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1. IT BL BK a cu al d bh oz E G O S a D JN20054BW3 C Ignition Switch Immobilizer Amplifier Joint Connector P 12 V Joint Connector R 12 V Joint Connector T 12 V ECU Main Relay System Relay Joint Connector D 12 V Joint Connector C 12 V ECU 10 Joint Connector E Ground 11 Immbilizer Kawasaki Diagnostic System Connector 12 Main Fuse 20 A 13 Battery 14 Joint Connector Y Ground 15 Joint Connector S Ground 16 Meter Unit 17 Buzzer 18 Joint Connector Q Ground RS OR eng 14 80 ELECTRICAL SYSTEM Relay Assembly Relay Assembly Removal e Remove the front access cover see Front Access Cover Removal Installation in the Hull Engine Hood chapter e Remove Relay Connectors A Relay Mounting Bolts B ECU Main Relay C Fuel Pump System Relay D Relay Assembly Installation e Installation is the reverse of removal Note the following e Run the leads properly see Cable Wire and Hose Rout ing section in the Appendix chapter e Apply a non permanent locking agent to the relay mount ing bolts e Tighten Torque Relay Mounting Bolts 2 5 N m 0 25 kgf m 22 in 1b Relay Assembly Inspection e Remove the relay assembly see Relay Assembly Re moval e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay assembly as shown in the figure Special Tool Han
2. 4016287BS2 Troubleshooting the DFI System FUEL SYSTEM DFI 3 21 When the service code character A is displayed for first ask the rider about the conditions B of trouble and then start to determine the cause C of problem As a pre diagnosis inspection check the ECU for ground and power supply the fuel line for no fuel leaks and for correct pressure The pre diagnosis items are not indicated by the Fl character red warning indicator light LED Fl warning indicator and buzzer sound Don t rely solely on the DFI self diagnosis function use common sense Even when the DFI system is operating normally the red warning indicator light LED may go on Fl character and Fl warning indicator may blink and the buzzer may sound under strong electrical interference Additional measures are not required Remove the ignition key to stop the char acter indicator light indicator and buzzer sound If the red warning indicator light LED still go on FI character and FI warning indicator blink and buzzer sounds when the vehicle is brought in for repair check the service code characters When the repair has been done all warning indications go off But the service code characters stored in memory of the ECU are not erased to preserve the problem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems When the watercraft is dow
3. w Ce Er C7 Get 77 Cl L LL D D OS SI ES O Se 2S7 JB09653BW5 C APPENDIX 16 13 Cable Wire and Hose Routing Fuel Pump Clamps Fuel Hose Fix the main harness and throttle cable to the delivery pipe with the band 40 Position the clamp screws as shown Holder Bow 16 14 APPENDIX Cable Wire and Hose Routing Ms AE o al SCH a Ki F4 Y AR ME po de Se Q SECH UD Z 8 nn med UO Il Sad a 0 O oO 6 JB098654BW5 C APPENDIX 16 15 Cable Wire and Hose Routing JO O1 amp N Fuel Hose Throttle Cable Main Harness Fix the 1 and 2 spark plug leads with the clamp Fix the 2 and 3 spark plug leads with the clamp White Tape Fix the main harness with the clamps Fix the 3 and 4 spark plug leads with the clamp Bands 50 The 1 spark plug lead must be positioned at a right angle to the engine center line The 2 spark plug lead must be positioned at a right angle to the engine center line The 3 spark plug lead must be positioned at a right angle to the engine center line The 4 spark plug lead must be positioned at 50 degrees to the engine center line Water Temperature Sensor Lead Camshaft Position Sensor Lead Fix the camshaft position sensor lead a
4. 6 22 ENGINE TOP END Cylinder Head Cylinder Head Warp Inspection e Remove the cylinder head see Cylinder Head Removal e Clean the cylinder head e Lay a straightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard KEE Service Limit 0 05 mm 0 0020 in x If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 GE14038BS1 Valves ENGINE TOP END 6 23 Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and shim OMark and record the valve lifter and shim locations so they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 22 B 57001 1202 Valve Installation e Replace the oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces do
5. AD Apply adhesive LN Apply a non permanent locking agent High Strength Loctite 271 equivalent R Replacement Parts SS Apply silicone sealant 13 4 HULL ENGINE HOOD Exploded View HULL ENGINE HOOD 13 5 Exploded View Torque Fastener J Remarks Ke ee feb Front Hatch Mounting Screws 18 in lb AD Latch Handle Screws 2 0 0 20 18 in lb Handrail Plate Nuts 9 8 1 0 in L Seat Lock Ratchet Pins D et Jess a ot Handrail Mounting Screws 4 0 0 41 35 in T Bracket Bolts 8 8 0 90 78 in lb 7 US and EUR Models AD Apply adhesive G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant WG Apply water resistance grease 13 6 HULL ENGINE HOOD Sealant Adhesive TB1521 92104 3701 gt ST923701ST Fittings HULL ENGINE HOOD 13 7 Seat Removal e Pull up A the latch handle B e Remove the rear seat up A and to the rear B e Pull up A the latch handle B e Remove the front seat up A and to the rear B Seat Installation e Insert the seat hooks A into the bracket B on the deck and slide it all the way forward by pushing the rear of the seat e Push down on the rear of the seat to lock it 13 8 HULL ENGINE HOOD Fittings e Insert the seat hooks A into the brackets B on the handrail plate and slide it all the way forward by pushing the rear of the sea
6. JFO08013BS1 Camshaft Camshaft Chain ENGINE TOP END 6 15 e Install the camshaft cap A and upper camshaft chain guide B While pushing the camshaft chain tighten all camshaft bolts and chain guide bolts Olnstall the longer white bolts to the 10 and 14 position shown by triangle marks OFirst tighten the all camshaft cap and chain guide bolts evenly to seat the camshaft in place then tighten all bolts following the specified tightening sequence 1 20 Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 106 in lb Upper Camshaft Chain Guide Bolts 12 N m 1 2 kgf m 106 in Ib e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Turn the crankshaft 2 turns counterclockwise to allow the tensioner to expand and recheck the camshaft chain tim ing e Install the cylinder head cover see Cylinder Head Cover Installation Piston TDC Finding This job can be done when the engine is on the hull and during camshaft installation e Install the piston top detector A in the hole of the 1 spark plug Special Tool TDC Measurement Tool 57001 1560 e Insert the gauge extender B into the detector e Viewing from the bow turn the crankshaft clockwise by using the shaft wrench until the gauge extender reaches its highest point Special Tool Shaft Wrench 57001 1551 e Remove the extender and install it to the gauge 6 16 ENGINE TOP END Camshaf
7. 0ssseeeeeeeeeeeeeeeeeeeeeeeinrirtrreesnenrrrrnnsssrrrrennn 13 11 side Cover Removal ui taa E 13 12 Side Cover Installation sise 13 13 Front Access Cover Removal Installation 13 13 Center Access Cover Removal Installation 13 13 Mirror Removal lnstallation aaaannnnnnnenaaaannnnnnensasnnnnnnnrnsrsrnrnrnnressnsnrnrrrrrrenennnnereresrsnnen 13 13 Handrail Plate Removal 00 Ia net a aa aaas 13 14 Handrail Plate Installaton iii 13 14 Handrail Removal Installation a aa a ii 13 14 Drain Plug Housing Removal oido inca 13 14 Drain Plug Housing Installation ii a lo ia esta 13 14 Exhaust Outlet Removal iii Exhaust Outlet Installaton ss stabilizer Removal o ad iaa Stabilizer Installation ENEE Wer td a da Reboarding Step Removal uc idas Reboarding Step Installation Hull ele E ET bubber PAS ici Tee SEENEN ele Rubber Parts Loan A Aa ai id Blind Rivet EE Blind Rivet Installation oia arcada traida REER Front Bumper Removal ee Front Bumper Installation Rear Bumper Removal sise Rear Bumper Installation oooooninnnnninnninncnnnnnnncnnnnconnncnnncnnn nr nn rr nn rr rn rr rn narrar Side Bumper Removal eee Side Bumper Installation See AI DUCE le VC EE Ar DUCE EE UE en BEE 13 2 HULL ENGINE HOOD Exploded View HULL ENGINE HOOD 13 3 Exploded View
8. 1 2 3 Impeller 147 Filter Cover Mounting Bolts KR 15 0 108 87 mb 9 8 1 0 9 8 1 0 5 Grate Mounting Bolts 6 Pump Cover Mounting Bolts 0 80 7 Pump Mounting Bolts 3 7 8 Pump Shaft Nut 9 Pump Cap Bolts 3 9 0 40 35 in 1b L 10 Pump Outlet Mounting Bolts 19 1 9 14 L 11 Steering Nozzle Pivot Bolts 19 1 9 14 L 12 Steering Cable Joint Bolt 9 8 1 0 87 mb L AG Apply lithium grease NLGI Grade No 2 CY Apply cyanoacrylate cement L Apply a non permanent locking agent LN Apply a non permanent locking agent High Strength Loctite 271 equivalent M Apply molybdenum disulfide grease R Replacement Parts SS Apply silicone sealant WG Apply water resistance grease 11 4 PUMP AND IMPELLER Specifications Item Standard Service Limit Jet Pump Impeller Outside Diameter 154 5 154 7 mm 6 083 6 091 in 153 5 mm 6 043 in Pump Case Inside Diameter 155 0 155 1 mm 6 102 6 106 in 156 1 mm 6 146 in Impeller Clearance 0 15 0 3 mm 0 0059 0 012 in 0 6 mm 0 024 in PUMP AND IMPELLER 11 5 Special Tools and Sealant Inside Circlip Pliers Impeller Holder 57001 143 57001 1695 ST5701438T ST571695ST Bearing Driver Set Liquid Gasket TB1211 57001 1129 56019 120 ST5711298T ST560120ST Impeller Wrench 57001 1228 8757122897 11 6 PUMP AND IMPELLER Pump and Impeller
9. JROSOOOBS1 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Leave the engine idle for several minutes with the water running e Turn off the water Leave the engine idling e Rev the engine a few times to clear the water out of the exhaust system Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water e Stop the engine remove the garden hose and the adapter e Install the flushing cap securely Torque Flushing Cap 0 90 N m 0 092 kgf m 8 0 in Ib Bilge System Flushing To prevent clogging the bilge system should be flushed out according to the Periodic Maintenance Chart or when ever you suspect it is blocked e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter e Remove the bilge hoses A from the breathers B e Remove Bolts C Breathers e Install the bilge hose from the hull bottom to the gar den hose turn the water on and flush it out for about a minute During this procedure water will flow into the engine compartment Do not allow a large amount of wa ter to accumulate in the engine compartment Remove the drain screws in the stern to drain the engine compart ment e Install t
10. 0000aeeeeeee 14 23 Starter Relay Removal 14 23 Starter Relay Installation 14 23 Starter Relay Inspection 14 23 Starter Motor Removal 14 24 Starter Motor Installation 14 24 Starter Motor Disassembly 14 25 Starter Motor Assembly 14 25 Brush Inspection 14 26 Commutator Cleaning and Inspection 14 27 Armature Inspection 14 27 Brush Lead Inspection 14 27 Brush Plate and Terminal Bolt Inspection 14 28 Reduction Gear Removal Installa e WEE 14 28 Reduction Gear Inspection 14 28 Charging System 14 30 Alternator Removal Installation 14 30 Alternator Output Voltage Inspection 14 30 Regulator Rectifier Removal Installation 14 31 Regulator Rectifier Inspection 14 31 Regulator Inspection 14 31 Ignition System ee 14 34 Crankshaft Sensor Removal 14 34 Crankshaft Sensor Installation 14 35 Timing Rotor Removal 14 35 Timing Rotor Installation 14 35 Crankshaft Sensor Inspection 14 36 Crankshaft Sensor Peak Voltage Inspection 14 36 Ignition Coil Removal 14 37 Ignition Coil Installation 14 38 Ignition Coil Inspection 14 39 Ignition Coil Prim
11. O This digit in the hull number changes from one machine to another BE amp Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1451 01 Printed in Japan
12. Vehicle down Sensor Installation Vehicle down Sensor Input Voltage Inspection Vehicle down Sensor Output Voltage Inspection Immobilizer Amplifier Service Code Character 35 Innb Amplifier Input Voltage Inspection Blank Key Detection Service Code Character 36 Ignl User Key Inspection Fuel Pump Relay Service Code Character 45 46 F P1 Fuel Pump Relay Removal Installation Fuel Pump Relay Inspection Ignition Coils Service Code Character 51 52 COL1 COLA adi Ignition Coil Removal Installation Ignition Coil Primary Winding Resistance Inspection Ignition Coil Input Voltage Inspechon asnaanaeneeneeeeeeee System Relay Service Code Character 57 rEL2 3 51 3 52 3 53 3 53 3 53 3 53 3 54 3 54 3 54 3 54 3 56 3 56 3 57 3 57 3 58 3 61 3 61 3 62 3 62 3 64 3 64 3 64 3 66 3 66 3 66 3 66 3 68 3 2 FUEL SYSTEM DFI System Relay Removal Installa WM tie System Relay Inspection Engine Overheating Service Code Character 71 HEAT Low Engine Oil Pressure Service Code Character 72 OILP Oil Temperature Sensor Service Code Character 73 OILt Oil Temperature Sensor Removal Installation Oil Temperature Sensor Output Voltage Inspection Oil Temperature Sensor Resista
13. e Emission Related Items PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean AD Apply adhesive EO Apply engine oil G Apply grease L Apply a non permanent locking agent Medium Strength Loctite 242 Equivalent LN Apply a non permanent locking agent High Strength Loctite 271 Equivalent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Part S Follow the specified tightening sequence SS Apply silicone sealant Torque Fastener Nem kgf m ftlb Remarks Fuel System DEI Air Box Mounting Bolts 7 8 0 80 69 in lb L Air Box Bracket Mounting Bolts 8 8 0 90 78 in lb Air Box Flame Arrester Bolts 2 5 0 25 22 in lb Air Box Assembly Bolts 2 5 0 25 22 in lb L 1 Bracket Bolts 8 8 0 90 78 in lb L Camshaft Position Sensor Bolt 10 1 0 89 in lb L Crankshaft Sensor Screws 45 0 46 40 in lb E Delivery Pipe Assy Mounting Bolts 7 8 0 80 69 in lb Delivery Pipe Fitting 20 2 0 15 Delivery Pipe Plug 11 1 1 97 in lb L ECU Mounting Bolts 3 0 0 31 27 in lb L Fuel Filler Hose Clamp Screws 2 9 0 30 26 in lb Fuel Pump Rubber Holder Clamp Screws 2 9 0 30 26 in lb Intake Air Temperature Sensor 20 2 0 15 Intake Manifold Drain Plug 20 2 0 15 Intake Manifold Pla
14. e Apply molybdenum disulfide oil solution to all cam parts journals and tappets NOTE OThe exhaust camshaft has a 320 EX mark A and the intake camshaft has a 320 IN mark B Be careful not to mix up these shafts NOTE OAlso the intake and exhaust camshafts have the groove identification Groove A of Intake Camshaft Groove B of Exhaust Camshaft x If the camshaft position sensor rotor is removed install it as follows Olnsert the pin A into the holes B in the camshaft and boss C OFit the projection A of the rotor B on the camshaft re cess C OApply a non permanent locking agent high strength Loc tite 271 equivalent to the threads of the camshaft position sensor rotor bolt D and tighten it Torque Camshaft Position Sensor Rotor Bolt 12 N m 1 2 kgf m 106 in Ib 6 14 ENGINE TOP END Camshaft Camshaft Chain e Using the shaft wrench A turn the crankshaft counter clockwise B and set the crankshaft at 1 4 piston TDC see Piston TDC Finding Special Tool Shaft Wrench 57001 1551 e Pull the tension side exhaust side of the chain taut to install the chain e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown in the figure OThe timing marks must be aligned with the cylinder head upper surface A EX Mark B 1 Pin C 2 Pin D IN Mark E 31 Pin F 32 Pin G
15. lf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor Connector B R lead ECU terminal 9 C BK W lead ECU terminal 32 D x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation J616250BS1 J616296BS1 FUEL SYSTEM DFI 3 45 Intake Air Pressure Sensor Service Code Character 12 bOSt Intake Air Pressure Sensor Output Voltage Inspection e Measure the output voltage at the intake air pressure sen sor in the same way as input voltage inspection note the following ODisconnect the intake air pressure sensor connector and connect the measuring adapter A between these con nectors as shown in the figure Main Harness B Intake Air Pressure Sensor C Digital Meter D Special Tool Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter W sensor G R lead Digital Meter BK sensor BK W lead e Measure the output voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition s
16. Breather Removal e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter e Pull the hoses A off the breathers B e Unscrew the mounting bolts C and remove the breathers Breather Installation e Be sure the small hole A in the breather is open before installing it e Tighten the breather mounting bolts Breather Cleaning and Inspection e Check that the small hole in the top of the breather is open by blowing in one end of the breather and plugging the other x lf the hole is plugged clean it with compressed air Do not open it with a pointed object like a needle or a piece of wire because the hole may be enlarged If the hole is too large the bilge system may not suck water out of the hull as it should Filter Removal e Remove the engine see Engine Removal Installation chapter e Pull the hose A off the filter e Unscrew the mounting screw B and remove the filter C Starboard Side D Port Side E COOLING AND BILGE SYSTEMS 9 5 Bilge System Filter Installation e Align the projection A on the filter B with the hole C on the bracket D e Tighten the filter mounting screw E 4103012BS1 Filter Cleaning and Inspection e Flush the filter thoroughly with fresh water and shake it dry e Water must flow freely through the filter but large debris mus
17. Overall Height 1 150 mm 45 3 in Curb Mass 423 kg 932 7 Ib Fuel Tank Capacity 78 L 20 6 US gal Engine Oil Grade API SG SH SJ SL or SM with JASO MA MAT or MA2 Viscosity SAE 10W 40 Capacity 5 0 L 5 3 US qt Electrical Equipment Battery 12V 18 Ah Maximum Generator Output 16 A 14 V t This information shown here represents results under controlled conditions and the information may not be correct under other conditions Specifications subject to change without notice and may not apply to every country Unit Conversion Table Prefixes for Units GENERAL INFORMATION 1 13 Units of Length km x 0 6214 mile Prefix Symbol Power m x 3 281 ft mega M x 1000 000 mm x 0 03937 in kilo k x 1000 centi c x 0 01 Units of Torque milli m x 0 001 Nem x 0 1020 kgf m micro u x 0 000001 N m S 0 7376 ft lb N m x 8 851 in Ib kgf m x 9 807 N m Units of Mass kgf m x 7 233 ft lb kg x 2 205 Ib kgf m x 86 80 in Ib g x 0 03527 OZ Units of Pressure Units of Volume kPa x 0 01020 kgf cm L x 0 2642 gal US kPa x 0 1450 psi L x 0 2200 gal IMP kPa x 0 7501 cmHg L x 1 057 qt US kgf cm x 98 07 kPa L x 0 8799 qt IMP kgf cm x 14 22 psi L x 2 113 pint US cmHg x 1 333 kPa L x 1 816 pint IMP mL S 0 03381 oz US Units of Speed mL x 0 02816 oz IMP km h x 0 6214 mph mL x 0 06102 cu in Units of Power Units of Force kW x 1 360 PS N x 0 1020 kg kW
18. Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump and can not be removed Fuel Filter Cleaning OThe fuel filter A is built into the fuel pump and can not be cleaned or checked x If the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set Fuel Pump Screen Cleaning e Refer to the Fuel Pump Screen Cleaning in the Periodic Maintenance chapter FUEL SYSTEM DFI 3 111 Fuel Pump Fuel Pump Circuit I O O1 PB amp N o Ignition Switch Joint Connector P 12 V Joint Connector R 12 V Fuel Pump Joint Connector T 12 V ECU Main Relay Fuel Pump Relay System Relay Joint Connector L 12 V ji JC16315BW3 C 10 Joint Connector D 12 V 11 ECU 12 Joint Connector C 12 V 13 Joint Connector E Ground 14 Main Fuse 20 A 15 Battery 16 Joint Connector Y Ground 17 Joint Connector S Ground 3 112 FUEL SYSTEM DFI Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions To avoid a possi ble fire or explosion 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 includes any appliance with a pilot light e Draw the fuel out from the fuel tank with a commercially available pump e Remove Engine see Engine R
19. Special Tool Box Wrench 27 mm 57001 1749 Torque Steering Cable Nut 39 2 N m 4 0 kgf m 29 ft lb OEngage the groove A on the steering cable with the opening portion B on the cable bracket as shown OApply water resistance grease to the joint ball Olnstall the steering cable both end to the joints The steer ing cable ends must be inserted to the joints a minimum of 5 mm 0 2 in OApply a non permanent locking agent to the cable joint bolt and the steering cable bracket bolts OTighten Torque Steering Cable Joint Bolt 9 8 N m 1 0 kgf m 87 in Ib Steering Cable Bracket Bolts 9 8 N m 1 0 kgf m 87 in lb e Adjust the steering cable see Steering Cable Adjust ment Steering Cable Inspection e Refer to the Steering Cable Shift Cable Inspection in the Periodic Maintenance chapter 12 8 STEERING Steering Cable Steering Cable Lubrication NOTE OThe steering cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced Handlebars STEERING 12 9 Handlebar Removal e Remove Screws A Handlebar Pad B e Remove Air Temperature Sensor for Meter Unit A Buzzer B Inner Pad C e Remove Bolts A Handlebar Pad Holder B e Remove Start Stop Switch Case A Throttle Case B Bands C Handlebar Clamp Bolts D Handlebar Clamps E Handlebars F Handlebar Installation e Installation is the reverse of removal Note t
20. x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range and read the tester x If the tester does not read 0 Q the lead is defective Re place the lead or the main harness Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity Ifthe harness is open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself x If an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts re
21. D lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Throttle Position Sensor Resistance Inspection e Remove the ignition key e Remove the throttle body assy see Throttle Body Assy Removal e Connect a digital meter A to the throttle position sensor connector B e Measure the throttle position sensor resistance Throttle Position Sensor Resistance Connections R lead C BK W lead D J016335BS1 Standard 4 6k0 x If the reading is out of the standard replace the sensor x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation 3 42 FUEL SYSTEM DFI Throttle Position Sensor Service Code Character 11 tPS Throttle Position Sensor Circuit E E off 400 R EM BK W 1 Joint Connector F 5 V 2 ECU 3 Throttle Position Sensor 4 Joint Connector B Ground FUEL SYSTEM DEI 3 43 Intake Air Pressure Sensor Service Code Character 12 bOSt Intake Air Pressure Sensor Removal NOTICE A shock to the intake air pressure sensor can dam age it Do not drop the intake air pressure sensor e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Intake Air Pressure Sensor Connector A e Remove Intake Air
22. Engine Mounting Bolts 36 3 3 7 27 L Engine Bottom End Alternator Cover Bolts L 40 mm 20 2 0 15 Alternator Cover Bolts L 60 mm 20 2 0 15 Connecting Rod Nuts see text MO R Coupling 110 11 2 81 Coupling Cover Bolts 8 8 0 90 78 in lb L Crankcase Bolts M6 12 1 2 106 in lb S Crankcase Bolts M8 L 45 mm 30 3 1 22 S Crankcase Bolt M8 L 55 mm 30 3 1 22 S Crankcase Bolts M8 L 85 mm 30 3 1 22 MO S Crankcase Bolts M10 50 5 1 37 MO S Engine Bracket Mounting Bolts 32 3 3 24 L Oil Passage Plug R1 4 7 8 0 80 69 in lb L Oil Passage Plugs R3 8 20 2 0 15 L Output Cover Bolts 7 8 0 80 69 in lb Output Shaft 265 27 0 195 MO Oil Catch Cover Bolts 7 8 0 80 69 in lb Stator Coil Grommet Holder Plate Bolts 8 8 0 90 78 in lb L Stator Coil Mounting Bolts 12 1 2 106 mb L Cooling and Bilge Systems Flushing Cap 0 90 0 092 8 0 in lb Water Pipe Mounting Bolts 7 8 0 80 69 in lb Water Hose Clamp Screws 2 5 0 25 22 in lb Water Hose Clamp Screw 3 0 0 31 27 in lb Water Hose Clamp Screws 4 0 0 41 35 in lb Water Hose Joints 11 1 1 97 in lb L Water Hose Joint Water Pipe 20 2 0 15 L Drive System Coupling 265 27 0 195 Drive Shaft Holder Mounting Bolts 22 2 2 16 L 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torgus Remarks N m kgf m Pump and Impeller Filter Cover Mounting Bolts 9 8 1 0 87 mb L Grate Mounting Bolts 9 8 1 0 87 in lb L Impeller 147 15 0 108 M Pump Brac
23. Lead Connector C Adapter BL lt BK gt G lt R gt e Insert the ignition key in the ignition switch to turn it on and insert the lanyard key under the stop button ELECTRICAL SYSTEM 14 37 Ignition System e Pushing the starter button turn the engine 4 5 seconds to measure the crankshaft sensor peak voltage ODo not operate the starter for longer than 5 seconds Wait 15 seconds before using it again e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 2 5 V or more x If the tester reading is not specified one check the crank shaft sensor see Crankshaft Sensor Inspection Ignition Coil Removal e Remove Seat see Seat Removal in the Hull Engine Hood chap ter e Remove the bracket bolts A e Disconnect Regulator Rectifier Connector A Vehicle down Sensor Lead Connector B e Disconnect the ignition coil primary lead connectors A e Take the spark plug caps off the engine e Remove Bolts A and Nuts Collars B Ignition Coils C 14 38 ELECTRICAL SYSTEM Ignition System e Take the spark plug leads A off the ignition coil B Ignition Coil Installation e Lubricate the spark plug leads with the penetrating rust inhibitor e Connect the spark plug lead to each ignition coil as fol lows 1 Spark Plug Lead Length 340 mm 2 Spark Plug Lead Length 450 mm 3 Spark Plug Lead Length 540 mm 21 3 in C 4 Spar
24. SR ae Kawasaki ULTRA LX JET SKi Watercraft Service Manual SET AT 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 Taiwan KAWASAKI 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 Guide General Information Periodic Maintenance Fuel System DFI Engine Lubrication System Exhaust System Engine Top End Engine Removal Installation Engine Bottom End Cooling and Bilge Systems Drive System ES Pump and Impeller 0 Oo Ion A ION lech Hull Engine Hood Electrical System Storage Appendix SEIS watercraft ULTRA LX Kawasaki JET SKi Watercraft Service Manual 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 Divisio
25. e Remove Steering Cable Bracket Bolts A Plate B e Remove the steering holder mounting nuts A and wash ers e Raise the steering holder e Loosen the locknut A e Slide the outer sleeve B to take the ball joint off the steer ing shaft e Remove the steering cable ball joint and locknut from the steering cable e Remove Holder A Steering Cable Bracket B e Loosen the locknut A e Remove Steering Cable Joint Bolt B Steering Cable Joint C Pump Cover see Pump Removal in the Pump and Im peller chapter STEERING 12 7 Steering Cable e Unscrew the large nut steering cable nut in the hull with the box wrench OSpecial tool box wrench A is useful to remove the large nut steering cable nut Special Tool Box Wrench 27 mm 57001 1749 OWhen using the box wrench avoid bending the steering cable Such a bend to the cable can damage it e Slide off the snap ring A washer B and O ring C e Pull out the steering cable toward the rear JLO3000BS1 Steering Cable Installation e Installation is the reverse of removal Note the following OSlide a short piece of rubber or plastic tubing over the front cable end to guide the cable through the hull OLubricate the outside of the new cable to ease cable in stallation OReplace the O ring with a new one OApply water resistance grease to the new O ring OTighten the steering cable nut with the box wrench
26. e Remove Steering Neck Mounting Bolts A Steering Neck B with Adjustable Steering Holder C 12 12 STEERING Steering e Remove Cotter Pin A Steering Shaft Locknut B Washer C Holder D e Remove Grommet Mounting Plate Bolts A Grommet Mounting Plate B Lock Plate Mounting Bolts C Lock Plate D e Disconnect Steering Position Sensor Lead Connector Buzzer Lead Connector Air Temperature Sensor for Meter Unit Lead Connector Throttle Case Lead Connectors Start Stop Switch Case Lead Connector Throttle Cable Upper End at Throttle Case e Remove the center access cover A e Remove Steering Cable Bracket Bolts A Plate B JL068161 P STEERING 12 13 Steering e Remove Steering Holder Nuts A and Washer Clamp B e Raise the steering holder e Take the steering cable ball joint A off the steering shaft e Remove Steering Shaft Nut A Steering Shaft B Steering Holder C Steering Installation e Replace the steering holder gasket A with a new one e Check the bushings B for damage and wear x If the bushings are damaged or worn replace them with new ones e Apply water resistance grease C to the bushings e Install the bushings and the washer D JLO6022BS2 12 14 STEERING Steering e Apply water resistance grease A to the steering shaft B e Install the steering shaft A e Tighten the steering shaft
27. e Tighten Torque Pump Outlet Mounting Bolts 19 N m 1 9 kgf m 14 ft Ib 11 18 PUMP AND IMPELLER Pump and Impeller e Apply a non permanent locking agent to the thread of the steering nozzle pivot bolts A e Install the steering nozzle B so that the projection C faces rightward e Install the washers e Tighten Torque Steering Nozzle Pivot Bolts 19 N m 1 9 kgf m 14 ft Ib Impeller Inspection e Refer to Impeller Inspection in the Periodic Maintenance chapter Impeller Outside Diameter Measurement e Remove the impeller see Pump Disassembly e Measure the impeller outside diameter If the impeller is worn smaller than the service limit re place it Impeller Outside Diameter Standard 154 5 154 7 mm 6 083 6 091 in Service Limit 153 5 mm 6 043 in Pump Inspection e Visually inspect the pump case A If there are deep scratches inside the pump case replace it e Measure the inside diameter B of the pump case If the pump case is worn beyond the service limit replace it Pump Case Inside Diameter Standard 155 0 155 1 mm 6 102 6 106 in Service Limit 156 1 mm 6 146 in Impeller Clearance Inspection e Impeller clearance is critical to proper performance If the pump case and impeller are not visibly damaged poor performance may be caused by too much impeller clear ance e To check the impeller clearance remove the grate and insert a feele
28. 9 Joint Connector C 12 V 20 Meter Unit 10 ECU 21 Buzzer 11 Joint Connector E Ground 22 Joint Connector Q Ground 14 68 ELECTRICAL SYSTEM Immobilizer System This watercraft is equipped with an immobilizer system to protect the watercraft from theft This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU Electronic Control Unit Ifthe code does not match ignition system injectors and fuel pump will not operate and the engine will not start Abstract e f the red warning indicator light LED immobilizer warning symbol and the following character blink on the meter unit and the buzzer sound goes off after the key is pressed this shows a fault in the immobilizer system Imb Immobilizer Amplifier Failure Service Code 35 Ignl Not Matching Key Code Service Code 36 ORefer to the service code or character to identity the faulty component e If all coded keys FPO key orange colored and SLO key yellow colored and marked SLO are lost the ECU will have to be replaced e The immobilizer system can not function until the user key code is registered in the ECU e A total of six keys can be registered in the ECU at any one time Operational Cautions Do not expose the keys to excessively high temperature Do not place keys close to magnets Do not place a heavy item on any key Do not damage the plastic covers Do not give shocks to the keys One registered key is needed to
29. A e Apply a non permanent locking agent to the steering po sition sensor mounting screws B e Tighten the steering position sensor mounting screws e Install the band C OHold the steering position sensor and its lead e Install the steering shaft and the steering shaft nut see Steering Installation in the Steering chapter ELECTRICAL SYSTEM 14 47 Kawasaki Smart Steering KSS System Kawasaki Smart Steering System Inspection e Inspect the smart steering system with the watercraft in the water e Center the handlebar in the straight ahead position e Squeeze the throttle lever and allow it to approx 4 000 r min rem or above for 4 seconds or more e Release the throttle lever e Within 1 second turn the handlebar all the way to the left or right and check the engine speed increases to approx 3 300 r min rpm and then decreases to approx 2 600 r min rpm e Center the handlebar in the straight ahead position and check the engine speed decreases to an idle speed x If the Kawasaki Smart Steering system does not operate normally inpsect the steering position sensor clearance Steering Position Sensor Clearance Inspection e Take the steering holder off the hull see Steering Re moval in the Steering chapter e Check the clearance A between the steering position sensor B and the magnet C with feeler gauge Steering Position Sensor Clearance Standard 0 5 1 5 mm 0 02 0
30. B as shown in the figure before installing the water temperature sensor C 5 10 mm 0 2 0 4 in D NOTE OWhen filling the engine oil in the hollow of the exhaust manifold remove the exhaust manifold Fill the engine oil and install the water temperature sensor J616302BS1 Overfilling the engine with oil may damage the fit ting boss Do not overfill the engine oil e Tighten Torque Water Temperature Sensor 14 7 N m 1 5 kgf m 11 ft lb FUEL SYSTEM DFI 3 51 Water Temperature Sensor Service Code Character 14 AqUt Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Disconnect the water temperature sensor connector and connect the measuring adapter A between these con nectors as shown in the figure Main Harness B Water Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Water Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor G Y lead Digital Meter BK sensor BK W lead e Measure the output voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Output Voltage Standard About DC 3 5 4 0 V at 20 C 68 F NOTE OThe output vol
31. BN leads C Fuel Pump Operating Voltage ei D Connections to Adapter El Digital Meter R pump R W lead Digital Meter BK pump BK lead e Measure the operating voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on JC08018BS1 Operating Voltage Standard Battery Voltage for 3 seconds and then 0 V e Remove the ignition key lf the reading stays on battery voltage and never shows O V check the fuel pump relay see Relay Assembly In spection in the Electrical System chapter lf the fuel pump relay is normal check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If there is still no battery voltage check the fuel pump relay see Relay Assembly Inspection in the Electrical System chapter x If the fuel pump relay is normal check the wiring for con tinuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is in specification but the pump does not op erate replace the fuel pump see Fuel Pump Removal In stallation 3 110 FUEL SYSTEM DFI Fuel Pump
32. ECU checks immobilizer amplifier NOTE 2 Is the time to press key long Does ECU confirm key 2 code normally NOTE 5 Y Y Y Y Red warning indicator light LED blinks Registry of user keys completed Y Y End NOTE 6 End NOTE 8 NOTE T short time within 2 seconds long time 2 seconds or more ECU confirms the following O Time of Transmitting and Receiving Signals O Receiving Signals ECU confirms the following Not Registered User Key Key Registration Waiting Time Continue with the procedure to register the second and later keys before the 15 seconds period has elapsed ECU confirms the following inserted key is the user key 2 End Process Registration mode will be ended after 2 seconds End Process Registration mode will be ended instantaneously Registration mode will be ended after 15 seconds Red warning indicator light LED blinks Immobilizer Amplifier Failure JN20061B F ELECTRICAL SYSTEM 14 77 Immobilizer System Immobilizer System Parts Replacement Immobilizer Amplifier Ignition Switch Replacement e Move the handlebar to full forward position e Remove the center storage lid see Center Storage Lid Removal Installation in the Hull Engine Hood chapter e Remove Plate A Bolts B and Washers NOTE OHold the clip nuts C on the immobilizer amplifier igni tion switch e Remove the front access cover
33. KSS System Steering Position Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Connect a digital meter A to the steering position sensor lead connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Connections to Steering Position Sensor Lead Connector Digital Meter Y BK main harness Y W Digital Meter BK main harness BK e Insert the ignition key in the ignition switch to turn it on e Turn the steering shaft fully left or right e Measure the output voltage Steering Position Sensor Output Voltage Standard Approx 0 V NOTE OWhen the steering shaft is centered in straight ahead position the output voltage standard value is battery voltage e Remove the ignition key x If the reading is out of the standard check the wiring see Steering Position Sensor Circuit Then if the wiring is good replace the steering position sensor x If the reading is the standard but the Kawasaki Smart Steering system does not operate inspect the following ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter 4N18026BS1 ELECTRICAL SYSTEM 14 49 Kawasaki Smart Steering KSS System Kawasaki Smart Steering System Circuit s ni ue R Y We JN18028BW3 C Ignition Switch Joint Connector P 12 V Joint Connector R 12 V Joint Connect
34. Multifunction Meter Check 1 7 FPO Full Power Operation Mode Display Inspection e Using the FPO key orange colored insert the ignition key in the ignition switch to turn it on e Check that the FPO appears in the display A for 2 sec onds before the normal display appears lf the display function does not work replace the meter unit Meter Unit Inspection e Remove the meter unit see Meter Unit Removal 1 Battery R 2 Ground BK 3 Speed Sensor Steering Position Sensor R BL 4 Ignition Switch R W 5 Buzzer BK W 6 Buzzer R BK 7 Fuel Level Sensor W R 8 ECU communication Signal BL BK 9 Unused 10 Speed Sensor Signal G R 11 Water Temperature Sensor BR 12 Water Temperature Sensor BK BR 13 Air Temperature Sensor LG 14 Air Temperature Sensor BK R NOTICE Do not drop the meter unit Place the meter unit so that it faces upward If the meter unit is left upside ida down or sideways for a long time or dropped it will malfunction Do not short each terminal Check 2 1 Meter Unit Power Supply Inspection e Using auxiliary leads connect the 12 V battery to the me ter unit connector as follows OConnect the battery terminal to the terminal 1 OConnect the battery terminal to the terminal 2 e Connect the terminal 4 to the battery terminal e Check the following items OFollowing
35. Oil Pressure Switch Removal e Remove Intake Manifold see Intake Manifold Removal in the Fuel System DFI chapter Oil Pressure Switch Connector A Disconnect e Place a rag or cloth under the oil pressure switch A and remove the oil pressure switch ODo not damage the connect part B of the switch Oil Pressure Switch Installation e Apply a non permanent locking agent to the threads of the oil pressure switch and tighten it Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb e Connect the oil pressure switch connector e Install the removed parts see appropriate chapters EXHAUST SYSTEM 5 1 Exhaust System Table of Contents EXploded WEE 5 2 Exhaust Manifolds sinniet E nn ent in a 5 4 Exhaust Manifold Removal a etia 5 4 Exhaust Manifold Installation ranas 5 4 Exhaust Manifold Cleaning and Inspection 5 5 Exhaust Pipe eene ep eea eee E eE E EEE RRA ARO EN gek anes setenad di AAA aida ExhaustPipe Removals insten A E ES Exhaust Pipe Installation Exhaust Pipe Cleaning and Inspection NN te eelef eege dd T 5 8 Water Box Muffler Removal ses 5 8 Water Box Muffler Installation seen 5 8 Exhaust Hose Inspection seins ee i ee aee A ee iE aea T E E a RE a Ds 5 10 5 2 EXHAUST SYSTEM Exploded View JEG2032BH5 EXHAUST SYSTEM 5 3 Exploded View j
36. Pump Removal e Turn the craft on its left side e Disconnect the shift cable ball joint at the rear end see Shift Cable Removal in the Steering chapter e Remove Pump Cover Mounting Bolts A and Washers Speed Sensor Screws B e Remove the pump cover C with the reverse bucket D e Remove the joint bolt A to free the steering cable joint e Loosen the clamps A on the intake water hoses and pull off the hoses B e Remove the pump mounting bolts A e Slide the pump B rearward to disengage the drive shaft and remove it from the hull e To remove the pump bracket perform the following pro cedures ORemove Bolts A and Washers Grate B Pump and Impeller PUMP AND IMPELLER 11 7 OTake out the pump bracket mounting bolts A and wash ers in the hull OTake out the pump bracket mounting bolts A and wash ers OCut the sealant at the indicated area A in the figure and remove the pump bracket B Pump Installation e Strip off all the old sealant around the pump bracket e Liberally coat the outside edge of the pump bracket with silicon sealant A to form a seal between the bracket and the hull Sealant Liquid Gasket TB1211 56019 120 JK04113BS1 11 8 PUMP AND IMPELLER Pump and Impeller e Install the pump bracket A to the hull e Apply a non permanent locking agent High Strength Loctite 271 equivalent to the pump bracket mounting bolts M8 B a
37. Sensor for Meter Unit Removal Installation 14 54 14 47 14 2 ELECTRICAL SYSTEM Water Temperature Sensor for Meter Unit Inspection Air Temperature Sensor for Meter Unit Removal Installation Air Temperature Sensor for Meter Unit Inspection Multifunction Meter Meter Unit Removal Meter Unit Installation Meter Unit Operation Inspection Meter Unit Inspection Immobilizer System Operational Cautions 14 55 14 55 14 56 14 58 14 58 14 58 14 59 14 63 Key Registration Immobilizer System Parts Replacement Immobilizer System Inspection Relay Assembly Relay Assembly Removal Relay Assembly Installation Relay Assembly Inspection Switches Parts Location ELECTRICAL SYSTEM 14 3 1 2 3 11 12 13 Oln this photo the front access cover has been removed Start Stop Switch Case Meter Unit Ignition Switch Immobilizer Amplifier Air Temperature Sensor for Meter Unit Buzzer Regulator Rectifier Ignition Coils Vehicle down Sensor Water Temperature Sensor Spark Plugs ECU ECU Main Relay Fuel Pump System Relay NOTE 14 4 ELECTRICAL SYSTEM Parts Location 14 Immobilizer Kawasaki Diagnostic System Conne
38. on the valve seat x If the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 27 6 27 8 mm 1 087 1 094 in Intake 32 6 32 8 mm 1 283 1 291 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Exhaust 0 8 1 2 mm 0 031 0 047 in Intake 0 5 1 0 mm 0 020 0 039 in GE15007BS2 C GE15011782 C 6 26 ENGINE TOP END Valves Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar B 57001 1128 Valve Seat Cutter Holder 65 C 57001 1208 For Exhaust Valve Seat Valve Seat Cutter 45 30 57001 1187 Valve Seat Cutter 32 630 57001 1120 Valve Seat Cutter 60 30 57001 1123 For Intake Valve Seat Valve Seat Cutter 45 35 57001 1116 Valve Seat Cutter 32 635 57001 1121 Valve Seat Cutter 55 35 57001 1247 x l the manufacturer s instructions are not available use the following procedure 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
39. 0 9457 in TIR 0 02 mm 0 0008 in or less 0 16 mm 0 0063 in 23 92 mm 0 942 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Cylinder Head Warp Usable Range 1 190 1 795 kPa 12 1 18 3 kgf cm 173 260 psi at 430 r min rpm Valves Valve Clearance Exhaust Intake Valve Head Thickness Exhaust Intake Valve Stem Bend Valve Stem Diameter Exhaust Intake Valve Guide Inside Diameter Exhaust Intake Valve Valve Guide Clearance Wobble Method Exhaust Intake Valve Seat Cutting Angle Valve Seating Surface Outside Diameter Exhaust Intake Width Exhaust Intake Valve Spring Free Length Exhaust Inner Exhaust Outer Intake Inner 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 24 mm 0 0059 0 0094 in 0 8 mm 0 031 in 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 4 955 4 970 mm 0 1951 0 1957 in 4 975 4 990 mm 0 1959 0 1965 in 5 000 5 012 mm 0 1969 0 1973 in 5 000 5 012 mm 0 1969 0 1973 in 0 09 0 17 mm 0 0035 0 0067 in 0 03 0 11 mm 0 0012 0 0043 in 32 45 55 60 27 6 27 8 mm 1 087 1 094 in 32 6 32 8 mm 1 283 1 291 in 0 8 1 2 mm 0 031 0 047 in 0 5 1 0 mm 0 020 0 039 in 38 1 mm 1 50 in 46 0 mm 1 81 in 38 0 mm 1 50 in 0 4 mm 0 016 in 0 3 mm 0 012 in TIR 0 05 mm 0 002 in 4 94 mm 0 194 in 4 96 mm 0 19
40. 03 mm 0 0398 0 0406 in Service Limit Top A 1 02 mm 0 0402 in Second B 1 11 mm 0 0437 in lf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Inspection e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top 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 Top A 0 80 mm 0 0315 in Second B 0 90 mm 0 0354 in lf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap between the ends ofthe ring with a thick ness gauge B Piston Ring End Gap Standard Top 0 25 0 40 mm 0 0098 0 0157 in Second 0 40 0 55 mm 0 0157 0 0217 in Service Limit Top 0 7 mm 0 028 in Second 0 8 mm 0 031 in x lf the end gap of either ring is greater than the service limit replace all the rings GE160707S1 GE160708
41. 1 6126 in x If any journal has worn past the service limit replace the crankshaft with a new one x If the measured journal 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 Crankshaft Main Journal Diameter Marks None 40 984 40 992 mm 1 61354 1 61386 in 1 40 993 41 000 mm 1 61389 1 61417 in m Crankshaft Main Journal Diameter Marks 1 mark or no mark 6105041981 JH11025B 1 C ENGINE BOTTOM END 8 29 Crankshaft and Connecting Rods e Measure the main bearing inside diameter and mark A the upper crankcase half B in accordance with the inside diameter OCrankcase main bearing inside diameter marks are O mark and no mark NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks O 44 000 44 008 mm 1 73228 1 73259 in None 44 009 44 016 mm 1 73263 1 73290 in Marking Position 5 4 3 2 1 JH11024B 1 C e Select the proper bearing insert in accordance with the combination coding of the crankcase and crankshaft e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage Crankcase Main Crankshaft Main Bearing Insert ue KE EE E Siz
42. 20 A A Spare Fuse 20 A B e Inspect the fuse element x 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 for a short circuit Housing A Fuse Element B Terminals C Blown Element D Installation of a fuse with a higher rating may cause damage to wiring and components When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit ni18007 P 6P200001S1 STORAGE 15 1 Storage Table of Contents Preparation Tor IO ia aid da idad anda 15 2 Cooling Syste mM denni dd un 15 2 Discharging water in the exhaust system c ccceeeeeeeeeseneceeeeeeeeeeseseceeeseeeeeeeenetenseneenes 15 2 Bilge VS Mii is 15 3 Engine Oilein tddi Dd rita dea 15 3 Fuel SySteM is A A 15 3 inte UE 15 4 AIP BOX EE 15 4 DIO Vi IS ls A Mean Melle eae ieee i AAA A ade id AAA 15 4 Re lee EE 15 5 Lube Jet Pump Bearings Sal iii ic 15 5 A AS 15 5 Removal from Storage tia AA A sateen eee ce N 15 6 Bt ele Te E 15 6 General Inspection see 15 6 Fuel SS YSU IN asec tee ae O ne ln ane 15 6 OSU RUM do EE 15 7 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
43. Backfiring when deceleration Spark plug dirty broken or gap maladjusted Fuel pressure too low Fuel pump trouble Throttle position sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble After fire Spark plug burned or gap maladjusted Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 2 Inspect see chapter 3 spect see chapter 3 spect see chapter 3 spect see chapter 3 spect see chapter 3 Inspect see chapter 3 Replace see chapter 2 Fuel injector trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Actions Firing incorrect Ignition coil shorted or not in good contact Inspect or reinstall see chapter 14 Ignition coil trouble Inspect see chapter 14 Spark plug dirty broken or gap maladjusted Inspect a
44. C 194 F 1 182 1 481 kO 100 C 212 F 0 9025 1 142 kQ lf the digital meter does not show the specified values replace the sensor Air Temperature Sensor for Meter Unit Removal Installation e Remove Front Access Cover see Front Access Cover Removal in the Hull Engine Hood chapter Steering Pad see Steering Removal in the Steering chapter Rivets A JN10104BS2 14 56 ELECTRICAL SYSTEM Sensors e Disconnect the air temperature sensor for meter unit lead connector Green 2 pin A e Remove Grommet Holding Plate Bolts A Plate B Grommet C e Take the air temperature sensor for meter unit off the tube e Installation is the reverse of removal Note the following ORun the sensor properly see Cable Wire and Hose Routing section in the Appendix chapter OApply a non permanent locking agent to the grommet holding plate bolts Air Temperature Sensor for Meter Unit Inspection e Remove the air temperature sensor for meter unit see Air Temperature Sensor for Meter Unit Removal Instal lation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend an accurate thermometer B with heat sensitive portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the te
