KDS 2016

KDS Intermediate 2016
Technical Training
KDS
KDS Intermediate
Intermediate
Kawasaki Motors Corp., U.S.A.

Technical Services
Copyright 2016
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Technical
KDS Training
Intermediate 2016
Technical Training

Course Assets Checklist
Lesson Tool / Item 
Introduction to the Course Laptop
KDS student laptops (5)
Vehicle
KDS kit
PowerPoint
Projector
Lesson plan
Wireless connection
Troubleshooting Basics Aerosol brake spray
Compression tester
Leakdown tester
Duct tape
KDS’ Seven Functions Demonstration vehicle
KIPASS Concours 14
Spare key fobs
Spare tire pressure sensors
General Air blow gun
Batteries, vehicles
Eyewash station
Fast Orange hand cleaner
Inspection mirrors
Laptop x 5 for student use
Loctite stick
Magnet, telescoping
Copyright © 2016 Kawasaki Motors Corp., U.S.A. 1 5

Technical Training

Technical Training
Mechanics gloves, nitrile
Muffin tins
Oil, air filter
Oil, engine
Oil drain pan
Oil funnel
Safety glasses
Shop towels, box of 200
Socket adapter, 3/8” to ½”
Sp plug sockets 14mm, 5/8”, 18mm, 13/16”
Torque wrench, in-lb
Torx wrench set, security
Vise jaws soft
Ziplock bags
6 Copyright © 2016 Kawasaki Motors Corp., U.S.A.

Ninja H2TM Technical Survey
Technical
Technical Training Training
NinjaInstructor
H2TM Technical Survey Instructor Prep
Prep Checklist
Classroom tables and chairs set up?
Vehicles have good batteries?
Vehicles start and run?
Sufficient gasoline?
Engine coolant?
Distilled water?
Sufficient shop towels?
Sufficient basic tools available?
Assets accounted for? (see assets checklist)
Fire extinguisher in good condition?
Shop ventilation working?
Demos ready?
Training aids ready?
Combination of demos and lectures planned?
Lesson plan reviewed ahead of time and ready at hand?
Wireless connection available?
K-Dealer accessible and logged-on?
Class videos run okay on laptop?
Instructor flash drive containing course content available?
Service manuals available?
Sign-in sheet copied off?
Final quiz available?

Technical Training
Table of Contents
Introduction to the Course 11
Student Task Checkoff Sheet 15
Troubleshooting Basics 19
Kawasaki Diagnostic System Available Resources 29
Kawasaki Diagnostic System Hardware Basics 37
Connecting Kawasaki Diagnostic System to a Vehicle 51
Installing the Kawasaki Diagnostic System Software 57
The Seven Kawasaki Diagnostic System Functions 65
KIPASS 75
Kawasaki Diagnostic System Beyond the Basics 93
Appendix 99

Technical Training
Kawasaki Diagnostic System Intermediate

Introduction to the Course
Lesson Objectives
The student will:
1. Learn and anticipate the direction and scope of this three-day course.
2. Be informed of the location of the restrooms and fire extinguishers.
Benefit to the Student
The introduction will “break the ice” and prepare the student to get into the mood
to learn. It sets the tone, perspective, and pace of the course.
Lesson
A. Introduction
1. Welcome
2. Point out locations of restrooms, coffee, fire extinguishers, nearby
lunch spots
3. Two-day course
4. Show course map, thumb through student book, and show certificate Viewing the workshop
in the back should put into
perspective what the
5. Discuss objectives -- see workstation check-off sheet course is about, and
6. Hours of class 8:30am ~ 5:00pm put the student in the
frame of mind to apply
7. Describe day’s schedule, times of breaks (10:00, 12:00, 2:00) what they are getting
8. Take attendance online in KDU, or if prefer, on paper using the sign-in in the classroom out
there in the lab.
sheet
9. Mention appropriate dress, expectations of instructor and student
10. Take whole class briefly to view workshop
The path is
ILT-->Manage Events
and Sessions-->
Search-->View
Sesssions-->View
Roster-->Attendance
and Scoring
Taking attendance

Technica
al Training
g
Technical Training
Sign‐In Sheet
Student Sign-in Sheet
Kawasaki Hands‐O
On Course::
n:
Location D
Date:
Please print
p clearlly, name/d
dealer num
mber
Instructtor: Please copy this sheet for each

e class instructed
d.

KDS Intermediate
Technical Training
Technical Training
Student ______________________________
KDS Intermediate 2016 Tasks
Section Task Instr Comments Ck
Introduction Install KDS from CD and update
Identify KDS hardware
Connect KDS to three Kawasakis
Navigate to all seven KDS functions
Create a Real Time Monitor file
Use KDS to troubleshoot a vehicle
Tips for success:

1. Use the manual! 4. Stay busy, look for additional projects
2. Use 90 in-lbs on all 6mm bolts unless instructed otherwise 5. Engines will be left in running condition
3. Use your resources, including K-Dealer, and your instructor 6. Take time to learn

Technical Training
B. Interest-generating demo
1. Have a bike prepared with a non-running cylinder
a. Remove ignition coil wire at ECU
b. Raise engine rpm slightly before demo to prevent engine stalling
2. Have KDS hooked up and at the Actuator screen
3. Pull student interest in
The term “power a. Show bike not running well
balance” is not
found in the
b. Ask students what they think is the problem
KDS software or c. Get some discussion going about what to do to troubleshoot
literature. It is an
automotive term
4. Show how to troubleshoot using a “power balance” procedure
meaning cut one a. Each time “kill” a cylinder in Actuator, note rpm on tach
cyliinder at a time
and see what the
b. Write each cylinder’s rpm on the whiteboard
results are. c. Each time you kill a cylinder the resulting idle rpm should be the same
d. If one time you kill a cylinder the rpm barely changes or does not
chanage at all then you know this cylinder is the “sick” one
Demonstrating usefulness of KDS using the Actuator function

Technical Training
C. With class back in classroom

1. Generate enthusiasm about what students are going to learn
a. Discuss demo
b. Ask students how they have used KDS
2. Ask class how many brought laptops
3. Ask everyone if they know their laptops’ operating system
4. Show how to quickly find their operating system
a. Start-->Computer-->Computer (right click)-->Properties
b. Read under System section
5. Supply students with wireless login
6. Have each student who has a laptop log onto Malwarebytes and scan their
laptop for viruses
a. www.malwarebytes.org
b. Free 30-day trial
7. While the laptops are scanning, continue with course, the next chapter
being Troubleshooting Basics
Viewing the operatring system type on the laptop

Troubleshooting
Technical Training

Troubleshooting Basics
Lesson Objectives
The student will:
1. Demonstrate understanding that KDS doesn’t repair vehicles, technicians do.
The student will get a refresher on basic troubleshooting, basics that will serve
the technician in many troubleshooting scenarios.
Lesson
A. Performance issues are not always DFI related
1. Remember, not all engine performance issues on a fuel injected vehicle are
necessarily fuel injection system problems
a. Don’t forget basic troubleshooting outside the use of KDS
b. Show service manual reminder re basic troubleshooting
2. Also, don’t leave out wiring and connectors -- very common trouble area
a. Visual inspection
b. Fit of connectors
c. Continuity in wiring harness end to end
From a street model Kawasaki service manual

Technical Training
3. No-start scenarios are usually the easiest to diagnose

a. Usually much easier to diagnose than internittent type problems
b. You can test an engine in a very general way by using an aerosol can of
brake cleaner spray sprayed into the intake while cranking the engine
c. “Quick and dirty”, but it allows you to give your customer an idea of what
he is up against in a no-start condition
d. Be sure and warn about possible (though not likely) fire hazard – keep
a fire extinguisher handy
4. Intermittent and driveability problems are the most difficult to solve
a. Oftentimes they are subject to conditions
b. Can be hard to duplicate
c. See the troubleshooting guide in the service manual appendix
5. Ways to duplicate conditions when troubleshooting intermittent problems
a. Run vehicle on a dyno to apply a consistent load
b. Use a heat gun to warm part or a chilling aerosol to cool it

