Kawasaki STX-15F - Manual

LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch...

MAINTENANCE AND ADJUSTMENTS Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine Sl engine repair establishment or individual. EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLIN...

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 andrepair work. A basic knowledge of mechanics,the proper use...

NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to bedone. ○ Indicates a procedural sub-step or how to dothe work of the procedural step it follows. Italso precedes the text of a NOTE.Indicates a c...

GENERAL INFORMATION 1-1 1 General Information Table of Contents Smart Learning Operation mode (SLO) (JT1500-A2 model ∼ ) ............................................... 1-2 Before Servicing .................................................................................................................

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...

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 descriptions ha...

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

GENERAL INFORMATION 1-5 Before Servicing CAUTION Turn the capsized boat clockwise so that the port side always faces downward. Turningcounterclockwise can cause water in the exhaust system to run into the engine, with pos-sible engine damage. Battery Ground Before completing any service on the water...

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 duringwatercraft disassembly can cause excessive wear and de-crease performance of the watercraft. Arrangemen...

GENERAL INFORMATION 1-7 Before Servicing Assembly Order In most cases assembly order is the reverse of disassem- bly, however, if assembly order is provided in this ServiceManual, follow the procedures given. Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, ...

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 applythem excessively. Excessive application can clog oil pa...

GENERAL INFORMATION 1-9 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 mi...

1-10 GENERAL INFORMATION Model Identification JT1500-A1 Left Side View JT1500-A1 Right Side View

GENERAL INFORMATION 1-11 General Specifications Items JT1500-A1 ∼ A2 Engine Type 4-stroke, DOHC, 4-cylinder, water cooled Displacement 1 498 mL (91.4 cu in.) Bore and Stroke 83 × 69.2 mm (3.27 × 2.72 in.) Compression Ratio 10.6 : 1 Maximum Horsepower 118 kW (160 PS) @7 500 r/min (rpm) Maximum Torque...

1-12 GENERAL INFORMATION General Specifications Items JT1500-A1 ∼ A2 Overall Width 1 180 mm (46.5 in.) Overall Height 1 050 mm (41.3 in.) Dry Weight 338 kg (745 lb) Fuel Tank Capacity 62 L (16.4 US gal) Engine Oil Type API SE, SF or SGAPI SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 5.0 L (5....

GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 Units of Mass kg × 2.205 = lb g × 0.03527 = oz Units of Volume L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L ...

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart ................................................................................................... 2-2 Torque and Locking Agent..................................................................................

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

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: A...

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

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Inlet Side Camshaft Chain Guide Bolts 12 1.2 104 in·lb L Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb L Camshaft Chain Tensioner Cap Bolt 20 2.0 14 Camshaft Position Sensor Rotor Bolt 12 1.2 104 in·...

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Pump Cover Mounting Bolts 7.9 0.80 69 in·lb L Grate Mounting Bolts 9.8 1.0 87 in·lb L Filter Cover Mounting Bolts 9.8 1.0 87 in·lb L Steering Handlebar Clamp Bolts 16 1.6 12 L Start/stop Switch Case Mounting Sc...

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

2-8 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Lever Free Play about 2 mm (0.08 in.) – – – Engine LubricationSystem Engine Oil: Type API SE, SF or SGAPI SH or SJ with JASO MA – – – Viscosity SAE 10W-40 – – – Capacity 4.0 L (4.2 US qt, with or without the fil...

PERIODIC MAINTENANCE 2-9 Special Tools and Sealant Oil Filter Wrench:57001-1249 Shaft Wrench:57001-1551

2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Control System Inspection • Inspect the throttle lever free play [A].If the free play is incorrect, adjust the throttle cable. Throttle Lever Free Play Standard: about 2 mm (0.08 in.) • Check that the throttle lever moves...

PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Air Filter Inspection and Cleaning • Remove: Air Filter (see Fuel System (DFI) chapter)Flame Arrester [A] (see Air Filter Disassembly in FuelSystem (DFI) chapter) • Clean the flame arrester [A]. • Visually inspect the flame arrester for damag...

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures • The fuel vent check valve [C] must be mounted so thatthe arrow [D] on its case is pointing toward the fuel tank. Fuel Pump Screen Cleaning • Remove the fuel pump (see Fuel System chapter). • Wash the fuel pump screen [A] in non-flammable of...

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

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Depending on the atmospheric temperature of your ridingarea, the engine oil viscosity should be changed accord-ing to the chart shown. • Install the filler cap. Torque - Oil Filler Cap: 1.0 N·m (0.10 kgf·m, 8.7 in·lb) • Check the oil level ...

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

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the valve clearance between the cam and thevalve lifter with a thickness gauge [A]. 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.) ○ When positioning #1 piston TDC at the en...

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures INLET VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold).2. Check present shim size.3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines ...

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures EXHAUST VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold).2. Check present shim size.3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the line...

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Apply molybdenum disulfide oil to the valve lifters and ap-ply engine oil to the shims, and install them. • Install the camshafts. Be sure to install the camshaftsproperly (see Engine Top End chapter). • Remeasure any valve clearance that w...

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

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Leave the engine idle for several minutes with the waterrunning. • Turn off the water. Leave the engine idling. • Rev the engine a few times to clear the water out of theexhaust system. CAUTION Do not run the engine without cooling water su...

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Pump and Impeller Impeller Inspection • Examine the impeller. [A]If there is pitting, deep scratches, nicks or other damage,replace the impeller. NOTE ○ Minor nicks and gouges in the impeller blades can beremoved with abrasive paper or carefu...

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

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the battery terminals [B] are not corroded.If necessary, remove the battery (see Electrical Systemchapter) and clean the terminals and cable ends using asolution of baking soda and water. • After attaching both cables, coat the t...

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

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Lubricate the following with a penetrating rust inhibitor [B]. Throttle Cable [A] Steering Nozzle Pivots [A]Reverse Bucket Pivots [B] • With the cable disconnected at both ends, the cableshould move freely [A] within the cable housing.If ca...

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

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Make sure the above hoses are routed properly and se-cured with the clamps away from any moving parts andsharp edged portions. Plastic Clamp [A]Hose [B]Hose Fitting [C] NOTE ○ The majority of bilge hoses have no clamps at the hoseends. Meta...

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

FUEL SYSTEM (DFI) 3-3 Fuel System Diagram 1. Fuel Pump2. Clamps (JT1500-A1 Model) Double Spring Clamps (JT1500-A2 Model ∼ ) (Installation Procedure: Pull up the clamp stopper [A] with pliers [B].) 3. Main Line4. Fuel Filter5. Supply Line6. Return Line7. Delivery Pipe8. Fuel Injectors9. Fuel Tank

FUEL SYSTEM (DFI) 3-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Oil Pressure Switch 15 1.5 11 SS 2 Fuel Filler Tube Clamp Screws 2.9 0.30 26 in·lb 3 Fuel Level Sensor Clamp Screw 2.9 0.30 26 in·lb 4 Fuel Filter Mounting Bolts 8.8 0.90 78 in·lb L 5. Meter Unit6. Buzzer7. Fuel Vent C...

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

FUEL SYSTEM (DFI) 3-13 DFI Parts Location 1. Fuel Injector #12. Fuel Injector #23. Fuel Injector #34. Fuel Injector #45. Inlet Air Pressure Sensor6. Inlet Air Temperature Sensor7. Throttle Sensor8. ISC (Idle Speed Controller)9. Camshaft Position Sensor 10. Water Temperature Sensor 11. Crankshaft Sen...

