Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year)

FUEL SYSTEM (DFI) 3-7

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Switch Housing Screws

3.5

0.36

31 in·lb

Fuel Level Sensor Bolts

6.9

0.70

Fuel Pump Bolts

9.8

1.0

87 in·lb

L, S

Clutch Cover Bolt

9.8

1.0

87 in·lb

5. Throttle Cable (Accelerator)
6. Throttle Cable (Decelerator)
7. CAL and SEA Models
8. Other than CAL and SEA Models

CL: Apply cable lubricant.

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

FUEL SYSTEM (DFI) 3-13

DFI System

Part Name

1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
4. Fan Motor
5. Stick Coils
6. Air Switching Valve
7. Speed Sensor
8. Subthrottle Valve Actuator
9. Subthrottle Sensor

10. Main Throttle Sensor

11. Inlet Air Pressure Sensor

12. Water-proof Joint D
13. Vehicle-down Sensor
14. Injectors
15. Water-proof Joint E
16. Water Temperature Sensor
17. Inlet Air Temperature Sensor
18. Crankshaft Sensor
19. Oxygen Sensor (Equipped Models)
20. ECU (Electronic Control Unit)
21. Joint Connector
22. Self-diagnosis Terminal
23. Kawasaki Diagnostic System Connector
24. Fuel Pump
25. Frame Ground
26. Battery 12 V 10 Ah
27. Main Fuse 30 A
28. Fuel Pump Relay
29. ECU Main Relay
30. Radiator Fan Relay
31. Fuse Box
32. Oxygen Sensor Heater Fuse 10 A
33. Radiator Fan Fuse 15 A
34. ECU Fuse 15 A
35. Ignition Fuse 10 A
36. Water-proof Joint A
37. Water-proof Joint B
38. Speedometer
39. Tachometer
40. Water Temperature Warning Indicator Light (LED)
41. FI Indicator Light (LED)
42. Water-proof Joint C
43. Frame Ground

○

Lead Color Codes:

BK: Black

BL: Blue

BR: Brown

CH: Chocolate

DG: Dark Green

G: Green

GY: Gray

LB: Light Blue

LG: Light Green

O: Orange

P: Pink

PU: Purple

R: Red

W: White

Y: Yellow

3-14 FUEL SYSTEM (DFI)

DFI System

Terminal Numbers of ECU Connectors

Terminal Names

1. Subthrottle Valve Actuator: BK/BL
2. Subthrottle Valve Actuator: G/Y
3. Water Temperature Warning Indicator Light:

BL/W

4. Oxygen Sensor: BL/Y
5. Speed Sensor: LG/R
6. Main Throttle Sensor: Y/W
7. Inlet Air Pressure Sensor: Y/BL
8. Power Supply to Sensors: BL
9. Vehicle-down Sensor: Y/G

10. Neutral Switch: LG

11. Crankshaft Sensor (+): R/BK

12. Power Supply to ECU (from ECU Main Re-

lay): BR/W

13. External Communication Line: LG/BK
14. Subthrottle Valve Actuator: P
15. Subthrottle Valve Actuator: W/BL
16. Unused
17. Water Temperature Sensor: O
18. Self-diagnosis Terminal: O/BK
19. Subthrottle Sensor: BR
20. Inlet Air Temperature Sensor: Y
21. Unused
22. Ground for Sensors: BR/BK

23. Oxygen Sensor Heater: P/BK
24. Crankshaft Sensor (–): Y/BK
25. Unused
26. Ground for ECU: BK/Y
27. Power Supply to ECU (from Battery): W/BK
28. Engine Stop Switch: R
29. Starter Lockout Switch: R/G
30. Starter Button: BK/R
31. Fuel Pump Relay: BR/Y
32. Air Switching Valve: R/BL
33. Injector #2: BL/G
34. Injector #1: BL/R
35. Stick Coil #1: BK
36. Sidestand Switch: G/BK
37. Fan Relay: P/BL
38. External Communication Line: LG/W
39. Meter Unit (Tachometer): LB
40. FI Indicator Light: BR/R
41. –
42. Ground for Fuel System: BK/Y
43. Ground for Ignition System: BK/Y
44. Stick Coil #2: BK/G

3-18 FUEL SYSTEM (DFI)

Specifications

Item

Standard

Digital Fuel Injection System

Idle Speed

1 300 ±50 r/min (rpm)

Throttle Body Assy:

Type

Two barrel type

Bore

38 mm (1.5 in.)

