ECU (Electronic
Control Unit) and coolant temperature gauge in the meter
unit.

○

Measure the resistance across the terminals and the body
(for the gauge) at the temperatures shown in the table.
If the hand tester does not show the specified values, re-
place the sensor.

Water Temperature Sensor

Resistance for ECU [C]

Resistance (k

Ω

)

Temperature

(Terminal [1] - [3])

+0.14

20°C (68°F)

2.45

–0.13

80°C (176°F)

0.318 ±0.008

110°C (230°F)

0.1417 ±0.0018

Resistance for Water Temperature Gauge [D]

Resistance (k

Ω

)

Temperature

(Terminal [2] - Body)

50°C (122°F)

7.115 ±0.285

80°C (176°F)

2.37 ±0.237

120°C (248°F)

0.69 ±0.41

Speed Sensor Removal

•

Remove:

Lower Fairing (see Frame chapter)
Engine Sprocket Cover (see Final Drive chapter)
Speed Sensor Lead Connector [A]
Clamp [B]

16-90 ELECTRICAL SYSTEM

Switches and Sensors

•

Remove:

Speed Sensor Mounting Bolt [A]
Speed Sensor [B]

Speed Sensor Installation

•

Apply grease or engine oil to the O-ring [A] on the speed
sensor.

•

Tighten:

Torque - Speed Sensor Mounting Bolt: 12 N·m (1.2 kgf·m,

106 in·lb)

Speed Sensor Inspection

•

Remove:

Speed Sensor (see Speed Sensor Removal)

•

Connect the speed sensor connector [A] with a battery
[B], 10 k

Ω

resistor [C] and hand tester [D] as shown.

•

Set the tester to the DC 25 V range.

Special Tool - Hand Tester: 57001-1394

•

Trace [A] the speed sensor surface with the screw driver.

○

Then the tester indicator should flick [B].
If the tester indicator does not flick, replace the speed
sensor.

Fuel Level Sensor Inspection

•

Remove:

Fuel Tank (see Fuel System (DFI) chapter)
Fuel Level Sensor Lead Connector [A]

○

Push the stopper [B] upward [C] and pull out the connec-
tor.

ELECTRICAL SYSTEM 16-91

Switches and Sensors

•

Remove:

Bolts [A]
Fuel Level Sensor [B]

•

Check that the float moves up and down smoothly without
binding. It should go down under its own weight.
If the float does not move smoothly, replace the sensor.

Float in Full Position [A]
Float in Empty Position [B]
Float Arm Stoppers [C]

•

Using the hand tester, measure the resistance across the
terminals in the fuel level sensor lead connector [D].

Special Tool - Hand Tester: 57001-1394

If the tester readings are not as specified, or do not
change smoothly according as the float moves up and
down, replace the sensor.

Fuel Level Sensor Resistance

Standard:

Full position: 8

∼

Ω

Empty position: 122

∼

126

Ω

•

Apply a non-permanent locking agent to the threads of
the level sensor mounting bolts and tighten it.

Torque - Fuel Level Sensor Bolts: 6.9 N·m (0.70 kgf·m, 61

in·lb)

Fuel Reserve Switch Inspection (1)

•

Fill the fuel tank with fuel.

•

Close the fuel tank cap surely.

•

Remove the fuel tank (see Fuel System (DFI) chapter).

•

Connect the test light [A] (12 V 3.4 W bulb a socket with
leads) and the 12 V battery [B] to the fuel pump connector
[C].

Connections

Battery (+)

→

12 V 3.4 W Bulb (one side)

12 V 3.4 W Bulb (other side)

→

R/BK Lead Terminal

Battery (–)

→

BK/W Lead Terminal

Special Tool - Needle Adapter Set: 57001-1457

If the test light turn on, the reverse switch is defective.
Replace the fuel pump.

16-92 ELECTRICAL SYSTEM

Switches and Sensors

Fuel Reserve Switch Inspection (2)

•

Remove:

Fuel Pump (see Fuel System (DFI) chapter)

•

Connect the test light (12 V 3.4 W bulb in a socket with
leads) and the 12 V battery to the fuel pump connector as
shown.

