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

FUEL SYSTEM (DFI) 3-39

Self-Diagnosis

Service Code Table

Service

Code

FI Indicator Light (LED)

Problems

Main throttle sensor 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

Crankshaft sensor malfunction, wiring
open or short

and

Speed sensor malfunction, wiring
open or short
First 24 is displayed and then 25,
repeatedly

Vehicle-down sensor, malfunction,
wiring open or short

Subthrottle sensor malfunction, wiring
open or short

Oxygen sensor inactivation, wiring
open or short (Equipped Models)

Stick (Ignition) coil #1 malfunction,
wiring open or short

Stick (Ignition) coil #2 malfunction,
wiring open or short

Radiator fan relay malfunction, wiring
open or short

Subthrottle valve actuator
malfunction, wiring open or short

Air switching valve malfunction, wiring
open or short

Oxygen sensor heater malfunction,
wiring open or short (Equipped
Models)

Oxygen sensor malfunction, wiring
open or short (Equipped Models)

Notes:

○

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.

○

When no service code is displayed, the electrical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.

3-40 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

Main Throttle

Sensor

Main Throttle Sensor
Output Voltage
0.2

∼

4.8 V

If the main throttle sensor system fails (the
output voltage 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 main 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 = 150

∼

800 mmHg

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

- N

method.

Inlet Air

Temperature

Sensor

Inlet Air Temperature
Ta = –30°C

∼

+120°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 40°C.

Water

Temperature

Sensor

Water Temperature
Tw = –30°C

∼

+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 80°C.

Crankshaft

Sensor

Crankshaft sensor must
send 22 signals to
the ECU at the one
cranking.

If crankshaft sensor generates other than 22
signals, the engine stops by itself.

and

Speed Sensor

Speed sensor must
send 4 signals to the
ECU at the one rotation
of the engine sprocket.
The gear position is
decided by the signal of
the speed sensor.

If the speed sensor system fails (no signal,
wiring short or open), the speedometer shows
0, and the ECU sets the top (6) gear position.

Vehicle-down

Sensor

Output Voltage (signal)
Vd = 0.65

∼

4.45 V

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

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 ECU drive the subthrottle valve
to the full closed position, and it stops the
current to the actuator.

Oxygen Sensor

(Equipped

Models)

The oxygen sensor is
active and sensor must
send signals (output
voltage) continuously to
the ECU.

If the oxygen sensor is not activated, the ECU
stops oxygen sensor feedback mode.

FUEL SYSTEM (DFI) 3-41

Self-Diagnosis

Service

Codes

Parts

Output Signal Usable

Range or Criteria

Backups by ECU

Stick Coil #1*

The stick coil primary
winding must send
signals continuously to
the ECU.

If the stick coil #1 primary winding 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*

The stick coil primary
winding must send
signals continuously to
the ECU.

If the stick coil #2 primary winding 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.

Subthrottle

Valve Actuator

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

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

Oxygen Sensor

(Equipped

Models)

The oxygen sensor
heater raise
temperature of the
sensor for its earlier
activation. 12V-6.6W,
0.55A

If the oxygen sensor heater fails (wiring short
or open), the ECU stops the current to the
heater.

Oxygen Sensor

(Equipped

Models)

The oxygen sensor
must send signals
(output voltage)
continuously to the
ECU

If the oxygen sensor output voltage is incorrect,
the ECU stops oxygen sensor feed back mode.

Note:
(1) D-J Method and

- N Method: When the engine load is light like at idling or low speed, the ECU

determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor
output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J
method (low-speed mode). As the engine speed increases, and the engine load turns middle to
heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle
sensor output voltage) and the engine speed. This method is called

- N method (high-speed

mode).

(*) This depends on the number of stopped cylinders.

3-42 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11)

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 throttle body assy, especially on a
hard surface. Such a shock to the sensor can dam-
age it.

Main Throttle Sensor Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the left upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Disconnect the main throttle sensor connector and con-
nect the harness adapter [A] between these connectors.

Special Tool - Throttle Sensor Setting Adapter:

57001

-1538

•

Connect a digital meter to the harness adapter leads.

Main Throttle Sensor Input Voltage

Connections to Adapter:

Digital Meter (+)

→

BK (sensor BL) lead

Digital Meter (–)

→

W (sensor BR/BK) lead

•

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

•

Turn the ignition switch ON.

