Professional Documents
Culture Documents
Ninja ZX-10RR
© 2018 Kawasaki Heavy Industries, Ltd. First Edition (1): Dec. 11, 2018
1
How to Use This Manual
Whenever you see symbols, heed their instructions! Always follow safe operating and
maintenance practices.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
This manual contains following symbol which will help you distinguish different types of
information.
NOTE
○ NOTE indicates information that may help or guide you in the operation or service of the
vehicle.
2
User License Agreement
For Kawasaki FI Calibration Tool
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 FI Calibration Tool Software ("SOFTWARE"). By installing, copying, or
otherwise using the SOFTWARE, you shall agree to be bound by the terms of this AGREEMENT. If
you will not agree to the terms of this AGREEMENT, promptly uninstall the SOFTWARE and destroy
all the SOFTWARE, including its COPY if you have made one.
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 and/or its licensor. The SOFTWARE is protected by copyright
laws and international treaty provisions.
2. GRANT OF LICENSE
(1) By purchasing the SOFTWARE, you are granted a license to use the SOFTWARE under
following conditions (2) and (3).
(2) USE: The SOFTWARE is licensed, not sold. You may install and 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/or its licensor, 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, decompile, 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
SOFTWARE 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.
3
6. LIMITED WARRANTY
(1) CUSTOMER REMEDIES: Kawasaki's and its suppliers’ entire liability and your exclusive
remedy shall be 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 warranties, either express or implied, including, but not
limited to, implied warranties of 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 INCLUDING PERSONAL INJURY AND
LOSS OF LIFE: 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 including personal injury and loss of life 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 exclusion or limitation of liability for
consequential or incidental damages, the above limitation may not apply to you.
7. EXPORT LIMITATION
You shall agree not to export 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.
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Table of Contents
1. Overview of ZX-10R FI Calibration Tool ····································································· 7
1.1 System Functions ································································································ 7
1.2 Requirements for Personal Computer (PC) ······························································· 8
1.3 System Configuration ··························································································· 8
2. Installation Procedure ··························································································· 10
2.1 Installation Procedure ························································································· 10
2.2 Uninstallation Procedure ····················································································· 13
3. Program Operations ······························································································ 15
3.1 Start Procedure ································································································· 15
3.2 Map Editing Method ··························································································· 19
3.2.1 Editing a Map ····························································································· 19
3.2.2 Editing a Map Axis ······················································································ 22
3.2.3 Editing a Setup Value ·················································································· 24
3.3 Cell (Data) Editing Functions ················································································ 26
3.3.1 Selecting Multiple Cells (Data) ······································································ 26
3.3.2 Copying a Selected Cell ··············································································· 26
3.3.3 Pasting Data from the Clipboard (only Available for 2D and 3D Maps) ··············· 26
3.3.4 Changing Data in Multiple Cells ···································································· 27
3.3.5 Selecting All Cells ······················································································· 27
3.4 ECU Data Change Method ·················································································· 28
3.4.1 Reading and Writing Data ············································································ 29
3.5 Verify (Compare) Method····················································································· 30
3.6 Monitoring Functions ·························································································· 32
3.6.1 Setting Monitoring Items·············································································· 32
3.6.2 Starting and Ending Monitoring ···································································· 33
3.6.3 Making a Setting for Graph Display During Monitoring ···································· 34
3.7 File Save Operations ·························································································· 37
3.7.1 Saving an ECU Data File ·············································································· 37
3.7.2 Saving a Logging Data File ·········································································· 37
3.8 Logging Data Display Operations ·········································································· 39
3.8.1 Opening a Logging Data File ········································································ 39
3.8.2 Changing a Graph Display Setting for Logging Data ······································· 40
4. Menu List ············································································································· 42
4.1 Main Menu ······································································································· 42
4.2 Tool Bar (Icon)··································································································· 43
5. Component Connection and Function Description···················································· 44
5.1 Connecting the Main Harness for Racing ································································ 44
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5.2 Setting the FI Tool Program·················································································· 44
6. Appendix ············································································································· 56
6.1 Precautions ······································································································ 56
6.1.1 Precautions when Using Communication Adaptor ·········································· 56
6.1.2 Service Environment of Communication Adaptor ··········································· 56
6.1.3 Connecting the Communication Adapter ······················································· 56
6.1.4 Interruption During Data Writing to ECU ························································ 57
6.2 Troubleshooting ································································································· 57
6.3 Service Code ···································································································· 58
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1. Overview of ZX-10R FI Calibration Tool
This ZX-10R FI Calibration Tool (simply referred to as Tool) has been developed to adjust the fuel
injection characteristic and ignition timing of a ZX-10R racer so that optimum conditions for circuits
and rider’s skills can be obtained. The following table summarizes the available setup functions.
