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STX-15F
JET SKI
Watercraft
®
Service Manual

Summary of Contents

  • Page 1

    STX-15F JET SKI Watercraft ® Service Manual...

  • Page 2

    Kawasaki Heavy Industries, Ltd. registered in U.S.A., Japan, Austria, Benelux, Sweden, Denmark, Switzerland, France, Canada, Finland, Norway, Greece, Italy, U.K., Portugal, Thailand, and Taiwan. ® KAWASAKI JET SKI is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.

  • Page 3

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

  • Page 5

    The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your JET SKI latest information on product improvements incorporated after this publication.

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    ampere(s) ABDC after bottom dead center alternating current ATDC after top dead center BBDC before bottom dead center bottom dead center BTDC before top dead center °C degree(s) Celsius direct current farad(s) °F degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) Read OWNER’S MANUAL before operating.

  • Page 7

    A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted on service station pumps. Emission Control Information To protect the environment in which we all live, Kawasaki has incorporated an exhaust emis- sion control system in compliance with applicable regulations of the United States Environmental Protection Agency.

  • Page 8

    Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki JET ® watercraft parts. Special tools, gauges, and testers that are necessary when servicing ® Kawasaki JET SKI watercraft are introduced by the Special Tool Manual.

  • Page 9

    This model, JT1500A, is mounted with a four -stroke engine. ® When the JET SKI watercraft is submerged and swamped, the four-stroke engine needs special care and systematic procedure for re- covery compared with the two-stroke engine.

  • Page 11: Table Of Contents

    General Information Smart Learning Operation mode (SLO) (JT1500-A2 model )... Before Servicing ... Model Identification... General Specifications... Unit Conversion Table ... GENERAL INFORMATION 1-1 Table of Contents 1-10 1-11 1-13...

  • Page 12: General Information, Smart Learning Operation Mode (slo) (jt1500-a2 Model ), General Information

    1-2 GENERAL INFORMATION Smart Learning Operation mode (SLO) (JT1500-A2 model ) This watercraft is equipped with the Smart Learning Operation mode (SLO) and normal operation mode (Full Power Operation, FPO). The SLO mode reduces the maximum watercraft speed by ap- proximately 30 percent for a use by unskilled operators.

  • Page 13

    Kawasaki Diagnostic System (KDS) Software KDS software version 2.2 that runs on Windows personal computer (PC) will be available as a di- agnostic tool for watercraft with Kawasaki DFI system. You need the following items to use the KDS. KDS Software Version 2.2 (CD-ROM)

  • Page 14: Before Servicing

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

  • Page 15

    Before Servicing Turn the capsized boat clockwise so that the port side always faces downward. Turning counterclockwise can cause water in the exhaust system to run into the engine, with pos- sible engine damage. Battery Ground Before completing any service on the watercraft, discon- nect the battery wires from the battery to prevent the engine from accidentally turning over.

  • Page 16

    Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with...

  • Page 17

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

  • Page 18

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

  • Page 19

    Before Servicing Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when in- stalling to prevent deformation. Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation.

  • Page 20: Model Identification

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

  • Page 21

    General Specifications Items Engine Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition System Lubrication System Carburetion System Starting System Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Tuning Specifications Spark plug: Type Ignition Timing...

  • Page 22: General Specifications

    1-12 GENERAL INFORMATION General Specifications Items Overall Width Overall Height Dry Weight Fuel Tank Capacity Engine Oil Type Viscosity Capacity Electrical Equipment Battery Maximum Generator Output †: This information shown here represents results under controlled conditions, and the information may not be correct under other conditions. Specifications subject to change without notice, and may not apply to every country.

  • Page 23: Unit Conversion Table

    Unit Conversion Table Prefixes for Units Prefix Symbol mega kilo centi milli micro µ Units of Mass × 2.205 × 0.03527 Units of Volume × 0.2642 × 0.2200 × 1.057 × 0.8799 × 2.113 × 1.816 × 0.03381 × 0.02816 ×...

  • Page 25

    Periodic Maintenance Periodic Maintenance Chart ... Torque and Locking Agent... Specifications ... Special Tools and Sealant ... Periodic Maintenance Procedures... Fuel System... Throttle Control System Inspection... Air Filter Drain Caps Inspection and Cleaning ... Air Filter Inspection and Cleaning ... Fuel Vent Check Valve Inspection ...

  • Page 26

    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. Description Inspect throttle control system (e) Inspect/clean air filter drain caps Inspect/clean air filter Inspect fuel vent check valve...

  • Page 27

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

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    2-4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Oil Passage Joints Oil Cooler Assembly Bolts Oil Pressure Switch Oil Passage Bolt Oil Filter Oil Cooler Positioning Bolt Oil Pan Bolts Dipstick Tube Bolts Oil Pump Sprocket Bolt Oil Pump Cover Bolts Oil Pressure Relief Valve Oil Pipe Bolts Chain Guide Spring Plate Bolt...

  • Page 29

    Torque and Locking Agent Fastener Inlet Side Camshaft Chain Guide Bolts Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Position Sensor Rotor Bolt Water Hose Joint Oil Passage Joint Engine Removal/Installation Engine Mounting Bolts Engine Damper Mounting Bolts Engine Bottom End Crankshaft Sensor Cover Bolts Engine Bracket Mounting Bolts...

  • Page 30

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Pump Cover Mounting Bolts Grate Mounting Bolts Filter Cover Mounting Bolts Steering Handlebar Clamp Bolts Start/stop Switch Case Mounting Screws Throttle Case Mounting Screws Steering Shaft Locknut Steering Shaft Nut Steering Holder Mounting Bolts Steering Neck Mounting Bolts Steering Cable Joint Bolt Ball Joint...

  • Page 31

    Torque and Locking Agent Fastener Starter Relay Mounting Nut Starter Cable Mounting Nut Timing Rotor Bolt Crankshaft Sensor Screws Rubber Grommet Holder Screws Crankshaft Sensor Cover Bolts Oil Temperature Sensor Camshaft Position Sensor Bolt Spark Plugs Regulator/rectifier Bolts Replay Assembly Bolts ECU Mounting Bolts Main Fuse Mounting Bracket Bolt Multifunction Meter Mounting Bolts...

  • Page 32

    2-8 PERIODIC MAINTENANCE Specifications Item Fuel System Throttle Lever Free Play about 2 mm (0.08 in.) Engine Lubrication System Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 4.0 L (4.2 US qt, with or without the filter) 5.0 L (5.3 US qt, when engine is completely dry) Engine Top End Valve Clearance:...

  • Page 33

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

  • Page 34

    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.) •...

  • Page 35

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

  • Page 36

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

  • Page 37

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

  • Page 38

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

  • Page 39

    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 reed, replace the air suction valve as an assembly.

  • Page 40

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the valve clearance between the cam and the valve lifter with a thickness gauge [A]. Valve Clearance Standard: IN 0.15 0.24 mm (0.0059 EX 0.22 0.31 mm (0.0087 ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders...

  • Page 41

    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 intersect. This shim will give the proper clearance.

  • Page 42

    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 lines intersect. This shim will give the proper clearance.

  • Page 43

    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 camshafts properly (see Engine Top End chapter). • Remeasure any valve clearance that was adjusted.

  • Page 44

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

  • Page 45

    Periodic Maintenance Procedures • Leave the engine idle for several minutes with the water running. • Turn off the water. Leave the engine idling. • Rev the engine a few times to clear the water out of the exhaust system. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolu-...

  • Page 46

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

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    Periodic Maintenance Procedures Steering Shaft [B] Hull/Engine Hood Drain Plug Inspection • Check the drain plugs [A] for cracks or damage and the drain plug mounting screws [B] are tightened securely. • Check the seals [C] for damage. If necessary, replace the drain plugs or seals. Electrical System Battery Charging Condition Inspection Battery charging condition can be checked by measuring...

  • Page 48

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

  • Page 49

    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).

  • Page 50

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

  • Page 51

    Periodic Maintenance Procedures All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check Nuts, Bolts, and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition.

  • Page 52

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

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

  • Page 55

    Fuel System (DFI) Fuel System Diagram ... Exploded View... Specifications ... Special Tools and Sealant ... DFI Parts Location... DFI System... DFI Servicing Precautions ... Self-Diagnosis ... Self-diagnosis Outline... Service Code (Character) Table ... Troubleshooting the DFI System ... Throttle Sensor (Service Code/Character-11/tPS) ...

