Kawasaki JET SKI STX-15F manual

STX-15F JET SKI ® W atercraft Service Manual[...]

is a trademark of Kawasaki Heavy Industries, Ltd. registered in U.S.A., Japan, Austria, Benelux, Sweden, Denmark, Switzerland, France, Canada, Finland, Norway , Greece, Italy , U.K., Portugal, Thailand, and T aiwan. KA W ASAKI JET SKI ® is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.[...]

This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference G[...]

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STX-15F JET SKI ® W atercraft Service M anual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products and Machinery[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) A TDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct cu[...]

MAINTENANCE AND ADJUSTMENTS Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine Sl engine repair establishment or individual. EMISSION CONTROL INFORMA TION Fuel Information THIS ENGINE IS CERTIFIED T O OPERA TE ON UNLEADED REGULAR GR ADE GASOLINE ONL Y . A minimum of 87 octane of the antikn[...]

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be[...]

NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take b[...]

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GENERAL INFORMA TION 1-1 1 General Information T able of Contents Smart Learning Operation mode (SLO) (JT1500-A2 model ∼ ) ............................................... 1-2 Before Servicing ................................................................................................................ ..... 1-3 Model Identification.............[...]

1-2 GENERAL INFORMA TION Smart Learning Operation mode (SLO ) (JT1500-A2 model ∼ ) This watercraft is equipped with the Smart Learning Operation mode (SLO) and normal op eration mode (Full Power Operation, FPO). The SLO mode reduces the maximum watercraft speed by ap- proximately 30 percent for a use by unskilled o perators. T o change the SLO mo[...]

GENERAL INFORMA TION 1-3 Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper- ation on watercraft, read the precautions given bel ow . T o facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descrip tions have been included in each chapter wherever ne[...]

1-4 GENERAL INFORMA TION Before Servicing • Obtain a standard garden hose [A] and a garden hose adapter [B] as shown. C: Garden Hose Fitting of Adapter D: Flushing Fitting of Adapter E: Thread: Rp 3/4 ○ Optional part (P/No. 92005-3746) is available as a garden hose adapter . • Open the front storage compartment cover . • Remove the flushing[...]

GENERAL INFORMA TION 1-5 Before Servicing CAUTION T urn the capsized boat clockwise so that the port side always faces downward. T urning counterclockwise can cause water in the exhaust system to run into the engine, with pos- sible engine damage. Battery Ground Before completing any service on the watercraft, discon- nect the battery wires from th[...]

1-6 GENERAL INFORMA TION Before Servicing Cleaning Watercraft before Disassembly Clean the watercraft thoroughly before disassembly . Dirt or other foreign materials entering into sealed areas during watercraft disassembly can cause excessive wear and de- crease performance of the watercraft. Arrangement and Cleaning of Removed Parts Disassembled p[...]

GENERAL INFORMA TION 1-7 Before Servicing Assembly Order In most cases assembly order is the reverse of disassem- bly , however , if assembly order is provided in this Service Manual, follow the procedures given. Tightening Sequence Generally , when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten the[...]

1-8 GENERAL INFORMA TION Before Servicing Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains be- fore applying liquid gasket or locking agent. Do not apply them excessively . Excessive application can clog oil pas- sages and cause serious damage. Press For i[...]

GENERAL INFORMA TION 1-9 Before Servicing Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. T ake care not to open the clip excessively when in- stalling to prevent deformation. Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- ca[...]

1-10 GENERAL INFORMA TION Model Identification JT1500-A1 Left Side View JT1500-A1 Right Side View[...]

GENERAL INFORMA TION 1- 1 1 General Specifications Items JT1500-A1 ∼ A2 Engine Ty p e 4-stroke, D OHC, 4-cylinder , water cooled Displacement 14 9 8m L( 9 1 . 4c ui n . ) Bore and Stroke 83 × 69.2 mm (3.27 × 2.72 in.) Compression Ratio 10.6 : 1 Maximum Horsepower 1 1 8k W( 1 6 0P S )@ 75 0 0r / m i n( r p m ) Maximum T orque 152 N·m (15.5 kgf?[...]

1-12 GENERAL INFORMA TION General Specifications Items JT1500-A1 ∼ A2 Overall Width 11 8 0m m( 4 6 . 5i n . ) Overall Height 10 5 0m m( 4 1 . 3i n . ) Dry Weight 338 kg (745 lb) Fuel T ank Capacity 62 L (16.4 US gal) Engine Oil Ty p e API S E, SF or SG API SH or SJ with JASO MA Vis c os i t y SAE 10W-40 Capacity 5.0 L (5.3 US qt) Electrical Equip[...]

GENERAL INFORMA TION 1-13 Unit Conversion T able Prefixes for Units Prefix Symbol Power mega M × 1 000 000 kilo k ×1 0 0 0 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (imp) L× 2 . [...]

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PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart ................................................................................................... 2-2 T orque and Locking Agent ...................................................................................................... 2-3 Specifications ....[...]

2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the watercraft in good running condition. The initial maintenance is vitally important and must not be neglected. Frequency Description Initial 10 Hours Every 25 Hours Every 50 Hours Every 100 Hours Refer- ence Inspect th[...]

PERIODIC MAINTENANCE 2-3 T orque and Locking Agent The following table list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or silicone sealant. Letters used in the “Remarks” column mean: EO: Apply oil to the threads and seating surface. L: Apply a non-permanent locking agent to the th[...]

2-4 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Oil Passage Joints 11 1.1 95 in·lb L Oil Cooler Assembly Bolts 7.8 0.80 69 in·lb Oil Pressure Switch 15 1.5 11 SS Oil Passage Bolt 78 8.0 58 S Oil Filter 18 1.8 13 EO Oil Cooler Positioning Bolt 20 2.0 14 S Oil Pan Bolts 7.8 0.80 69 in·lb S Dipstick T [...]

PERIODIC MAINTENANCE 2-5 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Inlet Side Camshaft Chain Guide Bolts 12 1.2 104 in·lb L Camshaft Chain T ensioner Mounting Bolts 9.8 1.0 87 in·lb L Camshaft Chain T ensioner Cap Bolt 20 2.0 14 Camshaft Position Sensor Rotor Bolt 12 1.2 104 in·lb L W ater Hose Joint 11 1.1 95 in·lb [...]

2-6 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Pump Cover Mounting Bolts 7.9 0.80 69 in·lb L Grate Mounting Bolts 9.8 1.0 87 in·lb L Filter Cover Mounting Bolts 9.8 1.0 87 in·lb L Steering Handlebar Clamp Bolts 16 1.6 12 L Start/stop Switch Case Mounting Screws 3.9 0.40 35 in·lb Throttle Case Moun[...]

PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Starter Relay Mounting Nut 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lb Starter Cable Mounting Nut 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lb T iming Rotor Bolt 20 2.0 14 L Crankshaft Sensor Screws 4.4 0.45 39 in·lb L Rubber Grommet Holder Screws 4.4 0.45 [...]

2-8 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Lever Free Pla y about 2 mm (0.08 in.) ––– Engine Lubrication System Engine Oil: Ty p e API SE, SF or SG API SH or SJ with JASO MA ––– Viscos ity SAE 10W-40 ––– Capacity 4.0 L (4.2 US qt, with or without the filter) 5.0 L (5.3 US qt, when engi[...]

PERIODIC MAINTENANCE 2-9 Special T ools and Sealant Oil Filter W rench: 57001-1249 Shaft Wrenc h: 57001-1551[...]

2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Control System Inspection • Inspect the throttle lever free play [A]. If the free play is incorrect, adjust the throttle cable. Throttle Lever Fr ee Play Standard: about 2 mm (0.08 in.) • Check that the throttle lever moves smoothly from full open to close, and the t[...]

PERIODIC MAINTENANCE 2-1 1 Periodic Maintenance Procedures Air Filter Inspection and Cleaning • Remove: Air Filter (see Fuel System (DFI) chapter) Flame Arrester [A] (see Air Filter Disassembly in Fuel System (DFI) chapter) • Clean the flame arrester [A]. • Visually inspect the flame arrester for damage. If necessary , replace it with a new o[...]

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures • The fuel vent check valve [C] must be mounted so that the arrow [D] on its case is pointing toward the fuel tank. Fuel Pump Screen Cleaning • Remove the fuel pump (see Fuel System chapter). • W ash the fuel pump screen [A] in non-flammable of high -flash point solvent. Use a brush to[...]

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures • In a well-ventilated area, start the engine while cooling the cooling system. ○ Open the front storage compartment cover . ○ Remove the flushing cap (see Cooling System Flushing). ○ Screw a garden hose adapter [A] onto the flushing fitting [B]. ○ Attach a garden hose [C] to a gar[...]

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed accord- ing to the chart sho wn. • Install the filler cap. T orque - Oil Filler Ca p: 1.0 N·m (0.10 kg f·m, 8.7 in·lb) • Check the oil level (see Engine Lubrication System chap[...]

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine T op End Air Suction V alve Inspection • Remove the air suction valve (see Engine T op End chap- ter). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as a[...]

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the valve clearance between the cam and the valve lifter with a thickness gauge [A]. V alve Cleara nce Standard: IN 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in. ) EX 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in. ) ○ When positioning #1 piston TDC at the end of the compression stroke: Inle[...]

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures INLET V AL VE CLEARANCE ADJU STMENT CHART 1. Measure the clearance ( when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper cl[...]

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures EXHAUST V AL VE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper cl[...]

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Apply molybdenum disulfide oil to the valve lifters and ap- ply engine oil to the shims, and install them. • Install the camshafts. Be sure to install the c amshafts properly (see Engine T op End chapter). • Remeasure any valve clearance that was adjusted. • Readjust if necessary .[...]

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Obtain a standard garden hose [A] and a garden hose adapter [B] as shown. Garden Hose Fitting of Adapter [C] Flushing Fitting of Adapter [D] Thread: Rp 3/4 [E] NOTE ○ Optional part (P/No. 92005-3746) is available as a gar- den hose adapter . • Open the front storage compartment cover[...]

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Leave the engine idle for several minutes with the water running. • T urn off the water . Leave the engine idling. • Rev the engine a few times to c lear the water out of the exhaust system. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especial[...]

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Pump and Impeller Impeller Inspection • Examine the impeller . [A] If there is pitting, deep scratches, nicks or other damage, replace the impeller . NOTE ○ Minor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing. Smooth leading edges are especi[...]

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Steering Shaft [B] Hull/Engine Hood Drain Plug Inspection • Check the drain plugs [A] for cracks or damage and the drain plug mounting screws [B] are tightened securely . • Check the seals [C] for damage. If necessary , replace the drain plugs or seals. Electrical System Battery Charging[...]

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the battery terminals [B] are not corroded . If necessary , remove the battery (see Electrical System chapter) and clean the terminals and cable ends using a solution of baking soda and water . • After attaching both cables, coat the terminals and cable ends with grease to p[...]

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Lubricate the following with grease. ○ Pull the throttle lever and hold it. Throttle Cable End at Throttle Lever [A] Throttle Cable End [A] at Throttle Body ○ Remove the storage pocket (see Hull/Engine Hood chap- ter). Steering Cable Ball Joint [A] at Steering S haft ○ Remove the s[...]

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Lubricate the following with a penetrating rust inhibitor [B]. Throttle Cable [A] Steering Nozzle Pivots [A] Reverse Bucket Pivots [B] • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating,[...]

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check Nuts, Bolts, and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness[...]

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Make sure the above hoses are routed properly and se- cured with the clamps away from any moving parts and sharp edged portions. Plastic Clamp [A] Hose [B] Hose Fitting [C] NOTE ○ The majority of bilge hoses have no clamps at the hose ends. Metal Clamp [A] Hose [B] Hose Fitting [C] NOT[...]

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Rubber Strap Inspection • Check the following rubber straps for any deterioration or damage. Pull on squeeze the straps and look for cracks. Battery Straps [A] Fuel T ank Straps W ater Box Muffler Straps If a strap is damage in any way , replace it.[...]

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FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) T able of Contents Fuel System Diagram ........................ 3-3 Exploded View ................................... 3-4 Specifications .................................... 3-10 Special T ools and Sealant ................. 3-12 DFI Parts Location ............................. 3-13 DFI System ..............[...]

3-2 FUEL SYSTEM (DFI) Throttle Lever , Cable and Case ......... 3-65 Free Play Inspection .................... 3-65 Throttle Cable Adjustment ........... 3-65 Throttle Case Removal/Disas- sembly ....................................... 3-65 Throttle Case Assembly/Installa- tion ............................................ 3-66 Throttle Cable Removal[...]

FUEL SYSTEM (DFI) 3-3 Fuel System Diagram 1. Fuel Pump 2. Clamps (JT1500-A1 Model) Double Spring Clamps (JT1500-A2 Model ∼ ) (Installation Procedure: Pull up the clamp stopper [A] with pliers [B].) 3. Main Line 4. Fuel Filter 5. Supply Line 6. Return Line 7. Delivery Pipe 8. Fuel Injectors 9. Fuel T ank[...]

3-4 FUEL SYSTEM (DFI) Exploded View[...]

FUEL SYSTEM (DFI) 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 V e hicle- down Senso r Mounting Sc rews 1.5 0.15 13 in·lb 2 Bracket Mounting Bolts – – – L 3 Inlet Manifold Mounting Bolts 25 2.5 18 L 4 Inlet Manifold Mounting Nuts 20 2.0 14 5 Delivery Pipe Mounting Bolts 7.8 0.80 69 in·lb 6 Inlet Air Pressure Sensor Bo[...]

3-6 FUEL SYSTEM (DFI) Exploded View[...]

FUEL SYSTEM (DFI) 3-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Oil Pressure Switch 15 1.5 11 SS 2 Fuel Filler T ube Clamp Screws 2.9 0.30 26 in·lb 3 Fuel Level Sensor Clamp Screw 2.9 0.30 26 in·lb 4 Fuel Filter Mounting Bolts 8.8 0.90 78 in·lb L 5. Meter Unit 6. Buzzer 7. Fuel V ent Check V alve 8. Fuel Level Sensor 9. Fue[...]

3-8 FUEL SYSTEM (DFI) Exploded View[...]

FUEL SYSTEM (DFI) 3-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Filter Mounting Bolts 9.8 1.0 87 in·lb 2 Air Filter Bracket Mounting Bolts 7.8 0.80 69 in·lb L 3 Throttle Cable Locknut 7.8 0.80 69 in·lb 4 Throttle Case Mounting Screws 3.9 0.40 34 in·lb G: Apply grease. L: Apply a non-permanent locking agent.[...]

3-10 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±100 r/min (rpm) -both in and out of water Throttle Assy: Ty p e Single type Bore 60 mm (2.36 in.) ECU (Electronic Control Unit): Make Mitsubishi Electric Ty p e Digital memory type, with built in IC igniter , sealed with resin Operating range Engine[...]

FUEL SYSTEM (DFI) 3-1 1 Specifications Item Standard Throttle Lever and Cables Throttle Lever Free Play about 2 mm (0.08 in.)[...]

3-12 FUEL SYSTEM (DFI) Special T ools and Sealant Oil Pressure Gauge, 5 kgf/cm² : 57001-125 Hand T ester: 57001-1394 Needle Adapter Set: 57001-1457 Fuel Pressure Gauge Adapter: 57001-1463 Throttle Sensor Set ting Adapter: 57001-1521 Sensor Harness Adapter: 57001-1561 Harness Adapter: 57001-1562 Kawasaki Bond (Sili cone Sealant): 56019-120 Kawasaki[...]