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

3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram

FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. Fuel Injector #12. Fuel Injector #23. Fuel Injector #34. Fuel Injector #45. Joint Connector H6. Inlet Air Temperature Sensor7. Inlet Air Pressure Sensor8. Joint Connector E9. Joint Connector J 10. Crankshaft Sensor 11. Relay Assembly (Main Relay/Fuel Pu...

3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Tachometer Signal2. ECU Main Relay3. Unused4. SLO (Smart Learning Operation) Mode (JT1500-A2 Model ∼ ) 5. Oil Pressure Switch6. Engine Stop Switch7. Inlet Air Temperature Sensor8. Ground for Sensors9. Ignition Swi...

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

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

FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ After 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) -Sealsof Connector • Always check battery condition before replacing the DF...

3-22 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode. [A] Push the “SET” button with “MODE” button at thesame time for 3 seconds or more. [B] Push either “SET” or “MODE” button for more thanone second or more. User M...

FUEL SYSTEM (DFI) 3-23 Self-Diagnosis Service Code (Character) Table Service Code (used in ECU) Service Code Character (displayed on Meter Unit) Possible Problems Fail-Safe Function 11 Throttle sensor malfunction,wiring open or short The ECU locks ignition timing intothe ignition timing at closed th...

FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Hull No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ alw...

3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). Poor runningor no power athigh speed □ knocking (fuel poor quality or incorrect). □ engine overheating. □ engine oil...

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 ahard surface. Such a shock to the sensor can dam-age it. • Remove:Seat (see Hull/Engine Hood chapter)Air filter (see air Filter Removal...

3-28 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) • Adjust the throttle sensor positioning as follows. ○ Install the air filter temporarily. ○ After warming up the engine, check the idling speed. Idle Speed Standard: 1 300 ±100 r/min (rpm) ○ Stop the engine and turn the ignition...

3-30 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) Output Voltage Inspection • Measure the output voltage at the ECU in the same wayas input voltage inspection. Note the following. Digital Voltmeter [A]Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Throttle Sensor Ou...

FUEL SYSTEM (DFI) 3-31 Throttle Sensor (Service Code/Character-11/tPS) • Disconnect the throttle sensor connector and connect thesetting adapter [A] between the harness connector andthrottle sensor connector. • Connect a digital meter to the setting adapter leads. Special Tool - Throttle Sensor Sett...

FUEL SYSTEM (DFI) 3-33 Inlet Air 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 • Turn the ignition switch off. • Remove: Seat (see Hull/Engine Hood chapter)Inlet A...

3-36 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) Inlet Air Temperature Removal/Installation CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. • Remove the air filter (see Air Filter Removal). • Disconnect the con...

FUEL SYSTEM (DFI) 3-37 Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) If the output voltage is out of the specified, check the ECUfor its ground, and power supply (see ECU Power SupplyInspection). If the ground and power supply are good,replace the ECU.If the output voltage is far out...

FUEL SYSTEM (DFI) 3-39 Water Temperature Sensor (Service Code/Character-14/AqUt) Water Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. • Disconnect the sensor connector [A], and unscrew thewater temperature...

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. • See the Ignition system section in Electric System chap-ter. Camshaft Po...

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 banks110 ∼ 130° or more to either side (in fact falls down), the weight turns and shuts off the signal. The ECU sens...

FUEL SYSTEM (DFI) 3-45 Vehicle-down Sensor (Service Code/Character-31/dOS) Vehicle-down Sensor Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) • Connect a digital volt meter [A] to the connector [B] of thevehicle-down sensor lead with the needle ad...

FUEL SYSTEM (DFI) 3-47 Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Fuel Injector Removal WARNING Gasoline is extremely flammable and can be ex-plosive under certain conditions. Turn the ignitionswitch OFF. Disconnect the battery (–) cable ter-minal. Do not smoke. Ma...

3-48 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) • Replace the seals [A] with new ones. • Apply grease to the inside and outside of seals. • Install: Delivery Pipe AssemblyCollars • Install the clamps [A] as shown. • Tighten: Torque - Delivery Pipe...

FUEL SYSTEM (DFI) 3-49 Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) • Remove connectors for injector [A]. • Connect each test light set [B] to the injector harness con-nector [C]. • Turn the ignition switch ON. • While cranking the engine with the starter motor, watc...

3-50 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Injector Voltage Inspection • Turn the ignition switch OFF. • Connect a digital voltmeter [A] to the connector [B], withthe needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Injector ...

FUEL SYSTEM (DFI) 3-51 Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Injector Fuel Line Inspection • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressurepump [A] to the supply joint of the delivery pipe [B] withthe fu...

3-52 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) 1. Fuel Injector #12. Fuel Injector #23. Fuel Injector #34. Fuel Injector #45. Joint Connector H6. Main Relay in Relay Assembly7. Joint Connector F8. Connector C 9. Connector D 10. Joint Connector R ...

FUEL SYSTEM (DFI) 3-53 Ignition Coils (Service Code/Character-51, 52/COL1, COL2) Ignition Coil #1, #4: Service Code 51-COL1Ignition Coil #2, #3: Service Code 52-COL2 Ignition Coil Removal/Installation CAUTION Never drop the ignition coils, especially on a hardsurface. Such a shock to the ignition co...

FUEL SYSTEM (DFI) 3-55 Engine Overheating (Service Code/Character-71/HEAt) • If the service code is displayed, check the doubtful parts referring to the following table. Possible Causes Action (Chapter) Water passage clogged, loosened or damaged Inspect (see 9 chapter) Incorrect engine oil level Ins...

FUEL SYSTEM (DFI) 3-57 Oil Temperature Sensor (Service Code/Character-73/OILC or 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. ...

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

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 in...

FUEL SYSTEM (DFI) 3-61 ECU • Check the ECU power source voltage with a tester [A]. ○ Position the terminal in accordance with terminal numbersof ECU connector [B] in this chapter figure. ECU Power Source Inspection Tester Connections: 2 (R/G) Terminal – Battery ( − ) Terminal 9 (R/W) Terminal – Batt...

3-62 FUEL SYSTEM (DFI) ECU ECU Power Source Circuit 1. Main Relay in Relay assembly2. Joint Connector F3. Connector C4. Connector D5. Ignition Switch6. Start Switch7. Joint Connector R8. Main Fuse 20 A9. Battery 10. ECU 11. Joint Connector P 12. Joint Connector S

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

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 Ω range Criteria: When battery is connected → 0 Ω When battery is disconnected → ∞ Ω If the relay does not work as specified, replace the relayasse...

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

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

FUEL SYSTEM (DFI) 3-67 Throttle Lever, Cable and Case • Tighten: Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40 kgf·m, 34 in·lb) • Swing the throttle lever so that the throttle valve is fullyopen. WARNING Operation with an improperly assembled throttlecase could result in an unsafe riding con...

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

FUEL SYSTEM (DFI) 3-69 Throttle Lever, Cable and Case • Tighten: Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40 kgf·m, 34 in·lb) • Route the following correctly (see Cable, Wire, and HoseRouting in Appendix chapter). Throttle CableSteering CableFuel Tank Vent HoseStart/Stop Switch LeadsBuzzer...

3-70 FUEL SYSTEM (DFI) Air Filter Air Filter Removal • Remove the seat (see Hull/Engine Hood chapter). • Remove the rear storage pocket. • Disconnect the following from the air filter [A]. Air Suction Valve Hose [B]Oil Separator Tank Hose [C] • Remove the oil separator tank [D] (see Engine Lubricati...

FUEL SYSTEM (DFI) 3-71 Air Filter Air Filter Disassembly • Remove: Air Filter (see Air Filter Removal)Air Filter Bolts [A] • Remove: Bolts [A]Flame Arrester [B]Hose [C]Duct [D]Air Filter Bracket Mounting Bolts [E]Air Filter Bracket [F] • Remove the air screen [A] Air Filter Assembly • Visually inspe...

