FUEL SYSTEM (DFI) 3-1
Fuel System (DFI) |
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Table of Contents |
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3 |
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Exploded View........................................................................................................................ |
3-4 |
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DFI Parts Location.................................................................................................................. |
3-8 |
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DFI Wiring Diagram ................................................................................................................ |
3-10 |
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Specifications ......................................................................................................................... |
3-12 |
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Special Tools .......................................................................................................................... |
3-14 |
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DFI Servicing Precautions ...................................................................................................... |
3-15 |
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DFI Servicing Precautions ................................................................................................ |
3-15 |
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Troubleshooting the DFI System ............................................................................................ |
3-17 |
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Outline ................................................................................................................................. |
3-17 |
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Outline............................................................................................................................... |
3-17 |
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Inquiries to Rider.................................................................................................................. |
3-21 |
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Inquiries to Rider............................................................................................................... |
3-21 |
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DFI System Troubleshooting Guide ....................................................................................... |
3-24 |
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DFI System Troubleshooting Guide.................................................................................. |
3-24 |
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Self-Diagnosis ........................................................................................................................ |
3-33 |
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Self-diagnosis Outline.......................................................................................................... |
3-33 |
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Self-diagnosis Outline ....................................................................................................... |
3-33 |
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Self-diagnosis Procedures................................................................................................... |
3-33 |
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Self-diagnosis Procedures ................................................................................................ |
3-33 |
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Service Code Clearing Procedures ..................................................................................... |
3-34 |
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Service Code Clearing Procedures................................................................................... |
3-34 |
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How to Read Service Codes................................................................................................ |
3-36 |
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How to Read Service Codes............................................................................................. |
3-36 |
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How to Erase Service Codes............................................................................................... |
3-36 |
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How to Erase Service Codes ............................................................................................ |
3-36 |
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Service Code Table.............................................................................................................. |
3-37 |
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Service Code Table........................................................................................................... |
3-37 |
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Backups ............................................................................................................................... |
3-38 |
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Backups ............................................................................................................................ |
3-38 |
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Main Throttle Sensor (Service Code 11) ................................................................................ |
3-40 |
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Main Throttle Sensor Removal/Adjustment ...................................................................... |
3-40 |
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Input Voltage Inspection.................................................................................................... |
3-40 |
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Output Voltage Inspection................................................................................................. |
3-41 |
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Resistance Inspection....................................................................................................... |
3-42 |
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Inlet Air Pressure Sensor (Service Code 12).......................................................................... |
3-43 |
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Removal............................................................................................................................ |
3-43 |
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Installation......................................................................................................................... |
3-43 |
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Input Voltage Inspection.................................................................................................... |
3-43 |
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Output Voltage Inspection................................................................................................. |
3-44 |
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Inlet Air Temperature Sensor (Service Code 13).................................................................... |
3-47 |
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Removal/Installation.......................................................................................................... |
3-47 |
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Output Voltage Inspection................................................................................................. |
3-47 |
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Sensor Resistance Inspection .......................................................................................... |
3-48 |
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Water Temperature Sensor (Service Code 14) ...................................................................... |
3-49 |
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Removal/Installation.......................................................................................................... |
3-49 |
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Output Voltage Inspection................................................................................................. |
3-49 |
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3-2 FUEL SYSTEM (DFI)
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Sensor Resistance Inspection .......................................................................................... |
3-50 |
Atmospheric Pressure Sensor (Service Code 15).................................................................. |
3-51 |
Removal............................................................................................................................ |
3-51 |
Input Voltage Inspection.................................................................................................... |
3-51 |
Output Voltage Inspection................................................................................................. |
3-52 |
Crankshaft Sensor (Service Code 21).................................................................................... |
3-54 |
Crankshaft Sensor Removal/Installation........................................................................... |
3-54 |
Crankshaft Sensor Inspection........................................................................................... |
3-54 |
