Ninja ZX-6RR Ninja ZX-10R

Kawasaki FI Calibration Tool Instruction Manual

IMPORTANT
This manual provides how to change the fuel injection amount, sub-throttle opening, and ignition timing of the racing ECU for the 2003 Ninja ZX-6RR, 2004 Ninja ZX-6RR/ZX-10R, and 2005 Ninja ZX-6RR/ZX-10R. This manual instructs the dealing method briefly for the mechanic and being familiar with the personal computer (PC). As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-6RR and ZX-10R. ZX600-K1: P/No. 99924-1311-01 ZX600-M1: P/No. 99924-1333-01 ZX600-N1: P/No. 99924-1346-01 ZX1000-C1/C2: P/No. 99924-1322-01/02 AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE, IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS. THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE.

2005 Kawasaki Heavy Industries, Ltd.

First Edition (1) Jan. 24, 2005

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.

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.

Contents
1. KAWASAKI FI CALIBRATION TOOL OUTLINE ............................................. 6 1.1 SYSTEM FUNCTION ...................................................................................... 6 1.2 PERSONAL COMPUTER (PC) REQUIREMENT .................................................. 7 1.3 SYSTEM CONFIGURATION ............................................................................. 8 2. INSTALLATION PROCEDURE OF SETTING PROGRAM............................. 9 2.1 INSTALLING PROCEDURE .............................................................................. 9 2.2 FILE STRUCTURE ....................................................................................... 13 2.3 UNINSTALLING PROCEDURE ........................................................................ 14 3. OPERATING THE PROGRAM ..................................................................... 16 3.1 STARTING.................................................................................................. 16 3.2 EACH MAP EDIT METHOD ........................................................................... 19 3.2.1 Map Edit ............................................................................................ 19 3.2.2 Map Axis Edit .................................................................................... 23 3.2.3 Multi Map Edit ................................................................................... 25 3.2.4 Individual Value Edit .......................................................................... 27 3.3 CHANGING ECU DATA................................................................................ 30 3.4 OTHER FUNCTIONS .................................................................................... 34 3.4.1 Monitoring Function........................................................................... 34 3.4.2 Data Edit during Engine Operation.................................................... 36 3.4.3 Title Editor (Memo)............................................................................ 36 3.4.4 Default Directory Setting Function..................................................... 37 3.5 FILE SAVING .............................................................................................. 37 3.6 CHANGING THE TARGET MACHINE ............................................................... 38 3.7 NEW USABLE FUNCTIONS ........................................................................... 39 3.7.1 Plural Cells Data Selecting................................................................ 39 3.7.2 Plural Cells Data Copying ................................................................. 39 3.7.3 Plural Cells Data Changing Method .................................................. 40 4. MENU LIST .................................................................................................. 41 4.1 PULL DOWN MENU ..................................................................................... 41 4.1.1 File .................................................................................................... 41 4.1.2 Edit(E) ............................................................................................... 41 4.1.3 Monitor .............................................................................................. 41 4.1.4 Set..................................................................................................... 41 4.1.5 Window ............................................................................................. 42
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4.1.6 Help................................................................................................... 42 4.2 TOOL BAR (ICON)....................................................................................... 42 5. APPENDIX ................................................................................................... 43 5.1 CONNECTING METHOD ............................................................................... 43 5.1.1 05 ZX-6RR with Optional Meter and Racing Main Harness ............. 43 5.1.2 05 ZX-6RR with Original Meter and Standard Main Harness, Sub harness ...................................................................................................... 44 5.1.3 05 ZX-10R with Racing Main Harness ............................................. 45 5.1.4 05 ZX-10R with Original Meter and Standard Main Harness ............ 46 5.2 CAUTION ITEMS WHEN USING THE I/F BOX ................................................... 47 5.2.1 Caution when using the I/F Box ........................................................ 47 5.2.2 System Requirements of I/F Box....................................................... 47 5.2.3 Caution when communicating between Setting Tool and ECU.......... 47 5.3 TROUBLESHOOTING ................................................................................... 49

1. Kawasaki FI Calibration Tool Outline

1.1 System Function
Kawasaki FI Calibration Tool is developed to modify the mapping of the racing machine to gain operating conditions suitable for the course and the riders skill. The following are the available setting functions.
Table 1 FI Tool Function

Functions

Model Name Available Setting Range -30 % ~ +30 % -30 % ~ +30 % -30 % ~ +30 % -30 % ~ +30 % -10 % ~ +10 % -15CA~ +5CA -50 % ~ +50 % -45 % ~ +45 % -50 % ~ +50 % -30 % ~ +30 % -1000 ~ +300 rpm 0 ~ +400 rpm 0 ~ +300 rpm -1000 ~ +700rpm Use or Not Use

03 04 04 05 05 ZX-6R ZX-6R ZX-10 ZX-6R ZX-10 R R R R R -- -- --- --- - -- - -- --- -- - ---- -- - - - -- - - -- -- - --- -

1) Adjust the injected fuel rate at acceleration 2) Adjust the injected fuel rate of No.1 and No.4 cylinder 3) Adjust the injected fuel rate of No.2 and No.3 cylinder 4) Adjust the injected fuel rate of primary and secondary injector* 5) Adjust the ignition timing 6) Adjust the sub-throttle opening angle 7) Adjust the exhaust device opening angle 8) Adjust the all injected fuel rates of all operating area simultaneously 9) Adjust the value of engine over revolution limiter 10) Set the fuel cut or not at deceleration 11) Set the sub throttle controlled or not 12) Set the exhaust device controlled or not

Controlled or Full Open Fixed Controlled or Full Open Fixed Controlled or not, 13) Set the Auto Shifter set Ig. Cut Time by Ignition Cut Length gear range Controlled or not, 14) Set the Pit Road RPM set Upper Limit Limit RPM by gear range Note: mark shows the model has the function.