Input Voltage

Standard:

DC 4.75

∼

5.25 V

•

Turn the ignition switch OFF.
If the input voltage is normal, check the 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 Continuity Inspection

ECU Connector [A]

←→

Main Throttle Sensor Connector [B]

BL lead (ECU terminal 8) [C]

BR/BK lead (ECU terminal 22) [D]

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

FUEL SYSTEM (DFI) 3-43

Main Throttle Sensor (Service Code 11)

Main Throttle Sensor 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 and con-
nect the harness adapter [A] between these connectors.

Special Tool - Throttle Sensor Setting Adapter:

57001

-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

R (sensor Y/W) lead

Digital Meter (–)

→

W (sensor BR/BK) lead

•

Start the engine and warm it up thoroughly.

•

Check idle speed to ensure the throttle opening is correct.

Idle Speed

Standard:

1 300 ±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 the ignition switch OFF.

•

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

•

Turn the ignition switch ON.

Output Voltage

Standard:

DC 1.005

∼

1.035 V at idle throttle opening

DC 4.2

∼

4.4 V at full throttle opening

(for reference)

NOTE

○

Open the throttle, confirm the output voltage will be
raise.

○

The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.

○

When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.005 × 4.75 ÷ 5.00 = 0.955 V
1.035 × 4.75 ÷ 5.00 = 0.983 V
Thus, the valid range is 0.955

∼

0.983 V

•

Turn the ignition switch OFF.
If the output voltage is out of the standard, inspect the
main throttle sensor resistance (see Main Throttle Sensor
Resistance Inspection).

3-44 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11)

If the output voltage is normal, check the wiring for conti-
nuity.

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Main Throttle Sensor Connector [B]

Y/W lead (ECU terminal 6) [C]

BR/BK lead (ECU terminal 22) [D]

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

Main Throttle Sensor Resistance Inspection

•

Turn the ignition switch OFF.

•

Remove the left upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

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 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 ECU Removal/Installation).

Main Throttle Sensor Circuit

1. ECU
2. Main Throttle Sensor
3. Water-proof Joint D
4. Water-proof Joint E

FUEL SYSTEM (DFI) 3-45

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 upper fairing (see Upper Fairing Removal in
the Frame chapter).

•

Disconnect the inlet air pressure sensor connector [A] and
the vacuum hose [B].

•

Remove the bolt [C], and take off the inlet air pressure
sensor [D].

Inlet Air Pressure Sensor Installation

•

Installation is the reverse of removal.

Inlet Air Pressure Sensor Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the upper fairing (see Upper Fairing Removal in
the Frame chapter).

•

Disconnect the inlet air pressure sensor connector and
connect the harness adapter [A] between these connec-
tors.

Special Tool - Measuring Adapter: 57001-1700

•

Connect a digital meter to the harness adapter leads.

Inlet Air Pressure Sensor Input Voltage

Connections to Adapter:

Digital Meter (+)

→

R (sensor BL) lead

Digital Meter (–)

→

BK (sensor BR/BK) lead

•

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

•

Turn the ignition switch ON.

Input Voltage

Standard:

DC 4.75

∼

5.25 V

•

Turn the ignition switch OFF.
If the reading is within the standard, check the output volt-
age (see Inlet Air Pressure Sensor Output Voltage Inspec-
tion).

3-46 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

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

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Inlet Air Pressure Sensor Connector [B]

BL lead (ECU terminal 8) [C]

BR/BK lead (ECU terminal 22) [D]

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

Inlet Air Pressure Sensor Output Voltage
Inspection

•

Measure the output voltage at the inlet air pressure sen-
sor in the same way as input voltage inspection, note the
following.

○

Disconnect the inlet air pressure sensor connector and
connect the harness adapter [A] between these connec-
tors.

Special Tool - Measuring Adapter: 57001-1700

Inlet Air Pressure Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

W (sensor Y/BL) lead

Digital Meter (–)

→

BK (sensor BR/BK) lead

•

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

•

Turn the ignition switch ON.

Output Voltage

Usable Range:

DC 3.80

∼

4.20 V at standard

atmospheric pressure (101.32 kPa,
76 cmHg)

NOTE

○

The output voltage changes according to local atmo-
spheric pressure.

•

Turn the ignition switch OFF.
If the reading is out of the usable range, replace the sen-
sor.

FUEL SYSTEM (DFI) 3-47

Inlet Air Pressure Sensor (Service Code 12)

If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connector.

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Inlet Air Pressure Sensor Connector [B]

Y/BL lead (ECU terminal 7) [C]

BR/BK lead (ECU terminal 22) [D]

If the wiring is good, check the sensor for various vacuum.