Technical Training
6. Mechanical, electrical, fuel

a. Use the more air/less air tests to differentiate between mechanical,
electrical, fuel
b. More air -- test run with SMALL air leak introduced into airbox
c. Less air -- install air filter element with half its surface area duct taped Using the choke as a
over means of doing the
less air test is prob-
d. Result of each test will point out either richness or leanness lematic as this method
e. If no result, then 90 percent sure not a fuel related problem introduces more into
the equation. Keep it
7. Cylinder compression and leakdown simple.
a. Discuss things that can affect cylinder compression
Due to the normal
1) Powersports engines generally are susceptible to self-tightening valve recession wear
valve clearances process. Some en-
gines are worse than
2) Carbon buildup around valves also affects cylinder compression others however.
3) Don’t forget KACR-equipped vehicles exhibit abnormally low compres-
sion readings (can overcome this by loosening valve clearances to
end or even a bit beyond end of range – if compression comes up,
likely engine compression is good – if not, then not)
b. Discuss effects low cylinder compression has on performance
1) Hard starting
2) Softened throttle reponse
3) Loss of maximum power
c. Open K-Tech News online, Vol. 20, Issue 3, pg 12
1) Mention trick of adding a squirt of engine oil to check piston rings
2) Compression test often not good to use all by itself
3) Cylinder leakdown test pinpoints trouble compression test only hints at
4) Leakdown test can actually find things compression test can’t, such
as trick of lowering test pressure and sliding piston down bore to check
for grooved cylinder
5) Compare uses and interrelatedness of cylinder compression and
leakdown
d. The real magic is in using the two tests together Retarded camshaft is
1) Lower than normal compression but good leakdown = retarded common in engines
that use aftermarket
camshaft or rusty or otherwise damaged cylinders K&N filters, as they
2) Higher than normal compression but good leakdown = advanced prematurely wear the
engine’s cam chain.
camshaft
3) Good compression but high leakdown = carboned or burnt valves

Technical Training
B. Testing fuel pumps

1. Poor performance
2. Stalling
3. Fuel pump voltage test
a. Battery fully charged
b. Listen for pump sound with keyswitch on
4. If no sound, check for voltage to fuel pump
a. Use generic test cable 57001-1700 or use needle probes 57001-1457
b. BK/BL and BK/Y
c. Keyswitch on, engine stopped
d. Should read equal to battery voltage for 3 seconds, then 0
e. If results differ, check fuel pump relay, see service manual for more
test information
5. Fuel pump pressure test per the service manual
a. Disconnect fuel hose
b. Install fuel pressure test rig made from following pieces
1) Gauge = 57001-164 (superceded from 57001-125 listed in service
manual)
2) Fuel gauge adapter 57001-1593
Hose is from a
Kawasaki Jet Ski
3) Kawasaki hose 51044-3705
c. Turn keyswitch on, start engine and let it idle
d. Look for 41~46 psi (or manual spec) at idle, and revved up
e. Lower means a bad fuel pump or clogged fuel pump filter
f. Higher means a bad pressure regulator necessitating pump replacement

Technical Training
6. Fuel pump volume test per the service manual

a. Remove fuel tank cap to relieve pressure
b. Remove hose from fuel pump
c. Attach spare fuel hose to pump outlet and route inside a measuring cup
d. Put fuel tank cap back on
e. Turn on keyswitch, capture resulting fuel output
f. Repeat two or three times for accuracy
g. Minimum output is supposed to be 50cc per service manual
7. Fuel pump pressure and volume tests supplmenting the service manual
a. KMC has found that the service manual pressure and volume tests are
not adequate to find a bad fuel pump
b. Here is how the tests should be modified
c. The pump must first be operated for over 10 minutes of continuous high
speed use, with a pressure gauge attached – this is different from the
service manual Show the fuel pump
testing video
d. The resulting pressure should not fall below 40 psi the whole time -- this
is the same as the service manual
e. The resulting key-on volume immediately after 10+ minutes of testing
must be 100cc minimum -- this is different from the service manual’s
50cc
KMC fuel pump tests video

Technical Training
Chapter Highlights
1. Remember to think beyond DFI
2. The basics: Mechanical, electrical, fuel
3. Cylinder compression and leakdown
4. Testing fuel pumps
You may be required to turn in or show this page to your instructor

Resources
Technical Training

Kawasaki Diagnostic System Available Resources
Lesson Objectives
The student will:
1. Discover resources that are available from Kawasaki to aid in the use of
KDS.
Being properly informed is half the battle. Knowing where to find information is
a part of providing customers excellent service and is critical to performing good
work.
Lesson
A. Where to get Kawasaki Diagnostic System (KDS)
1. Software CD 57001-1802
2. Update to the program, not the actual program
a. Required
b. KDS 3 for 32 bit Windows
c. KDS 3 for 64 bit Windows
B. Review online training (eLearning) course
1. Course, Introduction to KDS There is a ton of
valuable help for using
2. On Kawasaki Dealer University (KDU) KDS out there, waiting
3. If necessary, take time to familiarize class with KDU for the user.
4. Assist those needing help logging onto KDU
5. Explain progression from TLN to KDU and current KDU issues The booklets are no
longer available under
6. KDU will eventually be very powerful part number but are
C. Instruction booklets free to download
from K-Dealer, and
1. KDS 3 Setup Manual the setup, instruction
2. KDS 3 Instruction Manual manuals, and quick
reference sheet (but
3. KDS 3 Quick Reference Sheet not the connection
4. KDS 3 Component List guide) self-install onto
the desktop when
5. KDS 3 Connection Guide installing KDS.
D. Live help
1. Product Support Hot Line 800-854-3800
2. Mark Franzen on the Hot Line is particularly helpful
a. He frequently logs in remotely to dealer’s PC to help straighten
things out
3. Training opportunities such as this one
E. Other
1. This training booklet
a. Take it back to the shop and make use of it as a daily resource
b. Keep this booklet with your KDS set

Technical Training
KDS Resources
KDS Component List
KDS Connection Guide

KDS Quick Reference Sheet
KDS Setup Manual

KDS Instruction Manual

Technical Training
KDS 3 in K-Tech News
2007 Vol. 20, Issue 3 Pg 6 New Kawasaki Diagnostic System Now Available
Pg 2 All About KSD 3

Vol. 20, Issue 4
Pg 3 Using KDS 3 on the Concours 14
2008
Vol. 21, Issue 2 Pg 4 KDS For Everyone
Vol. 22, Issue 1 Pg 10 Mule Connector Confusion

2009
Vol. 22, Issue 2 Pg 10 VN1700 KDS Connector
2010 Vol. 22, Issue 4 Pg 10 New KDS Connectors for 2010 Motorcycle, PWC Models
KDS Tip: Save Snapshot of Good Reading

Vol. 23, Issue 4 Pg 8
KDS3 Update to Include 2011 Models
2011 Vol. 24, Issue 2 Pg 8 Kawasaki Diagnostic System (KDS) Primer, Part One
Vol. 24, Issue 3 Pg 6 Kawasaki Diagnostic System (KDS) Primer, Part Two
2012 Special Edition 2012 Pg 8 Kawasaki Diagnostic System (KDS) Primer, Part Three
Intances of KDS 3 only.
K-Tech News Vol. 20, Issue

4, containing article, All
About KDS 3

Technical Training
KDS Service Bulletins
ST07‐02 Large hull (Ultra) Jet Ski relay cable availability

2007
ST07‐03 Introducing KDS version 3
ST08‐02 KDS now part of Kawasaki Essential Tool Program

2008
KDS applicable to new 2009 DFI Mules
ST08‐03
KDS program updates will be available on K‐Dealer
KDS CD availability and pricing
ST10‐02
KDS Instruction Manual available for download from K‐Dealer
2010
ST10‐03 KDS parts broken down with pictures and part numbers
2011 ST11‐01 KDS 3 version 3.0.0.4 now compatible with 64‐bit systems
ST12‐04 2012 update to version 3.1.2.0 available on K‐Dealer

2012
ST12‐05 2013 update to version 3.1.3.0 available on K‐Dealer
2013 ST13‐02 2014 update to version 3.1.4.0 available on K‐Dealer
Service bulletin ST07-03

announcing the new USB
capable KDS version 3

Technical Training
Chapter Highlights
1. Where to get KDS
2. KDU course, Introduction to KDS
3. KDS booklets
4. KDS resources, bulletins and other publications

Hardware
Technical Training

Kawasaki Diagnostic System Hardware Basics
Lesson Objectives
The student will:
1. Properly identify KDS hardware
2. Distinguish obsolete or incorrect hardware from correct KDS hardware

