Kawasaki Diagnostic Software Version 3 KDS v.3 Instruction Manual
Contents
1. 13 Section 4 Menu Items 14 4 1 Menu Structure 14 4 2 Function of Menu Items 15 Section 5 KDS 3 Operation for KI PASS System 16 5 1 Starting KDS 3 16 5 2 Diagnosis 17 5 3 Real Time Monitor 18 5 3 1 Selecting Display Items 18 5 3 2 Saving Service Data 19 5 3 3 Printing 20 5 4 Tire Air Pressure Measuring System TPMS Sensor Replacement 21 5 4 1 Deleting TPM2. 39 6 4 7 Second Air Solenoid Test 39 6 4 8 OCV Solenoid Test 40 6 5 Real Time Monitor Graph 40 6 5 1 Graph Display Items Selection 41 6 5 2 Displaying Graphs 41 6 5 3 Printing 41 Section 7 KDS for ABS System 42 7 1 Outline 42 7 2 Installing the Software 42 7 3 Connection of the Cable 42 7 3 1 ZG1400A 42 7 3 2 ER650B EX
3. 10 3 2 4 VN1600 VN2000 10 3 2 5 ZX636 ZX600 ZR1000 ZR750 ZX1000 C 11 3 2 6 JT1200B D JT1500A 11 3 2 7 VN900B D 11 3 2 8 ER650 EX650 12 3 2 9 ZX1400 12 3 2 10 KLE650 12 3 2 11 07 ZR750 ZR1000 12 3 2 12 JT1500B JT1500C 13 3 2 13 KSF450B 13 3 2 14 VN1500 J LIN R
4. 1 1 2 KDS Version 3 System Configuration 2 1 3 ZG1400A B System Configuration 3 1 4 Personal Computer PC Minimum System Requirements for KDS 3 3 Section 2 Installation Procedures 4 2 1 Installation of KDS 3 Adapter 4 2 2 Initial Installation of KDS 3 Software 6 Section 3 Cable Connection 9 3 1 Required Tools 9 3 2 Connecting PC to ECU 9 3 2 1 ZG1400A B 9 3 2 2 ZX1200 A B 10 3 2 3 VN1500 P
5. 6 2 1 Selecting Display Items 33 6 2 2 Saving Service Data 35 6 2 3 Printing 36 6 3 Diagnosis 36 6 4 Actuator Test 37 6 4 1 Selecting Test Item 37 6 4 2 Selecting Display Items 37 6 4 3 Injector Operation Test 37 6 4 4 Fuel Pump Test 38 6 4 5 Ignition Coil No Test 39 6 4 6 Sub Throttle Valve Actuator Test
6. 4 pin B Battery C ECU Fig 3 2 5 Connection of ZX636 B 3 2 6 JT1200B D JT1500A o Remove the seat and rear storage pocket o Disconnect the 8 pin connector C and insert the relay cable 57001 1535 between the connector o Connect the lead of relay cable to the terminal of battery o Remove the cover of diagnostic port A o Connect the adapter cable to the diagnostic port on harness A Diagnostic Port 4 pin B Relay Assembly C 8 pin Connector D Battery The relay cable must be connected to prevent loss of communication due to the ECU timing out if the engine is not started Fig 3 2 6 Connection of JT1200 B 3 2 7 VN900B D o Remove the seat o Remove the right side cover A o Access to the Diagnostic Port B from right side o Remove the cover and connect the adapter cable to the diagnostic port on harness A Right Side Cover B Diagnostic Port 4 pin Fig 3 2 7 Connection of VN900 B D KDS Version 3 Instruction Manual 12 3 2 8 ER650 EX650 o Remove the seat o Remove the cover of Diagnostic Port A o Connect the adapter cable to the diagnostic port on harness A Diagnostic Port for KDS 4 pin port B Diagnostic Port for ABS 8 pin port ABS model only Fig 3 2 8 Connection of ER650 3 2 9 ZX1400 o Remove the seat o Remove the cover of Diagnostic Port A o Connect the adapter cable to the diagnostic port on harness A Diagnostic Port for KDS 4 pin port B Diagnos
7. Fig 6 12 appears o Select a folder and press Enter or Save to save the data under a CSV file The file name by default will consist of YY year MM month DD day and two incremental numeric digits 00 99 ECU Parts No Model Name Model Year and Specification are saved automatically in the data NOTE CSV comma separated value Fig 6 12 Save Folder sample o A message will appear after saving the file Select OK Fig 6 13 Saving Completed KDS Version 3 Instruction Manual 36 6 2 3 Printing All or selected data from the ECU can be printed 6 3 Diagnosis o Select Diagnosis on the FI ECU Related Menu Fig 6 5 By Clicking Print at Fig 6 8 Fig 6 14 appears o Select a print option and select OK to print If a printer is not connected to the PC a screen print will be created o Select Cancel to return to the previous screen Fig 6 14 Print Option o If there are no failures the message No service codes exist appears o If a failure exists it will be listed Note Five items or less can be displayed at a time Select the scroll button to see the messages Fig 6 15 FI ECU Diagnosis o Select Failure history Fig 6 15 to see previous problems Latest three records are shown On some models latest two records are shown Note From the pull down menu you can select Engine Warning Monitoring or All Information Failure history can be saved and printed in the same way as the Real Time
8. 5 51 appears o Select OK Fig 5 51 FI ECU Registration KDS Version 3 Instruction Manual 29 5 8 Steering Lock Unit ECU Replacement To replace the Steering Lock ECU Fig 5 52 appears o Select Return Fig 5 52 FI ECU Registration Fig 5 53 appears o Select OK This completes the registration process Fig 5 53 ECU Registration o Replace the Steering Lock Unit o Start KDS 3 and go to the Main Menu but do not select any options yet o Depress the steering lock switch do not turn switch Select With Smart System within 10 seconds Fig 5 54 Fig 5 54 KDS Main Menu Fig 5 55 appears o Select Steering Lock Unit Registration Fig 5 55 Selection Fig 5 56 appears o Select Yes Fig 5 56 Starting Registration KDS Version 3 Instruction Manual 30 5 9 Smart ECU Replacement To replace the Smart ECU The Smart ECU is provided with two fob keys as a set o On completion of this procedure KDS 3 will close o Confirm the release of the steering lock by pushing the switch ON o Confirm meter operation by turning on the ignition switch o After turning the ignition switch ON reconnect KDS 3 and register the Immobilizer Keys and TPMS sensors according to sections 5 6 and 5 4 Fig 5 57 appears o Select OK Fig 5 57 Registration Fig 5 58 appears o Select OK Re start KDS 3 and turn ON the vehicle Fig 5 58 Registration Finished o Replace the Smart ECU o Start KDS 3 and go to the
