Warning: The ignition system produces extremely high voltage. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock.
Caution: Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This isto prevent ECU (Electric Control Unit) damage. Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the ECU.
Crankshaft Sensor Removal
Remove:
- Lower Fairing (See Lower Fairing Removal in the Frame chapter)
- Right Rear Frame Cover (See Rear Frame Cover Removal in the Frame chapter)
- Crankshaft Sensor Lead Connector [A]
![](https://motoinstruction.ru/img/kawasaki/23/129152.jpg)
Remove:
- Rubber Boot (Slide Out) [A]
- Oil Pressure Switch Lead Terminal [B]
![](https://motoinstruction.ru/img/kawasaki/23/129153.jpg)
Remove:
- Clamp [A]
- Clutch Cover (See Clutch Cover Removal in the Clutch chapter)
![](https://motoinstruction.ru/img/kawasaki/23/129154.jpg)
Remove:
- Bolts [A]
- Crankshaft Sensor [B]
- Pull out the grommet [C].
![](https://motoinstruction.ru/img/kawasaki/23/129155.jpg)
Crankshaft Sensor Installation
- Route the crankshaft sensor lead correctly (See Cable, Wire, and Hose Routing section in the Appendix chapter).
Tighten:
Torque - Crankshaft Sensor Bolts: 6.0 Nm (0.61 kgf·m, 53 in·lb)
- Apply silicone sealant [A] to the crankshaft sensor lead grommet.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
- Install the removed parts (see appropriate chapters).
![](https://motoinstruction.ru/img/kawasaki/23/129156.jpg)
Crankshaft Sensor Inspection
- Disconnect the crankshaft sensor lead connector [A] (See Crankshaft Sensor Removal).
- Set the hand tester to the x 100 Q range and connect (+) lead to the black lead and (-) lead to the yellow lead in the connector.
Special Tool - Hand Tester: 57001-1394
Crankshaft Sensor Resistance: 376-564 Ω
If there is more resistance than the specified value, the coil has an open lead and must be replaced. Much less than this resistance means the coil is shorted, and must be replaced.
- Using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground.
Any tester reading less than infinity (~) indicates a short, necessitating replacement of the crankshaft sensor assembly.
![](https://motoinstruction.ru/img/kawasaki/23/129157.jpg)
Crankshaft Sensor Peak Voltage Inspection
Note: Be sure the battery is fully charged. Using the peak voltage adapter [A] is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements.
- Disconnect the crankshaft sensor lead connector (See Crankshaft Sensor Removal).
- Set the hand tester [B] to the x DC 10 V range, and connect it peak voltage adapter.
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
- Connect the black lead of the adapter to black lead and red lead to yellow lead in the crankshaft sensor connector.
- Turn the engine stop switch to run position.
- Turn the ignition switch ON.
![](https://motoinstruction.ru/img/kawasaki/23/129158.jpg)
- Pushing the starter button, turn the engine 4-5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage.
- Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage Standard: 1.9 V or more
If the tester reading is not specified one, check the crankshaft sensor (See Crankshaft Sensor Inspection).
Timing Rotor Removal
Remove:
- Clutch Cover (See Clutch Cover Removal in the Clutch chapter)
- Crankshaft Sensor (See Crankshaft Sensor Removal)
- Holding the timing rotor [A] with the rotor holder [B] and unscrew the rotor bolt [C].
Special Tool - Rotor Holder: 57001-1567
![](https://motoinstruction.ru/img/kawasaki/23/129159.jpg)
Timing Rotor Installation
- Align the pin [A] of the crankshaft to the groove [B] of the timing rotor
- Install the washer.
- Holding the timing rotor with the rotor holder and tighten the rotor bolt.
Special Tool - Rotor Holder: 57001-1567
Torque - Timing Rotor Bolt: 40 №m (4.1 kgf·m, 30 ft·lb)
- Install the removed parts (see appropriate chapters).
![](https://motoinstruction.ru/img/kawasaki/23/129160.jpg)
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal
- Remove the air cleaner housing (See Air Cleaner Housing Removal in the Fuel System (DFI) chapter).
- Open the clamp [A].
- Disconnect the stick coil connectors [B].
- Pull the stick coils [C] off the spark plugs.
![](https://motoinstruction.ru/img/kawasaki/23/129161.jpg)
Caution: Do not pry the connector part of the coil while removing the coil.
Stick Coil (Ignition Coil together with Spark Plug Cap) Installation
- Insert the stick coils [A] so that the coil heads faces the arrow marks [B].
Caution: Do not tap the coil head while installing the coil.
- Connect the stick coil connectors.
- Run the hoses and harness correctly (See Cable, Wire, and Hose Routing section in the Appendix chapter).
- Install the removed parts (see appropriate chapters).
![](https://motoinstruction.ru/img/kawasaki/23/129162.jpg)
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection
- Remove the stick coils (See Stick Coil (Ignition Coil together with Spark Plug Cap) Removal).
- Measure the primary winding resistance [A] as follows.
Connect the hand tester between the coil terminals.
Set the tester to the x 1 Ω range, and read the tester.
- Measure the secondary winding resistance [B] as follows. OConnect the tester between the plug terminal and (-) coil terminal.
Set the tester to the x 1 k Ω range and read the tester.