Note: * +: primary injector rate down and secondary injector rate up. -: primary injector rate up and secondary injector rate down. Note: CA shows rotating angle of crankshaft.

1.2 Personal Computer (PC) Requirement

The Kawasaki FI Calibration system operates on a Personal Computer (PC) having a serial communication port with the racing electronic control unit (ECU) on the motorcycle through an interface box (I/F Box). Table 2 PC Requirement Items Operating System CPU Memory Hard Disk Drive Display Resolution Port Connector Other Recommendation Windows XP (US version, Japanese version) Pentium 150 MHz or faster 64 MB or more 2 MB or more of free space 1024 x 768 pixels or more, more than 256 colors RS232C (D-sub 9 pin), I/F Box cable can be connected to COM 1 ports Equipped with a mouse or a pointer equivalent to mouse NOTE

Even if the recommended PC is used, the Kawasaki FI Calibration Tool program could not operate correctly depending on the other applications installed to the PC.

If your PC does not equip 9-pin connector, use a suitable USB-RS232C adapter. Some adapter cannot be communicated correctly depending on its specification.

1.3 System Configuration

The Kawasaki FI Calibration tool kit consists of (1) Racing ECU, (2) Racing Main Harness or Standard Harness plus Racing Sub-harness, (3) I/F Box, and (4) Setting Program. The Setting Program must be installed to your PC.

(4) Setting Program installed to your PC

(1) ECU

Connector for Tool Kit (6P)

Serial Cable (RS-232C, 9P) (3) I/F Box (2) Harness

Fig. 1 Setting Tool Connection Table 3 Setting Tool for 2005 Model ZX-6RR
Meter Type (1) ECU (2) I/F Box (3) Harness

ZX-10R

(4) Shift SW

Optional Optional Original Meter Original Meter Meter Meter Racing ECU P/No. 21175-0074 Racing ECU P/No. 21175-0073 Racing I/F Box: P/No. 26031-0025 or 26031-0240. Whichever is available Racing Main Racing Racing Main Racing Main Harness Harness Harness Main Harness 26031-0328 26031-0325 26031-0328 26031-0326 plus plus Sub-harness Racing Sub-harness 26031-0308 Sub-harness 26031-0307 or 26031-0327 plus Racing Sub-harness Std. Main Harness 26031-0244 26031-1058 Plus Std. Main Harness 26031-1058 Contact type of SW can be used. --Recommend the Shift Sensor made by Battle Factory or Dynajet.

(5) Setting CD or FD Program NOTE: The detail of connecting method is shown in section 5.1.

2. Installation Procedure of Setting Program

Program files will be supplied to users through Internet from kawasakidirect. Download the Software Kawasaki FI Calibration. EXE to your PC and uncompress to suitable folder NOTE Before installing the new Setting Program to the PC in which old version Program is installed, save the old est files as back-up and then un-install the previous Program.

2.1 Installing Procedure

(1) Execute Setup.exe to start the Setup program. (2) Then the screen shown in Fig. 2 appears.

Fig. 2 Setting Screen of Setup Program Click Next to install the Program. Click Cancel to stop installing procedure. (3) The Product License Agreement screen shown in Fig. 3 appears.

Fig. 3 Product License Agreement

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Click Agree when you agree to the Product License Agreement. Click Not agree when you do not agree to the Product License Agreement. Then the installing procedure is stopped. (4) Next the Serial Information screen shown in Fig. 4 appears. Enter the information in both columns.

Fig. 4 User Information Registration / Authentication (Sample) The Serial No is informed to you from the dealer. The default settings of User Name and Serial No are vacant. If you omit any of them, Next button is grayed out. When the Serial No is wrong, an error message shown in Fig. 5 appears on the screen. Input the correct Serial No in the column.

Fig. 5 Error Message Click Next to install the Program. Click Cancel to stop the installing procedure.

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(5) The destination folder selection screen shown in Fig. 6.appears.

Fig. 6 Choosing Destination Folder Choose the destination folder. The default setting is C:Program FilesRACE FI-Tool. If you want to install the Program to another folder, click the Browse button to display the Choose Folder screen shown in Fig. 7. Then choose the folder.

Fig. 7 Choose Folder Screen

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Click Install to start the installing procedure. Click Cancel to stop the installing procedure. (6) After the Kawasaki FI Calibration Tool program is installed, the Setup finish screen shown in Fig. 8 appears.

Fig. 8 Setup Finish Screen If the destination folder has a file that has the same name of the file to be copied and whose time stamp is newer than that for the file to be copied, the message screen shown in Fig. 9 appears and the file cannot be copied. However, the installing procedure is normally finished because the destination folder has the new data file with newer time stamp.

Fig. 9 Message Dialog when overwriting was not performed (7) Click OK button to finish the setup. After the setup is finished, the shortcut icon for Kawasaki FI Calibration Tool program is registered on both the Desktop and the Start Menu. Click Cancel during the setup operation to quit the setup.

