Fuel System DFI

Exploded View 3-4

DFI Parts Location 3-8

DFI Wiring Diagram 3-10

Specifications 3-12

Special Tools 3-14

DFI Servicing Precautions 3-15

DFI Servicing Precautions 3-15

Troubleshooting the DFI System 3-17

Outline 3-17

Outline 3-17

Inquiries to Rider 3-21

Inquiries to Rider 3-21

DFI System Troubleshooting Guide 3-24

DFI System Troubleshooting Guide 3-24

Self-Diagnosis 3-33

Self-diagnosis Outline 3-33

Self-diagnosis Outline 3-33

Self-diagnosis Procedures 3-33

Self-diagnosis Procedures 3-33

Service Code Clearing Procedures 3-34

Service Code Clearing Procedures 3-34

How to Read Service Codes 3-36

How to Read Service Codes 3-36

How to Erase Service Codes 3-36

How to Erase Service Codes 3-36

Service Code Table 3-37

Service Code Table 3-37

Backups 3-38

Backups 3-38

Main Throttle Sensor (Service Code 11) 3-40

Main Throttle Sensor Removal/Adjustment 3-40

Input Voltage Inspection 3-40

Output Voltage Inspection 3-41

Resistance Inspection 3-42

Inlet Air Pressure Sensor (Service Code 12) 3-43

Removal 3-43

Installation 3-43

Input Voltage Inspection 3-43

Output Voltage Inspection 3-44

Inlet Air Temperature Sensor (Service Code 13) 3-47

Removal/Installation 3-47

Output Voltage Inspection 3-47

Sensor Resistance Inspection 3-48

Water Temperature Sensor (Service Code 14) 3-49

Removal/Installation 3-49

Output Voltage Inspection 3-49

Sensor Resistance Inspection 3-50

Atmospheric Pressure Sensor (Service Code 15) 3-51

Removal 3-51

Input Voltage Inspection 3-51

Output Voltage Inspection 3-52

Crankshaft Sensor (Service Code 21) 3-54

Crankshaft Sensor Removal/Installation 3-54

Crankshaft Sensor Inspection 3-54

Camshaft Position Sensor (Service Code 23) 3-55

Camshaft Position Sensor Removal/Installation 3-55

Camshaft Position Sensor Inspection 3-55

Speed Sensor (Service Code 24, 25) 3-56

Speed Sensor Removal/Installation 3-56

Speed Sensor Inspection 3-56

Input Voltage Inspection 3-56

Output Voltage Inspection 3-56

Vehicle-down Sensor (Service Code 31) 3-58

Removal 3-58

Installation 3-58

Inspection 3-58

Subthrottle Sensor (Service Code 32) 3-61

Subthrottle Sensor Removal/Adjustment 3-61

Input Voltage Inspection 3-61

Output Voltage Inspection 3-62

Resistance Inspection 3-63

Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) 3-64

Removal/Installation 3-64

Input Voltage Inspection 3-64

Subthrottle Valve Actuator (Service Code 62) 3-66

Subthrottle Valve Actuator Removal 3-66

Audible Inspection 3-66

Visual Inspection 3-66

Resistance Inspection 3-66

Input Voltage Inspection 3-67

FI Indicator LED Light 3-68

LED Light Inspection 3-69

ECU 3-70

ECU Removal 3-70

ECU Installation 3-70

ECU Power Supply Inspection 3-70

DFI Power Source 3-73

ECU Fuse Removal 3-73

ECU Fuse Installation 3-73

ECU Fuse Inspection 3-73

ECU Main Relay Removal 3-73

ECU Main Relay Inspection 3-73

Fuel Line 3-74

Fuel Pressure Inspection 3-74

Fuel Flow Rate Inspection 3-75

Fuel Pump 3-77

Fuel Pump Removal 3-77

Fuel Pump Installation 3-77

Operation Inspection 3-78

Operating Voltage Inspection 3-78

Pressure Regulator Removal 3-79

Pump Screen, Fuel Filter Cleaning 3-79

Fuel Pump 3-80