FUEL SYSTEM (DFI) 3-13 DFI Parts Location 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Inlet Air Pressure Sensor 6. Inlet Air T emperature Sensor 7. Throttle S ensor 8. ISC (Idle Speed Controller) 9. Camshaft Position Sensor 10. W ater T emperature Sensor 1 1. Crankshaft Sensor 12. Oil Pressure Switch 13. Oil T[...]

3-14 FUEL SYSTEM (DFI) DFI Parts Location 14. Ignition Switch 15. Meter Unit 16. Buzzer 17. Fuel Pump 18. Fuel Level Sensor 19. V ehicle-down Sensor 20. Ignition Coil #1, #4 21. Ignition Coil #2, #3 22. Main Fuse 20 A 23. ECU (Electronic Control Unit) 24. Diagnosis Connector 25. Relay Assembly (Main Relay/Fuel Pump Relay) 26. Battery[...]

FUEL SYSTEM (DFI) 3-15 DFI Parts Location Dummy Page[...]

3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram[...]

FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Joint Connector H 6. Inlet Air T emperature Sensor 7. Inlet Air Pressure Sensor 8. Joint Connector E 9. Joint Connector J 10. Crankshaft Sensor 1 1. Relay Assembly (Main Relay/Fuel Pump Relay) 12. Joint Connector F 13. Conn[...]

3-18 FUEL SYSTEM (DFI) DFI System T erminal Numbers of ECU Connectors T erminal Names 1. T achometer Signal 2. ECU Main Relay 3. Unused 4. SLO (Smart Learning Operation) Mode (JT1500-A2 Model ∼ ) 5. Oil P ressure Switch 6. Engine Stop Switch 7. Inlet Air T emperature Sensor 8. Ground for Sensors 9. Ignition Switch 10. Steering Position Sensor 1 1[...]

FUEL SYSTEM (DFI) 3-19 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○ Do not reverse the battery cabl[...]

3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions For JT1500-A2 ∼ ; ○ Install the double spring clamp in the posit ion as shown, and securely pull up the clamp stopper with pliers. Check the fuel system for leaks after hose installation. Fuel Hose [B] Double Spring Clamp [A] Fuel Pipe [C] CAUTION Do not reuse the double spring clamps on the fuel[...]

FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ After measurement, remove the needle adapt ers and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Ka wasaki Bond: 56019-120) -Se als of Connector • Always check battery condition before replacing the DFI parts. A fully charged battery is a mu[...]

3-22 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode. [A] P u s ht h e“ S E T ”b u t t o nw i t h“ M O D E ”b u t t o na tt h e same time for 3 seconds or more. [B] Push either “SET” or “MODE” button for more than one second or more. User Mode This i[...]

FUEL SYSTEM (DFI) 3-23 Self-Diagnosis Service Code (Character) T able Service Code (used in ECU) Service Code Character (displayed on Meter Unit) Possible Problems Fail-Safe Function 11 Throttle sensor malfunction, wiring open or short The ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J met[...]

3-24 FUEL SYSTEM (DFI) Self-Diagnosis Note: (1) D-J Method: the DFI control m ethod from medium to heavy engine load. When the engine load is light like at idling or low speed, the ECU determines the i njection quantity by calculating from the throttle vacuum (vacuum sensor output voltage) and engine speed (crankshaft sensor output voltage). (2) α[...]

FUEL SYSTEM (DFI) 3-25 T roubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Y ear of initial registration: Model: Engine No.: Hull No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy , □ rain, □ snow , □ always, □ other: T emperature □ hot[...]

3-26 FUEL SYSTEM (DFI) T roubleshooting the DFI System □ spark plug loose (tighten it). □ spark plug dirty , broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). Poor running or no power at high speed □ knocking (fuel poor quality or incorrect). □ engine overheating. □ engine oil level too high. □ engine oil vi[...]

FUEL SYSTEM (DFI) 3-27 Throttle Sensor (Service Code/Character-1 1/tPS) Throttle Sensor Removal/Adjustment CAUTION Never drop the throttle sensor [A], especially on a hard surface. Such a shock to the sensor can dam- age it. • Remove: Seat (see Hull/Engine Hood chapter) Air filter (see air Filter Removal) • Use a T orx wrench [A] (T20, B = 3.86[...]

3-28 FUEL SYSTEM (DFI) Throttle Sensor (Service Cod e/Character-1 1/tPS) • Adjust the throttle sensor positioning as follows. ○ Install the air filter temporarily . ○ After warming up the engin e, check the idling speed. Idle Speed Standard: 1 300 ±100 r/mi n (rpm) ○ Stop the engine and turn the ignition switch OFF . ○ Disconnect the thr[...]

FUEL SYSTEM (DFI) 3-29 Throttle Sensor (Service Code/Character-1 1/tPS) • T urn the ignition switch ON and push the lanyard key un- der the stop button. • Pushing the start button, run the engine 5 ∼ 6 seconds at idling to measure the sensor input voltage. ○ W ait 15 seconds before using the starter again. Input V oltage at ECU Standard: 4.[...]

3-30 FUEL SYSTEM (DFI) Throttle Sensor (Service Cod e/Character-1 1/tPS) Output V oltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital V oltmeter [A] Connector [B] Special T ool - N eedle Adapter Set: 57001-1457 Throttle Sensor Output V oltage Connections to ECU Meter ([...]

FUEL SYSTEM (DFI) 3-31 Throttle Sensor (Service Code/Character-1 1/tPS) • Disconnect the throttle sensor connector and connect the setting adapter [A] between the harness connector and throttle sensor connector . • Connect a digital meter to the setting adapter leads. Special T ool - Throttle Sensor Setting Adapter: 57001 -1521 Throttle Sensor [...]

3-32 FUEL SYSTEM (DFI) Throttle Sensor (Service Cod e/Character-1 1/tPS) 1. ECU 2. Joint C onnector E 3. Throttle Sensor[...]

FUEL SYSTEM (DFI) 3-33 Inlet Air Pressure Sensor (Service Code/C haracter-12/bOSt) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal • T urn the ignition switch off. • Remove: Seat (see Hull/Engine Hood chapter) Inlet Air Pressure Sensor Bolts [A] Inlet Air Pr[...]

3-34 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Serv ice Code/Character-12/bOSt) If the reading is within the standard range, and check the input voltage at the sensor connector . • Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the harness connector and inlet air pressure sensor connector . • C[...]

FUEL SYSTEM (DFI) 3-35 Inlet Air Pressure Sensor (Service Code/C haracter-12/bOSt) If the output voltage is far out of the usable range, check the output voltage at the sensor connector [A]. • Measure the output voltage at the sensor in the same way as input voltage inspection. Note the following. [B] Inlet Air Pressure Sensor Special T ool - Sen[...]

3-36 FUEL SYSTEM (DFI) Inlet Air T emperature Sensor (Service Code/Character-13/AIrt) Inlet Air T e mperature Removal/Installa tion CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove the air filter (see Air Filter Removal). • Disconnect the connector [A] from the inlet air tempera- t[...]

FUEL SYSTEM (DFI) 3-37 Inlet Air T emperature Sensor (Service Code/Character-13/AIrt) If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power S upply Inspection). If t he ground and power supply are good, replace the ECU. If the output voltage is far out of the specified, check the wiring (see ne[...]

3-38 FUEL SYSTEM (DFI) Inlet Air T emperature Sensor (Service Code/Character-13/AIrt) 1. ECU 2. Joint C onnector E 3. Joint C onnector H 4. Inlet Air T emperature Sensor[...]

FUEL SYSTEM (DFI) 3-39 W ater T emperature Sensor (Serv ice Code/Character-14/AqUt) Water T emperature Se nsor Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Disconnect the sensor connector [A], and unscrew the water temperature sensor [B]. • When installing the wat[...]

3-40 FUEL SYSTEM (DFI) W ater T emperature Sensor (Service Code/Character-14/ AqUt) • Connect a digital voltmeter [A] to the ECU connector [B], with the needle adapter set. Special T ool - N eedle Adapter Set: 57001-1457 W ater T emperature Sensor Output V oltage Connections to ECU Meter (+) → G/Y lead (te rminal 35) Meter (–) → BK/W lead ([...]

FUEL SYSTEM (DFI) 3-41 W ater T emperature Sensor (Serv ice Code/Character-14/AqUt) 1. ECU 2. Joint Connector E 3. W ater T emperature Sensor Sensor Resistance Inspection • Remove the water temperature sensor (see W ater T em- perature Sensor Removal/Installation). • Refer to Electrical System chapter for water temperature sensor inspection.[...]

3-42 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code/Character-21/ CrAg) Crankshaft Sensor Removal/Installation • See the Ignition System section in Electrical System chapter . Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals. • Crank the engine and measure [...]

FUEL SYSTEM (DFI) 3-43 Camshaft Position Sensor (Servi ce Code/Character-23/CAAg) Camshaft Position Sensor Removal/Installation The camshaft position sensor detect s the position of the camshaft, and distinguishes the cylinder . • See the Ignition system section in Electric System chap- ter . Camshaft Position Sensor Inspection ○ The camshaft p[...]

3-44 FUEL SYSTEM (DFI) V ehicle-down Sensor (Servi ce Code/Character-31/dOS) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the watercraft banks 11 0 ∼ 130° or more to either side (in fact falls down), the weight turns and shuts off the signal. The ECU senses this change, and stops the fuel pump, th[...]

FUEL SYSTEM (DFI) 3-45 V ehicle-down Sensor (Servi ce Code/Character-31/dOS) V ehicle-down Sensor Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel T ank (see Fuel T ank Removal) • Connect a digital volt meter [A] to the connector [B] of the vehicle-down sensor lead with the needle adapter set [C]. Special T ool - N eedle[...]

3-46 FUEL SYSTEM (DFI) V ehicle-down Sensor (Servi ce Code/Character-31/dOS) • T urn the ignition switch OFF . • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bo nd: 56019-120) -Seals of V ehicle-down Sensor Connector If the output voltage is normal, the wir[...]

FUEL SYSTEM (DFI) 3-47 Fuel Injectors (Service Code/Character -41, 42, 43, 44/In J1, InJ2, InJ3, InJ4) Fuel Injector Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Disconnect the battery (–) cable ter- minal. Do not smoke. Make sure the area is well-ventilated [...]

3-48 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character- 41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) • Replace the seals [A] with new ones. • Apply grease to the inside and outside of seals. • Install: Delivery Pipe Assembly Collars • Install the clamps [A] as shown. • T ighten: T orque - Delivery Pipe Mounting Bol ts: 7.8 N·m (0.80 kg [...]

FUEL SYSTEM (DFI) 3-49 Fuel Injectors (Service Code/Character -41, 42, 43, 44/In J1, InJ2, InJ3, InJ4) • Remove connectors for injector [A]. • Connect each test light set [B] to the i njector harness con- nector [C]. • T urn the ignition switch ON. • While cranking the engine with the starter motor , watch the test lights. If the test light[...]

3-50 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character- 41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Injector V oltage Inspection • T urn the ignition switch OFF . • Connect a digital voltmeter [A] to the connector [B], with the needle adapter set. Special T ool - N eedle Adapter Set: 57001-1457 Injector Power Source V olt age Connector to Inj[...]

FUEL SYSTEM (DFI) 3-51 Fuel Injectors (Service Code/Character -41, 42, 43, 44/In J1, InJ2, InJ3, InJ4) Injector Fuel Line Inspection • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the supply joint of the delivery pipe [B] with the fuel hose [C] (both ends connected with the [...]

3-52 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character- 41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Joint Connector H 6. Main Relay i n Relay Assembly 7. Joint Connector F 8. Connector C 9. Connector D 10. Joint Connector R 1 1. Main Fuse 20 A 12. Battery 13. ECU 1[...]

FUEL SYSTEM (DFI) 3-53 Ignition Coils (Service Code/Character-51, 52/COL1, CO L2) Ignition Coil #1, #4: Service Code 51-COL1 Ignition Coil #2, #3: Service Code 52-COL2 Ignition Coil Removal/Installat ion CAUTION Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can dam- age it. • See Ignition System se[...]

3-54 FUEL SYSTEM (DFI) Ignition Coils (Service Code/C haracter-51, 52/COL1, COL2) 1. Main Relay in Relay Assembly 2. Joint C onnector F 3. Connector C 4. Connector D 5. Joint C onnector R 6. Main Fuse 20 A 7. Starter Motor 8. Battery 9. ECU 10. Ignition Coils 1 1. Joint Connector P 12. Joint Connector S[...]

FUEL SYSTEM (DFI) 3-55 Engine Overheating (Servic e Code/Character-71/HEAt) • If the service code is displayed, check the doubtful parts referring to the following table. Possible Causes Action (Chapter) W ater passage clogged, loosened or damaged Inspect (see 9 chapter) Incorrect engine oil level Inspect (see 4 chapter) Engine oil poor quality o[...]

3-56 FUEL SYSTEM (DFI) Low Engine Oil Pressure ( Service Code/Character-72/OILP) • If the service code is displayed, check the doubt ful parts referring to the following table. Possible Causes Action (Chapter) Oil leak Inspect (see 4 chapter) Engine oil level too low Inspect (see 4 chapter) Engine oil viscosity too low Inspect (see 4 chapter) Oil[...]

FUEL SYSTEM (DFI) 3-57 Oil T emperature Sensor (Service Code/Character-73/OILC or 73/OILt) Service Code/Charact er JT1500-A1: 73/OILC JT1500-A2 ∼ : 73/OILt Oil T emp erature Sensor Remova l/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Engine (see Engine Removal/In[...]

3-58 FUEL SYSTEM (DFI) Oil T emperature Sensor (Service Cod e/Character-73/OILC or 73/OI Lt) • T urn the ignition switch OFF . If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If t he ground and power supply are good, replace the ECU. If the output voltage is far out [...]

FUEL SYSTEM (DFI) 3-59 Engine Oil Overheating (Servi ce Code/Character-76/OILH) JT1500-A2 model ∼ ; • If the service code is displayed, check the doubtful parts referring to the following table. Possible causes Action (Chapter) Incorrect engine oil level Inspect (see 4 chapter) Engine oil poor quality or incorrect Change (see 4 chapter) Oil tem[...]

3-60 FUEL SYSTEM (DFI) ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seat (see Hull/Engine Hood chapter) Bolts [A] • Disconnect the ECU lead connector [A]. • Remove: ECU [B] ECU Installation • Connect the ECU connector and install it. • Apply a non-permanent lock[...]

FUEL SYSTEM (DFI) 3-61 ECU • Check the ECU power source voltage with a tester [A]. ○ Position the terminal in accordance with terminal numbers of ECU connector [B] in this chapter figure. ECU Power Source Inspect ion T ester Connections: 2( R / G )T e r m i n a l–B a t t e r y( − )T e r m i n a l 9( R / W )T e r m i n a l–B a t t e r y( ?[...]

3-62 FUEL SYSTEM (DFI) ECU ECU Power Source Circuit 1. Main Relay in Relay assembly 2. Joint C onnector F 3. Connector C 4. Connector D 5. Ignition Switch 6. Start Sw itch 7. Joint C onnector R 8. Main Fuse 20 A 9. Battery 10. ECU 1 1. Joint Connector P 12. Joint Connector S[...]

FUEL SYSTEM (DFI) 3-63 DFI Power Source Main Fuse Inspection • Refer to the Electrical System chapter for the ECU Fuse Inspection. Relay Assembly Removal CAUTION Never drop the relay , especially on a hard surface. Such a shock to the relay can damage it. • Remove: Seats (see Frame chapter) Bolt [A] Relay Assembly [B] Connector [C] (disconnect)[...]

3-64 FUEL SYSTEM (DFI) DFI Power Source Fuel Pump Relay Relay Coil T erminals [6] and [8] Relay Switch T erminals [5] and [7] T esting Relay T ester range: 1 Ω range Criteria: When batt ery is connected → 0 Ω When battery is disconnected →∞Ω If the relay does not work as specified, replace the relay assembly . Hand T ester [A] Battery [[...]

