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Kawasaki JET SKI ULTRA LX Service Manual

Other manuals for JET SKI ULTRA LX: Service Manual

Summary of JET SKI ULTRA LX

  • Page 1

    Ultra 250x jet ski ® watercraft service manual.

  • Page 2

    Is a trademark of kawasaki heavy industries, ltd. Registered in u.S.A., japan, austria, benelux, sweden, denmark, switzerland, france, canada, finland, norway, greece, italy, u.K., portugal, thailand, and taiwan. Kawasaki jet ski ® is a trademark of kawasaki heavy industries, ltd. Registered in aust...

  • Page 3: Quick Reference Guide

    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 th...

  • Page 5: Ultra 250X

    Ultra 250x jet ski ® watercraft service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality as...

  • Page 6

    List of abbreviations a ampere(s) lb pound(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc after top dead center n newton(s) bbdc before bottom dead center pa pascal(s) bdc bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inch...

  • Page 7

    Maintenance and adjustments maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine sl engine repair establishment or individual. Emission control information fuel information this engine is certified to operate on unleaded premium grade gasolin...

  • Page 8: Foreword

    Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...

  • Page 9

    Note ○ this note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • indicates a procedural step or work to be done. ○ indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a note. Indicates...

  • Page 11: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 12

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly oper- ation on watercraft, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions h...

  • Page 13

    General information 1-3 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. • open the front storage c...

  • Page 14

    1-4 general information before servicing caution turn the capsized boat clockwise so that the port side always faces downward. Turning counterclockwise can cause water in the exhaust system to run into the engine, with pos- sible engine damage. Battery ground before completing any service on the wat...

  • Page 15

    General information 1-5 before servicing cleaning watercraft before disassembly clean the watercraft thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during watercraft disassembly can cause excessive wear and de- crease performance of the watercraft. Arrangem...

  • Page 16

    1-6 general information 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,...

  • Page 17

    General information 1-7 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 ...

  • Page 18

    1-8 general information 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 m...

  • Page 19

    General information 1-9 before servicing harness connector apply grease [a] on all connectors of harness [b] for water resistance. Do not apply grease on the only connector of inlet air pressure sensor..

  • Page 20

    1-10 general information model identification jt1500b7f left side view jt1500b7f right side view hull identification number (hin) engine number.

  • Page 21

    General information 1-11 general specifications items jt1500b7f engine type 4-stroke, dohc, 4-cylinder, water cooled displacement 1 498 cm³ (91.4 cu in.) bore and stroke 83 × 69.2 mm (3.27 × 2.72 in.) compression ratio 7.8 : 1 maximum horsepower 184 kw (250 ps) @7 750 r/min (rpm) maximum torque 237 ...

  • Page 22

    1-12 general information general specifications items jt1500b7f overall width 1 195 mm (47.0 in.) overall height 1 150 mm (45.3 in.) dry weight 416 kg (917 lb) fuel tank capacity 78 l (20.6 us gal) engine oil type api se, sf or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 5.0 l (5....

  • Page 23

    General information 1-13 unit conversion table prefixes for units prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass kg × 2.205 = lb g × 0.03527 = oz units of volume l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us) l ...

  • Page 25: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-2 torque and locking agent..................................................................................

  • 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. Frequency description initial 10 hours every 25 hours eve...

  • Page 27

    Periodic maintenance 2-3 periodic maintenance chart frequency description initial 10 hours every 25 hours every 50 hours every 100 hours reference check all hoses, hose clamps, nuts, bolts, and fasteners • • 2-32 (e): emission related items.

  • Page 28

    2-4 periodic maintenance 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: ...

  • Page 29

    Periodic maintenance 2-5 torque and locking agent torque fastener n·m kgf·m ft·lb remarks pulley bolt 19 1.9 14 belt cover bolts 4.9 0.50 43 in·lb l intercooler plate bolts 8.8 0.90 69 in·lb l intercooler bracket bolts 7.8 0.80 69 in·lb intercooler mounting bolts 30 3.1 22 water hose joint 11 1.1 95...

  • Page 30

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks exhaust pipe mounting bolts (l = 95 mm) 35 3.6 26 mark plate bolts 5.0 0.51 44 in·lb water hose joint 20 2.0 14 l muffler body bolts 35 3.6 26 exhaust tube clamp screws 2.9 0.30 26 in·lb water hose joint 11 1.1...

  • Page 31

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks output shaft 245 25.0 180 mo coupling 110 11 81 crankcase bolts (m10) 50 5.0 36 mo, s crankcase bolts (m8) 29 3.0 22 mo, s crankcase bolts (m8) 29 3.0 22 s crankcase bolts (m6) 12 1.2 104 in·lb s cooling and bi...

  • Page 32

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks reverse bucket pivot bolts 19 1.9 14 l hull/engine hood stabilizer bolts 9.8 1.0 87 in·lb ln front bumper bolts – – – l exhaust outlet bolts – – – l handrail plate nuts 9.8 1.0 87 in·lb l side cover nuts – – – ...

  • Page 33

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankshaft sensor cover bolts 7.8 0.80 69 in·lb spark plugs 13 1.3 113 in·lb the next table, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only...

  • Page 34

    2-10 periodic maintenance specifications item standard service limit fuel system throttle lever free play about 2 mm (0.08 in.) – – – engine lubrication system engine oil: type api se, sf or sg api sh, sj or sl with jaso ma – – – viscosity sae 10w-40 – – – capacity 4.0 l (4.2 us qt, with or without ...

  • Page 35

    Periodic maintenance 2-11 special tools and sealant oil filter wrench: 57001-1249 shaft wrench: 57001-1551 belt measuring gauge: 57001-1697.

  • Page 36

    2-12 periodic maintenance periodic maintenance procedures fuel system throttle control system inspection • inspect the throttle lever free play [a]. If the free play is incorrect, adjust the throttle cable. Throttle lever free play standard: about 2 mm (0.08 in.) • check that the throttle lever move...

  • Page 37

    Periodic maintenance 2-13 periodic maintenance procedures supercharger drive belt for wear/damage and belt tension inspection • inspect the supercharger drive belt tension as follows. • disconnect the following from the oil separator tank. Breather hose (to air box) breather hose (to cylinder head c...

  • Page 38

    2-14 periodic maintenance periodic maintenance procedures • check that the gauge indicator [a] is within the area [b] of recess. Belt tension range standard: 500 ∼ 960 nm [c] tension is weak. [d] tension is strong. If the gauge indicator is without the area of recess, adjust the belt tension. • loos...

  • Page 39

    Periodic maintenance 2-15 periodic maintenance procedures if the belt teeth [a] are wear, replace the belt with a new one (see engine removal in the engine removal/instal- lation chapter). Whenever the belt is replaced, inspect the engine and supercharger pulleys (see engine removal in the engine re...

  • Page 40

    2-16 periodic maintenance periodic maintenance procedures fuel vent check valve inspection the fuel vent check valve is mounted in the fuel tank vent hose to prevent fuel from spilling during riding. Air can flow into the tank to allow fuel to be drawn out by the fuel pump, but fuel cannot flow out ...

  • Page 41

    Periodic maintenance 2-17 periodic maintenance procedures throttle shaft spring inspection • remove the seat (see seat removal in the hull/engine hood chapter). • check the throttle shaft spring [a] by pulling the throttle lever. If the springs are damaged or weak, replace the throttle body. Engine ...

  • Page 42

    2-18 periodic maintenance periodic maintenance procedures • drain the oil thoroughly from the dipstick tube [a] using a commercially-available vacuum pump [b]. Warning do not discard the engine oil as the engine oil is toxic substance and will pollute the environment. Contact your local authority fo...

  • Page 43

    Periodic maintenance 2-19 periodic maintenance procedures • replace the filter with a new one. • apply engine oil to the gasket [a] before installation. • tighten the filter with the oil filter wrench. Torque - oil filter: 18 n·m (1.8 kgf·m, 13 ft·lb) • pour in the specified type and amount of oil (...

  • Page 44

    2-20 periodic maintenance periodic maintenance procedures ○ using the shaft wrench [a], turn the crankshaft counter- clockwise [b] and set the crankshaft at #1, 4 piston tdc. Special tool - shaft wrench: 57001-1551 ○ the timing marks [a] must be aligned with the cylinder head upper surface [b] as sh...

  • Page 45

    Periodic maintenance 2-21 periodic maintenance procedures • to change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note ○ mark and record the valve lifter and shim locations so they can be reinstalled in th...

  • Page 46

    2-22 periodic maintenance 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 line...

  • Page 47

    Periodic maintenance 2-23 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 li...

  • Page 48

    2-24 periodic maintenance 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 camshaft installation in the engine top end chapter). • remea...

  • Page 49

    Periodic maintenance 2-25 periodic maintenance procedures note ○ the jt1500b has the damper with white mark [a]. Cooling and bilge systems cooling system flushing to prevent sand or salt deposits from accumulating in the cooling system, it must be flushed occasionally. Flush the system according to ...

  • Page 50

    2-26 periodic maintenance periodic maintenance procedures • start the engine and allow it to idle before turning on the water. Caution the engine must be running before the water is turned on or water may flow back through the exhaust pipe into the engine, resulting in the pos- sibility of severe in...

  • Page 51

    Periodic maintenance 2-27 periodic maintenance procedures • before reconnecting the hoses to the plastic breather fit- ting make sure the small hole [a], on top of the breather fitting is clear. • reconnect the bilge hoses. Pump and impeller impeller inspection • examine the impeller. [a] if there i...

  • Page 52

    2-28 periodic maintenance periodic maintenance procedures handlebar pivot lubrication • check the bushings for damage and wear. If the bushings are damaged or worn, replace them. • grease: bushings [a] steering shaft [b] hull/engine hood drain plug inspection • check the drain plugs [a] for cracks o...

  • Page 53

    Periodic maintenance 2-29 periodic maintenance procedures electrical system battery charging condition inspection battery charging condition can be checked by measuring battery terminal voltage. • disconnect the battery terminal cables (see battery re- moval in the electrical system chapter). Cautio...

  • Page 54

    2-30 periodic maintenance periodic maintenance procedures • visually inspect the spark plugs. If the spark plug center electrode [a] and/or side elec- trode [b] are corroded or damaged, or if the insulator [c] is cracked, replace the plug. • measure the gaps [d] with a wire-type thickness gauge. If ...

  • Page 55

    Periodic maintenance 2-31 periodic maintenance procedures ○ remove the steering cover (see steering cover removal in the hull/engine hood chapter). Steering cable ball joint [a] at steering shaft ○ remove the left side cover (see side cover removal in the hull/engine hood chapter). Shift cable ball ...

  • Page 56

    2-32 periodic maintenance periodic maintenance procedures • 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. All ...

  • Page 57

    Periodic maintenance 2-33 periodic maintenance procedures hose and hose connect inspection • check the following hoses for leakage [a], hardening, cracking [b], checking, cuts, abrasions, breaks and bulges [c]. And make sure the hoses are not kinked or pinched. Fuel vent hose oil hoses cooling hoses...

  • Page 58

    2-34 periodic maintenance periodic maintenance procedures • check that the hose joints are securely connected. ○ push and pull [a] the hose joint [b] back and forth more than two times, and make sure it is locked. If it does not locked, reinstall the hose joint. Warning make sure the hose joint is i...

