Engine fuel supply system of motorcycle Kawasaki KLE 650 Versys (2007-2025)

Exploded View of Fuel System
No.FastenerTorqueRemarks Nmkg·fmft·lb 1Fuel Pump Bolts9.81.087 in·lbL, S 2Right Switch Housing Screws3.50.3631 in·lb 3Sidestand Switch Bolt3.90.4035 in·lbL 4. Injectors 5. Throttle Body Assy 6. Throttle Cable (Accelerator) 7. Throttle Cable...

DFI System
1. Inlet Air Pressure Sensor; 2. Crankshaft Sensor; 3. Injector; 4. Main Throttle Sensor; 5. Delivery Pipe; 6. Subthrottle Sensor; 7. Subthrottle Valve; 8. Main Throttle Valve; 9. Subthrottle Valve Actuator; 10. Fuel Pump; 11. Pressure Regulator;...

DFI System Wiring Diagram
Part Name 1. Oxygen Sensor (Europe Models) 2. Crankshaft Sensor 3. Inlet Air Temperature Sensor 4. Water Temperature Sensor 5. Water-proof Joint E 6. Injectors 7. Vehicle-down Sensor 8. Water-proof Joint D 9. Inlet Air Pressure Sensor 10. Main...

Specifications of fuel system (DFI)
ItemStandard Digital Fuel Injection System Idle Speed1 300±50 r/min (rpm) Throttle Body Assy: TypeTwo barrel type Bore38 mm (1.50 in.) ECU (Electronic Control Unit): MakeDENSO TypeDigital memory type, with built in IC igniter, sealed with resin...

Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Fork Oil Level Gauge: 57001-1290 Hand Tester: 57001-1394 Throttle Sensor Setting Adapter #1: 57001-1400 Peak Voltage Adapter: 57001-1415 Needle Adapter Set: 57001-1457 Throttle Sensor Setting Adapter:...

DFI Servicing Precautions
There are a number of important precautions that should be followed servicing the DFI system. This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a...

Troubleshooting the DFI System
Outline When an abnormality in the DFI system occurs, the FI indicator light (LED) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit). With the engine...

Inquiries to Rider
Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information...

Engine Doesn’t Start, Starting Difficulty
Symptoms or possible CausesActions (chapter) Starter motor not rotating: Ignition and engine stop switches not ONTurn both switches ON. Starter lockout switch or neutral switch troubleInspect (see chapter 16). Starter motor troubleInspect (see...

Poor Running at Low Speed
Symptoms or Possible CausesActions (chapter) Spark weak: Battery voltage lowInspect and charge (see chapter 16). Spark plug dirty, broken or gap maladjustedReplace (see chapter 2). Stick coil troubleInspect the stick coil (see chapter 16). Stick...

Poor Running or No Power at High Speed
Symptoms or Possible CausesActions (chapter) Firing incorrect: Spark plug dirty, broken or maladjustedReplace (see chapter 2). Stick coil troubleInspect stick coil (see chapter 16). Stick coil shorted or not in good contactReinstall or inspect stick...

Self-diagnosis Outline
The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system...

Self-diagnosis Procedures
When a problem occurs with the DFI system and ignition system, the FI indicator light (LED) [A] goes on. Note: Use a fully charged battery when conducting self-diagnosis. Otherwise, the light (LED) blinks very slowly or doesn't blink. Keep the...

Service Code Clearing Procedures
Enter the self-diagnosis dealer mode 2 (See Self-diagnosis Procedures). Note: Make sure to keep the grounding until the following opening and grounding starts. Pull the clutch lever in more than 5 seconds, and then release it. Repeat opening [B] and...

How to Read Service Codes
Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below. Read 10th digit and unit digit as the FI indicator light (LED) blinks. When there are a number of problems, all the service codes can be...

How to Erase Service Codes
Even if the ignition switch is turned OFF, the battery or the ECU are disconnected or the problem is solved, all service codes remain in the ECU. Refer to the Service Code Clearing Procedure for the service code erasure.