9. Main Menu Fig 5 59 but do not select any options yet o After depressing the steering lock switch do not turn switch select With Smart System o Register the steering lock unit as outlined in section 5 8 Fig 5 59 KDS Main Menu 5 10 Smart System Parts Replace and KDS 3 Operation No Replacement Parts KDS 3 Operation Remarks Steering Lock ECU Smart ECU FI ECU TPMS Fob Key 1 o 1Start KDS 2Steering lock push switch ON then start communication 3Register steering lock unit compulsory 4KDS closes After steering lock switch ON confirm the release of steering lock o Steering lock unit ID is necessary for Smart ECU registration 2 o o 1Start KDS 2Steering lock push switch ON then start communication 3Register steering lock unit compulsory 4KDS closes After steering lock switch ON confirm the release of steering lock 5Confirm meter initialization 6Ignition switch ON register immobilizer key and TPMS o Steering lock unit ID o FI ECU ID o Immobilizer ID o TPMS ID 3 o 1 Ignition switch ON Start KDS 2 Register FI ECU compulsory 3After steering lock switch ON confirm the release of steering lock Confirm meter initialization o FI ECU ID 4 o 1 Ignition switch ON Start KDS 2 Register TPMS sensor ID o TPMS ID 5 o o o 1Start KDS 2Steering lock push switch ON then start communication 3Register steering lock uni
10. appears Fig 7 8 If there are no failures the message No service codes exist appears Fig 7 8 Current Failure No Code o If a failure exists it will be listed Fig 7 9 Fig 7 9 Current Failure Code KDS Version 3 Instruction Manual 45 o After repairing the failure restart KDS ABS Fig 7 10 will appear o Confirm No service codes exist then select Intermittent failure to see if there are any codes Fig 7 10 Current Failure The ABS Intermittent failure screen will appear Fig 7 11 Fig 7 11 Intermittent Failure o To erase the intermittent failure codes select Erase Stored Service Codes Fig 7 11 o Select Yes then select OK Fig 7 12 Fig 7 12 Erase procedures o Confirmation the ABS Intermittent failure has been erased is shown on screen Fig 7 13 After confirming select Return to finish Fig 7 13 Erase Confirming
11. o When all fob keys are lost Smart ECU must be replaced The same operation with No 2 is necessary When registering additional fob minimum one available fob is necessary o New fob ID KDS Version 3 Instruction Manual 32 Section 6 KDS 3 Operations for FI System 6 1 Starting KDS 3 o Turn on the PC o Start KDS Version 3 from the start menu Or double click the KDS 3 icon on the desktop screen Fig 6 1 KDS 3 icon Fig 6 2 will appear o Read the instructions and perform the preliminary inspection o Select OK after performing the preliminary inspection Fig 6 2 Inspection Fig 6 3 will appear On Smart System equipped models select With Smart System On non Smart System equipped models select Without Smart System Fig 6 3 Main Menu KDS Version 3 Instruction Manual 33 6 2 Real Time Monitor 6 2 1 Selecting Display Items o Select a group from the pull down menu Fig 6 6 Select Engine Warning Monitoring or All Information All Information includes Engine Warning and Monitoring The KDS Main Menu and Model Information screen will appear Fig 6 4 o Select Fuel Injection Fig 6 4 KDS Main Menu and Model Information FI ECU Related Menu will appear Fig 6 5 o Select one of the following Real Time Monitor Actuator Tests Real Time Monitor Graph Diagnosis Fig 6 5 FI ECU Related Menu Fig 6 6 appears after selecting the Real Time Monitor on the FI ECU Related Me
12. 650B 43 7 3 3 ZX1400B 43 7 4 Menu Structure 43 7 5 Operation 44 7 5 1 Starting KDS for ABS 44 KDS Version 3 Instruction Manual 1 Section 1 Kawasaki Diagnostic System Version 3 Outline 1 1 System Function KDS Version 3 was developed for Smart equipped Motorcycles with DFI non Smart equipped motorcycles with DFI and DFI equipped PWC and ATV The following functions are available Smart System equipped Models 1 Register the Steering Lock unit FI ECU 2 Register the Fobs Immobilizer key 3 Register or delete the TPMS sensor ID 4 Diagnose the Smart System 5 Monitor the Smart System NOTE Smart System components must be registered to the Smart ECU in order to function correctly DFI equipped Vehicles 1 Display ECU and model information 2 Perform diagnostics 3 Display save and print service data 4 Actuate individual injectors and other actuators 5 Di
