FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)
Table of Contents
Exploded View................................... |
3-4 |
DFI System........................................ |
3-10 |
DFI Parts Location............................. |
3-16 |
Specifications .................................... |
3-19 |
Special Tools and Sealant ................. |
3-21 |
DFI Servicing Precautions ................. |
3-23 |
DFI Servicing Precautions .............. |
3-23 |
Troubleshooting the DFI System ....... |
3-25 |
Outline ............................................ |
3-25 |
Inquiries to Rider............................. |
3-29 |
DFI System Troubleshooting Guide .. |
3-32 |
Self-Diagnosis ................................... |
3-37 |
Self-diagnosis Outline..................... |
3-37 |
Self-diagnosis Procedures.............. |
3-38 |
Service Code Reading ................. |
3-41 |
Service Code Erasing .................. |
3-41 |
Backups .......................................... |
3-43 |
Main Throttle Sensor (Service Code |
|
11)................................................... |
3-46 |
Main Throttle Sensor |
|
Removal/Adjustment ................. |
3-46 |
Main Throttle Sensor Input |
|
Voltage Inspection..................... |
3-46 |
Main Throttle Sensor Output |
|
Voltage Inspection..................... |
3-47 |
Main Throttle Sensor Resistance |
|
Inspection.................................. |
3-48 |
Inlet Air Pressure Sensor #1 (Service |
|
Code 12) ......................................... |
3-49 |
Inlet Air Pressure Sensor #1 |
|
Removal .................................... |
3-49 |
Inlet Air Pressure Sensor #1 |
|
Installation ................................. |
3-49 |
Inlet Air Pressure Sensor #1 Input |
|
Voltage Inspection..................... |
3-49 |
Inlet Air Pressure Sensor #1 |
|
Output Voltage Inspection ......... |
3-50 |
Inlet Air Temperature Sensor (Service |
|
Code 13) ......................................... |
3-55 |
Inlet Air Temperature Sensor |
|
Removal/Installation.................. |
3-55 |
Inlet Air Temperature Sensor |
|
Output Voltage Inspection ......... |
3-55 |
Inlet Air Temperature Sensor |
|
Resistance Inspection ............... |
3-56 |
Water Temperature Sensor (Service |
|
Code 14) ......................................... |
3-58 |
Water Temperature Sensor |
|
Removal/Installation.................. |
3-58 |
Water Temperature Sensor |
|
|
|
Output Voltage Inspection ......... |
3-58 |
|
|
Water Temperature Sensor |
|
|
|
|
3 |
|
|
Resistance Inspection ............... |
3-59 |
|
|
Inlet Air Pressure Sensor #2 (Service |
|
|
|
Code 16) ......................................... |
3-60 |
|
|
Inlet Air Pressure Sensor #2 |
|
|
|
Removal .................................... |
3-60 |
|
|
Inlet Air Pressure Sensor #2 |
|
|
|
Installation ................................. |
3-60 |
|
|
Inlet Air Pressure Sensor #2 Input |
|
|
|
Voltage Inspection..................... |
3-60 |
|
|
Inlet Air Pressure Sensor #2 |
|
|
|
Output Voltage Inspection ......... |
3-61 |
|
|
Crankshaft Sensor (Service Code |
|
|
|
21)................................................... |
3-65 |
|
|
Crankshaft Sensor |
|
|
|
Removal/Installation.................. |
3-65 |
|
|
Crankshaft Sensor Resistance |
|
|
|
Inspection.................................. |
3-65 |
|
|
Crankshaft Sensor Peak Voltage |
|
|
|
Inspection.................................. |
3-65 |
|
|
Speed Sensor (Service Code 24)...... |
3-67 |
|
|
Speed Sensor Removal/Installa- |
|
|
|
tion ............................................ |
3-67 |
|
|
Speed Sensor Inspection............. |
3-67 |
|
|
Speed Sensor Input Voltage |
|
|
|
Inspection.................................. |
3-67 |
|
|
Speed Sensor Output Voltage |
|
|
|
Inspection.................................. |
3-68 |
|
|
Gear Position Switch (Service Code |
|
|
|
25)................................................... |
3-70 |
|
|
Gear Position Switch |
|
|
|
Removal/Installation.................. |
3-70 |
|
|
Gear Position Switch Resistance |
|
|
|
Inspection.................................. |
3-70 |
|
|
Gear Position Switch Output |
|
|
|
Voltage Inspection..................... |
3-70 |
|
|
Vehicle-down Sensor (Service Code |
|
|
|
31)................................................... |
3-72 |
|
|
Vehicle-down Sensor Removal .... |
3-72 |
|
|
