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800 SX-R JET SKI®Watercraft Service Manual

1. a 4 4 Exparision InstallatiOT 7 4 5 Expansion Chamber Cleaning and 4 5 Exhaust Manifold ER o M dt teas de tee neces 4 6 Exhaust Manifold 4 6 Exhaust Manifold memes 4 6 Exhaust Manifold Cleaning and Inspection ssseseeeiieeeeeeeeinrirttteesieninrrnssssinernnnnnnsnsenne 4 6 Water Box Muffler iieri eene donee ca qe Se PLE baa Be et ee ae pete adipe ada 4 7 Water Box Muffler Removal nenne rennen rr nennen nnne 4 7 Water Box Muffler Inspection pp 4 7 4 2 EXHAUST SYSTEM Exploded View acr EA Lom EXHAUST SYSTEM 4 3 Exploded View Torque No Fastener kgf m 1 Pipe Mounting Bolts 29 3 0 22 L 2 Front Muffler Mounting Bolts 29 3 0 22 E 3 Water Hose Joints 11 1 1 95 in Ib L 4 Manifold Mounting Nuts 20 2 0 14 S 5 Expansion Chamber Mounting Bolts 29 3 0 L 6 Muffler Bracket Mounting Bolts 29 3 0 22 L 7 Water Box Muffler Bracket Mounting Screws 4 9 0 50 43 in Ib L 8 Water Box Muffler A J8800 A1 Model B JS800 A2 Model L Apply a non permanent locking agent S Follow the specified tightening sequence 4 4 EXHAUST SYSTEM Expansion Chamber Expansion Removal e
2. END Coupling e Remove Engine see Engine Removal Installation chapter Coupling Damper Magneto Cover e Holding the flywheel unscrew the coupling Special Tools Rotor Holder Hex 30 57001 1368 A Coupling Holder 57001 1230 B Installation e Apply a non permanent locking agent to the coupling threads e Screw the coupling onto the crankshaft and tighten it Torque Coupling 130 N m 13 5 kgf m 96 ft Ib Coupling Damper Inspection e Refer to the Coupling Damper Inspection in the Periodic Maintenance chapter ENGINE BOTTOM END 7 7 Magneto Flywheel Removal e Remove the engine hood see Hull Engine Hood chap ter e Remove the mounting bolts A and take off the magneto cover B NOTE OThe flywheel can be removed without removing the fuel tank if the rotor puller 57001 1258 is used e Holding the flywheel remove the flywheel bolt Special Tool Rotor Holder Hex 30 57001 1368 A e Pull the flywheel off the crankshaft Special Tool Rotor Puller M18 x 1 5 57001 1258 B CAUTION Do not strike the flywheel with a hammer as the magnets may be damaged Installation e Using a high flash point solvents clean off any oil or dirt that may be on the flywheel bolt the crankshaft taper or in the tapered hole in the flywheel e Fit the woodruff key A securely in the crankshaft before installing the magneto flywheel e Install the
3. 13 15 Reduction Gear Removal Installa fole 13 15 Reduction Gear Inspection 13 15 Starter Motor Remowval 13 15 Starter Motor Installation 13 15 Starter Motor Disassembly 13 16 Starter Motor Assembly 13 16 Brush Inspection 13 17 Brush Spring Inspection 13 17 Commutator Cleaning and 13 17 Armature Inspection 13 18 Brush Plate Inspection 13 18 Brush and Lead Assembly 13 18 Starter Relay 13 19 Starter Relay Installation 13 19 Starter Relay Inspection 13 20 Charging System 13 21 Charging System Inspection 13 21 Regulator rectifier Removal 13 22 Regulator rectifier Installation 13 22 Regulator rectifier Inspection 13 22 Ignition System 13 23 Crankshaft Sensor Inspection 13 23 Ignition Coil Removal 13 24 Ignition Coil Installation 13 24 Ignition Coil Inspection 13 24 CDI Igniter Removal 13 25 CDI Igniter Installation 13 26 Ignition Coil Primary Peak Voltage
4. END Specifications Standard Service Limit Cylinder Head Cylinder Compression Cylinder Head Warp Cylinder Piston Cylinder Inside Diameter Piston Diameter 16 9 mm 0 67 up from bottom of skirt Piston Cylinder Clearance Oversize Piston and Rings Piston Ring Groove Clearance Top Keystone Second Keystone Piston Ring Groove Width Top Keystone Second Keystone Piston Ring Thickness Top Keystone Second Keystone Piston Ring End Gap Top Second Usable range 892 1 372 kPa 9 1 14 kgf cm 129 199 psi Open throttle 82 000 82 015 mm 3 228 3 229 in 81 900 81 915 mm 3 224 3 225 in 0 085 0 115 mm 0 0033 0 0045 in 0 5 mm 0 02 and 1 0 mm 0 04 0 25 0 40 mm 0 0098 0 0157 0 25 0 40 mm 0 0098 0 0157 in 0 05 mm 0 002 in 82 10 mm 3 232 in 81 75 mm 3 219 in 0 7 mm 0 028 in 0 7 mm 0 028 in Special Tools ENGINE TOP END 5 5 Compression Gauge 20 kgf cm 57001 221 7570221ST C Piston Pin Puller Assembly 57001 910 7570910ST C Piston Ring Compressor Grip 57001 1095 7571095ST C Piston Ring Compressor Belt 67 79 57001 1097 7571097ST C Compression Gauge Adapter M14 x 1 25 57001 1159 875711595 6 5 6 END Engine
5. Torque No Fastener kgf m Fib Remarks 1 Water Hose Joint 9 8 1 0 87 L 2 Steering Nozzle Pivot Bolts 8 8 0 90 LN 3 Pump Outlet Mounting Bolts L 4 Pump Cap Bolts L 5 Impeller 98 10 6 Mounting Bolts 22 2 2 16 L 7 Pump Cover Mounting Bolts 6 9 0 70 61 L 8 Grate Mounting Bolts 7 8 0 80 69 in Ib L 9 Steering Cable Ball Joint 9 8 1 0 87 LN 10 Pump Shaft 98 10 72 HG Apply high grease water resistance grease Chevron Black Pearl Grease EP NLGI2 or equiv alent L Apply a non permanent locking agent LN Apply a non permanent locking agent High Strength Loctite 271 equivalent M Apply molybdenum disulfide grease WG Apply water resistance grease 10 4 PUMP IMPELLER Specifications ltem Standard Service Limit Jet Pump Impeller Outside Diameter 139 5 139 7 mm 5 492 5 500 in 138 5 mm 5 453 in Pump Case Inside Diameter 140 0 140 1 5 512 5 516 in 141 1 mm 5 555 in Impeller Clearance 0 15 0 30 mm 0 0059 0 012 in 0 60 mm 0 024 in Special Tools PUMP AND IMPELLER 10 5 Oil Seal amp Bearing Remover 57001 1058 875710585 C Bearing Driver Set 57001 1129 7571129ST C Impeller Wrench 57001 1228 875712285 Bearing Remover Head 15 x 17 57001 1267 875712675 C Bearing Remover Shaft 13 57001 1377 875713775 Kawasaki Bond Sili
6. Installation Coat the grommets A with water resistant grease e Tighten Torque Stator Mounting Bolts 12 N m 1 2 kgf m 8 5 16 e Apply non permanent locking agent to following screws and tighten them Torque Set Screw 2 5 N m 0 25 kgf m 22 in lb Grommet Clamp Screws 2 5 N m 0 25 kgf m 22 in Ib 7 10 END Stator JS800 A1 Olnsert the connector pins onto the connector as shown PU A R B D BR E BK F BR G e JS800 A2 Olnsert the connector pins onto the connector as shown BL A G B BR C BK D BR E Slip the crankshaft sensor bracket projections A into the holes B on the cover Apply non permanent locking agent to crankshaft sensor screws and tighten them Torque Crankshaft Sensor Bracket Screws 2 5 N m 0 25 kgf m 22 in Ib JH08000BS1 ENGINE BOTTOM END 7 11 Crankcase Splitting e Remove the engine see Engine Removal Installation chapter e Remove the following from the engine Exhaust Manifold Starter Motor Carburetor Inlet Manifold Cylinder Head Cylinder Block Pistons Coupling Magneto Flywheel Reduction Gear NOTE OAlways remove the coupling before removing the mag neto flywheel or there won t be any way to hold the crankshaft while unscrewing the coupling e Remove the 6 mm crankcase bolts A first and the 8 mm bolts B ePry the point A indica
7. U aa haai 7 6 Coupling Damper 7 6 det ack 7 7 aie EE 7 7 stat 7 7 EE 7 8 c 7 8 Installation 7 9 Crank6ase ed sU e E CL P RE Ease te Pe e VENER aU ML BEB ak oa 7 11 E 7 11 PISSEIMIDIY shes cute 7 11 Crankshaft Maintenance 7 13 Connecting Rod Berig TWISE 7 13 Connecting Rod Big End Radial ee 7 14 Connecting Rod Big End Side Clearance pp 7 14 Crankshaft Main Bearing Wear nn nnne 7 14 Crankshaft R UNOUL tiere dete ie e ADI 7 14 Crankshaft Assembly Specifications essem nenne 7 15 7 2 END Exploded View JH02017885 C ENGINE BOTTOM END 7 3 Exploded View Torque No Fastener em ftlb Remarks 1 Magneto Cover Cap Bolts 8 8 0 90 78 in Ib L 2 Magneto Cover Mounting Bolts 8 8 78 in Ib L 3 Coupling 130 13 5 96 L 4 Set Screw 2 5 22 in lb L 5 Flywheel Bolt 130 96 LN 6 Crankshaft Sensor Bracket Screws 2 5 0 25 22 in lb 7 Grommet Clamp Screws 2 5 0 25 22 in lb L 8 Stator Mounting Bolts 12
8. 13 43 Inlet Air Temperature Sensor Installation 13 43 Inlet Air Temperature Sensor 13 43 U86 5 xot ce diete seek cadets RR Sd 13 44 Fuse 13 44 13 2 ELECTRICAL SYSTEM Exploded View JS800 A1 S GS ELECTRICAL SYSTEM 13 3 Exploded View JS800 A1 Torque No Fastener Nm Korn ftlb Remarks 1 Electric Case Connector Mounting Bolts 8 8 0 90 78 in Ib L 2 Spark Plugs 27 2 8 20 3 Joints 3 9 0 40 35 in Ib 4 Starter Relay Lead Mounting Nuts 4 4 0 45 39 in Ib 5 Electric Case Mounting Bolts 8 8 0 90 78 in lb L 6 Water Temperature Sensor Mounting Bolts 8 8 0 90 78 in Ib 7 Water Temperature Sensor 27 2 8 20 8 Regulator rectifier Mounting Bolts 8 8 0 90 78 in Ib L 9 CDI Igniter Mounting Bolts 8 8 0 90 78 in Ib L 10 Ignition Coil Mounting Bolts 8 8 0 90 78 in Ib L 11 Electric Case Bolts 8 8 0 90 78 in Ib L 12 Switch Case Mounting Screws 3 9 0 40 35 in Ib G Apply grease L Apply a non permanent locking agent Si Apply silicone grease WG Apply water resistance grease 13 4 ELECTRICAL SYSTEM Exploded View JS800 A2 O ELECTRICAL SYSTEM 13 5 Exploded View JS800 A2 No Fastener Remarks kgf m ft Ib 1 Electric Case Con
9. FE ER epe Pen 5 5 Engine s 5 6 Disasseribly and Assembly oec tut ce ald gad nach Lom 5 6 DISASSEMDI e 5 6 PASSED 5 7 Maintenance and Inspection Ne 5 10 Compression Measurement pp 5 10 Cylinder Head Warp Inspection 8 5 11 Cylinder Wear InspectOn oer de E O adr edes 5 11 Piston Diameter Measurement 5 12 Piston Cylinder Clearance beet ee NEU cance REO RE GREC GC essed 5 12 Boring and HONING uos 5 12 Piston Ring Piston Ring Groove 5 13 Piston Ringi End Ads 5 13 5 2 END Exploded View a ae 0 D UA 0 77 GE pU Acc ENGINE TOP END 5 3 Exploded View No Fastener Jorane Remarks kgf m ft Ib 1 Water Hose Joint 11 1 1 95 in Ib L 2 Water Hose Joint 11 1 1 L 3 Cylinder Head Nuts 29 3 0 22 S 4 Oylinder Stud L 5 Cylinder Base Nuts 34 3 5 6 Cable Holder Bolts 29 3 0 22 L A J8800 A1 Model B J8800 A2 Model L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the 4 stroke engine oil and molybdenum disulfide grease in a weight ratio 10 1 5 4
10. Handle Pole and Handlebar Table of Contents a eeo ET TA A E I 11 2 Steernng E 11 4 Steering Cable Adjustment 2 11 4 steering Cable Removal tereti eerte o 11 4 Steering Cable Installation pp 11 6 Steering Cable Inspection Deas em Edd 11 6 Steering Cable EUbrcaliofi c aetas sius 11 6 Handlebai a ae 11 7 Hand Grip 11 7 Handlebar Removal v 11 7 Harndlebar Installauofris eto cen de io pue 11 8 Handlebar Steering Pivot 11 9 Handle Pole and Bracket cniin hae prt re burst epu ed 11 11 FREMOV alive px 11 11 Installations 11 12 11 2 HANDLE AND HANDLEBAR Exploded View HANDLE POLE AND HANDLEBAR 11 3 Exploded View No Fastener Erde Remarks kgf m ft Ib 1 Steering Support Bracket Mounting Bolts L 2 Steering Pivot Stud Smaller Threads LN 3 Pole Pivot Shaft 87 m 4 Handle Pole Pivot Shaft Nut 5 Y 25 5 Handlebar Clamp Screws 18 1 8 13 LN 6 Pole Bracket Bolts 14 L 7 Handle Pole Cover Screws 13 in Ib 8 Handlebar Plat
11. OPress the small grease seal and the large grease seals bearing and small grease seals come out of the holder Sleeve A Blocks B Press C Special Tool Bearing Driver Set 57001 1129 lt 15 Drive Shaft Holder Assembly Installation e Replace the grease seals with new ones e Press the bearing and grease seals into the drive shaft holder noting the following Olnstall the parts in this order Two Small Grease Seals A One Bearing B Two Large Grease Seals C Bow D Special Tool Bearing Driver Set 57001 1129 Olnstall the seals so that the sides with the spring face out ward OFill the gaps between the seals with water resistance grease E e Install the circlip e Apply water resistance grease F to the bearing inner surface and grease seal lips e Apply G silicone sealant to the back of the flange as shown Sealant Kawasaki Bond Silicone Sealant 56019 120 OTighten the drive shaft holder mounting bolts within 15 minutes after application of the silicone sealant 41404005852 C e Install the drive shaft holder on the bulkhead so that the circlip side face toward the front e Apply a non permanent locking agent to the drive shaft holder mounting bolts tighten them loosely e Install the drive shaft 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 Bolt
12. Fuel Hose Main Fuel Hose Reserve Choke Cable Bracket Run all the cables wires and hoses behind the bracket Fuel Hose Supply Flushing Hose JS800 A2 Model Band JS800 A3 Model JS800 A1 Model 15 20 APPENDIX Cable Wire and Hose Routing Port Side J809074BW5 C APPENDIX 15 21 Cable Wire Hose Routing 70 2 8 330 13 0 570 mm 22 4 in 170 mm 6 69 in 350 mm 13 8 in 600 mm 23 6 in 40 mm 1 6 in 160 mm 6 30 in Holder Standard Point 15 22 APPENDIX Troubleshooting Starting difficulty or failure to start Ignition System e Fault in fuel system e Lack of compression No Spark e Faulty or fouled spark plug e Faulty plug wire insulation e Faulty CDI igniter e Faulty ignition coil e Faulty magneto e Battery voltage low Fuel System check that fuel tank contains fuel Outside Carburetor e Fuel feed line leaking or clogged e Pulse line leaking or clogged e Fuel filter screen clogged e Vent line clogged e Faulty fuel pump Inside Carburetor e Carburetor diaphragm damaged e Mixture screw not adjusted e Water in carburetor e Float arm not adjusted Battery Starter System e Faulty magneto solenoid switch e Battery voltage low e Starter motor brushes worn e Faulty reduction gear e Faulty starter lockout switch and or lanyard key n
13. Cable Electric Case Inlet Air Temperature Sensor Leads Battery Cable Battery Coupling Cover Starter Motor 15 10 APPENDIX Cable Wire and Hose Routing E HESUM BOW Gam CQ ce M AEN ac E D ME OEE Viewed from Stern Viewed from Port Side APPENDIX 15 11 Cable Wire and Hose Routing gt Cylinder Head Cap Position the clamp screw as shown Water Hose Joint Position as shown Exhaust Chamber Exhaust Manifold Starter Motor Inlet Cooling Hose Magneto Leads Clamp Inlet Cooling Water from the Pump JS800 A1 Model JS800 A2 Model 15 12 APPENDIX Cable Wire and Hose Routing Viewed from 4 JB09070BW5 APPENDIX 15 13 Cable Wire Hose Routing Water Box Muffler Exhaust Tube Exhaust Pipe Exhaust Chamber Bracket Plate Deck To Tail Pipe Position the clamp screws as shown Position the clamp screw to the mark 15 14 APPENDIX Cable Wire and Hose Routing APPENDIX 15 15 Cable Wire and Hose Routing Handle Pole Start Stop Switch Throttle Case Start Stop Switch Leads Throttle Cable Steering Cable Run the throttle cable over the start stop switch leads and to the lef
14. e Apply a non permanent locking agent to the following bolts and tighten them Torque Engine Mounting Bolts 49 N m 5 0 kgf m 36 ft Ib e Check the gap between the engine bed and the dampers by rocking the engine lf there is a gap inspect a suitable shim between the en gine bed and the damper to achieve a good fit Shim Selection Part Number of Shim Thickness 92025 3705 0 3 mm 0 012 in 92025 3706 0 5 mm 0 020 in 92025 3707 1 0 mm 0 039 in 92025 3708 1 5 mm 0 059 in e Apply a non permanent locking agent to the following bolts and tighten them Torque Engine Bed Mounting Bolts 36 N m 3 7 kgf m 27 ft lb e After installing the engine in the hull check the following Throttle Cable Choke Cable Fuel and Exhaust Leaks WARNING Do not run the engine a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas which can be lethal CAUTION Operate the engine only for short periods without cooling water Overheating will cause severe en gine and exhaust system damage 7 1 Engine Bottom End Table of Contents Exploded eM 7 2 7 4 Special Tools and 7 5 COU Y 7 6 MIO 7 6 cm
15. 13 40 ELECTRICAL SYSTEM Water Temperature Sensor JS800 A1 Water Temperature Sensor Installation e Be sure the O ring A is in place e Install the water temperature sensor B in the holder C e Tighten Torque Water Temperature Sensor 27 N m 2 8 kgf m 20 ft Ib e Be sure holder assembly A is in the position as shown e Apply a non permanent locking agent to the water tem perature sensor mounting bolt B and tighten it C Washer Torque Water Temperature Sensor Mounting Bolt 8 8 N m 0 90 kgfm 78 in Ib Water Temperature Sensor Inspection Remove the water temperature sensor see Water Tem perature Sensor Removal e Suspend the sensor A in a container of water so that the temperature sensing protection is submerged e Suspend a thermometer in the water NOTE OThe sensor and thermometer must not touch the con tainer sides or bottom Place the container over a source of heat and gradually rise the temperature of the water while stirring the water gently e Using the hand tester measure the internal resistance of the sensor at the temperatures shown in the table Special Tool Hand Tester 57001 1394 If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Function and Resistance O Rising temperature From OFF to ON at 90 100 C 194 212 F O Falling temperature From ON to OFF within 7 C 45 F of ON temperature
16. IR Kawasaki 800 SX R JET SKI Watercraft Service Manual SETER 25 7 is a trademark of Kawasaki Heavy Industries Ltd registered 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 Exhaust System Engine Top End Engine Removal Installation Engine Bottom End Cooling and Bilge Systems Drive System Pump and Impeller Handle Pole and Handlebar 11 Hull Engine Hood Electrical System Storage O1 G N SO O CO A By Oo NO gt Appendix FS watercraft 800 SX R Kawasaki JET SKIWatercraft 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 witho
17. Run the flushing hose under the fuel hoses Band JS800 A3 Model 15 6 APPENDIX Cable Wire and Hose Routing A Viewed from Bow JB09124BW5 APPENDIX 15 7 Cable Wire Hose Routing 5 Start Stop Switch Leads Clamp Magneto Leads To Start Stop Switch Bypass Cooling Hose From Cylinder Head To Bypass Outlet Cooling Hose From Water Box Muffler Water Temperature Sensor Position the clamp screw as shown To Hull Starter Motor Cable Battery Cable Electric Case Water Temperature Sensor Leads Magneto Cover Stopper Be sure that the clamps touch the stoppers Starter Motor Protect Tube J8800 A1 Model only Cable Wire and Hose Routing 15 8 APPENDIX JS800 A2 55552255050 2 Viewed from Bow S 72 SS D XS OSS e 1 975522055555 5500 Sere 7 RR Rarer RRS lt QU UOS KERR RSE SERIE 55655556055 JB09125BW5 Viewed from Stern APPENDIX 15 9 Cable Wire Hose Routing OONOARWN Start Stop Switch Leads Clamp Magneto Leads To Start Stop Switch Bypass Cooling Hose From Cylinder Head To Bypass Outlet Cooling Hose From Water Box Muffler Water Temperature Sensor Leads To Hull Starter Motor Cable Battery
18. see Battery Removal Spark Plug Caps A Battery Cable B Starter Motor Cable C Starter and Stop Switch Lead Connector D Electric Case Connector E 4 pin and 3 pin Connectors ORemove Temperature Sensor Hoses A e JS800 A2 ORemove Battery Cable see Battery Removal Spark Plug Caps A Starter and Stop Switch Lead Connector B Band C Connectors D Electric Case Connector E 2 pin and 3 pin Connectors ORemove Clamp F Battery Cable G Starter Motor Cable H 5 1 2 Os Q LI LATI ID 9 Gas SS OES PE Remove Electric Case Mounting Bolts A and Clamp B Electric Case C ELECTRICAL SYSTEM 13 31 Electric Case Electric Case Installation e Apply a light coating of water resistance grease to the electric case connector O ring A e Apply a non permanent locking agent to the electric case mounting bolts and tighten them Torque Electric Case Mounting Bolts 8 8 0 90 kgf m 78 in lb Electric Case Disassembly e JS800 A1 ORemove Electric Case see Electric Case Removal Electric Case Bolts A OOpen the electric case ORemove Starter Relay A CDI Igniter B Regulator rectifier C ORemove Ignition Coil A Water Temperature Sensor B See Temperature Sensor Removal e JS800 A2 ORemove Electric Case see Electric Case Removal Electric Case Bolts A Inlet Air Temp
19. End Disassembly and Assembly Disassembly e JS800 A1 ORemove Engine Hood see Hull Engine Hood chapter Cooling Hoses A Spark Plug Caps and Spark Plugs B Carburetor see Carburetor Removal in the Fuel System chapter Exhaust Pipe Front Muffler and Expansion Chamber as a set see Exhaust System chapter ORemove the water hose joint A and another joint B ORemove the cylinder head nuts C and lift off the cylinder head D e JS800 A2 ORemove Engine Hood see Hull Engine Hood chapter Cooling Hoses A Spark Plug Caps and Spark Plugs B Carburetor see Carburetor Removal in the Fuel System chapter Exhaust Pipe Front Muffler and Expansion Chamber as a set see Exhaust System chapter ORemove the water hose joint A and another joint B ORemove the cylinder head nuts C and lift off the cylinder head D e Remove Exhaust Manifold A Cable Holder B ENGINE END 5 7 e Remove the cylinder base nuts A and lift off the cylinder B e Stuff clean rags into the crankcase opening to prevent dirt or foreign objects from falling into the crankcase e Remove the piston pin snap ring A with a pliers B e Remove the piston Use a piston pin puller assembly if the pin is tight Special Tool Piston Pin Puller Assembly 57001 910 Assembly e If any parts in the piston assemblies require replacement or if the cylinder is h
20. ON Less than 0 5 OFF More than 1 MQ NS 2 48100158682 C ELECTRICAL SYSTEM 13 41 Water Temperature Sensor JS800 A2 A water temperature sensor is installed on the exhaust pipe Whenever the cooling water temperature rises to 100 C 212 F or higher the contacts the water temper ature sensor does and the igniter works to cut spark inter mittently The engine speed decreases to 3 500 rpm If the watercraft slows down even with the throttle on and the engine running return to shore immediately and check the cooling system for clogging CAUTION If the watercraft slows down while running return to the shore immediately Overheating will cause severe engine and exhaust system damage Do not operate the craft until the source of the problem is found and correct Water Temperature Sensor Removal e Cut the bands A e Disconnect the water temperature sensor connector B e Remove the water temperature sensor A from exhaust pipe Water Temperature Sensor Installation e Remove Expansion Chamber see Expansion Chamber Removal chapter e Fill the hollow of the exhaust pipe A with the specified silicone grease B as shown before installing the water temperature sensor C 5 mm 0 2 in D Specified Engine Oil 10W 30 Silicone Grease Kawasaki Bond Silicone Grease 92137 1002 e Tighten Torque Water Temperature Sensor 15 N m 1 50 kgf m