13. G1400A B System Configuration 1 4 Personal Computer PC Minimum System Requirements for KDS 3 Table 1 a PC Requirement NOTE Do not use a screen saver Do not use power management mode When changing an ECU exit KDS and then restart You must use the PC as an administrator USB cable should be purchased locally Hardware Requirements CPU Pentium 133 MHz or faster OS Operating System Windows 2000 XP Vista Hard Disk 20 MB or more of free space 40 MB or more is recommended Display SVGA Disk device CD ROM or DVD drive Printer Black and White or Color Interface port USB port USB Cable Should be used between PC and Converter BUFFALO USBC2 SBK length 2 0 m If this cable is not available use a similarly specified double shielded cable with a maximum length of 2 m KDS Version 3 Instruction Manual 4 Section 2 Installation Procedures NOTE All screenshots in this Manual are from a PC operating on Windows XP You must install two software programs on your PC One is for the KDS 3 Adapter converter and the other is for the KDS software 2 1 Installation of KDS 3 Adapter The PC detects the KDS Adapter and starts the Found New Hardware Wizard o Select No not this time a new screen will appear o Select Install from a specific location Advanced on the next screen Then select Next gt o Start your PC and then insert the CD P N 57001 1650 o Open the CD and save the KDSAdap
14. Kawasaki Diagnostic Software Version 3 KDS v 3 Instruction Manual Foreword This Instruction Manual explains the operating principles of KDS to diagnose Kawasaki s Smart KI PASS Digital Fuel Injection DFI and ABS systems This manual is a brief introduction to KDS 3 and assumes that the technician is familiar with PC usage User License Agreement Kawasaki Diagnostic System Software This User License Agreement AGREEMENT is a legal agreement between you either an individual or a single entity and Kawasaki Heavy Industries Ltd a Japanese company Kawasaki for the Kawasaki Diagnostic System software SOFTWARE By installing copying or otherwise using the SOFTWARE you shall agree to be bound by the terms of this AGREEMENT If you do not agree to the terms of this AGREEMENT promptly return the unused SOFTWARE to the supplier from which you obtained it for a full refund 1 COPYRIGHT All title and copyrights in and to the SOFTWARE including but not limited to any images photographs and text incorporated into the SOFTWARE and the accompanying printed materials are owned by Kawasaki The SOFTWARE is protected with copyright laws and international treaty provisions 2 GRANT OF LICENSE 1 By purchasing the CD ROM which has the SOFTWARE in it you are granted license of Kawasaki s rights and you may use the SOFTWARE under following conditions 2 and 3 2 USE The SOFTWARE is licensed not sold You may install an
15. Monitor Fig 6 16 Failure history KDS Version 3 Instruction Manual 37 6 4 Actuator Test 6 4 1 Selecting Test Item 6 4 2 Selecting Display Items After selecting the actuator test item select Engine Information in the combo box The procedure is the same as 6 2 1 6 4 3 Injector Operation Test To perform an Actuator Test select Actuator Tests on the FI ECU Related Menu o First select Actuator Test item o Second select display items While the test is running the parameter values will be displayed Up to five parameters can be displayed at a time Click the scroll buttons to scroll by line Fig 6 17 FI ECU Related Menu Fig 6 18 appears after Actuator Tests is selected o Select the test item from the pull down menu list NOTE Available actuator test items for each model are displayed on the screen Fig 6 18 Actuator test selection o Select Injector number to be tested o Select display items o Run engine at idle speed o Select Start to begin test Fig 6 19 Fig 6 19 Injector Test KDS Version 3 Instruction Manual 38 Select Stop to finish testing The test lasts for about 5 seconds and will stop automatically 6 4 4 Fuel Pump Test o While the engine is running monitor the change in Engine Speed and listen to the engine Fig 6 20 is a sample of the injector operation test Fig 6 20 Injector Test Fig 6 21 shows the injector test has been completed Fig 6 21 Test Comple
16. Option o Enter comment then select OK Fig 5 13 Fig 5 13 Comment sample KDS Version 3 Instruction Manual 20 5 3 3 Printing Data obtained through communication with the ECU can be printed o Fig 5 14 appears Select a folder and select Enter or Save to save the data as a CSV file By default the file name will consist of YY year MM month DD day and two incremental numeric digits 00 99 ECU Parts No Model Name Model Year amp Specification are saved automatically in the data NOTE CSV comma separated value Fig 5 14 Save Folder sample o A message will appear after saving the file Select OK Fig 5 15 Fig 5 15 Save Completed o Select Print Fig 5 11 Fig 5 16 will appear o Select a print option and select OK to print If a printer is not connected to the PC a screen print will be created o Select Cancel to return to the previous screen Fig 5 16 Print Option KDS Version 3 Instruction Manual 21 5 4 Tire Air Pressure Measuring System TPMS Sensor Replacement When a TPMS sensor is replaced the replacement sensor s ID must be registered with the Smart ECU 5 4 1 Deleting TPMS ID o Select Tire Air Pressure Sensor ID Deletion on the KI PASS Related Menu Fig 5 17 KI PASS Related Menu o Currently registered sensor IDs are shown Fig 5 18 o Select the wheel sensor to delete In this example the Front Wheel is selected Fig 5 18 TPMS ID o When Fig 5 19 appears s
17. S ID 21 Contents 5 5 Fob Registration 23 5 5 1 Additional Fob Registration 23 5 5 2 Fob Re registration 25 5 6 Immobilizer Key Registration Smart ECU Replacement 26 5 7 FI ECU Replacement 28 5 8 Steering Lock Unit ECU Replacement 29 5 9 Smart ECU Replacement 30 5 10 Smart System Parts Replace and KDS 3 Operation 31 Section 6 KDS 3 Operations for FI System 32 6 1 Starting KDS 3 32 6 2 Real Time Monitor 33