  • Page 59: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents fuel system diagram ........................ 3-3 exploded view................................... 3-4 specifications .................................... 3-10 special tools and sealant ................. 3-12 dfi parts location.................

  • Page 60

    3-2 fuel system (dfi) ecu ................................................... 3-65 ecu removal .............................. 3-65 ecu installation ........................... 3-65 ecu power supply inspection..... 3-65 dfi power source ............................. 3-68 main fuse inspection............

  • Page 61

    Fuel system (dfi) 3-3 fuel system diagram 1. Fuel pump 2. Fuel hose 3. Supply line 4. Delivery pipe 5. Fuel injectors 6. Fuel tank.

  • Page 62

    3-4 fuel system (dfi) exploded view.

  • Page 63

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 vehicle-down sensor mounting screws 1.5 0.15 13 in·lb 2 bracket mounting bolts 8.8 0.90 78 in·lb l 3 inlet manifold mounting bolts 25 2.5 18 4 inlet manifold mounting nuts 20 2.0 14 5 delivery pipe mounting bolts 7.8 0...

  • Page 64

    3-6 fuel system (dfi) exploded view.

  • Page 65

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel filler tube clamp screws 2.9 0.30 26 in·lb 2 fuel pump holder clamp screws 2.9 0.30 26 in·lb 3. Meter unit 4. Buzzer 5. Fuel vent check valve 6. Fuel pump.

  • Page 66

    3-8 fuel system (dfi) exploded view.

  • Page 67

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil separator tank mounting bolts 8.8 0.90 69 in·lb l 2 air box bracket bolts 8.8 0.90 69 in·lb l 3 air box bolts 8.8 0.90 69 in·lb l 4 rear supercharger bolts 45 4.6 33 5 belt tensioner plate bolts 45 4.6 33 6 idler b...

  • Page 68

    3-10 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 300 ±100 r/min (rpm) - both in and out of water throttle assy: type single type bore 60 (2.36 in.) ecu (electronic control unit): make mitsubishi electric type digital memory type, with built in ic igniter...

  • Page 69

    Fuel system (dfi) 3-11 specifications item standard throttle lever and cables throttle lever free play about 2 mm (0.08 in.).

  • Page 70

    3-12 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 hand tester: 57001-1394 needle adapter set: 57001-1457 throttle sensor setting adapter: 57001-1521 sensor harness adapter: 57001-1561 harness adapter: 57001-1562 fuel pressure gauge adapter: 57001-1593 fuel hos...

  • Page 71

    Fuel system (dfi) 3-13 special tools and sealant kawasaki bond (silicone grease): 92137-1002 kawasaki bond (liquid gasket - gray): 92104-1063.

  • Page 72

    3-14 fuel system (dfi) 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. Water temperature sensor 11. Cranks...

  • Page 73

    Fuel system (dfi) 3-15 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. Ecu (electronic control unit) 24. Ecu main relay 25. Fuel pump relay 26. Batter...

  • Page 74

    3-16 fuel system (dfi) dfi system dfi system wiring diagram.

  • Page 75

    Fuel system (dfi) 3-17 dfi system 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. Joint connector 6 (power (5 v) - sensor) 5. Joint connector 5 (ground - sensor) 6. Joint connector 4 (power (12 v) - injector) 7. Injector #4 8. Injector #3 9. Injector #2 10. Injector #1 11. Inlet air ...

  • Page 76

    3-18 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Isc (idle speed controller) 2. Isc (idle speed controller) 3. Oil pressure switch 4. Unused 5. Crankshaft sensor (–) 6. Unused (to unused connector) 7. Camshaft position sensor 8. Charging temperature sensor 9. Po...

  • Page 77

    Fuel system (dfi) 3-19 dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a 12 v sealed battery as a p...

  • Page 78

    3-20 fuel system (dfi) dfi servicing precautions ○ when checking the dfi parts, do not run the engine for 15 seconds or more without auxiliary cooling (see general information chapter). Caution if running the engine without the auxiliary cooling for 15 seconds or more (even at idle speed), the rub- ...

  • Page 79

    Fuel system (dfi) 3-21 self-diagnosis self-diagnosis outline the self-diagnosis system has two modes and can be switched to another mode. [a] push the “set” button with “mode” button at the same time for 3 seconds or more. [b] push either “set” or “mode” button for more than one second or more. User...

  • Page 80

    3-22 fuel system (dfi) self-diagnosis service code (character) table service code (used in ecu) service code character (displayed on meter unit) possible problems fail-safe function 11 throttle sensor malfunction, wiring open or short the ecu locks ignition timing into the ignition timing at closed ...

  • Page 81

    Fuel system (dfi) 3-23 self-diagnosis service code (used in ecu) service code character (displayed on meter unit) possible problems fail-safe function 75 main (ecu) relay and system relay malfunction, wiring is open or relay is stuck – 76 engine oil overheat the ecu slows down the engine speed less ...

  • Page 82

    3-24 fuel system (dfi) troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: hull no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ alw...

  • Page 83

    Fuel system (dfi) 3-25 troubleshooting the dfi system □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). Poor running or no power at high speed □ knocking (fuel poor quality or incorrect). □ engine overheating. □ engine o...

  • Page 84

    3-26 fuel system (dfi) 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 seat removal in the hull/engine hood chapter) air filter...

  • Page 85

    Fuel system (dfi) 3-27 throttle sensor (service code/character-11/tps) • adjust the throttle sensor positioning as follows. ○ install the air filter temporarily. ○ after warming up the engine, check the idling speed. Idle speed standard: 1 300 ±100 r/min (rpm) ○ stop the engine and turn the ignition...

  • Page 86

    3-28 fuel system (dfi) 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 ∼ 6 seconds at idling to measure the sensor input voltage. ○ wait 15 seconds before using the starter ag...

  • Page 87

    Fuel system (dfi) 3-29 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 ...

  • Page 88

    3-30 fuel system (dfi) 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 se...

  • Page 89

    Fuel system (dfi) 3-31 throttle sensor (service code/character-11/tps) 1. Ecu 2. Joint connector 6 (power (5 v) - sensor) 3. Joint connector 5 (ground - sensor) 4. Throttle sensor.

  • Page 90

    3-32 fuel system (dfi) 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 seat removal in the hull/engine...

  • Page 91

    Fuel system (dfi) 3-33 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 a...

  • Page 92

    3-34 fuel system (dfi) 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...

  • Page 93

    Fuel system (dfi) 3-35 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. • disconnect the following to make service easy. Spark plug caps fuel...

  • Page 94

    3-36 fuel system (dfi) inlet air temperature sensor (service code/character-13/airt) if the output voltage is out of the specified, check the ecu for its ground, and power supply (see ecu power supply inspection). If the ground and power supply are good, replace the ecu. If the output voltage is far...

  • Page 95

    Fuel system (dfi) 3-37 inlet air temperature sensor (service code/character-13/airt) 1. Ecu 2. Joint connector 5 (ground - sensor) 3. Inlet air temperature sensor.

  • Page 96

    3-38 fuel system (dfi) 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 temperatu...

  • Page 97

    Fuel system (dfi) 3-39 water temperature sensor (service code/character-14/aqut) • connect a digital voltmeter [a] to the ecu connector [b], with the needle adapter set. Special tool - needle adapter set: 57001-1457 water temperature sensor output voltage connections to ecu meter (+) → g/y lead (ter...

  • Page 98

    3-40 fuel system (dfi) water temperature sensor (service code/character-14/aqut) 1. Ecu 2. Joint connector 5 (ground - sensor) 3. Water temperature sensor sensor resistance inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation). • refer to electrical s...

  • Page 99

    Fuel system (dfi) 3-41 charging temperature sensor (service code/character-19/pret) charging temperature sensor removal/installa- tion caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: seat (see seat removal in the hull/engine hood chap-...

  • Page 100

    3-42 fuel system (dfi) charging temperature sensor (service code/character-19/pret) 1. Ecu 2. Joint connector 5 (ground - sensor) 3. Charging temperature sensor sensor resistance inspection • remove the charging temperature sensor (see charging temperature sensor removal/installation). • refer to el...

  • Page 101

    Fuel system (dfi) 3-43 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 n...

  • Page 102

    3-44 fuel system (dfi) 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 ignition system section in electric system chapter. Camshaft positio...

  • Page 103

    Fuel system (dfi) 3-45 vehicle-down sensor (service code/character-31/dos) this sensor has a weight [a] with two magnets inside, and sends a signal to the ecu. But when the watercraft banks 110 ∼ 130° or more to either side (in fact falls down), the weight turns and shuts off the signal. The ecu sen...

  • Page 104

    3-46 fuel system (dfi) vehicle-down sensor (service code/character-31/dos) vehicle-down sensor inspection note ○ be sure the battery is fully charged. • remove the seat (see seat removal in the hull/engine hood chapter). • connect a digital volt meter [a] to the connector [b] of the vehicle-down sen...

  • Page 105

    Fuel system (dfi) 3-47 vehicle-down sensor (service code/character-31/dos) • turn the ignition switch off. • 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 ...

  • Page 106

    3-48 fuel system (dfi) immobilizer amplifier (service code/character-35/ida) amplifier input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the front access cover (see front access cover removal in the hull/engine hood chapter). • connect a d...

  • Page 107

    Fuel system (dfi) 3-49 key collation error (service code/character-36/ider) • this code appears in the following conditions. ○ the transponder [a] in the fpo mode and/or slo mode key is malfunction. ○ when the spare key of unregistration is used. • therefore, the service code 36 will disappear when ...

  • Page 108

    3-50 fuel system (dfi) 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 ...

  • Page 109

    Fuel system (dfi) 3-51 ignition coils (service code/character-51, 52/col1, col2) 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. System relay 5. Main (ecu) relay 6. Joint connector 2 7. Joint connector 1 8. Joint connector 11 (ground) 9. Joint connector 12 (ground) 10. Battery 11. Ma...

  • Page 110

    3-52 fuel system (dfi) engine overheating (service code/character-71/heat) • if the service code is displayed, check the doubtful parts referring to the following table. Possible causes action (chapter) water passage clogged, loosened or damaged inspect (see 9 chapter) incorrect engine oil level ins...

  • Page 111

    Fuel system (dfi) 3-53 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 action (chapter) oil leak inspect (see 4 chapter) engine oil level too low inspect (see 4 chapter) engine oil...

  • Page 112

    3-54 fuel system (dfi) oil temperature sensor (service code/character-73/oilt) oil temperature sensor removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: seat (see seat removal in the hull/engine hood chap- ter) oil te...

  • Page 113

    Fuel system (dfi) 3-55 oil temperature sensor (service code/character-73/oilt) • turn the ignition switch off. If the output voltage is out of the specified, check the ecu for its ground, and power supply (see ecu power supply inspection). If the ground and power supply are good, replace the ecu. If...

  • Page 114

    3-56 fuel system (dfi) main (ecu) relay and system relay (service code/character-75/rel) relay assembly removal caution never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • refer to relay assembly removal in the electrical sys- tem chapter. Relay assembly in...

  • Page 115

    Fuel system (dfi) 3-57 engine oil overheating (service code/character-76/oilh) • if the service code is displayed, check the doubtful parts referring to the following table. Possible causes action (chapter) incorrect engine oil level inspect (see 4 chapter) engine oil poor quality or incorrect chang...

  • Page 116

    3-58 fuel system (dfi) charging (intake) temperature overheating (service code/character-78/char) • if the service code is displayed, check the doubtful parts referring to the following table. Possible causes action (chapter) water passage clogged, loosened or damaged inspect (see 9 chapter) chargin...

