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Kawasaki STX-15F Jet Ski User Manual

1. 0 24 Crankshaft Side Clearance Sca e Pe vus e atu gen 0 26 C rankshelb 8 26 8 2 ENGINE BOTTOM END Exploded View ENGINE BOTTOM END 8 3 Exploded View Crankshaft SensorCoverBots 78 080 4 ComedigRodNus _____ 7 GrommetCoverBots 98 10 smb MegmtoCowrBos 2 20 4 Output Cover Bots 78 080 i 245 1 72 2 4 15 Crankcase Bolts 6 Do not apply any grease or Apply grease Apply a non permanent locking agent Apply liquid gasket Kawasaki Bond 92104 1062 Apply molybdenum disulfide grease Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 Replacement Parts Follow the specific tightening sequence Apply silicone sealant Apply water resistant grease r OW lt gt uy o 8 4 ENGINE BOTTOM END Specifications tem Standard Crankshaft Connecting Rods Connecting Rod Bend 0 2 100 mm 0 008 3 94 Connecting Rod Twist 0 2 100 mm 0 008 3 94 Connecting Rod Big End Side Clearance 10 13 0 38 mm 0 58 mm 0 0051 0 0150 in 0 023 in Connecting Rod Big end Bearing 0 041 0 071 mm 0 11 mm Insert crankpin Clearance 0 0016
2. AN I a E H r 1 gt m k oul a gt im 7 n E p 4 g 7 ari JD07005BW4 21 Oil Separator Tank 28 Oil Pipe from Cylinder to 34 Oil Hose from Cylinder 22 to Air Filter Cylinder Head to Oil Pan 23 to Oil Pan 29 Oil Passage from Main 35 Cylinder Oil Passage 24 Joint Cil Passage to Oil Pipe Joint 25 Camshaft Oil Passage 30 Crankshaft Oil Passage 36 Cylinder 26 Camshaft Cap Oil Pas 31 Oil Screen 37 Main Oil Passage sage 32 Oil Sump in Crank 38 to Oil Pan Sump 27 Passage from Oil Room 39 Oil Pipe Pipe to Camshaft Cap 33 Oil Seal 4 6 ENGINE LUBRICATION SYSTEM Specifications tem 1 Standard Engine Oil Grade API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 4 0 L 4 2 US qt with or without the filter 5 0 L 5 3 US qt when engine is completely dry Level Between upper and lower level lines see text Oil Pressure Measurement Oil pressure 3 000 r min rpm 461 kPa 4 7 kgf cm 67 psi oil temperature 74 C 165 F ENGINE LUBRICATION SYSTEM 4 7 Special Tool and Sealant Oil Pressure Gauge 10 kgf cm Kawasaki Bond Silicone Sealant 57001 164 56019 120 875701645 ST580120ST Oil Pressure Gauge Adapter PT 1 8 Kawasaki Bond Silicone Sealant 57001 1033 92104 0004 875710335
3. 14 42 Camshaft Position Sensor IS DOCH OM 14 43 Igniter Removal Installation 14 43 Igniter Inspection 14 43 Spark Plug Removal 14 46 Spark Plug Installation 14 46 Spark Plug Inspection 14 46 Spark Plug Adjustment 14 46 Spark Plug Cleaning 14 46 Kawasaki Smart Steering System 14 49 Steering Position Sensor and Magnet 14 49 Steering Position Sensor and Magnet Installation Inspection of Kawasaki Smart Steering System Steering Position Sensor eie ien Steering Position Sensor Input Voltage Inspection 14 51 Steering Position Sensor Output Voltage Inspection 14 52 SO Ol 14 54 Speed Sensor Removal Installa 14 54 Speed Sensor Inspection 14 54 Fuel Level Sensor Inspection 14 55 Throttle Sensor Removal Installa TER 14 55 Throttle Sensor Inspection 14 56 Water Temperature Sensor 14 56 Inlet Temperature Sensor cose d cadet aede 14 56 Oil Temperature Sensor ai ata aded 14 56 Multifunction Meter
4. 14 57 Display Function Inspection 14 57 14 2 ELECTRICAL SYSTEM MODE SET Button Inspection 14 58 SLO Smart Learning Operation Mode Inspection JT1500 A2 Modele tC ET 14 58 Fuel Level Gauge Symbol FUEL Characters Warning Light InSpectlof1 14 59 Speedometer Inspection 14 59 Speed Sensor Electric Source 14 60 Tachometer Inspection 14 61 Battery Symbol bAt Characters LED Inspection 14 61 Buzzer Inspection 14 62 Relay Assembly 14 64 REMOVA suciedad eund 14 64 Installation 14 64 Circuit Inspection 14 64 SWIICIIGS ens 14 66 Switch Inspection 14 66 EMEN NEN 14 67 Parts Location gt Bow Ignition Coil 2 3 Ignition Coil 1 4 Crankshaft Sensor Magneto Starter Motor Fuse Case Regulator Rectifier ECU Electronic Control Unit Starter Relay Battery Relay Assembly Main Relay Fuel Pump Relay ELECTRICAL SYSTEM 14 3 14 4 ELECTRICAL SYSTEM Parts Location 13 Water Temperature Sensor 14 Camshaft Position Sensor 15 Oil Temperature Sensor 16 Oil Pressure Switch 17 Speed Sensor P Parts Location 18 19 20 Fuel Level Sensor Steering Po
5. __ ____ ____ _____ _ 25 Inspect tighten engine mounting bolts or every year Inspectreplace coupling damper s Flush cooling system after each use in 2 19 salt water Inspect impeller blades for damage 2 22 Lubricate handlebar pivot disassemble BEEN 22 Inspect hull drain screws replace if qmm Inspect battery teminis Clean and gap spark plugs replace if 2 24 necessary e Lubricate throttle cable fitting at throttle 2 24 body Lubricate throttle cable and throttle fitting 2 24 at throttle case Lubricate steering cable shift cable ball joints and steering nozzle reverse bucket 2 24 pivots Check all hoses hose clamps nuts 2 27 bolts and fasteners e Emission Related Items PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following table list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or silicone sealant Letters used in the Remarks column mean EO Apply oil to the threads and seating surface L Apply a non permanent locking agent to the threads MO Apply molybdenum disulfide grease oil solution R Replacement Part 5 Tighten the fasteners following the specified sequence SS Apply silicone sealant to the threads Fuel System Vehicle down Sensor Mounting Screws 1 5 0 15 13 in Ib Bracket Mounting Bolt
6. und 6 34 Piston TDC Finding 6 16 Piston Ring Piston Ring Groove Camshaft Camshaft Cap Wear 6 18 rm 6 34 Camshaft Runout 6 18 Piston Ring Groove Width 6 34 Cam 6 18 Piston Ring Thickness 6 35 Camshaft Chain Removal 6 19 Piston Ring End Gap 6 35 Cylinder 6 20 Cylinder Compression Measurement 6 20 6 2 ENGINE TOP END Exploded View JF02013BW5 ENGINE END 6 3 Exploded View tuc ula Fer Mu Ar Suction Valve Gover Bots 10 2 Cylinder Head Cover Bots 98 10 Cylinder Head Bots 0 23 23 17 Fat MOS 6 Cylinder Head Bots 1 59 60 4 8 Cylinder Head Bots g 12 12 S _ _ EgmeHokBots 20 14 710 Camshaft Position SensorBot ____ 98 10 EO Apply engine L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 5 Follow the specific tightening sequence SS Apply silicone sealant 6 4 ENGINE END Exploded View END 6 5 Exploded View ss uim sa m Nm ftib Exhau
7. Joint Gonnector FUEL PUMP Lo E ieem ill ETE gii 1 YBO 1111 11 ______________ gt Bk gt _ 2 pr 26 eT TE 1 11 Connector 16 Connector D KDS Connector Connector Color Black BR Brown cH chocolate Water Camshaft MET Throttle 156 Qil oil Park Green Sensor Gontroller Sensor Switch L8 Light Blue Blue LG Light Green 0 Grange PU Purple LR 4 ow hite _ 98052 3717 Engine Side W2R3717AW5 14 14 ELECTRICAL SYSTEM Wiring Diagram JT1500 A2 Joint Connector 0 Fuel Pump Vehicle 58127 Id GG ore Down 5 c JL gt Sensor wite LL co Joint Connector P orr Fuel Level Sensor Buzzer Multifunction Meter e a 42 ao 11 11 I 5 G R OUT R Speed nom 1 o THE T E NI EE __ _ _ _ _ _ 1 Ignition DES 12 ou fr Regulat
8. Shift Cable Installation ohitt e able InsSpectlOlissse eh iio RR ved bc tat Sap Shift Cable Lubrication Reverse Bucket Removal Installation 12 20 Shift Lever Shaft Removal Installation 12 20 12 2 STEERING Exploded View STEERING 12 3 fib _ 2 Staristop Switch Case Mounting Screws 39 040 35mb 73 Throttle Case Mounting Screws 39 040 4 Steering Shaft Locknut 9 5 50 60 36 43 S Steering 6 Steering Holder Mounting Bots 20 20 149 8 Steering Cable JointBot 98 10 _ 9 Bal Joint 10 87imb L 10 Cabe Enant 98 10 12 Shift Cabe Nut 39 40 29 ___ 13 Steering Cable _ _39 40 29 ___ shiftLeverLocknut 20 20 us 15 Buzzer 16 Steering Position Sensor 17 Magnet G Apply grease L Apply a non permanent locking agent 12 4 STEERING Special Tool and Sealant Box Wrench 27 mm Kawasaki Bond Silicone Sealant 57001 1451 56019 120 ST580120ST Steering Cable Steering Cable Adjustment e Check the steering cable adjustment OCenter the handlebar in the straight ahead position e Check that the steering nozzle A is centered in the pump cavity OThe same distance B e f necessary
9. gt a e p Es D Viewed from i PEE q ime IGNITION SYSTEM ROUTING bm Viewed from FUEL AND Viewed from B Viewed from Viewed from E BOW JB09238BW5 APPENDIX 16 15 Cable Wire Hose Routing 1 Position clamp screw so its head faces forward JT1500 A1 Position the double spring clamp so that its pinch head faces forward JT1500 A2 Delivery Pipe Joints Delivery Pipe Inlet Air Pressure Sensor Protective Tube Throttle Body Assy Position the clamp screw so that its head faces backward JT1500 A1 Position the double spring clamp so that its pinch head faces backward JT1500 A2 4 Spark Plug Cap 3 Spark Plug Cap Fix the 2 and 3 spark plug leads with the clamp Fix the 3 and 4 spark plug leads with the clamp 2 Spark Plug Cap Air Suction Valve Hose 1 Spark Plug Cap Fix the 1 and 2 spark plug leads with the clamp Clamp JT1500 A1 Double Spring Clamp JT1500 A2 Fuel Filter Bracket Vehicle down Sensor lgnition Coils 4 Spark Plug Lead 3 Spark Plug Lead 2 Spark Plug Lead 1 Spark Plug Lead O ring Holder Fuel Pump Return Fuel Hose Main Fuel Hose
10. 2 10 Air Filter Drain Caps Inspection and 2 10 Air Filter Inspection and Cleaning 2 Dead oe bae ges aetate du 2 11 Fuel Vent Check Valve Inspection 2 11 Fuel Pume Screen Clean net uae on Rue ecu CEDERE ue 2 12 Throttle Shaft Spring 2 12 ENGINE TS 2 12 2 12 exiit UE 2 14 ENGINE TOD EDO eo opt e IMS LU 2 15 2 15 Clearance SPECION icis decus Dee bia o nes eee d ono cha ta 2 15 Engine Mounting Bolts Inspection and 55 2 19 Engine Bottom ENG assetto de bnt oto t ES atem 2 19 Couplibg Damper InspecllODlossendem RR cedat amv quus 2 19 Bilge Systems a Dep 2 19 Cooling System FIUsShING 2 19 Bilge Systemi 8 2 21 inse ON PEE 2 22 2 22 2 22 Steering Cable Shift Cable Inspection 2 22 Handlebar PVOtEUDCI ION aee rates
11. 1 e N N j Ce 4 N e N N oo N e N Co N 0 0 gt ui c 5 C c i o gt gt 4 o Install the shim of this thickness mm N 5 1 09 1 24 2 95 o 1 29 3 00 8 e CJ N to C a N ee 1 Measure the clearance when engine is cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 65 mm Measured clearance is 0 42 mm Replace 2 65 mm shim with 2 80 mm shim 5 Remeasure the valve clearance and readjust if nec essary PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Apply molybdenum disulfide oil to the valve lifters and ap ply engine oil to the shims and install them e Install the camshafts Be sure to install the camshafts properly see Engine Top End chapter e Remeasure any valve clearance th
12. 255 202 2 60 2 65 2 270 275 2 2 75 2 80 2 2 9 E 0 07 0 1 t 0 28 0 3 0 33 0 3 0 38 0 4 0 43 0 4 0 48 0 5 0 53 0 5 0 58 0 6 0 63 0 6 0 68 0 7 0 73 0 0 78 0 8 0 83 0 8 0 88 0 9 93 0 9 8 1 0 3 1 0 8 1 1 19 10 1 18 1 2 MIN N GJ e N N KINJN 4 N Oo N fay N d Ce N orzon N 09 di NIN e N o N Install the shim of this thickness 74 Bl N 0 gt N c e 8 e Valve Clearance Measurement mm 1 Measure the clearance when engine is cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 60 mm Measured clearance is 0 35 mm Replace 2 60 mm shim with 2 75 mm shim 5 Remeasure the valve clearance and readjust if nec essary 2 18 PERIODIC MAINTENANCE Peri
13. 2 22 cct LIE 2 23 Drain d doe di uu 2 23 mi lene wi gt EU 2 23 Battery Charging Condition Inspection 2 23 Battery Terminals 2 23 Spark Plug Cleaning and 2 24 UAT EN 6 a UT TU TERI 2 24 All Hoses Hose Clamps Nuts Bolts and Fasteners Check 2 27 Nuts Bolts and Fasteners Tightness 2 27 Hose ard Hose ub Lo tu begeben iud 2 27 TOO DOE 2 29 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the watercraft in good running condition The initial maintenance is vitally important and must not be neglected Frequency Initial 10 Every 25 Every 50 Every 100 Refer Description Hours Hours Hours Hours ence Inspect throttle control system e Inspect clean air filter drain caps Inspect clean air filter or every Inspect fuel vent check valve Clean fuel pump screen e Inspect throttle shaft spring replace throttle body if necessary e Replace engine oil Replace engine oil filter Check air suction valve or every year BEN
14. 29 16 78 in lb 14 27 14 87 in lb 35 72 14 87 in lb MO see text SS see text L SS 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Pump Cover Mounting Bolts Grate Mounting Bolts Filter Cover Mounting Bolts Steering Handlebar Clamp Bolts Start stop Switch Case Mounting Screws Throttle Case Mounting Screws Steering Shaft Locknut Steering Shaft Nut Steering Holder Mounting Bolts Steering Neck Mounting Bolts Steering Cable Joint Bolt Ball Joint Shift Cable End Nut Reverse Bucket Pivot Bolts Shift Cable Nut Steering Cable Nut Shift Lever Locknut Hull Engine Hood Crossmember Bolts Handrail Bolts Lock Assembly Nut Front Duct Bolts Damper Bolts Damper Bracket Bolts Front Storage Compartment Cover Bolts Hinge Bolts Front Storage Compartment Hook Bolts Steering Cover Bolts Meter Screen Bolts Seat Hook Bolts Seat Locknut Reboarding Step Bolts Mirror Stay Bolts Stabilizer Bolts Air inlet Duct Bolts Exhaust Outlet Bolts Electrical System Vehicle Down Sensor Mounting Screws Electrical Parts Bracket Screws Starter Relay Case Bolts Ignition Coil Mounting Bolts Water Temperature Sensor 7 8 9 8 4 9 0 80 1 0 0 50 69 87 87 in lb 12 35 35 36 43 14 5 12 87 87 in lb 87 in lb 14 29 29 69 87 in lb 43 in lb 87 in lb 13 43 1 10 69 78
15. 44 000 44 008 _ 1 7323 1 73259 44 009 44 016 1 73263 1 7329 Crankshaft Main Bearing Insert Thickness Brown 1 490 1 494 mm 0 05866 0 05882 in Black 1 494 1 498 mm 0 05882 0 05898 in 1 498 1 502 mm T PEN Blue 0 05898 0 05913 in Crankshaft Main Bearing Insert Selection Crankcase Crankshaft Bearing Insert Main Bearing Main Journal Bore Diameter Diameter Size Color Part Number Journal Nos Marking Marking 92139 3704 Brown 92139 3713 92139 3707 92139 3706 92139 3702 Blue 92139 3711 3 62130 3705 24 bearing inserts for Nos 2 and 4 journals have an oil groove respectively Black 92139 3712 3 1 5 3 2 4 1 5 3 2 4 1 59 3 2 4 8 6 Special Tools and Sealant Oil Seal amp Bearing Remover Output Shaft Wrench Hex 36 57001 1058 57001 1550 Y 8 75710885 ST571550ST Bearing Driver Set Grip 57001 1129 57001 1591 14 875711295 8 75718915 Coupling Holder 2 Flywheel amp Pulley Holder 57001 1423 57001 1605 8 57168055 Rotor Holder Rotor Puller 57001 1544 57001 1623 ST5715448T 75716238T Holder Attachment Kawasaki Bond Silicone Sealant 57001 1547 56019 120 ST5715478T ST580120ST 8 7 Special Tools and Sealant Kawasaki Bond Liquid G
16. 8 11 Magneto Cover Bearing 8 11 LUDICO c 8 11 Inspecllol etri dem 8 11 wA IRI RE m ERA 8 12 Magneto Flywheel 8 12 Magneto Flywheel 8 12 SAOP T 8 14 Stator REMOVA e CE 8 14 Stdtor STAN doasedetueedc qat Peter Poles unus uto bi eaten us 8 14 8 15 LTD DU TM 8 15 a 8 16 Crankshatt and Connecting Rods siue 8 18 Cra ankshat REMOVA _ 8 18 Crankshaft 8 18 Connecting Removal 8 19 Connecting ROG INSIANAUION 8 19 Connecting Rod Bend tut 8 21 CONNECTING Rod TWIS 8 22 Connecting Rod Big End Side 0 22 Connecting Rod Big End Bearing Insert Crankpin Wear 0 22 Crankshaft Main Bearing Insert Journal
17. R BL BK W BK JNi17057BW3 1 Joint Connector Q 2 Fuel Level Sensor Multifunction Meter Buzzer Multifunction Meter Speed Sensor 20 A Main Fuse Joint Connector R Starter Motor Battery Joint Connector P Ignition Switch ECU Electronic Control Unit 1500 2 model ELECTRICAL SYSTEM 14 63 14 64 ELECTRICAL SYSTEM Relay Assembly Removal e Remove the seat see Hull Engine Hood chapter e Remove the rear storage pocket e Remove Relay Assembly Connector A Clamp B Bolt C Relay Assembly D Installation e Apply a non permanent locking agent to the relay assem bly mounting bolt and tighten it securely e Route the relay assembly leads correctly see Cable Wire and Harness Routing in Appendix chapter Circuit Inspection e Remove the relay assembly e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay assembly as shown x If the tester does not read as specified replace the relay assembly ELECTRICAL SYSTEM 14 65 Relay Assembly Relay Assembly Circuit Inspection with the battery disconnected ECU Main Relay A Tester Connection Tester Reading 1 6 The actual reading varies with the hand tester used Relay Assembly Circuit Inspection with the battery connected Battery Connection
18. Relay A 12 94 000002 Fuel Pump Relay B __ 56 78 000 Apply positive lead Apply negative lead JNi10032BW2 C 14 66 ELECTRICAL SYSTEM Switches Switch Inspection e Using a hand tester check to see that only con nections shown in the table have continuity about zero ohms OFor the switch housing and the ignition switch refer to the tables in the Wiring Diagram x If the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Ignition Switch Y R Engine Oil Pressure Switch Connections Engine lubrication system is in good condition ELECTRICAL SYSTEM 14 67 Fuse Inspection e Remove Fuse Case e out the fuse e Inspect the fuse element x If it blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rat ing check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse 8 20000181 matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components STORAGE 15 1 Storage Table of Contents Preparation tOr idee arae Fe ene 15 2 ple
19. e oS m adu i S SZ bud WE VE NO 8 JK04045BW 2 5 15 JK04051B31 e Grease splines on the drive shaft with water resistant grease e Install the pump OApply a non permanent locking agent to the pump mount ing bolts and torque them Torque Pump Mounting Bolts 36 3 7 kgf m 27 ft Ib e Install the grate A OBe sure the trim seals B are in the position OApply a non permanent locking agent to the grate mount ing bolts and torque them Torque Grate Mounting Bolts 9 8 1 0 kgf m 87 in Ib JK040203Wi PUMP AND IMPELLER 11 9 Pump and Impeller e Be sure the seals A on the hull are in the position OCoat the outside edge A of the seal B with silicone sealant to form a seal between the hull and seal Install the pump cover OBe sure the seal A is in the position OApply a non prmanent locking agent to the pump cover mounting bolts and torque them Torque Pump Cover Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib Pump Disassembly e Unscrew the steering nozzle pivot bolts A and remove the steering nozzle B e Unscrew the pump outlet mounting bolts A and remove the pump outlet B 11 10 PUMP AND IMPELLER Pump and Impeller e Unscrew the pump cap bolts A and remove the pump cap B e Pull out the impeller seal on the impeller e Hold the shaft in the impell
20. reading is below specified refreshing charge 2 120 L is required see Refreshing Charge Electrical System chapter 11 5 xm 0 25 50 75 100 Battery Terminal Voltage Refreshing charge Battery Charge Standard 12 6 V or more is required e Connect the battery leads positive first Note Good 1 Battery Terminals Inspection Check the battery terminal screws for tightness and make sure terminal covers are in place 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 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check that the battery terminals B are not corroded necessary remove the battery see Electrical System chapter and clean the terminals and cable ends using a solution of baking soda and water e After attaching both cables coat the terminals and cable ends with grease to prevent corrosion e Install the battery see Electrical System chapter Spark Plug Cleaning and Inspection e Remove Seat see Hull Engine Hood chapter Spark Plug Caps Remove the spark plugs using the 16 mm plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1145 Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plu
21. CR9EK 0 7 0 8 0 028 0 031 3 01 300 r min 32 BTDC 3 000 r min rpm 1 300 100 r min rpm in water 1 300 100 r min rpm out of water 1 190 1 799 kPa 12 1 18 3 kgf cm 173 261 psi 430 r min rpm Direct drive from engine Axial flow single stage 4 250 N 434 kgf 955 Ib Steerable nozzle Water drag 4 0 m 13 1 ft 43 L h 11 4 US gal h full throttle 134 km 87 mile full throttle 1 hour and 26 minutes 3 person Dimensions Overall Length 3 120 mm 122 8 in 1 12 GENERAL INFORMATION General Specifications O JT1500 A1 A2 Overall Width 1 180 mm 46 5 in Overall Height 1 050 mm 41 3 in Dry Weight 338 kg 745 Ib Fuel Tank Capacity 62 L 16 4 US gal Engine Oil Type SE SF or SG SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 5 0 L 5 3 US qt Electrical Equipment Battery 12 V 18 Ah Maximum Generator Output 16 14 V T This information shown here represents results under controlled conditions and the information may not be correct under other conditions opecifications subject to change without notice and may not apply to every country GENERAL INFORMATION 1 13 Unit Conversion Table Units of Length Prefixes for Units km 0 6214 mile m o x 3281 Rf mega M x 1 000 000 mm x 0 03937 in kilo k x 1000 centi 0 01 Units of Torque milli m x 0 001 N m 01020 kgf m micro 0 000
22. HRY RES ung Hn oL m 7 m e X 9 D JC18063B32 3 52 FUEL SYSTEM DFI Fuel Injectors Service Code Character 41 42 43 44 InJ1 InJ2 InJ3 InJ4 CONDOR WN Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Joint Connector Main Relay in Relay Assembly Joint Connector Connector C 32 41 42 9 616052 4 Connector D Joint Connector R Main Fuse 20 A Battery Joint Connector P Joint Connector S FUEL SYSTEM 3 53 Ignition Coils Service Code Character 51 52 COL1 COL2 Ignition Coil 1 4 Service Code 51 COL 1 Ignition Coil 2 3 Service Code 52 COL2 Ignition Coil Removal Installation CAUTION Never drop the ignition coils especially on a hard surface Such a shock to the ignition coil can dam age it e See Ignition System section in Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Front Storage Pocket see Hull Engine Hood chapter e Disconnect the ignition coil primary lead connector s A JCIBBOT I e Connect the harness adapter A and a digital voltmeter B Special Tool Harness Adapter 57001 1562 e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the
23. 14 Reboarding Step Bos i 15 Miror 8 ti CY Apply cyanoacrylate cement L Apply a non permanent locking agent SY Apply synthetic rubber adhesive rir jr jr 13 4 HULL ENGINE HOOD Exploded View 4 e y HULL ENGINE 13 5 Exploded View c Fata Mu T gm 1 SmbizerBots 98 10 2 NrmetbutBos 73 phstOuetBos ti CY Apply cyanoacrylate cement L Apply a non permanent locking agent SS Apply silicone sealant SY Apply synthetic rubber adhesive 13 6 HULL ENGINE HOOD Fittings Seat Removal e Pull A the latch handle B e Remove the seat up A and to the rear B Seat Installation e Insert the seat hook A into the bracket B on the deck and slide it all the way forward by pushing the rear of the seat e Push down on the rear of the seat to lock it Front Storage Compartment Cover Removal e Remove Damper Bracket Mounting Bolts A Front Storage Compartment Cover Bracket Mounting Bolts B Front Storage Compartment Cover Assembly C HULL ENGINE 13 7 Fittings e To remove the hinge assembly remove the following Damper Bolt A Hinge Bolts B JM07021B32 Front Storage Compartment Cover Disassembly e Unscrew the front duct bolts A and remove the front duct B e
24. 9 4 CIOV ___________ _ 9 4 Fit r OM 9 5 Filter Cleaning and InspecllOh edad a 9 5 Cooling and Bilge oystem d medo svi sae data e s FIOSC deuda vv ca Hose Msalato er xc Cooling and System Coolifig SV SUS Mr WISIN n bordo veda Deed FUSANO Cooling and Bilge System Flow Diagram 9 8 Water PING ETE E DU OANA 9 10 Water TIpe TREINOV al Pid ID Cet E 9 10 Water Pipe INSTA 9 10 SUIDIMI mE 9 11 Summary Procedures after 9 11 Detailed Procedures after 9 13 9 2 COOLING AND BILGE SYSTEMS Exploded View J1020178W5 C COOLING AND BILGE SYSTEMS 9 3 Exploded View 71 Water Hose Joint L Shape Type 95 inv E NM Water Hose Joint Straight Shape Type ee 3 Water Hose Joint Straight Shape Type 95 in Ib NE 4 Cylinder Head 5 Water Pipe 6 Metal Clamp 7 Cylinder Head Gasket 8 Cylinder 9 Oil Cooler 10 Output Cover 11 Exhaust Pipe 12 Exhaust Pipe Gasket 13 Exhaust Manifold 14 15 1
25. Injector clogged Throttle body assy loose Throttle body assy gasket damaged Fuel line clogged Fuel pump operates intermittently Inlet air temperature sensor trouble Throttle sensor trouble Inlet air pressure sensor trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect opark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Ignition coil trouble Inlet air temperature sensor trouble Miscellaneous Throttle valve won t fully open Engine overheating Engine oil level too high Engine oil viscosity too high Air suction valve trouble Camshaft cam worn Overheating Firing incorrect opark plug dirty broken or maladjusted Spark plug incorrect IC igniter in ECU trouble Fuel air mixture incorrect Inlet air duct loose Air filter poorly sealed Air filter O ring damaged Compression high Carbon built up in combustion chamber Engine load faulty Engine oil level too high Engine oil viscosity too high Lubrication inadequate Engine oil level too low Engine oil poor quality or
26. e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the injector power source voltage OWait 15 seconds before using the starter again Power Source Voltage at Injector Connector Standard Battery Voltage x If the power source voltage is less than standard check the wiring see Wiring Diagram in this section relay Main Relay Inspection and ECU power source see ECU Power Supply Inspection e Remove the ECU Do not disconnect the connector e Connect a digital voltmeter A to the connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Injector Output Voltage Connections to Injector 1 Meter PU lead terminal 43 Meter Battery Terminal 4616036851 Connections to Injector 2 Meter O lead terminal 38 Meter Battery Terminal Connections to Injector 3 Meter BR lead terminal 39 Meter Battery Terminal Connections to Injector 4 Meter BL Y lead terminal 40 Meter Battery Terminal e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the output voltage OWait 15 seconds before using the starter again Output Voltage at Injector Connector Standard about 9 V or more the output
27. 0 31 mm 0 0087 0 0122 in Inlet 0 15 0 24 mm 0 0059 0 0094 in Valve Head Thickness Exhaust 0 8 mm 0 03 in 0 5 mm 0 02 in Inlet 0 5 mm 0 02 in 0 25 mm 0 0098 in Valve Stem Bend TIR 0 01 mm 0 0004 in or less TIR 0 05 mm 0 002 in Valve Stem Diameter Exhaust 4 955 4 970 mm 0 1951 0 1957 in 4 94 mm 0 194 in Inlet 4 975 4 990 mm 0 1959 0 1965 in 4 96 mm 0 195 in Valve Guide Inside Diameter Exhaust 5 000 5 012 mm 0 1969 0 1973 in 5 07 mm 0 200 in Inlet 5 000 5 012 mm 0 1969 0 1973 in 5 07 mm 0 200 in Valve valve Guide Clearance Wobble Method Exhaust 0 09 0 17 mm 0 0035 0 0067 in 0 35 mm 0 014 in Inlet 0 03 0 11 mm 0 0012 0 0043 in 0 29 mm 0 011 in Valve Seat Cutting Angle 45 32 60 55 Outside Diameter Exhaust 27 6 27 8 mm 1 087 1 094 in Inlet 32 6 32 8 mm 1 283 1 291 in Width Exhaust Inlet Valve Spring Free Length Exhaust Inner Exhaust Outer Inlet Inner 0 8 1 2 mm 0 03 0 047 in 0 5 1 0 mm 0 02 0 039 in 38 08 mm 1 499 in 45 97 mm 1 810 in 37 97 mm 1 495 in 36 7 mm 1 445 in 44 3 mm 1 744 in 36 5 mm 1 437 in 6 7 Specifications tem _ Standard Inlet Outer 45 78 mm 1 802 in 44 2 mm 1 740 in Cylinder Piston Cylinder Inside Diameter 82
28. Cooling Hose Left Water Box Muffler Cylinder Return Oil Hose Cylinder Oil Pan Air Filter Drain Cap White Mark Oil Separator Tank Hose Tank Air Filter Deck Port Side Oil Separator Tank Hose Cylinder Head Cover Tank Plate Air Suction Valve Hose Exhaust Manifold Flushing Hose Bypass Outlet Hose Breather Hose Cylinder Head Breather Case Run the flushing hose under the crossmember Fix the flushing hose with the band at the left end hole so that the hose does not touch the crossmember Flushing Cap 16 4 APPENDIX Cable Wire and Hose Routing ES T 7 6 NILNOY S3SOH peMelA M SS 2 1 9 110002 ANY 110 APPENDIX 16 5 Cable Wire Hose Routing Oil Cooler Cylinder Head Water Pipe Cylinder Oil Filter Oil Pan Battery Cable Starter Motor Starter Motor Cable 10 Cooling Hose Cylinder Head Left Water Box Muffler 11 Fix the No 10 cooling hose battery cable and starter motor cable with the band 12 Output Cover 13 Water Hose Joint Inlet 14 Water Hose joint Outlet 15 Return Oil Hose Cylinder Oil Pan 16 Protective Tube 16 6 APPENDIX Cable Wire and Hose Routing 1916 POMOIA 340g POMOIA O Gy
29. Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Disconnect the sensor connector A and unscrew the water temperature sensor B e When installing the water temperature sensor remove the exhaust manifold for the engine oil filling in the hollow of the exhaust manifold e Fill the hollow of the exhaust manifold A with the engine oil 10W 30 B as shown before installing the water tem perature sensor C D 5 mm 0 2 in e Tighten Torque Water Temperature Sensor 15 1 5 kgf m 11 ft Ib 4616023851 Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal Do not disconnect the connector 3 40 FUEL SYSTEM Water Temperature Sensor Service Code Character 14 AqUt e Connect a digital voltmeter A to the ECU connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Water Temperature Sensor Output Voltage Connections to ECU Meter G Y lead terminal 35 Meter BK W lead terminal 8 e Turn the ignition switch ON and push the lanyard key un jo dst der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the sensor output voltage OWait 15 seconds before using the starter again Output Voltage at ECU Standard about 3 4 V at 20 C 68 F NOTE OThe output voltage changes according to th
30. ELECTRICAL SYSTEM 14 49 Kawasaki Smart Steering System Steering Position Sensor and Magnet Removal e Remove the steering holder see Steering Removal in Steering chapter e Remove or disconnect Steering Position Sensor Lead Connector A Leads Clamp on Steering Holder Steering Position Sensor Mounting Screws B Steering Position Sensor C E CR P e Unscrew the mounting screw A and remove the magnet B Steering Position Sensor and Magnet Installation e Moving the steering shaft in the direction A and B check the steering shaft for excessive play x If necessary adjust the steering shaft nut or replace the bushings 15 P e Apply non permanent locking agent to steering position sensor mounting screws and magnet mounting Screw Install the steering position sensor to the steering holder and align the projection B on the magnet with the hole C on the steering shaft plate 14 50 ELECTRICAL SYSTEM Kawasaki Smart Steering System e Turning the steering shaft fully in left and right direction check whether the steering position sensor comes in con tact with the magnet e Check the clearance A between the steering position sensor B and the magnet C with feeler gauge Steering Position Sensor Clearance Standard 0 5 1 5 mm 0 02 0 06 in x necessary adjust the steering shaft nut e Check the operation of Kawasaki Smart Steering system Inspection of Kawa
31. Special Tools and Sealant DFI Parts Location Bub T TT DFI Servicing Precautions oelf Diagnosis Self diagnosis Outline Service Code Character Table Troubleshooting the System Throttle Sensor Service Code Character 11 tPS Throttle Sensor Removal Adjust Input Voltage Inspection Output Voltage Inspection Resistance Inspection Inlet Air Pressure Sensor Service Code Character 12 bOSt Inlet Air Pressure Sensor Inlet Pressure Sensor Installation Input Voltage Inspection Output Voltage Inspection Inlet Air Temperature Sensor Service Code Character 13 Alrt Inlet Air Temperature Remowval Installation Output Voltage Inspection Sensor Resistance Inspection Water Temperature Sensor Service Code Character 14 AqUI Water Temperature Sensor Remowval Installation Output Voltage Inspection Sensor Resistance Inspection Crankshaft Sensor Service Code Character 21 CrAg Crankshaft Sensor Remowval Installation Crankshaft Sensor Inspection Camshaft Position Sensor Se
32. e Turn the ignition switch on e Push the lanyard key under the stop button and start the engine and run it in 15 second periods until all fuel in the fuel system is with fresh fuel Wait 5 minutes between 15 seconds running periods CAUTION Do not run the engine without cooling water supply for more than 15 seconds at a time or severe engine and exhaust system damage will occur e Pull the lanyard key off the stop button and turn the igni tion switch off e Drain the fuel tank e eave the fuel filler cap loose to prevent condensation in the tank Engine e Remove the front storage pocket see Hull Engine Hood chapter e Disconnect both two connection on the ignition coil pri mary lead connectors A e Remove the spark plugs see Electrical System in Peri odic Maintenance chapter e Spray fogging oil directly into each cylinder e Turn the ignition switch on e Push the lanyard key under the stop button Turn the engine over several times with the start button to coat the cylinder walls with oil WARNING Do not lean over the engine when performing this procedure An air oil mist may be forcibly ejected from the spark plug holes and could get into your P eyes you do get some your eyes wash your eyes immediately with liberal amounts of clean fresh water Consult a physician as soon as pos sible e Pull the lanyard key off the stop button and turn the igni tion switch off
33. 10 iz SterngCabeJontBot 98 10 A JT1500 A1 Model B JT1500 A2 Model HG Apply high grade water resistance grease Chevron Black Pearl Grease EP NLGI 2 or equiva lent L Apply a non permanent locking agent M Apply molybdenum disulfide grease 55 Apply silicone sealant 11 4 PUMP AND IMPELLER Specifications tem Standard Jet Pump Impeller Outside Diameter 147 5 147 7 mm 5 8071 5 8149 in 146 5 mm 5 7677 in Pump Case Inside Diameter 148 0 148 1 mm 5 8268 5 8307 in 149 1 mm 5 8701 in Impeller Clearance 0 15 0 3 mm 0 0059 0 0118 in 0 6 mm 0 0236 in Special Tools and Sealant Oil Seal amp Bearing Remover 57001 1058 5757105857 Bearing Driver Set 57001 1129 875711295 Impeller Wrench 57001 1228 PUMP AND IMPELLER 11 5 Impeller Holder 57001 1393 Kawasaki Bond Silicone Sealant 56019 120 ST580120ST 11 6 PUMP IMPELLER Pump and Impeller Pump Removal e Turn the craft on its left side e Disconnect the reverse cable ball joint at the rear end e Unscrew the pump cover mounting bolts A and remove the pump cover B with the reverse bracket C e Unscrew the grate mounting bolts A and remove the grate B e Remove the joint bolts A and take off the steering cable joint e oosen the clamps B on the inlet cooling hose and pull off the hoses C e Unscrew the pump mounting bo
34. 100628 2 C ELECTRICAL SYSTEM 14 57 Multifunction Meter Display Function Inspection e Using the auxiliary wires connect the 12 V battery A to the meter unit B connector as follows JT1500 A2 model C JT1500 A1 model D OConnect the battery positive terminal to the terminal 1 OConnect the battery negative terminal to the terminal 2 1 Battery 2 BK Ground 3 R BL Speed Sensor 4 R W Ignition Switch 5 W R Fuel Level Sensor 6 BL BK Diagnosis Signal 7 GY Tachometer Pulse 8 G R Speed Sensor Pulse 9 BK W Buzzer 10 R BK Buzzer 11 Y BL SLO Smart Learning Operation Mode Battery Voltage Range 10 16 V e When the positive terminal of battery is connected _ 4417051882 to terminal 4 completely inspect that every LCD segment and LED warning light will be lit for several seconds just after disappearance of demonstrative fig ure expression e Check that when the terminals are disconnected all the LCD segments and LED warning light disappear the LCD segments and LED warning light will not ap pear replace the meter assembly 11 MODE Button 2 SET Button 3 Fuel Indicator 4 Fuel Level Gauge 5 Tachometer 6 Speedometer 7 LED Warning Light 8 Engine Oil Pressure Indicator 9 FI Indicator 10 Low Battery Voltage Indicator 11 Engine Cooling Water Temperature Indicator 12 Multifunction Display CAUTION Do not drop the meter
35. 4 Ignition Coils Fuel Level Sensor APPENDIX 16 23 16 24 APPENDIX Cable Wire and Hose Routing WIRE ROUTING AT BOW UN 4 lt NN lj N A 8 N f NN K K BOW J809138BW5 APPENDIX 16 25 Cable Wire Hose Routing 1 Multifunction Meter Lead Connector Blue and Yellow JT1500 A1 Blue and White JT1500 A2 2 Buzzer Lead Connector Blue 3 Start Stop Switch Lead Connector White 4 Fuel Tank 5 Holders and Bands 6 Main Harness 7 Shift Cable 8 Fuse Case 9 Regulator Rectifier 10 16 Pin Gray and 6 Pin White Connectors 11 ECU Electronic Control Unit 12 Starter Relay Case 13 Starter Relay Lead Connector Black 14 Battery Lead Connector Gray JT1500 A1 White JT1500 A2 15 Battery Cable 16 Speed Sensor Lead Connector Black 17 Speed Sensor Leads 18 Right Water Box Muffler Strap 19 Clamp 20 Battery Lead Connector Black 21 Magneto Lead Connector Black 22 Battery Cable 23 Starter Motor 24 Starter Motor Cable 25 Relay Assembly 16 26 APPENDIX Cable Wire and Hose Routing WIRE ROUTING AT STERN NOU lil 4 P c Cable Wire and Hose Routing Regulator rectifier ECU Electronic Control Unit Main Harness Clamp Electrical Parts Bracket To Starter Motor To Battery Relay Assembly Red Mark
36. Starter Relay Right Side Deck Main Harness APPENDIX 16 27 16 28 APPENDIX Cable Wire and Hose Routing ROUTING AT HANDLEBAR Cable Wire and Hose Routing Fuel Vent Pipe Hook the pipe the handlebar Throttle Cable Buzzer Leads Run the leads through the protective tube Protective Tube Band Clamp Start Stop Switch Leads Grommet on Steering Holder Multifunction Meter Leads Fuel Vent Hose Steering Holder Holder Steering Position Sensor Steering Shaft Reverse Side of Steering Holder APPENDIX 16 29 Jet 16 30 APPENDIX Cable Wire Hose Routing HOLDER LOCATION Starboard Side Cable Wire Hose Routing gt SD US OLD cet 80 mm 3 15 in 100 mm 1 18 in 180 mm 7 09 in 40 mm 1 5 in 105 mm 4 13 in 90 mm 3 54 in 50 mm 1 97 in 130 mm 5 12 in Detent Holder APPENDIX 16 31 16 32 APPENDIX Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed lt is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter motor trouble brushes worn Battery voltage low Starter relay not contacting or operating Start button not contacting Wiring open or shorted Ignition switch trouble
37. Supply Fuel Hose 20 Position the black white lead upward both ignition coils Position the red lead downward both ignition coils Clamp 16 16 APPENDIX Cable Wire and Hose Routing WIRE ROUTING WA TAH M 4 ES aun p EN 40 1 popa gt p n SS RII m NI Viewed from 09 099 CD 6500209 G0 602 D 9 WY Lx 220 4 si s NE up anr amd 115 D RS LS im E E EN PE Ta e Mire e 5 E T je 722 oim TUS el mur cma nd mec me Ca RE Tm 0 4 a II t V b d 09 9 03 Viewed from Starboard Side 20 JB09134BW5 APPENDIX 16 17 Cable Wire and Hose Routing gt X Suction Valve Hose to Air Filter Air Suction Valve Air Suction Valve Cover Rear Water Temperature Sensor Leads Exhaust Manifold Air Suction Valve Hose Fitting Air Suction Valve Cover Front Breather Hose Cylinder Head Cover Crankshaft Sensor Leads Fix the crankshaft sensor leads and the oil
38. c CI E gar B wa en res a 5 D 08 SASOH NI 1009 ANY o 4 46 APPENDIX 16 7 Cable Wire and Hose Routing Clamp Breather Hose Cylinder Head Breather Case Clamp Detail Position the clamp pinch heads as shown Air Suction Valve Air Suction Valve Hose Inlet Water Pipe Joint on the Cylinder Cooling Water from Left Water Box Muffler Cylinder Cylinder Head Cover 10 Output Cover 11 Protective Tube 12 Return Oil Hose Cylinder Oil Pan 13 Breather Hose Cylinder Breather Case 14 Breather Case 15 Oil Pan 16 Front Pinch Head 17 Rear Pinch Head 18 Position the clamp so that its pinch heads do not touch the oil separator tank hose gt 16 8 APPENDIX Cable Wire Hose Routing doj pomola d r CD 69 GD 09 9 89 69 09 0 2 0 Fe EMI i E 4 i m ___________ ___ HO S LL Nit Via tila ua _ eo BEKT 1 ASOH INI 1009 JB09130BW5 APPENDIX 16 9 Cable Wire and Hose Routing Refer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapter Install the clamp as shown noting i
39. A connected check the follow ing ground lead for continuity with the ignition switch OFF using a tester and needle adapter set B Battery C Tester Special Tool Needle Adapter Set 57001 1457 ECU Grounding Inspection 25 32 41 or 42 BK o Battery Terminal 0 Engine Ground o Battery Terminal 0 no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary 4616037851 e Check the ECU power source voltage with a tester A OPosition the terminal in accordance with terminal numbers of ECU connector B in this chapter figure ECU Power Source Inspection Tester Connections 2 R G Terminal Battery Terminal 9 R W Terminal Battery Terminal 28 Y R Terminal Battery Terminal 30 R Y Terminal Battery Terminal Terminal Voltage Ignition Switch OFF 2 R G Terminal Battery Voltage 9 R W Terminal 0 V 28 YIR Terminal 0 V 30 R Y Terminal 0 V Ignition Switch ON 2 R G Terminal Battery Voltage 9 R W Terminal Battery Voltage 28 Y R Terminal 0 V 30 R Y Terminal 0 V Ignition Switch ON and Start Button ON Terminals Battery Voltage OPushing the start button run the engine 3 4 seconds OWait 15 seconds before using the starter again x If the tester does not read as specified check the follow Ing Source Wiring see w