  • Page 56

    3-2 FUEL SYSTEM (DFI) Throttle Lever, Cable and Case... Free Play Inspection ... Throttle Cable Adjustment ... Throttle Case Removal/Disas- sembly... Throttle Case Assembly/Installa- tion ... Throttle Cable Removal ... Throttle Cable Installation ... Throttle Case and Cable Lubrication... Throttle Cable Inspection ... Air Filter ...

  • Page 57

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

  • Page 58

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

  • Page 59

    EO: Fill the hollow with the engine oil (10W-30). G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts Si: Fill the hollow with the specified silicone grease (Kawasaki Bond: 92137-1002). SO: Apply silicone oil to the O-ring. FUEL SYSTEM (DFI) 3-5 Torque N·m...

  • Page 60

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

  • Page 61

    8. Fuel Level Sensor 9. Fuel Filter 10. Fuel Pump A: JT1500-A1 Model B: JT1500-A2 Model L: Apply a non-permanent locking agent. R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120). FUEL SYSTEM (DFI) 3-7 Torque N·m kgf·m ft·lb 0.30 26 in·lb...

  • Page 62

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

  • Page 63

    Exploded View Fastener Air Filter Mounting Bolts Air Filter Bracket Mounting Bolts Throttle Cable Locknut Throttle Case Mounting Screws G: Apply grease. L: Apply a non-permanent locking agent. FUEL SYSTEM (DFI) 3-9 Torque N·m kgf·m ft·lb 87 in·lb 0.80 69 in·lb 0.80 69 in·lb 0.40...

  • Page 64

    3-10 FUEL SYSTEM (DFI) Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Operating range Fuel Pressure (High Pressure Line): Engine Idling Fuel Pump: Type Discharge Throttle Sensor: Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor: Input Voltage...

  • Page 65

    FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Throttle Lever and Cables Throttle Lever Free Play about 2 mm (0.08 in.)

  • Page 66

    Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Fuel Pressure Gauge Adapter: 57001-1463 Throttle Sensor Setting Adapter: 57001-1521 Sensor Harness Adapter: 57001-1561 Harness Adapter: 57001-1562 Kawasaki Bond (Silicone Sealant): 56019-120 Kawasaki Bond (Silicone Grease): 92137-1002...

  • Page 67

    DFI Parts Location 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Inlet Air Pressure Sensor 6. Inlet Air Temperature Sensor 7. Throttle Sensor 8. ISC (Idle Speed Controller) 9. Camshaft Position Sensor 10.

  • Page 68

    3-14 FUEL SYSTEM (DFI) DFI Parts Location 14. Ignition Switch 15. Meter Unit 16. Buzzer 17. Fuel Pump 18. Fuel Level Sensor 19. Vehicle-down Sensor 20. Ignition Coil #1, #4 21. Ignition Coil #2, #3 22. Main Fuse 20 A 23.

  • Page 69

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

  • Page 70

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

  • Page 71

    DFI System Part Name 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Joint Connector H 6. Inlet Air Temperature Sensor 7. Inlet Air Pressure Sensor 8. Joint Connector E 9. Joint Connector J 10.

  • Page 72

    3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Tachometer Signal 2. ECU Main Relay 3. Unused 4. SLO (Smart Learning Operation) Mode (JT1500-A2 Model ) 5. Oil Pressure Switch 6. Engine Stop Switch 7. Inlet Air Temperature Sensor 8.

  • Page 73

    DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.

  • Page 74

    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. Check the fuel system for leaks after hose installation. Fuel Hose [B] Double Spring Clamp [A] Fuel Pipe [C] CAUTION...

  • Page 75

    ○ 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) -Seals of Connector • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.

  • Page 76

    3-22 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode. Push the “SET” button with “MODE” button at the same time for 3 seconds or more. Push either “SET” or “MODE” button for more than one second or more.

  • Page 77

    Self-Diagnosis Service Code (Character) Table Service Service Code Code Character (used in (displayed on ECU) Meter Unit) Throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction,...

  • Page 78

    The service codes (characters) in the past are stored in the ECU. However, the characters cannot be displayed in the meter. The past service codes can be confirmed by using the Kawasaki Diagnostic System (see General Information chapter), and they can be erased.

  • Page 79

    Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Model: Engine No.: Date problem occurred: Environment when problem occurred. □ □ Weather fine, cloudy, □ □ Temperature hot, warm, Problem □ □ chronic, frequency □ □...

  • Page 80

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

  • Page 81

    Throttle Sensor (Service Code/Character-11/tPS) Throttle Sensor Removal/Adjustment CAUTION Never drop the throttle sensor [A], especially on a hard surface. Such a shock to the sensor can dam- age it. • Remove: Seat (see Hull/Engine Hood chapter) Air filter (see air Filter Removal) •...

  • Page 82

    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) ○...

  • Page 83

    Throttle Sensor (Service Code/Character-11/tPS) • Turn the ignition switch ON and push the lanyard key un- der the stop button. • Pushing the start button, run the engine 5 idling to measure the sensor input voltage. ○ Wait 15 seconds before using the starter again. Input Voltage at ECU Standard: 4.75 5.25 V DC...

  • Page 84

    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 way as input voltage inspection. Note the following. Digital Voltmeter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Throttle Sensor Output Voltage Connections to ECU Meter (+) →...

  • Page 85

    Throttle Sensor (Service Code/Character-11/tPS) • Disconnect the throttle sensor connector and connect the setting adapter [A] between the harness connector and throttle sensor connector. • Connect a digital meter to the setting adapter leads. Special Tool - Throttle Sensor Setting Adapter: -1521 Throttle Sensor Output Voltage Connections to Sensor...

  • Page 86

    3-32 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) 1. ECU 2. Joint Connector E 3. Throttle Sensor...

  • Page 87

    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 Air Pressure Sensor Bolts [A] Inlet Air Pressure Sensor Connector [B] Inlet Air Pressure Sensor [C]...

  • Page 88

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

  • Page 89

    Inlet Air Pressure Sensor (Service Code/Character-12/bOSt) If the output voltage is far out of the usable range, check the output voltage at the sensor connector [A]. • Measure the output voltage at the sensor in the same way as input voltage inspection. Note the following. [B] Inlet Air Pressure Sensor Special Tool - Sensor Harness Adapter: 57001-1561 Inlet Air Pressure Sensor Output Voltage...

  • Page 90

    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). •...

  • Page 91

    (see next diagram). • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of ECU Connectors If the wiring is good, check the sensor resistance. Sensor Resistance Inspection •...

  • Page 92

    3-38 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) 1. ECU 2. Joint Connector E 3. Joint Connector H 4. Inlet Air Temperature Sensor...

  • Page 93

    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 the water temperature sensor [B]. •...

  • Page 94

    If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of ECU Connectors 6 seconds at...

  • Page 95

    Water Temperature Sensor (Service Code/Character-14/AqUt) 1. ECU 2. Joint Connector E 3. Water Temperature Sensor Sensor Resistance Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation). • Refer to Electrical System chapter for water temperature sensor inspection. FUEL SYSTEM (DFI) 3-41...

  • Page 96

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

  • Page 97

    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 Position Sensor Inspection ○ The camshaft position sensor have no power source, and when the engine stops, the camshaft position sensor gen- erates no signal.

  • Page 98

    3-44 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code/Character-31/dOS) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the watercraft banks 130° or more to either side (in fact falls down), the weight turns and shuts off the signal.

  • Page 99

    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 the vehicle-down sensor lead with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down Sensor Power Source Voltage Connections to Sensor...

  • Page 100

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring.

  • Page 101

    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 ignition switch OFF. Disconnect the battery (–) cable ter- minal. Do not smoke. well-ventilated and free from any source of flame or sparks;...

  • Page 102

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

  • Page 103

    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, watch the test lights.

  • Page 104

    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], with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage Connector to Injector #1, #2, #3, #4 Meter (+) →...

  • Page 105

    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/pressure pump [A] to the supply joint of the delivery pipe [B] with the fuel hose [C] (both ends connected with the clamps [D]) as shown.

  • Page 106

    3-52 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Joint Connector H 6. Main Relay in Relay Assembly 7.

  • Page 107

    Ignition Coils (Service Code/Character-51, 52/COL1, COL2) Ignition Coil #1, #4: Service Code 51-COL1 Ignition Coil #2, #3: Service Code 52-COL2 Ignition Coil Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can dam- age it.