FUEL SYSTEM (DFI) 3-65 Throttle Lever , Cable and Case Free Play Inspection • Refer to Throttle Control System Inspection in the Peri- odic Maintenance chapter . Throttle Cable Adjustment • Refer to Throttle Cable Adjustment in the Periodic Main- tenance chapter . Throttle Case Removal/Disassembly • Unscrew the mounting screws [A] and remove [...]

3-66 FUEL SYSTEM (DFI) Throttle Lever , Cable and Case • Disassemble the throttle case. ○ Remove the circlip [A], flat washers [B], pin [C], throttle lever [D] and return spring [E] from the case [F]. Throttle Case Assembly/Installation • Insert the end of the return spring [A] in the throttle lever hole [B] and set the spring in the throttle[...]

FUEL SYSTEM (DFI) 3-67 Throttle Lever , Cable and Case • T ighten: T orque - Throttle Case Mounting Screws: 3.9 N·m (0.40 kgf·m, 34 in·lb) • Swing the throttle lever so that the throttle valve is fully open. WA R N I N G Operation with an improperly assembled throttle case could result in an unsafe riding condition. • Adjust the throttle c[...]

3-68 FUEL SYSTEM (DFI) Throttle Lever , Cable and Case • Remove the throttle case (see Throttle Case Removal). • Slide the rubber boot ou t of the place. • Unscrew the throttle cable fitting nut. • Remove the upper end of the cable from the case. ○ Use a screw driver [A] to separate the cable tip [B] from the throttle lever catch. • Rem[...]

FUEL SYSTEM (DFI) 3-69 Throttle Lever , Cable and Case • T ighten: T orque - Throttle Case Mounting Screws: 3.9 N·m (0.40 kgf·m, 34 in·lb) • Route the following correctly (see Cable, Wire, and Hose Routing in Appendix chapter). Throttle Cable Steering Cable Fuel T ank V ent Hose Start/Stop Switch Leads Buzzer Leads Multifunction Meter Leads [...]

3-70 FUEL SYSTEM (DFI) Air Filter Air Fil ter Removal • Remove the seat (see Hull/Engine Hood chapter). • Remove the rear storage pocket. • Disconnect the following from the a ir filter [A]. Air Suction V alve Hose [B] Oil Separator T ank Hose [C] • Remove the oil separator tank [D] (see Engine Lubrication System chapter). • Loosen the cl[...]

FUEL SYSTEM (DFI) 3-71 Air Filter Air Filter Disassembly • Remove: Air Filter (see Air Filter Removal) Air Filter Bolts [A] • Remove: Bolts [A] Flame Arrester [B] Hose [C] Duct [D] Air Filter Bracket Mounting Bolts [E] A i rF i l t e rB r a c k e t[ F ] • Remove the air screen [A] A i rF i l t e rA s s e m b l y • Visually insp ect the seal[...]

3-72 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection The normal idle speed is controlled by the ECU (Elec- tronic Control Unit). Idle Speed Standard: 1 300 ±100 r/min (rpm) -both in and out of water High Altitude Performance Adjustmen t High altitude adjustment is not required as the ECU con- trols the air/fuel mixture automatically . T[...]

FUEL SYSTEM (DFI) 3-73 Throttle Body Assy ISC (Idle Speed Controller) Removal/Installation • Remove Seat (see Hull/Engine Hood chapter) Air Filter (see Air Filter Removal) Bands [A] ISC connector [B] Stepping Motor Mounting Screws [C] Stepping Motor [D] ISC Actuator Mounting Bolts [E] ISC Actuator [F] • Clean the mating surface of throttle body[...]

3-74 FUEL SYSTEM (DFI) Throttle Body Assy ISC Resistance Inspection • Remove: Air Filter (from the throttle body assy) ISC Connector [A] (disconnect) • Measure the ISC resistance with the hand tester . Special T ool - Kawasaki Hand T ester: 57001-1394 ISC [A] Rotor [B] ISC Resis tance Connection: 1-2, 2-3, 4-5, 5-6 termina ls Standard: about 30[...]

FUEL SYSTEM (DFI) 3-75 Inlet Manifold Inlet Manifold Rem oval • Remove: Supply Fuel Hose [A] at Delivery Pipe Return Fuel Hose [B] at Delivery Pipe Delivery Pipe Mounting Bolts [C], Collars and Clamps • Remove the bands [D] and disconnect the following con- nectors. Camshaft Position Sensor Connector [E] Crankshaft Sensor Connector [F] • Disc[...]

3-76 FUEL SYSTEM (DFI) Inlet Manifold • Remove the inlet manifold [A] with the throttle body assy [B]. • Remove the throttle body assy from the inlet manifold (see Throttle Body Assy Removal). • Unscrew the inlet manifold plate bolts [A] and remove the plate [B] and gasket [C]. • Remove: Inlet Air T emperature Sensor [D] Inlet Manifold Drai[...]

FUEL SYSTEM (DFI) 3-77 Inlet Manifold • Replace the injector seals [A] with new ones. • Apply grease to the inside and outside of seals. • T ighten the delivery pipe mounting bolts [B]. T orque - Delivery Pipe Mounting Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Route the cable, wire and hose correctly (see Cable, Wire and Hose Routing in Ap[...]

3-78 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Be sure to place a piece of cloth under the fuel supply hose [A] of the fuel delivery pipe. WA R N I N G Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately . When the fuel hose is disconnected, fuel spill[...]

FUEL SYSTEM (DFI) 3-79 Fuel Line If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the fuel filter and measure the fuel pressure again. • Remove the fuel pressure gauge and adapter . • Run the fuel hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter . ○ F[...]

3-80 FUEL SYSTEM (DFI) Fuel Line • Prepare a measuring cylinder [A]. • Disconnect the fuel supply hose from the fuel delivery pipe, and set the measuring cylinder and fuel supply hose [B] as shown. • Close the fuel tank cap. WA R N I N G Wipe off spilled out fuel immediately . Be sure to hold the measuring cylinder vertical. • T urn the ign[...]

FUEL SYSTEM (DFI) 3-81 Fuel V ent Check V alve Fuel V ent Check Valve Mounting • Refer to Fuel V ent Check V alve Inspection in the Periodic Maintenance chapter . Fuel V ent Check V alve Inspection • Refer to Fuel V ent Check V alve Inspection in the Periodic Maintenance chapter .[...]

3-82 FUEL SYSTEM (DFI) Fuel Filter Fuel Filter Removal NOTE ○ The fuel filter is designed to be used th roughout the watercraft’s life without any maintenance if it is used under normal conditions. WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. Pull the lanyard key off the stop button. Make sure th[...]

FUEL SYSTEM (DFI) 3-83 Fuel Filter Fuel Filter Installation • Route the hose correctly (see Cable, Wire, and Hose Routing section in Appendix chapter). • Install the fuel hoses to the fuel filter , noting its “IN” fitting [A] and “OUT” fitting [B]. ○ For JT1500-A2 model ∼ ; R eplace the double spring clamps with new ones. ( see Fuel[...]

3-84 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. Pull the lanyard key off the stop button. Make sure the area is well-ventilated and free from any s[...]

FUEL SYSTEM (DFI) 3-85 Fuel Pump Fuel Pump Installation • Press down the rubber holder [A] onto the fuel pump [B] so the stepped part [C] of the holder completely contacts the flanged part [D] of the pump. • Pressing down the rubber holder onto the fuel pump, tighten the small diameter clamp [E]. NOTE ○ Install the rubber holder onto the fuel[...]

3-86 FUEL SYSTEM (DFI) Fuel Pump • Remove the front storage pocket (see Hull/Engine Hood chapter). • Connect the hand tester (25 V DC) [A] to the fuel pump lead connector [B], using the needle adapter set [C]. Special T ools - Hand T ester: 57001-1394 Needle Adapte r Set: 57001-1457 • T urn the ignition switch ON and push the lanyard key un- [...]

FUEL SYSTEM (DFI) 3-87 Fuel Pump Fuel Pump Relay Removal • Refer to the Relay Assembly Removal in the DFI Power Source section. Fuel Pump Relay Inspection • Refer to the Relay Assembly Inspection in the DFI Power Source section. 1. Relay Assembly 2. Joint Connector F 3. Connector C 4. Connector D 5. Joint Connector R 6. Main Fuse 20 A 7. Batter[...]

3-88 FUEL SYSTEM (DFI) Fuel T ank Fuel T ank Removal • Drain the fuel tank into a suitable container . WA R N I N G Gasoline is extremely flammable and can be explo- sive under certain conditions. Pull the lanyard key off the stop button. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this include[...]

FUEL SYSTEM (DFI) 3-89 Fuel T ank • Remove the fuel tank [A] out of the hull as shown. Fuel T ank Insta llation • Be sure the float [A] in place before putting the fuel tank into the hull. • Route the following correctly (see Cable, Wire, and Hose Routing section in Appendix chapter). Fuel Hoses Fuel T ank V ent Hose Fuel Level Sensor Leads O[...]

3-90 FUEL SYSTEM (DFI) Fuel T ank Fuel Filler and T ube Removal • Open the front storage compartment cover . • Loosen the fuel filler tube clamp screws [A] and remove the fuel filler tube [B]. • Remove the fuel filler cap [A]. • T ake out the screws [B] in the filler flange and remove the fuel filler [C]. Fuel Filler and T ube Installation [...]

ENGINE LUBRICA TION SYSTEM 4-1 4 Engine Lubrication System T able of Contents Exploded View .............................................................................................. .......................... 4-2 Engine Oil Flow Chart............................................................................................................. 4[...]

4-2 ENGINE LUBRICA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Breather Plate Bolts 7.8 0.80 69 in·lb 2 Oil Filler Cap 1.0 0.10 87 in·lb 3 Oil Passage Plugs 20 2. 0 14 L 4 Oil Separator T ank Mounting Screws 4.9 0.50 43 in·lb L 5 Breather Case Mounting Bolts 7.8 0.80 69 in·lb 6 Breather Pipe Bolts 8.8 0.90 78 in?[...]

4-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart A: Blowby Gas B: Supply Engine Oil Flow C: Return Engine Oil Flow D: Oil Sump 1. from Oil Pump Side Pas- sage 2. Oil Cooler 3. to Main Oil Passage 4. Oil Passage Bolt 5. Oil Pressure Switch 6. Oil Filter 7. Oil Passage (to Oil Filter) 8. Oil Passage (to Main O il Passage) 9. Oil Pipe (from Lower [...]

ENGINE LUBRICA TION SYSTEM 4-5 Engine Oil Flow Chart 21. Oil Separator T ank 22. to Air Filter 23. to Oil Pan 24. Joint 25. Camshaft O il Passage 26. Camshaft Cap Oil Pas- sage 27. Oil Passage (from Oil Pipe to Camshaft Cap) 28. Oil Pipe (from Cylinder to Cylinder Head) 29. Oil Passage (from Main Oil Passage to Oil Pipe) 30. Crankshaft Oil Passage [...]

4-6 ENGINE LUBRICA TION SYSTEM Specifications Item Standard Engine Oil Grade API SE, SF , or SG API SH or SJ with JASO MA Viscos ity SAE 10W-40 Capacity 4.0 L (4.2 US qt, with or without the filter) 5.0 L (5.3 US qt, when engine is completely dry) Level Between upper and lower level lines (see text) Oil Pressure Measurement Oil pressure @3 000 r/mi[...]

ENGINE LUBRICA TION SYSTEM 4-7 S p e c i a lT o o la n dS e a l a n t Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Ad apter , PT 1/8: 57001-1033 Oil Filter W rench: 57001-1249 Kawasaki Bond (Silicone Sealant ): 56019-120 Kawasaki Bond (Silicone Sealant ): 92104-0004[...]

4-8 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter WA R N I N G W atercraft operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury . Oil Level Inspection This watercraft engine is equipped with a semi-dry sump. In the semi-dry sump engine, the o [...]

ENGINE LUBRICA TION SYSTEM 4-9 Engine Oil and Oil Filter CAUTION Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly , the oil pressure warning light will light. If this light stays on when the engine is ru[...]

4-10 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter • Remove the seat (see Hull/Engine Hood chapter) • Remove the dipstick [A], wipe it dry and insert it back to the dipstick tube [B], and then remove it again to check the oil level. • Check the oil level using the hot level mark on the dipstick [A]. High Level Line when Hot [B] Low Lev[...]

ENGINE LUBRICA TION SYSTEM 4-1 1 Oil Cooler Oil Cooler Removal • Remove: Seat (see Hull/Engine Hood chapter) Air Filter with Inlet Duct (see Fuel System (DFI) chapter) Inlet Manifold (see Fuel System (DFI) chapter) • Disconnect the oil pressure switch connector [A]. • Loosen the clamp screws [B] and remove the o il cooler cooling hoses [C] fr[...]

4-12 ENGINE LUBRICA TION SYSTEM Oil Cooler • Apply engine oil to the thread [A] of the passage bolt and O-ring [B] of the oil filter [C]. • T ighten the oil filter (P/No. 16097-1072). T orqu e - Oil F ilter: 1 8 N·m (1 .8 kgf·m , 13 ft·lb) • Connect the oil pressure switch connector securely . • Install the cooling hoses (s ee Cable, Wir[...]

ENGINE LUBRICA TION SYSTEM 4-13 Oil Cooler Oil Cooler Inspection • Start the engine to check for water and oil leaks. If the water and oil leak, replace the O-rings. WA R N I N G Do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odor- less, poisonous gas which can be lethal. CAUTION Do not run the engine [...]

4-14 ENGINE LUBRICA TION SYSTEM Breather Case and Oil Separator T ank Breather Case Removal • Remove: Seat (see Hull/Engine Hood chapter) Exhaust Manifold (see Exhaust System chapter) Clamp [A] Breather Hose [B] Breather Case Mounting Bolts [C] • Pull the breather case [D] upward. Breather Case Installation If the breather pipe [A] removed, ins[...]

ENGINE LUBRICA TION SYSTEM 4-15 Breather Case and Oil Separator T ank • Remove: Breather Hose Clamp [A] Breather Hose [B] Oil Separator T ank [C] NOTE ○ Hold the hose end to the upward. The oil will flow out if the hose lies at the bottom. Oil Separator T ank Installation • When installing the breather hoses, avoid sharp bending, kicking, fla[...]

4-16 ENGINE LUBRICA TION SYSTEM Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Periodic Maintenance chapter) Engine (see Engine Removal/Installation chapter) • T urn the engine to the side. • Unscrew the dipstick tube bolts [A] and pull out the dip- stick tube [B]. • Unscrew the oil pan bolts [A] and remove the oil pan [B]. Oil Pa[...]

ENGINE LUBRICA TION SYSTEM 4-17 Oil Pump Sprocket, Oil Pu mp and Oil Pressure Relief V alve Oil Pump Sprocket Removal • Drain: Engine Oil (see Periodic Maintenance chapter) • Remove: Engine (see Engine Removal/Installation chapter) Oil Pan (see Oil Pan Removal) Crankshaft Sensor Cover Bolts [A] Crankshaft Sensor Cover [B] • Unscrew the oil pu[...]

4-18 ENGINE LUBRICA TION SYSTEM Oil Pump Sprocket, Oil Pump and Oil Pressure R elief V alve • Install the oil pump chain guide [A], collar [B], washer [C], and bolt [D] as shown. • Install the chain guide spring [A] and the spring plate [B]. ○ Insert the tab [C] of the spring plate in the hole [D] of the crankcase. T orque - Chain G uide Spri[...]