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2.2 File Structure

Files to be copied into a destination folder FI_Tool.exe FI_Tool.bmp FI_Tool FC.bmp MCN_LIST.DAT Setup.exe Uninstall file for execution Program file 256-color splash screen file Full-color splash screen file

Files to be copied into the ZX600K folder under the destination folder. FI_Tool.ini FI_Tool.stz Standard_data.est Setting file for FI_Tool.exe of ZX600K ZX600K Configuration File Data file for only ZX600K

Files to be copied into the ZX600K Work Folder

Files to be copied into the ZX600M folder under the destination folder. FI_Tool.ini FI_Tool.stz Standard_data.est Setting file for FI_Tool.exe of ZX600M ZX600M Configuration File Data file for only ZX600M

Files to be copied into the ZX600M Work Folder

Files to be copied into the ZXT00C folder under the destination folder. FI_Tool.ini FI_Tool.stz Standard_data.est Setting file for FI_Tool.exe of ZXT00C ZXT00C Configuration File Data file for only ZXT00C

Files to be copied into the ZXT00C Work Folder

Files to be copied into the ZX600N folder under the destination folder. FI_Tool.ini FI_Tool.stz Standard_data.est Setting file for FI_Tool.exe of ZX600N ZX600N Configuration File Data file for only ZX600N

Files to be copied into the ZX600N Work Folder

Files to be copied into the ZXT00C2 folder under the destination folder. FI_Tool.ini FI_Tool.stz Standard_data.est Setting file for FI_Tool.exe of ZXT00C2 ZXT00C2 Configuration File Data file for only ZXT00C2

Files to be copied into the ZXT00C2 Work Folder

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2.3 Uninstalling Procedure

Uninstalling operation can be executed on the Add/Remove service application in the Control Panel. (1) Open the Control Panel screen from My Computer or Explorer screen.

Fig. 10 Control Panel Screen Then click the Add/Remove icon. (2) Add/Remove Programs Properties screen appears.

Fig. 11 Add/Remove Programs Properties screen

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Click FI Calibration Tool and then click Add/Remove to start the Setup program. (3) The screen shown in Fig. 12 appears.

Fig. 12 Uninstall Starting Screen Click Yes to start the uninstalling procedure. (4) After the uninstallation is completed, Uninstall Completion screen shown in Fig. 13 appears.

Fig. 13 Uninstall Completion Screen If you tried to delete the program but you couldnt do it due to some reason (ex. the program is starting), the message shown in Fig. 14 appears. In such case, delete the files remaining in the screen folder by yourself.

Fig. 14 Message Dialog when some files were not deleted (3) Click OK button to complete the uninstalling procedure. In this step, setup.exe is left in the FI Calibration Tool folder, but it will be deleted when you start the PC next time. NOTE
When restarting after uninstallation is finished, the DOS window may remain

open. (It occurs on Windows98.) At that time close the window by yourself.

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3. Operating the Program

3.1 Starting
(1) Double-click the shortcut icon Kawasaki FI Calibration Tool on the Desktop screen or click the Kawasaki FI Calibration Tool in Program Menu on Start Menu. (2) Then Machine Select screen shown Fig. 15 appears.

Fig. 15 Machine Select Screen Click the target machine name, then click OK button or press Enter key. If you want to stop, click Cancel button. (3) The initial screen shown in Fig. 16 appears.

Pull down File menu

Fig. 16 Initial Screen

It starts to load the data file (EST file) to be edited on the initial screen. Go to the pull-down File menu and select Open, or click the FileOpen icon (left end) on the toolbar.

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(4) The Open dialog shown in Fig. 17 appears.

Fig. 17 Open Dialog Click the data file to be edited in the Open dialog screen. The selected data file name is shown in the File name. Then click the Open button. (4) The Menu dialog screen shown in Fig. 18 appears.

Fig. 18 Menu Dialog (in case of ZX1000-C2) Select the mode to be edited in the Menu dialog. The modes that can be used are as follows:
<MAP EDIT> MODE (IN CASE OF ZX1000-C2)

In this Mode you can edit the Compensations below. Click one Label in the Menu dialog and click the OK button or Enter (Return) button, or double click one Label, to display the Map Edit screen. Compensation for Acceleration: Regulates the rate of fuel injection at acceleration Comp. Map for Injection No.1: Regulate the rate of fuel injection at normal operation (For the #1 and #4 cylinders) Comp. Map for Injection No.2: Regulate the rate of fuel injection at normal operation (For the #2 and #3 cylinders) Comp. Map for Injection Rate: Regulate the rate of primary and secondary fuel injection
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Comp. Map for Spark Advance: Regulate the ignition timing Comp. Map for Sub Throttle: Regulate the sub-throttle opening
Comp.Map for Exhaust Valve: Regulate the exhaust valve opening Pit Road Limit RPM (05 ZX-10R only): Regulate the pit road limit RPM Auto Shifter Ignition Cut Length (05 ZX-10R only): Regulate the ignition cut length at auto shifting Extra Shift Indicate RPM (05 ZX-10R only): Regulate the shift indicate RPM (for optional meter) <SETTING VALUES EDIT> MODE

In this Mode you can edit the eight Values below. Click the Constants list button to display the Setting Values Edit screen. All Area Fuel Compensation Value: Regulate the rate of fuel injection for all operating ranges OverRev. shift Value: Regulate the off-set value from the standard OverRev Limiter Select Fuel Cut [Use: 0 / Not Use: 1]: Set the fuel-cut at deceleration Select Sub-throttle [Controlled: 0 / Full Open Fixed: 1]:
Set the sub throttle control Select Exhaust Valve [Controlled: 0 / Full Open Fixed :1]: Set the exhaust valve control Select Auto Shifter [Use: 0 / Not Use: 1]: Set the auto shifter control. Select Pit Road RPM Limit [Use: 0/ Not Use: 1]: Set the pit road RPM limit control. 05 ZX-10R only Select Extra Shift Indicator [Use: 0 / Not Use: 1]: Set the shift indicator control. 05 ZX-10R only Set when option meter is equipped.