Table 1-1 Functions and Setup Ranges
Function Range
(1) Fuel injection compensation at acceleration -50% to +50%
(2) Fuel injection compensation at normal run (#1 and #4 cylinders) -50% to +50%
(3) Fuel injection compensation at normal run (#2 and #3 cylinders) -50% to +50%
(4) Fuel injection compensation at normal run (#1 and #4 cylinders, -50% to +50%
entire operating range)
(5) Fuel injection compensation at normal run (#2 and #3 cylinders, -50% to +50%
entire operating range)
(6) Adjusting ratio between main and top injectors -50% to +50%
(7) Active/inactive of fuel cut at deceleration Active or Inactive
(8) Adjustment of ignition timing (#1 and #4 cylinders) -15 to +5
(9) Adjustment of ignition timing (#2 and #3 cylinders) -15 to +5
(10) Adjustment of throttle valve opening 0% to 300%
(11) Engine braking control Levels 1 to 10
(12) Idling speed setup 1,000 rpm to 2,500 rpm
(13) Adjustment of overrev limiter -1,000 rpm to 900 rpm
(14) Active/inactive of pit road rpm control and its setting Active or inactive, setting rpm (1,000
to 10,000 rpm)
(15) Setting of shift-up voltage range 0.29 V to 4.71 V
(16) Setting of shift-down voltage range 0.29 V to 4.71 V
(17) Setting of shift sensor type Setting of output level at
shift-up/down
(18) Adjustment of misfiring time for up-shifter 0 ms to 250 ms
(19) Setting of down-shifter Levels 1 to 5
(20) Adjustment of rpm for activation of external shift indicator RPM: 10,000 rpm to 15,000 rpm
(21) Setting of front tire perimeter Perimeter: 1,500 mm to 2,500 mm
(22) Setting of rear tire perimeter Perimeter: 1,500 mm to 2,500 mm
(23) Active/inactive of reduction ratio control for transmission kit and Active or inactive, reduction ratio
its setting (0.001 to 20.000)
(24) Setting of rear sprocket reduction ratio Reduction ratio (0.001 to 20.000)
(25) Setting of traction control Mode and actuation sensitivity
(26) Setting of wheelie control Mode and actuation sensitivity
(27) Active/inactive of launch control and its setting Active/inactive, rpm and degree of
output inhibition, control release
speed
(28) Presence/absence of electronic-control steering damper Present or absent
7
1.2 Requirements for Personal Computer (PC)
The Tool operates on a personal computer equipped with a USB communication port. The
computer is connected to the motorcycle’s racing electronic control unit (simply referred to as ECU)
via the USB port using a communication adaptor.
Table 1-2 Requirements for PC
Item Recommendation
Operating system (OS) Windows 7 SP1, 64-bit (US version, Japanese version)
Windows 7 SP1, 32-bit (US version, Japanese version)
Windows 8, 64-bit (US version, Japanese version)
Windows 8, 32-bit (US version, Japanese version)
Windows 10, 64-bit (US version, Japanese version)
Windows 10, 32-bit (US version, Japanese version)
Screen resolution 1024 x 768 pixels, 65536 colors or more
CPU Pentium 4, 1 GHz or higher
USB communication 2.0
Memory 2 GB or more
Hard disk drive Free space of 20 Mbytes or more
Others Mouse or pointing device equivalent to the mouse
NOTICE
Even under the recommended operating system, the Tool may not run because of a shortage
of memory caused by other applications installed in your PC.
In addition, a communication error may occur due to a heavy load to PC when other
applications are running at the same time.
(3) Harness
Connector (6P)
(5) USB cable
(4) Communication
(6) PC equipped with
adaptor (1) ECU
Calibration Tool
(2) Main harness
Fig. 1-1 System Configuration of the Tool
8
NOTE
○ The racing ECU can operate only in combination with the racing main harness: 26031-2113 or
26031-2471. Note that it does not operate with the standard main harness.
○ The racing ECU can be mounted to both ABS-equipped and non-ABS-equipped motorcycles
through the use of the racing main harness. If mounted to the ABS-equipped motorcycle,
however, ABS does not operate. When a racing ECU has been mounted to an ABS-equipped
motorcycle, operate the motorcycle bearing that ABS would not operate in mind.
○ If you ride an ABS-equipped motorcycle without racing ECU in a circuit, pay special attention to
the following: ABS is designed to prevent locking of the wheels when hard braking is performed
while the motorcycle is running straight. ABS is not designed to shorten the stopping distance. If
the surface is slippery or bumpy, or the course is descending, the stopping distance of an
ABS-equipped motorcycle may be longer than that of the non-ABS-equipped motorcycle.
WARNING
ABS cannot protect the rider from all possible hazards and is not a substitute for safe
riding practices. Be aware of how the ABS system operates and its limitations. It is the
rider's responsibility to ride at appropriate speeds and manner for weather, road
surface and traffic conditions.
9
2. Installation Procedure
Click the Next button to start installation or click the Cancel button to stop installation.
10
(7) The information registration screen (Fig. 2-3) is displayed. Enter a user name, company name,
and serial number.
None of the user name, company name, and serial number can be omitted. If any of them is
omitted, the Next button is grayed out and installation cannot proceed. The serial number is
case-sensitive and the upper- and lower-case letters should be entered as they are.
The serial number is on the label of the FI Calibration Tool CD.
(8) Upon completion of user information entry, preparation for installation is completed and the
installation confirmation screen (Fig. 2-4) is displayed.
Click the Install button to run the installer and click the Cancel button to stop the installer.
(9) Click the Install button to start installation. After completion of installation, the installation
completion screen (Fig. 2-5) is displayed.
11
(10) Click the Finish button to complete installation. Upon completion of installation, a short-cut for
the setup program is registered in the Start menu and desktop. To cancel installation partway,
click the Cancel button.
(11) To start the ZX-10R FI Calibration Tool, restart PC in accordance with the displayed message.
12
2.2 Uninstallation Procedure
(1) Click Programs in the Control Panel screen. To display the Control Panel screen, select Start
→ Settings in this order.
13
(3) Click the Change button to display the screen shown in Fig. 2-9. Select Remove and click the
Next button. To cancel the uninstallation procedure, click the Cancel button.
(4) Click the Next button displays the uninstallation confirmation dialog box (Fig. 2-10). Click the
Yes button to start uninstallation. Click the No button to cancel uninstallation.