12 V Battery [A]
Test Light [B]
Fuel Pump Connector [C]
Fuel Reserve Switch [D]

If the test light doesn’t light, replace the fuel pump.

NOTE

○

It may take a long time to turn on the test light in case
that the fuel reserve switch is inspected just after the
fuel pump is removed. Leave the fuel reserve switch
with leads for inspection connected for one (1) minute.

ELECTRICAL SYSTEM 16-93

Junction Box

The junction box [A] has fuses [B], relays, and diodes.

The relays and diodes can not be removed.

Junction Box Fuse Circuit Inspection

•

Remove:

Fuel Tank Cover (see Fuel System (DFI) chapter)
Rubber Cover
Connectors
Junction Box

•

Make sure all connector terminals are clean and tight, and
none of them have been bent.
Clean the dirty terminals, and straighten slightly-bent ter-
minals.

•

Check conductivity of the numbered terminals with the
hand tester.
If the tester does not read as specified, replace the junc-
tion box.

Fuse Circuit Inspection

Tester Connection

Tester Reading (

Ω

)

Tester Connection

Tester Reading (

Ω

)

1 - 1A

1A - 8

∞

1 - 2

2 - 8

∞

3A - 4

3A - 8

∞

6 - 5

6 - 2

∞

6 - 10

6 - 3A

∞

6 - 7

17 - 3A

∞

6 - 17

Starter Circuit/Headlight Relay Inspection

•

Remove the junction box.

•

Check conductivity of the following numbered terminals
by connecting the hand tester and one 12 V battery to the
junction box as shown.
If the tester does not read as specified, replace the junc-
tion box.

16-94 ELECTRICAL SYSTEM

Junction Box

Relay Circuit Inspection (with the battery disconnected)

Tester Connection Tester Reading (

Ω

)

Tester Connection

Tester Reading (

Ω

)

*7-8

∞

9-11

∞

*7-13

∞

12-13

∞

Head-

light Re-

lay

(+) (–)

*13 - 9

Not

∞

(+) (–)

13 - 11

∞

Starter

Circuit

Relay

(+) (–)

12-11

Not

∞

*: U.S.A, Canadian, Australian, and Malaysian Models

only
ZX1200-B3

∼

: All Models.

**: The actual reading varies with the hand tester used.

(+): Apply tester positive lead.
(–): Apply tester negative lead.

Relay Circuit Inspection (with the battery connected)

Battery

Connection

(+) (–)

Tester

Connection

Tester

Reading

(

Ω

)

Headlight Relay

*9-13

*7-8

Starter Circuit Relay

11-12

(+) (–)

13-11

Not

∞

*: U.S.A., Canadian, Australian, and Malaysian Models

only
ZX1200-B3

∼

: All Models.

**: The actual reading varies with the hand tester used.

(+): Apply tester positive lead.
(–): Apply tester negative lead.

Diode Circuit Inspection

•

Remove the junction box.

•

Check conductivity of the following pairs of terminals.

Diode Circuit Inspection

*13-8, *13-9, 12-11, 12-14,

Tester Connection

15-14, 16-14

*: U.S.A., Canadian, Australian, and Malaysian Models

only
ZX1200-B3

∼

: All Models.

The resistance should be low in one direction and more
than ten times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the junction box must be replaced.

NOTE

○

The actual meter reading varies with the meter used
and the individual diodes, but, generally speaking, the
lower reading should be from zero to one half the scale.

ELECTRICAL SYSTEM 16-95

Junction Box

Junction Box Internal Circuit (ZX1200-B1

∼

B2; U.S.A., Canadian, Australian, and

Malaysian/ZX1200-B3

∼

; All Models)

Junction Box Internal Circuit (ZX1200-B1

∼

B2; Other than U.S.A., Canadian,

Australian, and Malaysian Models)

A. Fan Fuse 15 A
B. Fan Fuse 15 A

C. Turn Signal Relay Fuse 10 A
D. Horn Fuse 10 A

E. Ignition Fuse 10 A

F. Headlight Fuse 10 A

G. Headlight Relay

H. Headlight Diodes

I. Starter Diode

J. Starter Circuit Relay

K. Interlock Diodes

L. Tail Light Fuse 10 A

16-96 ELECTRICAL SYSTEM

Fuse

30 A Main Fuse Removal

•

Remove:

Battery Tray (see Battery Removal)
Screw [A]
Cover [B]

•

Disconnect the Connector [A].