45. Code Character 23 CAA1 The camshaft position sensor detects the position of the camshaft and distinguishes the cylinder Camshaft Position Sensor Removal Installation e Refer to the Camshaft Position Sensor Removal Installa tion in the Electrical System chapter Camshaft Position Sensor Resistance Inspection e Refer to the Camshaft Position Sensor Inspection in the Electrical System chapter x If the reading is within the standard check the peak volt age see Camshaft Position Sensor Peak Voltage Inspec tion Camshaft Position Sensor Peak Voltage Inspection e Refer to the Camshaft Position Sensor Peak Voltage In spection in the Electrical System chapter x lf the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors 016308881 Wiring Continuity Inspection ECU Connector A Camshaft Position Sensor Connector B W BL lead ECU terminal 7 C BK W lead ECU terminal 15 BK R lead D x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation FUEL SYSTEM DEI 3 55 Camshaft Position Sensor Service Code Character 23 CAA1 Camshaft Position Sensor Circuit O 1 ECU 2 Joint
46. E Drive Shaft Holder Mounting Bolts L Apply a non permanent locking agent R Replacement Parts M Apply molybdenum disulfide grease SS Apply silicone sealant WG Apply water resistance grease 10 4 DRIVE SYSTEM Specification Item Standard Service Limit Drive Shaft Runout at 19 7 19 8 mm 0 776 0 780 in position 0 1 mm 0 0039 in at 618 8 19 2 mm 0 740 0 756 in position 0 2 mm 0 0079 in DRIVE SYSTEM 10 5 Special Tools Inside Circlip Pliers Coupling Holder 2 57001 143 57001 1423 ST5701438T ST571423ST Bearing Driver Set 57001 1129 ST5711298T 10 6 DRIVE SYSTEM Drive Shaft Drive Shaft Holder Drive Shaft Removal e Remove the engine see Engine Removal in the Engine Removal Installation chapter e Remove the drive shaft together with the coupling A out of the hull e Hold the drive shaft in a vise and loosen the coupling with the coupling holder A Special Tool Coupling Holder 2 57001 1423 Olnstall the coupling damper B to the coupling holder Oln the photo install the suitable tool C between the drive shaft and vise so that the drive shaft might set straight Drive Shaft Installation e Install the washer A on the drive shaft e Apply a non permanent locking agent to the threads B of the drive shaft e Tighten Torque Coupling 265 N m 27 0 kgf m 195 ft Ib Special Tool Coupling
47. JC16317BH3 C Ignition Switch Joint Connector P 12 V Joint Connector R 12 V Joint Connector T 12 V ECU Main Relay System Relay Joint Connector D 12 V ECU Joint Connector C 12 V 10 Joint Connector E Ground 11 Joint Connector M 12 V 12 Spark Plugs 13 Ignition Coils 14 Main Fuse 20 A 15 Battery 16 Joint Connector Y Ground 17 Joint Connector S Ground JO O1 amp ND 3 68 FUEL SYSTEM DFI System Relay Service Code Character 57 rEL2 System Relay Removal Installation e Refer to the Relay Assembly Removal Installation in the Electrical System chapter System Relay A System Relay Inspection e Refer to the Relay Assembly Inspection in the Electrical System chapter x If the system relay is normal check the wiring for conti nuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation FUEL SYSTEM DEI 3 69 System Relay Service Code Character 57 rEL2 System Relay Circuit BK BL BK R 7 E Bu O O O 1 Ignition Switch 7 Joint Connector E Ground 2 Joint Connector P 12 V 8 Main Fuse 20 A 3 Joint Connector R 12 V 9 Battery 4 System Relay 10 Joint Connector Y Ground 5 Joint Connector C 12
48. OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Chocolate O Orange W White DG Dark Green P Pink Y Yellow G Green 3 12 FUEL SYSTEM DFI DFI System Terminal Numbers of ECU Connectors JC16284BH2 DFI System FUEL SYSTEM DFI 3 13 Terminal Names ISC Idle Speed Controller BK BL ISC Idle Speed Controller Y BK Oil Pressure Switch BK Y Unused Crankshaft Sensor O BL Unused Camshaft Position Sensor W BL Unused Power Supply to Sensors R External Communication Line Immobilizer System LG R Water Temperature Sensor G Y Immobilizer Amplifier BL G Oil Temperature Sensor Y External Communication Line KDS P Ground for Control System BK R Unused Power Supply to ECU R Y ISC Idle Speed Controller BR W ISC Idle Speed Controller BL R Engine Stop Switch W Steering Position Sensor Y W Crankshaft Sensor R BK Intake Air Pressure Sensor G R Unused Unused Vehicle down Sensor BL W Unused Intake Air Temperature Sensor R BL ECU Communication Line to Meter Unit BL BK Throttle Position Sensor G W Immobilizer Amplifier O BK Ground for Sensors BK W Unused Battery Monitor Voltage Line O G Unused System Relay BL Unused Fuel Injector 3 BR Ground for Power BK ECU Main Rel
49. Oil Flow Chart QO yy ENGINE LUBRICATION SYSTEM 4 5 Engine Oil Flow Chart 1 Cylinder Head Cover 2 Oil Separator Tank 3 To Oil Pan 4 To Air Box A Blowby Gas B Return Engine Oil Flow 4 6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Vs AS JDO7054BW5 C ENGINE LUBRICATION SYSTEM 4 7 Engine Oil Flow Chart 1 Oil Passage From Oil Pipe to Camshaft Cap 2 Camshaft Oil Passage 3 Crankshaft Oil Passage 4 To Oil Pan 5 Oil Hose From Cylinder to Oil Pan A Supply Engine Oil Flow B Return Engine Oil Flow C Oil Sump 4 8 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart H e ai gt y SA gt Jo LA e Y 2 NJM W d o Ki L ES le a Na M S En 7 DY y JDOTOSSBWS C Engine Oil Flow Chart ENGINE LUBRICATION SYSTEM 4 9 pa FOODOANDOARWD Oil Pipe Oil Cooler Oil Passage Bolt Oil Pressure Switch Oil Filter Main Oil Passage Oil Pump Relief Valve Oil Screen Oil Pan Supply Engine Oil Flow 4 10 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 4 0 L 4 2 US at when filter is not removed 4 2 L 4 4 US at when filter is removed 5 0 L 5 3 US qt when engine is completely dry Level Between upper and lower level lines see text Oil Pressu
50. Pressure Sensor Bolts A Intake Air Pressure Sensor B Intake Air Pressure Sensor Installation e Apply silicone oil to the O ring A NOTICE Do not apply silicone oil to the sensor end sensing part B and the inside C of the sensor connector e Tighten Torque Intake Air Pressure Sensor Bolts 7 8 N m 0 80 kgf m 69 in lb mn P 3 44 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code Character 12 bOSt Intake Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Disconnect the intake air pressure sensor connector and connect the measuring adapter A between these con nectors as shown in the figure Main Harness B Intake Air Pressure Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Pressure Sensor Input Voltage Connections to Adapter Digital Meter R sensor R lead Digital Meter BK sensor BK W lead e Measure the input voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Input Voltage Standard DC 4 75 5 25 V e Remove the ignition key x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor Output Voltage In spection
51. SYSTEM 14 33 Charging System Charging System Circuit JNO7035BW2 1 Joint Connector P 12 V 2 Joint Connector C 12 V 3 Main Fuse 20 A 4 Alternator 5 Regulator Rectifier 6 Battery 7 Joint Connector S Ground 14 34 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plugs ignition coils or spark plug high tension leads while the engine is running or you could receive a severe electrical shock Disconnecting the battery cables or any other elec trical connections when the ignition switch is on or while the engine is running can damage the ECU Electronic Control Unit Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running Installing the battery cables backwards can damage the diodes and ECU Be sure to install the cables properly Crankshaft Sensor Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter e Cut the band A e Remove Crankshaft Sensor Cover Bolts A Crankshaft Cover B Dowel Pins C e Remove Rubber Grommet Holder Screws A Crankshaft Sensor Screws B Rubber Grommet C and Holder D Crankshaft Sensor E Ignition System ELECTRICAL SYSTEM 14 35 Crankshaft Sensor Installation e Run the sensor lead through the cover hole
52. System Flow Diagram Flushing Fitting Bypass Outlet Cylinder Head Water Pipe Oil Cooler Exhaust Manifold Exhaust Pipe Cylinder Output Cover 10 Water Box Muffler 11 Tail Pipe 12 Bilge Breathers 13 Pump 14 Cooling Water Filter Cover 15 Bilge Filters A Direction of Cooling System Flow B Direction of Bilge System Flow C Direction of Combined Exhaust Gas and Cooling Water Flow OONOARWN A 9 10 COOLING AND BILGE SYSTEMS Water Pipe Water Pipe Removal e Remove the intake manifold see Intake Manifold Re moval in the Fuel System DFI chapter e Loosen the clamp screw A and remove the water hose B e Unscrew the mounting bolts C and remove the water pipe D from the cylinder head Water Pipe Installation e Replace the O rings A with new ones and apply grease to new O rings e Install the O rings and water pipe e Tighten Torque Water Pipe Mounting Bolts 7 8 N m 0 80 kgf m 69 in lb e Install the water hose B to the water hose joint e Tighten Torque Water Hose Clamp Screw C 3 0 N m 0 31 kgf m 27 in lb 4104036BS1 COOLING AND BILGE SYSTEMS 9 11 After Submerging If water enters the engine it will cause severe dam age Do not operate the watercraft with water in the engine Do not try to start the engine until it is com pletely empty of water If water gets into the engine follow this procedure immediately If water is left in t
53. Time NOTE 4 Insert unregistered key and press key during short time or long time ECU checks immobilizer amplifier NOTE 2 Is the time to press key short Does ECU confirm key code normaily NOTE 5 Pre registration of user key n Red warning indicator light LED blinks Registry of key n completed End NOTE 6 Red warning indicator light LED blinks immobilizer amplifier pre registered key Y Regular Registration of User Key Key Registry Action NOTE 1 Registration mode will be ended when registered key is pressed during long time short time within 2 seconds long time 2 seconds or more 2 ECU confirms the following Time of Transmitting and Receiving Signals Receiving Signals 3 End Process Registration made will be ended when unregistered key is inserted 4 Key Registration Waiting Time Continue with the procedure to register the second and later keys before the 15 seconds period has elapsed 5 ECU confirms the following Not Registered User Key Number of registered key is within six 6 End Process Registration mode will be ended instantaneously 7 End Process Registration mode will be ended after 2 seconds 8 Registration mode will be ended after 15 seconds ECU checks NOTE 2 ls key the lastly Res warning indicator light LED blinks Red warning indicator light LED blinks End NOTE
54. Torque Front Hatch Mounting Screws 2 0 N m 0 20 kgf m 18 in lb e Apply a non permanent locking agent to the front duct bolts and tighten them securely 13 10 HULL ENGINE HOOD Fittings e Install the damper A on the meter cover B and install the meter cover 15 mm 0 59 in C Olf the hinge bracket A is disassembled apply a water resistance grease B to the following Bushings C Shaft D OReplace the rivets E with new ones Front Cover Removal Installation e Remove Front Storage Compartment Cover see Front Storage Compartment Cover Removal installation e Push in the pins A and remove the cover B JM07041BS1 Ws so AT tut b Fittings HULL ENGINE HOOD 13 11 e Remove Screws A Washers B Bolts C Front Cover D Front Inner Cover E OBe careful not to drop the bolts e Installation is the reverse of removal Note the following Olnstall the dampers A on the front cover B as shown in the figure 5 mm 0 20 in C 15 mm 0 59 in D Center Storage Lid Removal Installation e Open the middle storage lid A e Pull up B the lid e Installation is the reverse of removal 4M07043BS2 4M07044BS2 C 13 12 HULL ENGINE HOOD Fittings e To remove the lock A from the center storage lid turn and pull out the shaft B both sides e When installing the shafts push the shaft end C both sides into
55. Troubleshooting the DFI System Poor running O spark plug loose tighten it or no power at spark plug dirty broken or gap maladjusted remedy it high speed E O spark plug incorrect replace it O knocking fuel poor quality or incorrect use high octane gasoline O engine overheating O engine oil level too high O engine oil viscosity too high O other FUEL SYSTEM DEI 3 27 DFI System Troubleshooting Guide NOTE OThis 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 in D I system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or Possible Causes Actions Immobilizer system trouble Inspect see chapter 14 Vehicle down sensor operated Turn ignition switch OFF see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 14 Ignition coil shorted or not in good contact Inspect or reinstall see chapter 14 Ignition coil trouble Inspect see chapter 14 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter
56. V e Remove the ignition key x If the reading is within the standard check the output volt age see Throttle Position Sensor Output Voltage Inspec tion p 3 40 FUEL SYSTEM DFI Throttle Position Sensor Service Code Character 11 tPS sl the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Throttle Position Sensor Connector B R lead ECU terminal 9 C NA BK W lead ECU terminal 32 D x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Throttle Position Sensor Output Voltage Inspection e Measure the output voltage at the throttle position sensor in the same way as input voltage inspection note the fol lowing ODisconnect the throttle position sensor connector and connect the setting adapter A between these connec tors Special Tool Throttle Sensor Setting Adapter 57001 1521 IIA Y Throttle Position Sensor Output Voltage Connections to Adapter Digital Meter Y W sensor G W lead Digital Meter BK BL sensor BK W lead e Start the engine and warm it up thoroughly e Check idle speed to ensure t
57. aaa 9 4 Et ld alt oca ec ee 9 5 Filter Cleaning and Inspection antenne he ilndtin ess 9 5 Cooling and Bilge System e iii a mem ann nan hd dad 9 6 PROSCAR MOVE A tons de tt these de En 9 6 Hose Instala Mos disc da ee Rate Reese ne ALESIS ae 9 6 HOSE rss ET 9 6 Cooling and Bilge System FIUSHING cocina A Le relate di 9 7 Cooling System PUSO Ds add ce cet se deu den en ana 9 7 Bilge System FIUShing WE 9 7 Cooling and Bilge System Flow Diagram ss 9 8 Water PIPE erer anre A das ales 9 10 Water lee EE 9 10 Water Pipe Installation seen 9 10 a Es Shen den ne te MERE tigi fa eme nn nn cea Ar 9 11 Summary Procedures after Submerging eeeeeaeeeeeeeeeeeeeeenaaaaes 9 12 Detailed Procedures after Submerging s ENNEN 9 13 9 2 COOLING AND BILGE SYSTEMS Exploded View J102038845 C COOLING AND BILGE SYSTEMS 9 3 Exploded View Torque N m kgf m ft lb a Fusing 020 00 som Water Hose Clamp Screws 2 5 0 25 22in lb 4 Water Hose Clamp Seres 40 041 nb 5 Water Pipe Mounting Bols 78 oso 69imb Water Hose Joint Water Pipe 20 2 0 Water Hose Clamp Screw 3 0 0 31 27 ml Po AD Apply adhesive CY Apply cyanoacrylate cement G Apply grease L Apply a non permanent locking agent LN Apply a non permanent locking agent High Strength R Replacement Parts No Fastener 9 4 COOLING AND BILGE SYSTEMS Bilge System
58. chapter 3 Inspect see chapter 3 mlaja LD Fuel change Use the gasoline recommended in the Owner s Manual Replace it with the correct plug see chapter 2 Inspect see chapter 14 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect throttle cable and lever linkage see chapter 3 Engine overheating Water temperature sensor or crankshaft sensor trouble see Overheating of Troubleshooting Guide in chapter 16 Self Diagnosis FUEL SYSTEM DFI 3 31 The red warning indicator light LED A is used for the following warnings Fuel Level Low Battery Voltage Engine Cooling Water Temperature Engine Oil Pressure Oil Temperature Sensor Engine Oil Overheat Fl Immobilizer Self diagnosis Outline The self diagnosis system has two modes and can be switched to another mode by operating the meter unit User Mode The ECU notifies the rider of troubles in DFI system and ignition system by turning on the red warning indicator light LED A by blinking the FI character B and Fl warning indicator C and sounding the buzzer The ECU notifies the rider of troubles in the immobilizer system by blinking the service code character D red warn ing indicator light LED and immobilizer warning indicator E and sounding the buzzer When DFI ignition and immobilizer system parts are faulty the ECU initiates fail safe functio
59. circuit test OConnect the test light and the 12 V battery in the same manner as specified in the 1st step regulator circuit test OApply 12 V to the positive terminal OCheck infinity terminals respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the 2nd step regulator circuit test OMomentarily apply 24 V to the positive terminal by adding a 12 V battery OCheck infinity terminals respectively H more than 24 volts is applied or 24 volts applied for more than a few seconds the regulator rectifier may be damaged To prevent damage to the regu lator rectifier do not apply more than 24 volts and do not apply 24 volts for more than a few seconds x If the test light does not light when 24 Vis applied momen tarily to the positive terminal the regulator rectifier is defective Replace it x If the regulator rectifier passes all the tests described it may still be defective If the charging system still does not work properly after checking all the components and the battery test the regulator rectifier by replacing it with a known good unit e Repeat the test for another regulator rectifier JNO7016BS1 JNO7O18BS1 ELECTRICAL
60. clearance use a shim that is a few sizes smaller and remeasure the valve clearance e When installing the shim face the marked side toward the valve lifter At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation Using shim stock under the shim may cause it to pop out at high rpm and cause severe engine dam age Do not put shim stock under the shim Grinding the shim may cause it to fracture causing severe engine damage Do not grind the shim e Apply molybdenum disulfide oil solution to the valve lifter surface and install the lifter e Install the camshafts see Camshaft Installation in the En gine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the removed parts see appropriate chapters Engine Mounting Bolts Inspection and Tightness e Check the tightness of the engine mounting bolts A x If there are loose bolts remove the bolts e Apply a non permanent locking agent to the engine mounting bolts and tighten them Torque Engine Mounting Bolts 36 3 N m 3 7 kgf m 27 ft lb JRO8019BS2 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Engine Bottom End Coupling Damper Inspection e Remove Engine see Engine Removal in the Engine Removal In stallation chapter e Remove the coupling damper A and inspect it for wear B and deterioration x If it is grooved or misshapen
61. damage x If the spark plug lead is damaged replace the spark plug lead e Measure the lead resistance with the hand tester B Spark Plug Lead Resistance Standard 1 2 80 4 79 kQ 2 3 55 6 07 kQ 3 4 16 7 11 KQ 4 4 57 7 81 KQ If the hand tester does not read as specified replace the lead Ignition Coil Primary Peak Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the seat see Seat Removal in the Hull Engine Hood chapter e Take the spark plug caps A but do not remove the spark plugs e Install new spark plug B into the spark plug cap e Connect the peak voltage adapter A to the hand tester B and the harness adapter C Hand Tester Range DC 1 000 V Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Harness Adapter 57001 1562 Primary Lead Connections Harness Peak Voltage Aapter Adapter end Taster R BK gt BK W R gt Ignition Coil D Spark Plug E WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections JNOSO34BS1 Se E BK W 1_ R H _ BK JN08101BS2 ELECTRICAL SYSTEM 14 41 Ignition System e Insert the ignition key in the ignition switch to turn it on and insert the lanyard key under the stop button e Ground the new spark plug A onto the en
62. e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows a b c d a Present Shim Thickness b Measured Valve Clearance c Specified Valve Clearance Mean Value 0 265 mm Exhaust 0 195 mm Intake d Replace Shim Thickness Example Exhaust 2 100 0 6 0 265 2 435 mm OExchange the shim for the 2 450 size shim gt 0 ERE 4 3 2 JRO8016BS1 GI r ie en he PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 92025 1870 0 2 050 92025 1871 5 E 9 92025 1872 10 ee 2 150 92025 1873 15 92025 1874 20 2 250 92025 1875 25 eege 2 300 92025 1876 30 2 350 92025 1877 35 2 375 92180 1058 38 2 425 92025 1982 43 92025 1983 48 2 500 92025 1880 50 92025 1984 53 2 550 92025 1881 55 2 600 92025 1882 60 2 625 92180 1059 63 2 650 92025 1883 65 2 675 92180 1194 68 2 700 92025 1884 70 2 725 92180 1195 73 2 750 92025 1885 75 2 775 92180 1196 78 2 800 92025 1886 80 2 850 92025 1887 85 2 900 92025 1888 90 2 950 92025 1889 95 3 000 92025 1890 00 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Be sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance Olf there is no valve
63. engine and stop it e Remove the garden hose and garden hose adapter NOTICE The engine must be running before the water is turned on and the water must be turned off before the engine is stopped Do not run the engine without cooling water flow for more than 15 seconds e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Remove the oil filler cap A and the dipstick B a S Dirt and other foreign materials can cause serious engine damage To prevent engine damage do not allow dirt or foreign materials to enter the engine e Drain the oil thoroughly from the dipstick tube A using a commercially available vacuum pump B WARNING Used engine oil is toxic and pollutes the environ ment To protect the environment do not discard used engine oil always return it to an authorized recycling center 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pour in the specified type and amount of oil through the oil filler opening A Engine Oil Grade API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Amount 4 0 L 4 2 US qt when filter is not removed 4 2 L 4 4 US qt when filter is removed 5 0 L 5 3 US qt when engine is completely dry NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for the engine OAlthough 10W 40 en
64. in any way replace the cables e Be certain that each cable moves freely in both directions e Remove the cable joints at each end of each cable ORemove the cable joint bolt or ball joint from the cable joint NOTICE If the watercraft is laid on its right side water in the exhaust system may drain back into the engine a cause serious damage Never lay the watercraft on the right side OSlide the inner cable back A and forth B in each cable housings lf each cable does not move freely replace it JR12002BS1 JR12004BS1 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Handlebar Pivot Lubrication e Remove Steering Holder see Steering Removal in the Steering chapter e Check the bushings for damage and wear x If the bushings are damaged or worn replace them e Grease Bushings A Steering Shaft B Hull Engine Hood Drain Plug Inspection e Check the drain plugs A for cracks or damage and make sure the drain plug mounting screws B are tightened se curely e Check the seals C for damage x If necessary replace the drain plugs or seals JR13004BS2 J130000 P PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Electrical System Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Disconnect the
65. in Ib J611016BS1 J611017BS1 J611018BS1 JCO8020BS2 3 108 FUEL SYSTEM DFI Fuel Pump e Check the position A of the lower side clamp B around the entire circumference e Install the following to the fuel pump Fuel Hose see Fuel Hose Installation Fuel Tank Vent Hose Fuel Pump Connector Olnstall the vent hose so that the large side A of the hose fits the joint B Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged e Insert the ignition key in the ignition switch to turn it on and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Remove the ignition key x If the pump does not operate as described above check the operating voltage see Fuel Pump Operating Voltage Inspection Ba A a da JC08015BS1 FUEL SYSTEM DEI 3 109 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the center access cover see Center Access Cover Removal Installation in the Hull Engine Hood chapter e Disconnect the fuel pump connector and connect the measuring adapter A between these connectors as shown in the figure Main Harness B Fuel Pump C i Special Tool Measuring Adapter 57001 1700 Lo E 3 ME e Connect a digital meter D to the measuring adapter BK
66. in place e Be sure the dampers A on the water box muffler are in place EXHAUST SYSTEM 5 9 Water Box Muffler e Apply a non permanent locking agent to the water hose joints e Install the water hose joints A as shown in the figure 90 B View D C e Tighten Torque Water Hose Joints 11 N m 1 1 kgf m 97 in Ib JE05011BS2 e Loosen the clamp screw A and remove the front exhaust hose B e Make sure the two rings A are installed to the correct position x If the rings are damaged or warped replace the rings e Bind the two rings A by putting the paper tape B around the rings The paper tape can be burned out soon after firing e Install the front exhaust hose to the exhaust pipe JE07007BS1 5 10 EXHAUST SYSTEM Water Box Muffler e Install the water box muffler to the exhaust pipe e Install the rear exhaust hose so that the arrow mark A are left side e Install the clamp B as shown in the figure e Tighten Torque Rear Exhaust Hose Clamp Screw 5 0 N m 0 51 kgf m 44 in lb e For other clamps tighten the clamp securing the front ex haust hose noting its screw position and check the hose routing and clamp screw position see Cable Wire and Hose Routing section in the Appendix chapter Torque Front Exhaust Hose Clamp Screws 5 0 N m 0 51 kgf m 44 in lb e Install the removed parts see appropriate chapters Exhaus
67. in the Peri odic Maintenance chapter e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder Head Cover see Cylinder Head Cover Re moval Crankshaft Sensor Cover Bolts A Crankshaft Sensor Cover B e Using a wrench on the timing rotor bolt A turn the crank shaft clockwise until the line B TDC mark for 1 4 po sition on the timing rotor C is aligned with the mating surface D of the crankcase e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshafts see Camshaft Removal Dipstick Tube see Oil Pan Removal in the Engine Lu brication System chapter FOO P 6 20 ENGINE TOP END Cylinder Head e Remove Exhaust Side Camshaft Chain Guide Bolt Upper A Exhaust Side Camshaft Chain Guide Bolt Lower B Intake Side Camshaft Chain Guide Bolt C Camshaft Chain Guides D e Remove M6 Cylinder Head Bolts A M7 Cylinder Head Bolts B e Remove the M11 cylinder head bolts A and washers e Remove Cylinder Head Oil Pipe Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Replace the O rings A of the oil pipe B with new ones e Apply molybdenum disulfide oil solution to O rings e Install that the oil pipe A e Install a new cylinder head gasket B and dowel pins C Cylinder H
68. install it as shown in the figure OThis face B is alternator rotor side x If the reduction gear A is removed apply a molybdenum disulfide grease to both ends of its shaft e Install the reduction gear and the washer B e Apply grease to the boss outside A of the alternator rotor B 10 mm 0 39 in C e Install the alternator rotor to the crankshaft e Install the output shaft see Output Shaft Installation JH05017BS1 JHO5012BS1 Stator Coil ENGINE BOTTOM END 8 13 Stator Coil Removal e Remove Alternator Cover see Output Shaft Removal Stator Coil Grommet Holder Plate Bolts A Grommet Holder Plate B Stator Coil Mounting Bolts C with Washers Stator Coil D Stator Coil Installation e Apply water resistance grease to the outside of the grom met A e Apply a non permanent locking agent to the stator coil grommet holder plate bolts and tighten them Torque Stator Coil Grommet Holder Plate Bolts 8 8 N m 0 90 kgf m 78 in Ib e Apply a non permanent locking agent to the stator coil mounting bolts and put the washers e Tighten Torque Stator Coil Mounting Bolts 12 N m 1 2 kgf m 106 in Ib OWhen installing the stator coil fix the stator coil lead to the groove of the alternator cover OBe sure to the stator coil lead have no slack and bite 8 14 ENGINE BOTTOM END Crankcase Splitting Crankcase Splitting e Remove Engine see
69. joint and check the cable adjustment again e When adjustment is correct tighten the shift cable lock nut Shift Cable Removal e Lift up the steering cover see Steering Removal e Remove Plate Bolts A Plate B e Loosen the locknut A at the front end of the shift cable and take off the ball joint B and remove the locknut from the cable front end e Take the holder C off the cable bracket e Remove the cable bracket mounting bolts D e Slide the shift cable E off the cable bracket 1078060 P Reverse System STEERING 12 19 e Loosen the locknut A at the rear end of the shift cable and remove the ball joint B from the reverse bucket C e Unscrew the large nut shift cable nut in the hull with the box wrench OSpecial tool box wrench A is useful to remove the large nut shift cable nut Special Tool Box Wrench 27 mm 57001 1749 OWhen using the box wrench avoid bending the shift ca ble Such a bend to the cable can damage it e Slide off the snap ring A washer B and O ring C e Pull out the shift cable toward the rear Shift Cable Installation e Installation is the reverse of removal Note the following OSlide a short piece of rubber or plastic tubing over the front cable end to guide the cable through the hull OLubricate the outside of the new cable to ease cable in stallation OReplace the O ring with a new one OApply water resistance grease to
70. m 1 1 kgf m 97 in 1b JD10006BW2 4D10007BS1 ENGINE LUBRICATION SYSTEM 4 21 Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve Oil Pump Sprocket Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Oil Pan see Oil Pan Removal Oil Pump Sprocket Bolt A Washer B e Remove the oil pump body bolts A e Pull out the oil pump body A and remove the oil pump sprocket B Oil Pump Sprocket Installation e Check that dowel pins A and oil pipe B are in place on the crankcase e Replace the O ring C with a new one e Engage the oil pump chain with the oil pump sprocket A e Install the oil pump sprocket so that the 620 Mark B faces outward on the oil pump body e Install the oil pump body e Tighten Torque Oil Pump Body Bolts 7 8 N m 0 80 kgf m 69 in Ib e Apply a non permanent locking agent high strength Loc tite 271 equivalent to the oil pump sprocket bolt c e Install the oil pump sprocket bolt and washer gt Jupe P e Tighten g Torque Oil Pump Sprocket Bolt 16 N m 1 6 kgf m 12 ft Ib 4 22 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve Oil Pump Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Engine see Engine Removal in
71. manifold and after connecting the water box muffler to the exhaust pipe hook the rubber strap and install the hose f A e Ree A Exhaust Manifold EXHAUST SYSTEM 5 5 e Replace the exhaust manifold gasket A with a new one e Install the exhaust manifold washers B and collars C as shown in the figure e Apply a non permanent locking agent to the exhaust man ifold mounting bolts e Tighten the exhaust manifold mounting nuts and bolts fol lowing the specified tightening sequence Torque Exhaust Manifold Mounting Nuts 25 N m 2 5 kgf m 18 ft lb Exhaust Manifold Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Apply a non permanent locking agent to the exhaust pipe mounting plate bolts A and install the plate B and col lars C e Tighten Torque Exhaust Pipe Mounting Plate Bolts 30 N m 3 1 kgf m 22 ft lb e Connect the water box muffler to the exhaust pipe after binding the two rings with the paper tape see Exhaust Pipe Installation e Check the hose routing and clamp screw position see Cable Wire and Hose Routing section in the Appendix chapter e Install the clamps A as shown in the figure 30 B View E C e Tighten Torque Front Exhaust Hose Clamp Screws D 5 0 N m 0 51 kgf m 44 in Ib e Install the removed parts see appropriate chapters Exhaust Manifold Cleaning and Inspection e Remove the exhaust manifold parts see Exhaust Mani fold Rem
72. mode check that the clock display switches to the Hour setting mode by pushing the SET button for 2 seconds or more OThe hour display starts blinking when the mode switches e Check that the hour display changes by pushing the MODE button ein the Hour setting mode check that the clock display switches to the Minute setting mode by pushing the SET button OThe minute display starts blinking e Check that the minute display changes by pushing the MODE button e In the Minute setting mode check that the clock setting process completes by pushing the SET button lf the display function does not work replace the meter unit Check 1 3 Maximum Speed Engine RPM Display In spection e Insert the ignition key in the ignition switch to turn it on e Rotate the water wheel A by hand or compressed air Rotatory Direction B e In the Maximum Speed Engine RPM mode check that the speedometer A shows maximum speed OFirst the display shows 0 km h or O mile h and 0 rpm x If the display function does not work inspect the speed sensor See Speed Sensor Inspection x lf the speed sensor is good check the speed sensor power supply see Check 2 3 4N17128BS1 4N17129BS1 4N17130BS1 14 62 ELECTRICAL SYSTEM Multifunction Meter e Check that the display turns to 0 by pushing the SET button for 2 seconds or more OThe speedometer and engine speed display starts bli
73. nut B by hand and then loosen e Tighten the steering shaft nut A with the nut tightening plate B Special Tool Nut Tightening Plate 57001 1698 OTorque 2 6 N m 0 27 kgf m 23 in Ib the plate with nut Torque Steering Shaft Nut 2 9 N m 0 30 kgf m 26 in Ib e Remove the special tool e Loosen the steering shaft nut so that the threads A of the steering shaft nut are aligned with the holes B of the plate within second chance e Tighten the bolts C and check steering shaft turns freely with no play e Inspect the steering position sensor clearance see Steer ing Position Sensor Clearance Inspection in the Electrical System chapter e Apply water resistance grease to the joint ball e Install the steering cable to the steering shaft e Apply a non permanent locking agent to the steering ca ble bracket bolts e Tighten Torque Steering Cable Bracket Bolts 9 8 N m 1 0 kgf m 87 in lb Steering Holder Mounting Nuts 19 6 N m 2 0 kgf m 14 ft lb Steering Shaft Locknut 29 4 34 3 N m 3 0 3 5 kgf m 22 25 ft lb e Apply a non permanent locking agent to the grommet mounting plate bolts e Install the grommet and the grommet mounting plate JL068165 P A06B166 P JLO6025BS2 STEERING 12 15 Steering e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut cl
74. seating surfaces A on the lower crankcase for the M10 bolts B and M8 7 10 bolts C JH10003BS1 8 18 ENGINE BOTTOM END Crankcase Splitting e Tighten the crankcase bolts OFollowing the sequence numbers on the lower crankcase half tighten the M10 bolts 1 6 Torque Crankcase Bolts M10 50 N m 5 1 kgf m 37 ft lb OFollowing the sequence numbers tighten the M8 bolts 7 19 7 10 L 85 mm 3 3 in 11 18 L 45 mm 1 8 in 19 L 55 mm 2 2 in Torque Crankcase Bolts M8 30 N m 3 1 kgf m 22 ft lb OFollowing the sequence numbers tighten the M6 bolts 20 23 Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib JH10008BW2 e After tightening all crankcase bolts check that the crank shaft turn freely e Install the dowel pins A ENGINE BOTTOM END 8 19 Crankcase Splitting e Install the oil catch cover A e Tighten Torque Oil Catch Cover Bolts B 7 8 N m 0 80 kgf m 69 in Ib 8 20 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase see Crankcase Splitting e Remove the crankshaft A with the oil seal B Crankshaft Installation If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage before assembling engine to be sure the correct bear
75. service code characters can be stored and the display will begin starting from the lowest number service code character OThen after completing all codes the display is repeated until the ignition switch is turned OFF or either SET or MODE button is pushed for more than one second OFor example if three problems occurred in the order of 51 13 31 the service code characters are displayed each one second from the lowest number service code character in the order listed as shown below 13 Alrt 31 dOS 51 COL1 13 Alrt 31 dOS 51 COL1 gt repeated FI Trouble A Immobilizer Trouble B JC16294BW2 C Olf there is no problem or when the repair has been done FI and or immobilizer warning indicators go off and FI character and or service code character is not displayed Service Code Erasing OWhen repair has been done FI and or immobilizer warning indicators go off and FI character and or service code character is not displayed x But the service code characters stored in memory of the ECU are not erased to preserve the problem history In this model the problem history and the past service code characters can not be erased 3 36 FUEL SYSTEM DFI Self Diagnosis Service Code Character Table Service Service Code Code Character used in displayed on Problems Backups by ECU ECU Meter Unit Throttle position sensor The E
76. system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment e Pull the lanyard key off the stop button and remove the ignition key e Spray the spark plugs with fogging oil and reinstall the spark plugs and caps see Spark Plug Inspection in the Periodic Maintenance chapter e 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 white and a green blue leads from the main harness The 2 3 coil connector has a red white and green leads from the main harness NOTE OThe service codes 51 and 52 caused by this procedure are stored in the ECU Air Box e Disassemble the air box see Air Box Disassembly in the Fuel DFI System chapter e Wash and dry the flame arrester A e Assemble and install the air box see Air Box Assem bly Installation in the Fuel DFI System chapter Battery e Give a refresh charge before you store the watercraft and store it with the negative lead removed Give a refresh charge once a month during storage e Remove the battery see Battery Remove in the Electrical System chapter e Clean the exterior with a solution of baking soda and wa ter one heaping tablespoon of baking soda in one cup of water Rinse thoroughly with water e Coat both battery terminals with grease e Store the battery in a cool dry plac
77. the Engine Removal In stallation chapter Oil Pan see Oil Pan Removal Oil Pump Body see Oil Pump Sprocket Removal Oil Pump Cover Bolts A e Pull out the oil pump cover B and oil pump shaft C e Remove O ring A Inner Rotor B Outer Rotor C Oil Pump Installation e Replace the O ring with a new one e Apply molybdenum disulfide oil solution to the outer and the inner rotors outside e Install the outer rotor A and inner rotor B into the oil pump body e Apply molybdenum disulfide oil solution to the shaft e Assemble the oil pump cover C pin D onto the oil pump shaft E e Be sure the dowel pin F is in place in the oil pump body e Apply grease to the new O ring G and fit the O ring to the groove of the oil pump body e Insert the shaft assembly OFit the pin into the slot of the inner rotor e Fit the oil pump cover and tighten the oil pump cover bolts Torque Oil Pump Cover Bolts 7 8 N m 0 80 kgf m 69 in 1b e Install Oil Pump Sprocket see Oil Pump Sprocket Installation Oil Pan see Oil Pan Installation Oil Pump Inspection e Remove the oil pump parts e Visually inspect the oil pump outer inner rotors and cover x If there is any damage or uneven wear replace the rotors and cover ENGINE LUBRICATION SYSTEM 4 23 Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve Oil Screen Removal e Remove Engine see Engine Removal in the Engine Removal In st
78. the new O ring OTighten the shift cable nut with the box wrench Special Tool Box Wrench 27 mm 57001 1749 Torque Shift Cable Nut 39 2 N m 4 0 kgf m 29 ft lb JLO7BOE P B O D D JL07009BS1 12 20 STEERING Reverse System OEngage the groove A on the steering cable with the opening portion B on the cable bracket as shown OApply water resistance grease to the joint ball at each end of shift cable OAdjust the shift cable see Shift Cable Adjustment Shift Cable Inspection e Refer to the Steering Cable Shift Cable Inspection in the Periodic Maintenance chapter Shift Cable Lubrication NOTE OThe shift cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced Reverse Bucket Removal Installation e Disconnect the ball joint at rear end of the shift cable e Remove the pump cover see Pump Removal in the Pump Impeller chapter e Unscrew the pivot bolts A and remove the reverse bucket B e Installation is the reverse of removal Note the following OApply a non permanent locking agent High Strength Loctite 271 equivalent to the reverse bucket pivot bolts and torque them Torque Reverse Bucket Pivot Bolts 19 N m 1 9 kgf m 14 ft Ib OAfter installation check the shift cable adjustment see Shift Cable Adjustment Shift Lever Shaft Removal Installation e Remove the side covers see Side Cover Removal in the Hu
79. to the reduction gear shaft D e Replace the O ring A with a new one e Apply grease to the O ring and fit the O ring onto the groove of the alternator cover B e Install the alternator cover OBe sure to install the bushing C into the hole Torque Alternator Cover Bolts 20 N m 2 0 kgf m 15 ft lb e Replace the O ring A with a new one e Apply grease to the O ring and collar inside B e Install the collar so that the chamfer side C faces inward e Replace the gasket A with a new one e Install Dowel Pins B Gasket e Apply grease to the oil seal lip on the output cover e Install the output cover A e Tighten Torque Output Cover Bolts 7 8 N m 0 80 kgf m 69 in Ib ORun the stator coil lead B between the alternator cover C and the output cover as shown in the figure JH04008BS1 8 10 ENGINE BOTTOM END Coupling Output Shaft e Install the dowel pins A e Install the engine brackets B so that the holes C fit the dowel pins e Apply a non permanent locking agent to the thread of the engine bracket mounting bolts e Tighten Torque Engine Bracket Mounting Bolts 32 N m 3 3 kgf m 24 ft lb Coupling Damper Inspection e Refer to Coupling Damper Inspection in the Periodic Maintenance chapter Output Cover Oil Seal Replacement e Remove Output Cover see Output Shaft Removal e Using the bearing driver A remove the oil seals as a set Spe
80. with a press A e Using a press press A the bushing B and the ball bear ings C with a suitable bar D of 25 mm 0 98 in x L 65 mm 2 6 in over They come out of the pump case e Discard the removed bearings e Remove the circlip A Special Tool Inside Circlip Pliers 57001 143 4K04087BS2 PUMP AND IMPELLER 11 13 Pump and Impeller e Using a press remove the grease seals Special Tool Bearing Driver Set 57001 1129 A Pump Assembly e Before installing the pump bearing blow any dirt or for eign particles out of the pump case with compressed air e Before installing the pump bearing remove the filter cover A and check the filter inside or outside B on the pump case C if the foreign particles do nat cling to the filter e Replace the O ring D with a new one and install it e Install the dowel pin E e Apply lithium grease NLGI Grade No 2 to the O ring e Apply a non permanent locking agent to the filter cover mounting bolts F and tighten them Torque Filter Cover Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb JK04118BS1 e Apply a non permanent locking agent to the threads of the hose joints A e Install the hose joints as shown B 30 JK04119BS1 11 14 PUMP AND IMPELLER Pump and Impeller e Replace the grease seals A and circlip B with new ones e Using a press press each seal into the pump case C so tha
81. 0 31 27 in lb L 19 Relay Mounting Bolts 2 5 0 25 22 in lb L 20 Camshaft Position Sensor Bolt 10 1 0 89 in lb L 21 Crankshaft Sensor Screws 4 5 0 46 40 in lb L 22 Water Temperature Sensor 14 7 1 5 11 23 Oil Temperature Sensor 15 1 5 11 DG EO vro SO SS WG Fill the hollow with the heat transfer grease Heat Transfer Grease SCH 20 92137 1002 or equivalent Apply engine oil Apply grease Apply a non permanent locking agent Replacement Parts Apply silicone oil Apply silicone sealant 92104 0004 Apply water resistance grease 3 6 FUEL SYSTEM DFI Exploded View JC02093BW5 FUEL SYSTEM DFI 3 7 Exploded View CI fe E a CO Nm wn feib Fuel Filler Hose Clamp Screws 26 ml Fuel Pump Rubber Holder Clamp 29 0 30 26 in lb Screws i y 3 AU and EUR Models R Replacement Parts 3 8 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 9 Exploded View CCE E CO Nm kgtm fib Air Box Mounting Bolts 69 in Ib E Air Box Bracket Mounting Bolts 88 oan 78 in lb L Air Box Assembly Bolts 0 25 22 nb L 1 Air Box Flame Arrester Bolts 0 25 22 in lb L Apply a non permanent locking agent 3 10 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram PE ala ETES wee CE 228 E era ut d He A f Hal os mi LL IN ll hi ia HiT
82. 0 FUEL SYSTEM DFI Troubleshooting the DFI System The red warning indicator light LED A is used for the following warnings Fuel Level Low Battery Voltage Engine Cooling Water Temperature Engine Oil Pressure Oil Temperature Sensor Engine Oil Overheat Fl Immobilizer Outline When a problem occurs with DFI system and immobilizer system the warning indications to alert the rider are as fol lows In addition the condition of the problem is stored in the memory of the ECU DFI System FI Character Red Warning A Service Code Indicator Light Characters LED B Blinks Goes on Blinks Sounds FI Warning Indicator KOU PUZZer Immobilizer System Red Warning Immobilizer Indicator Light Warning Buzzer LED Indicator E Blinks Blinks Blinks Sounds Service Code Characters D With the engine stopped and turned in the self diagnosis mode the service code characters A are displayed on the LCD Liquid Crystal Display Ifthe problem is with the following parts the ECU can not recognize these problem Therefore the Fl character red warning indicator light LED Fl and or immobilizer warning indicators do not go on and or blink the buzzer does not sound and service code characters are not displayed LCD for Meter Unit Fuel Pump Fuel Injectors Ignition Coil Secondary Wiring and Ground Wiring ECU Power Source Wiring and Ground Wiring J616285BS1
83. 01 241 ST5702418T Top Dead Center Finder 57001 402 8757040297 Piston Pin Puller Assembly 57001 910 ST5709108T Piston Ring Compressor Grip 57001 1095 ST5710958T Valve Seat Cutter 45 935 57001 1116 Valve Seat Cutter 32 430 57001 1120 ST5711168T ST5711208T Valve Seat Cutter 32 635 57001 1121 ST5711218T Valve Seat Cutter 60 430 57001 1123 Q Valve Seat Cutter Holder Bar 57001 1128 N ST5711238ST ST5711288ST Special Tools and Sealant Valve Seat Cutter 45 430 57001 1187 ST571187ST Valve Spring Compressor Adapter D22 57001 1202 gS SS S T5712028T Valve Guide Arbor 65 57001 1203 d A SS T5712038T Valve Guide Reamer 65 57001 1204 T5712048T Valve Seat Cutter Holder 5 57001 1208 ST5712088ST ENGINE TOP END 6 7 Valve Seat Cutter 55 635 57001 1247 ST571247ST Compression Gauge Adapter M10 x 1 0 57001 1317 ST5713178T Piston Ring Compressor Belt 80 991 57001 1320 E ST571820ST Shaft Wrench 57001 1551 ST5715518T TDC Measurement Tool 57001 1560 ST5715608T 6 8 ENGINE TOP END Special Tools and Sealant Piston Base 8 Liquid Gasket TB121
84. 06 ft lb 7 250 r min rpm AU 152 N m 15 5 kgf m 112 ft lb 7 250 r min rpm US Ignition System Digital transistor Lubrication System Forced lubrication semi dry sump Carburetion System Fl fuel injection MIKUNI AC 60 x 1 Starting System Electric starter Cylinder Numbering Method Front bow to rear stern 1 2 3 4 Firing Order 1 2 4 3 Valve Timing Intake Open 22 5 BTDC Close 67 5 ABDC Duration 270 Exhaust Open 74 5 BBDC Close 9 5 ATDC Duration 264 Tuning Specifications Spark plug Type NGK CR9EK Terminal Threaded terminal Gap 0 7 0 8 mm 0 028 0 031 in Ignition Timing 3 ATDC 1 300 r min 32 BTDC 3 000 r min rpm Idle Speed 1 300 100 r min rpm in water 1 300 100 r min rpm out of water Compression Pressure 1 190 1 799 kPa 12 1 18 3 kgf cm 173 261 psi 430 r min rpm Drive System Coupling Direct drive from engine Jet Pump Type Axial flow single stage Thrust EUR Model 4 130 N 421 3 kgf 928 4 Ib Other than EUR Models 4 250 N 433 5 kgf 955 4 Ib Steering Steerable nozzle Braking Water drag 1 12 GENERAL INFORMATION General Specifications ltems JT1500KC Performance Minimum Turning Radius 4 0 m 13 1 ft Fuel Consumption 45 L h 11 9 US gal h full throttle Cruising Range 133 km 82 6 mile full throttle 1 hour and 38 minutes 3 person Dimensions Overall Length 3 370 mm 132 7 in Overall Width 1 195 mm 47 0 in
85. 06 in x If the clearance is the specified value but the smart steer ing system does not work inspect steering position sen sor input voltage see Steering Position Sensor Input Volt age Inspection lf necessary adjust the steering shaft nut see Steering Installation in the Steering chapter Steering Position Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the front access cover see Front Access Cover Removal in the Hull Engine Hood chapter e Connect a digital meter A to the steering position sensor lead connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 4N18025BS1 Connections to Steering Position Sensor Lead Connector Digital Meter RW main harness R BL Digital Meter BK main harness BK e Insert the ignition key in the ignition switch to turn it on e Center the steering shaft in the straight ahead position e Measure the input voltage Steering Position Sensor Input Voltage Standard Battery Voltage e Remove the ignition key x lf the reading is the standard inspect the steering posi tion sensor output voltage see Steering Position Sensor Output Voltage Inspection x If the reading is out of the standard check the following Main Fuse 20 A see Fuse Inspection Power Source Wiring see Steering Position Sensor Cir cuit 14 48 ELECTRICAL SYSTEM Kawasaki Smart Steering