<ECU Data Exchange> Mode

Click the Data Exchange button in the Menu dialog to display the Data Exchange screen. Click this button when you want to load the data in the ECU or write the edited data in the ECU.

<Multi Map Edit> Mode Click the Multi Map Edit button in the Menu dialog to display the Multi Map Edit screen. The Multi Map Edit can be used for the Comp. Map for Injection No.1 and No.2 and map edit for all cylinders can be carried out at the same time.

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3.2 Each Map Edit Method

3.2.1 Map Edit
Select one Label in the Menu dialog and click the OK button or the Enter (Return), or double click one Label to display the Map Edit Screen shown in Fig. 19.

Label

Fig. 19 Menu Dialog (in case of ZX600M) In the Map Edit Screen, the Map to be edited will be displayed as the two-dimensional graph (GRAPH) and the table (TABLE).
Tool bar Map switching button Map Z-axis switching button Z-axis: throttle opening angle (%)

Cursor Point
GRAPH Area

1. Select point with mouse or arrow keys. 2. Move using mouse or arrow keys.

TABLE Area

1. Select a cell by mouse or arrow keys mouse. 2. Input value or move the value by arrow key.

Fig. 20 Map Edit Screen (Compensation Map for Injection No.1 is shown as a sample.)

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NOTE
If you closed the GRAPH or TABLE, open the Menu dialog on the Menu button of

the Tool bar and select the subject Map.

If you switched the subject Map using Map switching button, only the display

switches. When editing the subject Map, switch the Map by selecting the editing point of the Graph or Table area of the subject Map. Data Edit can be carried out either in the GRAPH or TABLE area and the editing method for each area is as follows: [Editing method on the GRAPH area] Click a point on the graph to select the graph and the editing point of the engine rpm that is the nearest position to the clicked point. Drag & drop of the graph data: Press down the left button of the mouse to select the editing point. After that, move the editing point up or down. Then, the data will be changed to the possible setting value nearest to the release point. (The direction of the engine rpm cannot be changed.) Key allocation when a point on the line is selected (or {Shift} + ): Switches the selected point to the right-side rpm (or {Shift} + ): Switches the selected point to the left-side rpm (or {Page Up}): Increases the graph data by an LSB* at the selected point (or {Page Down}): Decreases the graph data by an LSB at the selected point {Shift} + (or {f2}): Switches the selected graph area (line number ) to another (Active row is moved down in the TABLE) {Shift} + (or {f3}): Switches the selected graph area (line number) to another(Active row is moved up in the TABLE) LSB*:
Least Significant Bit

[Editing on the TABLE area] Each value on the table can be directly edited by selecting the cell with mouse and putting value by key strokes. The values in the data are always changed to the nearest values that are possible to set. The values in the CPU are managed in hexadecimal data. Key allocation when a cell in the table is selected {Shift} + : Switches the selected cell to the right-side rpm {Shift} + : Switches the selected cell to the left-side rpm {Shift} + : Switches the selected cell to the upper-side cell {Shift} + : Switches the selected cell to the lower-side cell
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{Page Up}: Increases the selected point by an LSB* {Page Down}: Decreases the selected point by an LSB {Enter}: Defines data {Ctrl} + {Shift} + arrow: Switches the selected cells to the arrow direction LSB means Least Significant Bit.

Line 6.3 is now selected.

Cursor Point

Line 6.3 data The Line on which cursor exist is shown in bold.

Line 6.3

Cursor Point Fig. 21 Map Edit Screen (Compensation Map for Injection No.1 is shown as a sample.)

The available setting value is restricted within the following ranges (in case of ZX1000-C2). Compensation for Acceleration: from -30 % to +30 % Comp. Map for Injection rate and No.1/No.2: from -30 % to +30 % Comp. Map for Spark Advance: from -15CA to +5CA* Comp. Map for Sub Throttle: from -50% to +50%
Comp.Map for Exhaust Valve: from -50% to +50% Pit Road RPM Limit: from 1000 to 5000 rpm, when pit road limit SW is ON. Auto Shifter Ignition Cut Length: from 0 to 150 ms, when auto shifter control is operated. Extra Shift Indicate RPM: adjust the shift indicator lighting RPM within 10,000 and 15,000 rpm. This function is operated when the optional meter is equipped. *CA: crankshaft rotating angle.

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If a value out of the range is entered on the graph or table, the error message shown in Fig. 22 will appear and the available maximum or minimum value will be set.

Fig. 22 Error Message

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3.2.2 Map Axis Edit

In the TABLE area the axis data (Engine Revolution and Throttle Opening) can be edited by keying in the data directly after selecting the cell by mouse or keystrokes. The data is always exchanged to the nearest available setting value.

Axis data of Engine Revolution

Axis data of Throttle Opening

Fig. 23 Map Axis Editing (Original Axis Data)

Fig. 24 Map Axis Editing (Sample Screen After Changing the Axis Data)

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NOTE
The data of engine revolution must be set in a value always larger than the

left neighbor value and smaller than the right neighbor. If a value out of the available range is input, the data will be rounded within the available range.
The data of throttle opening must be set in a value always larger than the

upper neighbor value and smaller than the lower neighbor. If a value out of the available range is input, the data will be rounded within the available range.
If a value out of the available range is input to both ends of the axis data, the

error message will appear and the maximum or minimum available setting value will be set.
The axis data is applied to the all map simultaneously. Be caution that the

changed axis data is applied to other maps.

