Versys 300 error codes with new sprockets
This is my first post of the required two. I have some information on Versys 300 error codes after sprocket change. It is discussed here - Kawasaki Versys-X 300 Forum > Versys-X 300 General Discussion > Versys x300 - Sprockets/Re-gearing Causes Engine Fault Light. Hope admin will redirect it. Thanks.
I changed my rear sprocket to 38T keeping the original front (14T). It required 5 links from the stock chain to be removed. So, now transmission final reduction ratio is 2.714 (old one was 3.286). Everything was fine, but after 200 with something miles "check engine" came, and instead of the gear number on the display it shown just horizontal arrows. I checked the code; it was 25 - "Gear Position Sensor". The signal from the sensor to ECU was OK. It seemed like ECU problem, but the bike runs just fine. I decided to take my bike to the dealer, because ECU replacement on the Versys 300 cost about 1K. They confirmed my suspicions and placed an order for a new ECU, but Kawasaki disagreed. After more than a week negotiations, Kawasaki came to a conclusion that ECU is OK, but it accumulates errors from the transmission because of different reduction ratio. They suggested me to put original rear sprocket and see what happen. I said that it is impossible, because my chain is shortened for the smaller rear sprocket. I didn't expect so much stupidity from Kawasaki; since they made me a hard time while shortening the chain (it is a different story). I proposed to erase the code and will continue driving until the next time the code appears. They agreed. That time came two days ago after several hundred miles. I did the same procedure of checking signal from the sensor. Everything was OK, and I manually erased error code. 70 miles passed after that and the bike runs like nothing happened, no "check engine". Looks like ECU and sensor are good, but need reflash.
I was at dealership today and ask if they have technical abilities to reprogram ratio in the ECU firmware. The answer was that they need to talk to Kawasaki in such non-typical case and will call me back.
Just forget, my VX is non-ABS.
That is my story so far. To be continued...
Addendum about chain:
Be careful if you want to change the rear sprocket to a smaller one. In most cases it requires to shorten the chain. Sounds like not a big deal, but the problem is that Kawasaki don't know what chain they install on the production line. I ordered master link (catalog 92058) at my local dealer, but it didn't fit to the stock chain. As appears, the pin diameter of the new master link was 5.36 mm, whereas in the stock chain it was 5.16 mm. The dealer contacted Kawasaki, they said it is absolutely impossible, and sent one more "true verified" link. Guess what? It didn't fit again. After two weeks talking between Kawasaki and the dealer they finally sent a new chain with a master link. Everybody knows that OEM chains never match the retail one (it is done on purpose), but the manufacturer should know the difference and have listed catalog parts matched to the production line parts. Seems not Kawasaki ...
As a result, it took long three and half weeks to remove five links from my VX chain.