The KDS hardware is just as important as the software in properly using KDS.
The student will be proficient at using KDS.
Lesson
A. This chapter continues following and expanding on the online course,
Introduction to KDS
B. You’re still logged onto KDU and showing online course in class
1. Stop after each section, and expand and explain
2. Use the course to emphasize the material in this chapter and generate and
inspire discussion
3. Recommend also K-Tech News article, Kawasaki Diagnostic System
(KDS) Primer, Parts 1 through 3
The online program
C. The six must-have, minimally-required KDS pieces says five pieces, but it
1. Converter 57001-1725 is really six.
2. Software disk 57001-1802 If you have the obso-
3. USB cable T57001-0017 lete -1648 converter
you also need the
4. Comm cable 57001-1649 countermeasure cable.
a Terminates in an 8-pin connector
b. For 1999~2009 models
5. Comm cable 57001-1688
a. Terminates in a 4-pin connector
b. For 1999~2009 models
6. Comm cable 57001-1745
a. Y shaped
b. 2010 and later
c. Looks exactly like Y-cable 57001-1746, which is not a KDS
part at all but is an Ultra key registration cable for later models
d. Terminus connectors identical Bret changed the part
e. Upstream (entry point) connectors different number of the CD just
last year. Used to be
b. See pictures on subsequent pages -1650.

Technical Training
Communication Point Variations
Using both pre-2010 comm ca-

bles: the 8-pin 57001-1649 and
the 4-pin 57001-1688, resulting
in a connection point of 4 pins
Using just the 8-pin 57001-

1649 cable by itself, to
achieve an 8-pin connection
point
Using the 2010 and later

57001-1745 comm cable
that “Y” branches out into
both the requisite 4-pin and
6-pin connectors
Using no cables at all but

connecting the converter
directly to the bike’s wiring
harness. The Concours
requires this type of connec-
tion.

Technical Training
D. Extra KDS parts

Remember, these are
1. Jet Ski relay cables relay cables, not comm
a. Early one 57001-1535 for 122” long boats w/ battery in engine bay cables. They do not
connect KDS to the ve-
b. Later one 57001-1696 for 132” long (Ultra) boats w/ battery in front hicle, they essentially
storage compartment “hotwire” the vehicle.
c. Keeps ECU from timing out
d. Attach with pigtail disconnected, turn on boat, connect pigtail
2. Z1000 adapter cable
There was no 2009
a. 57001-1699 model year Z1000 and
b. 2007-2008 only 2010 and later use
different comm cable.
c. Wiring harness change to DIN (Bosch) style
3. Countermeasure cable
a. 57001-1724
b. Countermeasure for certain models that did not communicate well
due to voltage issues
c. Countermeasure circuit is built into later converter 57001-1725
d. See bulletin ST08-05
e. This part is needed only if you still have an original style
converter, 57001-1648
4. Carrying case
a. T57001-314
b. This case is part of new dealer tool package, and is available separately
Z1000 adapter cable

57001-1699
Jet Ski relay cables, 57001-1535 on top,

57001-1696 on bottom
Carrying case
Countermeasure T57001-314
cable 57001-1724

42
KDS Parts Minimum and Extra
Minimum Converter USB Comm Comm Comm Disk

6 Parts -1725 -0017 -1649 -1688 -1745 -1802
Add Z1000 Z1000

-1699
Add Jet Ski® Relay Relay

-1535 -1696
Add Case Poly Case

-314
Add C/Meas Cable

C/Meas Cable -1724
A graphical look at the minimum and extra KDS system pieces
Copyright © 2016 Kawasaki Motors Corp., U.S.A.

Technical Training
Technical Training
KDS Parts and Cables at a Glance
Converter Software disk USB cable

57001-1725 57001-1802 T57001-0017
2007~2008 Z1000 cable

Pre-2010 comm cables Post-2010 comm “Y” cable
57001-1699
57001-1649, 57001-1688 57001-1745
Countermeasure cable
Jet Ski relay cables 57001-1724
57001-1535, 57001-1696

Technical Training
E. Emphasize these points

1. The parts can be purchased only as individual pieces in the U.S. market
The UK gets it as a
kit with a different
a. No single part number for retail sale
carrying case than 2. Early and late converter boxes
ours too.
a. Converter 57001-1648 is early, obsolete
b. Converter 57001-1725 is later with built-in countermeasure
c. Either will work, but the older -1648 converter needs the extra part to
function properly, the countermeasure cable 57001-1724
3. Early and late comm cables
a. For 1999~2009 DFI vehicles use comm cables -1649 and -1688
b. For 2010 onward use comm cable -1745
4. Cables -1745 and -1746, both having a “Y” shape
a. KHI built and numbered two cables identically and consecutively that
have nothing to do with each other
b. 57001-1745 is the 2010 and later KDS comm cable
Refer back to
previous page, the
c. 57001-1746 is an Ultra key registration cable, no KDS relevance
part about what 5. Early and late Jet Ski relay cables
KDS is not de-
signed to do. KDS
a. The Jet Ski relay cable is needed to make KDS stay working longer than
has nothing to do 2~3 minutes.
with Ultra keys.
b. It keeps the ECU relay energized instead of turning itself off
c. The -1535 cable MUST be grounded at the battery negative terminal
d. The -1696 cable is used by connecting it with pigtail disconnected at first,
then the pigtail is connected afterward
Right to the battery
terminal, not 6. If you have a long blue cable in your KDS set, get it out of there! That is
through a jumper. NOT a KDS part but a KADIAG part
The basic KDS setup

Technical Training
Two Different Y Cables
-1745 and -1746 Y

cables compared.
One is used for
KDS, the other is
not.
Look the same, but their entry point connectors are very different.
KHI unfortuately made these two cables identical despite their
being used for completely different purposes.

Technical Training
KDS System Hardware
MUST be supplemented by update

Contains software and downloaded from K‐Dealer
57001‐1802 Software CD
resource manuals
Was 57001‐1650
Translates ECU to
57001‐1725 Converter Box Was 57001‐1648
laptop
Connects laptop to
C57001‐0017
T57001-0017 USB Cable Standard USB scanner cable, only 16 ft.
converter box
Comm Cable 6‐ Allows connection to 8‐ Three configurations of these two cables

57001‐1649 produces these possible connections:
pin to 8‐pin pin models
1) One by itself terminating in 8‐pin

2) Two together terminating in 4‐pin
Comm Cable 8‐ Allows connection to 4‐ 3) Neither cables used, converter
57001‐1688
pin to 4‐pin pin models attached direct to ECU 6‐pin
For 122” long boats Prevents ECU from timing out

Small Hull Jet Ski
57001‐1535 having battery in engine
Relay Cable
compartment Pigtail must be grounded at battery
For 132” Ultra boats Prevents ECU from timing out

Large Hull Jet Ski
57001‐1696 having battery in the
Relay Cable
storage compartment Keep pigtail ends connected
Replaces ‐1649 and ‐1688 comm cables

Comm Cable for
Due to wiring harness for 2010 and later
57001‐1745 2010 and Later
changes in later models
Models
Don’t confuse with 57001‐1746
Z1000 Adapter Due to wiring harness Fits canon style plug to newer Bosch
57001‐1699
Cable changes in later models style plug
Temporarily required
Countermeasure
57001‐1724 for certain models to Made obsolete by ‐1725 converter box
Cable
optimize connection
Standard blow‐molded
T57001‐314 Carrying Case poly case similar to Very roomy, has factory graphic on top
compression tester case
This list is slightly altered from the one on K-Dealer

Technical Training
Look Out For These Imposters!
If you spot this, get it out of there! It is the comm This is even worse! This long blue cable with a yellow
cable for the old KDS version 2. It has no compat- terminus and a serial connector is not even an old
ibility with the current KDS system. Note the serial KDS part but a part of the really old KADIAG system
connector. used on two-stroke direct injection Jet Ski watercraft
of the 1990s. Don’t keep it with your KDS set.
This looks like a converter box and it is one, but it is This special tool is not a KDS part either. This is the
from the version 2 days, once again. Smaller and key registration tool used for registering Ultra Jet Ski
lacking a USB port, this part is useless today. watercarft electronic keys. No relevance to KDS at
all.