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

FUEL SYSTEM (DFI) 3-73 Throttle Body Assy ISC (Idle Speed Controller) Removal/Installation • RemoveSeat (see Hull/Engine Hood chapter)Air Filter (see Air Filter Removal)Bands [A]ISC connector [B]Stepping Motor Mounting Screws [C]Stepping Motor [D]ISC Actuator Mounting Bolts [E]ISC Actuator [F] • Cle...

3-74 FUEL SYSTEM (DFI) Throttle Body Assy ISC Resistance Inspection • Remove: Air Filter (from the throttle body assy)ISC Connector [A] (disconnect) • Measure the ISC resistance with the hand tester. Special Tool - Kawasaki Hand Tester: 57001-1394 ISC [A]Rotor [B] ISC Resistance Connection: 1-2, 2-3...

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

3-76 FUEL SYSTEM (DFI) Inlet Manifold • Remove the inlet manifold [A] with the throttle body assy[B]. • Remove the throttle body assy from the inlet manifold (seeThrottle Body Assy Removal). • Unscrew the inlet manifold plate bolts [A] and remove theplate [B] and gasket [C]. • Remove: Inlet Air Temp...

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

3-78 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Be sure to place a piece of cloth under the fuel supplyhose [A] of the fuel delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel mustbe completely wiped up immediately.When the ...

FUEL SYSTEM (DFI) 3-79 Fuel Line If the fuel pressure is much lower than specified, and ifinspection above checks out good, replace the fuel filterand measure the fuel pressure again. • Remove the fuel pressure gauge and adapter. • Run the fuel hoses in accordance with the Cable, Wire,and Hose Routi...

FUEL SYSTEM (DFI) 3-81 Fuel Vent Check Valve Fuel Vent Check Valve Mounting • Refer to Fuel Vent Check Valve Inspection in the PeriodicMaintenance chapter. Fuel Vent Check Valve Inspection • Refer to Fuel Vent Check Valve Inspection in the PeriodicMaintenance chapter.

3-82 FUEL SYSTEM (DFI) Fuel Filter Fuel Filter Removal NOTE ○ The fuel filter is designed to be used throughout thewatercraft’s life without any maintenance if it is usedunder normal conditions. WARNING Gasoline is extremely flammable and can be ex-plosive under certain conditions. Pull the lanyardk...

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

3-84 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur-face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be ex-plosive under certain conditions. Pull the lanyardkey off the stop button. Make sure the a...

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

3-86 FUEL SYSTEM (DFI) Fuel Pump • Remove the front storage pocket (see Hull/Engine Hoodchapter). • Connect the hand tester (25 V DC) [A] to the fuel pumplead connector [B], using the needle adapter set [C]. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 • Turn the ignition s...

FUEL SYSTEM (DFI) 3-87 Fuel Pump Fuel Pump Relay Removal • Refer to the Relay Assembly Removal in the DFI PowerSource section. Fuel Pump Relay Inspection • Refer to the Relay Assembly Inspection in the DFI PowerSource section. 1. Relay Assembly2. Joint Connector F3. Connector C4. Connector D5. Joint...

3-88 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal • Drain the fuel tank into a suitable container. WARNING Gasoline is extremely flammable and can be explo-sive under certain conditions. Pull the lanyard keyoff the stop button. Do not smoke. Make sure thearea is well ventilated and free from any so...

FUEL SYSTEM (DFI) 3-89 Fuel Tank • Remove the fuel tank [A] out of the hull as shown. Fuel Tank Installation • Be sure the float [A] in place before putting the fuel tankinto the hull. • Route the following correctly (see Cable, Wire, and HoseRouting section in Appendix chapter). Fuel HosesFuel Tank...

3-90 FUEL SYSTEM (DFI) Fuel Tank Fuel Filler and Tube Removal • Open the front storage compartment cover. • Loosen the fuel filler tube clamp screws [A] and removethe fuel filler tube [B]. • Remove the fuel filler cap [A]. • Take out the screws [B] in the filler flange and remove thefuel filler [C]....

ENGINE LUBRICATION SYSTEM 4-1 4 Engine Lubrication System Table of Contents Exploded View ........................................................................................................................ 4-2 Engine Oil Flow Chart...................................................................

ENGINE LUBRICATION SYSTEM 4-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Breather Plate Bolts 7.8 0.80 69 in·lb 2 Oil Filler Cap 1.0 0.10 87 in·lb 3 Oil Passage Plugs 20 2.0 14 L 4 Oil Separator Tank Mounting Screws 4.9 0.50 43 in·lb L 5 Breather Case Mounting Bolts 7.8 0.80 69 in·l...

4-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart A: Blowby GasB: Supply Engine Oil Flow C: Return Engine Oil FlowD: Oil Sump 1. from Oil Pump Side Pas- sage 2. Oil Cooler3. to Main Oil Passage4. Oil Passage Bolt5. Oil Pressure Switch 6. Oil Filter7. Oil Passage (to Oil Filter)8. Oil Passage (to M...

ENGINE LUBRICATION SYSTEM 4-5 Engine Oil Flow Chart 21. Oil Separator Tank22. to Air Filter23. to Oil Pan24. Joint25. Camshaft Oil Passage26. Camshaft Cap Oil Pas- sage 27. Oil Passage (from Oil Pipe to Camshaft Cap) 28. Oil Pipe (from Cylinder to Cylinder Head) 29. Oil Passage (from Main Oil Passag...

4-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API SE, SF, or SGAPI 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 ...

ENGINE LUBRICATION SYSTEM 4-7 Special Tool and Sealant Oil Pressure Gauge, 10 kgf/cm²:57001-164 Oil Pressure Gauge Adapter, PT 1/8:57001-1033 Oil Filter Wrench:57001-1249 Kawasaki Bond (Silicone Sealant):56019-120 Kawasaki Bond (Silicone Sealant):92104-0004

4-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Watercraft operation with insufficient, deteriorated,or contaminated engine oil will cause acceleratedwear and may result in engine seizure, accident,and injury. Oil Level Inspection This watercraft engine is equipped with a semi-dry su...

ENGINE LUBRICATION SYSTEM 4-9 Engine Oil and Oil Filter CAUTION Racing the engine before the oil reaches every partcan cause engine seizure.If the engine oil gets extremely low or if the oil pumpor oil passages clog up or otherwise do not functionproperly, the oil pressure warning light will light. ...

4-10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter • Remove the seat (see Hull/Engine Hood chapter) • Remove the dipstick [A], wipe it dry and insert it back tothe dipstick tube [B], and then remove it again to checkthe oil level. • Check the oil level using the hot level mark on the dipstick[...

ENGINE LUBRICATION SYSTEM 4-11 Oil Cooler Oil Cooler Removal • Remove: Seat (see Hull/Engine Hood chapter)Air Filter with Inlet Duct (see Fuel System (DFI) chapter)Inlet Manifold (see Fuel System (DFI) chapter) • Disconnect the oil pressure switch connector [A]. • Loosen the clamp screws [B] and rem...

4-12 ENGINE LUBRICATION SYSTEM Oil Cooler • Apply engine oil to the thread [A] of the passage bolt andO-ring [B] of the oil filter [C]. • Tighten the oil filter (P/No. 16097-1072). Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb) • Connect the oil pressure switch connector securely. • Install the c...

ENGINE LUBRICATION SYSTEM 4-13 Oil Cooler Oil Cooler Inspection • Start the engine to check for water and oil leaks.If the water and oil leak, replace the O-rings. WARNING Do not run the engine in a closed area. Exhaustgases contain carbon monoxide, a colorless, odor-less, poisonous gas which can be...