•

Pull out the 30 A main fuse [B] from the starter relay with
a needle nose pliers.

30 A Headlight/Fan Fuse Removal

•

Remove:

Battery Tray (see Battery Removal)
Screw (see Main Fuse Removal)
Cover (see Main Fuse Removal)

•

Remove:

30 A Headlight/Fan Fuse [A]

Junction Box Fuse Removal

•

Remove:

Fuel Tank Cover Plate (see Fuel System (DFI) chapter)
Rubber Cover

•

Unlock the hook to lift up the lid [A].

•

Pull the fuses [B] straight out of the junction box with a
needle nose pliers.

ELECTRICAL SYSTEM 16-97

Fuse

15 A ECU Fuse Removal

•

Remove:

Fuel Tank Cover Plate (see Fuel System (DFI) chapter)
15 A ECU Fuse [A]

Fuse Installation

If a fuse fails during operation, inspect the electrical sys-
tem to determine the cause, and then replace it with a
new fuse of proper amperage.

•

Install the junction box fuses on the original position as
specified on the lid.

Fuse Inspection

•

Remove the fuse.

•

Inspect the fuse element.
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.

Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]

NOTE

○

A mass current flows to the battery according to the
state of the battery which needs refreshing charge when
the engine is turned causing main fuse blown out.

CAUTION

When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.

17-2 TROUBLESHOOTING

Troubleshooting Guide

NOTE

○

Refer to the Fuel System chapter for most
of DFI trouble shooting guide.

○

This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.

Engine Doesn’t Start, Starting

Difficulty:

Starter motor not rotating:

Starter lockout switch or neutral switch trou-

ble

Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown

Starter motor rotating but engine doesn’t
turn over:

Immobilizer system trouble (ZX1200-B3

∼

)

Starter clutch trouble
Vehicle-down sensor (DFI) coming off

Engine won’t turn over:

Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure

No fuel flow:

No fuel in tank
Fuel pump trouble
Fuel tank air vent obstructed
Fuel filter clogged
Fuel line clogged

Engine flooded:

Clean spark plug and adjust plug gap
Starting technique faulty
(When flooded, do not crank the engine with

the throttle fully opened. This promotes
engine flood because more fuel is sup-
plied automatically by DFI.)

No spark; spark weak:

Vehicle-down sensor (DFI) coming off
Ignition switch not ON
Engine stop switch turned OFF
Clutch lever not pulled in or gear not in neu-

tral

Battery voltage low

Immobilizer system trouble (ZX1200-B3

∼

)

Spark plug dirty, broken, or gap malad-

justed

Stick coil shorted or not in good contact
Stick coil trouble
Spark plug incorrect
IC igniter in ECU trouble
Camshaft position sensor trouble
Neutral, starter lockout, or sidestand switch

trouble

Crankshaft sensor trouble
Ignition switch or engine stop switch

shorted

Wiring shorted or open
Fuse blown

Fuel/air mixture incorrect:

Bypass screw and/or idle adjusting screw

maladjusted

Air passage clogged
Air cleaner clogged, poorly sealed, or miss-

ing

Compression Low:

Spark plug loose
Cylinder head not sufficiently tightened

down

No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or

sticking)

Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,

worn, or carbon accumulation on the
seating surface)

Poor Running at Low Speed:

Spark weak:

Battery voltage low
Spark plug dirty, broken, or maladjusted
Stick coil wiring trouble
Stick coil not in good contact
Spark plug incorrect
IC igniter in ECU trouble
Camshaft position sensor trouble
Crankshaft sensor trouble
Stick coil trouble
Immobilizer system trouble (ZX1200-B3

∼

)