40. A with pliers B Main Line Fuel Filter Supply Line Return Line Delivery Pipe Fuel Injectors Fuel Tank 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM DFI 3 5 Exploded View 1 VededownSensorMouningSoews 15 015 2 Bracket Mounting Bots _____ t 4 Inlet Manifold Mounting Nuts 2 20 75 Delivery Pipe Mounting Bots 78 080 Simi L6 Inlet Air Pressure Sensor Bots 78 080 emb 7 Throtie Gable Holder Bots 88 090 _ 78 intet Air Temperature Sensor 20 20 9 Throttle Body Assy Mounting Bois 2 20 710 inlet Manifold 20 20 inlet Manifold Plate Bots 78 080 16 Regulatorrectiier Bots 78 080 17 ecu ss f om 718 Throttle Sensor Mounting Screws 20 020 719 ISC Actuator Mounting Bots 49 050 43mb vm Coils Fuel Injectors 22 Main Fuse 20 A 23 Relay Assembly Main Relay Fuel Pump Relay A JT1500 A1 Model Clamps B JT1500 A2 Model Double Spring Clamps EO Fill the hollow with the engine oil 10W 30 G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Fill the hollow with the specified silicone grease Kawasaki Bond 92137 1002 SO Apply silicone oil to the O ring 3 6 FUEL SYSTEM Exploded V
41. Do not expose it to freezing temperatures Engine Mounting Bolts Torque all engine mounting bolts see Engine Re moval Installation chapter Torque Engine Mounting Bolts 36 3 7 kgf m 27 ft lb Lubrication Carry out all recommended lubrication procedures see Lubrication in Periodic Maintenance chapter 4106008851 Preparation for Storage General e Wash the engine compartment with fresh water and re move the drain screw in the stern to drain the water Wipe up any water left in the compartment 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 seat or block the seat up with 10 mm 0 39 in spacers to insure adequate ventilation and prevent corrosion e Cover the watercraft and store it in a clean dry place STORAGE 15 5 15 6 Removal from Storage Lubrication e Carry out all recommended lubrication procedures see the Periodic Maintenance chapter General Inspection e Check for binding or sticking throttle steering or shift mechanism The throttle lever must return fully when released e Clean and gap spark plugs see Electrical System in Pe riodic Maintenance chapter e Check all rubber hoses for weathering a cracking or looseness e
42. Inlet air pressure sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Crankshaft sensor trouble Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low opark plug dirty broken or maladjusted Ignition coil shorted or not in good contact Ignition coil trouble Spark plug incorrect Spark plug cap trouble Spark plug cap shorted or not in good con tact IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Fuel air mixture incorrect Air passage clogged Air filter poorly sealed Fuel tank air vent obstructed Fuel pump trouble Inlet air duct loose Fuel pump screen and or fuel filter clogged Throttle body assy loose Throttle body assy gasket damage Troubleshooting Guide Fuel line clogged Inlet air pressure sensor trouble Inlet air temperature sensor trouble Engine stalls easily Fuel pump trouble Fuel injector trouble Throttle sensor trouble Camshaft position sensor trouble Fuel pressure too low or too high Inlet air pressure sensor trouble Water temperature sens
43. OSet the tester to the x 1 kO and read the tester x If the hand tester does not read as specified replace the coil Winding Resistance Standard Primary windings 1 53 2 07 Q Secondary windings 12 50 16 91 x If the tester reads are as specified the ignition coil wind ings are probably good However if the ignition system still does not perform as it should after all other compo nents have been checked test replace the coil with one known to be good ELECTRICAL SYSTEM 14 41 JN08035B32 4408033851 14 42 ELECTRICAL SYSTEM Ignition System Measuring spark plug lead resistance e Check the spark plug lead A for visible damage x If the spark plug lead is damaged replace the spark plug lead e Measure the lead resistance with the hand tester B Spark Plug Lead Resistance Standard 3 75 6 25 x If the hand tester does not read as specified replace the lead Camshaft Position Sensor Removal e Remove Seat see Hull Engine Hood chapter e Cut off the clamp A e Disconnect the camshaft position sensor lead connector B e Remove Camshaft Position Sensor Bolt A Camshaft Position Sensor B Camshaft Position Sensor Installation e Apply grease or engine oil to the O ring on the camshaft position sensor e Tighten Torque Camshaft Position Sensor Bolt 9 8 N m 1 0 kgf m 87 6 Ignition System Camshaft Position Sensor Inspection e Remove Seat see Hull E
44. Shift Cable Ball Joint A at Reverse Lever Shift Cable Ball Joint A at Reverse Bucket EP CN 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures e ubricate the following with a penetrating rust inhibitor B Throttle Cable A 6004040151 Steering Nozzle Pivots A Reverse Bucket Pivots B e With the cable disconnected at both ends the cable should move freely A within the cable housing x cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004020231 PERIODIC MAINTENANCE 2 27 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 x If there are loose fasteners retighten them to spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Engine Cil Filter Cartridge
45. Starter Relay Remowval 14 26 Starter Relay Installation 14 26 Starter Relay Inspection 14 26 Starter Motor Remowval 14 27 Starter Motor Installation 14 27 Starter Motor Disassembly 14 28 Starter Motor Assembly 14 28 Brush Inspection 14 29 Commutator Cleaning and HS DE CHON sxe na 14 29 Armature Inspection 14 30 Brush Lead Inspection 14 30 Brush Plate and Terminal Bolt ttes 14 30 Reduction Gear Removal Installa 14 31 Reduction Gear Inspection 14 31 Charging System 14 33 Magneto Output Voltage 14 33 Regulator Rectifier Remowval Installation 14 33 Regulator Rectifier Inspection 14 34 Regulator Inspection 14 34 Ignition System 14 37 Crankshaft Sensor Removal 14 37 Crankshaft Sensor Installation 14 37 Timing Rotor Removal 14 38 Timing Rotor Installation 14 38 Crankshaft Sensor Inspection 14 38 Ignition Coil Removal 14 39 Ignition Coil Installation 14 40 Ignition Coil Inspection 14 41 Camshaft Position Sensor ISemoValiscsis iua cuti ges ox t 14 42 Camshaft Position Sensor Installation
46. adjust the steering cable OLoosen the locknut A on the end of the steering cable located to the right of the steering nozzle OTake out the cable joint bolt B and disconnect the cable joint C from the steering nozzle OCenter the handlebar in a straight ahead steering position OTurn the joint on the cable to adjust the steering OTemporarily tighten the cable joint bolt and connect the joint with the nozzle and check cable adjustment again OWhen adjustment is correct unscrew the cable joint bolt and apply a non permanent locking agent to it tighten the cable joint bolt and the steering cable locknut securely Torque Cable Joint Bolt 9 8 1 0 kgf m 87 in Ib OAs an additional check turn the handlebar all the way to the left and right and measure the distance between the nozzle and the edge of the pump cavity It should be equal at both extremes Steering Cable Removal e Remove the screws A and remove the front storage pocket B STEERING 12 5 12 6 STEERING Steering Cable e oosen the locknut A at the front end of the steering cable and slide back the outer sleeve of the ball joint and take off the ball joint B and remove the locknut from the cable front end e Pull the holder A off the cable bracket e Slide the steering cable B off the cable bracket C and if the cable is hard to remove unscrew the cable bracket mounting bolts D and remove the cable bracket e Turn
47. 0 80 kgf m 69 in Ib e Install Oil Pan see Oil Pan Installation rt E TES Jii P tcm 4011004851 4 20 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection e Remove Oil Pan see Cil Pan Removal Relief Valve A e Check to see if the valve A slides smoothly when push ing itin with a wooden or other soft rod and see if it comes back to its seat by spring B force NOTE Olnspect the valve its assembled state Disassembly and assembly may change the valve performance any rough spots are found during above inspection wash the valve clean with high flash point solvent blow out any foreign particles that may be in the valve with 86080401 P compressed air A WARNING Clean the relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent x cleaning does not solve the problem replace the relief valve as an assembly The relief valve is precisely made with no allowance for replacement of individual parts Apply a non permanent locking agent to the relief valve Install the relief valve Torque Oil Pressure Relief Valve 15 1 5 kgf m 11 ft 1 Oil Pump Sprocket Chain Removal e Split the crankcase see Engine Bottom End ch
48. 2 9 1 e Route the cable wire and hose correctly see Appendix chapter e Install the inner pad A on the handlebar putting the buzzer B into the hollow C on the inner pad STEERING 12 9 12 10 STEERING Handlebar e Install the bosses A on the pad holder to the holes B on the handlebar pad e Align A the projection B on the pad with the groove C on the pad STEERING 12 11 Steering Steering Removal e Remove the handlebar and pad holder see Handlebar Removal Unscrew the set screw A and take out the cap Unscrew the shift lever nut A and remove the shift lever e Remove the right stay A with the right mirror see Hull Engine Hood chapter e Unscrew the steering cover mounting bolts B C and lift up the steering cover D 12 12 STEERING Steering e Remove the front storage pocket see Hull Engine Hood chapter Disconnect Steering Position Sensor Lead Connector A Buzzer Connector B Multifunction Meter Lead Connectors C Steering Cable Ball Joint at Upper End Shift Cable Ball Joint at Upper End Take out the grommet mounting plate A and pull the grommet B Pull out the multifunction meter leads A and buzzer lead from the grommet Remove the steering cover Unscrew the steering neck mounting bolts A and remove the steering neck B STEERING 12 13 Steering e Remove the cotter pin A and stee
49. 3 67 3 68 FUEL SYSTEM Throttle Lever Cable and Case 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 Remove 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 e Remove the steering cover see Steering Removal in Steering chapter e Unscrew the grommet mounting bolts A and pull out the plate B and grommet C e Take the throttle cable A off the grommet B e Pull down the throttle cable Throttle Cable Installation e Lubricate the outside of the new cable with a penetrating rust inhibitor to ease cable installation e Slide the tip A of the cable lower end on the throttle pivot arm B Throttle Lever Cable and Case e Tighten Torque Throttle Case Mounting Screws 3 9 N m 0 40 kgf m 34 in Ib Route the following correctly see Cable Wire and Hose Routing in Appendix chapter Throttle Cable Steering Cable Fuel Tank Vent Hose Start Stop Switch Leads Buzzer Leads Multifunction Meter Leads Adjust the following Throttle Cable 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 x If the throttle lever does not return properly check the throttle routing cable adjustments and cable damage Th
50. 70 Fuel Filter 3 83 Air Filter Removal 3 70 3 84 Air Filter Installation 3 70 Fuel Pump Removal 3 84 Air Filter Disassembly 3 71 Fuel Pump Installation 3 85 Air Filter Assembly 3 71 Power Source Voltage Inspection 3 85 Throttle Body Assy 3 72 Operating Voltage Inspection 3 86 Idle Speed Inspection 3 72 Fuel Pump Relay Removal 3 87 High Altitude Performance Fuel Pump Relay Inspection 3 87 Adjustment 3 72 WANK 3 88 Throttle Body Assy Remowval 3 72 Fuel Tank 3 88 Throttle Body Assy Installation 3 72 Fuel Tank Installation 3 89 Throttle Body Assy Disassembly 3 72 Fuel Tank Cleaning 3 89 Throttle Bore Cleaning 3 72 Fuel Filler and Tube Remowval 3 90 ISC Idle Speed Controller Fuel Filler and Tube Installation 3 90 Removal Installation 3 73 ISC Idle Speed Controller Inspection 3 73 FUEL SYSTEM 3 3 Fuel System Diagram 40604018883 1 Fuel Pump 2 Clamps JT1500 A1 Model Double Spring Clamps JT1500 A2 Model Installation Procedure Pull up the clamp stopper
51. 879200048 6 Oil Filter Wrench 57001 1249 875712495 4 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Watercraft operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Oil Level Inspection This watercraft engine is equipped with a semi dry sump In the semi dry sump engine the oil level difference is very large between the level measured after just stopping and that after leaving for a long time It is necessary to check the specified amount of oil is in the engine before starting the engine every day At this time use the cold mark of the level gauge Then run the engine to lubricate the engine parts sufficiently After that it is necessary to check the level by using hot mark of the level gauge Preliminary Check e Remove the seat see Hull Engine Hood chapter e Whenever checking the engine oil level keep the water craft level side to side and fore to aft as much as possible Level Ground A Side Bumper B Parallel C e Remove the dipstick A wipe it dry and insert it back to the dipstick tube B and then remove it again to check the oil level e he oil level must be between the High A and Low B level lines on the dipstick C Use level lines when engine is cold High Level Line when Cold A Low Level Line when Cold B Dipstick C High Level Line when Hot D Low
52. 994 83 006 mm 3 2675 3 2679 83 10 mm 3 272 in Piston Diameter 82 919 82 934 mm 3 2645 3 2651 in 82 77 mm 3 259 in Piston cylinder Clearance 0 060 0 087 0 0024 0 0034 in Piston Ring groove Clearance Top 0 03 0 07 mm 0 0012 0 0028 in 0 17 mm 0 0067 in second 0 02 0 06 mm 0 0008 0 0024 in 0 16 mm 0 0063 in Piston Ring Groove Width Top 0 92 0 94 mm 0 0362 0 0370 in 1 02 mm 0 0402 in second 1 01 1 03 mm 0 0398 0 0406 in 1 11 mm 0 0437 in Piston Ring Thickness Top 0 87 0 89 mm 0 0343 0 0350 in 0 80 mm 0 0315 in Second 0 97 0 99 mm 0 0382 0 0390 in 0 90 mm 0 0354 in Piston Ring End Gap Top 0 25 0 40 mm 0 0098 0 0157 in 0 7 mm 0 0276 in Second 0 40 0 55 mm 0 0157 0 0217 in 0 8 mm 0 0315 in Valve Head Thickness Valve Stem Bend 0 02000551 8 02000881 Valve Head Thickness Valve Stem Diameter B 45 C 6 8 Special Tools and Sealant Compression Gauge 20 Valve Seat Cutter 45 535 57001 221 57001 1116 T5702218T Valve Spring Compressor Assembly Valve Seat Cutter 32 530 57001 241 57001 1120 ST5702418T 75711208T Top Dead Center Finder Valve Seat Cutter 32 535 57001 402 57001 1121 Piston Pin Puller Assembly Valve Seat Cutter 60 530 57001 910 57001 1123 875709105 8 75711235 Piston Ring Compressor Gri
53. A Special Tool Needle Adapter Set 57001 1457 Connections Camshaft Sensor Lead Adapter Hand Tester Black Red gt Yellow lt Black e urn the ignition switch and engine stop switch e Pushing the starter button turn the engine 4 5 seconds to measure the camshaft position sensor peak voltage e Repeat the measurement 5 or more times Camshaft Position Sensor Peak Voltage Standard 0 4 V or more x If the peak voltage is lower than the standard inspect the camshaft position sensor ELECTRICAL SYSTEM 14 45 14 46 ELECTRICAL SYSTEM Ignition System Spark Plug Removal e Refer to Spark Plug Inspection in the Periodic Mainte nance chapter Spark Plug Installation e Refer to Spark Plug Inspection in the Periodic Mainte nance chapter Spark Plug Inspection e Refer to Spark Plug Inspection in the Periodic Mainte nance chapter Spark Plug Adjustment e Refer to Spark Plug Adjustment in the Periodic Mainte nance chapter Spark Plug Cleaning e Refer to Spark Plug Cleaning in the Periodic Maintenance chapter Ignition System Ignition System Circuit ELECTRICAL SYSTEM 14 47 6 32 41 42 9 nui necs Joint Connector Joint Connector J Joint Connector E Crankshaft Sensor Relay Assembly Main Relay Fuel Pump Relay Joint Connector F Connector C Vehicle down Sensor en Ignition Switch Camshaft Position Sen Joint Connector Q
54. B Less than 0 2 mm 0 0079 in 0 6 mm 0 0236 in DRIVE SYSTEM 10 5 Special Tools and Sealant Bearing Driver Set Kawasaki Bond Silicone Sealant 57001 1129 56019 120 875711295 ST580120ST Coupling Holder 2 57001 1423 10 6 DRIVE SYSTEM Drive Shaft Drive Shaft Holder Drive Shaft Removal Installation e Remove the engine see Engine Removal Installation chapter Pull the drive shaft A out of the hull Hold the drive shaft in a vice and unscrew the coupling Special Tool Coupling Holder 57001 1423 A When installing the drive shaft be careful of the following items OApply a non permanent locking agent to the coupling threads and tighten it Torque Coupling 39 N m 4 0 kgf m 29 ft lb grease to the grease seal lips and the drive shaft spline Drive Shaft Holder Removal Disassembly Remove the drive shaft Unscrew the mounting bolts A and remove the drive shaft holder B from the bulkhead Disassemble the drive shaft holder ORemove the circlip A Drive Shaft Drive Shaft Holder OPress the small grease seal and the large grease seals bearing and small grease seals come out of the holder A Sleeve B Blocks C Press Drive Shaft Holder Assembly Installation 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 Sm
55. B and Clamps Remove the delivery pipe assembly from the cylinder head Push the lock A and disconnect the injector connectors Remove the fuel injectors CAUTION Never drop the injector especially on a hard sur face Such a shock to the injector can damage it Fuel Injector Installation Replace the O rings A of the injectors with new ones Apply grease to the O rings Insert the injectors into the delivery pipe and confirm whether they turn smoothly or not 3 48 FUEL SYSTEM DFI Fuel Injectors Service Code Character 41 42 43 44 InJ1 112 1143 1134 e Replace the seals A with new ones e Apply grease to the inside and outside of seals e Install Delivery Pipe Assembly Collars e Install the clamps A as shown e Tighten Torque Delivery Pipe Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib e Install the fuel hoses see Cable Wire and Hose Routing section in Appendix chapter OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram Audible Inspection e Start the engine e Apply the tip of a screwdriver A to the injector B Put the grip end onto your ear and listen whether the injector is clicking or not e A sound scope can also be used e Do the same for the other injector x If all the injectors click at a regular intervals the injectors are good OThe click interval becomes shorter as the engine speed rises
56. B from the hull e Unscrew the bolt C and remove the left mirror stay D NOTE OThe plate E on the inside of the hull will drop down when the last bolt is removed e Remove the left mirror see Mirror Removal HULL ENGINE HOOD 13 9 13 10 HULL ENGINE HOOD Fittings Mirror Stay Installation e Be sure the dampers A are in position both sides e he right plate A on the inside of the hull has a R mark B and the left plate C has L mark D e Apply a non permanent locking agent to the mirror stay bolts and tighten them securely e Install the damper A onto the hull NOTE OApply a little oil to the damper to make installation easy e Install the flushing fitting A into the damper B HULL ENGINE 13 11 Fittings Front Storage Pocket Removal e Remove the front storage pocket mounting screws A e Remove the front storage pocket B Front Storage Pocket Installation e Installation is the reverse of removal Storage Pocket Disassembly Assembly e o remove the storage pocket cover A turn and pull out the shaft B both side e When installing the shafts put the shaft end C both side into the hollow D on the storage pocket e To remove the rock A turn and pull out the shaft B both side e When installing the shafts push the shaft end C both side into the hollow D on the rock Crossmember Removal e Remove the front storage pocket see Front Stora
57. Bolts 16 N m 1 6 kgf m 12 ft Ib 12 16 STEERING Steering e Be sure that the damper A is in position e Apply a non permanent locking agent to the grommet mounting plate e Apply a non permanent locking agent to the steering cover mounting bolts e Install the steering cover mounting bolts to the steering COVer e Apply a non permanent locking agent to the shift lever nut e Apply a water resistant grease to the joint balls of the shift cable and shift link rod e Adjust the shift cable and steering cable Reverse System Shift Cable Adjustment e Check the shift cable adjustment e When the shift lever is in the F position the lower edge A of the bucket should be held above the top B of the steering nozzle with slight play so it doesn t interfere with the water flow from the jet pump e When the shift lever is in the R position the lower stop per C on the bucket should rest against the bottom D of the pump cover x If either position is incorrect adjust the shift cable e Put the shift lever in the R position e oosen the locknut A at the end of the shift cable e Slide back the outer sleeve and take the ball joint B off the ball e Turn the ball joint on the cable to adjust the shift cable e Connect the ball joint and check the cable adjustment again e When adjustment is correct tighten the shift cable lock nut Shift Cable Removal e ake outthe storage case screws A a
58. Check that the drain screw in the stern is securely tight ened e Check the fire extinguisher for a full charge e Check the battery charge if necessary and clean the ter minals Install the battery see Battery Installation in Elec trical System chapter Fuel System e Check and clean or replace the fuel pump screens as nec essary see Fuel System in Periodic Maintenance chap ter WARNING Gasoline is extremely flammable and can 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 source of flame or spark this includes any appliance with a pilot light e After refueling and before starting the engine tilt the seat to the rear for several minutes to ventilate the engine com partment WARNING concentration of gasoline fumes 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 with the specified oil Removal from Storage 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 withou
59. Detection Angle Output Voltage Fuel Injectors Type Nozzle Type Resistance Oil Temperature Sensor Resistance Output Voltage at ECU 1 300 100 r min rpm both in and out of water Single type 60 mm 2 36 Mitsubishi Electric Digital memory type with built in IC igniter sealed with resin Engine speed range 100 8 100 r min rpm approx 294 kPa 3 0 43 psi Impeller type 67 mL or more for 3 seconds 4 75 5 25 V DC between R and BK W leads 1 08 1 18 V DC between G W and BK W leads at idle throttle opening 4 6 4 75 5 25 V DC between BK W leads 3 75 4 25 V DC between G R and BK W leads at standard atmospheric pressure about 2 3 2 6 V 20 68 5 4 6 6 at 0 C 32 F 2 26 2 86 20 68 0 29 0 39 at 80 C 176 F see Electrical System chapter about 3 4 V 20 68 F Magnetic flux detection method more than 110 130 for each bank with sensor tilted 110 130 or more 0 65 1 35 V with sensor arrow mark pointed up 3 55 4 45 V INP 281 One spray type with 4 holes about 11 7 12 3 at 20 C 68 F same to water temperature sensor about 3 4 V 20 C 68 F FUEL SYSTEM DFI 3 11 Specifications tem Standard Throttle Lever and Cables Throttle Lever Free Play about 2 mm 0 08 in 3 12 FUEL SYSTEM Special Tools and Sealant Oil Pressure Gauge 5 Sensor Ha
60. Engine Oil Change in the Periodic Maintenance chapter Oil Filter Replacement e Refer to Oil Filter Replacement in the Periodic Mainte nance chapter ENGINE LUBRICATION SYSTEM 4 11 Cooler Oil Cooler Removal e Remove Seat see Hull Engine Hood chapter Air Filter with Inlet Duct see Fuel System DFI chapter Inlet Manifold see Fuel System chapter e Disconnect the oil pressure switch connector A e oosen the clamp screws B and remove the oil cooler cooling hoses C from the oil cooler e Remove the oil filter A with the oil filter wrench B rag or cloth C under the oil filter to receive the remaining oil Special Tool Oil Filter Wrench 57001 1249 e Unscrew the oil cooler positioning bolt A e Unscrew the oil passage bolt B and remove the oil cooler C e Place a rag or cloth D under the oil cooler to receive the remaining oil Oil Cooler Installation e Replace the O ring A with new one and apply grease to new e Fit the O ring on the oil cooler B securely e Install the oil cooler positioning bolt A and the oil pas sage bolt B temporarily OTighten the passage bolt first ONext tighten the positioning bolt Torque Oil Passage Bolt 78 N m 8 0 58 ft Ib Oil Cooler Positioning Bolt 20 N m 2 0 kgf m 14 10 4 12 ENGINE LUBRICATION SYSTEM Cooler e Apply engine oil to the thread A of the passage bolt and O ring B of
61. Engine Stop Switch Joint Connector R 13 14 15 16 Main Fuse 20 A Starter Motor Battery 12 V 18 Ah ECU Electric Control Unit JNOSOSTBH4 C Throttle Sensor Connector D lgnition Coils Spark Plugs Joint Connector P Joint Connector S 14 48 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good Ignition system wiring No good Repair or replace and connector inspection damaged part Good No good plug inspection Replace spark plug Good B No good Ignition coil winding resistance inspection gt Replace Ignition coil Good Voltage is less than Ignition coil primary peak voltage inspection the specified value Ignition coil is defective Voltage is zero Sport aramos tzer Lower resistance in a hand tester Use KAWASAKI Hand Tester 9 Crankshaft sensor peak voltage Camshaft position sensor peak voltage Inspect 1 Adapter connection is incorrect or Replace bad parts adapter is defective or inspect them with Ignition Switch and engine stop switch KAWASAKI Hand Crankshaft peak voltage Camshaft position sensor peak voltage Replace bad parts Inspect the ECU Power Supply No good Tester Good Inspect the wiring ECU is defective Replace ECU Connection and related parts JNO8038B 5
62. Ib Lower Upper Camshaft Chain Guide Bolts 12 1 2 104 in Ib S PERIODIC MAINTENANCE 2 5 Torque and Torque and Locking Agent 2 Agent IR E NE Inlet Side Camshaft Chain Guide Bolts Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Position Sensor Rotor Bolt Water Hose Joint Oil Passage Joint Engine Removal Installation Engine Mounting Bolts Engine Damper Mounting Bolts Engine Bottom End Crankshaft Sensor Cover Bolts Engine Bracket Mounting Bolts Timing Rotor Bolt Connecting Rod Nuts Oil Passage Plugs Stator Mounting Bolts Grommet Cover Bolts Magneto Cover Bolts Output Cover Bolts Output Shaft Coupling Crankcase Bolts M10 Crankcase Bolts M8 Crankcase Bolts M8 Crankcase Bolts M6 Cooling and Bilge Systems Breather Mounting Bolt Water Hose Joint L Shape Type Water Hose Joint Straight Shape Type Water Hose Joint Straight Shape Type Drive System Coupling 39 4 0 Drive Shaft Holder Mounting Bolts 22 2 2 Coupling Cover Bolts 8 8 0 90 Pump and Impeller Steering Nozzle Pivot Bolts 19 1 9 Pump Mounting Bolts 36 Sal Pump Outlet Mounting Bolts 19 1 9 Pump Cap Bolts 9 8 1 0 Pump Cap Plug 3 9 0 40 Impeller 98 10 Pump Bracket Mounting Bolts 2 19 1 9 Pump Bracket Mounting Bolts 4 9 8 1 0 104 in Ib 87 14 104 in Ib 95 95 69 22 22 14 104 in Ib 87 in lb 14 69 180 72 36 22 22 104 in Ib 95 in lb 14 95
63. Level Line when Hot E 4008000851 ENGINE LUBRICATION SYSTEM 4 9 Engine Oil and Oil Filter CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine is running above idle speed stop the engine immediately and find the cause x If the oil level is too high remove the excess oil using syring or some other suitable device x the oil level is too low add the oil to the low level line through the oil filter opening see Periodic Maintenance chapter Use the same type and make of oil that is al ready in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Ordinary standard Check e he preliminary is checked before the ordinary check e Install the removed parts e aunch the watercraft e Start the engine for several minutes e Ride the watercraft and run the engine at about 5 000 rpm for 5 minutes e Stop the engine and let it cool down for 10 minutes e Steady the watercraft in calm water to prevent movement or on the ground keep the watercraft level side to side and fore to aft as much
64. Meter Display ECU controls the maximum speed Mode Button ne JBOGOZIBWI C SLO mode is displayed on meter as SLO NOTE E OWhen shifted to the SLO mode the initial display as m di shown when the ignition switch is turned is shown Ti PET together with a buzzer sound OThen SLO is shown blinking at every three seconds OUnder the SLO mode all the meter displays and other functions work in the same manner as the normal oper ation Full Power Operation FPO mode J808032881 AS eroe Normal operation mode Full Power Operation mode FPO is shown by FPO display NOTE OWhen shifted to the normal operation mode Full Power Operation mode FPO the same initial display is first shown and followed by FPO for two seconds How ever FPO is shown only once when shifted and is not displayed thereafter OWhen the ignition switch is turned off and on again the J808033B81 same mode when turned off is displayed again AS fee GENERAL INFORMATION 1 3 Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper ation on watercraft read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptio
65. Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the front storage pocket see Hull Engine Hood chapter e Connect the hand tester A to the connector B using the needle adapter set Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the operating voltage OWait 15 seconds before using the starter again Pump Operating Voltage Connections Tester gt W R lead Tester BK lead Operating Voltage Standard Battery Voltage the reading stays on battery voltage but the pump doesn t work replace the pump there is no battery voltage at all check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good check the fuel pump wiring 4608005851 4608006851 FUEL SYSTEM 3 87 Fuel Pump Relay Removal e Refer to the Relay Assembly Removal in the DFI Power Source section Fuel Pump Relay Inspection e Refer to the Relay Assembly Inspection the DFI Power Source section R BL R BL BL BL R BK W 7 6 R G R G ed R Y R Y 6 R BK 32 41 42 R BL R BK R BK J616054BW4 C 1 Relay Assembly 7 Battery 2 Joint Conn
66. PRESE TREE a E 15 2 ile pel cM NR E uu T 15 2 m 15 2 15 2 15 3 15 4 15 4 Engine MOUNINO 8 AMETE 15 4 15 4 iustus 15 5 Removal from Storage meiraa E UU 15 6 PUTNAM n RR TERR 15 6 GG INS FAIS OS COUN arias crs cesta hae A 15 6 OnE RENT 15 6 THEME 15 7 15 2 Preparation for Storage During the winter or whenever the watercraft will not be in use for a long period of time proper storage is essential It consists of checking and replacing missing or worn parts lubricating parts to ensure that they do not become rusted and in general preparing the watercraft so that when the time comes to use it again it will be in top condition NOTE OPersonal watercraft is not meant to be left in the water for extended periods Continuous exposure to water over a long period of time will cause the hull paint to bubble and peel It also causes electrolytic erosion of the metal parts of the pump decreasing its service life Larger boats which are left
67. Remove Seat see Hull Engine Hood chapter Cylinder Head Cover see Engine Top End chapter e Position the crankshaft at 1 4 piston as follows OUsing the shaft wrench A turn the crankshaft counter clockwise B and set the crankshaft at 1 4 piston Special Tool Shaft Wrench 57001 1551 OThe timing marks A must be aligned with the cylinder head upper surface B as shown 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Measure the valve clearance between the cam and the valve lifter with a thickness gauge Valve Clearance Standard IN 0 15 0 24 mm 0 0059 0 0094 in EX 0 22 0 31 mm 0 0087 0 0122 in OWhen positioning 1 piston at the end of the compression stroke Inlet Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve e Bow A Camshaft Sprocket Position B 4808005851 OWhen positioning Z4 piston at the end of the compression stroke Inlet Valve Clearance of 2 and 4 Cylinders Exhaust Valve Clearance of 3 and 4 Cylinders Measuring Valve e Bow A Camshaft Sprocket Position B 4808006851 the valve clearance is within specified range first record the clearance and then adjust it e o change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness OMark
68. Replace the cylinder gasket with a new one and install the pins A and new cylinder gasket Exhaust Side B e Apply molybdenum disulfide oil solution to the cylinder bore external of pistons and piston rings e Insert the piston in the cylinder by two methods With the Hand e Position the crankshaft at 2 piston e Install the two cylinder head bolts A diagonally in the crankcase e Install the cylinder block B Pistons C OFirst insert the 2 3 pistons and then rotate the crank shaft at 90 angle Olnsert the piston rings with your thumbs the thin screw driver With the Special Tools e Install the two cylinder head bolts A diagonally in the crankcase e Slip the piston bases B under the pistons to hold them level e Compress the piston rings using the piston ring compres sor grips C and piston ring compressor belts D with Ei qu chamfered side upward i Special Tools Piston Base 8 57001 1604 X 2 Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor 080 091 57001 1320 e Push down vigorously the cylinder aligning the cylinder bores with all the piston heads e Install the cylinder so that its angle aligns the piston angle after removing the piston ring compressor belts e Install the removed parts 6 34 Cylinder Pistons Cylinder Wear e Since there is a difference in cylinder wear
69. Service Service Code Possible Problems Fail Safe Function Throttle sensor malfunction The ECU locks ignition timing into wiring open or short the ignition timing at closed throttle position and sets the DFI in the D J method see Note 1 Inlet air pressure sensor The ECU sets the DFI in the a N Malfunction wiring open or short method see Note 2 Inlet air temperature sensor The ECU sets the inlet air temperature Malfunction wiring open or short at 40 Water temperature sensor The ECU sets the water temperature malfunction wiring open or short at 70 Crankshaft sensor malfunction Wiring open or short The ECU continues to ignite cylinders in the same sequence following the last good signal Vehicle down sensor The ECU slows down the engine malfunction wiring open or speed less than 3 000 r min rpm by _ short stopping the ignition Injector 1 malfunction wiring open or short Injector 2 malfunction wiring Open or short Injector 3 malfunction wiring open or short Injector Z4 malfunction wiring pen or short Ignition coil 1 4 malfunction The ECU shuts off the injectors 1 4 Wiring open or short to stop fuel to the cylinders 1 4 Ignition coil 2 3 malfunction The ECU shuts off the injectors 2 3 to stop fuel to the cylinders 2 3 Wiring open or short The ECU slows down the engine Engine overheat speed less than 3 000 r min rpm by s
70. Standard Top A 0 92 0 94 mm 0 0362 0 0370 in Second B 1 01 1 03 mm 0 0398 0 0406 in Service Limit Top A 1 02 mm 0 0402 in Second B 1 11 mm 0 0437 x If the width of any of the two grooves is wider than the service limit at any point replace the piston GE18070431 JF11011B31 4211008851 GE18070731 ENGINE TOP END 6 35 Cylinder Pistons Piston Ring Thickness e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top A 0 87 0 89 mm 0 0343 0 0350 in Second B 0 97 0 99 mm 0 0382 0 0390 in Service Limit 0 80 0 0315 0 90 0 0354 any of the measurements is less than service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap between the ends ofthe ring with a thick ness gauge B Piston Ring End Gap Standard Top 0 25 0 40 mm 0 0098 0 0157 in 16071051 0 40 0 55 0 01
71. 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 OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you wil
72. Tank Cleaning e Remove the fuel tank see Fuel Tank Removal e Drain the tank into a suitable container Gasoline is extremely flammable and 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 Flush the tank repeatedly with high flash point solvent un til itis clean It may be necessary to put a few marbles or pieces of clean gravel into the tank and shake it to knock loose any foreign matter in the bottom Clean tank 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 3 90 FUEL SYSTEM Fuel Tank Fuel Filler and Tube Removal e Open the front storage compartment cover e oosen the fuel filler tube clamp screws A and remove the fuel filler tube B e Remove the fuel filler cap A e Take out the screws B in the filler flange and remove the fuel filler C Fuel Filler and Tube Installation e Clean the deck and filler on their mating surfaces with greaseless high flash point solvent A WARNING Clean the parts in a well ventilated area and take ample care th
73. V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also as a current limiter to protect the regulator rectifier from excessive current Do not use an ammeter instead of a test light Do the 1st step regulator circuit test OConnect the test light and the 12 V battery to the regula tor rectifier as shown OCheck infinity terminals respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test JN07015B31 JN07016B31 Charging System e Do the 2nd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the 1st step regulator circuit test OApply 12 V to the positive terminal OCheck infinity terminals respectively the test light turns on the regulator rectifier is defective Replace it Olf the test light does not turn on continue the test e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the 1st step regulator circuit test OMomentarily apply 24 V to the positive terminal by adding a 12 V battery OCheck infinity terminals respectively CAUTION Do not apply more than 24 volts If more than 24 volts is applied the regulator rectifier may be dam aged Do not apply 24 V more than a few
74. again e Remove the fuel pressure gauge and adapter e Run the fuel hoses in accordance with the Cable Wire and Hose Routing section in the Appendix chapter OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged WARNING Gasoline is extremely flammable and be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch OFF e Wait until the engine cools down e Open the fuel tank cap A to lower the pressure in the tank FUEL SYSTEM DFI 3 79 3 80 FUEL SYSTEM Fuel Line e Prepare a measuring cylinder A e Disconnect the fuel supply hose from the fuel delivery pipe and set the measuring cylinder and fuel supply hose B as shown e Close the fuel tank cap WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Turn the ignition switch ON e Push the start button for 3 seconds e Measure the discharge for 3 seconds Amount of Fuel Flow Standard 67 mL or more for 3 seconds x If the fuel flow is much less than the specified check the following Fuel Hos
75. and O ring C e Pull out the shift cable toward the rear shift Cable Installation e Slide a short piece of rubber or plastic tubing over the front cable end to guide the cable through the hull e ubricate the outside of the new cable to ease cable in stallation e Torque the shift cable nut Torque Shift Cable Nut 39 4 0 kgf m 29 ft Ib e Apply a non permanent locking agent to the cable bracket mounting bolt e Apply a water resistant grease to the joint ball at each end of shift cable e Adjust the shift cable see Shift Cable Adjustment Shift Cable Inspection e Refer to Steering Cable Shift Cable Inspection in the Pe riodic Maintenance chapter Shift Cable Lubrication NOTE OThe shift cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced STEERING 12 19 12 20 STEERING Reverse System Reverse Bucket Removal Installation e Disconnect the ball joint at rear end of the shift cable e Remove the pump cover e Unscrew the pivot bolts A and remove the reverse bucket B e Installation is the reverse of removal Note the following OApply a non permanent locking agent to the reverse bucket pivot bolts and torque them Torque Reverse Bucket Pivot Bolts 19 N m 1 9 kgf m 14 ft Ib OAfter installation check the shift cable adjustment Shift Lever Shaft Removal Installation e Remove oteering Cover see Steering Removal Steerin