Technical Training
Chapter Highlights
1. The six minimally-required pieces
2. How many communication points are there?
3. Extra KDS parts
4. Early and late Jet Ski watercraft relay cables
4. Imposter KDS parts

Connecting
Technical Training

Connecting the Kawasaki Diagnostic System to a Vehicle
Lesson Objectives
The student will:
1. Connect KDS to at least three different Kawasaki models
2. Distinguish between the handful of different connection points

Connecting KDS is part of learning to use KDS. The student will be able to con-
nect to different Kawasaki models having different connection types.
Lesson
A. Connecting KDS to a vehicle
1. Refer to the KDS Connection Guide
2. 4-pin connector Sometimes there is
more than one 4-pin
a. 80% or more of all Kawasaki models connector in the same
b. Where this 4-pin connector is located on the machine varies place, and often they
are identical. Make
c. Road bikes all have the connection under the seat the choice based on
d. Later Mules have the connection under seat also the correct color wires
shown in the service
e. Pre-2010 models: use -1649 and -1688 comm cables together manual.
f. 2010 and later models: use -1745 Y cable instead
3. 8-pin connector
a. The earliest VN1500s
b. Use -1649 comm cable by itself
4. 6-pin connector
a. Concours 14
b. Use neither cable, but connect converter directly to the bike’s
wiring harness
Connecting KDS to the Kawasaki Concours

Technical Training
Sample KDS Connection Points
EX650 KX450F
Brute Force 750 Jet Ski Ultra
Mule 620 Teryx 800
This is just a sampling, see the KDS Connection Guide for a more complete listing

Technical Training
Chapter Highlights
1. 4-pin, 8-pin, and 6-pin connections
2. Where on the vehicle are most 4-pin KDS connection points found?
3. Which is the most common pin number connector?

Installing
Technical Training

Installing the Kawasaki Diagnostic System Software
Lesson Objectives
The student will:
1. Install KDS from the KDS disk
2. Update KDS from K-Dealer

Perhaps the most difficult part of using KDS is properly installing and updating. The
student will gain this important skill.
Lesson
A. Have everyone who has a laptop uninstall KDS if already installed
B. Explain that the same process is used when KDS is not working properly
or is simply a very old version
1. Uninstall current KDS version
a. Start-->Control Panel-->Programs and Features-->Uninstall
b. “Kawasaki Diagnostic System Ver.3” All four of these files
c. “MIcrosoft SQL Server Compact 3.5 SP2 ENU” MUST be uninstalled.
d. “Microsoft SQL Server Compact 3.5 SP2 x64”
e. “Windows Driver Package - Mitsubishi Electric Corp. KDS USB Adapter”
2. Reboot computer
Purging the KDS files to do a clean reinstall

Technical Training
C. Create a system restore point to use during this training course

1. Start-->Control Panel-->System-->System Protection-->Create
2. This will make uninstalling a simpler process if it is necessary during the
duration of the course
Wiindows System
Restore is Kind
of a power undo,
and much simpler
than uninstalling
the four KDS files
every time a glitch
happens.
Making a System Restore point for class work

Technical Training
D. Installing KDS
1. The install process is 99 percent the same for both 32-bit and 64-bit, and KDS is not currently
for Windows 7 and Windows 8 compatible with Win
8.1
2. Only the wording of the choices varies slightly
3. XP laptops are quite a bit different however
E. Put the KDS CD into your disk drive
1. Most laptops will autostart the installer
2. If yours doesn’t, browse on the CD to find the InstKDS.exe file
F. Installation steps
1. Driver
a. Put the CD into the disk drive
b. Choose “Run InstKDS.exe” if it appears The headings “Driver,”
“Database 1” and so
c. OK-->Yes-->Next-->Install--> forth don’t show on
d. Finish--> the computer. But no
worries. The base
2. Database 1 program installation
a. Next-->Accept-->Next-->Install-->Yes--> is easy-peasy. Just
click Yes nor Next all
b. Finish--> the way througth. The
3. Database 2 headings are shown
only so you can show
a. Next-->Accept-->Next-->Install-->Yes--> the student that four
b. Finish--> things are happening.
4. Program
a. Yes-->Next-->Everyone-->Next-->Next-->
b. Close
c. Open KDS using your desktop icon as a double-check The CD can be copied
to a USB stick for in-
d. Close KDS program stalling onto notebook
laptops if needed.
One of the KDS installation screens

Technical Training
G. Install the KDS program update

The installation 1. A MUST to complete the KDS installation
is not complete
until the update is a. Otherwise you won’t have the latest software
installed. b. Otherwise you won’t get the Mule 820 KDS program, which is separate
Even K-Dealer says and available only with the KDS update download
must install CD first,
then the update.
2. The base program must already be installed
a. The KDS program update will not work or even install without the
base program already installed
b. You will get an “SQL missing” warning
3. Check and see which operating system you have
a. Start-->Computer-->Computer-->
b. Right click-->Properties
4. Download correct (32-bit or 64-bit) update from K-Dealer
a. K-Dealer-->Service-->Special Tools/KDS/KRS-->
Best practice is to
b. KDS Software Update, either 32-bit or 64-bit
download to a folder c. RIGHT CLICK, don’t left click, SAVE LINK AS
and save the file,
NOT run it while still
d. Browse to folder to save to
on K-Dealer. If you e. From this folder, double-click on msi file
forget to do this it
won’t be the end of
f. Next-->Everyone-->Next-->Next-->Yes-->
the world. g. Close
Finding Windows
version on your
laptop
Choosing the
correct KDS version
from K-Dealer - the
update version
number shown is
only an example

Technical Training
Chapter Highlights
1. Uninstalling KDS
2. Installing KDS
3. Two kinds of KDS
4. KDS base program and update

Seven Functions
Technical Training

Kawasaki Diagnostic System Seven Functions
Lesson Objectives
The student will:
1. Use all seven diagnostic tools within the KDS program
2. Demonstrate understanding of which tool is used when

The student will be comfortable using KDS and be able to dialogue with Kawa-
saki’s Product Support Hot Line in KDS terms.
Lesson
A. After reviewing online course, Introduction to KDS, including the seven KDS
functions
1. Run KDS connected live to a vehicle so you can show the location and ap-
pearance of each of these functions
2. Also recommend K-Tech News article, Kawasaki Diagnostic System
(KDS) Primer, Part 3, K-Tech News Special Edition 2012, page 8
KDS splash screen

Technical Training
B. The seven KDS functions

1. Diagnose
a. FI menu
b. Main Menu-->Fuel Injection Menu-->Diagnosis
c. Diagnosis scans all the sensors and parts and returns a list of failures
d. Clicking on one of the posted failures will show recommended next step
IN refers to intake,
in other words this
is a Concours that
is being shown.
KDS Diagnose window

Technical Training
2. Failure History
a. FI menu
b. Actually a part of Diagnose, Failure History records the last three items
that failed, and how many times they failed
c. Some models are erasable, some not
d. From within Diagnose, click on Failure History button
3. Real Time Monitor
a. FI menu
b. Main Menu-->Fuel Injection Menu-->Real Time Monitor
c. Digital multimeter like data in real time, as it happens
d. TPS position, engine rpm, temperatures, pressures,
KDS’ Real Time Monitor

Technical Training
4. Graphing
a. FI menu
b. A graphical version of the Real Time Monitor
c. Main Menu-->Fuel Injection Menu-->Real Time Monitor Graphs
d. Choose any three of 14 choices in a vertical roster
e. Refreshes right to left
f. 20 seconds viewable in the window
g. Up to 5 minutes data viewable overall
5. ABS
a. ABS menu
b. Uses a different connection on the vehicle, not the KDS connection
c. Start Menu-->ABS
d. Both fault data and ABS pump testing are available
KDS’ Graphing function

Technical Training
6. Actuator
a. FI menu
b. Test components by activating them while still on the vehicle Remember, the
c. Main Menu-->Fuel Injection Menu-->Actuator Concours tire pressure
sensors is why KDS
d. Testing components in some cases means turning them on while the was added to Kawa-
engine is not running, and in others it means turning something off while saki’s Essential Tool
Program in 2007.
the engine is running, as in our demo at the beginning of this class
e. Voltage, sound and operational function is noted while testing
f. See Actuator tests page
KDS’ Actuator function

Technical Training
Diagnostic Possibilities Using Actuator
Engine running tests

Power balance tests
To determine which cylinder is laboring
Simply shut off cylnder while watching engine rpm
Weak cylinder will drop much less rpm than the rest
Fuel injector
Short cylinder to test
Ignition coil
Short cylinder to test
Idle speed control (ISC)
Testing the ISC will speed the engine up
Listen to engine
Watch the vehicle's tachometer, if applicable
Engine off tests

Fuel injector
Listen for clicking sound
Ignition coil
Listen for snapping sound
Watch for spark if plug outside cylinder
Exhaust butterfly
Listen for clicking sound
Watch operation
Sub throttle
Listen for operation
Watch operation
Secondary air solenoid
Listen for operation
Variable valve timing (VVT) oil valve
Concours Listening to VVT valve
can be a challenge as
Listen for operation cooling fan operates
during Actuator test.

