Service Code Table
Service Code |
ABS Indicator Light (LED) |
Problems |
Light State |
12 |
|
Start code (not fault) |
After starts, turn off |
13 |
|
Rear inlet solenoid valve trouble (open, temperature abnormal) |
ON |
14 |
|
Rear outlet solenoid valve trouble (open, temperature abnormal) |
ON |
17 |
|
Front inlet solenoid valve trouble (open, temperature abnormal) |
ON |
18 |
|
Front outlet solenoid valve trouble (open, temperature abnormal) |
ON |
19 |
|
ABS solenoid valve relay trouble (wiring shorted or open, stuck relay (ON or OFF) or dropout) |
ON |
25 |
|
Front, rear wheel rotation difference abnormal (substandard tire, sensor rotor teeth number wrong) |
ON |
35 |
|
ABS motor relay trouble (wiring shorted or open, stuck relay (ON or OFF) |
ON |
42 |
|
Front wheel rotation sensor signal abnormal (sensor or rotor missing, too large clearance, rotor tooth worn or missing) |
ON |
43 |
|
Front wheel rotation sensor wiring (wiring shorted or open, connector bad connection) |
ON |
44 |
|
Rear wheel rotation sensor signal abnormal (sensor or rotor missing, too large clearance, rotor tooth worn or missing) |
ON |
45 |
|
Rear wheel rotation sensor wiring (wiring shorted or open, connector bad connection) |
ON |
52 |
|
Power supply voltage abnormal (under-voltage) |
ON |
53 |
|
Power supply voltage abnormal (over-voltage) |
ON |
55 |
|
ECU trouble (ECU operation abnormal) |
ON |
ABS
Indicator Light (LED) Inspection
• Turn the ignition switch ON.
If the ABS indicator light (LED) [A] lights, it is normal.
If the ABS indicator light (LED) does not light, go to step “ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)”.
•
Turn the ignition switch OFF.
If the ABS indicator light (LED) [A] does not light, it is
normal.
If the ABS indicator light (LED) lights, go to step “ABS In- dicator Light (LED) Lights (When the Motorcycle is Run- ning, - No Service Code)”.
ABS
Indicator Light (LED) is Unlit (When the Ignition Switch turned to
ON)
• Do the 1st step test.
○Check the terminal voltage between the orange/black and
black/yellow lead terminals of the meter connector [A].
Special Tool - Hand Tester: 57001-1394
Terminal Voltage
Standard: About 9 V
If the terminal voltage is not within the specification, 2nd step.
If the terminal voltage correct, replace the meter assem- bly.
•
Do the 2nd step test.
○Disconnect the ABS hydraulic unit connector and meter
connector.
○Check for continuity between the orange/black lead
terminal of the main harness side connector [A] and
orange/black lead terminal of the main harness side connector [B].
If there is the continuity in the lead, 3rd step.
If there is not the continuity in the lead, replace or repair the main harness.
• Do the 3rd step test.
○Check the battery terminal voltage (see 2nd Step in the
Power Supply Voltage Abnormal (Under-Voltage) (Ser-
vice Code 52)).
If the battery terminal voltage correct, replace the ABS hydraulic unit.
ABS
Indicator Light (LED) Lights (When the Motorcycle is Running, - No
Service Code)
• Do the 1st step test.
○Check the terminal voltage between the orange/black and
black/yellow lead terminals of the meter connector [A].
Special Tool - Hand Tester: 57001-1394
Terminal Voltage
Standard: About 9 ~ 12 V
If the terminal voltage is not within the specification, re- place the meter assembly.
If the terminal voltage correct, 2nd step.
•
Do the 2nd step test.
○Disconnect the ABS hydraulic unit connector.
○Check the terminal voltage between the orange/black and
black/yellow lead terminals of the main harness side con-
nector [A].
Special Tool - Hand Tester: 57001-1394
If the terminal voltage is about 9 12 V, replace the main harness.
If the terminal voltage is 0 V, replace the ABS hydraulic unit.
Solenoid
Valve Inspection (Service Code 13,14,17,18)
• Do the 1st step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty solenoid valve in the ABS hydraulic unit. Replace the ABS hydraulic unit. If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
ABS
Solenoid Valve Relay Inspection (Service Code 19)
• Do the 1st step test.
○Check the ABS solenoid valve relay fuse [A].