  • Page 108

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

  • Page 109

    Engine Overheating (Service Code/Character-71/HEAt) • If the service code is displayed, check the doubtful parts referring to the following table. Possible Causes Water passage clogged, loosened or damaged Incorrect engine oil level Engine oil poor quality or incorrect Water temperature sensor broken Jet pump or impeller damaged Oil cooler clogged Carbon build-up on combustion chamber...

  • Page 110

    3-56 FUEL SYSTEM (DFI) Low Engine Oil Pressure (Service Code/Character-72/OILP) • If the service code is displayed, check the doubtful parts referring to the following table. Possible Causes Oil leak Engine oil level too low Engine oil viscosity too low Oil filter clogged Oil pressure switch damaged Oil cooler clogged...

  • Page 111

    Fill the hollow of the oil pan [A] with the specified silicone grease [B] as shown, before installing the oil temperature sensor [C]. [D] 5 mm (0.2 in.) Silicone Grease-Kawasaki Bond: 92137-1002 • Tighten: Torque - Oil Temperature Sensor: 15 N·m (1.5 kgf·m, 11 ft·lb)

  • Page 112

    If the wiring is good, check the oil temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of ECU Connectors 1. ECU 2. Joint Connector E 3. Joint Connector J 4.

  • Page 113

    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 Incorrect engine oil level Engine oil poor quality or incorrect Oil temperature sensor broken Oil cooler clogged Oil pump malfunction Relief valve malfunction...

  • Page 114

    3-60 FUEL SYSTEM (DFI) 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]. •...

  • Page 115

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

  • Page 116

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

  • Page 117

    DFI Power Source Main Fuse Inspection • Refer to the Electrical System chapter for the ECU Fuse Inspection. Relay Assembly Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. •...

  • Page 118

    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 relay assembly.

  • Page 119

    Throttle Lever, Cable and Case Free Play Inspection • Refer to Throttle Control System Inspection in the Peri- odic Maintenance chapter. Throttle Cable Adjustment • Refer to Throttle Cable Adjustment in the Periodic Main- tenance chapter. Throttle Case Removal/Disassembly • Unscrew the mounting screws [A] and remove the han- dlebar pad [B].

  • Page 120

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

  • Page 121

    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 fully open. WARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition. •...

  • Page 122

    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. ○...

  • Page 123

    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 Hose Routing in Appendix chapter). Throttle Cable Steering Cable Fuel Tank Vent Hose Start/Stop Switch Leads Buzzer Leads Multifunction Meter Leads...

  • Page 124

    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] •...

  • Page 125

    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 •...

  • Page 126

    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 con- trols the air/fuel mixture automatically.

  • Page 127

    Throttle Body Assy ISC (Idle Speed Controller) Removal/Installation • Remove Seat (see Hull/Engine Hood chapter) Air Filter (see Air Filter Removal) Bands [A] ISC connector [B] Stepping Motor Mounting Screws [C] Stepping Motor [D] ISC Actuator Mounting Bolts [E] ISC Actuator [F] •...

  • Page 128

    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, 4-5, 5-6 terminals Standard: about 30 Ω...

  • Page 129

    Inlet Manifold Inlet Manifold Removal • Remove: Supply Fuel Hose [A] at Delivery Pipe Return Fuel Hose [B] at Delivery Pipe Delivery Pipe Mounting Bolts [C], Collars and Clamps • Remove the bands [D] and disconnect the following con- nectors. Camshaft Position Sensor Connector [E] Crankshaft Sensor Connector [F] •...

  • Page 130

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

  • Page 131

    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) •...

  • Page 132

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

  • Page 133

    Fuel Line If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the fuel filter and measure the fuel pressure again. • Remove the fuel pressure gauge and adapter. • Run the fuel hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter.

  • Page 134

    3-80 FUEL SYSTEM (DFI) Fuel Line • Prepare a measuring cylinder [A]. • Disconnect the fuel supply hose from the fuel delivery pipe, and set the measuring cylinder and fuel supply hose [B] as shown. • Close the fuel tank cap. WARNING Wipe off spilled out fuel immediately.

  • Page 135

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

  • Page 136

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

  • Page 137

    Fuel Filter Fuel Filter Installation • Route the hose correctly (see Cable, Wire, and Hose Routing section in Appendix chapter). • Install the fuel hoses to the fuel filter, noting its “IN” fitting [A] and “OUT” fitting [B]. ○ For JT1500-A2 model ;...

  • Page 138

    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 lanyard key off the stop button.

  • Page 139

    Fuel Pump Fuel Pump Installation • Press down the rubber holder [A] onto the fuel pump [B] so the stepped part [C] of the holder completely contacts the flanged part [D] of the pump. • Pressing down the rubber holder onto the fuel pump, tighten the small diameter clamp [E].

  • Page 140

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

  • Page 141

    Fuel Pump Fuel Pump Relay Removal • Refer to the Relay Assembly Removal in the DFI Power Source section. Fuel Pump Relay Inspection • Refer to the Relay Assembly Inspection in the DFI Power Source section. 1. Relay Assembly 2. Joint Connector F 3.

  • Page 142

    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 key off the stop button. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks;...

  • Page 143

    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 tank into the hull. • Route the following correctly (see Cable, Wire, and Hose Routing section in Appendix chapter).

  • Page 144

    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 remove the fuel filler tube [B]. • Remove the fuel filler cap [A]. •...

  • Page 145

    Engine Lubrication System Exploded View... Engine Oil Flow Chart... Specifications ... Special Tool and Sealant ... Engine Oil and Oil Filter... Oil Level Inspection... Engine Oil Change... Oil Filter Replacement ... Oil Cooler... Oil Cooler Removal... Oil Cooler Installation... Oil Cooler Disassembly... Oil Cooler Assembly ...

  • Page 146

    4-2 ENGINE LUBRICATION SYSTEM Exploded View...

  • Page 147

    Exploded View Fastener Breather Plate Bolts Oil Filler Cap Oil Passage Plugs Oil Separator Tank Mounting Screws Breather Case Mounting Bolts Breather Pipe Bolts Oil Passage Joints Oil Cooler Assembly Bolts Oil Pressure Switch 10 Oil Passage Bolt 11 Oil Filter 12 Oil Cooler Positioning Bolt 13 Oil Pan Bolts 14 Dipstick Tube Bolts...

  • Page 148

    4-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart A: Blowby Gas B: Supply Engine Oil Flow C: Return Engine Oil Flow D: Oil Sump 1. from Oil Pump Side Pas- sage 2. Oil Cooler 3. to Main Oil Passage 4. Oil Passage Bolt 5.

  • Page 149

    Engine Oil Flow Chart 21. Oil Separator Tank 22. to Air Filter 23. to Oil Pan 24. Joint 25. Camshaft Oil Passage 26. Camshaft Cap Oil Pas- sage 27. Oil Passage (from Oil Pipe to Camshaft Cap) ENGINE LUBRICATION SYSTEM 4-5 28.

  • Page 150

    4-6 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil Grade Viscosity Capacity Level Oil Pressure Measurement Oil pressure @3 000 r/min (rpm), oil temperature 74°C (165°F) Standard API SE, SF, or SG API SH or SJ with JASO MA SAE 10W-40 4.0 L (4.2 US qt, with or without the filter) 5.0 L (5.3 US qt, when engine is completely dry) Between upper and lower level lines (see text)

  • Page 151

    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 ENGINE LUBRICATION SYSTEM 4-7 Kawasaki Bond (Silicone Sealant): 56019-120 Kawasaki Bond (Silicone Sealant): 92104-0004...

  • Page 152

    4-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Watercraft operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Oil Level Inspection This watercraft engine is equipped with a semi-dry sump. In the semi-dry sump engine, the oil level difference is very large between the level measured after just stopping and that after leaving for a long time.

  • Page 153

    Engine Oil and Oil Filter CAUTION Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light.

  • Page 154

    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 to the dipstick tube [B], and then remove it again to check the oil level.

  • Page 155

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

  • Page 156

    • Apply silicon sealant to the joints and tighten them. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Cooler Assembly Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) Water Hose Joints: 20 N·m (2.0 kgf·m, 14 ft·lb) •...

  • Page 157

    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. Exhaust gases contain carbon monoxide, a colorless, odor- less, poisonous gas which can be lethal.

  • Page 158

    Torque - Breather Pipe Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Apply silicone sealant to the inside of the rubber grommet [D]. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Tighten the breather case mounting bolts. M6 × 55 Bolts [E] M6 ×...