4-14 ENGINE LUBRICATION SYSTEM Breather Case and Oil Separator Tank Breather Case Removal • Remove: Seat (see Hull/Engine Hood chapter)Exhaust Manifold (see Exhaust System chapter)Clamp [A]Breather Hose [B]Breather Case Mounting Bolts [C] • Pull the breather case [D] upward. Breather Case Installati...

ENGINE LUBRICATION SYSTEM 4-15 Breather Case and Oil Separator Tank • Remove: Breather Hose Clamp [A]Breather Hose [B]Oil Separator Tank [C] NOTE ○ Hold the hose end to the upward. The oil will flow out ifthe hose lies at the bottom. Oil Separator Tank Installation • When installing the breather hos...

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

ENGINE LUBRICATION SYSTEM 4-17 Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve Oil Pump Sprocket Removal • Drain: Engine Oil (see Periodic Maintenance chapter) • Remove: Engine (see Engine Removal/Installation chapter)Oil Pan (see Oil Pan Removal)Crankshaft Sensor Cover Bolts [A]Crankshaft...

4-18 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve • Install the oil pump chain guide [A], collar [B], washer [C],and bolt [D] as shown. • Install the chain guide spring [A] and the spring plate [B]. ○ Insert the tab [C] of the spring plate in the hole [D] of th...

ENGINE LUBRICATION SYSTEM 4-19 Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve • Install: Oil Pump Sprocket (see Oil Pump Sprocket Installation)Oil Pan (see Oil Pan Installation) Oil Pump Inspection • Remove the oil pump parts. • Visually inspect the oil pump outer, inner rotors and cover....

4-20 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Remove: Oil Pan (see Oil Pan Removal)Relief Valve [A] • Check to see if the valve [A] slides smoothly when push-ing it in with a wooden or other soft rod, and see if it com...

ENGINE LUBRICATION SYSTEM 4-21 Oil Pressure Measurement Oil Pressure Measurement • Remove: Seat (see Hull/Engine Hood chapter)Inlet Manifold (see Fuel System (DFI) chapter)Oil Pressure Switch Connector [A] (disconnect)Oil Pressure Switch [B] • Install the oil pressure gauge adapter [A] to the switch...

4-22 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement WARNING Take care against burns from hot engine oil thatwill drain through the oil passage when the gaugeadapter is removed. • Install: Oil Pressure Switch (see Oil Pressure Switch Installa-tion)Inlet Manifold

ENGINE LUBRICATION SYSTEM 4-23 Oil Pressure Switch Oil Pressure Switch Removal • Remove: Seat (see Hull/Engine Hood chapter)Inlet Manifold (see Fuel System (DFI) chapter) • Disconnect: Switch Connector [A] • Place a rag or cloth under the oil pressure switch [A] andremove the oil pressure switch. ○ ...

EXHAUST SYSTEM 5-1 5 Exhaust System Table of Contents Exploded View ........................................................................................................................ 5-2 Exhaust Manifold .............................................................................................

5-4 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Removal • Remove: Oil Separator Tank [A] with the Oil Separator Hoses (seeLubrication system)Air Filter [B] (see Fuel System chapter) • Disconnect: Spark Plug Caps [C] (see Periodic Maintenance chapter)Hoses [D]Water Temperature Sensor Connector [...

EXHAUST SYSTEM 5-5 Exhaust Manifold • Take out the exhaust manifold with the exhaust pipe fromthe hull. • Disconnect the hose [A] from the exhaust pipe. Exhaust Manifold Installation NOTE ○ Unhook the rubber strap and remove the front exhausttube from the water box muffler for easier installationof ...

5-6 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Cleaning and Inspection • Remove the exhaust manifold parts. • Clean the carbon deposits out of the exhaust passageswith a blunt, roundedged tool. • Flush foreign matter out of the water passages with freshwater. • Check the insides of the water p...

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

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

EXHAUST SYSTEM 5-9 Water Box Muffler Water Box Muffler Removal • Remove: Rear Storage PocketOil Separator Tank with Oil Separator Hoses (see theLubrication System chapter)Air Filter (see the Fuel System chapter) • Loosen: Joint Tube Clamp Screw (see Exhaust Manifold Re-moval) • Remove the front exha...

5-10 EXHAUST SYSTEM Water Box Muffler • Be sure the dampers [A] on the left side water box muffler[B] are in place. • Make sure the two rings [A] are installed to the correctposition.If the rings are damaged or warped, replace the rings withnew ones. • Bind the two rings [A] by putting the paper tap...

ENGINE TOP END 6-1 6 Engine Top End Table of Contents Exploded View ................................... 6-2 Specifications .................................... 6-6 Special Tools and Sealant ................. 6-8 Clean Air System ............................... 6-11 Air Suction Valve Removal............

ENGINE TOP END 6-11 Clean Air System Air Suction Valve Removal • Remove: Seat (see Hull/Engine Hood chapter)Hoses [A] • Remove: Air Suction Valve Cover Bolts [A]Air Suction Valve Covers [B]Air Suction Valve Assembly [C] Air Suction Valve Installation • Install the valve assembly [A] so that its reed...

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

ENGINE TOP 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 chainslack. Observe all the rules listed below:When removing the t...

6-14 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Seat (see Hull/Engine Hood chapter)Spark Plugs (see Periodic Maintenance chapter)Cylinder Head Cover (see Cylinder Head Cover Re-moval)Air Filter (see Fuel System (DFI) chapter) • Position the crankshaft at #1, #4 piston TDC as ...

ENGINE TOP END 6-15 Camshaft, Camshaft Chain Camshaft Installation • Be sure to install the following parts. Pins [A] • Apply molybdenum disulfide oil solution to all cam partsand journals. NOTE ○ The exhaust camshaft has a 320 EX mark [A] and theinlet camshaft has a 320 IN mark [B]. Be careful not ...

6-16 ENGINE TOP END Camshaft, Camshaft Chain • Remove the spark plugs. • Using the shaft wrench [A], turn the crankshaft counter-clockwise [B] and set the crankshaft at #1, 4 piston TDC(see Piston TDC Finding). Special Tool - Shaft Wrench: 57001-1551 • Pull the tension side (exhaust side) of the cha...

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

6-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Cut strips of plastigage (press gauge) to journal width.Place a strip on each journal parallel to the camshaft in-stalled in the correct position. • Measure each clearance between the camshaft journaland the camshaft cap usin...

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

6-20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Thoroughly warm up the engine, while checking that thereis no compression leakage from around the spark plugsor the cylinder head gasket. CAUTION Do not run the engine without cooling ...

ENGINE TOP END 6-21 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Carbon accumulation on piston and incombustion chamber possibly due todamaged valve stem oil seal and/ordamaged piston o...

6-22 ENGINE TOP END Cylinder Head • Remove: Engine Hook Bolts [A]Engine Hook [B]Cylinder Head Bolts [C] • Remove: Upper Dipstick Tube Bolts [A]Upper Exhaust Side Camshaft Chain Guide Bolt [B]M7 Cylinder Head Bolts [C] • Remove the M11 cylinder head bolts [A] and washers. • Take off the cylinder head...

ENGINE TOP END 6-23 Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sidesof the M11 cylinder head bolt washers [B] and the threadof head bolts [C]. • Install the cylinder head. • First, tighten the M11 cylinder head bolts following thetightening sequence [1 ∼ 10]. Torque - Cylind...

6-24 ENGINE TOP END Valves Valve Clearance Check • Refer to Valve Clearance Inspection and Adjustment inthe Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so...

ENGINE TOP END 6-25 Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface beforeinstallation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using thevalve guide arbor. The flange stops...