76. and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Loosen the clamp bolt B and pull out the fuel supply hose e For JT1500 A2 model Loosen the double spring clamp B with pliers and pull out the fuel supply hose e Quickly install the fuel pressure gauge adapter A be tween the fuel supply pipe and the fuel supply hose e Connect the pressure gauge B to the fuel pressure gauge adapter Special Tools Fuel Pressure Gauge Adapter 57001 1463 Oil Pressure Gauge 5 kgf cm 57001 125 WARNING Do not try to start the engine with the fuel hoses disconnected e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure idling Standard approx 294 kPa 3 0 kgf cm 43 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications xlIf the fuel pressure is much higher than the specified check the following Fuel Hose from Gauge Adapter to Fuel Pump Return Pipe for Sharp Bend Kinking or Clogging Fuel Pump x If the fuel pressure is much lower than specified check the following Fuel Line Leakage Fuel Injectors Fuel Pump Amount of Fuel Flow see Fuel Flow Rate Inspection Fuel Line x If the fuel pressure is much lower than specified and if inspection above checks out good replace the fuel filter and measure the fuel pressure
77. be switched to another mode Push the SET button with MODE button at the User Dealer same time for 3 seconds more B 5 21 button for than 4016030851 User Mode This is a standard mode and enters automatically after ignition switch ON The ECU notifies the rider of troubles DFI system and ignition system by flashing LED warn ing light A the Fl indicator B and FI character C when DFI system and ignition system parts are faulty and initiates fail safe function The buzzer sound goes on In case of se rious troubles ECU stops the injection ignition starter motor operation The buzzer sound can be stopped by pushing either SET or MODE button 4616021851 Dealer Mode The LCD in the meter unit displays service code charac ter to show problem s which the DFI system and ignition system has at the moment of diagnosis e o enter the dealer mode push the SET button B with MODE button C for 3 seconds or more e Read the service code character in the LCD display Re fer to the Service Code Character Table in the following section 4616022851 e o return the user mode push either SET or button for one second or more e he service code character s will not be shown on the LCD in the meter unit after the problems are solved FUEL SYSTEM DFI 3 23 Self Diagnosis Service Code Character Table
78. described on the battery case If the battery will not accept current after 5 minutes replace the battery Battery A Battery Charger B Standard Value C e Determine battery condition after refreshing charge ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below 12 0 less than 12 6 V Charge insufficient Recharge less than 12 0 V Unserviceable Replace ELECTRICAL SYSTEM 14 25 JN05002B31 14 26 ELECTRICAL SYSTEM Electric Starter System Starter Relay Removal e Remove Seat see Hull Engine Hood chapter Rear Storage Pocket see Hull Engine Hood chapter Battery see this chapter e Disconnect the negative battery cable from the battery terminal see Battery Removal e Disconnect the starter relay lead connector A e Slide out the rubber caps A e Remove the nuts B from the battery and starter terminals on the start relay switch e Remove the starter relay case bolts C and slide the starter relay switch from the relay case D being care ful not to lose any of the insulating washers or grommets Starter Relay Installation e Mount the starter relay switch A in the relay case B OCoat the insulating washers C and grommets D with water resistant grease OBe certain all insulating washers and grommets are in po sition OTighten the relay mounting nuts E securely Torque Starter R
79. in lb 11 r rr see text PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Nm 66 Starter Relay Mounting Nut 3 5 4 5 0 35 0 45 30 40 in Ib Starter Cable Mounting Nut 3 5 4 5 10 35 0 45 30 40 in Ib Timing Rotor Bolt 20 2 0 14 Crankshaft Sensor Screws 4 4 0 45 39 in lb Rubber Grommet Holder Screws 4 4 0 45 39 in Ib Crankshaft Sensor Cover Bolts 7 8 0 80 69 in lb Oil Temperature Sensor 15 1 5 11 see text Camshaft Position Sensor Bolt 9 8 1 0 87 in lb Spark Plugs 13 1 3 113 in Ib Regulator rectifier Bolts 7 8 0 80 69 in lb Replay Assembly Bolts 2 5 0 25 22 1 15 ECU Mounting Bolts 8 8 0 90 78 in lb Main Fuse Mounting Bracket Bolt 7 8 0 80 69 in lb Multifunction Meter Mounting Bolts 3 9 0 40 35 in lb Fuel Level Sensor Clamp Screw 2 9 0 30 26 in lb Start stop Switch Case Mounting Screws 3 9 0 40 35 in Ib Speed Sensor Mounting Bolts 3 9 0 40 35 in Ib L Starter Motor Through Bolts 6 4 0 65 56 in lb L R Starter Motor Mounting Bolts 8 8 0 90 78 in lb L Starter Motor Ground Bolt 7 8 0 80 69 Starter Motor Terminal 7 8 0 80 69 in lb Stator Coil Bolts 12 1 2 104 in Ib Grommet Holder Bolts 8 8 0 90 78 in lb The next table relating tightening torque to thread diameter lists the basic torque for the bolts nuts Use this table for only the bolts and nuts which do not require a specific
80. in the water must be hauled out periodically so the bottom of the hull can be scraped and repainted with anti fouling paint They also usually have a sacrificial anode to reduce electrolytic erosion of metal parts in contact with the water Cooling System e Clean the cooling system see the Periodic Maintenance chapter Bilge System e Clean the bilge system see the Periodic Maintenance chapter Before reconnecting the hoses to the plastic breather fitting blow air through both hoses A to force all water out of the bilge system Engine Oil e Change the engine oil see Engine Lubrication System in Periodic Maintenance chapter 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 Drain the fuel tank This should be done with a siphon or pump A Siphon Hose NOTE OLift the stern upward a little so that fuel and water in the bottom of the fuel tank may flow toward the fuel filter to completely drain the fuel tank J02B014 STORAGE 15 3 Preparation for Storage e Remove the fuel pump see the Fuel System chapter e Clean the fuel pump screen A see Fuel System in Pe riodic Maintenance chapter e Refill the fuel tank with fresh fuel approximately 10 L 2 6 gal U S
81. incorrect Oil cooler incorrect Oil cooler clogged Sensor incorrect Water temperature sensor broken Over Cooling Sensor incorrect Water temperature sensor broken Abnormal Engine Noise Knocking IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Magneto flywheel loose Oil Pressure Warning Light Goes On Oil pump damaged Oil screen clogged Oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Troubleshooting Guide Oil pressure switch damaged Wiring faulty O ring at the oil passage in the crankcase damaged Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery lead making
82. installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORoute the hoses according to Cable Wire and Hose Routing section in the Appendix chapter Olnstall the hose clamps in the position shown and se curely tighten the clamp bolts Check the fuel system for leaks after hose installation Fuel Hose A Clamp B Fuel Pipe C FUEL SYSTEM DFI 3 19 GC 17046951 3 20 FUEL SYSTEM DFI Servicing Precautions For JT1500 A2 Olnstall the double spring clamp in the position as shown and securely pull up the clamp stopper with pliers Check the fuel system for leaks after hose installation Fuel Hose B Double Spring Clamp A Fuel Pipe C CAUTION Do not reuse the double spring clamps on the fuel line Reusing will cause fuel leakage Replace the double spring clamps with new ones OReplace the fuel hose if it has been sharply bent or kinked OThe high pressure inside the fuel line can cause fuel to leak A or the hose to burst Bend and twist the fuel hose while examining it OReplace the hose if any cracks B or bulges C are no ticed OWhen checking the DFI parts do not run the engine for 15 seconds or more without auxiliary cooling see General Information chapter CAUTION If running the engine without the auxiliary cooling for 15 seconds or more even at idl
83. kind of clamp as the original Some of the clamps are metal for tighter clamping ability required when smooth fittings are used Plastic clamps are used where tight clamping is not required Hose Inspection e Refer to Hose and Hose Connect Inspection in the Peri odic Maintenance chapter COOLING AND BILGE SYSTEMS 9 7 Cooling and Bilge System Flushing Cooling System Flushing e Refer to Cooling System Flushing in the Periodic Mainte nance chapter Bilge System Flushing e Refer to Bilge System Flushing in the Periodic Mainte nance chapter 9 8 COOLING SYSTEMS Cooling and System Flow Diagram J1040128W5 C COOLING AND BILGE SYSTEMS 9 9 Cooling and Bilge System Flow Diagram Cylinder Head Water Pipe Cylinder Head Gasket Cylinder Oil Cooler Output Cover Exhaust Pipe Exhaust Pipe Gasket Exhaust Manifold 10 Exhaust Manifold Gasket 11 Flushing Fitting 12 Bypass Outlet 13 Left Water Box Muffler 14 Right Water Box Muffler 15 Tail Pipe 16 Cooling Water Filter Cover 17 Cooling Water Filter 18 Pump 19 Bilge Breather 20 Bilge Filter 21 Pump Outlet A Direction of Cooling System Flow B Direction of Bilge System Flow C Direction of Combined Exhaust Gas and Cooling Water Flow gt 9 10 COOLING BILGE SYSTEMS Water Pipe Water Pipe Removal e Remove the inlet manifold see Fuel System e Disconnect the cooling hose A onto the water pi
84. late ttt uu UE ce 13 14 13 15 13 16 0 8 972 LOCION ee 13 16 PRIVEE TR CINOVAl ______ _ ____ 13 18 PRIVEE Installallorjsouaii de doce c awa sadinmeaeate 13 18 Front Bumper Removals eta tapes d eon ap b 13 18 Frent eumper IA Stal lAU OM a sis tad siga Oa ________ ___ A CH Qe 13 18 13 18 Rear Bumper Installation 13 18 Side REMOVE 13 19 Side OM 13 19 13 2 HULL ENGINE HOOD Exploded View HULL ENGINE 13 3 72 10 73 Lock Assembly Nut 080 ra Front Duct Bots t i 6 Damper Brackets i 77 Front Storage Compartment Gover Bots i Hinge Bos 79 Front Storage Compartment Hook Bots i 10 Steering Covereos Meter Screen Bots 12 Seat Hookes o
85. m 14 ft lb Steering Nozzle Pivot Bolts 19 1 9 kgf m 14 ft lb Be sure the pump seal A is in place on the pump case JKO4051BS1 Impeller Inspection Refer to Impeller Inspection in the Periodic Maintenance chapter PUMP AND IMPELLER 11 15 Pump and Impeller Impeller Outside Diameter Measurement e Measure the impeller outside diameter x If the impeller is worn smaller than the service limit re place it Impeller Outside Diameter Standard 147 5 147 7 mm 5 8071 5 8149 in Service Limit 146 5 mm 5 7677 in Pump Inspection 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 the pump case is worn beyond the service limit replace it Pump Case Inside Diameter Standard 148 0 148 1 mm 5 8268 5 8307 in Service Limit 149 1 mm 5 8701 in Impeller Clearance 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 o 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 3 mm 0 0059 0 0118 in Service Limit 0 6 mm 0 0236 in If impeller clearance is incorrect determine if it is due to wear or damage see Pump and Impeller Inspectio
86. no fuel pump sound engine flooded do not crank engine with throttle opened which promotes engine flooding Engine stalls Poor running at ow speed L1 spark plug loose tighten it 3 26 FUEL SYSTEM DFI Troubleshooting the DFI System Poor running O spark plug loose tighten it or no power at spark plug dirty broken gap maladjusted remedy it high speed spark plug incorrect replace it knocking fuel poor quality or incorrect FUEL SYSTEM DFI 3 27 Throttle Sensor Service Code Character 11 tPS Throttle Sensor Removal Adjustment CAUTION Never drop the throttle sensor A especially on a hard surface Such a shock to the sensor can dam age it e Remove Seat see Hull Engine Hood chapter Air filter see air Filter Removal e Use a Torx wrench T20 B 3 86 mm 0 152 in to remove the throttle sensor mounting screws C NOTE the engine compartment there is not enough space between the throttle sensor and hull to remove the Torx screws So use an L shape Torx wrench 4616077851 e When installing throttle sensor note the following In the photo the throttle sensor has been removed from the throttle body for clarity OAlign A the projections B on the throttle sensor with the throttle shaft C as shown when putting the throttle sensor to the throttle body OTurn the throttle sensor counterclockwise A a little
87. seconds If 24 volts is applied for more than a few seconds the regulator rectifier may be damaged the test light does light when 24 V is applied momen tarily to the positive terminal the regulator rectifier is defective Replace it the regulator rectifier passes all the tests described it may still be defective If the charging system still does not work properly after checking all the components and the battery test the regulator rectifier by replacing it with a known good unit e Repeat the test for another regulator rectifier Charging System Circuit ELECTRICAL SYSTEM 14 35 JN07018B31 JN07009BW2 C 14 36 ELECTRICAL SYSTEM Charging System Load Main Fuse 20 A Joint Connector R Battery 12 V 18 Ah Joint Connector S Ground Regulator Rectifier Magneto 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 you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent ECU Electronic Control Unit damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and ECU Crankshaft Sensor Removal e Remove Engine see E
88. seconds or more OThe same initial display as shown when ignition switch turned on is shown together with two times buzzer sound OThen SLO 1 second and normal display Clock Time Trip Hour 3 seconds are shown blinking al ternately e Confirmation of the normal operation mode shift OTo change the SLO mode to normal operation mode push the MODE button for 7 seconds or more OThe same initial display is first shown and followed by FPO A for 2 seconds OHowever FPO is shown only once when shifted and not displayed thereafter x If the display function does not work replace the meter assembly NORMAL DISPLAY mM Time Trip 5810 ME 15 17046851 JN17050B31 ELECTRICAL SYSTEM 14 59 Multifunction Meter Fuel Level Gauge Symbol FUEL Characters Warning Light Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e Connect the variable rheostat A to the terminal 5 as shown JT1500 A2 model B JT1500 A1 model C e Check that the number of segments matches the resis tance value of the variable rheostat Resistance Value Display 2930 The LED warning light fuel symbol and FUEL acters flash at the same time JN17052B 2 e f any display function does not work replace the meter assembly Speedometer Inspection e Connect the 12 V battery and te
89. solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages 8 20 Crankshaft and Connecting Rods CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D x If the connecting rods big end bearing inserts or crank shaft are replaced with new ones select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse them See the table below for correct bolt and nut usage e Apply grease and oil to the following portions Apply molybdenum disulfide grease Do not apply grease and oil B Apply molybdenum disulfide oil solution C CAUTION Do not apply grease to the inner surface of the lower big end cap or to the outer surface of the lower bear ing insert e Install the bearing insert as shown to prevent its outer surface from scratch damage with connecting rod edge Connecting Rod Side Bearing Insert A Dowel Pin B Claw Side C Cap Side Bearing Insert D Connecting Rod Cap E e Replace the connecting rod big end bolts and nuts with new ones e Be sure to clean the bolts nuts and connecting rods thoroughly wit
90. start button run the engine 5 6 seconds at idling to measure the input voltage OWait 15 seconds before using the starter again Ignition Coil Input Voltage at Ignition Coil Connections for Ignition Coil 1 4 Meter R Y lead Meter Battery terminal Connections for Ignition Coil 2 3 Meter R Y lead Meter Battery terminal Input Voltage at ECU Standard Battery Voltage the reading is out of the standard check the wiring see next wiring diagram x the reading is good the input voltage is normal Crank the engine and check the peak voltage of the ignition coils see Electrical System chapter in order to check the primary coils 3 54 FUEL SYSTEM DFI Ignition Coils Service Code Character 51 52 COL1 COL2 32 41 42 D 2 JC616053BW4 Main Relay in Relay Assembly Joint Connector F Connector C Connector D Joint Connector R Main Fuse 20 A etarter Motor Battery ECU Ignition Coils Joint Connector P Joint Connector S gt N gt FUEL SYSTEM 3 55 Engine Overheating Service Code Character 71 HEAt e f the service code is displayed check the doubtful parts referring to the following table Water passage clogged loosened or damaged inspect see 9 chapter Incorrect engine oil ev see 4 chapter Change see 4 chapter inspect see 3 and 14 chapters inspect se
91. temperature sensor leads to the dipstick pipe with the band Dipstick Pipe Inlet Manifold Clamp the engine harness and the crankshaft sensor lead connector Engine Harness Inlet Air Pressure Sensor Run the inlet air pressure sensor leads under the delivery pipe Delivery Pipe Oil Temperature Sensor Leads Throttle Sensor Connector Injectors Pressure Switch Oil Filter Oil Cooler Oil Temperature Sensor ISC Idle Speed Controller Connector Camshaft Position Sensor Connector ECU Electronic Control Unit Connector Clamp the water temperature sensor and camshaft position sensor leads ISC Idle Speed Controller Fix the engine harness to the ISC with the band Crankshaft Sensor Lead Connector Fix the camshaft position sensor connector and water temperature sensor leads with the band Inlet Air Temperature Sensor Run the oil pressure switch lead between the cylinder and inlet manifold 16 18 APPENDIX Cable Wire and Hose Routing WIRE ROUTUNG AT CRANKSHAFT SENSOR AND MAGNETO COVER E 4 5 4 V SUA EA AIO Viewed from Top Viewed from Stern JB09135BW5 APPENDIX 16 19 Cable Wire and Hose Routing Crankshaft Sensor Leads Grommet Crankshaft Sensor Cover Reverse Side Crankshaft Sensor Magneto Cover Reverse Side Magneto Leads Plate for fixing the magneto leads Do not place the leads between the plate and m
92. the oil filter C e Tighten the oil filter P No 16097 1072 Torque Oil Filter 18 1 8 kgf m 13 ft lb e Connect the oil pressure switch connector securely e Install the cooling hoses see Cable Wire and Hose Rout ing in Appendix chapter e Install the inlet manifold see Fuel System DFI chapter Oil Cooler Disassembly e Remove Oil Cooler see Oil Cooler Removal Water Hose Joints A Oil Pressure Switch B Oil Cooler Assembly Bolts C e Remove the O ring A e Turn the oil cooler up side down and remove the assem bly bolts B e Separate the oil cooler Inside Oil Cooler Cover A O rings B Oil Cooler C Outside Oil Cooler Cover D 4009005851 Oil Cooler Assembly e Apply grease to new O rings and fit them on to each groove of the coolers securely e Apply silicon sealant to the joints and tighten them Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Cooler Assembly Bolts 7 8 N m 0 80 kgf m 69 in Ib Water Hose Joints 20 N m 2 0 kgf m 14 ft Ib e Install the oil cooler see Oil Cooler Installation ENGINE LUBRICATION SYSTEM 4 13 Cooler Oil Cooler Inspection e Start the engine to check for water and oil leaks water and oil leak replace the O rings Do not run engine a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas which can be lethal CAUTION Do not run the engi
93. the peak voltage of the crankshaft sensor see Electrical System chapter in or der to check the sensor e Check the wiring for continuity using the following dia gram JCi6049BW2 C 1 ECU 2 Joint Connector E 3 Joint Connector H 4 Crankshaft Sensor FUEL SYSTEM DFI 3 43 Camshaft Position Sensor Service Code Character 23 CAAg Camshaft Position Sensor Removal Installation The camshaft position sensor detects the position of the camshaft and distinguishes the cylinder e See the Ignition system section in Electric System chap ter Camshaft Position Sensor Inspection OThe camshaft position sensor have no power source and when the engine stops the camshaft position sensor gen erates no signal e Crank the engine and measure the peak voltage of the camshaft position sensor see Electrical System chapter in order to check the sensor e Check the wiring for continuity using the following dia gram TN oL OM C 1 ECU 2 Camshaft Position Sensor 3 44 FUEL SYSTEM DFI Vehicle down Sensor Service Code Character 31 dOS This sensor has a weight A with two magnets inside and sends a signal to the ECU But when the watercraft banks 110 130 or more to either side in fact falls down the weight turns and shuts off the signal The ECU senses this change and stops the fuel pump the fuel injectors and the ignition system Hall IC B Vehicle down Sensor Con
94. the slot of the inner rotor Insert the shaft assembly Be sure the dowel pin is in place in the pump body Fit the new O ring to the groove of the pump body Fit the oil pump cover and tighten the cover bolts Torque Oil Pump Cover Bolts 7 8 N m 0 80 kgf m 69 in Ib ENGINE LUBRICATION SYSTEM 4 19 Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve e Install Oil Pump Sprocket see Oil Pump Sprocket Installation Oil Pan see Oil Pan Installation Oil Pump Inspection e Remove the oil pump parts e Visually inspect the oil pump outer inner rotors and cover x If there is any damage or uneven wear replace the rotors and cover Oil Screen Removal e Remove Engine see Engine Removal Installation chapter Oil Pan see Oil Pan Removal Oil Screen Bolts A e Pull out the soil screen B to the coupling side Oil Screen Installation e Clean the oil screen A with high flash point solvent and remove any particles stuck to it WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Apply grease to the O ring A e Install the oil screen B e Tighten Torque Screen Bolts 7 8
95. the starter motor through bolts C with new ones e Tighten Torque Starter Motor Through Bolts 6 4 0 65 kgf m 56 in Ib Brush Inspection e Measure the length A of each brush If any is worn down to the service limit replace the nega tive brush assembly B and the positive brush assembly C Starter Motor Brush Length Standard 12 mm 0 4724 in Service Limit 6 5 mm 0 2559 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves ELECTRICAL SYSTEM 14 29 GP11061031 14 30 ELECTRICAL SYSTEM Electric Starter System e Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commwutator Diameter Standard 28 mm 1 1024 in Service Limit 27 mm 1 063 in Armature Inspection e Using the x 1 O hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading gt between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B 8 11080851 C x If there is any reading at all the armature has a short and the starter motor must be replaced 4 OEven if the foregoin
96. the watercraft on its left side and remove the pump cover see Pump Removal in Pump Impeller chapter CAUTION Never lay the watercraft on the right side Water in the exhaust system may drain back into the engine causing serious damage e oosen the locknut at the rear end of the steering ca ble and remove the joint bolt B e Remove the joint C and locknut from the cable end e Unscrew the large nut steering cable nut in the hull with a wrench OSpecial tool box wrench A is useful to remove the large nut steering cable nut Special Tool Box Wrench 57001 1451 e Slide off the snap ring A washer B and O ring C e Pull out the steering cable toward the rear STEERING 12 7 Steering Cable Steering Cable Installation e Slide a short piece of rubber or plastic tubing over the front cable end to guide the cable through the hull e Lubricate the outside of the new cable to ease cable in stallation Torque Torque Steering Cable Nut 39 N m 4 0 kgf m 29 ft Ib e Apply a non permanent locking agent to the cable joint bolt and the steering cable bracket mounting bolts if re moved Torque Cable Joint Bolt 9 8 N m 1 0 kgf m 87 in Ib e Apply a water resistant grease to the joint ball A e Adjust the steering cable see Steering Cable Adjust ment Steering Cable Inspection e Refer to Steering Cable Inspection in the Periodic Main tenance chapter Steering Cable Lu
97. tle link mechanism and throttle body assy A be cause they are adjusted or set surely at the man ufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy Throttle Bore Cleaning Remove the throttle body assy see Throttle Body Assy Removal Check the throttle bore A for carbon deposits by opening the valve If any carbon accumulates wipe the carbon off the throttle bore and throttle valve using a cotton pad CAUTION Do not rub these surfaces hard and do not use a carburetor cleaning solution 4609011851 Throttle Assy ISC Idle Speed Controller Removal Installation Remove Seat see Hull Engine Hood chapter Air Filter see Air Filter Removal Bands A ISC connector B Stepping Motor Mounting Screws Stepping Motor D ISC Actuator Mounting Bolts E ISC Actuator F e Clean the mating surface of throttle body and ISC actuator stepping motor e Replace the O ring A with a new one e Install the stepping motor B and tighten the screws e Install the ISC actuator D and tighten the bolts Torque ISC Actuator Mounting Bolts 4 9 0 50 kgf m 43 in Ib e Route the harness and tighten the bands correctly see Appendix chapter e After installing the ISC actuator check the Smart Steering System Operation in the water ISC Idle Speed Controller Inspection e Chec
98. to the stator mount ing bolts and put the washers e Tighten Torque Stator Mounting Bolts 12 N m 1 2 kgf m 104 in Ib OWhen installing the stator fix the stator lead to the groove of the magneto cover OBe sure to the stator lead have no slack and bite 8 15 Crankcase Splitting Crankcase Splitting e Remove Seat see Hull Engine Hood chapter le Engine see Engine Removal Installation chapter Se JA e Drain the engine oil see Periodic Maintenance chapter Os e Set the engine on a clean surface and hold the engine gt steady while parts are being removed lt Suitable Props AMALA Lower Crankcase Projections B 10004851 Remove Crankshaft Sensor Cover see Electrical System chap ter Cylinder Head see Engine Top End chapter Piston see Engine Top End chapter Starter Motor see Electrical System chapter Oil Pump Bodies see Engine Lubrication System chap ter Magneto Flywheel see Magneto Flywheel Removal Oil Filter Periodic Maintenance chapter Remove the crankcase bolts OFirst loosen the M6 bolts 1 4 ONext loosen the M8 bolts 5 17 OLast loosen the M10 bolts 18 23 Using the pry points split the crankcase halves Lift off the lower crankcase half 8 16 ENGINE BOTTOM END Crankcase Splitting Crankcase Assembly CAUTION The upper and lower crankcase halves are ma chined at the factor
99. unit Do not short the termi nals If the multifunction meter displays incorrectly while the engine is running first disconnect the bat JN17004B31 tery terminal lead and reconnect it again to recover the meter display Then check to see that the standard plugs and or plug caps are installed Install only the standard plugs and or plug caps The resistors are embed ded in both parts 14 58 ELECTRICAL SYSTEM Multifunction Meter MODE SET Button Inspection e Check that when the MODE button is pushed and held continuously the display rotates through the four modes 7 Clock Time Trip Hour an e Indicate the clock mode e Check that when the SET button is pushed for more than two seconds the meter display turns to the clock set mode x the display function does not work replace the meter assembly e Indicate the time mode e Check that when the SET button is pushed for more than two seconds the meter display turns to 00 00 x the display function does not work replace the meter assembly e Indicate the trip mode e Check that when the SET button is pushed for more than two seconds the meter display turns to 000 0 x the display function does not work replace the meter assembly SLO Smart Learning Operation Mode Inspection 1500 2 model e Confirmation of the SLO mode shift OTo change the normal operation mode to SLO mode push the MODE button for 7
100. 0 0028 in 0 0043 in Crankpin Diameter 38 984 39 000 mm 38 97 mm 1 5348 1 5354 in 1 534 in Marking None 38 984 38 992 mm 1 5348 1 5351 38 993 39 000 1 5352 1 5354 Connecting Rod Big End Bore Diameter 42 000 42 016 mm 1 6535 1 6542 in Marking None 42 000 42 008 mm 1 6535 1 65386 42 009 42 016 1 65389 1 6542 in Connecting Rod Big End Bearing Insert Thickness Brown 1 475 1 480 mm 0 05807 0 05827 1 480 1 485 0 05827 0 05846 in Blue 1 485 1 490 mm 0 05846 0 05866 in Connecting Rod Big End Bearing Insert Selection Con rod Big Crankpin Bearing Insert End Bore Diameter Diameter Size Color Part Number Marking Marking Crankshaft Side Clearance 0 05 0 24 mm 0 44 mm 0 0020 0 0094 in 0 017 in Crankshaft Runout TIR 0 03 mm 0 0012 in or less TIR 0 07 mm 0 0028 in Crankshaft Main Bearing Insert journal 0 030 0 054 mm 0 08 mm Clearance 0 0012 0 0021 in 0 0032 in 8 5 Specifications tem Standard Crankshaft Main Journal Diameter 40 984 41 000 mm 40 96 mm 1 6135 1 6142 in 1 613 in Marking None 40 984 40 992 mm 1 6135 1 61385 1 40 993 41 000 1 61389 1 6142 in Crankcase Bearing Bore Diameter 44 000 44 016 mm 1 7323 1 7329 in
101. 001 N m x 0 7376 ft Ib N m x 8 851 in Ib kgf m 9 807 N m Units of Mass kgf m x 7 233 ft Ib kg x 2 205 Ib x 86 80 inlb 0 03527 02 Units of Pressure Units of Volume kPa x 0 01020 kgf cm L x 0 2642 gal US kPa x 0 1450 L x 0 2200 gal imp kPa x 0 7501 L x 1 057 qt US kgf cm x 08 07 kPa 0 8799 qt imp kgf cm 14 22 psi L x 2 113 pint US cmHg x 1 333 kPa L x 1 816 pint imp mL x 0 03381 oz US Units of Speed mL x 0 02816 oz imp km h x 06214 mph mL x 0 06102 cu in Units of Power Units of Force kW x 1 360 PS N 5 0 1020 kg kW x 1 341 x 0248 5 x 0 7355 kW kg x 9807 PS x 0 9860 kg x 2 205 Ib Units of Temperature 5 40 F SUP HD aoc 68 104 1 6 212 248 284 60 80 100 120 140 160 180 200 1220 240 260 280 300 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Penodi Maintenance aie 2 2 LOCKING tance ad 2 3 SOS CIMCON 2 8 5 and epa aU xe a Iud 2 9 Periodic Maintenance 5 oorr e E EY EX EVE v ERE ea 2 10 miel TER 2 10 Throttle Control System
102. 0303 5 Valve Installation e Replace the oil seal with a new one e Apply thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards Valve Spring Paint Color EX Red IN Blue A Valve Stem GE150710S1 Oil Seal C Spring Seat Closed Coil End E Valve Springs Inner F Valve Springs Outer G Retainer H Split Keepers Valve Guide Removal Remove Valve see Valve Removal Oil Seal Spring Seat e the area around the valve guide to 120 150 C 248 x 302 F and hammer lightly on the valve guide arbor to remove the guide from top of the head 77 JN EP CAUTION Do not heat the cylinder head with a torch This will a GE150305 5 warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 5 57001 1203 Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F e Drive the valve guide in from the top of the head using the valve guide arbor The flange stops the guide from going in too far Special Tool Valve Guide Arbor 5 57001 1203 e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 5 57001 1
103. 10 130 or more right or left 0 65 1 35 V with sensor arrow mark pointed up 3 55 4 45 V 3 46 FUEL SYSTEM Vehicle down Sensor Service Code Character 31 dOS e Turn the ignition switch OFF e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of Vehicle down Sensor Connector the output voltage is normal the wiring is suspect Check the wiring x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU the output voltage is out of the specified replace the vehicle down sensor JCi6051BW2 C 1 ECU 2 Joint Connector E 3 Connector C 4 Vehicle down Sensor FUEL SYSTEM 3 47 Fuel Injectors Service Code Character 41 42 43 44 InJ1 112 InJ3 InJ4 Fuel Injector Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Disconnect the battery cable ter minal 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 Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Remove Seat see Hull Engine Hood chapter Fuel Hoses Delivery Pipe Mounting Bolts A Collars
104. 204 Valve to Guide Clearance Measurement Wobble Method If small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 17 mm 0 0035 0 0067 in Inlet 0 03 0 11 mm 0 0012 0 0043 in Service Limit Exhaust 0 35 mm 0 014 in Inlet 0 29 mm 0 011 in ENGINE TOP END 6 25 GE150306 5 GE15010431 6 26 ENGINE TOP END Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 27 6 27 8 mm 1 087 1 094 in Inlet 32 6 32 8 mm 1 283 1 291 i
105. 39 in A Less than 0 2 mm 0 0079 in B Service Limit 0 2 mm 0 0079 in A 0 6 mm 0 0236 in B JJ04008B31 PUMP AND IMPELLER 11 1 Pump and Impeller Table of Contents 99128 11 2 TET TT ERES 11 4 Special Tools and Se8larib nsse ee ves dens e ivi 11 5 8 11 6 PONIRE NT 11 6 SUA E UU Di 11 7 Pump DISASSOIMDIY gt w 11 9 PUMDASSSMDIY ec m 11 11 CHO Discs 11 14 Impeller Outside Diameter 11 15 PUMP TM 11 15 Itipeller Gear arie enata i so betta etim bad O t Doa mt 11 15 Water Filter Cover Removal Installation 2 11 15 11 2 PUMP AND IMPELLER Exploded View PUMP AND IMPELLER 11 3 Exploded View EE R We Fastener OR 2 Pump Bracket Mounting Bots 4 98 10 L _ 4 Grate Mounting Bots 98 10 9 7 _ 7 Pump capos 98 10 Sm Pump Outiet Mounting Bots 19 19 44 Ll 9 Steering Nozzle Pivot Bots 49 19 44 Ll 10 Pump CapPug 39 040 35imib CM Filter Cover Mounting Bots s
106. 57 0 0217 Service Limit Top 0 7 mm 0 0276 in Second 0 8 mm 0 0315 in the end gap of either ring is greater than the service limit replace all the rings ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents VIEW MENT EEUU 7 2 Engine 7 4 ENJING REMOVA 7 4 Aeon fuse cd 7 5 Engine Damper Installalloni assit teat ocd aeta 7 6 22 m iem ien 1 6 7 2 ENGINE REMOVAL INSTALLATION Exploded View J602006BW5 REMOVAL INSTALLATION 7 3 Exploded View Engine Mounting Bolt Engine Damper Mounting Bolt L Apply a non permanent locking agent 7 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Remove Seat see Hull Engine Hood chapter Oil Separator Tank see Lubrication Sytem e Plug the hose end A x the engine disassembles drain the oil see Engine Oil Change in Periodic Maintenance chapter e Remove Air Filter see Fuel System DFI chapter Inlet Manifold see Fuel System DFI chapter Exhaust Manifold see Exhaust System chapter Bolts A and Ignition Coil Bracket e Remove Cooling Hoses A OThe oil hose B is not
107. 6 17 18 19 20 Exhaust Manifold Gasket Bypass Outlet Nozzle Plastic Clamp Flushing Fitting Flushing Cap Detent Bypass Outlet 21 Left Water Box Muffler 22 Right Water Box Muffler 23 Tail Pipe 24 Cooling Water Filter Cover 25 Cooling Water Filter 26 Pump 27 Bilge Breather 28 Bilge Filter 29 Pump Outlet 30 Protective Tube A JT1500 A2 Model CY Apply cyanoacrylate cement G Apply grease L Apply a non permanent locking agent 55 Apply silicone sealant 9 4 COOLING AND SYSTEMS Bilge System Breather Removal e Remove Seat see Hull Engine Hood chapter Rear Storage Pocket e Pull the hoses A off the breather eUnscrew the mounting bolts B and remove the breathers C Breather Installation e Be sure the small hole A in the breather is open before installing it e Apply a non permanent locking agent to the breather mounting bolts and tighten them Breather Cleaning and Inspection e Check that the small hole in the top of the breather is open by blowing in one end of the breather and plugging the other the hole is plugged clean it with compressed air Do not open it with a pointed object like a needle or a piece of wire because the hole may be enlarged If the hole is too large the bilge system may not suck water out of the hull as it should Filter Removal Follow the next procedures to remove the right side filter A e Remove the engine see Engine Removal I
108. 6 Front Storage Compartment Cover Disassembly 13 7 Front Storage Compartment Cover 13 8 Mirror queen oo eR ade Open a e Pr b t Ute c t e et Ra pd Nn a v P 13 9 Miror MStallalOn 13 9 lt all geo iens tnis 13 9 Miror tA AO buta 13 10 Front Storage Pocket Removal a LH Ud EU Ue DR Dua EE 13 11 Front Storage Pocket uiua e mda etn eere e RUE seeks 13 11 Storage Pocket Disassembly Assembly nennen nnns 13 11 13 11 13 12 Handrail REMOVA 13 13 EODD aO 13 13 Drain Plug Housing 13 13 Drain 13 13 Exhaust Outlet REMOVA lepni exo faci oed ea reet ri Ded dua Exhaust Outlet Installation Stabilizer REMOVA ninen Stabilize IMS CAAT ON wem REPE 13 14
109. 984 40 992 mm 1 6135 1 61385 in 1 40 993 41 000 mm 1 61389 1 6142 in m Crankshaft Main Journal Diameter Marks 1 mark or no mark 61050304 5 6105041951 JH11009BWi C BOTTOM END 8 25 Crankshaft and Connecting Rods e Measure the main bearing bore diameter and mark B the upper crankcase half A in accordance with the bore diameter OCrankcase main bearing bore diameter marks are O mark and no mark NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Bore Diameter Marks 44 000 44 008 1 7323 1 73259 None 44 009 44 016 mm 1 73263 1 7329 Marking Position 5 4 3 H2 1 4 3 3 2 91 1 oft e Select the proper bearing insert in accordance with the combination coding of the crankcase and crankshaft e Install the new inserts crankcase halves and check insert journal clearance with the plastigage JH11004BWi C Crankcase Main Crankshaft Main Bearing Insert Bearing Bore Journal Diameter Diameter Marking Marking Size Color Part Number Journal No 92139 3704 1 Brown 92139 3713 24 _ 319997080 45 0 None Black 92139 3712 J 9219 3706 None None Blue 92139 3711 3 32139 9708 bearing inserts for Nos 2 and 4 journ
110. A Breather Hose B Oil Separator Tank C NOTE OHold the hose end to the upward The oil will flow out if the hose lies at the bottom Oil Separator Tank Installation e When installing the breather hoses avoid sharp bending kicking flattening or twisting and route the hoses accord ing to Hose Routing section in Appendix chapter e Apply a non permanent locking agent to the oil separator tank mounting screws e Tighten careful not to drop nuts Torque Oil Separator Tank Mounting Screws 4 9 N m 0 50 kgf m 43 in Ib Blowby Gas System Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly x they are not correct them Inspect the breather hoses A breather pipes and the air filter drain caps for damage or signs of deterioration Squeeze the hoses These hoses should not be hard and brittle nor should be soft or swollen Replace any damaged hoses e Check that the hoses and aps are securely connected OThe air filter drain caps A is provided beneath the air filter are housing catches the water or oil from the bottom of the air filter housing Usually water or oil does not collect at the bottom of the housing In the event that water is drawn in through the duct or if engine oil is blown back drain the housing e Pull the air filter drain plugs to drain the water or breather oil when changing engine oil 4 16 ENGINE LUB
111. A Upper Exhaust Side Camshaft Chain Guide Bolt B M7 Cylinder Head Bolts C e Remove the M11 cylinder head bolts A and washers e Take off the cylinder head Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that iS supplied with the new head Replace that the O rings of the oil pipe and apply molybdenum disulfide oil solution to them 4709000851 e Verify that the oil pipe is installed properly e Install a new cylinder head gasket B and knock pins Cylinder Head e Apply molybdenum disulfide oil solution A to both sides of the M11 cylinder head bolt washers B and the thread of head bolts C e Install the cylinder head e First tighten the M11 cylinder head bolts following the tightening sequence 1 10 Torque Cylinder Head Bolts M11 First 23 2 3 kgf m 17 ft lb Final 59 N m 6 0 kgf m 44 ft Ib e Next tighten the M7 cylinder head bolts following the tightening sequence 11 12 Torque Cylinder Head Bolts M7 20 N m 2 0 kgf m 14 ft Ib e Lastly tighten the M6 cylinder head bolts following the tightening sequence 13 14 Torque Cylinder Head Bolts 6 12 1 2 kgf m 104 e Apply grease to the O ring A Install O ring Upper Exhaust Side Camshaft Chain Guide Bolt B Tighten Torque Exhaust Side Camsha
