STX-15F JET SKI Watercraft Service Manual ®
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STX-15F JET SKI Watercraft Service Manual ® All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products and Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W Ω pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) perminute top dead center total indicator re
MAINTENANCE AND ADJUSTMENTS Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine Sl engine repair establishment or individual. EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted on service station pumps.
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
NOTE This note symbol indicates points of par○ ticular interest for more efficient and convenient operation. a procedural step or work to be • Indicates 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 a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
GENERAL INFORMATION 1-1 General Information 1 Table of Contents Smart Learning Operation mode (SLO) (JT1500-A2 model ∼)............................................... Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications...................................................
1-2 GENERAL INFORMATION Smart Learning Operation mode (SLO) (JT1500-A2 model ∼) This watercraft is equipped with the Smart Learning Operation mode (SLO) and normal operation mode (Full Power Operation, FPO). The SLO mode reduces the maximum watercraft speed by approximately 30 percent for a use by unskilled operators. To change the SLO mode to FPO mode, and back again, push the “MODE” button for 7 seconds or more. SLO mode is displayed on the meter as SLO.
GENERAL INFORMATION 1-3 Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on watercraft, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
1-4 GENERAL INFORMATION Before Servicing a standard garden hose [A] and a garden hose • Obtain 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. the front storage compartment cover. • Open Remove the flushing cap [A] on the brim of the storage • compartment. a garden hose adapter [A] onto the flushing fitting • Screw [B].
GENERAL INFORMATION 1-5 Before Servicing CAUTION Turn the capsized boat clockwise so that the port side always faces downward. Turning counterclockwise can cause water in the exhaust system to run into the engine, with possible engine damage. Battery Ground Before completing any service on the watercraft, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (–) first and then the positive (+).
1-6 GENERAL INFORMATION Before Servicing Cleaning Watercraft before Disassembly Clean the watercraft thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during watercraft disassembly can cause excessive wear and decrease performance of the watercraft. Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
GENERAL INFORMATION 1-7 Before Servicing Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given. Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction.
1-8 GENERAL INFORMATION Before Servicing Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage. Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area.
GENERAL INFORMATION 1-9 Before Servicing Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation. Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
1-10 GENERAL INFORMATION Model Identification JT1500-A1 Left Side View JT1500-A1 Right Side View
GENERAL INFORMATION 1-11 General Specifications JT1500-A1 ∼ A2 Items Engine Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition System Lubrication System Carburetion System Starting System Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Tuning Specifications Spark plug: Type Gap Ignition Timing Idle Speed Compression Pressure Drive System Coupling Jet Pump: Type Thrust Steering Braking Performance †Minim
1-12 GENERAL INFORMATION General Specifications Items Overall Width Overall Height Dry Weight Fuel Tank Capacity Engine Oil Type Viscosity Capacity Electrical Equipment Battery Maximum Generator Output JT1500-A1 ∼ A2 1 180 mm (46.5 in.) 1 050 mm (41.3 in.) 338 kg (745 lb) 62 L (16.4 US gal) API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 5.0 L (5.
GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units Prefix mega kilo centi milli micro Symbol M k c m µ Units of Length × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Mass kg g × × 2.205 0.03527 = = lb oz km m mm × × × 0.6214 3.281 0.03937 = = = mile ft in. = = = = = = kgf·m ft·lb in·lb N·m ft·lb in·lb = = = = = = kgf/cm² psi cmHg kPa psi kPa = mph = = = = PS HP kW HP Units of Torque N·m N·m N·m kgf·m kgf·m kgf·m × × × × × × 0.1020 0.7376 8.851 9.807 7.
PERIODIC MAINTENANCE 2-1 Periodic Maintenance 2 Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools and Sealant ...........................
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.
PERIODIC MAINTENANCE 2-3 Torque and Locking Agent The following table list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or silicone sealant. Letters used in the “Remarks” column mean: EO: Apply oil to the threads and seating surface. L: Apply a non-permanent locking agent to the threads. MO: Apply molybdenum disulfide grease oil solution. R: Replacement Part S: Tighten the fasteners following the specified sequence.