86. 1562 ST5715628T 14 14 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on ignition key is inserted or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and
87. 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU ground and power supply trouble Inspect see chapter 3 ECU trouble Inspect see chapter 3 No or little fuel in tank Supply fuel see Owner s Manual Fuel injector trouble Inspect and replace see chapter 3 Fuel pump not operating Inspect see chapter 3 Fuel pump relay trouble Inspect and replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor Running at Low Speed Spark weak A AN Inspect or reinstall see chapter 14 inspect see chapter 14 Inspect and replace see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Replace element or inspect sealing see chapter 3 Intake manifold loose Reinstall Throttle body assy loose Reinstall see chapter 3 see chapter 3 Throttle body assy gasket damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 3 28 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressu
88. 3 110 Fuel Filter Cleaning 3 110 Fuel Pump Screen Cleaning 3 110 Fuel Tank 408088 da need 3 112 Fuel Tank Removal 3 112 Fuel Tank Installation 3 113 Fuel Tank Cleaning oooooocccccccccnnn 3 113 Fuel Filler and Hose Removal 3 113 Fuel Filler and Hose Installation 3 114 FUEL SYSTEM DFI 3 3 Fuel System Diagram J004032BW3 C 1 Bow 2 Fuel Flow 3 Fuel Tank 4 Fuel Pump 5 Fuel Hose 6 Delivery Pipe Assy 7 Fuel Injectors 8 Throttle Body Assy 3 4 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 5 Exploded View No zl OO ErG ibh i Fastener 2 Delivery Pipe Assy Mounting Bots 78 080 Gomb 75 intake Manifold Mounting Nuts 20 20 15 7 Vehice down Sensor Mounting Screws 15 015 m3m 78 Throttle Case Mounting Screws s9 040 35imb o Throne Cable Locknut 196 20 4 10 intake Ar Pressure Sensor Bols 78 aa some Cr ISC Actuator Mounting Bols 50 ost smb 712 intake Air Temperature Sensor 2 20 15 713 Stepping Motor Mounting Screws 20 020 18miB CO Throttle Position Sensor Mounting 14 2 0 0 20 18 in lb Screws 15 Intake Manifold Plate Bolts 7 8 0 80 69 in lb 16 Intake Manifold Drain Plug 20 2 0 15 17 Throttle Body Assy Mounting Bolts 20 2 0 15 18 ECU Mounting Bolts 3 0
89. 3 OILt Oil Temperature Sensor Removal Installation A shock to the oil temperature sensor can damage it Do not drop the oil temperature sensor e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Oil Temperature Sensor A e Fill the hollow of the oil pan A with heat transfer grease B to 80 volume as shown in the figure before installing the oil temperature sensor C Heat Transfer Grease Heat Transfer Grease SCH 20 92137 1002 or equivalent NOTICE Overfilling the grease may damage the fitting boss JO16242851 0 Do not overfill with grease e Tighten Torque Oil Temperature Sensor 15 N m 1 5 kgf m 11 ft Ib Oil Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Disconnect the oil temperature sensor connector and connect the measuring adapter A between these con nectors as shown in the figure Main Harness B Oil Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Oil Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y lead Digital Meter BK sensor BK W lead SPP Tx e Measure the output voltage with the engine stopped and the connector joined e Insert the ignit
90. 5 in 5 08 mm 0 200 in 5 08 mm 0 200 in 0 35 mm 0 014 in 0 29 mm 0 011 in 36 7 mm 1 44 in 44 5 mm 1 75 in 36 5 mm 1 44 in ENGINE TOP END 6 5 Specifications Jen O Standard Service Limit Intake Outer 45 8 mm 1 80 in 44 2 mm 1 74 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 mm 3 259 in Piston Cylinder Clearance 0 060 0 087 mm 0 0024 0 0034 in Piston Ring Groove Clearance Top 0 03 0 07 mm 0 0012 0 0028 in 0 17 mm 0 0067 in Second 0 02 0 06 mm 0 0008 0 0024 in 0 16 mm 0 0063 in Piston Ring Groove Width Top 0 92 0 94 mm 0 0362 0 0370 in 1 02 mm 0 0402 in Second 1 01 1 03 mm 0 0398 0 0406 in 1 11 mm 0 0437 in Piston Ring Thickness Top 0 87 0 89 mm 0 0343 0 0350 in 0 80 mm 0 0315 in Second 0 97 0 99 mm 0 0382 0 0390 in 0 90 mm 0 0354 in Piston Ring End Gap Top 0 25 0 40 mm 0 0098 0 0157 in 0 7 mm 0 028 in Second 0 40 0 55 mm 0 0157 0 0217 in 0 8 mm 0 031 in Valve Head Thickness Valve Stem Bend E 6E02000581 6E02000681 Valve Head Thickness A Valve Stem Diameter B 45 C 6 6 ENGINE TOP END Special Tools and Sealant Compression Gauge 20 kgf cm 57001 221 T5702218T Valve Spring Compressor Assembly 570
91. 6B 57001 1604 92104 1064 gt ST5716048T ST9210648T ENGINE TOP END 6 9 Cylinder Head Cover Cylinder Head Cover Removal e Remove Seats see Seat Removal in the Hull Engine Hood chap d ter ROMS Spark Plug Caps A Wh S CH se Clamp and Breather Hose B e Open the clamps C Usa e JFOGBOA P e Remove Cylinder Head Cover Bolts A with Rubber Washers Cylinder Head Cover B WN PP TT O e Mss 4 OO e A S Cylinder Head Cover Installation e Be sure to install the following parts Dowel Pins A Plug Hole Gaskets B e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket A to the cylinder head as shown in the figure Sealant Liquid Gasket TB1216B 92104 1064 6 10 ENGINE TOP END Cylinder Head Cover e Replace the cylinder head cover gasket with a new one e Install the new cylinder head cover gasket and cylinder head cover e Install the rubber washers with the metal side A faces upward e Tighten Torque Cylinder Head Cover Bolts B 10 N m 1 0 kgf m 89 in Ib e Run the hose and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter 6E04070981 ENGINE TOP END 6 11 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal This is a non return type camshaft chain
92. 7 Registry of user keys Immobilizer Amplifier completed Failure End NOTE 8 JN20060B F ELECTRICAL SYSTEM 14 73 Immobilizer System Case 2 When the ECU is faulty and has to be replaced NOTE OBe sure the battery is fully charged OThe key registration unit is not required e Prepare the following New ECU A Current FPO Key B orange colored Current SLO Key C yellow colored and marked SLO o Replace JN20009BS1 ECU see ECU Removal and Installation in the Fuel Sys tem DFI chapter Pre registration of User Key 1 NOTE OKeep the other user key away from the ignition switch e Insert the current key user key 1 to the ignition switch and press it for a short time within 2 seconds or long time 2 seconds or more Verified OThe ECU confirms the following leycle gt Receiving signals from immobilizer amplifier are correct e The user key 1 is successfully pre registered in the ECU A and ECU starts the key registration mode a OThe red warning indicator light LED A blinks 1 time and stops for 1 second and then repeats this cycle 0 3second Gees NOTE E ka OOnly the first one cycle the buzzer sound B goes off JN20055BS1 6 synchronizing with the blink of the red warning indicator light LED Not Verified OThe red warning indicator light LED immobilizer symbol and letters A blink to display the collation error The AZ buzzer sound B g
93. 7 mm 1 06 in Three phase AC 14 2 15 2 V 48 72 V at 3 000 r min rpm 0 432 0 648 Q at 20 C 68 F Ignition System Ignition Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Type Gap Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Camshaft Position Sensor Resistance Camshaft Position Sensor Peak Voltage 1 44 2 16 Q 11 76 17 64 KQ 250 V or more NGK CR9EK 0 7 0 8 mm 0 028 0 032 in 408 612 Q at 20 C 68 F 2 5 V or more 400 460 Q at 20 C 68 F 0 4 V or more Kawasaki Smart Steering KSS System Steering Position Sensor Clearance 0 5 1 5 mm 0 02 0 06 in Sensors Fuel Level Sensor Resistance Full Position Empty Position Water Temperature Sensor Resistance Oil Temperature Sensor Resistance Air Temperature Sensor Resistance 2 40 117 1230 see text see text see text ELECTRICAL SYSTEM 14 13 Special Tools and Sealant Hand Tester Key Registration Unit 57001 1394 57001 1582 ST5713948T ST5715828ST Peak Voltage Adapter Flywheel amp Pulley Holder 57001 1415 IS 57001 1605 NEW c ST5716058T Needle Adapter Set Key Registration Adapter 57001 1457 57001 1746 ST571457ST ST571746ST Holder Attachment Liquid Gasket TB1211F 57001 1547 92104 0004 gt ST571547ST ST9200048T Harness Adapter 57001
94. 8 F About 2 mm 0 08 in FUEL SYSTEM DEI 3 17 Special Tools and Sealant Oil Pressure Gauge 5 kgf cm Fuel Hose 57001 125 57001 1607 ST5701258T ST571607ST Hand Tester Measuring Adapter 57001 1394 57001 1700 T5713948T Needle Adapter Set Liquid Gasket TB1211 57001 1457 56019 120 gt CAS ST571457ST C ST560120ST ST571700ST Throttle Sensor Setting Adapter Liquid Gasket TB1211F 57001 1521 92104 0004 ST571521ST ST920004ST Fuel Pressure Gauge Adapter Heat Transfer Grease SCH 20 57001 1593 92137 1002 ST5715938T 8792100297 3 18 FUEL SYSTEM DFI DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis 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 ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the engine ground OWhen charging remove the battery from the vehicle This is to prevent
95. Assembly EE ae A ent nee border dents ft de Shift Cable Removal coi einer rente Shift Cable Instalado estira aaa a labels alocada lali Shift Cable Inspection see Shift Cable LUBrICATIQN A a se a en ere ee Reverse Bucket Removal Installation ts Shift Lever Shaft Removal lnstallation aananaanenneenennennnnnnnnnnnnnnnrnnennnnnrnrnnrrnneenerrrnrenrenne 12 2 STEERING Exploded View Exploded View STEERING 12 3 Fastener Eg Start Stop Switch Case Mounting Screws gt 0 40 35 in lb A 2 Throttle Case Mounting Screws 0 40 35 in lb 3 Adjustable Steering Holder Nut Se 0 50 43 in lb 4 Handlebar Clamp Bolts 15 7 1 6 12 L S 5 Steering Neck Mounting Bolts 15 7 1 6 12 L 6 Steering Shaft Locknut 29 4 34 3 3 0 3 5 22 25 7 Steering Shaft Nut 2 9 0 30 26 in lb 8 Steering Holder Mounting Nuts 19 6 2 0 14 9 Steering Cable Bracket Bolts 9 8 1 0 87 in lb L 10 Shift Cable Nut 39 2 4 0 29 11 Steering Cable Nut 39 2 4 0 29 12 Steering Cable Joint Bolt 9 8 1 0 87 in lb L 13 Shift Cable End Nut 9 8 1 0 87 mb 14 Reverse Bucket Pivot Bolts 19 1 9 14 LN 15 Steering Position Sensor AD Apply adhesive L Apply a non permanent locking agent LN Apply a non permanent locking agent High Strength Loctite 271 equivalent R Replacement Parts S Follow the specific tightening seque
96. Big End Inside Diameter Diameter Marking Marking Size Color Part Number O None None Pink 92139 0724 None Yellow 92139 0723 92139 0722 Crankshaft Main Bearing Insert Journal Wear Inspection e Measure the bearing insert journal A clearance with a plastigage B NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 0010 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance 6105060181 8 28 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Main Bearing Insert Journal Clearance Standard 0 030 0 054 mm 0 0012 0 0021 in Service Limit 0 08 mm 0 0031 in If clearance is within the standard no bearing replace ment is required If clearance is between 0 055 mm 0 022 in and the ser vice limit 0 08 mm 0 0031 in replace the bearing in serts A with inserts painted green B Check insert jour nal clearance with the plastigage The clearance may ex ceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x If clearance exceeds the service limit measure the diam eter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 40 984 41 000 mm 1 61354 1 61417 in Service Limit 40 96 mm
97. CU confirms the following Receiving signals from immobilizer amplifier are correct The inserted key is the pre registered one lastly NOTE Olf the inserted key is not the pre registered one lastly the key registration mode will end instantaneously Start the procedure again pre registration of user key 1 e The pre registered keys are registered regularly in the ECU OThe red warning indicator light LED A blinks 1 time for 1 5 seconds and the buzzer sound B goes off 1 time synchronizing with the blink of the red warning indicator light LED e The key registration mode automatically ends e Remove the key registration unit and connect the immo bilizer Kawasaki diagnostic system connector NOTE OCheck that the engine can be started using all regis tered user keys 1 5seconds JN20059BS1 14 72 ELECTRICAL SYSTEM Immobilizer System Spare User Key Registration Flow Chart Pre registration of User Key 1 Pre registration of User Key n 2 6 Regular Registration of User Key Completion of User Key Registration Insert registered key and press key during short time NOTE 1 ECU checks immobilizer amplifier NOTE 2 Is registered key insert End NOTE 3 All user key codes in ECU eliminated Pre registration of User Key 1 Red warning indicator light LED blinks Registry of user key 1 completed gt Key Registration Waiting
98. CU locks ignition timing into 41 malfunction wiring open or the ignition timing at closed throttle short position and sets the DFI in the D J method see Note 1 Intake air pressure sensor Lrte EGU sets the DFI in the o N 12 malfunction wiring open or method see Note 2 short are alr temperature sensor The ECU sets the intake air 13 malfunction wiring open or o temperature at 40 C short Water temperat r sensor The ECU sets the water temperature dech at 70 C The ECU slows down the 14 malfunction wiring open or engine speed less than 3 000 r min short ose rpm by controlling the ignition 21 Crankshaft sensor malfunction The engine stops by itself wiring open or short Camshaft position sensor The ECU continues to ignite cylinders 23 malfunction wiring open or in the same sequence following the short last good signal Vehicle down sensor The ECU slows down the engine 31 malfunction wiring open or speed less than 3 000 r min rpm by short controlling the ignition Immobilizer amplifier 35 malfunction 36 Blank key detection 45 Fuel pump relay malfunction B wiring open Fuel pump relay malfunction 46 _ relay is stuck 51 Ignition coil 1 4 malfunction The ECU shuts off the injectors 1 4 wiring open or short to stop fuel to the cylinders 1 4 52 Ignition coil 2 3 malfunction The ECU shuts off the injectors 2 3 wiring open or short to stop fuel to the cylinders 2 3 System relay
99. Clean the fuel pump screen A see Fuel Pump Screen Cleaning in the Periodic Maintenance chapter e Refill the fuel tank with fresh fuel approximately 10 L 2 6 gal U S e Insert the ignition key in the ignition switch to turn it on e Push the lanyard key under the stop button and start the engine and run it in 15 second periods until all fuel in the fuel system is with fresh fuel Wait 5 minutes between 15 seconds running periods Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water e Pull the lanyard key off the stop button and remove the ignition key e Drain the fuel tank e Leave the fuel filler cap loose to prevent condensation in the tank 15 4 STORAGE Preparation for Storage Engine e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Disconnect both two connection on the ignition coil pri mary lead connectors A e Remove the spark plugs see Spark Plug Inspection in the Periodic Maintenance chapter e Spray fogging oil directly into each cylinder e Insert the ignition key in the ignition switch to turn it on e Push the lanyard key under the stop button Turn the engine over several times with the start button to coat the cylinder walls with oil WARNING The engine and exhaust
100. Connector E Ground 3 Camshaft Position Sensor 3 56 FUEL SYSTEM DFI Vehicle down Sensor Service 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 110 130 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 the fuel injectors and the ignition system Hall IC B Vehicle down Sensor Connector A Ground Terminal BK W B Output Terminal BL W C Power Source Terminal R G D Vehicle down Sensor Removal NOTICE A shock to the vehicle down sensor can damage it Do not drop the vehicle down sensor e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Bracket Bolts A and Washers e Remove Regulator Rectifier Lead Connector A Vehicle down Sensor Lead Connector B e Remove Screws A Vehicle down Sensor B 6017063851 JC16034BS1 3168257 FUEL SYSTEM DFI 3 57 Vehicle down Sensor Service Code Character 31 dOS Vehicle down Sensor Installation e The UP mark A of the sensor should face upward A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by th
101. Crankshaft Sensor Service Code Character 21 CrAg The crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Resistance Inspection e Refer to the Crankshaft Sensor Inspection in the Electrical System chapter x If the reading is within the standard check the peak volt age see Crankshaft Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Inspection e Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors J616306BS1 Wiring Continuity Inspection ECU Connector A Crankshaft Sensor Connector B R BK lead ECU terminal 22 C O BL lead ECU terminal 5 D x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Crankshaft Sensor Circuit 0 BL R BK BL R BK 3 0 BL JC16307BW2 1 ECU 2 Crankshaft Sensor 3 54 FUEL SYSTEM DFI Camshaft Position Sensor Service
102. DEI 3 47 Intake Air Temperature Sensor Service Code Character 13 Alrt Intake Air Temperature Sensor Removal Instal lation A shock to the intake air temperature sensor can damage it Do not drop the intake air temperature sensor e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the connector A e Remove the intake air temperature sensor B and washer e Install the intake air temperature sensor and washer A e Tighten Torque Intake Air Temperature Sensor 20 N m 2 0 kgf m 15 ft lb Intake Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the intake air temperature sensor connector and connect the measuring adapter A between these connectors as shown in the figure Main Harness B Intake Air Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor R BL lead Digital Meter BK sensor BK W lead e Measure the output voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Output Voltage Standard About DC 2 25 2 50 V at intake air temperature 20 C 68 F NOT
103. E OThe output voltage changes according to the intake air temperature R e R BL BK ee mee C SO gt 4016224BS1 3 48 FUEL SYSTEM DFI Intake Air Temperature Sensor Service Code Character 13 Alrt e Remove the ignition key x If the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation lf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Temperature Sensor Connector B R BL lead ECU terminal 28 C BK W lead ECU terminal 32 D x If the wiring is good check the intake air temperature sen sor resistance see Intake Air Temperature Sensor Resis tance Inspection Intake Air Temperature Sensor Resistance Inspection e Remove the intake air temperature sensor see Intake Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch
104. ECU damage by excessive voltage OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A ODo not insert the ignition key in the ignition switch to turn it on while any of the DFI electrical connectors are discon nected The ECU memorizes service codes ODo not spray water on the electrical parts DFI parts con nectors leads and wiring Olf a transceiver is installed on the vehicle make sure that the operation of the DFI system is not influenced by elec tric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen installing the fuel ho
105. EM 5 7 e Bind the two rings A securely by putting the paper tape B around the rings so that it is easy to insert the water box muffler into the exhaust pipe The paper tape can be burned out soon after firing e Install the front exhaust hose to the exhaust pipe Exhaust Pipe Cleaning and Inspection e Remove the exhaust pipe parts see Exhaust Pipe Re moval e Clean the carbon deposits out of the exhaust passages with a blunt round edged tool e Flush foreign matter out of the water passages with fresh water e Check the insides of the water passages for corrosion e Check the gasket surfaces for nicks or other damage x If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly replace the part JE07007BS1 5 8 EXHAUST SYSTEM Water Box Muffler Water Box Muffler Removal e Remove Oil Separator Tank see Oil Separator Tank Removal in the Engine Lubrication System chapter Air Box see Air Box Removal in the Fuel System DFI chapter e Loosen the clamp screws A and remove the water hoses B e Loosen the front exhaust hose clamp screw C ER D a SS ad f 0m P e Loosen the clamp screw A and remove the rear exhaust hose B e Unhook the rubber strap C from the water box muffler D e Remove the water box muffler backward Water Box Muffler Installation e Be sure the dampers A on the hull are
106. Engine Removal in the Engine Removal In stallation chapter e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed Suitable Blocks A Lower Crankcase Projections B e Remove Oil Cooler see Oil Cooler Removal in the Engine Lubri cation System chapter Pistons see Piston Removal in the Engine Top End chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Pump Sprocket see Oil Pump Sprocket Removal in the Engine Lubrication System chapter Oil Pump Chain see Oil Pump Chain Removal in the Engine Lubrication System chapter Alternator Rotor see Alternator Rotor Removal e Turn the engine upside down e Remove Bolts A Oil Catch Cover B JH10004BS1 ENGINE BOTTOM END 8 15 Crankcase Splitting e Remove the crankcase bolts following the specified se quence OFirst loosen the M6 bolts 1 4 OSecond loosen the M8 bolts 5 17 OLastly loosen the M10 bolts 18 23 JH10005BW2 e Using the pry points A split the crankcase halves 8 16 ENGINE BOTTOM END Crankcase Splitting e Tap lightly at the lower crankcase projections A with a plastic mallet B e Lift off the lower crankcase half to remove it Crankcase Assembly The upper and lower crankcase halves are ma ch
107. FUEL SYSTEM DFI ECU Main Relay Service Code Character 75 rEL ECU Main Relay Removal Installation e Refer to the Relay Assembly Removal Installation in the Electrical System chapter ECU Main Relay A SM d E Y gt em Y Vi ME Gers P ECU Main Relay Inspection e Refer to the Relay Assembly Inspection in the Electrical System chapter x If the ECU main relay is normal check the wiring for con tinuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation FUEL SYSTEM DEI 3 75 ECU Main Relay Service Code Character 75 rEL ECU Main Relay Circuit Eje Set DA o FE ERE m 7 Bing ae 3 d SCH 2 HA RAN BEE Ca EE z DO e FH D Sp 000 1 Ignition Switch 8 Joint Connector C 12 V 2 Joint Connector P 12 V 9 Joint Connector E Ground 3 Joint Connector R 12 V 10 Main Fuse 20 A 4 Joint Connector T 12 V 11 Battery 5 ECU Main Relay 12 Joint Connector Y Ground 6 Joint Connector D 12 V 13 Joint Connector S Ground 7 ECU 3 76 FUEL SYSTEM DFI Engine Oil Overheating Service Code Character 76 OILH e f the service code character OILH is displayed check the doubtful parts referring to
108. G BL W BK W RZN R Y Bag R W R W ECU Main Relay BK BK BK BK Y BK Buzzer Meter Unit AIR TEMP R R Y BK BK 6 8L G Y 0 BK H E EASY He AIR TEMP eo Fa PRE Elek ESS 2 ER a Sr VER Ca Se ese 253 ERES 2 Steering o tad ac 2 Position ss Po z Sensor ae Te ez Se E Le EE SG ZS ua K Ignition Switch color PU przen EA EA Ei x ze ER sel Za E gt a Zeimen eee ZSLES5 aso 59 Air dda eee Temperature PRE SES Sensor Til Joint Joint for Meter Connector Connector Speed GE S Ground Y Ground Sensor R Joint Joint ij Connector Connector 02v X 12v Starter Motor Switch Y R Y R Stop Switch TETHER ETHER TB K w DE Main 204 lt D x z z gt Starter Relay x 5 E E S zz PERS EZ ES R Regulator Rectifier Battery Fuse Case BL BL Water Temperature Sensor for Meter Unit Alternator W2LO639CH5 C Wiring Diagram ELECTRICAL SYSTEM 14 11 Fuel Pump System Crankshaft RelayRelay Sensor eat Pressure Sensor R BL 0 BL R BK R W W R GZR R W R Y R BL R G R BK W R Intake Air Intake Air Temperature Sensor Fuel R BL BKW Injectors 4 L Joint Connector 12 EFFE LSSSESS ETTET Joint Connect
109. GINE HOOD Fittings Handrail Plate Removal e Remove the rear and front seats see Seat Removal e Remove the handrail plate bolts A handrail plate nuts B washers and remove the handrail plate C Handrail Plate Installation e Be sure that the plugs A and the damper B are in posi tion Handrail Removal Installation e Remove the rear and front seats see Seat Removal e Disconnect the bilge hoses from the breather fitting e Remove the rear air ducts see Air Duct Removal e Remove the nuts A and washers B and remove the handrail C Drain Plug Housing Removal e Remove the screws A and remove the drain plug hous ing B Drain Plug Housing Installation e Check the seal A for damage x If necessary replace it with a new one Olnstall the new gasket B so that its OUT mark C faces outwards JM07036BS1 HULL ENGINE HOOD 13 15 Fittings Exhaust Outlet Removal e Remove the mounting bolts A and washers and remove the holder B and exhaust outlet C Exhaust Outlet Installation e Installation is the reverse of removal e Apply a non permanent locking agent to the mounting bolts and tighten them securely Stabilizer Removal _ eng A isis pl WIN i e Remove S PR MY Y j Stabilizer Bolts A z i Stabilizer B TES P Stabilizer Installation e Installation is the reverse of removal e Apply a non permanent locking a
110. Holder 2 57001 1423 A e Apply molybdenum disulfide grease to the drive shaft spline e Install the drive shaft to the hull Drive Shaft Holder Removal Disassembly e Loosen the clamp screw A DRIVE SYSTEM 10 7 Drive Shaft Drive Shaft Holder e Remove Drive Shaft see Drive Shaft Removal Drive Shaft Holder Mounting Bolts A e Remove the drive shaft holder B together with the pipe and tube e Loosen the clamp screw A e Remove Tube B Pipe C e Remove the circlip A Special Tool Inside Circlip Pliers 57001 143 e Using the press press A the small grease seal to remove the large grease seals B bearing C and small grease seals D come out of the holder E Blocks Special Tool Bearing Driver Set 57001 1129 KE 0 4J04012BS1 10 8 DRIVE SYSTEM Drive Shaft Drive Shaft Holder Drive Shaft Holder Assembly Installation e Replace the grease seals bearing and circlip A with new ones wea e Using a press press the bearing and grease seals into O the drive shaft holder noting the following Special Tool Bearing Driver Set 57001 1129 Olnstall the parts in this order Two Small Grease Seals B One Bearing C Two Large Grease Seals D Front E Olnstall the seals so that the sides with the spring face out ward OFill the gaps between the seals with water resistance grease F e Install the circlip Spe
111. ICATION SYSTEM 4 25 Oil Pressure Measurement Oil Pressure Measurement e Remove Intake Manifold see Intake Manifold Removal in the Fuel System DFI chapter Oil Pressure Switch Connector A Disconnect Oil Pressure Switch B e Install the oil pressure gauge adapter A to the switch hole Special Tool Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Install the oil pressure gauge B to the adapter Special Tool Oil Pressure Gauge 10 kgf cm 57001 164 e Install the removed parts see appropriate chapters e Launch the watercraft e Start the engine for several minutes e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is significantly below the specification inspect the oil pump and relief valve x If the oil pump and relief valve are not at fault inspect the rest of the lubrication system Oil Pressure Standard 461 kPa 4 7 kgf cm 67 psi at 3 000 r min rpm Oil Temperature 74 C 165 F e Stop the engine e Raise the watercraft to the land e Remove the intake manifold see Intake Manifold Re moval in the Fuel System DFI chapter e Remove the oil pressure gauge and adapter A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the oil passage when the gauge adapter is removed e Install the removed parts see appropriate chapters 4 26 ENGINE LUBRICATION SYSTEM Oil Pressure Switch
112. Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the ECU bracket see Air Temperature Sensor for Meter Unit Removal Installation in the Electrical Sys tem chapter e Connect a digital meter to the ignition switch connector A with needle adapter set Special Tool Needle Adapter Set 57001 1457 Amplifier Input Voltage Connections to Ignition Switch Connector Digital Meter R lead Digital Meter BK lead e Measure the input voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Input Voltage Standard Battery Voltage e Remove the ignition key x If the reading is out of the standard check the wiring see wiring diagram in next section Special Tool Hand Tester 57001 1394 x If the reading is within the standard check the wiring to ECU see wiring diagram in next section Special Tool Hand Tester 57001 1394 x lf the wiring is good replace the ignition switch see Immobilizer System Parts Replacement in the Electrical System chapter 3 62 FUEL SYSTEM DFI Blank Key Detection Service Code Character 36 Ignl e This code appears in the following conditions OThe transponder A in the FPO mode and or SLO mode key is malfunction OWhen the spare key of unregistration is used e Therefore the service code character Ign will disappear when the above issue is
113. LCD segments appear gradually Speedometer A Multifunction Meter B Fuel Level Gauge C Tachometer D OThe red warning indicator light LED E goes on 14 64 ELECTRICAL SYSTEM Multifunction Meter OThe FUEL A blinks for 5 seconds and then the Err B and the Fl warning symbol C start blinking OPush the MODE or SET button for 1 second the multi function meter switches to the normal display x If the meter does not work replace the meter unit Check 2 2 Speedometer Inspection e Connect the meter unit leads to the battery in the same circuit as Check 2 1 e Connect an oscillator A to the terminal 10 and the ground OThe speedometer displays the speed that rests on the frequency when the square wave is input OThe speedometer indicates approximately 40 mph 64 km h when the input frequency is approximately 214 Hz x If the display function does not work replace the meter unit x If the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit see Meter Unit Installation Olnsert the ignition key in the ignition switch to turn it on ORotate the water wheel A by hand Rotatory Direction B OCheck that the speedometer shows the speed x If the display function does not work inspect the speed sensor see Speed Sensor Inspection xlf the speed sensor is good check the speed sensor power supply see Check 2 3 Check 2 3 Speed Sensor Powe
114. Mounting Screws 3 9 N m 0 40 kgf m 35 in Ib e Swing the throttle lever so that the throttle cable pulley is fully open A WARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition Be sure the throttle case is assembled correctly e Adjust the throttle cable see Throttle Control System In spection in the Periodic Maintenance chapter Throttle Cable Removal e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Throttle Cable Upper End see Throttle Case Re moval Disassembly Steering Cover see Steering Removal in the Steering chapter e Remove Grommet Mounting Plate Bolts A Grommet Mounting Plate B e Pull up the grommet and take the throttle cable off the grommet e Pull down the throttle cable e Remove the band A on the delivery pipe assy B e Disconnect the throttle cable from the throttle body assy OSlide out the rubber cap OUnscrew the adjuster locknut A and slide the cable from the bracket OSlide the tip B of the cable lower end from the throttle pivot arm C Throttle Lever Cable and Case FUEL SYSTEM DFI 3 93 Throttle Cable Installation e Apply water resistance grease to the throttle cable ends e Install the throttle cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the throttle cable lower end see Throttle Body Assy Installation e Slide
115. Multifunction Meter e Check that the water temperature meter A matches the resistance value of the variable rheostat Variable Rheostat Resistance kQ 30 00 About 0 C 32 F 10 74 About 25 C 77 F x lf the display function does not work replace the meter unit Water Temperature Meter Check 2 6 Air Temperature Meter Inspection e Connect the meter unit leads to the battery in the same circuit as Check 2 1 e Connect the variable rheostat A to the terminal 13 and the terminal 14 e Check that the air temperature meter A matches the re sistance value of the variable rheostat Variable Rheostat 3 Resistance kQ Air Temperature Meter 30 00 About 0 C 32 F x If the display function does not work replace the meter unit ES JN17147BS2 ELECTRICAL SYSTEM 14 67 Multifunction Meter Multifunction Meter Circuit D R dt HI CL EES sl V Hei See nl y D 1 Ignition Switch 12 Water Temperature Sensor for Meter Unit 2 Joint Connector P 12 V 13 Main Fuse 20 A 3 Joint Connector R 12 V 14 Battery 4 Fuel Level Sensor Fuel Pump 15 Speed Sensor 5 Joint Connector T 12 V 16 Joint Connector Y Ground 6 ECU Main Relay 17 Joint Connector S Ground 7 System Relay 18 Joint Connector W 12 V 8 Joint Connector D 12 V 19 Air Temperature Sensor for Meter Unit
116. Pump Hull Pump Cooling Hose Water Box Muffler Hull Water Box Muffler Fix the No 10 and No 14 cooling hoses with the band Cooling Hose Output Cover Exhaust Pipe Cooling Hose Water Box Muffler Cylinder Position the clamp so that its screw head faces inside Cooling Hose Oil Cooler Exhaust Manifold Bow 16 8 APPENDIX Cable Wire and Hose Routing APPENDIX 16 9 Cable Wire and Hose Routing JO O1 amp ND Exhaust Manifold Exhaust Pipe Water Hose Joint Cooling Hose from the Output Cover 30 Water Hose Joint Cooling Hose from the Oil Cooler View from Port Side Upper Water Hose Joint Water Hose Joint Water Box Muffler Cylinder Water Hose Joint Water Box Muffler Hull Lower Water Hose Joint 90 View from A Bow Clamps 30 View from B Position the clamp so that their screw heads face to bow side Arrow Mark Exhaust Hose To Tail Pipe Dampers View from Top APPENDIX 16 11 Cable Wire and Hose Routing Right Rear Duct Right Bilge Hose Left Bilge Hose Left Rear Duct Water Box Muffler Right Bilge Breather Hose Left Bilge Breather Hose Right Front Duct Left Front Duct Run the left front duct through the right front duct rearward Band 225 mm 8 86 in 2000 J OO O1 ND _ 16 12 APPENDIX Cable Wire and Hose Routing
117. S ee Exhaust Manifold Mounting Nuts S Exhaust Manifold Mounting Bolts L S Water Hose Joints in L Exhaust Pipe Mounting Bolts 45 Exhaust Pipe Mounting Plate Bolts 30 3 1 22 E Front Exhaust Hose Clamp Screws 0 0 51 44 in lb 0 5 Rear Exhaust Hose Clamp Screws 5 0 51 44 in lb L Apply a non permanent locking agent LN Apply a non permanent locking agent High Strength R Replacement Parts S Follow the specified tightening sequence 5 4 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Removal e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter Oil Separator Tank see Oil Separator Tank Removal in the Engine Lubrication System chapter Band A Cut Clamp Screws B Loosen Water Hoses C Water Temperature Sensor D see Water Temperature Sensor Removal Installation in the Fuel System DFI chapter e Loosen the clamp screw A and remove the water hose B e Remove Bolts A and Collars Exhaust Pipe Mounting Plate B Front Exhaust Hose Clamp Screws C Loosen e Remove Exhaust Manifold Mounting Nuts A and Washers Exhaust Manifold Mounting Bolts B Washers and Col lars e Remove the exhaust manifold toward the front Exhaust Manifold Installation NOTE OUnhook the rubber strap and remove the front exhaust hose from the water box muffler for easier installation of the exhaust
118. S1 GE16071051 ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents E olle 1o E10 BE 7 2 Engine Removal InstallatiOn iseis anii Russie 7 4 Engine Removal sas Se nan Te e hol do td a anes ai 7 4 Engine Damper REMOWAl een 7 6 Engine Damper TEL EE 7 6 Engine Installation titane as 7 6 7 2 ENGINE REMOVAL INSTALLATION Exploded View JG02016BW5 ENGINE REMOVAL INSTALLATION 7 3 Exploded View 1 Engine Mounting Bol es ar ar EES L Apply a non permanent locking agent 7 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal x If the engine is to be disassembled after removal drain the engine oil see Engine Oil Change in the Periodic Maintenance chapter e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter Oil Separator Tank see Oil Separator Tank Removal in the Engine Lubrication System chapter Air Box see Air Box Removal in the Fuel System DFI chapter Intake Manifold see Intake Manifold Removal in the Fuel System DFI chapter Exhaust Manifold with Exhaust Pipe see Exhaust Man ifold Removal in the Exhaust System chapter e Cut the band A e Disconnect Camshaft Sensor Lead Connector B e Free the main harness from the clamps A e Disconnect Crankshaft Sensor Lead Connector B Oil Temperature Sensor Lead Connec
119. System ELECTRICAL SYSTEM 14 43 e Insert the ignition key in the ignition switch to turn it on and insert the lanyard key under the stop button e Pushing the starter button turn the engine 4 5 seconds to measure the peak voltage ODo not operate the starter for longer than 5 seconds Wait 15 seconds before using it again e Repeat the measurements 5 times or more times Camshaft Position Sensor Peak Voltage Standard 0 4 V or more xlf the reading is less than the standard inspect the camshaft position sensor see Camshaft Position Sensor Inspection IC Igniter Inspection OThe igniter is built in the ECU e Refer to the following items Ignition System Troubleshooting see Ignition System Troubleshooting ECU Power Supply Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter NOTICE Disconnecting the battery cables or any other elec trical connections when the ignition switch is on or while the engine is running can damage the igniter in the ECU Electronic Control Unit Do not discon nect the battery cables or any other electrical con nections when the ignition switch is on or while the engine is running Spark Plug Removal e Refer to the Spark Plug Inspection in the Periodic Main tenance chapter Spark Plug Installation e Refer to the Spark Plug Inspection in the Periodic Main tenance chapter Spark Plug Inspection e Refer to the Spark Plug Inspection in the Periodic Main t
120. U and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B R G lead ECU terminal 9 R lead C BK W lead ECU terminal 32 D x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation J616311BS1 Vehicle down Sensor Output Voltage Inspection e Remove the vehicle down sensor see Vehicle down Sensor Removal e Connect the measuring adapter A to the vehicle down sensor connectors as shown in the figure Special Tool Measuring Adapter 57001 1700 Main Harness B Vehicle down Sensor C e Connect a digital meter D to the measuring adapter leads Vehicle down Sensor Output Voltage Connections to Adapter Digital Meter W sensor BL W lead Digital Meter BK sensor BK W lead 4016238BS1 FUEL SYSTEM DFI 3 59 Vehicle down Sensor Service Code Character 31 dOS e Hold the sensor vertically e Measure the output voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on e Tiltthe sensor 110 130 or more A right or left then hold the sensor almost vertical with th
121. U and EUR Models C 4011031BS2 3 114 FUEL SYSTEM DFI Fuel Tank e Remove the left side cover see Side Cover Removal in the Hull Engine Hood chapter e Take out the nut A in the filler flange and remove the fuel filler B 4011014BS2 Fuel Filler and Hose Installation e Clean the deck and filler on their mating surfaces with greaseless high flash point solvent WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Do not use gasoline or low flash point solvents to clean parts e Note the following when installing the hose A OFit the white mark B of the hose to the mark C of the tank J611037BS1 Fuel Tank FUEL SYSTEM DFI 3 115 Olnstall the lower clamp A so that its screw head screw points inclined line B e Replace the fuel filler gasket A with a new one e Tighten the lower B and upper fuel filler hose clamp screws Torque Fuel Filler Hose Clamp Screws 2 9 N m 0 30 kgf m 26 in Ib Parallel with Fuel Tank at 20 25 mm 0 79 0 98 in height C AU and EUR Models D J611027BS1 JC11038BS2 ENGINE LUBRICATION SYSTEM 4 1 Engine Lubrication System Table of Contents d olle 1o S10 BEE 4 2 Engine Oil Flo
122. UEL SYSTEM DFI 3 39 Throttle Position Sensor Service Code Character 11 tPS OStart the engine with idle speed OTurn A the throttle position sensor and bring the sensor output voltage within the standard range Output Voltage Standard DC 1 08 1 18 V at idle throttle opening OTighten the throttle position sensor mounting screws Torque Throttle Position Sensor Mounting Screws 2 0 N m 0 20 kgf m 18 in lb ORecheck the output voltage is within the standard range OStop the engine and remove the ignition key ORemove the setting adapter and reconnect the throttle po sition sensor connector Throttle Position Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the handrail plate see Handrail Plate Removal in the Hull Engine Hood chapter e Disconnect the throttle position sensor connector e Connect the setting adapter A between the main har ness connector and throttle position sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1521 e Connect a digital meter to the setting adapter leads Throttle Position Sensor Input Voltage Connections to Adapter Digital Meter BL sensor R lead Digital Meter BK BL sensor BK W lead e Measure the input voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Input Voltage Standard DC 4 75 5 25
123. V 11 Joint Connector S Ground 6 ECU 3 70 FUEL SYSTEM DFI Engine Overheating Service Code Character 71 HEAt e f the service code character HEAt is displayed check the doubtful parts referring to the following table Possible Causes Actions Water passage clogged loosened or damaged Inspect see chapter 9 Incorrect engine oil level Inspect see chapter 4 Engine oil poor quality or incorrect Change see chapter 4 Water temperature sensor broken Inspect see chapters 3 and 14 Jet pump or impeller damaged Inspect see chapter 11 Oil cooler clogged Clean see chapter 4 Carbon build up on combustion chamber Clean see chapter 6 FUEL SYSTEM DFI 3 71 Low Engine Oil Pressure Service Code Character 72 OILP e f the service code character OILP is displayed check the doubtful parts referring to the following table Oil leak Inspect see chapter 4 Engine oil level too low Inspect see chapter 4 Engine oil viscosity too low Inspect see chapter 4 Oil filter clogged Clean see chapter 4 Oil pressure switch damaged a see chapters 3 and 14 Oil cooler clogged Camshaft bearing worn Crankshaft bearing worn d see chapter 8 Oil pressure relief valve stuck open O pump damaged Oil screen clogged Clean see chapter 4 O ring at the oil passage in the crankcase damaged Change see chapter 4 3 72 FUEL SYSTEM DFI Oil Temperature Sensor Service Code Character 7
124. WEE eii do it Model Identifica ME General Specifications Unit Conversion Table 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper ation on watercraft read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Kawasaki Diagnostic System KDS Software KDS software that runs on Windows personal computer PC will be available as a diagnostic tool for watercraft with Kawasaki DFI system You need the following items to use the KDS Item P No KDS3 Kit 57001 1747 KDS Software CD ROM 57001 1650 KDS3 Adapter 57001 1725 Communication Cable 57001 1745 KDS Adapter Cable 57001 1696 The connectors for the communication cable and KDS adapter cable are located in the front storage compartment cover Connect the communication cable A between the KDS connector 4 pin B and KDS3 Adapter Connect the KDS adapter cable C between the ignition switch immobilizer amplifier lead connectors 6 pin D NOTE OConnect the cable 57001 1696 to the ignition switch side connector first and then connect the ECU side c
125. aft Main Bearing Insert Journal Clearance Crankshaft Main Journal Diameter Marking None Crankcase Main Bearing Inside Diameter Marking O None Crankshaft Main Bearing Insert Thickness Pink Yellow Crankshaft Main Bearing Insert Selection 0 030 0 054 mm 0 0012 0 0021 in 40 984 41 000 mm 1 61354 1 61417 in 40 984 40 992 mm 1 61354 1 61386 in 40 993 41 000 mm 1 61389 1 61417 in 44 000 44 016 mm 1 73228 1 73290 in 44 000 44 008 mm 1 73228 1 73259 in 44 009 44 016 mm 1 73263 1 73290 in 1 490 1 494 mm 0 05866 0 05882 in 1 494 1 498 mm 0 05882 0 05898 in 1 498 1 502 mm 0 05898 0 05913 in 0 08 mm 0 0031 in 40 96 mm 1 6126 in Crankcase Main Crankshaft Main Bearing Insert reba V EE Size Color Part Number Journal Nos 92139 0727 O 1 Pink 92139 0730 92139 0733 Yellow None 1 None None Green The bearing inserts for Nos 2 and 4 journals have an oil groove 8 6 ENGINE BOTTOM END Special Tools and Sealant Oil Seal 8 Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 ST5710588T ST5711298T Coupling Holder 2 57001 1423 ST571423ST Rotor Holder 57001 1544 Holder Attachment 57001 1547 ST5715448T ST571547ST Flywheel amp Pulley Holder 57001 1605 O ST5716058T Rot
126. al injury This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly This model JT1500K is mounted with a four stroke engine When the JET SKi watercraft is submerged and swamped the four stroke engine needs special care and systematic procedure for re covery compared with the two stroke engine Therefore in this manual such procedures which are not shown in SMs for two stroke engines are explained thoroughly to cope with the cases Refer to the section After submerging in Chapter 9 Cooling and Bilge Systems for the summary and detailed procedures GENERAL INFORMATION 1 1 General Information Table of Contents Before De VICIO
127. allation e Replace the intake manifold gasket with a new one e Run the hoses leads and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter e Apply a non permanent locking agent to the intake mani fold mounting bolts and tighten them Torque Intake Manifold Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Intake Manifold Mounting Nuts 20 N m 2 0 kgf m 15 ft lb e Install the removed parts see appropriate chapters 3 100 FUEL SYSTEM DFI Fuel Line Fuel Hose Removal e Remove Seats see Seat Removal in the Hull Engine Hood chap ter e Be sure to place a piece of cloth A around the fuel hose joint WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Wipe off the dirt of the surface A around the connection using a cloth or a soft brush e Open and push up A the joint lock B with your fingers or thin blade screwdriver C Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion To pr
128. allation chapter Oil Pan see Oil Pan Removal Oil Screen Bolts A e Pull out the oil screen B to the coupling side C Oil Screen Installation e Clean the oil screen A with high flash point solvent and remove any particles stuck to it WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Replace the O ring A with a new one e Apply grease to the O ring and install it e Install the oil screen B e Tighten Torque Oil Screen Bolts 7 8 N m 0 80 kgf m 69 in Ib e Install Oil Pan see Oil Pan Installation Oil Pressure Relief Valve Inspection e Remove Oil Pan see Oil Pan Removal Oil Pressure Relief Valve A 4 24 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve e 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 B NOTE Olnspect the valve in its assembled state Disassembly O and assembly may change the valve perf
129. amper In spection in the Periodic Maintenance chapter 038102 J603011BS2 ENGINE REMOVAL INSTALLATION 7 7 Engine Removal Installation e Installation is the reverse of removal Note the following e Put the engine onto the hull with a lifter e Move the engine backward to engage the couplings A e Apply a non permanent locking agent to the engine mounting bolts and tighten them Torque Engine Mounting Bolts 36 3 N m 3 7 kgf m 27 ft Ib e Run the leads and the hoses properly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e After installing the engine in the hull check the following Throttle Cable Fuel and Exhaust Leaks A DANGER Exhaust gas contains carbon monoxide a color less odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water ENGINE BOTTOM END 8 1 Engine Bottom End Table of Contents Exploded WE 8 2 ee de TEE 8 4 Special Tools and Sealant ccc ccccccecccecceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeee
130. and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed e Check that the hose joints are securely connected see Hose and Hose Connect Inspection e Start the engine and check the fuel hose for leaks FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents Fuel System Diagram eeee Exploded View ek a ste rente Re DFI Parts Location Specifications Special Tools and Sealant DFI Servicing Precautions DFI Servicing Precautions Troubleshooting the DFI System Outlme cece cece eseeeeeeeeeeeaees Inquiries to Rider DFI System Troubleshooting Guide Self Diagnosis Self diagnosis Outline Self diagnosis Procedures Service Code Character Reading Service Code Erasing Service Code Character Table Throttle Position Sensor Service Code Character MAPS Throttle Position Sensor Removal Adjustment Throttle Position Sensor Input Voltage Inspection Throttle Position Sensor Output Voltage Inspection Throttle Position Sensor Resistance Inspection Intake Air Pressure Sensor Service Code Character 12 bOSt Intake Air Pressure Sensor Hemova Intake Air Pressure Sensor I