  • Page 117

    Fuel system (dfi) 3-59 fuel injectors 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. Make sure the area is well-ventilated and free from any source...

  • Page 118

    3-60 fuel system (dfi) fuel injectors fuel injector installation • replace the o-rings [a] of the injectors with new ones. • apply grease to the o-rings. • insert the injectors into the delivery pipe and confirm whether they turn smoothly or not. • replace the seals [a] with new ones. • apply grease...

  • Page 119

    Fuel system (dfi) 3-61 fuel injectors • 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. If the test lights flicker at regular inter...

  • Page 120

    3-62 fuel system (dfi) fuel injectors 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 mete...

  • Page 121

    Fuel system (dfi) 3-63 fuel injectors 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] (supply ends connected with the clamp [d]) as sho...

  • Page 122

    3-64 fuel system (dfi) fuel injectors 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. Joint connector 4 (power (12v) - injector) 5. Injector #4 6. Injector #3 7. Injector #2 8. Injector #1 9. System relay 10. Fuel pump relay 11. Main (ecu) relay 12. Joint connector 3 (switch (12 v)) ...

  • Page 123

    Fuel system (dfi) 3-65 ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu removal • remove: seat (see seat removal in the hull/engine hood chap- ter) front access cover (see front access cover re- moval/installation in the hull/engine hood chapte...

  • Page 124

    3-66 fuel system (dfi) ecu • 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: 17 (r/y) terminal – battery (−) terminal 36 (bl) terminal – batt...

  • Page 125

    Fuel system (dfi) 3-67 ecu ecu power source circuit 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. System relay 5. Main (ecu) relay 6. Joint connector 3 (switch (12 v)) 7. Joint connector 2 8. Joint connector 1 9. Joint connector 12 (ground) 10. Joint connector 11 (ground) 11. Batte...

  • Page 126

    3-68 fuel system (dfi) 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. • refer to the relay assembly removal in the ...

  • Page 127

    Fuel system (dfi) 3-69 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 • un...

  • Page 128

    3-70 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 ...

  • Page 129

    Fuel system (dfi) 3-71 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 c...

  • Page 130

    3-72 fuel system (dfi) throttle lever, cable and case • remove the steering cover (see steering removal in steering chapter). • unscrew the grommet mounting bolts [a] and pull out the plate [b] and grommet. • cut off the clamps [c] and remove the protect tube [d]. • take the throttle cable [e] off t...

  • Page 131

    Fuel system (dfi) 3-73 air box air box removal • remove the engine (see engine removal in the engine removal/installation chapter). • remove the air box [a] from the engine compartment. Air box installation • apply a non-permanent locking agent to the air box bracket bolts [a] and tighten them. Torq...

  • Page 132

    3-74 fuel system (dfi) supercharger supercharger removal • refer to engine removal in the engine removal/installa- tion chapter. ○ remove the exhaust manifold and then remove the su- percharger [a] from the engine compartment. • if necessary, remove the gear oil drain bolt [a] to drain the gear oil....

  • Page 133

    Fuel system (dfi) 3-75 supercharger • remove the pulley [a] with the bearing [b]. • unscrew the intake pipe bolts [a], remove the upper [b] and lower [c] intake pipe. Supercharger assembly • check that salt deposit is on the rotors [a]. • clean the rotors with cloth and blow the air, turning slowly ...

  • Page 134

    3-76 fuel system (dfi) supercharger • spin the bearing [a] by hand to check its condition. If it is noisy, does not spin smoothly, or has any rough spots, replace the pulley assy. • confirm whether the bearing absorbs water or salt water. If it absorbs water or salt water, replace the pulley assy. •...

  • Page 135

    Fuel system (dfi) 3-77 throttle body assy idle speed inspection the normal idle speed is controlled by the ecu (elec- tronic control unit). Idle speed standard: 1 300 ±100 r/min (rpm) -both in and out of water high altitude performance adjustment high altitude adjustment is not required as the ecu c...

  • Page 136

    3-78 fuel system (dfi) throttle body assy throttle body assy disassembly caution do not disassemble or adjust, the air screw, throt- tle link mechanism and throttle body assy [a], be- cause they are adjusted or set surely at the man- ufacturer. Adjustment of these parts could result in poor performa...

  • Page 137

    Fuel system (dfi) 3-79 throttle body assy • clean the mating surface of throttle body and isc actuator (stepping motor). • replace the o-ring [a] with a new one. • install the stepping motor [b] and tighten the screws [c]. • install the isc actuator [d] and tighten the bolts [e]. Torque - isc actuat...

  • Page 138

    3-80 fuel system (dfi) throttle body assy • 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 (at 20°c) connection: 1-3, 4-6 terminals standard: about 60 Ω (a...

  • Page 139

    Fuel system (dfi) 3-81 inlet manifold inlet manifold removal • remove the intercooler (see engine removal i the engine removal/installation chapter). • remove the spark plug leads and place them [a] out of the engine compartment. • disconnect the fuel hose form the delivery pipe. • disconnect the th...

  • Page 140

    3-82 fuel system (dfi) inlet manifold • place the delivery pipe with the harness [a] out of the engine compartment as shown. • unscrew the inlet manifold mounting bolts [a] and nuts [b]. • remove the inlet manifold [a] with two bolts [b] indicated in the figure. Inlet manifold installation • replace...

  • Page 141

    Fuel system (dfi) 3-83 inlet manifold • replace the injector seals [a] with new ones. • apply grease to the inside and outside of seals. • tighten the delivery pipe mounting bolts [b]. Torque - delivery pipe mounting bolts: 7.8 n·m (0.80 kgf·m, 69 in·lb) • route the cable, wire and hose correctly (s...

  • Page 142

    3-84 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. When t...

  • Page 143

    Fuel system (dfi) 3-85 fuel line fuel flow rate inspection note ○ be sure the battery is fully charged. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any applia...

  • Page 144

    3-86 fuel system (dfi) 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..

  • Page 145

    Fuel system (dfi) 3-87 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. Make sure th...

  • Page 146

    3-88 fuel system (dfi) 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]. No...

  • Page 147

    Fuel system (dfi) 3-89 fuel pump • install the fuel pump [a] in the fuel tank [b]. L/h [c] r/h [d] bow [e] 45° [f] • install the following to the fuel pump. Fuel hoses fuel tank vent hose fuel pump lead connector note ○ the main fuel hose is larger than the return fuel hose. Power source voltage ins...

  • Page 148

    3-90 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 • turn the ignition...

  • Page 149

    Fuel system (dfi) 3-91 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. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. Joint c...

  • Page 150

    3-92 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...

  • Page 151

    Fuel system (dfi) 3-93 fuel tank • remove the fuel tank [a] out of the hull as shown. ○ remove the fuel pump [b] (see fuel pump removal) 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 rout...

  • Page 152

    3-94 fuel system (dfi) fuel tank fuel filler and tube removal • remove the front access cover (see front access cover removal/installation in the hull/engine hood chapter). • loosen the fuel filler tube clamp screws [a] and remove the fuel filler tube [b]. • remove the left side cover (see side cove...

  • Page 153

    Fuel system (dfi) 3-95 fuel tank • note the following when installing the tube [a]. ○ fit [b] the parting line of tube to mark on the tank. ○ install the lower clamp [a] so that its screw head screw points straight line [b] or inclined line [c]. Fuel filler and tube installation • clean the deck and...

  • Page 155: Engine Lubrication System

    Engine lubrication system 4-1 4 engine lubrication system table of contents exploded view........................................................................................................................ 4-2 engine oil flow chart....................................................................

  • Page 156

    4-2 engine lubrication system exploded view.

  • Page 157

    Engine lubrication system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather plate bolts 7.8 0.80 69 in·lb 2 oil filler cap – – – hand-tighten 3 oil passage plugs 20 2.0 14 l 4 oil separator tank mounting screws 4.9 0.50 43 in·lb l 5 breather case mounting bolts 7.8 0.80 69 in·...

  • Page 158

    4-4 engine lubrication system engine oil flow chart.

  • Page 159

    Engine lubrication system 4-5 engine oil flow chart.

  • Page 160

    4-6 engine lubrication system engine oil flow chart.

  • Page 161

    Engine lubrication system 4-7 specifications item standard engine oil grade api se, sf, or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 4.0 l (4.2 us qt, with or without the filter) 5.0 l (5.3 us qt, when engine is completely dry) level between upper and lower level lines (see text...

  • Page 162

    4-8 engine lubrication system special tool and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt 1/8: 57001-1033 oil filter wrench: 57001-1249 kawasaki bond (silicone sealant): 56019-120 kawasaki bond (silicone sealant): 92104-0004.

  • Page 163

    Engine lubrication system 4-9 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...

  • Page 164

    4-10 engine lubrication system 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 li...

  • Page 165

    Engine lubrication system 4-11 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, and then remove it again to check the oil level. • check the oil level using the hot level mark on the dipstick [a...

  • Page 166

    4-12 engine lubrication system oil cooler oil cooler removal • remove: seat (see seat removal in the hull/engine hood chap- ter) 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...

  • Page 167

    Engine lubrication system 4-13 oil cooler • apply engine oil to the thread [a] of the passage bolt and o-ring [b] of the oil filter [c]. • tighten the oil filter (p/no. 16097-1072). Torque - oil filter: 18 n·m (1.8 kgf·m, 13 ft·lb) • connect the oil pressure switch connector securely. • install the ...

  • Page 168

    4-14 engine lubrication system 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...

  • Page 169

    Engine lubrication system 4-15 breather case and oil separator tank breather case removal • remove: seat (see seat removal in the hull/engine hood chap- ter) exhaust manifold (see exhaust manifold removal in the exhaust system chapter) clamp [a] breather hose [b] breather case mounting bolts [c] • p...

  • Page 170

    4-16 engine lubrication system 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 • when installing the breather ...

  • Page 171

    Engine lubrication system 4-17 oil pan oil pan removal • remove: engine oil (drain, see periodic maintenance chapter) engine (see engine removal/installation chapter) • turn the engine to the side. • unscrew the dipstick tube bolts [a] and pull out the dip- stick tube [b]. • unscrew the oil pan bolt...

  • Page 172

    4-18 engine lubrication system 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] cranksh...

  • Page 173

    Engine lubrication system 4-19 oil pump sprocket, oil pump and oil pressure relief valve • install the oil pump chain guide [a], collar [b], washer [c], and bolt [d] as shown. • install the chain guide spring [a] and the spring plate [b]. ○ insert the tab [c] of the spring plate in the hole [d] of t...

  • Page 174

    4-20 engine lubrication system 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...

  • Page 175

    Engine lubrication system 4-21 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 c...

  • Page 176

    4-22 engine lubrication system 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 swi...

  • Page 177

    Engine lubrication system 4-23 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 178

    4-24 engine lubrication system oil pressure switch oil pressure switch removal • remove: seat (see hull/engine hood chapter) inlet manifold (see fuel system (dfi) chapter) • disconnect: switch connector [a] • place a rag or cloth under the oil pressure switch [a] and remove the oil pressure switch. ...

  • Page 179: Exhaust System

    Exhaust system 5-1 5 exhaust system table of contents exploded view........................................................................................................................ 5-2 exhaust manifold ..............................................................................................

  • Page 180

    5-2 exhaust system exploded view.