If the fuse blown, 2nd step.
If the fuse correct, 4th step.
•
Do the 2nd step test.
○Disconnect the ABS hydraulic unit connector [A].
○Check for continuity between the white/red and black/yel-
low lead terminals of the ABS hydraulic unit connector.
If there is the continuity in the lead, replace the ABS hy- draulic unit.
If there is not the continuity in the lead, 3rd step.
•
Do the 3rd step test.
○Check for continuity between the white/red lead terminal
of the main harness side connector [A] and white/red lead
terminal of the fuse box [B] .
If there is the continuity in the lead, replace the fuse.
If there is not the continuity in the lead, replace or repair the main harness.
•
Do the 4th step test.
○Check the battery terminal voltage between the white/red
lead terminal of the fuse box [A] and ground.
Special Tool - Hand Tester 57001-1394
Battery Terminal Voltage Standard: Battery Voltage
If the battery terminal voltage is not within the specifica- tion, 5th step.
If the battery terminal voltage correct, 6th step.
•
Do the 5th step test.
○Check for continuity between the positive cable [A] of the
battery and white/red lead terminal of the main harness
side connector [B].
If there is the continuity in the lead, 4th step.
If there is not the continuity in the lead, replace or repair the main harness.
•
Do the 6th step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ABS solenoid valve relay in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)
• Do the 1st step test.
○Check the following and correct the faulty part.
Incorrect the tire pressure.
Tires not recommended for the motorcycle were installed (incorrect tire size).
Deformation of the wheel or tire.
Sensor rotor for missing teeth and clogging with foreign matter.
If the all parts correct, 2nd step.
•
Do the 2nd step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
ABS
Pump Motor Relay Inspection (Service Code 35)
• Do the 1st step test.
○Check the ABS pump motor relay fuse [A].
If the fuse blown, 2nd step.
If the fuse correct, 4th step.
•
Do the 2nd step test.
○Disconnect the ABS hydraulic unit connector.
○Check for continuity between the red/white and black/yel-
low lead terminals of the ABS hydraulic unit connector [A].
If there is the continuity in the lead, replace the ABS hy- draulic unit.
If there is not the continuity in the lead, 3rd step.
•
Do the 3rd step test.
○Check for continuity between the red/white lead terminal
of the main harness side connector [A] and red/white lead
terminal of the fuse box [B].
If there is the continuity in the lead, replace the fuse.
If there is not the continuity in the lead, replace or repair the main harness.
•
Do the 4th step test.
○Check the battery terminal voltage between the red/white
lead terminal of the fuse box [A] and ground.
Special Tool - Hand Tester: 57001-1394
Battery Terminal Voltage Standard: Battery Voltage
If the battery terminal voltage is not within the specifica- tion, 5th step.
If the battery terminal voltage correct, 6th step.
•
Do the 5th step test.
○Check for continuity between the positive cable [A] of the
battery and red/white lead terminal of the main harness
side connector [B].
If there is the continuity in the lead, 4th step.
If there is not the continuity in the lead, replace or repair the main harness.
• Do the 6th step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ABS pump motor relay in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
Front
Wheel Rotation Sensor Signal Abnormal (Service Code 42)
• Do the 1st step test.
○Measure the air gap between the front wheel rotation sen-
sor and sensor rotor.
Thickness Gauge [A]
Air Gap
Standard: 1 mm (0.04 in.)
If the measurement is over standard, check each part for deformation and looseness and correct accordingly. Recheck the air gap.
If the measurement is correct, 2nd step.
•
Do the 2nd step test.
○Check that there is iron or other magnetic deposits be-
tween the sensor [A] and sensor rotor [B], and the sensor
rotor slots for obstructions.
○Check the installation condition of the sensor for loose-
ness.
○Check the sensor and sensor rotor tip for deformation or
damage (e.g., chipped sensor rotor teeth).
If the sensor and sensor rotor in bad condition, remove the any deposits. Install the properly or replace faulty part.
If the all correct, 3rd step.
• Do the 3rd step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
Front
Wheel Rotation Sensor Wiring Inspection (Service Code 43)
• Do the 1st step test.
○Disconnect the ABS hydraulic unit connector and front
wheel rotation sensor connector.