Technical Training
Chapter Highlights
1. Name the seven basic KDS functions
2. KDS Real Time Monitor
3. What is the benefit of the Actuator KDS function?

KIPASS
Technical Training

Kawasaki Diagnostic System and KIPASS
Lesson Objectives
The student will:
1. Have opportunity to register a Concours key fob
2. Have opportunity to register a Concours tire pressure sensor
As the most KDS-dependant Kawasaki product, it benefits the student to at least
be familiar with the Concours’ unique use of KDS.
Lesson
A. KIPASS is found on the Kawasaki Concours
1. Remember that KDS was added to the Kawasaki Essential Tool Program
because of the Concours
2. As far as KDS is concerned, KIPASS consists of the keyless entry system
as well as the tire pressure monitoring system (TPMS)
3. TPMS specifically mandated KDS becoming an essential tool because
the tire pressure sensors have sealed in batteries requiring the sensor itself
be replaced every five years or less
Newer style sensor.
Concours TPMS sensor

Technical Training
B. What is KIPASS?
1. Kawasaki Intelligent Proximity Activation Start System
2. Essentially an advanced form of the Immobilizer system found on Euro
market Kawasaki motorcycle since 2004
a. Euro bikes and all market’s Jet Ski Ultras have Immobilizer
It appears Immo- b. Immobilizer simply reads the electronic key and refuses the wrong one
bilizer is coming to
the U.S. soon too. c. Euro Immobilizer uses a red master key and black user keys
prepared by the master key
d. The head of the key “talks” to the antenna located on the top of the
The red master
key on Euro bikes
keyswitch
is supposed to be e. The Jet Ski Ultra is similar, and half of the Concours’ KIPASS is very
stored in a safety
deposit box.
similar
On the left is a U.S. model ZX-6R keyswitch, on the right a

Euro model for the same bike. Note the red master key and
the red antenna indicator on the top of the switch.

Technical Training
3. KIPASS takes Immobilizer and adds to it sophisticated encrypted

communication via CAN bus between onboard ECUs
a. A high level data encryption system developed by Mitsubishi called MISTY
b. ECUs “handshake” together interdependently before allowing the key-
switch to operate
c. CAN bus twisted pair of wires interconnect the Concours’ three ECUs
d. KIPASS therefore is preemptive, whereas Immobilizer alone is more
preventative
The process once fob

is in range:
1) Smart ECU to fob

2) Fob to Smart ECU
3) Smart ECU to key-
switch ECU
4) Keyswitch ECU
back to Smart ECU
5) Smart ECU to en-
gine ECU
6) Engine ECU back to
Smart ECU
Now the keyswitch can

be rotated.
The Engine ECU is

also called the FI ECU
as that is what it con-
trols, fuel and ignition.
KIPASS operation on the Concours

Technical Training
4. Similarities: Jet Ski Ultra, Euro Ninja, and the Concours

a. The Jet Ski Ultra and the Concours both store six “keys”
b. The Euro Ninja, Jet Ski Ultra and the Concours all have parts of the
Thw Concours’
attenna is that
Immobilizer system
square projection c. The Euro Ninja, Jet Ski Ultra and the Concours all have antennas
on the front of the
keyswitch.
as part of their keyswtiches
5. Differences: Jet Ski Ulra, Euro Ninja, and the Concours
a. The Jet Ski Ultra ECU will allow erasing keys, the Concours not
You don’t even b. The Jet Ski Ultra requires only the -1582 dongle to register a key, while
need the dongle to
register the first two the Concours requires KDS
keys in an Ultra. c. A replacement Jet Ski Ultra ECU is shipped with no keys and is completely
The difference is,
blanked, ready to accept any keys registered to it, the Concours ECU is
removing keys in shipped with two fobs already registered to it
the Ultra results in
empty key slots.
d. The Jet Ski Ultra allows removal of all but one key, the Concours does
On the Concours, not allow removing of any fobs, only disassociating, turning off, fobs
disassociating fobs
does NOT open up
6. The Concours fobs have two sides
their slots. a. The front side is battery powered RF (radio frequency) and is called by
the manual, “Transponder”
b. The back side is non-battery enabled RF and is called by the manual
“Immobilizer”
c. When the front side’s battery runs down the fob can still function by
using its back, non-battery side
KDS Instruction 7. See Appendix for more information about KIPASS
Manual page 32.
8. See KDS Instruction Manual for details on replacing a Concours ECU
Using the Concours Immobilizer function

Technical Training
Jet Ski Ultra vs. Concours ECU and Fobs
Jet Ski Ultra six keys can be stored
Concours six fobs can be stored

Technical Training
Replacing a Concours TPMS Sensor
Write down the ID number found

Follows the video on the TPMS sensor
After installing the sensor and

the wheel, from the KDS main
menu, choose KIPASS
From the KIPASS menu,

choose Tire Pressure Sensor ID
Registration
Next, choose either the front or

rear wheel
Replace the existing ID with the

ID from the new sensor
Change the ID number in the

window, and click Registration,
then click Yes, then OK

Technical Training
Adding a Concours Key Fob
Registering the Transponder half
Follows the video
Just as with the TPMS sensor, This prccess can also

be used to make a
write down the fob’s ID number “shop” fob for each of
your customers who
buy Concours motor-
cycles from you.
From the KIPASS menu, choose

Fob Registration
From the Fob Registration menu,

choose Additional Registration
Lay the new fob on the fuel

tank’s rearward portion
Type in the new fob’s ID number

and click Additiona Registration,
then click OK

Technical Training
Registering the Immobilizer half
Remove the mechanical key

Follows the video
from the back of the fob, as well
as from all of the other, preexist-
ing fobs

Immobilizer Key Registration
When the window changes, click

on Immobilizer Key Registration
a second time.
Put the back of the fob onto the

keyswitch antenna, that rectan-
gular projection at the back of
the swtich.
When KDS changes screens

automatically in confirming the
registration, a window comes up
that says OK, click OK. Repeat for
all the fobs, not just the new one.
They all must be re-registered.

Technical Training
When done with all the added Follows the video

fobs, click Confirm Changed
Item.
It is best practice to dou-

ble-check that each Immobilizer
part of each fob is correctly reg-
istered by removing the batteries
and testing each one against the
keyswitch as if the fob’s batteries
were dead.
The keyswitch should be able to

be pushed downward, and the
key icon should appear on the
display. If this doesn’t happen,
the Immobilizer registration was
not done correctly.

Technical Training
Disassociating a Lost Concours Key Fob
If your customer loses one of his

Follows the video
fobs, for securtiy it is important to
disassociate the lost fob.
We do that by re-registering the

remaining fobs.

Fob Registration.
From the Fob Registration menu,

choose Re-registration.
Lay the remaining fobs on the

seat area.
Click OK, then Yes, then OK. If

the lost fob is recovered in the
future, use the exact same process
to re-register it. If the customer
decides instead to replace the lost
fob, use the Additional Registration
routine.