  • Page 181

    Exhaust system 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust manifold mounting nuts 25 2.5 18 2 exhaust manifold mounting bolts 30 3.1 22 3 bypass nozzle – – – ln 4 flushing hose joints 11 1.1 95 in·lb l 5 water temperature sensor 15 1.5 11 see chapter 3 6 exhaust pipe moun...

  • Page 182

    5-4 exhaust system exhaust manifold exhaust manifold removal • refer to engine removal in the engine removal/installa- tion chapter. • using the lifter, lift the engine as shown. • unscrew the exhaust manifold nuts [a] and bolts [b]. • disconnect the flushing hose [c]. • remove the exhaust manifold ...

  • Page 183

    Exhaust system 5-5 exhaust pipe and muffler body exhaust pipe and muffler body removal • remove the seats (see seat removal in the hull/engine hood chapter). • remove the rear grip plate (see rear grip plate removal in the hull/engine hood chapter). • remove: mark pate bolts [a] mark plate [b] cooli...

  • Page 184

    5-6 exhaust system exhaust pipe and muffler body exhaust pipe and muffle body cleaning and inspection • remove the exhaust pipe and muffler body 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 w...

  • Page 185

    Exhaust system 5-7 water box muffler water box muffler removal • remove: oil separator tank with oil separator hoses (see the lubrication system chapter) exhaust pipe and muffler body (see exhaust pipe and muffler body removal) intercooler (see intercooler removal in the cooling and bilge system cha...

  • Page 187: Engine Top End

    Engine top end 6-1 6 engine top end table of contents exploded view........................................................................................................................ 6-2 specifications ................................................................................................

  • Page 188

    6-2 engine top end exploded view.

  • Page 189

    Engine top end 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air suction valve cover bolts 9.8 1.0 87 in·lb 2 cylinder head cover bolts 9.8 1.0 87 in·lb 3 upper camshaft chain guide bolts 12 1.2 104 in·lb s 4 camshaft cap bolts 12 1.2 104 in·lb s 5 cylinder head bolts (m7) 20 2.0 1...

  • Page 190

    6-4 engine top end exploded view.

  • Page 191

    Engine top end 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust side camshaft chain guide bolts (upper) 25 2.5 18 2 exhaust side camshaft chain guide bolts (lower) 12 1.2 104 in·lb 3 upper camshaft chain guide bolts 12 1.2 104 in·lb s 4 inlet side camshaft chain guide bolt 12 ...

  • Page 192

    6-6 engine top end specifications item standard service limit camshafts cam height: exhaust 36.143 ∼ 36.257 mm (1.4229 ∼ 1.4274 in.) 36.04 mm (1.4189 in.) inlet 36.440 ∼ 36.554 mm (1.4346 ∼ 1.4391 in.) 36.34 mm (1.431 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in...

  • Page 193

    Engine top end 6-7 specifications item standard service limit inlet (outer) 45.78 mm (1.802 in.) 44.2 mm (1.740 in.) cylinder, piston cylinder inside diameter 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) 83.10 mm (3.272 in.) piston diameter 82.919 ∼ 82.934 mm (3.2645 ∼ 3.2651 in.) 82.77 mm (3.259 in.) p...

  • Page 194

    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,...

  • Page 195

    Engine top end 6-9 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 valve seat cutter, 55° - 35: 57001-1247 compression gauge ad...

  • Page 196

    6-10 engine top end special tools and sealant piston base, 8: 57001-1604 kawasaki bond (silicone sealant): 56019-120

  • Page 197

    Engine top end 6-11 clean air system air suction valve removal • remove: seat (see seat removal in the hull/engine hood chap- ter) 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 asse...

  • Page 198

    6-12 engine top end cylinder head cover cylinder head cover removal • remove: air suction valve hoses [a] spark plug caps [b] breather hoses [c] • remove the cylinder head cover bolts [a] and take off the cover [b]. Cylinder head cover installation • be sure to install the pins [a] and rubber gasket...

  • Page 199

    Engine top end 6-13 camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type camshaft chain tensioner [a]. The push rod does not return to its original po- sition once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing t...

  • Page 200

    6-14 engine top end camshaft chain tensioner • apply a non-permanent locking agent to the tensioner mounting bolts [a]. • tighten the tensioner mounting bolts. Torque - camshaft chain tensioner mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the spring [b], rod [c] and washer [d]. • tighten ...

  • Page 201

    Engine top end 6-15 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...

  • Page 202

    6-16 engine top end 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]. Be careful no...

  • Page 203

    Engine top end 6-17 camshaft, camshaft chain • remove the spark plugs. • using the shaft wrench [a], turn the crankshaft counter- clockwise [b] and set the crankshaft at #1, 4 piston tdc (see piston tdc finding). Special tool - shaft wrench: 57001-1551 • pull the tension side (exhaust side) of the c...

  • Page 204

    6-18 engine top end 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 ...

  • Page 205

    Engine top end 6-19 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 u...

  • Page 206

    6-20 engine top end camshaft, camshaft chain camshaft chain removal • split the crankcase (see engine bottom end chapter). • remove the camshaft chain [a] from the crankshaft sprocket..

  • Page 207

    Engine top end 6-21 cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • thoroughly warm up the engine, while checking that there is no compression leakage from around the spark plugs or the cylinder head gasket. Caution do not run the engine without coolin...

  • Page 208

    6-22 engine top end cylinder head the following table should be consulted if the obtainable compression reading is not within the us- able range. Problem diagnosis remedy (action) carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged pisto...

  • Page 209

    Engine top end 6-23 cylinder head • remove: engine hook bolts [a] engine hook [b] cylinder head bolts [c] • remove: upper dipstick tube bolts [a] upper exhaust side camshaft chain guide bolt [b] m7 cylinder head bolts [c] • remove the m11 cylinder head bolts [a] and washers. • take off the cylinder ...

  • Page 210

    6-24 engine top end 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]. Torque - cyl...

  • Page 211

    Engine top end 6-25 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 s...

  • Page 212

    6-26 engine top end valves valve guide removal • remove: valve (see valve removal) oil seal spring seat • heat the area around the valve guide to 120 ∼ 150°c (248 ∼ 302°f), and hammer lightly on the valve guide arbor [a] to remove the guide from the top of the head. Caution do not heat the cylinder ...

  • Page 213

    Engine top end 6-27 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. If the outside diameter is too large or too small, rep...

  • Page 214

    6-28 engine top end valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 215

    Engine top end 6-29 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. Widened width [a] of engagement by machining with 45° cutter ...

  • Page 216

    6-30 engine top end 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. ○ to make...

  • Page 217

    Engine top end 6-31 valves.

  • Page 218

    6-32 engine top end 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] ...

  • Page 219

    Engine top end 6-33 cylinder, pistons • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with your thumbs in the same manner. Piston/cylinder installation note ○ if a new cylinder is used, use new pis...

  • Page 220

    6-34 engine top end 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 [e] hollo...

  • Page 221

    Engine top end 6-35 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 ...

  • Page 222

    6-36 engine top end 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 ∼ 0.0350 in.) second [b] 0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.) service lim...

  • Page 223: Engine Removal/installation

    Engine removal/installation 7-1 7 engine removal/installation table of contents exploded view........................................................................................................................ 7-2 engine removal/installation .........................................................

  • Page 224

    7-2 engine removal/installation exploded view.

  • Page 225

    Engine removal/installation 7-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 engine mounting bolts 36 3.7 27 l 2 engine damper mounting bolts 16 1.6 12 l l: apply a non-permanent locking agent..

  • Page 226

    7-4 engine removal/installation engine removal/installation engine removal • remove: seat (see seat removal in the hull/engine hood chap- ter) rear grip plate (see rear grip plate removal in the hull/engine hood chapter) oil separator tank (see oil separator tank removal in the engine lubrication sy...

  • Page 227

    Engine removal/installation 7-5 engine removal/installation • loosen the clamp [a] and disconnect the tube [b] from the air box fitting. • disconnect the air suction valve hose [c] from the air box. • remove the bracket bolts [a] holding the air box. • slide the engine toward the front to disengage ...

  • Page 228

    7-6 engine removal/installation engine removal/installation • remove the rear supercharger bolts [a]. • loosen the clamp [a] and remove the tube [b] from the supercharger. • remove the supercharger from the engine compartment. • disconnect: starter motor cable [a] battery (–) cable [b] • disconnect ...

  • Page 229

    Engine removal/installation 7-7 engine removal/installation • lift the engine [a] from the engine compartment. Engine damper removal • remove: engine damper mounting bolts [a] engine damper [b] shim [c] (0 ∼ 2 pieces) bow [d] • record the number of shims of four positions so they can be put back in ...

  • Page 230

    7-8 engine removal/installation engine removal/installation • do not forget installing the supercharger drive belt [a] when engaging the couplings [b]. • torque: torque - front/rear [a] supercharger bolts: 45 n·m (4.6 kgf·m, 33 ft·lb) • install the new gasket [a] before installing the exhaust manifo...

  • Page 231

    Engine removal/installation 7-9 engine removal/installation • after installing the engine in the hull, check the following. Throttle cable fuel and exhaust leaks warning do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odor- less, poisonous gas which can be...

  • Page 233: Engine Bottom End

    Engine bottom end 8-1 8 engine bottom end table of contents exploded view........................................................................................................................ 8-2 specifications ..........................................................................................

  • Page 234

    8-2 engine bottom end exploded view.

  • Page 235

    Engine bottom end 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankshaft sensor cover bolts 7.8 0.80 69 in·lb 2 engine bracket mounting bolts 32 3.3 24 l 3 timing rotor bolt 20 2.0 14 l 4 connecting rod nuts – – – mo, see text 5 oil passage plugs 20 2.0 14 l 6 stator mounting bol...

  • Page 236

    8-4 engine bottom end specifications item standard service limit crankshaft, connecting rods connecting rod bend – – – 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – 0.2/100 mm (0.008/3.94 in.) connecting rod big end side clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm (0.023 in.) con...

  • Page 237

    Engine bottom end 8-5 specifications item standard service limit crankshaft main journal diameter: 40.984 ∼ 41.000 mm (1.6135 ∼ 1.6142 in.) 40.96 mm (1.613 in.) marking none 40.984 ∼ 40.992 mm (1.6135 ∼ 1.61385 in.) – – – 1 40.993 ∼ 41.000 mm (1.61389 ∼ 1.6142 in.) – – – crankcase main bearing bore ...

  • Page 238

    8-6 engine bottom end special tools and sealant oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 coupling holder #2: 57001-1423 rotor holder: 57001-1544 holder attachment: 57001-1547 output shaft wrench, hex 36: 57001-1550 grip: 57001-1591 flywheel & pulley holder: 57001-1605 ro...

  • Page 239

    Engine bottom end 8-7 special tools and sealant kawasaki bond (liquid gasket - black): 92104-1062.

  • Page 240

    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 attachme...

  • Page 241

    Engine bottom end 8-9 coupling • using the rotor holder [a], remove the output shaft [b]. Special tool - rotor holder: 57001-1544 coupling/output shaft installation • apply molybdenum disulfide oil solution to the seating sur- face of the output shaft. • using the rotor holder [a], install the outpu...

  • Page 242

    8-10 engine bottom end coupling • install: pins [a] gasket [b] • position the magnet lead [c] as shown. • apply grease to the oil seal lip. • install the output cover. ○ run the magneto lead [a] between the magneto cover [b] and the output cover [c] as shown. Torque - output cover bolts: 7.8 n·m (0....

