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Discussion Starter #1
When I bought my Gen 4 back in Nov. I noticed that every once in awhile when I started the bike the red FI warning light would not go off. If I turned the bike off and restarted it the light would then go out. I was able to retrieve the error code and it's 39 which the service manual says is a ECU/CAN communication problem.

Once I restart the bike and the light goes off it never comes on again while riding. The problem has gotten worse this week and it happens almost every time I start the bike forcing me to shut it off and do the restart.

I finally took the bike to the dealer today and they checked all the wiring connections and nothing wrong was found. The dealer called the Kawasaki service support center in So Cal but they have never heard of the problem. The dealer will continue working with the service center next week but for now its a mystery and my 10 is stuck in the shop.

Has anyone out there heard of this problem? Any ideas??

Oh the bike was totally stock until a month ago when I added a Leo link-pipe and Servo Buddy. Adding these made no difference in the FI light issue. The bike runs perfect without any other problems even when the FI light is stuck on.

Thanks
 

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When I bought my Gen 4 back in Nov. I noticed that every once in awhile when I started the bike the red FI warning light would not go off. If I turned the bike off and restarted it the light would then go out. I was able to retrieve the error code and it's 39 which the service manual says is a ECU/CAN communication problem.

Once I restart the bike and the light goes off it never comes on again while riding. The problem has gotten worse this week and it happens almost every time I start the bike forcing me to shut it off and do the restart.

I finally took the bike to the dealer today and they checked all the wiring connections and nothing wrong was found. The dealer called the Kawasaki service support center in So Cal but they have never heard of the problem. The dealer will continue working with the service center next week but for now its a mystery and my 10 is stuck in the shop.

Has anyone out there heard of this problem? Any ideas??

Oh the bike was totally stock until a month ago when I added a Leo link-pipe and Servo Buddy. Adding these made no difference in the FI light issue. The bike runs perfect without any other problems even when the FI light is stuck on.

Thanks
I was told the servo buddy doesn't work well on the gen 4. what i would do is put the servo back on just to see if it goes away. have you gotten a reflash done yet?
 

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In the service manual is sais the following:

39 FI/S-KTRC ECU communication error

ECU Communication Error (Service Code 39)
ECU Communication Line Inspection
○When the data is not sent from the ECU to the meter unit
for more than about 10 seconds, the service code 39 is
displayed.
○The data is sent through the CAN communication line.
○The service code 39 is detected with the meter unit.
○When the user mode, this communication error blinks the
following items besides the FI warning symbol [A].
Power Mode and S-KTRC Symbols
Yellow Color LED [C]
•Inspect the CAN communication line resistance (see CAN
Communication Line Resistance Inspection in the Fuel
System (DFI) chapter).
If the CAN communication line resistance is normal,
check the wiring according following procedure.
•Remove the ECU and meter unit, check the wiring for
continuity between main harness connector.
○Disconnect the ECU and meter unit connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Inspection
ECU Connector [A] ←→ Meter Unit Connector
GY/BL lead (ECU terminal 27) [C]
LB lead (ECU terminal 28) [D]
If the wiring is good, check the meter unit (see Meter Unit
Inspection in the Electrical System chapter).
If the meter unit is normal, replace the ECU (see ECU
Removal/Installation).

Manual can be found on the site.
 

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I agree with Nameless; Older Guy was testing the servo buddies and they could never get one to work on the gen 4. Eventually, they gave up last I heard. Try reconnecting the servo motor and seeing if that solves it.


Another problem could be an issues with the ECU's circuit board; maybe some of the soldering went bad (which would explain why it got worse over time). I'd ask the dealer if they can switch out ECU's with another gen 4 on the floor and see if that solves it.
 

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I agree with Nameless; Older Guy was testing the servo buddies and they could never get one to work on the gen 4. Eventually, they gave up last I heard. Try reconnecting the servo motor and seeing if that solves it.


Another problem could be an issues with the ECU's circuit board; maybe some of the soldering went bad (which would explain why it got worse over time). I'd ask the dealer if they can switch out ECU's with another gen 4 on the floor and see if that solves it.
:+1: good point too. although it may just need a new ECU anyways. Kawi will do everything else before they come to that conclusion because it would be the most costly anyways.
 

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Discussion Starter #6
The dealer just did the resistance test and it tested out OK. I'll take the servo motor to the dealer in case they want to put it back on but since I told them the problem started back when the bike was brand new and all stock they are thinking it's not part of the problem.

I haven't done the reflash yet because I'm afraid it will void the warranty. With all the expensive electronics on this bike I bought the extended warranty so I'll probably not be able to get the reflash done for a long time.

If they figure out what the problem is next week I'll post it.

Thanks for the suggestions...
 