  • Page 159

    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 if the hose lies at the bottom. Oil Separator Tank Installation •...

  • Page 160

    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].

  • Page 161

    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 Sensor Cover [B] •...

  • Page 162

    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]. ○...

  • Page 163

    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. If there is any damage or uneven wear, replace the rotors and cover.

  • Page 164

    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 comes back to its seat by spring [B] force.

  • Page 165

    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 hole.

  • Page 166

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

  • Page 167

    Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Connect the switch connector.

  • Page 169

    Exhaust System Exploded View... Exhaust Manifold ... Exhaust Manifold Removal ... Exhaust Manifold Installation ... Exhaust Manifold Cleaning and Inspection... Exhaust Pipe ... Exhaust Pipe Removal... Exhaust Pipe Installation... Exhaust Pipe Cleaning and Inspection ... Water Box Muffler ... Water Box Muffler Removal ... Water Box Muffler Installation ...

  • Page 170

    5-2 EXHAUST SYSTEM Exploded View...

  • Page 171

    Exploded View Fastener Exhaust Manifold Mounting Nuts Exhaust Manifold Mounting Bolts Bypass Nozzle Flushing Hose Joint Water Hose Joint Water Temperature Sensor Exhaust Pipe Mounting Plate Bolts Exhaust Pipe Mounting Bolts EO: Fill the hollow with the engine oil (10W-30). L: Apply a non-permanent locking agent.

  • Page 172

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

  • Page 173

    Exhaust Manifold • Take out the exhaust manifold with the exhaust pipe from the hull. • Disconnect the hose [A] from the exhaust pipe. Exhaust Manifold Installation NOTE ○ Unhook the rubber strap and remove the front exhaust tube from the water box muffler for easier installation of the exhaust manifold, and after connecting the water box muffler to the exhaust pipe, hook the rubber strap and install the tube.

  • Page 174

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

  • Page 175

    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 the exhaust pipe.

  • Page 176

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

  • Page 177

    Water Box Muffler Water Box Muffler Removal • Remove: Rear Storage Pocket Oil Separator Tank with Oil Separator Hoses (see the Lubrication System chapter) Air Filter (see the Fuel System chapter) • Loosen: Joint Tube Clamp Screw (see Exhaust Manifold Re- moval) •...

  • Page 178

    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 correct position. If the rings are damaged or warped, replace the rings with new ones.

  • Page 179

    Engine Top End Exploded View... Specifications ... Special Tools and Sealant ... Clean Air System... Air Suction Valve Removal... Air Suction Valve Installation... Air Suction Valve Check... Clean Air System Hose Inspection... Cylinder Head Cover ... Cylinder Head Cover Removal ... Cylinder Head Cover Installation .

  • Page 180

    6-2 ENGINE TOP END Exploded View...

  • Page 181

    Exploded View Fastener Air Suction Valve Cover Bolts Cylinder Head Cover Bolts Upper Camshaft Chain Guide Bolts Camshaft Cap Bolts Cylinder Head Bolts ( 7) Cylinder Head Bolts ( 11) Cylinder Head Bolts ( 11) Water Jacket Plugs Cylinder Head Bolts ( 6) Engine Hook Bolts Camshaft Position Sensor Bolt EO: Apply engine oil.

  • Page 182

    6-4 ENGINE TOP END Exploded View...

  • Page 183

    Exploded View Fastener Exhaust Side Camshaft Chain Guide Bolts (Upper) Exhaust Side Camshaft Chain Guide Bolts (Lower) Upper Camshaft Chain Guide Bolts Inlet Side Camshaft Chain Guide Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Position Sensor Rotor Bolt Water Hose Joint Oil Passage Joint 10.

  • Page 184

    6-6 ENGINE TOP END Specifications Item Camshafts Cam Height: Exhaust Inlet Camshaft Journal, Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp Valves Valve Clearance: Exhaust Inlet Valve Head Thickness: Exhaust Inlet Valve Stem Bend...

  • Page 185

    Specifications Item Inlet (Outer) Cylinder, Piston Cylinder Inside Diameter Piston Diameter Piston/cylinder Clearance Piston Ring/groove Clearance: Second Piston Ring Groove Width: Second Piston Ring Thickness: Second Piston Ring End Gap: Second Valve Head Thickness Valve Head Thickness [A] Valve Stem Diameter [B] 45°...

  • Page 186

    6-8 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: 57001-221 Valve Spring Compressor Assembly: 57001-241 Top Dead Center Finder: 57001-402 Piston Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 Valve Seat Cutter, 45° - 35: 57001-1116 Valve Seat Cutter, 32°...

  • Page 187

    Special Tools and Sealant Valve Seat Cutter, 45° - 30: 57001-1187 Valve Spring Compressor Adapter, 22: 57001-1202 Valve Guide Arbor, 5: 57001-1203 Valve Guide Reamer, 5: 57001-1204 Valve Seat Cutter Holder, 5: 57001-1208 ENGINE TOP END 6-9 Valve Seat Cutter, 55° - 35: 57001-1247 Compression Gauge Adapter, M10 ×...

  • Page 188

    6-10 ENGINE TOP END Special Tools and Sealant Piston Base, 57001-1604 Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 189

    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 reeds [B] side faces inside and it’s opening [C] side faces inlet side.

  • Page 190

    Replace the head cover gasket with a new one if dam- aged. • Apply silicone sealant [A] to the cylinder head cover gas- ket as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the washer with the metal side [A] faces upward. • Tighten: Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m,...

  • Page 191

    Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner [A]. The push rod does not return to its original po- sition once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.

  • Page 192

    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 follows. ○...

  • Page 193

    Camshaft, Camshaft Chain Camshaft Installation • Be sure to install the following parts. Pins [A] • Apply molybdenum disulfide oil solution to all cam parts and journals. NOTE ○ The exhaust camshaft has a 320 EX mark [A] and the inlet camshaft has a 320 IN mark [B].

  • Page 194

    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 •...

  • Page 195

    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 the gauge extender reaches its highest point.

  • Page 196

    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 journal and the camshaft cap using plastigage [A].

  • Page 197

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

  • Page 198

    NOTE ○ The service codes (COIL1 and COIL2) caused by this procedure are stored in the ECU. If necessary, these service codes can be erased by using the Kawasaki Diagnostic System (KDS). 18.3 kgf/cm²,...

  • Page 199

    Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Cylinder Carbon accumulation on piston and in compression is combustion chamber possibly due to higher than usable damaged valve stem oil seal and/or range damaged piston oil rings (This may be indicated by white exhaust smoke).

  • Page 200

    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.

  • Page 201

    Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sides of the M11 cylinder head bolt washers [B] and the thread of head bolts [C]. • Install the cylinder head. • First, tighten the M11 cylinder head bolts following the tightening sequence [1 10].

  • Page 202

    6-24 ENGINE TOP END Valves Valve Clearance Check • Refer to Valve Clearance Inspection and Adjustment in the 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 they can be installed in their original positions.

  • Page 203

    Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 150°C (248 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.

  • Page 204

    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 pattern on the valve seat.

  • Page 205

    Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.

  • Page 206

    6-28 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.

  • Page 207

    Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° or 55° angle until the seat width is within the specified range.

  • Page 208

    6-30 ENGINE TOP END Valves...

  • Page 209

    Cylinder, Pistons Cylinder Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Head (see Cylinder Head Removal) Dipstick Tube Bolts [A] Dipstick Tube [B] • Remove: Breather Case Mounting Bolts [A] Clamp [B] Breather Case [C] (with Hose) Oil Hose [D]...

  • Page 210

    6-32 ENGINE TOP END Cylinder, Pistons • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove • Remove the 3-piece oil ring with your thumbs in the same manner.

  • Page 211

    Cylinder, Pistons • The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 40° of angle from the opening of the top ring. [A] Top Ring [B] Second Ring [C] Oil Ring Steel Rails [D] Oil Ring Expander...

  • Page 212

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

  • Page 213

    Cylinder, Pistons Piston Ring Thickness • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top [A] 0.87 0.89 mm (0.0343 Second [B] 0.97 0.99 mm (0.0382 Service Limit: Top [A] 0.80 mm (0.0315 in.) Second [B]...

  • Page 215

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

  • Page 216

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View...

  • Page 217

    Exploded View Fastener Engine Mounting Bolts Engine Damper Mounting Bolts L: Apply a non-permanent locking agent. ENGINE REMOVAL/INSTALLATION 7-3 Torque N·m kgf·m ft·lb Remarks...