○Short the white and black lead terminals of the main har-
ness side connector [A] with a jumper lead, and check for
continuity between the white and black lead terminals of the main harness side connector [B].
If there is the continuity in the lead, 2nd step.
If there is not the continuity in the lead, replace or repair the main harness.
•
Do the 2nd step test.
○Check for continuity between the white lead terminal of
the sensor connector [A] and ground, and black lead ter-
minal of the sensor connector and ground.
If there is the continuity in the lead, replace the front wheel rotation sensor.
If there is not the continuity in the lead, 3rd step.
•
Do the 3rd step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
Rear
Wheel Rotation Sensor Signal Abnormal (Service Code 44)
• Do the 1st step test.
○Measure the air gap between the rear wheel rotation sen-
sor and sensor rotor.
Thickness Gauge [A]
Air Gap
Standard: 1 mm (0.04 in.)
If the measurement is over standard, check each part for deformation and looseness and correct accordingly. Recheck the air gap.
If the measurement is correct, 2nd step.
•
Do the 2nd step test.
○Check that there is iron or other magnetic deposits be-
tween the sensor [A] and sensor rotor [B], and the sensor
rotor slots for obstructions.
○Check the installation condition of the sensor for loose-
ness.
○Check the sensor and sensor rotor tip for deformation or
damage (e.g., chipped sensor rotor teeth).
If the sensor and sensor rotor in bad condition, remove the any deposits. Install the properly or replace faulty part.
If the all correct, 3rd step.
•
Do the 3rd step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
Rear
Wheel Rotation Sensor Wiring Inspection (Service Code 45)
• Do the 1st step test.
○Disconnect the ABS hydraulic unit connector and rear
wheel rotation sensor connector.
○Short the red and green lead terminals of the main har-
ness side connector [A] with a jumper lead, and check for
continuity between the red and green lead terminals of the main harness side connector [B].
If there is the continuity in the lead, 2nd step.
If there is not the continuity in the lead, replace or repair the main harness.
•
Do the 2nd step test.
○Check for continuity between the white lead terminal of
the sensor connector [A] and ground, and black lead ter-
minal of the sensor connector and ground.
If there is the continuity in the lead, replace the rear wheel rotation sensor.
If there is not the continuity in the lead, 3rd step.
•
Do the 3rd step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
Power
Supply Voltage Abnormal (Under-Voltage) (Service Code 52)
• Do the 1st step test.
○Disconnect the ABS Kawasaki self-diagnosis system con-
nector and ABS hydraulic unit connector.
○Check for continuity between the brown lead terminal of
the main harness side connector [A] and brown lead ter-
minal of the main harness side connector [B]. If there is the continuity in the lead, 2nd step.
If there is not the continuity in the lead, replace or repair the main harness.
•
Do the 2nd step test.
○Connect the ABS Kawasaki self-diagnosis system con-
nector and ABS hydraulic unit connector.
○Check the battery terminal voltage, connect the
hand tester to the brown terminal of ABS Kawasaki
self-diagnosis system connector [A] and ground.
Special Tool - Hand Tester: 57001-1394
Battery Terminal Voltage Standard: Battery Voltage
If the battery terminal voltage is not within the specifica- tion, 3rd step.
If the battery terminal voltage correct, 4th step.
• Do the 3rd step test.
○Charge or replace the battery.
•
Do the 4th step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
Power
Supply Voltage Abnormal (Over-Voltage) (Service Code 53)
• Do the 1st step test.
○Check the battery terminal voltage, connect the
hand tester to the brown terminal of ABS Kawasaki
self-diagnosis system connector [A] and ground.
Special Tool - Hand Tester: 57001-1394
Battery Terminal Voltage Standard: Battery Voltage
If the battery terminal voltage is not within the specifica- tion, 2nd step.
If the battery terminal voltage correct, 3rd step.
• Do the 2nd step test.
○Check the battery condition and regulator/rectifier (see
Charging Condition Inspection, Regulator/Rectifier In-
spection in the Electrical System chapter).
• Do the 3rd step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
ECU
Inspection (Service Code 55)
• Do the 1st step test.
○Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system is normal (service code is not stored; temporary failure.).
ABS
Hydraulic Unit Removal
• Drain the brake fluid from the front and rear brake lines.
○Drain the brake fluid through the bleed valve by pumping
the brake lever and pedal.