112. Bracket Mounting Bolts A e Remove Fuel Filter Mounting Bolts A Holder B Fuel Hoses C Fuel Filter D P Fuel Filter Fuel Filter Installation e Route the hose correctly see Cable Wire and Hose Routing section in Appendix chapter e Install the fuel hoses to the fuel filter noting its IN fitting A and OUT fitting B OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram Install the holder and apply a non permanent locking agent to the mounting bolts and tighten them Torque Fuel Filter Mounting Bolts 8 8 N m 0 90 kgf m 78 FUEL SYSTEM DFI 3 83 3 84 FUEL SYSTEM Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Pull the lanyard key off the stop button Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke JT1500 A1 model Remove the front storage pocket see Hull Engine Hood chapter Disconnect the fuel pump lead connector Loosen the clamp screws and pull out the main and return D fuel hoses e Cut off the clamp E and pull out the fuel vent hose F e oosen the lower side clamp screw G on the rub
113. C and check the filter inside or outside A on the pump case B if the foreign particles do not cling to the filter OApply high grade water resistant grease to the O ring D OApply a non permanent locking agent to the filter cover mounting bolts and torque them Torque Filter Cover Mounting Bolts 9 8 1 0 kgf m 87 in lb JT1500 A1 e Install a new bearing into the pump case A as far as it will go Special Tool Bearing Driver Set 57001 1129 B e Replace the grease seals with new ones if necessary and install them Special Tool Bearing Driver Set 57001 1129 OPress each seal A into the pump case so that the side with the spring faces outward Fill B the gap between the seals and between the seal and the bearing with high grade water resistance grease e Install the circlip C e Push the bushing D into the pump case e Visually inspect into the pump shaft O rings E and re place them if necessary e Apply molybdenum disulfide grease to the pump shaft and insert it from rear of the pump case JK04054B32 PUMP AND IMPELLER 11 13 Pump and Impeller JT1500 A2 e Replace the grease seals with new ones if necessary and install them Special Tool Bearing Driver Set 57001 1129 OPress each seal A into the pump case B so that the side with the spring faces outward OFill the gap between the grease seals C with high grade water resistance grease and apply it each greace se
114. Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Apply grease to the O rings A e Install the starter motor and tighten the mounting bolts Torque Starter Motor Mounting Bolts 8 8 0 90 kgf m 78 ELECTRICAL SYSTEM 14 27 JN08050431 14 28 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly e Remove the starter motor see Starter Relay Removal Take off the starter motor through bolts A and remove both end covers B and pull the armature out of the yoke C Remove the terminal locknut A and terminal bolt and then remove the brush with the brush plate C from the yoke 4406011851 Starter Motor Assembly Apply a thin coat of grease to the oil seal Fit the toothed washer into the end cover Install the plate cover A and the positive brush assembly in the yoke Tighten the terminal nut 0 securely JNOGO12BS1 Holding the spring ends with suitable plates put the armature among the brushes Electric Starter System e Install the O rings A and the washers B as shown e Fit the tongue A on the brush plate into the end cover groove B e Align the lines A on the yoke with the lines B on the both end covers e Replace
115. E ASSEIADIY 4 12 ISS CUO 4 13 Breather Case Oil Separator 4 14 Breather Case Re moyaliseuasieidei melee rv mb datas d dx MM edd 4 14 Breather Case MSat _ ___________ 4 14 Oil Separator Tank REMOVA tes teers Ne us D 4 14 Oil Separator Tank 4 15 Blowby Gas System trata led 4 15 m TT 4 16 Oll Pa REMOVA RUNE 4 16 OIL Pam Duo EC d wr Petri _____ 4 16 Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve 4 17 auc 4 17 4 17 REMOVA oer ee 4 18 OP 4 18 OHIP UMP MSD CCU ON uates c A 4 19 Oll Screen ISermoVvalzssssndetedescixv t eoe ve 4 19 6 Sereen OM sao uen 4 19 Cil Pressure Relief Valve 4 20 Oll Pump Sprocket Ch
116. Engine Mounting Bolts and bracket bolts Engine Damper Mounting Bolts Cylinder Head Cover Bolts Cylinder Head Bolts Drive Shaft Pump and Impeller Drive Shaft Holder Mounting Bolts Pump Mounting Bolts Pump Cover Mounting Bolts Pump Grate Mounting Bolts Steering Nozzle Pivot Bolts Reverse Bucket Pivot Bolts Steering Handlebar Clamp Bolts Steering Neck Mounting Bolts Steering Holder Mounting Bolts Steering Shaft Locknut Steering Cable Nut Steering Cable Joint Bolt Shift reverse Cable Nut Hull and Engine Hood Stabilizer Mounting Bolts Rear Grip Mounting Bolts Electrical System Spark Plugs Battery Terminal Hose and Hose Connect Inspection 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 Oil Hoses Cooling Hoses Bilge Hoses xlf a hose is damaged in any way replace it immediately and check all the others for damage 6603020251 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Make sure the above hoses are routed properly and se cured with the clamps away from any moving parts and sharp edged portions Plastic Clamp A Hose B Hose Fitting C NOTE OThe majority of bilge hoses have no clamps at the hose ends Metal Clamp A Hose B Hose Fitting C NOTE OCheck the fuel and exhaust tubes for signs of wear de terioration damage or leaka
117. Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Reduction gear trouble Vehicle down sensor DFI coming off Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Camshaft seizure No fuel flow No fuel in tank Fuel tank air vent obstructed Fuel pump screen and or fuel filter clogged Fuel injector trouble Fuel line clogged Engine flooded Clean spark plug and adjust plug gap Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood be cause more fuel is supplied automatically DFI No spark spark weak Ignition coil faulty Vehicle down sensor DFI coming off Vehicle down sensor trouble Ignition switch turned OFF and or lanyard key not pushed under stop button Battery voltage low opark plug dirty broken or gap malad justed Ignition coil shorted or not in good contact Ignition coil trouble opark plug incorrect Spark plug cap trouble Spark plug cap shorted or not in good con tact IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Wiring shorted or open Fuse blown Fuel air mixture incorrect Air passage clogged Air filter poorly sealed Fuel injector trouble Water or foreign matter in fuel Throttle sensor trouble Fuel pressure may be low Fuel pump trouble
118. Examine the bearing seal B for tears or leakage x the seal is torn or is leaking replace the bearing ENGINE BOTTOM END 8 11 JH04002B31 8 12 Magneto Flywheel Magneto Flywheel Removal e Remove Engine see Engine Removal Installation chapter Crankshaft Sensor Cover see Electrical System chap ter Coupling see Coupling Output Shaft Removal Magneto Cover see Coupling Output Shaft Removal OUsing the rotor puller A pull off the flywheel B Special Tool Rotor Puller 57001 1623 Grip 57001 1591 C CAUTION Do not hit the head of the rotor puller A loss in rotor magnetism may be caused Magneto Flywheel Installation e Using a high flash points solvents clean off any oil or dirt that may be on the crankshaft taper and in the tapered hole in the magneto flywheel e Install the O ring A directly as shown OThis face C is magneto flywheel side e Fit the woodruff key B securely in the crankshaft before installing the magneto flywheel x If the reduction gear D is removed apply a molybdenum disulfide grease to both ends of its shaft e Install the reduction gear and the washer Magneto Flywheel Apply grease to the boss outside A of the magneto fly wheel B 10 mm 0 39 in C Install the magneto flywheel NOTE OConfirm the magneto flywheel fit or not to the crankshaft before tightening it with specified torque Olnstall th
119. IR Kawasaki SIX 15F JET SKI Watercraft Service Manual DEM watercraft 15 a trademark of Kawasaki Heavy Industries Ltd registered in U S A Japan Austria Benelux Sweden Denmark Switzerland France Canada Finland Norway Greece Italy U K Portugal Thailand and Taiwan KAWASAKI JET SKI is a trademark of Kawasaki Heavy Industries Ltd registered in Australia This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Engine Lubrication System Exhaust System Engine Top End Engine Removal Installation Engine Bottom End Cooling and Bilge Systems Drive System Pump and Impeller Hull Engine Hood Electrical System Storage Appendix m gt gt 1 I0 0 gt O1 24 watercratt Kawasaki STX 15F JET SKI Watercraft Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying r
120. K W BL R BL BK W Y BK R BK R Y EEE R Y R BL R BL BL BL pe e R EP pe R Y 46 lil E I 6 09 JC16062BW5 DFI System Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Joint Connector H Inlet Air Temperature Sensor Inlet Air Pressure Sensor Joint Connector E Joint Connector J Crankshaft Sensor Relay Assembly Main Relay Fuel Pump Relay Joint Connector F Connector C Vehicle down Sensor Meter Unit Diagnosis Signal Ignition Switch Joint Connector Start Switch Joint Connector Main Fuse 20 A Starter Motor Battery ECU Electronic Control Unit Oil Pressure Switch Camshaft Position Sensor ISC Idle Speed Controller Diagnosis Connector Throttle Sensor Water Temperature Sensor Oil Temperature Sensor Connector D lgnition Coils Joint Connector P Fuel Pump Joint Connector S FUEL SYSTEM 3 17 3 18 FUEL SYSTEM DFI System Terminal Numbers of ECU Connectors E h 2 T3 4 s s 7 8s psp me opop 7 Ln Terminal Names AUN Tachometer Signal ECU Main Relay Unused SLO Smart Learning Operation Mode JT1500 A2 Model Oil Pressure
121. NGINE TOP END 6 17 6 18 ENGINE TOP END Camshaft Camshaft Chain Camshaft Camshaft Cap Wear e Cut strips of plastigage press gauge to journal width Place a strip on each journal parallel to the camshaft in stalled in the correct position e Measure each clearance between the camshaft journal and the camshaft cap using plastigage A e Tighten Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 104 in Ib Upper Camshaft Chain Guide Bolts 12 1 2 kgf m 104 in Ib NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 006 in any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 942 in x If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x If the clearance still remains out of the limit replace the cylinder head with camshaft cap Camshaft Runout Remove the camshaft see Camshaft Removal Set the camshaft on V blocks Measure runout with dial gauge at the specified place as shown the runout exceeds the service limit replace the camshaft Camshaft Runout Standard TIR 0 02 mm 0 0008 i
122. O Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 S Follow the specific tightening sequence 55 Apply silicone sealant see text 4 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Sure CUP acour Blowby Gas Supply Engine Oil Flow Return Engine Oil Flow Oil Sump from Oil Pump Side Pas sage Oil Cooler to Main Oil Passage Oil Passage Bolt Oil Pressure Switch 11 Filter Oil Passage to Oil Filter Oil Passage to Main Oil Passage Oil Pipe from Lower Crankcase to Upper Crankcase Oil Passage Plug Cil Pipe from Oil pump to Lower Crankcase fare co 2 NS ___ YY Cx No T N p 4 Al gt 2 5 e 3 T 2 e f 72 JD07004BW4 Oil Pressure Relief Valve Oil Pump Oil Sump in Oil Pan Pan Lower Crankcase Upper Crankcase Crankshaft Breather Case Breather Hose ENGINE LUBRICATION SYSTEM 4 5 Engine Oil Flow Chart He 182227 gt isi ili i 4 Ead lad ET V i Tm TRE Ld Ld 8 H 4 En
123. R8 Nm ftb 11 1 1 Oil Passage Joints 95 in Ib Oil Cooler Assembly Bolts Oil Pressure Switch Oil Passage Bolt Oil Filter Oil Cooler Positioning Bolt Oil Pan Bolts Dipstick Tube Bolts Oil Pump Sprocket Bolt Oil Pump Cover Bolts Oil Pressure Relief Valve Oil Pipe Bolts Chain Guide Spring Plate Bolt Oil Pump Body Plug Oil Pump Body Bolts Oil Screen Bolts Water Pipe Joints Exhaust System 69 11 58 13 14 69 69 11 69 11 69 69 14 69 69 14 Exhaust Manifold Mounting Nuts 25 2 5 18 5 Exhaust Manifold Mounting Bolts 25 2 5 18 5 Bypass Nozzle Flushing Hose Joint 11 1 1 95 in lb oS Water Hose Joint 11 1 1 95 in Ib oS Water Temperature Sensor 15 1 5 11 see chapter 3 Exhaust Pipe Mounting Plate Bolts 30 3 0 22 Exhaust Pipe Mounting Bolts 30 3 0 22 Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 in lb Cylinder Head Cover Bolts 9 8 1 0 87 in lb Upper Camshaft Chain Guide Bolts 12 1 2 104 in Ib S Camshaft Cap Bolts 12 1 2 104 in Ib S Cylinder Head Bolts M7 20 2 0 14 5 Cylinder Head Bolts M11 23 2 3 17 First MO S Cylinder Head Bolts M11 59 6 0 43 Final MO S Water Jacket Plugs 20 2 0 14 Cylinder Head Bolts M6 12 1 2 104 in Ib S Engine Hook Bolts 20 2 0 14 Camshaft Position Sensor Bolt 9 8 1 0 87 in lb Exhaust Side Camshaft Chain Guide Bolts 25 2 5 18 Upper Exhaust Side Camshaft Chain Guide Bolts 12 1 2 104 in
124. RICATION SYSTEM Pan Oil Pan Removal e Remove Engine Oil drain see Periodic Maintenance chapter Engine see Engine Removal Installation chapter e urn the engine to the side e Unscrew the dipstick tube bolts A and pull out the dip stick tube B e Unscrew the oil pan bolts A and remove the oil pan B Oil Pan Installation e Tighten the oil pan bolts following the tightening sequence 1 17 Torque Pan Bolts 7 8 N m 0 80 kgf m 69 in Ib e Apply grease to the O ring A on the dipstick tube B e Apply a non permanent locking agent to the dipstick tube bolts e Tighten all the dipstick tube bolts temporary OFirst tighten the oil pan side bolt Next tighten the cylin der head side bolts Torque Dipstick Tube Bolts 7 8 0 80 kgf m 69 in Ib ENGINE LUBRICATION SYSTEM 4 17 Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve Oil Pump Sprocket Removal e Drain Engine Oil see Periodic Maintenance chapter e Remove Engine see Engine Removal Installation chapter Oil Pan see Oil Pan Removal Crankshaft Sensor Cover Bolts A Crankshaft Sensor Cover B e Unscrew the oil pump chain guide bolt A e Unscrew the spring plate bolt A and remove the spring plate B spring C and the oil pump chain guide D e Unscrew the oil pump sprocket bolt E e Pull out the oil pump sprocket F together with the oil pump sprocket chain G Oil Pump Sprocket Installation e En
125. Remove the seat see Hull Engine Hood chapter e Remove the oil filler cap A and the dipstick B CAUTION Be careful not to allow any dirt or foreign materials to enter the engine e Drain the oil thorough from the dipstick tube A using a commercially available vacuum pump B WARNING Do not discard the engine oil as engine oil is toxic substance and will pollute the environment Contact your local authority for approved disposal methods e Pour in the specified type and amount of oil through the oil filler opening A Engine Oil Grade API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Amount 4 01 4 2 US qt with or without the filter 5 0 L 5 3 US qt when engine is completely dry 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures ODepending on the atmospheric temperature of your riding area the engine oil viscosity should be changed accord ing to the chart shown SAE 20W 40 SAE 10W 50 a N SAE 10W 40 __ SAE 10W 30 gt sae gt 6509011851 e Install the filler Torque Filler Cap 1 0 0 10 kgf m 8 7 in Ib e Check the oil level see Engine Lubrication System chap ter Oil Filter Replace e Remove Seat see Hull Engine Hood chapter e Drain the engine oil see Engine Oil Change e Place a reg or cloth under the oil filter to receive the re maining oil e Remov
126. Switch Engine Stop Switch Inlet Air Temperature Sensor Ground for Sensors Ignition Switch Steering Position Sensor Unused Power Supply to Sensors Cam Sensor Signal Cam Sensor Signal Crankshaft Sensor Unused Fuel Pump Relay ISC Idle Speed Controller ISC Idle Speed Controller ISC Idle Speed Controller ISC Idle Speed Controller Ignition Coil 1 4 Unused gt gt gt 46160188481 C Ground for External Diagnosis System Ground for Control System External Diagnosis System Signal Diagnosis Signal Start Button Vehicle down Sensor Power Supply to ECU from Battery Unused Ground for Control System Inlet Air Pressure Sensor Throttle Sensor Water Temperature Sensor External Diagnosis System Signal Oil Temperature Sensor Injector 2 Injector 3 Injector 4 Ground for Power System Ground for Power System Injector 1 Ignition Coil 222 23 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electr
127. U ECU Installation ECU Power Supply Inspection DFI Power Source Main Fuse Inspection Relay Assembly Removal Relay Assembly Inspection 3 43 3 43 3 44 3 44 3 44 3 45 3 47 3 47 3 47 3 48 3 48 3 49 3 49 3 50 3 51 3 53 3 53 3 53 3 55 3 56 3 57 3 57 3 57 3 58 3 59 3 60 3 60 3 60 3 60 3 63 3 63 3 63 3 63 3 2 FUEL SYSTEM Throttle Lever Cable and 3 65 ISC Resistance Inspection 3 74 Free Play Inspection 3 65 Inlet Manifold 3 75 Throttle Cable Adjustment 3 65 Inlet Manifold Removal 3 75 Throttle Case Removal Disas Inlet Manifold Installation 3 76 3 65 Fuel feted 3 78 Throttle Case Assembly Installa Fuel Pressure Inspection 3 78 3 66 Fuel Flow Rate Inspection 3 79 Throttle Cable Removal 3 67 Fuel Vent Check Valve 3 81 Throttle Cable Installation 3 68 Fuel Vent Check Valve Mounting 3 81 Throttle Case and Cable Fuel Vent Check Valve Inspection 3 81 3 69 UCU RING TEIL T 3 82 Throttle Cable Inspection 3 69 Fuel Filter 3 82 ALFI 3
128. Unscrew the lock assembly nut A and remove the lock assembly B 13 8 HULL ENGINE HOOD Fittings e Drill out the rivets A with a drill bit B of the correct size and remove the front duct cover C Rivet Removal Drill Bit Size 5 0 mm 0 2 in NOTE OStop drilling when the rivet head starts to turn with drill bit OTap the rivet out with a suitable punch and hammer Front Storage Compartment Cover Assembly e Secure the front duct cover to the front duct A with the rivets using a riveter B e Be sure that the trim seals A are in position e the lock assembly nut Torque Lock Assembly Nut 4 9 N m 0 50 kgf m 43 in Ib e Apply a non permanent locking agent to the following bolts Air Duct Bolts Hinge Bolts Damper Bolts Fittings Mirror Removal e Open the front storage compartment cover e Unscrew the nuts A and washers B and remove the mirrors C both sides Mirror Installation e Be sure that the washer A are in position Mirror Stay Removal e o remove the right mirror stay A remove the bolts B NOTE OThe plate C on the inside of the hull will drop down when the last bolt is removed e Remove the right mirror see Mirror Removal e o remove the left mirror stay perform the next proce dures OLoosen the clamp A and disconnect the flushing hose B e Remove the flushing cap e Pull up the flushing fitting A with the damper
129. W Terminal Meter gt BK Terminal JN18003B32 OTurn the ignition switch ON OCenter the handlebar in the straight ahead position OMeasure the input voltage Steering Position Sensor Input Voltage Standard Battery Voltage OTurn the ignition switch OFF If the reading is good inspect steering position sensor output voltage If the reading is out of the standard check the following Battery Voltage 20 A Main Fuse Power Source Wiring see Steering Position Sensor Cir cuit 14 52 ELECTRICAL SYSTEM Kawasaki Smart Steering System Steering Position Sensor Output Voltage Inspection e Measure the output voltage from the steering position sensor NOTE OBe sure the battery is fully charged OConnect a digital voltmeter A to the lead connector B of the steering position sensor using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Connections to Steering Position Sensor Connector Meter Y BK Terminal Meter gt Terminal OTurn the ignition switch ON OTurn the handlebar fully left or right OMeasure the output voltage Steering Position Sensor Output Voltage Standard approx 0 V NOTE OWhen the handlebar is centered in straight ahead posi tion the output voltage standard value is battery voltage OTurn the ignition switch OFF x reading is out of the standard suspect the following Damaged Steering Position Sensor Open Sensor Circuit the readin
130. act area Be sure to maintain proper alignment and use smooth movements when installing Ball Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease to the lip of seal before installing the seal 68020168 5 08020128 5 68020198 5 6802046851 Before Servicing Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft
131. age at the sensor connector A e Measure the output voltage at the sensor in the same way as input voltage inspection Note the following B Inlet Air Pressure Sensor Special Tool Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connections to Sensor Meter gt G R lead C Meter BK W lead D Output Voltage at Sensor Connector Usable Range 3 75 4 25 V DC at the standard atmospheric pressure 101 32 kPa or 76 cmHg absolute the output voltage is normal check the wiring for conti nuity see next diagram x the output voltage is out of the usable range replace the sensor 46168029851 e Turn the ignition switch OFF e Remove the sensor harness adapter Output Voltage Performance at Input Voltage 4 75 5 25 V P Vacuum Pressure Vo Output Voltage 0 46 66 101 32 P KPa abs 4616031851 JCi6046BW2 C 1 ECU 3 Joint Connector H 2 Joint Connector E 4 Inlet Air Pressure Sensor 3 36 FUEL SYSTEM Inlet Air Temperature Sensor Service Code Character 13 Alrt Inlet Air Temperature Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the air filter see Air Filter Removal e Disconnect the connector A from the inlet air tempera ture sensor e Remove the inlet air temperature sensor B and washer e Install the inlet air temperature sensor and
132. agneto cover Run the magneto leads along the hollow of the magneto cover Crankcase 10 Coupling 11 Output Cover 12 Run the magneto leads between the magneto cover and output cover Do not pinch the leads gt 16 20 APPENDIX Cable Wire and Hose Routing MAIN HARNESS ROUTING Cable Wire and Hose Routing gt Main Harness Rivet Washer oee wire routing at bow See wire routing at stern Clamp Speed Sensor Leads Water Box Muffler Strap Water Box Muffler APPENDIX 16 21 16 22 APPENDIX Cable Wire and Hose Routing WIRE ROUTING AT BOW See X 98 _ 2 N QJ gt 22777 Viewed from Port Side JB09137BW5 C Cable Wire Hose Routing Crossmember Steering Position Sensor Leads Holder and Clamp Fuel Vent Hose Throttle Cable Band Ignition Switch Lead Ignition Switch Lead Connector Black Steering Position Sensor Lead Connector White Fuel Level Sensor Lead Connector Black Main Harness Fuel Pump Fuel Pump Lead Connector White Steering Cable Fuel Filter Vehicle down Sensor Ignition Coil Lead Connectors Gray Vehicle down Sensor Lead Connector White Fuel Tank Bypass Outlet Hose 2 3 Ignition Coils 1
133. ain Removal raro na ai n Rr e Rr rei i c 4 20 Oil Pressure nennen nens se nsns se rsen sans nnns 4 21 Oil Pressure 4 21 OI PRESS USS WGI ________ _ __ 4 23 Oil Pressure Switch 4 23 Oil Pressure Switch Installation 4 23 4 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 4 3 Exploded View BesherPiteBots 99 Gib 2 foi Fierca 410 5 Breather Case Mounting Botts 78 oso 6 Breather Pipe Bots _ ss rinb Oil Cooter Assembly Bots _____ 78 oso 9 foi Pressure swin 15 18 M s Oi Passage Bot 78 58 8 18 19 EO 12 101 f m 20 s 113 78 Gib S 14 Dipstick Tube Bots 78 os enb LS _ 15 Ol Pump s o 16 O1 Pump Cover Bots 78 os Gib 17 Jol Pressue 38 i 118 78 99 Gb 719 Chain Guide Spring Plate Bot 78 oso GoloiPumBoyPug 0 9 i 21 O1 Pump Body Bots 78 os Gib 222 Screen Bots 78 99 EO Apply engine G Apply grease L Apply a non permanent locking agent M
134. al lip D e Install the circlip E e Install the bushing F into the pump case OFill with high grade water resistance grease G e nstall a new bearing into the pump case A as far as it will go Special Tool Bearing Driver Set 57001 1129 B e Visually inspect the pump shaft O rings A and replace if necessary e Install the O ring over the pump shaft B OGrease the O ring with high grade water resistance greace JK04062B31 e Apply molybdenum disulfide greace A to the thread of the pump shaft e Push the pump shaft B into the pump case JK04063B31 11 14 PUMP AND IMPELLER Pump and Impeller JT1500 A4 2 e Screw on the impeller and torque Special Tools Impeller Holder 57001 1393 Impeller Wrench 57001 1228 Torque Impeller 98 10 kgf m 72 ft Ib e Visually inspect impeller seal A and replace it if neces sary e Install the seal on the impeller JK04052B31 e Be sure the O rings A are in place on the pump cap B and plug C OApply high grade water resistance grease to the O rings JK04048B31 e Install the following Pump Cap Pump Cap Plug Pump Outlet Steering Nozzle OApply a non permanent locking agent to the thread of the following Pump Cap Bolts Pump Outlet Mounting Bolts Steering Nozzle Pivot Bolts Torque Pump Cap Plug 3 9 N m 0 40 kgf m 35 in Ib Pump Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib Pump Outlet Mounting Bolts 19 N m 1 9 kgf
135. all Grease Seals A One Bearing B Two Large Grease Seals C Front 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 to the bearing inner sur face and grease seal lips 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 Bolts 22 N m 2 2 kgf m 16 16 Make sure the clearance A between the engine coupling and the drive shaft coupling is 3 5 mm 0 12 0 20 DRIVE SYSTEM 10 7 S a 5 Q L5 Es 10 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 x If any measurement exceeds the service limit replace the shaft Drive Shaft Runout Standard Less than 0 1 mm 0 00
136. als have an oil groove respectively 8 26 and Connecting Rods Crankshaft Side Clearance e Insert a thickness gauge A between the thrust washer B and the crank web C at the No 3 main journal to determine clearance xIf the clearance exceeds the service limit replace the thrust washer as a set and check the width of the crank shaft 3 main journal Crankshaft Side Clearance Standard 0 05 0 24 mm 0 0020 0 0094 in Service Limit 0 44 mm 0 017 in e Measure the crankshaft 3 main journal width x If the measurement exceeds the standard replace the crankshaft B Crankshaft 3 Main Journal Width Standard 27 45 27 55 mm 1 0807 1 0846 in JH11066B31 Crankshaft Runout e Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 07 mm 0 0028 in JHi11000BWi C COOLING AND BILGE SYSTEMS 9 1 Cooling and Bilge Systems Table of Contents 91 210 VIEW P EEUU 9 2 BJS OV E 9 4 Breather REMOVA K 9 4 ____ ___ 9 4
137. anced 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 pinion gear does not function properly replace it Electric Starter Circuit 1 Main Fuse 20 A 2 Ignition Switch ELECTRICAL SYSTEM 14 31 JN06019BW2 C 14 32 ELECTRICAL SYSTEM Electric Starter System 3 Engine Starter Switch 4 Joint Connector R 5 Starter Motor 6 Battery 12 V 18 Ah 7 Starter Relay 8 Joint Connector S Ground ELECTRICAL SYSTEM 14 33 Charging System Magneto Output Voltage e Remove Seat see Hull Engine Hood chapter Air Filter with Duct see Fuel System chapter e Disconnect the 3 pin stator coil leads connector A e With the hand tester A check the magneto output in circuit according to the following table with the engine running at approximately 3 000 rpm WARNING To avoid electrical shock do not perform this test with the watercraft in the water CAUTION Do notrun the engine over 15 seconds without cool ing water Magneto Output Voltage Connections Meter Setting Standard Value Meter to Meter to 250 V AC White lead White lead 48 72 V the magneto output voltage is correct check the regu lator according to the regulator test procedure x the magneto output voltage is low check the stator coil resistance with a multimeter according to the following table Sta
138. and temporarily tighten the throttle sensor mounting screws 3 28 FUEL SYSTEM Throttle Sensor Service Code Character 11 tPS e Adjust the throttle sensor positioning as follows Olnstall the air filter temporarily OAfter warming up the engine check the idling speed Idle Speed Standard 1 300 100 r min rpm OStop the engine and turn the ignition switch OFF ODisconnect the throttle sensor connector and connect the throttle sensor setting adapter A between the harness connector and throttle sensor connector OConnect a digital meter to the sensor setting adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1521 Throttle Sensor Output Voltage Connections to Sensor Meter gt G W lead Meter BK W lead OStart the engine with idle speed OTurn A the throttle sensor and bring the sensor output voltage within the standard range Output Voltage at Sensor Standard 1 08 1 18 V DC at idle throttle opening OTighten the throttle sensor mounting screws Torque Throttle Sensor Mounting Screws 2 0 N m 0 20 18 in Ib ORecheck the sensor output voltage is within the standard range OStop the engine and turn the ignition switch OFF ORemove the setting adapter and reconnect the throttle sensor connector Input Voltage Inspection NOTE OBe sure the battery is fully charged Turn the ignition switch OFF Remove the ECU see ECU Removal Do not disconne
139. apter e Remove the camshaft chain A and the oil pump sprocket chain B LUBRICATION SYSTEM 4 21 Pressure Measurement Oil Pressure Measurement e Remove Seat see Hull Engine Hood chapter Inlet Manifold see Fuel System DFI chapter Oil Pressure Switch Connector A disconnect Oil Pressure Switch B e Install the oil pressure gauge adapter A to the switch hole Special Tool Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Install the oil pressure gauge to the adapter Special Tool Oil Pressure Gauge 10 kgf cm 57001 164 e Out off a rag or cloth e Install Inlet Manifold see Fuel System DFI chapter e aunch the watercraft e Start the engine for several minutes e Run the engine at the specified speed and read the oil pressure gauge x the oil pressure is significantly below the specification inspect the oil pump and relief valve x If the oil pump and relief valve are not at fault inspect the rest of the lubrication system Oil Pressure Standard 461 kPa 4 7 kgf cm 67 psi 3 000 r min rpm oil temperature 74 165 e Stop the engine e Raise the watercraft to the land e Remove Inlet Manifold Oil Pressure Gauge and Adapter 4 22 ENGINE LUBRICATION SYSTEM Pressure Measurement WARNING Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed e Install Oil Press
140. ard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the sensor input voltage OWait 15 seconds before using the starter again Input Voltage at Sensor Connector Standard 4 75 5 25 V DC e Turn the ignition switch OFF xf the reading is out of the standard range check the wiring see Wiring Diagram in this section x the reading is good the input voltage is normal Check the output voltage 4616027851 Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter G R lead terminal 33 Meter BK W lead terminal 8 Output Voltage at ECU 3618028851 C Usable Range 3 75 4 25 V DC at the standard atmospheric pressure 101 32 kPa 76 cmHg absolute NOTE OThe output voltage changes according to the local at mospheric pressure OThe vacuum sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute vacuum pressure the output voltage is within the usable range check the ECU for its ground power supply and wiring If the ground power supply and wiring are good replace the ECU FUEL SYSTEM DFI 3 35 Inlet Pressure Sensor Service Code Character 12 bOSt the output voltage is far out of the usable range check the output volt
141. aring inserts are seated in the saddles and the tangs in the bearing inserts are aligned with the notches in the saddles Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts Fit the thrust washers A to both sides of the upper crankcase 3 main bearing B Olnstall the thrust washer so that the oil grooves C face outward 8 19 Crankshaft and Connecting Rods e Install the crankshaft with the oil pump sprocket chain A and camshaft chain B hanging on them e Fit the oil seal A into the groove B of the crankcase e Assemble the crankcase see Crankcase Assembly Connecting Rod Removal e Split the crankcase see Crankcase Splitting e Remove the connecting rod nuts A e Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the connecting rods from the crankshaft Connecting Rod Installation WARNING Clean crankshaft bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the work ing area This includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point sol vents to clean them e After removing the connecting rods from the crankshaft clean them with high flash point
142. as possible NOTE OSince the trim and list of the watercraft will significantly affect the oil level be sure that the operator and or cargo are not aboard the watercraft when measuring the oil level make the fuel tank A full if it is not full as shown to keep watercraft level Fuel Tank Filler Neck B Fuel Full Level C Fuel D OThis measuring procedure with the watercraft afloat should be followed when the oil level is found low and to be added 4 10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter e Remove the seat see Hull Engine Hood chapter e Remove the dipstick A wipe it dry and insert it back to the dipstick tube B and then remove it again to check the oil level e Check the oil level using the hot level mark on the dipstick A High Level Line when Hot B Low Level Line when Hot C x oil level is too high drain the excess oil thoroughly from the dipstick tube A using a commercially available vacuum pump B x the oil level is too low add the oil to the high level line through the oil filler opening see Periodic Maintenance chapter Use the same type and make of oil that is al ready in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to
143. asaki Bond 56019 120 Seals of ECU Connectors JCi6061BW2 1 ECU 2 Joint Connector E 3 Joint Connector J 4 Oil Temperature Sensor Sensor Resistance Inspection e Remove the oil temperature sensor see Oil Temperature Sensor Removal Installation Refer to Electrical System chapter for oil temperature sen sor inspection FUEL SYSTEM DFI 3 59 Engine Overheating Service Code Character 76 OILH JT1500 A2 model e f the service code is displayed check the doubtful parts referring to the following table Inspect see 4 chapter 3 60 FUEL SYSTEM DFI ECU CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it ECU Removal Remove Seat see Hull Engine Hood chapter Bolts A Disconnect the ECU lead connector A Remove ECU B ECU Installation Connect the ECU connector and install it Apply a non permanent locking agent to the bolts and tighten them Torque ECU Mounting Bolts 8 8 N m 0 90 kgf m 78in Ib ECU Power Supply Inspection Visually inspect the terminals A of the ECU connectors If the connector is clogged with mud or dust blow it off with compressed air Replace the main harness if the terminals of the main har ness connector is cracked bent or otherwise damaged Replace the ECU if the terminals of the ECU connector is cracked bent or otherwise damaged e With the ECU connector
144. asket Black 92104 1062 8 8 ENGINE BOTTOM END Coupling Coupling Output Shaft Removal e Remove Engine see Engine Removal Installation chapter Crankshaft Sensor Cover see Electrical System chap ter e Holding the timing rotor unscrew the coupling Special Tools Fl ywheel amp Pulley Holder 57001 1605 A Holder Attachment 57001 1547 B Coupling Holder 2 57001 1423 C x If the coupling A and output shaft B removed together holding the coupling unscrew the output shaft with the output shaft wrench Collar D Special Tool Output Shaft Wrench Hex 36 57001 1550 e Remove Output Cover Bolts A Output Cover B e Remove Magneto Cover Bolts C Magneto Cover 8 9 Coupling e Using the rotor holder A remove the output shaft B Special Tool Rotor Holder 57001 1544 Coupling Output Shaft Installation e Apply molybdenum disulfide oil solution to the seating sur face of the output shaft e Using the rotor holder A install the output shaft B Special Tool Rotor Holder 57001 1544 Torque Output Shaft 245 25 0 kgf m 180 ft Ib e Apply silicone sealant A to the crankcase halves mating surfaces on the magneto cover e Be sure to install the dowel pins B e Apply grease to the O ring A and fit the O ring onto the groove of the magneto cover B e Install the magneto cover OBe sure to install the washer C and the sp
145. asure the bearing insert journal B clearance with a plastigage A NOTE the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 0010 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 030 0 054 mm 0 0012 0 0021 in Service Limit 0 08 mm 0 0032 in clearance is within the standard no bearing replace ment is required x If clearance is between 0 055 mm 0 022 in and the ser vice limit 0 08 mm 0 0032 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure x If clearance exceeds the service limit measure the diam eter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 40 984 41 000 mm 1 6135 1 6142 in Service Limit 40 96 mm 1 613 in If any journal has worn past the service limit replace the crankshaft with a new one x If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 40
146. at 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 A fire or explosion could result e Replace the fuel filler gasket A with a new one e Visually inspect the fuel filler cap gasket B for damage x If there is any doubt as to the condition of the fuel filler gasket replace the gasket with a new one e Tighten the fuel filler tube clamp screws Torque Fuel Filler Tube Clamp Screws 2 9 N m 0 30 26 1 1 ENGINE LUBRICATION SYSTEM 4 1 Engine Lubrication System Table of Contents 016 210 dci M 4 2 ERINE 2S ays 4 4 SDS CIC AU OL 4 6 opeclal ____________________ 4 7 Oll and OIN FIG det 4 8 OMS Vel INS PSCHON 4 8 4 CHANG E 4 10 OitFilter Replacement a e D e 4 10 C OOG ____ 4 11 REMOVA 4 11 6 Stall AO _ 4 11 4 12 Ol COOIE
147. at was adjusted e Readjust if necessary CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage Engine Mounting Bolts Inspection and Tightness e Check the tightness of the engine mounting bolts A there are loose bolts remove the bolts e Apply a non permanent locking agent to the engine mounting bolts and tighten them Torque Engine Mounting Bolts 36 3 7 kgf m 27 ft Ib Engine Bottom End Coupling Damper Inspection e Remove Seat see Hull Engine Hood chapter Engine see Engine Removal Installation chapter e Remove the coupling damper A and inspect it for wear B and deterioration If itis grooved or misshapen replace it with a new damper x If there is any doubt as to coupler condition replace it Cooling and Bilge Systems Cooling System Flushing To prevent sand or salt deposits from accumulating in the cooling system it must be flushed occasionally Flush the system according to the Periodic Maintenance Chart after each use in salt water or whenever there is reduced water flow from the bypass outlet on the right side of the hull 404002852 4809000851 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Obtain a standard garden hose A and a garden hose adapter B as shown Garden Hose Fitting of Adapt
148. ater and gasoline mixture will be forcibly ejected from the spark plug holes and could get into your eyes If you do get some in your eyes wash your eyes immediately with liberal amounts of clean fresh water Consult a physician as soon as possible 9 Remove the rear storage pocket and check the air filter A for water inside with its drain caps B 10 If you see water in the caps remove both caps and discharge the water Be sure to have a rag or cloth underneath for possible oily water And proceed to the next procedure No 11 NOTE you see water in the caps there is a great possibility that water has entered the inlet manifold If there is no water in the caps then proceed to No 12 11 Remove the drain plug A of the inlet manifold B and discharge water if any into a rag or cloth If you do not see water in the caps for the air filter mentioned above omit this procedure and proceed to the next procedure No 12 12 Spray the spark plugs clean and install them with their plug caps 9 14 COOLING BILGE SYSTEMS After Submerging 13 Reconnect the primary ignition coil lead connectors noting the 21 24 A and the 2 3 B coil connec tors The 1 4 coil connector has a red yellow and a green blue leads from the main harness The 2 3 coil connector has a red yellow and green black leads from the main harness NOTE OThe service codes COIL1 and COIL2 caused by this procedure are s