Fuel/air mixture incorrect:

Bypass screw maladjusted
Air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or miss-

ing

Fuel tank air vent obstructed

TROUBLESHOOTING 17-3

Troubleshooting Guide

Fuel pump trouble
Throttle body assy holder loose
Air cleaner duct loose

Compression low:

Spark plug loose
Cylinder head not sufficiently tightened

down

No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or

sticking)

Piston ring/groove clearance excessive
Cylinder head warped
Cylinder head gasket damaged
Valve spring broken or weak
Valve not seating properly (valve bent,

worn, or carbon accumulation on the
seating surface)

Other:

IC igniter in ECU trouble
Throttle body assy not synchronizing
Engine oil viscosity too high
Drive train trouble
Brake dragging
Air suction valve trouble
Vacuum switch valve trouble (ZX1200

-B1/B2)

Air switching valve trouble (ZX1200-B3

∼

)

Engine overheating
Clutch slipping

Poor Running or No Power at High

Speed:

Firing incorrect:

Spark plug dirty, broken, or maladjusted
Stick coil wiring trouble
Stick coil not in good contact
Spark plug incorrect
Camshaft position sensor trouble
IC igniter in ECU trouble
Crankshaft sensor trouble
Stick coil trouble

Fuel/air mixture incorrect:

Air cleaner clogged, poorly sealed, or miss-

ing

Air cleaner duct loose
Water or foreign matter in fuel
Throttle body assy holder loose
Fuel to injector insufficient (DFI)
Fuel tank air vent obstructed
Fuel line clogged
Fuel pump trouble (DFI)

Compression low:

Spark plug loose
Cylinder head not sufficiently tightened

down

No valve clearance

Cylinder, piston worn
Piston ring bad (worn, weak, broken, or

sticking)

Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,

worn, or carbon accumulation on the
seating surface.)

Knocking:

Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
IC igniter in ECU trouble
Camshaft position sensor trouble
Crankshaft sensor trouble

Miscellaneous:

Throttle valve won’t fully open
Brake dragging
Clutch slipping
Engine overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Air suction valve trouble
Vacuum switch valve trouble (ZX1200

-B1/B2)

Air switching valve trouble (ZX1200-B3

∼

)

Catalytic converter melt down due to muffler

overheating (KLEEN)

Overheating:

Firing incorrect:

Spark plug dirty, broken, or maladjusted
Spark plug incorrect
IC igniter in ECU trouble

Muffler overheating:

For KLEEN, do not run the engine even if

with only one cylinder misfiring or poor
running (Request the nearest service fa-
cility to correct it)

For KLEEN, do not push-start with a dead

battery (Connect another full-charged
battery with jumper cables, and start the
engine using the electric starter)

For KLEEN, do not start the engine under

misfire due to spark plug fouling or poor
connection of the stick coil

For KLEEN, do not coast the motorcycle

with the ignition switch off (Turn the igni-
tion switch ON and run the engine)

IC igniter in ECU trouble

Fuel/air mixture incorrect:

Throttle body assy holder loose
Air cleaner duct loose
Air cleaner poorly sealed, or missing

17-4 TROUBLESHOOTING

Troubleshooting Guide

Air cleaner clogged

Compression high:

Carbon built up in combustion chamber

Engine load faulty:

Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging

Lubrication inadequate:

Engine oil level too low
Engine oil poor quality or incorrect

Gauge incorrect:

Water temperature gauge broken
Water temperature sensor broken

Coolant incorrect:

Coolant level too low
Coolant deteriorated
Wrong coolant mixed ratio

Cooling system component incorrect:

Radiator fin damaged
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan switch trouble
Radiator fan relay trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged

Over Cooling:

Gauge incorrect:

Water temperature gauge broken
Water temperature sensor broken

Cooling system component incorrect:

Radiator fan switch trouble
Thermostat trouble

Clutch Operation Faulty:

Clutch slipping:

Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch hub or housing unevenly worn
No clutch lever play
Clutch inner cable trouble
Clutch release mechanism trouble

Clutch not disengaging properly:

Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
Clutch hub spline damaged

Clutch friction plate installed wrong
Clutch lever play excessive
Clutch release mechanism trouble

Gear Shifting Faulty:

Doesn’t go into gear; shift pedal doesn’t
return:

Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift pawl broken

Jumps out of gear:

Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or bro-

ken

Shift fork guide pin worn
Drive shaft, output shaft, and/or gear

splines worn

Overshifts:

Gear positioning lever spring weak or bro-

ken

Shift mechanism arm spring broken

Abnormal Engine Noise:

Knocking:

IC igniter in ECU trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating

Piston slap:

Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn

Valve noise:

Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Valve lifter worn

Other noise:

Connecting rod small end clearance exces-

sive

Connecting rod big end clearance exces-

sive

Piston ring/groove clearance excessive
Piston ring worn, broken, or stuck
Piston ring groove worn
Piston seizure, damage

TROUBLESHOOTING 17-5

Troubleshooting Guide

Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-

nection

Crankshaft runout excessive
Engine mount loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Vacuum switch valve damaged (ZX1200

-B1/B2)

Air switching valve damage (ZX1200-B3

∼

)

Alternator rotor loose
Catalytic converter melt down due to muffler

overheating (KLEEN)

Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Balancer shaft coupling rubber damper

damaged

Abnormal Drive Train Noise:

Clutch noise:

Clutch damper weak or damaged
Clutch housing/friction plate clearance ex-

cessive

Clutch housing gear worn
Wrong installation of outside friction plate

Transmission noise:

Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient

Drive line noise:

Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned

Abnormal Frame Noise:

Front fork noise:

Oil insufficient or too thin
Spring weak or broken

Rear shock absorber noise:

Shock absorber damaged

Disc brake noise:

Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble

Other noise:

Bracket, nut, bolt, etc.

not properly

mounted or tightened

Oil Pressure Warning Light Goes On:

Engine oil pump damaged
Engine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearing worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase

damaged

Exhaust Smokes Excessively:

White smoke:

Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high

Black smoke:

Air cleaner clogged

Brown smoke:

Air cleaner duct loose
Air cleaner poorly sealed or missing

Handling and/or Stability

Unsatisfactory:

Handlebar hard to turn:

Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade-

quate

Steering stem bent
Tire air pressure too low

Handlebar shakes or excessively vibrates:

Tire worn
Swingarm pivot bearing worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar clamp bolt loose
Steering stem nut loose
Front, rear axle runout excessive
Engine mounting bolt loose

Handlebar pulls to one side:

Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering maladjusted
Front fork bent
Right and left front fork oil level uneven

17-6 TROUBLESHOOTING

Troubleshooting Guide

Shock absorption unsatisfactory:

(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking

Brake Doesn’t Hold:

Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad

Brake fluid deteriorated
Primary or secondary cup damaged in master

cylinder

Master cylinder scratched inside

Battery Trouble:

Battery discharged:

Charge insufficient
Battery faulty (too low terminal voltage)
Battery lead making poor contact
Load excessive (e.g., bulb of excessive

wattage)

Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble

Battery overcharged:

Alternator trouble
Regulator/rectifier trouble
Battery faulty

MODEL APPLICATION

Year

Model

Beginning Frame No.

2002

ZX1200-B1

JKAZX9B1

□

2A000001 or

JKAZXT20ABA035001 or
JKAZX9B1

□

2A035001 or

ZXT20B-000001

2003

ZX1200-B2

JKAZX9B1

□

3A008001 or

JKAZXT20ABA041001 or
ZXT20B-008001

2004

ZX1200-B3

JKAZX9B1

□

4A012001 or

JKAZXT20ABA045001 or
ZXT20B-012001

2005

ZX1200-B4

JKAZX9B1

□

5A016001 or

JKAZXT20ABA048001 or
ZXT20B-016001

2006

ZX1200B6F

JKAZX9B1

□

6A019001 or

JKAZXT20ABA050001 or
ZXT20B-019001

□

:This digit in the frame number changes from one machine to another.

Part No.99924-1278-06

Printed in Japan

Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year) - page 18