• Remove:
Left Frame Cover (see Frame Cover Removal in the
Frame chapter)
Rear Fender Front (see Rear Fender Front Removal in the Frame chapter)
Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter)
•
Clean the ABS hydraulic unit.
Bolts
[A]
•
Remove:
Brake Pipe Joint Nuts [A] [B] [C] [D]
• Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter.
•
Disconnect the connector [A].
○Pull the lever [B] as shown.
• Remove the ABS hydraulic unit with bracket.
•
Remove:
Nuts
[A] and Bracket [B]
ABS
Hydraulic Unit Installation
•
Install the ABS hydraulic unit to the bracket.
• Route the lead correctly, and join connector [A] securely.
○Pull the lever [B] as shown.
• Route the brake pipes correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Tighten the joint nuts.
Torque - Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)
• Install the removed parts (see appropriate chapters).
ABS Hydraulic Unit Inspection
• Remove the ABS hydraulic unit (see ABS Hydraulic Unit Removal).
• Visually inspect the ABS hydraulic unit.
Replace the ABS hydraulic unit if any of them are cracked,
or otherwise damaged.
•
Visually inspect the connector terminals [A].
Replace the ABS hydraulic unit or main harness if either
of the terminals are cracked, bent, or otherwise damaged. If the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air.
Front
Wheel Rotation Sensor Removal
• Remove:
Fuel
Tank (see Fuel Tank
Removal in the Fuel
System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
Left Upper Inner Fairing (see Upper Inner Fairing Re- moval in the Frame chapter)
Bolt [A] Clamp [B]
•
Disconnect the connector [A].
Clamp
[A]
Bolt [B]
Front Wheel Rotation Sensor [C]
Front Wheel Rotation Sensor Installation
• Installation is the reverse of removal.
○Route the lead correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
Rear
Wheel Rotation Sensor Removal
• Remove:
Fuel
Tank (see Fuel Tank
Removal in the Fuel
System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
• Disconnect the connector [A].
•
Remove: Bolt [A]
Rear Wheel Rotation Sensor [B]
Rear Wheel Rotation Sensor Installation
• Installation is the reverse of removal.
○Route the lead correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
Wheel
Rotation Sensor Inspection
• Remove the front wheel rotation sensor [A] from the front fork.
• Remove the rear wheel rotation sensor [B] from the
caliper bracket.
• Visually inspect the wheel rotation sensors.
Replace the wheel rotation sensor if it is cracked, bent, or
otherwise damaged.
Wheel
Rotation Sensor Air Gap Inspection
• Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter).
• Measure the air gap between the sensor and sensor rotor
at several points by turning the wheel slowly.
Thickness Gauge [A]
Air Gap Standard:
Front 1 mm (0.04 in.)
Rear 1
mm (0.04
in.)
NOTE
○The sensor air gap cannot be adjusted.
If the air gap is not within the specification, inspect the hub bearing (see Hub Bearing Inspection in the Wheels/Tires chapter), sensor installation condition and sensor (see Wheel Rotation Sensor Inspection).
Wheel
Rotation Sensor Rotor Inspection
• Remove the front/rear brake discs (see Brake Disc Re- moval).
• Visually inspect the wheel rotation sensor rotor.
If the rotor is deformed or damaged (chipped teeth [A]),
replace the sensor rotor with the brake disc.
If there is iron or other magnetic deposits [B], remove the deposits.
Brake Hose and Pipe Removal/Installation
• Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter.
Brake Hose and Pipe Inspection
• Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance
chapter.
ABS
Solenoid Valve Relay Fuse Removal
• Remove the seat (see Seat Removal in the Frame chap- ter).
• Unlock the hook [A] to lift up the lid [B].
•
Pull out the relay fuse [A] from the fuse box with needle nose
pliers.
ABS
Motor Relay Fuse Removal
• Remove the seat (see Seat Removal in the Frame chap- ter).
• Unlock the hook [A] to lift up the lid [B].
•
Pull out the relay fuse [A] from the fuse box with needle nose
pliers.
Fuse Installation
• If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a
new fuse of proper amperage.
Fuse
Inspection
• Remove the fuse (see ABS Solenoid Valve Relay/ABS Motor Relay Fuse Removal).
• Inspect the fuse element.
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.
Housing [A]
Fuse
Element [B] Terminals [C] Blown Element [D]