14
3. Program Operations
(1) Double-click the short-cut icon on the desktop or select ZX-10R FI Calibration Tool via the
Programs field on the Start menu to start the Initial screen (Fig. 3-1). The main menu for
executing the functions of the Tool is at the top of the screen. At the tool bar below the main
menu, frequently-used functions are indicated by icons. The status bar at the bottom of the
screen indicates the names of data files currently editable on the Tool according to types.
Status bar
NOTE
○ In Windows setting the Decimal symbol should be a period '.' and the Digit grouping symbol
should be a comma ','.
○ If this definition is reversed, the software will not start and an error message will appears.
NOTE
○ In this case, please change Windows setting according by following procedures.
15
[Windows Setting Change Procedure]
Click Start button and Control Panel.
Click Region and Lauguage in Control Panel. Then Region and Language window opens.
Click Additional settings... in Formats tab. Then Customize Format window opens.
16
Input "." (period) into Decimal symbol box and input "," (comma) into Digit grouping symbol
box in Numbers tab.
(2) Load a data file (EDF file) to be edited at the initial screen. Click File → Open in this order or
select the File Open icon ( ) displays the Open dialog box (Fig. 3-6). Files loadable via this
dialog box are ECU data files (EDF files) and logging data files (LDF files).
Select a data file (EDF file) to be edited on the Open File dialog box and click the Open button
to display the data file.
17
(3) Select View → Parameter List on the main menu or click ( ) icon on the tool bar displays the
Parameter List (Fig. 3-7).
18
<Setup Value Edit> Screen
Double-click the Contents field of an item with “Parameter” indicated in the Type field of it in
the Parameter List screen to display the Setup value edit screen (Fig. 3-9).
To edit a map, double-click the Contents field of an item with “2D” or “3D” indicated in the Type
field of it in the Parameter List screen.
19
The screen switches to the map edit screen (Fig. 3-11). The two-dimensional (2D) graph and
table of a target edit map are displayed. The graph can be switched to a three-dimensional (3D)
graph via graph display switch list box.
Table
Cursor point
Z-axis
Z-axis switch
20
NOTE
○ If you close a map edit screen by mistake, you should open the target map again via the
Parameter List screen.
○ If a target edit map has been changed to another via the Parameter List screen with a map edit
screen displayed, the current map is closed and a new target edit map is displayed instead.
Data can be edited on both the graph and table screens and the editing methods are as follows.
(Note) One-bit resolution: Data is saved in hexadecimal format (H) and its least significant
value is changed every 1H.
If an input value exceeds a settable range, a warning message (Fig. 3-13) will be displayed and
the previous value will be restored.
21
3.2.2 Editing a Map Axis
On the table screen, axis data can be directly edited by selecting its cell with mouse or key
operation and inputting a value. Data is always converted into a settable value.
Fig. 3-14 Map Axis Edit Screen (before Axis Value Change)
Fig. 3-15 Map Axis Edit Screen (Sample Screen after Axis Value Change)
22
NOTE
○ Rpm axis data must be set in such a way that the input data shall always be larger than its left
adjacent data and smaller than its right adjacent data. If an input value exceeds a settable range,
the previous value will be restored.
○ Throttle opening axis data must be set in such a way that the input data shall always be larger
than its upper adjacent data and lower than its lower adjacent data. If an input value exceeds a
settable range, the previous value will be restored.
○ For each axis, if a value exceeding the settable range is input at the end of the axis, a warning
message will be displayed and the previous value will be restored.
If an input value exceeds a settable range, a warning message (Fig. 3-16) will be displayed.
NOTICE
Map axis data is common to all the maps. When changing this data, note that the values of
axes for all the other maps are also changed.
23
3.2.3 Editing a Setup Value
Double-click the Contents field of an item with “Parameter” indicated in its Type field of the
Parameter List screen (Fig. 3-17).
The setup values are shown in a parameter list. Each value in the list can be directly edited by
selecting its cell with the mouse and inputting a new value. Data is always converted into a settable
value.
(Note) One-bit resolution: Data is saved in hexadecimal format (H) and its least significant
value is changed every 1H.
24
If a value exceeding a settable range is inputted, a warning message (Fig. 3-19) will be displayed
and the previous value will be restored.
NOTICE
When changing a setting, change it gradually while checking the engine condition
(presence or absence of knocking) and/or measuring the air-fuel ratio. Restore to the
previous values if any abnormality is detected. Do not change a value greatly at once.
25
3.3 Cell (Data) Editing Functions
It is possible to select multiple cells in the table area of the map edit screen collectively. This
function is effective when copying data to a table of Microsoft Excel or the like or when changing
data in a range collectively.
Select a starting point (by clicking the left button of the mouse) and then select an ending point
(by clicking the left button while holding down the Shift key). In another way, hold down the left
button at the starting point, drag the mouse to the ending point, and release the button to determine
a range to be selected.
A selected cell (or cells) can be copied via the Windows clipboard function. The data thus copied
can be pasted to a table of Microsoft Excel or the like.
Copy: {Ctrl} + {C}
Paste: {Ctrl} + {V}
3.3.3 Pasting Data from the Clipboard (only Available for 2D and 3D Maps)
Data selected from a selected cell or a table of Microsoft Excel or the like can be pasted to a 2D
or 3D map. In this case, it can be pasted at a cursor position by selecting Edit → Paste in this order
on the main menu or by pressing {Ctrl} + {V} keys.
When a source data format does not match a destination data format, data cannot be pasted. If
the data to be pasted exceeds the cell range of the map, protruded data is not pasted.
26
3.3.4 Changing Data in Multiple Cells
Values in the selected cells can be changed collectively at the same time.