2-4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Oil Passage Joints Oil Cooler Assembly Bolts Oil Pressure Switch Oil Passage Bolt Oil Filter Oil Cooler Positioning Bolt Oil Pan Bolts Dipstick Tube Bolts Oil Pump Sprocket Bolt Oil Pump Cover Bolts Oil Pressure Relief Valve Oil Pipe Bolts Chain Guide Spring Plate Bolt Oil Pump Body Plug Oil Pump Body Bolts Oil Screen Bolts Water Pipe Joints Exhaust System Exhaust Manifold Mounting Nuts Exhaust Manifold Mounting Bolts Bypass Nozzle Flushing Hose Joi
PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Inlet Side Camshaft Chain Guide Bolts Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Position Sensor Rotor Bolt Water Hose Joint Oil Passage Joint Engine Removal/Installation Engine Mounting Bolts Engine Damper Mounting Bolts Engine Bottom End Crankshaft Sensor Cover Bolts Engine Bracket Mounting Bolts Timing Rotor Bolt Connecting Rod Nuts Oil Passage Plugs Stator Mounting Bolts Grommet Cover Bolts Magneto Cover B
2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Pump Cover Mounting Bolts Grate Mounting Bolts Filter Cover Mounting Bolts Steering Handlebar Clamp Bolts Start/stop Switch Case Mounting Screws Throttle Case Mounting Screws Steering Shaft Locknut Steering Shaft Nut Steering Holder Mounting Bolts Steering Neck Mounting Bolts Steering Cable Joint Bolt Ball Joint Shift Cable End Nut Reverse Bucket Pivot Bolts Shift Cable Nut Steering Cable Nut Shift Lever Locknut Hull/Engine Hood Crossmember Bolts Ha
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Starter Relay Mounting Nut Starter Cable Mounting Nut Timing Rotor Bolt Crankshaft Sensor Screws Rubber Grommet Holder Screws Crankshaft Sensor Cover Bolts Oil Temperature Sensor Camshaft Position Sensor Bolt Spark Plugs Regulator/rectifier Bolts Replay Assembly Bolts ECU Mounting Bolts Main Fuse Mounting Bracket Bolt Multifunction Meter Mounting Bolts Fuel Level Sensor Clamp Screw Start/stop Switch Case Mounting Screws Speed Sensor Mounting Bolts S
2-8 PERIODIC MAINTENANCE Specifications Item Standard Fuel System Throttle Lever Free Play about 2 mm (0.08 in.) Engine Lubrication System Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 4.0 L (4.2 US qt, with or without the filter) 5.0 L (5.3 US qt, when engine is completely dry) Engine Top End Valve Clearance: IN 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) EX 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) Electrical System Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.
PERIODIC MAINTENANCE 2-9 Special Tools and Sealant Oil Filter Wrench: 57001-1249 Shaft Wrench: 57001-1551
2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Control System Inspection the throttle lever free play [A]. • Inspect If the free play is incorrect, adjust the throttle cable. Throttle Lever Free Play Standard: about 2 mm (0.08 in.) that the throttle lever moves smoothly from full • Check open to close, and the throttle closes quickly and com- • pletely in all steering positions by the return spring.
PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Air Filter Inspection and Cleaning • Remove: Air Filter (see Fuel System (DFI) chapter) Flame Arrester [A] (see Air Filter Disassembly in Fuel System (DFI) chapter) the flame arrester [A]. • Clean Visually inspect the flame arrester for damage. • If necessary, replace it with a new one. Fuel Vent Check Valve Inspection The fuel vent check valve is mounted in the fuel tank vent hose to prevent fuel from spilling during riding.
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures fuel vent check valve [C] must be mounted so that • The the arrow [D] on its case is pointing toward the fuel tank. Fuel Pump Screen Cleaning the fuel pump (see Fuel System chapter). • Remove Wash the pump screen [A] in non-flammable of high • -flash pointfuel solvent. Use a brush to remove any contaminants trapped in the screens.