Bypass Screws (Turn out)

∼

2 1/2 (for reference)

ECU (Electronic Control Unit):

Make

DENSO

Type

Digital memory type, with built in IC igniter, sealed
with resin

Usable Engine Speed

100

∼

11 180 r/min (rpm)

Fuel Pressure (High Pressure Line):

With Engine Idling

294 kPa (3.0 kgf/cm², 43 psi) with fuel pump running

Fuel Pump:

Type

In-tank friction pump

Discharge

60 mL (2.0 US oz.) or more for 3 seconds

Fuel Injectors:

Type

INP-287

Nozzle Type

One spray type with 12 holes

Resistance

About 11.7

∼

12.3

Ω

at 20°C (68°F)

Main Throttle Sensor:

Non-adjustable and non-removable

Input Voltage

DC 4.75

∼

5.25 V

Output Voltage

DC 1.005

∼

1.035 V at Idle Throttle Opening

DC 4.2

∼

4.4 V at Full Throttle Opening

Resistance

∼

6 k

Ω

Inlet Air Pressure Sensor:

Input Voltage

DC 4.75

∼

5.25 V

Output Voltage

DC 3.80

∼

4.20 V at standard atmospheric pressure

(see this text for details)

Inlet Air Temperature Sensor:

Resistance

5.4

∼

6.6 k

Ω

at 0°C (32°F)

0.29

∼

0.39 k

Ω

at 80°C (176°F)

Output Voltage

About 2.25

∼

2.50 V at 20°C (68°F)

Water Temperature Sensor:

Resistance

see Electrical System chapter

Output Voltage

About 2.80

∼

2.97 V at 20°C (68°F)

Speed Sensor:

Input Voltage

About DC 9

∼

11 V at Ignition Switch ON

Output Voltage

About DC 0.05

∼

0.07 V or DC 4.5

∼

4.9 V at Ignition

Switch ON and 0 km/h (0 mph)

Vehicle-down Sensor:

Detection Method

Magnetic flux detection method

Detection Angle

more than 60

∼

70° for each bank

Input Voltage

DC 4.75

∼

5.25 V

FUEL SYSTEM (DFI) 3-19

Specifications

Item

Standard

Output Voltage

with the sensor tilted 60

∼

70° or more: 0.65

∼

1.35 V

with the sensor arrow mark pointed up: 3.55

∼

4.45 V

Subthrottle Sensor:

Non-adjustable and non-removable

Input Voltage

DC 4.75

∼

5.25 V

Output Voltage

DC 0.4

∼

0.6 V at Idle Throttle Opening

DC 3.825

∼

3.975 V at Full Throttle Opening

Resistance

∼

6 k

Ω

Subthrottle Valve Actuator:

Input Voltage

About DC 8.5

∼

10.5 V

Resistance

About 5.5

∼

7.5

Ω

Oxygen Sensor (Equipped Models):

Output Voltage (Rich)

DC 0.7 V or more

Output Voltage (Lean)

DC 0.2 V or less

Heater Resistance

11.7

∼

14.5

Ω

at 20°C (68°F)

Throttle Grip and Cables

Throttle Grip Free Play

∼

3 mm (0.08

∼

0.12 in.)

3-22 FUEL SYSTEM (DFI)

DFI Servicing Precautions

There are a number of important precautions that should

be followed servicing the DFI system.

○

This DFI system is designed to be used with a 12 V sealed
battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.

○

Do not reverse the battery cable connections. This will
damage the ECU.

○

To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is on or while the engine is running.

○

Take care not to short the cables that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.

○

When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.

○

Whenever the DFI electrical connections are to be dis-
connected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the con-
nector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the en-
gine.

○

Connect these connectors until they click [A].

○

Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memo-
rizes service codes.

○

Do not spray water on the electrical parts, DFI parts, con-
nectors, leads, and wiring.

○

If a transceiver is installed on the motorcycle, make sure
that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.

○

When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.

○

When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.

○

Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.

○

Before removing the fuel system parts, blow the outer sur-
faces of these parts clean with compressed air.

○

To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.

3-24 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Outline

When an abnormality in the DFI system occurs, the FI

indicator light (LED) goes on to alert the rider on the meter
panel. In addition, the condition of the problem is stored in
the memory of the ECU (electronic control unit). With the
engine stopped and turned in the self-diagnosis mode, the
service code [A] is indicated by the number of times the FI
indicator light (LED) blinks.