First, select a cell range according to the procedure described in 3.3.1. Position the cursor at the
starting point. Then, input a value at that cell and press the Enter key. The same value is inputted to
the cells of the selected range.
In another way, change the value of the starting cell by the unit of one-bit resolutions using
{PageUp}/{PageDown} keys.
To select all the cells, select Edit → Select All on the main menu or press {Ctrl} + {A} keys.
27
3.4 ECU Data Change Method
ECU PC
Continuous read
ROM and Data Being Edited
Read/Compare
28
3.4.1 Reading and Writing Data
Select Tools → Read and Write ECU Data on the main menu.
The data change window is displayed as shown in Fig. 3-25.
NOTE
○ Before starting to write or read data, make proper connection with a motorcycle.
○ When reading out data from ECU, note that read data is overwritten onto ECU data being edited.
If ECU data being edited needs to be retained, therefore, the data should be saved before the
ECU data is read. (For details on how to save the file, refer to 3.7 File Save Operations.)
○ After writing data to ECU, check that there is no difference between source data and destination
ECU data using the Verify (compare) function. Data may be written to ECU incorrectly depending
on the communication condition.
○ Data writing to ECU must be performed at least 10 seconds after turning on the power switch of
the motorcycle.
NOTICE
When a data transfer operation has been performed for ECU, wait until the fuel pump stops
before proceeding to the next operation or turning off the power of the motorcycle.
29
3.5 Verify (Compare) Method
PC screen data is compared with an arbitrary data. Click Tools → Verify ECU Data on the main
menu to display the target data selection window (Fig. 3-26).
30
(3) Displaying a Comparison Result of 2D and 3D Maps in Details
Double-click a row with “2D Map” or “3D Map” indicated in the Type field in the Verify Result List
screen (Fig. 3-28) to display detailed comparison result screens (Fig. 3-30 to 3-33). Because a 3D
map is displayed for each Z axis, the Z-axis to be displayed can be changed via the Z-axis list box
on the screen.
31
3.6 Monitoring Functions
Click Monitoring → Monitor Property on the main menu or click the Monitor Property icon ( )
on the tool bar to display the Monitor Property window (Fig. 3-34).
Add/remove items to
be monitored.
List of
monitorable items
Items to be monitored
NOTE
○ This setting is saved as monitor information data when the program terminates. Because this
setting is saved in a file different from ECU data files, multiple pieces of ECU data can be
monitored using the same monitor settings.
32
3.6.2 Starting and Ending Monitoring
33
NOTE
○ If you try to perform monitoring in the initial condition, no data is displayed in a graph. Before
starting monitoring, be sure to make settings for graph display according to a procedure shown in
3.6.3 Making a Setting for Graph Display During Monitoring.
○ Data of a maximum of 30 minutes can be saved as logging data. If 30 minutes have passed after
the start of monitoring (logging), previous data is overwritten in chronological order for logging.
○ If the capacity of PC free memory is not sufficient at the start of monitoring (logging), an error
message is displayed and no monitoring (logging) can be performed. If the error message is
displayed, terminate other currently-running application to increase free memory.
○ If a communication error occurs during monitoring, monitor data cannot be obtained. In this case,
the graph is drawn using the point data obtained in previous monitoring and an asterisk (*) is
shown at the upper part of the graph.
○ If a communication error state (including an ignition switch off state) continues for five seconds,
monitoring stops.
Channel tab
Graph 1
Graph 2
Selecting “2” causes a graph area to
be divided into two parts for display.
34
(2) Setting a Y axis gauge to be displayed on the graph window
Set a Y axis gauge to be displayed on the graph window via the Y Axis tab on the Monitor Graph
Property window. This setting specifies the Y axis gauge to be displayed from the monitor items set
on the Monitor Property window (Fig. 3-34). A Y axis gauge can be displayed separately for each
monitor item. A maximum of 8 Y axis gauges can be displayed for single division.
Y Axis tab
35
(3) Setting a scale to be displayed on the graph window
Set a scale to be displayed in the graph window via the Scale etc. tab on the Monitor Graph
Property window. Value variation can be easily checked by setting maximum and minimum values
according to a change range of monitor data.
This setting determines a display scale for an item set as a monitor item on the Monitor Property
window (Fig. 3-34).
A set of maximum/minimum values can be set for each monitor item.
Set a maximum/minimum
value for a graph display scale.
NOTICE
When a monitoring item label name is displayed, a complete label may not be displayed
within the screen depending on the size or resolution of the window.
36
3.7 File Save Operations
Click File → Save as ECU File on the main menu or click the Save As ECU File icon ( ) on the
tool bar to display a dialog box (Fig. 3-40) for naming and saving a file. Clicking the Save button
without renaming the file overwrites the data on the current file. Specifying a new file name and
clicking the Save button saves the data in a specified file.
When an attempt to quit this Tool has been made without saving data after editing ECU data, the
edited data is not reflected on the file concerned.
Fig. 3-40 Dialog Box for Naming and Saving the File
NOTE
○ The file extension is “.EDF”. This extension is assigned automatically at the time of file saving.
○ The file cannot be opened if the extension is changed.
37
Fig. 3-41 Dialog Box for Naming and Saving a File
NOTE
○ The file extension is “.LDF”. This extension is assigned automatically at the time of file saving.
○ The file cannot be opened if the extension is changed.
38
3.8 Logging Data Display Operations
To read a saved logging data file (LDF), click File → Open on the main menu or click the File
Open icon ( ) on the tool bar to display the Open dialog box. Select a logging data file (.LDF) and
click the Open button to display its logging data.
39
3.8.2 Changing a Graph Display Setting for Logging Data
A graph display setting for logging data can be changed. This operation can be performed after
completion of monitoring (or logging) or in a state where saved logging data has been read out.