6-26 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B]and valve seat [C]. ○ Measure the outside diameter [D] of the seating patternon the valve seat.If the outside diameter is too large or too small, repair...

ENGINE TOP END 6-27 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 otherpurposes 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...

6-28 ENGINE TOP END Valves • Measure the outside diameter of the seating surface witha vernier caliper.If the outside diameter of the seating surface is too small,repeat the 45° grind until the diameter is within the spec-ified range. Widened Width [A] of engagement by machining with45° cutterGround...

ENGINE TOP END 6-29 Valves If the seat width is too wide, make the 60° or 55° [A] grinddescribed below.If the seat width is within the specified range, lap the valveto the seat as described below. • Grind the seat at a 60° or 55° angle until the seat width iswithin the specified range. ○ To make the...

6-32 ENGINE TOP END Cylinder, Pistons • Carefully spread the ring opening with your thumbs andthen push up on the opposite side of the ring [A] to removeit. • Remove the 3-piece oil ring with your thumbs in the samemanner. Piston/Cylinder Installation NOTE ○ If a new cylinder is used, use new piston...

ENGINE TOP END 6-33 Cylinder, Pistons • The piston ring openings must be positioned as shown inthe figure. The openings of the oil ring steel rails must beabout 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 (Exh...

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

ENGINE TOP END 6-35 Cylinder, Pistons Piston Ring Thickness • Measure the piston ring thickness. ○ Use the micrometer to measure at several points aroundthe 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 Limi...

ENGINE REMOVAL/INSTALLATION 7-1 7 Engine Removal/Installation Table of Contents Exploded View ........................................................................................................................ 7-2 Engine Removal/Installation ........................................................

ENGINE REMOVAL/INSTALLATION 7-3 Exploded View Torque No Fastener N·m kgf·m ft·lb Remarks 1 Engine Mounting Bolts 36 3.7 27 L 2 Engine Damper Mounting Bolts 16 1.6 12 L L: Apply a non-permanent locking agent.

7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Remove: Seat (see Hull/Engine Hood chapter)Oil Separator Tank (see Lubrication Sytem) • Plug the hose end [A].If the engine disassembles, drain the oil (see Engine OilChange in Periodic Maintenance chapter). • Remove: Air F...

ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Remove: Engine Mounting Bolts [A] • Slide the engine toward the front to disengage the cou-pling [A]. • Using the lifter [A], raise the front side of the engine a littleand lift the engine [B] out off the hull [C]. Engine Damper Removal •...

7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Damper Installation • Install the shim(s) of the same number. • Apply a non-permanent locking agent to the enginedamper mount bolts, and tighten them. Torque - Engine Damper Mounting Bolts: 16 N·m (1.6 kgf·m, 12 ft·lb) Engine Install...

ENGINE BOTTOM END 8-1 8 Engine Bottom End Table of Contents Exploded View ........................................................................................................................ 8-2 Specifications .........................................................................................

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

8-4 ENGINE BOTTOM END Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm (0.023 in.) Con...

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

8-6 ENGINE BOTTOM END Special Tools and Sealant Oil Seal & Bearing Remover:57001-1058 Bearing Driver Set:57001-1129 Coupling Holder #2:57001-1423 Rotor Holder:57001-1544 Holder Attachment:57001-1547 Output Shaft Wrench, Hex 36:57001-1550 Grip:57001-1591 Flywheel & Pulley Holder:57001-1605 Ro...

ENGINE BOTTOM END 8-7 Special Tools and Sealant Kawasaki Bond (Liquid Gasket - Black):92104-1062

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

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

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

ENGINE BOTTOM END 8-11 Coupling • Replace the oil seals with new ones. • Apply thin coat grease to the oil seal lips [A]. • Pack grease [B] between the oil seal lip and housing ofthe oil seal (flywheel side oil seal [C]). • Press in the oil seals until they are bottomed. ○ Install the coupling oil s...

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

ENGINE BOTTOM END 8-13 Magneto Flywheel • Apply grease to the boss outside [A] of the magneto fly-wheel [B]. 10 mm (0.39 in.) [C] • Install the magneto flywheel. NOTE ○ Confirm the magneto flywheel fit or not to the crankshaftbefore tightening it with specified torque. ○ Install the output shaft and...

8-14 ENGINE BOTTOM END Stator Stator Removal • Remove: Engine (see Engine Removal/Installation chapter)Magneto Cover (see Coupling/Output Shaft Removal)Grommet Cover Mounting Bolts [A]Grommet Cover [B]Stator Mounting Bolts [C] with WashersStator Assembly [D] Stator Installation • Apply water resista...

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

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

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

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

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

8-20 ENGINE BOTTOM END Crankshaft and Connecting Rods CAUTION To minimize vibration, the connecting rods shouldhave the same weight mark. Big End Cap [A]Connecting Rod [B]Weight Mark, Alphabet [C]Diameter Mark [D] If the connecting rods, big end bearing inserts, or crank-shaft are replaced with new ...

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

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

ENGINE BOTTOM END 8-23 Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace thecrankshaft with a new one.If the measured crankpin diameters are not less than theservice limit, but do not coincide with the original diametermarkings on the crankshaft, make new marks ...

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

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

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

COOLING AND BILGE SYSTEMS 9-1 9 Cooling and Bilge Systems Table of Contents Exploded View ........................................................................................................................ 9-2 Bilge System............................................................................

COOLING AND BILGE SYSTEMS 9-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Water Hose Joint (L Shape Type) 11 1.1 95 in·lb SS 2 Water Hose Joint (Straight Shape Type) 20 2.0 14 SS 3 Water Hose Joint (Straight Shape Type) 11 1.1 95 in·lb SS 4. Cylinder Head5. Water Pipe6. Metal Clamp7....

9-4 COOLING AND BILGE SYSTEMS Bilge System Breather Removal • Remove: Seat (see Hull/Engine Hood chapter)Rear Storage Pocket • Pull the hoses [A] off the breather. • Unscrew the mounting bolts [B], and remove thebreathers [C]. Breather Installation • Be sure the small hole [A] in the breather is ope...

COOLING AND BILGE SYSTEMS 9-5 Bilge System Follow the next procedures to remove the left side filter [D]. • Remove the water box muffler [B] (see Exhaust Systemchapter). • Pull the hose [C] off the filter. • Unscrew the mounting screw [A] and remove the filter. Filter Installation • Align the projec...

9-6 COOLING AND BILGE SYSTEMS Cooling and Bilge System Hoses Hose Removal • The majority of bilge hoses have no clamps at the hoseends. The majority of bilge system hoses may be simplypulled off their fittings. NOTE ○ Some of the bilge system hoses have plastic clamps athose ends. • All the cooling ...

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

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

COOLING AND BILGE SYSTEMS 9-9 Cooling and Bilge System Flow Diagram 1. Cylinder Head2. Water Pipe3. Cylinder Head Gasket4. Cylinder5. Oil Cooler6. Output Cover7. Exhaust Pipe8. Exhaust Pipe Gasket9. Exhaust Manifold 10. Exhaust Manifold Gasket 11. Flushing Fitting 12. Bypass Outlet13. Left Water Box...

9-10 COOLING AND BILGE SYSTEMS Water Pipe Water Pipe Removal • Remove the inlet manifold (see Fuel System). • Disconnect the cooling hose [A] onto the water pipe fitting. • Unscrew the mounting bolts [B] and remove the waterpipe [C] from the cylinder head [D]. Water Pipe Installation • Apply grease ...

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 completelyempty of water; internal engine parts could be se-verely and immediately damaged. If water gets intothe engine, follow this procedure i...

COOLING AND BILGE 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. Disconnec...

