All about KDS3 (Part 1) – published 03/04/08
Contents
1. Record 1 Starter Switch Record 1 Failure Record Record 2 Throttle Opening Angle Record 2 Inlet Air Pressure Record 2 Water Temperature Record 2 Inlet Air Temperature Record 2 Atmospheric Pressure Record 2 Engine Speed Record 2 Battery Voltage Record 2 Gear Position Print Fes het Failure history FFD All Information deg mmHg C C mmHg rpm V kmh Throttle Sensor 7 4 T 1 a PU deg mmHg Cc Cc mmHg rpm V Service Data Record 2 Atmospheric Pressure Record 2 Engine Speed Record 2 Battery Voltage Record 2 Gear Position Record 2 Vehicle Speed Record 2 Starter Switch Record 2 Failure Record Record 3 Throttle Opening Angle Record 3 Inlet Air Pressure Record 3 Water Temperature Record 3 Inlet Air Temperature Record 3 Atmospheric Pressure Record 3 Engine Speed Record 3 Battery Voltage Record 3 Gear Position Record 3 Vehicle Speed Record 3 Starter Switch Record 3 Failure Record Values 753 3 0 12 1 0 0 0 OFF Inlet Air Pressure Sensor 754 2 20 0 40 0 753 3 0 12 1 0 0 0 OFF inlet Air Temperature Sensor stum In case of immobiliser component failure KDS3 cannot communicate with the ECU although the failure is recorded in the history The problem must be fixed before KDS3 can communicate However a warning will flash in the instrument panel of the motorcycle to indicate there is a problem Follow the service manual instruct2. the ECU However this is possible on some older models such as VN1500 P VN1600 A ZX1200 A B JT1200 B ZX600 K 636 B amp ZR1000 A What causes service codes to be stored Service codes are logged each time a sensor is out of usable range To simulate this you can disconnect a sensor with the ignition switched on and a service code will be logged The failure count for that component will increase each time this happens What is the function of the injector actuator test It is used as a cylinder drop test allowing the user to cut one cylinder at a time to aid diagnosis It basically stops fuel injection on the chosen cylinder On a ZG1400 apart from FI diagnosis is KDS 3 only needed to register key fobs No it also is needed to register other parts such as Smart ECU FI ECU Steering lock ECU amp TPMS sensors Further details can be found in the KDS 3 instruction manual If no service codes can be retrieved using KDS 3 is the DFI system OK and can assume that the problem is mechanical No The sensors may be OK but you need to be aware of the parameters under which sensors operate and when a service code is tripped Sensor operating ranges are listed in the Fuel System chapter in the service manual If a sensor remains within these parameters no service code will be displayed However if the sensor is giving a bad reading that is within the operating range for example a temperature sensor shows a very low temperatu
3. will install almost instantaneously Using KDS3 Using KDS on all but the 1400GTR is pretty simple however bear in mind a couple of things e First like any diagnostic aid KDS is only a tool you re the one doing the diagnosing not the computer e If at any time the vehicle s ignition switch is turned off or a cable is disconnected the KDS program will revert to its initial start screen Simply restore the connection and resume using the program Connection of KDS varies with the type of vehicle The two communications cables are designed to be used in three different configurations to suit the different kinds of connectors used on Kawasaki vehicles Refer to the KDS instruction manual noting the following e On nearly all Kawasaki street bikes and ATVs use both the communication cables together terminating in a 4 pin connector and attach to the 4 pin connector on the vehicle under the vehicle s seat or inside the service panel at the front of the KFX450R e For JT1200D JT1500A personal watercraft it s the same two cables and 4 pin connector only here the connector is found inside the hull near the rectifier Don t forget to add in the 57001 1535 relay cable as mentioned previously e For JT1500B C models it is the same except the 4 pin connector is located at the front of the craft near the battery and a different 57001 1696 relay cable must be connected to the harness near the ECU Using KDS3 continued e 1
4. 400GTR connection requires no communication cables at all the signal adapter attaches directly to a 6 pin connector under the seat e Onall VN1500 models except the VN1500 P only one communication cable is required to connect through a unique otherwise unused 8 pin connector found right on the ECU e ABS equipped models use the same communication cable as above to connect to a dedicated 8 pin connector on the harness for ABS diagnostics Start KDS and note that the first window that comes up reminds you that not all problems on fuel injected vehicles are necessarily fuel injection system problems In other words remember to check the usual stuff as you would on anon fuel injected model such as fuel quantity quality venting spark compression air filter condition etc Turn the ignition switch on and then click OK in the KDS Seems Dorel rie window The KDS start menu will appear offering four ic aa choices Select the appropriate option as needed Don t e nrenn If you cannot turn the ignition switch ON select VVith Smart System within 10 seconds after pushing in nob choose With Smart System unless the bike is a 1400GTR ees The KDS main menu then appears Now select either FI See fuel injection or KI PASS and continue KI PASS is the see keyless fob system on the 1400GTR C2006 KAWASAKI HEAVY INDUSTRIES LTD All rights reserved 1 EN You ll most often work in the FI menu 5 opti