Click Monitoring → Logging Graph Property on the main menu to display the Logging Graph
Property window (Fig. 3-44 to 3-46). This setting can be made in the same way as described in
3.6.3 Making a Setting for Graph Display During Monitoring.
40
Fig. 3-46 Logging Graph Property Screen (Scale etc. tab)
NOTICE
When displaying a monitoring item label name, a complete label may not be
displayed within the screen depending on the size or resolution of the window.
NOTE
○ Regarding ECU data files (EDF files) and logging data files (LDF files), the files of 2018 or former
years are not compatible with those of 2019 year. Even when taking over the past setting, set the
parameter again.
41
4. Menu List
42
4.2 Tool Bar (Icon)
A set of buttons corresponding to some menu items is arranged on the tool bar so that frequently
used functions can be called quickly. Each button is provided with a pictogram representing its
function. Positioning the mouse cursor over a button causes the function of the button to be
displayed as a tip help.
43
5. Component Connection and Function Description
Connect the main harness for racing according to the following procedure.
1. Remove the standard main harness and install the main harness for racing: 26031-2113 or
26031-2471 instead.
2. Remove the standard ECU and mount the ECU for racing: 21175-1540 instead.
3. Connect the communication adaptor connection harness to the 6-pin connector of the main
harness for racing.
4. Connect the communication adaptor connection harness with the communication adaptor.
NOTE
○ When installing the ECU for racing: 21175-1540 or main harness for racing: 26031-2113 or
26031-2471, take special care during driving because some functions of normal motorcycle,
such as the exhaust butterfly valve actuator, radiator fan, side stand warning, etc. have been
disabled.
○ The ECU for racing operates only in combination with the main harness for racing: 26031-2113
or 26031-2471. It does not operate in combination with the standard main harness.
○ The ECU for racing in combination with the main harness for racing can be installed to both the
ABS-installed and non-ABS installed models. When it is installed to the ABS-installed model,
however, ABS is disabled. When ECU for racing is installed to an ABS-installed motorcycle, drive
carefully remembering that ABS is disabled.
44
Engine Brake Control Level Gear 1 KEBC-OFF/L Adjusts engine braking performance (in 1st gear).
Engine Brake Control Level Gear 2 KEBC-OFF/L Adjusts engine braking performance (in 2nd gear).
Engine Brake Control Level Gear 3 KEBC-OFF/L Adjusts engine braking performance (in 3rd gear).
Engine Brake Control Level Gear 4 KEBC-OFF/L Adjusts engine braking performance (in 4th gear).
Engine Brake Control Level Gear 5 KEBC-OFF/L Adjusts engine braking performance (in 5th gear).
Adjusts engine braking performance (in 6th gear,
Engine Brake Control Level Gear 6 KEBC-OFF/L
neutral).
Engine Idling Rev Adjusts the idle rpm.
Over Rev Shift Value Adjusts the setting rpm of overrev limiter.
Select "Pit Road Rev Limit" Sets the presence/absence of pit road rpm control.
Pit Road Rev Limit Adjusts the setting rpm of pit road limiter.
Sets the lower-limit value for a shift-up judgment
Shift UP Judgment Voltage (Low) POWER-F/M/L
voltage.
Sets the upper-limit value for shift-up judgment
Shift UP Judgment Voltage (High) POWER-F/M/L
voltage.
Sets the lower-limit value for shift-down judgment
Shift DOWN Judgment Voltage (Low) POWER-F/M/L
voltage.
Sets the upper-limit value for shift-down judgment
Shift DOWN Judgment Voltage (High) POWER-F/M/L
voltage.
Select "Shifter Sensor Type" Sets the output difference at shift-up/shift-down.
Shift UP Ignition Cut Time Adjusts the ignition cut time at shift-up.
Shift Down Control Level Adjusts the shift-down performance level.
Shift Lamp Rev Adjusts the turning-on rpm for shift indicator.
Front Tire Circumferential Length POWER-F/M/L Sets the front tire perimeter.
Rear Tire Circumferential Length POWER-F/M/L Sets the rear tire perimeter.
Sets the selection/non-selection of the reduction ratios
Select "Gear Ratio"
for mission kit.
Gear Ratio "1st - 6th" POWER-F/M/L Sets the gear reduction ratios for mission kit.
Gear Ratio "Final" POWER-F/M/L Sets the rear sprocket gear reduction ratio.
Select TCS Mode "S-KTRC Indicator 1" Selects the basic setting for traction control mode 1.
Adjustment TCS Level "S-KTRC Indicator 1" Adjusts the values for traction control mode 1.
Select TCS Mode "S-KTRC Indicator 2" Selects the basic setting for traction control mode 2.
Adjustment TCS Level "S-KTRC Indicator 2" Adjusts the values for traction control mode 2.
Select TCS Mode "S-KTRC Indicator 3" Selects the basic setting for traction control mode 3.
Adjustment TCS Level "S-KTRC Indicator 3" Adjusts the values for traction control mode 3.
Select TCS Mode "S-KTRC Indicator 4" Selects the basic setting for traction control mode 4.
Adjustment TCS Level "S-KTRC Indicator 4" Adjusts the values for traction control mode 4.
Select TCS Mode "S-KTRC Indicator 5" Selects the basic setting for traction control mode 5.
Adjustment TCS Level "S-KTRC Indicator 5" Adjusts the values for traction control mode 5.
Select WHL Mode "S-KTRC Indicator 1" Selects the basic setting for wheelie control mode 1.
Adjustment WHL Level "S-KTRC Indicator 1" Adjusts the values for wheelie control mode 1.