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures a well-ventilated area, start the engine while cooling the • Incooling system. ○Open the front storage compartment cover. ○Remove the flushing cap (see Cooling System Flushing). ○Screw a garden hose adapter [A] onto the flushing fitting [B]. ○Attach a garden hose [C] to a garden hose adapter and • secure the hose clamp [D]. Warm up the engine and stop it.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed according to the chart shown. • Install the filler cap. Torque - Oil Filler Cap: 1.0 N·m (0.10 kgf·m, 8.7 in·lb) the oil level (see Engine Lubrication System chap• Check ter). Oil Filter Replace • Remove: Seat (see Hull/Engine Hood chapter) Drain engine oil (see Engine Oil Change). • Place the a reg • maining oil.
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection the air suction valve (see Engine Top End chap• Remove ter). inspect the reeds [A] for cracks, folds, warps, • Visually heat damage, or other damage. • If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder, or heat damage.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures the valve clearance between the cam and the • Measure valve lifter with a thickness gauge [A]. Valve Clearance Standard: IN 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) EX 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures INLET VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example Present shim is 2.60 mm. Measured clearance is 0.35 mm. Replace 2.60 mm shim with 2.75 mm shim. 5.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures EXHAUST VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example Present shim is 2.65 mm. Measured clearance is 0.42 mm. Replace 2.65 mm shim with 2.80 mm shim. 5.
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures molybdenum disulfide oil to the valve lifters and ap• Apply ply engine oil to the shims, and install them. the camshafts. Be sure to install the camshafts • Install properly (see Engine Top End chapter). any valve clearance that was adjusted. • Remeasure Readjust if necessary. • CAUTION Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures a standard garden hose [A] and a garden hose • Obtain adapter [B] as shown. Garden Hose Fitting of Adapter [C] Flushing Fitting of Adapter [D] Thread: Rp 3/4 [E] NOTE ○Optional part (P/No. 92005-3746) is available as a garden hose adapter. the front storage compartment cover. • Open Remove the flushing cap [A] on the brim of the storage • compartment. a garden hose adapter [A] onto the flushing fitting • Screw [B].
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures the engine idle for several minutes with the water • Leave running. off the water. Leave the engine idling. • Turn Rev the a few times to clear the water out of the • exhaust engine system. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damage will occur. off the engine, remove the garden hose and the • Switch adapter.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Pump and Impeller Impeller Inspection the impeller. [A] • Examine If there is pitting, deep scratches, nicks or other damage, replace the impeller. NOTE ○Minor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing. Smooth leading edges are especially important to avoid cavitation. Steering Steering Cable/Shift Cable Inspection the steering cable or shift cable.
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Steering Shaft [B] Hull/Engine Hood Drain Plug Inspection the drain plugs [A] for cracks or damage and the • Check drain plug mounting screws [B] are tightened securely. the seals [C] for damage. • Check If necessary, replace the drain plugs or seals. Electrical System Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage.
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures that the battery terminals [B] are not corroded. • Check If necessary, remove the battery (see Electrical System • • chapter) and clean the terminals and cable ends using a solution of baking soda and water. After attaching both cables, coat the terminals and cable ends with grease to prevent corrosion. Install the battery (see Electrical System chapter).
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures the following with grease. •○Lubricate Pull the throttle lever and hold it. Throttle Cable End at Throttle Lever [A] Throttle Cable End [A] at Throttle Body ○Remove the storage pocket (see Hull/Engine Hood chapter). Steering Cable Ball Joint [A] at Steering Shaft ○Remove the storage pocket (see Hull/Engine Hood chapter).
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures the following with a penetrating rust inhibitor [B]. • Lubricate Throttle Cable [A] Steering Nozzle Pivots [A] Reverse Bucket Pivots [B] the cable disconnected at both ends, the cable • With 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.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check Nuts, Bolts, and Fasteners Tightness Inspection the tightness of the bolts and nuts listed here. Also, • Check check to see that each cotter pin is in place and in good condition. NOTE ○For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures sure the above hoses are routed properly and se• Make cured with the clamps away from any moving parts and sharp edged portions. Plastic Clamp [A] Hose [B] Hose Fitting [C] NOTE ○The majority of bilge hoses have no clamps at the hose ends. Metal Clamp [A] Hose [B] Hose Fitting [C] NOTE ○Check the fuel and exhaust tubes for signs of wear, deterioration, damage or leakage. Replace if necessary.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Rubber Strap Inspection the following rubber straps for any deterioration or • Check damage. Pull on squeeze the straps and look for cracks. Battery Straps [A] Fuel Tank Straps Water Box Muffler Straps If a strap is damage in any way, replace it.
FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Fuel System Diagram ........................ Exploded View................................... Specifications .................................... Special Tools and Sealant ................. DFI Parts Location............................. DFI System........................................ DFI Servicing Precautions ................. Self-Diagnosis ................................... Self-diagnosis Outline.....................
3-2 FUEL SYSTEM (DFI) Throttle Lever, Cable and Case......... Free Play Inspection .................... Throttle Cable Adjustment ........... Throttle Case Removal/Disassembly....................................... Throttle Case Assembly/Installation ............................................ Throttle Cable Removal ............... Throttle Cable Installation ............ Throttle Case and Cable Lubrication................................. Throttle Cable Inspection ............. Air Filter ................
FUEL SYSTEM (DFI) 3-3 Fuel System Diagram 1. Fuel Pump 2. Clamps (JT1500-A1 Model) Double Spring Clamps (JT1500-A2 Model ∼) (Installation Procedure: Pull up the clamp stopper [A] with pliers [B].) 3. Main Line 4. Fuel Filter 5. Supply Line 6. Return Line 7. Delivery Pipe 8. Fuel Injectors 9.
3-4 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-5 Exploded View No.
3-6 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-7 Exploded View No. 1 2 3 4 Fastener Oil Pressure Switch Fuel Filler Tube Clamp Screws Fuel Level Sensor Clamp Screw Fuel Filter Mounting Bolts N·m 15 2.9 2.9 8.8 5. Meter Unit 6. Buzzer 7. Fuel Vent Check Valve 8. Fuel Level Sensor 9. Fuel Filter 10. Fuel Pump A: JT1500-A1 Model B: JT1500-A2 Model ∼ L: Apply a non-permanent locking agent. R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120). Torque kgf·m 1.5 0.30 0.30 0.
3-8 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-9 Exploded View No. 1 2 3 4 Fastener Air Filter Mounting Bolts Air Filter Bracket Mounting Bolts Throttle Cable Locknut Throttle Case Mounting Screws G: Apply grease. L: Apply a non-permanent locking agent. N·m 9.8 7.8 7.8 3.9 Torque kgf·m 1.0 0.80 0.80 0.
3-10 FUEL SYSTEM (DFI) Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Operating range Fuel Pressure (High Pressure Line): Engine Idling Fuel Pump: Type Discharge Throttle Sensor: Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor: Input Voltage Output Voltage Inlet Air Temperature Sensor: Output Voltage at ECU Resistance Water Temperature Sensor: Resistance Output Voltage at ECU Vehicle-down Sensor: Detection Met
FUEL SYSTEM (DFI) 3-11 Specifications Item Throttle Lever and Cables Throttle Lever Free Play Standard about 2 mm (0.08 in.
3-12 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Sensor Harness Adapter: 57001-1561 Hand Tester: 57001-1394 Harness Adapter: 57001-1562 Needle Adapter Set: 57001-1457 Kawasaki Bond (Silicone Sealant): 56019-120 Fuel Pressure Gauge Adapter: 57001-1463 Kawasaki Bond (Silicone Grease): 92137-1002 Throttle Sensor Setting Adapter: 57001-1521
FUEL SYSTEM (DFI) 3-13 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. Crankshaft Sensor 12. Oil Pressure Switch 13.
3-14 FUEL SYSTEM (DFI) DFI Parts Location 14. Ignition Switch 15. Meter Unit 16. Buzzer 17. Fuel Pump 18. Fuel Level Sensor 19. Vehicle-down Sensor 20. Ignition Coil #1, #4 21. Ignition Coil #2, #3 22. Main Fuse 20 A 23. ECU (Electronic Control Unit) 24. Diagnosis Connector 25. Relay Assembly (Main Relay/Fuel Pump Relay) 26.
