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 and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection/ignition/starter motor operation.
Dealer Mode 1
The FI indicator light (LED) emits service code(s) to show the problem(s) which the DFI system, and ignition system has at the moment of diagnosis.
Dealer Mode 2
The FI indicator light (LED) emits service code(s) to show the problem(s) which the DFI system, and ignition system had in the past.
Self-diagnosis procedures
When a problem occurs with the DFI system and ignition system, the FI indicator light (LED) [A] goes on.
![](https://motoinstruction.ru/img/kawasaki/13/118705.jpg)
Notes:
- Use a fully charged battery when conducting self-diagnosis. Otherwise, the light (LED) blinks very slowly or doesn't blink.
- Keep the self-diagnosis terminal grounded during self -diagnosis, with an auxiliary lead.
Remove the tool box (see Tool box removal in the Frame chapter).
Ground the self-diagnosis terminal [A] (Yellow lead) to the battery (-) terminal or battery (-) lead connector, using a wire.
![](https://motoinstruction.ru/img/kawasaki/13/118706.jpg)
Turn on the ignition switch.
Connect an auxiliary lead [E] to the self-diagnosis terminal [G] for grounding.
To enter the self-diagnosis dealer mode 1, ground [A] the self-diagnosis indicator terminal to the battery (-) terminal for more than 2 seconds [C], and then keep it grounded continuously [D].
![](https://motoinstruction.ru/img/kawasaki/13/118707.jpg)
Count the blinks of the light (LED) to read the service code. Keep the auxiliary lead ground until you finish reading the service code.
To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
Count the blinks of the light (LED) to read the service code. Keep the auxiliary lead ground until you finish reading the service code.
![](https://motoinstruction.ru/img/kawasaki/13/118708.jpg)
Auxiliary Lead [E]; Self-diagnosis Terminal [G]
Note. To enter the dealer mode 2 from the dealer mode 1, turn off the ignition switch once.
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 grounding [A] the lead (self-diagnosis terminal) more than five times [F] within 2 seconds [C] after the lead is grounded, and then keep it grounded continuously [D] for more than 2 seconds.
![](https://motoinstruction.ru/img/kawasaki/13/118709.jpg)
Auxiliary Lead [E]; Self-diagnosis Terminal [G]
![](https://motoinstruction.ru/img/kawasaki/13/118710.jpg)
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 stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open.
If there is no problem, no code and unlight.
For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the lowest number in the order listed.
(12 → 21) → (12 → 21) → · · · (repeated)
![](https://motoinstruction.ru/img/kawasaki/13/118711.jpg)
If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator light (LED) doesn't go on, and no service codes can be displayed.
- FI Indicator Light (LED)
- Fuel Pump
- Fuel Pump Relay
- DFI Main Relay
- ECU Power Source Wiring and Ground Wiring (see ECU power supply inspection)
- Fuel Injectors
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 Code | FI Indicator Light (LED) | Problems |
11 | ![]() | Main throttle sensor malfunction, wiring open or short |
12 | ![]() | Inlet air pressure sensor malfunction, wiring open or short |
13 | ![]() | Inlet air temperature sensor malfunction, wiring open or short |
14 | ![]() | Water temperature sensor malfunction, wiring open or short |
21 | ![]() | Crankshaft sensor malfunction, wiring open or short |
24 and 25 | ![]() | Speed sensor malfunction, wiring open or short First 24 is displayed and then 25, repeatedly |
31 | ![]() | Vehicle-down sensor, malfunction, wiring open or short |
32 | ![]() | Subthrottle sensor malfunction, wiring open or short |
33 | ![]() | Oxygen sensor #1 inactivation, wiring open or short (Europe Models) |
51 | ![]() | Ignition coil #1 malfunction, wiring open or short |
52 | ![]() | Ignition coil #2 malfunction, wiring open or short |
56 | ![]() | Radiator fan relay malfunction, wiring open or short |
62 | ![]() | Subthrottle valve actuator malfunction, wiring open or short |
64 | ![]() | Air switching valve malfunction, wiring open or short |
67 | ![]() | Oxygen sensor heater malfunction, wiring open or short (Europe Models) |
83 | ![]() | Oxygen sensor #2 inactivation, wiring open or short (Europe Models) |
94 | ![]() | Oxygen sensor #1 malfunction, wiring open or short (Europe Models) |
95 | ![]() | Oxygen sensor #2 malfunction, wiring open or short (Europe Models) |
Notes:
- The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.