When due to a malfunction, the FI indicator light (LED) re-

mains lit, ask the rider about the conditions [B] under which
the problem occurred and try to determine the cause [C].

First, conduct a self-diagnosis inspection and then a

non-self-diagnosis inspection.

The non-self-diagnosis

items are not indicated by the FI indicator light (LED). Don’t
rely solely on the DFI self-diagnosis function, use common
sense.

Even when the DFI system is operating normally, the FI

indicator light (LED) [A] may light up under strong electrical
interference. No repair needed. Turn the ignition switch
OFF to stop the indicator light.

When the FI indicator light (LED) goes on and the motor-

cycle is brought in for repair, check the service codes.

When the repair has been done, the light (LED) does not

go on. But the service codes stored in memory are not
erased to preserve the problem history, and the light (LED)
can display the codes in the self-diagnosis mode. The prob-
lem history is referred when solving unstable problems.

When the motorcycle is down, the vehicle-down sensor

is turned OFF and the ECU shuts off the fuel injectors and
ignition system. The FI indicator light (LED) blinks but the
service code cannot be displayed. The ignition switch is left
ON. If the starter button is pushed, the electric starter turns
but the engine does not start. To start the engine again,
raise the motorcycle, turn the ignition switch OFF, and then
ON. The vehicle-down sensor is turned ON and the light
(LED) goes OFF.

FUEL SYSTEM (DFI) 3-25

Troubleshooting the DFI System

○

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

•

Join the connector and insert the needle adapters [C]
inside the seals [B] from behind the connector until the
adapter reaches the terminal.

Special Tool - Needle Adapter Set: 57001-1457

CAUTION

Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.

•

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

•

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

•

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

CAUTION

Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.

○

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

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

•

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

•

Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.

•

Measure coil winding resistance when the DFI part is cold
(at room temperature).

•

Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, short,
etc. Deteriorated leads and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.

3-26 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

•

Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect the connectors securely.

•

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

○

Set the tester to the × 1

Ω

range, and read the tester.

If the tester does not read 0

Ω

, the lead is defective. Re-

place the lead or the main harness [B] or the sub harness.

○

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

○

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

•

Narrow down suspicious locations by repeating the con-
tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.

3-28 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Sample Diagnosis Sheet

Rider name:

Registration No. (license plate No.):

Year of initial registration:

Model:

Engine No.:

Frame No.:

Date problem occurred:

Mileage:

Environment when problem occurred.

Weather

□

fine,

□

cloudy,

□

rain,

□

snow,

□

always,

□

other:

Temperature

□

hot,

□

warm,

□

cold,

□

very cold,

□

always,

□

other:

Problem
frequency

□

chronic,

□

often,

□

once

Road

□

street,

□

highway,

□

mountain road (

□

uphill,

□

downhill),

□

bumpy,

□

pebble

Altitude

□

normal,

□

high (about 1 000 m or more)

Motorcycle conditions when problem occurred.

□

light up immediately after ignition switch ON, and goes off after 1

∼

2 seconds

(normal)

□

lights blinks immediately after ignition switch ON, and stays on (DFI problem)

□

lights up immediately after ignition switch ON, but goes off after about 10 seconds

(DFI problem)

□

unlights (light (LED), ECU or its wiring fault)

FI indicator
light (LED)

□

sometimes lights up (probably wiring fault)

□

starter motor not rotating

□

starter motor rotating but engine doesn’t turn over

□

starter motor and engine don’t turn over

□

no fuel flow (

□

no fuel in tank,

□

no fuel pump sound)

□

engine flooded (do not crank engine with throttle opened, which promotes engine

flooding)

□

no spark

Starting
difficulty

□

other

□

right after starting

□

when opening throttle grip

□

when closing throttle grip

□

when moving off

□

when stopping the motorcycle

□

when cruising

Engine stops

□

other

□

very low idle speed,

□

very high idle speed,

□

rough idle speed

□

battery voltage is low (charge the battery)

□

spark plug loose (tighten it)

□

spark plug dirty, broken, or gap maladjusted (remedy it)

□

backfiring

□

afterfiring

□

hesitation when acceleration

□

engine oil viscosity too high

□

brake dragging

□

engine overheating

Poor running
at low speed

□

clutch slipping

3-30 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

NOTE

○

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 in
DFI system.

○

The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits are 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.