ENGINE LUBRICA TION SYSTEM 4-19 Oil Pump Sprocket, Oil Pu mp and Oil Pressure Relief V alve • Install: Oil Pump Sprocket (see Oil Pump Sprocket Install ation) Oil Pan (see Oil Pan Installation) Oil Pump Inspection • Remove the oil pump parts. • Visually inspect th e oil pump outer , inner rotors and cover . If there is any damage or uneven we[...]

4-20 ENGINE LUBRICA TION SYSTEM Oil Pump Sprocket, Oil Pump and Oil Pressure R elief V alve Oil Pressure Relief V alve Inspection • Remove: Oil Pan (see Oil Pan Removal) Relief V alve [A] • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] force[...]

ENGINE LUBRICA TION SYSTEM 4-21 Oil Pressure Measurement Oil Pressure Measurement • Remove: Seat (see Hull/Engine Hood chapter) Inlet Manifold (see Fuel System (DFI) chapter) Oil Pressure Switch Connector [A] (disconnect) O i lP r e s s u r eS w i t c h[ B ] • Install the oil pressure gauge adapter [A] to the switch hole. Special T ool - Oil Pr[...]

4-22 ENGINE LUBRICA TION SYSTEM Oil Pressure Measurement WA R N I N G T ake care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed. • Install: Oil Pressure Switch (see Oil Pressure Switch Installa- tion) Inlet Manifold[...]

ENGINE LUBRICA TION SYSTEM 4-23 Oil Pressure Switch Oil Pressure Switch Removal • Remove: Seat (see Hull/Engine Hood chapter) Inlet Manifold (see Fuel System (DFI) chapter) • Disconnect: Switch Connector [A] • Place a rag or cloth under the oil pressure switch [A] and remove the oil pressure switch. ○ Do not damage the connect part [B] of t[...]

[...]

EXHAUST SYSTEM 5-1 5 Exhaust System T able of Contents Exploded View .............................................................................................. .......................... 5-2 Exhaust Manifold ................................................................................................................ .... 5-4 Exhaust Manifold[...]

5-2 EXHAUST SYSTEM Exploded View[...]

EXHAUST SYSTEM 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Exhaust Manifold Mounting Nuts 25 2.5 18 S 2 Exhaust Manifold Mounting Bolts 25 2.5 18 L, S 3 Bypass Nozzle – – – L 4 Flushing Hose Joint 11 1.1 95 in·lb SS 5 W ater Hose Joint 11 1.1 95 in·lb SS 6 W ater T emperature Sensor 15 1.5 11 see chapter 3 7 Exhaust [...]

5-4 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Removal • Remove: Oil Separator T ank [A] with the Oil Separator Hoses (see Lubrication system) Air Filter [B] (see Fuel System chapter) • Disconnect: Spark Plug Caps [C] (see Periodic Maintenance chapter) Hoses [D] W ater T emperature Sensor Connector [E] • Disconnect: Hoses [A] • Remove[...]

EXHAUST SYSTEM 5-5 Exhaust Manifold • T ake out the exhaust manifold with the exhaust pipe from the hull. • Disconnect the hose [A] from the exhaust pipe. Exhaust Manifold Installation NOTE ○ Unhook the rubber strap and remove the front exhaust tube from the water box muffler for easier installation of the exhaust manifold, and after connecti[...]

5-6 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Cleaning and Inspection • Remove the exhaust manifold parts. • Clean the carbon deposits out of the exhaust passages with a blunt, roundedged tool. • Flush foreign matter out of the water passages with fresh water . • Check the insides of the water passages for corrosion. Check the gasket[...]

EXHAUST SYSTEM 5-7 Exhaust Pipe Exhaust Pipe Removal • Remove: Exhaust Manifold with Exhaust Pipe (see Exhaust Man- ifold Removal) Exhaust Pipe Mounting Bolts [A] Exhaust Pipe [B] • Remove the joint tube [A] and the two rings. Exhaust Pipe Installatio n • Install the two rings [A] in the ring grooves of the exhaust pipe. If the two rings are [...]

5-8 EXHAUST SYSTEM Exhaust Pipe Exhaust Pipe Cleaning and Inspection • Remove the exhaust pipe parts. • Clean the carbon deposits out of the exhaust passages with a blunt, roundedged tool. • Flush foreign matter out of the water passages with fresh water . • Check the insides of the water passage for corrosion. • Check the gasket surface [...]

EXHAUST SYSTEM 5-9 W ater Box Muffler Water Box Muffler Removal • Remove: Rear Storage Pocket Oil Separator T ank with Oil Separator Hoses (see the Lubrication System chapter) Air Filter (see the Fuel System chapter) • Loosen: Joint T ube Clamp Screw (see Exhaust Manifold Re- moval) • Remove the front exhaust tube [A] b y loosing the clamp sc[...]

5-10 EXHAUST SYSTEM W ater Box Muffler • Be sure the dampers [A] on the left side water box muf fler [B] are in place. • Make sure the two rings [A] are installed t o the correct position. If the rings are damaged or warped, replace the rings with new ones. • Bind the two rings [A] by putting the paper tape [B] around the rings. The paper tap[...]

ENGINE TOP END 6-1 6 Engine T op End T able of Contents Exploded View ................................... 6-2 Specifications .................................... 6-6 Special T ools and Sealant ................. 6-8 Clean Air System ............................... 6-1 1 Air Suction V alve Removal ........... 6-1 1 Air Suction V alve Installation ...[...]

6-2 ENGINE TOP END Exploded View[...]

ENGINE TOP END 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Suction V alve Cover Bolts 9.8 1.0 87 in·lb 2 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb 3 Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S 4 Camshaft Cap Bolts 12 1.2 104 in ·lb S 5 Cylinder Head Bolts ( 7) 20 2.0 14 S 6 Cylinder Head Bolts ( 11 ) 23 2.3 [...]

6-4 ENGINE TOP END Exploded View[...]

ENGINE TOP END 6-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Exhaust Side Camshaft Chain Guide Bolts (Upper) 25 2.5 18 2 Exhaust Side Camshaft Chain Guide Bolts (Lower) 12 1.2 104 in·lb 3 Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S 4 Inlet Side Camshaft Chain Guide Bolt 12 1.2 104 in·lb L 5 Camshaft Chain T ensioner[...]

6-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 36.143 ∼ 36.257 mm (1.4229 ∼ 1.4274 in.) 36.04 mm (1.4189 in.) Inlet 36.440 ∼ 36.554 mm (1.4346 ∼ 1.4391 in.) 36.34 mm (1.431 in.) Camshaft Journal, Camshaft Cap Clearance 0.028 ∼ 0.071 mm (0.001 1 ∼ 0.0028 in.) 0.16 mm (0.006 in.) Camshaft Journ[...]

ENGINE TOP END 6-7 Specifications Item Standard Service Limit Inlet (Outer) 45.78 mm (1.802 in.) 44.2 mm (1.740 in.) Cylinder , Piston Cylinder Inside Diameter 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) 83. 10 mm (3. 272 in. ) Piston Diameter 82.919 ∼ 82.934 mm (3.2645 ∼ 3.2651 in.) 82.77 m m (3.25 9 in.) Piston/cylinder Clearance 0.060 ∼ 0[...]

6-8 ENGINE TOP END Special T ools and Sealant Compression Gauge, 20 kgf/cm² : 57001-221 V alve Spring Compressor Assembly: 57001-241 T op Dead Center Finder: 57001-402 Piston Pin Puller Assembly: 57001-910 Piston Ring Compr essor Grip: 57001-1095 Va l v e S e a t C u t t e r, 4 5 ° - 35: 57001-1 1 16 Va l v e S e a t C u t t e r, 3 2 ° - 30: 570[...]

ENGINE TOP END 6-9 Special T ools and Sealant V alve Seat Cutter , 45° - 30: 57001-1 187 V alve Spring Compress or Adapter , 22: 57001-1202 V alve Guide Arbor , 5: 57001-1203 V alve Guide Reamer , 5: 57001-1204 V alve Seat Cutte r Holder , 5: 57001-1208 V alve Seat C utter , 55° - 35: 57001-1247 Compression Gauge Adapter , M10 × 1.0: 57001-1317 [...]

6-10 ENGINE TOP END Special T ools and Sealant Piston Base, 8: 57001-1604 Kawasaki Bond (Sili cone Sealant): 56019-120[...]

ENGINE TOP END 6-1 1 Clean Air System Air Suction V alve Removal • Remove: Seat (see Hull/Engine Hood chapter) Hoses [A] • Remove: Air Suction V alve Cover Bolts [A] Air Suction V alve Covers [B] Air Suction V alve Assembly [C] Air Suction V alve Insta llation • Install the valve assembly [A] so that its reeds [B] side faces inside and it’s[...]

6-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Re moval • Remove: Air Suction V alve Hoses [A] Spark Plug Caps [B] Breather Hoses [C] • Remove the cylinder head cover bolts [A] and take off the cover [B]. Cylinder Head Cover Installation • Be sure to install the pins [A] and rubber gaskets [B]. • Replace the head cover gasket w[...]

ENGINE T OP END 6-13 Camshaft Chain T ensioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type camshaft chain tensioner [A]. The push rod does not return to its original po- sition once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner , do not take out the mounting bol[...]

6-14 ENGINE TOP END Camshaft, Camshaft Ch ain Camshaft Removal • Remove: Seat (see Hull/Engine Hood chapter) Spark Plugs (see Periodic Maintenance chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Air Filter (see Fuel System (DFI) chapter) • Position the crankshaft at #1, #4 piston TDC as follows. ○ Using the shaft wren ch [A],[...]

ENGINE T OP END 6-15 Camshaft, Camshaft Chain Camshaft Installation • Be sure to install the following parts. Pins [A] • Apply molybdenum disulfide oil solution to all cam parts and journals. NOTE ○ The exhaust camshaft has a 320 EX mark [A] and the inlet camshaft has a 320 IN mark [B]. Be careful not to m i xu pt h e s es h a f t s . If the [...]

6-16 ENGINE TOP END Camshaft, Camshaft Ch ain • Remove the spark plugs. • Using the shaft wrench [A], turn the cra nkshaft counter- clockwise [B] and set the crankshaft at #1, 4 piston TDC (see Piston TDC Finding). Special T ool - Shaft Wrench: 57001-1551 • Pull the tension side (exhaust side) of the chain taut to install the chain. • Engag[...]

ENGINE T OP END 6-17 Camshaft, Camshaft Chain • Remove: #1 Spark Plug (Front Side) • Install the piston top detector [A] in the hole of the plug. Special T ool - TDC Measurement T ool: 57001-1560 • Insert the gauge extender [B] into the detector . • Using the shaft wrench, turn the crankshaft until the gauge extender reaches its highest poi[...]

6-18 ENGINE TOP END Camshaft, Camshaft Ch ain Camshaft, Camshaft Cap Wear • Cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position. • Measure each clearance between the camshaft journal and the camshaft cap using plastigage [A]. • T ighten: T orque - [...]

ENGINE T OP END 6-19 Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Engine Bottom End chapter). • Remove the camshaft chain [A] from the crankshaft sprocket.[...]

6-20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Thoroughly warm up the engine, while checking that there is no compression leakage from around the spark plugs or the cylinder head gasket. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, espec[...]

ENGINE T OP END 6-21 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhau[...]

6-22 ENGINE TOP END Cylinder Head • Remove: Engine Hook Bolts [A] Engine Hook [B] Cylinder Head Bolts [C] • Remove: Upper Dipstick T ube Bolts [A] Upper Exhaust Side Camshaft Chain Guide Bolt [B] M7 Cylinder Head Bolts [C] • Remove the M1 1 cylinder head bolts [A] and washers. • T ake off the cylinder head. Cylinder Head Installation NOTE ?[...]

ENGINE T OP END 6-23 Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sides of the M1 1 cylinder head bolt washers [B] and the thread of head bolts [C]. • Install the cylinder head. • First, tighten the M1 1 cylinder head bolts follo wing the tightening sequence [1 ∼ 10]. T orque - Cylinder Head Bolts (M1 1): F i r s t : [...]

6-24 ENGINE TOP END Va l v e s V alve Clearance Check • Refer to V alve Clearance Inspection and Adjustment in the Periodic Maintenance chapter . V alve R emoval • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their [...]

ENGINE T OP END 6-25 Va l v e s V alve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor . The flange stops the guide from going in too [...]

6-26 ENGINE TOP END Va l v e s V alve Seat Inspection • Remove the valve (see V alve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat (see V alve Seat Repair).[...]

ENGINE T OP END 6-27 Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cu[...]

6-28 ENGINE TOP END Va l v e s • Measure the outside diameter of the seating surface with a vernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened Width [A] of engagement by machining with 45° cutter Ground V olume [B] by 32° cutter 32° [C[...]

ENGINE T OP END 6-29 Va l v e s If the seat width is too wide, make the 60° or 55° [A] grind described below . If the seat width is within the specified range, lap the valve to the seat as described below . • Grind the seat at a 60° or 55° angle until the seat width is within the specified range. ○ T o make the 60° or 55° grind, fit 60° [...]

6-30 ENGINE TOP END Va l v e s[...]

ENGINE T OP END 6-31 Cylinder , Pistons Cylinder Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Head (see Cylinder Head Removal) Dipstick T ube Bolts [A] Dipstick T ube [B] • Remove: Breather Case Mounting Bolts [A] Clamp [B] Breather Case [C] (with Hose) [...]

6-32 ENGINE TOP END Cylinder , Pistons • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it. • Remove the 3-piece oil ring with your thumbs in the same manner . Piston/Cylinder Installation NOTE ○ If a new cylinder is used, use n ew piston rings. ○ If new pistons and/or a ne[...]

ENGINE T OP END 6-33 Cylinder , Pistons • The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. [A] T op Ring [B] Second Ring [C] Oil Ring Steel Rails [D] Oil Ring Expander [E] Hollow (Exhaust Side) • Replace the cylinder [...]

6-34 ENGINE TOP END Cylinder , Pistons Cylinder Wear • Since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the two locations (total of four measure- ments) shown in the figure. If any of the cylinder inside diameter measurements ex- ceeds the service limit, repla[...]

ENGINE T OP END 6-35 Cylinder , Pistons Piston Ring Thickness • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: To p [ A ] 0.87 ∼ 0.89 mm (0.0343 ∼ 0.0350 in .) Second [B] 0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.) Service Limit: To p [ A ] 0.80 mm (0.0315 i[...]

[...]

ENGINE REMOV AL/INST ALLA TION 7-1 7 Engine Removal/Installation T able of Contents Exploded View .............................................................................................. .......................... 7-2 Engine Removal/Installation ..................................................................................................[...]

7-2 ENGINE REMOV AL/INST ALLA TION Exploded View[...]

ENGINE REMOV AL/INST ALLA TION 7-3 Exploded View T orque No Fastener N·m kgf·m ft·lb Remarks 1 Engine Mounting Bolts 36 3.7 27 L 2 Engine Damper Mounting Bolts 16 1.6 12 L L: Apply a non-permanent locking agent.[...]

7-4 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation Engine Removal • Remove: Seat (see Hull/Engine Hood chapter) Oil Separator T ank (see Lubrication Sytem) • Plug the hose end [A]. If the engine disassembles, drain the oil (see Engine Oil Change in Periodic Maintenance chapter). • Remove: Air Filter (see Fuel System (DFI) chapter)[...]

ENGINE REMOV AL/INST ALLA TION 7-5 Engine Removal/Installation • Remove: Engine Mounting Bolts [A] • Slide the engine toward the front to disengage the cou- pling [A]. • Using the lifter [A], raise the front side of the engine a little and lift the engine [B] out of f the hull [C]. Engine Damper Removal • Remove: Engine Damper Mounting Bolt[...]