Fuel Pump Relay Removal 3-80

Fuel Pump Relay Inspection 3-80

Fuel Injectors 3-81

Removal/Installation 3-81

Audible Inspection 3-81

Power Source Voltage Inspection 3-81

Output Voltage Inspection 3-82

Injector Signal Test 3-83

Injector Resistance Inspection 3-84

Injector Unit Test 3-84

Injector Fuel Line Inspection 3-84

Throttle Grip and Cables 3-87

Throttle Grip Play Inspection/Adjustment 3-87

Choke Lever Operation 3-87

Choke Lever Play Inspection 3-87

Choke Lever Play Adjustment 3-87

Cable Removal/Installation 3-87

Cable Lubrication and Inspection 3-87

Throttle Body Assy 3-88

Idle Speed Inspection 3-88

Engine Vacuum Synchronization Inspection/ Adjustment 3-88

High Altitude Performance Adjustment 3-88

Throttle Body Assy Removal 3-88

Throttle Body Assy Installation 3-90

Throttle Body Assy Disassembly 3-91

Throttle Body Assy Assembly 3-92

Air Cleaner 3-93

Element Removal/Installation 3-93

Air Cleaner Oil Draining 3-93

Air Cleaner Housing Removal 3-93

Fuel Tank 3-94

Fuel Tank Removal 3-94

Fuel Tank Installation 3-95

Fuel Tank and Cap Inspection 3-96

Fuel Tank Cleaning 3-96

Exploded View

Kawasaki Z750 Parts Diagrams

No.

Fastener

Torque

Remarks

Nm

kgfm

ftlb

1

Throttle cable plate bolt

6.0

0.60

52 inlb

2

Throttle body assy holder clamp bolts

2.0

0.20

17 in lb

3

Choke link holder screws

2.1

0.21

18 in lb

4

Delivery pipe screws

3.4

0.35

30 in lb

5

Fuel pump bolts

9.8

1.0

87 in lb

L,S

6

Fuel level sensor bolts

6.9

0.7

62 in lb

7

Bypass screws

0.2

0.02

1.7 in lb

8. Center adjusting screw

9. FI indicator LED light

10. Meter unit

11. Throttle cable (accelerator)

12. Throttle cable (decelerator)

13. Choke cable

14. Injector connectors

15. Main throttle sensor connector (grey)

16. Subthrottle sensor connector (black)

17. Subthrottle valve actuator connector

18. Throttle body assy connector

19. Main throttle sensor

20. Subthrottle sensor

21. Injectors

CL: Apply cable lubricant. EO: Apply engine oil to the seals and O-rings. G: Apply grease.

L: Apply a non-permanent locking agent. S: Follow the specified tightening sequence.

Exploded View

Kawasaki Z750 Fuel Sensor

No.

Fastener

Torque

Remarks

Nm

kgfm

ftlb

1

Inlet air pressure sensor bolt

12

1.2

104 inlb

2

Water temperature sensor

25

2.5

18

3

Vehicle down sensor bolts

2.0

0.20

17 in lb

4

Camshaft position sensor bolt

12

1.2

104 in lb

5

Camshaft position sensor rotor bolt

12

1.2

104 in lb

L

6

Air cleaner duct holder screws

3.8

0.39

34 in lb

7

Air cleaner housing mounting bolts

9.8

1.0

87 in lb

8

Air cleaner duct clamp bolts

2.0

0.20

17 in lb

9

Air cleaner housing screws

1.2

0.12

10 in lb

10

Air cleaner housing tapping screws

1.2

0.12

10 in lb

11

Speed sensor bolt

6.9

0.70

62 in lb

L

12. Inlet air pressure sensor

13. Stick coils (see Electrical System chapter)

14. ECU

15. Fuel pump relay

16. ECU main relay

17. Atmospheric pressure sensor

18. Crankshaft sensor (see Electrical System chapter)

19. Inlet air temperature sensor

20. Vacuum switch valve (see Engine Top End chapter)

21. Air suction valves

22. Grommet

L: Apply a non-permanent locking agent.