21. TIR 0 10 mm 0 0039 in I JHOSO008BS1 4 09009881 JHOSO10BS1 C ENGINE BOTTOM END 7 15 Crankshaft Maintenance Crankshaft Assembly Specifications If the crankshaft is disassembled use these specifica tions during rebuilding 0 5 mm 0 02 in A 0 45 0 55 mm 0 018 0 022 in B 97 5 mm 3 84 in C JH09011B8W3 6 COOLING AND BILGE SYSTEMS 8 1 Cooling and Bilge Systems Table of Contents Exploded VIeW diesen rone Pee RE v re Ete hates 8 2 BIGGS mM er 8 4 Breather Removal Lm 8 4 Breather InstallallOD 8 4 Breather Cleaning and 044414420 ntn 8 5 Bilge Filter Removal iet er 8 5 Bilge Filter Cleaning and Inspection 0 040000 8 5 Cooling and Bilge System oses oot piter te hene brit a he Hu E Hose Iristallauort coit coma Tbe et Anat na Se sea Hose Inspection eie iir Rr te EAR A Cooling and Bilge System FIushing pp Cooling System Flushidg x waters puestas Gate 8 7 Bilge System FIUSMING eer pesce tid cbe oe 8 7 8 2 COOLING AND BILGE SYSTEMS Ex
22. 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 3 locations total of 6 measurements shown in the figure 10 mm 0 39 in A 80 mm 3 15 in B 35 mm 1 38 in C any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder will have to be bored oversize and then honed Cylinder Inside Diameter Standard 82 000 82 015 mm 3 228 3 229 in and less than 0 01 mm 0 004 in difference between any two measurements Service Limit 82 10 mm 3 232 in or more than 0 05 mm 0 002 in difference between any two measurements JF04015BSi 6 5 12 Engine Top End Piston Diameter Measurement e Measure the outside diameter A of the piston 16 9 mm 0 67 in up B from the bottom of the piston at a ring angle to the direction of the piston pin Piston Diameter Standard 81 900 81 915 mm 3 224 3 225 in Service Limit 81 75 mm 3 219 in Olf the measurement is less than the service limit replace the piston NOTE OAbnormal wear such as a marked diagonal pattern across the piston skirt any mean a bent connecting rod or a misaligned crankshaft Piston Cylinder Clearance The piston to cylinder clearance must be checked and the standard value maintained anytime a piston or the cylin der block are replaced with new parts or whenever the cylinde
23. 1 2 8 5 9 Electric Case Cap Bolts 8 8 090 78 in lb L 10 Crankcase Bolts 6 mm dia 8 8 090 78 in Ib L S 11 Bolts 8 mm dia 29 22 L S A JS800 A1 Model J8800 A2 Model Apply grease Apply a non permanent locking agent Apply liquid gasket Kawasaki Bond 92104 1003 Apply a non permanent locking agent High Strength Loctite 271 equivalent Apply molybdenum disulfide grease Apply molybdenum disulfide oil solution Follow the specific tightening sequence Apply water resistance grease 7 4 END Specifications ltem Standard Service Limit Crankshaft Connecting Rods Crankshaft Runout TIR 0 04 mm 0 0016 in orless TIR 0 10 mm 0 0039 in Connecting Rod Side Clearance 0 45 0 55 mm 0 8 mm 0 018 0 022 in 0 0315 in Connecting Rod Radial Clearance 0 038 0 049 mm 0 10 mm 0 0015 0 0193 in 0 0039 in Connecting Rod Bend 0 05 mm 100 mm 0 2 mm 100 mm 0 002 in 3 937 in 0 008 in 3 937 in Connecting Rod Twist 0 15 mm 100 mm 0 2 mm 100 mm 0 006 in 3 937 in 0 008 in 3 937 in 7 5 Special Tools Sealant Coupling Holder Rotor Holder Hex 30 57001 1230 57001 1368 n L 7T5712308T T5713688T C Rotor Puller M18 x 1 5 Kawasaki Bond Liquid Gasket Black 57001 1258 92104 1003 875712585 6 879210035 7 6
24. 11 ft Ib 9100039 P JN10030BS1 6 13 42 ELECTRICAL SYSTEM Water Temperature Sensor JS800 A2 Water Temperature Sensor Inspection e Remove the water temperature sensor from exhaust pipe see Water Temperature Sensor Removal chapter e Suspend the sensor A in a container of water so that the temperature sensing projection is submerged e Suspend a thermometer B in the water NOTE OThe sensor and thermometer must not touch the con tainer side or bottom OPlace the container over a source of heat and gradually rise the temperature of the water while stirring the water gently OUsing the hand tester measure the internal resistance of the sensor at the temperatures shown in the table Special Tool Hand Tester 57001 1394 If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance Water Temperature Sensor Resistance 20 68 Approx 293 50 122 F Approx 78 5 90 194 F Approx 18 1 100 C 212 F Approx 13 2 JN10082BS2 C ELECTRICAL SYSTEM 13 43 Inlet Air Temperature Sensor JS800 A2 Inlet Air Temperature Sensor Removal e Disconnect the inlet air temperature sensor connector B e Remove the inlet air temperature sensor C from the bracket D Electric Case A Inlet Air Temperature Sensor Installation e Connect the inlet air temperature sensor connector and
25. 13 26 Crankshaft Sensor Peak Voltage 13 27 Spark Plug Removal 13 28 Spark Plug Installation 13 28 Spark Plug Inspection 13 28 Spark Plug Adjustment 13 28 Spark Plug Cleaning 13 28 Electri CaSe adea ens 13 30 Electric Case Remowval 13 30 Electric Case Installation 13 31 Electric Case Disassembly 13 31 Electric Case Assembly 13 32 Switches 13 36 Start Stop Switch Removal 13 36 Start Stop Switch Installation 13 36 Start Stop Switch Inspection 13 37 Water Temperature Sensor 75900 i rm etiara i nes 13 39 Water Temperature Sensor Water Temperature Sensor Installation Water Temperature Sensor Water Temperature Sensor JS800 A2 13 41 Water Temperature Sensor 13 41 Water Temperature Sensor Installation 13 41 Water Temperature Sensor 13 42 Inlet Air Temperature Sensor JS800 A2 nest pol ctr crabe poeta 13 43 Inlet Air Temperature Sensor
26. 8 0 90 78 L 3 Air Inlet Cover Mounting Bolts 8 8 0 90 78 L 4 Holder Plate Screw 0 98 0 10 8 7 in lb 5 Main Jet 1 8 0 18 16 in Ib 6 Pilot Jet 0 70 0 07 6 2 in lb 7 Float Arm Pin Screw 0 98 0 10 8 7 in lb 8 Carburetor Cover Screws 3 4 0 35 30 in Ib 9 Carburetor Plate Screws 2 0 0 20 18 in Ib 10 Inlet Manifold Mounting Nuts 9 8 1 0 87 in lb S 11 Fuel Pump Mounting Screws 0 70 0 07 6 2 in lb 12 Check Valve 13 Inlet Valve 14 Fuel Filter G Apply grease L Apply a non permanent locking agent S Follow the specific tightening sequence 3 6 FUEL SYSTEM Specifications Pop off Pressure Idle Speed in Water out of Water 262 kPa 2 67 kgf cm 38 psi 1 250 100 rpm 1 700 100 rpm Item Standard Service Limit Carburetor Make Type MIKUNI 40 38 x 2 38 Venturi Mixture Screws Low Speed 7 8 turn open High Speed 3 4 turn open Main Jet 132 5 Pilot Jet 72 5 Inlet Valve System Valve Seat Size 1 5 mm Arm Spring Load 809 Reed Valve Reed Warp Fuel Tank Capacity 17 L including 3 0 L reserve FUEL SYSTEM 3 7 Special Tools and Sealant Watercraft Strap Tool Kawasaki Bond Silicone Sealant 57001 1294 56019 120 875712945 875601205 3 8 FUEL SYSTEM Fuel System Diagram T Vent or Pulse mm Fue um J4C04013BW3 C To Th
27. 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 return spring the throttle lever does not return properly check the throttle routing cable adjustments and cable damage 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 or and up and down to ensure that the idle speed does not change xIf the idle speed increase check the throttle cable adjust ment and the cable routing Throttle Case and Cable Lubrication e Refer to the Lubrication in the Periodic Maintenance chapter Throttle Cable Inspection e Refer to the Lubrication in the Periodic Maintenance chapter 3 14 FUEL SYSTEM Choke Cable Choke Cable Adjustment e Refer to the Choke Cable Adjustment in the Periodic Maintenance chapter Choke Cable Removal e Remove the engine hood see Hull Engine Hood Re moval e Disconnect the choke cable from the carburetor ORemove the rubber cap A OUnscrew the adjuster locknut B and slide the cable from the bracket OSlide the tips C of the cable lower end from the pivot arm Loosen the locknut A and disconnect the cable tip B e Cut the bands OTurn A the choke cable counterclockwise and remove it from the bracket B Choke Cable Inspection e Refer to the Lubrication in the Periodic Maintenance chapter
28. Choke Cable Lubrication e Refer to the Lubrication in the Periodic Maintenance chapter Choke Knob Removal e Disconnect the choke cable end of the carburetor side see Choke Cable Removal e Remove the set screw A and take out the choke knob B and damper e Remove the choke indicator plate C from the hull FUEL SYSTEM 3 15 Choke Cable e Remove the cable holder mounting screws A e Remove the choke knob shaft B with cable 30060017 P e Loosen the locknut A and unscrew the cable B from the holder C e Slide the tip D of the choke inner cable out of the pulley on the choke knob shaft e Remove the pin and washer and pull out the choke knob shaft from the cable holder Choke Knob Shaft A Washer B Spring C Cable Holder D O ring E Washer F Pin G JC060086BSi 6 Choke Knob Installation e Grease the indicated area A the O ring is installed Cable Holder B O ring C Washer D Pin E Choke Knob Shaft F e Apply a non permanent locking agent to the set screw and tighten it e Route the choke cable according to the Cable Routing section in the Appendix chapter e Adjust the choke cable see Choke Cable Adjustment JC06007BSi 6 3 16 FUEL SYSTEM Carburetor Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Mixture Screw Adjustment Since every carburetor is adjusted individually
29. Cooling An auxiliary cooling supply may be used if the watercraft cannot be operated in water during ad justments If possible always operate the watercraft in water rather than use an auxiliary cooling supply JS800 A1 OLoosen the clamp and remove the cap A OConnect the garden hose B to the hose fitting see above JS800 A2 OObtain 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 gar den hose adapter ORemove the flushing cap A GENERAL INFORMATION 1 3 Before Servicing OScrew a garden hose adapter A onto the flushing fitting B OAttach a garden hose C to a garden hose adapter and secure the hose clamp D e Attach the garden 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 CAUTION Insufficient cooling supply will cause the engine and or exhaust system to overheat and severe damage will occur Excessive cooling supply may kill the engine and flood the cylin ders causing hydraulic lock Hydraulic lock will cause severe damage to the engine If the engine dies while using an auxiliary cooling supply the water must be shut off immediately Always turn the boat
30. EA ARA 6 6 cm 6 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 6 3 Exploded View No Fastener Remarks 1 Mounting Bolts 2 Bed Mounting Bolts 36 L 3 Engine Damper Mount Bolts 16 L A JS800 A1 A2 Model B JS800 A3 Model L Apply a non permanent locking agent 6 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e JS800 A1 ORemove Engine Hood see Hull Engine Hood chapter Air Inlet Cover A Spark Plug Caps B Hoses C Cable Holder D Throttle Cable and Choke Cable Ends E Exhaust Pipe F Front Muffler and Expansion Chamber as a set see Exhaust System chapter e JS800 A2 ORemove Bands A Water Temperature Sensor Connector B ORemove Engine Hood see Hull Engine Hood chapter Air Inlet Cover A Spark Plug Caps B Hoses C Cable Holder D Throttle Cable and Choke Cable Ends E Exhaust Pipe F Front Muffler and Expansion Chamber as a set see Exhaust System chapter e Remove Arrester Case A and Carburetor see Fuel System chapter e Remove Starter Cable A Cooling Hose B Battery Ground Cable C ENGINE REMOVAL INSTALLATION 6 5 Engine Removal Installation e Remove Electric Case Connector A see Electrical System chapter Bands B e Remove Connectors A Coupling Cover B e Re
31. Electric Case Bracket Electric Case Bracket Installation Engine Hood Latch Removal itae a Engine Hood Latch Installation ss nal Drain Plug Housing REMOVAL ete sn van sr p exige a Ee du Drain Plug Housing Installation ette tene illc et bes dom cra e Exhaust Outlet Exhaust Outlet 5 ED Front Bumper Front Bumper Front Cover iati tro d et o et e E Front Cover Corner Bumper Corner Bumper Installation 998 Side Bumper Side Bumper Aor seein wenn d Rear Bumper Hull REPIACEMENT Rubber Parts nsec th cSt oath Rubber Parts Location co ine rere deci eee trae ec re D e D te Lvs Deck Fin Pad Removal Deck Fin Pad In
32. 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 CDI Ignition System Flame Arrester Fuel Filter Screen Spark Plugs Carburetor and internal parts Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be 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 w
33. JS800 A1 ORemove or disconnect Engine Hood see Hull Engine Hood chapter Cooling Hose A Bypass Hose B Bow C e JS800 A2 ORemove Bands A Water Temperature Sensor Connector B ORemove or disconnect Engine Hood see Hull Engine Hood chapter Cooling Hose A Bypass Hose B Water Temperature Sensor C see Electrical System chapter Bow D e Remove Two Muffler Bracket Mounting Bolts A Five Exhaust Pipe Mounting Bolts B e Loosen the inlet tube clamp bolt C Bow D Remove the exhaust pipe A the front muffler and the expansion chamber C as a set Bow D EXHAUST SYSTEM 4 5 Expansion Chamber e Unscrew the bolts and remove the following Exhaust Pipe Front Muffler B Expansion Chamber C JE098019 P Expansion Installation e Assemble provisionally the exhaust pipe A the front muffler B and the expansion chamber C with the new gaskets D OApply a non permanent locking agent to the assembly bolts E and tighten them to the specified torque Torque Expansion Chamber Assembly Bolts 29 N m 3 0 kgf m 22 ft lb e Install the new gasket A e Install provisionally the muffler bracket B between the cylinder and the front muffler Bow C e Install the above assembly on the engine e Apply a non permanent locking agent to the bolts and tighten them in the following order Torque Exhaust Pipe Mounting Bolts A and Muffler Brack
34. Starter Relay Installation Fuse Assembly G CDI Igniter Connectors H OApply a non permanent locking agent to the following bolts and tighten them Torque Regulator rectifier Mounting Bolts 8 8 0 90 kgf m 78 in Ib CDI Igniter Mounting Bolts 8 8 N m 0 90 kgf m 78 Ignition Coil Mounting Bolts 8 8 0 90 kgf m 78 OWhen assembling the electric case A be careful not to pinch leads between electric cases At this time apply grease to the O ring B to assemble easily OApply a non permanent locking agent to the following bolts and tighten them with inlet air temperature sensor D bracket Torque Electric Case Bolts C 8 8 0 90 kgf m 78 in Ib JN09012BN2 JNO9013BSi 6 13 36 ELECTRICAL SYSTEM Switches Start Stop Switch Removal e Remove Engine Hood see Hull Engine Hood chapter Start Stop Switch Lead Connector A e Remove Handlebar Pad Screws A Handlebar Pad B e Remove Wiring Clamps A e Carefully pull the start stop switch wiring up through the handle pole e Remove Switch Case Mounting Screws A Switch Case B Start Stop Switch Installation OThe switch case mounting clamp has an indexing dowel A e Position the dowel in the handlebar hole B e Tighten Torque Switch Case Mounting Screws 3 9 N m 0 40 kgf m 35 in lb e Be certain the start stop switch winding does not interfere with throttl
35. Stop Switch Leads Starter Motor Cable Clamp the bypass cooling hose and 2 spark plug lead Clamp the 1 and 2 spark plug leads Cooling Hose Cylinder Head Exhaust Pipe Battery Cable Battery Cable Battery Cooling Hose Water Temperature Sensor Hull Electric Case Starter Motor To Hull Exhaust Chamber Cylinder Head Coupling Cover Position the clamp screw as shown 15 4 APPENDIX Cable Wire and Hose Routing JS800 A2 Viewed from Top Z N a es oY SY AZ APPENDIX 15 5 Cable Wire Hose Routing OMNDORWND Bypass Outlet Clamp Bypass Cooling Hose Cylinder Head Bypass Outlet To Start Stop Switch Cooling Hose Water Box Muffler Water Temperature Sensor Magneto Leads Start stop Switch Leads Water Temperature Sensor Lead Inlet Air Temperature Sensor Lead Starter Motor Cable Clamp the bypass cooling hose and 2 spark plug lead Clamp the 1 and 2 spark plug leads Cooling Hose Cylinder Head Exhaust Pipe Battery Cable Battery Cable Battery Cooling Hose Electric Case Fill the hollow with the specified silicone grease Kawasaki Bond Silicone Grease 92137 1002 To Hull Exhaust Chamber Cylinder Head Flushing Hose Position the clamp screw as shown Flushing Cap Flushing Fitting
36. bolts and nuts which do not require a specific torque value General Fasteners stainless bolt and nut Torque Threads dia mm Nem 6 5 9 8 8 0 60 0 90 52 78 in lb 8 16 22 1 6 2 2 11 6 15 9 10 30 41 3 1 4 2 22 30 2 6 PERIODIC Specifications Standard Service Limit Fuel System Idle Speed in Water out of Water Electrical System Battery Voltage Spark Plug Gap 1 250 100 r min rpm 1 700 100 r min rpm 12 6 V or more 0 7 0 8 mm 0 028 0 031 PERIODIC 2 7 Maintenance Procedures Fuel System Idle Speed Adjustment The normal idle speed setting is the lowest stable speed e Remove the engine hood see Hull Engine Hood chap ter e Start the engine e Check the engine speed using the engine revolution tester A for high accuracy e Turn the idle adjusting screw A as required to reach this setting Idle Speed in water 1 250 100 r min rpm out of water 1 700 100 r min rpm Carburetor Synchronization e Remove the carburetor see Fuel System chapter CAUTION Do not turn the pilot screws carelessly during syn chronization You may cause poor running at low engine speed e Check the mixture screws settings see Fuel System chapter the setting is incorrect adjust them see Fuel System chapter e T
37. bushings may need to be replaced e Remove the handlebar see Handlebar Removal in this section Take out the screws A and remove the handle pole cover B Take out the mounting bolts A and remove the steering support bracket B Separate the plastic bushings A from the handlebar plate B 11 10 HANDLE POLE AND HANDLEBAR Handlebar e Clean the steering pivot stud A and check the surface for corrosion and wear the stud is corroded or noticeably worn replace the stud Remove the stud from the steering support bracket NOTE OThe stud is installed with a locking agent If necessary heat the stud with a torch to make removal easier Clean the threads in the support bracket thoroughly apply a non permanent locking agent High Strength Loctite 271 equivalent to the smaller threads of the new stud and tighten it to the specified torque Torque Steering Pivot Stud 38 N m 3 9 kgf m 28 ft lb e Check the plastic bushings A and steel washers B for damage and wear x If the bushings or washers are damaged or worn replace them e When reassembling the steering pivot be sure to grease A the new bushings B and washers C well Handlebar Plate D e Tighten the steering pivot nut so that the steering action is smooth not loose NOTE OThe steering pivot nut usually needs to be readjusted af ter the first few hours of use after lubricating the steering bushings The gr
38. 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 GENERAL INFORMATION 1 1 General Information Table of Contents Before ServIGIHg edet acne cocto NA General Specifications tette ere asad b GL e Re da Unit Conversion Table pp 1 2 GENERAL INFORMATION Before Servicing Before starting to service a watercraft careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descrip tions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting 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 CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolutionary speed or severe engine and exhaust system damage will occur 2 Auxiliary
39. end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 16 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while the Jet Ski watercraft is driven leading to a major problem GENERAL INFORMATION 1 5 Before Servicing 17 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives therefore make sure to wipe it off and apply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their orig
40. flywheel e Apply a thin coat of engine oil to the flanged portion of flywheel bolt e Apply a non permanent agent High Strength Loctite 271 equivalent to the threads of flywheel bolt and tighten it Torque Flywheel Bolt 130 13 5 kgf m 96 ft Ib e Check that the knock pins A and the spring B are in place and replace the O ring e Apply a non permanent locking agentto the threads of the magneto cover mounting bolts and tighten them securely Torque Magneto Cover Mounting Bolts 8 8 N m 0 90 kgf m 78 ft lb e JS800 A2 Knock Pins A Spring B 7 8 END Stator Removal e Remove the engine hood see Hull Engine Hood chap ter e Remove the bolts A and electric case cap B e JS800 A1 ODisconnect the connectors A e JS800 A2 ODisconnect the connectors A Remove Magneto Cover A e Slide the pins out of the connectors OUse a screw driver A to depress the pin latches ENGINE BOTTOM END 7 9 Stator e Unscrew the grommet cap A from the electric case cap e Pull the leads one at a time through the grommet and cap OLubricate the grommet with a penetrating rust inhibitor 49069017 P e JS800 A1 OUnscrew the set screws A and stator mounting bolts B and remove the stator assembly e JS800 A2 OUnscrew the set screws A and stator mounting bolts B and remove the stator assembly
41. m 1 0 kgf m 87 in Ib Handle Pole Pivot Shaft Nut 33 N m 3 4 kgf m 25 ft Ib Clean the mating surfaces of the bracket and hull Tighten the handle pole bracket bolts Torque Handle Pole Bracket Bolts 19 1 9 kgf m 14 ft Ib JS800 A1 Handle Pole Bracket Studs 20 N m 2 0 kgf m 14 ft Ib JS800 A2 Handle Pole Bracket Nuts 19N m 1 9 14 ft Ib JS800 A2 HULL ENGINE 12 1 Hull Engine Hood Table of Contents Exploded A VPE 12 2 e 12 6 Engine Hood REMOVal ee optet 12 6 Engine Installation vc p 12 7 Engine Hood Hook Removal utt tudo er 12 8 Engine Hood Hook Installation 12 8 Engine Hood Plate REMOVAL eben iE seen EUR 12 9 Engine Hood Plate Installation br Do et 12 9 Engine Hood Damper Removal pp 12 9 Engine Hood Damper Installation 4 12 9 Fire Extinguisher Holder Removal pp 12 9 Fire Extinguisher Holder Installation 20 12 9 c r Handle Pole Pad Handle Pole Pad Battery Bracket Rernoval non pee ee e eb duces uc ot p es n iu des Battery Bracket Installation Ne
42. place the inlet air temperature sensor B into the bracket A Inlet Air Temperature Sensor Inspection e Remove the inlet air temperature sensor see Inlet Air Temperature Sensor Removal e Suspend the sensor A in a container of water so that the temperature sensing protection is submerged e Suspend a thermometer B in the water NOTE OThe sensor and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradually rise the temperature of the water while stirring the water gently e Using the hand tester measure the internal resistance of the switch across the connectors at the temperatures shown in the table Special Tool Hand Tester 57001 1394 If the hand tester does not show the specified values re place the sensor Inlet Air Temperature Sensor Resistance Water Temperature Sensor Resistance 10 50 3 74 20 68 247 50 122 F 0 833 70 158 0 448 JNXX023482 C 13 44 ELECTRICAL SYSTEM Fuse Fuse Inspection e Remove Engine Hood see Hull Engine Hood chapter Fuse Plug A e Pull the cap A and take out the fuse B 10 A e Inspect the fuse element If it blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than