131. and the cylinder head must be replaced Do not overgrind the seat e Measure the outside diameter of the seating surface with a vernier caliper x 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 Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 or 55 cutter 60 or 55 F e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact GE15011881 GE15011981 GE15012181 6 28 ENGINE TOP END Valves x If the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the se
132. ange Special Tool Hand Tester 57001 1394 e Connect the tester leads as shown in the figure x If resistance is less than infinite the starter relay switch is not returning and must be replaced JN06031BS1 JNOGO503S1 14 24 ELECTRICAL SYSTEM Electric Starter System e Connect the tester leads as shown in the figure e Activate starter relay switch by connecting a 12 V battery as shown in the figure x If the starter relay switch clicks and the hand tester indi cates zero resistance the starter relay switch is good x If the tester indicates high or infinite resistance the starter relay switch is defective and must be replaced Starter Motor Removal e Remove Seat see Seat Removal in the Hull Engine Hood chap ter Intake Manifold see Intake Manifold Removal in the Fuel System DFI chapter e Slide out the rubber caps A and remove the starter motor ground bolt and starter motor terminal nut e Remove Starter Motor Mounting Bolts A Starter Motor B Starter Motor Installation NOTICE Tapping the starter shaft or body could damage the motor Do not tap the starter motor shaft or body e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Apply grease to the new O rings A e Install the starter motor e Apply a non permanent locking agent to the starter motor mounting bolts e Tig
133. arator Tank Mounting Screws A and Nuts Bracket B e Remove Breather Hose Clamps A Breather Hoses B Oil Separator Tank C NOTE OHold the hose end to the upward The oil will flow out if the hose lies at the bottom Oil Separator Tank Installation e When installing the breather hoses avoid sharp bending kicking flattening or twisting and run the hoses according to Hose Routing section in Appendix chapter e Apply a non permanent locking agent to the oil separator tank mounting nuts and tighten them OBe careful not to drop the nuts Torque Oil Separator Tank Mounting Nuts 4 9 N m 0 50 kgf m 43 in Ib Blowby Gas System Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly x lf they are not correct them e Inspect the breather hoses A breather pipes and the air box drain caps for damage or signs of deterioration Squeeze the hoses These hoses should not be hard and brittle nor should be soft or swollen x Replace any damaged hoses e Check that the hoses and clamps are securely connected OThe drain caps A are provided beneath the air box B The drain cap catches the water or oil from the bottom of the air box housing Usually water or oil does not collect at the bottom of the housing In the event that water is drawn in through the duct or if engine oil is blown back drain the housing e Pull the drain caps to drai
134. ary Peak Voltage INSpection anaoeeeeeeeeee0 14 40 Camshaft Position Sensor Removal Installation 14 41 Camshaft Position Sensor Inspection 14 42 Camshaft Position Sensor Peak Voltage Inspection 14 42 IC Igniter Inspection 14 43 Spark Plug Removal 14 43 Spark Plug Installation 14 43 Spark Plug Inspection 14 43 Spark Plug Adjustment 14 43 Spark Plug Cleaning 14 43 Kawasaki Smart Steering KSS SS Rs pren nn sag 14 46 Steering Position Sensor and Magnet Removal e 14 46 Steering Position Sensor and Magnet Installation 14 46 Kawasaki Smart Steering System Inspechon Steering Position Sensor Clearance Inspection 14 47 Steering Position Sensor Input Voltage Inspection 14 47 Steering Position Sensor Output Voltage Inspection 14 48 A ire see nes 14 50 Speed Sensor Removal 14 50 Speed Sensor Installation 14 51 Speed Sensor Inspection 14 51 Fuel Level Sensor Inspection 14 52 Water Temperature Sensor Removal Installation 14 52 Water Temperature Sensor Inspection 14 53 Oil Temperature Sensor Removal Installation 14 53 Oil Temperature Sensor INSpection asnaanaeeeeeneeeeee0 14 54 Water Temperature
135. at charging cycle OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 V repeat the charging cycle and load test If still below 12 8 V the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the text see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery NOTICE This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 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 char
136. at outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn NOTICE The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above x If the seat width is too wide make the 60 or 55 A grind described below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 or 55 angle until the seat width is within the specified range OTo make the 60 or 55 grind fit 60 or 55 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 or 55 grind return to the seat width measurement step above Correct Width B O GE15012281 GE15012381 ENGINE TOP END 6 29 Valves e Lap the valve to the seat
137. attery cables A WARNING Electrical components including the battery can cause shocks and burns To prevent injury and damage to electrical components always discon nect the grounded cable first e Unhook the battery straps B e Carefully lift the battery from the battery compartment ELECTRICAL SYSTEM 14 17 Battery Battery Installation e For EUR model be sure the aluminum tray A is in posi tion under the battery compartment B e Be sure the battery damper C is in position in the battery compartment e Hook the battery straps e Connect the battery cables positive first OAfter attaching both cables coat the terminals and cable ends with water resistance grease to prevent corrosion OSlide the rubber caps over each terminal WARNING The shock contains high pressure nitrogen gas that when suddenly released can eject oil and internal shock parts at high velocity causing serious injury To avoid injury do not point a suitable tool toward your face or body when releasing nitrogen gas pres sure since an oil mist is often released with the ni trogen Always release nitrogen gas pressure be fore disassembling the rear shock absorber to pre vent explosive separation of parts Reversing the battery connections may damage the electrical system To prevent damage be sure the battery connections are correct Battery Activation Electrolyte Filling e Ma
138. ay R G Unused Fuel Injector 1 V Ignition Coil 1 4 G BL Main Switch R Y Entry Switch from Ignition Switch R BK Start Switch Y R Fuel Injector 4 BL Y Ground for Power BK Fuel Pump Relay G R Ignition Coil 2 3 G Fuel Injector 2 O KDS Kawasaki Diagnostic System 3 14 FUEL SYSTEM DFI DFI Parts Location Fuel Injector 4 A Fuel Injector 3 B OT TOPO O Fuel Injector 2 C Be Ap Fuel Injector 1 D Intake Air Pressure Sensor E Intake Air Temperature Sensor F Camshaft Position Sensor A Water Temperature Sensor A Oil Pressure Switch A Crankshaft Sensor B Oil Temperature Sensor C Throttle Position Sensor A ISC Idle Speed Controller B DFI Parts Location FUEL SYSTEM DFI 3 15 Buzzer A Meter Unit B Ignition Switch C Immobilizer Amplifier Ignition Key D Transponder Fuel Pump A Vehicle down Sensor B Ignition Coil 2 3 C Ignition Coil 1 4 D Relay Assy 2 A ECU Main Relay Relay Assy 1 B Fuel Pump Relay System Relay ECU C NOTE Oln this photo the front access cover has been removed Immobilizer Kawasaki Diagnostic System Connector A Main Fuse 20 A B Battery C NOTE Oln this photo the battery cover has been removed Speed Sensor A 3 16 FUEL SYSTEM DFI Specifications Item Standard Digital Fuel Injection System Idle Speed Thrott
139. battery cables see Battery Removal in the Electrical System chapter OBe sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage x lf the reading is 12 8 V or more no refresh charge is re quired however ifthe read is below the specified refresh charge is required see Refreshing Charge in the Electri cal System chapter Battery Terminal Voltage Standard 12 8 V or more Terminal Voltage V A Battery Charge Rate B Good C Refresh charge is required D Battery Terminals Inspection e Check the battery terminal screws A for tightness and make sure the terminal covers are in place WARNING Loose battery cables can create sparks which can cause a fire or explosion resulting in injury or death Make sure the battery terminal screws are tightened securely and the covers are installed over the termi nals e Check that the battery terminals are not corroded x If necessary remove the battery see Battery Removal in the Electrical System chapter and clean the terminals and cable ends using a solution of baking soda and water e After attaching both cables coat the terminals and cable ends with grease to prevent corrosion Spark Plug Inspection e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Spark Plug Caps e Remove the spark plugs using the 16 mm 0 63 in p
140. be good it may be defective in some manner not readily detectable within the hand tester If all other starter mo tor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection e Using the x 1 Q hand tester range measure the resis tance as shown A Terminal and Positive Brush B Brush Plate and Negative Brush Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has an open Replace the positive brush assembly and or the negative brush assembly GP110610S1 GP110608S1 14 28 ELECTRICAL SYSTEM Electric Starter System Brush Plate and Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown A Terminal Bolt and Brush Plate B Terminal Bolt and Yoke lf there is any reading the negative brush assembly and or positive brush assembly have a short Replace the negative and positive brush assemblies Reduction Gear Removal Installation e Remove the alternator rotor see Alternator Rotor Re moval in the Engine Bottom End chapter e When installing the reduction gear apply a molybdenum disulfide grease A to both ends of its shaft e Be sure to install the washer B Reduction Gear Inspection e Check that the pinion gear A turns freely clockwise B e When the pinion g
141. ce Chart for the frequency of the following items e Lubricate the following with grease OPull the throttle lever and hold it Throttle Cable End A at Throttle Lever N OI SSI A NKR SIS R TA2220 6S17005BS1 PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures ORemove the seats see Seat Removal in the Hull Engine Hood chapter Throttle Cable End A at Throttle Body ORemove the steering holder see Steering Removal in the Steering chapter Steering Cable Ball Joint A at Steering Shaft Steering Cable Joint A ORemove the left side cover see Side Cover Removal in the Hull Engine Hood chapter Shift Cable Ball Joint A at Shift Lever Shift Cable Ball Joint A at Reverse Bucket 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Lubricate the following with a penetrating rust inhibitor B Throttle Cable A Steering Nozzle Pivots A Reverse Bucket Pivots B e 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 if the cable is frayed B or if the cable housing is kinked C replace the cable 6004040181 6004020281 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures All Hoses Hose Clamps Nuts Bolts and Fasteners Check Nuts Bolts and Fasteners Tightness Inspecti
142. cial Tools With the Hand e Position the crankshaft at 2 3 piston TDC e Prepare two auxiliary head bolts with their head cut Olnstall the two bolts A diagonally in the crankcase e Install the cylinder block B Pistons C OFirst insert the 2 3 pistons and then rotate the crank shaft at 90 angle Olnsert the piston rings with your thumbs or the thin screwdriver yF11004BS1 C 6 32 ENGINE TOP END Cylinder Pistons With the Special Tools e Prepare two auxiliary head bolts with their head cut Olnstall the two bolts A diagonally in the crankcase e Slip the piston base B under the pistons to hold them level e Compress the piston rings using the piston ring compres sor grips C and piston ring compressor belts D Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 80 91 57001 1320 Piston Base 8 57001 1604 e Push down vigorously the cylinder aligning the cylinder bores with all the piston heads e Install the cylinder so that its angle aligns the piston angle after removing the piston ring compressor belts and piston base e Remove the two bolts e f the joints have been removed install the joints as shown in the figure 90 A OApply a non permanent locking agent to the threads of the joints and tighten them Torque Oil Passage Joint B 11 N m 1 1 kgf m 97 in lb Water Hose Joint C 11 Nam 1 1 kgf m 97 in Ib
143. cial Tool Bearing Driver Set 57001 1129 e Replace the oil seals with new ones e Apply thin coat grease to the oil seal lips A e Pack grease B between the oil seal lip and housing of the oil seal engine inside oil seal C e Press in the oil seals until they are bottomed Special Tool Bearing Driver Set 57001 1129 e Install the oil seal D so that the manufacturer s mark E faces outside e Install the engine inside oil seal so that the dust seal F side faces outside Oil Seal Inspection e Inspect the oil seal x Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged Alternator Cover Bearing Replacement Removing the ball bearing may damage it Do not remove the ball bearing unless absolutely neces Sary e Remove Alternator Cover see Output Shaft Removal e Using the oil seal amp bearing remover A remove the ball bearing from the alternator cover B OWhen removing the ball bearing hold the alternator cover Special Tool Oil Seal amp Bearing Remover 57001 1058 JHO4009BS1 Coupling Output Shaft ENGINE BOTTOM END 8 11 e Using a press and the bearing driver set A install the new bearing until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball Bearing Lubrication NOTE OSince the bearings are packed with grease and sealed on b
144. cial Tool Inside Circlip Pliers 57001 143 e Apply water resistance grease to the bearing inner sur face and grease seal lips G e Strip off the old sealant on the mating surface aes e Apply silicone sealant to the mating surface H of the drive shaft holder Le IL ba iw Leet LH 2 G f SZ 2 S eg Li e Stick the drive shaft holder A and pipe B e Install the tube C securely e Tighten the clamp screw D e Install the drive shaft holder on the bulkhead so that the circlip side face toward the front e Tighten the clamp screw A e Apply a non permanent locking agent to the drive shaft holder mounting bolts tighten them loosely e Install the drive shaft see Drive Shaft Installation e After installing the engine tighten the drive shaft holder mounting bolts to the specified torque to give proper cou pling alignment Torque Drive Shaft Holder Mounting Bolts 22 N m 2 2 kgf m 16 ft lb Drive Shaft Drive Shaft Holder DRIVE SYSTEM 10 9 e Make sure the clearance A between the engine coupling B and the drive shaft coupling C is 3 to 5 mm 0 12 to 0 20 in Drive Shaft Runout Inspection e Measure drive shaft runout by supporting the shaft in alignment jig and setting a dial gauge against the shaft at each point shown e Turn the drive shaft slowly The difference between the highest and lowes
145. coil primary peak voltage inspection Good Ignition coil is defective Replace ignition coil Voltage is zero or almost zero Inspect Lower resistance in a hand tester Use KAWASAKI Hand Tester Crankshaft sensor peak voltage Camshaft position sensor peak voltage No good Inspect Replace bad parts No good 1 Adapter connection is incorrect or adapter or inspect them is defective with KAWASAKI Ignition switch and engine stop switch Hand Tester Crankshaft sensor peak voltage Camshaft position sensor peak voltage Replace bad parts Inspect the ECU power supply No good Good Inspect the wiring connection and related parts ECU is defective Replace ECU JNO8038B F 14 46 ELECTRICAL SYSTEM Kawasaki Smart Steering KSS System Steering Position Sensor and Magnet Removal e Remove Front Access Cover see Front Access Cover Removal in the Hull Engine Hood chapter e Disconnect the steering position sensor lead connector A e Remove Steering Shaft see Steering Removal in the Steering chapter Steering Position Sensor Mounting Screws A Steering Position Sensor B e Remove Magnet Mounting Screw A Magnet B Steering Position Sensor and Magnet Installation e Install the magnet OFit the projection A and the hole B e Apply a non permanent locking agent to the magnet mounting screw e Tighten the magnet mounting screw e Install the steering position sensor
146. ct the ignition coil primary lead connectors noting the 1 4 A and the 2 3 B coil connec tors The 1 4 coil connector has a red white and a green blue leads from the main harness The 2 3 coil connector has a red white and green leads from the main harness NOTE OThe service codes 51 and 52 caused by this procedure are stored in the ECU 13 Start the engine by pressing the start button and run less than 15 seconds Running the engine with the watercraft out of the water for more than 15 seconds at a time will cause overheating resulting in engine and exhaust sys tem damage To prevent engine and exhaust sys tem damage do not run the engine with the water craft out of the water for more than 15 seconds at a time Never operate the engine at maximum speed out of the water 14 Ifthe engine does not start there may be water in the fuel system 15 If the fuel tank has water in it it must be emptied by pump or siphon Refill the tank with fresh fuel Do not dump contaminated fuel in places not designated for that purpose 16 Continued trouble may require cleaning ofthe fuel line to drain water 17 Remove the dipstick and check for the water pres ence in the engine oil If there is water in it oil looks milky 18 If the oil looks milky then change the oil and repeat procedures 13 and 17 until the oil does not turn milky any more WARNING Gasoline is extremely flammable and can be ex
147. cting Rod Twist 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance 0 13 0 38 mm 0 6 mm 0 0051 0 0150 in 0 024 in Connecting Rod Big End Bearing 0 041 0 071 mm 0 11 mm Insert Crankpin Clearance 0 0016 0 0028 in 0 0043 in Crankpin Diameter 38 984 39 000 mm 38 97 mm 1 53480 1 53543 in 1 5342 in Marking None 38 984 38 992 mm 1 53480 1 53512 in O 38 993 39 000 mm 1 53515 1 53543 in Connecting Rod Big End Inside Diameter 42 000 42 016 mm EE 1 65354 1 65417 in Marking None 42 000 42 008 mm EE 1 65354 1 65385 in O 42 009 42 016 mm EE 1 65389 1 65417 in Connecting Rod Big End Bearing Insert Thickness Pink 1 475 1 480 mm 0 05807 0 05827 in Yellow 1 480 1 485 mm 0 05827 0 05846 in Green 1 485 1 490 mm 0 05846 0 05866 in Connecting Rod Big End Bearing Insert Selection Connecting Rod Crankpin Bearing Insert Big End Inside Diameter Diameter Marking Marking None O Pink 92139 0724 Size Color Part Number None None Yellow 92139 0723 Crankshaft Side Clearance 0 05 0 24 mm 0 44 mm 0 0020 0 0094 in 0 017 in Crankshaft 3 Main Journal Width 27 45 27 55 mm 1 081 1 085 in Crankshaft Runout TIR 0 03 mm 0 0012 in or TIR 0 07 mm less 0 0028 in ENGINE BOTTOM END 8 5 Specifications Item Standard Service Limit Cranksh
148. ctor 15 Battery 12 V 18 Ah 16 Starter Relay 17 Fuse Case for Main Fuse 30 Aluminum Tray EUR Model only NOTE Oln this photo the battery cover has been removed 18 Speed Sensor 19 Intake Air Pressure Sensor 20 Intake Air Temperature Sensor 21 Camshaft Position Sensor 22 Alternator 23 Starter Motor ELECTRICAL SYSTEM 14 5 Parts Location 24 Oil Pressure Switch 25 Crankshaft Sensor 26 Oil Temperature Sensor 27 Water Temperature Sensor for Meter Unit 28 Fuel Level Sensor 29 Steering Position Sensor 14 6 ELECTRICAL SYSTEM Exploded View LT LOS G G DR REST VA Q JNO2089BW5 C ELECTRICAL SYSTEM 14 7 Exploded View A ss f os ome f t 2 Spark Plugs 1 3 115 in lb 3 Oil Temperature Sensor ie 1 5 11 4 Water Temperature Sensor 14 7 1 5 11 5 Regulator Rectifier Bolts 7 8 0 80 69 in lb 6 Bracket Bolts 8 8 0 90 78 in lb L 7 Vehicle down Sensor Mounting Screws 1 5 0 15 13 in lb 8 Camshaft Position Sensor Bolt 10 1 0 89 in lb L 9 Timing Rotor Bolt 20 2 0 15 L 10 Crankshaft Sensor Cover Bolts 7 8 0 80 69 in lb 11 Rubber Grommet Holder Screws 4 5 0 46 40 in lb L 12 Crankshaft Sensor Screws 4 5 0 46 40 in lb L 13 Stator Coil Bolts 12 1 2 106 in Ib L 14 Stator Coil Grommet Holder Plate Bolts 8 8 0 90 78 in lb L 15 Speed Sensor Mounting Screws 3 9 0 40 35 in lb L 16 Water Temperat
149. d Tester 57001 1394 x If the tester does not read as specified replace the relay assembly ELECTRICAL SYSTEM 14 81 Relay Assembly Relay Assembly Circuit Inspection with the battery disconnected Tester Connection Tester Reading Q Main ECU Relay A 3 4 2 Fuel Pump Relay A 1 2 Not en System Relay B de is 5 6 Not o The actual reading varies with the hand tester used Relay Assembly Circuit Inspection with the battery connected Battery Connection Main ECU Relay A Fuel Pump Relay A 1 2 Tester Connection Tester Reading Q 3 4 System Relay B Apply positive lead Apply negative lead 5 6 7 8 JN10032B 2 14 82 ELECTRICAL SYSTEM Switches Switch Inspection e Using the hand tester check to see that only the connec tions shown in the table have continuity Special Tool Hand Tester 57001 1394 OFor the ignition switch and switches on the handlebar re fer to the tables in the Wiring Diagram x If the switch has an open or short repair it or replace it with a new one Oil Pressure Switch Connections Oil Pressure Switch Connections Color SW Terminall Ground When engine is running Engine lubrication system is in good condition Fuse ELECTRICAL SYSTEM 14 83 Fuse Inspection e Remove Battery Cover see Battery Removal Fuse Case Cap A e Remove Main Fuse
150. des any appliance with a pilot light Do not smoke Remove the ignition key Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Remove the spark plug leads and place them A out of the engine compartment e Cut the band B e Disconnect Fuel Hose A see Fuel Hose Removal Fuel Injector Connectors B e Remove the bolts A and collars to pull out the fuel in jectors from the intake manifold together with the delivery pipe assy B NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the intake manifold e Pull out the fuel injectors A from the delivery pipe assy B NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy A shock to the fuel injector can damage it Do not drop the fuel injector Fuel Injectors FUEL SYSTEM DFI 3 79 Fuel Injector Installation e Before installation blow away dirt or dust from the intake manifold and delivery pipe assy by applying compressed air e Apply a non permanent locking agent to the threads of the fitting A e Tighten the fitting to the delivery pipe B Torque Delivery Pipe Fitting 20 N m 2 0 kgf m 15 ft Ib e Replace
151. e Do not expose it to freezing temperatures JFO09008BS1 Preparation for Storage STORAGE 15 5 Lubrication e Carry out all recommended lubrication procedures see Lubrication in Periodic Maintenance chapter Lube Jet Pump Bearings Seals NOTICE Failure to properly maintain the jet pump bearings can lead to premature failure and cause severe engine damage The jet pump bearings and seals should be serviced prior to prolonged storage to prevent any water that may be left in the pump from corroding the bearings and causing premature failure e Clean the pump see Lube Jet Pump Bearing and Seal Inspection in the Periodic Maintenance chapter Cleaning e Wash 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 Harsh solvents may attack the surface or smear the colors of the hull Use only a mild detergent in water to wash the hull e Apply a good grade of wax to all exterior hull surfaces e Lightly spray all exposed metal parts with a penetrating rust inhibitor e Remove the seat or block the seat up with 10 mm 0 39 in spacers to insure adequate ventilation and prevent corrosion e Cover the watercraft and store it in a clean dry place 15 6 STORAGE Removal from Storage Lubrication e Carry out all recommended lubrication procedures see the Periodic Maintenance chapt
152. e Color Part Number Journal No 92139 0727 1 5 Pink 92139 0730 2 4 92139 0733 92139 0726 Yellow 92139 0729 The bearing inserts for Nos 2 and 4 journals have an oil groove respectively 8 30 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Side Clearance Inspection e 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 Crankshaft Side Clearance Standard 0 05 0 24 mm 0 0020 0 0094 in Service Limit 0 44 mm 0 017 in e Measure the crankshaft 3 main journal width A x If the measurement exceeds the standard replace the crankshaft B Crankshaft 3 Main Journal Width Standard 27 45 27 55 mm 1 081 1 085 in JH11006BS1 Crankshaft Runout Inspection e Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 07 mm 0 0028 in JH11000B 1 COOLING AND BILGE SYSTEMS 9 1 Cooling and Bilge Systems Table of Contents EXI WEE 9 2 A 9 4 Breather Remove eer e Une in 9 4 Breather Installations fe tend Rens ment Rein ER 9 4 Breather Cleaning and INSpSCtioni idoneidad 9 4 Filter Removal is coi
153. e Install the crankshaft sensor A e Apply a non permanent locking agent to the sensor screws e Tighten Torque Crankshaft Sensor Screws 4 5 N m 0 46 kgf m 40 in lb e Install the rubber grommet B in the sensor cover hole e Run the sensor lead C as shown in the figure e Apply water resistance grease to the grommet outside e Apply a non permanent locking agent to the grommet holder screws e Tighten Torque Rubber Grommet Holder Screws 4 5 N m 0 46 kgf m 40 in Ib e Replace the crankshaft sensor cover O ring with a new one e Apply grease to the new O ring and install it e Apply sealant to the crankcase halves mating surface A as shown in the figure Sealant Liquid Gasket TB1211F 92104 0004 e Install Dowel Pins B Crankshaft Sensor Cover e Tighten Torque Crankshaft Sensor Cover Bolts 7 8 N m 0 80 kgf m 69 in Ib Timing Rotor Removal e Remove the crankshaft sensor cover see Crankshaft Sensor Removal e Hold the timing rotor A steady with the flywheel amp pulley holder B and unscrew the bolt C Special Tools Holder Attachment 57001 1547 Flywheel 8 Pulley Holder 57001 1605 Timing Rotor Installation e Fit the rotor to the crankshaft OAlign the pin A and groove B of the timing rotor and face the flat side marked side to the outside e Apply a non permanent locking agent to the rotor bolt e Tighten Torque Timing Rotor Bolt 20 N m 2 0 kgf m 15 ft Ib Sp
154. e Install the removed parts see appropriate chapters Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston NOTICE Snap rings are weakened and deform when re moved and may fall out scoring the cylinder wall and causing severe engine damage Do not re use snap rings always replace them e Using the piston pin puller A remove the piston pins Special Tool Piston Pin Puller Assembly 57001 910 e Remove the pistons from the connecting rods yF11005BS1 ENGINE TOP END 6 33 Cylinder Pistons e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation e Apply molybdenum disulfide oil solution to the oil ring ex pander and install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom e Apply molybde
155. e LCD e Push the SET button A with MODE button B for more than three seconds e The service code character C is displayed on the LCD e Any of the following procedures ends self diagnosis OWhen the service code characteris displayed on the LCD push either SET or MODE button for more than one second OWhen the ignition switch is turned OFF JC16293BS2 3 34 FUEL SYSTEM DFI Self Diagnosis Self Diagnosis Flow Chart Turn the ignition switch to OFF Turn the ignition switch to ON Push the SET button with MODE button for more than three seconds Then self diagnosis dealer mode starts The service code character s is displayed on the LCD Liquid Crystal Display Turn the ignition switch to OFF Locate the problem with the service code character table and inspect and repair DFI ignition and immobilizer system according to inspection procedure on all the service code characters Turn the ignition switch to ON Make sure the Fl character service code character and Fl and or immobilizer warning indicators go off Run the engine for several minutes at idling and run the watercraft at 30 km h 18 mph or above in order to confirm no problem JC16189B F FUEL SYSTEM DEI 3 35 Self Diagnosis Service Code Character Reading OThe service code character s is displayed on the LCD OWhen there are a character of problems all the
156. e and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor acceleration Fuel pressure too low Inspect see chapter 3 Water or foreign matter in fuel Fuel filter or pump screen clogged Fuel pump trouble Fuel injector trouble Throttle position sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Spark plug dirty broken or gap maladjusted Ignition coil trouble Stumble Fuel pressure too low Change fuel Inspect and clean fuel system see chapter 3 Inspect and replace fuel pump see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 2 Inspect see chapter 14 rl ll Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Throttle position sensor trouble Inspect see chapter 3 Intake air pressure sensor trouble Le LV a Inspect see chapter 3 DFI System Troubleshooting Guide FUEL SYSTEM DFI 3 29 Symptoms or Possible Causes Actions Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Surge Unstable fuel pressure Fuel injector trouble Water temperature sensor trouble
157. e arrow mark pointed up B and measure the output voltage Output Voltage Standard With sensor tilted 110 130 or more right or left DC 0 65 1 35 V With sensor arrow mark pointed up DC 3 55 4 45 V NOTE Olf you need to test again remove the ignition key and then insert the ignition key in the ignition switch to turn it on e Remove the ignition key x If the reading is out of the standard replace the sensor x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B BL W lead ECU terminal 26 C BK W lead ECU terminal 32 D lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 4016239BS2 J616312BS1 3 60 FUEL SYSTEM DFI Vehicle down Sensor Service Code Character 31 dOS Vehicle down Sensor Circuit E O Ep R G BL W BK W BK W a BK w BK W BL W R G 1 Joint Connector F 5 V 2 ECU 3 Vehicle down Sensor 4 Joint Connector B Ground JC16313BW2 FUEL SYSTEM DFI 3 61 Immobilizer Amplifier Service Code Character 35 Innb Amplifier
158. e clamp screws A and remove the oil cooler water hoses B from the oil cooler e Disconnect the oil pressure switch connector C e Remove the oil cooler positioning bolt A e Remove the oil passage bolt B and remove the oil cooler C e Place a rag or cloth D under the oil cooler to receive the remaining oil Oil Cooler Installation e Replace the O ring A with a new one and apply grease to new O ring e Fit the O ring on the oil cooler B securely e Install the oil cooler positioning bolt A and the oil pas sage bolt B temporarily OFirst tighten the oil passage bolt ONext tighten the oil cooler positioning bolt Torque Oil Passage Bolt 78 N m 8 0 kgf m 58 ft lb Oil Cooler Positioning Bolt 20 N m 2 0 kgf m 15 ft Ib 4 16 ENGINE LUBRICATION SYSTEM Oil Cooler e Install the water hoses see Cable Wire and Hose Rout ing section in the Appendix chapter e Replace the oil filter with a new one e Apply engine oil to the O ring A of the new oil filter B e Tighten the oil filter with the oil filter wrench Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 18 N m 1 8 kgf m 13 ft lb e Install the removed parts see appropriate chapters Oil Cooler Disassembly e Remove Oil Cooler see Oil Cooler Removal Oil Pressure Switch A Oil Cooler Assembly Bolts B Outside Oil Cooler Cover C e Remove O rings A DONNE P e Turn the oil co
159. e hull e Remove it again to check the oil level NOTE OAn accurate oil level cannot be obtained if the dipstick is not installed in the correct direction e Check the oil level using the hot level mark on the dipstick A High Level Line when Hot B Low Level Line when Hot C x lf the oil level is too high drain the excess oil thoroughly from the dipstick tube A using a commercially available vacuum pump B x If the oil level is too low add the oil to the high level line through the oil filler opening see Engine Oil Change in the Periodic Maintenance chapter Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter ENGINE LUBRICATION SYSTEM 4 15 Oil Cooler Oil Cooler Removal e Remove Intake Manifold see Intake Manifold Removal in the Fuel System DFI chapter e Remove the oil filter A with the oil filter wrench B OPlace a rag or cloth under the oil filter to receive the re maining oil Special Tool Oil Filter Wrench 57001 1249 e Loosen th
160. e proper tools and genuine Kawasaki JET SKi watercraft parts Special tools gauges and testers that are necessary when servic ing Kawasaki JET SKi watercraft are intro duced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE NOTICE is used to address practices not related to person
161. e reamer in a clockwise direction until the reamer turns freely in the guide Never turn the reamer counter clockwise or it will be dulled OOnce the guides are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 65 57001 1204 6E15045BS1 6E15046BS1 ENGINE TOP END 6 25 Valves Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 17 mm 0 0035 0 0067 in Intake 0 03 0 11 mm 0 0012 0 0043 in Service Limit Exhaust 0 35 mm 0 014 in Intake 0 29 mm 0 011 in Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern
162. e sensor bracket e Tighten Torque Vehicle down Sensor Mounting Screws 1 5 N m 0 15 kgf m 13 in Ib e Connect the connectors e Apply a non permanent locking agent to the threads of the bracket bolts and tighten them Torque Bracket Bolts 8 8 N m 0 90 kgf m 78 in Ib Vehicle down Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Disconnect the vehicle down sensor connector and con nectthe measuring adapter A between these connectors as shown in the figure Main Harness B Vehicle down Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Vehicle down Sensor Input Voltage Connections to Adapter Digital Meter R sensor R G lead Digital Meter BK sensor BK W lead e Measure the input voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Input Voltage Standard DC 4 75 5 25 V e Remove the ignition key x If the reading is within the standard check the output volt age see Vehicle down Sensor Output Voltage Inspec tion J616235BS1 J616236BS1 3 58 FUEL SYSTEM DFI Vehicle down Sensor Service Code Character 31 dOS lf the reading is out of the standard remove the EC
163. e water craft level side to side and fore to aft as much as possible Level Ground A Side Bumper B Parallel C e Remove the dipstick A wipe it dry and insert it back into the dipstick so that the finger grip is positioned toward the left side B of the hull e Remove it again to check the oil level NOTE OAn accurate oil level cannot be obtained if the dipstick is not installed in the correct direction e The oil level must be between the High and Low level lines on the dipstick Use level lines when engine is cold High Level Line when Cold A Low Level Line when Cold B Dipstick C High Level Line when Hot D Low Level Line when Hot E JDO8000BS1 ENGINE LUBRICATION SYSTEM 4 13 Engine Oil and Oil Filter 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 running above idle speed stop the engine immediately and find the cause x If the oil level is too high remove the excess oil using a syringe or some other suitable device x If the oil level is too low add the oil to the low level line through the oil filler opening see Engine Oil Change in the Periodic Maintenance chapter Use the same type and make of oil that is already in the engine NOTE Olf t
164. ead ENGINE TOP END 6 21 e Apply molybdenum disulfide oil solution to both sides A of the cylinder head bolt washers B and the thread C of head bolts D e Install the cylinder head e Tighten the M11 cylinder head bolts following the tighten ing sequence 1 10 Torque Cylinder Head Bolts M11 First 23 N m 2 3 kgf m 17 ft lb Final 60 N m 6 1 kgf m 44 ft lb e Tighten the M7 cylinder head bolts following the tightening sequence 11 12 Torque Cylinder Head Bolts M7 20 N m 2 0 kgf m 15 ft lb e Tighten the M6 cylinder head bolts following the tightening sequence 13 14 Torque Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 in Ib e Replace the O ring A with a new one e Install Camshaft Chain Guides B New O ring Exhaust Side Camshaft Chain Guide Bolt Lower C Exhaust Side Camshaft Chain Guide Bolt Upper D Collar E e Apply a non permanent locking agent to the intake side camshaft chain guide bolt F and install it e Tighten Torque Exhaust Side Camshaft Chain Guide Bolt Lower 12 N m 1 2 kgf m 106 in Ib Exhaust Side Camshaft Chain Guide Bolt Upper 25 N m 2 5 kgf m 18 ft lb Intake Side Camshaft Chain Guide Bolt 12 N m 1 2 kgf m 106 in Ib e Install the removed parts see appropriate chapters abi Y h Q a 00 00 h i dh S d O To el y A O RS Soe LI n a JF09010BS1 JF09012BS2
165. ear A turns counterclockwise B check that it advances along the shaft and the gear stops against the stopper C e Check that the pinion gear returns to the initial position quickly x If the pinion gear does not function properly replace it 4NO6033BS1 Electric Starter System ELECTRICAL SYSTEM 14 29 Electric Starter Circuit JNO06034BW3 C JO O1 amp ND Ignition Switch Joint Connector P 12 V Joint Connector R 12 V Joint Connector T 12 V ECU Main Relay System Relay Joint Connector D 12 V Joint Connector C 12 V ECU Main Fuse 20 A Battery Starter Relay Starter Motor Joint Connector S Ground Joint Connector X 12 V Engine Start Switch Engine Stop Switch Tether 14 30 ELECTRICAL SYSTEM Charging System Alternator Removal Installation e Refer to the Alternator Rotor Removal and Installation in the Engine Bottom End chapter Alternator Output Voltage Inspection e Remove Seat see Seat Removal in the Hull Engine Hood chap ter e Disconnect the stator coil lead connector A e With the hand tester A check the alternator output in circuit according to the following table Special Tool Hand Tester 57001 1394 WARNING Water is a high conductor of electricity and perform ing an electrical circuit inspection on water could cause severe electrical shock to you To pre
166. ecial Tools Holder Attachment 57001 1547 Flywheel 8 Pulley Holder 57001 1605 e Install the crankshaft sensor cover see Crankshaft Sen sor Cover Installation JNO8030BS1 14 36 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection e Remove Seat see Seat Removal in the Hull Engine Hood chap ter e Disconnect the crankshaft sensor lead connector Blue 2 pin A e Set the hand tester A to the x 100 Q range and connect it to the crankshaft sensor lead terminals G and BL Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 B Crankshaft Sensor Resistance Standard 408 612 Q at 20 C 68 F x If there is more resistance than the standard value the sensor has an open lead and must be replaced Much less than this resistance means the sensor is shorted and must be replaced Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Disconnect the crankshaft sensor lead connector A e Set the hand tester A to the x DC 10 V range and con nect the peak voltage adapter B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 C Connections Crankshaft Sensor Peak Voltage Hand Tester
167. ection counter clockwise viewed from stern side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color Grease 6B02046BS1 GB02026B S EFN pee f EN A 8 ves oiL h LT y d 68020218 6020238 Before Servicing GENERAL INFORMATION 1 9 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments Harness Connector Apply dielectric grease A on all connectors of harness B for water resistance Do not apply grease on the only connector of inlet air pressure sensor GBO2062BS1 4B02019BS2 1 10 GENERAL INFORMATION Model Identification JT1500KC Left Side View HOUSE P JT1500KC Right Side View Hull Identification Number HIN Engine Number GENERAL INFORMATION 1 11 General Specifications ems FTISDOKC Engine Type 4 stroke DOHC 4 cylinder water cooled Displacement 1 498 cm 91 4 cu in Bore and Stroke 83 x 69 2 mm 3 27 x 2 72 in Compression Ratio 10 6 1 Maximum Horsepower 112 KW 152 PS 7 500 r min rpm AU 118 KW 160 PS 7 500 r min rpm US Maximum Torque 144 N m 14 7 kgf m 1
168. ed e Remove the ignition key e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect the digital meter to the connector A with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Ignition Coil Input Voltage Connections to ECU Connector For Ignition Coil 1 4 Digital Meter G BL lead terminal 43 Digital Meter Battery terminal For Ignition Coil 2 3 Digital Meter gt G lead terminal 50 Digital Meter Battery terminal e Measure the input voltage to each primary winding of the ignition coils with the engine stopped and with the con nectors joined e Insert the ignition key in the ignition switch to turn it on Input Voltage Standard About Battery Voltage e Remove the ignition key e f the input voltage is within the standard replace the ECU see ECU Removal Installation x If the input voltage is out of the standard check the wiring for continuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 lf the wiring is good replace the ECU see ECU Re moval Installation x lf the wiring is not good replace the main harness FUEL SYSTEM DEI 3 67 Ignition Coils Service Code Character 51 52 COL1 COL2 Ignition Coil Circuit O Gebees DEER 33 E PU R EL er SE BK 8L R BK e ge 25m ll m a R W Il Da E dd 2
169. ed OPush and pull A the hose joint B back and forth more than two times and make sure it is locked x If it does not locked reinstall the hose joint WARNING Gasoline is extremely flammable and can be explo sive under certain conditions To prevent fuel leaks make sure the hose joint is installed correctly on the delivery pipe by sliding the joint JB02003BS1 JRO5012BS1 JRO5024BS1 JRO5025BS1 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Rubber Strap Inspection e Check the following rubber straps for any deterioration or damage Pull on squeeze the straps and look for cracks Battery Straps A Fuel Tank Straps Water Box Muffler Strap lfa strap is damage in any way replace it JRI5BORS P Fuel Hose Replacement WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the fuel hose see Fuel Hose Removal in the Fuel System DFI chapter e Replace the fuel hose with a new one e When installing the fuel hose route the hose according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose avoid sharp bending kink ing flattening or twisting
170. ed into the atmosphere by the exhaust of this engine The fuel ignition and exhaust systems of this engine have been carefully de signed and constructed to ensure an efficient engine with low exhaust pollutant levels Evaporative Emission Control System The evaporative emission control system for this watercraft consists of low permeation fuel hoses Maintenance Proper maintenance and repair are necessary to ensure that watercraft will continue to have low emission levels This Service Manual contains those maintenance and repair recommenda tions for this engine Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards Tampering with Emission Control System Prohibited Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related parts Fuel Pump Spark Plugs Fuel Injectors ECU Foreword This manual is designed pri
171. el Pump Removal in the Fuel System DFI chapter e Wash the fuel pump screen A in non flammable of high flash point solvent Use a soft brush to remove any con taminants trapped in the screens WARNING Gasoline and low flash point solvents are extremely flammable and can be explosive under certain con ditions To prevent a fire or explosion clean the fuel pump screen in a well ventilated area with a high flash point solvent away from any ignition sources including any appliance with a pilot light Throttle Shaft Spring Inspection e Remove Seats see Seat Removal in the Hull Engine Hood chap ter e Check the throttle shaft spring A by pulling the throttle lever lf the spring is damaged or weak replace the throttle body JC11001BS1 JRO5023BS1 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change e Level the watercraft port to starboard as well as fore to aft Level Ground A Side Bumper B Parallel C e Ina well ventilated area start the engine while cooling the cooling system OObtain a standard garden hose and a garden hose adapter see Cooling System Flushing OOpen the front storage compartment cover ORemove the flushing cap A OScrew a garden hose adapter B onto the flushing fitting C OAttach a garden hose D to a garden hose adapter and secure the hose clamp E e Warm up the
172. electric con trol unit replacement Case 4 When replacing the immobilizer amplifier igni tion switch e Prepare a new immobilizer amplifier ignition switch e Refer to the Immobilizer System Parts Replacement NOTE OThe key registration unit is not required B 1 5seconds JN20059BS1 4N20009BS1 14 76 ELECTRICAL SYSTEM Immobilizer System All Keys Initial Registration Flow Chart Pre registration of User Key 1 Pre registration of User Key 2 Regular Registration of User Key Completion of User Key Registration End NOTE 7 Regular Registration of User Key Key Registry Action Se Insert user key and press key during short time or long time NOTE1 ECU checks immobilizer amplifier NOTE 2 2 4 Y Pre registration of User Key 1 3 Y Red warning indicator light LED blinks 4 Registry of user key 1 completed 5 6 e dt 7 Key Registration Waiting Time NOTE 4 y A insert user key 2 and press key during short time or long time b4 ECU checks immobilizer amplifier NOTE 2 Does ECU confirm key 2 code normally NOTE 3 Y Pre registration of User Key 2 Y KA Red warning indicator light LED blinks Registry of user key 2 completed Key Registration Waiting Time NOTE 4 Y Insert user key 2 and press key during short time or long time Y
173. emoval in the Engine Removal In stallation Fuel Pump see Fuel Pump Removal Bracket for Vehicle down Sensor Ignition Coils and Regulator Rectifier see Vehicle down Sensor Re moval e Unhook the fuel tank straps A e Loosen the clamp screw B and remove the hose C 3118077 P e Remove the fuel tank A out of the hull as shown in the figure FUEL SYSTEM DFI 3 113 Fuel Tank Fuel Tank Installation e Installation is the reverse of removal note the following OBe sure the float A in place before putting the fuel tank into the hull Fuel Tank Cleaning WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the tank e Remove the fuel tank see Fuel Tank Removal e Flush the tank repeatedly with high flash point solvent un til it is clean It may be necessary to put a few marbles or pieces of clean gravel into the tank and shake it to knock loose any foreign matter in the bottom Fuel Filler and Hose Removal e Remove the front access cover see Front Access Cover Removal Installation in the Hull Engine Hood chapter e Loosen the fuel filler hose clamp screws A and remove the fuel filler hose B A
174. enance chapter Spark Plug Adjustment e Refer to the Spark Plug Inspection in the Periodic Main tenance chapter Spark Plug Cleaning e Refer to the Spark Plug Inspection in the Periodic Main tenance chapter 14 44 ELECTRICAL SYSTEM Ignition System Ignition System Circuit Zeas gt 32 ag eels te BAS TER x om AS E tes 4 O O 1 Ignition Switch 13 ECU 2 Joint Connector P 12 V 14 Joint Connector E Ground 3 Joint Connector R 12 V 15 Camshaft Position Sensor 4 Vehicle down Sensor 16 Joint Connector M 12 V 5 Joint Connector T 12 V 17 Spark Plugs 6 ECU Main Relay 18 Ignition Coils 7 System Relay 19 Main Fuse 20 A 8 Crankshaft Sensor 20 Battery 9 Joint Connector B Ground 21 Joint Connector Y Ground 10 Joint Connector F 5 V 22 Joint Connector S Ground 11 Joint Connector D 12 V 23 Engine Stop Switch Tether 12 Joint Connector C 12 V ELECTRICAL SYSTEM 14 45 Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery inspection Charge or replace battery Good No good 3 W Repair or replace damaged Ignition system wiring and connector inspection part Good No good Spark Plug inspection Replace spark plug Good No good Ignition coil winding resistance inspection Replace ignition coil Good No good Voltage is less than the specified value Ignition
175. end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V blocks C e Measure the difference in the heights of the arbor above the surface plate over a 100 mm 3 94 in distance on the arbor to determine the amount of connecting rod bend with the connecting rod held vertically and using a height gauge x If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit 0 2 100 mm 0 008 3 94 in Connecting Rod Twist Inspection e On surface plate set the big end arbor A on V block B e Measure the difference in the heights of the arbor C above the surface plate over a 100 mm 3 94 in dis tance on the arbor to determine the amount of connect ing rod twist with the connecting rod held horizontally and using a height gauge x If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance e Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service L
