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 symptom well. Be sure the battery is fully charged.
- Remove the fuel tank (See Fuel Tank Removal).
- Be sure to place a piece of cloth around the fuel hose joint and the delivery pipe.
- Insert a minus screwdriver [A] into the slit on the joint lock [B].
- Turn the driver to disconnect the joint lock.
- Remove the fuel hose [C].
![](https://motoinstruction.ru/img/kawasaki/23/128339.jpg)
Warning: Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
- Install the fuel pressure gauge adapter [A] and fuel hoses (Special Tool: 57001-1607) [B] between the fuel pump outlet pipe and the delivery pipe.
- Connect the pressure gauge [C] to the fuel pressure gauge adapter.
![](https://motoinstruction.ru/img/kawasaki/23/128340.jpg)
Special Tools-Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607
Warning: Do not try to start the engine with the fuel hoses disconnected.
- Temporarily, install the fuel tank.
- Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop.
Note: Turn the ignition switch ON and inspect the fuel line leakage after installing the special tools.
Caution: Do not drive the fuel pump without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.
- Start the engine, and let it idle.
- Measure the fuel pressure with the engine idling.
Fuel Pressure (Idling)
Standard: 294 kPa (3.0 kgf/cm², 43 psi)
Note: The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
If the fuel pressure is much lower than specified, the fuel pressure regulator in the fuel pump have been clogged or stuck. Replace the fuel pump (See Fuel Pump) section).
If the fuel pressure is much lower than specified, check the following.
Fuel Line Leakage
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the throttle body assy, or the fuel pump and measure the fuel pressure again (see appropriate sections).
- Remove the fuel pressure gauge, hoses and adapter.
Install:
- Fuel Hose (See Fuel Hose Replacement in the Periodic Maintenance chapter)
- Fuel Tank (See Fuel Tank Installation)
- Fuel Flow Rate Inspection
Note: Be sure the battery is fully charged.
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 smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
- Turn the ignition switch, and engine stop switch OFF.
- Wait until the engine cools down.
- Prepare a fuel hose (Special Tool: 57001-1607) and a measuring cylinder.
Special Tool - Fuel Hose: 57001-1607
- Remove the fuel tank bolts (See Fuel Tank Removal).
- Open the fuel tank cap [A] to lower the pressure in the tank.
- Be sure to place a piece of cloth around the fuel pump outlet pipe.
- Remove the fuel hose from the fuel pump (See Fuel Tank Removal).
![](https://motoinstruction.ru/img/kawasaki/23/128341.jpg)
Warning: Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
- Connect the prepared fuel hose [A] to the fuel pump outlet pipe.
- Secure the fuel hose with a clamp.
- Run the other side of the fuel hose into the measuring cylinder [B].
![](https://motoinstruction.ru/img/kawasaki/23/128342.jpg)
Warning: Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical.
- Close the fuel tank cap.
- With the engine stopped, turn the ignition switch ON. The fuel pump should operate for 3 seconds, and then should stop. Repeat this several times until the fuel hose is filled with fuel.
Caution: Do not drive the fuel pump without the fuel in the fuel tank.
- Measure the discharge for 3 seconds.
Repeat this operation several times.
Amount of Fuel Flow
Standard: 60 mL or more for 3 seconds
If the fuel flow is much less than the specified, check the battery condition (See Charging Condition Inspection in the Electrical System chapter).
If the battery is good, replace the fuel pump (See Fuel Pump Removal/Installation).
- After inspection, connect the fuel hose (See Fuel Tank Installation).
- Start the engine and check for fuel leakage.