•

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

•

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

•

Temporarily install the inlet air pressure sensor.

○

Connect a digital meter [C], vacuum gauge [D], the fork
oil level gauge [E] and the harness adapter to the inlet air
pressure sensor.

Special Tools - Fork Oil Level Gauge: 57001-1290

Vacuum Gauge: 57001-1369
Measuring Adapter: 57001-1700

Inlet Air Pressure Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

W (sensor Y/BL) lead

Digital Meter (–)

→

BK (sensor BR/BK) lead

○

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.

3-48 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

Suppose:

Pg: Vacuum Pressure (Gauge) to Sensor

Pl: Local Atmospheric Pressure (Absolute) measured by a barometer

Pv: Vacuum Pressure (Absolute) to Sensor
Vv: Sensor Output Voltage (V)

then

Pv = Pl – Pg

For example, suppose the following data is obtained:

Pg = 8 cmHg (Vacuum Gauge Reading)

Pl = 70 cmHg (Varometer Reading)

Vv = 3.2 V (Digital Meter Reading)

then

Pv = 70 – 8 = 62 cmHg (Absolute)

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 = 3.04

∼

3.49 V

Plot Vv (3.2 V) on the vertical line.

→

Point [3].

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

Pv = 24

∼

55 cmHg

FUEL SYSTEM (DFI) 3-51

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 (see Fuel Tank Removal).

•

Disconnect the connector [A].

•

Remove the screw [B].

•

Pull out the inlet air temperature sensor [C].

•

Put the inlet air temperature sensor into the air cleaner
housing.

•

Tighten the screw securely.

Inlet Air Temperature Sensor Output Voltage
Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the fuel tank (see Fuel Tank Removal).

•

Disconnect the inlet air temperature sensor connector
and connect the harness adapter [A] between these
connectors as shown in the figure.

Main Harness [B]
Inlet Air Temperature Sensor [C]

Special Tool - Measuring Adapter: 57001-1700

•

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

Inlet Air Temperature Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

R (sensor Y) lead

Digital Meter (–)

→

BK (sensor BR/BK) lead

•

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

•

Turn the ignition switch ON.

Output Voltage

Standard:

About DC 2.25

∼

2.50 V at inlet air

temperature 20°C (68°F)

NOTE

○

The output voltage changes according to the inlet air
temperature.

•

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

3-52 FUEL SYSTEM (DFI)

Inlet Air Temperature Sensor (Service Code 13)

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

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Inlet Air Temperature Sensor Connector [B]

Y lead (ECU terminal 20) [C]

BR/BK lead (ECU terminal 22) [D]

If the wiring is good, check the inlet air temperature sensor
resistance (see Inlet Air Temperature Sensor Resistance
Inspection).

Inlet Air Temperature Sensor Resistance
Inspection

•

Remove the inlet air temperature sensor (see Inlet Air
Temperature Sensor Removal/Installation).

•

Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion is 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 following.

Inlet Air Temperature Sensor Resistance

Standard:

5.4

∼

6.6 k

Ω

at 0°C (32°F)

0.29

∼

0.39 k

Ω

at 80°C (176°F)

If the reading is out of the standard, replace the sensor.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).

3-54 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.

•

Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).

•

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

•

Apply grease to the new O-ring on the water temperature
sensor.

•

Tighten:

Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106

in·lb)

•

Fill the engine with coolant and bleed the air from the cool-
ing system (see Coolant Change in the Periodic Mainte-
nance chapter).

Water Temperature Sensor Output Voltage
Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the left upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Disconnect the water temperature sensor connector and
connect the harness adapter [A] between these connec-
tors as shown in the figure.

Main Harness [B]
Water Temperature Sensor [C]

Special Tool - Measuring Adapter: 57001-1700

•

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

Water Temperature Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

R (sensor O) lead

Digital Meter (–)

→

BK (sensor BR/BK) lead

•

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

•

Turn the ignition switch ON.

Output Voltage

Standard: About DC 2.80

∼

2.97 V at 20°C (68°F)

NOTE

○

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

•

FUEL SYSTEM (DFI) 3-55

Water Temperature Sensor (Service Code 14)

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

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Water Temperature Sensor Connector [B]

O lead (ECU terminal 17) [C]

BR/BK lead (ECU terminal 22) [D]

If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).

Water Temperature Sensor Resistance Inspection

•

Refer to the Water Temperature Sensor Inspection in the
Electrical System chapter.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).