18. ay not apply to you 7 EXPORT LIMITATION You shall agree not to export the CD ROM with the SOFTWARE to foreign countries except for complying with local laws and rules 8 COMMERCIAL ARBITRATION In case of trouble with the AGREEMENT both parties assign Japan Commercial Arbitration Association and under the rule thereof to settle a dispute and the award thereof shall be final and binding upon both parties This KDS Version 3 uses encryption algorithm MISTY developed by MITSUBISHI ELECTRIC CORPORATION Windows is the registered trade mark of Microsoft Corporation And all the other brand names or product names are the company 2007 Kawasaki Heavy Industries Ltd Third Edition 3 24 August 2007 Section 1 Kawasaki Diagnostic System Version 3 Outline 1 1 1 System Function 1 Smart System equipped Models 1 DFI equipped Vehicles 1 ABS equipped Vehicles 1 Other Features
19. d by applicable law implied warranties on the SOFTWARE are limited to ninety 90 days 1 CUSTOMER REMEDIES Kawasaki s and its suppliers entire liability and your exclusive remedy shall be at Kawasaki s option either a return of the price paid or b replacement of the SOFTWARE This Limited Warranty is void if failure of the SOFTWARE has resulted from accident abuse or misapplication 2 NO OTHER WARRANTIES To the maximum extent permitted by applicable law Kawasaki and its suppliers disclaim all other merchantability and fitness for a particular purpose with regard to the SOFTWARE This limited warranty gives you specific legal rights You may have others which vary from country state or territory and jurisdiction to country state or territory and jurisdiction 3 NO LIABILITY FOR CONSEQUENTIAL DAMAGES To the maximum extent permitted by applicable law in no event shall Kawasaki or its suppliers be liable for any special incidental indirect or consequential damages whatsoever including without limitation damages for loss of business profits business interruption loss of business information or any other pecuniary loss arising out of the use of or inability to use the SOFTWARE even if Kawasaki has been advised of the possibility of such damages Because some countries states or territories and jurisdictions do not allow the exclusion or limitation of liability for consequential or incidental damages the above limitation m
20. d use one copy of the SOFTWARE on your computer 3 COPY You may either a make one copy of the SOFTWARE solely for backup or archival purposes or b install the SOFTWARE on a single computer provided you keep the original solely for backup or archival purposes All title and copyrights in and to the COPY are also owned by Kawasaki and you may not use the COPY for any other purpose than to recover the SOFTWARE on your computer 3 LIMITATIONS You may not modify reverse engineer de compile or disassemble the SOFTWARE 4 SOFTWARE TRANSFER You may permanently transfer all of your rights under this AGREEMENT when the recipient agrees to the terms of this AGREEMENT provided you retain no copies you transfer all of the CD ROM and printed materials accompanied with it 5 TERMINATION Without prejudice to any other rights Kawasaki may terminate this AGREEMENT if you fail to comply with the terms and conditions of this AGREEMENT In such event you must uninstall the SOFTWARE and destroy all of the SOFTWARE including its COPY if you have made one 6 LIMITED WARRANTY Kawasaki warrants that the CD ROM with the SOFTWARE be free from defects in materials and workmanship under normal use and service for a period of ninety 90 days from the date of purchase Some countries states or territories and jurisdictions do not allow limitations on duration of an implied warranty so the above limitation may not apply to you To the extent allowe
21. elect Yes Fig 5 19 TPMS ID Deletion o Next Fig 5 20 appears select OK Fig 5 20 TPMS ID Deletion OK Screen KDS Version 3 Instruction Manual 22 o Prepare a new TPMS sensor and record the ID TPMS sensors cannot be registered without ID registration o Replace the front TPMS sensor o Select TPMS ID Registration on the KI PASS Related Menu screen o On Fig 5 21 the Front Wheel ID is changed to 00000000 Next select Return Fig 5 21 TPMD ID Deletion o Fig 5 22 appears select Front Wheel Fig 5 22 TPMD ID Registration o When Fig 5 23 appears input the new TPMS ID and select Registration Fig 5 23 TPMS ID Registration o Fig 5 24 appears select Yes Fig 5 24 TPMS ID Registration o Fig 5 25 appears select OK Fig 5 25 TPMS ID Registration KDS Version 3 Instruction Manual 23 5 5 Fob Registration To register an additional fob or to re register an existing fob NOTE The maximum number of fobs that can be registered is 6 The motorcycle comes with 2 and an additional 4 can be registered A fob s memory slot in the Smart ECU cannot be erased 5 5 1 Additional Fob Registration Fig 5 26 appears o Select Return Fig 5 26 TPMS ID Registration o To confirm the new TPMS ID is registered correctly go to Real Time Monitor screen Fig 5 27 Fig 5 27 Registration Confirmation o Select Fob Registration on the KI PASS Related Menu Fig 5 28 Fig 5 28 KI PASS Related Menu Scree
