Fuel Injectors

Removal/Installation

• Refer to the Throttle Body Assy Disassembly/Assembly.

Audible Inspection

• Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end onto your ear, and listen whether the injector is clicking or not.

OA sound scope [B] can also be used.

• Do the same for the other injectors.

• If all the injectors click at a regular intervals, the injectors are good. The trouble may be related to the fuel line, requiring fuel pressure inspection (see Fuel Line section in this chapter).

OThe click interval becomes shorter as the engine speed rises.

• If any injector(s) doesn't click, the DFI circuit or the injector is suspect. Perform "Power Source Voltage Inspection", first.

Power Source Voltage Inspection

• Remove the ECU (see ECU section). Do not disconnect the ECU connector.

• Connect a digital meter [A] to the ECU connector [B], using the needle adapter [C].

Special Tool - Needle Adapter Set: 57001-1457

OMeasure the power source voltage with the engine stopped, and with the connector joined.

• Turn the ignition switch ON.

Injector Power Source Voltage at ECU Connections: Meter (+) ^ W/Y (terminal 13)

Meter (-) ^ Battery (-) Terminal Service Limit: Voltage (12.6 V or more)

• If the meter doesn't read as specified, check the following.

Main Fuse 30A (see Electrical System chapter) Fuel Pump Relay (see DFI Power Source section) Power Source Wiring (see Wiring diagram below) OTo check the W/R leads between the injector connector and the fuel pump relay, remove the fuel tank (see Fuel Tank Removal) and the seat cover (see Frame chapter).

• If the power source voltage is normal, check the output voltage of the injectors.

Kawasaki Setting Adapter 57001 1457

Output Voltage Inspection

• Turn the ignition switch OFF.

• Connect a digital voltmeter [A] to the ECU connector [B] with the needle adapter set [C].

Special Tool - Needle Adapter Set: 57001-1457

Injector Output Voltage Connections to Injector #1 Meter (+) ^ BL/R lead (terminal 36) Meter (-) ^ Battery (-) Terminal Connections to Injector #2 Meter (+) ^ BL/G lead (terminal 35) Meter (-) ^ Battery (-) Terminal Connections to Injector #3 Meter (+) ^ BL/BK lead (terminal 49) Meter (-) ^ Battery (-) Terminal Connections to Injector #4 Meter (+) ^ BL/Y lead (terminal 48) Meter (-) ^ Battery (-) Terminal

• Turn the ignition switch ON.

Output Voltage at Injector Connector Standard: Battery Voltage (12.6 V or more)

*If the output voltage is normal, perform "Injector Signal Test".

• If the output voltage is out of the standard, turn the ignition switch OFF, remove the fuel tank, and check the injector wiring for continuity.

Injector Wiring Inspection ECU Connector Injector Connectors

Terminal 36 ^ Injector #1 Terminal (BL/R)

Terminal 35 ^ Injector #2 Terminal (BL/G)

Terminal 49 ^ Injector #3 Terminal (BL/BK)

Terminal 48 ^ Injector #4 Terminal (BL/Y)

*If the wiring is good, inspect the resistance of the injectors (see Injector Resistance Inspection in chapter).

• Remove the needle adapter.

• Apply silicone sealant to the seals of the ECU connector for waterproofing.

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