5. Kawasaki Motors Europe Technical Information Section Copyright 2008 Kawasaki Motors Europe N V Edited from KMC K Tech News article Vol 20 Issue 4 All rights reserved Subject to the exceptions provided for by law no part of this publication may be reproduced and or published in print by photocopying on microfilm electronically or in any other way without the prior written consent of the copyright holder All about KDS3 Part 1 published 03 04 08 KDS Overview Since more Kawasaki vehicles now require KDS dealers are starting to discover the benefits of this service tool so it s a good time to cover KDS from start to finish KDS 3 has been designed to operate on Windows 2000 XP amp Vista platforms KDS is designed only for Kawasaki four stroke fuel injected vehicles you also may be familiar with a program we had in the past called KADIAG This was a DOS based application intended only for two stroke direct injected personal watercraft different program different hardware different application Don t confuse these two resources Benefits The benefits of using KDS are numerous KDS allows the troubleshooter to go beyond the vehicle s built in dealer mode self diagnosis capability with the ability to retrieve and save to file stored codes for example The KDS user can perform engine power balance tests where individual cylinders are dropped temporarily and the resulting change in idle co
6. ailuer Times ETV Actuator Failure Times Battery Voltage Malfunctions Times ECU Failuer Times ooooo co00wo0oqoo cococeoooco All about KDS3 FAQ published 18 11 08 PC REQUIREMENTS 1 Where can find information about the required operating systems This information is in the KDS 3 instruction manual on the K Care technical website under Special Tools Info Windows 2000 XP and Vista are the only compatible operating systems KDS 3 KIT 1 Are any other cables required that are not included in the kit Yes some cables are not included in the kit e For motorcycle o 57001 1699 4 pin to 4 pin adapter for Z750L M amp ZX1000B C models Note This cable is included in later kits P No 57001 1729 e For PWC o 57001 1535 for JT1200 JT1500A o 57001 1696 for JT1500B C models to prevent ECU timing out SOFTWARE 1 How can tell if am using the latest version of KDS 3 software Double click the KDS 3 shortcut Icon on your desktop and then select lt OK gt on the Important Information screen Both KDS 3 programme and database version numbers will be displayed on the bottom right hand corner of the next screen Check the numbers match the KDS software version in the Special Tools Section of the technical website The latest software will always be available on the website 2 have just received an e mail from KHI regarding their newly uploaded KDS 3 software on the EDD server is this
7. as needed e For ZR750L M amp ZR1000B C models an additional 4 pin to 4 pin adapter cable is needed P No 57001 1699 OE es e PWC Although KDS needs no further cables or adapters to connect to Kawasaki Jet Ski watercraft a special relay cable is needed to prevent the watercraft s ECU from timing out whilst communicating with KDS o Forall JT1200 and JT1500 A models this is relay cable 57001 15385 o Forthe JT1500 B and C models use relay cable 57001 1696 e A special storage case was provided by KME for all kits supplied initially to dealers Future kits may or may not include this case Installation of the software Installation of KDS3 onto a PC requires an added preliminary step to install the special signal adapter driver Turn on the PC and insert the KDS3 CD ROM A small black window will appear don t close it we ll come back to it later Connect the adapter to a Kawasaki fuel injected four stroke model and turn on the ignition switch Connect the USB cable to the adapter and then plug the other end of the USB cable into the computer A Found New Hardware wizard will appear Prompt the computer to search the KDS disk for the adapter driver and follow the prompts Once the driver is installed the New Hardware Wizard window will close and the black window will remain Turn the ignition switch off and type 1 in the black window then press enter on your keyboard Follow the prompts and KDS