22. holder o Pull out the ECU from the case o Remove the 8 Pin cover from ECU amp connect the cable to 8 pin port of ECU A ECU B Communication Cable Fig 3 2 14 Connection of VN1500 KDS Version 3 Instruction Manual 14 Section 4 Menu Items 4 1 Menu Structure The menu structure diagram and menu items outline are as shown in Fig 4 1 and Table 4 a followed by further explanation on each menu Some functions are not available on all models Fig 4 1 Menu Structure KDS Version 3 Instruction Manual 15 4 2 Function of Menu Items Table 4 a Menu Feature Menu Item Description amp Function With Smart System Select for ZG1400A B Without Smart System Select for all non Smart equipped models Model Information Displays model information KI PASS Select when diagnosing servicing KI PASS system and parts KI PASS Related Menu Select when diagnosing servicing KI PASS system and parts Unit Registration Select when servicing Steering Lock Unit or FI ECU FOB Registration Select when registering FOB Diagnosis Select when diagnosing KI PASS system Immobilizer Key Registration Select when registering Immobilizer Key Tire Air Pressure Sensor ID registration Select when registering TPMS ID Tire Air Pressure Sensor ID deletion Select when deleting TPMS ID Real Time Monitor Show current situation of KI PASS system Fuel Injection Select when diagnosing FI system and parts FI ECU Related Menu Select
23. ill stop automatically Fig 6 26 OCV Solenoid Test KDS Version 3 Instruction Manual 41 6 5 1 Graph Display Items Selection Select Real Time Monitor Graph from the FI ECU Related Menu then Select 6 5 2 Displaying Graphs 6 5 3 Printing Fig 6 27 appears o Select the item s on the pull down menu then OK or press the Enter key to confirm o Select Cancel to stop Fig 6 27 Selecting Items o Select Start to display the graphs o Select Stop to stop NOTE When displaying the graphs the Start button changes to a Stop button Fig 6 28 Graph sample o After selecting Print Fig 6 29 will appear o Select the start time and then select OK to begin printing Print size A4 Select Cancel to stop printing and return to the original screen Fig 6 29 Printing Graph o When printing has finished the completion screen appears Select OK Fig 6 30 Printing Completed KDS Version 3 Instruction Manual 42 Section 7 KDS for ABS System 7 1 Outline KDS for ABS has been developed as an optional function of KDS 3 This software can be used on models equipped with ABS such as the EX650B ER650B ZX1400B and ZG1400A 7 2 Installing the Software 7 3 Connection of the Cable Fig 7 2 shows a sample connection of KDS for ABS Fig 7 2 Sample connection of KDS ABS system A Personal Computer PC B USB cable C Converter 57001 1648 D Communication cable 6 pin 8 pin cable 57001 1649 E 8
24. ms Sub Throttle Opening Angle should be selected for this test o Make sure the engine is not running and then select Start Fig 6 24 is displayed when performing the test Fig 6 24 Sub Throttle Actuator Test KDS Version 3 Instruction Manual 40 6 4 7 Second Air Solenoid Test o Select Second Air Solenoid Test and select OK o Select Display Items o Make sure the engine is not running and then select Start 6 4 8 OCV Solenoid Test o Select OCV Solenoid Test and then select OK o Select display items o Make sure the engine is not running and then select Start 6 5 Real Time Monitor Graph The graph operates while the engine is running Parameter values from the ECU will be shown on the graphs Up to three graphs can be displayed and drawn for up to twenty seconds They are drawn by scrolling point by point Simultaneously numerical values are displayed on screen Fig 6 25 is displayed when performing the test o Listen for the sound of solenoid operation If the operating sound is not heard the solenoid or it s circuit has failed o Select Stop to finish testing The test lasts for about 5 seconds and will stop automatically Fig 6 25 Second Air Solenoid Test Fig 6 26 is displayed when performing the test o Listen for the sound of solenoid operation If the operating sound is not heard the solenoid or it s circuit has failed o Select Stop to finish testing The test lasts for about 5 seconds and w
25. n KDS Version 3 Instruction Manual 24 o Current information is displayed Fig 5 29 Two fobs are registered to the Smart ECU during production o Select Additional Registration if you want to register additional fobs Fig 5 29 Fob Registration Screen Fig 5 30 appears o Input the new fob ID then select Additional Registration with the new fob placed close to the Smart ECU NOTE The new fob s ID is located on the shipping package Fig 5 30 Fob Registration Fig 5 31 appears o Select OK Fig 5 31 Fob Registration Fig 5 32 appears o Select Return if you are finished or Additional Registration to register another fob Fig 5 32 Fob Registration Fig 5 33 is a sample of an additional registration o Enter the fob s ID number and select Additional Registration Fig 5 33 Additional Registration KDS Version 3 Instruction Manual 25 5 5 2 Fob Re registration Fig 5 34 appears o Select Return if completed Fig 5 34 Additional Registration o Select Re registration Fig 5 34 Select OK Fig 5 35 In this example there are 3 fobs Fig 5 35 Re registration o Fig 5 36 appears confirming the number of fobs select Yes Fig 5 36 Re registration Fig 5 37 appears o Select Return if completed Fig 5 37 Re registration KDS Version 3 Instruction Manual 26 5 6 Immobilizer Key Registration Smart ECU Replacement To register the Immobilizer keys supplied with a new Smar