Ignition Coil Winding Resistance
Primary Windings: 1.1-1.5 Ω
Secondary Windings: 10.8-16.2 k Ω
If the tester does not read as specified, replace the coil.
![](https://motoinstruction.ru/img/kawasaki/23/129163.jpg)
Stick Coil Primary Peak Voltage
Note: Be sure the battery is fully charged.
- Remove the stick coils (See Stick Coil (Ignition Coil together with Spark Plug Cap) Removal).
Do not remove the spark plugs.
- Measure the primary peak voltage as follows.
Install the new spark plug [A] into each stick coil [B], and ground them onto the engine.
Connect the peak voltage adapter [C] into the hand tester [D] which is set to the x DC 250 V range.
Connect the adapter to the lead wire-peak voltage adapter [E] which is connected between the stick coil connector and stick coil.
- ECU [F]
- Battery [G]
![](https://motoinstruction.ru/img/kawasaki/23/129164.jpg)
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Lead Wire-Peak Voltage Adapter: 57001-1449
Primary Lead Connection
Adapter (R, +) to lead wire-peak voltage adapter (R)
Adapter (BK, -) to lead wire-peak voltage adapter (W)
![](https://motoinstruction.ru/img/kawasaki/23/129165.jpg)
Warning: To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections.
- Turn the engine stop switch to run position.
- Turn the ignition switch ON.
- Pushing the starter button, turn the engine 4-5 seconds with the transmission in neutral to measure the primary peak voltage.
- Repeat the measurements 5 times for one stick coil.
Stick Coil Primary Peak Voltage
Standard: 88 V or more
- Repeat the test for the other stick coil.
If the reading is less than the specified value, check the following.
Stick Coils (See Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection).
Crankshaft Sensor (See Crankshaft Sensor Inspection) ECU (See ECU Power Supply Inspection in the Fuel System (DFI) chapter).
Spark Plug Removal
- Refer to the Spark Plug Replacement in the Periodic Maintenance chapter.
Spark Plug Installation
- Refer to the Spark Plug Replacement in the Periodic Maintenance chapter.
Spark Plug Condition Inspection
- Remove the spark plugs (See Spark Plug Replacement).
- Visually inspect the spark plugs.
If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated, replace the spark plug.
- Measure the gap [D] with a wire-type thickness gauge.
Spark Plug Gap: 0.8-0.9 mm (0.03-0.04 in.)
If the gap is incorrect, replace the spark plug. OUse the standard spark plug or its equivalent.
Spark Plug: CR9EIA-9
![](https://motoinstruction.ru/img/kawasaki/23/129166.jpg)
Interlock Operation Inspection
- Raise the rear wheel off the ground with stand [A].
1st Check
- Start the engine to the following conditions.
Condition
Transmission Gear — 1st Position
Clutch Lever — Release
Sidestand — Down or Up
Turn the ignition switch ON and push the starter button.
Then the starter motor should not turn when the starter system circuit is normality.
If the engine is start, inspect the starter lockout switch, neutral switch and relay box.
If their parts are normality replace the ECU.
2nd Check
- Start the engine to the following conditions.
Condition
Transmission Gear — 1st Position
Clutch Lever — Pulled in
Sidestand — Up
Turn the ignition switch ON and push the starter button.
Then the starter motor should turn when the starter system circuit is normality.
If the starter motor is not turn, inspect the starter lockout switch, neutral switch and relay box.
If their parts are normality replace the ECU.
![](https://motoinstruction.ru/img/kawasaki/23/129167.jpg)
3rd Check
- Inspect the engine for its secure stop after the following operations are completed.
- Run the engine to the following conditions.
Condition
Transmission Gear — 1st Position
Clutch Lever — Pulled in
Sidestand — Up
- Set the sidestand on the ground, then the engine will stop.
If whichever may not be stopped, inspect the neutral switch, starter lockout switch, sidestand switch and relay box.
If their parts are normality, replace the ECU.
IC Igniter Inspection
The IC igniter is built in the ECU [A].
- Refer to the Interlock Operation Inspection, Ignition System Troubleshooting chart and Fuel System (DFI) chapter for ECU Power Supply Inspection.
![](https://motoinstruction.ru/img/kawasaki/23/129168.jpg)
![](https://motoinstruction.ru/img/kawasaki/23/129169.jpg)
Ignition System Circuit
![](https://motoinstruction.ru/img/kawasaki/23/129170.jpg)
1. Ignition Switch; 2. Engine Stop Switch; 3. Spark Plugs; 4. Stick Coils; 5. Water-proof Joint C; 6. Speed Sensor; 7. Subthrottle Sensor; 8. Main Throttle Sensor; 9. Water-proof Joint D; 10. Vehicle-down Sensor; 11. Water-proof Joint E; 12. Water Temperature Sensor; 13. Neutral Switch; 14. Crankshaft Sensor; 15. Meter Unit; 16. Water-proof Joint A; 17. Water-proof Joint B; 18. Starter Lockout Switch; 19. ECU Fuse 15A; 20. Ignition Fuse 10 A; 21. Fuse Box; 22. ECU Main Relay; 23. Relay Box; 24. Main Fuse 30 A; 25. Starter Relay; 26. Battery 12 V 10 Ah; 27. Frame Ground; 28. Sidestand Switch; 29. Joint Connector; 30. ECU