8. be registered so dont discard the packaging before recording the number Melts ie mane wun e From the KI PASS menu select Fob Registration then choose Additional Registration e Lay the new fob within a few inches of the SMART ECU located in the centre of motorcycle under the seat e Type in the new fob s ID number and then click Additional Registration However you re not done yet as this procedure registers only the transmitting part of the fob and not the transponder portion The transponder is that part that allows the fob to work even when its internal battery is run down as a kind of emergency feature and this transponder must also be registered e Gather up all the available fobs and remove mechanical keys all existing fob s transponders must be re registered along with that of the new fob e From the KI PASS menu select Immobiliser Key Registration From within the new menu select Immobiliser Key Registration again Now double check each of the newly registered transponders 1 2 If a customer has lost one of the fobs encourage them to re register all remaining fobs so that the lost fob will be disassociated in the ECU preventing unauthorised use and providing the customer with the maximum security possible turn the key however as the key icon should now appear on the vehicle s Slide the fob over the projection on the ignition switch KDS will immediately recognise and regis ter the fob s tra
9. ider actuated via cables not to be confused with the ECU controlled throttle valve sensor Battery Voltage Malfunction Activated if battery voltage drops below 6 6V ECU Failure VN1700 models only The ECU can monitor its internal Electronic Throttle Valve ETV control circuit An ECU failure can be logged if a problem occurs with any of the following CPU verification TPS input circuit CPU circuit ETV relay Limp home mode FisFl W Real Time Monitor Engne Information Service Data Starter Switch Engine Emergency Stop Throttle Opening Angle Inlet Air Pressure Water Temperature inlet Air Temperature Engine Speed Battery Voltage Gear Position Vehicle Speed Engine Stopped Vehicle Down Sensor Voltage Engine Starting Mode Accelerator Opening Unknown item Real Time Monitor Values _ OFF ON 0 71 757 0 62 0 37 0 0 0 0 1 0 0 ON 40 OFF 0 70 0 Warring information Service Data Units Throttle Sensor Failure inlet Air Pressure Sensor Failure Inlet Air Temp Sensor Failure Water Temperature Sensor Failure Fuel Pump 2 Failure Crankshaft Sensor 1 Failure Vehicle Speed Sensor Failure Vehicle Down Sensor Failure Gear Position Sensor Failure ignition Coil 1 Failure Ignition Coil 2 Failure Failure Count Air Switching Valve Failures O2 Sensor 1 Failures 1 O2 Sensor Heater Failures Radiator Fan Relay Failures Accelerator Position Sensors F
10. ions to diagnose and repair Sensor short If the 5V sensor feed is internally shorted to ground KDS3 cannot communicate with the ECU In this case there is no visual indication of a FI related problem as the FI warning light does not illuminate The tell tale audible sign here is that the fuel pump does not operate when the ignition switch is turned on To identify the source of this problem connect fuel pump wiring amp fuel pipe and turn on the ignition switch One by one disconnect each 5V powered sensor when the faulty sensor is disconnected you should hear the fuel pump start up All about KDS3 Part 4 published 03 06 09 KDS3 Terminology This document explains the meaning of various terms used in the Service Data and Values columns in the Real Time Monitor screens of KDS3 Starter Switch ON The starter button is pressed starter motor turning OFF The starter button is not pressed Engine Emergency Stop ON The side stand switch circuit is activated to stop engine not the engine stop switch OFF At all other times Engine Stopped ON Engine is not running OFF Engine is running Engine Starting Mode ON Engine is cranking and r min is below idle OFF Engine stopped or r min is at idle or above Unknown Item This is a software error please ignore this item Accelerator Position Sensor Failure VN1700 models only This refers to the throttle pulley sensor which is r
11. mpared view starting and charging rates and adjust the engine idle on vehicles lacking tachometers such as the KFX450R and the KVF 750 and although throttle position sensors can be adjusted using a good multimeter KDS makes this task a simple one connection process But there s more With the introduction of the 1400GTR KDS plays an even larger role Registering key fobs replacing tyre pressure sensors and troubleshooting ABS all require the use of KDS Not Surprisingly KDS has now become an official Kawasaki Minimum Standard tool for motorcycle dealers Kit Components The KDS3 kit P No 57001 1687 includes the following parts e An adapter sometimes called a signal converter P N 57001 1648 The adapter translates between the vehicle s ECU and your personal computer e 2 communications cables for linking the signal adapter to the vehicle A 4 pin cable P N 57001 1649 and an 8 pin cable P N 57001 1688 are included On most models these cables are used together for connection e The KDS software disc P N 57001 1650 includes both the program itself and a separate driver for the signal adapter as well as an instruction manual in electronic form Note Periodically KDS software is updated whenever new related products are developed always check that you are using the latest available version Additional Parts e A double shielded USB A to B cable is required to connect the adapter to the PC This should be obtained locally