  • Page 243

    Engine bottom end 8-11 coupling • replace the oil seals with new ones. • apply thin coat grease to the oil seal lips [a]. • pack grease [b] between the oil seal lip and housing of the oil seal (flywheel side oil seal [c]). • press in the oil seals until they are bottomed. ○ install the coupling oil ...

  • Page 244

    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 pulle...

  • Page 245

    Engine bottom end 8-13 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 re...

  • Page 246

    8-14 engine bottom end 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 bei...

  • Page 247

    Engine bottom end 8-15 crankcase splitting crankcase assembly caution the upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • with high-flash point solvent, clean off the mating sur- faces of the crankcases halve...

  • Page 248

    8-16 engine bottom end 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]. • tighten the cra...

  • Page 249

    Engine bottom end 8-17 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...

  • Page 250

    8-18 engine bottom end crankshaft and connecting rods • install the crankshaft with the oil pump sprocket chain [a] and camshaft chain [b] hanging on them. • fit the oil seal [a] into the groove [b] of the crankcase. • assemble the crankcase (see crankcase assembly). Connecting rod removal • split t...

  • Page 251

    Engine bottom end 8-19 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...

  • Page 252

    8-20 engine bottom end 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. • next, tighten the nuts by 120° more. ○ m...

  • Page 253

    Engine bottom end 8-21 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 connec...

  • Page 254

    8-22 engine bottom end 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 ma...

  • Page 255

    Engine bottom end 8-23 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 clearan...

  • Page 256

    8-24 engine bottom end 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...

  • Page 257

    Engine bottom end 8-25 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 chec...

  • Page 259: Cooling And Bilge Systems

    Cooling and bilge systems 9-1 9 cooling and bilge systems table of contents exploded view........................................................................................................................ 9-2 specifications ..........................................................................

  • Page 260

    9-2 cooling and bilge systems exploded view.

  • Page 261

    Cooling and bilge systems 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water hose joint (l shape type) 11 1.1 95 in·lb l 2 water hose joint (straight shape type) 20 2.0 14 l 3 cooling hose clamp screws 2.5 0.25 22 in·lb 4 intercooler bracket bolts 7.8 0.80 69 in·lb 5 intercooler m...

  • Page 262

    9-4 cooling and bilge systems specifications item standard air bypass system relief valve opening pressure (close → open) –53.3 kpa (–400 ±30 mmhg) blow off valve opening pressure (close → open) more than 185 kpa (1 390 mmhg).

  • Page 263

    Cooling and bilge systems 9-5 sealant kawasaki bond (liquid gasket - gray): 92104-1063.

  • Page 264

    9-6 cooling and bilge systems bilge system breather removal • remove: seat (see seat removal in the hull/engine hood chap- ter) handrail plate (see handrail plate removal in the hull/engine hood chapter) • pull the hoses [a] off the breather. • unscrew the mounting bolts [b], and remove the breather...

  • Page 265

    Cooling and bilge systems 9-7 bilge system filter installation • align the projections [a] on the filters [b] with the holes [c] on the brackets [d]. Filter cleaning and inspection • flush the filter thoroughly with fresh water and shake it dry. • water must flow freely through the filter, but large...

  • Page 266

    9-8 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. • all the cooli...

  • Page 267

    Cooling and bilge systems 9-9 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..

  • Page 268

    9-10 cooling and bilge systems intercooler intercooler removal • remove the oil separator tank (see oil separator tank removal in the engine lubrication system). • disconnect: flushing hose [a] (exhaust manifold ∼ intercooler) duct [b] (blow off valve ∼ air box) tube [c] (relief valve ∼ intercooler)...

  • Page 269

    Cooling and bilge systems 9-11 intercooler intercooler installation • keep the clearance between the intercooler [a] and the corner [b] of right water box muffler as shown. Clearance [c]: more than 10 mm (0.3937 in.) • torque: torque - intercooler mounting bolts: 30 n·m (3.1 kgf·m, 22 ft·lb) • route...

  • Page 270

    9-12 cooling and bilge systems intercooler • when assembling, note the following. ○ replace the o-rings [a] and gasket [b] with new ones. ○ apply liquid gasket on the o-rings sealant - kawasaki bond (liquid gasket-gray): 92104 -1063 • torque: torque - intercooler cover bolts: 10 n·m (1.0 kgf·m, 89 i...

  • Page 271

    Cooling and bilge systems 9-13 air bypass system relief valve inspection • connect a vacuum gauge [a] and syringe [b] or fork oil level gauge to the vacuum hoses as shown. Special tools - fork oil level gauge: 57001-1290 air flow [c] • gradually raise the vacuum (lower the pressure) applied to the r...

  • Page 272

    9-14 cooling and bilge systems cooling and bilge system flow diagram.

  • Page 273

    Cooling and bilge systems 9-15 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 proced...

  • Page 274

    9-16 cooling and bilge systems after submerging summary procedures after submerging.

  • Page 275

    Cooling and bilge systems 9-17 after submerging detailed procedures after submerging 1. Ask the operator about the water level in the engine compartment. 2. If the drive shaft is already submerged, drain the wa- ter from the drain screws at the stern. Replace the pulley [a] bearing (pulley assembly)...

  • Page 276

    9-18 cooling and bilge systems after submerging 8. Pull and remove all the spark plug caps. 9. Remove all spark plugs. 10. Insert the ignition switch key, push the lanyard key under the stop button, and push the start button. 11. If there is water in the engine, it will be pumped out from the plug h...

  • Page 277

    Cooling and bilge systems 9-19 after submerging 16. Remove the dipstick and check for the water pres- ence in the engine oil. (if there is water in, oil looks milky.) 17. If the oil looks milky, then change the oil and repeat items 15 & 16 until the oil does not turn milky any more. 18. If the engin...

  • Page 279: Drive System

    Drive system 10-1 10 drive system table of contents exploded view........................................................................................................................ 10-2 specification ..................................................................................................

  • Page 280

    10-2 drive system exploded view.

  • Page 281

    Drive system 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coupling 39 4.0 29 2 drive shaft holder mounting bolts 22 2.2 16 l l: apply a non-permanent locking agent. M: apply molybdenum disulfide grease. Ss: apply silicone sealant. Wg: apply water resistance grease..

  • Page 282

    10-4 drive system specification item standard service limit drive shaft runout (see p10-8) [a] less than 0.1 mm (0.0039 in.) [b] less than 0.2 mm (0.0079 in.) 0.2 mm (0.0079 in.) 0.6 mm (0.0236 in.).

  • Page 283

    Drive system 10-5 special tools and sealant bearing driver set: 57001-1129 coupling holder #2: 57001-1423 kawasaki bond (silicone sealant): 56019-120

  • Page 284

    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] • wh...

  • Page 285

    Drive system 10-7 drive shaft/drive shaft holder ○ press the small grease seal, and the large grease seals, bearing, and small grease seals come out of the holder. [a] sleeve [b] blocks [c] press drive shaft holder assembly/installation • replace the grease seals with new ones. • press the bearing a...

  • Page 286

    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 ...

  • Page 287: Pump And Impeller

    Pump and impeller 11-1 11 pump and impeller table of contents exploded view........................................................................................................................ 11-2 specifications .......................................................................................

  • Page 288

    11-2 pump and impeller exploded view.

  • Page 289

    Pump and impeller 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 pump bracket mounting bolts (2) 19 1.9 14 ln, ss 2 pump bracket mounting bolts (4) 9.8 1.0 87 in·lb l 3 pump mounting bolts 36 3.7 27 l 4 grate mounting bolts 9.8 1.0 87 in·lb l 5 pump cover mounting bolts 7.8 0.80 69...

  • Page 290

    11-4 pump and impeller specifications item standard service limit jet pump impeller outside diameter 154.5 ∼ 154.7 mm (6.0827 ∼ 6.0905 in.) 153.5 mm (6.0433 in.) pump case inside diameter 155.0 ∼ 155.1 mm (6.1024 ∼ 6.1063 in.) 156.1 mm (6.1457 in.) impeller clearance 0.15 ∼ 0.3 mm (0.0059 ∼ 0.0118 i...

  • Page 291

    Pump and impeller 11-5 special tools and sealant oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 impeller wrench: 57001-1228 impeller holder: 57001-1695 kawasaki bond (silicone sealant): 56019-120

  • Page 292

    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]. • unscrew the grate mounting bolts [d] and remo...

  • Page 293

    Pump and impeller 11-7 pump and impeller ○ cut the sealant at the indicated area [a] in the figure and remove the pump bracket [b]. Pump installation • strip off all the old sealant around the pump intake. • liberally coat the outside edge of the pump bracket with silicon sealant [a] to form a seal ...

  • Page 294

    11-8 pump and impeller pump and impeller • be sure trim seal [a] is in place. • grease the splines on the drive shaft with molybdenum disulfide grease. • install the pump. ○ apply a non-permanent locking agent to the pump mount- ing bolts and torque them. Torque - pump mounting bolts: 36 n·m (3.7 kg...

  • Page 295

    Pump and impeller 11-9 pump and impeller • unscrew the pump outlet mounting bolts [a], and remove the pump outlet [b]. • 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. R...

  • Page 296

    11-10 pump and impeller pump and impeller • remove the bearing [c] from the pump shaft [b] with a press [a]. • press [a] the bussing [b] and the ball bearing [c]. They come out of the pump case. • remove the circlip. • remove the grease seals. Special tool - oil seal & bearing remover: 57001-1058 [a...

  • Page 297

    Pump and impeller 11-11 pump and impeller • 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. ○ fill the gap between the grease seals [a] w...

  • Page 298

    11-12 pump and impeller pump and impeller • screw on the impeller and torque. Special tools - impeller holder: 57001-1695 impeller wrench: 57001-1228 torque - impeller: 98 n·m (10 kgf·m, 72 ft·lb) • visually inspect impeller seal [a], and replace it if neces- sary. • install the seal on the impeller...

  • Page 299

    Pump and impeller 11-13 pump and impeller • when installing the water hose joint [a] for cooling inter- cooler and the cover [b], install them as follows. ○ apply high grade water resistance grease to the o-ring [c]. ○ apply a non premanent locking agent to the bolts [d]. ○ install the water hose jo...

  • Page 300

    11-14 pump and impeller pump and impeller water filter cover removal/installation • loosen the clamps [a] and pull off the hoses [b]. • remove the filter cover mounting bolts [c]. • take out the filter cover [d]. • replace the gasket with a new one. • installation is the reverse order of removal. • ...

  • Page 301: Steering

    Steering 12-1 12 steering table of contents exploded view........................................................................................................................ 12-2 special tools ..........................................................................................................

  • Page 302

    12-2 steering exploded view.

  • Page 303

    Steering 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 16 1.6 12 l 2 adjustable steering holder nut 20 2.0 14.5 3 steering neck mounting bolts 16 1.6 12 l 4 steering shaft locknut 49 ∼ 59 5.0 ∼ 6.0 36 ∼ 43 5 steering holder mounting nuts 20 2.0 14.5 l 6 throt...

  • Page 304

    12-4 steering special tools box wrench (27 mm): 57001-1451 nut tightening plate: 57001-1698.

  • Page 305

    Steering 12-5 steering cable steering cable adjustment • check the steering cable adjustment. ○ center the handlebar in the straight-ahead position. • check that the steering nozzle [a] is centered in the pump cavity. ○ the same distance [b]. • if necessary, adjust the steering cable. ○ loosen the l...

