Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

3-24 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits checked out good, be sure to check the ECU for ground and power supply. If the ground
and power supply are checked good, replace the ECU.
Engine Doesn’t Start, Starting Difficulty
Symptoms or possible Causes
Actions (chapter)
Starter motor not rotating:
Ignition and engine stop switches not ON Turn both switches ON.
Starter lockout switch or neutral switch trouble Inspect (see chapter 16)
Starter motor trouble Inspect (see chapter 16).
Battery voltage low Inspect and charge (see chapter 16).
Starter relays not contacting or operating Inspect the starter relay (see chapter 16).
Starter button not contacting Inspect and replace (see chapter 16).
Starter system wiring open or shorted Inspect the wiring (see chapter 16).
Ignition switch trouble Inspect and replace (see chapter 16).
Engine stop switch trouble Inspect and repair or replace (see chapter 16).
Main 30A or ignition fuse blown Inspect and replace (see chapter 16).
Starter motor rotating but engine doesn’t
turn over :
Starter clutch trouble Inspect (see chapter 9).
Starter idle gear trouble Inspect (see chapter 9).
Engine won’t turn over :
Valve seizure Inspect and replace (see chapter 5).
Cylinder, piston seizure Inspect and replace (see chapter 5).
Camshaft seizure Inspect and replace (see chapter 5).
Connecting rod small end seizure Inspect and replace (see chapter 9).
Connecting rod big end seizure Inspect and replace (see chapter 9).
Crankshaft seizure Inspect and replace (see chapter 9).
Transmission gear or bearing seizure Inspect and replace (see chapter 9).
Balancer bearing seizure Inspect and replace (see chapter 9).
No fuel flow :
No or little fuel in tank
Supply fuel (see Owner’s Manual).
Fuel pump not rotating Inspect (see chapter 3).
Fuel injector trouble Inspect and replace (see chapter 3).
Fuel tank air vent obstructed Inspect and repair (see chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator clogged Inspect and replace fuel pump (see chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Engine flooded :
Spark plug dirty, broken or gap maladjusted
Clean spark plugs and adjust plug gap (see
chapter 2).
Starting technique faulty
When flooded, don’t crank engine with throttle
fully opened.
No spark or spark weak :
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