176. enn Ann IN e iii LI Jr e GES IW E Se e EE A T mt It HH SE L e Dear IC IE CH ao H er ij i SON L all El Shi He dal E PE Sch IR wot ENT A R Y R E mire Ey BACH a ims ja tHE ER de Le mm e E me JE E Pt WEIER JC16283BW5 C DFI System FUEL SYSTEM DFI 3 11 Part Names Joint Connector F 5 V Joint Connector D 12 V Joint Connector C 12 V ECU Oil Pressure Switch Joint Connector E Ground Oil Temperature Sensor ISC Idle Speed Controller Throttle Position Sensor Camshaft Position Sensor Exhaust Water Temperature Sensor Immobilizer Kawasaki Diagnostic System Connector Joint Connector M 12 V Spark Plugs Ignition Coils Main Fuse 20 A Joint Connector Y Ground Battery Joint Connector S Ground Starter Motor Joint Connector X 12 V Engine Start Switch Engine Stop Switch Tether Meter Unit Joint Connector Q Ground Ignition Switch Immobilizer Amplifier Joint Connector P 12 V Joint Connector R 12 V Fuel Pump Vehicle down Sensor Joint Connector T 12 V ECU Main Relay Fuel Pump Relay System Relay Crankshaft Sensor Intake Air Pressure Sensor Intake Air Temperature Sensor Injector 1 Injector 2 Injector 3 Injector 4 Joint Connector L 12 V Joint Connector B Ground
177. er General Inspection e Check for binding or sticking throttle steering or shift mechanism The throttle lever must return fully when released e Clean and gap spark plugs see Spark Plug in the Periodic Maintenance chapter e Check all rubber hoses for weathering a cracking or looseness e Check that the drain screw in the stern is securely tight ened e Check the fire extinguisher for a full charge e Check the battery charge if necessary and clean the ter minals Install the battery see Battery Installation in Elec trical System chapter Fuel System e Check and clean or replace the fuel pump screens as nec essary see Fuel Pump Screen Cleaning in the Periodic Maintenance chapter WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the potential for serious burns Make sure the area is well venti lated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Remove the ignition key Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e After refueling and before starting the engine tilt the seat to the rear for several minutes to ventilate the engine com partment WARNING A concentration of gasoline fumes in the engine compartment can cause a fire or explosion To pre vent a fire or explosion remove the seat to vent the engine compartment e Chec
178. er Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to start the engine with the fuel hoses disconnected e Insert the ignition key in the ignition switch to turn it on e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure with Engine Idling Standard 294 kPa 3 0 kgf cm 43 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Remove the ignition key x If the fuel pressure is much higher than specified replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck x If the fuel pressure is much lower than specified check the following Fuel Line Leakage see Fuel Injector Fuel Line Inspec tion Amount of Fuel Flow see Fuel Flow Rate Inspection e After above checks measure the fuel pressure again e Remove the fuel pressure gauge hoses and adapter e Install the removed parts see appropriate chapters e Start the engine and check for fuel leakage Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the potential f
179. er holder e Pull the fuel pump A and rubber holder B through the opening gained after removal of the access hole on the deck 3 106 FUEL SYSTEM DFI Fuel Pump e Loosen the upper side clamp screw A and remove the rubber holder from the fuel pump Fuel Pump Installation e 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 e Pressing down the rubber holder onto the fuel pump e Set the upper side clamp small diameter onto the groove for clamp installation of the rubber holder se curely tighten the upper side clamp screw E Torque Fuel Pump Rubber Holder Clamp Screw 2 9 N m 0 30 kgf m 26 in Ib NOTE Olnstall the rubber holder onto the fuel pump so the rub ber holder top surface F must be below the top surface G of the fuel pump to prevent any water from collect ing on top of the pump JC08019BS2 Fuel Pump FUEL SYSTEM DFI 3 107 e Insert the fuel pump A in the fuel tank B Port Side C Starboard Side D Bow E 45 F e Press down the pump A so thatthe fuel pump completely contacts the top surface of the tank B eSet the lower side clamp large diameter onto the groove for clamp installation of the rubber holder se curely tighten the lower side clamp screw C Torque Fuel Pump Rubber Holder Clamp Screw 2 9 N m 0 30 kgf m 26
180. er name Registration No license plate No Year of initial registration Model Engine No Hull No Date problem occurred Mileage Environment when problem occurred Weather O fine O cloudy O rain O snow O always O other Temperature O hot O warm O cold O very cold O always O other Problem O chronic O often Donce frequency Altitude O normal O high about 1 000 m or more Watercraft conditions when problem occurred FI character O0 Goes on immediately after ignition switch ON and goes off after 2 3 seconds red warning normal indicator O Goes on immediately after ignition switch ON and the FI character and Fl light LED warning indicator on the LCD starts blinking DFI system problem Fl immobilizer warning indicator O Start blinks immediately after ignition switch ON and the service code character and immobilizer warning indicator on the LCD starts blinking immobilizer system problem O Does not go on or blink after ignition switch ON O light up ECU or meter unit replace O starter motor not rotating O starter motor rotating but engine does not turn over O starter motor and engine do not turn over O no fuel flow O no fuel in tank O no fuel pump sound O no spark Engine stalls O right after starting O when opening throttle lever Poor running at low speed O other 3 26 FUEL SYSTEM DFI
181. es off 0 3second synchronizing with the blink of the red warning indicator NS sa light LED LG SS 0 3second JN20058BS1 Regular Registration of User Key e Leave the user key 2 in the ignition switch e Press key for a long time 2 seconds or more OThe ECU confirms the following Receiving signals from immobilizer amplifier are correct The inserted key is the user key 2 NOTE Olf the inserted key is not the user key 2 the key regis tration mode will be end instantaneously Start the pro cedure again pre registration of user key 1 Immobilizer System ELECTRICAL SYSTEM 14 75 e The pre registered keys are registered regularly in the ECU OThe red warning indicator light LED A blinks 1 time for 1 5 seconds and the buzzer sound B goes off 1 time synchronizing with the blink of the red warning indicator light LED e The key registration mode automatically ends NOTE OCheck that the engine can be started using all regis tered user keys Case 3 When the following both keys are faulty or lost FPO Key orange colored SLO Key yellow colored and marked SLO If they are required the following are necessary NOTE OThe ECU must be replaced with a new one because the registration mode can not start in the state with no key e Prepare a new ECU A new FPO key B and new SLO key C NOTE OThe key registration unit is not required OThe key registration process is same as the
182. eseeeseeees 8 6 Coupling Output Shaft iii a A a di 8 7 Couplind Removal cionado ara tases rade T sta tent 8 7 Coupling Installations ss A AAA 8 7 Output Shaft Removal sise 8 7 Output Sha tinstallation z ss niet ne ht one nt RER add 8 8 Coupling Damper Inspection see 8 10 Output Cover Oil Seal Replacement ss 8 10 EI UN ee e EE 8 10 Alternator Cover Bearing Replacement ss 8 10 Ball Bearing Lubricante eeh ed 8 11 Ball Bearing Inspection nce eieeea mee eceeneicaveverseene stents 8 11 Alternator ROTOR ii A en den nn ne em ts 8 12 Alternator Rotor Removal see 8 12 Alternator Rotor Installation ooonoonicoddccnnnonnccnnccocnnncnnocnnonnnonnnnnnnonenonenonincnnnnnnninnninnninnn 8 12 e A TN 8 13 Stator ge UR ue TEE 8 13 Stator Coil Installaton see 8 13 Crankcase Splitting O A A AAA R AA 8 14 Cranikcase Splitting sites dictada squalene At detre tr tente suis 8 14 Crankcase Assembly sienne rata 8 16 Crankshaft and Connecting ROS ss vanne ont malentendus 8 20 Crankshaft Removal incio cial 8 20 El EI gl UE e EE 8 20 Connecting Rod Removal coco ec 8 21 Conn cting Rod Instala a RES ri 8 21 Connecting Rod Bend Inspection sers diri rin 8 25 Connecting Rod Twist INS PECHO iii A A dienes 8 25 Connecting Rod Big End Side Clearance eseeeeeeeeeririrttteeeeertiirtttsssrrinnrnrsssssrrrern rnnt 8 25 Connecting Rod Big End Bearing Insert Crankpin Wear Inspection 8 26 C
183. event fire or explosion from a damaged joint lock do not pry or excessively widen the joint lock ends when removing the fuel hose The joint lock has a retaining edge that locks around the housing e Remove the fuel hose e Cover the pipe A and the hose joint B with the vinyl bags C to avoid becoming dirty NOTE ODo not attempt to check the joint lock with fuel hose re moved from the pipe It will not lock into position unless the hose is attached to the pipe J616153BS1 J616154BS1 J616155BS1 FUEL SYSTEM DEI 3 101 Fuel Line Fuel Hose Installation e Check the joint lock for deformation and wear x If the joint lock is deformed A replace the fuel hose with a new one e Insert the hose joint A securely onto the pipe B and push down the joint lock C e Push and pull A the hose joints B back and forth more than two times and make sure they are locked and don t come off x If it comes off reinstall the hose joint Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove the fuel hose see Fuel Hose Removal 3 102 FUEL SYSTEM DFI Fuel Line e Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel outlet pipe and delivery pipe e Secure the fuel hoses with the clamps e Connect the pressure gauge C to the fuel pressure gauge adapt
184. f 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 38 992 mm 1 53480 1 53512 in O 38 993 39 000 mm 1 53515 1 53543 in G105236BS1 6105041751 A Crankpin Diameter Marks O mark or no mark JH11002B 1 Crankshaft and Connecting Rods ENGINE BOTTOM END 8 27 e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter Big End Cap A Connecting Rod B Weight Mark C A letter of the alphabet Inside Diameter Mark Around Weight Mark D O or no mark NOTE OTighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation OThe mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 42 000 42 008 mm 1 65354 1 65385 in O 42 009 42 016 mm 1 65389 1 65417 in e Select the proper bearing insert in accordance with the combination coding of the connecting rod and crankshaft e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage Connecting Rod Crankpin Bearing Insert
185. f the arcing distance is now normal the trouble is with the spark plug lead Measuring coil resistance If the Coil Tester is not available the coil can be checked for a broken or badly shorted winding with a tester How ever a tester can not detect layer shorts and shorts result ing from insulation breakdown under high voltage e Disconnect the primary leads from the coil terminals e Measure the primary winding resistance as follows A Special Tool Hand Tester 57001 1394 OConnect the hand tester between the coil terminals OSet the tester to the x 1 Q range and read the tester e Measure the secondary winding resistance as follows B ORemove the spark plug leads see Ignition Coil Removal OConnect the hand tester between the secondary lead ter minals OSet the tester to the x 1 kQ range and read the tester Winding Resistance Standard Primary windings 1 44 2 16 Q Secondary windings 11 76 17 64 kQ x If the hand tester does not read as specified replace the coil x If the tester reads are as specified the ignition coil wind ings are probably good However if the ignition system still does not perform as it should after all other compo nents have been checked test replace the coil with one known to be good JNOSO35BS2 C JNOSO33BS1 14 40 ELECTRICAL SYSTEM Ignition System Measuring spark plug lead resistance e Check the spark plug lead A for visible
186. fuel injector does not click check the fuel injector resistance see Fuel Injector Resistance Inspection Fuel Injector Resistance Inspection e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Disconnect the fuel injector connector A e Connect a digital meter to the terminals in each fuel injec tor A e Measure the fuel injector resistance Fuel Injector Resistance Standard About 11 7 12 3 Q at 20 C 68 F x If the reading is out of the standard replace the fuel in jector x lf the reading is within the standard check the power source voltage see Fuel Injector Power Source Voltage Inspection BI P Fuel Injectors FUEL SYSTEM DFI 3 81 Fuel Injector Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Disconnect the injector connector and connect the mea suring adapter A between these connectors as shown in the figure Main Harness B Fuel Injector 1 C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter lead Fuel Injector Power Source Voltage Connections to Adapter For Fuel Injector 1 2 3 4 Digital Meter R injector R W lead Digital Meter Battery terminal e Measure the power source voltage with the engine stopped e Insert the ignition key in
187. g Bolts A ECU Connectors B ECU C ECU Installation e Connect the ECU connectors and install it e Apply a non permanent locking agent to the threads of the ECU mounting bolts and tighten them Torque ECU Mounting Bolts 3 0 N m 0 31 kgf m 27 in Ib NOTE OAfter replacing the new ECU be sure to register FPO key and SLO key see Key Registration in the Electrical System chapter ECU Power Supply Inspection e Remove the front access cover see Front Access Cover Removal Installation in the Hull Engine Hood chapter e Visually inspect the ECU connectors lt the connector is clogged with mud or dust blow it off with compressed air e Remove the ECU see ECU Removal e Visually inspect the terminals A of the ECU connectors x If the terminals of the main harness connectors are dam aged replace the main harness x If the terminals of the ECU connectors are damaged re place the ECU J616329BS1 3 86 FUEL SYSTEM DFI ECU e Remove the ignition key e Disconnect the ECU connectors A e Set the hand tester B to the x 1 Q range and check the following wiring for continuity Special Tool Hand Tester 57001 1394 ECU Grounding Inspection Connections I BK leads ECU E terminal 39 or 48 gt Battery Terminal 11 BK R lead ECU terminal 15 111 Engine Ground lt gt Battery Terminal Criteria Both 0 Q lt gt Battery Terminal If no co
188. g on the output cover and tighten the clamp securely If the hose comes off during operation cooling wa ter could swamp the boat Connect the hose securely to the fitting If you are not confident you can perform storage procedures ask your Kawasaki JET SKi watercraft dealer for this service Preparation for Storage STORAGE 15 3 Bilge System e Clean the bilge system see Bilge System Flushing in the Periodic Maintenance chapter Before reconnecting the hoses to the plastic breather fitting blow air through both hoses A to force all water out of the bilge system Engine Oil e Change the engine oil see Engine Oil Change in the Pe riodic Maintenance chapter Fuel System WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the potential for serious burns Make sure the area is well venti lated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Remove the ignition key Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Drain the fuel tank This should be done with a siphon or pump Siphon Hose A NOTE OLift the stern upward a little so that fuel and water in the bottom of the fuel tank may flow toward the fuel filter to completely drain the fuel tank e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter e
189. g over Disconnect the ground wire first and then the positive When completed with the service first connect the positive wire to the positive terminal of the battery then the negative wire to the neg ative terminal DISASSEMBLY ASSEMBLY 68020248 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Before Servicing GENERAL INFORMATION 1 5 Solvent Use a high flash point solvent when cleaning parts High flash point solvent should be used according to directions of the solvent manufacturer 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 parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or ot
190. g table or an equivalent WARNING Many solvents and adhesives are flammable may be harmful to the skin and eyes and may emit harm ful vapors Read all product warnings before use Use only in a well ventilated area and never near an open flame For this Application Type Mats Synthetic Rubber Front and Rear Seats Gasket Adhesive Front Storage Compartment Cover P N 92104 3701 Gasket Detent Cyanoacrylate Cement Handlebar Grips NOTICE When the cement cures it may be impossible to reposition the part Be very careful that the part is positioned correctly when you apply the cement A WARNING Cyanoacrylate cement is harmful to the eyes and makes skin immediately stick to anything touched To prevent contact with cyanoacrylate cement al ways wear safety goggles and gloves If there is eye contact do not try to wash it out immediately contact a physician In case of skin contact do not touch any other part of your body allow the cement to cure and it will eventually wear off Rubber Parts Location Front Seat Gasket A 13 18 HULL ENGINE HOOD Rubber Parts Rear Seat Gasket A Front Storage Compartment Gasket A Center Storage Compartment Gasket A Center Access Cover Gasket A Mats A Rubber Parts HULL ENGINE HOOD 13 19 Blind Rivet Removal e Drill out the rivet with a drill bit A of the correct size Rivet Re
191. ge 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 ceeded its useful life Replace it Provided however the watercraft s starting system has no problem ELECTRICAL SYSTEM 14 21 Battery 44 DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water and seek medial at tention for more severe burns Interchange A sealed battery can fully display its performance only when combined with a proper watercraft electric system Therefore replace a sealed battery only on watercraft which was originally equipped with a sealed battery Be careful if a sealed battery is installed on watercraft which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection e Refer to Battery Charging Condition Inspection in the Pe riodic Maintenance chapter Refreshing Charge e Remove the battery A see Battery Removal e Refres
192. gent High Strength Loctite 271 equivalent to the stabilizer bolt and tighten them Torque Stabilizer Bolts 15 7 N m 1 6 kgf m 12 ft lb Reboarding Step Removal e Remove the reboarding step bolts A and washers and remove the reboarding step B Reboarding Step Installation e Installation is the reverse of removal e Apply a non permanent locking agent to the reboarding step bolts and tighten them securely 13 16 HULL ENGINE HOOD Hull Replacement To replace the hull remove the various parts in the follow ing suggested order Battery and Pad Exhaust Pipe Intake Manifold Engine and Mounts Air Filter Water Box Muffler Drive Shaft and Shaft Holder Pump and Hoses Steering Cover Handlebar and Steering Steering Cable Reverse Cable Fuel Tank and Filler Bilge and Cooling System Hose Bypass Hose and Outlet Bumpers Engine Hood Latch Front Storage Compartment Cover and Brackets Air Ducts Handrail The following parts cannot be removed from the hull and must be replaced Decals Labels Mats Registration Number if any If the new hull is to be painted do that first Then install removed parts in the reverse order of their removal Finally install the labels decals mats and the registration numbers Rubber Parts HULL ENGINE HOOD 13 17 NOTE OThe rubber parts on the watercraft are fastened in place with various adhesives To replace a rubber part use a cement in the followin
193. gine e Pushing the starter button turn the engine 4 5 seconds to measure the primary peak voltage ODo not operate the starter for longer 5 seconds Wait 15 seconds before using it again e Repeat the measurements 5 times for one ignition coil Ignition Coil Primary Peak Voltage Standard 250 V or more e Repeat the test for the other ignition coil x If the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection lf the ignition coils and crankshaft sensor are normal check the ECU see ECU Power Supply Inspection in the Fuel System DFI chapter Camshaft Position Sensor Removal Installation e Remove Seat see Seat Removal in the Hull Engine Hood chap ter e Cut the band A e Disconnect the camshaft position sensor lead connector B e Remove Camshaft Position Sensor Bolt A Camshaft Position Sensor B e Installation is the reverse of removal Note the following OReplace the camshaft position sensor O ring with a new one OApply grease to the new O ring OApply a non permanent locking agent to the camshaft po sition sensor bolt OTighten Torque Camshaft Position Sensor Bolt 10 N m 1 0 kgf m 89 in lb 14 42 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Inspection e Remove Seat see Seat Removal in the Hull Engine Hood chap ter Camshaft Position Senso
194. gine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area e Install the filler cap e Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Replacement e Remove Intake Manifold see Intake Manifold Removal in the Fuel System DFI chapter e Drain the engine oil see Engine Oil Change e Place a rag or cloth under the oil filter to receive the re maining oil e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 e Replace the filter with a new one e Apply engine oil to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 18 N m 1 8 kgf m 13 ft lb e Pour in the specified type and amount of oil see Engine Oil Change SAE 20W 50 SAE 20W 40 SAE 10W 50 0 SAE 10W 30 T I I 0 10 20 30 40 L 1 32 50 68 86 104 F GSO9010BS1 6605040281 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End cha
195. h charge by following method according to the bat tery terminal voltage NOTICE The battery is a sealed type and never needs to have water added Never remove the strip cap B even during charging or you may damage the battery Never add water Charge the battery with the cur rent and time as stated below 6P09001251 Terminal Voltage 11 5 less than 12 8 V Standard Charge 1 8A x 5 10 h see following chart Quick Charge 90Ax1 0h NOTICE If possible do not quick charge If the quick charge Charge Time h ol y 1 1 1 1 L 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 is done due to unavoidable circumstances do stan dard charge later on Battery Terminal Voltage V GP08021BS1 Terminal Voltage less than 11 5 V Charging Method 1 8 A x 20h 14 22 ELECTRICAL SYSTEM Battery NOTE Olncrease the charging voltage to a maximum voltage of 25 V ifthe 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 Olf the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case Ifthe battery will not accept current after 5 minutes replace the battery Battery A Battery Charger B Standard Value C e Determine battery condition after refreshing charge ODetermine the condition of the bat
196. have a new key or keys registered to ECU If both registered keys have been lost renew the ECU NOTE OSince the immobilizer system uses the electric wave for communication key identification error may occur where other electric waves abound NAS Key Registration Case 1 When the user key has been lost or additional spare user key is required NOTE OBe sure the battery is fully charged e Prepare a new spare user key e Remove the battery cover see Battery Cover Re moval Installation e Disconnect the immobilizer Kawasaki diagnostic system connector A e Connect the key registration unit A Special Tools Key Registration Unit 57001 1582 Key Registration Adapter 57001 1746 B Pre registration of User Key 1 NOTE OKeep the other user key away from the ignition switch e Insert the registered key user key 1 to the ignition switch and press it for a short time within 2 seconds Immobilizer System ELECTRICAL SYSTEM 14 69 Verified OThe ECU confirms the following Receiving signals from immobilizer amplifier are correct The inserted key is the registered one OAIl user key codes in ECU are eliminated e The user key 1 is successfully pre registered in the ECU and ECU starts the key registration mode OThe red warning indicator light LED A blinks 1 time and stops for 1 second and then repeats this cycle NOTE OOnly the first one cycle the buzzer sound B goes off synchroni
197. he big end nuts NOTICE Connecting rod bolts are designed to stretch when tightened reusing them can lead to catastrophic engine failure Never reuse connecting rod bolts See the table below for correct bolt and nut usage Be careful not to overtighten the nuts The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase 1 Bolt Length Measurement Method e Install new bolts and nuts in reused connecting rods e Dent both bolt head and bolt tip with a punch e Apply molybdenum disulfide oil solution to the threads A and seating surfaces B of the connecting rod nuts 6105040481 8 24 ENGINE BOTTOM END Crankshaft and Connecting Rods e Before tightening use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch Connecting Rod A Dent here with a punch B Nuts C Fit micrometer pins into dents D e Apply a small amount of molybdenum disulfide oil solution to the following Threads of Nuts and Bolts Ge Seating Surfaces of Nuts and Connecting Rods e Tighten the big end nuts until the bolt elongation reaches the length specified in the table e Check the length of the connecting rod bolts x If the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in use Bolt Length after _ Bolt Length before _ Bolt Stretch
198. he camshaft with a new one and measure the clearance again x If the clearance still remains out of the limit replace the cylinder head unit Camshaft Runout Inspection e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown xlf the runout exceeds the service limit replace the camshaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in JF03001BS1 ENGINE TOP END 6 17 Camshaft Camshaft Chain Cam Wear Inspection e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft O Cam Height Standard Exhaust 36 143 36 257 mm 1 4229 1 4274 in Intake 36 443 36 557 mm 1 4348 1 4392 in 6E11012281 Service Limit Exhaust 36 04 mm 1 419 in Intake 36 34 mm 1 431 in Camshaft Chain Removal e Remove Camshafts see Camshaft Removal Timing Rotor see Timing Rotor Removal in the Electrical System chapter Exhaust Side Camshaft Chain Guide Bolt Upper A Exhaust Side Camshaft Chain Guide Bolt Lower B Intake Side Camshaft Chain Guide Bolt C Camshaft Chain Guides D e Remove the camshaft chain A from the crankshaft sprocket 6 18 ENGINE TOP END Cylinder Head Cyli
199. he engine more than a few hours it will destroy the crankshaft bearings and damage other internal en gine parts If the watercraft becomes swamped water may enter the engine through the throttle body assy Water may also enter the fuel tank The following procedures explain the necessary steps you must provide Read the summary of the procedure first and then their detailed procedures carefully 9 12 COOLING AND BILGE SYSTEMS After Submerging Summary Procedures after Submerging Remove the drain screws and drain water in the engine compartment Is there water in the air No There is no water box drain caps Yes There is water Remove the caps and drain the water Remove the drain plug of the intake manifold and drain water Remove the spark plugs Crank the engine and discharge water in the engine Refill the fuel tank and fuel line with flesh fuel line with flesh fuel There may be water in the Fuel System Does the engine start after reinstalling the spark plugs Is there water in engine oil Is oil milky Change the oil Run the watercraft in water for at least 10 minutes to dry any remaining water and blow any foreign matter out JI06015B F COOLING AND BILGE SYSTEMS 9 13 After Submerging Detailed Procedures after Submerging 1 Remove the seats see Seat Removal in the Hull En gine Hood chapter 2 Remove the drain screws in the ster
200. he engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Ordinary standard Check e Perform the preliminary check before the ordinary check e Install the removed parts e Launch the watercraft e Start the engine for several minutes e Ride the watercraft and run the engine at about 5 000 rpm for 5 minutes e Stop the engine and let it cool down for 10 minutes e Steady the watercraft in calm water to prevent movement or on the ground keep the watercraft level side to side and fore to aft as much as possible NOTE OSince the trim and list of the watercraft will significantly affect the oil level be sure that the operator and or cargo are not aboard the watercraft when measuring the oil level OAlso make the fuel tank A full if it is not full as shown to keep the watercraft level Fuel Tank Filler Neck B Fuel Pump C Fuel Full Level D OThis measuring procedure with the watercraft afloat should be followed when the oil level is found low and to be added JDO8009BS1 4 14 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Remove the dipstick A wipe it dry and insert it back into the dipstick so that the finger grip is positioned toward the left side B of th
201. he following OAlign the hole A on the handlebars and the line B on the steering shaft holder 12 10 STEERING Handlebars OApply a non permanent locking agent to the handlebar clamp bolts OTighten Torque Handlebar Clamp Bolts 15 7 N m 1 6 kgf m 12 ft Ib OTighten the lower clamp bolt A first and then the upper clamp bolt B OThere will be a gap C at the upper part of the clamp after tightening ORun the cable and wires see Cable Wire and Hose Routing section in the Appendix chapter Olnstall the start stop switch case A and the throttle case B OFit the hole C and the projection D OTighten Torque Start Stop Switch Case Mounting Screws 3 9 N m 0 40 kgf m 35 in Ib Throttle Case Mounting Screws 3 9 N m 0 40 kgf m 35 in Ib Olnstall the handlebar pad OFit the holes A and the bosses B on both sides OAlign the projection A and the groove B STEERING 12 11 Steering Steering Removal e Remove Center Storage Lid see Center Storage Lid Removal in the Hull Engine Hood chapter Side Covers see Side Cover Removal in the Hull Engine Hood chapter Handlebars see Handlebar Removal Plate A Bolts B e Disconnect the shift cable ball joint C e Remove the steering cover nuts A and washers on both sides e Take the steering cover B off the hull e Open the clamp A e Remove Steering Pad A
202. he other hose from the hull bulkhead to the gar den hose turn the water on and flush it out for several minutes e Be sure the small hole A in the breather is open before installation e Install Breathers Bolts Bilge Hoses po P PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Pump and Impeller Impeller Inspection e Remove Impeller see Pump Disassembly in the Pump and Im peller chapter e Visually inspect the impeller A x If there is pitting deep scratches nicks or other damage replace the impeller NOTE OMinor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing Smooth leading edges are especially important to avoid cavita tion Jet Pump Bearing and Seal Inspection e Remove Pump see Pump Removal in the Pump and Impeller chapter e Spin the impeller A lightly and check for smoothly turn roughness binding or noise lf roughness binding or noise is found replace the jet pump bearings B and grease seals C see Pump Dis assembly in the Pump and Impeller chapter NOTE Olt is not necessary to remove the jet pump bearing for inspection Ifthe bearing is removed it will need to be replaced with a new one Steering Steering Cable Shift Cable Inspection e Check the steering cable or shift cable x If each cable or cable housing is kinked or frayed replace the cables x If each seal A at either end of each cable is damaged
203. he throttle opening is correct Idle Speed Standard 1 300 100 r min rpm FUEL SYSTEM DFI 3 41 Throttle Position Sensor Service Code Character 11 tPS e Remove the ignition key e Measure the output voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Output Voltage Standard DC 1 08 1 18 V at idle throttle opening DC 4 38 4 42 V at full throttle opening for reference NOTE OOpen the throttle confirm the output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 08 x 4 75 5 00 1 026 V 1 18 x 4 75 5 00 1 121 V Thus the valid range is 1 026 1 121 V e Remove the ignition key x If the reading is out of the standard check the throttle position sensor resistance see Throttle Position Sensor Resistance Inspection x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Throttle Position Sensor Connector B G W lead ECU terminal 30 C SE BK W lead ECU terminal 32
204. her damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit 68020058 68020048 1 6 GENERAL INFORMATION Before Servicing Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled 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 them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive
205. his section x lf the fuse ignition switch relay and wiring are good re place the ECU see ECU Removal Installation J616331BS1 3 88 FUEL SYSTEM DFI ECU ECU Power Source Circuit EO 5 Ka ex BL R BL o T R W R R 6 R Y R Y BL R En BK SE SR BK BL BK R O D 1 Ignition Switch 9 Joint Connector C 12 V 2 Joint Connector P 12 V 10 Joint Connector E Ground 3 Joint Connector R 12 V 11 Main Fuse 20 A 4 Joint Connector T 12 V 12 Battery 5 ECU Main Relay 13 Starter Motor 6 System Relay 14 Joint Connector Y Ground 7 Joint Connector D 12 V 15 Joint Connector S Ground 8 ECU DFI Power Source FUEL SYSTEM DFI 3 89 Main Fuse Removal e Refer to the Fuse Inspection in the Electrical System chapter Main Fuse Installation x If a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Fuse Inspection in the Electrical System chapter Main Fuse Inspection e Refer to the Fuse Inspection in the Electrical System chapter 3 90 FUEL SYSTEM DFI Throttle Lever Cable and Case Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riod
206. hose Rear Pinch Head Protective Tubes Return Oil Hose Cylinder Oil Pan Oil Separator Tank Hose Oil Separator Tank Oil Pan View from Port Side View from Stern Cooling Hose Cylinder Head Left Water Box Muffler Clamp the starter motor and battery cables with the band Water Pipe Oil Cooler Starter Motor Starter Motor Cable Battery Cable Oil Filter Water Hose Joint Intake Water Hose Joint Outlet Bow View from Starboard Side 16 6 APPENDIX Cable Wire and Hose Routing Cooling Hose Routing AT D K Ss A gt ZE sl CH RER E TA E 7 Sr Sat W 4 S att d 9 O O Gg 3 3 6B09650BW5 C APPENDIX 16 7 Cable Wire and Hose Routing JO O1 amp ND Bypass Outlet Bands Holder Bypass Outlet Hose Cooling Hose Pump Oil Cooler Clamps Oil Cooler Water Pipe on the Cylinder Head Position the clamp screw head as shown Cooling Hose Cylinder Head Water Pipe Joint under the Water Box Muffler Fix the cooling hose and the steering cable with the band Steering Cable Protective Tubes Water Temperature Sensor Position the clamp so that its screw head faces downward and outside Cooling Hose Output Cover Exhaust Pipe Output Cover Cooling Hose Pump Output Cover Oil Pan View from A Cooling Hose
207. hrottle body assy loose Throttle body assy gasket damage Fuel line clogged Intake air pressure sensor trouble 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 Intake air pressure sensor trouble Water temperature sensor trouble Air temperature sensor trouble Fuel line clogged Crankshaft sensor trouble Ignition coil trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Hesitation Too low fuel pressure Clogged fuel line Fuel pump trouble Fuel injector trouble Air temperature sensor trouble Throttle sensor trouble Water temperature sensor trouble Intake air pressure sensor trouble Loose injector connectors Crankshaft sensor trouble Ignition coil trouble Loose terminal of battery lead or engine ground lead Poor acceleration Too low fuel pressure Water or foreign matter in fuel Clogged fuel filter or pump screen Fuel pump trouble Fuel injector trouble Air temperature sensor trouble Water temperature sensor trouble Ignition coil trouble Engine oil level to high S
208. hten Torque Starter Motor Mounting Bolts 8 8 N m 0 90 kgf m 78 in lb JN06050481 Electric Starter System ELECTRICAL SYSTEM 14 25 e Apply a non permanent locking agent to the starter motor ground bolt e Tighten Torque Starter Motor Ground Bolt 8 8 N m 0 90 kgf m 78 in Ib Starter Motor Terminal Nut 8 8 N m 0 90 kgf m 78 in lb e Apply water resistance grease to the ground bolt and the terminal nut Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Take off the starter motor through bolts A and remove both end covers B and pull the armature out of the yoke C e Remove the terminal locknut A and terminal bolt B and then remove the brush with the brush plate C from the yoke Starter Motor Assembly e Apply a thin coat of grease to the oil seal A e Fit the toothed washer B into the end cover e Install the plate cover A and the positive brush assembly B in the yoke C e Tighten the terminal nut D securely E JNOGO11BS1 JNOGO12BS1 14 26 ELECTRICAL SYSTEM Electric Starter System e Holding the spring ends A with suitable plates B put the armature among the brushes e Install the new O rings A and the washers B as shown e Fit the tongue A on the brush plate into the end cover groove B e Replace the starter motor through bolts with new ones e Apply a non
209. i q y Initial 10 Every 25 Every 50 Every 100 RSR Description Hours Hours Hours Hours Inspect throttle control system e e 2 10 Inspect clean air box drain caps oe 2 11 Inspect fuel vent check valve 2 11 Clean fuel pump screen e 2 12 Inspect throttle shaft spring replace throttle e 2 12 body if necessary e Oo Replace engine oil or every 2 13 year Replace engine oil filter o 2 14 Inspect adjust valve clearance e e 2 15 LI Inspect tighten engine mounting bolts or every 2 18 year Inspect replace coupling damper e 2 19 Flush cooling system after each use in salt 2 19 water Flush bilge line and filter 2 20 Inspect impeller blades for damage e 2 21 remove KSE E E E E Initial 25 hours or one year whichever PUMP ng SE comes first then every 50 hours or every 2 21 bearings seals if necessary E year whichever comes first Inspect steering cable shift cable e 2 21 Lubricate handlebar pivot disassemble 2 22 Inspect hull drain plugs replace if e 2 29 necessary Inspect battery charging condition 2 23 Inspect battery terminals 2 23 Inspect spark plugs replace if necessary 2 2 e SS Lubricate throttle cable fitting at throttle 2 24 body Lubricate throttle cable and throttle fitting 2 24 at throttle case Lubricate steering cable shift cable ball joints and steering nozzle reverse bucket 2 24 pivots Inspect all hoses hose clamps nuts bolts o 2 27 and fasteners Replace fuel hose Every 5 years 2 29
210. ic Maintenance chapter Throttle Case Removal Disassembly e Remove the handlebar pad see Handlebar Removal in the Steering chapter e Remove the throttle case OUnscrew the throttle case mounting screws A separate the case halves B e Remove the throttle cable from the case OSlide the rubber boot A and rubber cap B out of the place OUnscrew the throttle cable fitting nut C OUse a screwdriver A to separate the tip B of the cable end from the case body Throttle Lever Cable and Case FUEL SYSTEM DFI 3 91 e Disassemble the throttle case ORemove the circlip A flat washers B pin C throttle lever D and return spring E from the case F Throttle Case Assembly Installation e Insert the end of the return spring A in the throttle lever hole B and set the spring in the throttle case C as shown in the figure e Install the throttle lever to the case e Lubricate the throttle cable before assembly installation OApply water resistance grease to the tips of the throttle cable end e Pulling the throttle cable A set the tip B of the cable end as shown in the figure e Tighten the cable fitting nut e Be sure the rubber cap A is in place on the throttle cable fitting nut end e Cover the cable fitting nut B with the rubber boot C JC05012BS1 3 92 FUEL SYSTEM DFI Throttle Lever Cable and Case e Tighten Torque Throttle Case
211. ical System Spark Plug Type Gap API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 4 0 L 4 2 US at when filter is not removed 4 2 L 4 4 US qt when filter is removed 5 0 L 5 3 US qt when engine is completely dry 0 15 0 24 mm 0 0059 0 0094 in 0 22 0 31 mm 0 0087 0 0122 in NGK CR9EK 0 7 0 8 mm 0 028 0 032 in PERIODIC MAINTENANCE 2 9 Special Tools Oil Filter Wrench Shaft Wrench 57001 1249 57001 1551 ST5712498T ST5715518T 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Control System Inspection e Check the throttle lever free play A Throttle Lever Free Play Standard About 2 mm 0 08 in x lf the free play is incorrect check the throttle cable e Check that the throttle lever moves smoothly from full open to close and the throttle closes quickly and com pletely in all steering positions by the return spring xlf the throttle lever does not return properly check the throttle cable routing cable adjustments and cable dam age Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine with
212. ide Diameter Standard 82 994 83 006 mm 3 2675 3 2679 in Service Limit 83 10 mm 3 272 in Piston Wear Inspection e Measure the outside diameter A of each piston 18 mm 0 71 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard 82 919 82 934 mm 3 2645 3 2651 in Service Limit 82 77 mm 3 259 in Piston Ring Piston Ring Groove Wear Inspection e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 03 0 07 mm 0 0012 0 0028 in Second 0 02 0 06 mm 0 0008 0 0024 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in JF11010BS1 GE16070481 yF11011BS1 JF11008BS1 Cylinder Pistons ENGINE TOP END 6 35 Piston Ring Groove Width Inspection e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top A 0 92 0 94 mm 0 0362 0 0370 in Second B 1 01 1
213. ier sa nn A ta 2 19 Cooling System Flushing si EE 2 19 Bilge Syst m Ce e EE 2 20 Pump and IMmpellSr sn cccccceteccske cocccestectcersaccesdedecshchecccsetuneccahecchsbecksucrtvecentactds EIERE 2 21 ue ele e EE 2 21 Jet Pump Bearing and Seal Inspection 2 21 le EE 2 21 Steering Cable Shift Cable Inspection us 2 21 Handlebar Pivot Lubrication nan rnnnnnnnns 2 22 ell Ge ee RE 2 22 Drain Plug Inspeccion in 2 22 Electrical Syster ire dd rando nan na nn a E ARA een iain 2 23 Battery Charging Condition Inspection ooonoccnnnccncnnnccccnnnananonnnnnncnnnnnnnnnnnnnnnnnnnnannnnnnnno 2 23 Battery Terminals JOER aerer deed add 2 23 Spark Plug Inspechon sise 2 23 L DICA OM a A A desi dt Se PO me agente 2 24 All Hoses Hose Clamps Nuts Bolts and Fasteners Check 2 27 Nuts Bolts and Fasteners Tightness Inspection 2 27 Hose and Hose Connect Inspection 2 22 cece cecceecccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeeeeees 2 27 Rubber Strap Inspection ccccceccccecceccceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeneeeeeeess 2 29 Fuel Hose Replacement ss 2 29 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 Frequenc it
214. imit 0 6 mm 0 024 in x If the clearance exceeds the service limit replace the con necting rod with a new one and then check clearance again If clearance is too large after connecting rod re placement the crankshaft also must be replaced 6105040681 G105331BS1 8 26 ENGINE BOTTOM END Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert Crankpin Wear Inspection e Measure the bearing insert crankpin A clearance with a plastigage B NOTE OTighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation ODo not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 041 0 071 mm 0 0016 0 0028 in Service Limit 0 11 mm 0 0043 in If clearance is within the standard no bearing replace ment is required lf clearance is between 0 072 mm 0 00284 in and the service limit 0 11 mm 0 0043 in replace the bear ing inserts A with inserts painted green B Check insert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x If the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 38 984 39 000 mm 1 53480 1 53543 in Service Limit 38 97 mm 1 5342 in x I
215. ined at the factory in the assembled state so the crankcase halves must be replaced as a set e With high flash point solvent clean off the mating sur faces of the crankcases halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves e Replace the O ring with a new one e Install Crankshaft and Connecting Rods A see Crankshaft y Installation P i E Dowel Pins B gt AS D ke Oil Passage Pipe C with New O ring Oil Seal D OApply grease to the new O ring e Check to see that the oil seal A is in the groove B of the crankcase ENGINE BOTTOM END 8 17 Crankcase Splitting e Apply liquid gasket A to the mating surface of the lower crankcase half NOTE OMake the application finish within 30 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket Sealant Liquid Gasket TB1215 92104 1065 Do not apply liquid gasket around the crankshaft main bearing inserts B and oil passage hole C SS EN e WS N O Wi 240 f alii 1 LE Gx H y Uy ESE A s O L L H A H d dir PEL lo H SI Ap E IO EJ O GR amp JH10006BW2 e Apply molybdenum disulfide oil solution to the bolt
216. ing inserts are installed e Fit the crankshaft main bearing inserts on the upper A and lower B crankcase halves 1 5 Bearing Inserts no Groove same part 2 4 Bearing Inserts Groove same part 3 Bearing Insert no Groove NOTE OBe sure the bearing inserts are seated in the saddles and the tangs in the bearing inserts are aligned with the notches in the saddles e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Fit the thrust washers A to both sides of the upper crankcase 3 main bearing B Olnstall the thrust washer so that the oil grooves C face outward 326110012 P ENGINE BOTTOM END 8 21 Crankshaft and Connecting Rods e Fit the oil seal A into the groove B of the crankcase e Assemble the crankcase see Crankcase Assembly Connecting Rod Removal e Split the crankcase see Crankcase Splitting e Remove the connecting rod nuts A e Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the connecting rods from the crankshaft Connecting Rod Installation A WARNING Gasoline and low flash point solvents are extremely flammable and can be explosive under certain con ditions To prevent a fire or explosion clean the crankshaft bolts nuts and connecting rods in a well ventilated area with a high fla
217. inyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODO not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container MEO2112BS1 GPO8139BS1 fo TS 6P090007S1 Battery ELECTRICAL SYSTEM 14 19 e Check the electrolyte flow x If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times NOTE OBe careful not to have the battery fall down e Keep the container in place Don t remove the container from the battery the battery requires all the electrolyte from the container for proper operation Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the container until it is completely empty e After filling let the battery sit for 20 60 minutes with the electrolyte container kept in place which is required for the electrolyte to fully permeate into the plates e Make sure that the container cells have em
218. ion key in the ignition switch to turn it on Output Voltage Standard About DC 3 5 4 0 V at 20 C 68 F NOTE OThe output voltage changes according to the oil temper ature in the engine FUEL SYSTEM DEI 3 73 Oil Temperature Sensor Service Code Character 73 OILt e Remove the ignition key lf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation sl the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Oil Temperature Sensor Connector B Y lead ECU terminal 13 C BK W lead ECU terminal 32 D x If the wiring is good check the oil temperature sensor re sistance see Oil Temperature Sensor Resistance Inspec tion J616320BS1 Oil Temperature Sensor Resistance Inspection e Refer to the Oil Temperature Sensor Inspection in the Electrical System chapter x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Oil Temperature Sensor Circuit O JC163218 2 1 ECU 2 Oil Temperature Sensor 3 Joint Connector B Ground 3 74