You cannot change the axis data at the Compensation for Acceleration

screen.
When you move from an Axis Data cell of Throttle Opening to a cell of

adjusting data by key operation, the cell of the adjusting data line before editing the Axis Data will be selected.

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3.2.3 Multi Map Edit

The Multi Map Edit can be used for the Comp. Map for Injection No.1 and No.2 and map edit for all cylinders can be carried out at the same time. Click the Multi Map Edit button in the Menu dialog

Fig. 25 Menu Dialog Screen Then the Multi Map Edit dialog shown in Fig. 26 appears.

Fig. 26 Multi Map Edit dialog Click the OK button to display the Multi Map Edit screen. The method of Multi Map Edit is the same as written above. Quit the Multi Map Editing Mode
Click the Individual Edit button in the Multi Map Edit dialog to quit the Multi Map editing mode and display the Map Edit screen set for the #1 Map. Or, click a Map menu other than the Multi Map in the Menu dialog to display the Map Edit screen for the selected Map.

Fig. 27 Multi Map Edit dialog

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CAUTION
Never edit the Multi Map setting by selecting the axis data in the Table editing area, or the axis data could be broken and the program could close.
NOTE
When selecting Multi Map editing mode, #2 Map data is overwritten with the

#1 Map data.
When both the Map area and Data area are closed in the Multi Map editing,

the Multi Map edit mode is automatically quitted.

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3.2.4 Individual Value Edit

In this Mode you can edit the four Values. Click the Constants list button on the Menu Dialog to display the Setting Values Edit screen.

Fig. 28 Menu Dialog Screen Then Fig. 29 appears.

Decimal data entry and display screen

Move with shift key arrow key

Fig. 29 Edit Constants List Screen for ZX1000-C2 <Setting Items: in case of ZX600N> The editable items in the Constants List are as follows: All Area Fuel Compensation Value: can be set in the range from 30 % to + 30 % (applied to all cylinders) OverRev shift Value: set the off-set value from the standard Over Rev Limiter, can be set in the range from 0 rpm to +300 rpm Select Fuel Cut: set the Yes or Not of Fuel Cut at decreasing the speed Select Exhaust Valve: set the Yes or Not of Exhaust Valve control

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<Setting Items: in case of ZX1000-C1/C2> The editable items in the Constants List are as follows: All Area Fuel Compensation Value: can be set in the range from 30 % to + 30 % (applied to all cylinders) OverRev shift Value: set the off-set value from the standard Over Rev Limiter, can be set in the range from 1,000 rpm to +700 rpm (ZX1000-C1 cannot be set this value.) Select Fuel Cut: set the Yes or Not of Fuel Cut at decreasing the speed Select Exhaust Valve: set the Yes or Not of Exhaust Valve control
Select Auto Shifter: set the Yes or Not of Auto Shifter control (ZX1000-C2 only) Select Pit Road RPM Limit: set the Yes or Not of Pit Road RPM control (ZX1000-C2 only) Select Extra Shift Indicator: set the Yes or Not of Extra Shift Indicator control (ZX1000-C2 only)

Key allocation when a cell in the table is selected {Shift} + : Switches the selected cell to the upper-side cell {Shift} + : Switches the selected cell to the lower-side cell {Page Up}: Increases the selected point by an LSB {Page Down}: Decreases the selected point by an LSB {Enter}: Defines the data
Input the value and press Enter.

Fig. 30 Edit Constants List (Setting Data Sample)

The setting values are shown in a table and each value can be directly edited by selecting the cell with mouse and putting value with keystrokes. The values in the data are always changed to the values nearest available setting values.

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If a value out of the range is put in the table, the error message shown in Fig. 31 will appear and the nearest available value will be set.

Fig. 31 Error Message NOTE

The total Fuel Compensation Value is limited within -30% to +30% range of the

original setting for fuel injection quantity. If the total value of [All Area Fuel

Compensation Value] multiplies [Compensation for Acceleration] or [Comp. Map for Injection No.1(No.2)] exceeds the limit, the total Fuel Compensation Value is set to 30% or +30%.
[Example] Comp. Map for Injection No.1 (or No. 2): 20% up All Area Fuel Compensation Value: 30% up 1.20 x 1.30 = 1.56, 1.56 > 1.30 So, Total Compensation Value = 30 % up Total Compensation Value 56 % up
When the Fuel Compensation Value is 0 %, the fuel injection quantity is controlled by

the Base Map. And the Base Map is calculated by water temperature, air temperature, intake air pressure, throttle position, altitude pressure, and etc.
The intermediate values of the Map are calculated linearly.

CAUTION
When changing the Map, change the values gradually by checking the

engine condition or measuring the Air/Fuel ratio.

Always select Fuel Cut=0 when your motorcycle is equipped with

catalyzer. If you failed, the muffler could burn out and break down.
When removing the exhaust valve actuator, set the Select Exhaust Valve

=1(Full Open Fixed) (1) The Side Stand Switch function does not operate. Be caution at running when equipping the side stand.