7-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation Engine Damper Installation • Install the shim(s) of the same number . • Apply a non-permanent locking agent to the engine damper mount bolts, and tighten them. T orque - Engine Damper Mounting Bolts : 16 N·m (1.6 kgf·m, 12 ft·lb) Engine Installation • Be sure there are no forei[...]

ENGINE BOTTOM END 8-1 8 Engine Bottom End T able of Contents Exploded View .............................................................................................. .......................... 8-2 Specifications ................................................................................................................. ........ 8-4 Special[...]

8-2 ENGINE BOTTOM END Exploded View[...]

ENGINE BOTTOM END 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Crankshaft Sensor Cover Bolts 7.8 0.80 69 in·lb 2 Engine Bracket Mounting Bolts 29 3.0 22 L 3 T iming Rotor Bolt 29 3.0 22 L 4 Connecting Rod Nuts – – – MO, see text 5 Oil Passage Plugs 20 2.0 14 L 6 Stator Mounting Bolts 12 1.2 104 in·lb L 7 Grommet Cover[...]

8-4 ENGINE BOTTOM END Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend ––– 0.2/100 mm (0.008/3.94 in.) Connecting Rod T wist ––– 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm (0.023 in.) Connecting Rod Big end Bearing Insert/cr[...]

ENGINE BOTTOM END 8-5 Specifications Item Standard Service Limit Crankshaft Main Journal Diameter: 40.984 ∼ 41.000 mm (1.6135 ∼ 1.6142 in.) 40.96 mm (1.613 in.) Marking None 40.984 ∼ 40.992 mm (1.6135 ∼ 1.61385 in.) ––– 1 40.993 ∼ 41.000 mm (1.61389 ∼ 1.6142 in.) ––– Crankcase Main Bearing Bore Diameter: 44.000 ∼ 44.016 m [...]

8-6 ENGINE BOTTOM END Special T ools and Sealant Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1 129 Coupling Holder #2: 57001-1423 Rotor Holder: 57001-1544 Holder Attachment: 57001-1547 Output Shaft Wr ench, Hex 36: 57001-1550 Grip: 57001-1591 Flywheel & Pulley Holder: 57001-1605 Rotor Puller: 57001-1623 Kawasaki Bond (S[...]

ENGINE BOTTOM END 8-7 Special T ools and Sealant Kawasaki Bond (Liqui d Gasket - Black): 92104-1062[...]

8-8 ENGINE BOTTOM END Coupling Coupling/Output Shaft Removal • Remove: Engine (see Engine Removal/Installation chapter) Crankshaft Sensor Cover (see Electrical System chap- ter) • Holding the timing rotor , unscrew the coupling. Special T ools - Flywheel & Pulley Holder: 57001-1605 [A] Holder Attachment : 57001-1547 [B] Coupling Holder #2: [...]

ENGINE BOTTOM END 8-9 Coupling • Using the rotor holder [A], remove the outp ut shaft [B]. Special T ool - Rotor Holder: 57001-1544 Coupling/Output Shaft Installation • Apply molybdenum disulfide oil solution to the seating sur- face of the output shaft. • Using the rotor holder [A], install the output shaft [B]. Special T ool - Rotor Holder:[...]

8-10 ENGINE BOTTOM END Coupling • Install: Pins [A] Gasket [B] • Position the magnet lead [C] as shown. • Apply grease to the oil seal lip. • Install the output cover . ○ Run the magneto lead [A] between the magneto cover [B] and the output cover [C] as shown. T orque - Output Cover Bolts: 7.8 N·m (0.80 kgf·m, 69 in· lb) • Install th[...]

ENGINE BOTTOM END 8-1 1 Coupling • Replace the oil seals with new ones. • Apply thin coat grease to the oil seal lips [A] . • Pack grease [B] between the oil seal lip and housing of the oil seal (flywheel side oil seal [C]). • Press in the oil seals until they are bottomed. ○ Install the coupling oil seal [D] so that the manufacturer ’s[...]

8-12 ENGINE BOTTOM END Magneto Flywheel Magneto Flywheel Removal • Remove: Engine (see Engine Removal/Installation chapter) Crankshaft Sensor Cover (see Electrical System chap- ter) Coupling (see Coupling/Output Shaft Removal) Magneto Cover (see Coupling/Output Shaft Removal) ○ Using the rotor puller [A], pull off the flywheel [B]. Special T oo[...]

ENGINE BOTTOM END 8-13 Magneto Flywheel • Apply grease to the boss outside [A] of the magneto fly- wheel [B]. 10 mm (0.39 in.) [C] • Install the magneto flywheel. NOTE ○ Confirm the magneto flywheel fit or not to the crankshaft before tightening it with specified torque. ○ Install the output shaft and tighten it with 70 N·m (7.0 kgf·m, 52[...]

8-14 ENGINE BOTTOM END Stator Stator Removal • Remove: Engine (see Engine Removal/Installation chapter) Magneto Cover (see Coupling/Output Shaft Removal) Grommet Cover Mounting Bolts [A] Grommet Cover [B] Stator Mounting Bolts [C] with Washers Stator Assembly [D] Stator Installation • Apply water resistant grease to the outside of the grom- met[...]

ENGINE BOTTOM END 8-15 Crankcase Splitting Crankcase Splitting • Remove: Seat (see Hull/Engine Hood chapter) Engine (see Engine Removal/Installation chapter). • Drain the engine oil (see Periodic Maintenance chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. Suitable Props [A] Lower Crankca[...]

8-16 ENGINE BOTTOM END Crankcase Splitting Crankcase Assembly CAUTION The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • With high-flash point solvent, clean off the mating sur- faces of the crankcases halves and wipe dry . • Using compressed air , blow[...]

ENGINE BOTTOM END 8-17 Crankcase Splitting • Install the oil pump sprocket chain [A] on the chain guide [B] of the lower crankcase [C]. • Apply molybdenum disulfide oil solution to the bolt seating surfaces [A] on the lower crankcase for the M10 bolts [B] and M8 [7 ∼ 10] bolts [C]. • T ighten the crankcase bolts. ○ Following the sequence [...]

8-18 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Camshaft Chain [A] Oil Pump Sprocket Chain [B] • Remove the crankshaft [C] with the oil seal [D]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones[...]

ENGINE BOTTOM END 8-19 Crankshaft and Connecting Rods • Install the crankshaft with the oil pump sprocket chain [A] and camshaft chain [B] hanging on them. • Fit the oil seal [A] into the groove [B] of the crankcase. • Assemble the crankcase (see Crankcase Asse mbly). Connecting Rod Removal • Split the crankcase (see Crankcase Splitting). ?[...]

8-20 ENGINE BOTTOM END Crankshaft and Connecting Rods CAUTION T o minimize vibration, the connecting rods should have the same weight mark. B i gE n dC a p[ A ] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] If the connecting rods, big end bearing i nserts, or crank- shaft are replaced with new ones, select the bearing insert and ch[...]

ENGINE BOTTOM END 8-21 Crankshaft and Connecting Rods • Apply small amount of molybdenum disulfide oil solution to the threads [A] and seating surfaces [B] of the c onnect- ing rod nuts. • First, tighten the nuts to the specified torque. See the table below . • Next, tighten the nuts by 120° more. ○ Mark [A] the connecting rod big end caps[...]

8-22 ENGINE BOTTOM END Crankshaft and Connecting Rods Connecting Rod T wist • On surface plate, set the big-end arbor [A] on V block [C]. • Measure the difference in the heights of the arbor [B] above the surface plate over a 100 mm (3.94 in.) dis- tance-on the arbor to determine the a mount of connect- ing rod twist with the connecting rod hel[...]

ENGINE BOTTOM END 8-23 Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankpin Diameter Marks None 38.984 ∼[...]

8-24 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear • Measure the bearing insert/journal [B] clearance with a plastigage [A]. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○ Do not turn the crankshaft during clearance measure- ment. ○ Journal clearance less[...]

ENGINE BOTTOM END 8-25 Crankshaft and Connecting Rods • Measure the main bearing bore diameter , and mark [B] the upper crankcase half [A] in accordance with the bore diameter . ○ Crankcase main bearing bore diameter marks are " ○ " mark and no mark. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assembl[...]

8-26 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Side Clearance • Insert a thickness gauge [A] between the thrust washer [B] and the crank web [C] at the No. 3 main journal to determine clearance. If the clearance exceeds the service limit, replace the thrust washer as a set and check the width of the crank- shaft #3 main journal.[...]

COOLING AND BILGE SYSTEM S 9-1 9 Cooling and Bilge Systems T able of Contents Exploded View .............................................................................................. .......................... 9-2 Bilge System.................................................................................................................... ...[...]

9-2 COOLING AND BILGE SYSTEMS Exploded View[...]

COOLING AND BILGE SYSTEMS 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater Hose Joint (L Shape T ype) 11 1.1 95 in·lb SS 2 W ater Hose Joint (Straight Shape T ype) 20 2.0 14 SS 3 W ater Hose Joint (Straight Shape T ype) 11 1.1 95 in·lb SS 4. Cylinder Head 5. W ater Pipe 6. Metal Clamp 7. Cylinder Head Gasket 8. Cylinder [...]

9-4 COOLING AND BILGE SYSTEMS Bilge System Breather Removal • Remove: Seat (see Hull/Engine Hood chapter) Rear Storage Pocket • Pull the hoses [A] of f the breather . • Unscrew the mounting bolts [B], and remove the breathers [C]. Breather Installation • Be sure the small hole [A] in the breather is open before installing it. • Apply a no[...]

COOLING AND BILGE SYSTEMS 9-5 Bilge System Follow the next procedures to remove the left s ide filter [D]. • Remove the water box muf fler [B] (see Exhaust System chapter). • Pull the hose [C] off the filter . • Unscrew the mounting screw [A] and remove the filter . Filter Installation • Align the projections [A] on the filters [B] with the[...]

9-6 COOLING AND BILGE SYSTEMS Cooling and Bilge System Hoses Hose Removal • The majority of bilge hoses have no clamps at the hose ends. The majority of bilge system hoses may be simply pulled off their fittings. NOTE ○ Some of the bilge system hoses have plastic clamps at hose ends. • All the cooling system hoses are clamped at both ends. Lo[...]

COOLING AND BILGE SYSTEMS 9-7 Cooling and Bilge S ystem Flushing Cooling System Flushing • Refer to Cooling System Flushing in the Periodic Mainte- nance chapter . Bilge System Flushing • Refer to Bilge System Flushing in the Periodic Mainte- nance chapter .[...]

9-8 COOLING AND BILGE SYSTEMS Cooling and Bilge System Flow Diagram[...]

COOLING AND BILGE SYSTEMS 9-9 Cooling and Bilge System Flow Diagram 1. Cylinder Head 2. W ater Pipe 3. Cylinder Head Gasket 4. Cylinder 5. Oil Cooler 6. Output Cover 7. Exhaust Pipe 8. Exhaust Pipe Gasket 9. Exhaust Manifold 10. Exhaust Manifold Gasket 1 1. Flushing Fitting 12. Bypass Outlet 13. Left Water Box Muffler 14. Right Water Box Muffler 15[...]

9-10 COOLING AND BILGE SYSTEMS Wa t e r P i p e Wa ter Pipe Removal • Remove the inlet manifold (see Fuel System). • Disconnect the cooling hose [A] onto the water pipe fitting. • Unscrew the mounting bolts [B] and remove the water pipe [C] from the cylinder head [D]. Water Pipe Installation • Apply grease to the O-rings [A] and install the[...]

COOLING AND BILGE SYSTEMS 9-1 1 After Submerging CAUTION Do not operate the watercraft with water in the en- gine. Do not try to start the engine until it is completely empty of water; internal engine parts could be se- verely and immediately damaged. If water gets into the engine, follow this procedure immediately! If water is left in the engine m[...]

9-12 COOLING AND BILGE SYSTEMS After Submerging[...]

COOLING AND BILGE SYSTEMS 9-1 3 After Submerging Detailed Procedures after S ubmerging 1. Remove the seat (see Hull/Engine Hood chapter). 2. Remove the drain screws in the stern to drain water out of the engine compartment. 3. Remove the front storage pocket ( see Hull/Engine Hood chapter). 4. Disconnect both two connectors [A] on the primary ignit[...]

9-14 COOLING AND BILGE SYSTEMS After Submerging 13. Reconnect the primary ignition coil lead connectors, noting the #1,#4 [A] and the #2, #3 [B] coil connec- tors. The #1, #4 coil connector has a red/yellow and a green/blue leads from the main harness. The #2, #3 coil connector has a red/yellow and green/black leads from the main harness. NOTE ○ [...]

COOLING AND BILGE SYSTEMS 9-1 5 After Submerging 18. If the fuel tank has water in it, it must be emptied by pump or siphon. Refill the tank with fresh fuel. D o not dump contaminated fuel in places not designated for that purpose. WA R N I N G Gasoline is extremely flammable and can be explo- sive under certain conditions. Pull the lanyard key off[...]

[...]

DRIVE SYSTEM 10-1 10 Drive System T able of Contents Exploded View .............................................................................................. .......................... 10-2 Specification .................................................................................................................. ......... 10-4 Special T oo[...]

10-2 DRIVE SYSTE M Exploded View[...]

DRIVE SYSTEM 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Coupling 39 4.0 29 2 Drive Shaft Holder Mounting Bolts 22 2.2 16 L 3 Coupling Cover Bolts 8.8 0.90 78 in·lb L L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. SS: Apply silicone sealant. WG: Apply water resistance grease.[...]

10-4 DRIVE SYSTE M Specification Item Standard Service Limit Drive Shaft Runout (see P10-8) [A] Less than 0.1 mm (0.0039 in.) [B] Less than 0.2 mm (0.0079 in.) 0.2 mm (0.0079 in.) 0.6 mm (0.0236 in.)[...]

DRIVE SYSTEM 10-5 Special T ools and Sealant Bearing Driv er Set: 57001-1 129 Coupling Holder #2: 57001-1423 Kawasaki Bond (Silicone Sealant ): 56019-120[...]

10-6 DRIVE SYSTE M Drive Shaft/Drive Shaft Holder Drive Shaft Removal/Installatio n • Remove the engine (see Engine Removal/Installation chapter). • Pull the drive shaft [A] out of the hull. • Hold the drive shaft in a vice, and unscrew the coupling. Special T ool - Coupling Holder: 57001-1423 [A] • When installing the drive shaft, be caref[...]

DRIVE SYSTEM 10-7 Drive Shaft/Drive Shaft Holder ○ Press the small grease seal, and the large grease seals, bearing, and small grease seals come out of the holder . [A] Sleeve [B] Blocks [C] Press Drive Shaft Holder Assembly/Installation • Replace the grease seals with new ones. • Press the bearing and grease seals into the drive shaft holder[...]

10-8 DRIVE SYSTE M Drive Shaft/Drive Shaft Holder Drive Shaft Runout • Measure drive shaft runout by supporting the shaft on V blocks and setting a dial gauge against the shaft at each point shown. • T urn the drive shaft slowly . The dif ference between the highest and lowest dial gauge reading is the runout. If any measurement exceeds the ser[...]

PUMP AND IMPELL ER 1 1-1 11 Pump and Impeller T able of Contents Exploded View .............................................................................................. ..................... ..... 1 1-2 Specifications ................................................................................................................. ........ 1 1-[...]

1 1-2 PUMP AND IMPELLER Exploded View[...]

PUMP AND IMPELLER 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Pump Bracket Mounting Bolts (2) 19 1.9 14 L, SS 2 Pump Bracket Mounting Bolts (4) 9.8 1.0 87 in·lb L 3 Pump Mounting Bolts 36 3.7 27 L 4 Grate Mounting Bolts 9.8 1.0 87 in·lb L 5 Pump Cover Mounting Bolts 7.9 0.80 69 in·lb L 6 Impeller 98 10 72 7 Pump Cap Bol[...]

