Kawasaki Ninja Service Manual: Fuel Injector Output Voltage Inspection

Kawasaki Ninja Service Manual / Fuel System (DFI) / Fuel Injectors / Fuel Injector Output Voltage Inspection

NOTE

Be sure the battery is fully charged.

Fuel Injector Output Voltage Inspection

Turn the ignition switch to OFF.
Remove the ECU (see ECU Removal).

Do not disconnect the ECU connector

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

Special Tool - Needle Adapter Set: 57001-1457

Primary Fuel Injector Output Voltage [C] Connections to ECU Connector:

For Primary Fuel Injector #1

Fuel Injector Output Voltage Inspection

Digital Meter (+) → BL/R lead (ECU terminal 47)

Digital Meter (–) → Battery (–) terminal

For Primary Fuel Injector #2

Digital Meter (+) → BL/O lead (ECU terminal 48)

Digital Meter (–) → Battery (–) terminal

For Primary Fuel Injector #3

Digital Meter (+) → BL/BK lead (ECU terminal 49)

Digital Meter (–) → Battery (–) terminal

For Primary Fuel Injector #4

Digital Meter (+) → BL/Y lead (ECU terminal 50)

Digital Meter (–) → Battery (–) terminal

Secondary Fuel Injector Output Voltage [D]

Connections to ECU Connector: For Secondary Fuel Injector #1

Digital Meter (+) → O/R lead (ECU terminal 57)

Digital Meter (–) → Battery (–) terminal

For Secondary Fuel Injector #2

Digital Meter (+) → O/G lead (ECU terminal 72)

Digital Meter (–) → Battery (–) terminal

For Secondary Fuel Injector #3

Digital Meter (+) → O/BK lead (ECU terminal 61)

Digital Meter (–) → Battery (–) terminal

For Secondary Fuel Injector #4

Digital Meter (+) → O/Y lead (ECU terminal 62)

Digital Meter (–) → Battery (–) terminal

Measure the output voltage with the engine stopped and with the connector joined.
Turn the engine stop switch to run position.
Turn the ignition switch to ON.

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

Turn the ignition switch to OFF.

If the reading is in specification, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).

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

Special Tool - Hand Tester: 57001-1394

Disconnect the ECU and injector connector.

Fuel Injector Output Voltage Inspection

Wiring Continuity Inspection (Primary Fuel Injectors) ECU Connector (Gray) [A] ←→ Primary Fuel Injector Connector [B]

For Primary Fuel Injector #1 [C]

BL/R lead (ECU terminal 47) [D]

For Primary Fuel Injector #2

BL/O lead (ECU terminal 48)

For Primary Fuel Injector #3

BL/BK lead (ECU terminal 49)

For Primary Fuel Injector #4

BL/Y lead (ECU terminal 50)

Wiring Continuity Inspection (Secondary Fuel Injectors) ECU Connector (Gray) [A] ←→ Secondary Fuel Injector Connector [E]

Fuel Injector Output Voltage Inspection

For Secondary Fuel Injector #1 [F]

O/R lead (ECU terminal 57) [G]

For Secondary Fuel Injector #2

O/G lead (ECU terminal 72)

For Secondary Fuel Injector #3

O/BK lead (ECU terminal 61)

For Secondary Fuel Injector #4

O/Y lead (ECU terminal 62)

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).

For Secondary Fuel Injectors

Remove the fuel tank (see Fuel Tank Removal). Disconnect the injector connector and connect the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Secon ...

Fuel Injector Fuel Line Inspection

Remove: Fuel Tank (see Fuel Tank Removal) Air Cleaner Housing (see Air Cleaner Housing Removal) Disconnect: Primary and Secondary Fuel Hoses (see Fuel Hose Replacement in the Periodic Mai ...

Other materials:

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Oxygen Sensor Removal/Installation Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Oxygen Sensor Lead Connector [A] Connect t ...

Crankshaft Side Clearance Inspection
Insert a thickness gauge [A] between the thrust washer [B] on the crankcase and the crank web [C] at the #3 main journal to determine clearance. If the clearance exceeds the service limit, replace the thrust washers as a set and check the width of the crankshaft #3 main journal. Cra ...

Piston Ring, Piston Ring Groove Wear Inspection
Check for uneven groove wear by inspecting the ring seating. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine pisto ...