149. ating 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 Federal law prohibits the following acts or the causing thereof 1 the removal o
150. aust pipe toward the front C EXHAUST SYSTEM 5 5 Exhaust Manifold e out the exhaust manifold with the exhaust pipe from the hull e Disconnect the hose A from the exhaust pipe Exhaust Manifold Installation NOTE OUnhook the rubber strap and remove the front exhaust tube from the water box muffler for easier installation of the exhaust manifold and after connecting the water box muffler to the exhaust pipe hook the rubber strap and install the tube e Replace the exhaust manifold gasket A with a new one e Install the exhaust manifold and the washers B and col lars C as shown e Apply a non permanent locking agent to the exhaust man ifold mounting bolts JE07006B31 e Tighten the exhaust manifold mounting nuts and bolts fol lowing the specified tightening sequence Torque Exhaust Manifold Mounting Nuts 25 2 5 kgf m 18 ft Ib Exhaust Manifold Mounting Bolts 25 2 5 18 16 Apply a non permanent locking agent to the exhaust pipe mounting plate bolts and install the collars Tighten 9 07005851 Torque Exhaust Pipe Mounting Plate Bolts 30 3 0 kgf m 22 ft lb Connect the water box muffler to the exhaust pipe after binding the two rings with the paper tape see Exhaust Pipe Installation If the water temperature sensor is removed see water temperature sensor removal installation in Fuel System chapter Check the hose routing and clamp
151. awasaki Bond 56019 120 Seals of ECU Connectors the wiring is good check the sensor resistance Sensor Resistance Inspection e Remove the inlet air temperature sensor see Inlet Air Temperature Sensor Removal e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the table Inlet Air Temperature Sensor Resistance Standard 5 4 6 6 at 0 32 8017030182 2 26 2 86 at 20 C 68 0 29 0 39 at 80 176 F If the measurement is out of the range replace the sensor x If the measurement is within the specified replace the ECU 3 38 FUEL SYSTEM Inlet Air Temperature Sensor Service Code Character 13 Alrt JC16047BW2 C 1 ECU 2 Joint Connector E 3 Joint Connector H 4 Inlet Air Temperature Sensor FUEL SYSTEM 3 39 Water Temperature Sensor Service Code Character 14 AqUt Water Temperature Sensor Removal Installation CAUTION
152. ber fuel pump holder H JT1500 A2 model e Remove the front storage pocket see Hull Engine Hood chapter e Disconnect the fuel pump lead connector A e oosen the double spring clamps B with priers and pull out the main C and return D fuel hoses e Cut off the clamp E and pull out the fuel vent hose F e oosen the lower side clamp screw G on the rubber fuel pump holder H e Pull the fuel pump A and rubber holder B through the opening gained after removal of the front strage pocket e oose the upper side clamp screw C and remove the rubber holder from the fuel pump Fuel Pump Installation e Press down the rubber holder A onto the fuel pump B so the stepped part C of the holder completely contacts the flanged part D of the pump e Pressing down the rubber holder onto the fuel pump tighten the small diameter clamp E NOTE Olnstall the rubber holder onto the fuel pump so the rub ber holder top surface F must be below the top surface Gl of the fuel pump to prevent any water from collect ing on top of the pump e Install the O ring A to the space between fuel pump B and rubber holder C so it completely contacts the flanged part D of the pump e Insert the fuel pump with rubber holder and O ring into the tank so its fuel hose fittings face starboard side see Ca ble Wire and Hose Routing in Appendix chapter And press down the pump so the O ring A
153. ble Backfiring when deceleration Spark plug dirty broken or gap maladjusted Too low fuel pressure Fuel pump trouble Throttle sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Inlet air pressure sensor trouble Air suction valve trouble After fire Crankshaft sensor trouble Spark plug burned gap maladjusted Inlet air temperature sensor trouble Water temperature sensor trouble Inlet air pressure sensor trouble Fuel injector trouble Run on dieseling Ignition switch trouble Engine switch trouble Fuel injector trouble Loose terminal of battery lead ground lead Carbon accumulating on valve seating sur face Engine overheating Other IC igniter in ECU trouble Engine oil viscosity too high Air suction valve trouble Engine overheating Intermittent any DFI fault and its recovery Poor Running or No Power at High Speed Firing incorrect opark plug dirty broken or maladjusted Ignition coil shorted or not in good contact Ignition coil trouble Spark plug incorrect Spark plug cap trouble Spark plug cap shorted not in good contact Camshaft position trouble IC igniter in ECU trouble Crankshaft sensor trouble Fuel air mixture incorrect Air filter poorly sealed Air filter O ring damaged Inlet air duct loose Water or foreign matter in fuel 16 34 APPENDIX Troubleshooting Guide Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble
154. blocks C e Measure the difference in the heights of the arbor above the surface plate over a 100 mm 3 94 in distance on the arbor to determine the amount of connecting rod bend with the connecting rod held vertically and using a height gauge connecting rod bend exceeds the service limit con necting rod must be replaced Connecting Rod Bend Service Limit 0 2 100 mm 0 008 3 94 in ENGINE BOTTOM END 8 21 6105040451 6105040551 6105040831 8 22 Crankshaft and Connecting Rods Connecting Rod Twist e On surface plate set the big end arbor A on V block e Measure the difference in the heights of the arbor B above the surface plate over 100 mm 3 94 in dis tance on the arbor to determine the amount of connect ing rod twist with the connecting rod held horizontally and using a height gauge x If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance e Measure connecting rod big end side clearance A Olnsert a thickness gauge B between the big end and ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in x clearance exceeds the service limit replace the con necting rod with a new on
155. bly Installation e Insert the end of the return spring A in the throttle lever hole B and set the spring in the throttle case C as shown e Install the control lever to the case e Lubricate the throttle cable before assembly installation e Apply water resistant grease to the tips of the throttle ca ble 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 4605012851 Throttle Lever Cable and Case e Tighten Torque Throttle Case Mounting Screws 3 9 N m 0 40 kgf m 34 in Ib Swing the throttle lever so that the throttle valve is fully open Operation with 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 Remove the band A on the delivery pipe B e Disconnect the throttle cable from the body assy OSlide out the rubber OUnscrew the adjuster locknut A and slide the cable from the bracket OSlide the tip A of the cable lower end from the throttle pivot arm e Unscrew the mounting screws A and remove the han dlebar pad B Take out the inner pad FUEL SYSTEM DFI
156. brication NOTE OThe steering cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced 12 8 STEERING Handlebar Handlebar Removal e Unscrew the mounting screws A and remove the han dlebar pad B e Remove the inner pad A pushing B the buzzer C e Unscrew the bolts A and remove the pad holder B e out the throttle case clamp screws and remove the throttle case A e ake out the switch case clamp screws and remove the switch case B e Unhook the pipe C e Cut off the clamp D e Unscrew the handlebar clamp bolts A and remove the handlebar clamps B and handlebar C 0502 P Handlebar Handlebar Installation e Install the pad holder OApply a non permanent locking agent to the pad holder bolts e Install the handlebar on the holder of the steering neck OApply a non permanent locking agent to the handlebar clamp bolts OAlign the punch mark A on the left side of the handlebar with the parting line B OTighten the front and then rear handlebar clamp bolts to the specified torque Torque Handlebar Clamp Bolts 16 N m 1 6 12 ft Ib e Be sure the pipe A is installed on the top end of the fuel vent hose B e Install the throttle case and switch case Tighten the screws Torque Throttle Case Mounting Screws 3 9 N m 0 40 kgf m 2 9 1 Switch Case Mounting Screws 3 9 0 40 kgf m
157. ch was originally equipped with a sealed battery Be careful if a sealed battery is installed on watercraft which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection e Refer to Battery Charging Condition Inspection in the Pe riodic Maintenance chapter Refreshing Charge e Remove the battery A see Battery Removal e Refresh charge by following method according to the bat tery terminal voltage WARNING This battery is sealed type Never remove strip of cap B even at charging Never add water Charge with current and time as stated below GP080705381 Terminal Voltage 11 5 less than 12 6 V Standard Charge 1 8 5 10 h see following chart Quick Charge 9 0 1 0 CAUTION If possible do not quick charge If the quick charge ao lt is done due to unavoidable circumstances do stan dard charge later on 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V Terminal Voltage less than 11 5 V Charging Method 1 8 20h Battery NOTE OIncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than five minutes at the increased voltage then check if the battery is drawing current Olf the battery will accept current decrease the voltage and charge by the standard charging method
158. completely con tacts the top surface of the tank E e Tighten the large diameter clamp F securely e Install the following to the fuel pump Fuel Hoses Fuel Tank Vent Hose Fuel Pump Lead Connector OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram NOTE OThe main fuel hose is larger than the return fuel hose Power Source Voltage Inspection NOTE OBe sure the battery is fully charged FUEL SYSTEM DFI 3 85 JC08003B32 JC08004B32 3 86 FUEL SYSTEM Fuel Pump e Remove the front storage pocket see Hull Engine Hood chapter Connect the hand tester 25 V DC A to the fuel pump lead connector B using the needle adapter set C Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn the ignition switch ON and push the lanyard key un der the stop button Pushing the start button run the engine 5 6 seconds at idling to measure the power source voltage OWait 15 seconds before using the starter again Pump Power Source Voltage Connections Tester gt W R lead D Tester Battery Terminal Power Source Voltage at Pump Lead Connector Standard Battery Voltage x If the reading is good the power source voltage is normal Inspect the operating voltage x If there is no battery voltage check the following Main Fuse 20 A Wiring for Fuel Pump Power Source see Fuel Pump Circuit in this chapter
159. ct the ECU connector Connect a digital voltmeter to the connector using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Throttle Sensor Input Voltage Connections to ECU Meter R lead terminal 12 Meter gt BK W lead terminal 8 4616024851 FUEL SYSTEM DFI 3 29 Throttle Sensor Service Code Character 11 tPS e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the sensor input voltage OWait 15 seconds before using the starter again Input Voltage at ECU Standard 4 75 5 25 V DC e Turn the ignition switch OFF x the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted If the ground power supply and wiring are good replace the ECU the input voltage is within the standard range check the input voltage at the throttle sensor connector e Remove the air filter temporarily see Air Filter Removal e Disconnect the throttle sensor connector and connect the setting adapter A between the harness connector and throttle sensor connector e Connect a digital meter to the setting adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1521 Throttle Sensor Input Voltage Connections to Sensor Meter lead Meter gt BK W lead e Install the air filter e Turn the
160. ctor voltage Injector Resistance Inspection e Remove the delivery pipe assembly e Disconnect the connector from the injector A e Measure the injector resistance with the hand tester B Special Tool Hand Tester 57001 1394 Injector Resistance Standard about 11 7 12 3 20 C 68 F the reading is out of the range perform the Injector Unit Test If the reading is normal perform the Injector Unit Test for confirmation Injector Unit Test Use two leads A and the same test light set as in Injector Signal Test Rating of Bulb C 12 V 3 3 4 W 12 V Battery D CAUTION Be sure to connect the bulb in series The bulb works a current limiter to protect the solenoid in the injector from excessive current 6517024451 e Connect the test light to the injector as shown e Open and connect F the end of the lead to the battery terminal repeatedly The injector should click If the injector does not click replace the injector 3 50 FUEL SYSTEM Fuel Injectors Service Code Character 41 42 43 44 InJ1 112 1143 1134 Injector Voltage Inspection e Turn the ignition switch OFF e Connect a digital voltmeter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Injector Power Source Voltage Connector to Injector 1 2 3 4 Meter gt R Y lead Meter Battery Terminal
161. ctors Camshaft Position Sensor Connector E Crankshaft Sensor Connector F e Disconnect Throttle Cable Lower End see Throttle Cable Removal Throttle Sensor Connector G on Throttle Body Assy ISC Idle Speed Controller Connector H on Throttle Body Assy Inlet Air Pressure Sensor Connector on Inlet Manifold Inlet Air Temperature Sensor Connector J on Inlet Man ifold LL Lm oT 9 QO cis LITE T m9 th 40 2 Ga 72 lt lt bart Y lt 4 T i IL 4442 pum a 2 ZZ JCi0015BW2 C B 3 76 FUEL SYSTEM Inlet Manifold e Remove the inlet manifold A with the throttle body assy B e Remove the throttle body assy from the inlet manifold see Throttle Body Assy Removal e Unscrew the inlet manifold plate bolts A and remove the plate B and gasket C e Remove Inlet Air Temperature Sensor D D Inlet Manifold Drain Plug E MES 5 Inlet Air Pressure Sensor Bolts i 1 Inlet Air Pressure Sensor G 4610016851 Inlet Manifold Installation e Replace the inlet manifold plate gasket with a new one e Tighten Torque Inlet Manifold Plate Bolts 7 8 N m 0 80 kgf m 69 in Ib Inlet Manifold Drain Plug 20 N m 2 0 kgf m 14 ft Ib Inlet Air Temperature Sensor 20 N m 2 0 14 ft Ib e Apply silicone oil to the O ring A on t
162. e 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 Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled maintenance Use proper tools and genuine Kawasaki JET SKI watercraft parts Special tools gauges and testers that are necessary when servicing Kawasaki JET SKI watercraft are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual care fully Don t take shortcuts Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive
163. e 11 chapter Clean see 4 chapter Clean see 6 chapter 3 56 FUEL SYSTEM DFI Low Engine Oil Pressure Service Code Character 72 OILP e f the service code is displayed check the doubtful parts referring to the following table Cil leak Inspect see 4 chapter Engine oil level too low Inspect see 4 chapter Engine oil viscosity too low Inspect see 4 chapter Oil filter clogged Clean see 4 chapter Oil pressure switch damaged Inspect see 3 and 14 chapters Oil cooler clogged Inspect see 4 chapter Camshaft bearing worn Inspect see 6 chapter Crankshaft bearing worn Inspect see 8 chapter Change see 4 chapter Change see 4 chapter Clean see 4 chapter Change see 4 chapter FUEL SYSTEM 3 57 Temperature Sensor Service Code Character 73 OILC 73 OILt Service Code Character JT1500 A1 73 OILC JT1500 A2 73 OILt Oil Temperature Sensor Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Engine see Engine Removal Installation chapter Temperature Sensor A e Fill the hollow of the oil pan A with the specified silicone grease B as shown before installing the oil temperature sensor C D 5 mm 0 2 in Silicone Grease Kawasaki Bond 92137 1002 e Tighten Torque Temperature Sensor 15 1 5 kgf m 11 ft Ib Output Voltage Inspection NOTE OBe sure the batter
164. e R 1 Een BL B E N Cm D o 0 2 c oo A Color BK Black BL S BR Brown a 4 pert Green RSEN Sensor Idle Speed Temperature Pressure Switch 2 L8 Light Blue Blue LG Light Green Grange Engine Side Grange Pu Purple Rd mite _ y 98052 37186 W2R3718CW5 C 14 16 ELECTRICAL SYSTEM Specifications tem Standard Battery Type Electric Starter System Starter Motor Brush Length Commutator Diameter Charging System Regulator rectifier Output Voltage Alternator Output Voltage Stator Coil Resistance Ignition System Ignition Coil Primary Winding Resistance Secondary Winding Resistance Spark Plug Type Gap Crankshaft Sensor Resistance 12 V 18 Ah 6 5 mm 0 2559 27 1 063 12 0 4724 28 1 1024 Battery Voltage 14 15 V 48 72V 0 432 0 648 1 53 2 07 12 50 16 91 0 7 0 8 0 0276 0 0315 408 612 O ELECTRICAL SYSTEM 14 17 Special Tools and Sealant Hand Tester Harness Adapter 57001 1394 57001 1562 ST5713948T 5757156257 Peak Voltage Adapter Flywheel amp Pulley Holder 57001 1415 57001 1605 5757141557 5757160557 Needle Ada
165. e Spray the spark plugs with fogging oil and reinstall the spark plugs and caps see Electrical System in Periodic Maintenance chapter 15 4 Preparation for Storage e Reconnect the primary ignition coil lead connectors not ing the 221 24 A and the 2 3 B coil connectors The 1 4 coil connector has a red yellow and a green blue leads from the main harness The 2 3 coil connec tor has a red yellow and green black leads from the main harness NOTE OThe service codes COIL1 and COIL2 caused by this procedure are stored in the ECU necessary these service codes can be erased by using the Kawasaki Diagnostic System KDS Air Filter e Remove the air filter see Fuel DFI System chapter e Disassemble the air filter see Fuel DFI System chap ter e Wash and dry the flame arrester A e Assemble and install the air filter see Fuel DFI System chapter Battery Give 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 see Electrical System in Periodic Maintenance chapter 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 CAUTION Do not allow any soda solution to enter the battery Coat both battery terminals with grease Store the battery in a cool dry place
166. e and then check clearance again If clearance is too large after connecting rod re placement the crankshaft also must be replaced Connecting Rod Big End Bearing Insert Crankpin Wear e Measure the bearing insert crankpin B clearance with a plastigage A NOTE OTighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation ODo not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 041 0 071 mm 0 0016 0 00280 in Service Limit 0 11 mm 0 0043 in If clearance is within the standard no bearing replace ment is required clearance is between 0 072 mm 0 00284 and the service limit 0 11 mm 0 0043 in replace the bearing inserts A with inserts painted blue B Check insert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 38 984 39 000 mm 1 5348 1 5354 in Service Limit 38 97 mm 1 534 in 6105040731 6105041731 BOTTOM END 8 23 Crankshaft and Connecting Rods If any crankpin has worn past the service limit replace the crankshaft with a new one If the measured crankpin diameters are not less than the se
167. e coolant temperature in the engine e Turn the ignition switch OFF x If the output voltage is out of the specified check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU If the output voltage is far out of the specified e g when the wiring is open the voltage is about 5 V check the wiring see next diagram x If the wiring is good check the water temperature sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors Orn OTST C4 0 f 616048 2 C FUEL SYSTEM DFI 3 41 Water Temperature Sensor Service Code Character 14 AqUt 1 ECU 2 Joint Connector E 3 Water Temperature Sensor Sensor Resistance Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation e Refer to Electrical System chapter for water temperature sensor inspection 3 42 FUEL SYSTEM Crankshaft Sensor Service Code Character 21 CrAg Crankshaft Sensor Removal Installation e See the Ignition System section in Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft have no power source and when the en gine stops the crankshaft generates no signals e Crank the engine and measure
168. e damaged piston oil rings This may be indicated by white exhaust smoke incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder Gas leakage around cylinder head Replace damaged gasket and compression is check cylinder head warp lower than usable Bad condition of valve seating Repair if necessary Repair if necessary necessary range 9 incorrect clearance Adjust the valve clearance incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston Replace the piston and or the ring grooves piston rings Cylinder Head Removal e Remove Engine see Engine Removal Installation chapter Cylinder Head Cover see Cylinder Head Cover Re moval e Unscrew the crankshaft sensor cover bolts A and re move the crankshaft sensor cover B ODrain the engine oil by one liter e Turn the crankshaft clockwise and set the crankshaft at 1 4 piston Mark A for 1 4 pistons Timing Mark B Crankcase halves mating surface e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshafts see Camshaft Removal JF08004B31 6 22 Cylinder Head e Remove Engine Hook Bolts A Engine Hook B Cylinder Head Bolts C e Remove Upper Dipstick Tube Bolts
169. e from Fuel Pump Supply Pipe to Fuel Filter for Sharp Bend Kinking or Clogging Fuel Pump Operation see Fuel Pump Operation Inspec tion Fuel Pump Screen see Fuel Pump Screen Cleaning above inspection checks out good replace the fuel pump and measure the amount of fuel flow again e After inspection connect the fuel hose e Start the engine and check for fuel leakage OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram Fuel Vent Check Valve Fuel Vent Check Valve Mounting e Refer to Fuel Vent Check Valve Inspection in the Periodic Maintenance chapter Fuel Vent Check Valve Inspection e Refer to Fuel Vent Check Valve Inspection in the Periodic Maintenance chapter FUEL SYSTEM DFI 3 81 3 82 FUEL SYSTEM Fuel Filter Fuel Filter Removal NOTE OThe fuel filter is designed to be used throughout the watercraft s life without any maintenance if it is used under normal conditions WARNING Gasoline is extremely flammable and be ex plosive under certain conditions Pull the lanyard key off the stop button Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke e Remove Front Storage Pocket see Hull Engine Hood chapter Fuel Hoses A e Disconnect Spark Plug Caps Vehicle down Sensor Lead Connector Ignition Coil Primary Lead Connectors e Remove
170. e one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature Color Codes BK Black LG Light Green BL Blue O Orange BR Brown P Pink CH Chocolate PU Purple DG Dark Green R Red G Green W White GY Gray Y Yellow LB Light Blue ELECTRICAL SYSTEM 14 19 Precautions OElectrical Connectors Female Connectors A Male Connectors B 8 07000381 14 20 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read t
171. e output shaft and tighten it with 70 N m 7 0 kgf m 52 ft lb of torque ORemove the output shaft OCheck the tightening torque with rotor puller Special Tool Rotor Puller 57001 1623 Grip 57001 1591 x If the magneto flywheel is not pulled out with 20 N m 2 0 kgf m 52 ft lb of drawing torque it is installed correctly x If the magneto flywheel is pulled out with under 20 N m 2 0 kgf m 52 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and magneto flywheel tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque Tighten the output shaft while holding the magneto fly wheel steady with the rotor holder Special Tool Rotor Holder 57001 1544 Torque Output Shaft 245 N m 25 180 ft lb Install Magneto Cover see Coupling Output Shaft Installation ENGINE BOTTOM END 8 13 JH05012B31 8 14 BOTTOM END Stator Stator Removal e Remove Engine see Engine Removal Installation chapter Magneto Cover see Coupling Output Shaft Removal Grommet Cover Mounting Bolts A Grommet Cover B Stator Mounting Bolts C with Washers otator Assembly D Stator Installation e Apply water resistant grease to the outside of the grom met e Apply a non permanent locking agent to the grommet cover bolts e Tighten Torque Grommet Cover Bolts 9 8 1 0 kgf m 87 in Ib e Apply a non permanent locking agent
172. e speed the rub ber component relative to the Exhaust System may be damaged OExecute the auxiliary cooling securely in case that fre quent engine running is required e When checking the parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors have seals including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set Insert the needle adapter inside the seal until the needle adapter reaches the terminal Digital Meter A Special Tool Needle Adapter Set 57001 1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals 4802015851 4616075851 DFI Servicing Precautions OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of Connector e Always check battery condition before replacing the parts A fully charged battery is a must for conducting accurate tests of the system e Do not directly connect a 12 V battery to a fuel injector Insert a resistor 5 7 or a bulb 12 V 3 3 4 W in series between the battery and the injector FUEL SYSTEM DFI 3 21 3 22 FUEL SYSTEM DFI Self Diagnosis Self diagnosis Outline The self diagnosis system has two modes and can
173. e the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 e Replace the filter with a new one e Apply engine oil to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Filter 18 1 8 kgf m 13 ft Ib e Pour in the specified type and amount of oil see Engine Oil Change 6605040251 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection e Remove the air suction valve see Engine Top End chap ter e Visually inspect the reeds A for cracks folds warps heat damage or other damage If there is any doubt as to the condition of the reed replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage SEMIS x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e
174. ecording or otherwise without the prior written permission of Quality Assurance Department 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 2003 Kawasaki Heavy Industries Ltd Second Edition 1 Oct 15 2004 K LIST OF ABBREVIATIONS ampere s pound s after bottom dead center meter s alternating current minute s after top dead center newton s before bottom dead center pascal s bottom dead center horsepower before top dead center pound s per square inch degree s Celsius revolution direct current revolution s perminute farad s top dead center degree s Fahrenheit total indicator reading foot feet volt s gram s watt s hour s ohms liter s Read OWNER S MANUAL before oper
175. ector F 8 ECU 3 Connector C 9 Joint Connector P 4 Connector D 10 Fuel Pump 5 Joint Connector R 11 Joint Connector S 6 Main Fuse 20 A 3 88 FUEL SYSTEM Fuel Tank Fuel Tank Removal e Drain the fuel tank into a suitable container 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 Remove the engine see Engine Removal Installation chapter e Remove the fuel pump see Fuel Pump Removal e Disconnect the following from the main harness Vehicle down Sensor Lead Connector A Ignition Coil Lead Connectors B e Remove the bracket C out of the engine compartment e Remove the fuel filler tube A from the fuel tank B Jc Bid P e Unhook the fuel tank straps A e Remove the fuel level sensor B FUEL SYSTEM DFI 3 89 Fuel Tank e Remove the fuel tank A out of the hull as shown Fuel Tank Installation e Be sure the float A in place before putting the fuel tank into the hull e Route the following correctly see Cable Wire and Hose Routing section in Appendix chapter Fuel Hoses Fuel Tank Vent Hose Fuel Level Sensor Leads Other Wire and Harness OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram Fuel
176. eering holder e Apply a non permanent locking agent to the air intake duct mounting bolts A STEERING 12 15 Steering e Torque the steering shaft locknut A Torque Steering Shaft Locknut 49 59 5 0 6 0 kgf m 36 43 ft lb Turning the steering shaft fully in left and right direction check whether the steering position Sensor comes in con tact with the magnet Check the clearance A between the steering position sensor B and the magnet C with feeler gauge Steering Position Sensor Clearance Standard 0 5 1 5 mm 0 02 0 06 in x necessary adjust the clearance by turning the steering shaft nut 106004851 e Replace the A with a new 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 1407000851 e Band the cotter over the nut e Install the steering holder e Apply a non permanent locking agent to the steering holder mounting bolts Torque Steering Holder Mounting Bolts 20 2 0 kgf m 14 5 in Ib e Install the steering neck A so that its arrow mark points toward the front e Apply a non permanent locking agent to the steering neck mounting bolts Torque Steering Neck Mounting
177. elay Mounting Nuts 4 N m 0 40 kgf m 35 in Ib 4406013851 e Replace the gasket A with a new one e Be sure the dowel pins B are in position e Be sure the grommet C is installed on the relay case D e Be sure the battery cable is connected to the battery ter minal having red mark Torque Starter Relay Case Bolts 7 8 N m 0 80 kgf m 69 in Ib Starter Cable Mounting Nuts 4 0 40 kgf m 35 in Ib Starter Relay Inspection e Remove the starter relay see Starter Relay Removal e Set hand tester to R x 1 O range e Connect meter leads to starter relay as shown x If resistance is less than infinite the starter relay switch is not returning and must be replaced Special Tool Hand Tester 57001 1394 4406050351 Electric Starter System e Set ohmmeter to R x 1 O range e Connect meter leads to starter relay as shown e Activate starter relay switch by connecting a 12 V battery as shown the starter relay switch clicks and the ohmmeter indi cates zero resistance the starter relay switch is good xlf the meter indicates high or infinite resistance the starter relay switch is defective and must be replaced starter Motor Removal e Remove Seat see Hull Engine Hood chapter Inlet Manifold see Fuel System chapter e Side out the rubber caps A and remove the terminal nuts e Remove the mounting bolts A e Pull out the starter motor B Starter Motor Installation CAUTION
178. en lubricate the throttle cable Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x If idle speed increases check the throttle cable ad justment and the cable routing Throttle Case and Cable Lubrication e Refer to the Lubrication in the Periodic Maintenance chapter Throttle Cable Inspection Refer to the Lubrication in the Periodic Maintenance chapter FUEL SYSTEM DFI 3 69 3 70 FUEL SYSTEM Air Filter Air Filter Removal e Remove the seat see Hull Engine Hood chapter e Remove the rear storage pocket e Disconnect the following from the air filter A Air Suction Valve Hose B Oil Separator Tank Hose C e Remove the oil separator tank D see Engine Lubrication System chapter JC09010B32 e oosen the clamp A on the inlet air duct B e Remove the air filter mounting bolts C e Remove the air filter A out of the engine compartment Air Filter Installation e Tighten Torque Air Filter Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib FUEL SYSTEM DFI 3 71 Air Filter Air Filter Disassembly e Remove Air Filter see Air Filter Removal Air Filter Bolts A e Remove Bolts A Flame Arrester B Hose C Duct D Air Filter Bracket Mounting Bolts E Air Filter Bracket F e Remove the air screen A Air Filter Assembly e Visually inspect the seal A for damage I
179. eplace the ECU x If the output voltage is far out of the standard range e g when the wiring is open the reading is O V check the output voltage at the sensor connector FUEL SYSTEM 3 31 Throttle Sensor Service Code Character 11 tPS e Disconnect the throttle sensor connector and connect the setting adapter A between the harness connector and throttle sensor connector e Connect a digital meter to the setting adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1521 Throttle Sensor Output Voltage Connections to Sensor Meter G W lead Meter BK W lead e Measure the sensor output voltage with the idle speed Output Voltage at Sensor Standard 1 08 1 18 V DC at idle throttle opening CAUTION Never drop the throttle sensor especially on a hard surface A shock to the sensor can damage it e After throttle sensor voltage inspection remove the set ting adapter the reading is out of the standard range inspect the throttle sensor resistance the output voltage is normal check the wiring for conti nuity see next diagram Resistance Inspection e Turn the ignition switch OFF e Remove Air Filter see Air Filter Removal e Disconnect the throttle sensor connector and connect the setting adapter A to the throttle sensor B Special Tool Throttle Sensor Setting Adapter 57001 1521 ODo not connect the harness connector 3618026851 e Connect a digi
180. eplace the cables e Be certain that each cable moves freely in both directions e Disconnect the cable joints at each end of each cable OTake out the cable joint bolt or ball joint and disconnect the cable joint 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 A and forth B in each cable housings x If each cable does not move freely replace it Handlebar Pivot Lubrication e Check the bushings for damage and wear x the bushings are damaged worn replace them e Grease Bushings A 12000851 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Steering Shaft B Hull Engine Hood Drain Plug Inspection e Check the drain plugs A for cracks or damage and the drain plug mounting screws B are tightened securely e Check the seals C for damage necessary replace the drain plugs or seals Electrical System Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage e Disconnect the battery terminal leads see Battery Re moval in Electrical System chapter CAUTION Be sure to disconnect the negative terminal lead first GP08070381 e Measure the battery terminal voltage NOTE v OMeasure with a digital voltmeter A which can be read 2 decimal place voltage
181. er C Flushing Fitting of Adapter D Thread Rp 3 4 E NOTE OOptional part P No 92005 3746 is available as a gar den hose adapter e Open the front storage compartment cover e Remove the flushing cap A on the brim of the storage compartment e Screw a garden hose adapter A onto the flushing fitting B e Attach a garden hose C to a garden hose adapter and secure the hose clamp D 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 right side of the hull PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Leave the engine idle for several minutes with the water running e Turn off the water Leave the engine idling e Rev the engine a few times to clear the water out of the exhaust system 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 Switch off the engine remove the garden hose and the adapter e Install the flushing cap securely Bilge System Flushing To prevent clogging the bilge system should be flushed
182. er holder taking care not to damage it Remove the impeller from the pump shaft and then pull out the pump shaft Special Tools Impeller Holder 57001 1393 A Impeller Wrench 57001 1228 B JK04053B32 JT1500 A1 e Pull out the bushing e Remove the circlip e Remove the grease seals Special Tool Oil Seal amp Bearing Remover 57001 1058 A PUMP AND IMPELLER 11 11 Pump and Impeller e Remove the bearing by tapping evenly around the bearing inner race from the front end of the pump case Special Tool Bearing Driver Set 57001 1129 B JT1500 A2 e Press A the bussing B and the ball bearing C They come out of the pump case e Remove the circlip e Remove the grease seals Special Tool Oil Seal amp Bearing Remover 57001 1058 A JT1500 A1 A2 e Insert a metal rod A into the pump cap B from the rear end remove the bearing by tapping evenly around the bearing inner race from the rear end of the pump cap Pump Assembly e Before installing the cap bearing blow any dirt or foreign particles out of the pump cap A with compressed air e Install new bearing into the cap as far as it will go Special Tool Bearing Driver Set 57001 1129 B 11 12 PUMP AND IMPELLER Pump and Impeller e Before installing the pump bearing blow any dirt or for eign particles out of the pump case with compressed air e Before installing the pump bearing remove the filter cover
183. eriodic Maintenance chapter e Remove Engine see Engine Removal Installation chapter Cylinder Head see Cylinder Head Removal Dipstick Tube Bolts A Dipstick Tube B e Remove Breather Case Mounting Bolts A Clamp B Breather Case C with Hose Oil Hose D e Remove Camshaft Chain Guide Bolts A Camshaft Chain Guide B Cylinder C Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston CAUTION Do not reuse the snap rings as removal weakens and deforms them They fall out and score the cylin der wall e Remove the piston pins with a piston pin puller A Special Tool Piston Pin Puller Assembly 57001 910 e Remove the pistons ENGINE TOP END 6 31 11005851 6 32 Cylinder Pistons e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner 4211006851 Piston Cylinder Installation O NOTE Olf a new cylinder is used use new piston rings Olf new pistons and or a new cylinder are installed apply thin coat of molybdenum disulfide oil solution to the new pistons and cylinder bores Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil rin
184. f necessary replace it with a new one e Install the flame arrester B hose C and duct D as shown e Install the air screen A aligning the marks B e Apply a non permanent locking agent to the air filter bracket mounting bolts and tighten them Torque Air Filter Bracket Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib 3 72 FUEL SYSTEM Throttle Assy Idle Speed Inspection The normal idle speed is controlled by the ECU Elec tronic Control Unit Idle Speed Standard 1 300 100 r min rpm both in and out of water High Altitude Performance Adjustment High altitude adjustment is not required as the ECU con trols the air fuel mixture automatically Throttle Body Assy Removal e Remove Seat see Hull Engine Hood chapter Air Filter from Throttle Body Assy Throttle Cable A see Throttle Cable Removal Air Inlet Duct ISC Idle Speed Controller Connector B Throttle Sensor Connector C Throttle Body Assy Mounting Bolts D Throttle Body Assy E Gasket Throttle Body Assy Installation e Install a new gasket e Tighten Torque Throttle Body Assy Mounting Bolts 20 N m 2 0 kgf m 14 ft lb Install the throttle cable and adjust the free play Bind the harness A and connector in the band Route the harness and tighten the band correctly see Appendix chapter Throttle Body Assy Disassembly CAUTION Do not disassemble or adjust the air screw throt
185. for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head ELECTRICAL SYSTEM 14 43 14 44 ELECTRICAL SYSTEM Ignition System e Remove Front Storage Pocket see Hull Engine Hood chapter e Install the peak voltage adapter A into the hand tester B e Connect the peak voltage adapter A to the ignition coil primary lead connector D using the harness adapter C Hand Tester B Ignition Coil E Spark Plugs Special Tools Hand Tester 57001 1394 Harness Adapter 57001 1562 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Hand Tester Range x DC 1 000 V Primary Lead Connections Adapter Adapter 1 4 Ignition Coil R lt BK W Ground 42 3 Ignition Coil R lt BK W Ground JN08037B32 WARNING To avoid extremely high voltage shocks do touch the spark plugs or tester connections e the ignition switch on and push the lanyard key under the stop button e Pushing the starter button 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 Repeatthe measurements 5 or more times for one ignition coil Ignition Coil Primary Peak Voltage Standard 250 V or more Repeat the test for the other ignition coil x If the reading is less than the specified value see Igni tion System Troubleshooti
