Kawasaki Ninja Service Manual: Fuel Pressure Inspection

Kawasaki Ninja Service Manual / Fuel System (DFI) / Fuel Line / Fuel Pressure Inspection

NOTE

Be sure the battery is fully charged.

Remove: Fuel Tank Covers (see Fuel Tank Removal) Fuel Tank Bolts (see Fuel Tank Removal) Primary Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter)

Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.

Install the fuel pressure gauge adapter [A] and fuel hoses (Special Tool: 57001-1607) [B] between the fuel outlet pipe and delivery pipe.
Secure the fuel hoses with the clamps.
Connect the pressure gauge [C] to the fuel pressure gauge adapter.

Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Fuel Pressure Gauge Adapter: 57001-1593

Fuel Hose: 57001-1607

Fuel Pressure Inspection

WARNING

Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death. Do not try to start the engine with the fuel hoses disconnected.

Turn the engine stop switch to run position.
Turn the ignition switch to ON.

The fuel pump should operate for 3 seconds, and then should stop.

NOTE

After turning on the engine stop switch and ignition switch, inspect the fuel leakage from the connected portion of the special tools.

NOTICE

Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.

Start the engine, and let it idle.
Measure the fuel pressure with the engine idling.

Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi)

NOTE

The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.

Turn the ignition switch to OFF.

If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check the following.

Fuel Line Leakage (see Fuel Injector Fuel Line Inspection) Amount of Fuel Flow (see Fuel Flow Rate Inspection)

After above checks, measure the fuel pressure again.

Remove the fuel pressure gauge, hoses and adapter.

Install the removed parts (see appropriate chapters).

Start the engine and check for fuel leakage.

Fuel Line

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Fuel Flow Rate Inspection

WARNINGGasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from ...

Other materials:

Air Cleaner Housing Removal
Remove the fuel tank (see Fuel Tank Removal). Disconnect the secondary fuel hose [A] from the delivery pipe of the nozzle assy [B] (see Fuel Hose Replacement in the Periodic Maintenance chapter). Disconnect the secondary fuel injector connectors [C]. Free the lead from the grooves [D]. ...

ECU Power Supply Inspection
Remove the upper air cleaner housing (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Remove the ECU (see ECU Removal). Visually inspect the ...

Bolts, Nuts and Fasteners Tightness Inspection
Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retighten them to ...