43. re move the engine hood hook C Engine Hood Hook Installation e Installation is the reverse of removal JM08006B5S1 JM08009B51 HULL ENGINE 12 9 Engine Hood Engine Hood Plate Removal e Remove the engine hood see Engine Hood Removal e Unscrew the mounting bolts A and remove the engine hood plate B Engine Hood Plate Installation e Installation is the reverse of removal Engine Hood Damper Removal e Remove the engine hood see Engine Hood Removal e Unscrew the mounting nuts A and remove the engine hood damper B JM08007BSi 6 Engine Hood Damper Installation e Install the washers C before tightening mounting nuts Fire Extinguisher Holder Removal e Remove the engine hood see Engine Hood Removal e Drill out the pop rivets A see Rivet Removal e Remove the extinguisher holder B Fire Extinguisher Holder Installation e Secure the fire extinguisher to the engine hood with rivets see Rivet Installation 12 10 HULL ENGINE HOOD Fittings Handle Pole Pad Removal CAUTION Do not remove the handle pole pad unless it is ab solutely necessary because the screw holes in the handle pole may be damaged by removal e Unscrew the handle pole cover screws A and remove the handle pole cover B e Unscrew the handlebar pad mounting screws C and re move the handlebar pad D e Disconnect the ball joint at upp
44. service limit replace all the brushes Starter Motor Brush Length Standard 12 5 mm 0 49 in Service Limit 6 5 mm 0 26 in Brush Spring Inspection e Check that the brush springs are in place and will snap the brushes firmly into place lf not reinstall or replace the spring Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves 6 11061051 6 13 18 ELECTRICAL SYSTEM Electric Starter System e Measure the diameter A of the commutator B Replace the starter motor with 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 O ohmmeter range measure the resistance between any two commutator segments A If there is a high resistance or no reading gt between any two segments a winding is open and the starter motor must be replaced e Using the highest ohmmeter range measure the resis tance between the commutator and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced Even if the foregoing checks show the armature to be good it may be defective in some manner not readily de tectable with an ohmmeter If all other starter motor and starter motor circuit components check good but the starter motor still does n
45. the outside of the new cable to ease cable in stallation Torque Handle Pole Cover Screws 1 5 N m 0 15 kgf m 13 in Ib Steering Cable Inspection e Refer to the Steering section in the Periodic Maintenance chapter Steering Cable Lubrication e Refer to the Steering section in the Periodic Maintenance chapter 4003001851 C HANDLE POLE HANDLEBAR 11 7 Handlebar Hand Grip Removal Installation e The hand grips are bonded to the handlebar To remove them cut the grips lengthwise with a sharp knife and peel A them off the bar WARNING Read all warnings and cautions on any solvents and adhesives used Many of these products are flammable may be harmful to the skin and eyes and may give off harmful vapors Use these sol vents and adhesives only in a well ventilated area and never near an open flame e Apply an adhesive to the inside of grip e Slide the grip into position on the handlebar Handlebar Removal e Remove Handlebar Pad Mounting Screws A Handlebar Pad B e Remove Throttle Case Screws C Throttle Cases D e Remove Switch Case Screws E Switch Cases F 11 8 HANDLE POLE AND HANDLEBAR Handlebar e Remove Steering Cable Ball Joint A Wiring Clamp Screw B Wiring Clamps C e Remove the cotter pin A and take the steering pivot nut B off the steering pivot stud e Remove the handlebar C with the handlebar plate f
46. them Torque CDI Igniter Mounting Bolts C 8 8 N m 0 90 kgf m 78 in lb Electric Case Bolts 8 8 0 90 kgf m 78 in Ib e JS800 A2 Olnstall Connectors A Collars B Plate C Bolts D OApply a non permanent locking agent to the following bolts and tighten them Torque CDI Igniter Mounting Bolts D 8 8 N m 0 90 78 in lb Electric Case Bolts 8 8 0 90 kgf m 78 in Ib Ignition Coil Primary Peak Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the electric case see Electric Case Removal and open the case see Electric Case Disassembly e Pull all the spark plug caps from the spark plugs and push the caps A fully onto the spark plug cap holder NOTE OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head Olnstall the peak voltage adapter B to the hand tester C and needle adapter set D OConnect the adapter between the BK W and O leads in the ignition coil primary lead connector Ignition Coil E CDI Igniter F JN08028BS1 C JN08055BS1 C JN08026BS1 C ELECTRICAL SYSTEM 13 27 Ignition System Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Hand Tester Range 250 V DC Primary Lead Connections Ignition Coil Adapter Tester
47. 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 cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Engine Engine Bed Mounting Bolts Air Inlet Cover Mounting Bolts Carburetor Mounting Bolts Inlet and Exhaust Manifold Nuts Exhaust Pipe Mounting Bolts Exhaust Chamber Mounting Bolts Cylinder Head Nuts Cylinder Base Nuts Drive Shaft and Pump Drive Shaft Holder Mounting Bolts Pump Mounting Bolts Pump Cover Mounting Bolts Pump Grate Mounting Bolts Steering Nozzle Pivot Bolts Handle Pole and Handlebar Handlebar Clamp Screws Handle Pole Pivot Shaft Nut Steering Pivot Nut Hull and Engine Hood Towing Eyes Bumper Rivets Cable Joint Balls Threads Electrical System Spark Plug Caps Starter Motor Mounting Bolts Battery Terminal Ground Cable Mounting Nut Hose and Hose Connect Inspection e Check the following hoses for leakage A hardening cracking B checking cuts abrasions breaks and bulges C And make sure the hoses are not kinked or pinched Fuel Hoses Fuel Vent Hose Cooling Hoses Bilge Hoses xIf a hose is damaged in any way replace it immediately and check all the others for damage 4 6603020281 6 2 22 PERIODIC Mai
48. watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating 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 REGULAR GRADE GASOLINE ONLY A minimum of 87 octane of the antiknock index is recommended The antiknock index is posted on service station pumps 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 Exhaust Emission Control System This system reduces the amount of pollutants discharged 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 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
49. 01 1095 A Piston Ring Compressor Belt 67 79 57001 1097 B e Thoroughly molybdenum disulfide oil solution to the cylin der bores e Slide the cylinder block down over the crankcase studs onto the crankcase CAUTION Do not force the cylinder block Make sure the rings are in position e Install the cylinder base nuts and cross tighten them Torque Cylinder Base Nuts 34 3 5 kgf m 25 16 e Place a new cylinder head gasket on the cylinder head OThe mark A of the gasket must face upward and EX mark B must face toward the exhaust side of the engine Front C JF04013BS1 C END 5 9 e Install the cylinder head e Tighten Torque Cylinder Head Nut 29 N m 3 0 kgf m 22 ft Ib OThe tightening sequence numbers are marked on the cylinder head Exhaust Side A e Install Exhaust Manifold see Exhaust System chapter Cable Holder i 9 e Apply a non permanent locking agent to the thread of ca ble holder bolts and tighten them Torque Cable Holder Bolts 29 N m 3 0 kgf m 22 ft Ib e JS800 A1 OApply a non permanent locking agent to the thread of wa ter hose joint and install it as follows 90 A e Tighten Torque Water Hose Joint 11 1 1 kgf m 95 in Ib Olnstall the cooling hose JF04014BSi 6 OApply a non permanent locking agent to the thread of wa ter hose jo
50. 4 6 STORAGE Removal from Test Run A WARNING Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death Start the engine and run it only for 15 seconds Check for fuel oil and exhaust leaks Any leaks must be repaired CAUTION Do not run the engine without cooling water supply for more than 15 seconds or severe engine and ex haust system damage will occur Install the engine hood see Hull Engine Hood chapter making sure it is locked APPENDIX 15 1 Appendix Table of Contents Cable Wire and Hose Routing idet t 15 2 PPOMUDISS 15 22 15 2 APPENDIX Cable Wire and Hose Routing JS800 A1 Viewed from Top Zh A se LX NS BOW 9 SG fen r O7 Bf ke o e NS EOS HE bo ONZO pu X AO Ys lt EE 4 lt 5 Viewed from Stern APPENDIX 15 3 Cable Wire Hose Routing OMNDOARWND Bypass Outlet Clamp Bypass Cooling Hose Cylinder Head Bypass Outlet To Start Stop Switch Cooling Hose Water Box Muffler Water Temperature Sensor Magneto Leads Start
51. 6 Terminal Voltage 11 5 12 6 V Standard Charge 1 8 A x 5 10 h see following chart Quick Charge 9 0A x 1 0h CAUTION If possible do not quick charge If the quick charge is done due to unavoidable circumstances do stan dard charge later on Terminal Voltage less than 11 5 V Charging Method 1 8 x 20h NOTE ORaise the voltage initially 25 V as maximum and charge for about 5 minutes as a yardstick If ammeter shows no change in current after 5 minutes you need a new battery The current if it can flow into the battery tends to become excessive Adjust the voltage as often as possible to keep the current at standard value 1 8 A Battery A Battery Charger B Standard Value C Current Starts to flow D 8 08060351 6 13 14 ELECTRICAL SYSTEM Battery Battery Standard Charge Time Chart for Reference Charge Time pop i 26 12 8 13 0 V Battery Terminal Voltage JN05006BWN3 C e Determine battery condition after refreshing charge ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below 12 0 12 6 V or lower Charge Insufficient Recharge 12 0 V or lower Unserviceable Replace ELECTRICAL SYSTEM 13 15 Electric Starter System Reduction Gear Removal Installation e Before removing the reduction gear remove the magneto flywhee
52. 8 turn 2 000 6 600 1 4 turn 3 000 10 000 3 8 turn NOTE OThe adjustment of the low speed screw is not required on the actual usage Carburetor Synchronization e Refer to the Carburetor Synchronization in the Periodic Maintenance chapter 40070258861 JC07026BS1 C FUEL SYSTEM 3 17 Carburetor Carburetor Removal e Remove the engine hood see Hull Engine Hood chap ter e Remove Air Inlet Cover Mounting Bolts A Air Inlet Cover B e Pull out the flame arrester A e Remove Flame Arrester Case Mounting Bolts A Flame Arrester Case B e Disconnect Throttle Cable End A Choke Cable End B Band Cut off C Fuel Return Hoses at Carburetor Remove D e Remove Bands Cut off A Pulse Hose B Fuel Supply Hose C 3 18 FUEL SYSTEM Carburetor eRemove the carburetor mounting bolts A e Lift the carburetor B off the inlet manifold Carburetor Installation e Install a new gaskets under the carburetor e Fit the holes of the carburetor onto the pins A of the inlet manifold e Apply a non permanent locking agent to the carburetor mounting bolts flame arrester case mounting bolts and air inlet cover mounting bolts Connect the fuel hoses and pulse hose correctly see Fuel System Diagram Tighten Torque Carburetor Mounting Bolts 18 N m 1 8 kgf m 13 ft Ib e Install the arrester case as shown Long edge to outside diamet
53. BK W gt R WARNING To avoid extremely high voltage shocks do not touch the spark plug leads or tester connections e Push the lanyard key under the stop switch and position the starter interlock switch to the right e Pushing the starter switch crank the engine 4 5 seconds to measure the primary peak voltage ODo not operate the starter for longer than 5 seconds Wait 15 seconds before using it again e Repeat the measurements 5 or more times Ignition Coil Primary Peak Voltage Standard 150 V or more xIf the reading is less than the specified value check the following Ignition Coil see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection xIf the ignition coil and crankshaft sensor are good condi tion replace the CDI igniter Crankshaft Sensor Peak Voltage Inspection NOTE sure the battery is fully charged e Remove Electric Case Connector A e Pull all the spark plug caps from the spark plugs and push the caps B fully onto the spark plug cap holders NOTE OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head e Connect the available peak voltage adapter C to the hand tester D and needle adapter set E Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Hand Tester Ra
54. Cus 2 7 Throttle Cable Adjustment et I Ci 2 8 Choke Cable eo eee rn eMe bu e Dv So e bua ent e deus ise eb 2 9 Fuel Filter Screen Cleaning 2 9 Fuel Vent Check Valve 2 10 Flame Arrester Cleaning and 2 11 Throttle Shaft Spring Inspectigom 2 12 Engine Bottom ENA o ores e tese 2 13 Coupling Damper Inspectionm 9 9 2 13 Gooling and Bilge Syslerfis 2 13 Gooling Syster Flushing uo ede Cle ree pe becas Gp idee 2 13 Bilge System Elushllg eee tec ended eet cal noo nt 2 15 Pump 1 nne nne 2 15 Pump Impeller Inspection 2 15 2 16 Steering Cable Inspection Ne 2 16 Steering Cable Lubrication 2 16 Handlebar Pivot 2 16 SVSUEIT ET 2 17 Battery Charging Condition Inspection 2 17 Spark Pl g Inspectiorz s s cos esie eb REPRE dS 2 18 Spark Plug Adjustment rone o Lena fedes t
55. Float Arm Level Diaphragm Inspection Adjustment e Remove Carburetor see Carburetor Removal Carburetor Cover see Carburetor Disassembly e Measure the float arm level A between the contact por tion B on the float arm and the carburetor case surface C Float Arm Level 0 0 0 2 mm 0 0 0 08 If the float arm level is incorrect bend the float arm very slightly to change the float arm level JC07023BS2 C FUEL SYSTEM 3 25 Fuel Pump Fuel Pump Removal e Remove the carburetor see Carburetor Removal e Remove the fuel pump body screws A and take the fuel pump cover B off the carburetor e Cut the band A and pull out the bypass hose B CAUTION The fuel pump cover and fuel pump body should not be disassembled If leakage is evident or internal damage is sus pected replace the fuel pump cover C and body D e Remove the diaphragm A e Remove the O ring A Pull out the fuel filter B 3 26 FUEL SYSTEM Fuel Pump Fuel Pump Installation e Install the cover A to the body B e Fit the projection C in the hole D Fuel Filter Inspection and Cleaning e Remove the fuel filter see Fuel Pump Removal e Check the fuel filter screen A for any break or deteriora tion If the screen has any break or is deteriorated they may allow dirt to reach the carburetor causing poor running Replace the fuel filt
56. Installation 3 33 ese 3 16 Fuel Filter Screen Cleaning 3 33 Carburetor Synchronization 3 16 oot cd ate diat uda 3 34 Carburetor Remowval 3 17 Fuel Tap Remowval 3 34 Carburetor Installation 3 18 Fuel Tap Installation 3 34 Carburetor Disassembly 3 18 Fuel Tap 3 34 Carburetor Assembly 3 20 Carburetor Cleaning and 3 22 3 2 FUEL SYSTEM Exploded View Oy at FUEL SYSTEM 3 3 Exploded View Fastener Throttle Cable Adjuster Locknuts Remarks Choke Cable Adjuster Locknuts 3 Case Screws 3 9 0 40 35 in Ib A J8800 A1 A2 Model B J8800 A3 Model C Tighten the clamp from left side G Apply grease L Apply a non permanent locking agent SS Apply silicone sealant 3 4 FUEL SYSTEM Exploded View A SNO amp x WY Sd Se ERN Y 0 ic gt 0 RR 0 g gs D 07 2 2 4 2 Y Qui a lt FUEL SYSTEM 3 5 Exploded View No Fastener Torque Remarks kgf m ft Ib 1 Carburetor Mounting Bolts 18 1 8 13 L 2 Arrester Case Mounting Bolts 8
57. Installation e Secure the corner bumper A to the hull with the rivets pushing up B the corner bumper see Rivet Installation JM07014BSi 6 OWhen installing the corner bumper the clearance A be tween the flange B and the bumper bottom end C must be as small as possible JM07015BSi 6 12 16 HULL ENGINE HOOD Fittings Side Bumper Removal e Remove the front bumper see Front Bumper Removal e Remove the corner bumpers see Corner Bumper Re moval e Drill out the pop rivets A see Rivet Removal e Remove the side bumper B Side Bumper Installation e Note the shape of side bumper Upper Side A Lower Side B OWhen installing the side bumper C the clearance D between the flange E and bumper bottom end F must be as small as possible e Install the side bumper A from rearward OMake sure that the rear end B of side bumper touches the front end C of corner bumper e Secure the side bumper to the hull with the rivets see Rivet Installation Rear Bumper Removal e Unscrew the bushing A and nut e Drill out the pop rivets B and washer e Remove the rear bumper C Rear Bumper Installation e Secure the rear bumper to the hull with the rivets see Rivet Installation JM07016BS51 C JM07017BS2 C HULL ENGINE 12 17 Hull Replacement e To replace the hull remove the various parts in the follow ing suggested order Battery and B
58. Limit 0 10 mm 0 0039 in Connecting Rod Big End Side Clearance e Measure big end side clearance A Olnsert feeler gauges between the big end and either crank half to determine clearance x If the measured value exceeds the service limit the crank shaft should be either replaced or rebuilt Connecting Rod Big End Side Clearance Standard 0 45 0 55 mm 0 018 0 022 in Service Limit 0 8 mm 0 0315 in Crankshaft Main Bearing Wear e Wash the bearings in high flash point solvent blow them dry DO NOT SPIN THEM and lubricate them with en gine oil A WARNING Solvent is toxic and flammable Avoid prolonged contact with skin and keep away from open flame Use only in a well ventilated area Eye protection should be worn when compressed air is used to dry parts Do not direct air towards anyone Use 172 kPa 1 75 kgf cm 25 psi maximum nozzle pres sure Turn each bearing over by hand and see that it makes no noise turns smoothly and has no rough spots If any of the bearings are defective replace them Crankshaft Runout Check crankshaft alignment by measuring runout OWith the crankshaft on V blocks A rotate the crank shaft slowly and measure runout at each of the locations shown If the runout at any point exceeds the service limit the crankshaft must be either replaced or rebuilt Crankshaft Runout Either Location Standard TIR 0 04 mm 0 0016 in or less Service Limit
59. O5001BS1 C PERIODIC 2 9 Maintenance Procedures e f necessary adjust the throttle cable e Loosen and turn the locknuts A at the bracket until the stop on the shaft lever hits against the idle adjust screw with slight cable slack e Tighten the locknuts securely Torque Throttle Cable Adjustment Nuts 20 2 0 kgf m 14 ft lb 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 lf the throttle lever does not return properly check the throttle cable routing cable adjustments and cable dam age Then lubricate the throttle cable Run the engine at the idle speed and turn the handlebar all the way to the right and left or and up and down to ensure that the idle speed does not change lf the idle speed increase check the throttle cable adjust ment and the cable routing Choke Cable Adjustment e Remove the engine hood see Hull Engine Hood chap ter e When the choke knob is turned to the OFF position the choke butterfly valve A in the carburetor should be com pletely open B The choke pivot arm C should stand all the way toward the starboard side of the boat with mini mal cable slack e When the choke knob is turned to the position the choke butterfly valve in the carburetor should be com pletely closed D Check th
60. alf JH0800BBS1 C ENGINE BOTTOM END 7 13 Crankshaft Maintenance The crankshaft changes the reciprocating motor of the piston into rotating motion to drive the jet pump Crank shaft trouble such as excessive play or runout will multi ply the stress caused by the intermittent force on the piston and will result in not only rapid crankshaft bearing wear but also noise power loss vibration and shorted engine life A defective crankshaft should always be detected at an early stage and repaired immediately The following explanation concerns the most common crankshaft problems and the method for measuring play runout and con rod alignment it does not cover crankshaft disassembly because of the highly specialized equipment that is required If crankshaft components become dam aged or worn the entire shaft should be replaced as an as sembly or rebuilt by a properly equipped shop Connecting Rod Bend Twist OSet the crankshaft in an alignment jig or in V blocks on a surface plate OSelect an arbor of the same diameter as the connecting rod small end and at least 100 mm long and insert the arbor through the connecting rod small end OWith the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connect rod bend If connecting rod bend exceeds the service limit the con n
61. ant WG Apply water resistance grease 9 4 DRIVE SYSTEM Specifications Item Standard Service Limit Drive Shaft Runout Refer to page 9 8 A TIR 0 1 mm 0 004 in or less B TIR 0 2 mm 0 008 in or less TIR 0 2 mm 0 008 in TIR 0 6 mm 0 024 in Special Tools DRIVE SYSTEM 9 5 Bearing Driver Set 57001 1129 7571129ST C Coupling Holder 2 57001 1423 875714235 6 Kawasaki Bond Silicone Sealant 56019 120 875601205 9 6 DRIVE SYSTEM Drive Shaft Drive Shaft Holder Drive Shaft Removal Installation e Remove the engine see Engine Removal Installation chapter e Pull the drive shaft A out of the hull e Hold the drive shaft in a vice and unscrew the coupling Special Tool Coupling Holder 57001 1423 A e When installing the drive shaft be careful of the following items OApply a non permanent locking agent to the threads of drive shaft and tighten the coupling Torque Coupling 39 N m 4 0 kgf m 29 ft Ib OApply water resistance grease to the grease seal lips OApply molybdenum disulfide grease to the drive shaft spline Drive Shaft Holder Removal Disassembly e Remove the drive shaft e Unscrew the mounting bolts A and remove the drive shaft holder B from the bulkhead e Disassemble the drive shaft holder ORemove the circlip A DRIVE SYSTEM 9 7 Drive Shaft Drive Shaft Holder