  • Page 218

    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 Oil Change in Periodic Maintenance chapter). •...

  • Page 219

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

  • Page 220

    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 engine damper mount bolts, and tighten them. Torque - Engine Damper Mounting Bolts: kgf·m, 12 ft·lb) Engine Installation •...

  • Page 221

    Engine Bottom End Exploded View... Specifications ... Special Tools and Sealant ... Coupling ... Coupling/Output Shaft Removal ... Coupling/Output Shaft Installation ... Coupling Damper Inspection... Output Cover Oil Seal Replacement... Oil Seal Inspection ... Magneto Cover Bearing Replacement... Ball Bearing Lubrication ... Ball Bearing Inspection ...

  • Page 222

    8-2 ENGINE BOTTOM END Exploded View...

  • Page 223

    D: Do not apply any grease or oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1062). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1).

  • Page 224

    8-4 ENGINE BOTTOM END Specifications Item Crankshaft, Connecting Rods Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Clearance Connecting Rod Big end Bearing Insert/crankpin Clearance Crankpin Diameter: Marking: None ○ Connecting Rod Big End Bore Diameter: Marking None ○...

  • Page 225

    Specifications Item Crankshaft Main Journal Diameter: Marking None Crankcase Main Bearing Bore Diameter: Marking ○ None Crankshaft Main Bearing Insert Thickness: Brown Black Blue Crankshaft Main Bearing Insert Selection Crankcase Crankshaft Main Bearing Main Journal Bore Diameter Diameter Marking Marking ○...

  • Page 226

    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 Rotor Puller: 57001-1623 Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 227

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

  • Page 228

    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 Attachment: 57001-1547 [B] Coupling Holder #2: 57001-1423 [C] If the coupling [A] and output shaft [B] removed together,...

  • Page 229

    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 shaft [B]. Special Tool - Rotor Holder: 57001-1544 Torque - Output Shaft: 245 N·m (25.0 kgf·m, 180 ft·lb) •...

  • Page 230

    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.

  • Page 231

    Coupling • Replace the oil seals with new ones. • Apply thin coat grease to the oil seal lips [A]. • Pack grease [B] between the oil seal lip and housing of the oil seal (flywheel side oil seal [C]). •...

  • Page 232

    8-12 ENGINE BOTTOM END Magneto Flywheel Magneto Flywheel Removal • Remove: Engine (see Engine Removal/Installation chapter) Crankshaft Sensor Cover (see Electrical System chap- ter) Coupling (see Coupling/Output Shaft Removal) Magneto Cover (see Coupling/Output Shaft Removal) ○ Using the rotor puller [A], pull off the flywheel [B]. Special Tool - Rotor Puller: 57001-1623 Grip: 57001-1591 [C] CAUTION...

  • Page 233

    Magneto Flywheel • Apply grease to the boss outside [A] of the magneto fly- wheel [B]. 10 mm (0.39 in.) [C] • Install the magneto flywheel. NOTE ○ Confirm the magneto flywheel fit or not to the crankshaft before tightening it with specified torque. ○...

  • Page 234

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

  • Page 235

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

  • Page 236

    ○ Moreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket. Sealant - Kawasaki Bond: 92104-1062 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts [B], and oil passage hole [C].

  • Page 237

    Crankcase Splitting • Install the oil pump sprocket chain [A] on the chain guide [B] of the lower crankcase [C]. • Apply molybdenum disulfide oil solution to the bolt seating surfaces [A] on the lower crankcase for the M10 bolts [B] and M8 [7 10] bolts [C].

  • Page 238

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

  • Page 239

    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 •...

  • Page 240

    8-20 ENGINE BOTTOM END Crankshaft and Connecting Rods CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] If the connecting rods, big end bearing inserts, or crank- shaft are replaced with new ones, select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed.

  • Page 241

    Crankshaft and Connecting Rods • Apply small amount of molybdenum disulfide oil solution to the threads [A] and seating surfaces [B] of the connect- ing rod nuts. • First, tighten the nuts to the specified torque. See the table below. •...

  • Page 242

    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- ing rod twist with the connecting rod held horizontally, and using a height gauge.

  • Page 243

    Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.

  • Page 244

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

  • Page 245

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

  • Page 246

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

  • Page 247

    Cooling and Bilge Systems Exploded View... Bilge System... Breather Removal ... Breather Installation ... Breather Cleaning and Inspection... Filter Removal... Filter Installation... Filter Cleaning and Inspection ... Cooling and Bilge System Hoses ... Hose Removal ... Hose Installation ... Hose Inspection ... Cooling and Bilge System Flushing...

  • Page 248

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

  • Page 249

    Exploded View Fastener Water Hose Joint (L Shape Type) Water Hose Joint (Straight Shape Type) Water Hose Joint (Straight Shape Type) 4. Cylinder Head 5. Water Pipe 6. Metal Clamp 7. Cylinder Head Gasket 8. Cylinder 9. Oil Cooler 10. Output Cover 11.

  • Page 250

    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 the breathers [C]. Breather Installation •...

  • Page 251

    Bilge System Follow the next procedures to remove the left side filter [D]. • Remove the water box muffler [B] (see Exhaust System chapter). • Pull the hose [C] off the filter. • Unscrew the mounting screw [A] and remove the filter. Filter Installation •...

  • Page 252

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

  • Page 253

    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. COOLING AND BILGE SYSTEMS 9-7...

  • Page 254

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

  • Page 255

    Cooling and Bilge System Flow Diagram 1. Cylinder Head 2. Water Pipe 3. Cylinder Head Gasket 4. Cylinder 5. Oil Cooler 6. Output Cover 7. Exhaust Pipe 8. Exhaust Pipe Gasket 9. Exhaust Manifold 10. Exhaust Manifold Gasket 11. Flushing Fitting 12.

  • Page 256

    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 water pipe [C] from the cylinder head [D]. Water Pipe Installation •...

  • Page 257

    After Submerging CAUTION Do not operate the watercraft with water in the en- gine. Do not try to start the engine until it is completely empty of water; internal engine parts could be se- verely and immediately damaged. If water gets into the engine, follow this procedure immediately! If water is left in the engine more than a few hours, it will destroy the crankshaft bearings and damage...

  • Page 258

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

  • Page 259

    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.

  • Page 260

    The service codes (COIL1 and COIL2) caused by this procedure are stored in the ECU. If necessary, these service codes can be erased by using the Kawasaki Diagnostic System (KDS). 14. Start the engine by pressing the start button and run less than 15 seconds.

  • Page 261

    After Submerging 18. If the fuel tank has water in it, it must be emptied by pump or siphon. Refill the tank with fresh fuel. Do not dump contaminated fuel in places not designated for that purpose. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.

  • Page 263

    Drive System Exploded View... Specification ... Special Tools and Sealant ... Drive Shaft/Drive Shaft Holder ... Drive Shaft Removal/Installation... Drive Shaft Holder Removal/Disassembly ... Drive Shaft Holder Assembly/Installation... Drive Shaft Runout... Table of Contents DRIVE SYSTEM 10-1 10-2 10-4 10-5 10-6 10-6 10-6...

  • Page 264

    10-2 DRIVE SYSTEM Exploded View...

  • Page 265

    Exploded View Fastener Coupling Drive Shaft Holder Mounting Bolts Coupling Cover Bolts L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. SS: Apply silicone sealant. WG: Apply water resistance grease. DRIVE SYSTEM 10-3 Torque N·m kgf·m ft·lb 0.90 78 in·lb Remarks...

  • Page 266

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

  • Page 267

    Special Tools and Sealant Bearing Driver Set: 57001-1129 Coupling Holder #2: 57001-1423 DRIVE SYSTEM 10-5 Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 268

    10-6 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft Removal/Installation • Remove the engine (see Engine Removal/Installation chapter). • Pull the drive shaft [A] out of the hull. • Hold the drive shaft in a vice, and unscrew the coupling. Special Tool - Coupling Holder: 57001-1423 [A] •...

  • Page 269

    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. •...

  • Page 270

    10-8 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft Runout • Measure drive shaft runout by supporting the shaft on V blocks and setting a dial gauge against the shaft at each point shown. • Turn the drive shaft slowly. The difference between the highest and lowest dial gauge reading is the runout.

  • Page 271

    Pump and Impeller Exploded View... Specifications ... Special Tools and Sealant ... Pump and Impeller ... Pump Removal ... Pump Installation ... Pump Disassembly ... Pump Assembly ... Impeller Inspection... Impeller Outside Diameter Measurement ... Pump Inspection ... Impeller Clearance... Water Filter Cover Removal/Installation ...