12. n making a diagnosis Select Warning Information from the pull down menu to see Pem the Failure Records alone Failure history FFO Warming Intormabon Service Data Values Record 1 Failure Record Throttle Sensor Record 2 Failure Record inlet Air Pressure Sensor Record 3 Failure Record inlet Air Temperature Sensor Select All Information from the pull down menu to see the sensor values at the time of failure Scroll down to see more records Note A failure record is only shown if a sensor is out of range not if it is giving an incorrect value within the expected working range For example if a water temperature sensor is showing 0 degrees C even though the engine is warm The range expected for this sensor is 30 to 120 degrees C so the ECU does not see any failure However the fuel injection system will provide a fuel mixture for a cold engine even though it is warm and rich running will result An example of the importance of a skilled technician s interpretation being needed With some failures KDS3 cannot communicate with the ECU Immobiliser failure Fei View Failure history FFD AI intommebon Service Data Units Record 1 Throttle Opening Angle Record 1 Inlet Air Pressure Record 1 Water Temperature Record 1 Inlet Air Temperature Record 1 Atmospheric Pressure Record 1 Engine Speed Record 1 Battery Voltage Record 1 Gear Position Record 1 Vehicle Speed
13. nsponder Replace the fob with the second fob and repeat continuing for all of the customer s fobs Once all of the transponders have been registered click Confirm Changed Item to complete the process Open each fob and temporarily remove the battery and reassemble Test the emergency transponder by sliding the fob over the projection on the ignition switch Depress the ignition switch to turn on the vehicle you don t need to instrument display If it does the transponder is working Starting from the KI PASS menu select Fob Registration then Registration Place all of the remaining fobs near the smart ECU When KDS asks if you have all the fobs together choose yes and only the fobs present are recognised by the smart ECU lf at some point the customer recovers the lost fob you can use this same process to re associate it together with the existing fobs Remember to lay all three fobs near the smart ECU If on the other hand the customer ends up buying a replacement for the lost fob follow the procedure for adding a fob above It may be useful to compare the Immobilizer and KI PASS on the 1400GTR model with other Kawasaki immobiliser equipped models Where these vehicles are similar is that they all use electronic keys in fact the Immobiliser circuits on each are very similar e Each vehicle s ECU can store up to six key codes and each vehicle is delivered to the customer with just two keys and two key slots alread
14. ons are available e REAL TIME MONITOR allows you to do such things ascheck sensor values but also more immediate jobs such as throttle position sensor TPS adjustment and idle adjustment e REAL TIME MONITOR GRAPHS offers moving graphs on any three values you select including voltage throttle position engine rom etc This is useful for comparing readings at different throttle openings and can be used to check charging voltage and voltage drop in the starting system e ACTUATOR selection will bring up a list of actuators to test Some such as the fuel pump or ignition coils can be tested by turning them on Others such as fuel injectors can be tested by turning them off for 5 second intervals while you compare the resulting engine rom drop e DIAGNOSIS displays the same information as the on board dealer mode one e ERASE STORED CODES this function only applies to some models KDS can be a very useful tool in your service department Learn to use it and become familiar with its many features and prepare yourself to meet your customer s expectations by providing the best possible diagnostic service KDS 3 should be stored in the carrying case which conveniently holds all cables adapter and master CD ROM All about KDS3 Part 2 published 25 06 08 Using KDS3 for 1400 GTR On ZG1400 models in addition to fuel injection diagnosis the following procedures require the use of KDS 3 0 e Replacement of the Tire Pres
15. rased et Teper i i Engine Speed To help confirm a diagnosis an experienced technician can Battery Voltage compare the displayed sensor values against those expected Engne Stopped to determine if the system has a problem or not The failure Inlet Air Pressure Sensor Failure Inlet Air Temp Sensor Failure count can be used to determine which sensor failures are e e Gare eae Fuel Purnp 2 Failure likely to be related to any current problem under investigation crarsshartsensor 1 Faiure Camshaft Sensor Failure _ ___ Prim D I ag n OSs is Kawasaki Diagnostic System i i r Fl ECU Diagnosis In the FI ECU Diagnosis screen if any current active Service jijetair Temperature Sensor codes exist a description of the out of range sensor or Throttle Sensor i Inlet Air Pressure Sensor sensors is shown Atmospheric Pressure Sensor Sub Throttle Actuator Sub Throttle Sensor Failure history Return Failure History If a service code fault code is triggered a failure record is generated The last 3 failure records are displayed together with up to 15 sensor s values recorded at the time of each of those failures Scroll down the screen to see record 1 record 2 and record 3 in sequence Note that record 1 is the most recent failure Note The displayed value of any failed sensor is the default value as described in the service manual under Back Ups by ECU Be careful to remember this whe