186. from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Seat see Hull Engine Hood chapter Cap Bolt A Washer B Spring C Rod D e Remove the mounting bolts E and take off the camshaft chain tensioner 6 10070151 Camshaft Chain Tensioner Installation e Apply grease to the O ring A Release the stopper and push the push rod into the tensioner body D fully Install the tensioner body so that the stopper faces down ward Apply a non permanent locking agent to the tensioner mounting bolts A Tighten the tensioner mounting bolts Torque Camshaft Chain Tensioner Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Install the spring rod and washer 0 Tighten the cap bolt Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 14 16 6 14 ENGINE END Camshaft Camshaft Chain Camshaft Removal e Remove Seat see Hull Engine Hood chapter opark Plugs see Periodic Maintenance chapter Cylinder Head Cover see Cylinder Head Cover Re moval Air Filter see Fuel System DFI chapter e Position the crankshaft at 1 4 piston as follows OUsing
187. ft Chain Guide Bolt Upper 25 N m 2 5 kgf m 18 ft Ib Install the camshafts see Camshaft Installation Cylinder Head Warp Remove the cylinder head see Cylinder Head Removal Clean the cylinder head Lay astraightedge across the lower surface of the cylinder head at several positions Measure the space between the straightedge A and the head with a thickness gauge B Cylinder Head Warp Standard Service Limit 0 05 0 002 If cylinder head is warped more than service limit replace it the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 ENGINE TOP END 6 23 4209001851 1 EE EE EE 3 0 4209002851 4209003851 6 24 ENGINE TOP END Valves Valve Clearance Check e Refer to Valve Clearance Inspection and Adjustment in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and shim OMark and record the valve lifter and shim locations so they Gt can be installed in their original positions anal 4210000851 e Using valve spring compressor assembly remove valve Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 222 57001 1202 B GE15
188. g Cable Ball Joint at Upper End disconnect e Unscrew the mounting bolts A on the inside of the hull and remove the shift lever holder B e Assemble the shift lever holder noting the following e Grease Shift Lever Shaft A Bushings B e Apply silicone sealant to the mating surface between the shift lever holder bottom and steering holder upper sur face e Apply a non permanent locking agent to the lever nut C and the shift lever holder mounting bolts E e Torque the shift lever locknut D Torque Shift Lever Locknut 20 N m 2 0 14 5 ft Ib e 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 Before connecting the shift and steering cables apply a water resistant grease to their joint balls JL07002B31 07802 P JL07003B31 1407000851 HULL ENGINE 13 1 Hull Engine Hood Table of Contents PEE 13 2 LI MEC 13 6 DEAL E UU UU UM E 13 6 Installallold erat 13 6 Front Storage Compartment Cover 2 13
189. g checks show armature to be good it may be defective in some manner not readily detectable within the hand tester If all other starter mo tor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection e Using the x 1 O hand tester range measure the resis tance as shown A Terminal and Positive Brush B Brush Plate and Negative Brush Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has open Replace the positive brush assembly and or the Fx negative brush assembly wins Brush Plate and Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown A Terminal Bolt and Brush Plate B Terminal Bolt and Yoke there is any reading the negative brush assembly and or positive brush assembly have a short Replace the negative and positive brush assemblies Electric Starter System Reduction Gear Removal Installation e Before removing the reduction gear remove the magneto flywheel 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 be rotated freely B e Rotate the pinion gear clockwise all the way The pinion gear will be adv
190. g is the standard but the Kawasaki Smart Steering system does not operate suspect the ECU and idle speed control in the throttle body JN18004B32 ELECTRICAL SYSTEM 14 53 Kawasaki Smart Steering System Steering Position Sensor Circuit EIE _ R BL R BL JNi18007BWN3 Joint Connector Q Multifunction Meter Steering Position Sensor 20 A Main Fuse Joint Connector R Battery Joint Connector S Joint Connector P Ignition Switch ECU Electronic Control Unit 14 54 ELECTRICAL SYSTEM Sensors Speed Sensor Removal Installation Unscrew the mounting bolts A and remove the speed sensor assembly B Unscrew the cap e Pull out the speed sensor connector and disconnect it e When installing the speed sensor assembly note the fol lowing OApply silicone sealant around the grommet A and lead wires Speed Sensor Inspection e Remove the speed sensor e Connect the battery and tester leads to the sensor as shown Hand Tester Battery JN10003B32 5 e Rotate the waterwheel by hand slowly e Measure the output voltage of the speed sensor G R BK W 0 battery voltage twice a rotation Rotate it slowly x If the voltage does not rise from zero to battery voltage twice a rotation replace the sensor e Measure the output voltage of the sensor at higher speeds ORotate the waterwheel in a fair s
191. g may also be cleaned using a high flash point solvent and a wire brush or other tool If the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug Use the standard spark plug or its equivalent e Measure the gaps D with a wire type thickness gauge the gap is incorrect carefully bend the side electrode with a tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in al DS INNER RSLS PED lt lt KEG 555 4 SV SH 0517005851 e Insert the spark plug vertically into the plug hole with spark plug installed in the plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1145 e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib Lubrication As in all marine craft adequate lubrication and corrosion protection is an absolute necessity to provide long reliable service Refer to the Periodic Maintenance Chart for the frequency of the following items PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures e Lubricate the following with grease OPull the throttle lever and hold it Throttle Cable End at Throttle Lever A Throttle Cable End A at Throttle Body the storage pocket see Hull Engine Hood chap ter Steering Cable Ball Joint A at Steering Shaft the storage pocket see Hull Engine Hood chap ter
192. g of the oil seal flywheel side oil seal C e Press in the oil seals until they are bottomed Olnstall the coupling oil seal D so that the manufacturer s marks E face coupling side Olnstall the flywheel side oil seal so that the dust seal side face out Oil Seal Inspection e Inspect the oil seal OReplace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged Magneto Cover Bearing Replacement CAUTION Do not remove the ball bearing unless it is neces sary Removal may damage it Remove Magneto Cover see Coupling Output Shaft Removal Using the oil seal and bearing remover A remove the ball bearing from the magneto cover B OWhen removing the ball bearing hold the magneto cover Special Tool Oil Seal and Bearing Remover 57001 1058 e Using a press and the bearing driver set A install the new bearing until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball Bearing Lubrication NOTE OSince the bearings are packed with grease and sealed on both sides lubrication is not required Ball Bearing Inspection NOTE Olt is not necessary to remove the bearings for inspec tion If the bearing is removed it will need to be re placed with a new one Spin A it by hand to check its condition x If it is noisy does not spin smoothly has any rough spots it must be replaced e
193. g steel rails one above the expander one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom 8 18013081 e Do not mix up the top and second ring e Install the top ring A so that the mark B faces up Olnstall the second ring C so that the RN mark D faces up OApply molybdenum disulfide oil solution to the piston rings 0 6060451 NOTE Olf a new piston is used use new piston ring e Install the piston with its marking hollow facing exhaust side e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston journals JF11010B81 OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall 6 33 Cylinder Pistons e he piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring A Top Ring B Second Ring C Oil Ring Steel Rails D Oil Ring Expander E Hollow Exhaust Side e
194. gage the oil pump chain A to the oil pump sprocket B e Install the sprocket with the chain to the oil pump shaft C e Apply a non permanent locking agent to the sprocket bolt e Tighten Torque Oil Pump Sprocket Bolt 15 1 5 kgf m 11 ft Ib Install the oil pump chain guide A and collar as shown 4 18 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket Oil Pump and Oil Pressure Relief Valve e Install the oil pump chain guide A collar B washer C and bolt D as shown e Install the chain guide spring A and the spring plate B Olnsert the tab C of the spring plate in the hole D of the crankcase Torque Chain Guide Spring Plate Bolt 7 8 N m 0 80 kgf m 69 in Ib Install Oil Pan see Oil Pan Installation Oil Pump Removal Drain Engine Oil see Periodic Maintenance chapter Remove Engine see Engine Removal Installation chapter Oil Pan see Oil Pan Removal Oil Pump Sprocket see Oil Pump Sprocket Removal Oil Pump Cover Bolts A Pull out the oil pump cover Pull out the oil pump shaft A with inner rotor Remove the outer rotor C Oil Pump Installation Apply molybdenum disulfide oil solution to the outer and the inner rotors out side Install the outer rotor A into the oil pump body Apply molybdenum disulfide oil solution to the shaft Assemble the pin inner rotor onto the oil pump shaft D OFit the pin into
195. ge Pocket Removal e Disconnect the steering cable upper end A P 13 12 HULL ENGINE HOOD Fittings e Pull out the holder e Unscrew the mounting bolts D and remove the cable bracket C with the cable B e remove the right side cover pull the holder A off the cable bracket e Unscrew the mounting nuts A and washers B and the left C and right D covers e Unscrew the crossmember bolts E and bracket F and remove the crossmember G JM07020B32 Crossmember Installation e Apply a non permanent locking agent to the crossmem ber bolts and torque them Torque Crossmember Bolts 7 8 N m 0 80 kgf m 69 in Ib e Be sure that the dampers A are in position e Apply a non permanent locking agent to the cable bracket mounting bolts and tighten them securely HULL ENGINE 13 13 Fittings Handrail Removal e Remove the seat see this chapter e Disconnect the bilge hoses from the breather fitting e Unscrew the mounting nut A and washer inside the hull and remove the lock assembly B e Holding the nuts and washers inside hull unscrew the mounting bolts C and remove the handrail D Hanarail Installation e When installing the lock assembly and handrail align the projection A and stud bolt B on the lock assembly with holes C on the hull Drain Plug Housing Removal e Unscrew the screws A and remove the drain plug hous ing B Drain Plug Hou
196. ge Replace if necessary OMake sure the above tubes are secured with the metal gear clamps away from any parts JT1500 A2 Double Spring Clamp A Hose B Hose Fitting C NOTE OCheck the fuel hoses for signs of wear deterioration damage or leakage Replace if necessary OMake sure the above hoses are secured with the double spring clamps away from any parts CAUTION Do not reuse the double spring clamps on the fuel line Reusing will cause fuel leakage Replace the double spring clamps with new ones e Replacement procedure for the double spring clamp is as follows ORemove the double spring clamp with pliers and discon nect the fuel hose Olnstall the fuel hose and insert the new double spring clamp A with the clamp stopper B OPull up the clamp stopper with pliers C NOTE OPosition the double spring clamp on the fuel hose cor rectly 4802003851 4802015851 4802016851 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Rubber Strap Inspection e Check the following rubber straps for any deterioration or damage Pull on squeeze the straps and look for cracks Battery Straps A Fuel Tank Straps Water Box Muffler Straps If a strap is damage in way replace it FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents Fuel System Diagram Exploded
197. h high flash point solvent because the new connecting rods bolts and nuts are treated with anti rust solution CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 6105060151 6105035851 61050421 Crankshaft and Connecting Rods e Apply small amount of molybdenum disulfide oil solution to the threads A and seating surfaces B of the connect ing rod nuts e First tighten the nuts to the specified torque See the table below e Next tighten the nuts by 120 more OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly OTighten the hexagon nut by 2 corners Connecting Torque Angle N m Rod I Sont kgf m ft lb Use the bolts and nuts 21 6 2 2 16 120 attached to new con rod Another new bolts and nuts Used Replace the bolts and 21 6 2 2 16 120 nuts with new ones CAUTION Be careful not to overtighten the nuts Connecting Rod Bend e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end caps e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V
198. he inlet air pressure sensor B NOTE ODo not apply silicone oil to the inside of inlet air pressure sensor connector e Install the inlet air pressure sensor on the inlet manifold Torque Inlet Air Pressure Sensor Bolts 7 8 N m 0 80 kgf m 69 in Ib Replace the inlet manifold gasket A with a new one and install it as shown Apply a non permanent locking agent to the inlet manifold mounting bolts and tighten them Torque Inlet Manifold Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Inlet Manifold Mounting Nuts 20 N m 2 0 kgf m 14 ft lb FUEL SYSTEM 3 77 Inlet Manifold e Replace the injector seals A with new ones e Apply grease to the inside and outside of seals e Tighten the delivery pipe mounting bolts Torque Delivery Pipe Mounting Bolts 7 8 0 80 69 e Route the cable wire and hose correctly see Cable Wire and Hose Routing in Appendix chapter OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram 4610017851 3 78 FUEL SYSTEM Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Be sure to place a piece of cloth under the fuel supply hose A of the fuel delivery pipe WARNING prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose
199. he spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume by 32 cutter 32 C Correct Width D Ground Volume E by 60 or 55 cutter 60 or 55 e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfte
200. he tester x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary JN04015B31 JN04014B31 ELECTRICAL SYSTEM 14 21 Battery Removal e Disconnect the battery cables A WARNING prevent possible personal injury and damage to electrical components always disconnect the grounded cable first e Unhook the battery straps B e Carefully lift the battery from the engine compartment Installation e Be sure the battery damper A is in position in the battery compartment e Hook the battery straps e Connect the battery cables positive first OAfter attaching both cables coat the terminals and cable ends with 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 Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for JT1500 A1 YTX20L BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec F z POPE 8 08070181 trolyte volume and
201. hten it Torque Camshaft Position Sensor Rotor Bolt 12 1 2 kgf m 104 in Ib e Remove Coupling Cover Bolts A Clamps B Coupling Cover C 6 16 ENGINE END Camshaft Camshaft Chain e Remove the spark plugs e Using the shaft wrench A turn the crankshaft counter clockwise B and set the crankshaft at 1 4 piston see Piston TDC Finding Special Tool Shaft Wrench 57001 1551 e Pull the tension side exhaust side of the chain taut to install the chain e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown OThe timing marks must be aligned with the cylinder head upper surface EX mark B 1 Pin C 2 Pin D IN mark E 31 Pin F e Install the camshaft cap and upper camshaft chain guide B While pushing the camshaft chain tighten all camshaft bolts and chain guide bolts Olnstall the longer white bolts to the 10 and 14 position shown by triangle marks OFirst tighten the all camshaft cap and chain guide bolts evenly to seat the camshaft in place then tighten all bolts following the specified tightening sequence Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 104 in Ib Upper Camshaft Chain Guide Bolts 12 1 2 kgf m 104 in Ib Tighten the camshaft chain tensioner see Camshaft Chain Tensioner installation OTurn the crankshaft counterclockwise two turns Install the cyl
202. ical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the engine ground OWhen charging remove the battery from the vehicle This is to prevent ECU damage by excessive voltage OWhenever the DFI electrical connections are to be discon nected first turn off the ignition switch Conversely make sure that all the electrical connections are firmly connected before starting the engine ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes Olf a transceiver is installed on the vehicle make sure that the operation of the system is not influenced by elec tric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen
203. iew 4 ay a FUEL SYSTEM 3 7 Exploded View 2 Fuel Filer Tube Clamp Screws 29 030 26ib 3 Fuel Level Sensor Clamp Screw 29 030 26inb 4 Fuel Fiter Mounting Bots 090 Meter Unit Buzzer Fuel Vent Check Valve Fuel Level Sensor Fuel Filter Fuel Pump JT1500 A1 Model JT1500 A2 Model Apply a non permanent locking agent Replacement Parts Apply silicone sealant Kawasaki Bond 56019 120 gt 3 8 FUEL SYSTEM Exploded View 4602027815 FUEL SYSTEM DFI 3 9 Exploded View Mounting Bolt 98 10 Sib Air Filter Bracket Mounting Bolts 69 in Ib 73 Throttle Cable Locknut Sob Throttle Case Mounting Screws 34inlb G Apply grease L Apply a non permanent locking agent 3 10 FUEL SYSTEM Specifications tem Standard Digital Fuel Injection System Idle Speed Throttle Assy Type Bore ECU Electronic Control Unit Make Type Operating range Fuel Pressure High Pressure Line Engine Idling Fuel Pump Type Discharge Throttle Sensor Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Output Voltage at ECU Resistance Water Temperature Sensor Resistance Output Voltage at ECU Vehicle down Sensor Detection Method
204. igh flash point solvent Use a brush to remove any contami nants trapped in the screens WARNING Clean fuel pump screen a well ventilated area and 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 Throttle Shaft Spring Inspection e Remove the seat see Hull Engine Hood chapter e Check the throttle shaft spring A by pulling the throttle lever x If the springs are damaged or weak replace the throttle body Engine Lubrication System Engine Oil Change e evel the watercraft port to starboard as well as fore to aft Level Ground A Side Bumper B Parallel C 4613002851 4805008851 4008003851 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures e n a well ventilated area start the engine while cooling the cooling system OOpen the front storage compartment cover ORemove the flushing cap see Cooling System Flushing 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 Warm up the engine and stop it CAUTION The engine must be running before the water is turned on and the water must be turned off before the engine is stopped Do not run the engine without cooling water flow for more than 15 seconds e
205. ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the sensor input voltage OWait 15 seconds before using the starter again Input Voltage at Sensor Standard 4 75 5 25 V DC e Turn the ignition switch OFF x the reading is out of the range check the wiring see wiring diagram in this section xlf the reading is good check the output voltage of the sensor 3 30 FUEL SYSTEM Throttle Sensor Service Code Character 11 tPS Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Voltmeter A Connector B Special Tool Needle Adapter Set 57001 1457 Throttle Sensor Output Voltage Connections to ECU Meter G W lead terminal 34 J616025B81 C Meter BK W lead terminal 8 e Start the engine e Check idle speed to ensure throttle opening is correct Idle Speed Standard 1 300 100 r min rpm e Measure the sensor output voltage with the idle speed Output Voltage at ECU Standard 1 08 1 18 V DC at idle throttle opening CAUTION Never drop the throttle sensor can especially on a hard surface A shock to the sensor can damage it x If the output voltage is within the standard range check the ECU for a good ground and power supply see ECU Power Supply Inspection If the ground and power sup ply are good r
206. in Japan
207. in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown in the figure If any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder A 10 mm 0 39 in B 60 mm 2 36 in Cylinder Inside Diameter Standard 82 994 83 006 mm 3 2675 3 2679 in Service Limit 83 10 mm 3 272 in Piston Wear e Measure the outside diameter A of each piston 18 mm 0 71 in B up from the bottom of the piston at a right angle to the direction of the piston pin x the measurement is less than the service limit replace the piston Piston Diameter Standard 82 919 82 934 mm 3 2645 3 2651 in Service Limit 82 77 mm 3 259 in Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 03 0 07 mm 0 0012 0 0028 in Second 0 02 0 06 mm 0 0008 0 0024 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in Piston Ring Groove Width e Measure the piston ring groove width OUse vernier caliper at several points around the piston
208. inder head cover see Cylinder Head Cover installation Piston TDC Finding This job can be done when the engine is on the hull and during camshaft installation Prepare a suitable wire for pointer Using the coupler cover bolt A hold the wire pointer TESTI 05 6 7 8 3 4 41 2 2909 4208001851 Camshaft Camshaft Chain e Remove 1 Spark Plug Front Side e Install the piston top detector A in the hole of the plug Special Tool TDC Measurement Tool 57001 1560 e Insert the gauge extender B into the detector Using the shaft wrench turn the crankshaft until the gauge extender reaches its highest point Special Tool Shaft Wrench 57001 1551 Remove the extender and install it to the gauge Install the top dead center finder A and the gauge with the extender Special Tool Top Dead Center Finder 57001 402 OSet the gauge at position that the needle on the gauge rotates a few turns Set the gauge to read 0 Turn the crankshaft counterclockwise until the needle will stop fluctuating then scribe a mark A on the coupling at the tip of the wire pointer e Turn the crankshaft clockwise until the needle will stop fluctuating then describe a mark A on the coupling at the tip of the wire pointer Turn the crankshaft so that the wire pointer is halfway between the two described marks OThe crankshaft is now at TDC for 1 and 4 Cylinders E
209. ing INSTALLING DIRECTION OF WATER HOSE JOINT gts oct X 18 Viewed from JB091318W5 C APPENDIX 16 11 Cable Wire and Hose Routing Exhaust Manifold Exhaust Pipe Water Hose Point Cooling Hose from the Output Cover 30 Water Hose Joint Cooling Hose from the Oil Cooler Upper Water Hose Joint Cooling Hose Fitting Left Water Box Muffler Cylinder Cooling Hose Fitting Left Water Box Muffler Drain Lower Water Hose Joint 45 Water Box Muffler Position the clamp so that their screw heads face forward To Tail Pipe White Marks F Mark R Mark Exhaust Tubes Right Water Box Muffler 16 12 APPENDIX Cable Wire and Hose Routing BILGE HOSE ROUTING ER Pas BOW Cable Wire Hose Routing Right Rear Duct Right Bilge Hose Left Bilge Hose Left Rear Duct Left Water Box Muffler Position the left rear duct inside the left bilge hose as shown Position the right rear duct under the right bilge hose as shown Right Water Box Muffler Right Bilge Breather Left Bilge Breather Left Bilge Filter Right Bilge Filter APPENDIX 16 13 16 14 APPENDIX Cable Wire and Hose Routing 18 e ee ae md LEE ____ m cE
210. ing is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery 8 09000981 NOTE ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 volts repeat the charging cycle and load test If still below 12 6 volts the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see this chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than gi
211. ion e Be sure the dampers A on the hull bottom and muffler body are in place EXHAUST SYSTEM 5 9 5 10 EXHAUST SYSTEM Water Box Muffler e Be sure the dampers A on the left side water box muffler B are in place e Make sure the two rings A are installed to the correct position x If the rings are damaged or warped replace the rings with new ones e Bind the two rings A by putting the paper tape B around the rings The paper tape can be burned out soon after firing e Install the joint tube to the exhaust pipe e Install the left water box muffler to the exhaust pipe e Tighten the clamp securing the front exhaust tube noting its screw position and check the hose routing and clamp screw position see Cable Wire and Hose Routing in Ap pendix chapter Water Box Muffler Inspection e Remove the left water box muffler e Empty water out of the water box e Check the inlet spigot for damage caused by excessive heat x If there is heat damage to the inlet spigot check the cool ing system for blockage see Cooling System Cleaning and Inspection and the fuel system for proper adjustment see Fuel System chapter 4 0 5003851 JE07007B31 6 1 Engine Top End Table of Contents Exploded View 6 2 Cylinder Head Removal 6 21 Specifications or ees 6 6 Cylinder Head Installation 6 22 Special Too
212. ire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oll 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following 05077 MES Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced ENGINE TOP END 6 27 8 15011881 6 28 ENGINE TOP END Valves e Measure the outside diameter of the seating surface with a vernier caliper x the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within t
213. iring diagram below Main Fuse 20 A see Electrical System chapter ECU Main Relay see DFI Power Source section Ignition Switch see Electrical System chapter Start Switch see Electrical System chapter FUEL SYSTEM DFI 3 61 4616039851 3 62 FUEL SYSTEM ECU ECU Power Source Circuit R W Y R R R R Y R Y R rar Ge T J 6 Main Relay in Relay assembly Joint Connector F Connector C Connector D Ignition Switch Start Switch Joint Connector R Main Fuse 20 A Battery ECU Joint Connector P Joint Connector S R PU Y R gt NO R G R Y BK R W 6 32 41 42 8 JC16055BW4 C FUEL SYSTEM 3 63 DFI Power Source Main Fuse Inspection e Refer to the Electrical System chapter for the ECU Fuse Inspection Relay Assembly Removal CAUTION Never drop the relay especially on a hard surface Such a shock to the relay can damage it e Remove Seats see Frame chapter Bolt A Relay Assembly B Connector C disconnect Band D Cut Relay Assembly Inspection e Remove the relay assembly e Connect the hand tester A and one 12 V battery B to the relay connector C as shown Special Tool Hand Tester 57001 1394 Main Relay Relay Coil Terminals 3 and 4 Relay Switch Terminals 1 and 2 Testing Relay Tester range 1 range Criteria When battery is connected 0 Q When bat
214. k idle speed with a tachometer in the multifunction meter OWith the engine idling open and close the throttle lever Idle Speed Standard 1 300 100 r min rpm both in and out of water x the idle speed is within the standard the ISC operates properly x If the idle speed is out of the specified range inspect the audible operation e Run the engine and then stop the engine e Certain buzzing and humming sounds will be emitted from the ISC A after the engine stop x If the ISC sounds inspect the ISC resistance the ISC does not sound replace the steeping motor FUEL SYSTEM DFI 3 73 4616076851 3 74 FUEL SYSTEM Throttle ISC Resistance Inspection e Remove Air Filter from the throttle body assy ISC Connector A disconnect e Measure the ISC resistance with the hand tester Special Tool Kawasaki Hand Tester 57001 1394 ISC A Rotor B ISC Resistance Connection 1 2 2 3 4 5 5 6 terminals Standard about 30 at 20 Connection 1 3 4 6 terminals Standard about 60 at 20 lf the reading is out of the specified value replace the steeping motor QD 4 5 6 4516058852 FUEL SYSTEM DFI 3 75 Inlet Manifold Inlet Manifold Removal e Remove Supply Fuel Hose A at Delivery Pipe Return Fuel Hose B at Delivery Pipe Delivery Pipe Mounting Bolts C Collars and Clamps e Remove the bands D and disconnect the following con ne
215. l find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly This model JT1500A is mounted with a four stroke engine When the JET SKI watercraft is submerged and swamped the four stroke engine needs special care and systematic procedure for re covery compared with the two stroke engine Therefore in this manual such procedures which are not shown in SMs for two stroke engines are explained thoroughly to cope with the cases Refer to the section After submerging in Chapter 9 Cooling and Bilge Systems for the summary and detailed procedures GENERAL INFORMATION 1 1 General Information Table of Contents Smart Learning Operation mode SLO JT1500 A2 model 1 2 T T m 1 3 82 8 eC 1 10 General SpeciicatlofiS cesses dun ________ _____ 1 11 Init e 1 13 1 2 GENERAL INFORMATION Smart Learning Operation mode SLO JT1500 A2 model This watercraft is equipped with the Smart Learning Operation mode SLO and normal operation mode Full Power Operation FPO The SLO mode reduces the maximum watercraft speed by ap proximately 30 percent for a use by unskilled operators To change the SLO mode to FPO mode and back again push the MODE button for 7 seconds or more Multifunction Meter
216. ller Bilge and Cooling System Hose Bypass Hose and Outlet Bumpers Engine Hood Latch Front Storage Compartment Cover and Brackets Handgrip The following parts cannot be removed from the hull and must be replaced Decals Labels Mats Registration Number if any If the new hull is to be painted do that first Then install removed parts in the reverse order of their removal Finally install the labels decals mats and the registration numbers 13 16 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 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 Mats Synthetic Rubber Engine Hood Gasket Adhesive Front Storage Compartment Cover P N 92104 3701 Trim Seal Detents Cyanoacrylate Cement Handlebar Grips CAUTION Be very careful that the part is positioned correctly when you apply the cement It may be impossible to reposition the part WARNING Do not get cyanoacrylate cement your eyes or on your skin 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 you
217. ls and Sealant 6 8 Cylinder Head Warp 6 23 Clean Air 5 6 11 WAIN CS M 6 24 Air Suction Valve Remowval 6 11 Valve Clearance Check 6 24 Air Suction Valve Installation 6 11 Valve 6 24 Air Suction Valve Check 6 11 Valve Installation 6 24 Clean Air System Hose Valve Guide Removal 6 24 WIS DECOM 6 11 Valve Guide Installation 6 25 Cylinder Head Cover 6 12 Valve to Guide Clearance Cylinder Head Cover Removal 6 12 Measurement Wobble Cylinder Head Cover Installation 6 12 6 25 Camshaft Chain Tensioner 6 13 Valve Seat Inspection 6 26 Camshaft Chain Tensioner Valve Seat Repair 6 26 Removal cei oc bci aee 6 13 Cylinder Pistons 6 31 Camshaft Chain Tensioner Cylinder 6 31 Installation 6 13 Piston Removal 6 31 Camshaft Camshaft Chain 6 14 Piston Cylinder Installation 6 32 Camshaft Removal 6 14 Cylinder 6 34 Camshaft Installation 6 15
218. lts A e Slide the pump B to the rear to disengage the drive shaft and remove it from the hull e o remove the pump bracket perform the following pro cedures OTake out the pump bracket mounting bolts A and washer in the hull JK04020831 PUMP AND IMPELLER 11 7 Pump and Impeller OTake out the pump bracket mounting bolts A the sealant at the indicated area A in the figure and remove the pump bracket B Pump Installation e Strip off all the old sealant around the pump intake e Liberally coat the outside edge of the pump bracket with silicon sealant A to form a seal between the bracket and the hull Sealant Kawasaki Bond Silicone Sealant 56019 120 4 D I 5 5 E amp 5 aW J 9 9 9 99 9 9 9 9 9 PRR KKK KRG TO zn 052525252 6252 004056944 CSS wey M 21876797999 60 0 9 OLX Beto X T 5062 4 04020182 Install the pump bracket A to the hull OApply a non permanent locking agent to the following bolts and torque them Torque Pump Bracket Mounting Bolts 2 19 1 9 14 ft Ib Pump Bracket Mounting Bolts 4 C 9 8 1 0 kgf m 87 in lb OAs for the pump bracket mounting bolts 2 in the hull the bolt heads should be wrapped in silicone sealant 11 8 PUMP AND IMPELLER Pump and Impeller mad ee
219. lug hole e Using the starter motor turn the engine with the throttle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 1 185 1 795 kPa 12 1 18 3 172 260 psi 0430 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs see Periodic Maintenance chap ter Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib e Reconnect the primary ignition coil lead connectors not ing the 1 4 A and the 2 3 B coil connectors the 1 4 coil connector has a red yellow and a green blue leads from the main harness The 2 3 coil connec tor has a red yellow and green black leads from the main harness NOTE OThe service codes COIL1 and COIL2 caused by this procedure are stored in the ECU necessary these service codes can be erased by using the Kawasaki Diagnostic System KDS JI06008BS1 6 21 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us able range Remedy Action Cylinder Carbon accumulation on piston and in Remove the carbon deposits compression is combustion chamber possibly due to and replace damaged parts if higher than usable damaged valve stem oil seal and or necessary rang
220. m 22 16 Water Pipe Joint F 30 078021 JE07007B31 4 07015851 5 8 EXHAUST SYSTEM Exhaust Pipe Exhaust Pipe Cleaning and Inspection e Remove the exhaust pipe parts e Clean the carbon deposits out of the exhaust passages with a blunt roundedged tool e Flush foreign matter out of the water passages with fresh water e Check the insides of the water passage for corrosion e Check the gasket surface for nicks or other damage x If there is excessive corrosion or if the gasket surfaces so badly damaged that they will not seal properly replace the part Water Muffler Water Box Muffler Removal e Remove Rear Storage Pocket Oil Separator Tank with Oil Separator Hoses see the Lubrication System chapter Air Filter see the Fuel System chapter e oosen Joint Tube Clamp Screw see Exhaust Manifold Re moval e Remove the front exhaust tube A by loosing the clamp screws B e Unhook the rubber strap C from the left water box muf fler e Remove Hoses A Exhaust Manifold B see Exhaust Manifold Removal e Remove the left water box muffler by pulling it to the rear NOTE OWhen removing the left water box muffler remove the water box muffler A from the deck with turning it with the welding spot B and rivets C OOnly left side water box muffler should be removed or inspected e Remove the joint tube from the exhaust pipe Water Box Muffler Installat
221. ms If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Memory of Service Code Character The service codes characters in the past are stored in the ECU However the characters cannot be displayed in the meter The past service codes can be confirmed by using the Kawasaki Diagnostic oystem see General Information chapter and they can be erased FUEL SYSTEM 3 25 Troubleshooting the System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Date problem occurred Environment when problem occurred Weather O fine cloudy rain snow O always O other hot warm O cold O very cold O always chronic O often O once frequency Altitude normal O high about 1 000 m or more Watercraft conditions when problem occurred Warning turn on immediately after ignition switch ON and turn off after 1 2 seconds LED light FI normal character FI O lights blink after ignition switch and stay DFI problem mark 1unlights LED light meter unit ECU or its wiring fault sometimes lights up probably wiring fault starter motor not rotating starter motor rotating but engine doesn t turn over starter motor and engine don t turn over no fuel flow n no fuel in tank
222. n OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width is too wide too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Exhaust 0 8 1 2 mm 0 03 0 047 in Inlet 0 5 1 0 mm 0 02 0 039 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Valve Seat Cutter Holder 25 57001 1208 B Valve Seat Cutter Holder Bar 57001 1128 C For Inlet Valve Seat Valve Seat Cutter 45 035 57001 1116 Valve Seat Cutter 32 035 57001 1121 Valve Seat Cutter 55 035 57001 1247 For Exhaust Valve Seat Valve Seat Cutter 45 030 57001 1187 Valve Seat Cutter 32 030 57001 1120 Valve Seat Cutter 60 030 57001 1123 If the manufacturer s instructions are not available use the following procedure Special Tools GE15011732 GE15070981 Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a w
223. n Water Filter Cover Removal Installation e oosen the clamps A and pull off the hoses B e Remove the filter cover mounting bolts C e Take out the filter cover D e Replace the gasket with a new one e Installation is the reverse order of removal e Apply a non permanent locking agent to the filter cover mounting bolts and torque them Torque Filter Cover Mounting Bolts 9 8 1 0 kgf m 87 in lb STEERING 12 1 Steering Table of Contents 12 2 12 4 12 5 Steering Cable AGIUSUN SNE En Le Ra E Or eet Cete 12 5 Steed CapleIREMOVAl 12 5 oteerng Gable Stala UON ___ ________ adito 12 7 oteernng Cable 12 7 oteerind 12 7 PUAN AN ge o 12 8 mizigielizierz anciano All NETT EO 12 8 Handlebar INSTA ANON aestus tc 12 9 ao Ac 12 11 REMOVA ict sss oe 12 11 SESS MII ib 12 14 Reverse S 12 17 12 17 Silt CADIC REMOVAL vse
224. n or less Service Limit TIR 0 1 mm 0 004 in Cam Wear Remove the camshaft see Camshaft Removal Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 36 143 36 257 mm 1 4229 1 4274 in Inlet 36 440 36 554 mm 1 4346 1 4391 in Service Limit Exhaust 36 04 mm 1 419 in Inlet 36 34 1 431 in 2080028 5 4203001851 GE11012231 Camshaft Camshaft Chain Camshaft Chain Removal e Split the crankcase see Engine Bottom End chapter e Remove the camshaft chain A from the crankshaft sprocket ENGINE TOP END 6 19 6 20 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e horoughly warm up the engine while checking that there is no compression leakage from around the spark plugs or the cylinder head gasket CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damaged will occur e Stop the engine e Remove the front storage pocket see Hull Engine Hood chapter e Disconnect both two connection on the ignition coil pri mary lead connectors A e Remove opark Plugs see Periodic Maintenance chapter e Attach the compression gauge A and adapter B firmly into the spark p
225. n the middle of the valve face the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment section of Periodic Maintenance chapter ENGINE TOP END 6 29 8 15012381 GE15012031 6 30 ENGINE TOP END Valves Valve Seat Repair START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Results 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seat Width Tool Vernier Caliper Purpose check seat width against spec Results 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase width of seat area beyond spec to increase O D 60 or 55 Grind Tool 60 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage Cylinder Pistons Cylinder Removal e Drain the engine oil see P