Camshaft Position Sensor (Service Code 23)........................................................................ |
3-55 |
Camshaft Position Sensor Removal/Installation ............................................................... |
3-55 |
Camshaft Position Sensor Inspection ............................................................................... |
3-55 |
Speed Sensor (Service Code 24, 25)..................................................................................... |
3-56 |
Speed Sensor Removal/Installation.................................................................................. |
3-56 |
Speed Sensor Inspection.................................................................................................. |
3-56 |
Input Voltage Inspection.................................................................................................... |
3-56 |
Output Voltage Inspection................................................................................................. |
3-56 |
Vehicle-down Sensor (Service Code 31)................................................................................ |
3-58 |
Removal............................................................................................................................ |
3-58 |
Installation......................................................................................................................... |
3-58 |
Inspection.......................................................................................................................... |
3-58 |
Subthrottle Sensor (Service Code 32).................................................................................... |
3-61 |
Subthrottle Sensor Removal/Adjustment .......................................................................... |
3-61 |
Input Voltage Inspection.................................................................................................... |
3-61 |
Output Voltage Inspection................................................................................................. |
3-62 |
Resistance Inspection....................................................................................................... |
3-63 |
Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) ...................................................... |
3-64 |
Removal/Installation.......................................................................................................... |
3-64 |
Input Voltage Inspection.................................................................................................... |
3-64 |
Subthrottle Valve Actuator (Service Code 62) ........................................................................ |
3-66 |
Subthrottle Valve Actuator Removal ................................................................................. |
3-66 |
Audible Inspection............................................................................................................. |
3-66 |
Visual Inspection............................................................................................................... |
3-66 |
Resistance Inspection....................................................................................................... |
3-66 |
Input Voltage Inspection.................................................................................................... |
3-67 |
FI Indicator LED Light............................................................................................................. |
3-68 |
LED Light Inspection......................................................................................................... |
3-69 |
ECU........................................................................................................................................ |
3-70 |
ECU Removal ................................................................................................................... |
3-70 |
ECU Installation ................................................................................................................ |
3-70 |
ECU Power Supply Inspection.......................................................................................... |
3-70 |
DFI Power Source .................................................................................................................. |
3-73 |
ECU Fuse Removal .......................................................................................................... |
3-73 |
ECU Fuse Installation ....................................................................................................... |
3-73 |
ECU Fuse Inspection ........................................................................................................ |
3-73 |
ECU Main Relay Removal ................................................................................................ |
3-73 |
ECU Main Relay Inspection .............................................................................................. |
3-73 |
Fuel Line................................................................................................................................. |
3-74 |
Fuel Pressure Inspection .................................................................................................. |
3-74 |
Fuel Flow Rate Inspection ................................................................................................ |
3-75 |
Fuel Pump .............................................................................................................................. |
3-77 |
Fuel Pump Removal ......................................................................................................... |
3-77 |
Fuel Pump Installation ...................................................................................................... |
3-77 |
Operation Inspection......................................................................................................... |
3-78 |
Operating Voltage Inspection............................................................................................ |
3-78 |
Pressure Regulator Removal............................................................................................ |
3-79 |
Pump Screen, Fuel Filter Cleaning ................................................................................... |
3-79 |
Fuel Pump .............................................................................................................................. |
3-80 |
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FUEL SYSTEM (DFI) 3-3 |
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Fuel Pump Relay Removal ............................................................................................... |
3-80 |
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Fuel Pump Relay Inspection ............................................................................................. |
3-80 |
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Fuel Injectors.......................................................................................................................... |
3-81 |
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Removal/Installation.......................................................................................................... |
3-81 |
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Audible Inspection............................................................................................................. |
3-81 |
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Power Source Voltage Inspection ..................................................................................... |
3-81 |
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Output Voltage Inspection................................................................................................. |
3-82 |
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Injector Signal Test............................................................................................................ |
3-83 |
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Injector Resistance Inspection .......................................................................................... |
3-84 |
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Injector Unit Test ............................................................................................................... |
3-84 |
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.............................................................................................Injector Fuel Line Inspection |
3-84 |
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3 |
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Throttle Grip and Cables ........................................................................................................ |
3-87 |
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Throttle Grip Play Inspection/Adjustment.......................................................................... |
3-87 |
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Choke Lever Operation..................................................................................................... |
3-87 |
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Choke Lever Play Inspection ............................................................................................ |
3-87 |
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Choke Lever Play Adjustment........................................................................................... |
3-87 |
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Cable Removal/Installation ............................................................................................... |
3-87 |
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Cable Lubrication and Inspection...................................................................................... |
3-87 |
