Caution

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

OAfter measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B] for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector

• 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 wires for signs of burning, fraying, short, etc. Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system.

• If any wiring is deteriorated, replace the wiring.

• 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.

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

OConnect the hand tester between the ends of the leads.

OSet the tester to the x 1 Q range, and read the tester.

• If the tester does not read 0 Q, the lead is defective. Replace the lead or the main harness or the sub harness.

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

OWhen 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 replaced.

★ Narrow down suspicious locations by repeating the continuity 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.

OLead Color Codes:

BK

Black

G: Green

P: Pink

BL

Blue

GY: Gray

PU: Purple

BR

Brown

LB: Light blue

R: Red

CH

Chocolate

LG: Light green

W: White

DG

Dark green

O: Orange

Y: Yellow

OThere are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method.

(Voltage Check Method)

OThis method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor.

OSometimes this method can detect a fault of the ECU.

• Refer to each sensor inspection section for detail in this chapter.

• Use a fully charged battery and a digital meter [D] which can be read two decimal places voltage or resistance.

(Resistance Check Method)

OThis method is simple. No need for a fully charged battery and the needle adapter. Just do the following especially when a sensor [A] is suspect.

• Turn the ignition switch OFF and disconnect the connectors.

• Inspect the sensor resistance, using a digital meter (see each sensor inspection in this chapter).

• Inspect the wiring and connectors [B] for continuity, using the hand tester [C] (analog tester) rather than a digital meter.

Special Tool - Hand Tester: 57001-1394

*If the sensor, the wiring and connections are good, inspect the ECU for its ground and power supply (see this chapter). If the ground and power supply are good, the ECU is suspect. Replace the ECU.

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