Ignition Switch off: Terminal 16 (br/w): 0 V
Terminal 17 (W/BK): Battery Voltage (12.8 V or more) Ignition Switch ON:
Both: Battery Voltage (12.8 V or more)
If the meter does not read as specified, check the follow- ing:
Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter)
ECU Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
ECU Main Relay (see Relay Circuit Inspection in the Electrical System chapter)
Power Source Wiring (see wiring diagram below)
If the inspection checks good, the ECU is damaged. Re- place the ECU (see ECU Removal/Installation). The ECU itself cannot be checked or serviced.
ECU Power Source Circuit
ECU
Water-proof Joint C
Ignition Switch
Water-proof Joint A
ECU Main Fuse 15 A
ECU Main Relay
Relay Box
Main Fuse 30 A
Battery
Frame Ground
Joint Connector
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 run-
ning 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).
• Remove the left center fairing (see Center Fairing Re-
moval in the Frame chapter).
• 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.
•
Remove the fuel hose [C].
•
Install the fuel pressure gauge adapter [A] and fuel
hoses between the fuel pump outlet pipe [B] and the delivery
pipe [C].
• Connect the pressure gauge [D] to the fuel pressure gauge adapter.
Special
Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Fuel
Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607
• Temporarily, install the fuel tank [E].
Clamps [F]
• 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: 323 kPa (3.3 kgf/cm², 47 psi)
After 3 seconds from Ignition Switch ON, with pump stopped:
Standard: 265 kPa (2.7 kgf/cm², 38 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: 333 kPa (3.4 kgf/cm², 48 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 fuel passage) is no faults. Check the DFI electronic control system (injectors, sensors, crankshaft sensor, and ECU).
If the fuel pressure is much lower than specified, check the following.
Fuel Line Leakage
Fuel Pump Operation (check the sound of the pump) Amount of Fuel Flow (see Fuel Flow Rate Inspection)
If the fuel pressure is much higher than specified, check the following.
Delivery Pipe Clogging Injector Clogging
• Remove the fuel pressure gauge and adapter.
• Install the removed parts (see appropriate chapters).
Fuel Flow Rate Inspection
NOTE
○Be
sure the battery is fully charged.
• Turn the ignition switch, and engine stop switch OFF.
• Wait until the engine cools down.
• Prepare a plastic hose of the inside diameter 7.5 mm
(0.30 in.) and a measuring cylinder.
• Remove the fuel tank bolt (see Fuel Tank Removal).
•
Open the fuel tank cap [A] to lower the pressure in the tank.
•
Connect the plastic hose [A] to the fuel pump outlet
pipe.
• Secure the plastic hose with a clamp [B].
• Run the other side of the plastic hose into the measuring
cylinder
[C].
• Temporarily install the fuel tank and 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 plastic hose is filled with fuel.
• Measure the discharge for 3 seconds with the plastic hose
filled with fuel.
○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, re- place the fuel pump (see Fuel Pump Removal/Installa- tion).
• After inspection, install the fuel tank (see Fuel Tank Instal-
lation).
• Start the engine and check for fuel leakage.
Fuel Pump Removal
•
Draw the fuel out from the fuel tank with a commercially
available electric pump.
• Remove the fuel tank (see Fuel Tank Removal).
○Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
• Turn the fuel tank upside down.
• Remove:
Fuel Pump Bolts [A]
Fuel Pump [B] and gasket
•
Discard the fuel pump gasket.
Fuel
Pump Installation
• Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air.
• Replace the fuel pump gasket [A] with a new one.
•
Apply a non-permanent locking agent to the threads of the fuel
pump bolts.
• Tighten the fuel pump bolts to a snug fit, tighten them
alternating diagonally.
Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Tighten the pump bolts again alternating diagonally to check the tightness.
Fuel Pump Operation Inspection
NOTE
○Be sure the battery is fully charged.
○Just listen to the pump sound in the fuel tank to confirm
pump operation.
• Turn the ignition switch ON and make sure that the fuel pump operates (make light sounds) for 3 seconds, and
then stops.
• Turn the ignition switch OFF.
If the pump does not work as described above, inspect
the operating voltage.
Fuel Pump Operating Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Remove the left side cover (see Side Cover Removal in
the Frame chapter).
•
Connect the hand tester (25 V DC) to the fuel pump con-
nector [A] with needle adapter set.
Special Tools - Hand Tester: 57001-1394