  • Page 306

    12-6 steering steering cable • slide back the outer sleeve of the ball joint and take off the ball joint. • remove the cable bracket mounting bolts [a]. • loosen the locknut [a] at the front end of the steering cable and take off the ball joint [b], and remove the locknut from the cable front end. •...

  • Page 307

    Steering 12-7 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. • torque: torque - steering cable nut: 39 n·m (4.0 kgf·m, 29...

  • Page 308

    12-8 steering handlebar handlebar removal • unscrew the mounting screws [a] and remove the han- dlebar pad [b]. • remove the inner pad [a] and the buzzer [b]. • unscrew the bolts [a] and remove the pad holder [b]. • take out the throttle case clamp screws and remove the throttle case [a]. • take out...

  • Page 309

    Steering 12-9 handlebar ○ align [a] the hole [b] on the handlebar [c] with the mark [d] on the steering shaft holder [e]. ○ tighten the lower clamp bolts [a] first, and then the upper clamp bolts [b] to the specified torque. There will be a gap [c] at the upper part of the clamp after tightening. To...

  • Page 310

    12-10 steering steering steering removal • remove the center storage compartment lid (see right/left cover removal in the hull/engine hood chapter). • remove the right/left cover (see right/left cover re- moval in the hull/engine hood chapter). • remove the handlebar and pad holder (see handlebar re...

  • Page 311

    Steering 12-11 steering • remove the cotter pin [a]. • unscrew the nut [b] and bolt [c], and take off the washers [d]. • pull out the shaft [a], and remove the bushings [b] and adjustable steering holder [c]. • unscrew the steering neck mounting bolts [a] and remove the steering neck. • remove: cott...

  • Page 312

    12-12 steering steering • unscrew the grommet mounting plate bolts [a] and re- move the grommet mounting plate [b]. • pull up the grommet [c]. • disconnect: steering position sensor lead connector buzzer connector multifunction meter lead connectors steering cable ball joint at upper end switch case...

  • Page 313

    Steering 12-13 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. • grease: bushings [c] • put the washer [d] on the st...

  • Page 314

    12-14 steering steering • put the nut tightening plate [a] on the steering shaft nut [b]. • fasten the plate with two bolts [c]. Special tool - nut tightening plate: 57001-1698 • put the square portion [d] of the torque wrench on the square portion of the plate. • torque (2.6 n·m, 0.27 kgf·m, 23 in·...

  • Page 315

    Steering 12-15 steering • turning the steering shaft fully in left and right direction, check whether the steering position sensor comes in con- tact with the magnet. • check the clearance [a] between the steering position sensor [b] and the magnet [c] with feeler gauge. Steering position sensor cle...

  • Page 316

    12-16 steering steering • replace the cotter pin [a] with a new one. Note ○ when inserting the cotter pin, if the slots in the locknut do not align with the cotter pin hole in the steering shaft, tighten the locknut clockwise [b] up to next alignment. ○ it should be within 30 degree. ○ loosen once a...

  • Page 317

    Steering 12-17 steering • install the tilt lever [a] on the adjustable steering holder. ○ align [b] the projection on the rod with the hole on the tilt lever..

  • Page 318

    12-18 steering 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 p...

  • Page 319

    Steering 12-19 reverse system • loosen the locknut [a] at the front end of the shift cable and take off the ball joint [b], and remove the locknut from the cable front end. • pull the holder [c] off the cable bracket [d]. • remove the cable bracket mounting bolts [e]. • slide the shift cable [f] off...

  • Page 320

    12-20 steering reverse system shift 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. • torque the shift cable nut. Torque - shift cable nut: 39 n·m...

  • Page 321

    Steering 12-21 reverse system • unscrew the steering cover bolts (see steering removal). • remove: shift lever holder bolts [a] collars [b] shift lever holder [c] shift lever bracket [d] shift lever shaft [e] ○ lift up the steering cover [f] (see steering removal). • assemble the shift lever holder,...

  • Page 323: Hull/engine Hood

    Hull/engine hood 13-1 13 hull/engine hood table of contents exploded view........................................................................................................................ 13-2 fittings ...............................................................................................

  • Page 324

    13-2 hull/engine hood exploded view.

  • Page 325

    Hull/engine hood 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 stabilizer bolts 9.8 1.0 87 in·lb ln 2 front bumper bolts – – – l 3 exhaust outlet bolts – – – l l: apply a non-permanent locking agent. Ln: apply a non-permanent locking agent (high strength: loctite 271 equivalent). ...

  • Page 326

    13-4 hull/engine hood exploded view.

  • Page 327

    Hull/engine hood 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handrail plate nuts 9.8 1.0 87 in·lb l 2 side cover nuts – – – l 3 front duct bolts – – – l 4 damper bracket bolts – – – l 5 seat lock bolts – – – l 6 front storage compartment cover bolts – – – l 7 steering cover bolt...

  • Page 328

    13-6 hull/engine hood fittings seat removal • pull up [a] the latch handle [b]. • remove the rear seat up [a] and to the rear [b]. • pull up [a] the latch handle [b]. • remove the front seat up [a] and to the rear [b]. Seat installation • insert the seat hook [a] into the bracket [b] on the deck and...

  • Page 329

    Hull/engine hood 13-7 fittings • insert the seat hook [a] into the brackets [b] on the handrail plate and slide it all the way forward by pushing the rear of the seat. • push down on the rear of the seat to lock it. Front storage compartment cover removal • pull [a] the latch handle [b]. • open [c] ...

  • Page 330

    13-8 hull/engine hood fittings • remove: lock assembly nut [a] lock assembly bolts [b] bracket lock assembly [c] • remove: screen bolts [a] screen [b] front storage compartment cover assembly • when installing the screen [a] on the front storage com- partment cover, insert its projection [b] into th...

  • Page 331

    Hull/engine hood 13-9 fittings • insert the front duct portions [a] indicated in the figure into the ribs [b] of the front storage cover. • apply a non-permanent locking agent to the front duct bolts and tighten them securely. • if the hinge bracket [a] is disassembled, apply a water -resistant grea...

  • Page 332

    13-10 hull/engine hood fittings side cover removal • to remove the right side cover, remove the following. Center storage lid (see center storage lid removal/in- stallation) side cover nuts [a] and washers • disconnect the rear end [a] of the flushing line. • to remove the left side cover, remove th...

  • Page 333

    Hull/engine hood 13-11 fittings front access cover removal/installation • open the front storage compartment cover. • remove the front storage case. • push in the pins [a] and remove the front access cover [b]. • to install the front access cover, pull up the pin head [a] as shown and install the ri...

  • Page 334

    13-12 hull/engine hood fittings handrail plate removal • remove the rear and front seats (see seat removal). • take out the handrail plate nuts [a] and washers [b], and remove the handrail plate [c]. Handrail plate installation • be sure that the plugs [a] and the damper [b] are in posi- tion. Handr...

  • Page 335

    Hull/engine hood 13-13 fittings drain plug housing installation • check the seal [a] for damage. If necessary, replace new ones. ○ install the new gasket [b] so that its “out” mark [c] faces outwards. Exhaust outlet removal • unscrew the mounting bolts [a] and remove the holder [b] and exhaust outle...

  • Page 336

    13-14 hull/engine hood hull replacement to replace the hull, remove the various parts in the follow- ing suggested order. Battery and pad exhaust pipe inlet manifold engine and mounts air filter water box muffler drive shaft and shaft holder pump and hoses steering cover handlebar and steering steer...

  • Page 337

    Hull/engine hood 13-15 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. Many of these produc...

  • Page 338

    13-16 hull/engine hood rubber parts rear seat gasket [a] front storage compartment gasket [a] center storage compartment gasket [a] mats [a] 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...

  • Page 339

    Hull/engine hood 13-17 rubber parts rivet installation • secure the parts to the hull with the rivets using a riveter [a]. Front bumper removal • take out the plugs [a]. • take out the mounting bolts [b], nuts [c] and washers [d]. • drill out the rivets [e] and washers [f] (see rivet re- moval). • r...

  • Page 340

    13-18 hull/engine hood rubber parts • remove the trim strip [a] from the side bumper [b]. • drill out the rivets [a] (see rivet removal). Side bumper installation • secure the side bumpers to the hull flange with the rivets (see rivet installation). • install the trim strip. Air duct removal • to re...

  • Page 341

    Hull/engine hood 13-19 rubber parts • to remove the rear air ducts from the deck, remove the handrail plate (see handrail plate removal). • drill out the rivets [a] (see rivet removal). • remove: clamp [b] rear air duct [c] damper [d] duct [e] air duct installation • secure the air duct to the deck ...

  • Page 343: Electrical System

    Electrical system 14-1 14 electrical system table of contents parts location......................................................................................................................... 14-3 exploded view.......................................................................................

  • Page 344

    14-2 electrical system igniter removal/installation............................................................................................... 14-41 igniter inspection............................................................................................................... 14-41 spark plug ...

  • Page 345

    Electrical system 14-3 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. Ecu main relay 11. Fuel pump relay.

  • Page 346

    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 347

    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 26. Starter relay 27. Battery.

  • Page 348

    14-6 electrical system exploded view.

  • Page 349

    Electrical system 14-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 vehicle-down sensor mounting screws 1.5 0.15 13 in·lb 2 bracket bolts 8.8 0.90 78 in·lb l 3 starter relay case bolts 7.8 0.80 69 in·lb 4 water temperature sensor 15 1.5 11 see text 5 starter relay mounting nuts 3.5 ∼ ...

  • Page 350

    14-8 electrical system exploded view.

  • Page 351

    Electrical system 14-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 multifunction meter mounting bolts 3.9 0.40 35 in·lb 2 start/stop switch case mounting screw 3.9 0.40 35 in·lb 3 speed sensor mounting bolts 3.9 0.40 35 in·lb l 4. Multifunction meter 5. Battery 6. Buzzer g: apply gre...

  • Page 352

    14-10 electrical system exploded view.

  • Page 353

    Electrical system 14-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter motor through bolts 6.4 0.65 56 in·lb l, r 2 starter motor mounting bolts 8.8 0.90 78 in·lb l 3 starter motor ground bolt 8.8 0.90 78 in·lb 4 starter motor terminal nut 8.8 0.90 78 in·lb 5 stator coil bolts 1...

  • Page 354

    14-12 electrical system wiring diagram jt1500b7f.

  • Page 355

    Electrical system 14-13 wiring diagram jt1500b7f.

  • Page 356

    14-14 electrical system specifications item standard service limit battery type 12 v 18 ah – – – electric starter system starter motor: brush length 12 mm (0.4724 in.) 6.5 mm (0.2559 in.) commutator diameter 28 mm (1.1024 in.) 27 mm (1.063 in.) charging system regulator/rectifier output voltage batt...

  • Page 357

    Electrical system 14-15 special tools and sealant hand tester: 57001-1394 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 holder attachment: 57001-1547 harness adapter: 57001-1562 key registration unit: 57001-1582 flywheel & pulley holder: 57001-1605 kawasaki bond (silicone sealant):...

  • Page 358

    14-16 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 ...

  • Page 359

    Electrical system 14-17 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, clea...

  • Page 360

    14-18 electrical system battery battery cover removal/installation • open the front storage compartment cover. • remove the front storage case. • push in the pins [a] and remove the battery cover [b]. • to install the battery cover, pull up the pin head [a] as shown and install the rivet [b]. • push...