FUEL SYSTEM (DFI) 3-15 DFI Parts Location Dummy Page
3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram
FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Joint Connector H 6. Inlet Air Temperature Sensor 7. Inlet Air Pressure Sensor 8. Joint Connector E 9. Joint Connector J 10. Crankshaft Sensor 11. Relay Assembly (Main Relay/Fuel Pump Relay) 12. Joint Connector F 13. Connector C 14. Vehicle-down Sensor 15. Meter Unit (Diagnosis Signal) 16. Ignition Switch 17. Joint Connector Q 18. Start Switch 19. Joint Connector R 20.
3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Tachometer Signal 2. ECU Main Relay 3. Unused 4. SLO (Smart Learning Operation) Mode (JT1500-A2 Model ∼) 5. Oil Pressure Switch 6. Engine Stop Switch 7. Inlet Air Temperature Sensor 8. Ground for Sensors 9. Ignition Switch 10. Steering Position Sensor 11. Unused 12. Power Supply to Sensors 13. Cam Sensor (+) Signal 14. Cam Sensor (–) Signal 15. Crankshaft Sensor 16. Unused 17. Fuel Pump Relay 18.
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 power source. ○Do not reverse the battery cable connections. This will damage the ECU.
3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions For JT1500-A2 ∼; ○Install the double spring clamp in the position as shown, and securely pull up the clamp stopper with pliers. Check the fuel system for leaks after hose installation. Fuel Hose [B] Double Spring Clamp [A] Fuel Pipe [C] CAUTION Do not reuse the double spring clamps on the fuel line. Reusing will cause fuel leakage. Replace the double spring clamps with new ones. ○Replace the fuel hose if it has been sharply bent or kinked.
FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○After measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of Connector check battery condition before replacing the DFI • Always parts. A fully charged battery is a must for conducting • accurate tests of the DFI system. Do not directly connect a 12 V battery to a fuel injector. Insert a resistor (5 ∼ 7 Ω) or a bulb (12 V, 3 ∼ 3.
3-22 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode. [A] Push the “SET” button with “MODE” button at the same time for 3 seconds or more. [B] Push either “SET” or “MODE” button for more than one second or more. User Mode This is a standard mode and enters automatically after ignition switch ON.
FUEL SYSTEM (DFI) 3-23 Self-Diagnosis Service Code (Character) Table Service Service Code Code Character (used in (displayed on ECU) Meter Unit) 12 13 14 21 23 31 41 42 43 44 51 52 71 72 (JT1500-A1) 76 Fail-Safe Function Throttle sensor malfunction, wiring open or short 11 73 Possible Problems (JT1500-A2 ∼) (JT1500-A2 ∼) The ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method (see Note 1).
3-24 FUEL SYSTEM (DFI) Self-Diagnosis Note: (1) D-J Method: the DFI control method from medium to heavy engine load. When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (vacuum sensor output voltage) and engine speed (crankshaft sensor output voltage).
FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Hull No.: Date problem occurred: Mileage: Environment when problem occurred. □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Weather Temperature □ hot, □ warm, □ cold, □ very cold, □ always Problem □ chronic, □ often, □ once frequency Altitude □ normal, □ high (about 1 000 m or more) Watercraft conditions when problem occurred.
3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System Poor running or no power at high speed □ □ □ □ □ □ □ □ spark plug loose (tighten it). spark plug dirty, broken, or gap maladjusted (remedy it). spark plug incorrect (replace it). knocking (fuel poor quality or incorrect). engine overheating. engine oil level too high. engine oil viscosity too high.
FUEL SYSTEM (DFI) 3-27 Throttle Sensor (Service Code/Character-11/tPS) Throttle Sensor Removal/Adjustment CAUTION Never drop the throttle sensor [A], especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Seat (see Hull/Engine Hood chapter) Air filter (see air Filter Removal) a Torx wrench [A] (T20, B = 3.86 mm (0.152 in.)) to • Use remove the throttle sensor mounting screws [C].
3-28 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) the throttle sensor positioning as follows. •○Adjust 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 switch OFF. ○Disconnect the throttle sensor connector and connect the throttle sensor setting adapter [A] between the harness connector and throttle sensor connector.