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3.3 Changing ECU Data

The racing ECU has two kinds of memory called ROM and RAM. So, there are two data exchange methods. ROM: Read Only Memory. Non-Volatile Memory. The content in the memory is held even if the power source is turned off. RAM: Random Access Memory. Volatile Memory. The content in the memory is deleted when the power source is turned off. The CPU can read the content from the memory and write content into the memory. (1) ROM data exchange: All data can be exchanged collectively and it takes about one and a half minutes. Even if the Ignition switch turns off the data will not be erased. But the data cannot be exchanged when the engine is running.
(2) RAM data exchange:

The data can be exchanged when the engine is running, but the data is erased when the Ignition switch turns off.

ECU Memory
ROM

Personal Computer
Temporary Memory

Write/Read/Verify
RAM File Data Edit Data

Write Only (by shift + return operation)

Fig. 32 The Data Flow between ECU and PC

Click the Data Exchange button in the Menu dialog

Fig. 33 Menu Dialog

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Then the Data Exchange screen shown in Fig. 34 appears.

Fig. 34 Data Exchange Screen In the Data Exchange screen, you can read, write and verify the data among the ECU data edit data and file data. The operation contents are shown on the screen step by step.

Fig. 35 Data Exchange Screen The use and operation for each button is as follows: [Read] Click this button to read the data into the PC memory. (Essential operation) You can read data from the following three data sources: Read from ECU Data: read the ECU data into the PC memory (when Monitor is in the Start condition, the display is grayed out.) Edit Data: read the editing data into the PC memory File Data: read the (*.EST) data into the PC memory

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[Write] Click this button to write the read data of the PC operating memory into the ECU or memory in PC. At this time it is necessary that ignition switch is ON but engine is not running. Write Data ECU: write the data into ECU (when Monitor is in the Start condition, the display is grayed out.) Edit: write the data into the editing area as editing data NOTE
After writing the data into the ECU, confirm the data to be written in is the

same with the data in the ECU by using the Verify function. The data may be written into the ECU incorrectly according to the communication conditions.
The usable number of writing into the ECU is 65,500 times. If it exceeds the

limited number, error message of NOT Writing will appear. At that time replace with a new one.
Be caution, if you select Edit, the present editing data can be lost. Write the data into ECU after confirming that the Ignition is turned on and the

fuel pump and sub throttle valve are stopping. CAUTION After writing the data into the ECU, wait until the fuel pump and the sub throttle valve stops. Then execute next operation or turn off the ignition switch. [Verify] Click this button to select the data to be compared with the read data. Compare with : ECU Data: (when Monitor is in the Start condition, the display is grayed out.) Edit Data File Data (*.EST) When the read data is same as the selected data, Same appears on the status indication area, and when they are different, Not same appears. NOTE
Verify the data with the ECU data after confirming that the Ignition is turned

on and the fuel pump and sub throttle valve are stopping.

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CAUTION After verifying the data, wait until the fuel pump and the sub throttle valve stops. Then execute next operation or turn off the ignition switch. [Clear] Click this button to clear the data exchange area on the PC. [Close]
Click this button to finish the data change (clear the operating memory) and close the Data Exchange screen.

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3.4 Other Functions

3.4.1 Monitoring Function
In this mode, the data inside the ECU can be displayed during engine operation. Go to the pull down Monitor menu and select Monitor or click Monitor icon on the toolbar. The Monitor dialog shown in Fig. 36 appears. (This window can be resident)

Fig. 36 Monitor Dialog Click Start key to start displaying. When display starts, the key name will change to Stop. When the Stop key is pressed during exchange process, the key name will change to Start. Pressing Enter key can change the screen from Monitor dialog screen to Main Window. To set the data inside the ECU, which can be monitored from the Monitor dialog, go to the pull down Monitor menu and select Item set, or click Set Item icon on the toolbar. After the dialog shown in Fig. 37 appears, select the item that you want to set.

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Add/delete the items to be output on the monitor display

Items list

Items to be output on the monitor

Fig. 37 Item Setting Dialog Setting Monitor dialog items >>[A]: Add items selected from the list to the Monitor Dialog Item area <<[D]: Delete items from the Monitor Dialog Item area Details of monitoring items are as follows (in case of ZX600M): Comp_Asynchronous Injection: ECU calculating result in the running condition at monitoring based on the setting value of Compensation for Acceleration Comp_Injection Pulse #1 and Comp_Injection Pulse #4: ECU calculating result in the running condition at monitoring based on the setting value of Comp. Map for Injection No.1 (#1/#4: No.1/No.4 Cylinder) Comp_Injection Pulse #2 and Comp_Injection Pulse #3: ECU calculating result in the running condition at monitoring based on the setting value of Comp. Map for Injection No.2 (#2/#3: No.2/No.3 Cylinder) Comp_Spark Advance Value: ECU calculating result in the running condition at monitoring based on the setting value of Comp. Map for Spark Advance Comp_Sub Throttle Value: ECU calculating result in the running condition at monitoring based on the setting value of Comp. Map for Sub Throttle Engine Speed: Engine Speed at monitoring Intake Air Temperature: Intake Air Temperature at monitoring Throttle Position: Throttle Opening at monitoring Water Temperature: Water Temperature at monitoring

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Pit Road SW [OFF:0/ON:1]: Condition of Pit Road RPM Limit SW at monitoring When Select Pit Road RPM Limit is set 0 (Used), you can monitor. (ZX1000-C2 only) Shifter SW [OFF:0/ON:1]: Condition of Shifter SW at monitoring When Select Auto Shifter is set 0 (Used), you can monitor. (ZX1000-C2 only)

3.4.2 Data Edit during Engine Operation

You can reflect the Map and edit contents for each setting in the ECU during engine operation. Data editing method is the same as shown above. [Exchanging edit data during engine operation] After data editing, press the Shift + Return keys to reflect the edit data in ECU. NOTE
Data can be communicated to the ECU by one point (cell). The reflected data is effective only during engine operation. (It cannot be saved in

the ECU.) Be sure to save the edit data.