  • Page 361

    Electrical system 14-19 battery battery installation • be sure the battery damper [a] is in position in the battery compartment. • hook the battery straps. • connect the battery cables, positive first. ○ after attaching both cables, coat the terminals and cable ends with grease to prevent corrosion....

  • Page 362

    14-20 electrical system battery • take the electrolyte container out of the vinyl bag. • detach the strip of cap [a] from the container. Note ○ do not discard the strip of cap because it is used as the battery plugs later. ○ do not peel back or pierce the seals [b] on the container. • place the elec...

  • Page 363

    Electrical system 14-21 battery initial charge • place the strip [a] of caps loosely over the filler ports. • newly activated sealed batteries require an initial charge. Standard charge 1.8 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activated...

  • Page 364

    14-22 electrical system battery 3) when you do not use the watercraft for months: give a refresh charge before you store the watercraft and store it with the negative lead re- moved. Give a refresh charge once a month during storage. 4) battery life: if the battery will not start the engine even aft...

  • Page 365

    Electrical system 14-23 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. ○ if the battery will accept current, decrea...

  • Page 366

    14-24 electrical system electric starter system starter relay removal • remove: battery cover (see battery cover removal/installation in the hull/engine hood chapter) battery (see this chapter) • disconnect the negative battery cable from the battery terminal. (see battery removal). • disconnect the...

  • Page 367

    Electrical system 14-25 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 ...

  • Page 368

    14-26 electrical system electric starter system starter motor disassembly • remove the starter motor (see starter motor removal). • take off the starter motor through bolts [a] and remove both end covers [b] and pull the armature out of the yoke [c]. • remove the terminal locknut [a] and terminal bo...

  • Page 369

    Electrical system 14-27 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. • replace the starter motor through bolts [c] wi...

  • Page 370

    14-28 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 inspectio...

  • Page 371

    Electrical system 14-29 electric starter system reduction gear removal/installation • before removing the reduction gear, remove the magneto flywheel (see magneto flywheel removal in the engine bottom end chapter). • when installing the reduction gear, apply a molybdenum disulfide grease [a] to both...

  • Page 372

    14-30 electrical system electric starter system electric starter circuit 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. System relay 5. Main (ecu) relay 6. Joint connector 3 (switch (12v)) 7. Joint connector 2 8. Joint connector 1 9. Engine stop switch/tether 10. Engine start switch...

  • Page 373

    Electrical system 14-31 charging system magneto output voltage • remove: seat (see seat removal in the hull/engine hood chap- ter) air filter with duct (see air filter removal in the fuel system chapter) • disconnect the 3-pin stator coil leads connector [a]. • with the hand tester [a] check the mag...

  • Page 374

    14-32 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 s...

  • Page 375

    Electrical system 14-33 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. ○ check infinity ( ∼ ) terminals respectively. If the t...

  • Page 376

    14-34 electrical system charging system charging system circuit 1. Joint connector 1 2. Joint connector 12 (ground) 3. Main fuse 20 a 4. Battery 5. Regulator/rectifier 6. Magneto 7. Joint connector 8 (vcc).

  • Page 377

    Electrical system 14-35 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 ot...

  • Page 378

    14-36 electrical system ignition system • apply grease to the o-ring and fit it in the groove of the sensor cover. • 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 • i...

  • Page 379

    Electrical system 14-37 ignition system ignition coil removal • remove: seat (see seat removal in the hull/engine hood chap- ter) • disconnect the ignition coil primary lead connectors [a]. • remove the bracket bolts [a]. • disconnect the regulator/rectifier lead connector [a] and vehicle-down senso...

  • Page 380

    14-38 electrical system ignition system ignition coil installation • connect the spark plug lead to each ignition coil as fol- lows. #1 spark plug lead length 340 mm (13.4 in.) [a] #2 spark plug lead length 450 mm (17.7 in.) [b] #3 spark plug lead length 540 mm (21.3 in.) [c] #4 spark plug lead leng...

  • Page 381

    Electrical system 14-39 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...

  • Page 382

    14-40 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 ∼ 6.25 kΩ...

  • Page 383

    Electrical system 14-41 ignition system camshaft position sensor inspection • remove: seat (see seat removal in the hull/engine hood chap- ter) 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...

  • Page 384

    14-42 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...

  • Page 385

    Electrical system 14-43 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 c...

  • Page 386

    14-44 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 ma...

  • Page 387

    Electrical system 14-45 ignition system ignition system circuit 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. System relay 5. Main (ecu) relay 6. Joint connector 3 (switch (12 v)) 7. Joint connector 2 8. Joint connector 1 9. Ignition switch (immobi- lizer amplifier) 10. Joint conne...

  • Page 388

    14-46 electrical system ignition system.

  • Page 389

    Electrical system 14-47 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 moun...

  • Page 390

    14-48 electrical system kawasaki smart steering system • turning the steering shaft fully in left and right direction, check whether the steering position sensor comes in con- tact with the magnet. • check the clearance [a] between the steering position sensor [b] and the magnet [c] with feeler gaug...

  • Page 391

    Electrical system 14-49 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 sens...

  • Page 392

    14-50 electrical system kawasaki smart steering system steering position sensor output voltage inspection • measure the output voltage from 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 s...

  • Page 393

    Electrical system 14-51 kawasaki smart steering system steering position sensor circuit 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. System relay 5. Main (ecu) relay 6. Joint connector 3 (switch (12 v)) 7. Joint connector 2 8. Joint connector 1 9. Joint connector 15 (ground) 10. M...

  • Page 394

    14-52 electrical system sensors speed sensor removal/installation • disconnect the speed sensor connector [a]. • 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...

  • Page 395

    Electrical system 14-53 sensors speed sensor inspection • remove the speed sensor. • connect the battery and tester leads to the sensor as shown. • rotate the waterwheel by hand slowly. • measure the output voltage of the speed sensor. G/r (+), bk/w (–) → 0 ∼ battery voltage; twice a rotation (rotat...

  • Page 396

    14-54 electrical system sensors • check that the float moves up and down smoothly without binding. It should go down under its own weight. If the float does not move smoothly, replace the sensor. Float in full position [a] float in empty position [b] float arm stoppers [c] 235.2 mm (9.2598 in.) from...

  • Page 397

    Electrical system 14-55 sensors water temperature sensor inspection • remove the water temperature sensor (see fuel (dfi) system chapter). • suspend the sensor [a] in a container of water so that the temperature-sensing projection is submerged. • suspend an accurate thermometer [b] in the water. Not...

  • Page 398

    14-56 electrical system sensors charging temperature sensor inspection • remove the charging temperature sensor (see feul (dfi) system chapter). • suspend the sensor [a] in a container of water so that the temperature-sensing projection is submerged. • suspend an accurate thermometer [b] in the wate...

  • Page 399

    Electrical system 14-57 multifunction meter meter unit inspection • remove the meter unit (see steering removal in the steering chapter) [a]. [1] battery (+): r [2] ground (–):bk [3] ignition switch (+): r/w [4] speed sensor (+):r/bl [5] buzzer (–): bk/w [6] buzzer (+): r/bk [7] fuel level sensor: w...

  • Page 400

    14-58 electrical system multifunction meter • using the auxiliary wires, connect the 12 v battery to the meter unit connector as follows. ○ connect the battery positive terminal to the terminal [1]. ○ connect the battery negative terminal to the terminal [2]. • connect the terminal [3] to the termin...

  • Page 401

    Electrical system 14-59 multifunction meter tachometer (analogue) inspection • connect the 12 v battery and terminals in the same man- ner as specified in the “display function inspection”. ○ when the terminals are connected, the tachometer nee- dle momentary points to the last reading, and then ret...

  • Page 402

    14-60 electrical system multifunction meter low battery voltage warning inspection • connect the 12 v battery and terminals in the same man- ner as specified in the “display function inspection”. • when the input voltage to the terminal [1] is lowered to 11.5 v or less, check that the bat character ...

  • Page 403

    Electrical system 14-61 multifunction meter • indicate the clock mode. • check that when the set button in clock mode is pushed for more than two seconds, the display turns to hour setting mode. ○ the hour display starts flashing. Press the mode button to set the hour. • in the hour setting mode, pr...

  • Page 404

    14-62 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 t...

  • Page 405

    Electrical system 14-63 multifunction meter • disconnect the terminal [3] temporary and connect again. ○ when oscillator input frequency is approximately 182 hz, the display [a] shows the approximately 64 km/h or ap- proximately 40 mile/h. If the display function does not work, replace the meter uni...

  • Page 406

    14-64 electrical system multifunction meter slo (smart learning operation) mode display inspec- tion note ○ inspect with the meter unit installed on the watercraft. • confirm the slo mode display, following the specified sequence. ○ first, using the slo mode ignition key (yellow-colored and marked s...

  • Page 407

    Electrical system 14-65 multifunction meter multifunction meter circuit 1. Ecu 2. Joint connector 8 (vcc) 3. Joint connector 7 (vcc) 4. System relay 5. Main (ecu) relay 6. Joint connector 3 (switch (12 v)) 7. Fuel pump 8. Joint connector 2 9. Joint connector 1 10. Joint connector 15 (ground) 11. Buz...

  • Page 408

    14-66 electrical system immobilizer system this watercraft is equipped with an immobilizer system to protect the watercraft from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ecu (electronic control unit). If the code does not ma...

  • Page 409

    Electrical system 14-67 immobilizer system pre-registration of user key 1 • insert the registered key (user key 1) to the ignition switch and press key [a] for a short time (within 2 seconds). Verified • the ecu confirms the following. ○ receiving signals from immobilizer amplifier are correct. ○ th...

  • Page 410

    14-68 electrical system immobilizer system pre-registration of user key n (2 ∼ 6) • remove the user key 1 and insert the unregistered key (user key 2) and press key for a short time (within 2 sec- onds). Note ○ continue with the procedure to register the second and later keys before the 15 seconds p...

  • Page 411

    Electrical system 14-69 immobilizer system • the user key 2 is successfully pre-registered in the ecu. ○ the led warning light [a] blinks 2 times and stops for 1 second and then repeats this cycle. Also the buzzer [b] sound goes off 2 times. Note ○ only the first one cycle, the buzzer sounds goes of...

  • Page 412

    14-70 electrical system immobilizer system • the user key is registered regularly in the ecu. ○ the led warning light [a] blinks 1 time for 1.5 seconds and the buzzer sound [b] goes off 1 time synchronizing with the blink of led warning light. • the registration mode automatically ends. • remove the...

  • Page 413

    Electrical system 14-71 immobilizer system spare user key registration flow chart.

  • Page 414

    14-72 electrical system immobilizer system case 2: when the electric control unit (ecu) is faulty and has to be replaced. • prepare the following. New ecu [a] current fpo key [b] (full power operation mode: or- ange-colored) current slo key [c] (smart learning operation mode: yellow-colored and mark...

  • Page 415

    Electrical system 14-73 immobilizer system not verified ○ the led warning light, immobilizer indicator and char- acter [a] blink to display the collation error. The buzzer sound goes off [b]. (refer to the following failure illustra- tions). Immobilizer amplifier failure (service code/character -35/...

  • Page 416

    14-74 electrical system immobilizer system key collation error (service code/character-36/ider) • the user key 2 is successfully pre-registered in the ecu. ○ the led warning light [a] blinks 2 times and stops for 1 second and then repeats this cycle. Also the buzzer [b] sound goes off 2 times. Note ...