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

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 notdump contaminated fuel in places not designated forthat purpose. WARNING Gasoline is extremely flammable and can be explo-sive under cert...

DRIVE SYSTEM 10-1 10 Drive System Table of Contents Exploded View ........................................................................................................................ 10-2 Specification .................................................................................................

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

10-6 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft Removal/Installation • Remove the engine (see Engine Removal/Installationchapter). • 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] • Whe...

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

PUMP AND IMPELLER 11-1 11 Pump and Impeller Table of Contents Exploded View ........................................................................................................................ 11-2 Specifications ......................................................................................

PUMP AND IMPELLER 11-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Pump Bracket Mounting Bolts (2) 19 1.9 14 L, SS 2 Pump Bracket Mounting Bolts (4) 9.8 1.0 87 in·lb L 3 Pump Mounting Bolts 36 3.7 27 L 4 Grate Mounting Bolts 9.8 1.0 87 in·lb L 5 Pump Cover Mounting Bolts 7.9 0.80 69 ...

11-4 PUMP AND IMPELLER Specifications Item Standard Service Limit Jet Pump Impeller Outside Diameter 147.5 ∼ 147.7 mm (5.8071 ∼ 5.8149 in.) 146.5 mm (5.7677 in.) Pump Case Inside Diameter 148.0 ∼ 148.1 mm (5.8268 ∼ 5.8307 in.) 149.1 mm (5.8701 in.) Impeller Clearance 0.15 ∼ 0.3 mm (0.0059 ∼ 0.0118 i...

PUMP AND IMPELLER 11-5 Special Tools and Sealant Oil Seal & Bearing Remover:57001-1058 Bearing Driver Set:57001-1129 Impeller Wrench:57001-1228 Impeller Holder:57001-1393 Kawasaki Bond (Silicone Sealant):56019-120

11-6 PUMP AND IMPELLER Pump and Impeller Pump Removal • Turn the craft on its left side. • Disconnect the reverse cable ball joint at the rear end. • Unscrew the pump cover mounting bolts [A], and removethe pump cover [B] with the reverse bracket [C]. • Unscrew the grate mounting bolts [A] and remov...

PUMP AND IMPELLER 11-7 Pump and Impeller ○ Take out the pump bracket mounting bolts [A]. ○ Cut the sealant at the indicated area [A] in the figure andremove the pump bracket [B]. Pump Installation • Strip off all the old sealant around the pump intake. • Liberally coat the outside edge of the pump b...

11-8 PUMP AND IMPELLER Pump and Impeller • Be sure trim seal [A] is in place. • Grease the splines on the drive shaft with water resistantgrease. • Install the pump. ○ Apply a non-permanent locking agent to the pump mount-ing bolts and torque them. Torque - Pump Mounting Bolts: 36 N·m (3.7 kgf·m, 27...

PUMP AND IMPELLER 11-9 Pump and Impeller • Be sure the seals [A] on the hull are in the position. ○ Coat the outside edge [A] of the seal [B] with siliconesealant to form a seal between the hull and seal. • Install the pump cover. ○ Be sure the seal [A] is in the position. ○ Apply a non-prmanent loc...

11-10 PUMP AND IMPELLER Pump and Impeller • Unscrew the pump cap bolts [A], and remove the pumpcap [B]. • Pull out the impeller seal on the impeller. • Hold the shaft in the impeller holder, taking care not todamage it. Remove the impeller from the pump shaft andthen pull out the pump shaft. Special...

PUMP AND IMPELLER 11-11 Pump and Impeller • Remove the bearing by tapping evenly around the bearinginner race from the front end of the pump case [A]. Special Tool - Bearing Driver Set: 57001-1129 [B] JT1500-A2 ∼ ; • Press [A] the bussing [B] and the ball bearing [C]. Theycome out of the pump case. ...

11-14 PUMP AND IMPELLER Pump and Impeller JT1500-A1, A2 ∼ ; • Screw on the impeller and torque. Special Tools - Impeller Holder: 57001-1393 Impeller Wrench: 57001-1228 Torque - Impeller: 98 N·m (10 kgf·m, 72 ft·lb) • Visually inspect impeller seal [A], and replace it if neces-sary. • Install the sea...

PUMP AND IMPELLER 11-15 Pump and Impeller Impeller Outside Diameter Measurement • Measure the impeller outside diameter.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.)...

STEERING 12-5 Steering Cable Steering Cable Adjustment • Check the steering cable adjustment. ○ Center the handlebar in the straight-ahead position. • Check that the steering nozzle [A] is centered in the pumpcavity. ○ The same distance [B]. • If necessary, adjust the steering cable. ○ Loosen the lo...

12-6 STEERING Steering Cable • Loosen the locknut [A] at the front end of the steeringcable, and slide back the outer sleeve of the ball joint andtake off the ball joint [B] and remove the locknut from thecable front end. • Pull the holder [A] off the cable bracket. • Slide the steering cable [B] of...

STEERING 12-7 Steering Cable Steering Cable Installation • Slide a short piece of rubber or plastic tubing over the frontcable end to guide the cable through the hull. • 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 f...

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

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

STEERING 12-11 Steering Steering Removal • Remove the handlebar and pad holder (see HandlebarRemoval). • Unscrew the set screw [A] and take out the cap [B]. • Unscrew the shift lever nut [A] and remove the shift lever[B]. • Remove the right stay [A] with the right mirror (seeHull/Engine Hood chapter...

STEERING 12-13 Steering • Remove the cotter pin [A] and steering shaft locknut [B]. • Take out the holder [C]. • Unscrew the steering holder mounting bolts [A], nuts, andwashers, and lift up the steering holder [B]. • Take out the air intake duct mounting bolts [A] and removethe air intake duct [B] ...

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

STEERING 12-15 Steering • Torque the steering shaft locknut [A]. Torque - Steering Shaft Locknut: 49 ∼ 59 N·m (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 clea...

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

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

STEERING 12-19 Reverse System • Turn the water craft on its left side and remove the pumpcover (see Pump/Impeller chapter). CAUTION Never lay the watercraft on the right side. Water inthe exhaust system may drain back into the engine,causing serious damage. • Loosen the locknut [A] at the rear end o...

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

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

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

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

13-8 HULL/ENGINE HOOD Fittings • Drill out the rivets [A] with a drill bit [B] of the correct sizeand remove the front duct cover [C]. Rivet Removal Drill Bit Size 5.0 mm (0.2 in.) NOTE ○ Stop drilling when the rivet head starts to turn with drillbit. ○ Tap the rivet out with a suitable punch and ha...

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

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

HULL/ENGINE HOOD 13-11 Fittings Front Storage Pocket Removal • Remove the front storage pocket mounting screws [A]. • Remove the front storage pocket [B]. Front Storage Pocket Installation • Installation is the reverse of removal. Storage Pocket Disassembly/Assembly • To remove the storage pocket co...

13-12 HULL/ENGINE HOOD Fittings • Pull out the holder [A]. • Unscrew the mounting bolts [D] and remove the cablebracket [C] with the cable [B]. • To remove the right side cover, pull the holder [A] off thecable bracket. • Unscrew the mounting nuts [A] and washers [B] and theleft [C] and right [D] co...

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

13-14 HULL/ENGINE HOOD Fittings Stabilizer Removal • Unscrew the stabilizer bolts [A] and remove the stabilizer[B]. Stabilizer Installation • Install the stabilizer as shown. Stabilizer [A]Chine Line [B]111 ±3 mm (4.37 ±0.12 in.) [C]8 ±2 mm (0.31 ±0.08 in.) [D] • Apply a non-permanent locking agent ...