1 1-4 PUMP AND IMPELLER Specifications Item Standard Service Limit Jet Pump Impeller Outside Diameter 147.5 ∼ 147.7 mm (5.8071 ∼ 5.8149 in.) 146 .5 mm (5.7677 in.) Pump Case Inside Diameter 148.0 ∼ 148.1 mm (5.8268 ∼ 5.8307 in.) 149.1 mm (5.8701 in.) Impeller Clearance 0.15 ∼ 0.3 mm (0.0059 ∼ 0.01 18 in.) 0.6 mm (0.0236 in.)[...]

PUMP AND IMPELL ER 1 1-5 Special T ools and Sealant Oil Seal & Bearing Remover: 57001-1058 Bearing Driv er Set: 57001-1 129 Impeller Wre nch: 57001-1228 Impeller Holder: 57001-1393 Kawasaki Bond (Silicone Sealant ): 56019-120[...]

1 1-6 PUMP AND IMPELLER Pump and Impeller Pump Removal • T urn the craft on its left side. • Disconnect the reverse cable ball joint at the rear end. • Unscrew the pump cover mounting bolts [A], and remove the pump cover [B] with the reverse bracket [C]. • Unscrew the grate mounting bolts [A] and remove the grate [B]. • Remove the joint b[...]

PUMP AND IMPELLER 1 1-7 Pump and Impeller ○ T ake out the pump bracket mounting bolts [A]. ○ Cut the sealant at the indicate d area [A] in the figure and remove the pump bracket [B]. Pump Installation • Strip off all the old sealant around the pump intake. • Liberally coat the outside edge of the pump bracket with silicon sealant [A] to for[...]

1 1-8 PUMP AND IMPELLER Pump and Impeller • Be sure trim seal [A] is in place. • Grease the splines on the drive shaft with water resistant grease. • Install the pump. ○ Apply a non-permanent locking agent to the pump mount- ing bolts and torque them. T orque - Pump Mounting Bol ts: 36 N·m (3.7 kgf·m, 27 ft·l b) • Install the grate [A][...]

PUMP AND IMPELLER 1 1-9 Pump and Impeller • Be sure the seals [A] on the hull are in the position. ○ Coat the outside edge [A] of the seal [B] with silicone sealant to form a seal between the hull and seal. • Install the pump cover . ○ Be sure the seal [A] is in the position. ○ Apply a non-p rmanent locking agent to the pump cover mountin[...]

1 1-10 PUMP AND IMPELLER Pump and Impeller • Unscrew the pump cap bolts [A], and remove the pump cap [B]. • Pull out the impeller seal on the impeller . • Hold the shaft in the impeller holder , taking care not to damage it. Remove the impeller from the pump shaft and then pull out the pump shaft. Special T ools - Impeller Holder: 57001-1393 [...]

PUMP AND IMPELLER 1 1-1 1 Pump and Impeller • Remove the bearing by tapping evenly around the bearing inner race from the front end of the pump case [A]. Special T ool - Bearing Driver Set: 57001-1 129 [B] JT1500-A2 ∼ ; • Press [A] the bussing [B] and the ball bearing [C]. They come out of the pump case. • Remove the circlip. • Remove the[...]

1 1-12 PUMP AND IMPELLER Pump and Impeller • Before installing the pump bearing, blow any dirt or for- eign particles out of the pump case with compressed air . • Before installing the pump bearing, remove the filter cover [C], and check the filter inside or outside [A] on the pump case [B] if the foreign particles do not cling to the filter . [...]

PUMP AND IMPELLER 1 1-13 Pump and Impeller JT1500-A2 ∼ ; • Replace the grease seals with new ones, if necessary , and install them. Special T ool - Bearing Driver Set: 57001-1 129 ○ Press each seal [A] into the pump case [B] so that the side with the spring faces outward. ○ Fill the gap between the grease s eals [C] with high grade water re[...]

1 1-14 PUMP AND IMPELLER Pump and Impeller JT1500-A1, A2 ∼ ; • Screw on the impeller and torque. Special T ools - Impeller Holder: 57001-1393 Impeller W rench: 57001-1228 T orque - Im peller: 98 N·m (10 kgf·m, 72 ft·lb) • Visually inspect impeller seal [A], and replace it if neces- sary . • Install the seal on the impeller . • Be sure [...]

PUMP AND IMPELLER 1 1-15 Pump and Impeller Impeller Outside Di ameter Measurement • Measure the impeller outside diameter . If the impeller is worn smaller than the service limit, re- place it. Impeller O utside Diame ter Standard: 147.5 ∼ 147.7 mm (5.8071 ∼ 5.814 9 in.) Service Limit: 1 46.5 mm (5.7 677 in.) Pump Inspection • Examine the p[...]

[...]

STEERING 12-1 12 Steering T able of Contents Exploded View .............................................................................................. .......................... 12-2 Special T ool and Sealant ........................................................................................................ 12 -4 Steering Cable ............[...]

12-2 STEERI NG Exploded View[...]

STEERING 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Handlebar Clamp Bolts 16 1.6 12 L 2 Start/stop Switch Case Mounting Screws 3.9 0.40 35 in·lb 3 Throttle Case Mounting Screws 3.9 0.40 35 in·lb 4 Steering Shaft Locknut 49 ∼ 59 5.0 ∼ 6.0 36 ∼ 43 5 Steering Shaft Nut – – – Hand-T ight 6 Steering Holder Mountin[...]

12-4 STEERI NG S p e c i a lT o o la n dS e a l a n t Box Wrench (27 mm): 57001-1451 Kawasaki Bond (Sili cone Sealant): 56019-120[...]

STEERING 12-5 Steering Cable Steering Cable Adjustment • Check the steering cable adjustment. ○ Center the handlebar in the straight-a head position. • Check that the steering nozzle [A] is centered in the pump cavity . ○ The same distance [B]. • If necessary , adjust the steering cable. ○ Loosen the locknut [A] on the end of the steeri[...]

12-6 STEERI NG Steering Cable • Loosen the locknut [A] at the front end of the steering cable, and slide back the outer sleeve of the ball joint and take off the ball joint [B] and remove the locknut from the cable front end. • Pull the holder [A] off the cable bracket. • Slide the steering cable [B] off the cable bracket [C], and if the cabl[...]

STEERING 12-7 Steering Cable Steering Cable Installation • Slide a short piece of rubber or plastic tubing over the front cable end to guide the cable through the hull. • Lubricate the outside of the new cable to ease cable in- stallation. • T orque: T orque - Steering Cable Nut: 39 N·m (4.0 kgf·m, 2 9 ft·lb) • Apply a non-permanent lock[...]

12-8 STEERI NG Handlebar Handlebar Removal • Unscrew the mounting screws [A] and remove the han- dlebar pad [B]. • Remove the inner pad [A], pushing [B] the buzzer [C]. • Unscrew the bolts [A] and remove the pad holder [B]. • T ake out the throttle case clamp screws and remove the throttle case [A]. • T ake out the switch case clamp screw[...]

STEERING 12-9 Handlebar Handlebar Installation • Install the pad holder . ○ Apply a non-permanent locking agent to the pad holder bolts. • Install the handlebar on the holder of the steering neck. ○ Apply a non-permanent lockin g agent to the handlebar clamp bolts. ○ Align the punch mark [A] on the left side of the handlebar with the part[...]

12-10 STEERING Handlebar • Install the bosses [A] on the pad holder to the holes [B] on the handlebar pad. • A l i g n[ A ]t h ep r o j e c t i o n[ B ]o nt h ep a dw i t ht h eg r o o v e[ C ] on the pad.[...]

STEERING 12-1 1 Steering Steering Removal • Remove the handlebar and pad holder (see Handlebar Removal). • Unscrew the set screw [A] and take out the cap [B]. • Unscrew the shift lever nut [A] and remove the shift lever [B]. • Remove the right stay [A] with the right mirror (see Hull/Engine Hood chapter). • Unscrew the steering cover moun[...]

12-12 STEERING Steering • Remove the front storage pocket (see Hull/Engine Hood chapter). • Disconnect: Steering Position Sensor Lead Connector [A] Buzzer Connector [B] Multifunction Meter Lead Connectors [C] Steering Cable Ball Joint at Upper End Shift Cable Ball Joint at Upper End • T ake out the grommet mounting plate [A] and pull the grom[...]

STEERING 12-13 Steering • Remove the cotter pin [A] and steering shaft locknut [B]. • T ake out the holder [C]. • Unscrew the steering holder mounting bolts [A], nuts, and washers, and lift up the steering holder [B]. • T ake out the air intake duct mounting bolts [A] and remove the air intake duct [B] from the steering holder [C]. • Disc[...]

12-14 STEERING Steering Steering Installation • Replace the gasket [A] on the steering holder [B] with a new one. • Check the bushings for damage and wear before in- stalling the steering holder . If the bushings are damaged or worn, replace them. • Grease: Bushings [A] Steering Shaft [B] • Install the steering shaft and the steering shaft [...]

STEERING 12-15 Steering • T orque the steering shaft locknut [A]. T orque - Steering Shaft Locknut: 49 ∼ 59 N·m (5.0 ∼ 6.0 kgf·m, 36 ∼ 43 ft·lb) • T urning the steering shaft fully in left and right direction, check whether the steering position sensor comes in con- tact with the magnet. • Check the clearance [A] between the steering[...]

12-16 STEERING Steering • Be sure that the damper [A] is in position. • Apply a non-permanent locking agent to the grommet mounting plate. • Apply a non-permanent locking agent to the steering cover mounting bolts. • Install the steering cover mounting bolts to the steering cover . • Apply a non-permanent locking agent to the shift lever [...]

STEERING 12-17 Reverse System Shift Cable Adjustment • Check the shift cable adjustment. • When the shift lever is in the “F” position, the lower edge [A] of the bucket should be held above the top [B] of the steering nozzle with slight play so it doesn’t interfere with the water flow from the jet pump. • When the shift lever is in the [...]

12-18 STEERING Reverse System • Pull the holder [A] off the cable bracket. • Remove the right side cover (see Hull/Engine Hood chap- ter). • Unscrew the bolts [A] and remove the cable bracket. NOTE ○ The collors on the inside of the hull will drip down when the bolts are removed. • Remove the ball joint [A] and cable bracket [B] from the [...]

STEERING 12-19 Reverse System • T urn the water craft o n its left side and remove the pump cover (see Pump/Impeller chapter). CAUTION Never lay the watercraft on the right side. Water in the exhaust system may drain back into the engine, causing serious damage. • Loosen the locknut [A] at the rear end of the shift cable, and remove the ball jo[...]

12-20 STEERING Reverse System Reverse Bucket Removal/Installation • Disconnect the ball joint at rear end of the shift cable. • Remove the pump cover . • Unscrew the pivot bolts [A] and remove the reverse bucket [B]. • Installation is the reverse of removal. Note the following. ○ Apply a non-permanent locking ag ent to the reverse bucket [...]

HULL/ENGINE HOOD 13-1 13 Hull/Engine Hood T able of Contents Exploded View .............................................................................................. .......................... 13-2 Fittings .................................................................................................................................... 13-6 S[...]

13-2 HULL/ENGINE HOOD Exploded View[...]

HULL/ENGINE HOOD 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Crossmember Bolts 7.8 0.80 69 in·lb L 2 Handrail Bolts 9.8 1.0 87 in·lb L 3 Lock Assembly Nut 4.9 0.50 43 in·lb 4 Front Duct Bolts – – – L 5 Damper Bolts – – – L 6 Damper Bracket Bolts – – – L 7 Front Storage Compartment Cover Bolts – – ?[...]

13-4 HULL/ENGINE HOOD Exploded View[...]

HULL/ENGINE HOOD 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Stabilizer Bolts 9.8 1.0 87 in·lb L 2 Air Inlet Duct Bolts – – – L 3 Exhaust Outlet Bolts – – – L CY : Apply cyanoacrylate cement. L: Apply a non-permanent locking agent. SS: Apply silicone sealant. SY : Apply synthetic rubber adhesive.[...]

13-6 HULL/ENGINE HOOD Fittings Seat Removal • Pull [A] the latch handle [B]. • Remove the seat up [A] and to the rear [B]. Seat Installation • Insert the seat hook [A] into the bracket [B] on the deck and slide it all the way forward by pushing the rear of the seat. • Push down on the rear of the seat to lock it. Front Storage Compartment C[...]

HULL/ENGINE HOOD 13-7 Fittings • T o remove the hinge assembly , remove the following. Damper Bolt [A] Hinge Bolts [B] Front Storage Compartment Cove r Disassembly • Unscrew the front duct bolts [A] and remove the front duct [B]. • Unscrew the lock assembly nut [A] and remove the lock assembly [B].[...]

13-8 HULL/ENGINE HOOD Fittings • Drill out the rivets [A] with a drill bit [B] of the c orrect size and remove the front duct cover [C]. Rivet Remo val Drill Bit S ize 5.0 mm (0.2 in.) NOTE ○ Stop drilling when the rivet head starts to turn with drill bit. ○ T ap the rivet out with a suitable punch and hammer . Front Storage Compartment Cover[...]

HULL/ENGINE HOOD 13-9 Fittings Mirror Removal • Open the front storage compartment cover . • Unscrew the nuts [A] and washers [B] and remove the mirrors [C] (both sides). Mirror Installation • Be sure that the washer [A] are in position. Mirror Stay Removal • T o remove the right mirror stay [A], remove the bolts [B]. NOTE ○ The plate [C][...]

13-10 HULL/ENGINE HOOD Fittings Mirror Stay Installation • Be sure the dampers [A] are in position (both sides). • The right plate [A] on the inside of the hull has a R mark [B] and the left plate [C] has L mark [D]. • Apply a non-permanent locking agent to the mirror stay bolts and tighten them securely . • Install the damper [A] onto the [...]

HULL/ENGINE HOOD 13-1 1 Fittings Front Storage Pocket Removal • Remove the front storage pocket mounting screws [A]. • Remove the front storage pocket [B]. Front Storage Pocket Installation • Installation is the reverse of removal. Storage Pocket Disassembly/Assembly • T o remove the storage pocket cover [A], turn and pull out the shaft [B][...]

13-12 HULL/ENGINE HOOD Fittings • Pull out the holder [A]. • Unscrew the mounting bolts [D] and remove the cable bracket [C] with the cable [B]. • T o remove the right side cover , pull the holder [A] off the cable bracket. • Unscrew the mounting nuts [A] and washers [B] and the left [C] and right [D] covers. • Unscrew the crossmember bol[...]

HULL/ENGINE HOOD 13-13 Fittings Handrail Removal • Remove the seat (see this chapter). • Disconnect the bilge hoses from the breather fitting. • Unscrew the mounting nut [A] and washer inside the hull, and remove the lock assembly [B]. • Holding the nuts and washers inside hull, unscrew the mounting bolts [C], and remove the handrail [D]. H[...]

13-14 HULL/ENGINE HOOD Fittings Stabilizer Removal • Unscrew the stabilizer bolts [A] and remove the stabilizer [B]. Stabilizer Installation • Install the stabilizer as shown. Stabilizer [A] Chine Line [B] 1 1 1 ±3 mm (4.37 ±0.12 in.) [C] 8± 2m m( 0 . 3 1± 0 . 0 8i n . ) [ D ] • Apply a non-permanent locking agent to the stabilizer bolt a[...]

HULL/ENGINE HOOD 13-15 Hull Replacement T o replace the hull, remove the various parts in the follow- ing suggested order . Battery and Pad Exhaust Pipe and Expansion Chamber Inlet Manifold Engine and Mounts Air Filter Wa t er B o x M u f f l e r Drive Shaft and Shaft Holder Pump and Hoses Steering Cover Handlebar and Steering Steering Cable Revers[...]