26. nnect the USB cable C to the Adapter Fig 3 2 1 Tool Connection KDS Version 3 Instruction Manual 10 2 ABS system o Remove seat o Locate the 8 pin connector A on the main harness and remove the cover ABS port o Connect cable 57001 1649 B to the 8 pin ABS port o Connect the 6 pin connector on 57001 1649 to the Adapter C o Connect the computer s USB cable D to the Adapter Fig 3 2 1 1 Tool Connection ABS 3 2 2 ZX1200 A B o Remove the rear compartment cover o Remove the cover on the harness o Connect the adapter cable to the diagnostic port on harness A Diagnostic port 4 pin on harness B Communication Cable Fig 3 2 2 Connection of ZX1200 A B 3 2 3 VN1500 P o Remove the seat o Remove the cover of Diagnostic Port A o Connect the adapter cable to the diagnostic port on harness A Diagnostic Port 4 pin B Battery C ECU Fig 3 2 3 Connection of VN1500 P 3 2 4 VN1600 VN2000 o Remove the seat VN1600 A B o Remove the seat and battery cover VN2000 A o Remove the cover of Diagnostic Port A o Connect the adapter cable to the diagnostic port on harness A Diagnostic Port 4 pin B Battery C ECU Fig 3 2 4 Connection of VN1600 A KDS Version 3 Instruction Manual 11 3 2 5 ZX636 ZX600 ZR1000 ZR750 ZX1000 C o Remove the seat o Remove the cover of Diagnostic Port A o Connect the adapter cable to the diagnostic port on harness A Diagnostic Port
27. nu Component values and warning information from the ECU can be viewed on screen Up to 10 items can be displayed simultaneously service data can be saved or printed Fig 6 6 Real Time Monitor KDS Version 3 Instruction Manual 34 o Click Select Fig 6 6 Fig 6 7 will appear On this screen items can be selected and displayed for service information NOTE Use the space key to check or uncheck each item for display purpose Press the arrow keys upward or downward on the keyboard to move the items o To confirm your selection select OK or press the Enter key To return to the previous selection select Cancel Fig 6 7 Select Items Fig 6 8 is a sample of All Information Other items selected to be monitored can be seen by selecting the scroll button or moving the scroll bar Fig 6 8 Real Time monitor Selection of units o Select View V located on the upper Tool Bar then select Unit U Fig 6 9 appears o Select units from pull down menu o After confirming the units select OK Once units are selected they will be applied to all displays Fig 6 9 Unit Selection KDS Version 3 Instruction Manual 35 6 2 2 Saving Service Data Data obtained through communication with the ECU can be saved o Select Save Fig 6 8 Fig 6 10 will appear o Select an option and then select OK Fig 6 10 Select Save Option o Enter comment then select OK Fig 6 11 Fig 6 11 Comment sample
28. p ECU Part Number o Select Diagnosis on the KI PASS Related Menu to display current failure codes Fig 5 6 is a sample screen Fig 5 6 Diagnosis KDS Version 3 Instruction Manual 18 5 3 Real Time Monitor 5 3 1 Selecting Display Items o To display current KI PASS component condition select Real Time Monitor in the KI PASS Related Menu Fig 5 7 is a sample screen Fig 5 7 Real Time Monitor o First select the group from the pull down menu There are four groups Engine Information Warning Information Monitoring Information and All Information All Information includes Engine Warning and Monitor Information o Choose Select Fig 5 8 Real Time Monitor Fig 5 9 will appear o Select items and then select OK On this screen items can be selected and displayed for service information NOTE Use the space key to check or uncheck each item for display purpose Press the arrow keys upward or downward on the keyboard to move the items Fig 5 9 Select Items KDS Version 3 Instruction Manual 19 5 3 2 Saving Service Data Fig 5 10 is a sample screen Fig 5 10 Real Time Monitor NOTE To see the screen more clearly you can maximize the screen and enlarge the column widths Fig 5 11 Fig 5 11 Real Time Monitor Data obtained through communication with the ECU can be saved o Select Save Fig 5 11 o Select one option and then select OK Fig 5 12 Fig 5 12 Select Save
29. pin connector to main harness F ABS ECU 7 3 1 ZG1400A The software is installed at the same time as KDS Version 3 and the icon will be visible on the desktop screen as in Fig 7 1 Fig 7 1 KDS 3 icon o Remove seat o Locate the 8 pin connector A on the main harness and remove the cover ABS port o Connect cable 57001 1649 B to the 8 pin ABS port o Connect the 6 pin connector on the 57001 1649 to the Adapter C o Connect the computer s USB cable D to the Adapter Fig 7 3 ABS Port on ZG1400A KDS Version 3 Instruction Manual 43 7 3 2 ER650B EX650B 7 3 3 ZX1400B 7 4 Menu Structure The menu structure diagram is shown in Fig 7 6 Fig 7 6 ABS Structure o Remove seat o Remove the ABS Port B cover o Connect the 8 pin connector on 57001 1649 to the ABS port A Diagnostic Port for KDS 4 pin port B Diagnostic Port for ABS 8 pin port Fig 7 4 ABS Port on ER650B o Remove seat o Remove the ABS Port B cover o Connect the 8 pin connector on 57001 1649 to the ABS port A Diagnostic Port for KDS 4 pin port B Diagnostic Port for ABS 8 pin port Fig 7 5 ABS Port on ZX1400B KDS Version 3 Instruction Manual 44 7 5 Operation 7 5 1 Starting KDS for ABS o Turn on the PC o Start KDS Version 3 from the start menu Or double click the KDS 3 icon on the desktop screen o Go to Main Menu Fig 7 7 o Select ABS Fig 7 7 Start Menu o Next the ABS Current Failure screen
