Kawasaki 16bit OBD Flash Tool v4.1c

Kawasaki 16bit OBD Flash tool v4.1 by mr_hollywood@cogeco.
ca (Sep 2017)
These instructions detail how to read and flash the ECU ROM contents of your 16bit Kawasaki ZX12R ECU via the OBD
K-Line interface. This program will only work on flashable 16bit ECUs (68HC916 MCU) with a working bootloader (see list
of compatible ECUs below). Please note that flash/erase functionality is not included in the demo version.
If the Flash tool is unable to connect to the ECU, please run the K-line test outlined here to the ensure your hardware
setup is working correctly:
https://docs.google.com/viewer?
a=v&pid=sites&srcid=ZGVmYXVsdGRvbWFpbnxtcmhvbGx5d29vZGszfGd4OjQ0YThhM2M3ZTU3ZWE1Yzk
Hardware required:
 A USB OBD2 II 409 Interface VAG-COM Cable with CH340 chipset. FTDI chipset cables may not work and are
not recommended.
 A Windows personal computer with a free USB port.
 A regulated 12VDC power supply.
 An adaptor cable is also required to connect the OBD to the ECU and a regulated power supply. These are not
sold in stores and must be hand-made. You can find instructions on how to make an adaptor here:
https://sites.google.com/site/mrhollywoodk3/home/obd-bootloader-utilities
Here’s the adaptor cable wiring diagram:
NOTES:
ECU pin 29 should only be connected during flashing/erasing.

Software Installation:
Required files:
 The USB OBD2 II 409 Interface CDROM install disk.

 The KawaFlash tool install program comprised of the following files:
o setup.exe
o KawaFlash.CAB
o SETUP.LST
Installing the USB OBD2 II 409 Interface VAG-COM Cable (Tmart SKU: Q00547) driver:
 Double-click the “usb driver.EXE” program in the “KKL409.1” folder to install the Windows COM port driver then plug
the OBD device into the PC.
 Open the Windows Device Manager to "Computer/properties/device Manager/Ports (COM & LPT)"
o Double-click the USB-SERIAL CH340 (COMx) and select the Port settings tab and enter the following
settings:
Bps: 57,600
Bits: 8
Parity: None
Stop: 1
Flow: None
o Click the “Advanced…” button and select the lowest COM Port number available.
o Uncheck the “Use FIFO buffers” option
Installing the Kawasaki 16bit OBD Flash tool:

 Any previous versions of the program should be de-installed before running the setup.
 Copy the Kawasaki Flash tool install program to a temporary folder on your hard drive
 Double-click the setup.exe file to install the program. You can then delete the temporary install folder.
 Run KawaFlash.exe to start the program
Connecting the ECU:
 With the USB OBD connected and the Flash tool running, plug your adaptor cable into the ECU, USB OBD and turn
on the power supply.
Using the Flash tool:

The Flash tool is fairly simple and intuitive to use:
1. Select the Serial port (COM port) your USB OBD is using from the dropdown list. It may take several seconds
for a device to appear in the list after being plugged in.
2. Click the “Connect” button to establish a connection to the ECU. You should get the message” ECU
bootloader ready” if communication to the ECU has been established. You cannot select any other action until
the connection is made.
3. Select an “Action” from the dropdown list. The options are:

 Read
 Flash (licensed version only)
4. Select a “Target” from the dropdown list. The options will vary depending on the previously selected action:
Action Target Explanation

Read Flash ROM Dump the complete 96k of flash rom from $00000 - $17FFF
Read BE Flash Dump the 2k of BE flash at $90000 containing the bootloader.
Read Registers Dump the $FF000 to $FFC3F “register” address space
Flash ROM1 Maps This will erase and re-flash the $10000-$17FFF (ROM module 1)
address space where the ECU fuel and timing maps reside.
(this option is only available in the licensed version)
 All “Read” actions will create both binary (bin) and iHex (hex) format files in the folder you select. These files
will overwrite any existing file of the same name without asking.
 Although flashing the “ROM1 Maps” only re-flashes the last 32k of ROM, the complete 96k bin file is required.
The first 64k of the file will be compared to ECU ROM to ensure that the binary file is compatible with the ECU
being flashed. If these do not match, you will get a “ROM id mismatch” error and the erase / re-flash operation
will be aborted. If the IDs match, you will be prompted by a pop-up window to ensure that 12v is connected to
ECU pin 29 before proceeding to erase the ECU.
 A progress at the bottom of the application window will activate during the longer operations to keep you
informed of progress.
Known issues:
 The “Action” and “Target” dropdowns are a little quirky and may require re-clicking to enable the “Execute”
button.
 Aborting the program (or removing power) during a reflash operation may permanently damage the ECU. If
the program or operating system hangs, wait a minimum of 3 minutes before powering everything down.
 The software has been tested on a limited number of Windows versions. Win7 32bit is the recommended
operating system (although some Windows XP SP3 computers will work).
 If invalid code is programmed into ROM2 ($00000-$07FFF), the bootloader may fail to operate properly.
Resolving this issue will require “notching” the ECU and erasing it via BDM.
What’s next:
 Having an inexpensive and non-destructive tool for dumping these ECUs allows us to collect and compare the code of
different ECU models, years and versions. So if you dump your ECU, let us know about it…
 The demo version of this tool will allow you to read your ECU and learn about the ECU features that can be modified.
Once you’ve tested your setup, you can decide whether to proceed with obtaining a license to enable flash/erase
functionality. For more info you can contact me at [email protected] or [email protected]
 You can find additional resources related to understanding and reflashing the 16bit Kawasaki ZX12R ECUs here:
https://sites.google.com/site/mrhollywoodk3/home/other-16bit-ecus/kawasaki
And once again…
Warnings:
 The ECU “Program” (pin 29) must be powered using a regulated 12VDC power source during flash/erase. Failure to
do so will result in permanent damage to the ECU. If you don’t know what that means, find out, or walk away. An
overvoltage of just 0.5v on that pin will fry your ECU.
 ESD precautions should be taken at all times to ensure the ECU and USB OBD are not damaged by static electricity
discharge.
 Incorrect connections (misaligned pins, shorts or reverse connection) may result in permanent damage to the ECU
and USB OBD, so double-check your connections before applying power.
 It is highly recommend that you have a (working) spare ECU on hand in the event your ECU is damaged accidentally.
As with any delicate electronics undertaking, there are risks involved.
 Reasonable efforts have been made to ensure that the information presented here is correct and that the software will
perform as expected. Nevertheless, you are solely responsible for any damages you may incur, no matter the cause.
Proceed at your own risk.
Acknowledgements:
Special thanks go out to:
- Iron Pony, without who’s help the project would not have been possible.
- RidgerRacer, for his incredible contributions to the ECU hacking scene.
- Psyche, for his pioneering work on Denso K-Line interfacing.
- And last but not least, my wife, for putting up with hours of endless hacking techno-babble.
[email protected]

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Kawasaki 16bit OBD Flash tool v4.1 by mr_hollywood@cogeco.

 A Windows personal computer with a free USB port.

 A regulated 12VDC power supply.

Here’s the adaptor cable wiring diagram:

ECU pin 29 should only be connected during flashing/erasing.

 The USB OBD2 II 409 Interface CDROM install disk.

Installing the Kawasaki 16bit OBD Flash tool:

Connecting the ECU:

Using the Flash tool:

3. Select an “Action” from the dropdown list. The options are:

Action Target Explanation

And once again…

Special thanks go out to:

- RidgerRacer, for his incredible contributions to the ECU hacking scene.

- Psyche, for his pioneering work on Denso K-Line interfacing.

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