Technical Training
Cheat Sheet
Cheat Concours TPMS
Sheet Concours TPMS &and
Fobs FOBs
 Replacing the TPMS sensor

1. KI-PASS Menu  Real Time Monitor  old TPMS sensor number
2. New sensor ID number from package
3. KI-PASS menu  Tire pressure sensor ID registration
4. Choose wheel
5. YES  type in new sensor ID number  Registration  YES  OK
6. KI-PASS Menu  Real Time Monitor  new TPMS sensor number
 Adding a fob, front side

1. Fob ID number (use second number on crate fob)
2. KI-PASS Menu  Fob Registration
3. Fob Rregistration Menu  Additional Rregistration
4. Lay new fob
5. Type in fob number
6. Click Additional Registration
 Adding a fob, back side

1. Mechanical keys out of ALL fobs
2. KI-PASS Menu  Iimmobilizer Key Registration Menu
3. Immobilizer Key Registration Menu  Iimmobilizer Key Registration
4. Fob on keyswitch projection  confirm  OK
5. Next fob on keyswitch projection  Iimmobilizer Key Registration
6. Confirm changed item
7. Remove battery from each fob to test immobilizer
 Removing a fob, front side

1. KI-PASS Menu  Fob Registration Menu
2. Lay in-use fobs
3. Fob Registration Menu  Re-register  OK
 Removing a fob, back side (duplicate of adding a fob, back side)

1. Mechanical keys out of ALL fobs
2. KI-PASS Menu  Iimmobilizer Key Registration Menu
3. Immobilizer Key Registration Menu  Iimmobilizer Key Registration
4. Fob on keyswitch projection  confirm  OK
5. Next fob on keyswitch projection  Iimmobilizer Key Registration
6. Confirm changed item
7. Remove battery from each fob to test immobilizer
View KDS: TPMS and FOBs video also

Technical Training
C. Apparent ZG1400 KIPASS system malfunction

1. Some users report keyswitch will not communicate with ECUs and thus
motorcycle can’t be started
2. Has happened after stopping and then restarting
3. Is not a KIPASS malfunction, despite user forum declarations
D. Four known solutions
1. Some have been able to jar keyswitch sharply
a. Intuitively these folks have determined keyswith plunger is sticking
b. Sharp impact does in fact jar loose stuck keyswitch microswitch
2. Some have unplugged and replugged keyswtich cable
a. This resets KIPASS
b. Works because stuck microswitch causes KIPASS to time out
c. However, if microswitch stays stuck or sticks again, not a solution
3. Some dealers have chamfered microswitch opening to allow microswitch
pin to move more freely
a. This is a good idea regardless
b. But not a reliable long-term solution by itself
Hot Line has a 4. Replacing the microswitch return spring with a different, stronger spring
supply of springs. a. This was done by the factory for the 2012 model year
b. Relatively easy and inexpensive
ZG1400 Concours keyswitch

Technical Training
ZG1400 Keyswitch Modification
The keyswitch must be removed from

the fork assembly. It is mounted with
one-time use bolts.
After unbolting the keyswitch from the fork

bridge (upper), remove the keyswitch top
cover.
Remove the keyswitch side cover housing

the keyswitch ECU.
Now the microswitch, the part that initially ac-

tivates the process that causes the KIPASS
ECUs to talk to each other, is exposed.

Technical Training
So remove the microswitch.
Now the microswitch spring is exposed.

Remove and replace the spring.
Reassemble the ksyswitch and afterward

remember to get new bolts (92153-1426)
to remount the keyswitch to the fork
bridge.

Technical Training
Chapter Highlights
1. Describe what KIPASS does
2. Similarities between KIPASS and Immobilizer
3. Differences between KIPASS and Immobilizer
4. The two “sides” of the Concours key fob
5. What’s important about a new Concours key fob wrapper?
6. How is the Concours key fob Immobilizer tested?

Beyond the Basics
Technical Training

Kawasaki Diagnostic System Beyond the Basics
Lesson Objectives
The student will:
1. Learn of idiosycrasies and special features of KDS
2. Learn of the Denso DST-i tool
To round out the student’s knowledge of KDS it is helpful to be aware of some
unexpected features.
Lesson
A. Things KDS does NOT do
1. Register Jet Ski Ultra keys Some of this is shown
in online course.
2. Adjust fuel or ignition on adjustable ECUs, such as found on KX models
3. Take the place or have anything to do with KADIAG
a. KADIAG = DOS based serial communication program
b. Was used to diagnose and service direct injection two-stroke Kawasaki
Jet Ski watercraft
c. If you have a blue cable, put it somewhere far away from your KDS set! Same with a serial port
4. Take the place of common sense or basic fuel/electrical/mechanical cable. That’s a KDS
v2 part.
diagnostics
Repeated from a previ-

ous chapter.
From the KDS Setup Manual

Technical Training
B. KDS idiosycrasies
1. Not all Kawasaki vehicles work the same with KDS
a. Some allow erasing stored fault codes, some do not
b. VN1500/1600 most friendly, will even show run history (only vehicle that
Ultra watercraft shows run history)
cannot be erased. c. JT1200/1500 least friendly, i.e. times out easily, least data available
2. If temps, rpm or battery display incorrectly, reboot KDS
3. Mule DFI injectors are sometimes absent in KDS
4. Mule TPS main and sub are sometimes indistinguishable in KDS
5. Fuel injectors do not code in KDS
6. Crankshaft position and vehicle down sensors often show as indecipherable
faults such as “internal control”
7. Sensors that produce wrong values won’t always code because the ECU
is programmed to expect too wide a range of possible values
8. Mule 820 shows negative intake air pressure when engine is not running
9. 2011 KX models not included in KDS database, they don’t work
10. VN1600 frequently displays incorrect temperatures
11. if KDS was communicating before the update and is not after the update
uninstall KDS and reinstall just the update
This procedure 12. The VN1700 KDS connector is buried pretty deep and hard to find
updates just the 13. Many KDS models have two identical 4-pin connectors right next to
database.
each other
a. Use the manual to tell them apart by wire color
b. Mule 620 - the non-KDS connector is EPS
c. Teryx - the non-KDS connector is EPS
d. Mule 820 - use the connector that has only three wires
e. KFX450R
14. If a sensor has a shorted feed wire, the vehicle’s fuel pump often will not
work - look for this by unplugging 5v powered sensors until the fuel pump
audibly turns on
15. Although the Mule 820’s TPS is not slotted, it can be adjusted and some-
times it has been found to need adjustment
16. If Mule is run in gear with wheels off the floor / ground, a failure of the
vehicle’s speed sensor will register in Failure History and Real Time
Monitor
17. Listening for the OCV on Concours Actuator test may be difficult as the
engine fan comes on with OCV test
a. 2008~2009 Fan on with OCV valve
b. 2010 OCV valve is not able to be tested with Actuator function, though
the fan will come on during test
c. 2011~2016 As above, fan comes on with OCV test

Technical Training
C. A few Kawasaki models beginning in 2016 are now able to have its ECU re-
flashed at the dealership
1. Why
a. For recalls, campaigns, updates
b. In non-U.S. markets facilitates power-down tuning
2. Special software, “Kawasaki VCI” (Vehicle Communication Interface)
a. “Gameboy” appearing box, made by Denso
b. Communicates with KHI
c. Goes between the laptop and vehicle
d. Used in combination with KDS, for now
3. Vehicle must be K-Dealer registered at time of sale
New Denso DST-i

Technical Training
Chapter Highlights
1. Is KDS used to register Jet Skl Ultra electronic keys?
2. What is KADIAG?
3. Warning in service manuals to think outside of DFI
4. KDS idiosycrasies

Appendix
Technical Training
Appendix
KDS History
A. Version 1
1. October 2002 1st modern Kawas-
ki DFI 1999 Drifter.
a. v1.0 Before introduction
b. 2003 model year of KDS dealers had
to rely on onbaord
c. KDS kit 57001-1531 $232 diagnostic for the
d. Serial port (not USB) system VN1500s.
e. Installed two programs, one KDS, the other ABS Today, laptops aren’t
even available with
f. The ABS program supported the continued appearance of ABS on serial ports.
non-U.S. models
2. August 2003
a. v1.1
b. Update package T57001-1531
c. Jet Ski relay cable introduced, 57001-1535
d. Updated to include Jet Ski, ZX6R, Z1000
B. Version 2
1. February 2004
a. v2.0
b. Kit 57001-1552
2. June 2004
a. v2.04
b. Updated to include VN2000, ZX-10R
3. January 2005
a. v2.1
b. Kit discontinued, only individual parts available
4. March 2005
a. v2.2
b. 2005 model year product
5. November 2005 v2.4 was a very stable,
good-performing ver-
a. v2.3 sion of KDS.
b. 2006 model year product
Except for 57001-
6. December 2006 1470 cable as it has
a. v2.4 duplicate application
for race ECU on the
b. Last appearance of version 2 KFX450.
c. 2007 model year
d. Parts for KDS v2 discontinued December 2008