Water Temperature Sensor Circuit

1. ECU
2. Water-proof Joint E
3. Water Temperature Sensor

3-56 FUEL SYSTEM (DFI)

Crankshaft Sensor (Service Code 21)

Start the engine and switch the diagnosis mode to Dealer

1 mode to know all the problem that the DFI system has at
the time of self-diagnosis. If the engine cannot be started,
the self-diagnosis system does not detect dynamic condi-
tion of the crankshaft sensor. In this case, turn off the igni-
tion switch and turn it on again to enter the Dealer 2 mode.
In this mode, the system tells all the troubles which the DFI
system had in both static and dynamic conditions.

Crankshaft Sensor Removal/Installation

•

Refer to the Crankshaft Sensor Removal/Installation in
the Electrical System chapter.

Crankshaft Sensor Resistance Inspection

•

Refer to the Crankshaft Sensor Inspection in the Electrical
System chapter.
If the reading is within the standard, check the peak volt-
age (see Crankshaft Sensor Peak Voltage Inspection).

Crankshaft Sensor Peak Voltage Inspection

•

Refer to the Crankshaft Sensor Peak Voltage Inspection
in the Electrical System chapter.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Crankshaft Sensor Connector [B]

R/BK lead (ECU terminal 11) [C]

Y/BK lead (ECU terminal 24) [D]

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

3-58 FUEL SYSTEM (DFI)

Speed Sensor (Service Code 24, 25)

Speed Sensor Removal/Installation

•

Refer to the Speed Sensor Removal/Installation in the
Electrical System chapter.

Speed Sensor Inspection

•

Refer to the Speed Sensor Inspection in the Electrical
System chapter.

Speed Sensor Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the left upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Disconnect the speed sensor connector [A] and connect
the harness adapter [B] between the harness connector
and speed sensor connector.

Special Tool - Throttle Sensor Setting Adapter #1: 57001

-1400

•

Connect a digital meter to the harness adapter leads.

Speed Sensor Input Voltage

Connections to Adapter:

Digital Meter (+)

→

BL (sensor P) lead [C]

Digital Meter (−)

→

BK/BL (sensor BK) lead [D]

•

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

•

Turn the ignition switch ON.

Input Voltage

Standard:

About DC 9

∼

11 V at Ignition Switch ON

•

Turn the ignition switch OFF.
If the reading is out of the range, check the wiring (see
wiring diagram in this section), and meter unit (see Meter
Unit Inspection in the Electrical System chapter).
If the reading is good, check the output voltage.

FUEL SYSTEM (DFI) 3-59

Speed Sensor (Service Code 24, 25)

Speed Sensor Output Voltage Inspection

•

Before this inspection, inspect the input voltage (see
Speed Sensor Input Voltage Inspection).

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the left upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Disconnect the speed sensor connector [A] and connect
the harness adapter [B] between the harness connector
and speed sensor connector.

Special Tool - Throttle Sensor Setting Adapter #1: 57001

-1400

•

Connect a digital meter to the harness adapter leads.

Speed Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

Y/W (sensor Y) lead [C]

Digital Meter (–)

→

BK/BL (sensor BK) lead [D]

•

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

•

Turn the ignition switch ON.

Output Voltage

Standard:

About DC 0.05

∼

0.07 V or DC 4.5

∼

4.9 V

NOTE

○

Rotate the rear wheel by hand, confirm the output volt-
age will be raise or lower.

•

Turn the ignition switch OFF.
If the reading is out of the range, check the speed sensor
(see Speed Sensor Inspection in the Electrical System
chapter) and the wiring to ECU (see wiring diagram in this
section).
If the reading, speed sensor and wiring are good, check
the ECU for its ground, and power supply (see ECU
Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-61

Vehicle-down Sensor (Service Code 31)

Vehicle-down Sensor Removal

CAUTION

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

•

Remove:

Right Frame Cover (see Frame Cover Removal in the
Frame chapter)
Connector [A]
Vehicle-down Sensor [B] and Dampers [C]

Vehicle-down Sensor Installation

•

Replace the mounting dampers with new ones.

•

The UP mark [A] of the sensor should face upward.

WARNING

Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power.

The

rider could lose balance during certain riding situ-
ations like leaning over in a turn with the potential
for an accident resulting in injury or death. Ensure
that the vehicle-down sensor is held in place by the
sensor brackets.

Vehicle-down Sensor Inspection

NOTE

○

Be sure the battery is fully charged.