FUEL SYSTEM (DFI) 3-29 Throttle Sensor (Service Code/Character-11/tPS) the ignition switch ON and push the lanyard key un• Turn der the stop button. the start button, run the engine 5 ∼ 6 seconds at • Pushing idling to measure the sensor input voltage. ○Wait 15 seconds before using the starter again. Input Voltage at ECU Standard: 4.75 ∼ 5.25 V DC the ignition switch OFF. • Turn If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted.
3-30 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) Output Voltage Inspection the output voltage at the ECU in the same way • Measure as input voltage inspection. Note the following. Digital Voltmeter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Throttle Sensor Output Voltage Connections to ECU Meter (+) → G/W lead (terminal 34) Meter (–) → BK/W lead (terminal 8) the engine. • Start Check idle speed to ensure throttle opening is correct.
FUEL SYSTEM (DFI) 3-31 Throttle Sensor (Service Code/Character-11/tPS) the throttle sensor connector and connect the • Disconnect setting adapter [A] between the harness connector and • throttle sensor connector. Connect a digital meter to the setting adapter leads. Special Tool - Throttle Sensor Setting Adapter: -1521 57001 Throttle Sensor Output Voltage Connections to Sensor Meter (+) → G/W lead Meter (–) → BK/W lead • Measure the sensor output voltage with the idle speed.
3-32 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) 1. ECU 2. Joint Connector E 3.
FUEL SYSTEM (DFI) 3-33 Inlet Air Pressure Sensor (Service Code/Character-12/bOSt) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal the ignition switch off. • Turn Remove: • Seat (see Hull/Engine Hood chapter) Inlet Air Pressure Sensor Bolts [A] Inlet Air Pressure Sensor Connector [B] Inlet Air Pressure Sensor [C] Inlet Air Pressure Sensor Installation • Apply silicone oil to the O-ring [A].
3-34 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code/Character-12/bOSt) • • If the reading is within the standard range, and check the input voltage at the sensor connector. Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the harness connector and inlet air pressure sensor connector. Connect a digital meter to the harness adapter leads.
FUEL SYSTEM (DFI) 3-35 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.
3-36 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) Inlet Air Temperature Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the air filter (see Air Filter Removal). • Remove the connector [A] from the inlet air tempera• Disconnect ture sensor. • Remove the inlet air temperature sensor [B] and washer. the inlet air temperature sensor and washer [A].
FUEL SYSTEM (DFI) 3-37 Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) • If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU. If the output voltage is far out of the specified, check the wiring (see next diagram). Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing.
3-38 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) 1. ECU 2. Joint Connector E 3. Joint Connector H 4.
FUEL SYSTEM (DFI) 3-39 Water Temperature Sensor (Service Code/Character-14/AqUt) Water Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the sensor connector [A], and unscrew the • Disconnect water temperature sensor [B]. installing the water temperature sensor, remove the • When exhaust manifold for the engine oil filling in the hollow of the exhaust manifold.
3-40 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code/Character-14/AqUt) a digital voltmeter [A] to the ECU connector [B], • Connect with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Water Temperature Sensor Output Voltage Connections to ECU Meter (+) → G/Y lead (terminal 35) Meter (–) → BK/W lead (terminal 8) the ignition switch ON and push the lanyard key un• Turn der the stop button.
FUEL SYSTEM (DFI) 3-41 Water Temperature Sensor (Service Code/Character-14/AqUt) 1. ECU 2. Joint Connector E 3. Water Temperature Sensor Sensor Resistance Inspection the water temperature sensor (see Water Tem• Remove perature Sensor Removal/Installation). to Electrical System chapter for water temperature • Refer sensor inspection.
3-42 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code/Character-21/CrAg) Crankshaft Sensor Removal/Installation the Ignition System section in Electrical System • See chapter. Crankshaft Sensor Inspection ○The crankshaft have no power source, and when the en- • • gine stops, the crankshaft generates no signals. Crank the engine and measure the peak voltage of the crankshaft sensor (see Electrical System chapter) in order to check the sensor.
FUEL SYSTEM (DFI) 3-43 Camshaft Position Sensor (Service Code/Character-23/CAAg) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. See the Ignition system section in Electric System chapter. • Camshaft Position Sensor Inspection ○The camshaft position sensor have no power source, and • • when the engine stops, the camshaft position sensor generates no signal.