Technical Training
C. Version 3
1. June 2007
a. v3.0
b. First USB version
c. First version to combine KDS ABS diagnostics into one program
Even though new
Concours a 2008
d. Service bulletin ST07-03
model, it was e. Added to the Kawasaki Essential Tool Program because of the
released a year
early.
Concours’ TPMS
2. October 2007
a. KDS 3.0 auto-shipped as a kit
Euro kit is slightly b. “Secret” part number 57001-1687A
different kit using
a different carry-
c. This part number only for auto-ship and new dealer set up
ing case. d. Cannot retail purchase by kit in the U.S. market, though can outside U.S.
e. European kit part number 57001-1687
3. October 2007
a. v3.01 ATV issues patch
4. June 2008
a. Auto-shipped to Mule dealers because of new 2009 DFI Mules
b. Service bulletin ST08-03
5. June 2008
Converter a. v3.0.2
57001-1648 is
pre-countermea-
6. August 2008
sure, needsd a. v3.0.3
countermeasrue
added. 57001-
7. August 2008
1725 converter is a. Countermeasure cable added
post-countermea-
sure, has counter-
b. Service bulletin ST-08-05
measure built in. c. Later incorporated into converter
KDS needs to be
8. Decemeber 2008
updated each year a. v3.0.4
because vehicles
get new part num-
b. Added Flash installer
bers on their ECUs c. Announced price of KDS CD
and KDS reads this
number inside the
c. Service bulletin ST08-09
ECU. 9. February 2009
a. v3.0.5
b. TPS voltage issue
10. February 2009
a. v3.0.6
b. Fahrenheit temps issue
c. v3.0.7
d. VN1700 ETV support added
11. January 2010
a. Y-cable type comm cable introduced
b. Because Kawasaki’s vendors changed wire harness connectors
c. Service bulletin ST-10-01

Technical Training
12. February 2010

a. v3.0.9.2
13. March 2010
a. First bulletin to enumerate individual KDS parts
14. February 2011
a. v3.0.9.4
b. Added 64-bit operating system compatibilty
c. Service bulletin ST11-01
15. March 2012
a. v3.1.2.0
16. September 2012
a. v3.1.3.0
b. 2013 models
18. December 2014
a. v3.1.4.0
b. 2014 models
19. August 2014
a. v3.1.4.3
b. 2015 models
20. July 2015
a. v3.1.4.9
b. 2016 models
21. September 2015
a. v3.1.4.10
b. Real Time Monitor issues addressed

Technical Training
KDS 3 Parts
KDS System Evolution
Chronology
This table shows how the number and kinds of parts grew throughout KDS’ histo-
ry. The center is the beginning, as you go outward parts are added or changed.
The outermost circle is the latest and most current.

Technical Training
KDS 3 PC Requirements
From KDS Setup Manual

Technical Training
Kawasaki Concours KIPASS Primer
For some years now, manufacturers such as Harley-Davidson,

Honda, Ducati, Moto-Guzzi and others have had electronic
keys, that is, keys that have wireless communication built into
them, in addition to their mechanical function, for security
reasons. Kawasaki has since 2004 (and will start soon in the
U.S.) sold streetbikes in Europe that have Kawasaki's version of
wireless-enhanced keys known as the Immobilizer system. In
Kawasaki's system, the head of the ignition key communicates
via radio waves with the bike's ECU (computer), via a short
range antenna near the top of the keyswitch. If the key head
and ECU fail to communicate, the keyswitch lock will not rotate
even though the key is inserted. Kawasaki's Concours 14 sport-
tourer's KIPASS (Kawasaki Intelligent Proximity Activation Start
System) takes the company's already-existing Immobilizer system several steps further. Instead of just
one ECU there are three and instead of the key's head being the transponder, it's the keychain's battery-
powered key "fob" that does the work, much as in many cars today. The KIPASS system is part of an
innovative overall electronics package Kawasaki calls the Smart System that includes the Concours tire
pressure monitoring system (TPMS).
The Mitsubishi-designed MISTY- (a communications technology

similar to G3 cell network encryption) based KIPASS system
uses two communication paths. From keyfob to ECU is radio
freqency (RF). From each of the Concours' three ECUs to each
other is a hardwired twisted pair cable called a CAN bus. CAN,
or controller area network, is simply a Bosch-developed flip-flop
signal path for a motor vehicle's mutliple ECUs to
intercommunicate in a durable, high security way.
How KIPASS Works

This is how the Kawasaki Concours is started. The central
ECU, called the Smart ECU (because it also controls the
TPMS), constantly sends out RF waves, even with the
keyswitch turned off. When the keyfob is within 5 feet of the Smart ECU, the keyfob "transponds," that is,
receives the Smart ECU's signal and returns it with its own unique electronic signature attached. The
Smart ECU compares this signature with its six previously stored
registrations and if there is a match, the Smart ECU then seeks
security confirmation from the other two ECUs, one at a time.
Acknowledgement by the keyswitch ECU via the CAN bus permits
the keyswitch to be pushed down and then rotated. At the same
time, the Smart ECU seeks security confirmation from the FI (engine)
ECU via CAN, in order for the fuel injection and ignition systems to be
activated.
The bike's three ECU are registered with the Smart ECU at
Kawasaki’s factory, so confirmation between ECUs is ensured.
Replacement of any of the ECUs however requires re-registration of
all of the ECUs using a personal computer software application called
Kawasaki Diagnostic System (KDS) that is supplied to authorized
Kawasaki dealers. The KIPASS system's inter-ECU registration makes it impossible for someone to
simply substitute one of the ECUs in order to steal the vehicle.

Technical Training
KIPASS Keyfobs
In the event the keyfob's battery runs down, the keyfob cannot
transpond the Smart ECU's signal the normal way. Provision is
therefore made to use the keyswitch ECU's short range
antenna, by laying the back side of the keyfob directly on the
keyswitch, permitting the RF portion of the process to continue
to work, but now more like it does in the Euro Immobilizer
system. Not surprisingly, this emergency or backup
communication method is called by Kawasaki the Immobilizer
path, while the normal way is called the Transponder path
(official service manual terms). The keyfob itself therefore has
two RF communication paths: the longer range (5 feet)
transponder path, amplified by the fob's battery, and the shorter
(10mm) Immobilizer path unpowered by the fob's battery and meant for emergency use. Both of these
paths are RF, one is simply shorter than the other. Also, each of these paths must be separately
registered into the Smart ECU whenever an extra keyfob is added, an eventuality the dealer software
takes into account.
Two keyfobs come inside the crate from the factory, and these are pre-registered with the bike's Smart
ECU. For that matter, should someone purchase a new Smart ECU for any reason, it also comes with
two keyfobs inside the ECU's parts box, also pre-registered to the new ECU. Extra keyfobs are available,
and every Smart ECU has six total fob memory spaces. This means a brand new Concours has four
extra, unused spaces as delivered. The dealer software (KDS) kit, consisting of a software disk and
several cables, is needed to register extra keyfobs. Whenever registering a new or replacement keyfob,
all the keyfobs in the vehicle owner's possession must be included in the registration episode. Any that
are not present during the process will no longer be recognized. This designed-in feature allows the easy
disassociation from the Smart ECU of any fob that is lost. Simply re-registering the remaining fobs will
count the lost fob out of the system. If the fob is subsequently recovered, it is easily reassociated by
again registering all the keyfobs at the same time, and including that recovered fob. Registering an all-
new keyfob is a little different. This requires the secure ID code that is printed on the keyfob's parts
wrapper. If the wrapper and its ID code is for any reason lost
before the fob is registered, the fob can never be registered,
as the ID code is not marked on the fob. Tire pressure
monitoring system sensors are registered, again using KDS, in
much the same way as are keyfobs, with the difference being
their ID codes are marked on the part itself, and not on the
parts wrapper. The difference is one of security, obviously.
Another difference is found in already registered components.
An already registered keyfob's ID number cannot be retrieved
using KDS. However an already registered TPMS sensor can
be thus retrieved. Again, for security.
Once the Smart ECU has its six memory slots filled, no more keyfobs can be added. Even if one or more
fobs are lost, if all six slots are filled, none can be erased and so no new keyfobs can be added. The
MISTY technology does not permit a fob to be erased, only disassociated. The rest of the Smart system
is a bit more lenient, as TPMS sensors can be completely individually erased, and the Immobilizer side of
the fobs can also be completely erased from the keyswitch ECU.
As already mentioned, when registering a new keyfob, both its long range (Transponder) and its short
range (Immobilizer) sides must be registered. If only the longer range side is registered, then the
emergency low-battery backup (Immobilizer) feature will not work. Kawasaki dealers are even
encouraged to temporarily remove a newly registered keyfob's battery to test confirm the Immobilizer's
proper function.