Map Axis data cannot be edited. When editing Map Axis data, use the Data

Exchange function.

3.4.3 Title Editor (Memo)

You can record the title (memo) for each edit data. Go to the pull-down Set menu to select Title. The Title Editor dialog appears. You can set the mode with the mouse and directly edit the data with keystroke.

Fig. 38 Title Editor Dialog

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3.4.4 Default Directory Setting Function

In this mode, you can set the default folder when File Open is carried out. Go to the pull down Set menu to select Directory. The Directory dialog shown in Fig. 39 appears. Directly enter the folder name by keystroke or use the Browsing function in the folder search dialog to select the folder from the existing folders. Use the full path name to write in the File Path.

Fig. 39 Directory Dialog

3.5 File Saving

You can save the data. After editing the Map, click File and next click Save.button Put the name in the column and then click the Save button. NOTE
The file extension is .est. When saving the extension is attached automatically. If you change the extension, you cannot open the file. When saving the data you can record the title (memo). Refer the 3.4.3 section.

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3.6 Changing the Target Machine

You can change the editing data according to the target machine. To change the target machine, go to the pull down Set menu and select Machine Select. Then the dialog shown in Fig. 40 appears.

Fig. 40 Machine Select Dialog After you select the machine that you want to set by mouse operation or key operation, click OK button or press Enter (Return) key. Then the machine change
confirming dialog shown Fig. 41 appears.

Fig. 41 Machine Change Confirming dialog Clicking OK button or pressing Enter key can change the target machine from next starting.
NOTE
Selecting Cancel button in the Fig. 40 or Fig. 41 cannot execute the machine

changing.

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3.7 New Usable Functions

3.7.1 Plural Cells Data Selecting
You can select the plural cells. This is useful when copying the data to excel file or changing the data simultaneously. (See Fig. 42). Select the start point [Click (Left button)], and select the end point [{Shift} + Click (Left button)] or [{Shift} + {Ctrl} + arrow key]

1. Click Left button

2. {Shift} + Click Left button

or {Shift} + {Ctrl} + arrow key

Fig. 42 Data Selecting Method

3.7.2 Plural Cells Data Copying

You can copy the selected data to Microsoft Excel file by using Microsoft Windows clipboard. Copy: {Ctrl} + {C} or [Pull down menu] [Edit] [Copy] Paste: {Ctrl} + {V} or [Pull down menu] [Edit] [Paste] FI Calibration Tool

Microsoft Excel sheet

Copy: {Ctrl} + {C} Paste: {Ctrl} + {V}

Fig. 43 Data Copying Method

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3.7.3 Plural Cells Data Changing Method

You can change the value of plural cells simultaneously. Directly input the value + {Enter} or press {Page Up} / {Page Down} key.
One {Page Up} increases 0.78 points and one {Page Down} decreases 0.78 points. FI Calibration Tool

input value, ex.(5) + {Enter}. or {PageUp} / {PageDown}

Fig. 44 Data Changing Method

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4. Menu List
4.1 Pull down Menu
4.1.1 File
Open Close Save Menu Exit F1 Alt + F4 Ctrl + O Loads data file Closes the loaded file. Names the file and saves it. Displays the Menu dialog. Finishes FI_Tool

4.1.2 Edit(E)
Undo Copy Paste Multi Map Edit Individual Edit Ctrl + Z Ctrl + C Ctrl + V Cancels the data edit. Temporarily saves the data in cell(s) into clipboard Paste the data in the clipboard. Displays the Multi Map Edit setting dialog. Finishes the Multi Map Edit.

4.1.3 Monitor
Monitor Start Stop Item set Displays the Monitor dialog. Starts the Monitor Exchange Finishes the Monitor Exchange Displays the Monitor Item Setting Dialog

4.1.4 Set
RS232C Title Constants list Data Exchange Directory Machine Select Displays the RS232C setting dialog Displays the Title setting dialog Displays the Constants list setting dialog Displays the Data Exchange setting dialog Displays the Directory setting dialog Displays the Machine Select dialog

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4.1.5 Window
Open Cascade Title All Monitor Dialog MAP-***** TABLE-***** Opens Map or Table window Cascades two or more windows Titles two or more windows Switches the graph mode on the Map screen between All and Single Moves the cursor to the Monitor dialog Displays the active windows list Displays the active windows list

4.1.6 Help
Tool box About Kawasaki Calibration Tool Displays the tool box dialog FI Displays the Version dialog.

4.2 Tool Bar (Icon)

Fig. 45 Tool Box Dialog

Explanation from the left side y Open the file (File - Open) y Save the file (File - Save) y Open the Menu dialog (File - Menu) y Copy (Edit - Copy) y Paste (Edit - Paste) y Undo (Edit - Undo) y Open the multi edit dialog (Edit - Multi Map Edit) y Open the Monitor dialog (Monitor - Monitor) y Open the Set Monitor Data dialog (Monitor - Item set) y Open the Data Exchange dialog (Set - Data Exchange) y Open the Constants list dialog (Set - Constants list)

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5. Appendix
5.1 Connecting Method
5.1.1 05 ZX-6RR with Optional Meter and Racing Main Harness
When installing the Racing Main Harness, refer the Race Kit Manual of ZX600-N1 (P/No. 99929-1868-01).