  • Page 272

    11-2 PUMP AND IMPELLER Exploded View...

  • Page 273

    Exploded View Fastener Pump Bracket Mounting Bolts (2) Pump Bracket Mounting Bolts (4) Pump Mounting Bolts Grate Mounting Bolts Pump Cover Mounting Bolts Impeller Pump Cap Bolts Pump Outlet Mounting Bolts Steering Nozzle Pivot Bolts 10 Pump Cap Plug Filter Cover Mounting Bolts 12 Steering Cable Joint Bolt A: JT1500-A1 Model B: JT1500-A2 Model...

  • Page 274

    11-4 PUMP AND IMPELLER Specifications Item Jet Pump Impeller Outside Diameter Pump Case Inside Diameter 148.0 Impeller Clearance Standard 147.5 147.7 mm (5.8071 5.8149 in.) 148.1 mm (5.8268 5.8307 in.) 0.15 0.3 mm (0.0059 0.0118 in.) Service Limit 146.5 mm (5.7677 in.) 149.1 mm (5.8701 in.) 0.6 mm (0.0236 in.)

  • Page 275

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

  • Page 276

    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 remove the pump cover [B] with the reverse bracket [C]. •...

  • Page 277

    Liberally coat the outside edge of the pump bracket with silicon sealant [A] to form a seal between the bracket and the hull. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the pump bracket [A] to the hull. ○...

  • Page 278

    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 resistant grease. • Install the pump. ○ Apply a non-permanent locking agent to the pump mount- ing bolts and torque them.

  • Page 279

    Pump and Impeller • Be sure the seals [A] on the hull are in the position. ○ Coat the outside edge [A] of the seal [B] with silicone sealant to form a seal between the hull and seal. • Install the pump cover. ○...

  • Page 280

    11-10 PUMP AND IMPELLER Pump and Impeller • Unscrew the pump cap bolts [A], and remove the pump cap [B]. • Pull out the impeller seal on the impeller. • Hold the shaft in the impeller holder, taking care not to damage it.

  • Page 281

    Pump and Impeller • Remove the bearing by tapping evenly around the bearing inner 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]. They come out of the pump case.

  • Page 282

    11-12 PUMP AND IMPELLER Pump and Impeller • Before installing the pump bearing, blow any dirt or for- eign particles out of the pump case with compressed air. • Before installing the pump bearing, remove the filter cover [C], and check the filter inside or outside [A] on the pump case [B] if the foreign particles do not cling to the filter.

  • Page 283

    Pump and Impeller JT1500-A2 ; • Replace the grease seals with new ones, if necessary, and install them. Special Tool - Bearing Driver Set: 57001-1129 ○ Press each seal [A] into the pump case [B] so that the side with the spring faces outward. ○...

  • Page 284

    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.

  • Page 285

    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 Service Limit: 146.5 mm (5.7677 in.) Pump Inspection •...

  • Page 287

    Exploded View... Special Tool and Sealant ... Steering Cable... Steering Cable Adjustment ... Steering Cable Removal ... Steering Cable Installation ... Steering Cable Inspection... Steering Cable Lubrication... Handlebar ... Handlebar Removal ... Handlebar Installation ... Steering ... Steering Removal ... Steering Installation ...

  • Page 288

    12-2 STEERING Exploded View...

  • Page 289

    Exploded View Fastener Handlebar Clamp Bolts Start/stop Switch Case Mounting Screws Throttle Case Mounting Screws Steering Shaft Locknut Steering Shaft Nut Steering Holder Mounting Bolts Steering Neck Mounting Bolts Steering Cable Joint Bolt Ball Joint 10 Shift Cable End Nut 11 Reverse Bucket Pivot Bolts 12 Shift Cable Nut 13 Steering Cable Nut...

  • Page 290

    12-4 STEERING Special Tool and Sealant Box Wrench (27 mm): 57001-1451 Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 291

    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 pump cavity. ○ The same distance [B]. • If necessary, adjust the steering cable. ○...

  • Page 292

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

  • Page 293

    Steering Cable Steering Cable Installation • Slide a short piece of rubber or plastic tubing over the front cable end to guide the cable through the hull. • Lubricate the outside of the new cable to ease cable in- stallation. •...

  • Page 294

    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]. •...

  • Page 295

    Handlebar Handlebar Installation • Install the pad holder. ○ Apply a non-permanent locking agent to the pad holder bolts. • Install the handlebar on the holder of the steering neck. ○ Apply a non-permanent locking agent to the handlebar clamp bolts. ○...

  • Page 296

    12-10 STEERING Handlebar • Install the bosses [A] on the pad holder to the holes [B] on the handlebar pad. • Align [A] the projection [B] on the pad with the groove [C] on the pad.

  • Page 297

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

  • Page 298

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

  • Page 299

    Steering • Remove the cotter pin [A] and steering shaft locknut [B]. • Take out the holder [C]. • Unscrew the steering holder mounting bolts [A], nuts, and washers, and lift up the steering holder [B]. • Take out the air intake duct mounting bolts [A] and remove the air intake duct [B] from the steering holder [C].

  • Page 300

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

  • Page 301

    Steering • Torque the steering shaft locknut [A]. Torque - Steering Shaft Locknut: 49 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. •...

  • Page 302

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

  • Page 303

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

  • Page 304

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

  • Page 305

    Reverse System • Turn the water craft on its left side and remove the pump cover (see Pump/Impeller chapter). CAUTION Never lay the watercraft on the right side. Water in the exhaust system may drain back into the engine, causing serious damage. •...

  • Page 306

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

  • Page 307

    Hull/Engine Hood Exploded View... Fittings ... Seat Removal ... Seat Installation ... Front Storage Compartment Cover Removal ... Front Storage Compartment Cover Disassembly ... Front Storage Compartment Cover Assembly ... Mirror Removal ... Mirror Installation ... Mirror Stay Removal ... Mirror Stay Installation ...

  • Page 308

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

  • Page 309

    Exploded View Fastener Crossmember Bolts Handrail Bolts Lock Assembly Nut Front Duct Bolts Damper Bolts Damper Bracket Bolts Front Storage Compartment Cover Bolts Hinge Bolts Front Storage Compartment Hook Bolts 10 Steering Cover Bolts 11 Meter Screen Bolts 12 Seat Hook Bolts 13 Seat Locknut 14 Reboarding Step Bolts 15 Mirror Stay Bolts...

  • Page 310

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

  • Page 311

    Exploded View Fastener Stabilizer Bolts Air Inlet Duct Bolts Exhaust Outlet Bolts CY: Apply cyanoacrylate cement. L: Apply a non-permanent locking agent. SS: Apply silicone sealant. SY: Apply synthetic rubber adhesive. HULL/ENGINE HOOD 13-5 Torque N·m kgf·m ft·lb 87 in·lb –...

  • Page 312

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

  • Page 313

    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 lock assembly [B].

  • Page 314

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

  • Page 315

    Fittings Mirror Removal • Open the front storage compartment cover. • Unscrew the nuts [A] and washers [B] and remove the mirrors [C] (both sides). Mirror Installation • Be sure that the washer [A] are in position. Mirror Stay Removal •...

  • Page 316

    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]. •...

  • Page 317

    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 cover [A], turn and pull out the shaft [B] (both side).

  • Page 318

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

  • Page 319

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

  • Page 320

    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] •...

  • Page 321

    Hull Replacement To replace the hull, remove the various parts in the follow- ing suggested order. Battery and Pad Exhaust Pipe and Expansion Chamber Inlet Manifold Engine and Mounts Air Filter Water Box Muffler Drive Shaft and Shaft Holder Pump and Hoses Steering Cover Handlebar and Steering Steering Cable...

  • Page 322

    13-16 HULL/ENGINE HOOD Rubber Parts NOTE ○ The rubber parts on the watercraft are fastened in place with various adhesives. To replace a rubber part, use a cement in the following table, or an equivalent. WARNING Read all warnings and cautions on any solvents and adhesives used.

  • Page 323

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

  • Page 324

    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 with drill bit.

  • Page 325

    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 •...

  • Page 327

    Spark Plug Installation ... 14-24 Spark Plug Inspection ... 14-24 Spark Plug Adjustment ... 14-24 Spark Plug Cleaning ... 14-26 Kawasaki Smart Steering System ... 14-26 Steering Position Sensor and 14-26 Magnet Removal ... 14-26 Steering Position Sensor and 14-27 Magnet Installation ...

