Kawasaki J300 - Service manual > Fuel Line
Fuel Pressure Inspection
NOTE
- Be sure the battery is fully charged.
- Remove the fuel hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter).
- Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the fuel pipe of the intake manifold.
WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
- Install the fuel pressure gauge adapter [A] and fuel hoses (Special Tool: 57001-1607) [B] between the fuel outlet pipe and delivery pipe.
- Secure the fuel hoses with the clamps.
- Connect the pressure gauge [C] 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
WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death. Do not try to start the engine with the fuel hoses disconnected.
- Turn the engine stop switch to run position.
- Turn the ignition switch on.
- The fuel pump should operate for 3 seconds, and then should stop.
NOTE
- After turning on the engine stop switch and ignition switch, inspect the fuel leakage from the connected portion of the special tools.
NOTICE Do not drive the fuel pump for 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.
- Start the engine, and let it idle.
- Measure the fuel pressure with the engine idling.
Fuel Pressure (with Engine Idling)
Standard: 294 +-6 kPa (3.0 +-0.06 kgf/cm², 43 +-0.87 psi)
NOTE
- The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
- Turn the ignition switch off.
If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check the following.
Fuel Line Leakage (see Fuel Injector Fuel Line Inspection)
Amount of Fuel Flow (see Fuel Flow Rate Inspection) - After above checks, measure the fuel pressure again.
- Remove the fuel pressure gauge, hoses and adapter.
- Install the fuel hose (see Fuel Hose Replacement in the Periodic Maintenance chapter).
- Start the engine and check for fuel leakage.
Fuel Flow Rate Inspection
WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
NOTE
- Be sure the battery is fully charged.
- Turn the ignition switch off.
- Wait until the engine cools down.
- Prepare a fuel hose (Special Tool: 57001-1607) and a measuring cylinder.
Special Tool - Fuel Hose: 57001-1607
- Disconnect the fuel hose from the fuel pump (see Fuel Hose Replacement
in the Periodic Maintenance chapter).
- Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.
WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
- Connect the prepared fuel hose [A] to the fuel outlet pipe of the fuel pump.
- Secure the fuel hose with a clamp.
- Insert the fuel hose into the measuring cylinder [B].
WARNING Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
- Turn the engine stop switch to run position.
- Turn the ignition switch on.
- The fuel pump should operate for 3 seconds, and then should stop.
NOTICE Do not drive the fuel pump for 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.
- Measure the discharge for 3 seconds.
- Repeat this operation several times.
Amount of Fuel Flow
Standard: 50 mL (1.7 US oz.) or more for 3 seconds
- Turn the ignition switch off.
If the fuel flow is much less than the specified, replace the fuel pump (see Fuel Pump Removal/Installation).
- Install the removed parts (see appropriate chapters).
- Start the engine and check for fuel leakage.
See also:
Kawasaki J300 - Service manual > ECU
ECU Removal NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. Remove: Front Fairing (see Front Fairing Removal in the Frame chapter) Nuts [A] Bracket [B] ECU [C] Disconnect the ECU connector [D].
Kawasaki J300 - Service manual > Fuel Pump
Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