13-16 HULL/ENGINE HOOD Rubber Parts NOTE ○ The rubber parts on the watercraft are fastened in place with various adhesives. T o replace a rubber part, use a cement in the following table, or an equivalent. WA R N I N G Read all warnings and cautions on any solvents and adhesives used. Many of these products are flammable, may be harmful to the sk[...]

HULL/ENGINE HOOD 13-17 Rubber Parts Front Storage Compartment Gasket [A] Front Storage Compartment Cover T rim Seal [B] Detent [A] Mats [A] Damper on Deck [A] (starboard side only) 20 mm (0.79 in.) [B] 30 mm (1.18 in.) [C][...]

13-18 HULL/ENGINE HOOD Rubber Parts Rivet Removal • Drill out the rivet with a drill bit [A] of the correct size. Rivet Remo val Drill Bit S ize 5.0 mm (0.2 in.) NOTE ○ Stop drilling when the rivet head [B] starts to turn with drill bit. ○ T ap the rivet out with a suitable punch and hammer . Rivet Installation • Secure the parts to the hul[...]

HULL/ENGINE HOOD 13-19 Rubber Parts Side Bumper Removal • T ake out the plugs [A]. • Drill out the rivets [B] (see Rivet Removal). • Remove the corner bumper [C]. • Remove the trim strip [A] from the side bumper [B]. • Drill out the rivets [A] (see Rivet Removal). Side Bumper Installation • Secure the side bumpers to the hull flange wit[...]

[...]

ELECTRICAL SYSTEM 14-1 14 Electrical System T able of Contents Parts Location.................................... 14-3 Exploded View ................................... 14-6 Wiring Diagram .................................. 14-12 Specifications .................................... 14-16 Special T ools and Sealant ................. 14-17 Precautions[...]

14-2 ELECTRICAL SYSTEM MODE/SET Button Inspection ..... 14-58 SLO (Smart Learning Operation) Mode Inspection (JT1500-A2 model ∼ ) .................................... 14-58 Fuel Level Gauge/Symbol/FUEL Characters/W arning Light Inspection .................................. 14-59 Speedometer Inspection .............. 14-59 Speed Sensor Electric So[...]

ELECTRICAL SYSTEM 14-3 Parts Location 1. Bow 2. Ignition Coil #2, #3 3. Ignition Coil #1, #4 4. Crankshaft Sensor 5. Magneto 6. Starter Motor 7. Fuse Case 8. Regulator/Rectifier 9. ECU (Electronic Control Unit) 10. Starter R elay 1 1. Battery 12. Relay Assembly (Main Relay/Fuel Pump Relay)[...]

14-4 ELECTRICAL SYSTEM Parts Location 13. W ater T emperature Sensor 14. Camshaft Position Sensor 15. Oil T emperature Sensor 16. Oil Pressure Switch 17. Speed Sensor[...]

ELECTRICAL SYSTEM 14-5 Parts Location 18. Fuel Level Sensor 19. Steering Position Sensor 20. Buzzer 21. Multifunction Meter 22. Starter S witch 23. Engine Stop Switch 24. Lanyard Key (T ether Code) 25. Ignition Switch[...]

14-6 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 14-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 V ehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb 2 Electrical Parts Bracket Screws 4.9 0.50 43 in·lb L 3 Starter Relay Case Bolts 7.8 0.80 69 in·lb 4 Ignition Coil Mounting Bolts 8.8 0.90 78 in·lb L 5 W ater T emperature Sensor 15 1.5 11 see text 6 Star[...]

14-8 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 14-9 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Multifunction Meter Mounting Bolts 3.9 0.40 35 in·lb L 2 Fuel Level Sensor Clamp Screw 2.9 0.30 26 in·lb 3 Start/stop Switch Case Mounting Screw 3.9 0.40 35 in·lb 4 Speed Sensor Mounting Bolts 3.9 0.40 35 in·lb L 5. Multifunction Meter 6. Fuel Level Sensor 7[...]

14-10 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 14-1 1 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Starter Motor Through Bolts 6.4 0.65 56 in·lb L, R 2 Starter Motor Mounting Bolts 8.8 0.90 78 in·lb L 3 Starter Motor Ground Bolt 8.8 0.90 78 in·lb 4 Starter Motor T erminal Nut 8.8 0.90 78 in·lb 5 Stator Coil Bolts 12 1.2 104 in·lb L 6 Grommet Holder Bolt[...]

14-12 ELECTRICAL SYSTEM Wiring Diagram JT1500-A1[...]

ELECTRICAL SYSTEM 14-13 Wiring Diagram JT1500-A1[...]

14-14 ELECTRICAL SYSTEM Wiring Diagram JT1500-A2 ∼[...]

ELECTRICAL SYSTEM 14-15 Wiring Diagram JT1500-A2 ∼[...]

14-16 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Ty p e 12 V 18 Ah ––– Electric Starter System Starter Motor: Brush Length 12 mm (0.4724 in.) 6.5 mm (0.2559 in.) Commutator Diameter 28 mm (1.1024 in.) 27 mm (1.063 in.) Charging System Regulator/rectifier Output V oltage Battery V oltage 14 ∼ 1 5V ––– Alternat[...]

ELECTRICAL SYSTEM 14-17 Special T ools and Sealant Hand T ester: 57001-1394 Peak V oltage Adapte r: 57001-1415 Needle Adapter Se t: 57001-1457 Holder Atta chment: 57001-1547 Harness Adapter: 57001-1562 Flywheel & Pulley Holder: 57001-1605 Kawasaki Bond (Silicone Sealant ): 56019-120 Kawasaki Bond (Silicone Gr ease): 92137-1002[...]

14-18 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be followed servicing electrical systems. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an electrical system. A fully charged batte[...]

ELECTRICAL SYSTEM 14-19 Precautions ○ Electrical Connectors Female Connectors [A] Male Connectors [B][...]

14-20 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty , clean it carefully . If it is damaged, replace i[...]

ELECTRICAL SYSTEM 14-21 Battery Removal • Disconnect the battery cables [A]. WA R N I N G T o prevent possible personal injury and damage to electrical components, always disconnect the grounded cable first. • Unhook the battery straps [B]. • Carefully lift the battery from the engine compartment. Installation • Be sure the battery damper [[...]

14-22 ELECTRICAL SYSTEM Battery • Check to see that there is no peeling, tears or holes in the seal sheet on the top of the batt ery . • Place the battery on a level surface. • Remove the seal sheet [A]. CAUTION Do not remove the seal sheet sealing the filler ports [B] until just before use. NOTE ○ A battery whose seal sheet has any peeling[...]

ELECTRICAL SYSTEM 14-23 Battery Initial Charge • Place the strip [A] of caps loosely over the filler ports. • Newly activated sealed batteries require an initial charge. Standard Charge 1.8 A × 5 ∼ 10 hours If using a recommended battery charger , follow the charger ’s instructions for newly activated sealed battery . Kawasaki-recommended [...]

14-24 ELECTRICAL SYSTEM Battery 3) When you do not use the watercraft for months: Give a refresh charge before you store the watercraft and store it with the negative lead re- moved. Give a refresh charge once a month during storage. 4) Battery life: If the battery will not start the engine even after several refresh charges, the battery has ex- ce[...]

ELECTRICAL SYSTEM 14-25 Battery NOTE ○ Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially . Charge for no more than five minutes at the increased voltage then check if the battery is drawing current. ○ If the battery will accept current, decrease the voltage and charge by the standard cha[...]

14-26 ELECTRICAL SYSTEM Electric Starter System Starter Relay Removal • Remove: Seat (see Hull/Engine Hood chapter) Rear Storage Pocket (see Hull/Engine Hood chapter) Battery (see this chapter) • Disconnect the negative battery cable from the battery terminal. (see Battery Removal). • Disconnect the starter relay lead connector [A]. • Slide[...]

ELECTRICAL SYSTEM 14-27 Electric Starter System • Set ohmmeter to R × 1 Ω range. • Connect meter leads to starter relay as shown. • Activate starter relay switch by connecting a 12 V battery as shown. If the starter relay switch clicks and the ohmmeter indi- cates zero resistance, the starter relay switch is good. If the meter indicates hi[...]

14-28 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Relay Removal). • T ake off the starter motor through bolts [A] and remove both end covers [B] and pull the armature out of the yoke [C]. • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the [...]

ELECTRICAL SYSTEM 14-29 Electric Starter System • Install the O-rings [A] and the washers [B] as shown. • Fit the tongue [A] on the brush plate into the end cover groove [B]. • Align the lines [A] on the yoke with the lines [B] on the both end covers. • Replace the starter motor through bolts [C] with new ones. • T ighten: T orque - Start[...]

14-30 ELECTRICAL SYSTEM Electric Starter System • Measure the diameter [A] of the commutator [B]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator Diameter Standard: 28 mm (1.1024 i n.) Service Limit: 27 mm (1.063 in.) Armature Inspection • Using the × 1 Ω hand tester range, mea[...]

ELECTRICAL SYSTEM 14-31 Electric Starter System Reduction Gear Removal/Installation • Before removing the reduction gear , r emove the magneto flywheel (see Engine Bottom End chapter). • When installing the reduction gear , apply a molybdenum disulfide grease [A] to both ends of its shaft. Reduction Gear Inspection • Rotate the pinion gear [A[...]

14-32 ELECTRICAL SYSTEM Electric Starter System 3. Engine Starter Switch 4. Joint C onnector R 5. Starter Motor 6. Battery 12 V 18 Ah 7. Starter Relay 8. Joint C onnector S (Ground)[...]

ELECTRICAL SYSTEM 14-33 Charging System Magneto Output V oltage • Remove: Seat (see Hull/Engine Hood chapter) Air Filter with Duct (see Fuel System chapter) • Disconnect the 3-pin stator coil leads connector [A]. • With the hand tester [A] check the magneto output (in circuit) according to the following table with the engine running at approx[...]

14-34 ELECTRICAL SYSTEM Charging System • T ighten: T orque - Regulator/rectifi er Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) • When installing the bracket, apply a non-permanent lock- ing agent to the bracket mounting screws and tighten them securely . Regulator/Rectifier I nspection • With the hand tester set to the R × 1 k Ω range, test t[...]

ELECTRICAL SYSTEM 14-35 Charging System • Do the 2nd step regulator circuit test. ○ Connect the test light a nd the 12 V battery in the same manner as specified in the “1st step regulator circuit test”. ○ A p p l y1 2Vt ot h ep o s i t i v e( + )t e r m i n a l . ○ Check infinity ( ∼ ) terminals respectively . If the test light turns [...]

14-36 ELECTRICAL SYSTEM Charging System 1. Load 2. Main Fuse 20 A 3. Joint C onnector R 4. Battery 12 V 18 Ah 5. Joint C onnector S (Ground) 6. Regulator/Rectifier 7. Magneto[...]

ELECTRICAL SYSTEM 14-37 Ignition System WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition [...]

14-38 ELECTRICAL SYSTEM Ignition System • Apply grease to the O-ring and fit it in the groove of the sensor cover . • Apply silicone sealant [A] to the crankcase halves mating surface on the right and left sides of th e crankshaft sensor mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the crankshaft sensor cover . T orq[...]

ELECTRICAL SYSTEM 14-39 Ignition System Ignition Coil Removal • Remove: Seat (see Hull/Engine Hood chapter) Front Storage Pocket (see Hull/Engine Hood chapter) Spark Plug Caps (see Periodic Maintenance chapter) Clamp [A] (JT1200-A1 model) Double Spring Clamp [A] (JT1200-A2 model ∼ ) Fuel Supply Hose End [B] • Bracket Bolts [A] (see Electric C[...]

14-40 ELECTRICAL SYSTEM Ignition System • Pull out the spark plug lead [B] from the ignition coil [A]. Lubricate the leads with penetrating rust inhibitor . Ignition Coil Installa tion • Connect the spark plug lead to each ignition coil as fol- lows. #1 Spark Plug Lead Length 340 mm (13.4 in.) [A] #2 Spark Plug Lead Length 450 mm (17.7 in.) [B][...]

ELECTRICAL SYSTEM 14-41 Ignition System Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance. • Remove the ignition coil (see Ignition Coil Remova l). • Connect the ignition coil [A] (with the spark plug cap left installed on the spark p[...]

14-42 ELECTRICAL SYSTEM Ignition System Measuring spark plug lead resistance • Check the spark plug lead [A] for visible damage. If the spark plug lead is damaged, replace the spark plug lead. • Measure the lead resistance with the hand tester [B]. Spark Plug Lead Resistance Standard: 3.75 ∼ 6.25 k Ω If the hand tester does not read as spec[...]

ELECTRICAL SYSTEM 14-43 Ignition System Camshaft Position Sensor Inspection • Remove: Seat (see Hull/Engine Hood chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) • Set the hand tester [B] to the × 10 Ω range and connect it to the yellow and black leads in the connector . Special T ool - H and T ester: 57001-1394 If there i[...]

14-44 ELECTRICAL SYSTEM Ignition System • Remove: Front Storage Pocket (see Hull/Engine Hood chapter) • Install the peak voltage adapter [A] into the hand tester [B]. • Connect the peak voltage adapter [A] to the ignition coil primary lead connector [D], using the harness adapter [C]. Hand T ester [B] Ignition Coil [E] Spark Plugs [F] Special[...]

ELECTRICAL SYSTEM 14-45 Ignition System Crankshaft Sensor Peak V oltage Check NOTE ○ Be sure the battery is fully charged. • Connect the peak voltage adapter [A] to the hand tester [B]. Special T ool - Peak V oltage Adapter: 57001-1415 Ty p e : K E K - 5 4 - 9 - B • Connect the adapter the crankshaft sensor lead connec- tor [C], using the nee[...]

14-46 ELECTRICAL SYSTEM Ignition System Spark Plug Removal • Refer to Spark Plug Inspection in the Periodic Mainte- nance chapter . Spark Plug Installation • Refer to Spark Plug Inspection in the Periodic Mainte- nance chapter . Spark Plug Inspection • Refer to Spark Plug Inspection in the Periodic Mainte- nance chapter . Spark Plug Adjus tme[...]

ELECTRICAL SYSTEM 14-47 Ignition System Igniti on System Circuit 1. Joint Connector H 2. Joint Connector J 3. Joint Connector E 4. Crankshaft Sensor 5. Relay A ssembly (Main Relay/Fuel Pump Relay) 6. Joint Connector F 7. Connector C 8. V ehicle-down Sensor 9. Ignition Switch 10. Joint Connector Q 1 1. Engine Stop Switch 12. Joint Connector R 13. Ma[...]

14-48 ELECTRICAL SYSTEM Ignition System[...]

ELECTRICAL SYSTEM 14-49 Kawasaki Smart Steering System Steering Position Sensor and Magnet Removal • Remove the steering holder (see Steering Removal in Steering chapter). • Remove or disconnect: Steering Position Sensor Lead Connector [A] Leads Clamp on Steering Holder Steering Position Sensor Mounting Screws [B] Steering Position Sensor [C] ?[...]

14-50 ELECTRICAL SYSTEM Kawasaki Smart Steering System • T urning the steering shaft fully in left and right direction, check whether the steering position sensor comes in con- tact with the magnet. • Check the clearance [A] between the steering position sensor [B] and the magnet [C] with feeler gauge. Steering Position Sensor Clearance Standar[...]

ELECTRICAL SYSTEM 14-51 Kawasaki Smart Steering System Steering Position Sensor Input V oltage Inspection • Measure the input voltage to the steering position sensor . NOTE ○ Be sure the battery is fully charged. ○ Connect a digital voltme ter [A] to the lead connector [B] of the steering position sensor using the needle adapter set [C]. Spec[...]