  • Page 417

    Electrical system 14-75 immobilizer system • the registration mode automatically ends. Note ○ insert the registered user keys and press them. ○ check that the engine can be started using all regis- tered user keys. Case 3: when the following both keys are faulty or lost. Fpo key (full power operatio...

  • Page 418

    14-76 electrical system immobilizer system all keys initial registration flow chart.

  • Page 419

    Electrical system 14-77 immobilizer system immobilizer system parts replacement immobilizer amplifier (ignition switch) replacement • remove the steering cover (see steering cover removal in the steering chapter). • disconnect the lead connector and remove the immobi- lizer amplifier (ignition switc...

  • Page 420

    14-78 electrical system immobilizer system immobilizer system circuit 1. Ecu 2. Joint connector 8 (vcc) 3. System relay 4. Joint connector 2 5. Joint connector 1 6. Ignition switch (immobilizer amplifier) 7. Joint connector 15 (ground) 8. Multifunction meter 9. Battery 10. Joint connector 12 (ground...

  • Page 421

    Electrical system 14-79 relay assembly relay assembly removal • remove the seat (see seat removal in the hull/engine hood chapter). • remove the front access cover (see front access cover removal/installation in the hull/engine hood chapter). • push in the pins [a] and remove the bracket. • remove: ...

  • Page 422

    14-80 electrical system relay assembly relay assembly circuit inspection (with the battery disconnected) tester connection tester reading (Ω) 3-4 ∞ main ecu relay [a] fuel pump relay [a] 1-2 not ∞* 7-8 ∞ system relay [b] 5-6 not ∞* (*): the actual reading varies with the hand tester used. Relay asse...

  • Page 423

    Electrical system 14-81 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. If the switch has an open or short, re...

  • Page 424

    14-82 electrical system 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...

  • Page 425: Storage

    Storage 15-1 15 storage table of contents preparation for storage .......................................................................................................... 15-2 cooling system...............................................................................................................

  • Page 426

    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, prep...

  • Page 427

    Storage 15-3 preparation for storage • remove the fuel pump (see the fuel system chapter). • clean the fuel pump screen [a] (see fuel system in pe- riodic maintenance chapter). • refill the fuel tank with fresh fuel approximately 10 l (2.6 gal u.S.). • turn the ignition switch on. • push the lanyard...

  • Page 428

    15-4 storage preparation for storage • reconnect the primary ignition coil lead connectors, not- ing the #1,#4 [a] and the #2, #3 [b] coil connectors. The #1, #4 coil connector has a red/yellow and a green/blue leads from the main harness. The #2, #3 coil connec- tor has a red/yellow and green/black...

  • Page 429

    Storage 15-5 preparation for storage general • wash the engine compartment with fresh water and re- move the drain screw in the stern to drain the water. 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 s...

  • Page 430

    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...

  • Page 431

    Storage 15-7 removal from storage • remove the belt cover bolts [a] and belt cover [b] (see supercharger drive belt for wear/damage and belt ten- sion inspection in the periodic maintenance chapter). • crank the engine for several times and check that the en- gine pulley and supercharger pulley rota...

  • Page 433: Appendix

    Appendix 16-1 16 appendix table of contents cable, wire and hose routing ............................................................................................... 16-2 troubleshooting guide ...........................................................................................................

  • Page 434

    16-2 appendix cable, wire and hose routing.

  • Page 435

    Appendix 16-3 cable, wire and hose routing 1. Cooling hose (muffler body ∼ hull) 2. Flushing hose (exhaust manifold ∼ intercooler) 3. Throttle cable 4. Flushing hose (flushing fitting ∼ exhaust manifold) 5. Bypass outlet hose 6. Fuel hose 7. Oil temperature sensor 8. Cooling hose (oil cooler ∼ front...

  • Page 436

    16-4 appendix cable, wire and hose routing.

  • Page 437

    Appendix 16-5 cable, wire and hose routing 1. Supercharger 2. Position the clamp screw head, as shown. 3. White arrow mark 4. Intercooler 5. Position the clamp screw head under the (intercooler ∼ throttle body) as shown. 6. Throttle body.

  • Page 438

    16-6 appendix cable, wire and hose routing.

  • Page 439

    Appendix 16-7 cable, wire and hose routing 1. Duct (relief valve ∼ air box) 2. Duct (blow off valve ∼ air box) 3. Band 4. Relief valve 5. Pulse hose 6. Clamp 7. Clamps: face up 8. Blow off valve 9. From hull (cooling hose) 10. Intercooler 11. White mark 12. Arrow mark 13. To rear of cylinder head (c...

  • Page 440

    16-8 appendix cable, wire and hose routing.

  • Page 441

    Appendix 16-9 cable, wire and hose routing 1. Clamp 2. 45° 3. Air suction valve hose 4. Face up 5. Bracket 6. Duct.

  • Page 442

    16-10 appendix cable, wire and hose routing.

  • Page 443

    Appendix 16-11 cable, wire and hose routing 1. Cooling hose (output cover ∼ oil cooler) 2. Cooling hose (oil cover ∼ front of cylinder head) 3. White mark 4. Breather hose (breather case ∼ cylinder head) 5. Muffler body 6. Cooling hose (cylinder ∼ left water box muffler) 7. Oil separator tank hose (...

  • Page 444

    16-12 appendix cable, wire and hose routing.

  • Page 445

    Appendix 16-13 cable, wire and hose routing 1. Clamp the two cables, sensor leads and the cooling hose to the oil pipe with the band. 2. Cooling hose (oil cooler ∼ front of cylinder head) 3. Protect tube 4. Oil filter 5. Oil cooler 6. Clamp the starter motor and battery (–) cables, with the band. 7....

  • Page 446

    16-14 appendix cable, wire and hose routing.

  • Page 447

    Appendix 16-15 cable, wire and hose routing 1. Clamp 2. Breather hose (breather case ∼ cylinder head) 3. Cooling hose (oil cooler ∼ front of cylinder head) 4. Protect tube 5. Breather case 6. Cooling hose (cylinder ∼ left water box muffler) 7. Return oil hose (cylinder ∼ breather case).

  • Page 448

    16-16 appendix cable, wire and hose routing.

  • Page 449

    Appendix 16-17 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 5. Flushing hose 6. To flushing fitting 7. Deck 8. ...

  • Page 450

    16-18 appendix cable, wire and hose routing.

  • Page 451

    Appendix 16-19 cable, wire and hose routing 1. Flushing cap 2. Clamp 3. Right side cover 4. Flushing line.

  • Page 452

    16-20 appendix cable, wire and hose routing.

  • Page 453

    Appendix 16-21 cable, wire and hose routing 1. Exhaust manifold 2. Exhaust pipe 3. Muffler body 4. 45° 5. Dampers 6. Face forward. 7. Arrow marks 8. To tail pipe.

  • Page 454

    16-22 appendix cable, wire and hose routing.

  • Page 455

    Appendix 16-23 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. Right water box muffler 7. Right bilge breather 8. Left bilge breather 9. Left bilge filter 10. Right bilge filter 11. Left front duct 12. Right front ...

  • Page 456

    16-24 appendix cable, wire and hose routing.

  • Page 457

    Appendix 16-25 cable, wire and hose routing 1. Fuel hose 2. Fuel pump 3. Clamp 4. Holder 5. O-ring 6. Install the clamp so that its screw position faces backwards..

  • Page 458

    16-26 appendix cable, wire and hose routing.

  • Page 459

    Appendix 16-27 cable, wire and hose routing 1. Fuel hose 2. Throttle cable 3. Main harness 4. Fix the #1 and #2 spark plug leads with the clamp. 5. Fix the #2 and #3 spark plug leads with the clamp. 6. Fix the #3 and #4 spark plug leads with the clamp. 7. Bolts 8. Clamps 9. To speed sensor 10. Fix t...

  • Page 460

    16-28 appendix cable, wire and hose routing.

  • Page 461

    Appendix 16-29 cable, wire and hose routing 1. Charging temperature sensor leads 2. Stator coil leads connector 3. Air bypass duct 4. Throttle sensor 5. Oil pressure switch 6. Oil temperature sensor 7. Crankshaft sensor 8. Vehicle-down sensor 9. Regulator/rectifier 10. #2, #3 ignition coil 11. #1, #...

  • Page 462

    16-30 appendix cable, wire and hose routing.

  • Page 463

    Appendix 16-31 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. Run ...

  • Page 464

    16-32 appendix cable, wire and hose routing.

  • Page 465

    Appendix 16-33 cable, wire and hose routing 1. Fuel pump relay 2. Ecu main relay 3. 20 a fuse 4. Ecu 5. Regulator/rectifier 6. Vehicle-down sensor 7. #1 ignition coil 8. #2 ignition coil 9. #3 ignition coil 10. #4 ignition coil 11. Black lead 12. Red lead.

  • Page 466

    16-34 appendix cable, wire and hose routing.

  • Page 467

    Appendix 16-35 cable, wire and hose routing 1. Battery (–) cable 2. Battery (–) lead 3. Connector for diag and key registration 4. Starter relay 5. Red mark 6. Battery (+) cable 7. To starter motor 8. Starter relay leads 9. Battery (+) lead 10. Battery.

  • Page 468

    16-36 appendix cable, wire and hose routing.

  • Page 469

    Appendix 16-37 cable, wire and hose routing 1. Fuel vent hose 2. Start/stop switch leads 3. Multifunction leads 4. Grommet 5. Throttle cable 6. Buzzer leads 7. Clamp 8. Protect tube 9. Handlebar pad 10. Buzzer leads 11. Steering shaft 12. Steering position sensor.

  • Page 470

    16-38 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 rot...

  • Page 471

    Appendix 16-39 troubleshooting guide fuel injector trouble water or foreign matter in fuel throttle sensor trouble fuel pressure may be low fuel pump trouble inlet air pressure sensor trouble inlet air temperature sensor trouble water temperature sensor trouble crankshaft sensor trouble compression ...

  • Page 472

    16-40 appendix troubleshooting guide ignition coil trouble compression low spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder he...

  • Page 473

    Appendix 16-41 troubleshooting guide after fire crankshaft sensor trouble spark plug burned or gap maladjusted inlet air temperature sensor trouble water temperature sensor trouble inlet air pressure sensor trouble fuel injector trouble run-on (dieseling) ignition switch trouble engine switch troubl...

  • Page 474

    16-42 appendix troubleshooting guide cylinder head warped valve spring broken or weak valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.) knocking carbon built up in combustion chamber fuel poor quality or incorrect spark plug incorrect ic igniter in ecu tro...

  • Page 475

    Appendix 16-43 troubleshooting guide connecting rod bent piston pin, piston pin hole worn valve noise valve clearance incorrect valve spring broken or weak camshaft bearing worn valve lifter worn other noise connecting rod small end clearance excessive connecting rod big end clearance excessive pist...

  • Page 476

    16-44 appendix troubleshooting guide poor steering control (since faulty steering is dangerous, this problem should be examined by an authorized jet ski dealer) handlebar hard to turn steering maladjusted bushing damaged or cracked steering shaft bent no lubricant on steering pivot steering cable da...

  • Page 477

    Model application year model beginning hull no. 2007 jt1500b7f us-kaw30001 □ 607 us-kaw39001 □ 607 □ :this digit in the hull number changes from one machine to another. Part no.99924-1377-01 printed in japan.