  • Page 328

    14-2 ELECTRICAL SYSTEM MODE/SET Button Inspection ... SLO (Smart Learning Operation) Mode Inspection (JT1500-A2 model ) ... Fuel Level Gauge/Symbol/FUEL Characters/Warning Light Inspection... Speedometer Inspection ... Speed Sensor Electric Source Inspection... Tachometer Inspection... 14-58 Battery Symbol/bAt Characters/LED Inspection ... Buzzer Inspection ... 14-58 Relay Assembly...

  • Page 329

    Parts Location 1. Bow 2. Ignition Coil #2, #3 3. Ignition Coil #1, #4 4. Crankshaft Sensor 5. Magneto 6. Starter Motor 7. Fuse Case 8. Regulator/Rectifier 9. ECU (Electronic Control Unit) 10. Starter Relay 11. Battery 12. Relay Assembly (Main Relay/Fuel Pump Relay) ELECTRICAL SYSTEM 14-3...

  • Page 330

    14-4 ELECTRICAL SYSTEM Parts Location 13. Water Temperature Sensor 14. Camshaft Position Sensor 15. Oil Temperature Sensor 16. Oil Pressure Switch 17. Speed Sensor...

  • Page 331

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

  • Page 332

    14-6 ELECTRICAL SYSTEM Exploded View...

  • Page 333

    EO: Fill the hollow of the exhaust manifold with engine oil (10W-30). G: Apply grease. L: Apply a non-permanent locking agent. Si: Fill the hollow of the oil pan with the specified silicone grease (Kawasaki Bond: 92137-1002). WG: Apply water resistant grease. ELECTRICAL SYSTEM 14-7 Torque N·m...

  • Page 334

    14-8 ELECTRICAL SYSTEM Exploded View...

  • Page 335

    Exploded View Fastener Multifunction Meter Mounting Bolts Fuel Level Sensor Clamp Screw Start/stop Switch Case Mounting Screw Speed Sensor Mounting Bolts 5. Multifunction Meter 6. Fuel Level Sensor 7. Buzzer ELECTRICAL SYSTEM 14-9 Torque N·m kgf·m ft·lb 0.40 35 in·lb 0.30 26 in·lb 0.40...

  • Page 336

    14-10 ELECTRICAL SYSTEM Exploded View...

  • Page 337

    Exploded View Fastener Starter Motor Through Bolts Starter Motor Mounting Bolts Starter Motor Ground Bolt Starter Motor Terminal Nut Stator Coil Bolts Grommet Holder Bolts 7. Fuse G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement parts.

  • Page 338

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

  • Page 339

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

  • Page 340

    14-14 ELECTRICAL SYSTEM Wiring Diagram JT1500-A2...

  • Page 341

    ELECTRICAL SYSTEM 14-15 Wiring Diagram JT1500-A2...

  • Page 342

    14-16 ELECTRICAL SYSTEM Specifications Item Battery Type Electric Starter System Starter Motor: Brush Length Commutator Diameter Charging System Regulator/rectifier Output Voltage Alternator Output Voltage Stator Coil Resistance Ignition System Ignition Coil: Primary Winding Resistance Secondary Winding Resistance Spark Plug: Type Crankshaft Sensor Resistance Standard 12 V 18 Ah...

  • Page 343

    Special Tools and Sealant Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Needle Adapter Set: 57001-1457 Holder Attachment: 57001-1547 ELECTRICAL SYSTEM 14-17 Harness Adapter: 57001-1562 Flywheel & Pulley Holder: 57001-1605 Kawasaki Bond (Silicone Sealant): 56019-120 Kawasaki Bond (Silicone Grease): 92137-1002...

  • Page 344

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

  • Page 345

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

  • Page 346

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

  • Page 347

    Battery Removal • Disconnect the battery cables [A]. WARNING To prevent possible personal injury and damage to electrical components, always disconnect the grounded cable first. • Unhook the battery straps [B]. • Carefully lift the battery from the engine compartment. Installation •...

  • Page 348

    14-22 ELECTRICAL SYSTEM Battery • Check to see that there is no peeling, tears or holes in the seal sheet on the top of the 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.

  • Page 349

    Standard Charge 1.8 A × 5 If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.

  • Page 350

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

  • Page 351

    Battery NOTE ○ Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than five minutes at the increased voltage then check if the battery is drawing current. ○...

  • Page 352

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

  • Page 353

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

  • Page 354

    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 remove both end covers [B] and pull the armature out of the yoke [C].

  • Page 355

    Electric Starter System • Install the O-rings [A] and the washers [B] as shown. • Fit the tongue [A] on the brush plate into the end cover groove [B]. • Align the lines [A] on the yoke with the lines [B] on the both end covers.

  • Page 356

    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...

  • Page 357

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

  • Page 358

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

  • Page 359

    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 (in circuit) according to the following table with the engine running at approximately 3 000 rpm.

  • Page 360

    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 tighten them securely. Regulator/Rectifier Inspection • With the hand tester set to the R ×...

  • Page 361

    Charging System • Do the 2nd step regulator circuit test. ○ Connect the test light and the 12 V battery in the same manner as specified in the “1st step regulator circuit test”. ○ Apply 12 V to the positive (+) terminal. ○...

  • Page 362

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

  • Page 363

    Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.

  • Page 364

    Apply silicone sealant [A] to the crankcase halves mating surface on the right and left sides of the crankshaft sensor mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the crankshaft sensor cover. Torque - Crankshaft Sensor Cover Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)

  • Page 365

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

  • Page 366

    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.

  • Page 367

    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 spark plug cap left installed on the spark plug lead) to the tester [B], and mea- sure the arcing distance.

  • Page 368

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

  • Page 369

    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 - Hand Tester: 57001-1394 If there is more resistance than the specified value, the sensor coil has an open lead and must be replaced.

  • Page 370

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

  • Page 371

    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 connec- tor [C], using the needle adapter set [D].

  • Page 372

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

  • Page 373

    Ignition System Ignition System Circuit 1. Joint Connector H 2. Joint Connector J 3. Joint Connector E 4. Crankshaft Sensor 5. Relay Assembly (Main Relay/Fuel Pump Relay) 6. Joint Connector F 7. Connector C 8. Vehicle-down Sensor ELECTRICAL SYSTEM 14-47 9.

  • Page 374

    14-48 ELECTRICAL SYSTEM Ignition System...

  • Page 375

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

  • Page 376

    2 800 rpm. • Center the handlebar in the straight-ahead position, and check the engine speed decreases to an idle speed. If the Kawasaki Smart Steering system does not operate normally, check the steering position sensor clearance. Steering Position Sensor Clearance •...

  • Page 377

    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 sensor using the needle adapter set [C].

  • Page 378

    If the reading is out of the standard, suspect the following. Damaged Steering Position Sensor Open Sensor Circuit If the reading is the standard, but the Kawasaki Smart Steering system does not operate, suspect the ECU and idle speed control in the throttle body.

  • Page 379

    Kawasaki Smart Steering System Steering Position Sensor Circuit 1. Joint Connector Q 2. Multifunction Meter 3. Steering Position Sensor 4. 20 A Main Fuse 5. Joint Connector R 6. Battery 7. Joint Connector S 8. Joint Connector P 9. Ignition Switch 10.

  • Page 380

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

  • Page 381

    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 If the voltage does not rise from zero to battery voltage twice a rotation, replace the sensor. •...

  • Page 382

    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 the temperature-sensing projection is submerged.

  • Page 383

    Multifunction Meter Display Function Inspection • Using the auxiliary wires, connect the 12 V battery [A] to the meter unit [B] connector as follows. JT1500-A2 model JT1500-A1 model [D] ○ Connect the battery positive terminal to the terminal [1]. ○ Connect the battery negative terminal to the terminal [2].

  • Page 384

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

  • Page 385

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

  • Page 386

    14-60 ELECTRICAL SYSTEM Multifunction Meter • If the oscillator is not available, the speedometer can be checked 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 the speed sen- sor electric source voltage and speed sensor.

  • Page 387

    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 input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [7].

  • Page 388

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

  • Page 389

    Multifunction Meter 3. Buzzer 4. Multifunction Meter 5. Speed Sensor 6. 20 A Main Fuse 7. Joint Connector R 8. Starter Motor 9. Battery 10. Joint Connector P 11. Ignition Switch 12. ECU (Electronic Control Unit) A: JT1500-A2 model ELECTRICAL SYSTEM 14-63...