3-44 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code/Character-31/dOS) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the watercraft banks 110 ∼ 130° or more to either side (in fact falls down), the weight turns and shuts off the signal. The ECU senses this change, and stops the fuel pump, the fuel injectors, and the ignition system.
FUEL SYSTEM (DFI) 3-45 Vehicle-down Sensor (Service Code/Character-31/dOS) Vehicle-down Sensor Inspection NOTE ○Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) a digital volt meter [A] to the connector [B] of the • Connect vehicle-down sensor lead with the needle adapter set [C].
3-46 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code/Character-31/dOS) the ignition switch OFF. • Turn Remove needle adapter set, and apply silicone • sealant tothe the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring. If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
FUEL SYSTEM (DFI) 3-47 Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Fuel Injector Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) cable terminal. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
3-48 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) the seals [A] with new ones. • Replace Apply grease to the inside and outside of seals. • • Install: Delivery Pipe Assembly • • Collars Install the clamps [A] as shown. Tighten: Torque - Delivery Pipe Mounting Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) the fuel hoses (see Cable, Wire, and Hose Routing • Install section in Appendix chapter).
FUEL SYSTEM (DFI) 3-49 Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) connectors for injector [A]. • Remove each test light set [B] to the injector harness con• Connect nector [C]. the ignition switch ON. • Turn While the engine with the starter motor, watch • the testcranking lights. If the test lights flicker at regular intervals, the injector circuit in the ECU, and the wiring are good. Perform the “Injector Resistance Inspection”.
3-50 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Injector Voltage Inspection the ignition switch OFF. • Turn a digital voltmeter [A] to the connector [B], with • Connect the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage Connector to Injector #1, #2, #3, #4 Meter (+) → R/Y lead Meter (–) → Battery (–) Terminal the ignition switch ON and push the lanyard key un• Turn der the stop button.
FUEL SYSTEM (DFI) 3-51 Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Injector Fuel Line Inspection the injector fuel line for leakage as follows: •○Check Connect a commercially available vacuum/pressure pump [A] to the supply joint of the delivery pipe [B] with the fuel hose [C] (both ends connected with the clamps [D]) as shown. ○Plug the return joint of the delivery pipe with a rubber plug [E]. ○Tighten the clamp [F].
3-52 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4. Fuel Injector #4 5. Joint Connector H 6. Main Relay in Relay Assembly 7. Joint Connector F 8. Connector C 9. Connector D 10. Joint Connector R 11. Main Fuse 20 A 12. Battery 13. ECU 14. Joint Connector P 15.
FUEL SYSTEM (DFI) 3-53 Ignition Coils (Service Code/Character-51, 52/COL1, COL2) Ignition Coil #1, #4: Service Code 51-COL1 Ignition Coil #2, #3: Service Code 52-COL2 Ignition Coil Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can damage it. • See Ignition System section in Electrical System chapter. Input Voltage Inspection NOTE ○Be sure the battery is fully charged. • Turn the ignition switch OFF.
3-54 FUEL SYSTEM (DFI) Ignition Coils (Service Code/Character-51, 52/COL1, COL2) 1. Main Relay in Relay Assembly 2. Joint Connector F 3. Connector C 4. Connector D 5. Joint Connector R 6. Main Fuse 20 A 7. Starter Motor 8. Battery 9. ECU 10. Ignition Coils 11. Joint Connector P 12.
FUEL SYSTEM (DFI) 3-55 Engine Overheating (Service Code/Character-71/HEAt) • If the service code is displayed, check the doubtful parts referring to the following table.
3-56 FUEL SYSTEM (DFI) Low Engine Oil Pressure (Service Code/Character-72/OILP) • If the service code is displayed, check the doubtful parts referring to the following table.
FUEL SYSTEM (DFI) 3-57 Oil Temperature Sensor (Service Code/Character-73/OILC or 73/OILt) Service Code/Character JT1500-A1: 73/OILC JT1500-A2 ∼: 73/OILt Oil Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
3-58 FUEL SYSTEM (DFI) Oil Temperature Sensor (Service Code/Character-73/OILC or 73/OILt) the ignition switch OFF. • Turn If the output voltage is out of the specified, check the ECU • for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU. If the output voltage is far out of the specified (e.g. when the wiring is open, the voltage is about 5 V), check the wiring (see next diagram).