30. splay save and print real time sensor values 6 Display and print graphs of real time sensor values 7 Erase stored service data ABS equipped Vehicles 1 Diagnose the ABS system 2 Erase stored service data Other Features 1 Software can be used in ten languages 2 Software operates on Windows 2000 XP Vista 3 Three units SI Metric English can be selected to display sensor values NOTE Some functions are not available on all models KDS Version 3 Instruction Manual 2 1 2 KDS Version 3 System Configuration KDS Version 3 operates on a PC and communicates with the unit via a USB communications port communication cable and a signal converter KDS consist of 1 CD 2 Signal Converter 3 Communication Cables Fig 1 shows the KDS 3 Kit parts for ZG1400A B 1 CD KDS 3 software P NO 57001 1650 2 Adapter Signal converter P No 57001 1648 3 Communication cables P No 57001 1649 6 pin 8 pin P No 57001 1688 8 pin 4 pin Fig 1 1 KDS 3 Tools A Personal Computer PC C Converter 57001 1648 E Smart ECU B USB cable D 6 pin connector of main harness Fig 1 2 Sample connection of ZG1400 system A Personal Computer PC C Converter 57001 1648 E 8 pin 4 pin cable 57001 1688 B USB cable D 6 pin 8 pin cable 57001 1649 F 4 pin connector of main harness G FI ECU Fig 1 3 Sample connection of other DFI vehicles KDS Version 3 Instruction Manual 3 1 3 Z
31. t ECU o Select Immobilizer Key Registration on the KI PASS Related Menu Fig 5 38 Fig 5 38 KI PASS Related Menu Fig 5 39 appears o Select Immobilizer Key Registration Fig 5 39 Immobilizer Key Registration Fig 5 40 appears Fig 5 40 Immobilizer Key Registration o Remove the key from the fob Place the fob s cutout where the head of the key was located over the projection in front of the ignition switch See Fig 5 41 Fig 5 41 Location of Key KDS Version 3 Instruction Manual 27 Fig 5 42 appears select OK Fig 5 42 Key Registration OK A confirmation screen will appear Fig 5 43 o To register more fobs repeat the procedure When Fig 5 41 appears select OK Fig 5 43 Updated Immobilizer Key Registration Fig 5 44 appears o When all fobs have been registered select Confirm changed item Fig 5 44 Confirmed Key Registration Fig 5 45 appears o Select Yes Fig 5 45 Key Registration Fig 5 46 appears o Select OK Fig 5 46 Confirmation KDS Version 3 Instruction Manual 28 5 7 FI ECU Replacement To replace the FI ECU Fig 5 47 appears o Select Return to complete the process Fig 5 47 Confirmation o Select Unit Registration on the KI PASS Related Menu Fig 5 48 Fig 5 48 KI PASS Related Menu o Select FI ECU then select Registration Fig 5 49 Fig 5 49 FI ECU Selection Fig 5 50 appears o Select Yes Fig 5 50 FI ECU Selection Fig
32. t compulsory 4KDS closes After steering lock switch ON confirm the release of steering lock 5Confirm meter initialization 6Ignition switch ON register immobilizer key and TPMS o Steering lock unit ID o FI ECU ID o Immobilizer ID o TPMS ID 6 o o o 1Start KDS 2Steering lock push switch ON then start communication 3Register steering lock unit compulsory 4KDS closes After steering lock switch ON confirm the release of steering lock 5Confirm meter initialization 6Ignition switch ON register immobilizer key and TPMS o Steering lock unit ID o FI ECU ID o Immobilizer ID o TPMS ID 7 o o 1Start KDS 2Steering lock push switch ON then start communication 3Register steering lock unit compulsory 4KDS closes After steering lock switch ON confirm the release of steering lock 5Confirm meter initialization o Steering lock unit ID o FI ECU ID 8 o o o o 1Put No 1 fob close to steering lock and push switch ON 2Registering immobilizer key show Registration OK if not show Registration no good 3 Put No 2 fob close to steering lock and push switch ON 4If immobilizer key is registered successfully automatically write the ID to steering lock ECU and display the mark which show ignition switch ON 5If ignition switch ON write the ID to the FI ECU and initialize the Meter unit o Steering lock unit ID o FI ECU ID o Immobilizer ID o TPMS ID 9
33. ted o Select Fuel Pump Test from the pull down menu and select OK o Select display items o Make sure the engine is not running and select Start Fig 6 22 is displayed when performing the test o Listen carefully for the sound of fuel pump operation If the operating sound is not heard the fuel pump and or its electrical circuit have failed o Select Stop to finish testing The test lasts for about 5 seconds and will stop automatically Fig 6 22 Fuel Pump Test KDS Version 3 Instruction Manual 39 6 4 5 Ignition Coil No Test o Select Ignition Coil No Test from the pull down menu then select OK o Select display items o Make sure the engine is not running and then select Start NOTE Before performing the Ignition coil test remove the spark plugs from the cylinder head 6 4 6 Sub Throttle Valve Actuator Test o Monitor the voltage of the Sub Throttle Actuator Opening Angle and listen for the sound of actuator operation If the Voltage goes above 3 8 volts the actuator is operating correctly Refer to the data in the service manual Select Stop to finish testing The test lasts for about 5 seconds and will stop automatically Fig 6 23 is displayed during test o Confirm spark at the plugs o Select Stop to finish testing The test lasts for about 5 seconds and will stop automatically Fig 6 23 Ignition Coil Test o Select Sub Throttle Actuator Test from the pull down menu and select OK o Select display ite