Service Code Table
Service CodeFI Indicator Light (LED)Problems 11Main throttle sensor malfunction, wiring open or short 12Inlet air pressure sensor malfunction, wiring open or short 13Inlet air temperature sensor malfunction, wiring open or short 14Water temperature...

Backups of Self-Diagnosis
The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service CodesPartsOutput Signal Usable Range or CriteriaBackups by ECU 11Main Throttle SensorMain Throttle Sensor Output Voltage...

Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Removal/Adjustment Caution: Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock to...

Inlet Air Pressure Sensor (Service Code 12)
Caution: Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal Remove the left middle fairing (See Middle Fairing Removal in the Frame chapter). Disconnect the inlet air...

Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Removal/Installation Caution: Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Remove the fuel tank (See Fuel Tank Removal). Disconnect the connector [A]. Remove the screw...

Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation Caution: Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Drain the coolant (See Coolant Change in the Periodic Maintenance chapter). Disconnect the sensor...

Crankshaft Sensor (Service Code 21)
Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of the...

Speed Sensor (Service Code 24, 25)
Speed Sensor Removal/Installation Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Inspection Refer to the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection...

Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Removal Caution: Never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. Remove: Bolts [A] Connector [B] Vehicle-down Sensor [C] Vehicle-down Sensor Installation The UP mark [A]...

Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Removal/Adjustment Caution: Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the...

Oxygen Sensor-not activated (Service Code 33) (Europe Models)
Oxygen Sensor Removal/Installation Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection Warm up the engine thoroughly until the radiator fan starts. Turn the ignition switch OFF. Disconnect the...

Stick Coils #1, #2: (Service Code 51, 52)
Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil Removal/Installation Caution: Never drop the stick coils, especially on a hard surface. Such a shock to the stick coil can damage it. Refer to the Stick Coil (Ignition Coil...

Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation Radiator fan relay is built in the relay box [A]. Remove the relay box (See Relay Box Removal in the Electrical System chapter). Radiator Fan Relay Inspection Refer to the Relay Circuit Inspection in the...

Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Removal Caution: Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the...

Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection Refer to the Air Switching Valve Operation Test/Unit Test in the Electrical System chapter....

Oxygen Sensor Heater (Service Code 67) (Europe Models)
The oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxygen sensor (see Oxygen Sensor Removal in the Electrical System chapter). Oxygen Sensor Heater Inspection Disconnect the oxygen sensor lead...

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
Oxygen Sensor Removal/Installation Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection Warm up the engine thoroughly until the radiator fan starts. Turn the ignition switch OFF. Disconnect the...

FI Indicator Light (LED)
Inspection Flow Chart FI Indicator Light (LED) Inspection Remove the meter unit (See Meter Unit Removal in the Electrical System chapter). Using two auxiliary leads, supply battery power to the FI indicator light (LED) [A]. 12 V Battery [B] FI...

ECU — removal and installation
Caution: Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal Remove the seat covers (See Seat) Cover Removal in the Frame chapter). Open the clamps [A]. Disconnect the connectors [B]. Remove the bolts...

Fuel Line Inspection
Fuel Pressure Inspection Note: This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. It is preferable to measure the fuel pressure while running the motorcycle just when trouble occurred in order to know...

Fuel Pump — removal and installation
Fuel Pump Removal Caution: Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. Warning Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated...

Fuel Injectors — removal and installation
Removal/Installation Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection Start the engine. Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or...

Throttle Grip and Cables
Throttle Grip Free Play Inspection Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Throttle Grip Free Play Adjustment Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Throttle...

Throttle Body Assy
Idle Speed Inspection Refer to the Idle Speed Inspection in the Periodic Maintenance chapter. Engine Vacuum Synchronization Inspection/Adjustment Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle...

Air Cleaner — removal and installation
Air Cleaner Element Removal/Installation Refer to the Air Cleaner Element Replacement in the Periodic Maintenance chapter. Air Cleaner Element Inspection Remove the air cleaner element (See Air Cleaner Element Replacement in the Periodic Maintenance...

Fuel Tank — removal and installation
Fuel Tank Removal Warning: Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not...