2011 Kawasaki Z750 Battery Removal

DFI: DFI Parts (this chapter)

1. Water temperature Sensor (DFI)

2. Inlet Air Pressure Sensor (DFI)

3. Injectors (DFI)

5. Inlet Air Temperature Sensor (DFI)

6. Sealed Battery

7. Junction Box

10. Stick Coils

11. Throttle Body Assy

12. Self-diagnosis Terminal

13. Neutral Switch

14. Vehicle Down Sensor (DFI)

15. Atmospheric Pressure Sensor (DFI)

16. Delivery Pipe

17. ECU Main Relay

18. Fuel Pump Relay (DFI)

19. Turn Signal Relay

20. Subthrottle Sensor (DFI)

21. Main Throttle Sensor (DFI)

22. Ignition Switch

23. FI Indicator LED Light (DFI)

24. Crankshaft Sensor

25. Camshaft Position Sensor

26. Fuel Pump Screen

27. Return Fuel Check Valve

28. Pressure Regulator

29. Fuel Filter

Fuel Pump Z750s
[1], [2], [10], [13], [22] and [24] are not included.

DFI Wiring Diagram

Z750 Wiring Diagram

Terminal Names

1. Power Supply to Sensors

2. Main Throttle Sensor Signal

3. Subthrottle Sensor Signal

4. Atmospheric Pressure Sensor Signal

5. Water Temperature Sensor Signal (+)

6. Unused

7. Ignition Switch Signal

8. Unused

9. Camshaft Position Sensor Signal (+)

10. Unused

11. Crankshaft Sensor Signal (+)

12. Unused

13. Power Supply to ECU, Injectors, and Fuel Pump

14. Ground to sensors

15. Unused

16. Vehicle-down Sensor Signal

17. Inlet Air Pressure Sensor Signal

18. Inlet Air Temperature Sensor Signal (+)

19. Unused

20. Speed Sensor Signal

21. Unused

22. Camshaft Position Sensor Signal (-)

23. Unused

24. Crankshaft Sensor Signal (-)

25. Unused

26. ECU Power Source Circuit Ground to Battery (-) Terminal

Part Name

A. ECU (Electronic Control Unit)

B. Crankshaft Sensor

C. Inlet Air Pressure Sensor

D. Water Temperature Sensor

E. Atmospheric Pressure Sensor

F. Inlet Air Temperature Sensor

G. Camshaft Position Sensor

H. Speed Sensor

I. Main Throttle Sensor J. Subthrottle Sensor K. Injectors #1, #2, #3, #4 L. Subthrottle Valve Actuator M. Stick Coils #1, #2, #3, #4 N. Engine Stop Switch O. Joint Connector D P. see Electrical System chapter Q. Ground Terminal R. Ground Terminal S. ECU Main Relay

27. Engine Stop Switch Signal

28. Starter Lockout Switch Signal

29. Electric Starter Button Signal

30. Fuel Pump Relay Signal

31. Subthrottle Valve Actuator Drive Signal

32. Subthrottle Valve Actuator Drive Signal

33. Unused

34. Tachometer Signal

35. Injector #2 Signal

36. Injector #1 Signal

37. Stick Coil #3 Signal

38. Stick Coil #2 Signal

39. Stick Coil #1 Signal

40. Interlock Circuit Signal

41. Self-diagnosis Signal (generated by grounding this terminal and shown by FI indicator LED light)

42. Unused

43. Battery Power ON-OFF Signal

44. Subthrottle Valve Actuator Drive Signal

45. Subthrottle Valve Actuator Drive Signal

46. External Diagnosis System Signal

47. FI Indicator LED Light Signal

48. Injector #4 Signal

49. Injector #3 Signal

50. DFI System Ground

51. Ignition System Ground

52. Stick Coil #4 Signal

T. Ignition Switch U. FI Indicator LED Light V. Tachometer W. Speedometer X. Ignition Fuse 10 A Y. Junction Box Z. Fuel Pump Relay a. ECU Fuse 15 A

b. Vehicle-down Sensor d. Starter Relay e. Joint Connector C

f. Sealed Battery g. Fuel Pump h. Self-diagnosis Terminal j. Joint Connector B

k. Main Fuse 30 A m. Throttle Body Assy Connector n: Connector Locks p: ECU Connector

Item

Standard

Digital Fuel Injection System

Idle Speed

1 100 ±50 r/min (rpm)

Throttle Assy:

Type

Four barrel type

Bore

</>34 mm (1.34 in.)