219. itch Removal ss 4 26 Oil Pressure Switch Installation 0aeaeneenaenennennnnnernnnnennnnnnnerrrrrnnrenernrnnrnrrnrinnernrnrrnrrnrrnne 4 26 4 2 ENGINE LUBRICATION SYSTEM Exploded View JDO2036BW5 C Exploded View ENGINE LUBRICATION SYSTEM 4 3 No Breather Plate Bolts Oil Filler Cap Oil Cooler Assembly Bolts Oil Pressure Switch Oil Cooler Positioning Bolt Fastener _ mi O Nm kom mp 7e os em pin Cre oso mb e pis TS Oil Passage Bolt Oil Filter 13 COIN OD Oil Passage Joints 97 in lb Oil Passage Plugs R3 8 15 Oil Passage Plug R1 4 69 in lb Oil Separator Tank Mounting Nuts 43 in lb Dipstick Tube Bolts 78 in lb Oil Pump Sprocket Bolt 12 Oil Pump Cover Bolts 69 in lb Oil Pressure Relief Valve 11 Oil Pump Body Plug 15 Oil Pump Body Bolts 69 in lb 18 Oil Screen Bolts 0 80 69 inlb 19 Oil Catch Cover Bolts 0 80 69 inlb 20 Oil Pan Bolts 2 0 15 EO Apply engine oil G Apply grease L Apply a non permanent locking agent LN Apply a non permanent locking agent High Strength Loctite 271 equivalent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 4 4 ENGINE LUBRICATION SYSTEM Engine
220. ition Coil Mounting Bolts 8 8 0 90 78 mb L PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Meter Unit Mounting Bolts Oil Temperature Sensor Regulator Rectifier Bolts Relay Mounting Bolts 22 in lb Rubber Grommet Holder Screws 40 in lb Spark Plugs 115 in lb Speed Sensor Mounting Screws 35 in lb Starter Motor Ground Bolt 78 in lb Starter Motor Mounting Bolts 78 in lb Starter Motor Terminal Nut 78 in lb Starter Motor Through Bolts y 57 in lb Starter Relay Terminal Bolts a 49 in lb Stator Coil Bolts 106 mb Stator Coil Grommet Holder Plate Bolts 78 in lb Timing Rotor Bolt E 15 Vehicle down Sensor Mounting Screws 13 in lb Water Temperature Sensor 11 Water Temperature Sensor for Meter Unit 78 in lb The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners stainless bolt and nut Threads Diameter Torque mm N m kgf m ft Ib 0 60 0 90 52 78 in lb 12 16 31 42 22 30 2 8 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Lever Free Play About 2 mm 0 08 in Engine Lubrication System Engine Oil Type Viscosity Capacity Engine Top End Valve Clearance Intake Exhaust Electr
221. k Plug Lead Length 600 mm 23 6 in D e Apply a non permanent locking agent to the ignition coil mounting bolts E e Install the ignition coils F to the bracket G BK W Leads H R Leads I e Tighten Torque Ignition Coil Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib e Apply a non permanent locking agent to the bracket bolts e Tighten Torque Bracket Bolts 8 8 Nm 0 90 kgf m 78 in Ib 13 4 in A 17 7 in B PR LR JNO8099BW2 C Ignition System ELECTRICAL SYSTEM 14 39 Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance e Remove the ignition coil see Ignition Coil Removal e Connect the ignition coil A with the spark plug cap left installed on the spark plug lead to the tester B and mea sure the arcing distance Auxiliary Wires C WARNING To avoid extremely high voltage shocks do not touch the coil body or leads 3 Needle Arcing Distance Standard 7 mm 0 28 in or more x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective e To determine which part is defective measure the arcing distance again with the spark plug leads removed from the ignition coil see Ignition Coil Removal x If the arcing distance is subnormal as before the trouble is with the ignition coil itself I
222. k for fuel leaks Repair if necessary e Check the engine oil level Fill the oil with the specified oil STORAGE 15 7 Removal from Storage Test Run DANGER Exhaust gas contains carbon monoxide a color less odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area e Start the engine and run it only for 15 seconds Check for fuel oil and exhaust leaks Any leaks must be repaired Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water e Install the seat making sure it is locked APPENDIX 16 1 Appendix Table of Contents Cable Wire and Hose Routing cts DA A Maas ieee nee 16 2 it EE 16 26 Cable Wire and Hose Routing 16 2 APPENDIX Oil Hose Routing a AAA lt poo PESE UU o4 TD K ER i E Zi KS QuE a AR AS m Gm dar Wen AND ala EL Ges KL on CR ey 7 Sata i Sech Jet W LAA NUL ay ET V k LA Ser AN A QUE d JB09648BW5 C APPENDIX 16 3 Cable Wire and Hose Routing JO O1 amp ND Throttle Cable Delivery Pipe Fix the main harness a
223. kO 100 C 212 F 0 9025 1 142 kQ x lf the digital meter does not show the specified values replace the sensor Oil Temperature Sensor Removal Installation e Refer to the Oil Temperature Sensor Removal Installation in the Fuel System DFI chapter JN10103BS2 14 54 ELECTRICAL SYSTEM Sensors Oil Temperature Sensor Inspection e Remove the oil temperature sensor see Oil Tempera ture Sensor Removal Installation in the Fuel System DFI chapter e Suspend the sensor A in a container of water so that the threaded portion is submerged e Suspend an accurate thermometer B with temperature sensing portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently e Measure the internal resistance of the sensor with a digital meter OThe sensor sends electric signals to the ECU OMeasure the resistance across the terminals and the body for the gauge at the temperatures shown in the table Oil Temperature Sensor Resistance Oil Temperature Sensor Resistance 20 C 68 F 12 17 13 92 kO 50 C 122 F 4 025 4 810 kQ 90 C 194 F 1 182 1 481 kO 100 C 212 F 0 9025 1 142 kO x If the digital meter does not show the specified values replace the sensor Water Temperature Sen
224. ke sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name JT1500K YTX20L BS Each battery comes with its own specific elec trolyte container using the wrong container may overfill the battery with incorrect electrolyte which can shorten battery life and deteriorate battery per formance Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type GPO8135BS1 14 18 ELECTRICAL SYSTEM Battery Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume 44 DANGER Sulfuric acid in battery electrolyte can cause severe burns To prevent burns wear protective clothing and safety glasses when handling electrolyte If the electrolyte comes in contact with your skin or eyes wash the area with liberal amounts of water and seek medical attention for more severe burns e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge e Remove the electrolyte container from the v
225. ket Mounting Bolts M6 9 8 1 0 87 mb L Pump Bracket Mounting Bolts M8 19 1 9 14 LN SS Pump Cap Bolts 3 9 0 40 35 in lb L Pump Cover Mounting Bolts 7 8 0 80 69 in lb L Pump Mounting Bolts 36 3 7 27 L Pump Outlet Mounting Bolts 19 1 9 14 E Pump Shaft Nut 98 10 72 Steering Cable Joint Bolt 9 8 1 0 87 mb L Steering Nozzle Pivot Bolts 19 1 9 14 L Steering Adjustable Steering Holder Nut 4 9 0 50 43 in lb Handlebar Clamp Bolts 15 7 1 6 12 LS Reverse Bucket Pivot Bolts 19 1 9 14 LN Start Stop Switch Case Mounting Screws 3 9 0 40 35 mb Shift Cable End Nut 9 8 1 0 87 in lb Shift Cable Nut 39 2 4 0 29 Steering Cable Bracket Bolts 9 8 1 0 87 mb L Steering Cable Joint Bolt 9 8 1 0 87 in lb L Steering Cable Nut 39 2 4 0 29 Steering Holder Mounting Nuts 19 6 2 0 14 Steering Neck Mounting Bolts 15 7 1 6 12 L Steering Shaft Locknut 29 4 34 3 3 0 3 5 22 25 Steering Shaft Nut 2 9 0 30 26 in lb Throttle Case Mounting Screws 3 9 0 40 35 in lb Hull Engine Hood Bracket Bolts 8 8 0 90 78 mb L Front Hatch Mounting Screws 2 0 0 20 18 in lb AD Handrail Mounting Screws 4 0 0 41 35 mb Handrail Plate Nuts 9 8 1 0 87 in lb L Latch Handle Screws 2 0 0 20 18 in lb Seat Lock Ratchet Pins 27 2 8 20 L Stabilizer Bolts 15 7 1 6 12 LN Electrical System Bracket Bolts 8 8 0 90 78 mb L Camshaft Position Sensor Bolt 10 1 0 89 in lb L Crankshaft Sensor Cover Bolts 7 8 0 80 69 in lb Crankshaft Sensor Screws 4 5 0 46 40 in lb L ECU Mounting Bolts 3 0 0 31 27 in lb L Ign
226. l Sensor Resistance Standard Full position 2 4 Q Empty position 117 123 Q x If the tester readings are not as specified or do not change smoothly according as the float moves up and down replace the sensor Water Temperature Sensor Removal Installation e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter JN10102BS2 4N10086BS1 Sensors ELECTRICAL SYSTEM 14 53 Water Temperature Sensor Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter e Suspend the sensor A in a container of water so that the threaded portion is submerged e Suspend an accurate thermometer B with temperature sensing portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently e Measure the internal resistance of the sensor with a digital meter OThe sensor sends electric signals to the ECU OMeasure the resistance across the terminals and the body for the gauge at the temperatures shown in the table Water Temperature Sensor Resistance Water Temperature Sensor Resistance 20 C 68 F 12 17 13 92 kO 50 C 122 F 4 025 4 810 kO 90 C 194 F 1 182 1 481
227. le Body Assy Throttle Valve Bore ECU Make Type Fuel Pressure High Pressure Line Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Throttle Position Sensor Input Voltage Output Voltage Resistance Intake Air Pressure Sensor Input Voltage Output Voltage Intake Air Temperature Sensor Output Voltage Resistance Water Temperature Sensor Output Voltage Vehicle down Sensor Input Voltage Output Voltage Oil Temperature Sensor Output Voltage Throttle Lever and Cable Throttle Lever Free Play 1 300 100 r min rpm both in and out of water Single type p60 mm 2 36 in Mitsubishi Electric Digital memory type with built in IC igniter sealed with resin 294 kPa 3 0 kgf cm 43 psi with engine idling Impeller type 83 mL 2 8 US oz or more for 3 seconds INP 281 Fine atomizing type with 4 holes About 11 7 12 3 Q at 20 C 68 F DC 4 75 5 25 V DC 1 08 1 18 V at idle throttle opening DC 4 38 4 42 V at full throttle opening for reference 4 6kO DC 4 75 5 25 V DC 3 75 4 25 V at standard atmospheric pressure 101 32 kPa 76 cmHg About DC 2 25 2 50 V at 20 C 68 F 5 4 6 6 KQ at 0 C 32 F 0 29 0 39 kQ at 80 C 176 F About DC 3 5 4 0 V at 20 C 68 F DC 4 75 5 25 V With sensor tilted 110 130 or more right or left DC 0 65 1 35 V With sensor arrow mark pointed up DC 3 55 4 45 V About DC 3 5 4 0 V at 20 C 6
228. ll Engine Hood chapter e Disconnect the shift cable ball joint A at upper end e Unscrew the shift lever bolt B and remove the shift lever C AOTBOS P JLO7006BS1 STEERING 12 21 Reverse System e Lift up the steering cover A see Steering Removal e Remove Bolts B Washer C Collars D Shift Lever Holder E Shift Lever Bracket F Shift Lever Shaft G e Installation is the reverse of removal Note the following OAlign the slot A on the shift lever shaft with the projection B on the shift lever OApply a non permanent locking agent Hight Strength Loctite 271 equivalent to the shift lever bolt OBefore connecting the shift cable apply a wa ter resistance grease to its joint ball 1078054 P Olnspect the reverse lever A is properly locked B to for ward OAdjust the position if necessary see Shift Cable Adjust ment HULL ENGINE HOOD 13 1 Hull Engine Hood Table of Contents EXPplOdOd WE 13 2 LEE 13 6 ele E 13 7 Seat REMOVAL eiii a a a 13 7 Seat Installation cueca aiii 13 7 Front Storage Compartment Cover Removal lnstallation seeeesseeeeeeeeeeeeeeene eneen 13 8 Front Storage Compartment Cover Disassembly ooooocococccccccccccccconcnononcnccccnnnnnn nn nc ccnnnnnnn 13 8 Front Storage Compartment Cover Assembly 13 9 Front Cover Removal Installation ss 13 10 Center Storage Lid Removal lnstallation
229. lug wrench A vertically Owner s Tool Spark Plug Wrench 16 mm 92110 1145 6PO80108S1 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Visually inspect the spark plugs xlf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the spark plug e Measure the gap D with a wire type thickness gauge x If the gap is incorrect replace the spark plug Spark Plug Gap 0 7 0 8 mm 0 028 0 032 in e Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench A and finger tighten it first Owner s Tool Spark Plug Wrench 16 mm 92110 1145 Tightening the spark plug with the wrench at an an gle may break the spark plug insulator To avoid breaking the insulator be sure the wrench fits firmly on the plug at a right angle e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib e Be sure to install the plug caps so that the plug cap leads are positioned at a right angle to the engine center line see Cable Wire and Hose Routing section in the Appen dix chapter e Be sure the spark plug caps are installed by pulling up it lightly Lubrication As in all marine craft adequate lubrication and corrosion protection is an absolute necessity to provide long reliable service Refer to the Periodic Maintenan
230. ly 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 Battery voltage low Starter relay not contacting or operating Start button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Immobilizer system trouble Starter motor rotating but engine doesn t turn over Reduction gear trouble Vehicle down sensor DFI coming off Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Camshaft seizure No fuel flow No fuel in tank Fuel tank air vent obstructed Fuel pump screen and or fuel filter clogged Fuel injector trouble Fuel line clogged Engine flooded Clean spark plug and adjust plug gap Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood be cause more fuel is supplied automatically by DFI No spark spark weak Ignition coil faulty Vehicle down sensor DFI coming off Vehicle down sensor trouble Ignition switch turned OFF and or lanyard key not pushed under stop button Battery voltage low Spark plug dirty broken or gap malad justed Ignition coil shorted or not in good contact Ignition coil trouble Spark plug incorrect Spark plug cap trouble Spark pl
231. m h E Ib LCD LED min mph OZ Pa PS psi qt rpm SLO TDC TIR V W Q Kawasaki Diagnostic System kilometers per hour liter s pound s Liquid Crystal Display Light Emission Diode meter s minute s miles per hour newton s ounce s pascal s horsepower pound s per square inch quart s revolution revolution s per minute second s Smart Learning Operation top dead center total indicator reading volt s watt s ohm s COUNTRY AND AREA CODES Australia us Europe United States MAINTENANCE AND ADJUSTMENTS Maintenance replacement or repair of the emission control devices and systems may be performed by any marine SI engine repair establishment or individual EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GRADE GASOLINE ONLY with an octane rating equal to or higher than that shown below Minimum Octane Rating Antiknock Index 87 Research Octane Number RON 91 The Antiknock Index is an average of the Research Octane Number RON and the Motor Octane Number MON Emission Control Information To protect the environment in which we all live Kawasaki has incorporated an exhaust emis sion control system in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Exhaust Emission Control System This system reduces the amount of pollutants discharg
232. malfunction relay 57 is stuck The ECU slows down the engine 71 Engine overheat speed less than 3 000 r min rpm by controlling the ignition The ECU slows down the engine 72 Engine oil pressure too low speed less than 3 000 r min rpm by controlling the ignition Oil temperature sensor The ECU sets the oil temperature 73 malfunction wiring open or at 60 C The ECU slows down the short engine speed less than 3 000 r min rpm by controlling the ignition Self Diagnosis FUEL SYSTEM DFI 3 37 Service Code Character displayed on Meter Unit Problems ECU main relay malfunction Backups by ECU wiring is open or relay is stuck Engine oil overheat The ECU slows down the engine speed less than 3 000 r min rpm by controlling the ignition Note 1 D J Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum intake air pressure sensor output volt age and engine speed crankshaft sensor output voltage This method is called D J method 2 a N Method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle position sensor output voltage and the engine speed This method is called a N method 3 38 FUEL SYSTEM DFI Throttle Position Sensor Service Code Character 11 tPS Th
233. marily 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 understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your JET SKi watercraft e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Us
234. moval Drill Bit Size 5 0 mm 0 2 in NOTE OStop drilling when the rivet head B starts to turn with drill bit OTap the rivet out with a suitable punch and hammer Blind Rivet Installation e Secure the parts to the hull with the rivets using a blind rivet fastening tool A Front Bumper Removal e Remove the plugs A e Remove the mounting bolts B nuts C and washers D e Drill out the rivets E and washers F see Blind Rivet Removal e Remove the front bumper G Front Bumper Installation e Secure the front bumper to the hull flange with the rivets see Blind Rivet Installation Rear Bumper Removal e Remove the corner bumpers A and trim strip B ORemove the plugs C ODrill out the rivets D and washers E see Blind Rivet Removal e Remove the rear bumper F Rear Bumper Installation e Secure the bumpers to the hull flange with the rivets see Blind Rivet Installation JMO5019BS1 JMO5020BS1 13 20 HULL ENGINE HOOD Rubber Parts Side Bumper Removal e Remove the plugs A e Drill out the rivets B and washers C see Blind Rivet Removal e Remove the corner bumper D e Remove the trim strip A from the side bumper B e Drill out the rivets see Blind Rivet Removal e Remove the side bumper Side Bumper Installation e Secure the side bumpers to the hull flange with the rivets see Blind Rivet Installation e Install the trim strip Ai
235. mperature of the oil while stirring the oil gently bg mio P JN10105BS2 ELECTRICAL SYSTEM 14 57 Sensors e Measure the internal resistance of the sensor with a digital meter OThe sensor sends electric signals to the meter unit OMeasure the resistance across the terminals at the tem peratures shown in the table Air Temperature Sensor for Meter Unit Resistance Oil Temperature Sensor Resistance 20 C 68 F 12 17 13 92 kQ 50 C 122 F 4 025 4 810 kO 90 C 194 F 1 182 1 481 kO 100 C 212 F 0 9025 1 142 kQ lf the digital meter does not show the specified values replace the sensor 14 58 ELECTRICAL SYSTEM Multifunction Meter Meter Unit Removal e Remove Front Access Cover see Front Access Cover Removal in the Hull Engine Hood chapter Steering Cover see Steering Removal in the Steering chapter Rivets A e Disconnect the meter unit lead connectors Blue 2 pin A Blue 4 pin B Yellow 4 pin C Black 2 pin D Green 2 pin E e Remove Nuts A Plate B Grommet C e Remove Bolts A Washers and Collars B Meter Unit C Meter Unit Installation e Installation is the reverse of removal Note the following OBe sure the nuts A collars B rubber dampers C and the washers D are in place OApply a non permanent locking agent to the meter unit mounting bolts E OTighten Torque Meter Uni
236. n In case of seri ous troubles ECU stops the injection ignition starter motor operation NOTE OThe buzzer sound can be stopped by pushing either SET F or MODE G button J616285BS1 4016291BS2 3 32 FUEL SYSTEM DFI Self Diagnosis Dealer Mode The LCD Liquid Crystal Display display the service code character s A to show the problem s which the DFI sys tem ignition system and immobilizer system has at the mo ment of diagnosis Self diagnosis Procedures OWhen a problem occurs with the DFI system ignition sys tem and immobilizer system the warning indications are as follows DFl Ignition System FI Character Red Warning FI Warning A Service Code Indicator Light Buzzer Characters LED By ___ indieater Blinks Goes on Blinks Sounds Immobilizer System Red Warning Immobilizer Indicator Light Warning Buzzer Service Code Characters D LED Indicator E Blinks Blinks Blinks Sounds NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the character indicator light and indicators do not go on or blink very slowly 4016292BS2 JC16286BS2 Self Diagnosis FUEL SYSTEM DFI 3 33 e Insert the ignition key in the ignition switch to turn it on Olf the immobilizer system has trouble the service code character is displayed immediately on th
237. n the vehicle down sensor operates and the ECU shuts off the fuel pump relay fuel injectors and ignition system To start the engine again raise the watercraft remove the ignition key and then ON Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them 3 22 FUEL SYSTEM DFI Troubleshooting the DFI System e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors A have seals B including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set C Insert the needle adapter inside the seal until the needle adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 If the needle adapter is inserted at an angle it may create a short circuit between the terminals and damage the electrical system To avoid a short circuit insert the needle adapter straight along the terminal in the connector e Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Insert the ignition key in the ig
238. n Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your JET SKi watercraft dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2011 Kawasaki Heavy Industries Ltd First Edition 0 Jul 25 2011 LIST OF ABBREVIATIONS ABDC AC Ah ATDC BBDC BDC BTDC C cmHg cu in DC DFI ECU E FPO ft gal AU EUR ampere s after bottom dead center alternating current ampere hour after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius centimeters of mercury Cubic inch s direct current Digital Fuel Injection Electronic Control Unit farad s degree s Fahrenheit Full Power Operation foot feet gram s gallon s hour s horsepower s Integrated Circuit inch s Idle Speed Control KDS k
239. n caps B x If there is water in the caps remove the caps and dis charge the water NOTE OBe sure to have a rag or cloth underneath for possible oily water Air Box Inspection and Cleaning e Remove Air Box see Air Box Removal in the Fuel System DFI chapter Flame Arrester A see Air Box Disassembly in the Fuel System DFI chapter e Clean the flame arrester A e Visually inspect the flame arrester for damage x If necessary replace it with a new one Fuel Vent Check Valve Inspection The fuel vent check valve is mounted in the fuel tank vent hose to prevent fuel from spilling during riding Air can flow into the tank to allow fuel to be drawn out by the fuel pump but fuel cannot flow out the check valve e Remove the center access cover see Center Access Cover Removal Installation in the Hull Engine Hood chapter e Cut off the bands A e Pull out each end of the fuel vent check valve B from the vent hoses C 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Blow through the fuel vent check valve from each end x If the check valve will allow air to flow as shown it is OK x If air will flow through the check valve in both direction or in neither direction the check valve must be replaced e The fuel vent check valve A must be mounted so that the arrow B on its case is pointing toward the fuel tank Fuel Pump Screen Cleaning e Remove the fuel pump see Fu
240. n hose to a faucet Do not turn on the water until the engine is running and turn it off immediately when the engine stops The engine requires 2 4 L min 2 5 qts min at 1 800 rpm and 7 0 L min 7 4 qts min at 6 000 rpm NOTICE Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water An excessive supply of cooling water may cause the engine to stop and flood the cylinders creating the potential for hydraulic lock which causes severe engine damage To prevent engine damage when using an auxiliary cooling supply shut the water off immediately if the engine stops running 1 4 GENERAL INFORMATION Before Servicing Rolling to the right side can cause water in the exhaust system to run into the engine with possible engine damage To prevent engine damage always turn the boat on its left side JB02024B 1 C Rolling the capsized watercraft counterclockwise to its STARBOARD side can cause wa ter in the exhaust system to run into the engine with possible engine damage Always turn the capsized boat clockwise so that the PORT side always faces downward JB02025B 1 C Battery Ground Before completing any service on the watercraft discon nect the battery wires from the battery to prevent the engine from accidentally turnin
241. n the water or breather oil when changing engine oil Wio P ENGINE LUBRICATION SYSTEM 4 19 Oil Pan Oil Pan Removal e Remove Engine Oil drain see Engine Oil Change in the Periodic Maintenance chapter Engine see Engine Removal in the Engine Removal In stallation chapter e Turn the engine to the side e Cut the band A e Remove the dipstick tube bolts B and pull out the dipstick tube C e Remove Clamps A and Hoses B Oil Pan Bolts C Oil Pan D Oil Pan Gasket 4 20 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation e Replace the oil pan gasket with a new one e Install the oil pan A e Tighten the oil pan bolts following the tightening sequence 1 20 Torque Oil Pan Bolts 20 N m 2 0 kgf m 15 ft lb e Apply grease to the O ring A on the dipstick tube B e Apply a non permanent locking agent to the dipstick tube bolts e Tighten the dipstick tube bolts temporary OFirst tighten the oil pan side bolts ONext tighten the cylinder head side bolts Torque Dipstick Tube Bolts 8 8 N m 0 90 kgf m 78 in Ib e When installing the oil passage joints A to the oil pan B note the following as shown in the figure Parallel C Oil Passage Joint and Bottom Surface of Oil Pan Do nat protrude the oil passage joint from the oil pan D e Apply a non permanent locking agent to the oil passage joints and tighten them Torque Oil Passage Joints 11 N
242. n to drain water out of the engine compartment 3 Check the air box A for water inside with its drain caps B 4 If you see water in the caps remove the caps and discharge the water Be sure to have a rag or cloth underneath for possible oily water 5 Remove the drain plug A of the intake manifold B and discharge water if any into a rag or cloth 6 Disconnect both two connection on the ignition coil primary lead connectors A 7 Pull and remove all the spark plug caps 8 Remove all spark plugs see Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter 9 Insert the ignition key in the ignition switch to turn it on push the lanyard key under the stop button and push the start button 10 If there is any water in the engine it will be pumped out of the spark plug holes Do not operate the starter for longer than 5 seconds Wait 15 seconds before using it again Be sure that all the water is out of the engine 11 Spray the spark plugs clean and install them with their plug caps WARNING A water and gasoline mixture will be forcibly ejected from the spark plug holes and could injure your eyes To prevent eye injury do not lean over the engine when performing this procedure If gas does get in your eyes immediately wash them with plenty of clean fresh water and consult a physician as soon as possible 9 14 COOLING AND BILGE SYSTEMS After Submerging 12 Reconne
243. nce WG Apply water resistance grease 12 4 STEERING Special Tools Nut Tightening Plate Box Wrench 27 mm 57001 1698 57001 1749 D ECO ST571698ST ST571749ST STEERING 12 5 Steering Cable Steering Cable Adjustment e Check the steering cable adjustment e Center the handlebars A in the straight ahead position e Check that the steering nozzle A is centered in the pump cavity Same Distance B x If the nozzle position is incorrect adjust the steering ca ble e Loosen the locknut A of the steering cable e Take out the steering cable joint bolt B and disconnect the cable joint C from the steering nozzle e Center the handlebars in the straight ahead position e Turn the cable joint to adjust the steering e Temporarily tighten the cable joint bolt and check the ca ble adjustment again e When adjustment is correct unscrew the cable joint bolt and apply a non permanent locking agent to it And tighten the cable joint bolt and the steering cable locknut securely Torque Steering Cable Joint Bolt 9 8 N m 1 0 kgf m 87 in Ib e As an additional check turn the handlebars all the way to the left and right and measure the distance between the nozzle and the edge of the pump cavity It should be equal at both extremes Steering Cable Removal e Remove Steering Cover see Steering Removal Center Access Cover A 12 6 STEERING Steering Cable
244. nce Inspechon ECU Main Relay Service Code Character 75 rEL ECU Main Relay Removal Installation ECU Main Relay Inspection Engine Oil Overheating Service Code Character 76 OILH Red Warning Indicator Light LED Light LED Inspection Fuel Injectors s Fuel Injector Removal Fuel Injector Installation Fuel Injector Audible Inspection Fuel Injector Resistance Inspection Fuel Injector Power Source Voltage Inspection Fuel Injector Output Voltage Inspection Fuel Injector Fuel Line Inspection Eesen ECU Identification ECU Removal ECU Installation ECU Power Supply Inspection DFI Power Source Main Fuse Removal Main Fuse Installation Main Fuse Inspection Throttle Lever Cable and Case Free Play Inspection Free Play Adjustment Throttle Case Removal Disas 3 68 3 68 3 70 3 71 3 72 3 72 3 72 3 73 3 74 3 74 3 74 3 76 3 77 3 77 3 78 3 78 3 79 3 79 3 80 3 81 3 82 3 83 3 85 3 85 3 85 3 85 3 85 3 89 3 89 3 89 3 89 3 90 3 90 3 90 3 90 Throttle Case Assembly Installa TOM ree eat O 3 91 Throttle Cable Removal 3 92 Throt
245. nd bulges C And make sure the hoses are not kinked or pinched Fuel Vent Hose Oil Hoses Water Hoses Bilge Hoses d lf a hose is damaged in any way replace it immediately and check all the others for damage 6003020281 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e 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 OThe majority of bilge hoses have no clamps at the hose ends Metal Clamp A Hose B Hose Fitting C NOTE OCheck the fuel and exhaust hoses for signs of wear de terioration damage or leakage Replace if necessary OMake sure the above hoses are secured with the metal gear clamps away from any parts e If the watercraft is not properly handled the high pressure inside the fuel line can cause fuel to leak A or the hose to burst e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Center Access Cover see Center Access Cover Re moval Installation in the Hull Engine Hood chapter e Check the fuel hose x Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Hose B e Check that the hose joints are securely connect
246. nd a green blue leads from the main harness The 2 3 coil connector has a red white and green leads from the main harness NOTE OThe service codes 51 and 52 caused by this procedure are stored in the ECU JFO9008BS1 Cylinder Head ENGINE TOP END 6 19 The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and in compression is combustion chamber possibly due to higher than usable damaged valve stem oil seal and or range damaged piston oil rings This may be indicated by white exhaust smoke Remove the carbon deposits and replace damaged parts if necessary Incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder Gas leakage around cylinder head compression is Replace damaged gasket and check cylinder head warp lower than usable Bad condition of valve seating Repair if necessary range 9 Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Piston seizure Bad condition of piston ring and or piston ring grooves Replace the piston and or cylinder Inspect the cylinder and replace repair the cylinder and or piston as necessary Replace the piston and or the piston rings Cylinder Head Removal e Drain the engine oil see Engine Oil Change
247. nd replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Replace element or inspect sealing see chapter 3 Intake manifold loose Reinstall see chapter 3 Throttle body assy loose Reinstall see chapter 3 Throttle body assy gasket damage Replace see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Fuel injector clogged Replace see chapter 3 Inspect and repair see chapter 3 3 30 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently Fuel pump bearings may wear Replace the fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Intake air temperature sensor trouble Throttle position sensor trouble Knocking Fuel poor quality or incorrect Spark plug incorrect Ignition coil trouble ECU trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Miscellaneous Throttle valve will not fully open Inspect see chapter 3 Inspect see
248. nd throttle cable to the delivery pipe with the band Main Harness View from A View from B Horizontal Plane Position the clamp pinch head below the horizontal plane White Mark Oil Separator Tank Hose Tank Air Box Clamps Air Box Cooling Hose Cylinder Left Water Box Muffler Oil Pan Position the clamp pinch head as shown Oil Separator Tank Hose Tank Oil Pan Cooling Hose Pump Output Cover Return Oil Hose Cylinder Oil Pan Output Cover Exhaust Pipe Cooling Hose Output Cover Exhaust Pipe Band Oil Separator Tank Cooling Hose Left Water Box Muffler Cylinder View from C Air Box Drain Caps Bow Flushing Cap Breather Hose Cylinder Head Breather Case Flushing Hose Bypass Outlet Hose Plate Deck Port Side Oil Separator Tank Hose Cylinder Head Cover Tank View from Top 16 4 APPENDIX Cable Wire and Hose Routing Oil and Cooling Hoses Routing O A LR Q y S Wwe ALE EK SE ae eh in EA NB JP a H ISS A FRA e JB09649BW5 C APPENDIX 16 5 Cable Wire and Hose Routing J O O1 ND A Water Pipe Joint on the Cylinder Cooling Water from Water Box Muffler Clamps Front Pinch Head Position the clamp so that its pinch heads do not touch the oil separator tank
249. nd tighten them and washers Torque Pump Bracket Mounting Bolts M8 19 N m 1 9 kgf m 14 ft lb e Apply a non permanent locking agent to the pump bracket mounting bolts M6 C and tighten them and washers Torque Pump Bracket Mounting Bolts M6 9 8 N m 1 0 kgf m 87 in lb OAs for the pump bracket mounting bolts M8 in the hull the bolt heads should be wrapped in silicone sealant D E View F JK04114BW2 C e Be sure trim seal A is in place PUMP AND IMPELLER 11 9 Pump and Impeller e Apply molybdenum disulfide grease to the spline A on the drive shaft e Install the pump e Apply a non permanent locking agent to the pump mount ing bolts and tighten them with the washers Torque Pump Mounting Bolts 36 N m 3 7 kgf m 27 ft lb e Apply silicone sealant A to the grate Sealant Liquid Gasket TB1211 56019 120 e Install the grate A e Apply a non permanent locking agent to the grate mount ing bolts B and tighten them with the washers Torque Grate Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Apply water resistance grease to the joint ball e Apply a non permanent locking agent to the steering ca ble joint bolt A and tighten it Torque Steering Cable Joint Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install the intake water hoses A to the pump and tighten the clamp screws B 11 10 PUMP AND IMPELLER Pump and Impeller e Install the s
250. nd water temperature sensor lead with the band Fix the camshaft position sensor connector and water temperature sensor lead to the engine hook with the band View from A Bow 16 16 APPENDIX Cable Wire and Hose Routing Speed Sensor Lead Routing APPENDIX 16 17 Cable Wire and Hose Routing 1 Speed Sensor Lead 2 Exhaust Hose 3 Run the speed sensor lead through the exhaust hose rearward 4 Bands 5 Speed Sensor 16 18 APPENDIX Cable Wire and Hose Routing Wire Routing at Crankshaft Sensor and Alternator Cover 6 e JB098656BW5 C APPENDIX 16 19 Cable Wire and Hose Routing Crankshaft Sensor Leads Grommet Crankshaft Sensor Cover Crankshaft Sensor Alternator Cover Stator Coil Leads Plate for holding the stator coil leads Do not place the leads between the plate and alternator cover 8 Run the stator coil leads along the hollow of the alternator cover 9 Crankcase 10 Coupling 11 Output Cover 12 Run the stator coil leads between the alternator cover and output cover Do not pinch the leads 13 View from Top 14 View from Stern NOOR WD A 16 20 APPENDIX Cable Wire and Hose Routing HE eg O Cable Wire and Hose Routing APPENDIX 16 21 J O O1 amp N ECU Main Relay Fuel Pump Relay System Relay ECU View from Bow View from P
251. nder Compression Measurement NOTE OUse the battery which is fully charged e Thoroughly warm up the engine while checking that there is no compression leakage from around the spark plugs or the cylinder head gasket Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water e Stop the engine e Disconnect the ignition coil primary lead connectors see Ignition Coil Removal in the Electrical System chapter e Remove Spark Plugs see Spark Plug Inspection in the Periodic Maintenance chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 1190 1 795 kPa 12 1 18 3 kgf cm 173 260 psi at 430 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs see Spark Plug Inspection in the Periodic Maintenance chapter e Reconnect the ignition coil primary lead connectors not ing the 1 4 A and the 2 3 B coil connectors the 1 4 coil connector has a red white a
252. nition switch to turn it on and measure the voltage with the connector joined Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts To avoid DFI or electrical damage be sure the needle adapters are inserted correctly OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Liquid Gasket TB1211 56019 120 e Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying short etc Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system If any wiring is deteriorated replace the wiring 6017572081 6017037351 Troubleshooting the DFI System FUEL SYSTEM DFI 3 23 e Pull each connector A apart and inspect it for corrosion dirt and damage
253. nk ing x If the display function does not work replace the meter unit Check 1 4 Trip Meter Inspection e In the Trip Meter mode check it by the same way as Check 1 3 x If the display function does not work replace the meter unit e Check that the display turns to 000 0 by pushing the SET button for 2 seconds or more OThe Trip Meter blinks until the display is reset x If the display function does not work replace the meter unit Check 1 5 Time Meter Inspection e In the Time Meter mode check that the display turns to 00 00 by pushing the SET button for 2 seconds or more OThe Time Meter blinks until the display is reset x If the display function does not work replace the meter unit Check 1 6 SLO Smart Learning Operation Mode Dis play Inspection e Using the SLO key yellow colored and marked SLO in sert the ignition key in the ignition switch to turn it on e Check that the display A switch to the normal display 3 seconds and the SLO 1 second alternately as follows second 3 seconds 1 Clock HOUR TRIP TRIP HOUR rpm Maximum Speed il SLO WATER TEMP AIR TEMP JN17133BN3 NOTE OUnder the SLO mode all the meter displays and other functions work in the same manner as the FPO Full Power Operation mode x If the display function does not work replace the meter unit JN17142BS1 JN17131BS1 MITE G ELECTRICAL SYSTEM 14 63
254. nnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnononnnns 6 17 Camshaft Chain Removal see 6 17 A E EEN 6 18 Cylinder Compression Measurement 6 18 Cylinder Head Removal id ai 6 19 Cylinder Head BR ET e EE 6 20 Cylinder Head Warp Inspection sie 6 22 VE UE 6 23 Valve Clearance Inspection nana rnnccnninn 6 23 Valve e E EE 6 23 Valve Installation escorial 6 23 Valve Guide Removal iii 6 24 Valve Guide Installation iarsna a a A aae aa A A 6 24 Valve to Guide Clearance Measurement Wobble Method 6 25 Valve Seat Inspection serie iiir Ea ERE EEE EEE EE A a i a e 6 25 MED Ke EE 6 26 Cylinder dE EE 6 31 E Mile ie Ne EE 6 31 Cylinder Installation 6 31 Piston Gul EE 6 32 Piston Installation EE 6 33 Cylinder Wear Inspection ardid ne ca en EA 6 34 Piston Wear Inspechon se 6 34 Piston Ring Piston Ring Groove Wear Inspection oooooococonoccccccccnonanonaccnnnnnnnncnnnnana conc 6 34 Piston Ring Groove Width Inspection seseeeeeeeeesesrirreettteeeeirrnrttteesssrtrnnnnssssttnenrnnnseneet 6 35 Piston Ring Thickness Inspection cocidas decree Lic a es ett 6 35 Piston Ring End Gap Inspection 6 35 6 2 ENGINE TOP END Exploded View JF02039845 C Exploded View ENGINE TOP END 6 3 Fastener Exhaust Side Camshaft Chain Guide Bolt Upper 18 Remarks Camshaft Chain Tensioner Mo
255. nstallation Intake Air Pressure Sensor Input Voltage Inspection Intake Air Pressure Sensor Output Voltage Inspection Intake Air Temperature Sensor Service Code Character 13 Alrt Intake Air Temperature Sensor Removal Installation Intake Air Temperature Sensor Output Voltage Inspection Intake Air Temperature Sensor Resistance Inspection Water Temperature Sensor Service Code Character 14 AqUt Water Temperature Sensor Removal Installation 3 39 3 40 3 41 3 43 3 43 3 43 3 44 3 45 3 47 3 47 3 47 3 48 3 50 3 50 Water Temperature Sensor Output Voltage Inspection Water Temperature Sensor Resistance Inspection Crankshaft Sensor Service Code Character 21 CrAg Crankshaft Sensor Removal Installation Crankshaft Sensor Resistance Inspection Crankshaft Sensor Peak Voltage Inspechon nssnooseneeeeeeeeeeeeeeeeea Camshaft Position Sensor Service Code Character 23 CAA1 Camshaft Position Sensor Removal Installation Camshaft Position Sensor Resistance Inspection Camshaft Position Sensor Peak Voltage Inspection Vehicle down Sensor Service Code Character 31 d08 Vehicle down Sensor Removal
256. ntinuity check the connectors the starter motor cable for engine ground or main harness and repair or replace them if necessary J616330BS1 ECU FUEL SYSTEM DFI 3 87 x If the wiring is good check the power source voltage of the ECU NOTE OBe sure the battery is fully charged e Connect the ECU connectors e Connect a digital meter A to the connectors B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Power Supply Inspection Connections I Digital Meter Terminal 17 R Y Digital Meter Battery terminal Il Digital Meter Terminal 44 R Y Digital Meter Battery terminal 111 Digital Meter Terminal 45 R BK Digital Meter Battery terminal Ignition Switch OFF Terminal 17 R Y 0 V Terminal 44 R Y 0 V Terminal 45 R BK 0 V Ignition Switch ON Terminal 17 R Y Battery Voltage Terminal 44 R Y Battery Voltage Terminal 45 R BK Battery Voltage while pushing ignition switch x If the reading is out of the specification check the follow ing Main Fuse 20 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter System Relay see Relay Assembly Inspection in the Electrical System chapter ECU Main Relay see Relay Assembly Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in t
257. num disulfide oil solution to the top and second rings NOTE ODo not mix up the top and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up NOTE Olf a new piston is used use new piston ring e Install the piston with its dent mark A facing exhaust side JF11006BS1 6E16013081 6E160604S1 JF11043BS1 6 34 ENGINE TOP END Cylinder Pistons e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring compress it only enough to install it and no more Snap rings are weakened and deform when re moved and may fall out scoring the cylinder wall and causing severe engine damage Do not re use snap rings always replace them e Install the cylinder see Cylinder Installation Cylinder Wear Inspection e 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 x If any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Ins
258. ockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B e Install the steering neck A with the adjustable steering holder B so that its narrow side C faces the rear as shown in the figure e Apply a non permanent locking agent to the steering neck mounting bolts D e Tighten Torque Steering Neck Mounting Bolts 15 7 N m 1 6 kgf m 12 ft lb e Adjust the steering cable see Steering Cable Adjust ment e Install the removed parts see appropriate chapters Adjustable Steering Holder Disassembly e Remove Steering Pad see Steering Removal Cotter Pin A Adjustable Steering Holder Nut B and Bolt Washers C Adjustable Steering Holder D Bushings E 12 16 STEERING Steering e Take the followings off the adjustable steering holder A Rivets B Shaft C Tilt Lever D Springs E Adjustable Rod F JLO6012BS2 Adjustable Steering Holder Assembly e Insert the adjustable rod B into the adjustable steering holder A OAlign C the projections on the rod with the grooves on the holder e Be sure that the springs A are in place e Install the tilt lever A on the adjustable steering holder OAlign B the projection on the adjustable rod with the hole on the tilt lever Steering STEERING 12 17 e Ap
259. oes off refer to the following failure illustrations na Immobilizer Amplifier Failure Service Code Character TA 35 Imb A on or UU 0 2second Key Collation Error Service Code Character 36 Ignl 0 3second JN20057BS1 14 74 ELECTRICAL SYSTEM Immobilizer System Pre registration of User Key 2 e Remove the user key 1 e Insert the user key 2 and press it for a short time within 2 seconds or long time 2 seconds or more NOTE OContinue with the procedure to register the first and sec ond keys before the 15 seconds period has elapsed the registration mode automatically finishes and the red warning indicator light LED will switch off OThe ECU confirms the following Receiving signals from immobilizer amplifier are correct The inserted key is the unregistered one Not Verified OThe red warning indicator light LED immobilizer symbol and letters A blinks to display the collation error The buzzer sound B goes off refer to the following failure illustrations Immobilizer Amplifier Failure Service Code Character 35 Imb or UU 0 2second Key Collation Error Service Code Character 36 Ignl 0 3second JN20057BS1 e The user key 2 is successfully pre registered in the ECU OThe red warning indicator light LED A blinks 2 times second e and stops for 1 second and then repeats this cycle O JU NOTE 0 OOnly the first one cycle the buzzer sounds B go
260. oler up side down e Remove O ring A Oil Cooler Assembly Bolts B Inside Oil Cooler Cover C e Remove O rings A ENGINE LUBRICATION SYSTEM 4 17 Oil Cooler Oil Cooler Assembly e Replace the O rings A with new ones e Apply grease to new O rings and fit them on to each groove of the coolers securely e Assemble the oil cooler Inside Oil Cooler Cover B Oil Cooler C Outside Oil Cooler Cover D e Tighten the oil cooler assembly bolts Torque Oil Cooler Assembly Bolts 7 8 Nm 0 80 kgf m 69 in lb e Install the oil cooler see Oil Cooler Installation JD09008BS1 Oil Cooler Inspection e Start the engine to check for water and oil leaks x If the water and oil leak replace the O rings A DANGER Exhaust gas contains carbon monoxide a color less odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water 4 18 ENGINE LUBRICATION SYSTEM Oil Separator Tank Oil Separator Tank Removal e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter Oil Sep
261. on e 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 OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x lf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Engine Oil Filter Engine Mounting Bolts and bracket bolts Engine Damper Mounting Bolts Cylinder Head Cover Bolts Cylinder Head Bolts Crankcase Bolts Drive Shaft Pump and Impeller Drive Shaft Holder Mounting Bolts Pump Mounting Bolts Pump Cover Mounting Bolts Grate Mounting Bolts Steering Nozzle Pivot Bolts Reverse Bucket Pivot Bolts Steering Handlebar Clamp Bolts Steering Neck Mounting Bolts Steering Holder Mounting Nuts Steering Shaft Locknut Steering Cable Nut Steering Cable Joint Bolt Shift Cable Nut Hull and Engine Hood Stabilizer Bolts Handrail Plate Nuts Electrical System Spark Plugs Battery Terminal Hose and Hose Connect Inspection e Check the following hoses for leakage A hardening cracking B checking cuts abrasions breaks a
262. on built up in combustion chamber Engine load faulty Engine oil level too high Engine oil viscosity too high Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect Oil cooler clogged Sensor incorrect Water temperature sensor broken Over Cooling Sensor incorrect Water temperature sensor broken Abnormal Engine Noise Knocking IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Alternator rotor loose Oil Pressure Warning Indicator Light Goes On Oil pump damaged Oil screen clogged Oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Troubleshooting Guide Wiring faul
263. once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance chapter 6E15012081 6 30 ENGINE TOP END Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Results 45 Grind Machinist s dye on seat Tool 45 Cutter Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seat Width Tool Vernier Caliper Purpose check seat width against spec I Resul
264. onnector A Communication Cable 57001 1745 B KDS Adapter Cable 57001 1696 y Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever trou bleshooting or presence of symptoms indicate that adjustments may be required Whenever running of the engine is required during maintenance it is best to have the watercraft in water GENERAL INFORMATION 1 3 Before Servicing Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water Auxiliary Cooling An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjust ments If possible always operate the watercraft in water rather than use an auxiliary cooling supply e 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 OOptional part P No 92005 3748 is available as a garden hose adapter e Open the front storage compartment cover e Remove the flushing cap A on the brim of the storage compartment e Screw a garden hose adapter A onto the flushing fitting B e Attach a garden hose C to a garden hose adapter and secure the hose clamp D SCHEI P e Attach the garde