34. ter inf and KDSAdapter sys files to a location on your PC o Connect the KDS 3 Adapter PN 57001 1648 to your PC with the USB cable NOTE Purchase a USB cable locally with a maximum length no longer than 2m Fig 2 1 Files in CD o Connect the KDS Adapter to the connector 6 pin type on the main harness o Turn ON the ignition KDS Adapter Signal Converter Fig 2 2 Starting the Wizard KDS Version 3 Instruction Manual 5 Selection of Search Option o Select Don t search Then select Next gt Fig 2 3 Search Selection Selection of Device Driver o Select Show compatible hardware o Select KDS Adapter o Then select Next gt Fig 2 4 Selection of Device Driver o Select the location of KDSAdapter inf file o Then select Open Fig 2 5 Locate Driver Fig 2 6 Selection of Driver KDS Version 3 Instruction Manual 6 2 2 Initial Installation of KDS 3 Software Installation in progress screen Fig 2 7 Installation o Finished select Finish Fig 2 8 Installation Complete o Start Windows o Insert the KDS CD into the CD drive o CD autolaunches or navigate to the drive location then double click InstKDS exe Fig 2 9 KDS 3 File Folder KDS Version 3 Instruction Manual 7 o Select the language Then select OK Language abbreviation are as follows DE German EL Greek EN English ES Spanish FR French IT Italian NL Netherlands PT Portuguese SV Swedish Fig 2 10 Language Selec
35. tic Port for ABS 8 pin port ABS model only Fig 3 2 9 Connection of ZX1400 3 2 10 KLE650 o Remove the seat o Remove the cover of Diagnostic Port A o Connect the adapter cable to the diagnostic port on harness A Diagnostic Port for KDS 4 pin port Fig 3 2 10 Connection of KLE650 3 2 11 07 ZR750 ZR1000 o Remove the seat o Remove the cover of Diagnostic Port A o First connect the Connection cable 57001 1699 to the diagnostic port on harness o Second connect the Adapter cable A Diagnostic Port for KDS 4 pin port Fig 3 2 11 Connection of ZR750 ZR1000 KDS Version 3 Instruction Manual 13 3 2 12 JT1500B JT1500C o Open the front storage compartment cover o Remove the front storage case o Push in the pins and remove the battery cover o Connect the communication cable to the Diagnostic Port A near the battery A Diagnostic Port for KDS 4 pin port Fig 3 2 12 Connection of JT1500B JT1500C o Insert the Adapter cable 57001 1696 between the 6 pin connector B on harness o Then connect the leads of the Adapter cable Fig 3 2 12 1 Connection of JT1500B JT1500C 3 2 13 KSF450B o Remove the cover of Diagnostic Port A o Connect the adapter cable to the diagnostic port on harness The port is located under the front fender left side A Diagnostic Port for KDS 4 pin port Fig 3 2 13 Connection of KSF450B 3 2 14 VN1500 J L N R o Remove the seat and battery
36. tion Installation program starts automatically o Select Next gt Fig 2 11 Installation Wizard o Select Installation Folder The default folder is C Program Files Kawasaki Diagnostic System Ver 3 o Select Just me o Then select Next gt Fig 2 12 Selection of Installation Folder KDS Version 3 Instruction Manual 8 o Follow the on screen instructions Fig 2 13 Install Shield Wizard Installation in progress screen Fig 2 14 Beginning Installation Installation completes o Select Close Fig 2 15 Installation Complete KDS Version 3 Instruction Manual 9 Section 3 Cable Connection Detail of Connection 1 Connect to main harness of vehicle 2 USB port of KDS 3 Adapter 3 Connect to KDS 3 Adapter 4 Connect to PC 5 6 pin port Connect to KDS 3 Adapter 6 8 pin port Connect to ABS ECU port of main harness 7 8 pin port Connect to No 6 port 8 4 pin port Connect to KDS port of main harness 3 2 Connecting PC to ECU Refer to the following diagrams or the Service Manual for the location of the diagnostic ports 3 1 Required Tools A KDS 3 Adapter 57001 1648 B Com Cable 6 pin 8 pin 57001 1649 C KDS 3 Software 57001 1650 D Com Cable 8 pin 4 pin 57001 1688 E USB Cable Fig 3 1 Required Tools 3 2 1 ZG1400A B 1 Smart and DFI systems o Remove seat o Locate the 6 pin connector A on the main harness and remove the cover o Connect the 6 pin connector to the Adapter B o Co
37. when diagnosing monitoring FI system and parts Real Time Monitor Displays engine running conditions and previous codes Actuator Test Run or stop the actuator Graph Draw and display the graph Real Time Monitor Displays engine running conditions and previous codes Diagnosis Displays self diagnosing codes stored on the ECU ABS Select when diagnosing ABS system ABS Current Failure Show current failure of ABS system Intermittent Failure Show previous failure of ABS system Erase Stored Service Codes Erase service codes KDS Version 3 Instruction Manual 16 Section 5 KDS 3 Operation for KI PASS System The ZG1400A B KI PASS Smart system requires code verification for the ECU units to function correctly 5 1 Starting KDS 3 o Turn on the PC o Start KDS Version 3 from the start menu Or double click the KDS 3 icon on the desktop screen Fig 5 1 KDS 3 icon Fig 5 2 will appear o Read the instructions and perform the preliminary inspection o Select OK after performing the preliminary inspection Fig 5 2 Important Screen Fig 5 3 will appear o On Smart System equipped models select With Smart System Fig 5 3 Main Menu KDS Version 3 Instruction Manual 17 5 2 Diagnosis o The KDS Main Menu and Model Information screen will appear o Select KI PASS Fig 5 4 Main Menu amp Model Information o Select one of the options from the KI PASS Related Menu Fig 5 5 KI PASS Related Menu am
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