Select WHL Mode "S-KTRC Indicator 2" Selects the basic setting for wheelie control mode 2.
Adjustment WHL Level "S-KTRC Indicator 2" Adjusts the values for wheelie control mode 2
Select WHL Mode "S-KTRC Indicator 3" Selects the basic setting for wheelie control mode 3.
Adjustment WHL Level "S-KTRC Indicator 3" Adjusts the values for wheelie control mode 3
Select WHL Mode "S-KTRC Indicator 4" Selects the basic setting for wheelie control mode 4.
Adjustment WHL Level "S-KTRC Indicator 4" Adjusts the values for wheelie control mode 4.
Select WHL Mode "S-KTRC Indicator 5" Selects the basic setting for wheelie control mode 5.
Adjustment WHL Level "S-KTRC Indicator 5" Adjusts the values for wheelie control mode 5.
Select "Launch Control" Sets the presence/absence of launch control.
Launch Control Rev Limit Shift Value KLCM-1/2/3 Sets the limit rpm for the launch control mode.
Sets the rear wheel speed to release the limitation of
Launch Control Cancel Rear Speed A KLCM-1/2/3
rpm for the launch control mode.
Sets the rear wheel speed at the end of launch control
Launch Control Cancel Rear Speed B KLCM-1/2/3
mode.
Sets the output control level in the launch control
Launch Control Level KLCM-1/2/3
mode.
Select "Electronic Steering Damper" Sets presence/absence of electronic steering damper.
45
(2) Contents of FI_TOOL Items and Setup Methods
NOTICE
When changing a setting, change it gradually while checking the engine condition
(presence or absence of knocking) and/or measuring the air-fuel ratio. Restore to the
previous values if any abnormality is detected. Do not change a value greatly at once.
Fuel-related Setting
Fuel adjustment can be made by changing a fuel map so as to realize your optimum engine
specification.
When changing the feel at acceleration, set Select "Comp. Acceleration" to “1” (otherwise set it
to “0”) and change Comp. for Acceleration.
This setting can be changed separately for each of three power modes (F/M/L).
To adjust setting by designating the ranges of throttle opening and rpm, change Comp. Map for
Injection.
This setting can be made separately for a combination of #1 and #4 cylinders and a combination
of #2 and #3 cylinders.
In addition, this setting can be made separately for each of three power modes (F/M/L).
To increase or decrease the injection rate to the entire operation range uniformly, make
adjustment using Comp. Common Parameter for Injection.
This setting can be made separately for a combination of #1 and #4 cylinders and a combination
of #2 and #3 cylinders.
When changing the injection ratio between top and main injectors, change Comp. Map for
Top_Main Injection Ratio.
To activate the fuel-cut system at deceleration, set Select “Fuel Cut” to “0” (otherwise set it to
“1”).
NOTICE
When a standard muffler or a third party’s muffler with catalyst is installed to the
motorcycle, the fuel-cut system must be set to “0” to protect the catalyst.
NOTE
○ When a too quick response of the acceleration is felt at start-up curve, adjust the ignition timing
of the #2 and #3 cylinders to most retarded to change the acceleration to a mild feeling.
46
NOTE
○ There is an area where the throttle opening is less than the throttle grip opening on the base map.
For these area the throttle opening can be increased up to the throttle grip opening at the
maximum by setting a value to 100% or more.
NOTE
○ In case jerky engine response is felt when a grip is opened a little in the cornering, it is
recommended to adjust the throttle opening so that the range where the running resistance is
equal to engine output (the vehicle neither accelerates nor decelerates) becomes wider.
NOTICE
For safety, be sure to change a value gradually while checking the actual engine braking
performance.
NOTICE
When setting the engine brake setting below the 4,000 rpm at 6th gear low, the engine rpm
tends to overshoot the idle speed after revving up the engine in the neutral gear.
NOTICE
For the ZX1002E/F/H, set over-rev limiter setting within the range from -1,000 to +600 rpm.
The standard setting is 0 rpm. If adjusted out of the setting range, the engine could be
damaged. The standard setting of the ZX1002H is +600 rpm.
NOTICE
The pit road limiter setting of the 1st gear is also reflected in the neutral gear position.
When the rpm does not rise in the neutral gear, turn off the pit road limiter switch.
47
Auto Shifter Setting
An auto shifter enables to shift up and down without disengaging the clutch.
Shift-up function operates at 2,500 rpm or higher, and shift-down function operates at 2,500 rpm
or higher. For safety, the shift-down function does not start to operate until the throttle valve is
fully closed. Be sure to close the throttle valve fully when shifting down.
To perform shifting successively, take your foot off the shift pedal to return it to its home position
every time a shift operation is finished. The auto shifter may not function if the pedal is operated
without returning it to its home position.
Shift UP/DOWN Judgment Voltage (Low)/(High) can be used to adjust a voltage range where
the auto shifter operates. This function is used to match your shift sensor to this system or to
improve the shift feel.
This setting can be made separately for each of three power modes (F/M/L).
Select "Shifter Sensor Type" is used to select road shift or race (reverse) shift and to make
proper settings for a shift sensor in use. “4” should be selected in the case that a sensor output
increases at shift-up and decreases at shift-down and “5” should be selected in the case that a
sensor output decreases at shift-up and increases at shift-down.
When a standard shift sensor is used, set “4” for road shift and “5” for race shift.
Shift Sensor Type Road Shift Race (Reverse) Shift
+ for pushing / - for pulling
4 5
(standard sensor)
- for pushing / + for pulling 5 4
When changing from the road shift to race shift while using the same shift-sensor, the Shift
UP/DOWN voltage ranges should be swapped using Shift UP/DOWN Judgment Voltage
(Low)/(High).