ECU (Electronic Control Unit):

Make

Denso

Type

Digital memory type, with built in IC igniter, sealed with resin

Usable engine speed

100 ~ 12 240 r/min (rpm)

Fuel Pressure (high pressure line):

Right after Ignition SWON

310 kPa (3.2 kgf/cm2, 46 psi) with fuel pump running

After 3 sec from Ignition SW ON

290 kPa (2.9 kgf/cm2, 43 psi) with fuel pump stopped

With engine idling

310 kPa (3.2 kgf/cm2, 46 psi) with fuel pump running

Fuel Pump:

Type

In-tank friction pump

Discharge

67 mL or more for 3 seconds

Fuel Injectors:

Type

INP-285

Nozzle type

One spray type with 4 holes

Resistance

about 11.7 ~ 12.3 Q at 20°C (68°F)

Main Throttle Sensor:

Non-adjustable and non-removable

Input voltage

4.75 ~ 5.25 V DC between BL and BR/BK leads

Output voltage at idle throttle

0.99 ~ 1.03 V DC between Y/W and BR/BK leads

opening

Output voltage at full throttle

4.19 ~ 4.39 V DC between Y/W and BR/BK leads

opening

Resistance

4 ~ 6kQ

Inlet Air Pressure Sensor or

Atmospheric Pressure Sensor:

Input voltage

4.75 ~ 5.25 V DC between BL and BR/BK leads

Output voltage

3.74 ~ 4.26 V DC at standard atmospheric pressure (see this text for details)

Inlet Air Temperature Sensor:

Resistance

1.6 ~ 3.7 kQ at 20°C (68°F) 0.24 ~ 0.43 kQ at 80°C (176°F)

Output voltage at ECU

about 2.25 ~ 2.50 V @20°C (68°F)

Water Temperature Sensor:

Resistance

see Electrical System chapter

Output voltage at ECU

about 2.80 ~ 2.97 V @20°C (68°F)

Speed Sensor:

Input voltage at sensor

about 9 ~ 11 V DC at Ignition SW ON

Output voltage at sensor

about 0.05 ~ 0.07 V DC at Ignition SW ON and 0 km/h

Vehicle-down Sensor:

Detection method

Magnetic flux detection method

Detection angle

More than 60 ~ 70° for each bank

Item

Standard

Detection time

Within 0.5 ~ 1.0 sec.

Output voltage

with the sensor tilted 60 ~ 70° or more: 3.7 ~ 4.4 V with sensor arrow mark pointed up: 0.4 ~ 1.4 V

Subthrottle Sensor:

Non-adjustable and non-removal

Input voltage

4.75 ~ 5.25 V DC between BL and BR/BK leads

Output voltage at idle throttle

0.48 ~ 0.52 V DC between BR and BR/BK leads

opening

Output voltage at full throttle

3.6 ~ 3.8 V DC between BR and BR/BK leads

opening

Resistance

4 ~ 6kQ

Subthrottle Valve Actuator:

Resistance

about 5 ~ 7kQ

Input voltage

about 8.5 ~ 10.5 V DC

Throttle Grip and Cables

Throttle grip free play

2 ~ 3 mm (0.08 ~ 0.12 in.)

Choke Cable

Choke cable free play

0 ~ 0.5 mm (0 ~ 0.02 in.)

+1 0

Responses

  • RIAN
    Where is main fuse kawasaki z750?
    6 years ago
  • simret
    How to diagnos dfi system?
    4 years ago
  • jakub
    How to install a kawasaki fd851 dfi?
    4 years ago
  • annabel scott
    How to replace throttle cable on z750?
    4 years ago

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