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Throttle Body Assy ................................................................................................................. |
3-88 |
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Idle Speed Inspection ....................................................................................................... |
3-88 |
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Engine Vacuum Synchronization Inspection/ Adjustment................................................. |
3-88 |
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High Altitude Performance Adjustment ............................................................................. |
3-88 |
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Throttle Body Assy Removal............................................................................................. |
3-88 |
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Throttle Body Assy Installation.......................................................................................... |
3-90 |
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Throttle Body Assy Disassembly ...................................................................................... |
3-91 |
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Throttle Body Assy Assembly ........................................................................................... |
3-92 |
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Air Cleaner.............................................................................................................................. |
3-93 |
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Element Removal/Installation ........................................................................................... |
3-93 |
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Air Cleaner Oil Draining .................................................................................................... |
3-93 |
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Air Cleaner Housing Removal........................................................................................... |
3-93 |
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Fuel Tank................................................................................................................................ |
3-94 |
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Fuel Tank Removal ........................................................................................................... |
3-94 |
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Fuel Tank Installation ........................................................................................................ |
3-95 |
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Fuel Tank and Cap Inspection .......................................................................................... |
3-96 |
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Fuel Tank Cleaning ........................................................................................................... |
3-96 |
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3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
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No. |
Fastener |
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Torque |
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Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Throttle cable plate bolt |
6.0 |
0.60 |
52 in·lb |
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2 |
Throttle body assy holder clamp bolts |
2.0 |
0.20 |
17 in·lb |
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3 |
Choke link holder screws |
2.1 |
0.21 |
18 in·lb |
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4 |
Delivery pipe screws |
3.4 |
0.35 |
30 in·lb |
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5 |
Fuel pump bolts |
9.8 |
1.0 |
87 in·lb |
L,S |
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6 |
Fuel level sensor bolts |
6.9 |
0.7 |
62 in·lb |
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7 |
Bypass screws |
0.2 |
0.02 |
1.7 in·lb |
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8. |
Center adjusting screw |
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9. |
FI indicator LED light |
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10. |
Meter unit |
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11. |
Throttle cable (accelerator) |
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12. |
Throttle cable (decelerator) |
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13. |
Choke cable |
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14. |
Injector connectors |
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15. |
Main throttle sensor connector (grey) |
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16. |
Subthrottle sensor connector (black) |
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17. |
Subthrottle valve actuator connector |
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18. |
Throttle body assy connector |
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19. |
Main throttle sensor |
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20. |
Subthrottle sensor |
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21. |
Injectors |
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CL: |
Apply cable lubricant. |
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EO: |
Apply engine oil to the seals and O-rings. |
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G: |
Apply grease. |
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L: |
Apply a non-permanent locking agent. |
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S: |
Follow the specified tightening sequence. |
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3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
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No. |
Fastener |
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Torque |
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Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Inlet air pressure sensor bolt |
12 |
1.2 |
104 in·lb |
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2 |
Water temperature sensor |
25 |
2.5 |
18 |
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3 |
Vehicle down sensor bolts |
2.0 |
0.20 |
17 in·lb |
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4 |
Camshaft position sensor bolt |
12 |
1.2 |
104 in·lb |
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5 |
Camshaft position sensor rotor bolt |
12 |
1.2 |
104 in·lb |
L |
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6 |
Air cleaner duct holder screws |
3.8 |
0.39 |
34 |
in·lb |
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7 |
Air cleaner housing mounting bolts |
9.8 |
1.0 |
87 |
in·lb |
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8 |
Air cleaner duct clamp bolts |
2.0 |
0.20 |
17 |
in·lb |
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9 |
Air cleaner housing screws |
1.2 |
0.12 |
10 in·lb |
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10 |
Air cleaner housing tapping screws |
1.2 |
0.12 |
10 in·lb |
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11 |
Speed sensor bolt |
6.9 |
0.70 |
62 in·lb |
L |
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12. Inlet air pressure sensor
13. Stick coils (see Electrical System chapter)
14. ECU
15. Fuel pump relay
16. ECU main relay
17. Atmospheric pressure sensor
18. Crankshaft sensor (see Electrical System chapter)
19. Inlet air temperature sensor
20. Vacuum switch valve (see Engine Top End chapter)
21. Air suction valves
22. Grommet
L: Apply a non-permanent locking agent.
3-8 FUEL SYSTEM (DFI)
DFI Parts Location
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DFI: |
DFI Parts (this chapter) |
10. |
Stick Coils |
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21. |
Main Throttle Sensor |
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1. |
Water temperature Sen- |
11. |
Throttle Body Assy |
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(DFI) |
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sor (DFI) |
12. |
Self-diagnosis Terminal |
22. |
Ignition Switch |
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2. |
Inlet Air Pressure Sensor |
13. |
Neutral Switch |
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23. |
FI Indicator LED |
Light |
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(DFI) |
14. |
Vehicle Down |
Sensor |
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(DFI) |
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3. |
Injectors (DFI) |
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(DFI) |
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24. |
Crankshaft Sensor |
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4. |
Fuel Pump (DFI) |
15. |
Atmospheric |
Pressure |
25. |
Camshaft Position |
Sen- |
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5. |
Inlet Air Temperature |
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Sensor (DFI) |
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sor |
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Sensor (DFI) |
16. |
Delivery Pipe |
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26. |
Fuel Pump Screen |
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6. |
Sealed Battery |
17. |
ECU Main Relay |
27. |
Return Fuel Check Valve |
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7. |
Junction Box |
18. |
Fuel Pump Relay (DFI) |
28. |
Pressure Regulator |
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8. |
ECU Fuse 15 A |
19. |
Turn Signal Relay |
29. |
Fuel Filter |
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9. |
ECU (DFI) |
20. |
Subthrottle Sensor (DFI) |
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FUEL SYSTEM (DFI) 3-9
DFI Parts Location
[1], [2], [10], [13], [22] and [24] are not included.
3-10 FUEL SYSTEM (DFI)
DFI Wiring Diagram