Engine Won’t Turn Over

Symptoms or Possible Causes

Actions

Neutral, starter lockout or sidestand switch
trouble

Inspect each switch (see chapter 16).

Vehicle-down sensor operated

Turn ignition switch OFF (see chapter 3).

Vehicle-down sensor trouble

Inspect (see chapter 3).

Crankshaft sensor trouble

Inspect (see chapter 16).

Stick coil shorted or not in good contact

Inspect or Reinstall (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Spark plug dirty, broken or gap maladjusted

Inspect and replace (see chapter 2).

Spark plug incorrect

Replace it with the correct plug (see chapter 2).

ECU ground and power supply trouble

Inspect (see chapter 3).

ECU trouble

Inspect (see chapter 3).

No or little fuel in tank

Supply fuel (see Owner’s Manual).

Fuel injector trouble

Inspect and replace (see chapter 3).

Fuel pump not operating

Inspect (see chapter 3).

Fuel pump relay trouble

Inspect and replace (see chapter 3).

Fuel filter or pump screen clogged

Inspect and replace fuel pump (see chapter 3).

Fuel pressure regulator trouble

Inspect fuel pressure and replace fuel pump (see
chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Poor Running at Low Speed

Symptoms or Possible Causes

Actions

Spark weak:

Stick coil shorted or not in good contact

Inspect or Reinstall (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Spark plug dirty, broken or gap maladjusted

Inspect and replace (see chapter 2).

Spark plug incorrect

Replace it with the correct plug (see chapter 2).

ECU trouble

Inspect (see chapter 3).

Fuel/air mixture incorrect:

Little fuel in tank

Supply fuel (see Owner’s Manual).

Air cleaner clogged, poorly sealed, or missing

Clean element or inspect sealing (see chapter 2).

Air duct loose

Reinstall (see chapter 3).

Throttle body assy holder loose

Reinstall (see chapter 3).

Throttle body assy dust seal damage

Replace (see chapter 3).

Fuel injector O-ring damage

Replace (see chapter 3).

Fuel filter or pump screen clogged

Inspect and replace fuel pump (see chapter 3).

FUEL SYSTEM (DFI) 3-31

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions

Fuel pressure regulator trouble

Inspect fuel pressure and replace fuel pump (see
chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Unstable (rough) idling:

Fuel pressure too low or too high

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Engine vacuum not synchronizing

Inspect and adjust (see chapter 2).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Engine stalls easily:

Spark plug dirty, broken or gap maladjusted

Inspect and replace (see chapter 2).

Stick coil trouble

Inspect (see chapter 16).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Fuel pressure too low or too high

Inspect (see chapter 3).

Fuel pressure regulator trouble

Inspect fuel pressure and replace fuel pump (see
chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Poor acceleration:

Fuel pressure too low

Inspect (see chapter 3).

Water or foreign matter in fuel

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

Fuel filter or pump screen clogged

Inspect and replace fuel pump (see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

3-32 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Spark plug dirty, broken or gap maladjusted

Inspect and replace (see chapter 2).

Stick coil trouble

Inspect (see chapter 16).

Stumble:

Fuel pressure too low

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Surge:

Unstable fuel pressure

Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and replace fuel pump) (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Backfiring when deceleration:

Spark plug dirty, broken or gap maladjusted

Inspect and replace (see chapter 2).

Fuel pressure too low

Inspect (see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Air switching valve trouble

Inspect and replace (see chapter 16).

Air suction valve trouble

Inspect and replace (see chapter 5).

After fire:

Spark plug burned or gap maladjusted

Replace (see chapter 2).

Fuel injector trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Other:

Intermittent any DFI fault and its recovery

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

FUEL SYSTEM (DFI) 3-33

DFI System Troubleshooting Guide

Poor Running or No Power at High Speed

Symptoms or Possible Causes

Actions

Firing incorrect:

Stick coil shorted or not in good contact

Inspect or Reinstall (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Spark plug dirty, broken or gap maladjusted

Inspect and replace (see chapter 2).

Spark plug incorrect

Replace it with the correct plug (see chapter 2).

ECU trouble

Inspect (see chapter 3).

Fuel/air mixture incorrect:

Air cleaner clogged, poorly sealed, or missing

Clean element or inspect sealing (see chapter 2).

Air duct loose

Reinstall (see chapter 3).

Throttle body assy holder loose

Reinstall (see chapter 3).

Throttle body assy dust seal damage

Replace (see chapter 3).