Fig. 46 Connecting Method (1) Replace the ECU with Racing ECU.
(2) Replace the Standard Main Harness with Racing Main Harness. (3) Connect the connector of I/F Box to the connecting port [2] of ECU [1].

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5.1.2 05 ZX-6RR with Original Meter and Standard Main Harness, Sub harness
(1) Replace the ECU with Racing ECU. (2) Connect the Sub-harness connectors to the diagnosis line of Main Harness. (3) Insert the two leads of Sub-harness to the ECU connector as shown.
ECU Racing Sub harness Standard main Harness I/F Box harness Connect Sub-harness to the diagnosis line of Main Harness. White/Green lead of Sub-harness Red lead of Sub-harness Insert the White/Green lead Insert the Red lead

Fig. 47 Connecting Method

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(4) When inserting the leads, follow the method [A] and [B] shown below, or the edge of the lead could damage the rubber seal inside connector.

Fig. 48 Inserting Method of Leads

5.1.3 05 ZX-10R with Racing Main Harness

Connecting method (1) Remove the Standard Main Harness and install the Racing Main Harness (P/No. 26031-0328). (2) Replace the standard ECU with Racing ECU (P/No. 21175-0073). (3) Connect the 6-pin connector of I/F Box to the 6-pin connector of Racing Main Harness (4) Connect the 12-pin connector of Sub-harness* to the 12-pin connector of Racing Main Harness * P/No. 26031-0307 is used for Optional Meter. * P/No. 26031-0308 is used for Standard Meter. (5) Connect other leads according to the ZX-10R Race Kit Manual (P/No. 99929-1870).

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5.1.4 05 ZX-10R with Original Meter and Standard Main Harness

When replacing the ECU, refer the Service Manual of ZX1000-C1/C2. (1) Replace the original ECU with Racing ECU. (2) Insert the Racing Sub-harness between Racing ECU and Standard Main Harness. (3) Connect the connector of I/F Box to the connecting port of Racing Sub-harness.

Fig. 49 Connecting Method

1. ECU 2. Racing Sub-harness 3. Connect to the I/F Box. 4. Bullet Terminal (4) Pull off the #22 pin (red/green lead) from the ECU connector of the Standard Main Harness. ( mark shows the #22 pin, and X marks show no pin.) Then install the bullet terminal in the packing of the Racing Sub-harness and connect it to the bullet terminal of the Sub-harness.

Fig. 50 View from Main Harness Connector

(5) Connect the Pit Road RPM Limit SW to the Clutch SW connector and connect the Shifter SW to the Side Stand SW connector. Refer the ZX-10R Race Kit Manual (P/No. 99929-1870) to connect other leads.

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5.2 Caution Items when using the I/F Box

5.2.1 Caution when using the I/F Box
1. When connecting/detaching the I/F Box to/from the connector of the motorcycle, keep the ignition switch turned off. 2. Do not use the I/F Box except setting usage of the motorcycle ECU.. 3. Never connect the I/F Box with connectors other than the specified connectors. 4. Never run the motorcycle with I/F Box and the PC connected to the ECU. 5. Install the connector for the terminal protection in the motorcycle connector, except when you connect the setting tool. 6. Never use the I/F Box near the place where a strong magnetic field, such as near the televisions and the radios, is generated and static electricity is generated. 7. Do not touch the terminal of the I/F Box connector directly, and do not keep the I/F Box in the place where static electricity is generated.

5.2.2 System Requirements of I/F Box

(1) Rated Voltage: 12 V (2) Operation Voltage: 8 ~16 V (3) Ambient Temperature: 5 ~ 35C

5.2.3 Caution when communicating between Setting Tool and ECU

Confirm the serial communication port of PC before using the setting tool. It is necessary to match the communication port of the setting tool with the PC side. (1) Confirmation method of the communication port Open the Property of the System and check the serial port in the device manager. Correct serial port is COM1.

Fig. 51 Device Manager of System Property

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When ? mark or x mark is displayed on the COM1, the communication between ECU and PC cannot be done. Cancel the ? mark or x mark by referring the PC Instruction Manual or Help function of the Windows. (2) Setting Method of the Setting Tool
Select the RS232C in the toolbar Set of the Setting Tool. When the Dialog is opened, select the Port on the PC side and click the OK button. (If the communication port is COM1, select the Port1.)

(3) Connecting Method of Setting Tool

Motorcycle 6Pin connector Harness D-sub 9Pin To the serial communications port Personal computer I/F Box

Fig. 52 Connecting Method of I/F Box

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5.3 Troubleshooting
Refer the below table when you have troubles. Table 4 Troubleshooting NO. 1 Trouble Program cannot be installed. 2 Program does not work. 3 PC cannot communicate with ECU. Incorrect setting of serial port. ECU is not powered ON. Cause understood Countermeasure manual carefully and understand it. Operating method not Read

PC does not match with Select suitable PC. required specifications. Incorrect connection of communication cable. Available OS is Windows XP (JP/US version) Confirm connection. (Refer to connecting method.) Confirm setting of serial port. COM1 is correct. (Refer to 5.2.3) Confirm ignition switch is turned ON.

Cannot write data to The Engine is running. ECU or read data from ECU. (DataExchange function does not work.)

Perform when is ON.

DataExchange engine is not

running but ignition switch

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Doc. No. 99929-1872-01