Technical Training
If the bike's battery runs down or is disconnected, the KIPASS system will not operate. That is, the
keyswitch cannot be pushed down and rotated because the while RF thing is not happening. The
keyfob's battery is similarly vulnerable. If a keyfob is stored on the vehicle, this will of course be within 5
feet of the Smart ECU. The fob and ECU will in this case continuously communicate, which will
dramatically shorten the life of the keyfob's 5-year rated battery. Naturally, a keyfob should not be kept
on the vehicle anyway, since this would make the vehicle able to be started at any time. (Sure, you could
remove the key from the keyswitch, but the vehicle was not designed to be used this way, a fact that can
be attested to by the deliberately ungainly size and shape of the key's head.) A worst-case scenario
concerning keyfobs is possible on the 2010 and later Concours having the computer controlled glovebox.
Since a keyfob is required to operate the glovebox, leaving a fob in the glovebox where its battery can
more quickly run down can result in the unfortunate situation wherein the bike cannot be started because
the fob having a dead battery is inside the glovebox and the glovebox cannot be opened until the
keyswitch is operated. A Catch-22 in other words.
Should the rider take his or her keyfob out of range after the
vehicle is started (the fob falls out of a pocket), the bike will
continue to run but the instrument display will show
“transponder out of range.” The vehicle can still be ridden,
since the engine is already started. However, if the keyswitch
is turned off while the fob is out of range, the keyswitch will
lock. Well, almost. Actually, a special feature makes this
recoverable. The KIPASS system always stays on for 10
seconds after the keyswitch is turned off. The keyswitch can
be pushed down and turned within that time, meaning the
bike ridden, even without the fob in range. Someone who
suddenly realizes their fob is not in their pocket can therefore
push the switch down and restart the bike, if done within 10
seconds of having switched the key off. Beyond 10 seconds
however, the KIPASS system will lock off, and a keyfob will then be necessary to make the keyswitch
work again.
Starting in 2010, one of the two keyfobs that come in the new Concours crate is not a full featured fob but
one having the Immobilizer function only and not the transponder function. It therefore does not have a
battery. This fob is almost slim enough to be carried inside a wallet.
Interesting Technical Points

The name of the technology underlying the KIPASS system is called MISTY, which is reportedly an
ancronym made from the first names of the five Mitsubishi engineers who worked on the original PC
communications encryption project for the Japanese government in the late 1990s.
The red light on the left side of the Concours’ instruments that flashes regularly indicating the presence of
KIPASS doesn't really do anything. It simply flashes continuously for a total of 24 hours. If the keyswitch
is not depressed within that time, the light will stop flashing. KIPASS is not affected, just the light.
Operating KIPASS by pushing down the keyswitch with a keyfob in proximity will start the light flashing
again for a new 24-hour cycle.
The Concours owner's manual has some interesting warnings concerning the KIPASS system. One such
warning is that riders having heart pacemakers need to stay more than 9 feet away from the Smart ECU.
Since the Smart ECU is just a few inches below the seat, this effectively prevents people with
pacemakers from being able to ride a Concours 14 safely. Another statement cautions that KIPASS
function can be impaired when the vehicle is near large glass windows or under bridges.
There is no master keyfob. Each keyfob is unique, and operationally they are all equal. However, the
Concours owner's manual does recommend that two or more keyfobs not be kept close together as they
may interfere with each other.

Technical Training
There have been a few reports that the push-down and

turn phase of the KIPASS system has not worked
correctly, when a registered keyfob was present, and thus
the vehicle could not be started. Usually this happens
some short time after turning the keyswitch off, such as
after having breakfast at a restaurant. This has been
found to be due to a microswitch inside the keyswitch
which has for some reason stuck in the on position,
resulting in the KIPASS system overloading and
disengaging, a fault mode in which the vehicle cannot be
started because the keyswitch can then not be pushed
down. Owners report that a hard knock on the keyswitch
has in some cases dislodged the microswitch and normal
function has resumed. A better emergency technique is to
find the cable for the keyswitch under the left cowling and
disconnect and reconnect it, similar to rebooting a
personal computer. A well-known field fix practiced by some Kawasaki dealers is to chamfer the edges of
the microswitch housing with a sharp knife, which seems to make the microswitch less prone to sticking.
Better yet, replacing the microswitch's internal spring with a slightly stronger one having similar
dimensions consistently overcomes any extra friction the microswitch may build up. In fact, Kawasaki's
U.S. headquarters is aware of and sanctions this latter fix for those few who have experienced the
KIPASS
keyswitchlockup issue.
lockup issue.
Conclusion
The point of KIPASS is lost on some people. In the U.S., insurance companies are not as successful at
lobbying legislation favoring their business as they are in Europe. Thus the issue of theft is not as
important to Americans. The fact is, KIPASS offers such a huge theft deterence that systems like it are
nearly mandatory outside the U.S. Here's why. A purely mechanical locks offers at most a few thousand
unique key combinations, and in many cases, depending on the vehicle, only hundreds. Electronic
systems such as Immobilizer and KIPASS increase security by providing combinations of codes that
potentially number into the hundreds of thousands.
Mitsubishi engineers who developed MISTY are believed to be:

Matsui Mitsuru
Ichikawa Tetsuya
Sorimachi Jun
Tokita Toshio
Yamagishi Atsuhiro

Acknowledges that
has successfully completed

2‐Day Hands‐On Course
Manager, Service Training and Communications
Instructor, Technical Training

KDS 2016

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KDS Intermediate 2016

Kawasaki Motors Corp., U.S.A.

Copyright © 2016 Kawasaki Motors Corp., U.S.A. 1

KDS Intermediate 2016

• Have fun! • Take notes!

• Ask questions! • Get your hands dirty!

• Challenge yourself! • Learn!

KDS Intermediate 2016

Lesson Tool / Item 

Introduction to the Course Laptop

KDS student laptops (5)

Troubleshooting Basics Aerosol brake spray

KDS’ Seven Functions Demonstration vehicle

Spare key fobs

Spare tire pressure sensors

General Air blow gun

Fast Orange hand cleaner

Laptop x 5 for student use

Copyright © 2016 Kawasaki Motors Corp., U.S.A. 1 5

KDS Intermediate 2016

Mechanics gloves, nitrile

Oil, air filter

Oil drain pan

Shop towels, box of 200

Socket adapter, 3/8” to ½”

Sp plug sockets 14mm, 5/8”, 18mm, 13/16”

Torque wrench, in-lb

Torx wrench set, security

Vise jaws soft

6 Copyright © 2016 Kawasaki Motors Corp., U.S.A.

Classroom tables and chairs set up?

Vehicles have good batteries?

Vehicles start and run?

Sufficient shop towels?

Sufficient basic tools available?

Assets accounted for? (see assets checklist)

Fire extinguisher in good condition?

Shop ventilation working?

Training aids ready?

Combination of demos and lectures planned?

Lesson plan reviewed ahead of time and ready at hand?

Wireless connection available?

K-Dealer accessible and logged-on?

Class videos run okay on laptop?

Instructor flash drive containing course content available?

Service manuals available?

Sign-in sheet copied off?

Final quiz available?

Copyright © 2016 Kawasaki Motors Corp., U.S.A. 7

Introduction to the Course 11

Student Task Checkoff Sheet 15

Kawasaki Diagnostic System Available Resources 29

Kawasaki Diagnostic System Hardware Basics 37

Connecting Kawasaki Diagnostic System to a Vehicle 51

Installing the Kawasaki Diagnostic System Software 57

The Seven Kawasaki Diagnostic System Functions 65

Kawasaki Diagnostic System Beyond the Basics 93

Copyright © 2016 Kawasaki Motors Corp., U.S.A. 9

Kawasaki Diagnostic System Intermediate