HULL/ENGINE HOOD 13-15 Hull Replacement To replace the hull, remove the various parts in the follow- ing suggested order. Battery and PadExhaust Pipe and Expansion ChamberInlet ManifoldEngine and MountsAir FilterWater Box MufflerDrive Shaft and Shaft HolderPump and HosesSteering CoverHandlebar and S...

13-16 HULL/ENGINE HOOD Rubber Parts NOTE ○ The rubber parts on the watercraft are fastened in placewith various adhesives. To replace a rubber part, use acement in the following table, or an equivalent. WARNING Read all warnings and cautions on any solventsand adhesives used. Many of these products ...

13-18 HULL/ENGINE HOOD Rubber Parts Rivet Removal • 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 ○ Stop drilling when the rivet head [B] starts to turn withdrill bit. ○ Tap the rivet out with a suitable punch and hammer. Rivet Insta...

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

ELECTRICAL SYSTEM 14-1 14 Electrical System Table of Contents Parts Location.................................... 14-3 Exploded View ................................... 14-6 Wiring Diagram .................................. 14-12 Specifications .................................... 14-16 Special Tools...

14-2 ELECTRICAL SYSTEM MODE/SET Button Inspection ..... 14-58 SLO (Smart Learning Operation) Mode Inspection (JT1500-A2model ∼ ) .................................... 14-58 Fuel Level Gauge/Symbol/FUEL Characters/Warning LightInspection .................................. 14-59 Speedometer Inspection ...

ELECTRICAL SYSTEM 14-3 Parts Location 1. Bow2. Ignition Coil #2, #33. Ignition Coil #1, #44. Crankshaft Sensor5. Magneto6. Starter Motor7. Fuse Case8. Regulator/Rectifier9. ECU (Electronic Control Unit) 10. Starter Relay 11. Battery 12. Relay Assembly (Main Relay/Fuel Pump Relay)

14-4 ELECTRICAL SYSTEM Parts Location 13. Water Temperature Sensor14. Camshaft Position Sensor15. Oil Temperature Sensor16. Oil Pressure Switch17. Speed Sensor

ELECTRICAL SYSTEM 14-5 Parts Location 18. Fuel Level Sensor19. Steering Position Sensor20. Buzzer21. Multifunction Meter22. Starter Switch23. Engine Stop Switch24. Lanyard Key (Tether Code)25. Ignition Switch

ELECTRICAL SYSTEM 14-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Vehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb 2 Electrical Parts Bracket Screws 4.9 0.50 43 in·lb L 3 Starter Relay Case Bolts 7.8 0.80 69 in·lb 4 Ignition Coil Mounting Bolts 8.8 0.90 78 in·lb L 5 Water Tempe...

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

14-18 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be followed servicing electrical systems. ○ Do not reverse the battery cable connections. This willburn out the diodes on the electrical parts. ○ Always check battery condition before condemning otherparts of...

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

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

ELECTRICAL SYSTEM 14-21 Battery Removal • Disconnect the battery cables [A]. WARNING To prevent possible personal injury and damageto electrical components, always disconnect thegrounded cable first. • Unhook the battery straps [B]. • Carefully lift the battery from the engine compartment. Installat...

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

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

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 aft...

ELECTRICAL SYSTEM 14-25 Battery NOTE ○ Increase the charging voltage to a maximum voltage of25 V if the battery will not accept current initially. Chargefor no more than five minutes at the increased voltagethen check if the battery is drawing current. ○ If the battery will accept current, decrease ...

14-26 ELECTRICAL SYSTEM Electric Starter System Starter Relay Removal • Remove: Seat (see Hull/Engine Hood chapter)Rear Storage Pocket (see Hull/Engine Hood chapter)Battery (see this chapter) • Disconnect the negative battery cable from the batteryterminal. (see Battery Removal). • Disconnect the st...

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

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

ELECTRICAL SYSTEM 14-29 Electric Starter System • Install the O-rings [A] and the washers [B] as shown. • Fit the tongue [A] on the brush plate into the end covergroove [B]. • Align the lines [A] on the yoke with the lines [B] on theboth end covers. • Replace the starter motor through bolts [C] with...

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

ELECTRICAL SYSTEM 14-31 Electric Starter System Reduction Gear Removal/Installation • Before removing the reduction gear, remove the magnetoflywheel (see Engine Bottom End chapter). • When installing the reduction gear, apply a molybdenumdisulfide grease [A] to both ends of its shaft. Reduction Gear...

ELECTRICAL SYSTEM 14-33 Charging System Magneto Output Voltage • Remove: Seat (see Hull/Engine Hood chapter)Air Filter with Duct (see Fuel System chapter) • Disconnect the 3-pin stator coil leads connector [A]. • With the hand tester [A] check the magneto output (incircuit) according to the followin...

14-34 ELECTRICAL SYSTEM Charging System • Tighten: Torque - Regulator/rectifier Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) • When installing the bracket, apply a non-permanent lock-ing agent to the bracket mounting screws and tightenthem securely. Regulator/Rectifier Inspection • With the hand tester set...

ELECTRICAL SYSTEM 14-35 Charging System • Do the 2nd step regulator circuit test. ○ Connect the test light and the 12 V battery in the samemanner as specified in the “1st step regulator circuit test”. ○ Apply 12 V to the positive (+) terminal. ○ Check infinity ( ∼ ) terminals respectively. If the te...

ELECTRICAL SYSTEM 14-37 Ignition System WARNING The ignition system produces extremely high volt-age. Do not touch the spark plugs, ignition coils, orspark plug leads while the engine is running, or youcould receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other...

14-38 ELECTRICAL SYSTEM Ignition System • Apply grease to the O-ring and fit it in the groove of thesensor cover. • Apply silicone sealant [A] to the crankcase halves matingsurface on the right and left sides of the crankshaft sensormount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Inst...

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

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

ELECTRICAL SYSTEM 14-41 Ignition System Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance. • Remove the ignition coil (see Ignition Coil Removal). • Connect the ignition coil [A] (with the...

14-42 ELECTRICAL SYSTEM Ignition System Measuring spark plug lead resistance • Check the spark plug lead [A] for visible damage.If the spark plug lead is damaged, replace the spark pluglead. • Measure the lead resistance with the hand tester [B]. Spark Plug Lead Resistance Standard: 3.75 ∼ 6.25 k Ω ...

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

14-44 ELECTRICAL SYSTEM Ignition System • Remove: Front Storage Pocket (see Hull/Engine Hood chapter) • Install the peak voltage adapter [A] into the hand tester[B]. • Connect the peak voltage adapter [A] to the ignition coilprimary lead connector [D], using the harness adapter [C]. Hand Tester [B]I...

ELECTRICAL SYSTEM 14-45 Ignition System Crankshaft Sensor Peak Voltage Check NOTE ○ Be sure the battery is fully charged. • Connect the peak voltage adapter [A] to the hand tester[B]. Special Tool - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B • Connect the adapter the crankshaft sensor lead co...

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

ELECTRICAL SYSTEM 14-47 Ignition System Ignition System Circuit 1. Joint Connector H2. Joint Connector J3. Joint Connector E4. Crankshaft Sensor5. Relay Assembly (Main Relay/Fuel Pump Relay) 6. Joint Connector F7. Connector C8. Vehicle-down Sensor 9. Ignition Switch 10. Joint Connector Q 11. Engine ...

ELECTRICAL SYSTEM 14-49 Kawasaki Smart Steering System Steering Position Sensor and Magnet Removal • Remove the steering holder (see Steering Removal inSteering chapter). • Remove or disconnect: Steering Position Sensor Lead Connector [A]Leads Clamp on Steering HolderSteering Position Sensor Mountin...