•

Connect a digital meter [A] to the connector [B] of the
vehicle-down sensor [C] with the needle adapter set [D].

Special Tool - Needle Adapter Set: 57001-1457

Vehicle-down Sensor Power Source Voltage

Connections to Sensor Connector:

Meter (+)

→

BL lead [E]

Meter (–)

→

BR/BK lead [F]

•

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

Input Voltage

Standard:

DC 4.75

∼

5.25 V

•

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.
If the power source is normal, check the output voltage.

3-62 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31)

•

Remove the vehicle-down sensor (see Vehicle-down
Sensor Removal).

○

Do not disconnect the sensor connector.

•

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

Special Tool - Needle Adapter Set: 57001-1457

Vehicle-down Sensor Output Voltage

Connections to Sensor Connector:

Meter (+)

→

Y/G lead [E]

Meter (–)

→

BR/BK lead [F]

•

Hold the sensor vertically.

•

Turn the ignition switch ON, and measure the output volt-
age with the connector joined.

○

Tilt the sensor 60

∼

70° or more [C] right or left, then hold

the sensor almost vertical with the arrow mark pointed up
[D], and measure the output voltage.

Output Voltage

Standard:

with sensor tilted 60

∼

70° or more right or

left: 0.65

∼

1.35 V

with sensor arrow mark pointed up: 3.55

∼

4.45 V

NOTE

○

If you need to test again, turn the ignition switch OFF,
and then ON.

•

Turn the ignition switch OFF.
If the output voltage is normal, check the wiring.
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the output voltage is out of the specified, replace the
vehicle-down sensor.

3-64 FUEL SYSTEM (DFI)

Subthrottle Sensor (Service Code 32)

Subthrottle Sensor Removal/Adjustment

CAUTION

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

Subthrottle Sensor Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the air cleaner housing (see Air Cleaner Housing
Removal).

•

Turn the ignition switch OFF.

•

Disconnect the subthrottle sensor connector and connect
the harness adapter [A] between these connectors.

Special Tool - Throttle Sensor Setting Adapter #1: 57001

-1400

•

Connect a digital meter to the harness adapter leads.

Subthrottle Sensor Input Voltage

Connections to Adapter:

Digital Meter (+)

→

BL (sensor BL) lead

Digital Meter (–)

→

BK/BL (sensor BK) lead

•

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

•

Turn the ignition switch ON.

Input Voltage

Standard:

DC 4.75

∼

5.25 V

•

Turn the ignition switch OFF.
If the reading is within the standard, check the output volt-
age (see Subthrottle Sensor Output Voltage Inspection).

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

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Subthrottle Sensor Connector [B]

BL lead (ECU terminal 8) [C]

BR/BK lead (ECU terminal 22) [D]

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

FUEL SYSTEM (DFI) 3-65

Subthrottle Sensor (Service Code 32)

Subthrottle Sensor Output Voltage Inspection

•

Remove the air cleaner housing (see Air Cleaner Housing
Removal).

•

Measure the output voltage at the subthrottle sensor in
the same way as input voltage inspection. Note the fol-
lowing.

○

Disconnect the subthrottle sensor connector and connect
the harness adapter [A] between these connectors.

Special Tool - Throttle Sensor Setting Adapter #1: 57001

-1400

Subthrottle Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

Y/W (sensor Y) lead

Digital Meter (–)

→

BK/BL (sensor BK) lead

•

Turn the ignition switch ON.

•

Measure the output voltage when the subthrottle valve is
fully opened or completely closed by hand.

Output Voltage

Standard:

DC 0.4

∼

0.6 V (at idle throttle opening)

DC 3.825

∼

3.975 V (at full throttle opening)

NOTE

○

Turn the lever counterclockwise, confirm the output volt-
age will be raise.

○

The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.

○

When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
0.4 × 4.75 ÷ 5.00 = 0.38 V
0.6 × 4.75 ÷ 5.00 = 0.57 V
Thus, the valid range is 0.38

∼

0.57 V

•

Turn the ignition switch OFF.
If the output voltage is out of the standard, inspect the
subthrottle sensor resistance.

If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Subthrottle Sensor Connector [B]

BR lead (ECU terminal 19) [C]

BR/BK lead (ECU terminal 22) [D]

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

3-66 FUEL SYSTEM (DFI)

Subthrottle Sensor (Service Code 32)

Subthrottle Sensor Resistance Inspection

•

Turn the ignition switch OFF.

•

Disconnect the subthrottle sensor connector.