226. nd Bilge Systems chapter Check the coupling damper for wear damage see Cou pling Damper Inspection in Engine Bottom End chapter Install the inlet manifold see Fuel System chapter Apply a non permanent locking agent to the engine mounting bolts and tighten them Torque Engine Mounting Bolts 36 N m 3 7 kgf m 27 ft lb After installing the engine in the hull check the following Throttle Cable Fuel and Exhaust Leaks A WARNING Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas which can be lethal CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damage will occur 8 1 Engine Bottom End Table of Contents 8 2 8 4 Special Tools and usse re Fred Pb end vete a e De 8 6 Ec 8 8 COuplING OUIDUL Shalt REMOV al quu Dr casam 8 8 Coupling Output Shaft Installation 8 9 Coupling Damper INSPSCUON CRY 8 10 Output Cover Oil Seal 8 10 Oll Seal knots beide
227. nd remove the stor age case B e oosen the locknut A at the front end of the shift cable B STEERING 12 17 MOTHS PP 12 18 STEERING Reverse System e Pull the holder A off the cable bracket e Remove the right side cover see Hull Engine Hood chap ter e Unscrew the bolts A and remove the cable bracket NOTE OThe collors on the inside of the hull will drip down when the bolts are removed e Remove the ball joint A and cable bracket B from the shift cable C E avs e Cut off the band A holding the shift cable B and inlet cooling hose C for the oil cooler JL07004B31 e Cut off the band A holding the shift cable B Bow C Reverse System e Turn the water craft on its left side and remove the pump cover see Pump Impeller chapter CAUTION Never lay the watercraft on the right side Water in the exhaust system may drain back into the engine causing serious damage e oosen the locknut A at the rear end of the shift cable and remove the ball joint B from the reverse bucket C e Disconnect the shift cable from the fitting at the middle of the hull OUnscrew the large nut shift cable nut in the hull with a wrench OSpecial tool box wrench A is useful to remove the large nut shift cable nut Special Tool Box Wrench 57001 1451 e Pull the cable from the cable detente in the engine com partment e Slide off the snap ring A washer B
228. ne without cooling water supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damage will occur 4 14 ENGINE LUBRICATION SYSTEM Breather Case and Oil Separator Tank Breather Case Removal e Remove Seat see Hull Engine Hood chapter Exhaust Manifold see Exhaust System chapter Clamp A Breather Hose B Breather Case Mounting Bolts C e Pull the breather case D upward Breather Case Installation If the breather pipe A removed install the pipe as follow OApply grease to the O ring B Olnstall the O ring to the short length pipe side C of the breather pipe Olnstall the breather pipe so that the short length pipe side faces downward Torque Breather Pipe Bolts 8 8 0 90 kgf m 78 in Ib Apply silicone sealant to the inside of the rubber grommet D Sealant Kawasaki Bond Silicone Sealant 92104 0004 Tighten the breather case mounting bolts M6 x 55 Bolts E x 45 Bolt Torque Breather Case Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib Install the breather hose clamp pinch head as shown JDbi4000BWi Oil Separator Tank Removal Remove Seat see Hull Engine Hood chapter Breather Hose Clamps A slide out Breather Hoses B Mounting Screws Braket OBe careful not to drop the nuts C ENGINE LUBRICATION SYSTEM 4 15 Breather Case and Oil Separator Tank e Remove Breather Hose Clamp
229. necessary removal NOTE the oil is in the engine and the removed hose lies down the oil will flow out from hose end e Remove Starter Motor Cables A Cooling Hoses B e Disconnect Alternator Lead Connector A REMOVAL INSTALLATION 7 5 Engine Removal Installation e Remove Engine Mounting Bolts A e Slide the engine toward the front to disengage the cou pling A e Using the lifter A raise the front side of the engine a little and lift the engine B out off the hull C Engine Damper Removal e Remove Engine Damper Mounting Bolts A Engine Damper B Shim C 0 2 pieces Bow D e Record the number of shims of four positions so they can be put back in the same position CAUTION Install the shims to the same position Incorrect shims could cause drive shaft misalignment a 7 mi i 1 Y C i CIN A EX cae L5 H 4603009852 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Damper Installation e Install the shim s of the same number e Apply a non permanent locking agent to the engine damper mount bolts and tighten them Torque Engine Damper Mounting Bolts 16 1 6 kgf m 12 ft lb Engine Installation Be sure there are no foreign objects and parts inside of the hull Clean the bilge filter see Filter Cleaning and Inspection in Cooling a
230. nector A Ground Terminal BK W B Output Terminal BL W C Power Source Terminal R G D Vehicle down Sensor Removal CAUTION Never drop the down sensor especially on a hard surface Such a shock to the sensor can damage it Remove Seat see Hull Engine Hood chapter Front Storage Pocket see Hull Engine Hood chapter Bracket Bolts A and Washers Remove Vehicle down Sensor Connector A Screws B Vehicle down Sensor C Vehicle down Sensor Installation The UP mark A of the sensor should face upward A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the down sensor is held in place by the sensor brackets Tighten Torque Vehicle down Sensor Mounting Screws 1 5 0 15 kgf m 13 in Ib gc 70208 tif 4616034851 P FUEL SYSTEM 3 45 Vehicle down Sensor Service Code Character 31 dOS Vehicle down Sensor Inspection NOTE OBe sure the battery is fully charged Remove Fuel Tank see Fuel Tank Removal Connect a digital volt meter A to the connector of the vehicle down sensor lead with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Power Source Voltage Connections
231. ng table to determine whether igniter is good or no good Ignition System Crankshaft Sensor Peak Voltage Check NOTE OBe sure the battery is fully charged e Connect the peak voltage adapter A to the hand tester B Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B e Connect the adapter the crankshaft sensor lead connec tor C using the needle adapter set D Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Connections Adapter Adapter R Crankshaft Sensor G BL Hand Tester Range x DC 10 V e Turn the ignition switch on and push the lanyard key under the stop button e Pushing the starter button 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 2 5 V or more x If the reading is less than the specified value check the crankshaft sensor see Crankshaft Sensor Inspection Camshaft Position Sensor Peak Voltage Inspection e Remove Seat see Hull Engine Hood chapter e Set the digital meter B to the 10 V DC range e Connect the peak voltage adapter C to the digital meter Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B e Connect the peak voltage adapter to the camshaft sensor lead connector D using the needle adapter set
232. ngine Hood chapter Camshaft Position Sensor Lead Connector A discon nect e Set the hand tester B to the x 10 O range and connect it to the yellow and black leads in the connector Special Tool Hand Tester 57001 1394 x If there is more resistance than the specified value the sensor coil has an open lead and must be replaced Much less than this resistance means the sensor coil is shorted and must be replaced Camshaft Position Sensor Resistance 400 460 e Using the highest resistance range of the tester mea sure the resistance between the camshaft position sensor leads and chassis ground Any tester reading less than infinity indicates a short necessitating replacement of the camshaft position sen Sor Igniter Removal Installation e Refer to ECU Removal in the Fuel System DFI chapter Igniter Inspection OThe igniter is built in the ECU Electronic Control Unit 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 igniter in the ECU damage Ignition Coil Primary Peak Voltage Check NOTE OBe sure the battery is fully charged Remove Seat see Hull Engine Hood chapter Pull all the spark plug caps from the spark plugs Install the new spark plugs A into each plug caps and ground them onto the engine NOTE OMaintain the correct value of compression pressure
233. ngine Removal Installation chapter Crankshaft Sensor Cover Bolts A Crankshaft Cover B e Unscrew Rubber Grommet Holder Screws A Crankshaft Sensor Screws B e Push out the rubber grommet C with the Holder D e Remove the crankshaft sensor E Crankshaft Sensor Installation e Run the sensor lead through the cover hole e Install the crankshaft sensor OApply a non permanent locking agent to the sensor Screws Torque Crankshaft Sensor Screws 4 4 0 45 kgf m 39 Install the rubber grommet in the sensor cover hole OApply water resistant grease to the grommet outside OApply a non permanent locking agent to the grommet holder screws ORun the sensor lead C as shown Torque Rubber Grommet Holder Screws 4 4 N m 0 45 kgf m 39 in Ib ELECTRICAL SYSTEM 14 37 JNOSOSOBS1 14 38 ELECTRICAL SYSTEM Ignition System e Apply grease to the O ring and fit it in the groove of the sensor cover e Apply silicone sealant A to the crankcase halves mating surface on the right and left sides of the crankshaft sensor mount Sealant Kawasaki Bond Silicone Sealant 56019 120 e Install the crankshaft sensor cover Torque Crankshaft Sensor Cover Bolts 7 8 N m 0 80 69 in Ib e Install the Engine see Engine Removal Installation chap ter Timing Rotor Removal e Remove the engine see Engine Removal e Remove the crankshaft sensor cover see Crankshaft Sensor Rem
234. nition Coil Removal e Connect the ignition coil A with the spark plug cap left installed on the spark plug lead to the tester B and mea sure the arcing distance Auxiliary Wires C WARNING To avoid extremely high voltage shocks do touch the coil or lead 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 leads removed from the ignition coil see Ignition Coil Removal x If the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug lead Measuring coil resistance If the Coil Tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester However a hand tester can not detect layer shorts and shorts resulting from insulation breakdown under high age e Disconnect the primary leads from the coil terminals e Measure the primary winding resistance as follows A OConnect the tester between the coil terminals OSet the tester to the x 1 O range and read the tester e Measure the secondary winding resistance as follows B the spark plug leads see Ignition Coil Removal OConnect the tester between the secondary lead terminals
235. nput frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 7 JT1500 A2 model B JT1500 A1 model C OThe tachometer indicates approximately 3 000 r min rpm in case the input frequency would be approxi mately 100 Hz the tachometer does not work normally replace me ter assembly duty t TX100 50 JNI7O55B83 Battery Symbol bAt Characters LED Inspection Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection Check that the battery symbol bAt characters LED flash when the input voltage to the terminal A is lowered to 12 volts or less And check that the meter returns in the state of normality when the input voltage to the black lead terminal is raised to 12 5 V or more any display function does not work replace meter as sembly JN17010B32 14 62 ELECTRICAL SYSTEM Multifunction Meter Buzzer Inspection e Make sure that the buzzer sounds correctly when turning the ignition switch key to the ON position and warning the trouble after connecting the buzzer between 9 and 10 e f the output voltage between 9 and 10 is out of the range during the buzzer sound replace the meter assy Output Voltage 7 14 V for normal sound 2 4 V for low sound Hand tester A JN17013B32 Multifunction Meter Circuit G R lt gt
236. ns have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Kawasaki Diagnostic System KDS Software KDS software version 2 2 that runs on Windows personal computer PC will be available as a di agnostic tool for watercraft with Kawasaki DFI system You need the following items to use the KDS KDS Software Version 2 2 CD ROM 57001 1503 oignal Converter 5 001 1504 Communication Cable and Cable Adapter 5 001 1470 Relay Cable 5 001 1535 The connectors for the communication cable and relay cable are located in the front of the battery Connect the communication cable to the KDS connector 4 pin A and the relay cable between the relay assembly B connectors 8 pin C Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever trou bleshooting or presence of symptoms indicate that adjustments may be required Whenever running of the engine is required during maintenance it is best to have the watercraft in water 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 Auxiliary Cooling An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adj
237. nspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air filter housing throttle body and air suction valve covers xlf they are not correct them Replace them if they are damaged ENGINE TOP END 6 11 JF05001BS31 6 12 Cylinder Head Cover Cylinder Head Cover Removal e Remove Air Suction Valve Hoses A Spark Plug Caps B Breather Hoses C e Remove the cylinder head cover bolts A and take off the cover B Cylinder Head Cover Installation e Be sure to install the pins A and rubber gaskets B e Replace the head cover gasket with a new one if dam aged e Apply silicone sealant A to the cylinder head cover gas ket as shown Sealant Kawasaki Bond Silicone Sealant 56019 120 e Install the washer with the metal side A faces upward e Tighten Torque Cylinder Head Cover Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Route the hoses correctly see Appendix chapter 4206001851 8 04070981 ENGINE END 6 13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner A The push rod does not return to its original po sition once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts
238. nstallation chapter Pull the hose off the filter Unscrew the mounting screw and remove the filter 4103004852 COOLING AND BILGE SYSTEMS 9 5 Bilge System Follow the next procedures to remove the left side filter D e Remove the water box muffler B see Exhaust System chapter e Pull the hose C off the filter e Unscrew the mounting screw A and remove the filter 4103005852 Filter Installation e Align the projections A on the filters B with the holes C on the brackets D 4103006851 Filter Cleaning and Inspection e Flush the filter thoroughly with fresh water and shake it dry e Water must flow freely through the filter but large debris must not x the filter cannot be cleaned or if it is broken and allows debris to pass through replace it 9 6 COOLING SYSTEMS Cooling and Bilge System Hoses Hose Removal e The majority of bilge hoses have no clamps at the hose ends The majority of bilge system hoses may be simply pulled off their fittings NOTE OSome of the bilge system hoses have plastic clamps at hose ends e All the cooling system hoses are clamped at both ends Loosen the clamps and pull the hoses off Hose Installation e To install the bilge filter hose push the hose over the end of the filter NOTE OSome of the bilge system hoses have plastic clamps at hose ends e When installing the cooling system hoses be sure to use the same
239. odic Maintenance Procedures EXHAUST VALVE CLEARANCE ADJUSTMENT CHART Parens TTT Tarra a On a aT a TT war 5 5 5 trotz Tefo Thicknessv s 200 205 210 215 20 225 2 30 2 95 2 40 2 s 2 50 255 zo es 7o 275 80 094 200 2 05 2 10 2 15 220 225 250 2 35 50 2 55 E 226 vo pss 20 p 25 pao ss po s L eo 006 210215 220 225 230 215 240 246 250 2 60 2 00 205 2 10 2 15 2 20 2 25 2 30 2 35 2 40 2 45 2 50 2 2 65 27012 275 oso 5 zo ss os 60 2552 e095 270 275 200 2 ss so pas Specie No Change Required 205 210215220 225 230 235 240 246 250 255 260 268 270 2 7 2 60 245 290 255 300 2 10 15 2 20 2 25 20 as 2 o 24s 259 25 250 66 zo 276 280 eo 56 noo 40 044 215 2 peso pes m rop rs penes pas eoo on 45 0 49 220 22s 2 0 235 2401245 zso zss eo 265 2 o as 2 0 as 2o 2 ss aoo 50 0 54 2212 30 55 0 59 2 30 2 35 240245 250 255 2 60 2 65 270 275 280288 2801295 300 60 0 64 2 35 2 40 2 45 2 50 2 65 0 69 2 40 2 2 60 2 074 2 45 2 50 2 55 2 0 2 65 75 0 79 2 50 2 55 2 60 2 65 2 7 80 0 84 85 089 2 50 265 270 P 90 0 94 Tu E 0 99 2 70 2 25012 295329 0 1 04 2 75 2 80 2 85 2 p NPM TN
240. ods 19 Continued trouble may require cleaning of the fuel line to drain water 20 Try to start the engine procedure No 14 and proceed to the procedures No 15 and 16 21 Reinstall the seat and secure it 22 Reinstall the drain screws in the stern 23 Finally run the watercraft IN WATER for at least 10 minutes to dry any remaining water and blow any for eign matter like salt out through the exhaust DRIVE SYSTEM 10 1 Drive System Table of Contents PN D TEE 10 2 ____ _____ 10 4 TOOS ando ealah 10 5 Drive SnsteDrive Shalt Olde Fort CO eere 10 6 Drivehartisemoval InstallatiOri ssm ace 10 6 Drive Shaft Holder Removal Disassembly 10 6 Drive Shaft Holder 10 7 Drive Shaft SUDOULD 10 8 10 2 DRIVE SYSTEM Exploded View 5 10 3 Exploded View EMEN E 40 29 CemingCovrBos ss Tein Li _ L Apply a non permanent locking agent M Apply molybdenum disulfide grease 55 Apply silicone sealant WG Apply water resistance grease 10 4 DRIVE SYSTEM Specification Wem 1 Standard Drive Shaft Runout see P10 8 A Less than 0 1 mm 0 0039 in 0 2 mm 0 0079 in
241. olts C yn NL JH10003B31 e Tighten the crankcase bolts OFollowing the sequence numbers on the lower crankcase half tighten the M10 bolts 1 6 Torque Crankcase Bolts M10 50 N m 5 0 kgf m 36 ft Ib OFollowing the sequence numbers tighten the 8 bolts 7 10 Torque Crankcase Bolts M8 29 N m 3 0 kgf m 22 16 OFollowing the sequence numbers tighten the M8 bolts 11 19 JH10002BS1 Torque Crankcase Bolts 8 29 3 0 22 ft Ib OFollowing sequence numbers tighten the M7 bolts 20 23 Torque Crankcase Bolts M6 12 N m 1 2 kgf m 104 in Ib e After tightening all crankcase bolts check the following item OCrankshaft turn freely 8 18 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase see Crankcase Splitting e Remove Camshaft Chain A Oil Pump Sprocket Chain B Remove the crankshaft with the oil seal Crankshaft Installation CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed Fit the crankshaft main bearing inserts on the upper and lower B crankcase halves 1 5 Bearing Inserts no Groove same 2 4 Bearing Inserts Groove same 3 Bearing Insert no Groove NOTE OBe sure the be
242. or Coil E Starter Hu Rectifier 4 Led Lot Li Motor Magneto A A Joint Connector S k PI RE ar ugs Y Joint Connector R GND 2 ili 55 Main 20 by Fuse Gase x Steering i om o Position RETIR p EIE elc Ignition Switch Stop Switch Start Switch 0 0 wm TETHER eee es Bee ae ___ ek 78 001 err Jojo ____ gt Pusu Pusu 213718085 ELECTRICAL SYSTEM 14 15 Wiring Diagram JT1500 A2 Relay Assembly Crankshaft Inlet Air Injector Injector Injector Injector Main Fuel Sensor inlet Air Temperature 3 as Joint Gonnector H i ECU Pump eater POWER 12V GND SENSOR SENSOR Joint Connector E 771771077 Connector J POWER GND SENSOR GND SENSOR SENSOR ___________ G D Joint Gonnector FUEL PUMP H E 52 O o oOo mm BK BL 5 _ ______ BK 5 22 tt hh ee __________ fl 5 OBRO a 8 D dE
243. or trouble Inlet air temperature sensor trouble Fuel line clogged Crankshaft sensor trouble Ignition coil trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Hesitation Too low fuel pressure Clogged fuel line Fuel pump trouble Fuel injector trouble Inlet air temperature sensor trouble Throttle sensor trouble Water temperature sensor trouble Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor trouble Ignition coil trouble Loose terminal of battery lead or engine ground lead Poor acceleration Too low fuel pressure Water or foreign matter in fuel Clogged fuel filter or pump screen Fuel pump trouble Fuel injector trouble Inlet air temperature sensor trouble Water temperature sensor trouble Ignition coil trouble Engine oil level to high Spark plug dirty broken or gap maladjusted Stumble Too low fuel pressure APPENDIX 16 33 Fuel injector trouble Throttle sensor malfunction Water temperature sensor trouble Inlet air pressure sensor trouble Surge Unstable fuel pressure Fuel injector trouble Water temperature sensor trou
244. ossible oily water THROTTLE CLOSED RELEASED THROTTLE OPEN APPLIED 4805007851 PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures Air Filter Inspection and Cleaning e Remove Air Filter see Fuel System DFI chapter Flame Arrester A see Air Filter Disassembly in Fuel oystem DFI chapter e Clean the flame arrester A e Visually inspect the flame arrester for damage If necessary replace it with a new one Fuel Vent Check Valve Inspection The fuel vent check valve is mounted in the fuel tank vent hose to prevent fuel from spilling during riding Air can flow into the tank to allow fuel to be drawn out by the fuel pump but fuel cannot flow out the check valve e Remove the front storage pocket see Hull Engine Hood chapter e Cut off the bands A e Pull out each end of the fuel vent check valve B from the vent hoses C e Blow through the fuel vent check valve from each end If the check valve will allow air to flow as shown it is OK x air will flow through the check valve in both direction or in neither direction the check valve must be replaced 4611001851 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures e he fuel vent check valve C must be mounted so that the arrow D on its case is pointing toward the fuel tank Fuel Pump Screen Cleaning e Remove the fuel pump see Fuel System chapter e Wash the fuel pump screen A in non flammable of h
245. 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 B 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 wa ter to accumulate in the engine compartment Remove the drain screws in the stern to drain the engine compart ment 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 Before reconnecting the hoses to the plastic breather fit ting make sure the small hole A on top of the breather fitting is clear e Reconnect the bilge hoses 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Pump and Impeller Impeller Inspection e Examine the impeller A x If there is pitting deep scratches nicks or other damage replace the impeller NOTE OMinor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing Smooth leading edges are especially important to avoid cavita tion Steering Steering Cable Shift Cable Inspection e Examine the steering cable or shift cable each cables or cable housings are kinked or frayed replace the cables x If the each seal A at either end of each cable is damaged in any way r
246. oval e Remove the timing rotor A OHolding the timing rotor with the flywheel and pulley holder B and unscrew the bolt C Special Tools Flywheel amp Pulley Holder 57001 1605 Flywheel and Pulley Holder Adapter 57001 1547 D Timing Rotor Installation e Fit the rotor to the crankshaft e Apply a non permanent locking agent to the rotor bolt e Tighten the rotor bolt Torque Timing Rotor Bolt 20 2 0 kgf m 14 ft Ib e Install the crankshaft sensor cover see Crankshaft Sen sor Cover Installation Crankshaft Sensor Inspection e Remove Seat see Hull Engine Hood chapter e Disconnect the 2 pin crankshaft sensor leads connector Blue A e Set the hand tester to the x 100 O range zero it and connect it to the crankshaft sensor lead terminals G and BL in the connector x If there is more resistance than the specified value the sensor has an open lead and must be replaced Much less than this resistance means the sensor is shorted and must be replaced Crankshaft Sensor Resistance Standard 408 6120 Ignition System Ignition Coil Removal e Remove Seat see Hull Engine Hood chapter Front Storage Pocket see Hull Engine Hood chapter Spark Plug Caps see Periodic Maintenance chapter Clamp A JT1200 A1 model Double Spring Clamp A JT1200 A2 model Fuel Supply Hose End B e Bracket Bolts A see Electric Case Removal Disassem bly e Disconnect the ignition coil primar
247. p Valve Seat Cutter Holder Bar 57001 1095 57001 1128 5757109557 75711288T ENGINE TOP END 6 9 Special Tools and Sealant Valve Seat Cutter 45 530 Valve Seat Cutter 55 535 57001 1187 57001 1247 8 5711875 Valve Spring Compressor Adapter 22 Compression Gauge Adapter M10 x 1 0 57001 1202 57001 1317 875712025 Valve Guide Arbor 5 Piston Ring Compressor Belt 580 091 57001 1203 57001 1320 8 5713175 875712035 Valve Guide Reamer 25 Shaft Wrench 57001 1204 57001 1551 875712045 57571581857 Valve Seat Cutter Holder 55 TDC Measurement Tool 57001 1208 57001 1560 875712085 5757156057 6 10 Special Tools and Sealant Piston Base 658 Kawasaki Bond Silicone Sealant 57001 1604 56019 120 8 757168045 ST580120ST Clean Air System Air Suction Valve Removal e Remove Seat see Hull Engine Hood chapter Hoses A e Remove Air Suction Valve Cover Bolts A Air Suction Valve Covers B Air Suction Valve Assembly C Air Suction Valve Installation e Install the valve assembly A so that its reeds B side faces inside and it s opening C side faces inlet side e Install the air suction valve covers Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Air Suction Valve Check e Refer to Air Suction Valve in the Periodic Maintenance chapter Clean Air System Hose I
248. parts WG Apply water resistant grease 14 12 ELECTRICAL SYSTEM Wiring Diagram JT1500 A1 Joint Connector 0 LL Fuel Joint Connector P Vehicle SWi2V Down rl k 2 p Switch Fuel Level Sensor Sensor OUT GND Buzzer Multifunction Meter 16P EN Connector G R Sensor EKW GND EK Connector D 6P p EE O Q Regulator Coil L3 Li Starter C Peete 2 EM 1 Led Lot Li Motor 5 Magneto 49 lJoint Connector 5 k PI 5424 ugs Y Joint Connector R GND BN 5 Main 20 o i Je Fuse Case s Steering eo Position Lr Ignition Switch Stop Switch Start Switch Hci Aaa 7 Hutt REOR podra dye err Jojo W2L3717AW5 ELECTRICAL SYSTEM 14 13 Wiring Diagram JT1500 A1 Relay Assembly Crankshaft Inlet Air Injector Iniector Injector Injestor Main Fuel Sensor inlet Air Temperature a ki Joint Connector H i 02 Pressure d IN z SENSOR GND SENSOR C Sensor 3 Joint Connector 77771 voint Connector J GND POWER 5V GND SENSOR SENS R SENSOR Inanal IUt tt ta G D
249. pe fitting e Unscrew the mounting bolts B and remove the water pipe C from the cylinder head D Water Pipe Installation e Apply grease to the O rings A and install the water pipe with the mounting bolts e Install cooling hose B cylinder head water box muffler to the water pipe fitting and secure the hose clamp C 4104009851 COOLING AND BILGE SYSTEMS 9 11 After Submerging CAUTION Do not operate the watercraft with water in the en gine Do not try to start the engine until it is completely empty of water internal engine parts could be se verely and immediately damaged If water gets into the engine follow this procedure immediately If water is left in the engine more than a few hours it will destroy the crankshaft bearings and damage other internal engine parts If the watercraft becomes swamped water may enter the engine through the throttle body Water may also enter the fuel tank The following procedures explain the necessary steps you must provide Read the summary of the procedure first and then their detailed procedures carefully Summary Procedures after Submerging 9 12 COOLING AND BILGE SYSTEMS After Submerging Remove the drain screws and drain water in the engine compartment Remove the spark plugs Crank the engine and discharge water in the engine Is there water in the air filter drain caps No There is no water Yes There is water Remo
250. peed by air BK W approx 5 V x the sensor voltage does not reach 5 volts when spun with compressed air replace the sensor Fuel Level Sensor Inspection e Open the front storage compartment cover e Disconnect the fuel level sensor 2 pin connector e oosen the clamp and remove the fuel level sensor out of the fuel tank e Set the hand tester ohmmeter to the x 1 kO range Special Tool Hand Tester 57001 1394 e Connect the tester leads the W R and BK W leads to check the switching operation of the float Meter Reading When sensor is held upright A approx 8 03 kQ When sensor is held upside down B approx 0 The meter should read as specified If it does not replace the fuel level sensor Throttle Sensor Removal Installation e Refer to Throttle Sensor Removal Installation in the Fuel oystem chapter ELECTRICAL SYSTEM 14 55 JN02050432 14 56 ELECTRICAL SYSTEM Sensors Throttle Sensor Inspection e Refer to Throttle Sensor Section in the Fuel System chap ter Water Temperature Sensor Inspection e Remove the water temperature sensor see Feul DFI System chapter e Suspend the sensor A in a container of water so that the temperature sensing projection is submerged e Suspend an accurate thermometer B in the water NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the tem
251. perature 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 x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance 20 68 293 50 1226 78 5 90 194 F 18 1 100 212 13 2 Inlet Temperature Sensor Inspection e Refer to Inlet Air Temperature Sensor Section in the Fuel oystem chapter Oil Temperature Sensor Inspection e Remove the oil temperature sensor see Feul DFI Sys tem chapter e Suspend the sensor A in a container of water so that the temperature sensing projection is submerged e Suspend an accurate thermometer B in the water NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently e Using the hand tester measure the internal resistance of the sensor at the temperatures shown in the table x If the hand tester does not show the specified values re place the sensor Oil Temperature Sensor Resistance 20 68 293 50 122 78 5 90 C 194 F 18 1 100 212 13 2 10062852 C 4
252. poor contact Magneto trouble Wiring faulty Regulator rectifier trouble Battery overcharged Magneto trouble Regulator rectifier trouble Battery faulty Poor Performance through Engine Runs Properly Jet pump Intake area obstructed Impeller or pump case damaged Excessive clearance between impeller and pump case Poor Steering Control Since faulty steering is dangerous this problem should be examined by an authorized Jet Ski dealer Handlebar hard to turn Steering maladjusted Bushing damaged or cracked Steering shaft bent No lubricant on steering pivot Steering cable damaged or improperly routed APPENDIX 16 35 Engine Activates Slow Down Mode Cooling water temperature gets high Weeds or debris in jet pump Cooling water line clogged Low oil pressure Low oil level Improper engine oil quality Water temperature sensors malfunction wiring open or short Vehicle down sensor malfunction wiring open or short temperature sensor gets high Low oil level Oil pump malfunction Relief valve malfunction Weeds or debris in jet pump Cooling water line clogged Oil temperature sensor malfunction wiring open or short MODEL APPLICATION Beginning Hull No 2004 J11500 A1 6000111304 2005 JT1500 A2 05 500010405 digit in the hull number changes from one machine to another E E Kawasaki KAWASAKI INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1325 02 Printed
253. pter Set Kawasaki Bond Silicone Sealant 57001 1457 56019 120 8T5714578T ST580120ST Holder Attachment Kawasaki Bond Silicone Grease 57001 1547 92137 1002 UU ST5715478T 14 18 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be followed servicing electrical systems ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings ODo not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involv
254. r ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling GENERAL INFORMATION 1 7 68020118 5 08020128 5 68020138 5 08020148 5 08020156 5 1 8 GENERAL INFORMATION Before Servicing Liquid Gasket Locking Agent For applications that require Liquid Gasket or a Locking agent clean the surfaces so that no oil residue remains be fore applying liquid gasket or locking agent Do not apply them excessively Excessive application can clog oil pas sages and cause serious damage Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con t
255. r BOX MUMET 5 9 Water Box Muffler nnn nnns ns 5 9 Water Box Muffler Installation 5 9 Water Box ptura 5 10 5 2 EXHAUST SYSTEM Exploded View JE02010BW5 EXHAUST SYSTEM 5 3 Exploded View mE Mej BpssNzde t Water Temperature Sensor _____ 15 18 seechapteri 8 Exhaust Pipe Mounting Bots 9 30 22 EO Fill the hollow with the engine oil 10W 30 L Apply a non permanent locking agent 5 Follow the specific tightening sequence SS Apply silicone sealant SY Apply synthetic rubber adhesive 5 4 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Removal e Remove Cil Separator Tank A with the Oil Separator Hoses see Lubrication system Air Filter B see Fuel System chapter e Disconnect opark Plug Caps C see Periodic Maintenance chapter Hoses D Water Temperature Sensor Connector E e Disconnect Hoses A e Remove Bolts A and Collars Exhaust Pipe Mounting Plate B e oosen Joint Tube Clamp Screws C e Remove the exhaust manifold mounting nuts A and bolts B e Remove the exhaust manifold from the engine JE07014B31 e Disconnect the exhaust pipe A from the left water box muffler B by pulling the exhaust manifold with the ex h
256. r Installation e Secure the bumpers to the hull flange with the rivets see Rivet Installation HULL ENGINE 13 19 Rubber Parts Side Bumper Removal e ake out the plugs A e Drill out the rivets B see Rivet Removal e Remove the corner bumper C JM05007B31 e Remove the trim strip A from the side bumper B e Drill out the rivets A see Rivet Removal Side Bumper Installation e Secure the side bumpers to the hull flange with the rivets see Rivet Installation e Install the trim strip ELECTRICAL SYSTEM 14 1 Electrical System Table of Contents Parte LOCallohus 14 3 Exploded 14 6 Wiring 14 12 14 16 Special Tools and Sealant 14 17 14 18 Electrical Wiring 14 20 Wiring Inspection 14 20 Batte 14 21 REMOVA 14 21 Installation 14 21 Electrolyte Filling 14 21 Initial Charge 14 23 PrecautlloliS eo renda n Libo eid 14 23 Interchange 14 24 Charging Condition Inspection 14 24 Refreshing Charge 14 24 Electric Starter System 14 26
257. r 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 Engine Hood Gasket A Rear Storage Trim Seal B HULL ENGINE 13 17 Rubber Parts Front Storage Compartment Gasket A Front Storage Compartment Cover Trim Seal B Detent A JM07024B31 Mats A Damper on Deck A starboard side only 20 mm 0 79 in B 30 mm 1 18 in C K Ss 54 p SS JM05009B32 13 18 HULL ENGINE HOOD Rubber Parts Rivet Removal e Drill out the rivet with a drill bit A of the correct size 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 Rivet Installation e Secure the parts to the hull with the rivets using a riveter A Front Bumper Removal e ake out the plugs A e out the mounting screw B and nuts C e Drill out the rivets D see Rivet Removal e Remove the front bumper E JM05006B31 Front Bumper Installation e Secure the front bumper to the hull flange with the rivets see Rivet Installation Rear Bumper Removal e Remove the corner bumpers A and trim strip B OTake out the plugs C ODrill out the rivets D see Rivet Removal e Remove the rear bumper E JM05008B31 Rear Bumpe
258. r making the 32 grind return to the seat O D mea surement step above e measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat O D measurement step above 6 5011951 6 5012151 6 5012251 Valves If the seat width is too wide make the 60 or 55 A grind described below If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 or 55 angle until the seat width is within the specified range OTo make the 60 or 55 grind fit 60 or 55 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 or 55 grind return to the seat width measurement step above Correct Width B e the valve to the seat once the seat width and O D are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound A Lapper B Valve Seat C Valve e he seating area should be marked about i
259. r 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 Digital Transistor Ignition System Fuel Pump Spark Plugs Throttle Body and Internal Parts Fuel Injectors ECU 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 with the procedures before starting work and then do the work car
260. rder the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings Oil seals Grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 068020108 5 Before Servicing Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a qua
261. record valve lifter and shim locations so E HEN LEN D they can be reinstalled in their original positions there is no clearance select a shim which is several sizes smaller and then measure the clearance 4808002851 e o select new shim which brings clearance within the specified range refer to the Valve Clearance Adjustment Charts PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures INLET VALVE CLEARANCE ADJUSTMENT CHART ro spere pe 5 2 00 2 05 2 10 2 15 2 20 2 25 12 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 200 2 06 2 10 2 15 2 20 2 25 12 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 280 2 00 2 05 2 10 2 15 2 20 2 25 230 2 35 2 40 2 45 2 50 2 55 2 60 2 65 270 275 2 80 2 85 2 249 216 210215 220225 250 2 35 240 245 2 50 2 55 2 60 mue Clearance No pur 95 2 10 2 15 2 20 225 2 30 2 35 12 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 290 2 95 3 00 102151220225 20 23s 0 45 5055 75 zo 90 5600 1 aps penes e pepe 221230125 2 o s aso ss 260 pes 7o27 za 2ss aco ss 00 papas enoss penes m ers pa res son o 2 35 240245 250 258 260 245 270275 280245 290 235 300 240246 2502 60 2 65 2
262. ring D into the hole E of the bushing Torque Magneto Cover Bolts 20 N m 2 0 kgf m 14 ft Ib e Apply grease to the O ring A and collar inside e nstall the collar B so that the chamfer side C faces inward 8 10 Coupling e Install Pins A Gasket B e Position the magnet lead C as shown e Apply grease to the oil seal lip e Install the output cover ORun the magneto lead A between the magneto cover B and the output cover C as shown Torque Output Cover Bolts 7 8 0 80 kgf m 69 in Ib JH04001B31 e Install the coupling damper to the coupling e Holding the timing rotor screw the coupling onto the out put shaft and tighten it Special Tools amp Pulley Holder 57001 1605 Holder Attachment 57001 1547 Coupling Holder 2 57001 1423 Torque Coupling 98 N m 10 0 kgf m 72 ft Ib e Install Crankshaft Sensor Cover Engine see Engine Removal Installation chapter Coupling Damper Inspection e Refer to Coupling Damper Inspection in the Periodic Maintenance chapter Output Cover Oil Seal Replacement e Remove Output Cover see Coupling Output Shaft Removal e Using the bearing driver A remove the oil seals as a set Special Tool Bearing Driver Set 57001 1129 Coupling e Replace the oil seals with new ones e Apply thin coat grease to the oil seal lips A e Pack grease B between the oil seal lip and housin
263. ring shaft locknut B e out the holder C e Unscrew the steering holder mounting bolts A nuts and washers and lift up the steering holder B e out the air intake duct mounting bolts A and remove the air intake duct B from the steering holder C e Disconnect the switch case lead connector and pull the leads A out of the hull e Disconnect the pipe at the fuel vent hose upper end and pull down the fuel vent hose B e Disconnect the throttle cable upper end at the throttle case and pull down the throttle cable C e Remove the lock plate A e out the steering shaft nut B and pull down steer ing shaft C e Remove the steering holder 12 14 STEERING Steering Steering Installation e Replace the gasket A on the steering holder B with a new one e Check the bushings for damage and wear before in stalling the steering holder x If bushings are damaged or worn replace them e Grease Bushings A Steering Shaft B e Install the steering shaft and the steering shaft nut Hand Tighten A to the steering holder Olf steering is too tight turn the steering shaft nut counter clockwise to loosen OIf steering is too loose turn the steering shaft nut clock wise to tighten NOTE OThe steering shaft must be turned smoothly when the cable is connected Turn the steering shaft nut 1 6 or less turn at a time e Install the air intake duct B to the st