265. or 2 O lead ECU terminal 51 For Fuel Injector 3 BR lead ECU terminal 38 For Fuel Injector 4 BL Y lead ECU terminal 47 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Fuel Injector Fuel Line Inspection e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Fuel Hose see Fuel Hose Removal e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with the fuel hose C supply end with the clamps D as shown in the figure OApply soap and water solution to the areas E as shown in the figure OWatching the pressure gauge squeeze the pump lever and build up the pressure until the pressure reaches the maximum pressure Injector Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi NOTICE High pressure could damage seals in the fuel line Do not exceed the maximum pressure during pres sure testing OWatch the gauge for at least 6 seconds x If the pressure holds steady the fuel line is good x If the pressure drops at once or if bubbles are found in the area the fuel line is leaking Replace the delivery pipe assy injectors and related parts ORepeat the leak test and check the fuel line for no leak age e Install the fuel hose see F
266. or B Ground BK W BK W Pk BK W BK W BK W BK W Joint Connector F 5V DN d R Joint Connector D 12V Joint Connector c 12v LG R Sr BL G Y H BK R R Y x we G R BL R BL BL BK D 0 8K BK 9 6 z o Ignition Ce 0000 134 283 Spark Plugs GO R W R W R G Joint Connector H 12V por div BK W W BL Immobilizer Kawasaki Diagnostic System Connector Water Temperature Sensor C Camshaft Position Sensor GO Ei gt i R Y R Y BK BL Y BK BR N BL R sc Idle Speed Controller Throttle Position Sensor BK W BK BK 8L BK R Y BK W Joint Connector E Ground oil Temperature Sensor ECU S oil Pressure Switch Red 98052 06390 BK BR e o P Pu R v w LC W2ROG39CWS C 14 12 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Model Name Capacity Voltage Electric Starter System Starter Motor Brush Length Commutator Diameter Charging System Type Regulator Rectifier Output Voltage Alternator Output Voltage Stator Coil Resistance Sealed Battery YTX20L BS 12 V 18 Ah 12 8 V or more 12 mm 0 47 in Service Limit 6 5 mm 0 26 in 28 mm 1 10 in Service Limit 2
267. or Puller 57001 1623 ST5716238ST Liquid Gasket TB1211F 92104 0004 gt KR ST9200048T Liquid Gasket TB1215 92104 1065 ST921065ST Coupling Output Shaft ENGINE BOTTOM END 8 7 Coupling Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Cooler see Oil Cooler Removal in the Engine Lubri cation System chapter Crankshaft Sensor Cover see Crankshaft Sensor Re moval in the Electrical System chapter e Place the wooden block A under the engine mounting brackets on the exhaust side e Hold the engine with a suitable belt B tightly e While holding the timing rotor C with the flywheel 8 pul ley holder D loosen the coupling E with the coupling holder F Special Tools Coupling Holder 2 57001 1423 Holder Attachment 57001 1547 Flywheel 8 Pulley Holder 57001 1605 Coupling Installation e Place the wooden block A under the engine mounting brackets on the intake side e Hold the engine with a suitable belt B tightly e While holding the timing rotor C with the flywheel 8 pul ley holder D tighten the coupling E with the coupling holder F Special Tools Coupling Holder 2 57001 1423 Holder Attachment 57001 1547 Flywheel 8 Pulley Holder 57001 1605 Torque Coupling 110 N m 11 2 kgf m 81 ft lb Output Shaft Remo
268. or T 12 V ECU Main Relay System Relay Joint Connector D 12 V Joint Connector C 12 V ECU Joint Connector E Ground Main Fuse 20 A Battery Joint Connector Y Ground Joint Connector S Ground Joint Connector W 12 V Steering Position Sensor Meter Unit Joint Connector Q Ground JO O1 amp N E E A E ns OO Y OO P ND 14 50 ELECTRICAL SYSTEM Sensors Speed Sensor Removal e Remove Reboarding Step see Reboarding Step Removal in the Hull Engine Hood chapter Reverse Bucket see Reverse Bucket Removal in the Steering chapter Water Box Muffler see Water Box Muffler Removal in the Exhaust System chapter e Disconnect the speed sensor lead connector A e Remove the band A e Remove the speed sensor mounting screws A meme e Remove the cap A and take the speed sensor lead off the hull Sensors ELECTRICAL SYSTEM 14 51 Speed Sensor Installation e Run the speed sensor lead properly see Cable Wire and Hose Routing section in the Appendix chapter e Apply silicone sealant around the grommet A and lead wires B e Install Cap A Speed Sensor B Nuts C e Apply a non permanent locking agent to the speed sensor mounting screws D e Tighten Torque Speed Sensor Mounting Screws 3 9 N m 0 40 kgf m 35 in lb e Install the removed parts see appropriate chapters Speed Sensor Inspection e Remove the speed
269. or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary 68020108 p lt lt OA 7 aea J a fa oF i J TO ER A w SH o L 68020118 S NS pel eR A AK Do ty 9 pes 51 Jee TA en A 1045 Z ADF ai I ar Edi P a Ds A 68020128 66020138 y H KA S Ss PA e KS a rz 65020148 S GENERAL INFORMATION 1 7 Before Servicing Gasket O ring Hardening shrinkage or damage of both gaskets pr and O rings after disassembly can reduce sealing per CZ NA H formance Remove old gaskets and clean the sealing SA ak surfaces thoroughly so that no gasket material or other ee ALE material remains Install new gaskets and replace used oh O rings when re assembling LO 020158 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 6020168 Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing 68020178 Ball Bearing Do not remove
270. or serious burns Make sure the area is well venti lated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Remove the ignition key Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Fuel Line FUEL SYSTEM DFI 3 103 e Remove the ignition key e Wait until the engine cools down e Prepare a measuring cylinder e Open the fuel tank cap A to lower the pressure in the tank e Remove the fuel hose from the delivery pipe see Fuel Hose Removal e Insert the fuel hose A into the measuring cylinder B WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e Insert the ignition key in the ignition switch to turn it on e Push the start button for 3 seconds e Measure the discharge for 3 seconds Amount of Fuel Flow Standard 83 mL 2 8 US oz or more for 3 seconds e Remove the ignition key x If the fuel flow is much less than the specified check the following Fuel Pump Operation see Fuel Pump Operation Inspec tion Fuel Pump Screen see Fuel Pump Screen Cleaning lt above inspection checks out good replace the fuel pump and measure the amount of fuel flow again e After inspection connect the fuel hose e Start the engine and check for fuel leakage 3 104 FUEL SYSTEM DFI Fuel Vent Check Valve Fuel Ven
271. ormance If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with Ga06060251 6 compressed air WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Do not use gasoline or low flash point solvents to clean the relief valve xlf cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precisely made with no allowance for re placement of individual parts e Apply a non permanent locking agent high strength Loc tite 271 equivalent to the oil pressure relief valve Excessive non permanent on the threads may block the oil passage and cause severe engine damage To prevent the oil passage from becom ing blocked do not apply excessive non permanent locking agent to the threads e Install the oil pressure relief valve Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft JD Oil Pump Chain Removal Installation e Remove Camshaft Chain see Camshaft Chain Removal in the Engine Top End chapter Oil Pump Sprocket see Oil Pump Sprocket Removal e Remove the oil pump chain A e Installation is the reverse of removal ENGINE LUBR
272. ort Side Bow Regulator Rectifier Vehicle down Sensor View from Top 1 Ignition Coil Lead 2 Ignition Coil Lead 3 Ignition Coil Lead 4 Ignition Coil Lead View from Stern Black Lead Red Lead View from A 16 22 APPENDIX Cable Wire and Hose Routing JB09658BW5 C Cable Wire and Hose Routing APPENDIX 16 23 ch 2000 X00 BON Starter Relay Connector Starter Relay Cable Run the starter relay cable and leads through the battery rearward Wrap the leads with the black tape Fuse Case Starter Relay Immobilizer Kawasaki Diagnostic System Connector Battery Cable Battery Battery Cable Bow 16 24 APPENDIX Cable Wire and Hose Routing gt y i S Si y AE LS d J y AD yl p Y 7 S d ES GG y I P p S d APPENDIX 16 25 Cable Wire and Hose Routing Joo ND A Bow Throttle Cable Buzzer Lead Meter Unit Leads Fuel Vent Hose Left Handlebar Switch Lead Protective Tube Bands Air Temperature Sensor Buzzer 50 mm 1 97 in White Tape Steering Holder Steering Position Sensor Band 16 26 APPENDIX Troubleshooting Guide NOTE ORefer to the Fuel System DFI chapter for most of DFI troubleshooting guide OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simp
273. oth sides lubrication is not required Ball Bearing Inspection NOTE Olt is not necessary to remove the bearings for inspec tion If the bearing is removed it will need to be re placed with a new one e Spin A it by hand to check its condition x If it is noisy does not spin smoothly or has any rough spots it must be replaced e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing GJ060305S1 8 12 ENGINE BOTTOM END Alternator Rotor Alternator Rotor Removal e Remove Output Shaft see Output Shaft Removal e Using the rotor puller A remove the alternator rotor B from the crankshaft Special Tool Rotor Puller 57001 1623 OTighten the rotor puller bolts C until the bottom surfaces of the bolts are flush D with the surface of the alterna tor rotor as shown in the figure For reference the photo shows the alternator rotor removed from the crankshaft OThe bolt length will be about 63 mm 2 5 in E after tightened Overtightening the bolts can damage the crankcase oil seal Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a high flash points solvents clean off any oil or dirt that may be on the crankshaft taper and in the tapered hole in the alternator rotor e Replace the O ring A with a new one and
274. out providing sufficient cooling water x If the idle speed increase check the throttle cable adjust ment and the cable routing e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Check throttle cable adjustment e With the throttle lever released the upper stop A on the throttle pivot arm B should rest against the stopper C on the throttle body and there should be slight slack in the throttle cable e When the throttle lever is fully applied pulled the lower stop D on the pivot arm should be all the way up against the stopper on the throttle body x If necessary adjust the throttle cable e Loosen and turn the locknuts A at the bracket until the upper stop on the pivot arm hits against the stopper on the throttle body with slight cable slack e Tighten the locknuts securely Torque Throttle Cable Locknuts 19 6 N m 2 0 kgf m 14 ft Ib NOTE OMake sure that the throttle pivot arm stops against the stopper on the throttle body with the throttle lever re leased THROTTLE CLOSED RELEASED THROTTLE OPEN APPLIED JRO5007BS1 PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures Air Box Drain Caps Inspection and Cleaning e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Remove the handrail plate see Handrail Plate Removal in the Hull Engine Hood chapter e Inspect the air box A for water inside with its drai
275. oval e Clean the carbon deposits out of the exhaust passages with a blunt round edged tool e Flush foreign matter out of the water passages with fresh water e Check the insides of the water passages for corrosion e Check the gasket surfaces for nicks or other damage x If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly replace the part YEO7027BS1 JE07030BS1 5 6 EXHAUST SYSTEM Exhaust Pipe Exhaust Pipe Removal e Remove the exhaust manifold with exhaust pipe see Ex haust Manifold Removal e Remove the exhaust pipe mounting bolts A and wash ers e Remove the exhaust pipe B e Loosen the clamp screw A e Remove the front exhaust hose B and the two rings Exhaust Pipe Installation e Replace the exhaust pipe gasket with a new one e Apply a non permanent locking agent to the water hose joint e Install the new gasket A and the water hose joint B as shown in the figure 30 C Section F F D e Tighten Torque Water Hose Joint 11 N m 1 1 kgf m 97 in lb e Install the exhaust pipe mounting bolts and washers as follows and tighten them Torque Exhaust Pipe Mounting Bolts E 45 N m 4 6 kgf m 33 ft lb e Install the two rings A in the ring grooves of the exhaust pipe x If the two rings are damaged or warped replace the rings JE07031BS1 Exhaust Pipe EXHAUST SYST
276. ove the throttle body assy see Throttle Body Assy Removal e Check the throttle bore A for carbon deposits by opening the valve x If any carbon accumulates wipe the carbon off the throttle bore and throttle valve using a cotton pad NOTICE Do not rub these surfaces hard and do not use a carburetor cleaning solution ISC Idle Speed Controller Removal Installation e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Air Box see Air Box Removal Bands A ISC Connector B Stepping Motor Mounting Screws C Stepping Motor D ISC Actuator Mounting Bolts E ISC Actuator F e Clean the mating surface of throttle body and ISC actuator stepping motor e Replace the O ring A with a new one e Install the stepping motor B and tighten the screws C Torque Stepping Motor Mounting Screws 2 0 N m 0 20 kgf m 18 in lb e Install the ISC actuator D and tighten the bolts E Torque ISC Actuator Mounting Bolts 5 0 N m 0 51 kgf m 44 in lb e Run the harness and tighten the bands correctly see Ca ble Wire and Hose Routing section in the Appendix chap ter e After installing the ISC actuator check the Smart Steering System Operation in the water ISC Idle Speed Controller Inspection e Check idle speed with a tachometer in the multifunction meter OWith the engine idling open and close the throttle lever Idle Speed Standard 1 300 100 r min rpm both in and out of
277. p bolt E JFO7007BS1 Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 kgf m 15 ft lb 6 12 ENGINE TOP END Camshaft Camshaft Chain Camshaft Removal e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter Spark Plugs see Spark Plug Inspection in the Periodic Maintenance chapter Cylinder Head Cover see Cylinder Head Cover Re moval e Position the crankshaft at 1 4 piston TDC as follows OUsing the shaft wrench A turn the crankshaft counter clockwise B and set the crankshaft at 1 4 piston TDC Special Tool Shaft Wrench 57001 1551 OThe timing marks A must be aligned with the cylinder head upper surface B as shown in the figure e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts A and Upper Camshaft Chain Guide Bolts B Upper Camshaft Chain Guide C Camshaft Cap D Camshafts e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase A kinked cam chain could damage both the chain and the sprocket on the crankshaft The crankshaft can be turned while the camshafts are removed but always pull the cam chain taut to avoid kinking the chain on the crankshaft sprocket ENGINE TOP END 6 13 Camshaft Camshaft Chain Camshaft Installation e Be sure to install the following parts Dowel Pins A
278. park plug dirty broken or gap maladjusted APPENDIX 16 27 Stumble Too low fuel pressure Fuel injector trouble Throttle sensor malfunction Water temperature sensor trouble Intake air pressure sensor trouble Surge Unstable fuel pressure Fuel injector trouble Water temperature sensor trouble Backfiring when deceleration Spark plug dirty broken or gap maladjusted Too low fuel pressure Fuel pump trouble Throttle sensor trouble Air temperature sensor trouble Water temperature sensor trouble Intake air pressure sensor trouble After fire Crankshaft sensor trouble Spark plug burned or gap maladjusted Air temperature sensor trouble Water temperature sensor trouble Intake air pressure sensor trouble Fuel injector trouble Run on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loose terminal of battery lead or ECU ground lead Carbon accumulating on valve seating sur face Engine overheating Other IC igniter in ECU trouble Engine oil viscosity too high Engine overheating Intermittent any DFI fault and its recovery Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Ignition coil shorted or not in good contact Ignition coil trouble Spark plug incorrect Spark plug cap trouble Spark plug cap shorted not in good contact Camshaft position sensor trouble IC igniter in ECU trouble Crankshaft sensor trouble Fuel air mixture incorrect Air box poorly
279. peed sensor to the pump cover A with the screws B e Install the pump cover e Apply a non prmanent locking agent to the pump cover mounting bolts C and tighten them Torque Pump Cover Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib Pump Disassembly e Remove Steering Nozzle Pivot Bolts A and Washers Steering Nozzle B e Remove Pump Outlet Mounting Bolts A Pump Outlet B Spacer e Remove Pump Cap Bolts A and Washers Pump Cap B e Remove Filter Cover Mounting Bolts A Filter Cover B O ring Dowel Pin PUMP AND IMPELLER 11 11 Pump and Impeller e Remove Impeller Seal A Trim Seal B 048159 P e Install the impeller wrench A into the impeller B Special Tool Impeller Wrench 57001 1228 e Turn the pump case upside down and hold the impeller wrench with a vise e Remove the pump shaft nut C a ae C KC Tei o a 4K04129BS2 e Using a vise hold the shaft in the impeller holder A tak ing care not to damage it e Insert the impeller wrench B to the impeller Special Tools Impeller Wrench 57001 1228 Impeller Holder 57001 1695 e Loosen the impeller wrench to remove the impeller from the pump shaft JK04115BS2 11 12 PUMP AND IMPELLER Pump and Impeller e Pull the pump shaft A together with the bearing B from the pump case e Remove the bearing C from the pump shaft B
280. permanent locking agent to the starter motor through bolts e Tighten Torque Starter Motor Through Bolts 6 4 N m 0 65 kgf m 57 in lb Brush Inspection e Measure the minimum length A of each brush If any is worn down to the service limit replace the nega tive brush assembly B and the positive brush assembly C Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 6 5 mm 0 26 in JNOGOTOBS1 Electric Starter System ELECTRICAL SYSTEM 14 27 Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator B x 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 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 Q hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to
281. place the ECU J616290BS1 6017029281 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System DFI Diagnosis Flow Chart Red Warning indicator light Red Warning indicator light Service code character red LED does not go on LED goes on Fl warning indicator light and or blink FI character character and Fl warning LED and immobilizer and Fl and or immobilizer indicator blink and buzzer warning indicator blink and warning indicator do not sounds buzzer sounds blink and buzzer does not sound Conduct non self diagnosis inspection Conduct self diagnosis Conduct self diagnosis inspection DFI system inspection immobilizer system End General fuel system throttle body assy air cleaner fuel tank etc Conduct general fuel system inspection JC16338B F Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any areas help you decide if it is a DFI system problem or a general engine problem and will FUEL SYSTEM DEI 3 25 Troubleshooting the DFI System Sample Diagnosis Sheet Rid
282. plo sive under certain conditions To avoid a possi ble fire or explosion 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 includes any appliance with a pilot light WARNING Gasoline is toxic and pollutes the environment To protect the environment do not discard gasoline always return it to an authorized recycling center 19 Reinstall the seat and secure it 20 Reinstall the drain screws in the stern 21 Finally run the watercraft IN WATER for at least 10 minutes to dry any remaining water and blow any for eign matter like salt out through the exhaust JFO09008BS1 DRIVE SYSTEM 10 1 Drive System Table of Contents E leie Ee WE 10 2 Speci CATO EE 10 4 Special I00lS aih a AA ab 10 5 Drive Shaft Drive Shaft Holder 10 6 Drive Sha t RemoOVal 4 4 mnt leds aid aros deagos 10 6 Drive Shaft Installation nnnesnneeenentenrtttrtttrtttnttnrttnntttntttntttAEEAAEEEEEEEAEEAEEEEAEEEEE EEA E EEEE EEEE 10 6 Drive Shaft Holder Removal Disassembly cccccescesseeceeeeeeeeeeeeseeeeeneeeeeeeeeeveceeteneee 10 6 Drive Shaft Holder Assembly Installation 10 8 Drive Shaft Runout Inspechon 10 9 10 2 DRIVE SYSTEM Exploded View JJ02023BW5 DRIVE SYSTEM 10 3 Exploded View A E E7 A
283. ply water resistance grease A to the steering neck B and the adjustable rod C e Install Bushings A Adjustable Steering Holder B Washers C Adjustable Steering Holder Nut D and Bolt e Tighten Torque Adjustable Steering Holder Nut 4 9 N m 0 50 kgf m 43 in Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B JL06024BS1 HJO7007BS1 GJ04109BS1 12 18 STEERING Reverse System Shift Cable Adjustment e Check the shift cable adjustment e 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 e When the shift lever is in the R position the lower stop per A on the bucket should rest against the bottom B of the pump cover x If either position is incorrect adjust the shift cable e Put the shift lever in the R position e Loosen the locknut A of the shift cable e Slide back the outer sleeve and take the ball joint B off the ball e Turn the ball joint to adjust the shift cable e Connect the ball
284. pressed ball or needle unless removal is ER absolutely necessary Replace with new ones whenever SS dd Je removed Press bearings with the manufacturer and size NA L NA marks facing out Press the bearing into place by putting NT d pressure on the correct bearing race as shown Ba p y Er 3 Pressing the incorrect race can cause pressure between DT kt LZS the inner and outer race and result in bearing damage i gt 777 6020188 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal A is necessary Replace with new ones whenever removed d EY z i Press new oil seals with manufacture and size marks facing INS x out Make sure the seal is aligned properly when installing Sy y E AL 680201 8 1 8 GENERAL INFORMATION Before Servicing Apply specified grease to the lip of seal before installing the seal Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take 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 cation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive dir
285. pter e Position the crankshaft at 1 4 piston TDC as follows OUsing the shaft wrench A turn the crankshaft counter clockwise B and set the crankshaft at 1 4 piston TDC Special Tool Shaft Wrench 57001 1551 OThe timing marks A must be aligned with the cylinder head upper surface B as shown in the figure e Measure the valve clearance between the cam and the valve lifter with a thickness gauge A Valve Clearance Standard Intake 0 15 0 24 mm 0 0059 0 0094 in Exhaust 0 22 0 31 mm 0 0087 0 0122 in 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures OWhen positioning 1 piston TDC at the end of the compression stroke Intake Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve e Bow A Camshaft Sprocket Position B OWhen positioning 4 piston TDC at the end of the compression stroke Intake Valve Clearance of 2 and 4 Cylinders Exhaust Valve Clearance of 3 and 4 Cylinders Measuring Valve e Bow A Camshaft Sprocket Position B xlf the valve clearance is not within the specified range first record the clearance and then adjust it e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifter and shim so that they can be reinstalled in their original positions
286. ptied com pletely and remove the container from the battery e Place the strip of caps A loosely over the filler ports press down firmly with both hands to seat the strip of caps into the battery don t pound or hammer When properly installed the strip of caps will be level with the top of the battery Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to the battery NOTE OCharging the battery immediately after filling can shorten service life MEO2114BS1 SC Gi LJ LJ UI lek Tic 6P08012BS1 GPO8010BS1 14 20 ELECTRICAL SYSTEM Battery Initial Charge e Newly activated sealed batteries require an initial charge Standard Charge 1 8A x 5 10 hours lf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO2 Yuasa MB 2040 2060 Christie C10122S xlf the above chargers are not available use equivalent one e Let battery sit 30 minutes after initial charge then check voltage using a voltmeter Voltage immediately after charging becomes temporarily high For accurate mea suring let the battery sit for given time NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used If voltage is not at least 12 8 V repe
287. r Duct Removal e To remove the front air ducts from the deck remove the steering cover see Steering Removal in the Steering chapter e Drill out the rivets A see Blind Rivet Removal e Remove Clamp B Front Air Duct C Damper D Duct E JMO5021BS1 4M05022BS2 HULL ENGINE HOOD 13 21 Rubber Parts e To remove the rear air ducts from the deck remove the handrail plate see Handrail Plate Removal e Drill out the rivets A see Blind Rivet Removal e Remove Clamp B Rear Air Duct C Damper D Duct E 4M05023BS2 Air Duct Installation e Secure the air duct to the deck with the rivets see Blind Rivet Installation ELECTRICAL SYSTEM 14 1 Electrical System Table of Contents Parts Location 14 3 Exploded View 14 6 Wiring Diagram 14 10 Specifications 14 12 Special Tools and Sealant 14 13 PDrecautons 14 14 Electrical Wiring css dd 14 15 Wiring Inspection 14 15 Date iaa tdi 14 16 Battery Cover Removal Installa MOM ais 14 16 Battery Removal 14 16 Battery Installation 14 17 Battery Activation 14 17 Precautions 14 20 Interchange sine 14 21 Charging Condition Inspection 14 21 Refreshing Charge 14 21 Electric Starter System
288. r Lead Connector A Discon nect e Set the hand tester B to the x 100 Q range and connect it to the yellow and black leads in the connector Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 C Camshaft Position Sensor Resistance Standard 400 460 Q at 20 C 68 F x If there is more resistance than the specified value the sensor coil has an open lead and must be replaced Much less than this resistance means the sensor coil is shorted and must be replaced e Using the highest resistance range of the tester mea sure the resistance between the camshaft position sensor leads and chassis ground x Any tester reading less than infinity indicates a short necessitating replacement of the camshaft position sen sor Camshaft Position Sensor Peak Voltage Inspection e Disconnect the camshaft position sensor lead connector see Camshaft Position Sensor Removal e Set the hand tester A to the DC 2 5 V range and connect it peak voltage adapter B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 e Connect the adapter to the terminals of the camshaft po sition sensor lead connector C Connections Camshaft Position Sensor Lead Peak voltage Hand Tester Adapter Connector BK D R gt Y E BK gt EN Ki Ki dt gt S mm P R BK GP10511BS1 Ignition
289. r Supply Inspection e Connect the meter unit leads to the battery in the same circuit as Check 2 1 e Set the hand tester A to the DC 25 V range and connect it to the meter unit as follows Special Tool Hand Tester 57001 1394 OConnect the tester terminal to the terminal 3 OConnect the tester terminal to the terminal 2 x If the power supply voltage shows a much lower than 10 8 V replace the meter unit ANITIESE 6 4N17139BS1 ELECTRICAL SYSTEM 14 65 Multifunction Meter Check 2 4 Fuel Level Gauge Inspection e Connect the meter unit leads to the battery in the same circuit as Check 2 1 e Connect the variable rheostat A to the terminal 7 and the battery terminal e Check that the segments number of the fuel level gauge A matches the resistance value of the variable rheostat Variable Rheostat Resistance Q Fuel Level Gauge 5 8 Segments Appear 60 1 Segment Blinks 100 All Segments Disappear OThe fuel level gauge is updated every 10 seconds x lf the display function does not work replace the meter unit Check 2 5 Water Temperature Meter Inspection e Connect the meter unit leads to the battery in the same circuit as Check 2 1 e Connect the variable rheostat A to the terminal 11 and the terminal 12 JN17140BS2 ANITI 68 G JN17145BS2 14 66 ELECTRICAL SYSTEM
290. r box cover e Apply a non permanent locking agent to the air box as sembly bolt L 60 mm and mounting bolts e Tighten Torque Air Box Assembly Bolts 2 5 N m 0 25 kgf m 22 in Ib Air Box Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib 3 96 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Inspection The normal idle speed is controlled by the ECU Idle Speed Standard 1 300 100 r min rpm both in and out of water Throttle Body Assy Removal e Remove the air box see Air Box Removal e Unscrew the adjuster locknut A and slide the cable from the bracket e Slide the tip B of the cable lower end from the throttle pivot arm C e Remove Bands A ISC Connector B Throttle Position Sensor Connector C Bolts D Throttle Body Assy E with Gasket Throttle Body Assy Installation e Replace the gasket with a new one e Installation is the reverse of removal e Tighten Torque Throttle Body Assy Mounting Bolts 20 N m 2 0 kgf m 15 ft lb Throttle Body Assy Disassembly Adjustment of the air screw throttle link mecha nism and throttle body assy A could result in poor performance requiring replacement of the throttle body assy Do not remove disassemble or adjust the air screw throttle link mechanism and throttle body assy they are precisely set at the manufac turer JC09011BS1 Throttle Body Assy FUEL SYSTEM DFI 3 97 Throttle Bore Cleaning e Rem
291. r gauge A between the tip of the impeller blade B and the pump case C Impeller Clearance Standard 0 15 0 3 mm 0 0059 0 012 in Service Limit 0 6 mm 0 024 in If impeller clearance is incorrect determine if it is due to wear or damage see Pump and Impeller Inspection JK04131BS1 PUMP AND IMPELLER 11 19 Pump and Impeller Water Filter Cover Removal Installation e Loosen the clamps A and pull off the water hoses B e Remove the filter cover mounting bolts C e Take out the filter cover D e Replace the O ring with a new one e Apply lithium grease NLGI Grade No 2 to the O ring e Installation is the reverse order of removal e Apply a non permanent locking agent to the filter cover mounting bolts and tighten them Torque Filter Cover Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb STEERING 12 1 Steering Table of Contents Elei e WEE 12 2 Special os iii A A AO en ans 12 4 o en dE Ad aa TE tela alien En Ann kets 12 5 Steering Cable Adjustment voii 12 5 St ering Cable ne ET 12 5 steering Cable Installation cd 12 7 Steering Cable MS POCORN sete apica nn anne ct nn da 12 7 Steering Cable Ele t EE 12 8 A O 12 9 Handlebar Removal ins en ntm dd cloacas 12 9 Hlandlebar Installation endettement ere 12 9 SEELEN 12 11 SUGSMMG REMOVAL viii AA A A A E 12 11 Steering Installation EEN 12 13 Adjustable Steering Holder Disassembhy 12 15 Adjustable Steering Holder
292. r lead as shown in the figure Connections Battery gt RW lead Battery gt BK W lead x If the buzzer does not work replace the buzzer e By pushing the MODE button A less than a second each time check that the multifunction display B changes as follows CLOCK HOUR TRIP TRIP HOUR AIR WATER Maximum rpm TEMP TEMP Speed ron Blinks JN17126BN3 NOTE OThese modes will shift in series when the MODE button pushed for 2 seconds or more OWhen the multifunction meter displays a warning push the MODE or SET button for 1 second to return to the normal display OThe MODE button operates when the engine is running slower than 3 000 r min rpm x If the display function does not work replace the meter unit e In the Hour mode check that the Mile Km display A switches to the km h or mile h by pushing the SET but ton B for more than 3 seconds OThe Mile Km display starts blinking and the multifunction meter disappears NOTE OMile Km Display can alternate between English and metric modes mile and km in the digital meter Make sure that km or mile according to local regulations is correctly displayed before riding x If the display function does not work replace the meter unit BK W 3 R W 4N17124BS1 Multifunction Meter ELECTRICAL SYSTEM 14 61 Check 1 2 Clock Setting Inspection e In the Clock
293. rankshaft Main Bearing Insert Journal Wear Inspection 8 27 Crankshaft Side Clearance Inspection 8 30 Crankshaft Runout Inspection se 8 30 8 2 ENGINE BOTTOM END Exploded View Vas AE A i al Se ENGINE BOTTOM END 8 3 Exploded View 27 Engine Bracket Mounting Bots 32 24 ERC 108 int 7 ae Grommet ower Piste Bais Be 78 irb Output Shaft 195 Coupling 81 Oil Passage Plugs R3 8 15 Oil Passage Plug R1 4 A e 69 in lb Alternator Cover Bolts L 40 mm f 15 Coupling Cover Bolts d 78 mb Alternator Cover Bolts L 60 mm d 15 Output Cover Bolts 69 in lb Oil Catch Cover Bolts d E 69 in lb Crankcase Bolt M8 L 55 mm 22 Crankcase Bolts M10 37 Crankcase Bolts M8 L 45 mm 22 17 Crankcase Bolts M6 f 106 in Ib 18 Crankcase Bolts M8 L 85 mm G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant WG Apply water resistance grease 8 4 ENGINE BOTTOM END Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend EE 0 2 100 mm 0 008 3 94 in Conne
294. re Measurement Oil Pressure 461 kPa 4 7 kgf cm 67 psi at 3 000 r min rpm Oil Temperature 74 C 165 F ENGINE LUBRICATION SYSTEM 4 11 Special Tools Oil Pressure Gauge 10 kgf cm Oil Filter Wrench 57001 164 57001 1249 ST5701648T ST5712498ST Oil Pressure Gauge Adapter PT 1 8 57001 1033 ST5710338T 4 12 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Insufficient deteriorated or contaminated engine oil causes accelerated engine wear and may result in sudden catastrophic engine failure that can lead to an accident resulting in serious injury or death Change the engine oil according to the periodic maintenance chart and check the oil level regularly between oil changes Oil Level Inspection This watercraft engine is equipped with a semi dry sump In the semi dry sump engine the oil level difference is very large between the level measured after just stopping and that after leaving for a long time It is necessary to check the specified amount of oil is in the engine before starting the engine every day At this time use the cold mark of the level gauge Then run the engine to lubricate the engine parts sufficiently After that it is necessary to check the level by using hot mark of the level gauge Preliminary Check e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Whenever checking the engine oil level keep th
295. re regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Throttle position sensor trouble Unstable rough idling Fuel pressure too low or too high Fuel injector trouble Throttle position sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Engine stalls easily Spark plug dirty broken or gap maladjusted Ignition coil trouble Throttle position sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Inspect Inspect Inspect Inspect Inspect Inspect see chapter 3 see chapter 3 see chapter 3 see chapter 3 see chapter 3 see chapter 3 D LN DA jajaja Inspect and replace see chapter 2 Inspect see chapter 14 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble am D PAS DAS DAS Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Fuel pressure regulator trouble Inspect fuel pressur
296. 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 cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODO not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing GE15133BS1 Valves ENGINE TOP END 6 27 Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following A tate Cutter angle B ST OD tient Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth Overgrinding the seat will reduce valve clearance by sinking the valve into the head Ifthe valve sinks too far into the head it will be impossible to ad just the clearance
297. replace it with a new damper see Coupling Installation in the Engine Bottom End chap ter x If there is any doubt as to coupler condition replace it Cooling and Bilge Systems Cooling System Flushing To prevent sand or salt deposits from accumulating in the cooling system it must be flushed occasionally Flush the system according to the Periodic Maintenance Chart after each use in salt water or whenever there is reduced water flow from the bypass outlet on the right side of the hull e Obtain a standard garden hose A and a garden hose adapter B as shown in the figure Garden Hose Fitting of Adapter C Flushing Fitting of Adapter D Thread Rp 3 4 E NOTE OOptional part P No 92005 3748 is available as a gar den hose adapter e Open the front storage compartment cover e Remove the flushing cap A e Screw a garden hose adapter B onto the flushing fitting C e Attach a garden hose D to a garden hose adapter and secure the hose clamp E e Start the engine and allow it to idle before turning on the water If the water is turned on before the engine is run ning water may flow back through the exhaust pipe and into the engine causing severe engine damage To prevent engine damage be sure the engine is running before turning the water on e Immediately turn on the water and adjust the flow so that a little trickle of water comes out of the bypass outlet A on the right side of the hull
298. rottle Position Sensor Removal Adjustment A shock to the throttle position sensor can damage it Do not drop the throttle position sensor e Remove Throttle Body Assy see Throttle Body Assy Removal Throttle Position Sensor Mounting Screws A Throttle Position Sensor B e When installing the throttle position sensor note the fol lowing OReplace the O ring A with a new one OAlign the projections B on the throttle position sensor with the throttle shaft C as shown when putting the throt tle position sensor to the throttle body assy OTurn the throttle position sensor counterclockwise A a little and temporarily tighten the throttle position sensor mounting screws e Adjust the throttle position sensor positioning as follows Olnstall the throttle body assy and air box temporarily OAfter warming up the engine check the idle speed Idle Speed Standard 1 300 100 r min rpm OStop the engine and remove the ignition key ODisconnect the throttle position sensor connector and connect the throttle sensor setting adapter A between the harness connector and throttle position sensor con nector Special Tool Throttle Sensor Setting Adapter 57001 1521 OConnect a digital meter to the throttle sensor setting adapter leads Throttle Position Sensor Output Voltage Connections to Adapter Digital Meter Y W sensor G W lead Digital Meter BK BL sensor BK W lead F
299. s outer surface from scratch damage with connecting rod edge Connecting Rod Side Bearing Insert A Dowel Pin B Claw Side C Cap Side Bearing Insert D Connecting Rod Cap E e Replace the connecting rod big end bolts and nuts with new ones e Be sure to clean the bolts nuts and connecting rods thoroughly with high flash point solvent because the new connecting rods bolts and nuts are treated with anti rust solution Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 6105060181 E JH11015BS1 JE JH11016BS1 Crankshaft and Connecting Rods ENGINE BOTTOM END 8 23 e Install the crankshaft see Crankshaft Installation e Install each connecting rod on its original crankpin Olnstall the cap on the connecting rod aligning the weight and diameter marks OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten t
300. sealed Air box O ring damaged Intake air duct loose Water or foreign matter in fuel 16 28 APPENDIX Troubleshooting 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 Air temperature sensor trouble Throttle sensor trouble Intake air pressure sensor trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Ignition coil trouble Air temperature sensor trouble Miscellaneous Throttle valve won t fully open Engine overheating Engine oil level too high Engine oil viscosity too high Camshaft cam worn Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect IC igniter in ECU trouble Fuel air mixture incorrect Intake air duct loose Air box poorly sealed Air box O ring damaged Compression high Carb
301. see Front Access Cover Removal Installation in the Hull Engine Hood chapter e Disconnect the immobilizer amplifier ignition switch lead connector A e Remove the grommet A from the immobilizer amplifier ignition switch lead e Pull out the immobilizer amplifier ignition switch e Installation is the reverse of removal Note the following NOTE ORoute the immobilizer amplifier ignition switch lead not to interfere with the steering cable and shaft Olnstall the immobilizer amplifier ignition switch so that the letters of the switch faces upward e Replace the seal with a new one ECU Electric Control Unit Replacement e Refer to ECU Removal and Installation in the Fuel System DFI chapter 14 78 ELECTRICAL SYSTEM Immobilizer System Immobilizer Relational Parts Replacement Chart Failed or Lost Part FPO Key SLO Key Immobilizer Orange Yellow Amplifier ECU FPO Key Orange SLO Key i Yellow Immobilizer Amplifier ECU o Replacement Part o Main Replacement Part Immobilizer System Inspection e Refer to the Amplifier Input Voltage Inspection in the Fuel System DFI chapter e Refer to the User Key Inspection in the Fuel System DFI chapter ELECTRICAL SYSTEM 14 79 Immobilizer System Immobilizer System Circuit AN BK BL R BK R RZY BK BK R ue IT S 0 BK i R of Hic FE PO mr
302. sensor see Speed Sensor Removal e Connect the speed sensor lead connector A to the bat tery B and the hand tester C as shown in the figure Special Tool Hand Tester 57001 1394 e Set the hand tester to DC 25 V range e Measure the speed sensor output voltage in low speed ORotate the waterwheel A by hand slowly Output Voltage in Low Speed G BK 0 battery voltage twice a rotation x If the voltage does not rise from zero to battery voltage twice a rotation replace the speed sensor e Measure the speed sensor output voltage in high speed ORotate the waterwheel A in a fair speed by compressed air B Output Voltage in High Speed G BK approx 5 V x If the voltage does not reach 5 volts when spun with com pressed air replace the speed sensor 4N10100BS1 JN10106BS1 14 52 ELECTRICAL SYSTEM Sensors Fuel Level Sensor Inspection e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter e Check that the float moves smoothly without binding and it should lower fully by own weight x If the float does not move smoothly replace the sensor Float in Full Position A 121 5 6 mm 4 783 0 2 in B Float in Empty Position C 318 5 6 mm 12 54 0 2 in D e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector Special Tool Hand Tester 57001 1394 Fuel Leve
303. ses avoid sharp bending kink ing flattening or twisting and run the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals GC170368S1 FUEL SYSTEM DFI 3 19 DFI Servicing Precautions Olf the watercraft is not properly handled the high pressure inside the fuel line can cause fuel to leak A or the hose to burst Check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed OTo maintain the correct fuel air mixture F A there must be no intake air leaks in the DFI system Be sure to install the oil filler cap A after filling the engine oil Torque Oil Filler Cap Hand tighten OWhen checking the DFI parts do not run the engine for 15 seconds or more without auxiliary cooling see Before Servicing section in the General Information chapter NOTICE Running the engine without auxiliary cooling for 15 seconds or more even at idle speed may damage the rubber components in the Exhaust System Do not run the engine for more than 15 seconds with out auxiliary cooling water OExecute the auxiliary cooling securely in case that fre quent engine running is required o JRO5012BS1 JC 168274 8 3 2
304. sh point solvent away from any ignition sources including any ap pliance with a pilot light e After removing the connecting rods from the crankshaft clean them with high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages 8 22 ENGINE BOTTOM END Crankshaft and Connecting Rods NOTICE Using connecting rods with different weight marks increases engine vibration To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D x If the connecting rods big end bearing inserts or crank shaft are replaced with new ones select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed Connecting rod bolts are designed to stretch when tightened reusing them can lead to catastrophic engine failure Never reuse connecting rod bolts See the table below for correct bolt and nut usage e Apply molybdenum disulfide grease to the connecting rod upper bearing A e Apply molybdenum disulfide oil solution to the inner sur faces B of the bearing inserts NOTICE Do not apply grease to the inner surface of the lower big end cap or to the outer surface of the lower bear ing insert e Install the bearing insert as shown to prevent it
305. solved User Key Inspection e Register the user key correctly see Key Registration in the Electrical System chapter x If the service code character Ignl appears again the transponder in the key is malfunction replace it FUEL SYSTEM DFI 3 63 Blank Key Detection Service Code Character 36 Ignl Immobilizer System Circuit a a jetar to E JN20054BW3 C Ignition Switch Immobilizer Amplifier Joint Connector P 12 V Joint Connector R 12 V Joint Connector T 12 V ECU Main Relay System Relay Joint Connector D 12 V Joint Connector C 12 V ECU Joint Connector E Ground Immobilizer Kawasaki Diagnostic System Connector Main Fuse 20 A Battery Joint Connector Y Ground 15 Joint Connector S Ground 16 Meter Unit Buzzer 18 Joint Connector Q Ground e ed eS 10 11 12 13 14 3 64 FUEL SYSTEM DFI Fuel Pump Relay Service Code Character 45 46 F P1 F P2 Fuel Pump Relay Removal Installation e Refer to the Relay Assembly Removal Installation in the Electrical System chapter Fuel Pump Relay A Fuel Pump Relay Inspection e Refer to the Relay Assembly Inspection in the Electrical System chapter x If the fuel pump relay is normal check the wiring for con tinuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 x If the wiring is good check the ECU for i
306. sor for Meter Unit Removal Installation e Remove Air Box see Air Box Removal in the Fuel System DFI chapter Band A Water Temperature Sensor for Meter Unit Lead Con nector B Water Temperature Sensor for Meter Unit C e Installation is the reverse of removal Note the following OTighten Torque Water Temperature Sensor for Meter Unit 8 8 N m 0 90 kgf m 78 in Ib JN10103BS2 Sensors ELECTRICAL SYSTEM 14 55 Water Temperature Sensor for Meter Unit Inspection e Remove the water temperature sensor for meter unit see Water Temperature Sensor for Meter Unit Re moval Installation e Suspend the sensor A in a container of water so that the threaded portion is submerged e Suspend an accurate thermometer B with temperature sensing portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently e Measure the internal resistance of the sensor with a digital meter OThe sensor sends electric signals to the meter unit OMeasure the resistance across the terminals at the tem peratures shown in the table Water Temperature Sensor for Meter Unit Resistance Water Temperature Sensor Resistance 20 C 68 F 12 17 13 92 kO 50 C 122 F 4 025 4 810 kQ 90
307. t e Push down on the rear of the seat to lock it Front Storage Compartment Cover Removal Installation e Pull A the latch handle B e Open C the front storage compartment cover D e Remove Hinge Bracket Nuts A and Washers Front Storage Compartment Cover Assembly B e Installation is the reverse of removal Front Storage Compartment Cover Disassembly e Remove Hinge Bolts A Damper Washer B Damper Pin C Hinge D Screws E Meter Cover F Front Duct Bolts G Front Hatch Mounting Screws H Front Duct I ment P Fittings HULL ENGINE HOOD 13 9 e Remove Lock Assembly Nut A Lock Assembly Bolts B Bracket Lock Assembly C e Remove Screen Bolts A Screen B Front Storage Compartment Cover Assembly e When installing the screen A on the front storage com partment cover insert its projection B into the recess C on the front storage compartment cover e Apply a non permanent locking agent to the screen bolts and tighten them securely e Install the washer A on the lock assembly e Align the projections B on the lock assembly with the holes C on the front duct e Apply a non permanent locking agent to lock assembly bolts and tighten them securely e Tighten the lock assembly nut e Insert the front storage cover projections A into the ribs B of the front duct e Tighten the front hatch mounting screws C both sides