•

Connect a digital meter [A] to the subthrottle sensor con-
nector [B].

•

Measure the subthrottle sensor resistance.

Throttle Sensor Resistance

Connections:

BL lead [C]

←→

BK lead [D]

Standard:

∼

6 k

Ω

If the reading is out of the range, replace the throttle body
assy (see Throttle Body Assy Removal/Installation).
If the reading is within the range, but the problem still
exists, replace the ECU (see ECU Removal/Installation).

Subthrottle Sensor Circuit

1. ECU
2. Subthrottle Sensor
3. Water-proof Joint D
4. Water-proof Joint E

FUEL SYSTEM (DFI) 3-67

Oxygen Sensor-not activated (Service Code 33) (Equipped Models)

Oxygen Sensor Removal/Installation

•

Refer to the Oxygen Sensor Removal/Installation in the
Electrical System chapter.

Oxygen Sensor Inspection

•

Warm up the engine thoroughly until the radiator fan
starts.

•

Turn the ignition switch OFF.

•

Disconnect the oxygen sensor connector and connect the
harness adapter [A] between these connectors.

Special Tool - Oxygen Sensor Measuring Adapter: 57001

-1682

•

Connect a digital meter to the harness adapter leads.

Oxygen Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

BL (sensor BL) lead

Digital Meter (−)

→

BR (sensor W) lead

•

Remove the air switching valve hose from the fitting.

•

Install the suitable plug [A] on the fitting [B] and shut off
the secondary air.

•

Turn the ignition switch ON.

•

Start the engine, and let it idle.

•

Measure the output voltage with the connector joined.

Output Voltage (with Plug)

Standard:

DC 0.7 V or more

•

Next, remove the plug from the fitting [A] with idling.

•

Measure the output voltage with the connector joined.

Output Voltage (without Plug)

Standard:

DC 0.2 V or less

•

Turn the ignition switch OFF.

3-68 FUEL SYSTEM (DFI)

Oxygen Sensor-not activated (Service Code 33) (Equipped Models)

If the reading is out of the standard (with plug: DC 0.7 V
or more, without plug: DC 0.2 V or less), remove the ECU
and check the wiring for continuity between main harness
connectors.

Special Tool - Hand Tester: 57001-1394

○

Disconnect the ECU and sensor connectors.

Wiring Continuity Inspection

ECU Connector [A]

←→

Oxygen Sensor Connector [B]

BL/Y lead (ECU terminal 4) [C]

BR/BK lead (ECU terminal 22) [D]

If the wiring is good, replace the sensor.
If the reading is within the standard (with plug: DC 0.7 V
or more, without plugs: DC 0.2 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).

Oxygen Sensor Circuit

1. Ignition Switch
2. Water-proof Joint E
3. Oxygen Sensor
4. ECU
5. Frame Ground
6. Main Fuse 30 A
7. Battery 12 V 10 Ah
8. Fuse Box
9. Oxygen Sensor Heater Fuse 10 A

10. Water-proof Joint C

11. Frame Ground

FUEL SYSTEM (DFI) 3-69

Stick Coils #1, #2: (Service Code 51, 52)

Stick Coil #1: Service Code 51
Stick Coil #2: Service Code 52

Stick Coil Removal/Installation

•

Refer to the Stick Coil Removal/Installation in the Electri-
cal System chapter.

Stick Coil Primary Winding Resistance Inspection

•

Refer to the Stick Coil Inspection in the Electrical System
chapter.
If the reading is within the standard, check the input volt-
age (see Stick Coil Input Voltage Inspection).

Stick Coil Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the ECU (see ECU Removal).

○

Do not disconnect the ECU connectors.

•

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

Special Tool - Needle Adapter Set: 57001-1457

Stick Coil Input Voltage

Connections to ECU Connector:

For Stick Coil #1

Digital Meter (+)

→

BK lead (terminal 35)

Digital Meter (–)

→

BK/Y lead (terminal 43)

For Stick Coil #2

Digital Meter (+)

→

BK/G lead (terminal 44)

Digital Meter (–)

→

BK/Y lead (terminal 43)

•

Measure the input voltage to each primary winding of the
stick coils with the engine stopped and with the connec-
tors joined.

•

Turn the engine stop switch to run position.

•

Turn the ignition switch ON.

Input Voltage

Standard:

Battery Voltage

•

Turn the ignition switch OFF.
If the input voltage is out of the standard, check the wiring
for continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the input voltage is within the standard, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).

Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year) - page 4