Notes:
- 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 when the trouble has 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 screw driver [A] into the slit on the joint lock [B].
Turn the driver to disconnect the joint lock.
Pull [C] the fuel hose joint [D] out of the delivery pipe.
![](https://motoinstruction.ru/img/kawasaki/13/118824.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. Cover the hose connection with a clean shop towel to prevent fuel spillage.
Install the fuel pressure gauge adapter [A] between the fuel tank outlet pipe [B] and the inlet pipe [C] to the delivery joint [D].
Put the fuel pressure gauge adapter outside the frame.
Connect the pressure gauge [E] to the fuel pressure gauge adapter.
- Fuel Tank [F]
- Fuel Pump [G]
- Front [H]
→: Fuel Flow
![](https://motoinstruction.ru/img/kawasaki/13/118825.jpg)
Special tools:
- Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607
- Oil Pressure Gauge: 57001-125
Temporarily, install the removed parts.
Warning! Do not try to start the engine with the fuel hoses disconnected.
Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop.
Measure the fuel pressure with the engine stopped.
Fuel pressure:
- right after Ignition Switch ON, with pump running:
- Standard: 304 kPa (3.1 kgf/cm², 44 psi)
- after 3 seconds from Ignition Switch ON, with pump stopped:
- Standard: 280 kPa (2.9 kgf/cm², 41 psi, residual fuel pressure)
The system should hold the residual pressure about 30 seconds.
Start the engine, and let it idle.
Measure the fuel pressure with the engine idling.
Fuel pressure (idling):
- Standard: 304 kPa (3.1 kgf/cm², 44 psi)
Note. The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
★ If the fuel pressure is normal, the fuel circulation system (fuel pump, pressure regulator, and oil passage) is no faults. Check the DFI electronic control system (injectors, sensors, crankshaft sensors, and ECU).
★ If the fuel pressure is much higher than the specified, check the following:
- Delivery pipe clogging
- Injector clogging
★ If the fuel pressure is much lower than specified, check the following:
- Fuel Pump for Operation (check the sound of the pump)
- Fuel Line Leakage or Clogging
- 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 fuel pump assy (the fuel filter may be clogged) and measure the fuel pressure again.
Remove the fuel pressure gauge and adapter.
Pull [A] the joint lock [B] fully as shown.
![](https://motoinstruction.ru/img/kawasaki/13/118826.jpg)
Insert the fuel hose joint [A] straight onto the delivery pipe.
Push [B] the joint lock [C] until the hose joint clicks.
![](https://motoinstruction.ru/img/kawasaki/13/118827.jpg)
Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn't come off.
![](https://motoinstruction.ru/img/kawasaki/13/118828.jpg)
Warning! Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.
★ If it comes off, reinstall the hose joint.
Run the fuel hose correctly (see Cable, wire and hose routing section in the Appendix chapter).
Install the removed parts.