14-52 ELECTRICAL SYSTEM Kawasaki Smart Steering System Steering Position Sensor Output Voltage Inspection • Measure the output voltage from the steering position sensor . NOTE ○ Be sure the battery is fully charged ○ Connect a digital voltmeter [A] to the lead connector [B] of the steering position sensor using the needle adapter set [C]. Spe[...]

ELECTRICAL SYSTEM 14-53 Kawasaki Smart Steering System Steering Position Senso r Circuit 1. Joint Connector Q 2. Multifunction Meter 3. Steering Position S ensor 4. 20 A Main Fuse 5. Joint Connector R 6. Battery 7. Joint Connector S 8. Joint Connector P 9. Ignition Switch 10. ECU (Electronic Control Unit)[...]

14-54 ELECTRICAL SYSTEM Sensors Speed Sensor Remova l/Installation • Unscrew the mounting bolts [A] and remove the speed sensor assembly [B]. • Unscrew the cap [A]. • Pull out the speed sensor connector and disconnect it. • When installing the speed sensor assembly , note the fol- lowing. ○ Apply silicone sealant around the grommet [A] an[...]

ELECTRICAL SYSTEM 14-55 Sensors • Rotate the waterwheel by hand slowly . • Measure the output voltage of the speed sensor . G/R (+), BK/W (–) → 0 ∼ battery volt age; twice a rotation (Rotate it slowl y .) If the voltage does not rise from zero to battery voltage twice a rotation, replace the sensor . • Measure the output voltage of the [...]

14-56 ELECTRICAL SYSTEM Sensors Throttle Sensor Inspection • Refer to Throttle Sensor Section in the Fuel System chap- ter . Water T emperature Sensor Inspection • Remove the water temperature sensor (see Feul (DFI) System chapter). • Suspend the sensor [A] in a container of water so that the temperature-sensing projection is submerged. • S[...]

ELECTRICAL SYSTEM 14-57 Multifunction Meter Display Function Inspec tion • Using the auxiliary wires, connect the 12 V battery [A] to the meter unit [B] connector as follows. JT1500-A2 model ∼ [C] JT1500-A1 model [D] ○ Connect the battery positive terminal to the terminal [1]. ○ Connect the battery negative termina l to the terminal [2]. [1[...]

14-58 ELECTRICAL SYSTEM Multifunction Meter MODE/SET B utton Inspection • Check that when the MODE button is pushed and held continuously , the display rotates through the four modes. • Indicate the clock mode. • Check that when the SET button is pushed for more than two seconds, the meter display turns to the clock set mode. If the display f[...]

ELECTRICAL SYSTEM 14-59 Multifunction Meter Fuel Level Gauge/Symbol/FUEL Characters/Warning Light Inspection • Connect the 12 V battery and terminals in the same man- ner as specified in the “Display Function Inspection”. • Connect the variable rheostat [A] to the terminal [5] as shown. JT1500-A2 model ∼ [B] JT1500-A1 model [C] • Check [...]

14-60 ELECTRICAL SYSTEM Multifunction Meter • If the oscillator is not available, the speedometer can be checked as follows. ○ Install the meter unit. ○ T urn on the ignition switch. ○ Rotate the waterwheel by hand. ○ Check that the speedometer shows the speed. If the speedometer does not work, check the speed sen- sor electric source vol[...]

ELECTRICAL SYSTEM 14-61 Multifunction Meter T achometer Inspection • Connect the 12 V battery and terminals in the same man- ner as specified in the “Display Function Inspection”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input i[...]

14-62 ELECTRICAL SYSTEM Multifunction Meter Buzzer Inspection • Make sure that the buzzer sounds correctly when turning the ignition switch key to the “ON” position and warning the trouble after connecting the buzzer between [9] and [10]. • If the output voltage between [9] and [10] is out of the range during the buzzer sound, replace the m[...]

ELECTRICAL SYSTEM 14-63 Multifunction Meter 3. Buzzer 4. Multifunction Meter 5. Speed Sensor 6. 20 A Main Fuse 7. Joint Connector R 8. Starter Motor 9. Battery 10. Joint Connector P 1 1. Ignition Switch 12. ECU (Electronic Control Unit) A: JT1500-A2 model ∼[...]

14-64 ELECTRICAL SYSTEM Relay Assembly Removal • Remove the seat (see Hull/Engine Hood chapter). • Remove the rear storage pocket. • Remove: Relay Assembly Connector [A] Clamp [B] Bolt [C] Relay Assembly [D] Installation • Apply a non-permanent locking agent to the relay assem- bly mounting bolt and tighten it securely . • Route the relay[...]

ELECTRICAL SYSTEM 14-65 Relay Assembly Relay Assembly Circuit Inspectio n (with the battery disconnected) T ester Connection T ester Read ing ( Ω ) 3-4 ∞ ECU Main Relay [A] 1-2 Not ∞ * 7-8 ∞ Fuel Pump Relay [B] 5- 6 Not ∞ * (*): The actual reading varies with the hand tester used. Relay Assembly Circuit In spection (with the bat tery conn[...]

14-66 ELECTRICAL SYSTEM Switches Switch Inspection • Using a hand tester , check to see that only the con- nections shown in the table have continuity (about zero ohms). ○ For the switch housing and the ignition switch, refer to the tables in the Wiring Diagram. If the switch has an open or short, repair it or replace it with a new one. Special[...]

ELECTRICAL SYSTEM 14-67 Fuse Inspection • Remove: Seat Fuse Case [A] • T ake out the fuse [A]. • Inspect the fuse element. If it blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rat- ing, check the wiring and related components f[...]

[...]

STORAGE 1 5-1 15 Storage T able of Contents Preparation for Storage .......................................................................................................... 15-2 Cooling System ................................................................................................................. 1 5-2 Bilge System ......................[...]

15-2 STORAGE Preparation for Storage During the winter , or whenever the watercraft will not be in use for a long period of time, proper storage is essential. It consists of checking and replacing missing or worn parts; lubricating parts to ensure that they do not become rusted; and, in general, preparing the watercraft so that when the time comes [...]

ST ORAGE 15-3 Preparation for Storage • Remove the fuel pump (see the Fuel System chapter). • Clean the fuel pump screen [A] (see Fuel System in Pe- riodic Maintenance chapter). • Refill the fuel tank with fresh fuel approximately 10 L ( 2.6 gal U.S.). • T urn the ignition switch on. • Push the lanyard key under the stop button, and start[...]

15-4 STORAGE Preparation for Storage • Reconnect the primary ignition coil lead connectors, not- ing the #1,#4 [A] and the #2, #3 [B] coil connectors. The #1, #4 coil connector has a red/yellow and a green/blue leads from the main harness. The #2, #3 coil connec- tor has a red/yellow and green/black leads from the main harness. NOTE ○ The servi[...]

ST ORAGE 15-5 Preparation for Storage General • W ash the engine compartment with fresh water and re- move the drain screw in the stern to drain the water . Wipe up any water left in the compartment. CAUTION Use only a mild detergent in water to wash the hull. Harsh solvents may attack the surface or smear the colors. • Apply a good grade of wa[...]

15-6 STORAGE Removal from Storage Lubrication • Carry out all recommended lubrication procedures (see the Periodic Maintenance chapter). General In spection • Check for binding or sticking throttle, steering or shift mechanism. The throttle lever must return fully when released. • Clean and gap spark plugs (see Electrical System in Pe- riodic[...]

ST ORAGE 15-7 Removal from Storage Te s t R u n WA R N I N G Do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odor- less, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. • Start the engine and run it only for 15 seconds. Check for fuel, oil and exhaust le[...]

[...]

APPENDIX 16-1 16 Appendix T able of Contents Cable, Wire and Hose Routing ............................................................................................... 16-2 T roubleshooting Guide ........................................................................................................... 16-32[...]

16-2 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-3 Cable, Wire and Hose Routing 1. Crossmember 2. Cylinder Head Cover 3. Throttle Cable 4. Delivery Pipe 5. Fix the throttle cable to the delivery pipe with the band. 6. Inlet Manifold 7. Horizontal Plane 8. Position the clamp pinch head below the horizontal plane. 9. Throttle Body Assy 10. Air Filter 11 . C l a m p 12. Cooling H ose (Cy[...]

16-4 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-5 Cable, Wire and Hose Routing 1. Oil Cooler 2. Cylinder Head 3. W ater Pipe 4. Cylinder 5. Oil Filter 6. Oil Pan 7. Battery ( − ) Cable 8. Starter Motor 9. Starter M otor Cable 10. Cooling Hose (Cylinder Head ∼ Left W ater Box Muffler) 1 1. F ix the No.10 cooling hose, battery ( − ) cable and starter motor cable with the band. 12[...]

16-6 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-7 Cable, Wire and Hose Routing 1. Clamp 2. Breather Hose (Cylinder Head ∼ Breather Case) 3. Clamp Detail 4. Position the clamp pinch heads as shown. 5. Air Suction V alve 6. Air S uction V alve Hose 7. Inlet Water Pipe Joint on the Cylinder (Cooling W ater from Left W ater Box Muffler) 8. Cylinder 9. Cylinder Head Cover 10. Output Cov[...]

16-8 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-9 Cable, Wire and Hose Routing Refer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapt er . Install the clamp as shown, noting its screw head direction. 1. Bypass Outlet 2. Clamp 3. Holder 4. Bypass Outlet Hose: Run the bypass outlet hose between the fuel tank and the straps as shown. 5. Cooling Hose (Oil Cool[...]

16-10 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-1 1 Cable, Wire and Hose Routing 1. Exhaust Manifold 2. Exhaust Pipe 3. Water Hose Point (Cooling Hose from the Output Cover) 4. 30° 5. Water Hose Joint (Cooling Hose from the Oil Cooler) 6. Upper Water Hose Joint 7. Cooling H ose Fitting (Left W ater Box Muffler ∼ Cylinder) 8. Cooling Hose Fitting (Left W ater Box Muffler ∼ Drain)[...]

16-12 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-13 Cable, Wire and Hose Routing 1. Right Rear Duct 2. Right Bilge Hose 3. Left Bilge Hose 4. Left Rear Duct 5. Left Water Box Muffler 6. Position the left rear duct inside the left bilge hose as shown. 7. Position the right rear duct under the right bilge hose as shown. 8. Right Water Box Muffler 9. Right Bilge Breather 10. Left Bilge B[...]

16-14 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-15 Cable, Wire and Hose Routing 1. Position the c lamp screw so that its head faces forward (JT1500-A1). Position the double spring clamp so that its pinch head faces forward (JT1500-A2 ∼ ). 2. Delivery Pipe Joints 3. Delivery Pipe 4. Inlet Air Pressure Sensor 5. Protective T ube 6. Throttle Body Assy 7. Position the clamp screw so th[...]

16-16 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-17 Cable, Wire and Hose Routing 1. Air Suction V alve Hose (to Air Filter) 2. Air Suction V alve 3. Air S uction V alve Cover (Rear) 4. Water T emperature Sensor Leads 5. Exhaust Manifold 6. Air Suction V alve Hose Fitting 7. Air S uction V alve Cover (Front) 8. Breather Hose 9. Cylinder Head Cover 10. Crankshaft S ensor Leads 1 1. Fix [...]

16-18 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-19 Cable, Wire and Hose Routing 1. Crankshaft S ensor Leads 2. Grommet 3. Crankshaft S ensor Cover (Reverse Side) 4. Crankshaft Sensor 5. Magneto Cover (Reverse Side) 6. Magneto Leads 7. Plate for fixing the magneto leads: Do not place the leads between the plate and magneto cover . 8. Run the magneto leads along the hollow of the magne[...]

16-20 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-21 Cable, Wire and Hose Routing 1. Band 2. Main Harness 3. Rivet 4. W asher 5. See wire routing at bow . 6. See w ire routing at stern. 7. Clamp 8. Speed Sensor Leads 9. W ater Box Muffler Strap 10. W ater Box Muffler[...]

16-22 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-23 Cable, Wire and Hose Routing 1. Crossmember 2. Steering Position Sensor Leads 3. Holder and Clamp 4. Fuel V ent Hose 5. Throttle Cable 6. Band 7. Ignition Switch Lead 8. Ignition Switch Lead Connector (Black) 9. Steering Position Sensor Lead Connector (White) 10. Fuel Level Sensor Lead Connector (Black) 1 1. Main Harness 12. Fuel Pum[...]

16-24 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-25 Cable, Wire and Hose Routing 1. Multifunction Meter Lead Connector (Blue and Y ellow: JT1500-A1), (Blue and White: JT1500 -A2 ∼ ) 2. Buzzer Lead Connector (Blue) 3. Start/Stop Switch Lead Connector (W hite) 4. Fuel T ank 5. Holders and Bands 6. Main Harness 7. Shift Cable 8. Fuse Case 9. Regulator/Rectifier 10. 16 Pin (Gray) and 6 [...]

16-26 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-27 Cable, Wire and Hose Routing 1. Regulator/rectifier 2. ECU (Electronic Control Unit) 3. Main Harness 4. Clamp 5. Electrical Parts Bracket 6. T o Starter Motor 7. T o Battery 8. Relay Assembly 9. Red Mark 10. Starter Relay 1 1. Right Side Deck 12. Main Harness[...]

16-28 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-29 Cable, Wire and Hose Routing 1. Fuel V ent Pipe: Hook the pipe at the handlebar . 2. Throttle Cable 3. Buzzer Leads (Run the leads through the protective tube.) 4. Protective T ube 5. Band 6. Clamp 7. Start/Stop Switch Leads 8. Grommet on Steering Holder 9. Multifunction Meter Leads 10. Fuel V ent Hose 1 1. Steering Holder 12. Holder[...]

16-30 APPENDIX Cable, Wire and Hose Routing[...]

APPENDIX 16-31 Cable, Wire and Hose Routing 1. 80 mm (3.15 i n.) 2. 100 mm (1.18 in.) 3. 180 mm (7.09 in.) 4. 40 mm (1.57 i n.) 5. 105 mm (4.13 in.) 6. 90 mm (3.54 i n.) 7. 50 mm (1.97 i n.) 8. 130 mm (5.12 in.) 9. Detent 10. Holder[...]

16-32 APPENDIX T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty Starter motor not rotating Starter motor trouble (brushes worn) Ba[...]

APPENDIX 16-33 T roubleshooting Guide Fuel line clogged Inlet air pressure sensor trouble Inlet air temperature sensor trouble Engine stalls easily Fuel pump trouble Fuel injector trouble Throttle sensor trouble Camshaft position sensor trouble Fuel pressure too low or too high Inlet air pressure sensor trouble W ater temperature sensor trouble Inl[...]

16-34 APPENDIX T roubleshooting Guide Fuel to injector insufficient (DFI) Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble (DFI) Injector clogged Throttle body assy loose Throttle body assy gasket damaged Fuel line clogged Fuel pump operates intermittently Inlet air temperature sensor trouble Throttle sensor trouble Inlet air press[...]

APPENDIX 16-35 T roubleshooting Guide Oil pressure switch damaged Wiring faulty O-ring at the oil passage in t he crankcase damaged Battery T rouble Battery discharged Charge insufficient Battery faulty (too low terminal voltage) Battery lead making poor contact Magneto trouble Wiring faulty Regulator/rectifier trouble Battery overcharged Magneto t[...]

MODEL APPLICA TION Ye a r Model Beginning Hull No. 2004 JT1500-A1 KA W60001 □ 304 2005 JT1500-A2 US-KA W50001 □ 405 □ :This digit in the hull number changes from one machine to another . Part No.99924-1325-02 Printed in Japan[...]