264. rminals in the same man ner as specified in the Display Function Inspection e The speed equivalent the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the terminal 8 JT1500 A2 model B JT1500 A1 model C Olndicates approximately 60 mph in case the input fre quency would be approximately 265 Hz Olndicates approximately 60 km h in case the input fre quency would be approximately 165 Hz 0 duty t TX100 50 JNI7O053B83 14 60 ELECTRICAL SYSTEM Multifunction Meter e f the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit OTurn on the ignition switch ORotate the waterwheel by hand OCheck that the speedometer shows the speed x speedometer does not work check the speed sen sor electric source voltage and speed sensor Speed Sensor Electric Source Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e Set the hand tester A to the DC 25 V range and connect it to the terminals 3 and 2 x voltage is less than 7 V replace the meter assembly JN17008B32 ELECTRICAL SYSTEM 14 61 Multifunction Meter Tachometer Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e he revolutions per minute rpm equivalent to the i
265. rness Adapter 57001 125 57001 1561 875701255 Hand Tester Harness Adapter 57001 1394 57001 1562 875713845 ST5715628T Needle Adapter Set Kawasaki Bond Silicone Sealant 57001 1457 56019 120 8T5714578T ST580120ST Fuel Pressure Gauge Adapter Kawasaki Bond Silicone Grease 57001 1463 92137 1002 8757146357 Throttle Sensor Setting Adapter 57001 1521 75715218T DFI Parts Location gt Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Inlet Air Pressure Sensor Inlet Air Temperature Sensor Throttle Sensor ISC Idle Speed Controller Camshaft Position Sensor Water Temperature Sensor Crankshaft Sensor Pressure Switch Oil Temperature Sensor FUEL SYSTEM DFI 3 13 3 14 FUEL SYSTEM DFI Parts Location 14 15 16 17 18 19 20 21 22 23 24 25 26 Ignition Switch Meter Unit Buzzer Fuel Pump Fuel Level Sensor Vehicle down Sensor Ignition Coil 1 4 Ignition Coil 2 3 Main Fuse 20 A ECU Electronic Control Unit Diagnosis Connector Relay Assembly Main Relay Fuel Pump Relay Battery FUEL SYSTEM 3 15 DFI Parts Location Dummy Page 3 16 FUEL SYSTEM DFI System DFI System Wiring Diagram O Lire 2 4 nm R Y iB p QD R R BK W BK W BK W BK W BK W BK W BK W B
266. rvice 23 3 27 3 27 3 28 3 30 3 31 3 33 3 33 3 33 3 33 3 34 3 36 3 36 3 36 3 37 3 39 3 39 3 39 3 41 3 42 3 42 3 42 3 43 Camshaft Position Sensor Remowval Installation Camshaft Position Sensor INSPECCION cona Vehicle down Sensor Service Code Character 31 dOS Vehicle down Sensor Removal Vehicle down Sensor Installation Vehicle down Sensor Inspection Fuel Injectors Service Code Character 41 42 43 44 InJ1 InJ2 InJ3 InJ4 Fuel Injector Removal Fuel Injector Installation Audible Inspection Injector Signal Test Injector Resistance Inspection Injector Unit Injector Voltage Inspection Injector Fuel Line Inspection Ignition Coils Service Code Character 51 52 COL1 COE T Ignition Coil Removal Installation Input Voltage Inspection Engine Overheating Service Code Character 7 1 HEAt Low Engine Oil Pressure Service Code Character 72 OILP Temperature Sensor Service Code Character 73 OILC or TS OIBUsse dieta o E Oil Temperature Sensor Remowval Installation Output Voltage Inspection Sensor Resistance Inspection Engine Oil Overheating Service Code Character 76 OILH EC
267. rvice limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 38 984 38 992 mm 1 5348 1 5351 in O 38 993 39 000 mm 1 5352 1 5354 in A Crankpin Diameter Marks mark or no mark 4 3 i H 9 ED JHi11002BWi e Measure connecting rod big end bore diameter mark each connecting rod big end in accordance with the bore diameter Big End Cap A Connecting Rod B Weight Mark C A letter of the alphabet Bore Diameter Mark Around Weight Mark D or no mark NOTE 0105060151 OTighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation OThe mark already on the big end should almost coincide with the measurement Connecting Rod Big End Bore Diameter Marks None 42 000 mm 42 008 mm 1 6535 1 65386 in 42 009 42 016 1 65389 1 6542 e Select the proper bearing insert in accordance with the combination coding of the connecting rod and crankshaft e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage Con rod Big End Crankpin Bearing Insert Bore Diameter Diameter i Marking Marking Size Color o Brown o We Bw 8 24 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert Journal Wear e Me
268. s Inlet Manifold Mounting Bolts 25 2 5 18 Inlet Manifold Mounting Nuts 20 2 0 14 Delivery Pipe Mounting Bolts 7 8 0 80 69 in lb Inlet Air Pressure Sensor Bolts 7 8 0 80 69 in lb Throttle Cable Holder Bolts 8 8 0 90 78 in lb L Inlet Air Temperature Sensor 20 2 0 14 Throttle Body Assy Mounting Bolts 20 2 0 14 Inlet Manifold Drain Plug 20 2 0 14 Inlet Manifold Plate Bolts 7 8 0 80 69 Crankshaft Sensor Screws 4 4 0 45 39 in Ib 7 8 0 80 69 Oil Temperature Sensor 15 1 5 11 see text Water Temperature Sensor 15 1 5 11 see text Regulator Rectifier Bolts 7 8 0 80 69 in lb ECU Mounting Bolts 8 8 0 90 78 in Ib L Throttle Sensor Mounting Screws 2 0 0 20 18 in lb ISC Actuator Mounting Bolts 4 9 0 50 43 Oil Pressure Switch 15 1 5 11 SS Fuel Filler Tube Clamp Screws 2 9 0 30 26 Fuel Level Sensor Clamp Screw 2 9 0 30 26 in lb Fuel Filter Mounting Bolts 8 8 0 90 78 in lb L Air Filter Mounting Bolts 9 8 1 0 87 in lb Air Filter Bracket Mounting Bolts 7 8 0 80 69 in lb L Throttle Cable Locknut 7 8 0 80 69 in Ib Throttle Case Mounting Screws 3 9 0 40 35 in lb Engine Lubrication System Breather Plate Bolts 69 in Ib Oil Filler 8 7 in lb Oil Passage Plugs 14 Oil Separator Tank Mounting Screws 43 in lb Breather Case Mounting Bolts 69 1 15 Breather Pipe Bolts 78 in Ib 2 4 PERIODIC MAINTENANCE Torque and Locking Agent _ _ remm ks Dum
269. s E UND JB02006BWi GENERAL INFORMATION 1 5 Before Servicing CAUTION Turn the capsized boat clockwise so that the port side always faces downward Turning counterclockwise can cause water in the exhaust system to run into the engine with pos sible engine damage JB02007BWi Battery Ground Before completing any service on the watercraft discon nect the battery wires from the battery to prevent the engine from accidentally turning over Disconnect the ground wire first and then the positive When completed with the service first connect the positive wire to the positive terminal of the battery then the negative wire to the neg ative terminal DISASSEMBLY ASSEMBLY 08020248 5 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 5 Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 68020056 5 1 6 GENERAL INFORMATION Before Servicing Cleaning Watercraft before Disassembly Clean the watercraft thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during watercraft disassembly can cause excessive wear and de crease performance of the watercraft Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the o
270. saki Smart Steering System the smart steering system with the watercraft in the water e Center the handlebar in the straight ahead position e Squeeze the throttle lever and allow it to approx 4 000 rpm or above for 4 seconds or more e Release the throttle lever e Within 1 second turn the handlebar all the way to the left or right and check the engine speed increases to approx 2 800 rpm e Center the handlebar in the straight ahead position and check the engine speed decreases to an idle speed x If the Kawasaki Smart Steering system does not operate normally check the steering position sensor clearance Steering Position Sensor Clearance e Check the clearance A between the steering position sensor B and the magnet C with feeler gauge Steering Position Sensor Clearance Standard 0 5 1 5 mm 0 02 0 06 in the clearance is the specified value inspect steering position sensor input voltage x necessary adjust the steering shaft nut ELECTRICAL SYSTEM 14 51 Kawasaki Smart Steering System Steering Position Sensor Input Voltage Inspection e Measure the input voltage to the steering position sensor NOTE OBe sure the battery is fully charged OConnect a digital voltmeter A to the lead connector B of the steering position sensor using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Connections to Steering Position Sensor Connector Meter R
271. screw position see Cable Wire and Hose Routing in Appendix chapter 5 6 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Cleaning and Inspection e Remove the exhaust manifold parts e Clean the carbon deposits out of the exhaust passages with a blunt roundedged tool e Flush foreign matter out of the water passages with fresh water e Check the insides of the water passages for corrosion Check the gasket surfaces for nicks or other damage x If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly replace the part EXHAUST SYSTEM 5 7 Exhaust Pipe Exhaust Pipe Removal e Remove Exhaust Manifold with Exhaust Pipe see Exhaust Man ifold Removal Exhaust Pipe Mounting Bolts A Exhaust Pipe B e Remove the joint tube A and the two rings Exhaust Pipe Installation e Install the two rings A in the ring grooves of the exhaust pipe If the two rings are damaged or warped replace the rings e Bind the two rings A securely by putting the paper tape B around the rings so that it is easy to insert the water box muffler into the exhaust pipe The paper tape can be burned out soon after firing e Install the joint tube to the exhaust pipe e Replace the exhaust pipe gasket A with a new one as shown e Install the exhaust pipe B to the exhaust manifold C and tighten the bolts D Torque Exhaust Pipe Mounting Bolts 30 N m 3 0 kgf
272. sing Installation e Check the seal A for damage necessary replace new ones Olnstall 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 Exhaust Outlet Installation e Apply a non permanent locking agent to the mounting bolts and tighten them securely 13 14 HULL ENGINE HOOD Fittings Stabilizer Removal e Unscrew the stabilizer bolts A and remove the stabilizer B Stabilizer Installation e Install the stabilizer as shown Stabilizer A Chine Line B 111 x3 mm 4 37 0 12 in C 8 2 mm 0 31 0 08 in D e Apply a non permanent locking agent to the stabilizer bolt and torque them Torque Stabilizer Bolts 9 8 N m 1 0 kgf m 87 in Ib JM07028B31 Reboarding Step Removal e Unscrew the reboarding step bolts A and remove the reboarding step B Reboarding Step Installation e Apply a non permanent locking agent to the reboarding step bolts and tighten them securely HULL ENGINE 13 15 Hull Replacement To replace the hull remove the various parts in the follow ing suggested order Battery and Pad Exhaust Pipe and Expansion Chamber Inlet Manifold Engine and Mounts Air Filter Water Box Muffler Drive Shaft and Shaft Holder Pump and Hoses Steering Cover Handlebar and Steering Steering Cable Reverse Cable Crossmember Fuel Tank and Fi
273. sition Sensor Buzzer Multifunction Meter Starter Switch Engine Stop Switch Lanyard Key Tether Code Ignition Switch ELECTRICAL SYSTEM 14 5 P 14 6 ELECTRICAL SYSTEM Exploded View JN02042B8BW5 C ELECTRICAL SYSTEM 14 7 Exploded View Nm kgfm ftib Vehicle down Sensor Mounting Screws 15 045 13mb _ 4 ignition Goil Mounting Bots 88 090 78mb t 7 i 1 2 see tex 13 Camshaft Position SensorBot 98 10 87in tL 4 17 ECU Mounting Bots 090 78mb EO Fill the hollow of the exhaust manifold with engine 10W 30 G Apply grease L Apply a non permanent locking agent Si Fill the hollow of the oil pan with the specified silicone grease Kawasaki Bond 92137 1002 WG Apply water resistant grease 14 8 ELECTRICAL SYSTEM Exploded View JN02033BW5 ELECTRICAL SYSTEM 14 9 Exploded View Wm fib Fuel Level Sensor Clamp Screw ______ 29 030 26m 3 Staristop Switch Case Mounting Screw 39 040 35mb 5 Multifunction Meter 6 Fuel Level Sensor T Buzzer 14 10 ELECTRICAL SYSTEM Exploded View J ELECTRICAL SYSTEM 14 11 Exploded View n n 2 12 104 int 76 GrmmetHoder amp ots 88 090 T78mb T Fuse G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement
274. specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance 14 22 ELECTRICAL SYSTEM Battery e Check to see that there is no peeling tears or holes in the seal sheet on the top of the battery e Place the battery on a level surface e Remove the seal sheet A CAUTION Do not remove the seal sheet sealing the filler ports B until just before use NOTE OA battery whose seal sheet has any peeling tears or holes requires a refreshing charge initial charge e Take the electrolyte container out of the vinyl bag e Detach the strip of cap A from the container NOTE ODo not discard the strip of cap because it is used as the battery plugs later ODo not peel back or pierce the seals B on the container e Place the electrolyte container upside down aligning the six seals with the six battery filler ports e Push the container down strongly enough to break the seals Now the electrolyte should start to flow into the battery NOTE ODo not tilt the container as the electrolyte flow may be interrupted e Check the electrolyte flow x no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the batter
275. st Side Camshaft Chain Guide Bolts Upper 25 25 18 Exhaust Side Camshaft Chain Guide Bolts Lower 12 12 104imlb Camshaft Chain Tensioner Mounting Bots 98 10 L Camshaft Chain Tensioner Cap Bot 20 20 10 Closed coil end faces downward 11 A marking hollow faces exhaust side EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence SS Apply silicon sealant 6 6 ENGINE TOP END Specifications tem Standard Camshafts Cam Height Exhaust 36 143 36 257 mm 1 4229 1 4274 in 36 04 mm 1 4189 in Inlet 36 440 36 554 mm 1 4346 1 4391 in 36 34 mm 1 431 in Camshaft Journal Camshaft 0 028 0 071 mm 0 0011 0 0028 in 0 16 mm 0 006 in Cap Clearance Camshaft Journal Diameter 23 950 23 972 mm 0 9429 0 9438 in 23 92 mm 0 942 in Camshaft Bearing Inside 24 000 24 021 mm 0 9449 0 9457 in 24 08 mm 0 948 in Diameter Camshaft Runout TIR 0 02 mm 0 00068 in or less TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression usable range 1 185 1 795 kPa 12 1 18 3 kgf cm 172 260 psi 9430 r min rpm Cylinder Head Warp Valves Valve Clearance Exhaust 0 22
276. t cooling water supply for more than 15 seconds at a time or severe engine and exhaust system damage will occur Install the seat making sure it is locked STORAGE 15 7 APPENDIX 16 1 Appendix Table of Contents Cable Wire and Hose nnn nnns 16 2 Troubleshooting ero PTT 16 32 16 2 APPENDIX Cable Wire and Hose Routing KA e 0 08 5 eu sei 1 LS H nm yn 2 Viewed from gt E f D 3 0 5 6 LIC EC 9 i w AT 9 p Um 62 00 62 69 6 GO 09 OIL HOSES ROUTING 48099127885 C 16 3 Cable Wire Hose Routing Crossmember Cylinder Head Cover Throttle Cable Delivery Pipe Fix the throttle cable to the delivery pipe with the band Inlet Manifold Horizontal Plane Position the clamp pinch head below the horizontal plane Throttle Body Assy Air Filter Clamp Cooling Hose Cylinder Left Water Box Muffler Oil Pan Position the clamp pinch head as shown Oil Separator Tank Hose Tank Oil Pan Cooling Hose Pump Output Cover Output Cover Exhaust Pipe Cooling Hose Output Cover Exhaust Pipe Band Oil Separator Tank
277. t disconnect the ECU connector Connect a digital voltmeter to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter R lead terminal 12 Meter BK W lead terminal 8 Turn the ignition switch ON and push the lanyard key un JC16024BS1 der the stop button Pushing the start button run the engine 5 6 seconds at idling to measure the sensor input voltage OWait 15 seconds before using the starter again Input Voltage at ECU Standard 4 75 5 25 V DC Turn the ignition switch OFF x If the reading is less than the standard check the ECU for its ground power supply and wiring If the ground power supply and wiring are good replace the ECU 3 34 FUEL SYSTEM Inlet Air Pressure Sensor Service Code Character 12 bOSt x the reading is within the standard range and check the input voltage at the sensor connector e Disconnect the inlet air pressure sensor connector and connect the harness adapter A between the harness connector and inlet air pressure sensor connector e Connect a digital meter to the harness adapter leads B Inlet Air Pressure Sensor Special Tool Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Input Voltage Connections to Sensor Meter lead C Meter gt BK W lead D e Turn the ignition switch ON and push the lany
278. tal meter C to the harness adapter leads e Measure the throttle sensor resistance Throttle Sensor Resistance Connections to Harness Adapter R lead D BK BL lead E Standard 4 6 the reading is out of the range replace the throttle body assy xlf the reading is within the range but the problem still exists replace the ECU 3 32 FUEL SYSTEM DFI Throttle Sensor Service Code Character 11 tPS JCi6045BW 2 1 ECU 2 Joint Connector E 3 Throttle Sensor FUEL SYSTEM 3 33 Inlet Pressure Sensor Service Code Character 12 bOSt CAUTION Never drop the sensor especially on a hard surface Such a shock to the part can damage it Inlet Air Pressure Sensor Removal e Turn the ignition switch off e Remove Seat see Hull Engine Hood chapter Inlet Air Pressure Sensor Bolts A Inlet Air Pressure Sensor Connector B Inlet Air Pressure Sensor C Inlet Air Pressure Sensor Installation e Apply silicone oil to the O ring CAUTION Do not apply silicone oil to the sensor end sensing part B and the inside C of the sensor connector e Tighten Torque Inlet Air Pressure Sensor Bolts 7 8 N m 0 80 kgf m 69 in Ib KEMST Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the throttle sensor Turn the ignition switch OFF Remove the ECU see ECU Removal Do no
279. tery is disconnected x the relay does not work as specified replace the relay assembly 4016043852 3 64 FUEL SYSTEM DFI DFI Power Source Fuel Pump Relay Relay Coil Terminals 6 and 8 Relay Switch Terminals 5 and 7 Testing Relay Tester range 1 range Criteria When battery is connected 0 Q When battery is disconnected x If the relay does not work as specified replace the relay assembly Hand Tester A Battery B J618044B32 Throttle Lever Cable and Case Free Play Inspection e Refer to Throttle Control System Inspection in the Peri odic Maintenance chapter Throttle Cable Adjustment e Refer to Throttle Cable Adjustment in the Periodic Main tenance chapter Throttle Case Removal Disassembly e Unscrew the mounting screws A and remove the han dlebar pad B e Remove the throttle case OUnscrew the throttle case mounting screws C separate the case halves 0 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 FUEL SYSTEM DFI 3 65 3 66 FUEL SYSTEM Throttle Lever Cable and Case e Disassemble the throttle case ORemove the circlip A flat washers B pin C throttle lever D and return spring E from the case F Throttle Case Assem
280. the shaft wrench A turn the crankshaft counter clockwise B and set the crankshaft at 1 4 piston Special Tool Shaft Wrench 57001 1551 OThe timing marks A must be aligned with the cylinder head upper surface B as shown e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts A Upper Camshaft Chain Guide B Camshaft Cap C Camshafts e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket 6 15 Camshaft Camshaft Chain Camshaft Installation e Be sure to install the following parts Pins A e Apply molybdenum disulfide oil solution to all cam parts and journals NOTE OThe exhaust camshaft has a 320 EX mark A and the inlet camshaft has a 320 IN mark B Be careful not to mix up these shafts T If the camshaft position sensor rotor is removed install it as follows Olnsert the pin A into the holes B in the camshaft and boss C OFit the projection A of the rotor B on the camshaft re cess C OApply a non permanent locking agent to the camshaft po sition sensor rotor bolt D and tig
281. to Sensor Meter R G lead D Meter BK W lead Turn the ignition switch ON and push the lanyard key un der the stop button Pushing the start button run the engine 5 6 seconds at idling to measure the sensor power sours voltage OWait 15 seconds before using the starter again Power Source Voltage at Sensor Standard 4 75 5 25 V Turn the ignition switch OFF x If there is no standard voltage check the following Battery see Electrical System chapter Fuse 20 4516040832 C Wiring Vehicle down Sensor Power Source see next diagram the power source is normal check the output voltage e Turn the ignition switch OFF e Remove the vehicle down sensor Do not disconnect the connector e Connect a digital volt meter A to the connector with nee dle adapter set B Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Output Voltage Connections to Sensor Meter BL W lead D Meter BK W lead E e Hold the sensor vertically e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the sensor output voltage OTilt the sensor 110 130 or more C right or left then hold the sensor and measure the output voltage OWait 15 seconds before using the starter again J618041B32 Output Voltage at Sensor Standard with sensor tilted 1
282. to positive direction counter clockwise viewed from stern sinde Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color GENERAL INFORMATION 1 9 GB02026B OMI 5 1 10 GENERAL INFORMATION Model Identification JT1500 A1 Left Side View JT1500 A1 Right Side View General Specifications GENERAL INFORMATION 1 11 O JT1500 A1 A2 Engine Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition System Lubrication System Carburetion System Starting System Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Tuning Specifications Spark plug Type Gap Ignition Timing Idle Speed Compression Pressure Drive System Coupling Jet Pump Type Thrust Steering Braking Performance TMinimum Turning Radius TFuel Consumption TCruising Range 4 stroke DOHC 4 cylinder water cooled 1 498 mL 91 4 cu in 83 x 69 2 mm 3 27 x 2 72 in 10 6 1 118 kW 160 PS 7 500 r min rpm 152 N m 15 5 kgf m 112 1 ft lb 7 250 r min rpm Digital transistor Forced lubrication semi dry sump Fl fuel injection MIKUNI AC 60 x 1 Electric starter Front bow to rear stern 1 2 3 4 1 2 4 3 22 5 BTDC 67 5 ABDC 270 74 5 9 5 264
283. topping ignition The ECU slows down the engine Camshaft position sensor Malfunction wiring open or short Engine oil pressure too low speed less than 3 000 r min rpm by stopping the ignition JT1500 A1 Oil temperature sensor The ECU sets the oil temperature at malfunction wiring open or 60 C AA an A Cy 6 Short The ECU slows down the engine JT1500 A2 speed less than 3 000 r min rom by stopping the ignition 73 an 1 ey 0t 05 JT1500 A2 The ECU slows down the engine 76 Engine oil overheat speed less than 3 000 r min rpm by stopping the ignition 3 24 FUEL SYSTEM DFI Self Diagnosis Note 1 D J Method the control method from medium to heavy engine load When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum vacuum sensor output voltage and engine speed crankshaft sensor output voltage 2 a N Method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed 3 If both throttle sensor system and inlet air pressure fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the a N method 4 The ECU may be involved in these proble
284. tor Coil Resistance Test Meter Setting otandard Value Meter to Meter to White lead White lead 0 432 0 648 Q x If the coil has normal resistance but the voltage check shows the charging system to be defective then the permanent magnets in the flywheel have probably weak ened necessitation flywheel replacement Regulator Rectifier Removal Installation e Remove the seat see Hull Engine Hood chapter e Unscrew the mounting bolts A and remove the regula tor rectifier B e Disconnect the connector C 14 34 ELECTRICAL SYSTEM Charging System e Tighten Torque Regulator rectifier Bolts 7 8 N m 0 80 kgf m 69 in Ib e When installing the bracket apply a non permanent lock ing agent to the bracket mounting screws and tighten them securely Regulator Rectifier Inspection e With the hand tester set to the R x 1 kO range test the regulator rectifier according the following table Special Tool Hand Tester 57001 1394 Regulator Rectifier Unit Tester Lead Connection ee De 89 7 ato so ea s00 500 500 2 20 s00 500 5 500 e z s00 500 89 2 40 2 20 2 20 2 20 Tester lead Connection x If any of the values obtained do not agree with the above table the regulator rectifier must be replaced Regulator Inspection OTo test the regulator out of circuit use three 12
285. tored in the ECU necessary these service codes can be erased by using the Kawasaki Diagnostic System KDS 14 Start the engine by pressing the start button and run less than 15 seconds CAUTION Do not run the engine with the watercraft out of the water for more than 15 seconds at a time Overheat ing will cause severe engine and exhaust system damage Never operate the engine at maximum speed out of the water Severe engine damage may occur 15 Remove the dipstick A and check for the water pres ence in the engine oil If there is water in it oil looks milky 16 If the oil looks milky then change the oil and repeat procedures 14 and 15 until the oil does not turn milky any more 17 If the engine does not start there may be water in the fuel system JI06008BS1 COOLING AND BILGE SYSTEMS 9 15 After Submerging 18 If the fuel tank has water in it it must be emptied by pump or siphon Refill the tank with fresh fuel Do not dump contaminated fuel in places not designated for that purpose 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 A WARNING Gasoline is toxic substance Dispose of gasoline properly Contact your local authorities for ap proved disposal meth
286. torque value of the values are for use with dry solvent cleaned threads General Fasteners stainless bolt and nut Torque 5 9 8 8 0 60 0 90 52 78 16 22 1 6 2 2 12 16 30 41 3 1 4 2 22 30 2 8 PERIODIC MAINTENANCE Specifications Standard Fuel System Throttle Lever Free Play about 2 mm 0 08 in Engine Lubrication System Engine Oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 4 0 L 4 2 US qt with or without the filter 5 0 L 5 3 US qt when engine is completely dry Engine Top End Valve Clearance IN 0 22 0 31 0 0087 0 0122 Electrical System Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in PERIODIC MAINTENANCE 2 9 Special Tools and Sealant Oil Filter Wrench Shaft Wrench 57001 1249 57001 1551 875712495 ST5715518T 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Control System Inspection e Inspect the throttle lever free play A x If the free play is incorrect adjust the throttle cable Throttle Lever Free Play Standard about 2 mm 0 08 in e Check that the throttle lever moves smoothly from full open to close and the throttle closes quickly and com pletely in all steering positions by the return spring lf the throttle lever does not return properly check the throttle cable routing cable adjustments and cable dam age Then lubricate the thro
287. ts screw head direction Bypass Outlet Clamp Holder Bypass Outlet Hose Run the bypass outlet hose between the fuel tank and the straps as shown Cooling Hose Oil Cooler Exhaust Manifold Run the cooling hose between the fuel tank and the straps as shown Cooling Hose Pump Oil Cooler Oil Cooler Water Pipe on the Cylinder Head Position the clamp screw head as shown Cooling Hose Cylinder Head Water Pipe Joint under the Left Water Box Muffler Protective Tube Cooling Hose Output Cover Exhaust Pipe Output Cover Cooling Hose Pump Output Cover Oil Pan Band Right Water Box Muffler Position the clamp so that its screw head faces downward and outside Position the clamp so that its screw head faces backward Pump Drain Cooling Hose Pump Output Cover Left Water Box Muffler Cooling Hose Left Water Box Muffler Hull Fix the No 26 and 27 cooling hoses with the band Cooling Hose Output Cover Exhaust Pipe Cooling hose left water box muffler cylinder Run the No 27 cooling hose under the No 26 cooling hose as shown Exhaust Pipe Position the clamp so that its screw head faces inside Exhaust Manifold Cooling Hose Oil Cooler Exhaust Manifold Fuel Tank Fuel Tank Strap Shift Cable Fix the No 6 cooling hose and the shift cable with the band 16 10 APPENDIX Cable Wire Hose Rout
288. ttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x If the idle speed increase check the throttle cable adjust ment and the cable routing e Remove the seat see Hull Engine Hood chapter e Check throttle cable adjustment e With the throttle lever released the upper stop A on the throttle pivot arm B should rest against the stopper C on the throttle body and there should be slight slack in the throttle cable e When the throttle lever is fully applied pulled the lower stop D on the pivot arm should be all the way up against the stopper on the throttle body x necessary adjust the throttle cable e oosen and turn the locknuts A at the bracket until the upper stop on the pivot arm hits against the stopper on the throttle body with slight cable slack e Tighten the locknuts securely Torque Throttle Cable Locknuts 7 8 N m 0 80 kgf m 69 in Ib NOTE OMake sure that the throttle pivot arm stops against the stopper on the throttle body with the throttle lever re leased Air Filter Drain Caps Inspection and Cleaning e Remove the seat see Hull Engine Hood chapter e Remove the rear storage pocket e Inspect the air filter A for water inside with its drain caps B x If there is water the caps remove both caps and dis charge the water NOTE OBe sure to have a rag or cloth underneath for p
289. ure Switch see Oil Pressure Switch Installa tion Inlet Manifold ENGINE LUBRICATION SYSTEM 4 23 Pressure Switch Oil Pressure Switch Removal e Remove Seat see Hull Engine Hood chapter Inlet Manifold see Fuel System DFI chapter e Disconnect Switch Connector Place rag or cloth under the oil pressure switch A and remove the oil pressure switch ODo not damage the connect part B of the switch Oil Pressure Switch Installation Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb Connect the switch connector Install the removed parts EXHAUST SYSTEM 5 1 Exhaust System Table of Contents 5 2 2 6 eee ee een 5 4 Exhaust REMOVAL ueluti 5 4 Exhaust Uo eio 5 5 Exhaust Manifold Cleaning and 5 6 5 7 amp 106 6 m m 5 7 Exhaust Pipe iesu tro tup i e auto unus 5 7 Exhaust Pipe Cleaning and Inspection 5 8 Wate
290. ust ments If possible always operate the watercraft in water rather than use an auxiliary cooling supply 1 4 GENERAL INFORMATION Before Servicing e Obtain a standard garden hose A and a garden hose adapter B as shown C Garden Hose Fitting of Adapter D Flushing Fitting of Adapter E Thread Rp 3 4 OOptional part P No 92005 3746 is available as a garden hose adapter e Open the front storage compartment cover e Remove the flushing cap A on the brim of the storage compartment e Screw a garden hose adapter A onto the flushing fitting B e Attach a garden hose C to a garden hose adapter and secure the hose clamp D 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 CAUTION Always turn the boat 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 rde D 4 Me
291. ve the caps and drain the water Remove the drain plug of inlet manifold and drain water Does the engine start Refill the fuel tank and fuel line after reinstalling the with flesh fuel line with flesh fuel spark plugs There may be water in the Fuel oystem Is there water in engine oil Is oil milky Change the No Run the watercraft in water for at least 10 minutes to dry any remaining water and blow any foreign matter out 41960008 COOLING SYSTEMS 9 13 After Submerging Detailed Procedures after Submerging 1 Remove the seat see Hull Engine Hood chapter 2 Remove the drain screws in the stern to drain water out of the engine compartment 3 Remove the front storage pocket see Hull Engine Hood chapter 4 Disconnect both two connectors A on the primary ignition leads located near the ignition coil 5 Pull and remove all the spark plug caps 6 Remove all spark plugs see Spark Plug Cleaning and Inspection in Periodic Maintenance chapter 7 Turn the ignition switch on push the lanyard key un der the stop button and push the start button 8 If there is any water in the engine it will be pumped out of the spark plug holes A Do not operate the starter for longer than 5 seconds Wait 15 seconds before using it again Be sure that all the water is out of the engine WARNING Do not lean over the engine when performing this procedure A w
292. ven above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 14 24 ELECTRICAL SYSTEM Battery 3 When you do not use the watercraft for months Give a refresh charge before you store the watercraft and store it with the negative lead re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the watercraft s starting system has no problem WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper watercraft electric system Therefore replace a sealed battery only on watercraft whi
293. voltage is out of the standard replace the ECU FUEL SYSTEM DFI 3 51 Fuel Injectors Service Code Character 41 42 43 44 InJ1 InJ2 InJ3 InJ4 Injector Fuel Line Inspection e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the supply joint of the delivery pipe B with the fuel hose C both ends connected with the clamps D as shown OPlug the return joint of the delivery pipe with a rubber plug E OTighten the clamp OApply soap and water solution to the areas G as shown OWatching the pressure gauge squeeze the pump lever H and build up the pressure until the pressure reaches the maximum pressure Fuel Line Maximum Pressure Standard 300 kPa 3 06 44 psi CAUTION During pressure testing do not exceed the maxi mum pressure for which the system is designed OWatch the gauge for at least 6 seconds x the pressure holds steady the system is good x If the pressure drops at once or if bubbles are found in the area the line is leaking Replace the delivery pipe injectors and related parts e Repeat the leak test and check the fuel line for no leak age e Run the hoses correctly see Cable Wire and Hose Rout ing section in Appendix chapter OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System Diagram gt 4 HE SEAT 49 We aeta
294. washer A e Tighten Torque Inlet Air Temperature Sensor 20 N m 2 0 14 ft Ib Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal Do not disconnect the ECU connector e Connect a digital voltmeter to the ECU connector using needle adapter set Special Tool Needle Adapter Set 57001 1457 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter R BL lead terminal 7 Meter BK W lead terminal 8 e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the sensor output voltage OWait 15 seconds before using the starter again Output Voltage at ECU Standard about 2 3 2 6 V at inlet air temperature 20 C 68 F NOTE OThe output voltage changes according to the inlet air temperature Turn the ignition switch OFF FUEL SYSTEM 3 37 Inlet Temperature Sensor Service Code Character 13 Alrt the output voltage is out of the specified check ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU x the output voltage is far out of the specified check the wiring see next diagram e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant K
295. x If either injector doesn t click perform the Injector Signal Test for injector operation Injector Signal Test e Prepare four test lights set with male terminals as shown Rating of Bulb A 12 V 3 3 4 W Terminal Width B 1 8 mm 0 07 in Terminal Thickness C 0 8 mm 0 03 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main har ness connector female leading to harness repair or replacement 6617024251 FUEL SYSTEM DFI 3 49 Fuel Injectors Service Code Character 41 42 43 44 InJ1 112 InJ3 InJ4 e Remove connectors for injector A e Connect each test light set B to the injector harness con nector C e Turn the ignition switch ON e While cranking the engine with the starter motor watch the test lights xlf the test lights flicker at regular intervals the injector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection 6017024351 Olnjector signals can be also confirmed by connecting the hand tester 10 V AC instead of the test light set to the injector harness female connector Crank the en gine with the starter motor and check to see if the hand oscillates at regular intervals Special Tool Hand Tester 57001 1394 the test light doesn t flicker or the test hand doesn t oscillates check the wiring and connectors again If the wiring is good check the inje
296. y in the assembled state so the crankcase halves must be replaced as a set e With high flash point solvent clean off the mating sur faces of the crankcases halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves e Install Crankshaft A and Connecting Rods see Crankshaft Installation Camshaft Chain B Oil Pump Sprocket Chain C Dowel Pins D Cil Passage Pipe E with O ring Oil Seal F e Before fitting the lower case on the upper case check the following OBe sure to hang the camshaft and oil pump sprocket chain on the crankshaft OCheck to see that the oil seal A is in the groove B of the crankcase e Apply liquid gasket A to the mating surface of the lower crankcase half NOTE OMake the application finish within 30 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket Sealant Kawasaki Bond 92104 1062 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts B and oil passage hole C JH10001B31 BOTTOM END 8 17 Crankcase Splitting e Install the oil pump sprocket chain A on the chain guide B of the lower crankcase C e Apply molybdenum disulfide oil solution to the bolt seating surfaces A on the lower crankcase for the M10 bolts B and 8 7 10 b
297. y is fully charged e Remove the ECU see this chapter Do not disconnect the connector e Connect a digital voltmeter A to the ECU connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Water Temperature Sensor Output Voltage Connections to ECU Meter Y lead terminal 37 Meter BK W lead terminal 8 e Turn the ignition switch ON and push the lanyard key un der the stop button e Pushing the start button run the engine 5 6 seconds at idling to measure the sensor output voltage OWait 15 seconds before using the starter again Output Voltage at ECU Standard about 3 4 V at 20 C 68 F NOTE The output voltage changes according to the oil temper ature in the engine 4616059851 4616060851 3 58 FUEL SYSTEM DFI Temperature Sensor Service Code Character 73 OILC 73 OILt e Turn the ignition switch OFF x If the output voltage is out of the specified check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU x If the output voltage is far out of the specified e g when the wiring is open the voltage is about 5 V check the wiring see next diagram xlf the wiring is good check the oil temperature sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kaw
298. y lead connectors A and vehicle down sensor lead connector B e Pull up the bracket A together with the ignition coils B vehicle down sensor C and fuel filter D installed e Unscrew the nuts A and remove the bolts collars B and ignition coils C ELECTRICAL SYSTEM 14 39 14 40 ELECTRICAL SYSTEM Ignition System e Pull out the spark plug lead B from the ignition coil A Lubricate the leads with penetrating rust inhibitor Ignition Coil Installation e Connect the spark plug lead to each ignition coil as fol lows 1 Spark Plug Lead Length 340 mm 2 Spark Plug Lead Length 450 mm 3 Spark Plug Lead Length 540 mm 4 Spark Plug Lead Length 600 mm OMarked E is a number of each lead e Apply a non permanent locking agent to the ignition coil mounting bolts e Install the 1 4 ignition coil and 2 3 ignition coil to the bracket H Torque Ignition Coil Mounting Bolts 7 8 N m 0 80 kgf m 69 in Ib OApply a non permanent locking agent to the bracket bolts 13 4 in A 17 7 in B 21 3 in C 23 6 in D e Install the removal parts OFor JT1500 A2 model Replace the double spring clamps with new ones see Fuel System DFI chapter Ignition System Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance e Remove the ignition coil see Ig
299. y requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery e Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 60 minutes after filling GPO8024B31 8 09000881 8 09000881 ELECTRICAL SYSTEM 14 23 Battery Initial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial charge Standard Charge 1 8 5 10 hours xlf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate Ill 8 08018 81 Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 xlf the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter f it is not at least 12 6 volts repeat charging cycle e After charg

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