62. at the choke pivot arm C stands all the way toward the port side of the boat without cable slack e f necessary adjust the choke cable OTurn the choke knob to the OFF position counterclock wise completely OLoosen the adjust nuts A and turn the nuts to allow a little cable slack OTighten the locknuts Torque Choke Cable Adjust Nuts 20 N m 2 0 kgf m 14 ft Ib Fuel Filter Screen Cleaning Remove the engine hood see Hull Engine Hood chap ter Cut the bands of the fuel hoses Pull out each hoses A from the fuel filter assembly fit tings e Unscrew the fuel filter assembly mounting screws B Remove the fuel filter assembly 2 10 PERIODIC Maintenance Procedures e Wash the fuel filler screens A in non flammable or high flash point solvent Use a brush to remove any contami nants trapped in the screens A WARNING Clean the fuel filter screens in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline low flash point solvent A fire or explosion could result e When installing the fuel filter assembly note the following OBe sure the O ring A on the fuel tank is in position OTighten the mounting screws OBe sure the hoses are connected correctly with their fit tings e JS800 A1 Reser
63. at the fac tory using a flow meter specific mixture screw settings can not be given After adjustment a cap A is installed over each mixture screw head B with the point straight level C to identify proper mixture screw settings for each unit DO NOT CHANGE THESE SETTINGS If the carburetor is tam pered with and these settings cannot be relocated set the mixture screws to the following guide line e Pull out the mixture screw caps To set each screw turn it in until seats lightly and then back it out the specified number of turns Mixture Screw Turns out Low Speed ower Dj High Speed upper E These guideline represent a starting point from which additional fine tuning of the carburetor may be necessary CAUTION Do not force the mixture screws into their seats You could damage the screws or the carburetor Operating the watercraft with the high speed screw at too lean a setting screwed in clockwise too far could cause serious engine damage High Altitude Performance Adjustment The normal carburetor settings are best for sea level see Mixture Screw Adjustment If the watercraft is used at the higher elevations the lower atmospheric pressure makes the carburetion richer To obtain the proper carburetor set ting at higher elevations turn in the high speed screw ac cording to the following table Turn the high speed screw Altitude m ATO in the normal position 1 000 3 300 1
64. ble does not move freely replace it 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 Handlebar Pivot Lubrication e Remove the handlebar plate see Handlebar Steering Pivot Maintenance in the Handle Pole and Handlebar chapter e Check the bushings A and washers B for damage and wear x If the bushings or washers are damaged or worn replace them PERIODIC 2 17 Maintenance Procedures e Grease A the bushings B and washers C Handlebar Plate D J804000BSi 6 Electrical System Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage e Disconnect the battery cables see Electrical System chapter CAUTION Be sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter A which can be read one decimal place voltage If the reading is below the specified refreshing charge is required Battery Terminal Voltage Standard 12 6 V or more 8 08010851 6 0 25 50 75 100 Battery Charge Sh gt Terminal Voltage Refreshing Charge i Good is required JNO5005BSi 6 2 18 PERIODIC Maintenance Procedures Spa
65. bracket A so that its cham fer side E faces the side wall F and position the form closely to the side wall OFix the form top with the exhaust tube bracket G OBe sure that the form is away from the carburetors and fuel hoses JM07019BS2 C 12 12 HULL ENGINE HOOD Fittings Electric Case Bracket Removal e Remove the electric case see Electrical System chapter e Remove the engine hood latch A see Engine Hood Latch Removal e Unscrew the electric case bracket bolts B and remove the electric case bracket C Electric Case Bracket Installation e Apply a non permanent locking agent to the electric case bracket bolts and tighten them securely Engine Hood Latch Removal e Remove the engine hood see Engine Hood Removal e Remove Engine Hood Latch Nuts A Plate B Spark Plug Cap Holder C Engine Hood Latch D Engine Hood Latch Installation e Installation is the reverse of removal JM07011BS2 C JM07012BS2 C HULL ENGINE 12 13 Fittings Drain Plug Housing Removal e Unscrew the screws A and remove the drain plug hous ing B Drain Plug Housing Installation e Check the seal A for damage necessary replace new e Install the new gasket B so that its OUT mark C faces outwards Exhaust Outlet Removal e Unscrew the mounting bolts A and remove the holder B and exhaust outlet C Exhaust Outlet Installation
66. cable ball joints and steering 2 20 nozzle pivots Check all hoses clamps nuts bolts and fasteners e 2 21 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 Letters used in the Remarks column mean L Apply a non permanent locking agent Medium Strength Loctite 242 Equivalent LN Apply a non permanent locking agent High Strength Loctite 271 Equivalent S Tighten the fasteners following the specified sequence SS Apply silicone sealant to the threads Fastener Remarks Fuel System Throttle Cable Adjust Nuts 20 Choke Cable Adjust Nuts 20 Throttle Case Screws 3 9 35 in Ib Carburetor Mounting Bolts 18 13 L Main Jet 1 8 16 in Ib Pilot Jet 0 70 6 2 Float Arm Pin Screw 0 98 8 7 Carburetor Cover Screws 3 4 30 in Ib Carburetor Plate Screws 2 0 18 in Ib Inlet Manifold Mounting Nuts 9 8 1 0 87 5 Air Inlet Mounting Bolts 8 8 0 90 78 in Ib L Flame Arrester Case Mounting Bolts 8 8 0 90 78 in lb L Handle Pole Cover Screws 1 5 0 15 13 in Ib Handle Plate Screws 0 98 0 10 8 7 in lb Exhaust System Exhaust Pipe Mounting Bolts 29 L Front Muffler Mounting Bolts 29 L Water Hose Joints 11 95 in Ib L Exhaust Manifold Mounting Nuts 20 14 5 Chamber Mounting Bolts 29 22 L Muffler Bracket Mounti
67. cone Sealant 56019 120 875601205 10 6 PUMP AND IMPELLER Pump and Impeller Pump Removal e Turn the craft on its left side e Unscrew the mounting bolts A and remove the grate B and the pump cover C e Slip the steering cable connector A off the ball e Loosen the clamp and pull off the hoses B e Unscrew the pump mounting bolts A e Slide the pump to the rear to disengage the drive shaft and remove it from the hull Pump Installation e Grease the splines on the drive shaft with molybdenum disulfide grease and be sure the O ring is in place inside the pump shaft e Be sure the trim seal A is in place Bow B e When installing the pump case A be careful that the trim seal B is stayed in place Bow C Olf necessary apply water or oil to the surface of the trim seal NOTE ONo need to apply silicone sealant between the pump trim seal and the hull PUMP AND IMPELLER 10 7 Pump and Impeller When installing the drive shaft A fit the drive shaft into the spline of the impeller such that no clearances B exist between the shaft end and the O ring C Bow D e Apply a non permanent locking agent to the pump mount ing bolts and tighten them Torque Pump Mounting Bolts 22 N m 2 2 kgf m 16 ft Ib e Connect the hose and steering cable e Install the pump cover A and the pump grate B OApply a non permanent locking agent to the fo
68. ction e Checkthe valve stops A for deformation cracks or other damage lf there is any doubt as to the condition of a stop replace the reed valve assembly with a new one 2610006851 6 3 30 FUEL SYSTEM Fuel Tank Fuel Tank Removal e Remove the engine hood see Hull Engine Hood chap ter e fthe level of the fuel is above the inlet neck siphon some fuel out to prevent spilling it A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop switch 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 JS800 A2 OCut the band B for water temperature sensor lead A OLoosen the clamp A and remove the flushing hose B Water Temperature Sensor C Remove Cooling Hose End Exhaust pipe side Bolts A Clamp Loosen e Pull the exhaust pipe front muffler and expansion cham ber as a set backward B JG11003BS1 FUEL SYSTEM 3 31 Fuel Tank e Remove Choke Cable Adjuster Nut A Throttle Cable Adjuster Lock Nut B Cable Holder Bolts C Cable Holder D Magneto Cover Bolts E e Pull out the magneto cover F frontward e JS800 A1 OPush down the holders A and remove the rubber straps B ORemove the fuel filter see Fuel Filter Cleaning C Special Tool Watercraf
69. e A away from the ball slightly and lift the cable from the handlebar ball joint B and the steering nozzle ball joint C CAUTION Never lay the watercraft on the right side Water in the exhaust system may drain back into the engine causing serious damage e Loosen the locknut A and then remove the handlebar ball joint B from the ball C and the locknut from the cable end e Disconnect the steering cable from the cable holder on the handle pole OUnbolt the cable holder A e Remove the pump cover see Pump Removal in the Pump Impeller chapter e Disconnect the steering cable from the fitting at the rear of the hull OUnscrew the steering cable nut A while holding the fitting in the hull with a wrench OSlide off the snap ring B washer C and O ring D Bow E e Remove Exhaust Manifold see Exhaust Manifold Removal in the Exhaust System chapter e Pull the cable from cable detent A in the engine com partment e Remove the cable by carefully pulling B rear section of the cable through the hull C 11 6 HANDLE HANDLEBAR Steering Cable e Lay the handle pole a little rearwards and remove the cable by carefully pulling the front section of the cable A through the handle pole Steering Cable Installation e Install the plastic or rubber hose A on the front end of the steering cable to protect the cable when putting into the handle pole e Lubricate
70. e Apply a non permanent locking agent to the mounting bolts and tighten them securely Rivet Removal e Drill out the pop rivet with a drill bit A of the correct size Pop Rivet Removal 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 12 14 HULL ENGINE HOOD Fittings Rivet Installation e Secure the parts to the hull with the rivets using a riveter A Front Bumper Removal e Drill out the pop rivets A see Rivet Removal e Remove the front bumper B Front Bumper Installation e Insert the projection A on the front bumper B into the hole C of bracket D e Secure the front bumper to the hull with the rivets see Rivet Installation Front Cover Removal e Remove the front bumper see Front Bumper Removal e Drill out the pop rivets A see Rivet Removal e Remove the engine hood see Engine Hood Removal e Unscrew the front cover screws and washers A HULL ENGINE 12 15 Fittings e Separate the fuel filler cap A from the chain clip B e Remove the front cover C Front Cover Installation e Secure the front cover to the hull with the rivets see Rivet Installation Corner Bumper Removal e Drill out the pop rivets A see Rivet Removal e Remove the plate B and the corner bumper C Corner Bumper
71. e Battery Removal 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 Cover both battery terminals with grease Store the battery in a cool dry place Do not expose it to freezing temperatures Lubrication Carry out all recommended lubrication procedures see Lubrication in the Periodic Maintenance chapter e During the storage lubricate the following with penetrat ing rust inhibitor as well Steering Cable Joint Connector at Steering Nozzle 14 4 STORAGE Preparation for Storage General e Remove the engine hood see Hull Engine Hood chap ter e Wash the engine compartment with fresh water and re move the drain screw A in the stern to drain the water Wipe up any water left in the compartment CAUTION Use only a mild detergent in water to wash the hull Harsh solvents may attack the surface or smear the colors 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 engine hood or block the engine hood up with 10 mm spacers to insure adequate ventilation and prevent corrosion Cover the watercraft and store it in a clean dry place STORAGE 14 5 Removal from Storage Lubrication e Carry out all recommended lubrication procedures see Lubrication in
72. e Handle Pole Vent Line Fuel vent check valve The fuel vent check valve must be mounted so that the arrow is pointing toward the fuel tank Fuel Filter RETURN VENT RESERVE ON Return Line Fuel Supply Line Reserve Line Main Line Fuel Tap Carburetor Pulse Line Engine Side Bow Fuel Tank WN EE EX V3 5X ow a ey 274 DAA FUEL SYSTEM 3 9 Throttle Cable and Case Throttle Cable Adjustment Refer to the Throttle Cable Adjustment in the Periodic Maintenance chapter Throttle Case Removal Disassembly e Unscrew the handlebar pad screws A and remove the handlebar pad B e Remove the throttle case OUnscrew the throttle case screws C and separate the case halves D e Disconnect the throttle cable from the case OSlide the rubber boots A and rubber cap B out of the place OUnscrew the throttle cable fitting nut C OUse screw driver A to separate the tip B of the cable end from the case body 3 10 FUEL SYSTEM Throttle Cable and Case e Disassemble the throttle case the circlip A flat washer B Pin C throttle control 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 control lever hole B and set the spring in the throttle case C as shown e Install the control leve
73. e Pivot Bolt 60 in Ib LN 9 Wiring Clamp Screw 26 in lb L 10 Steering Cable Nut 11 Pole Bracket Studs 20 2 0 14 L 12 Handle Pole Bracket Nuts 19 1 9 14 13 Steering Cable 2 J8800 A1 Model B JS800 A2 Model G Apply grease L Apply a non permanent locking agent LN SS Apply silicone sealant Apply a non permanent locking agent High Strength Loctite 271 equivalent 11 4 HANDLE POLE AND HANDLEBAR Steering Cable Steering Cable Adjustment e Check steering cable adjustment OLower the handle pole A and center the handlebar B in the straight ahead position e Check that the steering nozzle A is centered B in the pump cavity Nearly Same Length C necessary adjust the steering cable Unscrew the mounting screws A and remove the han dlebar pad B ORaise the handle pole A and loosen the locknut B on the steering cable ODisconnect the ball joint by sliding the outer sleeve C away from the ball D slightly and lifting the cable from the ball OTurn the ball joint on the cable to adjust the steering OConnect the ball joint and check cable adjustment again OWhen adjustment is correct tighten the steering cable locknut Steering Cable Removal e Remove Handlebar Pad Screws A and Handlebar Pole Cover B HANDLE POLE AND HANDLEBAR 11 5 Steering Cable e Disconnect the ball joint at each end of the steering cable OSlide each outer sleev
74. e cable or choke cable movement when the handlebar is moved ELECTRICAL SYSTEM 13 37 Switches Start Stop Switch Inspection e Examine the start stop switch case and wiring lf the switch case is broken or damaged in any way re place the switch assembly xIf the wiring is damaged repair it or replace the switch assembly e Test the start switch A OSet a hand tester to the x 1 O range Special Tool Hand Tester 57001 1394 OConnect the tester leads to the red blue and yellow red start switch leads CPosition the starter interlock switch B to the right OCheck switch resistance with the start button released and with the start button depressed Start Switch Resistance Start Button Reading Released Q Depressed Almost 0 lf either meter reading is incorrect replace the start stop Switch e Test the starter interlock switch ORepeat the start switch A test with the starter interlock Switch B to the left OBoth meter readings should be either reading is less than replace the start stop switch 13 38 ELECTRICAL SYSTEM Switches e Test the stop switch OPush the lanyard key B under the stop switch OSet a hand tester to the x 1 O range Special Tool Hand Tester 57001 1394 OConnect the tester leads to the black and white stop Switch leads OCheck switch resistance with the stop button released and with the st
75. e sure to use the same kind of clamp as the original Some of the clamps are metal for tighter clamping ability required when smooth fitting 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 8 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 DRIVE SYSTEM 9 1 Drive System Table of Contents Exploded Per E ED 9 2 HP 9 4 Special TOONS oes 9 5 Drive Shaft Drive Shaft 9 6 Drive Shaft Removal Installation pp 9 6 Drive Shaft Holder Removal Disassembly pp 9 6 Drive Shaft Holder 9 7 Drive ShattRUlo uL rr 9 8 Exploded View 40 4402013885 C DRIVE SYSTEM 9 3 Exploded View Fastener 2 Drive Shaft Holder Mounting Bolts 3 Drive Shaft L Apply a non permanent locking agent M Apply molybdenum disulfide grease SS Apply silicone seal
76. e the small hole A on top of the breather fitting is clear e Reconnect the bilge hoses Pump and Impeller Pump and Impeller Inspection e Examine the impeller A lf 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 JK04026BSi 6 e Examine the pump case A If there are deep scratches inside the pump case replace it 2 16 PERIODIC Maintenance Procedures Steering Steering Cable Inspection e Remove the steering cable see Steering Cable Removal in the Handle Pole and Handlebar chapter e Examine the steering cable the cable or cable housing is kinked A replace the cable x lf the seal A at either end of the cable is damaged in replace the cable e Be certain that the cable moves freely in both directions e Disconnect the cable joint at each end of the cable OSlide each outer sleeve A away from the ball slightly and lift the cable from the handlebar ball joint B and the steering nozzle ball joint C CAUTION Never lay the watercraft on the right side Water in the exhaust system may drain back into the engine causing serious damage OSlide the inner cable back and forth in the cable housing If the ca
77. ease squeezes out of the bushings a little and the steering feels loose e Apply a non permanent locking agent to wiring clamp screw and tighten it to the specified torque Torque Wiring Clamp Screw 2 9 0 30 kgf m 26 in lb 4004000851 C HANDLE POLE AND HANDLEBAR 11 11 Handle Pole and Bracket Removal e Remove Engine Hood see Hull Engine Hood Removal Handlebar Switch Lead Connector A in rear of engine compartment Handlebar see Handlebar Removal in this chapter Handle Pole Cover see Handlebar Steering Pivot Main tenance Stern B e Take out the mounting bolts A and remove the steering support bracket B e Remove the throttle cable lower end from the carburetor assembly e Pull out from the steering pole Throttle Cable A Handlebar Switch Lead B Steering Cable C e Remove Handle Pole Pivot Shaft Nut A Handle Pole Pivot Shaft B e Lift the handle pole C out of the bracket Two washers D fall out e Remove the handle pole spring 11 12 HANDLE HANDLEBAR Pole Bracket Installation e Grease the washers with water resistant grease e Install the handle pole pivot shaft and tighten to the spec ified torque before putting on the pivot shaft nut Be sure the handle pole moves up and down smoothly before con tinuing If it does not decrease the pivot shaft torque slightly Torque Handle Pole Pivot Shaft 9 8 N
78. ecting rod or crankshaft must be replaced 100 mm 3 937 in A Connecting Rod Bend Standard under 0 05 100 mm 0 002 3 937 in Service Limit 0 2 100 mm 0 008 3 937 in e Measure connecting rod twist OWith the crankshaft still in the alignment jig hold the con necting rod horizontally and measure the amount that the arbor varies from being parallel with the crankshaft over a 100 length of the arbor to determine the amount of con necting rod twist If connecting rod twist exceeds the service limit the con necting rod or crankshaft must be replaced 100 mm 3 937 in A Connecting Rod Twist Standard under 0 15 100 mm 0 006 3 937 in Service Limit 0 2 100 mm 0 008 3 937 in JHO9006BSi 6 JH09007BSi 6 7 14 END Crankshaft Maintenance Connecting Rod Big End Radial Clearance e Check big end radial clearance OSet the crankshaft in an alignment jig or on V blocks and place a dial gauge against the connecting rod big end OPush the connecting rod first towards the gauge and then in the opposite directions The difference between the two gauge readings is the radial clearance If the radial clearance exceeds the service limit the crank shaft assembly must be replaced or disassembled and the crankpin needle bearing and connecting rod big end examined for wear Connecting Rod Big End Radial Clearance Standard 0 038 0 049 mm 0 0015 0 0193 in Service
79. ene ee 2 18 Spark PIUG E MU 2 18 6 2 18 All Hoses Hose Clamps Nuts Bolts and Fasteners Check 2 21 Nuts Bolts and Fasteners Tightness 1 2 21 Hose and Hose Connect mee 2 21 Rubber Strap nennen 2 22 2 2 PERIODIC Periodic Maintenance Chart Frequency Initial 10 Every 25 Every 100 See Page Description Hours Hours Hours g Adjust carburetor e 2 7 Clean fuel filter screens e 2 9 Inspect fuel vent check valve e 2 10 Inspect clean flame arrester e 2 11 Inspect carburetor throttle shaft spring replace 2 12 carburetor if necessary Inspect replace coupling damper e 2 13 Flush cooling system after each use in salt water 2 13 Flush bilge line and filter 2 15 Inspect impeller blade for damage remove e 2 15 Inspect steering cable e 2 16 Lubricate handlebar pivot disassemble 2 16 Inspect battery charging condition e 2 17 Clean and gap spark plugs replace if necessary e 2 18 Lubricate throttle cable fitting and choke cable fitting e 2 18 at carburetor Lubricate choke cable and throttle cable and throttle qun e 2 18 cable fitting at throttle case Lubricate steering
80. er e Wash the fuel filter screen in non flammable or high point solvent Use a brush to remove any contaminants strapped in the screen WARNING Clean the fuel screen well ventilated area take ample 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 A fire or explosion could result FUEL SYSTEM 3 27 Flame Arrester Flame Arrester Removal e Refer to the Flame Arrester Cleaning and Inspection in the Periodic Maintenance chapter Flame Arrester Installation e Refer to the Flame Arrester Cleaning and Inspection in the Periodic Maintenance chapter Flame Arrester Cleaning e Refer to the Flame Arrester Cleaning and Inspection in the Periodic Maintenance chapter 3 28 FUEL SYSTEM Inlet Manifold Reed Valves Inlet Manifold and Reed Valve Removal e Remove Engine Hood see Hull Engine Hood chapter Air Inlet Cover see Carburetor Removal Flame Arrester Case see Carburetor Removal Carburetor see Carburetor Removal e Remove the inlet manifold mounting nuts A and remove the inlet manifold B e Pull out the gaskets and the reed valves A 108006 P Inlet Manifold and Reed Valve Installation e Replace the gaskets with new ones e Install the reed valves so that the UP mark A is up e Install the inlet manifold gasket so that