Water or foreign matter in fuel

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

Fuel injector O-ring damage

Replace (see chapter 3).

Fuel injector clogged

Inspect and repair (see chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Fuel pump operates intermittently and often DFI
fuse blows.

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

Fuel pump trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Cracked or obstructed inlet air pressure sensor
vacuum hose

Inspect and repair or replace (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Knocking:

Fuel poor quality or incorrect

Fuel change (Use the gasoline recommended in
the Owner’s Manual).

Spark plug incorrect

Replace it with the correct plug (see chapter 2).

Stick coil trouble

Inspect (see chapter 16).

ECU trouble

Inspect (see chapter 3).

Engine vacuum not synchronizing

Inspect and adjust (see chapter 2).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature 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 will not fully open

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

3-34 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions

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

(see Overheating of Troubleshooting Guide in
chapter 17)

Air switching valve trouble

Inspect and replace (see chapter 16).

Air suction valve trouble

Inspect and replace (see chapter 5).

Exhaust Smokes Excessively:

(Black smoke)

Air cleaner element clogged

Clean element (see chapter 2).

Fuel pressure too high

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

(Brown smoke)

Air duct loose

Reinstall (see chapter 3).

Fuel pressure too low

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

FUEL SYSTEM (DFI) 3-35

Self-Diagnosis

Self-diagnosis Outline

The self-diagnosis system has three modes and can be

switched to another mode by grounding the self-diagnosis
terminal.

User Mode

The ECU notifies the rider of troubles in DFI system and

ignition system by lighting the FI indicator when DFI system
and ignition system parts are faulty, and initiates fail-safe
function. In case of serious troubles, the ECU stops the
injection/ignition/starter motor operation.
Dealer Mode 1

The FI indicator light (LED) 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 Procedures

○

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

NOTE

○

Use

fully

charged

battery

when

conducting

self-diagnosis.

Otherwise, the light (LED) blinks

very slowly or does not blink.

○

Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.

•

Remove the seat (see Seat Removal in the Frame chap-
ter).

•

Ground the self-diagnosis terminal [A] (Orange/Black
lead) to the battery (–) terminal or battery (–) cable
connector, using a wire.

•

Turn on the ignition switch.

•

Connect an auxiliary lead [A] to the self-diagnosis terminal
[B] for grounding.

•

To enter the self-diagnosis dealer mode 1, ground [C] the
self-diagnosis indicator terminal to the battery (–) terminal
for more than 2 seconds [D], and then keep it grounded
continuously [E].

○

Count the blinks of the light (LED) to read the service
code. Keep the auxiliary lead ground until you finish read-
ing the service code.

3-36 FUEL SYSTEM (DFI)

Self-Diagnosis

•

To enter the self-diagnosis dealer mode 2, open [A] and
ground [B] the lead more than five times [C] within 2 sec-
onds [D] after the lead is first grounded, and then keep it
grounded continuously [E] for more than 2 seconds.

○

Count the blinks of the light (LED) to read the service
code. Keep the auxiliary lead ground until you finish read-
ing the service code.

Auxiliary Lead [F]
Self-diagnosis Terminal [G]

NOTE

○

To enter the dealer mode 2 from the dealer mode 1, turn
off the ignition switch once.

Service Code Clearing Procedures

•

Enter the self-diagnosis dealer mode 2 (see Self
-diagnosis Procedures).

NOTE

○

Make sure to keep the grounding until the following
opening and grounding starts.

•

Pull the clutch lever in more than 5 seconds, and then
release it.

•

Repeat opening

[A] and

grounding [B] the lead

(self-diagnosis terminal) more than five times [C] within 2
seconds [D] after the lead is grounded, and then keep it
grounded continuously [E] for more than 2 seconds.

Auxiliary Lead [F]
Self-diagnosis Terminal [G]

3-38 FUEL SYSTEM (DFI)

Self-Diagnosis

How to Read Service Codes

○

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

○

Read 10th digit and unit digit as the FI indicator light (LED) 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 and unlight.

○

For example, if two problems occurred in the order of 21, 12, 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
light (LED) does not go on, and no service codes can be displayed.

FI Indicator Light (LED)
Fuel Pump
Fuel Pump Relay
ECU Main Relay
ECU Power Source Wiring and Ground Wiring (see ECU Inspection)
Fuel Injectors

How to Erase Service Codes

○

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

○

Refer to the Service Code Clearing Procedure for the service code erasure.

Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year) - page 3