- When no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical parts of the DFI system and the engine are suspect.
Backups
The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles.
Service Codes | Parts | Output Signal Usable Range or Criteria | Backups by ECU |
11 | Main Throttle Sensor | Main Throttle Sensor Output Voltage 0.20 - 4.8 V | If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method. Also, the main throttle sensor system and inlet air pressure fails, the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the a-N method. |
12 | Inlet Air Pressure Sensor | Inlet Air Pressure (absolute) Pv = 50 mmHg - 890 mmHg | If the inlet air pressure sensor system fails (the signal Pv is out of the usable range, wiring short or open), the ECU sets the DFI in the a - N·method. |
13 | Inlet Air Temperature Sensor | Inlet Air Temperature Ta = -30°C - +120°C | If the inlet air temperature sensor fails (the signal is out of the usable range, wiring short or open), the ECU sets Ta at 40°C. |
14 | Water Temperature Sensor | Water Temperature Tw = -30°C - +120°C | If the water temperature sensor system fails (the signal is out of the usable range, wiring short or open), the ECU sets Tw at 80°C. |
21 | Crankshaft Sensor | Crankshaft sensor must send 17 signals (output signal) to the ECU at the one cranking. | If crankshaft sensor generates other than 17 signals, the engine stops by itself. |
24 and 25 | Speed Sensor | Speed sensor must send 26 signals (output signal) to the ECU at the one rotation of the transmission gear. The gear position is decided by the signal of the speed sensor. | If the speed sensor system fails (no signal, wiring short or open), the speedometer shows 0, and the ECU sets the top (5) gear position. |
31 | Vehicle-down Sensor | Vehicle-down Sensor Output Voltage (signal) Vd = 0.65 V - 4.45 V | If the vehicle-down sensor system has failures (the output voltage Vd is more than usable range, wiring open), the ECU shuts off the fuel pump, the fuel injectors and the ignition system. |
32 | Subthrottle Sensor | Subthrottle Sensor Output Voltage 0.15 - 4.85 V | If the subthrottle sensor system fails (the signal is out of the usable range, wiring short or open), the actuator locks sub throttle valve at full open position. |
33 | Oxygen Sensor #1 (Europe Models) | The oxygen sensor is active and sensor must send signals (output voltage) continuously to the ECU. | If the oxygen sensor is not activated, the ECU stops oxygen sensor feedback mode. |
51 | Ignition Coil #1* | The stick coil primary winding must send signals (output voltage) continuously to the ECU. | If the ignition primary winding #1 has failures (no signal, wiring short or open), the ECU shuts off the injector #1 to stop fuel to the cylinder #1, though the engine keeps running. |
52 | Ignition Coil #2* | The stick coil primary winding must send signals (output voltage) continuously to the ECU. | If the ignition primary winding #2 has failures (no signal, wiring short or open), the ECU shuts off the injector #2 to stop fuel to the cylinder #2, though the engine keeps running. |
62 | Subthrottle Valve Actuator | The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU. | If the subthrottle valve actuator fails (the signal is out of the usable range, wiring short or open), the ECU stops the current to the actuator. |
64 | Air Switching Valve | The air switching valve solenoid opens and shuts the air switching valve according to the signal from the ECU. | (Europe Models) When air switching valve solenoid does not operate, ECU ends the oxygen sensor feedback mode. (Other than Europe Models) ECU does not backup. |
67 | Oxygen Sensor #1 (Europe Models) | The oxygen sensor heater raise temperature of the sensor for its earlier activation. 12V-36W, 1.5 A | If the oxygen sensor heater fails (wiring short or open), the ECU stops the current to the heater. |
83 | Oxygen Sensor #2 (Europe Models) | The oxygen sensor is active and sensor must send signals (output voltage) continuously to the ECU. | If the oxygen sensor is not activated, the ECU stops oxygen sensor feedback mode. |
94 | Oxygen Sensor #1 (Europe Models) | The oxygen sensor must send signals (output voltage) continuously to the ECU | If the oxygen sensor output voltage is incorrect, the ECU stops oxygen sensor feedback mode. |
95 | Oxygen Sensor #2 (Europe Models) | The oxygen sensor must send signals (output voltage) continuously to the ECU | If the oxygen sensor output voltage is incorrect, the ECU stops oxygen sensor feedback mode. |
Note:
- (1) D-J Method and a - N Method: When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method (low-speed mode). As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle sensor output voltage) and the engine speed. This method is called a - N·method (high-speed mode).
- (*) This depends on the number of stopped cylinders.