81. er A Short edge to outside diameter B Engine Side C e Tighten Torque Frame Arrester Case Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Air Inlet Cover Mounting Bolts 8 8 N m 0 90 kgf m 78 in lb e Adjust the throttle and choke cables see Throttle Cable Adjustment Choke Cable Adjustment Carburetor Disassembly A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light JC07022BS1 FUEL SYSTEM 3 19 Carburetor eRemove the carburetor see Carburetor Removal e Unscrew the carburetor cover screws A and take off the carburetor 2 NET ji wa v o e Remove Diaphragm A CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm e Unscrew the float arm set screw A e Remove Float Arm B Pin C Spring Inlet Valve D e Remove the mounting screws A and drop out the plate B with the check valve C e Remove Gasket A Main Jet B Pilot Jet C Screw D Plate E Inlet Valve Holder F 3 20 FUEL SYSTEM Carburetor NOTE Olf the mixture screws need to be removed check num ber of return r
82. er Leave the engine idling e Rev the engine a few times to clear the water out of the exhaust system CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damage will occur e JS800 A1 OSwitch off the engine remove the garden hose install the fitting cap e JS800 A2 OSwitch off the engine remove the garden hose and the adapter Olnstall the flushing cap securely 6108002 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures 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 Disconnect both bilge hoses A at the plastic breather fitting e Connect the bilge filter hoses from the hull bottom to the garden hoses 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 water to accumulate in the engine compartment Remove the drain screws in stern to drain the engine compartment e Connect the other hoses from the hull bulkhead to the garden hose turn the water on and flush it out for several minutes e Remove the breather fitting see Cooling and Bilge Sys tem chapter e Before reconnecting the hoses to the plastic breather fit ting make sur
83. er end of steering cable OSIide the outer sleeve A away from the ball slightly and lift the cable from the ball e Unscrew the steering support bracket bolts B and re move the steering support bracket C with the handlebar e Unscrew the handle pole pad screws A and remove the handle pole pad B Handle Pole Pad Installation e Apply a non permanent locking agent to the steering sup port bracket mounting bolts and tighten them securely e Tighten the lower handle pole cover screws Torque Handle Pole Cover Screws 1 5 N m 0 15 kgf m 13 in Ib Battery Bracket Removal e Remove the battery see Electrical System chapter e Unscrew the battery bracket bolts A and remove the bat tery bracket B HULL ENGINE 12 11 Fittings e For French model JS800 A1 JS800A6F remove the following Exhaust Bracket see Exhaust System Form Battery Bracket Bolts Form Bracket D Battery Bracket E Battery Bracket Installation e Apply a non permanent locking agent to the battery bracket bolts e Four bolt holes A are on the bracket left side Tighten the battery bracket bolts B securely noting the bolt positions e For French model 5800 1 5800 6 ATF note the following Olnstall the form bracket A OAlign B the front portion of form C with the rear portion of front form D Olnsert the form C to the form
84. erature Sensor B and Bracket C 13 32 ELECTRICAL SYSTEM Electric Case OOpen the electric case ORemove Starter Relay A CDI Igniter B Regulator rectifier C ORemove Ignition Coil A Electric Case Assembly e JS800 A1 OApply water resistance grease to the grommets A and O ring B OWhen installing the joints C apply water resistance grease to the O ring D and tighten it Torque Joints 3 9 0 40 kgf m 35 in Ib OWhen inserting the spark plug leads E of ignition coil into the grommets apply silicone grease to the inside F of the grommets JN08005BS2 C ELECTRICAL SYSTEM 13 33 Electric Case ORun the lead connectors A of the igniter and regula tor rectifier through the electric case hole before installing the regulator rectifier OConnect the ground lead black terminals of the regula tor rectifier igniter and starter relay to the regulator recti fier mounting bolt B Olnstall Ignition Coil C see Ignition Coil Installation Regulator rectifier D see Regulator rectifier Installa tion CDI Igniter E see CDI Igniter Installation Starter Relay F see Starter Relay Installation Water Temperature Sensor G see Water Temperature Sensor Installation Fuse Assembly H OApply a non permanent locking agent to the following bolts and tighten them Torque Regulator rectifier Mounting Bolts 8 8 0 90 k
85. et Mounting Bolts B 29 3 0 kgf m 22 416 Bow C e Install the engine hood see Hull Engine Hood chapter JEO3004BSi 6 Expansion Chamber Cleaning and Inspection e Remove the expansion chamber see Expansion Cham ber Removal e Scrape any carbon deposits out of the expansion cham ber with a blunt or roundedged tool Excessive deposits will cause the engine to run poorly e Check the expansion chamber carefully for cracks Also look for corrosion both inside and out 4 6 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Removal e Remove the exhaust pipe the front muffler and the ex pansion chamber as a set see Expansion Chamber Re moval e Disconnect the inlet cooling hose A from the lower part of the exhaust manifold B e Remove the six exhaust manifold mounting nuts C e Take the exhaust manifold off the cylinder Exhaust Manifold Installation e Install the exhaust manifold gaskets so that each arrow A points upwards and is on the outside of the flange Bow B e The cooling hose clamp bolt A should face toward cylin der B and another hose clamp bolt C outside e Tighten the exhaust manifold mounting nuts following the specified tightening sequence Torque Exhaust Manifold Mounting Nuts 20 2 0 kgf m 14 ft Ib Bow D e The clamp bolt A of the inlet tube B should be inside as shown Bow C Exhaust Manifold Cleaning and Inspection e Remove the exhaust mani
86. f the flame arrester clean with com pressed air A A WARNING Eye protection should be worn when compressed air is used to dry parts Do not direct air toward anyone Use 172 kPa 1 75 kgf cm 25 psi maxi mum nozzle pressure e Visually inspect the flame arrester If the rubber holder screen and expanders are broken replace them as a set e When assembling the flame arrester put the screen A between two expander B Apply a non permanent locking agent to the threads of the air inlet cover bolts Tighten Torque Air Inlet Cover Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Throttle Shaft Spring Inspection e Remove Flame Arrester see Flame Arrester Cleaning and In spection Flame Arrester Case Bolts A Flame Arrester Case B e Check the throttle shaft springs A by pulling the throttle lever If the springs are damaged or weak replace the carbure tors PERIODIC 2 13 Maintenance Procedures Engine Bottom End Coupling Damper Inspection e Remove the engine see Engine Removal Installation chapter e With the engine removed remove the coupling damper and inspect it for wear A and deterioration If it is grooved or misshapen replaced it with a new damper lf there is any doubt as to coupler condition replace it Cooling and Bilge Systems Cooling System Flushing To prevent sand or salt deposits from accumulat
87. fold parts see Exhaust Mani fold Removal e Clean the carbon deposits out of the exhaust passage with a blunt or roundedged tool e Check the insides of the water passages for corrosion If there is excessive corrosion flush foreign matter out of the water passages with fresh water EXHAUST SYSTEM 4 7 Water Box Muffler Water Box Muffler Removal e Remove Engine Hood see Hull Engine Hood chapter Muffler Bracket A Exhaust Pipe B Front Muffler C and Expansion Chamber as a set see Expansion Chamber Removal e Remove or disconnect Magneto Cover see Magneto Flywheel Removal in the Engine Bottom End chapter Fuel Tank see Fuel System chapter Outlet Tube A Inlet Tube B e Take the water box muffler C out of the hull Water Box Muffler Inspection e Remove the water box muffler see Water Box Muffler Removal e Empty water out of the water box e Check the inlet spigot for damage caused by excessive heat xIf there is heat damage to the inlet spigot check the cool ing system for blockage see Cooling System Flushing in the Periodic Maintenance chapter ENGINE END 5 1 Engine Top End Table of Contents Exploded VieW eig rie e TER OR Wa ERE EE ee REC HA DAR e tetera ER ER lines 5 2 Specifications asip eh ten n RR e RA lends EGET NR 5 4 Speclal TOONS ss 4 n e ied De e a n d e lated e ED LAE
88. ful that the part is positioned correctly when you apply the cement It may be impossible to reposition the part A WARNING Do not get any cyanoacrylate cement in your eyes or on your skin If you do get some in your eyes do not try to wash it out Contact a physician im mediately If you do get some on your fingers do not touch any other part of your body your fingers will stick to anything they touch Allow the cement to cure and it will eventually wear off Rubber Parts Location Front Side Mat A Side Deck Mats B Deck Floor Mat C HULL ENGINE 12 19 Rubber Parts Engine Hood Gasket Trim Seal B Upper Side of Engine Hood Gasket Bonding Area D NOTE OJoint E the both ends of gasket with cyanoacrylate ce ment at the center of rear Be sure cyanoacrylate ce ment doesn t come out F from bottom of gasket JM05003BS2 C Handle Pole Bracket Damper A Detente A 12 20 HULL ENGINE HOOD Rubber Parts Water Box Muffler Damper A NOTE OWater box muffler damper A protect the hull B against the edge of water box muffler C Deck Fin Pad Removal e Pull down the side deck mat A and unscrew the screws B e JS800 A1 ORemove the engine hood see Engine Hood Removal ORemove the corner bumper see Corner Bumper Re moval ODrill out the pop rivets A see Rivet Removal ORemove Plate B Collar Deck Fi
89. g are half covered with the cap or the figures E of NGK R are completely covered Spark Plug Inspection e Refer to the Spark Plug Inspection in the Periodic Main tenance chapter Spark Plug Adjustment e Refer to the Spark Plug Adjustment in the Periodic Main tenance chapter Spark Plug Cleaning e Refer to the Spark Plug Cleaning in the Periodic Mainte nance chapter ELECTRICAL SYSTEM 13 29 Ignition System Ignition System Troubleshooting Faulty ignition Malfunctioned engine Ignition system wiring No good Repair or replace and connector inspection Good good Spark plug inspection Replace Good N d Good Voltage is less than the specified value Peak voltage measurement is repeated 5 or more times No good Good Ignition coil primary peak voltage inspection Good Voltage is zero Voltage is OK or almost zero Defective ignition coil Inspect Inspect 1 Adapter connection is Lower resistance in a incorrect or adapter is hand tester Use defective KAWASAKI Hand Tester 2 Battery voltage Battery voltage 3 Crankshaft sensor peak Crankshaft sensor peak voltage voltage Replace No good Replace bad parts Igniter is defective Replace bad parts or inspect them with KAWASAKI Hand Tester No good JN08027B F 13 30 ELECTRICAL SYSTEM Electric Case Electric Case Removal e JS800 A1 ORemove Battery Cable
90. g 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 WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment 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 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 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
91. g water supply for more than 15 seconds especially in high revo lutionary speed or severe engine and exhaust sys tem damage will occur J002000BS1 C STORAGE 14 3 Preparation for e Remove the air inlet cover A from the carburetor assem bly Bow B e Lift out the flame arresters A and clean them if neces sary see Flame Arrester Cleaning and Inspection in the Periodic Maintenance chapter e Spray a penetrating rust inhibitor down the carburetor bore e Install the flame arresters e Reinstall the cover apply a non permanent locking agent to the threads of the air inlet cover bolts Torque Air Inlet Cover Mounting Bolts 8 8 0 90 kgf m 78 in Ib Engine Remove the spark plugs and push the plug caps fully onto the plug cap holders A on the rear of the engine compart ment e Pour one ounce of motor oil into each cylinder CAUTION Do not use too much oil or the crank seals may be damaged when the engine is next started 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 e Pull the lanyard key off the stop button e Reinstall the spark plugs and caps Battery 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 Remove the battery se
92. gf m 78 in Ib CDI Igniter Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Ignition Coil Mounting Bolts 8 8 N m 0 90 kgf m 78 JN09006BN2 13 34 ELECTRICAL SYSTEM Electric Case OWhen assembling the electric case be careful not to pinch leads between electric cases At this time apply grease to the O ring B to assemble easily OApply a non permanent locking agent to the following bolts and tighten them Torque Electric Case Bolts C 8 8 N m 0 90 kgf m 78 in Ib e JS800 A2 OApply water resistance grease to the grommets and O ring B OWhen installing the joints C apply water resistance grease to the O ring D and tighten it Torque Joint 3 9 0 40 kgf m 35 in Ib OWhen inserting the spark plug leads E of ignition coil into the grommets apply silicone grease to the inside F of the grommets JN08011BS2 C ELECTRICAL SYSTEM 13 35 Electric Case ORun the lead connectors A of the igniter and regula tor rectifier through the electric case hole before installing the regulator rectifier OConnect the ground lead black terminals of the regula tor rectifier igniter and starter relay to the regulator recti fier mounting bolt B Olnstall Ignition Coil C see Ignition Coil Installation Regulator rectifier D see Regulator rectifier Installa tion CDI Igniter E see CDI Igniter Installation Starter Relay F see
93. hers B and grommets are in position JNOG008BSi C 13 20 ELECTRICAL SYSTEM Electric Starter System e Connect the ground lead black A to the ground mount ing bolt e Connect the battery cable to the relay terminal B having red lead and red color of the thread end C Starter Relay Inspection Set the hand tester A to x 1 range Special Tool Hand Tester 57001 1394 Connect tester leads to starter relay as shown M6 Terminals C resistance is less than infinite the starter relay is not returning and must be replaced e Set the hand tester A to x 1 range Special Tool Hand Tester 57001 1394 Connect tester leads to starter relay as shown Activate starter relay by connecting a 12 V battery C as shown Y R Lead D BK Lead E x lf the starter relay clicks and the tester indicates zero re sistance the starter relay is good If the tester indicates high or infinite resistance the starter relay is defective and must be replaced JN08007BS1 C JNO8009BS1 C ELECTRICAL SYSTEM 13 21 Charging System Charging System Inspection e JS800 A1 ORemove Electric Case Connector A 3 pin Connector B e JS800 A2 ORemove Electric Case Connector A 3 pin Connector B e With a multimeter check the charging coil output voltage according to the following table with the engine mounting at approximatel
94. hrottle 32 minutes Dimensions Overall Length Overall Width Overall Height Dry Weight JS800 A1 A6F A8F Curb Mass JS800A9F Air Draft 1 Maximum Draft 2 Fuel Tank Capacity 2 300 mm 90 55 in 730 mm 28 7 in 735 mm 28 9 in 159 kg 351 Ib 180 kg 397 Ib 515 20 3 in 17 L 4 5 US gal including 3 L 0 8 US gal reserve 1 8 GENERAL General Specifications ltems JS800 A1 6 Engine Oil Type 2 stroke Certified for Service TC W3 Electrical Equipment Battery 12 V 18 Ah Maximum generator Output 6 6 A 14 V 6 000 r min rpm 1 Vertical distance between the floating plane in the light craft condition and the highest point of the craft structure namely the handle top 2 Draft in the fully loaded craft condition 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 GENERAL INFORMATION 1 9 Prefixes for Units Prefix Symbol Power mega M x 1 000 000 kilo k x 1000 centi C x 0 01 milli m x 0 001 micro u x 0 000001 Units of Mass kg x 2 205 Ib g x 0 03527 OZ Units of Volume L 0 2642 05 L x 0 2200 gal imp L x 1 057 qt US L x 0 8799 qt imp L x 2 113 pint US L x 1 816 p
95. ide long reliable service Refer to the Periodic Maintenance Chart for the frequency of the following items e Lubricate the following with a penetrating rust inhibitor Throttle Cable A Choke Cable A 79 9 0 0 0 0 9 9 0 NS ISS 2277202 A 5 SSA GP10012681 6604010251 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Steering Nozzle 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 e Lubricate the following with a grease Throttle Cable Ends A 2 20 PERIODIC Periodic Maintenance Procedures Choke Cable Ends B Steering Cable Ball Joints C PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures All Hoses Hose Clamps Nuts Bolts and Fasteners Check Nuts Bolts and Fasteners Tightness Inspection 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 there are loose fasteners retighten them to the spec ified torque following the specified
96. ighten them Torque Ignition Coil Mounting Bolts 8 8 0 90 kgf m 78 in Ib 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 e Connect the ignition coil A with the spark plug cap left installed on the high tension lead to the tester B and measure the arcing distance WARNING To avoid extremely high voltage shocks do not touch the coil or lead x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing Distance Standard 7 mm 0 28 in or more e To determine which part is defective measure the arcing distance again with the spark plug caps removed from the ignition coil xIf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug caps JN08024BS1 60 ELECTRICAL SYSTEM 13 25 Ignition System Measuring coil resistance If the Coil Tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester However a hand tester can not detect layer shorts and shorts resulting from insulation breakdown under high volt age e Disconnect the primary leads from the coil terminals e Measure the primary winding resistance as foll
97. inal function once they are removed There fore always replace these parts with new ones every time they are removed Although the pre viously mentioned gasket O ring ball bearing needle bearing grease seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 19 Electrical Wires All the electrical wires are either one color or two color A two color wire is identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless in structed otherwise electrical wires must be connected to wires of the same color Two Color Electrical Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Yellow Red 68020601 1 20 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 21 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or dete riorated performance re
98. ine the impeller A 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 OMeasure the impeller outside diameter If the impeller is worn smaller than the service limit re place it Impeller Outside Diameter Standard 139 5 139 7 mm 5 492 5 500 Service Limit 138 5 mm 5 453 in e Examine the pump case A x If there are deep scratches inside the pump case replace it OMeasure the inside diameter of the pump case x If the pump case is worn beyond the service limit replace it Pump Case Inside Diameter Standard 140 0 140 1 mm 5 512 5 516 in Service Limit 141 1 mm 5 555 in Impeller Clearance 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 impeller clearance remove the grate and insert a feeler gauge A between the tip of the impeller blade B and the pump case C Impeller Clearance Standard 0 15 0 30 mm 0 0059 0 012 in Service Limit 0 60 mm 0 024 in If impeller clearance is incorrect determine if it is due to wear or damage see Pump and Impeller Inspection JKO4026BS1 C HANDLE POLE AND HANDLEBAR 11 1
99. ing 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 left side of the hull e JS800 A1 OLoosen the clamp screw A and pull out the rubber band B ORemove the fitting cap C on the exhaust pipe OConnect a garden hose A to the fitting e JS800 A2 OObtain 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 NOTE OOptional part P No 92005 3748 is available as a gar den hose adapter 2 14 PERIODIC Maintenance Procedures ORemove the flushing cap A OScrew a garden hose adapter A onto the flushing fitting B OAttach a garden hose C to a garden hose adapter and secure the hose clamp D e Start the engine and allow it to idle before turning on the water CAUTION The engine must be running before the water is turned on or water may flow back through the exhaust pipe into the engine resulting in the pos sibility of severe internal damage 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 left side of the hull e Leave the engine idle for several minutes with the water running e Turn off the wat
100. int imp mL x 0 03381 oz US mL x 0 02816 oz imp mL x 0 06102 cu in Units of Force N x 0 1020 kg N x 0 2248 Ib kg x 9 807 N kg x 2 205 Ib Units of Temperature SEC agente 32 40 20 0 20 40 40 20 26 7 104 40 48 9 Units of Length km X 0 6214 m X 3 281 mm X 0 03937 Units of Torque 0 1020 0 7376 8 851 kgfm 9 807 7 233 kgfm 86 80 Units of Pressure kPa 0 01020 kPa 0 1450 kPa 0 7501 kgf cm 98 07 kgf cm 14 22 cm Hg x 1 333 Units of Speed km h x 0 6214 Units of Power kW x 1 860 kW x 1 341 PS x 0 7355 PS x 0 9863 5 F 40 40 248 80 100 1120 284 176 212 80 100 120 140 160 180 200 220 240 260 280 300 1140 714 933 116 138 mile kgf m ft Ib in Ib N m ft Ib in lb kgf cm psi cmHg kPa psi kPa mph PS HP kW HP 320 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance 2 2 Torque and Locking Agent itte eot Eo Ee Re edicta cta Lo d ieee 2 3 CIO LL LL 2 6 Periodic Maintenance Procedures ua eerte Paene orte ie De d en Hn pui dee 2 7 SVS VOM ME c TTE 2 7 Idle Speed Adjustment reir ene RR eo Rec 2 7 Carburetor Synchronization epe ossi tub ecu te