Vehicle-down Sensor Installation . |
3-72 |
|
|
Vehicle-down Sensor Input |
|
|
|
Voltage Inspection..................... |
3-73 |
|
|
Vehicle-down Sensor Output |
|
|
|
Voltage Inspection..................... |
3-74 |
|
|
Subthrottle Sensor (Service Code |
|
|
|
32)................................................... |
3-76 |
|
|
Subthrottle Sensor |
|
|
|
Removal/Adjustment ................. |
3-76 |
|
|
3-2 FUEL SYSTEM (DFI)
Subthrottle Sensor Input Voltage |
|
Inspection.................................. |
3-76 |
Subthrottle Sensor Output Voltage |
|
Inspection.................................. |
3-77 |
Subthrottle Sensor Resistance |
|
Inspection.................................. |
3-78 |
Oxygen Sensor - not activated |
|
(Service Code 33 (Equipped |
|
Models)).......................................... |
3-79 |
Oxygen Sensor Removal/Installa- |
|
tion ............................................ |
3-79 |
Oxygen Sensor Inspection........... |
3-79 |
Exhaust Butterfly Valve Actuator |
|
Sensor (Service Code 34) .............. |
3-82 |
Exhaust Butterfly Valve Actuator |
|
Sensor Removal/Installation ..... |
3-82 |
Exhaust Butterfly Valve Actuator |
|
Sensor Input Voltage Inspection |
3-82 |
Exhaust Butterfly Valve Actuator |
|
Sensor Output Voltage |
|
Inspection.................................. |
3-83 |
Exhaust Butterfly Valve Actuator |
|
Sensor Resistance Inspection... |
3-84 |
Immobilizer Amplifier (Service Code |
|
35 (Equipped Models)) ................... |
3-85 |
Antenna Resistance Inspection ... |
3-85 |
Amplifier Input Voltage Inspection |
3-85 |
Blank Key Detection (Service Code |
|
36 (Equipped Models)) ................... |
3-86 |
User Key Inspection..................... |
3-86 |
ECU Communication Error (Service |
|
Code 39) ......................................... |
3-88 |
ECU Communication Line |
|
Inspection.................................. |
3-88 |
Stick Coils #1, #2, #3, #4 (Service |
|
Code 51, 52, 53, 54) ....................... |
3-89 |
Stick Coil Removal/Installation..... |
3-89 |
Stick Coil Primary Winding |
|
Resistance Inspection ............... |
3-89 |
Stick Coil Input Voltage |
|
Inspection.................................. |
3-89 |
Radiator Fan Relay (Service Code |
|
56)................................................... |
3-91 |
Radiator Fan Relay |
|
Removal/Installation.................. |
3-91 |
Radiator Fan Relay Inspection..... |
3-91 |
Subthrottle Valve Actuator (Service |
|
Code 62) ......................................... |
3-93 |
Subthrottle Valve Actuator |
|
Removal .................................... |
3-93 |
Subthrottle Valve Actuator |
|
Inspection.................................. |
3-93 |
Subthrottle Valve Actuator |
|
Resistance Inspection ............... |
3-93 |
Subthrottle Valve Actuator Input |
|
Voltage Inspection..................... |
3-94 |
Exhaust Butterfly Valve Actuator |
|
(Service Code 63)........................... |
3-96 |
Exhaust Butterfly Valve Actuator |
|
Removal .................................... |
3-96 |
Exhaust Butterfly Valve Actuator |
|
Installation ................................. |
3-96 |
Exhaust Butterfly Valve Actuator |
|
Inspection.................................. |
3-98 |
Exhaust Butterfly Valve Actuator |
|
Resistance Inspection ............... |
3-98 |
Air Switching Valve (Service Code |
|
64)................................................... |
3-100 |
Air Switching Valve |
|
Removal/Installation.................. |
3-100 |
Air Switching Valve Inspection ..... |
3-100 |
Oxygen Sensor Heater (Service |
|
Code 67 (Equipped Models)).......... |
3-101 |
Oxygen Sensor Heater |
|
Removal/Installation.................. |
3-101 |
Oxygen Sensor Heater |
|
Resistance Inspection ............... |
3-101 |
Oxygen Sensor Heater Power |
|
Source Voltage Inspection ........ |
3-102 |
Oxygen Sensor - Incorrect Output |
|
Voltage (Service Code 94 |
|
(Equipped Models)) ........................ |
3-104 |
Oxygen Sensor Removal/Installa- |
|
tion ............................................ |
3-104 |
Oxygen Sensor Inspection........... |
3-104 |
Warning Indicator Light (LED) ........... |
3-107 |
Light (LED) Inspection ................. |
3-107 |
ECU ................................................... |
3-108 |
ECU Identification ........................ |
3-108 |
ECU Removal .............................. |