Shift Sensor Type Road Shift Race (Reverse) Shift
Shift UP Judgment Voltage High 4.00 V 2.21 V
Shift UP Judgment Voltage Low 2.79 V 0.51 V
Shift Down Judgment Voltage High 2.21 V 4.00 V
Shift Down Judgment Voltage Low 0.51 V 2.79 V
NOTE
○ When shift feeling is hard, adjust the shift voltage closer to 2.5 V. When gear shifting is sensitive,
it is recommended to adjust the shift voltage away from the 2.5 V.
The ignition cut time for shift-up can be set by Shift UP Ignition Cut Time.
A shorter setting time makes shift-up more difficult and a longer setting increases the shock when
restarting ignition.
Shift-down performance can be selected from among five modes 1 to 5 by Shift Down Control
Level.
When the mode “5” is selected, shift-down performance is the highest.
48
Setting when Changing Gear Ratio or Sprocket
If these settings are not correct, they may cause engine malfunction such as misfiring.
When using a transmission kit, set Select "Gear Ratio" to “1” and set the gear ratios (gear
reduction ratios) of the built-in transmission by Gear Ratio "1st - 6th".
This setting can be made separately for each of three power modes (F/M/L).
When changing the rear sprocket (gear reduction ratio), set a gear reduction ratio changed by
Gear Ratio "Final."
This setting can be made separately for each of three power modes (F/M/L).
The extent of the traction control intervention can be adjusted by changing the tire perimeter.
Change the tire perimeter in reference to the following table.
However, when changing the tire perimeter, the vehicle speed displayed in the meter differs from
that of CAN output.
The front tire perimeter affects the front wheel rotation speed of CAN output. The rear tire
perimeter affects the rear wheel rotation speed of CAN output and the vehicle speed in the meter
display.
WARNING
When switching the traction control (S-KTRC) mode, a standard ECU requires to fully
close the throttle valve (or to turn the control off, it requires to stop the motorcycle),
but the racing ECU is free from these restrictions (throttle valve opening and
stoppage). Note these differences in operation between standard ECU and racing ECU.
49
NOTICE
For safety, be sure to change the setting gradually, checking how traction control
performance changes.
Riding Skill
Experts Beginners
NOTICE
Special care should be taken when riding in Wheelie Control Level 1. No wheelie control is
performed. For safety, be sure to change the setting gradually, checking a change of
wheelie control performance.
Experts Beginners
50
Setting and Adjustment for Traction Control and Wheelie Control
The following table summarizes setting and adjustment ranges for traction control and wheelie
control.
As seen from setting examples, a combination of setting level and step of the traction control and
wheelie control can be set for each of meter indication 1 to 5.
Select TCS Mode "S-KTRC Indicator" Level Level Level Level Level
Level setting for traction control 1 to 5 1 to 5 1 to 5 1 to 5 1 to 5
Adjustment TCS Level "S-KTRC Indicator" Adjustment Adjustment Adjustment Adjustment Adjustment
Adjustment step for selected level -5 to +5 -5 to+5 -5 to +5 -5 to +5 -5 to +5
Select WHL Mode "S-KTRC Indicator" Level Level Level Level Level
Level setting for wheelie control 1 to 5 1 to 5 1 to 5 1 to 5 1 to 5
Adjustment WHL Level "S-KTRC Indicator" Adjustment Adjustment Adjustment Adjustment Adjustment
Adjustment step for selected level -5 to +5 -5 to +5 -5 to +5 -5 to +5 -5 to +5
[Setting Example 1]
Indicator 1: Traction Level 1, Adjustment Step -3 Indicator 1: Wheelie Level 2, Adjustment Step -3
Indicator 2: Traction Level 1, Adjustment Step +2 Indicator 2: Wheelie Level 2, Adjustment Step +4
Indicator 3: Traction Level 3, Adjustment Step -1 Indicator 3: Wheelie Level 3, Adjustment Step -1
Indicator 4: Traction Level 4, Adjustment Step -2 Indicator 4: Wheelie Level 3, Adjustment Step +2
Indicator 5: Traction Level 4, Adjustment Step +4 Indicator 5: Wheelie Level 5, Adjustment Step -1
[Setting Example 2]
All of Indicators 1 to 5: Traction Level 1, Adjustment Volume +2
All of Indicators 1 to 5: Wheelie Level 3, Adjustment Volume +2
51
Launch Control Setting
The launch control system fixes the engine rpm at a fixed rpm at the time of start to let the rider
concentrate on engaging the clutch. This system helps riders not having confidence in starting
skills.
Select “Launch Control” should be set to “0” to make launch control operable.
To enter the launch control mode, shift the gear to neutral or the 1st gear and press the
START/STOP switch and MODE switch at the same time for one second or longer. The engine
rpm is set around a preset value if the motorcycle is not moving. The preset rpm is obtained by
correcting the basic 9,000 rpm with the value set by Launch Control Rev Limit Shift Value
(KLCM-1,2,3) (-3,000 to +2,000 rpm).
When the motorcycle exceeds the speed set by Launch Control Cancel Rear Speed A
(KLCM-1,2,3), the engine rpm fixation is cancelled.
When the motorcycle exceeds the speed set by Launch Control Cancel Rear Speed B
(KLCM-1,2,3) or shifts up to the 3rd gear, this function is released.
As for values in Launch Control Cancel Rear Speed A/B, “A” should be smaller than “B”.
An output control level can be adjusted by Launch Control Level (KLCM-1,2,3) for each engine
speed band. A setting range consists of 11 steps from -5 to +5, and if a value of -5 is set, the
output control level becomes the lowest.