16. re when the engine is hot then running problems may occur Use the real time monitor option in KDS 3 to see the actual sensor values and confirm if they match expectations This function within KDS 3 can be very useful for diagnosing DFI related problems
17. software different to the one on the K Care technical website No we will always upload the latest version to the K Care technical website as soon as it becomes available 3 Why am I having a problem with KDS 3 connecting to a recently released model Check that you are using the latest software version The software database is updated each time new models are introduced If the model is not in the database KDS 3 will not work CONNECTION 1 Where can find information about how to connect KDS 3 The KDS 3 instruction manual contains connection information for most models 2 Which adapter cables do need to connect to models with a 4 pin adapter port Join both kit cables 57001 1688 amp 57001 1649 together so the joined cable ends in a 4 pin plug 3 Why are there two 4 pin ports on some models Most DFI models have two 4 pin ports one for programming the ECU during production which cannot be used with by KDS and the other for KDS connection Check the KDS user manual to make sure you have selected the correct port IN USE 1 Why is the TPS output reading displayed in degrees rather than volts on some models Kawasaki uses different manufacturers for DFI systems typically Mitsubishi and Denso TPS values are displayed in volts by Mitsubishi ECUs and in degrees by Denso ECUs Currently KDS 3 cannot convert the Denso values to volts Can stored service codes be erased Generally you cannot erase stored service codes from
18. sure Monitoring System TPMS wheel sensor e Registering new key fobs TPMS Tyre Pressure Monitor Sensor The TPMS sensor will need to be replaced when its sealed in battery runs down or if it has been damaged Always record the ID code which can be found on the label attached directly to the new sensor This step is very important and will save you a lot of time Kawasaki Diagnostic Systern i KI PASS Related M Install the new sensor refit the tyre and install the sent KEPASS ECU Part Number 21175 rs wh eel i Fuel Injection ECU Pat Number 2 75 5 Steering lock ECU Part Number 27006 0038 Connect and start KDS From the start menu select Smart System 5 and then KI PASS from the Mal n Unit Registration immobilizer Key Registratiatr Menu When the KI PASS related menu appears choose Tire Air Pressure Sensor ID Registration Finally select the appropriate Front or Rear Wheel type in the Diagnosis Tite Air Pressure Sensor IO Deletion new sensors ID number and click Re Registration You re done FOB Registration ire Air Pressure Sensor ID Registration Real Time Monitor Retum Key FOBS New fobs need to be registered to the vehicle Start by writing down the ID number found on the outside of the new fob s package Important note For security reasons unlike the tyre pressure sensor the fob s ID number is on the packaging not on the part itself Without this ID number the new fob cannot
19. y taken up in the ECU It should be noted however that all ECUs except the KI PASS one have re writable memories On the KI PASS ECU once a key slot is registered it can not be over written only activated or deactivated e Each vehicle allows the technician to increase or decrease the number of working keys From there things get very different Obviously the 1400GTR KI PASS system is much more sophisticated and adds features such as TPMS and the ability to sense when the fob is out of range which the others do not In fact you can look at the other immobiliser systems as being simply preventative locking out the wrong key while the 1400GTR system is more preemptive requiring a sort of daisy chain of confirmations between no fewer than three onboard ECUs before the system will power up All about KDS3 Part 3 published 16 09 08 Using KDS3 for Diagnosis Use this information together with the KDS3 user manual Three of the most commonly used options in KDS3 when troubleshooting DFI systems are Real Time Monitor Diagnosis and Failure History Real Time Monitor Use this function to view the actual real time values of up to 10 different sensors Real time monitor also displays a failure count for all available fo a sensors The failure count shows all sensor failures including Ararat those which are not current Sar Swen Note that they are not displayed in order of occurrence nor Throtie Opening Angie can they be e
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