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Speed Freak
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did you get the recall performed on your bike for the rear wiring harness? Maybe something is shorting out?

Other than that cant think of to much.
 

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Discussion Starter #8
Yes Garth they checked my VIN in their computer and their records showed that the wiring recall work was done on my bike at the dealership before I bought it. I talked to the mechanic again and he said he was having problems doing the checks on the system because the service manual has some errors in the instructions. He called Kawi in So Cal and they acknowledged there are errors in the manual and they are preparing an amendment. They gave him the info on how to do the checks which he did and still nothing wrong was found. He's thinking eventually after Kawi can't figure it out, they will send a new ECU.

Thank you...
 

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Discussion Starter #10
Update-

All diagnostic tests were done and Kawi is unable to determine why the problem is occurring. Kawi authorized a new ECU so it's on order.
 

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Newfie Bullet
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ecu

The dealer just did the resistance test and it tested out OK. I'll take the servo motor to the dealer in case they want to put it back on but since I told them the problem started back when the bike was brand new and all stock they are thinking it's not part of the problem.

I haven't done the reflash yet because I'm afraid it will void the warranty. With all the expensive electronics on this bike I bought the extended warranty so I'll probably not be able to get the reflash done for a long time.

If they figure out what the problem is next week I'll post it.

Thanks for the suggestions...
I don't think its legal for them to void the warranty unless they can prove 100% that it was the flash that broke the bike..Don't quote me on that but it comes to mind based on a discussion I once had yrs ago..Go flash my friend GOOO FLASHH
Another way around is keep stocker ecu and buy 2nd ecu and flash that..
 

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In the US the Magnusson Moss act protects you from a voided warranty. The agent/dealer has to prove that what ever mod you made directly led to the failure. "If" they can do that then they can deny a warranty claim for that particular problem, but they can't void the entire warranty.
 

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Discussion Starter #13
OK you talked me into the Flash and maybe I can talk the dealer into giving me my old ECU when they replace it with the new one.
 

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OK you talked me into the Flash and maybe I can talk the dealer into giving me my old ECU when they replace it with the new one.
dont think they will GIVE you an ecu. usually they have to send that back to kawi.
 

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The dealer just did the resistance test and it tested out OK. I'll take the servo motor to the dealer in case they want to put it back on but since I told them the problem started back when the bike was brand new and all stock they are thinking it's not part of the problem.

I haven't done the reflash yet because I'm afraid it will void the warranty. With all the expensive electronics on this bike I bought the extended warranty so I'll probably not be able to get the reflash done for a long time.

If they figure out what the problem is next week I'll post it.

Thanks for the suggestions...
At least yours runs well all the time!.. Mine cuts back to three cylinders sometimes for no reason then clears out when I hit the stop/ start button. *see long thread on cylinder dropping our intermittantly... Mine throws No codes it just suddenly starts to fire on just three cylinders for a while.

Kawasaki definately has some wiring or ECU issues with their bikes!

<Speedy><
 

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Discussion Starter #16
Speedy14 that is a crazy problem. Is the dealer planning on fixing it?
 

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Discussion Starter #17
Update Jan 26th,

The dealer replaced the ECU and they said the problem was cured. I left the dealer and stopped for gas around the corner. When I started the bike the FI light stayed on and again error code 39 was back. So back to the dealer it went. They said the next step will be to replace the meters/speedo etc. Luckily Kawi sent my dealer a new ECU and a meter/speedo unit just in case the ECU wasn't the problem.

This is too weird. The new ECU did improve the problem because replacing it made the problem occur less frequently but it didn't cure it. I'll update when I get it back again...
 

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Update Jan 26th,

The dealer replaced the ECU and they said the problem was cured. I left the dealer and stopped for gas around the corner. When I started the bike the FI light stayed on and again error code 39 was back. So back to the dealer it went. They said the next step will be to replace the meters/speedo etc. Luckily Kawi sent my dealer a new ECU and a meter/speedo unit just in case the ECU wasn't the problem.

This is too weird. The new ECU did improve the problem because replacing it made the problem occur less frequently but it didn't cure it. I'll update when I get it back again...
I replaced the meter /guage. Did not make any difference whatsoever with my problem. Mine still will intermittently run on three cylinders for a short time. (But it also does not throw a code.) Evidently it has some sort of wiring harness issue. I will be making a formal complaint with Kawasaki soon! :BangHead:
 

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Discussion Starter #19
Update,

Well they replaced the meters and no luck, the error code still comes on. The dealer will call Kawi next week and they expect the next step to be a wiring harness replacement...
 

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Discussion Starter #20
Update 02/22/12-

Kawi authorized a new wiring harness and the dealer is installing it today. I'm keeping my fingers crossed that this fixes the problem because if it doesn't Kawi has no idea how to fix it.
 
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