101. int and install it as follows 30 A e Tighten Torque Water Hose Joint 11 1 1 kgf m 95 in Ib Olnstall the cooling hose e JS800 A2 OApply a_non permanent locking agent the water hose joints and install them as follows 40 30 e Tighten Torque Water Hose Joint 11 1 1 kgf m 95 in Ib 5 10 END Engine Top End Olnstall the cooling hoses A e Start the engine to check for fuel and oil leaks exhaust leaks and excessive vibration WARNING Do not run the engine a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas which can be lethal CAUTION Do not run the engine for more than 15 seconds without cooling water Maintenance and Inspection Compression Measurement e Thoroughly warm up the engine while checking that there is no compression leakage from around the spark plugs or the cylinder head gasket CAUTION Do not run the engine for more than 15 seconds without cooling water e Stop the engine e Remove the engine hood see Hull Engine Hood chap ter e Remove the spark plugs and screw a compression gauge firmly into the spark plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 A Compression Gauge Adapter M14 x 1 25 57001 1159 B e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops risi
102. ith 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 e Be alert for problems and non scheduled maintenance e Use 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 locatin
103. l see Engine Bottom End chapter e When installing the reduction gear apply a molybdenum disulfide grease A to both ends of its shaft Reduction Gear Inspection e Rotate the pinion gear A counterclockwise The gear must rotate freely B e Rotate the pinion gear clockwise all the way The pinion gear will be advanced along the reduction gear shaft and stopped against the stopper A e Release the pinion gear The pinion gear must return to the initial position rapidly xIf the pinion gear does not function properly replace it Starter Motor Removal e Disconnect Exhaust Manifold see Exhaust System chapter Battery Ground Cable A Starter Motor Cable B e Remove the starter motor mounting bolts C and pull off the starter motor D CAUTION Do not tap the starter motor shaft or body Tapping on the shaft or body could damage the motor Starter Motor Installation e Clean the starter motor lugs A and crankcase B where the starter motor is grounded e Apply a small amount of engine oil to the O ring e Apply a non permanent locking agent to the starter motor mounting bolt and the battery ground cable mounting bolt e Connect the battery ground cable e Tighten Torque Starter Motor Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Battery Ground Cable Mounting Bolt 8 8 N m 0 90 kgf m 78 in Ib 13 16 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly e Unscrew the
104. llowing bolts and tighten them Torque Pump Cover Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib Grate Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib Pump Disassembly e Unscrew the mounting bolts A and remove the steering nozzle B e Unscrew the mounting bolts A and remove the pump outlet B e Unscrew the cap bolts A and remove the pump 10 8 PUMP AND IMPELLER Pump and Impeller e Hold the shaft in a vise taking care not to damage it e Remove the impeller from the pump shaft Special Tool Impeller Wrench 57001 1228 A e Pull out the pump shaft A and then the bushing B e Remove the grease seals A Special Tool Oil Seal amp Bearing Remover 57001 1058 B e Use the bearing remover special tools to remove the pump bearings Pump Case A Pump Bearings B Collar C Special Tools Bearing Remover Shaft 513 57001 1377 D Bearing Remover Head 15 x 17 57001 1267 E JKO4035BS1 60 PUMP AND IMPELLER 10 9 Pump and Impeller Pump Assembly e Before installing the pump bearings blow any dirt or for eign particles out of the pump case with compressed air NOTE Olnstall the pump bearings so that the marked side faces out e Install the new bearings in the order listed by pushing the outer race with the bearing drivers A Rear Pump Bearing until it bottoms out B Collar C Front Pump Bearing im
105. ly with the white mark B faced bow e Put the tube onto the tank as shown 10 mm 0 39 in A 7611005851 6 Fuel Filter Screen Cleaning e Refer to the Fuel Filter Screen Cleaning in the Periodic Maintenance chapter 3 34 FUEL SYSTEM Fuel Tap Fuel Tap Removal e Unscrew the set screw A and take out the fuel tap knob B e Remove the indicate plate C from the hull e Unscrew the mounting screws A and take out the fuel tap B e Cut the band A e Pull the fuel hoses B off the fuel tap C Fuel Tap Installation e Connect the fuel hoses to the fuel tap correctly ON A Fuel Supply B Reserve C e Apply a non permanent locking agent to the fuel tap mounting screws and tighten them securely Fuel Tap Cleaning If the fuel tap becomes clogged with foreign matter it must be cleaned e Remove the fuel tap A see Fuel Tap Removal e Use compressed air to blow B through supply hose fitting C while switching the fuel tap right and left between the ON and RES positions e Do this until only blockage is forced out NOTE not use too high air pressure 172 kPa 1 8 kgf cm 25 psi max 3129056 P 4012000851 C EXHAUST SYSTEM 4 1 Exhaust System Table of Contents Exploded VieW 2 ait awed eta 4 2 Expansion Chamber 4 4
106. mall hole in the top of the breather is open by blowing in one end of the breather and plugging the other xIf 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 well as it should Bilge Filter Removal e Remove the electric case see the Electrical System e Remove the mounting screws A and take out the bilge filter Bilge Filter Cleaning and Inspection e Wash the bilge filter thoroughly with fresh water and shake it dry OUse a brush to remove any contaminants trapped in the bilge filter e Water must flow freely through the bilge filter but large debris must not xIf the bilge filter cannot be cleaned or if it is broken and allows debris to pass through replace it 8 6 COOLING AND BILGE SYSTEMS Cooling and Bilge System Hoses Hose Removal e None of the bilge system hoses A has a clamp To re move this hose remove the bilge filter see Bilge Filter Removal The bilge system hoses without clamps may be simply pulled off their fittings e All the cooling system hoses A are clamped at both ends Loosen the clamps and pull the hoses off e J5800 A2 Hose Installation e To install the bilge filter hose push the hose over the end of the bilge filter e When installing the cooling system hoses b
107. mg 9045 4o31uS 31 35 oul sug SUuO 399UuUO YOLIMS 7427 403e n328y 1osueg 191 4070p 49149189 38 18 8 493185 dois euiSug yoring 14238 euiSug W1 3709C85 6 ELECTRICAL SYSTEM 13 11 iagram D iring W JS800 A2 1 34217 en g 34311 yeg 9102 0200 2 401009 91 8 26086 493185 4096 sul3u3 yorlmgs 31836 oul sug suol349euuo0 YO IMS Aego puey 1291 91439813 A a fid u 1 4 88 ya 48 291199 0 0 1192 12021 M 38 9131721 BR BK BR BL I I I 019u8egy gt 0 18 1 18 DK1 u 18 18 Asa Asa A a ERIT 18 40108 1942635 9314 y EE V A 4 1 oF ous sug fid u L2 18 8 18 8 78 8 oT gt 48 8 8 o 4 Ck A 0035 DCO 18 90 133 1osueg a4n3eB43dua1 aT E 3aJn3Baduas1 11 W2 3716AW5 6 13 12 ELECTRICAL SYSTEM Battery Battery Removal e Remove Engine Hood see Hull Engine Hood chapter Air Inlet Cover A see Frame Arrester Cleaning and Inspection in the Periodic Maintenance chapter ODisconnect the bat
108. move Engine Bed Mounting Bolts A e Slide the engine toward the front A to disengage the cou plings B and then lift the engine out of the hull e Remove Engine Mounting Bolts A Engine Bed B 6 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Mount Removal e Remove Engine Damper Mount Bolts A Engine Mounts B Shim C e Record the number of the shims as installed to the original position Engine Mount Installation e Install the shim s of the same number If the shim numbers are unknown refer to the following table Numerical Letters A Numbers of Shim NOTE OThe amount of original shims should be recorded prior to installation The contents of the above table are for reference e Apply a non permanent locking agent to the engine mount bolts and tighten them Torque Engine Damper Mount Bolts 16 N m 1 6 kgf m 12 ft Ib Engine Installation e Be sure there are no foreign objects and parts inside of the hull e Clean the bilge filter see Bilge Filter Cleaning and Inspec tion in the Cooling and Bilge Systems chapter e Check the coupling damper for wear damage see Cou pling Damper Inspection in the Periodic Maintenance chapter e Install the engine bed so that small notches A are on the magneto end of the engine as shown Front Side B JGO3001BS1 C ENGINE REMOVAL INSTALLATION 6 7 Engine Removal Installation
109. n Pad C e JS800 A2 ORemove the engine hood see Engine Hood Removal ORemove the corner bumper see Corner Bumper Re moval ODrill out the pop rivets A see Rivet Removal ORemove the deck fin pad B JM05004BS2 C HULL ENGINE 12 21 Parts Deck Fin Pad Installation e JS800 A1 OApply silicone sealant A to the holes for rivets Olnstall the collars B and plate C on the front D of deck fin pad and use the long rivets E securing the plate C NOTE OFor the right side rivets E secure the plate with the bracket F of bilge breather G JM05011BS2 C e JS800 A2 OApply silicone sealant A to the holes for rivets OSecure the deck fin pad to the hull with the rivets see Rivet Installation JM05010BS2 C ELECTRICAL SYSTEM 13 1 Electrical System Table of Contents Exploded View 5800 1 13 2 Exploded View JS800 A2 13 4 Exploded 13 6 Specifications 13 8 Special Tools 13 9 Wiring 13 10 Battery 13 12 Battery Removal 13 12 Battery Installation 13 12 Charging Condition Inspection 13 12 Refreshing Charge 13 13 Electric Starter System
110. nce When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a part first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them 7 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 8 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads 9 Edges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over 10 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com m
111. nector Mounting Bolts 8 8 0 90 78 in Ib L 2 Spark Plugs 27 2 8 20 3 Joints 3 9 0 40 35 in Ib 4 Starter Relay Lead Mounting Nuts 4 4 0 45 39 in lb 5 Electric Case Mounting Bolts 8 8 0 90 78 in Ib L 6 Water Temperature Sensor 15 1 5 11 see text 7 Regulator rectifier Mounting Bolts 8 8 0 90 78 in lb L 8 CDI Igniter Mounting Bolts 8 8 0 90 78 in Ib L 9 Coil Mounting Bolts 8 8 0 90 78 in Ib L 10 Electric Case Bolts 8 8 0 90 78 in Ib L 11 Switch Case Mounting Screws 3 9 0 40 35 in Ib Sg Fill the hollow with the specified silicone grease Kawasaki Bond Silicone Grease 92137 1002 Apply grease Apply a non permanent locking agent Si WG Apply silicone grease Apply water resistance grease 13 6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 13 7 Exploded View No Fastener b Remarks N m kgf m ft Ib 1 Battery Ground Cable Mounting Bolt 8 8 0 90 78 L 2 Starter Motor Cable Mounting Nut 7 8 0 80 69 in lb Starter Motor Mounting Bolts 8 8 0 90 78 in lb L 4 Starter Motor Retaining Bolts 6 3 0 65 56 in Ib L 5 JS800 A1 A3 6 JS800A6F G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 13 8 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Capacity Electric Starter System Starter Motor Brush Length Commutato
112. ng the compression is the highest reading obtainable e Repeat the measurement for the other cylinder Cylinder Compression Usable Range 892 1 372 kPa 9 1 14 kgf cm 129 199 psi open throttle ENGINE TOP END 5 11 Engine Top End xIf the cylinder compression is higher than the usable range check the following OCarbon buildup on the piston head and cylinder head clean off any carbon on the piston head and cylinder head OCylinder head gasket cylinder base gaskets use only the proper gaskets The use of a gasket of incorrect thickness will change the compression If cylinder compression is lower than the usable range check the following OGas leakage around the cylinder head replace the dam aged gasket and check the cylinder head for warp OPiston cylinder clearance piston seizure OPiston rings piston ring groove wear Cylinder Head Warp Inspection e Lay straightedge A across the lower surface of the head B at several different points and measure warp by inserting a thickness gauge C between the straightedge and the head If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 002 in Cylinder Wear Inspection e Inspect the inside of the cylinder for scratches and abnor mal wear xIf the cylinder is damaged or badly worn replace it with a new one
113. ng Bolts 29 L Water Box Muffler Bracket Mounting Screws 4 9 L Engine Top End Cylinder Head Nuts 29 S Cable Holder Bolts 29 L Cylinder Base Nuts 34 Water Hose Joint 11 L Cylinder Stud L Engine Removal Installation Engine Mounting Bolts 49 5 0 36 L Engine Bed Mounting Bolts 36 3 7 27 L Engine Damper Mount Bolts 16 1 6 12 L Engine Bottom End Magneto Cover Cap Bolts 8 8 0 90 78 L Magneto Cover Mounting Bolts 8 8 0 90 78 in lb L 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Coupling Set Screw Flywheel Bolt Crankshaft Sensor Bracket Screw Grommet Clamp Screws Stator Mounting Bolts Electric Case Cap Bolts Crankcase Bolts 6 mm dia Crankcase Bolts 8 mm dia Cooling and Bilge Systems Water Hose Joint Drive System ft lb 22 in lb 96 22 in lb 22 in lb 8 5 78 in lb 78 in lb 22 Remarks Coupling 39 4 0 29 Drive Shaft Holder Mounting Bolts 22 2 2 16 L Pump and Impeller Water Hose Joint 9 8 1 0 87 in lb L Steering Nozzle Pivot Bolts 8 8 0 90 78 in lb L Pump Outlet Mounting Bolts L Pump Cap Bolts L Impeller 72 Pump Mounting Bolts 16 L Pump Cover Mounting Bolts 61 in lb L Grate Mounting Bolts 69 in lb L Steering Cable Ball Joint 87 in lb L Pump Shaft 72 Handle Pole and Handlebar Steering Support Bracket Mounting Bolts L Steering Pivot Stud 28 LN small Handle Pole Cover Screws 13 in Ib Handle Pole Pivot Shaft 87 in lb Handle Pole Piv
114. nge 10 V DC 13 28 ELECTRICAL SYSTEM Ignition System e Connect the adapter between the and BL leads in the crankshaft sensor lead connector Crankshaft Sensor Adapter Tester G BL gt R e Push the lanyard key under the stop switch and position the starter interlock switch to the right e Pushing the starter switch crank 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 measurements 5 or more times Crankshaft Sensor Peak Voltage Standard 3 0 V or more If the reading is less than the specified value check the crankshaft sensor see crankshaft sensor Inspection Spark Plug Removal Pull off the spark plug caps e Unscrew the spark plugs OBe careful to avoid breaking the ceramic on the spark plugs Spark Plug Installation e Be sure the spark plug threads are clean and dry e Tighten Torque Spark Plugs 27 N m 2 8 kgf m 20 ft Ib OBe careful to avoid breaking the ceramic on the spark plugs e Install the spark plug cap onto the spark plug securely OPush the cap onto the plug so that the distance between the lower end A of the cap and the upper surface B of the plug hexagonal nut is 6 mm 0 24 in C NOTE OFor easier correct installation of the spark plug cap push the cap onto the plug until the figures BR8ES D printed on the plu
115. ntenance 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 JBO2003BS1 0 Metal Clamp A Hose B Hose Fitting C NOTE OCheck the fuel and exhaust tubes for signs of wear de terioration damage or leakage Replace if necessary OMake sure the above tubes are secured with the metal gear clamps away from any parts JB02002BS1 C 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 lf a strap is damage way replace it FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded 3 2 Pop off Pressure Inspection 3 23 Specifications 3 6 Float Arm Level and Diaphragm Special Tools and Sealant 3 7 Inspection and Adjustment 3 24 Fuel System Diagram 3 8 F el dest scart 3 25 Throttle Cable and 3 9 Fuel Pump Removal 3 25 Throttle Cable Adjustment 3 9 Fuel Pump Installation 3 26 Throttle Case Removal Disas Fuel Fil
116. o put a few marbles or pieces of clean gravel into the tank and shake it to knock loose any foreign matter in the bottom A WARNING Clean the tank in a well ventilated area and take ample care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the tank A fire or explosion could result SBOP FUEL SYSTEM 3 33 Fuel Tank Fuel Filler and Tube Removal e Remove Fuel Tank see Fuel Tank Removal Water Box Muffler A see Exhaust System chapter e Loosen the clamp B and twist the filler tube C off the bottom of the filler e Unscrew the fuel cap A e Take out the screws B in the filler flange cut the sealant C and pull the filler away from the hull Fuel Filler and Tube Installation e Clean the hull and the filler on their mating surfaces with a graceless high flash point solvent WARNING Clean the parts in a well ventilated area and take ample care that there are no sparks or flame any where near the working area this includes any ap pliance with pilot light Do not use gasoline or a low flash point solvent A fire or explosion could result e Apply an even layer of silicone sealant to the mating sur faces of the washer filler and gasket A Sealant Kawasaki Bond Silicone Sealant 56129 120 e Put the tube onto the filler ful
117. on its left side Rolling to the right side can cause water in the exhaust system to run into the engine with possible engine damage 3 Dirt Before removal and disassembly clean the SKI watercraft Any sand entering the engine will shorten the life of the watercraft For the same reason before installing a new part clean off any dust or metal filings 4 Battery Ground Disconnect the ground cable from the battery before performing any disassembly operations on the JET SKI watercraft This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the leads from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive cable to the positive terminal of the battery 5 Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation or assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assem bled in the same way It is preferable to mark and record the locations and routing whenever possible 1 4 GENERAL INFORMATION Before Servicing 6 Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the seque
118. oned or replaced be sure to check B Y the critical clearances of the new parts against the values given in Specifications Oma e Install the piston rings so that the R mark A faces up wards as shown Top Ring B Second Ring C 7 D JF04012BSi 6 e When installing the piston rings by hand first fit one end of the piston ring against the pin in the ring groove spread the ring opening with the other hand and then slip the ring into the groove e Check to see that the pin A in each piston ring groove is between the ends of the piston ring e Apply molybdenum disulfide oil solution to the surface of each piston pin e Mount the piston on the connecting rod with the arrow A on its crown pointing to the left exhaust side of the engine 5 8 END e When installing piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse rings as removal weakens and de forms them They could fall out and score the cylin der wall e Fit a new piston pin snap ring into the side of each piston so that the snap ring opening A does not coincide with the slits B of the piston pin hole e Set the new cylinder base gasket in place on the crankcase e Apply molybdenum disulfide oil solution to the surface of the pistons e Compress the piston rings Special Tools Piston Ring Compressor Grip 570
119. only available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 11 Gasket O ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 12 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious dam age 13 Press When using a press or driver to install a part such as a drive shaft holder bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 14 Ball Bearing Do not remove a ball bearing unless it is absolutely necessary Replace any ball bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that con tacts the press fit portion and press it evenly over the base component 15 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the
120. op button depressed Stop Switch Resistance Stop Button Reading Released Q Depressed Almost 0 If either meter reading is incorrect replace the start stop Switch ELECTRICAL SYSTEM 13 39 Water Temperature Sensor JS800 A1 water temperature sensor is installed on the bypass hose Whenever the cooling water temperature rises to 95 203 F or higher the contacts in the water temper ature sensor does and the igniter works to cut spark inter mittently The engine speed decreases to 3 500 rpm If the watercraft slows down even with the throttle on and the engine running return to shore immediately and check the cooling system for clogging CAUTION If the watercraft slows down while running return to the shore immediately Overheating will cause severe engine and exhaust system damage Do not operate the craft until the source of the problem is found and correct Water Temperature Sensor Removal e Open the electric case see Electric Case Removal Dis assembly e Remove Water Temperature Sensor Mounting Bolt A and Washer e Disconnect the water temperature sensor leads A B Y and R Y e Unscrew the grommet cap B and slide off the grommet C e Pull off the water temperature sensor assembly D out of the electric case e Slide off the rubber cap A and unscrew the water tem perature sensor B from the holder C JNi0014BSi C
121. ot Shaft Nut 25 Handlebar Clamp Screws 13 LN Handle Pole Bracket Bolts JS800 A1 14 L Handle Pole Bracket Studs JS800 A2 14 L Handle Pole Bracket Nuts JS800 A2 14 Steering Cable Nut 29 Handlebar Plate Pivot Bolt 60 in lb LN Wiring Clamp Screw 26 L Hull Engine Hood Front Cover Screws L Exhaust Outlet Bolts L Battery Bracket Bolts L Strap Bolts L PERIODIC 2 5 Torque Locking Fastener Remarks Strap Bracket Bolt Engine Hood Plate Bolts L Electric Case Bracket Bolts L Electrical System Electric Case Connector Mounting Bolts 8 8 78 L Spark Plugs 27 20 Joints 3 9 35 in Ib Starter Relay Lead Mounting Nuts 4 4 39 in lb Electric Case Mounting Bolts 8 8 78 in lb L Water Temperature Sensor Mounting Bolt 8 8 78 L JS800 A1 Water Temperature Sensor JS800 A1 27 20 Water Temperature Sensor JS800 A2 15 11 see text Regulator rectifier Mounting Bolts 8 8 L CDI Igniter Mounting Bolts 8 8 L Ignition Coil Mounting Bolts 8 8 L Electric Case Bolts 8 8 E Switch Case Mounting Screws 2 0 Battery Ground Cable Mounting Bolt 8 8 L Starter Motor Cable Mounting Nut 7 8 Starter Motor Mounting Bolts 8 8 E Starter Motor Retaining Bolts 6 3 L This table relating tightening torque of the stainless bolt and the nut to thread diameter lists the basic torque for the bolts and nuts Use this table for only the