When the same setting is made in the above parameter for KLCM-1,2,3, the same launch
control takes place.
NOTICE
For safety, be sure to change the setting gradually, checking a change of performance of
output control level.
52
WARNING
When the two power mode settings are quite different from each other, switching the
power mode settings while running could create a risk of unexpected maneuver of the
motorcycle such as sudden acceleration.
NOTICE
Although the standard ECU requires the motorcycle being standing still to switch its power
mode, the power mode of the racing ECU can be switched while the motorcycle is running
by pushing and holding the START/STOP switch for a few seconds. In this case, however,
the stop watch function of the meter will stop.
As for a map of the following items, an independent map is available for each of the engine
braking mode OFF and L. For other items, a common map is used for OFF and L modes.
A maximum of two types of map settings can be compared with each other without rewriting ECU
data. In addition, the same setting can be used for all modes, as in the settings for traction control.
Engine Brake Control Level Gear 1
Engine Brake Control Level Gear 2
Engine Brake Control Level Gear 3
Engine Brake Control Level Gear 4
Engine Brake Control Level Gear 5
Engine Brake Control Level Gear 6
NOTICE
Stop the motorcycle to switch the engine braking mode.
Item Description
Comp. Acceleration Current value for fuel injection compensation at
acceleration set in Comp. for Acceleration
Current value for fuel injection compensation (for #1 and #4
Comp. Injection Pulse #1, #4
cylinders) set in Comp. Map for Injection (#1, #4)
Current value for fuel injection compensation (for #2 and #3
Comp. Injection Pulse #2, #3
cylinders) set in Comp. Map for Injection (#2, #3)
Comp. Ignition Advance Value Current value for ignition timing (for #1 and #4 cylinders)
#1, #4 set in Comp. Map for Ignition Advance (#1, #4)
Comp. Ignition Advance Value Current value for ignition timing (for #2 and #3 cylinders)
#2, #3 set in Comp. Map for Ignition Advance (#2, #3)
Current value for throttle valve opening rate correction set
ETV Adjustment Value
in ETV Adjustment Map Gear
Current value for adjusting the ratio between main and top
Top_Main Injection Ratio
injectors set in Comp. Map for Top_Main Injection Ratio
Engine Speed Current value for engine rpm
Intake Air Temperature Current value for intake air temperature
Water Temperature Current value for coolant temperature
Current values for fuel injection compensation set in Comp.
Fuel Injection Coefficient #1, #4 Map for Injection (#1, #4) and Comp. Common Parameter
for Injection (#1, #4)
Current value for fuel injection compensation set in Comp.
Fuel Injection Coefficient #2, #3 Map for Injection (#2, #3) and Comp. Common Parameter
for Injection (#2, #3)
Shift Sensor Output Current value for shift sensor outputs
53
Item Description
Display of fault codes of sensors, etc.
Diagnosis Code (For details on fault codes, refer to the motorcycle’s service
manual.)
Throttle Grip Position Current value for throttle grip opening
Throttle Valve Position Current value for throttle valve opening
Pit Road SW [OFF:0 / ON:1] Status of pit road limiter switch
Shift up Flag [OFF:0 / ON:1] Judgment status for auto shifter shift-up control operation
Judgment status for auto shifter shift-down control
Shift down Flag [OFF:0 / ON:1]
operation
Launch mode Flag [OFF:0 / ON:1] Status of launch control
54
55
6. Appendix
6.1 Precautions
Rated voltage: 12 V
Ambient temperature: 0 to 60°C
Connect the communication adaptor. Confirm that the power is supplied. Then, open System
Properties and confirm that ZX-10R FI Calibration Tool Adaptor has been listed under
Universal serial bus controller in Device Manager and is active normally.
56
6.1.4 Interruption During Data Writing to ECU
If writing to ECU is interrupted because of broken harness or the like, ECU may not start
normally. To recover ECU, it is necessary to rewrite data to ECU. If the confirmation message
dialog box (Fig. 6-2) is displayed during communication with ECU, click the Yes (Y) button to
rewrite data to ECU.
Fig. 6-2 Confirmation Message Dialog Box for ECU Data Recovery
6.2 Troubleshooting
*Note that a communication error message appears two times depending on a communication
condition.
57
6.3 Service Code
The service code displayed in FI calibration tool and the service code displayed on the meter
are different in some.
Refer to the service manual to check the following service code comparison table for the
content of each service code.
58
Service code
Service
on the FI
code on the System Problems
calibration tool
meter
monitor
Secondary fuel injector #2 malfunction, wiring open or
129 4B FI
short
Secondary fuel injector #3 malfunction, wiring open or
130 4C FI
short
Secondary fuel injector #4 malfunction, wiring open or
131 4D FI
short
51 51 FI Stick coil #1 malfunction, wiring open or short
52 52 FI Stick coil #2 malfunction, wiring open or short
53 53 FI Stick coil #3 malfunction, wiring open or short
54 54 FI Stick coil #4 malfunction, wiring open or short
58 58 ETV ETV actuator malfunction, wiring open or short
94 94 FI Fuel supply system trouble
97 97 ETV Battery monitor voltage is low
98 98 ETV ECU/ETV circuit malfunction, wiring open or short
156 E8E FI IMU malfunction
157 E8F FI IMU communication error or wiring open
Copyright Notice
Microsoft Windows is a registered trademark of Microsoft Corporation.
Company names and product names are generally trademarks or registered trademarks of
respective companies concerned.
59
KAWASAKI HEAVY INDUSTRIES, LTD.
Motorcycle & Engine Company
Doc No. 99958-0630