3-108 |
ECU Installation ........................... |
3-109 |
ECU Power Supply Inspection..... |
3-109 |
DFI Power Source ............................. |
3-112 |
ECU Fuse Removal ..................... |
3-112 |
ECU Fuse Installation .................. |
3-112 |
ECU Fuse Inspection ................... |
3-112 |
ECU Main Relay |
|
Removal/Installation.................. |
3-112 |
ECU Main Relay Inspection ......... |
3-112 |
Fuel Line............................................ |
3-113 |
Fuel Pressure Inspection ............. |
3-113 |
Fuel Flow Rate Inspection ........... |
3-114 |
Fuel Pump ......................................... |
3-116 |
Fuel Pump Removal .................... |
3-116 |
Fuel Pump Installation ................. |
3-117 |
Fuel Pump Operation Inspection . |
3-117 |
Fuel Pump Operating Voltage |
|
Inspection.................................. |
3-118 |
Pressure Regulator Removal....... |
3-119 |
Fuel Filter Cleaning...................... |
3-119 |
Fuel Injectors ..................................... |
3-120 |
Primary Fuel Injector |
|
Removal/Installation.................. |
3-120 |
FUEL SYSTEM (DFI) 3-3
Secondary Fuel Injector |
|
Removal/Installation.................. |
3-120 |
Fuel Injector Audible Inspection... |
3-120 |
Fuel Injector Resistance |
|
Inspection.................................. |
3-121 |
Fuel Injector Power Source |
|
Voltage Inspection..................... |
3-122 |
Fuel Injector Output Voltage |
|
Inspection.................................. |
3-124 |
Fuel Injector Fuel Line Inspection |
3-126 |
Throttle Grip and Cables ................... |
3-128 |
Free Play Inspection .................... |
3-128 |
Free Play Adjustment................... |
3-128 |
Cable Installation ......................... |
3-128 |
Cable Lubrication ......................... |
3-128 |
Throttle Body Assy ............................ |
3-129 |
Idle Speed Inspection/Adjustment |
3-129 |
Synchronization Inspection/Ad- |
|
justment..................................... |
3-129 |
Throttle Body Assy Removal........ |
3-129 |
Throttle Body Assy Installation..... |
3-130 |
Throttle Body Assy Disassembly . |
3-131 |
Throttle Body Assy Assembly ...... |
3-132 |
Nozzle Assy....................................... |
3-133 |
Nozzle Assy Removal .................. |
3-133 |
Nozzle Assy Installation ............... |
3-133 |
Nozzle Assy Disassembly............ |
3-134 |
Nozzle Assy Assembly................. |
3-134 |
Air Cleaner......................................... |
3-136 |
Air Cleaner Element |
|
Removal/Installation.................. |
3-136 |
Air Cleaner Element Inspection ... |
3-136 |
Air Cleaner Oil Draining ............... |
3-136 |
Air Cleaner Housing Removal...... |
3-136 |
Air Cleaner Housing Installation... |
3-138 |
Air Cleaner Housing Disassembly |
3-138 |
Air Cleaner Housing Assembly .... |
3-139 |
Air Line .............................................. |
3-140 |
Air Inlet Duct Removal ................. |
3-140 |
Air Inlet Duct Installation .............. |
3-140 |
Fuel Tank ........................................... |
3-141 |
Fuel Tank Removal ...................... |
3-141 |
Fuel Tank Installation ................... |
3-143 |
Fuel Tank Inspection .................... |
3-145 |
Fuel Tank Cleaning ...................... |
3-145 |
Evaporative Emission Control System |
|
(CAL, SEA and TH Models)............ |
3-146 |
Parts Removal/Installation ........... |
3-146 |
Hose Inspection ........................... |
3-146 |
Separator Inspection.................... |
3-146 |
Separator Operation Test............. |
3-147 |
Canister Inspection ..................... |
3-147 |
3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
No. |
Fastener |
|
Torque |
|
Remarks |
|
|
|
|
||||
N·m |
kgf·m |
ft·lb |
||||
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||||
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|
1 |
Air Cleaner Housing Assembly Screws |
1.2 |
0.12 |
11 in·lb |
|
|
|
|
|
|
|
|
|
2 |
Air Cleaner Housing Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
|
|
|
|
|
|
|
|
3 |
Air Cleaner Housing Mounting Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
|
|
|
|
|
|
|
4 |
Air Inlet Duct Mounting Bolts |
9.8 |
1.0 |
87 in·lb |
L |
|
|
|
|
|
|
|
5.CAL, SEA and TH Models
6.Immobilizer System Equipped Models L: Apply a non-permanent locking agent.