14-50 ELECTRICAL SYSTEM Kawasaki Smart Steering System • 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 positionsensor [B] and the magnet [C] with feeler gauge. ...

ELECTRICAL SYSTEM 14-51 Kawasaki Smart Steering System Steering Position Sensor Input Voltage Inspection • Measure the input voltage to the steering position sensor. NOTE ○ Be sure the battery is fully charged. ○ Connect a digital voltmeter [A] to the lead connector [B]of the steering position senso...

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

ELECTRICAL SYSTEM 14-53 Kawasaki Smart Steering System Steering Position Sensor Circuit 1. Joint Connector Q2. Multifunction Meter3. Steering Position Sensor4. 20 A Main Fuse5. Joint Connector R6. Battery7. Joint Connector S8. Joint Connector P9. Ignition Switch 10. ECU (Electronic Control Unit)

14-54 ELECTRICAL SYSTEM Sensors Speed Sensor Removal/Installation • Unscrew the mounting bolts [A] and remove the speedsensor assembly [B]. • Unscrew the cap [A]. • Pull out the speed sensor connector and disconnect it. • When installing the speed sensor assembly, note the fol-lowing. ○ Apply silico...

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

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

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

14-58 ELECTRICAL SYSTEM Multifunction Meter MODE/SET Button Inspection • Check that when the MODE button is pushed and heldcontinuously, the display rotates through the four modes. • Indicate the clock mode. • Check that when the SET button is pushed for more thantwo seconds, the meter display turns...

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

14-60 ELECTRICAL SYSTEM Multifunction Meter • If the oscillator is not available, the speedometer can bechecked as follows. ○ Install the meter unit. ○ Turn on the ignition switch. ○ Rotate the waterwheel by hand. ○ Check that the speedometer shows the speed.If the speedometer does not work, check t...

ELECTRICAL SYSTEM 14-61 Multifunction Meter Tachometer Inspection • Connect the 12 V battery and terminals in the same man-ner as specified in the “Display Function Inspection”. • The revolutions per minute (rpm) equivalent to the inputfrequency is indicated in the oscillator [A] if the squarewave (...

14-62 ELECTRICAL SYSTEM Multifunction Meter Buzzer Inspection • Make sure that the buzzer sounds correctly when turningthe ignition switch key to the “ON” position and warningthe trouble after connecting the buzzer between [9] and[10]. • If the output voltage between [9] and [10] is out of therange ...

ELECTRICAL SYSTEM 14-63 Multifunction Meter 3. Buzzer4. Multifunction Meter5. Speed Sensor6. 20 A Main Fuse7. Joint Connector R8. Starter Motor9. Battery 10. Joint Connector P 11. Ignition Switch 12. ECU (Electronic Control Unit) A: JT1500-A2 model ∼

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

ELECTRICAL SYSTEM 14-65 Relay Assembly Relay Assembly Circuit Inspection (with the battery disconnected) Tester Connection Tester Reading ( Ω ) 3-4 ∞ ECU Main Relay [A] 1-2 Not ∞ * 7-8 ∞ Fuel Pump Relay [B] 5-6 Not ∞ * (*): The actual reading varies with the hand tester used. Relay Assembly Circuit ...

14-66 ELECTRICAL SYSTEM Switches Switch Inspection • Using a hand tester, check to see that only the con-nections shown in the table have continuity (about zeroohms). ○ For the switch housing and the ignition switch, refer to thetables in the Wiring Diagram.If the switch has an open or short, repair...

ELECTRICAL SYSTEM 14-67 Fuse Inspection • Remove: SeatFuse Case [A] • Take out the fuse [A]. • Inspect the fuse element.If it blown out, replace the fuse. Before replacing a blownfuse, always check the amperage in the affected circuit.If the amperage is equal to or greater than the fuse rat-ing, che...

STORAGE 15-1 15 Storage Table of Contents Preparation for Storage .......................................................................................................... 15-2 Cooling System ..............................................................................................................

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

STORAGE 15-3 Preparation for Storage • Remove the fuel pump (see the Fuel System chapter). • Clean the fuel pump screen [A] (see Fuel System in Pe-riodic Maintenance chapter). • Refill the fuel tank with fresh fuel approximately 10 L (2.6gal U.S.). • Turn the ignition switch on. • Push the lanyard k...

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

STORAGE 15-5 Preparation for Storage General • Wash the engine compartment with fresh water and re-move the drain screw in the stern to drain the water. Wipeup 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 smea...

15-6 STORAGE Removal from Storage Lubrication • Carry out all recommended lubrication procedures (seethe Periodic Maintenance chapter). General Inspection • Check for binding or sticking throttle, steering or shiftmechanism. The throttle lever must return fully whenreleased. • Clean and gap spark pl...

STORAGE 15-7 Removal from Storage Test Run WARNING Do not run the engine in a closed area. Exhaustgases contain carbon monoxide, a colorless, odor-less, poisonous gas. Breathing exhaust gas leadsto carbon monoxide poisoning, asphyxiation, anddeath. • Start the engine and run it only for 15 seconds. ...

APPENDIX 16-1 16 Appendix Table of Contents Cable, Wire and Hose Routing ............................................................................................... 16-2 Troubleshooting Guide ...........................................................................................................

APPENDIX 16-3 Cable, Wire and Hose Routing 1. Crossmember2. Cylinder Head Cover3. Throttle Cable4. Delivery Pipe5. Fix the throttle cable to the delivery pipe with the band.6. Inlet Manifold7. Horizontal Plane8. Position the clamp pinch head below the horizontal plane.9. Throttle Body Assy 10. Air F...

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 its screw head direction. 1. Bypass Outlet2. Clamp3. Holder4. Bypass Outlet Hose: Run the bypass outlet hose between the fuel tank and th...

APPENDIX 16-11 Cable, Wire and Hose Routing 1. Exhaust Manifold2. Exhaust Pipe3. Water Hose Point (Cooling Hose from the Output Cover)4. 30°5. Water Hose Joint (Cooling Hose from the Oil Cooler)6. Upper Water Hose Joint7. Cooling Hose Fitting (Left Water Box Muffler ∼ Cylinder) 8. Cooling Hose Fitti...

APPENDIX 16-13 Cable, Wire and Hose Routing 1. Right Rear Duct2. Right Bilge Hose3. Left Bilge Hose4. Left Rear Duct5. Left Water Box Muffler6. Position the left rear duct inside the left bilge hose as shown.7. Position the right rear duct under the right bilge hose as shown.8. Right Water Box Muffl...

APPENDIX 16-17 Cable, Wire and Hose Routing 1. Air Suction Valve Hose (to Air Filter)2. Air Suction Valve3. Air Suction Valve Cover (Rear)4. Water Temperature Sensor Leads5. Exhaust Manifold6. Air Suction Valve Hose Fitting7. Air Suction Valve Cover (Front)8. Breather Hose9. Cylinder Head Cover 10. ...

APPENDIX 16-21 Cable, Wire and Hose Routing 1. Band2. Main Harness3. Rivet4. Washer5. See wire routing at bow.6. See wire routing at stern.7. Clamp8. Speed Sensor Leads9. Water Box Muffler Strap 10. Water Box Muffler

16-32 APPENDIX Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving everypossible cause for each problem listed. Itis meant simply as a rough guide to assistthe troubleshooting for some of the morecommon difficulties. Engine Doesn’t Start, Starting Difficulty Starter motor not rotatin...

MODEL APPLICATION Year Model Beginning Hull No. 2004 JT1500-A1 KAW60001 □ 304 2005 JT1500-A2 US-KAW50001 □ 405 □ :This digit in the hull number changes from one machine to another. Part No.99924-1325-02 Printed in Japan