122. ot pushed under stop button Engine starts but stops right away Compression e Faulty crankshaft oil seal e Crankcase joint leak e Worn piston and rings e Head gasket leak e Spark plug leak Fuel System Outside Carburetor e Misuse of choke e Fuel filter screen clogged e Fuel feed line leaking or clogged e Pulse line leaking or clogged e Vent line clogged e Faulty fuel pump Inside Carburetor e Water in carburetor e Carburetor diaphragm damaged e Mixture screw not adjusted e Float arm not adjusted Electrical System e Faulty or fouled spark plug e Poor wiring connection e Faulty magneto Engine misfires does not run smoothly Fuel System APPENDIX 15 23 Troubleshooting Fuel mixture too lean Fault in Carburetor e Wrong mixture screw e Obstruction in fuel passage or outlet e Diaphragm leaking or damaged e Float arm not adjusted Other e Poor fuel supply fuel filter screens hoses or vent line clogged e Carburetor mounting loose e Faulty fuel pump Fuel mixture too rich Fault in Carburetor e Diaphragm needle dirty or damaged e Float arm not adjusted e Choke not adjusted e Mixture screw not adjusted Other e Flame arrester clogged Electrical System Other e Ignition timing wrong Weak Spark e Reduced ignition coil output e High voltage insulation breakdown e Spark plug fouled e Spark plug gap wrong e Poor wiring connection spark plug cap e Faulty CDI igniter e Faulty magneto e Battery voltage low Abnormal engine
123. ot turn over or only turns over weakly re place the starter motor with a new one Brush Plate Inspection e Using the x 1 O ohmmeter range measure the resistance between the brush A and the brush plate B If there is not close to zero ohms the brush plate has an open and the brush plate must be replaced e Using the highest ohmmeter range measure the resis tance between the brush plate B and the brush holders C x If there is any reading at all the brush holder has a short and the brush plate must be replaced Brush and Lead Assembly Inspection e Using the x 10 ohmmeter range measure the resistance between the brushes x lf there is high resistance or no reading a lead is open and the brush and lead assembly must be replaced GP11080851 C ELECTRICAL SYSTEM 13 19 Electric Starter System Starter Relay Removal e JS800 A1 OOpen the electric case see Electric Case Disassembly ODisconnect Ground Lead A Y R Lead B R Lead C e JS800 A2 OOpen the electric case see Electric Case Disassembly ODisconnect Ground Lead A Y R Lead B R Lead C e Remove the nuts A from the battery and starter terminals on the starter relay e Slide the starter relay from the electric case being careful not to lose any of the insulating washers or grommets Starter Relay Installation e Coat the grommets A with water resistance grease e Be certain all insulating was
124. otations of mixture screws beforehand e Use a screw driver A to remove the cap B from the mixture screw e To remove the mixture screws turn them counterclock wise A until they come out Do not lose the spring B washer C and O ring D on each screw Carburetor Assembly e f the mixture screws were removed install them as shown High Speed Screw A Low Speed Screw B OApply a non permanent locking agent to the cap C in side e Apply grease to the O ring A on the inlet valve holder B e Install Inlet Valve Holder Holder Plate Screw e Tighten Torque Holder Plate Screw 0 98 N m 0 10 kgf m 8 7 in lb JC07024BS2 C P FUEL SYSTEM 3 21 Carburetor e Install Main Jet A Pilot Jet B e Tighten Torque Main Jet 1 8 N m 0 18 kgf m 16 in Ib Pilot Jet 0 70 N m 0 07 kgf m 6 2 in Ib e Install the gasket and plate e Tighten the screws Torque Carburetor Plate Screws 2 0 0 20 kgf m 18 in Ib e Assemble the carburetor cover as shown Float Arm A Spring B Pin C Inlet Valve D OCheck the float arm level see Float Arm Level Inspection and Adjustment e Tighten Torque Float Arm Pin Screw 0 98 N m 0 10 kgf m 8 7 in Ib Install Diaphragm Carburetor Cover Tighten Torque Carburetor Cover Screws 3 4 N m 0 35 kgf m 30 in Ib NOTE OAfter the carburetor has been disassembled and cleaned it should be p
125. ou could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent CDI igniter Crankshaft Sensor Inspection e JS800 A1 ORemove the electric case connector A ODisconnect the 4 pin connector B e JS800 A2 ORemove the electric case connector A ODisconnect the 2 pin connector e Set the hand tester to the x 100 range zero it connect it to the crankshaft sensor lead terminals Green and Blue in the connector Special Tool Hand Tester 57001 1394 there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance Standard 396 594 13 24 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal e Open the electric case see Electric Case Disassembly e Pull the spark plug cap A and slide off the protector tubes B e Unscrew the grommet caps C and slide off the grom mets Lubricate the leads with a penetrating rust inhibitor e Disconnect the ignition coil primary lead connectors A e Unscrew the ignition coil mounting bolts B and remove the ignition coil C Ignition Coil Installation e Apply a non permanent locking agent to the ignition coil mounting bolts and t
126. ove the upper end of the cable from the case OUse a screw driver A to separate the cable tip B from the throttle lever catch 3 12 FUEL SYSTEM Throttle Cable and Case e Unscrew the handle pole cover screws e Remove the handle pole cover B e Unfasten the throttle cable A from the cable holders B e Cut off the band A and pull the rubber tube B down ward Pull out the throttle cable A from the rubber holder B e Pull the throttle cable from the handle pole OLubricate the cable passage A in the handle pole with a penetrating rust inhibitor OReach under the front deck and pull the throttle cable from the handle pole 4005010851 C FUEL SYSTEM 3 13 Throttle Cable and Case Throttle Cable Installation e Lubricate the outside of the new cable with a penetrating rust inhibitor to ease cable installation e Install the throttle cable to the rubber holder A as shown Rubber Holder A Rubber Tube B Band C Steering Cable Passage D Harness Passage E Throttle Cable Passage F Fuel Tank Vent Tube Passage Bow H e Install the handlebar pad ORun the leads of the switch housing through the hollow area A of handle pad when installing the pad e Route the following correctly see Cable Wire and Hose Routing in the Appendix chapter Throttle Cable Steering Cable Fuel Tank Vent Tube Switch Housing Harness e Adjust the following Throttle
127. ows A OConnect the tester between the coil terminals OSet the tester to the x 1 O range and read the tester dA EN e Measure the secondary winding resistance as follows B ORemove the plug caps by turning them counterclockwise OConnect the tester between the high tension leads OSet the tester to the x 100 O range and read the tester If the hand tester does not read as specified replace the Winding Resistance Standard Primary windings 0 08 0 1 Secondary windings 3 5 4 7 xIf the tester reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good e Check the high tension lead for visible damage xIf the high tension lead is damaged replace the coil CDI Igniter Removal e Remove the electric case see Electric Case Removal and open the case see Electrical Case Disassembly e JS800 A1 ORemove CDI Igniter Mounting Bolts A CDI Igniter B and Plate ODisconnect CDI Igniter Lead Connectors e JS800 A2 ORemove CDI Igniter Mounting Bolts A CDI Igniter B Plate and Collars Connectors C Cee 4 Re yer tet oe z 4 13 26 ELECTRICAL SYSTEM Ignition System CDI Igniter Installation e JS800 A1 Olnstall Connectors A Plate B OApply a non permanent locking agent to the following bolts and tighten
128. peller side D OWhen installing the front pump bearing support both inner and outer races of the rear pump bearing with a bearing driver Special Tool Bearing Driver Set 57001 1129 e Install the grease seals using the same special tool used for bearing installation OPress each seal into the pump case so that the side with the spring faces outward Fill the gap of the seal with high grade water resistance grease e Push the bushing onto the pump shaft e Apply high grade water resistance grease to the pump shaft O rings and molybdenum disulfide to the thread of the pump shaft and insert the shaft from the rear of the pump case e Screw the impeller on the pump shaft Special Tool Impeller Wrench 57001 1228 e Tighten Torque Impeller 98 10 kgf m 72 ft Ib cuve ISSSSSSSSSSSA bd CP DSSSAAASSAS SAY 1 4 T e Grease with molybdenum disulfide grease Lips A of Impeller Grease Seal Bore B of Impeller JK04038BSi 6 e Install the new O ring A in place on the pump cap A e Install Pump Outlet Steering Nozzle eApply anon permanent locking agent to the thread of the following bolts Pump Cap Bolts Pump Outlet Mounting Bolts Steering Nozzle Pivot Bolts e Tighten Torque Steering Nozzle Pivot Bolts 8 8 0 90 kgf m 78 KOOI P 10 10 PUMP AND IMPELLER Pump and Impeller Pump and Impeller Inspection e Exam
129. place the damaged parts 1 6 INFORMATION Model Identification JS800 A1 Left Side View JS800 A1 Right Side View 8038010 5 48038011 5 GENERAL INFORMATION 1 7 General Specifications Items JS800 A1 6 Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition System Lubrication System Carburetion System Starting System Tuning Specifications Spark Plug Type Gap Terminal Ignition Timing Carburetor Idle Speed Compression Pressure Drive System Coupling Jet Pump Type Thrust Steering Braking Performance TMinimum Turning Radius tFuel Consumption TCruising Range 2 stroke 2 cylinder crankcase reed valve water cooled 781 cm 47 7 cu in 82 x 74 mm 3 23 x 2 91 in 7 2 1 58 85 kW 80 PS 6 250 r min rpm 94 2 Nm 9 6 kgf m 69 5 ft lb 95 750 r min rpm Digital DC CDI Gas oil premix ratio 60 1 MIKUNI 40 38 x 2 Electric starter NGK BR8ES 0 7 0 8 mm 0 028 0 031 in Solid post 13 BTDC 1 250 r min 20 2 BTDC 34 000 r min rpm 1 250 100 r min rpm in water 1 700 100 r min rpm out of water 892 1 373 kPa 9 1 14 kgf cm 129 199 psi 9490 r min rpm Direct drive from engine Axial flow single stage 3 100 N 317 kgf 697 Ib Steerable nozzle Water drag 3 2 m 10 5 ft 32 L h 8 5 US gal h full throttle 40 km 75 mile full t
130. ploded View COOLING AND BILGE SYSTEMS 8 3 Exploded View Fastener Remarks 1 Water Hose Joint 9 8 1 0 87 L A JS800 A1 Model B JS800 A2 Model C JS800 A3 Model L Apply a non permanent locking agent 8 4 COOLING AND BILGE SYSTEMS Bilge System Breather Removal e Remove the engine hood see Hull Engine Hood chap ter e Pull the hoses A off the breather e Drill out the pop rivet with a drill bit of the correct size Pop Rivet Removal Drill Bit Size 5 0 mm 0 2 in NOTE OStop drilling when the rivet head A starts to turn with drill bit OTap the rivet out of the hull with a suitable punch and hammer e Remove the breather with bracket B e Separate the breather A from the bracket Breather Installation e Be sure the small hole A in the breather is open before installing it e Align the holes on the bracket A and the washer B with the mounting hole on the breather C e Secure the bracket and the washer to the breather with a pop rivet D Riveter E Jt098005 JI03001B51 60 J103003BS1 COOLING AND BILGE SYSTEMS 8 5 Bilge System e Apply silicone sealant to the hole A for pop rivet e Use the long pop rivet B securing the plate C with the bracket D of the bilge breather E JI103002BS1 C Breather Cleaning and Inspection e Check that the s
131. r Diameter Charging System Regulator rectifier Output Voltage Charging Coil Output Voltage Charging Coil Resistance Brown Brown Regulator rectifier Resistance Sealed battery 12 V 18 Ah 12 5 mm 0 49 in 28 mm 1 10 in 14 0 15 0 V Battery voltage 20V 07 110 the text 6 5 mm 0 26 27 mm 1 06 in Ignition System Ignition Timing Crankshaft Sensor Resistance Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Ignition Coil Primary Peak Voltage Crankshaft Sensor Peak Voltage Spark Plug Type Gap Start Stop Switch Start Button Released Depressed Stop Button Released Depressed Temperature Sensor Temperature Sensor Resistance 13 BTDC 91 250 r min rpm 20 2 4 000 r min rpm 396 5940 7 mm 0 28 in or more 0 08 0 10 3 5 4 7 150 V or more 3 0 V or more NGK BR8ES 0 7 0 8 mm 0 028 0 031 in Q Almost 0 Q Almost 0 the text ELECTRICAL SYSTEM 13 9 Special Tools Hand Tester Needle Adapter Set 57001 1394 57001 1457 7571394ST C T5714578T C Peak Voltage Adapter Kawasaki Bond Silicone Grease 57001 1415 92137 1002 875714155 C 13 10 ELECTRICAL SYSTEM iagram D iring W JS800 A1 MO 9 A 18919 34811 34311 uee45 yaeg 918 09040 9 101 09 060L8 19086 youl
132. r is rebored and oversize pistons installed e The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing the difference between the two values e Measure the piston diameter as just described and sub tract this value from the measurement The difference is the piston clearance Piston Cylinder Clearance 0 085 0 115 mm 0 0033 0 0045 in Boring and Honing When boring and honing a cylinder note the following OThere are two sizes of oversize pistons available Oversize Pistons and Rings 0 5 mm 0 02 in oversize 1 0 mm 0 04 in oversize OBefore boring a cylinder first measure the exact diameter of the oversize piston and then according to the standard clearance in the Service Date Section determine the re bore diameter However if the amount of boring neces sary would make the inside diameter greater than 1 0 mm 0 04 in oversize the cylinder block must be replaced OCylinder inside diameter must not vary more than 0 01 mm 0 0004 in at any point OBe wary of measurements taken immediately after boring since the heat affects cylinder diameter the case of a rebored cylinder and oversize piston the service limit for the cylinder is the diameter that the cylin der was bored to plus 0 1 mm 0 004 in and the service limit for the piston is the oversize piston original diameter minus 0 15 mm 0 006 in If the exact figure for
133. r to the case e Lubricate the throttle cable before assembly installation e Apply water resistance grease to the tips of the throttle cable end e Pulling the throttle cable A position the tips B of the cable end as shown 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 4005011851 C FUEL SYSTEM 3 11 Throttle Cable and Case e Tighten Torque Throttle Case Screws 3 9 0 40 kgf m 35 in Ib e Swing the throttle control lever so that the carburetor throt tle valve is fully open WARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition e Adjust the throttle cable see Throttle Cable Adjustment Throttle Cable Removal e Remove the engine hood see Hull Engine Hood chap ter e Disconnect the throttle cable from the carburetor OSlide out the rubber cap A OUnscrew the adjuster locknut B and slide the cable from the bracket OSlide the tip C of the cable lower end from the shaft lever e Holding the handle pole with stopper OSet the stopper A to the groove B e Unscrew the handlebar pad screws A e Remove the handlebar pad B e Remove the throttle case see Throttle Case Removal e Slide the rubber boot out of the place e Unscrew the throttle cable fitting nut e Rem
134. racket Pump and Hoses Handle Pole with Bracket Air Intake Cover Carburetor Exhaust Pipe and Expansion Chamber Electric Case and Bracket Water Box Muffler Engine and Mounts Fuel Tank Drive Shaft and Shaft Holder Control Cables Engine Hood Latch Bilge Breather Bilge and Cooling Hose Fuel Filler Assembly Bypass Hose and Outlet Cable Detentes Hose Holder and Bracket Bumpers and Pads The following parts cannot be removed from the hull and must be replaced Decals Labels Registration Number if any If the new hull is to be painted do that first Then install the parts removed in the reverse order of their removal Finally install the labels decals mats and the registration numbers 12 18 HULL ENGINE HOOD Rubber Parts NOTE OThe rubber parts on the watercraft are fastened in place with various adhesives To replace a rubber part use a cement in the following table or an equivalent WARNING Read all warnings cautions solvents and adhesives used Many of these products flammable may be harmful to the skin and eyes and may give off harmful vapors Use these sol vents and adhesives only in a well ventilated area and never near an open flame For this Application Type Mats Synthetic Rubber Adhesive Water Box Muffler Damper P N 92104 3701 Engine Hood Gasket Cyanoacrylate Cement Detentes Handlebar Grips Handle Pole Bracket Damper CAUTION Be very care
135. retaining bolts A and remove the both end covers e Pull the armature out the pinion gear end e Remove the brush plate A from the leads B Yoke C e Remove the nut and terminal bolt A and then remove the brush B and the plastic holder C Starter Motor Assembly e Install the terminal bolt as shown Nut A Spring Washer B Washer C Large Insulator D Small Insulators E Terminal Bolt F O ring G Plastic Holder H e Install the brush plate as follows Olnstall the brush plate A on the yoke fitting and the brush leads B into the notches C in the plate Fit the brush plate tongue D into the yoke notch E ELECTRICAL SYSTEM 13 17 Electric Starter System Olnsert the armature into the yoke OKeeping the motor upright install the brush spring A Fit the spring on the spring post B halfway the post must be positioned in the D shaped end of the spring Turn the other end of the spring a half turn clockwise C and fit the end in the brush groove D Push the spring onto the post to the stepped portion Brush E OTo install the end covers on the yoke align A the mark on the each end cover with the marks on the yoke OApply a non permanent locking agent to the starter motor retaining bolts and tighten them Torque Starter Motor Retaining Bolts 6 3 N m 0 65 kgf m 56 in lb Brush Inspection e Measure the length of each brush any is worn down to the
136. rimed before starting the engine to save the battery Pull off the fuel return hose A at the carburetor and blow through it until fuel appears at the fuel return fitting on the carburetor The fuel system in now full of fuel A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key of 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 3 22 FUEL SYSTEM Carburetor Carburetor Cleaning and Inspection e Disassemble the carburetor see Carburetor Disassem bly A WARNING Solvent is toxic and flammable Avoid prolonged contact with skin and keep away from open flame Use only in a well ventilated area Eye protection should be worn when compressed air is used to dry parts Do not direct air towards anyone Use 172 kPa 1 75 kgf cm 25 psi maximum nozzle pres sure e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e When the parts are clean dry them with compressed air e Blow out the air and fuel passages with compressed air e Inspect the check valve A for damage or deterioration and replace it if necessary e Check these rubber parts for damage O ring A Diaphragm B Gasket C any of these parts are not in good condition replace them e Check the pla
137. rk Plug Inspection e Remove the spark plugs see Electrical System chapter e Examine the ceramic insulator C and electrodes A B the insulator appears glazed or very white or if there are gray metallic deposits on the electrodes combus tion chamber temperatures are too high Refer to Trou bleshooting insulator appears dry and sooty the fuel air mixture is overly rich the insulator and electrodes are wet and oily an im proper oil type or an excess oil output may be the cause If the ceramic insulator is cracked replace the plug If the electrodes are badly worn or burned replace the plug e Examine the spark plug threads threads are damaged replace the plug Spark Plug Adjustment e Measure the spark plug gap D OCheck the distance between the electrodes with feeler gauge or a wire gauge Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in If the gap is not within specifications adjust it e Adjustthe gap by carefully bending the side electrode with a tool designed for this purpose Spark Plug Cleaning e Clean the electrodes and the ceramic insulator around the center electrode with an abrasive blasting device OBe certain that all abrasive particles are removed from the plug e Clean the entire plug in a high flash point solvent Lubrication As in all marine craft adequate lubrication and corrosion protection is an absolute necessity to prov
138. rom the handle pole e Remove the pad and take out the screws A and sepa rate the handlebar from the handlebar plate B Handlebar Installation e Apply a non permanent locking agent High Strength Loctite 271 equivalent to the handlebar clamp screws and tighten them Torque Handlebar Clamp Screws 18 N m 1 8 kgf m 13 ft Ib Grease the steering pivot thoroughly and tighten the steering pivot nut to allow the handlebar turn smoothly without play Replace the cotter pin A with a new one NOTE OWhen inserting the cotter pin if the slots in the locknut do not align with the cotter pin hole in the steering shaft tighten the locknut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin over the nut e Apply a non permanent locking agent to the wiring clamp screw and tighten it to the specified torque Torque Wiring Clamp Screw 2 9 0 30 kgf m 26 in lb HJ07007BS1 C HANDLE POLE HANDLEBAR 11 9 Handlebar e Fit the projection A of the switch case into the hole B of the handlebar e Tighten Torque Throttle Case Screws 3 9 0 40 kgf m 35 in Ib Switch Case Mounting Screws 3 9 0 40 kgf m 35 in Ib Handlebar Steering Pivot Maintenance e f the steering pivot feels loose or overtight the pivot may need lubrication or the
139. s 22 N m 2 2 kgf m 16 ft Ib 9 8 DRIVE SYSTEM Drive Shaft Drive Shaft Holder Drive Shaft Runout e Measure drive shaft runout by supporting the shaft on V blocks and setting a dial gauge against the shaft at each point shown e Turn the drive shaft slowly The difference between the highest and lowest dial gauge reading is the runout If any measurement exceeds the service limit replace the shaft Drive Shaft Runout Standard TIR 0 1 mm 0 004 in or less A TIR 0 2 mm 0 008 in or less B Service Limit TIR 0 2 mm 0 008 in A TIR 0 6 mm 0 024 in B 4404020281 C PUMP AND IMPELLER 10 1 Pump and Impeller Table of Contents Exploded iie n rd ERR RR PEN 10 2 Specifications Hm 10 4 mr PC UE 10 5 Pu mp and Impell8r avast ices nk ees 10 6 So Rs de 10 6 P rmp Iristallation 2 n Ere ere tercer eer o P re e Pare etc a er re dd 10 6 Pump Disassembly m esu Riu e cuc 10 7 PUMP Cci on 10 9 Pump and Impeller Inspection eee 10 10 Impeller Clearance iir rer kt RR Pr Ce Fe ER ERE RR RAM n e XR ERR KR CRAS 10 10 PUMP AND IMPELLER 10 3 Exploded View