308. t Camshaft Chain e Install the top dead center finder A and the gauge B with the extender Special Tool Top Dead Center Finder 57001 402 e Set the gauge to the 0 e Viewing from the bow turn the crankshaft clockwise by using the shaft wrench and read a maximum scale value of the dial gauge Special Tool Shaft Wrench 57001 1551 NOTE OThe scale value of the dial gauge reaches a maximum at the TDC Camshaft Camshaft Cap Wear Inspection e Remove the camshaft cap see Camshaft Removal e 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 e Tighten the camshaft cap bolts and upper camshaft chain guide bolts to the specified torque see Camshaft Instal lation NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap e Remove the camshaft cap again measure each clear ance between the camshaft journal and the camshaft cap using plastigage A Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 0063 in If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 942 in x If the camshaft journal diameter is less than the service limit replace t
309. t Check Valve Mounting e Refer to the Fuel Vent Check Valve Inspection in the Pe riodic Maintenance chapter Fuel Vent Check Valve Inspection e Refer to the Fuel Vent Check Valve Inspection in the Pe riodic Maintenance chapter FUEL SYSTEM DFI 3 105 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo sive under certain conditions To avoid a possi ble fire or explosion 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 includes any appliance with a pilot light NOTICE A shock to the fuel pump can damage it Do not drop the fuel pump e Remove the center access cover see Center Access Cover Removal Installation in the Hull Engine Hood chapter e Disconnect the fuel pump connector A e Pull the fuel hose joint B out of the fuel pump pipe see Fuel Hose Removal A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared SON P for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Cut the band C and pull out the fuel tank vent hose D e Loosen the lower side clamp screw E on the fuel pump rubb
310. t Hose Inspection e Remove the exhaust hoses A see Water Box Muffler Removal e Check the exhaust hoses for damage caused by exces sive heat x lf there is heat damage to the exhaust hose check the cooling system for blockage see Cooling and Bilge Sys tem Flow Diagram section in the Cooling and Bilge Sys tems chapter JE05012BS2 JE05013BS2 ENGINE TOP END 6 1 Engine Top End Table of Contents Exploded WE 6 2 Specifications ai Tdci 6 4 Special Tools and Sealant ccc ccccccecccecceeceeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeseeeeseeeeeeeseeeseeees 6 6 Cylinder Head COVE ui ld A ii ne ia ks 6 9 Cylinder Head Cover Removal incidido tdi eege 6 9 Cylinder Head Cover Installation tato 6 9 Camshaft Chain Tensioner cccccccccecccceeceeeceeeeeeeeeeeeeeeeeeeceneeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeess 6 11 Camshaft Chain Tensioner Removal ssssssesssenesessrrrtrrrrrtrrrrrrrrrrrrrrrrrrttrrtrtrttrrttrtrtrrrrnnt 6 11 Camshaft Chain Tensioner Installation oooononcccnnnnnnnnnnnnnnnnnnnnnononnnnnnnnnnnnnnnnnnnnnnnnnos 6 11 Camshaft Camshaft Cham 6 12 Camshaft Removals esso rendement ee donne drone nine tete 6 12 Camshaft Installation scsi menant basada dnd 6 13 Piston TDC Finding EE 6 15 Camshaft Camshaft Cap Wear Inspection 6 16 Camshaft Runout Inspection 6 16 Cam Wear Inspection oooooocccccccncconcconccnncnnnnnnnnnnnnnnnnonnnnnn
311. t Mounting Bolts 9 8 N m 1 0 kgf m 87 in 1b ORun the meter unit leads properly see Cable Wire and Hose Routing section in the Appendix chapter 2178012 P 4N17122BS1 Multifunction Meter ELECTRICAL SYSTEM 14 59 Meter Unit Operation Inspection If the meter unit is left upside down or sideways for a long time or dropped it will malfunction Do not drop the meter unit Place the meter unit so that it faces upward Do not short each terminal NOTE OBe sure the battery is fully charged OBe sure the wiring is normality see Meter Unit Circuit Check 1 1 Switching Inspection e Insert the ignition key in the ignition switch to turn it on and check the following OFollowing LCD segments appear gradually Speedometer A Multifunction Meter B Fuel Level Gauge C Tachometer D OThe red warning indicator light LED E goes on OThe buzzer sounds twice x If the LCD segments do not work replace the meter unit x lf the red warining indicator light LED does not go on replace the meter unit x If the buzzer does not work inspect the buzzer e Remove Front Access Cover see Front Access Cover Removal in the Hull Engine Hood chapter Rivets A e Disconnect the buzzer connector blue 2 pin A IO P LA W D Lil gt T Es V WM le 14 60 ELECTRICAL SYSTEM Multifunction Meter e Connect the battery to the buzze
312. t dial gauge reading is the runout If any measurement exceeds the service limit replace the shaft Drive Shaft Runout Service Limit 0 1 mm 0 0039 in A at 19 7 19 8 mm 0 776 0 780 in position 0 2 mm 0 0079 in B at 18 8 19 2 mm 0 740 0 756 in position 4J04022BS1 JJ04018BS1 PUMP AND IMPELLER 11 1 Pump and Impeller Table of Contents Exploded Mi Weiss A Sn ri nn latente 11 2 eelere EE 11 4 Special Tools and Sealant ccc cccccecccecceeccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeseenseeees 11 5 Pump and Impeller 53 52 Areata aaa aa ue nf de EE Ee dun dd 11 6 PUMp RemMOV alii Ao tad acts 11 6 Pump Installation 11 7 PUMP DISASSe MDI o 11 10 A led ne dan det Eet 11 13 Impeller Inspection 11 18 Impeller Outside Diameter Measurement 11 18 PUMP Inspection 11 18 Impeller Clearance Inspection neee 11 18 Water Filter Cover Removal Installation ooo ccocconccncccncconccnnccnnncnnnonncnnncnoncconaconacincnns 11 19 11 2 PUMP AND IMPELLER Exploded View Exploded View PUMP AND IMPELLER 11 3 No Fastener o Fastener O N Pump Bracket Mounting Bolts M6 9 8 Torque kgf m ft lb 87 mb Remarks m Pump Bracket Mounting Bolts M8 19 1 9 14 LN SS 1 0
313. t not x If the filter cannot be cleaned or if it is broken and allows debris to pass through replace it 9 6 COOLING AND BILGE SYSTEMS Cooling and Bilge System Hoses Hose Removal e 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 OSome of the bilge system hoses have plastic clamps at hose ends e All the cooling system hoses are clamped at both ends Loosen the clamps and pull the hoses off Hose Installation e To install the bilge filter hose push the hose over the end of the filter NOTE OSome of the bilge system hoses have plastic clamps at hose ends e When installing the cooling system hoses be sure to use the same kind of clamp as the original Some of the clamps are metal for tighter clamping ability required when smooth fittings are used Plastic clamps are used where tight clamping is not required Hose Inspection e Refer to the Hose and Hose Connect Inspection in the Periodic Maintenance chapter COOLING AND BILGE SYSTEMS 9 7 Cooling and Bilge System Flushing Cooling System Flushing e Refer to the Cooling System Flushing in the Periodic Maintenance chapter Bilge System Flushing e Refer to the Bilge System Flushing in the Periodic Main tenance chapter 9 8 COOLING AND BILGE SYSTEMS Cooling and Bilge System Flow Diagram J104035BW5 C COOLING AND BILGE SYSTEMS 9 9 Cooling and Bilge
314. t the side with the spring faces outward Special Tool Bearing Driver Set 57001 1129 e Fill the gap between the grease seals with lithium grease NLGI Grade No 2 and apply it each grease seal lip D e Install the circlip Special Tool Inside Circlip Pliers 57001 143 e Install the bushing E into the pump case e Fill with lithium grease NLGI Grade No 2 F e Using a press press the new bearings into the pump case A until they bottom out Special Tool Bearing Driver Set 57001 1129 B e Using a press install the pump shaft A into the bearing B until it bottoms out 4K04122BS2 4K04123BS2 Pump and Impeller PUMP AND IMPELLER 11 15 e Replace the O ring A with a new one e Install the O ring over the pump shaft B e Apply lithium grease NLGI Grade No 2 to the O ring e Replace the O ring A with a new one and install it e Apply lithium grease NLGI Grade No 2 to the O ring e Install the pump shaft B into the pump case e Apply molybdenum disulfide grease C to the thread of the pump shaft e Make sure the gap D between the bearing surface and pump case surface is over than 9 mm 0 35 in e Using a vise hold the pump shaft in the impeller holder A taking care not to damage it e Insert the impeller wrench B to the impeller Special Tools Impeller Wrench 57001 1228 Impeller Holder 57001 1695 e Tighten the impeller wrench with specified torq
315. tage changes according to the water tem perature in the engine e Remove the ignition key x If the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation lf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Water Temperature Sensor Connector B G Y lead ECU terminal 11 C BK W lead ECU terminal 32 D x If the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Resistance Inspection 8 G Y Ee BK W L SO gt J616228BS1 JC16304BS1 3 52 FUEL SYSTEM DFI Water Temperature Sensor Service Code Character 14 AqUt Water Temperature Sensor Resistance Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit IN el Ka BK W 6 Y JC163058 2 1 ECU 2 Water Temperature Sensor 3 Joint Connector B Ground FUEL SYSTEM DEI 3 53
316. te Bolts 7 8 0 80 69 in lb Intake Air Pressure Sensor Bolts 7 8 0 80 69 in lb ISC Actuator Mounting Bolts 5 0 0 51 44 in lb Intake Manifold Mounting Bolts 25 2 5 18 L Intake Manifold Mounting Nuts 20 2 0 15 Oil Temperature Sensor 15 1 5 11 Relay Mounting Bolts 2 5 0 25 22 in lb L Throttle Position Sensor Mounting Screws 20 2 0 18 in lb Stepping Motor Mounting Screws 2 0 0 20 18 in lb Throttle Body Assy Mounting Bolts 2 0 0 20 15 in lb Throttle Cable Locknut 19 6 2 0 14 Throttle Case Mounting Screw 3 9 0 40 35 in lb Vehicle down Sensor Mounting Screws 1 5 0 15 13 in lb Water Temperature Sensor 14 7 1 5 11 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torgus Remarks N m kgf m ftib Engine Lubrication System Breather Plate Bolts 7 8 0 80 69 in lb Dipstick Tube Bolts 8 8 0 90 78 mb L S Oil Catch Cover Bolts 7 8 0 80 69 in lb Oil Cooler Assembly Bolts 7 8 0 80 69 in lb Oil Cooler Positioning Bolt 20 2 0 15 S Oil Filler Cap a e 7 tune Oil Filter 18 1 8 13 EO R Oil Pan Bolts 20 2 0 15 S Oil Passage Bolt 78 8 0 58 S Oil Passage Joints 11 1 1 97 mb L Oil Passage Plug R1 4 7 8 0 80 69 in lb L Oil Passage Plug R3 8 20 2 0 15 L Oil Pressure Relief Valve 15 1 5 11 LN Oil Pressure Switch 15 1 5 11 L Oil Pump Body Bolts 7 8 0 80 69 in lb Oil Pump Body Plug 20 2 0 15 L Oil Pump Cover Bolts 7 8 0 80 69 in lb Oil Pump Sprocket Bolt 16 1 6 12 LN Oil Screen Bolts 7 8 0 80 69 in lb Oil Separator Tank Mounting N
317. tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below The camshaft chain tensioner can be damaged if not removed and reset causing severe engine damage To prevent damaging the cam chain tensioner do not loosen the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Tensioner Installation Turning the crankshaft while the cam chain ten sioner is removed can upset the timing and damage the valves Do not turn the crankshaft when the tensioner is removed e Remove Seats see Seat Removal in the Hull Engine Hood chap ter Cap Bolt A Washer B Spring C Rod D Mounting Bolts E Camshaft Chain Tensioner Body F JF07006BS1 Camshaft Chain Tensioner Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Release the stopper B and push the push rod C into the tensioner body D e Install the tensioner body so that the stopper faces down ward e Apply a non permanent locking agent to the threads of the tensioner mounting bolts A and tighten them Torque Camshaft Chain Tensioner Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Install Rod B Spring C Washer D e Tighten the ca
318. ter Set 57001 1457 Fuel Injector Output Voltage Connections to ECU Connector For Fuel Injector 1 Digital Meter gt V lead ECU terminal 42 Digital Meter Battery terminal For Fuel Injector 2 Digital Meter gt O lead ECU terminal 51 Digital Meter Battery terminal For Fuel Injector 3 Digital Meter BR lead ECU terminal 38 Digital Meter Battery terminal For Fuel Injector 4 Digital Meter BL Y lead ECU terminal 47 Digital Meter Battery terminal e Measure the output voltage with the engine stopped and with the connector joined e Insert the ignition key in the ignition switch to turn it on Output Voltage Standard Battery Voltage for 3 seconds and then 0 V e Remove the ignition key x lf the reading is in specification check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation J616325BS1 Fuel Injectors FUEL SYSTEM DFI 3 83 x If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and injector connectors Wiring Continuity Inspection ECU Connector A Fuel Injector Connector B For Fuel Injector 1 V lead ECU terminal 42 C For Fuel Inject
319. tery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below Criteria Judgement 12 8 V or more Good 12 0 less than 12 8 V Charge insufficient Recharge less than 12 0 V Unserviceable Replace b IAI La JNO5002BS1 Electric Starter System ELECTRICAL SYSTEM 14 23 Starter Relay Removal e Remove Battery Cover see Battery Cover Removal Installation e Disconnect the negative battery cable A e Unhook the battery straps B e Disconnect the starter relay lead connector C e Slide out the rubber caps D and remove the starter relay terminal bolts e Take the starter relay E off the bracket F Starter Relay Installation e Install the rubber damper A to the starter relay B as shown in the figure e Install the starter relay and tighten the starter relay termi nal bolts A Starter Motor Cable B Battery Positive Cable C Torque Starter Relay Terminal Bolts 5 5 N m 0 56 kgf m 49 in lb e Apply water resistance grease to both terminals e Fill the terminal rubber caps full with water resistance grease and install the rubber caps on the terminal bolts e Connect the starter relay lead connector e Hold the starter relay lead and the starter motor cable with the battery strap Starter Relay Inspection e Remove the starter relay see Starter Relay Removal e Set the hand tester to x 1 Q r
320. the O rings A of each fuel injector B with new ones e Apply grease to the O rings e Insert each fuel injectors to the delivery pipe assy C and confirm whether the injectors turn smoothly or not e Replace the dust seals A with new ones e Apply grease to the inside and outside of dust seals e Insert the new dust seals to the intake manifold B e Install the fuel injectors along with the delivery pipe assy to the intake manifold e Install the collars A clamps B and bolts C as shown in the figure e Tighten Torque Delivery Pipe Assy Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib e Run the hoses leads and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Fuel Injector Audible Inspection NOTE OBe sure the battery is fully charged e Remove the seats see Seat Removal in the Hull Engine Hood chapter FE J616319BS1 3 80 FUEL SYSTEM DFI Fuel Injectors e Start the engine e Apply the tip of a screwdriver A to the fuel injector B Put the grip end onto your ear and listen whether the fuel injector is clicking or not OA sound scope can also be used OThe click interval becomes shorter as the engine speed rises e Do the same for the other fuel injectors x If all the fuel injectors click at a regular intervals the fuel injectors are normal e Remove the ignition key lf any
321. the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the following Intake Air Temperature Sensor Resistance Standard 5 4 6 6 kQ at 0 C 32 F 0 29 0 39 kQ at 80 C 176 F x If the reading is out of the standard replace the sensor x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Cap CC MAA J616300BS1 4016226BS2 FUEL SYSTEM DEI 3 49 Intake Air Temperature Sensor Service Code Character 13 Alrt Intake Air Temperature Sensor Circuit eg hr cams JC163018 2 1 ECU 2 Intake Air Temperature Sensor 3 Joint Connector B Ground 3 50 FUEL SYSTEM DFI Water Temperature Sensor Service Code Character 14 AqUt Water Temperature Sensor Removal Installation A shock to the water temperature sensor can dam age it Do not drop the water temperature sensor e Remove the seats see Seat Removal in the Hull Engine Hood chapter e Cut the band A e Disconnect the connector B e Unscrew the water temperature sensor A e Fill the hollow of the exhaust manifold A with the engine oil 10W 30
322. the following table Possible Causes Incorrect engine oil level Engine oil poor quality or incorrect Oil temperature sensor broken Oil cooler clogged Oil pump malfunction Relief valve malfunction Water passage clogged loosened or damaged Weeds or debris in jet pump Actions Inspect see chapter 4 Change see chapter 4 Inspect see chapters 3 and 14 Clean see chapter 4 Inspect see chapter 4 Inspect see chapter 4 Inspect see chapter 9 Inspect see chapter 11 FUEL SYSTEM DEI 3 77 Red Warning Indicator Light LED Light LED Inspection The red warning indicator light LED A is used for the following warnings Fuel Level Low Battery Voltage Engine Cooling Water Temperature Engine Oil Pressure Oil Temperature Sensor Engine Oil Overheat Fl JG16285BS1 C Immobilizer e Refer to the Meter Unit Operation Inspection in the Elec trical System chapter Red Warning Indicator Light LED Fl Immobilizer Circuit JC16324BH2 1 Joint Connector Q Ground 2 ECU 3 Joint Connector E Ground 4 Joint Connector Y Ground 5 Joint Connector S Ground 6 Meter Unit 3 78 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Removal WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the potential for serious burns Make sure the area is well venti lated and free from any source of flame or sparks this inclu
323. the hollows D on the lock Side Cover Removal e For US and EUR models remove the steering front cover A e To remove the left side cover remove the following e Remove the fuel filler cap A e Pull up the shift lever A e Remove Bolts B Nuts and Washers Nut C and Washer Left Side Cover D e To remove the right side cover A remove the following Center Storage Lid see Center Storage Lid Removal In stallation Bolts B Nuts and Washers Nut C and Washer MED P HULL ENGINE HOOD 13 13 Fittings e Loosen the clamp screw A e Remove the flushing hose B Side Cover Installation e Installation is the reverse of removal noting the following OBe sure that the rear end of flushing line is connected with its fitting surely Front Access Cover Removal Installation e Open the front storage compartment cover e Remove the front storage case e Push in the pins A and remove the front access cover B e Installation is the reverse of removal Center Access Cover Removal Installation e Remove the steering cover see Steering Removal in the Steering chapter e Pull out the center access cover A e Installation is the reverse of removal Mirror Removal Installation e Remove the side cover see Side Cover Removal e Remove the nuts A and washers and remove the mirrors B both sides e Installation is the reverse of removal 13 14 HULL EN
324. the ignition switch to turn it on Power Source Voltage Standard Battery Voltage for 3 seconds and then 0 V e Remove the ignition key x If the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Assembly In spection in the Electrical System chapter lf the fuel pump relay is normal check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If there is still no battery voltage check the fuel pump relay see Relay Assembly Inspection in the Electrical System chapter x If the fuel pump relay is normal check the power source wiring see Fuel Injector Circuit Special Tool Hand Tester 57001 1394 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is in specification check the output voltage see Fuel Injector Output Voltage Inspection J616252BS1 3 82 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition key e Remove the ECU see ECU Removal ODo not disconnect the ECU connector e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adap
325. the tip A of the cable lower end on the throttle pivot arm B e Install the removed parts see appropriate chapters e After installation adjust the cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter Throttle Cable Lubrication e Refer to the Lubrication in the Periodic Maintenance chapter DEED P 3 94 FUEL SYSTEM DFI Air Box Air Box Removal e Remove Handrail Plate see Handrail Plate Removal in the Hull Engine Hood chapter Clamp Screw A Loosen Clamp B Air Box C Air Box Installation e Installation is the reverse of removal e Apply a non permanent locking agent to the air box bracket mounting bolts and tighten them Torque Air Box Bracket Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Air Box Disassembly e Remove Air Box see Air Box Removal Air Box Bolts A e Remove Bolts A Flame Arrester B Hose C Duct D Air Box Bracket Mounting Bolts E Air Box Bracket F e Remove the air screen A 30178017 P 3178019 P FUEL SYSTEM DFI 3 95 Air Box Air Box Assembly e Visually inspect the seal A for damage x If necessary replace it with a new one e Install the flame arrester B hose C and duct D as shown in the figure e Tighten Torque Air Box Flame Arrester Bolts 2 5 N m 0 25 kgf m 22 in lb EI P e Install the air screen A aligning the marks B e Install the ai
326. tight and examine leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring ELECTRICAL SYSTEM 14 15 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range and read the tester x If the tester does not read 0 Q the lead is defective Re place the lead or the wiring harness B if necessary JNO3005BS1 14 16 ELECTRICAL SYSTEM Battery Battery Cover Removal Installation e Open the front storage compartment cover see Front Storage Compartment Cover Removal in the Hull Engine Hood chapter e Remove the front storage case e Push in the pin heads A and remove the battery cover B e To install the battery cover pull up the pin head A as shown and install the rivet B e Push in the pin head A Battery Removal e Disconnect the b
327. tightening tightening Connect Usable Range of ing Rod Connecting Rod Assy Bolt Stretch Use the bolts attached to Attached to 0 20 0 29 mm New new ton rod new con rod 0 0079 0 0114 in New New Replace the Replace the 0 20 0 29 mm Used bolts with new nuts with new 0 0079 0 0114 ones ones in 2 Rotation Angle Method If you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method e Install new bolts and nuts in reused connecting rod e Apply molybdenum disulfide oil solution to the threads A and seating surfaces B of the connecting rod nuts 6105040481 e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 5 OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly Connecting Torque Angle Bolt Nut Rod Assy N m kgf m ft lb Use the bolts attached to Attached to 18 1 8 13 120 6105040581 New new con rod new con rod New New 18 1 8 13 120 Replace the Replace the Used bolts with nuts with new 18 1 8 13 120 new ones ones Crankshaft and Connecting Rods ENGINE BOTTOM END 8 25 Connecting Rod Bend Inspection e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end caps e Select an arbor A of the same diameter as the connect ing rod big
328. tion is the reverse of removal Note the following OApply a non permanent locking agent to the bracket bolts OTighten Torque Regulator Rectifier Bolts 7 8 N m 0 80 kgf m 69 in Ib Bracket Bolts 8 8 N m 0 90 kgf m 78 in Ib Regulator Rectifier Inspection e With the hand tester set to the x 1 KQ range test the regulator rectifier according the following table Special Tool Hand Tester 57001 1394 Regulator Rectifier Inspection Unit kQ Tester Lead Connection Terminal JNO7015BS1 2 20 500 500 o 2 40 2 20 GI Tester lead Connection x lf any of the values obtained does not match with the above table the regulator rectifier must be replaced Regulator Inspection OTo test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads The test light works as an indicator and also as a current limiter to protect the regulator rectifier from excessive current Do not use an ammeter instead of a test light 14 32 ELECTRICAL SYSTEM Charging System e Do the 1st step regulator circuit test OConnect the test light and the 12 V battery to the regula tor rectifier as shown OCheck infinity terminals respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test e Do the 2nd step regulator
329. tle Cable Installation 3 93 Throttle Cable Lubrication 3 93 AIP BOX utili daa 3 94 Air Box Removal 3 94 Air Box Installation 3 94 Air Box Disassembly 3 94 Air Box Aesembhy 3 95 Throttle Body Assy 3 96 Idle Speed Inspection 3 96 Throttle Body Assy Removal 3 96 Throttle Body Assy Installation 3 96 Throttle Body Assy Disassembly 3 96 Throttle Bore Cleaning 3 97 ISC Idle Speed Controller Removal Installation 3 97 ISC Idle Speed Controller Inspection 3 97 ISC Resistance Inspection 3 98 Intake Manifold 3 99 Intake Manifold Removal 3 99 Intake Manifold Installation 3 99 Fuel Une 3 100 Fuel Hose Removal 3 100 Fuel Hose Installation 3 101 Fuel Pressure Inspection 3 101 Fuel Flow Rate Inspection 3 102 Fuel Vent Check Valve 3 104 Fuel Vent Check Valve Mounting 3 104 Fuel Vent Check Valve Inspection 3 104 Fuel PUMP 3 105 Fuel Pump Removal 3 105 Fuel Pump Installation 3 106 Fuel Pump Operation Inspection 3 108 Fuel Pump Operating Voltage Inspection 3 109 Pressure Regulator Removal
330. tor C e Disconnect Oil Pressure Switch Connector A e Loosen the clamp screw B and remove the water hose C ENGINE REMOVAL INSTALLATION 7 5 Engine Removal Installation e Disconnect Starter Motor Terminals A e Disconnect Alternator Lead Connector A e Remove Bolts A and Clamps Coupling Cover B e Loosen the clamp screw A and remove the water hose B e Remove the engine mounting bolts A 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Move the engine forward to separate the couplings A e Lift the engine with a lifter A and remove the engine as shown in the figure Engine Damper Removal e Remove Engine Damper Mounting Bolts A Engine Damper B Shim C 0 3 pieces Bow D e Record the number of shims of four positions so that they can be put back in the same position NOTICE Incorrect shims could cause drive shaft misalign ment Install the shims to the same position Engine Damper Installation e Install the shim s of the same number e Apply a non permanent locking agent to the engine damper mounting bolts and tighten them Torque Engine Damper Mounting Bolts kgf m 12 ft lb 15 7 N m 1 6 Engine Installation e Be sure there are no foreign objects and parts inside of the hull e Clean the bilge filters see Filter Cleaning and Inspection in the Cooling and Bilge Systems chapter e Inspect the coupling damper see Coupling D
331. ts Too narrow Too wide Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase width of seat 60 or 55 Grind area beyond spec to increase O D Tool 60 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve and seat area check valve head for damage FINISHED GE15134B F Cylinder Pistons ENGINE TOP END 6 31 Cylinder Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder Head see Cylinder Head Removal e Remove Clamp A Oil Hose B Cylinder C Cylinder Installation NOTE Olf a new cylinder is used use new piston ring e Install the knock pins A and new cylinder gasket B e 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 Top Ring A Second Ring B Oil Ring Steel Rail Upper C Oil Ring Expander D Oil Ring Steel Rail Lower E Dent F 30 40 G e Apply molybdenum disulfide oil solution to the cylinder bore piston rings and piston skirt e Insert the piston in the cylinder by either of the follow ing two methods With the Hands of With the Spe
332. ts ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation FUEL SYSTEM DEI 3 65 Fuel Pump Relay Service Code Character 45 46 F P1 F P2 Fuel Pump Relay Circuit CT HFE 0 E en Eee E R Y ne R BK 2 SE SS a R DI BK Di K BL e S T of D ds 1 Ignition Switch 10 Joint Connector D 12 V 2 Joint Connector P 12 V 11 ECU 3 Joint Connector R 12 V 12 Joint Connector C 12 V 4 Fuel Pump 13 Joint Connector E Ground 5 Joint Connector T 12 V 14 Main Fuse 20 A 6 ECU Main Relay 15 Battery 7 Fuel Pump Relay 16 Joint Connector Y Ground 8 System Relay 17 Joint Connector S Ground 9 Joint Connector L 12 V 3 66 FUEL SYSTEM DFI Ignition Coils Service Code Character 51 52 COL1 COL2 Ignition Coil 1 4 Service Code Character 51 COL1 Ignition Coil 2 3 Service Code Character 52 COL2 Ignition Coil Removal Installation e Refer to the Ignition Coil Removal Installation in the Elec trical System chapter Ignition Coil Primary Winding Resistance Inspection e Refer to the Ignition Coil Inspection in the Electrical Sys tem chapter x If the reading is within the standard check the input volt age see Ignition Coil Input Voltage Inspection Ignition Coil Input Voltage Inspection NOTE OBe sure the battery is fully charg
333. ty O ring at the oil passage in the crankcase damaged Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery cable making poor contact Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty Poor Performance through Engine Runs Properly Jet pump Intake area obstructed Impeller or pump case damaged Excessive clearance between impeller and pump case Poor Steering Control Since faulty steering is dangerous this problem should be examined by an authorized Jet Ski dealer Handlebar hard to turn Steering maladjusted APPENDIX 16 29 Bushing damaged or cracked Steering shaft bent No lubricant on steering pivot Steering cable damaged or improperly routed Engine Activates Slow Down Mode Cooling water temperature gets high Weeds or debris in jet pump Cooling water line clogged Low oil pressure Low oil level Improper engine oil quality Water temperature sensors malfunction wiring open or short Vehicle down sensor malfunction wiring open or short Oil temperature sensor gets high Low oil level Oil pump malfunction Oil pressure relief valve malfunction Weeds or debris in jet pump Cooling water line clogged Oil temperature sensor malfunction wiring open or short MODEL APPLICATION Year Model Beginning Hull No US KAW500010112 Se 9T1500KC Us KAW5900101112
334. ue Torque Impeller 147 N m 15 0 kgf m 108 ft Ib 4K04115BS2 11 16 PUMP AND IMPELLER Pump and Impeller e Measure the gap A between impeller end and pump case end x If the gap is not over than 10 5 mm 0 413 in disassem ble the pump again e Turn the pump case upside down e Using a vise hold the pump shaft in the impeller wrench A e Tighten Torque Pump Shaft Nut B 98 N m 10 kgf m 72 ft Ib e Visually inspect impeller seal A and replace it if neces sary e Apply cyanoacrylate cement to the impeller seal e Install the seal on the impeller JK04126BS2 CCP Hof Ta JK04127BS2 KOMISI P Pump and Impeller PUMP AND IMPELLER 11 17 e Replace the O rings A with new ones and install them e Apply lithium grease NLGI Grade No 2 to the O rings B Pump Cap C Pump Cap Plug e Apply a non permanent locking agent to the threads of the pump cap bolts A e Install the pump cap bolts and washers e Tighten Torque Pump Cap Bolts 3 9 N m 0 40 kgf m 35 in Ib e Apply a non permanent locking agent to the threads of the pump cap plug B and tighten it e Install the trim seal A to the pump case e Install the spacer so that the marked side A faces down ward e Apply a non permanent locking agent to the thread of the pump outlet mounting bolts A e Install the pump outlet B
335. uel Hose Installation e Start the engine and check for fuel leakage J616326BS1 4016327BS2 3 84 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Circuit EEE ey ZII lt gt e Sei EE Se PU ll g cesse BK BL R BK RS C OATH we TL kort ey HE KE EB CHE sl TEO ji q ne JC16328BH3 C Ignition Switch Joint Connector P 12 V Joint Connector R 12 V Joint Connector T 12 V ECU Main Relay Fuel Pump Relay System Relay Fuel Injector 1 Fuel Injector 2 10 Fuel Injector 3 11 Fuel Injector 4 12 Joint Connector L 12 V 13 Joint Connector D 12 V 14 Joint Connector C 12 V 15 ECU 16 Joint Connector E Ground 17 Main Fuse 20 A 18 Battery 19 Joint Connector Y Ground 20 Joint Connector S Ground SOK 00 NO OS NES ECU FUEL SYSTEM DFI 3 85 ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the watercraft cannot clear the regulation Model Part Number A Specification US 21175 0751 JT1500K AU 21175 0768 EUR ECU Removal A shock to the ECU can damage it Do not drop the ECU e Remove Front Access Cover see Front Access Cover Re moval Installation in the Hull Engine Hood chapter Mountin
336. ug cap shorted or not in good con tact IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Wiring shorted or open Fuse blown Fuel air mixture incorrect Air passage clogged Air box poorly sealed Fuel injector trouble Water or foreign matter in fuel Throttle sensor trouble Fuel pressure may be low Fuel pump trouble Intake air pressure sensor trouble Intake air temperature sensor trouble Water temperature sensor trouble Crankshaft sensor trouble Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Ignition coil shorted or not in good contact Ignition coil trouble Spark plug incorrect Spark plug cap trouble Spark plug cap shorted or not in good con tact IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Fuel air mixture incorrect Air passage clogged Air box poorly sealed Fuel tank air vent obstructed Fuel pump trouble Intake air duct loose Fuel pump screen and or fuel filter clogged Troubleshooting Guide T
337. und B goes off refer to the following failure illustrations Immobilizer Amplifier Failure Service Code Character 35 Imb Key Collation Error Service Code Character 36 Ignl e The user key 2 is successfully pre registered in the ECU OThe red warning indicator light LED A blinks 2 times and stops for 1 second and then repeats this cycle NOTE OOnly the first one cycle the buzzer sounds B goes off synchronizing with the blink of the red warning indicator light LED e Continue the procedures to register additional 4 user keys NOTE OThe ECU can store up the six key codes FPO key x n and SLO key x n Red Warning Indicator Light LED Blink and Buzzer Sound Red Warning Indicator Light LED Blinks and Remarks Buzzer Sound Stop User Key 3 3 times 1 second Repeat User Key 4 4 times 1 second Repeat User Key 5 1 second Repeat User Key 6 6 times 1 second Repeat NOTE OOnly the first cycle the buzzer sound goes off synchro nizing with the blink of red warning indicator light LED Red Warning Indicator Light LED Blinks and Buzzer Sound 0 3second second JU Lo 0 3second _ SE 0 3second JN20057BS1 ely O Sof A JN20058BS1 Immobilizer System ELECTRICAL SYSTEM 14 71 Regular Registration of User Key e Leave the user key 1 6 in the ignition switch e Press key for a long time 2 seconds or more OThe E
338. unting Bolts 89 in lb Camshaft Chain Tensioner Cap Bolt 15 Cylinder Head Cover Bolts 89 in lb Spark Plugs 115 in lb Breather Plate Bolts 69 in lb Harness Clamp Mounting Bolts 78 in lb L Oil Filler Cap Hand tighten Exhaust Side Camshaft Chain Guide 106 in lb Bolt Lower 106 ini 106 ini 106 ini 15 Cylinder Head Bolts M11 First 17 Cylinder Head Bolts M11 Final 44 16 Cylinder Head Bolts M7 20 2 0 15 1 Water Jacket Plugs 19 6 2 0 14 1 2 7 12 106 int 15 97 into cet EO Apply engine oil G Apply grease L Apply a non permanent locking agent LN Apply a non permanant locking agent High Strength Loctite 271 equivalent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 6 4 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 1 419 in Intake 36 443 36 557 mm 1 4348 1 4392 in 36 34 mm 1 431 in Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout 0 028 0 071 mm 0 0011 0 0028 in 23 950 23 972 mm 0 9429 0 9438 in 24 000 24 021 mm 0 9449
339. ure Sensor for Meter Unit 8 8 0 90 78 in lb 17 Intake Air Temperature Sensor 18 Intake Air Pressure Sensor 19 Air Temperature Sensor for Meter Unit 20 Buzzer 21 Steering Position Sensor 22 Magnet DG Fill the hollow with the heat transfer grease Heat Transfer Grease SCH 20 92137 1002 or equivalent EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant WG Apply water resistantce grease 14 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 14 9 Exploded View Fast Torque Ge Nm kgfm feb 2 starter Relay Terminal Bols 55 ose 49imb 3 Starter Motor Mounting Bots 88 oso 78imb vo OO e 5 Starter Motor Through Bolts 0 65 57 in lb 6 Starter Motor Terminal Nut S 0 90 78 in lb 7 IECH Mounting Bolts 3 0 0 31 27 in lb L 8 Relay Mounting Bolts 2 5 0 25 22 ml L 9 Aluminum Tray EUR Model G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts WG Apply water resistance grease 14 10 ELECTRICAL SYSTEM Wiring Diagram Immobilizer Ignition Switch Joint Joint Connector Connector P 12 R 12 Amplifier pees zz reese 22 ceded Py R BK BL R BK EX INMOG TX 1MMOB Joint Connector Ground BK Vehicle Fuel down Pump Sansor Joint Connector T 12 R
340. uts 4 9 0 50 43 in lb L Exhaust System Exhaust Manifold Mounting Bolts 25 25 18 L S Exhaust Manifold Mounting Nuts 25 2 5 18 S Exhaust Pipe Mounting Bolts 45 4 6 33 Exhaust Pipe Mounting Plate Bolts 30 3 1 22 L Front Exhaust Hose Clamp Screws 5 0 0 51 44 in lb Rear Exhaust Hose Clamp Screws 5 0 0 51 44 in lb Water Hose Joints 11 1 1 97 mb L Engine Top End Camshaft Cap Bolts L 40 mm 12 1 2 106 in lb S Camshaft Cap Bolts L 50 mm 12 1 2 106 mb S Camshaft Chain Tensioner Cap Bolt 20 2 0 15 Camshaft Chain Tensioner Mounting Bolts 10 1 0 89 in lb L Camshaft Position Sensor Rotor Bolt 12 1 2 106 mb LN Cylinder Head Bolts M11 Final 60 6 1 44 MO S Cylinder Head Bolts M11 First 23 2 3 17 MO S Cylinder Head Bolts M6 12 1 2 106 in lb S Cylinder Head Bolts M7 20 2 0 15 S Cylinder Head Cover Bolts 10 1 0 89 in lb Breather Plate Bolts 7 8 0 80 69 in lb Engine Hook Bolts 20 2 0 15 PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Exhaust Side Camshaft Chain Guide Bolt Lower 12 1 2 106 in lb Exhaust Side Camshaft Chain Guide Bolt Upper 25 2 5 18 Harness Clamp Mounting Bolts 8 8 0 90 78 in lb L Intake Side Camshaft Chain Guide Bolt 12 1 2 106 in lb L Oil Passage Joints 11 1 1 97 in lb L Spark Plugs 13 1 3 115 in lb Upper Camshaft Chain Guide Bolts 12 1 2 106 in lb S Water Hose Joint 11 1 1 97 in lb L Water Jacket Plugs 19 6 2 0 14 L Engine Removal Installation Engine Damper Mounting Bolts 15 7 1 6 12 L
341. val e Remove Coupling see Coupling Removal Output Cover Bolts A Output Cover B 8 8 ENGINE BOTTOM END Coupling Output Shaft e Remove Alternator Cover Bolts A Alternator Cover B e Remove Engine Bracket Mounting Bolts A Engine Brackets B e Place the wooden block under the engine to avoid dam age to the engine e Turn the engine so that the intake ports face upward e Hold the engine with a suitable belt tightly e While holding the alternator rotor A with the rotor holder B remove the output shaft C Special Tool Rotor Holder 57001 1544 Output Shaft Installation e Turn the engine so that the exhaust ports face upward e Place the wooden block under the engine to avoid dam age to the engine e Hold the engine with a suitable belt tightly e Apply molybdenum disulfide oil solution to the seating sur face of the output shaft e While holding the alternator rotor A with the rotor holder B tighten the output shaft C Special Tool Rotor Holder 57001 1544 Torque Output Shaft 265 N m 27 0 kgf m 195 ft lb Coupling Output Shaft ENGINE BOTTOM END 8 9 e Apply silicone sealant A to the crankcase halves mating surfaces on the alternator cover Sealant Liquid Gasket TB1211F 92104 0004 e Be sure to install the dowel pins B e Be sure to install the washer C on the reduction gear shaft e Apply molybdenum disulfide grease
342. vent shocks do not inspect the electrical system while the boat is in the water and do not touch the alter nator output leads while the engine is running Operating the engine without cooling water for more than 15 seconds especially at high rpm will cause severe engine and exhaust system damage To avoid engine damage do not run the engine without providing sufficient cooling water Alternator Output Voltage at 3 000 r min rpm Connections Tester Range Reading Tester to Tester to 250 V AC W lead W lead 48 72 V x If the alternator output voltage is correct check the regu lator see Regulator Rectifier Inspection x lf the alternator output voltage is low check the stator coil resistance with a digital meter according to the following table Stator Coil Resistance at 20 C 68 F Tester Range Reading Tester to Tester to x If the coil has normal resistance but the voltage check shows the charging system to be defective then the permanent magnets in the alternator rotor have probably weakened necessitation alternator rotor replacement ELECTRICAL SYSTEM 14 31 Charging System Regulator Rectifier Removal Installation e Remove the seat see Seat Removal in the Hull Engine Hood chapter e Remove Bracket Bolts A e Disconnect the connector A e Remove Regulator Rectifier Bolts B Regulator Rectifier C e Installa
343. w Chart erostean MAR Ria A a A E A tn nes 4 4 Specifications rire A a Aae ae A aaa aa aaa tenes 4 10 Special TOONS EE 4 11 Engine Qil and el IN EE 4 12 Oil Level Inspection see 4 12 14 Engine On Changement Se en aa nn Ten ee AN Ge 4 14 Oil Filter Replacement seen 4 14 AA NN 4 15 Oil Cooler Removal T 4 15 Oil Cooler Installation tina ata 4 15 Ol Cooler eet cio nn G eii lea a 4 16 leen te EE 4 17 Oil Gooler Inspection idad lloc natalidad rasa the cinc ninia das 4 17 Oil Separator Tankian da dad 4 18 Oil Separator Tank REMOVAL siens 4 18 Oil Separator Tank Installation ssenneeeeeneeeeeeeseeeeeererrrrerrrrrrrrrrrrrrrerrrrrttrrttrrtrrrterrrrrrrrent 4 18 Blowby Gas System Inspection EE 4 18 A AS 4 19 Oll Pan Removal rta da ge 4 19 EUR GEI El DE UE e EE 4 20 Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve 4 21 Oil Pump Sprocket Removal sise 4 21 Oil Pump Sprocket Installation ss 4 21 OIUPUMP REMOVAl EE 4 22 SUR Silder 4 22 OIPUMp INSpectiON DEET 4 22 Oil Screen HRemoval a E N E EE on aa aei EEE eea aani 4 23 OilScreen Wl E EU e ET 4 23 Oil Pressure Relief Valve Inspection 4 23 Oil Pump Chain Removal Installation ooococcccnnccnncnnnncnnnnnnnononnnnnnnnnonnnnnnnnnnnnninnnos 4 24 Oil Pressure Measurement 4 25 Oil Pressure Measurement sise 4 25 A 5h T E rater desire eitrtenenseestatas dada eege tentes 4 26 Oil Pressure Sw
344. water x If the idle speed is within the standard the ISC operates properly x If the idle speed is out of the specified range inspect the audible operation 2168317 P J616076BS1 3 98 FUEL SYSTEM DFI Throttle Body Assy e Run the engine and then stop the engine e Certain buzzing and humming sounds will be emitted from the ISC A after the engine stop x If the ISC sounds inspect the ISC resistance x If the ISC does not sound replace the steeping motor ISC Resistance Inspection e Remove Air Box see Air Box Removal ISC Connector A Disconnect e Measure the ISC resistance with the hand tester Special Tool Hand Tester 57001 1394 ISC A Rotor B ISC Resistance Connection 1 2 2 3 4 5 5 6 terminals Standard About 30 Q at 20 C 68 F Connection 1 3 4 6 terminals Standard About 60 Q at 20 C 68 F x If the reading is out of the specified value replace the steeping motor 130 ieee 4 5 6 JC16058BS2 C FUEL SYSTEM DEI 3 99 Intake Manifold Intake Manifold Removal e Remove Throttle Body Assy see Throttle Body Assy Removal Fuel Injector with Delivery Pipe Assy see Fuel Injector Removal e Disconnect Intake Air Temperature Sensor Connector A Intake Air Pressure Sensor Connector B e Free the main harness C from the clamps e Remove Intake Manifold Mounting Bolts D and Nuts E Intake Manifold F Intake Manifold Inst
345. witch to turn it on Output Voltage Usable Range DC 3 75 4 25 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to local atmo spheric pressure e Remove the ignition key x If the reading is out of the usable range replace the sen sor Output Voltage Performance at Input Voltage 4 75 5 25 V P Vacuum Pressure Vo Output Voltage J616251BS1 v 4 000 o 1 842 0 789 7 20 46 66 101 32 P KPa abs JC16031BS1 3 46 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code Character 12 bOSt x If the reading is within the usable range remove the ECU and check the wiring for continuity between main harness connector Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors CW CC MATAR AN Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor Connector B G R lead ECU terminal 23 C PISE ZE BK W lead ECU terminal 32 D x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection e f the ground and power supply are good replace the ECU see ECU Removal Installation Intake Air Pressure Sensor Circuit E THO JC16299BW2 1 Joint Connector F 5 V 2 ECU 3 Intake Air Pressure Sensor 4 Joint Connector B Ground FUEL SYSTEM
346. wn wards OPainted side faces upward Valve Spring Paint Color EX Red IN Blue Valve Stem A Spring Seat B Oil Seal C Closed Coil End D Valve Spring Inner E Valve Spring Outer F Retainer G Split Keepers H Paint Mark I ELIT JRO8002BS1 6E15043BS1 JF10008BS1 6 24 ENGINE TOP END Valves Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head Heating the cylinder head with a torch will warp the head To prevent warping the cylinder head soak it in hot oil Special Tool Valve Guide Arbor 5 57001 1203 Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F NOTICE Heating the cylinder head with a torch will warp the head To prevent warping the cylinder head soak it in hot oil e 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 far Special Tool Valve Guide Arbor 5 57001 1203 e Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer A even if the old guide is reused OTurn th
347. worn parts lubricating parts to ensure that they do not become rusted and in general preparing the watercraft so that when the time comes to use it again it will be in top condition Since Jet Ski personal watercraft are not designed to be docked in the water for extended periods pro longed immersion in water will cause the hull paint to bubble and peel as well as electrolytic erosion of some metal parts in the jet pump To prevent paint damage and electrolytic erosion remove your Jet Ski watercraft from the water at the end of each day s use do not leave it in the water overnight Your Jet Ski watercraft will last longer and look bet ter if you remove itfrom the water atthe end of every day s use Cooling System e Clean the cooling system see Cooling System Flushing in the Periodic Maintenance chapter e When storing the watercraft in an area where the temper ature drops below freezing perform the following Discharging water in the exhaust system NOTICE Water in the exhaust system could freeze during cold weather and damage the exhaust pipe Dis charge water from the exhaust system after flush ing the cooling system e After flushing remove the cooling water hose C from the fitting B on the engine output cover A at the rear of the engine Lead the hose to the lowest level in the engine room so that water remaining in the exhaust pipe D drains out Air Box E e Connect the hose to fittin
348. x 1 341 HP N x 0 2248 Ib PS x 0 7355 kW kg x 9807 N PS x 0 9863 HP kg x 2 205 Ib Units of Temperature 5 oF oF 4 32 68 104 176 212 248 284 40 20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 40 20 mi 40 i i 80 400 dE 440 160 17 8 4 4 26 7 48 9 71 1 93 3 116 138 p PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart see 2 2 Torque and Locking Ee RAA A asta AE annee tm MESSE 2 3 Specifications EE 2 8 Special TODS EE 2 9 Periodic Maintenance Procedures 2 10 SR In 2 10 Throttle Control System Inspection ss 2 10 Air Box Drain Caps Inspection and Cleaning 2 11 Air Box Inspection and CIGAMing EE 2 11 Fuel Vent Check Valve Inspection cecceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 11 Fuel Pump Screen Cleaning radica ege ege Eesen 2 12 Throttle Shaft Spring Inspection ss 2 12 Engine Ettel WEE 2 13 Engine ON AGG ciini nro A A des Race A AA AE taa 2 13 Oil Elter Replacement nesporna lia drid 2 14 Engine Top NEE 2 15 Valve Clearance Inspection Ennen EEEn 2 15 Engine Mounting Bolts Inspection and Tightness ooooooocccccccncccccconananannncncnonananan non ccncnnnnnns 2 18 Engine Bottom ENA ducto aitor 2 19 Coupling Damper Inspection see 2 19 Cooling and Bilge Syste MS
349. zing with the blink of red warning indicator light LED Not Verified OThe red warning indicator light LED immobilizer symbol and letters A blink to display the collation error The buzzer sound B goes off refer to the following failure illustrations Immobilizer Amplifier Failure Service Code Character 35 Imb Key Collation Error Service Code Character 36 Ignl Pre registration of User Key n 2 6 e Remove the user key 1 e Insert the unregistered key user key 2 and press it for a short time within 2 seconds NOTE OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed the registration mode automatically finishes and the red warning indicator light LED will switch off OAt this procedure the unregistered key user key 2 is pressed for a long time 2 seconds or more the pro cedure goes to the regular registration of user key see Regular Registration of User Key OThe ECU confirms the following Receiving signals from immobilizer amplifier are correct The inserted key is the unregistered one The number of the registered key is six or less 3second lsecond 0 3second ST Ka R R JN20055BS1 0 3second JN20057BS1 14 70 ELECTRICAL SYSTEM Immobilizer System Not Verified OThe red warning indicator light LED immobilizer symbol and letters A blink to display the collation error The buzzer so

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