  • Page 390

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

  • Page 391

    Relay Assembly Relay Assembly Circuit Inspection (with the battery disconnected) ECU Main Relay [A] Fuel Pump Relay [B] (*): The actual reading varies with the hand tester used. Relay Assembly Circuit Inspection (with the battery connected) Battery Connection ECU Main Relay [A] Fuel Pump Relay [B] (+): Apply positive lead.

  • Page 392

    14-66 ELECTRICAL SYSTEM Switches Switch Inspection • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). ○ For the switch housing and the ignition switch, refer to the tables in the Wiring Diagram.

  • Page 393

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

  • Page 395

    Preparation for Storage ... Cooling System... Bilge System ... Engine Oil ... Fuel System ... Engine... Air Filter... Battery... Engine Mounting Bolts ... Lubrication ... General ... Removal from Storage... Lubrication ... General Inspection... Fuel System ... Test Run... Storage Table of Contents STORAGE 15-1 15-2...

  • Page 396

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

  • Page 397

    Preparation for Storage • Remove the fuel pump (see the Fuel System chapter). • Clean the fuel pump screen [A] (see Fuel System in Pe- riodic Maintenance chapter). • Refill the fuel tank with fresh fuel approximately 10 L (2.6 gal U.S.).

  • Page 398

    NOTE ○ The service codes (COIL1 and COIL2) caused by this procedure are stored in the ECU. If necessary, these service codes can be erased by using the Kawasaki Diagnostic System (KDS). Air Filter • Remove the air filter (see Fuel (DFI) System chapter).

  • Page 399

    Preparation for Storage General • Wash the engine compartment with fresh water and re- move the drain screw in the stern to drain the water. Wipe up any water left in the compartment. CAUTION Use only a mild detergent in water to wash the hull. Harsh solvents may attack the surface or smear the colors.

  • Page 400

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

  • Page 401

    Removal from Storage Test Run WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odor- less, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. • Start the engine and run it only for 15 seconds. Check for fuel, oil and exhaust leaks.

  • Page 403

    APPENDIX 16-1 Appendix Table of Contents Cable, Wire and Hose Routing ... 16-2 Troubleshooting Guide ... 16-32...

  • Page 404

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

  • Page 405

    Cable, Wire and Hose Routing 1. Crossmember 2. Cylinder Head Cover 3. Throttle Cable 4. Delivery Pipe 5. Fix the throttle cable to the delivery pipe with the band. 6. Inlet Manifold 7. Horizontal Plane 8. Position the clamp pinch head below the horizontal plane. 9.

  • Page 406

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

  • Page 407

    Cable, Wire and Hose Routing 1. Oil Cooler 2. Cylinder Head 3. Water Pipe 4. Cylinder 5. Oil Filter 6. Oil Pan 7. Battery (−) Cable 8. Starter Motor 9. Starter Motor Cable 10. Cooling Hose (Cylinder Head 11. Fix the No.10 cooling hose, battery (−) cable and starter motor cable with the band. 12.

  • Page 408

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

  • Page 409

    Cable, Wire and Hose Routing 1. Clamp 2. Breather Hose (Cylinder Head 3. Clamp Detail 4. Position the clamp pinch heads as shown. 5. Air Suction Valve 6. Air Suction Valve Hose 7. Inlet Water Pipe Joint on the Cylinder (Cooling Water from Left Water Box Muffler) 8.

  • Page 410

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

  • Page 411

    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 Outlet 2. Clamp 3. Holder 4. Bypass Outlet Hose: Run the bypass outlet hose between the fuel tank and the straps as shown. 5.

  • Page 412

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

  • Page 413

    Cable, Wire and Hose Routing 1. Exhaust Manifold 2. Exhaust Pipe 3. Water Hose Point (Cooling Hose from the Output Cover) 4. 30° 5. Water Hose Joint (Cooling Hose from the Oil Cooler) 6. Upper Water Hose Joint 7. Cooling Hose Fitting (Left Water Box Muffler 8.

  • Page 414

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

  • Page 415

    Cable, Wire and Hose Routing 1. Right Rear Duct 2. Right Bilge Hose 3. Left Bilge Hose 4. Left Rear Duct 5. Left Water Box Muffler 6. Position the left rear duct inside the left bilge hose as shown. 7. Position the right rear duct under the right bilge hose as shown. 8.

  • Page 416

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

  • Page 417

    Cable, Wire and Hose Routing 1. Position the clamp screw so that its head faces forward (JT1500-A1). Position the double spring clamp so that its pinch head faces forward (JT1500-A2 ). 2. Delivery Pipe Joints 3. Delivery Pipe 4. Inlet Air Pressure Sensor 5.

  • Page 418

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

  • Page 419

    Cable, Wire and Hose Routing 1. Air Suction Valve Hose (to Air Filter) 2. Air Suction Valve 3. Air Suction Valve Cover (Rear) 4. Water Temperature Sensor Leads 5. Exhaust Manifold 6. Air Suction Valve Hose Fitting 7. Air Suction Valve Cover (Front) 8.

  • Page 420

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

  • Page 421

    Cable, Wire and Hose Routing 1. Crankshaft Sensor Leads 2. Grommet 3. Crankshaft Sensor Cover (Reverse Side) 4. Crankshaft Sensor 5. Magneto Cover (Reverse Side) 6. Magneto Leads 7. Plate for fixing the magneto leads: Do not place the leads between the plate and magneto cover. 8.

  • Page 422

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

  • Page 423

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

  • Page 424

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

  • Page 425

    Cable, Wire and Hose Routing 1. Crossmember 2. Steering Position Sensor Leads 3. Holder and Clamp 4. Fuel Vent Hose 5. Throttle Cable 6. Band 7. Ignition Switch Lead 8. Ignition Switch Lead Connector (Black) 9. Steering Position Sensor Lead Connector (White) 10.

  • Page 426

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

  • Page 427

    Cable, Wire and Hose Routing 1. Multifunction Meter Lead Connector (Blue and Yellow: JT1500-A1), (Blue and White: JT1500 -A2 ) 2. Buzzer Lead Connector (Blue) 3. Start/Stop Switch Lead Connector (White) 4. Fuel Tank 5. Holders and Bands 6. Main Harness 7.

  • Page 428

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

  • Page 429

    Cable, Wire and Hose Routing 1. Regulator/rectifier 2. ECU (Electronic Control Unit) 3. Main Harness 4. Clamp 5. Electrical Parts Bracket 6. To Starter Motor 7. To Battery 8. Relay Assembly 9. Red Mark 10. Starter Relay 11. Right Side Deck 12.

  • Page 430

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

  • Page 431

    Cable, Wire and Hose Routing 1. Fuel Vent Pipe: Hook the pipe at the handlebar. 2. Throttle Cable 3. Buzzer Leads (Run the leads through the protective tube.) 4. Protective Tube 5. Band 6. Clamp 7. Start/Stop Switch Leads 8. Grommet on Steering Holder 9.

  • Page 432

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

  • Page 433

    APPENDIX 16-31 Cable, Wire and Hose Routing 1. 80 mm (3.15 in.) 2. 100 mm (1.18 in.) 3. 180 mm (7.09 in.) 4. 40 mm (1.57 in.) 5. 105 mm (4.13 in.) 6. 90 mm (3.54 in.) 7. 50 mm (1.97 in.) 8.

  • Page 434

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

  • Page 435

    Troubleshooting Guide Fuel line clogged Inlet air pressure sensor trouble Inlet air temperature sensor trouble Engine stalls easily Fuel pump trouble Fuel injector trouble Throttle sensor trouble Camshaft position sensor trouble Fuel pressure too low or too high Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Fuel line clogged...

  • Page 436

    16-34 APPENDIX Troubleshooting Guide Fuel to injector insufficient (DFI) Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble (DFI) Injector clogged Throttle body assy loose Throttle body assy gasket damaged Fuel line clogged Fuel pump operates intermittently Inlet air temperature sensor trouble Throttle sensor trouble Inlet air pressure sensor trouble Compression low...

  • Page 437

    Excessive clearance between impeller and pump case Poor Steering Control (Since faulty steering is dangerous, this problem should be examined by an authorized Jet Ski dealer) Handlebar hard to turn Steering maladjusted Bushing damaged or cracked Steering shaft bent No lubricant on steering pivot...

  • Page 438

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

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