140. se pull the latch all the way up and unhook its upper portion A e Pull up A the rear portion of engine hood B a little and slide C it rearward disengaging the hood hooks D from the brackets E at the handle pole pivot e Pull up A the engine hood B and remove it JM08002BS1 HULL ENGINE 12 7 Engine Hood CAUTION Do not lift up A the rear portion of engine hood before disengage the hood hooks from the bracket at the handle pole pivot or engine hood inside will be damaged JMOB8008BSi C Engine Hood Installation e Put down A the engine hood B parallel with the engine opening C positioning the ducts D into the engine room spaces E e Put the engine hood A on the deck B and line up C the hood and deck in center e Push the engine hood A forward B JMO8010BSi C 12 8 HULL ENGINE HOOD Engine Hood e Make sure the hood hooks A engage into the brackets B at the handle pole pivot Engine Hood C e Push down A the rear side of engine hood B e Push the latch down and turn the latch lock knob counter clockwise CAUTION Do not install A the engine hood B with an angle like the JS750 or engine hood inside will be dam aged Engine Hood Hook Removal e Remove the engine hood see Engine Hood Removal e Unscrew the mounting bolt A and or nuts B and
141. sound During normal cruising e Slight piston seizure e Piston ring broken or sticking e Main bearing worn or damaged During sudden acceleration e Excessive clearance between connecting rod small end and piston pin or between pin and piston e Excessive connecting rod big end clearance Pinging e Ignition timing too advanced e Carbon accumulation in cylinder head e Poor quality gasoline e Spark plug wrong heat range When the engine is idling while cold e Excessive piston clearance e Piston rings worn e Piston worn e Connecting rod bent twisted Low engine power This trouble often has more than one cause and trouble symptoms may not be clear Ignition System e Spark plug gap or heat range wrong e Ignition timing wrong e Reduced ignition coil output e Loose wiring connection in ignition circuit 15 24 APPENDIX Troubleshooting Fuel System e Insufficient fuel supply to carburetor e Carburetor diaphragm damaged e Pulse line leaking or clogged e High speed nozzle clogged e Throttle valve does not fully open e Fuel filter screen clogged e Faulty fuel pump Other e Flame arrester clogged e Muffler or exhaust system clogged e Water or foreign matter in gasoline e Exhaust gas leak in engine compartment Overheating e Ignition wrong e Carburetor not adjusted e Carbon accumulation in combustion chamber e Wrong type of gasoline or oil e Wrong gas oil mixture e Cooling water line leaking or clogged Heavy Fuel Consump
142. stallation 4 2 201 0 0000 12 2 HULL ENGINE HOOD Exploded View HULL ENGINE 12 3 Exploded View OONOARWN 10 11 Front Cover Screws Exhaust Outlet Bolts Battery Bracket Bolts Strap Bolts Strap Bracket Bolt Front Bumper Side Bumper Corner Bumper Drain Plug Holder French Model JS800 A1 5800 6 CY Apply cyanoacrylate cement 55 Apply silicone sealant SY Apply synthetic rubber adhesive L Apply a non permanent locking agent 12 4 HULL ENGINE HOOD Exploded View HULL ENGINE 12 5 Exploded View Engine Hood Plate Bolts Electric Case Bracket Bolts Engine Hood Engine Hood Latch Deck Fin Pads Front Side Mat Side Deck Mat Deck Floor Mat Rear Bumper Handle Pole Pad Handle Pole Bracket Damper JS800 A1 Model B JS800 A2 Model CY Apply cyanoacrylate cement gt L Apply a non permanent locking agent SS Apply silicone sealant SY Apply synthetic rubber adhesive 12 6 HULL ENGINE HOOD Engine Hood Engine Hood Removal e Raise the handle pole all the way up and while holding it swing up the handle pole stopper pin A and hook its end into the rest B in the handle pole bracket e Turn the latch lock knob clockwi
143. stic tip A on the inlet valve needle B It should be smooth without any grooves scratches or tears If the plastic tip is damaged C replace the valve e Push the rod D in the other end of the inlet valve needle and then release it E x If the rod does not spring out replace the inlet valve nee dle 30758052 P 6606014351 0 FUEL SYSTEM 3 23 Carburetor Check the tapered portion of the mixture screw for wear or damage lf the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it Pop off Pressure Inspection e Remove the engine hood see Hull Engine Hood chap ter e Pull the fuel supply hose A and return hose B out of their fittings on the carburetor e Connect the hose of the air pump gauge tester A to the fuel supply fitting e Obstruct the fuel return fitting B securely with a finger e Pump the tester until the supply release pressure is reached see by a sudden pressure drop Pop off Pressure Standard 262 kPa 2 67 kgf cm 38 0 psi NOTE OPressure inspection should be performed three times to obtain a valid reading If the pop off pressure value is not specified inspect the float arm level see Float Arm Level Inspection and Ad justment NOTE ODo not stretch or cut the float arm spring e Inspect other carburetor 3 24 FUEL SYSTEM Carburetor
144. t Strap Tool 57001 1294 e JS800 A2 OCut the band C A Flushing Hose OPush down the holders and remove the rubber straps B ORemowve the fuel filter D see Fuel Filter Cleaning Special Tool Watercraft Strap Tool 57001 1294 e Loosen the clamp bolt A and remove the fuel filler tube B from the fuel tank 118024 e Turn the fuel tank as shown 3 32 FUEL SYSTEM Fuel Tank e Clear the fuel tank to the engine and hull Fuel Tank Installation e Fuel tank installation is reverse of removal e Be sure the O ring A is on the fuel tank e Apply a non permanent locking agent to the magneto cover mounting bolts cable holder bolts and exhaust pipe mounting bolts and tighten them securely Torque Cable Holder Bolts 29 N m 3 0 kgf m 22 ft Ib Exhaust Pipe Mounting Bolts 29 3 0 kgf m 22 ft lb Magneto Cover Mounting Bolts kgf m 78 in lb 8 8 0 90 Fuel Tank Cleaning e Remove the fuel tank see Fuel Tank Removal e Drain the tank into a suitable container WARNING Gasoline is flammable be sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Flush the tank repeatedly with high flash point solvent un til itis clean It may be necessary t
145. t become rusted and in general preparing the watercraft so that when the time comes to use it again it will be in top condition Cooling System e Clean the cooling system see Cooling System Flushing in the Periodic Maintenance chapter 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 Fuel System A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Drain the fuel tank This should be done with a siphon or pump Siphon Hose A Bow B Clean the filter screens A see Fuel Filter Screen Clean ing in the Periodic Maintenance chapter e Inspect replace the fuel filters see Fuel Filter Inspection and Cleaning in the Fuel System chapter e Leave the fuel filter cap loose to prevent condensation in the tank 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 carburetor is used up Wait 5 minutes between 15 second running periods e Pull the lanyard key off the stop button CAUTION Do not run the engine without coolin
146. t of the handlebar pivot Handlebar Pivot Clips Run the throttle cable through the clips and make sure the brass clamp is positioned between two clips 11 Clamp 12 Grommet 13 Cap 14 Throttle Cable 15 Start Stop Switch Leads 16 Steering Cable 17 Fuel Vent Hose OOANDABRWDN 15 16 APPENDIX Cable Wire and Hose Routing DEVON Trom Stern EZ 555 gt 5 V M 22 A VS SA 12 46 0 2 809072845 C APPENDIX 15 17 Cable Wire and Hose Routing OONOARWN Bypass Cooling Hose Fuel Tank Strap Steering Cable and Throttle Cable Water Box Muffler Fuel Vent Hose Start Stop Switch Leads Run the leads above the fuel filler tube Fuel Filler Tube Form Fit the cables to the form recess and run the cables between the fuel tank and the strap Steering Cable Throttle Cable Fuel Tank Fuel Tank Strap Install the detent to the end of engine mount surface Engine Mount Surface End Bracket Run the steering cable to the right of the bracket 15 18 APPENDIX Cable Wire and Hose Routing 9 m ihe S X AN A 9 0060 O APPENDIX 15 19 Cable Wire Hose Routing 5 Fuel Filter Assembly Fuel Tank Air Intake Cover Battery Clamp Fuel Vent Hose Fuel Hose Return
147. ted in the figure to split the crankcase halves apart and then remove the lower crankcase half e Lift the crankshaft assembly out of the upper crankcase half Assembly e Visually inspect the crankshaft O ring A and replace it e Grease the inner surface of the collar B e Taper C of collar is adjusted to the inside and attaches to shaft 7 12 END e Grease the lips of the seals e Pack grease A between the rear oil seals coupling side e Install the oil seal as shown Double Lips Seals A Single Lip Seal B Projection Side C Flat Surface D e Place the crankshaft assembly A in the upper crankcase B half so that the position ring C on the crankshaft as sembly fits into the groove D in the crankcase e Insert the knock pin E into the hole F e Check that the knock pins A are in place e With a high flash point solvent clean off the mating sur face of the crankcase halves and wipe dry e Apply liquid gasket to the mating surface of the lower crankcase half Sealant Kawasaki Bond Liquid Gasket Black 92104 1003 e Install the lower crankcase half onto the upper half e Apply a non permanent locking agent to the crankcase bolts and tighten them Torque Crankcase 8 Bolts 29 N m 3 0 kgf m 22 ft lb Crankcase M6 Bolts 8 8 0 90 kgf m 78 in Ib OThe tightening sequence numbers are marked on the lower crankcase h
148. ter Inspection and sembly codd tte ltd 3 9 Cleaning erc 3 26 Throttle Case Assembly Installa Flame 3 27 3 10 Flame Arrester Removal 3 27 Throttle Cable Removal 3 11 Flame Arrester Installation 3 27 Throttle Cable Installation 3 13 Flame Arrester Cleaning 3 27 Throttle Case and Cable Inlet Manifold Reed Valves 3 28 3 13 Inlet Manifold Reed Valve Throttle Cable Inspection 3 13 Removal 3 28 Choke 3 14 Inlet Manifold and Reed Valve Choke Cable Adjustment 3 14 Installation 3 28 Choke Cable Removal 3 14 Reed Valve Inspection 3 29 Choke Cable Inspection 3 14 Reed Valve Holder Inspection 3 29 Choke Cable Lubrication 3 14 Reed Valve Stop Inspection 3 29 Choke Knob Removal 3 14 Fuel Tank bein 3 30 Choke Knob Installation 3 15 Fuel Tank Removal 3 30 Carburetor 2 3 16 Fuel Tank Installation 3 32 Idle Speed Adjustment 3 16 Fuel Tank Cleaning 3 32 Mixture Screw Adjustment 3 16 Fuel Filler and Tube Removal 3 33 High Altitude Performance Fuel Filler and Tube
149. tery negative cable A first and then the positive cable A WARNING To prevent possible personal injury and damage to electrical components always disconnect the grounded cable first OUnhook the battery straps B Carefully lift the battery A from the engine compartment as shown Battery Installation sure the battery dampers in position in the bat tery compartment Hook the battery straps Connect the battery cables positive first OAfter attaching both cables coat the terminals and cable ends with grease to prevent corrosion OSlide the protective boot over each terminal A 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 CAUTION Do not reverse the battery connections Charging Condition Inspection e Refer to the Battery Charging Condition Inspection in the Periodic Maintenance chapter ELECTRICAL SYSTEM 13 13 Battery Refreshing Charge e Remove the battery A see Battery Removal e Refresh charge by following method according to the bat tery terminal voltage CAUTION This battery is sealed type Never remove sealing caps B even at charging Never add water Charge with current and time as stated below JNO5004BSi
150. the UP mark A facing is up e Install the inlet manifold A e Tighten the mounting nuts following the sequence indi cated in the figure Torque Inlet Manifold Mounting Nuts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts 7 3 6 10 4010005851 C FUEL SYSTEM 3 29 Inlet Manifold Reed Valves Reed Valve Inspection e Check reed warp by measuring the clearance A between each reed B and the valve holder C xIf any one of the clearance measurements exceeds the service limit replace the reed valve assembly with a new one Reed Warp Service Limit 0 2 mm 0 008 in e Check the mounting screw tightness e Visually inspect the reeds for cracks folds or other dam age xIf there is any doubt as to the condition of a reed replace the reed valve assembly reed becomes wavy replace the reed valve assembly with a new one even if reed warp is less than there service limit Olnstall the reed and stop onto the reed valve holder align ing the chamfered corner of the reed with that of the reed stop Reed Valve Holder Inspection e Check the reed A contact areas of the valve holder for grooves scratches or other damage e Check that the rubber coating B on the valve holder does not show any signs of separation from the holder x lf there is any doubt as to the condition of the rubber coat ing replace the reed valve assembly with a new one Reed Valve Stop Inspe
151. the Periodic Maintenance chapter General Inspection e Check for binding or sticking throttle choke or steering mechanism The throttle lever must return fully when re leased e Clean and gap spark plugs see Spark Plug Cleaning and Spark Plug Adjustment in the Periodic Maintenance chap ter e Check all rubber hoses for weathering a cracking or loose ness 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 e Install the battery see Battery Installation in the Electrical System chapter Fuel System e Check and clean or replace the fuel filter screens as nec essary see Fuel Filter Screen Cleaning in the Periodic Maintenance chapter WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or spark this includes any appliance with a pilot light e After refueling and before starting the engine tilt the en gine hood to the rear for several minutes to ventilate the engine compartment A WARNING A concentration of gasoline fumes in the engine compartment can cause a fire or explosion e Check for fuel leaks Repair if necessary e Check the engine oil level Fill the oil tank with the speci fied oil 1
152. the fuse rat ing check the wiring and related components for a short circuit A Normal B Failed CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components GP20000BS1 C STORAGE 14 1 Storage Table of Contents Preparation ENE 14 2 GOOMMG SY SUSI 14 2 Bilge eere 14 2 Me p T 14 2 yel Y 14 3 Battery T 14 3 Lubrication S 14 3 Geriefdl bf tuat 14 4 Removal from Storage ee 14 5 14 5 General Inspection iere tra e EE EHE RC E CX FERRE 14 5 F l Syste M E 14 5 ORETTE Due te tO Cs E EE AAE Ee Aaa E JA cela he 14 6 14 2 STORAGE Preparation for Storage During the winter or whenever the watercraft will not be in use for a long period of time proper storage is essential It consists of checking and replacing missing or worn parts lubricating parts to ensure that they do no
153. the re bored diameter is unknown it can be roughly determined by measuring the diameter at the base of the cylinder CQ JFO4016BS1 C ENGINE END 5 13 Piston Ring Piston Ring Groove Inspection e Visually inspect the piston rings and the piston ring grooves xIf the rings are worn unevenly or damaged they must be replaced If the piston ring groove are worn unevenly or damaged the piston must be replaced and fitted with new rings Piston Ring End Gap Place the piston ring inside the cylinder using the piston 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 A between the ends of the ring B with a thickness gauge If the gap is wider than the service limit the ring is worn excessively and must be replaced Piston Ring End Gap Standard Top 0 25 0 40 mm 0 0098 0 0157 in Second 0 25 0 40 mm 0 0098 0 0157 in Service Limit Top 0 7 mm 0 028 in Second 0 7 mm 0 028 in JF04017BSi 6 REMOVAL INSTALLATION 6 1 Engine Removal Installation Table of Contents Exploded i e 6 2 Engine Removal lnstallation sabe oua pu itte dat diui 6 4 Engine FREMOV HT T 6 4 Engine Mo nt Removal s RT 6 6 Engine Mount Installation Stell ALO My asta ROE
154. tion e Carburetor not adjusted e Flame arrester clogged e Muffler or exhaust system clogged e Worn cylinder piston or piston ring e Fuel feed line leaking e Carburetor diaphragm needle dirty or damaged Poor performance though engine runs properly Jet Pump e Inlet area obstructed e Impeller or pump case damaged e 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 e Handlebar pivot nut too tight e Bushings damaged or cracked e Handlebar plate or pivot bent e No lubricant on steering pivot e Steering cable damaged or improperly routed MODEL APPLICATION Year Model Beginning Hull No 2003 JS800 A1 KAW6000101203 2004 JS800 A2 KAW300010304 2005 JS800 A3 US KAW200010405 2006 JS800A6F US KAW100010506 5 7000111607 JS800A7F 05 790010607 2008 JS800A8F US KAW10001 708 2009 JS800A9F US KAWT0001 01809 This digit in the hull number changes from one machine to another US KAW79001 0809 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1314 07 Printed in Japan
155. tion e Run the regulator rectifier lead connector A and CDI ig niter lead connector through the electric case hole before installing the regulator rectifier B e Apply a non permanent locking agent to the following bolts and tighten them Torque Regulator rectifier Mounting Bolts C 8 8 0 90 kgf m 78 in Ib CDI Igniter Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Electric Case Bolts 8 8 0 90 kgf m 78 in Ib Regulator rectifier Inspection e With a multimeter set to the x 1 kO range test the regu lator rectifier according the following table Regulator rectifier Resistance a X JNO7007BS1 60 Tester Lead Connection If any of the values obtained do not agree with the above table the regulator rectifier must be replaced Tester Lead Connection Terminal Red Red Purple Brown Brown Black Black Red 0 18 110 18 110 15 80 15 80 Red Purple 0 18 110 18 110 15 80 15 80 E Brown 1 0 6 0 1 0 6 0 30 160 18 110 18 110 Brown 1 0 6 0 1 0 6 0 30 160 18 110 18 110 2 0 12 2 0 12 1 0 6 0 1 0 6 0 0 Black 2 0 12 2 0 12 1 0 6 0 1 0 6 0 0 ELECTRICAL SYSTEM 13 23 Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plugs ignition coils or spark plug leads while the engine is running or y
156. urn out the idle adjusting screw A until there is a clear ance B between the adjusting screw end and throttle shaft lever C e Turn in the idle adjusting screw until the adjusting screw end just touches the throttle shaft lever 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Turn in the adjusting screw 3 4 turn from the point to keep the specified throttle valve A opening in the front carbu retor e Measure the distance from the bottom of the carburetor bore lower end to the valve edge shown as e Remove Synchronizing Screw Cap A e Turn the synchronizing screw A so that the valve edge in the rear carburetor keeps the same distance within 0 2 mm 0 008 in tolerance as in the front carburetor e Open and close the throttle a few times to make sure that the throttle valves A are synchronized Readjust if nec essary e Install the carburetor e Adjust the idle speed throttle control and choke cables Throttle Cable Adjustment e Remove the engine hood see Hull Engine Hood chap ter e Check throttle cable adjustment OWith the throttle lever released A the lower stop on the shaft lever B should rest against the idle adjust screw C and there should be slight slack in the throttle cable OWhen the throttle lever is fully applied pulled D the upper stop on the shaft lever B should be all the way up against the stop on the carburetor JR
157. ut the prior written permission of Quality Assurance Division Consumer Products and Machinery 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 2002 Kawasaki Heavy Industries Ltd Seventh Edition 1 Jun 11 2008 K LIST OF ABBREVIATIONS A ampere s Ib pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s perminute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W
158. ve Line A Main ON Line B Return Line C Fuel Tank Vent Line D e JS800 A2 Reserve Line A Main ON Line B Return Line C Fuel Tank Vent Line D 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 PERIODIC 2 11 Maintenance Procedures e Remove the engine hood see Hull Engine Hood chap ter e Cut the bands A e Pull out each end of the fuel vent check valve B from the vent tubes C e Blow through the fuel vent check valve from catch end xIf the check valve will allow air to flow as shown it is OK lf air will flow through the check valve both direction or in neither direction the check valve must be replaced 7611001851 6 e The fuel vent check valve C must be mounted so that the arrow D on its case is pointing toward the fuel tank JCi13002BSi 6 Flame Arrester Cleaning and Inspection e Remove Engine Hood see Hull Engine Hood chapter Air Inlet Cover Mounting Bolts A Air Inlet Cover B e Remove Flame Arresters A 2 12 PERIODIC Periodic Maintenance Procedures e Disassemble the flame arrester Rubber Holder A Expanders B Screen C e Blow each parts o
159. y 3 000 rpm r min A WARNING To avoid electrical shock do not perform this test with the watercraft in the water CAUTION Do not run the engine over 15 seconds without cool ing water Take care not over rev the engine while running it with no load Charging Coil Output Voltage Connections Standard Meter Range Meter Meter Value 250 V AC Brown lead Brown lead 20 V xIf the charging coil output voltage is correct check the regulator according to the regulator test procedure lf the charging coil output voltage is low check the charg ing coil resistance with a multimeter according to the fol lowing table Charging Coil Resistance Meter Range pranaard Meter Meter Value xIf the charging coil has normal resistance but the volt age check shows the charging system to be defective then the permanent magnets in the flywheel have proba bly weakened the flywheel must be replaced 13 22 ELECTRICAL SYSTEM Charging System Regulator rectifier Removal e Remove the electric case see Electric Case Removal and open the case see Electric Case Disassemble e JS800 A1 ORemove CDI Igniter A Regulator rectifier Mounting Bolts B Regulator rectifier C ODisconnect Regulator rectifier Lead Connectors e JS800 A2 ORemove CDI Igniter A Connectors B Regulator rectifier Mounting Bolts C Regulator rectifier D Regulator rectifier Installa

800 SX-R JET SKI®Watercraft Service Manual

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800 SX-R JET SKI&reg;Watercraft Service Manual

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800 SX-R JET SKI®Watercraft Service Manual