R: Replacement Parts
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
No. |
Fastener |
|
Torque |
|
Remarks |
|
|
|
|
||||
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
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|
|
|
|
|
|
1 |
Delivery Pipe Assy Mounting Screws (Nozzle |
3.43 |
0.35 |
30 in·lb |
|
|
Assy) |
|
|||||
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||
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|
|
|
|
|
2 |
Delivery Pipe Assy Mounting Screws (Throttle |
3.43 |
0.35 |
30 in·lb |
|
|
Body Assy) |
|
|||||
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|
|
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||
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|
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|
|
3 |
Inlet Air Temperature Sensor Screw |
0.80 |
0.081 |
7.1 in·lb |
|
|
|
|
|
|
|
|
|
4 |
Nozzle Assy Mounting Screws |
1.2 |
0.12 |
11 in·lb |
S |
|
|
|
|
|
|
|
|
5 |
Throttle Body Assy Holder Bolts |
12 |
1.2 |
106 in·lb |
L |
|
|
|
|
|
|
|
|
6 |
Throttle Body Assy Holder Clamp Bolts |
2.9 |
0.30 |
26 in·lb |
|
|
|
|
|
|
|
|
|
7 |
Throttle Cable Holder Plate Bolt |
3.9 |
0.40 |
35 in·lb |
L |
|
|
|
|
|
|
|
8. WVTA (78.2 H) Model CL: Apply cable lubricant. EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R:Replacement Parts
S:Follow the specified tightening sequence.
3-8 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-9
Exploded View
No. |
Fastener |
|
Torque |
|
Remarks |
|
|
|
|
||||
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
|
|
|
|
|
|
|
1 |
Canister Bracket Screws |
1.2 |
0.12 |
11 in·lb |
|
|
|
|
|
|
|
|
|
2 |
Crankshaft Sensor Bolts |
5.9 |
0.60 |
52 in·lb |
|
|
|
|
|
|
|
|
|
3 |
Exhaust Butterfly Valve Actuator Mounting Screws |
4.3 |
0.44 |
38 in·lb |
|
|
|
|
|
|
|
|
|
4 |
Exhaust Butterfly Valve Actuator Pulley Bolt |
4.9 |
0.50 |
43 in·lb |
|
|
|
|
|
|
|
|
|
5 |
Fuel Pump Bolts |
9.8 |
1.0 |
87 in·lb |
L, S |
|
|
|
|
|
|
|
|
6 |
Gear Position Switch Screws |
2.9 |
0.30 |
26 in·lb |
L |
|
|
|
|
|
|
|
|
7 |
Oxygen Sensor (Equipped Models) |
25 |
2.5 |
18 |
|
|
|
|
|
|
|
|
|
8 |
Separator Bracket Mounting Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
|
|
|
|
|
|
|
9 |
Speed Sensor Bolt |
6.9 |
0.70 |
61 in·lb |
L |
|
|
|
|
|
|
|
|
10 |
Water Temperature Sensor |
25 |
2.5 |
18 |
|
|
|
|
|
|
|
|
11.Other than CAL, SEA and TH Models
12.CAL, SEA and TH Models
G: Apply grease.
L: Apply a non-permanent locking agent.
R:Replacement Parts
S:Follow the specified tightening sequence.