FUEL SYSTEM (DFI) 3-59 Engine Oil Overheating (Service Code/Character-76/OILH) JT1500-A2 model ∼; If the service code is displayed, check the doubtful parts referring to the following table.
3-60 FUEL SYSTEM (DFI) ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seat (see Hull/Engine Hood chapter) Bolts [A] the ECU lead connector [A]. • Disconnect Remove: • ECU [B] ECU Installation the ECU connector and install it. • Connect Apply a non-permanent locking agent to the bolts and • tighten them. Torque - ECU Mounting Bolts: 8.8 N·m (0.
FUEL SYSTEM (DFI) 3-61 ECU the ECU power source voltage with a tester [A]. •○Check Position the terminal in accordance with terminal numbers of ECU connector [B] in this chapter figure.
3-62 FUEL SYSTEM (DFI) ECU ECU Power Source Circuit 1. Main Relay in Relay assembly 2. Joint Connector F 3. Connector C 4. Connector D 5. Ignition Switch 6. Start Switch 7. Joint Connector R 8. Main Fuse 20 A 9. Battery 10. ECU 11. Joint Connector P 12.
FUEL SYSTEM (DFI) 3-63 DFI Power Source Main Fuse Inspection to the Electrical System chapter for the ECU Fuse • Refer Inspection. Relay Assembly Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • Remove: Seats (see Frame chapter) Bolt [A] Relay Assembly [B] Connector [C] (disconnect) Band [D] (Cut) Relay Assembly Inspection the relay assembly. • Remove Connect hand tester [A] and one 12 V battery [B] to • the relay the connector [C] as shown.
3-64 FUEL SYSTEM (DFI) DFI Power Source Fuel Pump Relay Relay Coil Terminals [6] and [8] Relay Switch Terminals [5] and [7] Testing Relay Tester range: Criteria: 1 Ω range When battery is connected → 0 Ω When battery is disconnected → ∞ Ω If the relay does not work as specified, replace the relay assembly.
FUEL SYSTEM (DFI) 3-65 Throttle Lever, Cable and Case Free Play Inspection to Throttle Control System Inspection in the Peri• Refer odic Maintenance chapter. Throttle Cable Adjustment to Throttle Cable Adjustment in the Periodic Main• Refer tenance chapter. Throttle Case Removal/Disassembly the mounting screws [A] and remove the han• Unscrew dlebar pad [B]. the throttle case. •○Remove Unscrew the throttle case mounting screws [C] separate the case halves [D]. the throttle cable from the case.
3-66 FUEL SYSTEM (DFI) Throttle Lever, Cable and Case the throttle case. •○Disassemble Remove the circlip [A], flat washers [B], pin [C], throttle lever [D] and return spring [E] from the case [F]. Throttle Case Assembly/Installation the end of the return spring [A] in the throttle lever • Insert hole [B] and set the spring in the throttle case [C] as • shown. Install the control lever to the case. the throttle cable before assembly/installation. • Lubricate Apply water • ble end.
FUEL SYSTEM (DFI) 3-67 Throttle Lever, Cable and Case • Tighten: Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40 kgf·m, 34 in·lb) the throttle lever so that the throttle valve is fully • Swing open. WARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition. • Adjust the throttle cable (see Throttle Cable Adjustment). Throttle Cable Removal the engine hood (see Hull/Engine Hood chap• Remove ter).
3-68 FUEL SYSTEM (DFI) Throttle Lever, Cable and Case the throttle case (see Throttle Case Removal). • Remove Slide the rubber boot out of the place. • Unscrew the throttle cable fitting nut. • Remove the upper of the cable from the case. •○Use a screw driver end [A] to separate the cable tip [B] from the throttle lever catch. the steering cover (see Steering Removal in • Remove Steering chapter). the grommet mounting bolts [A] and pull out the • Unscrew plate [B] and grommet [C].
FUEL SYSTEM (DFI) 3-69 Throttle Lever, Cable and Case • Tighten: Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40 kgf·m, 34 in·lb) the following correctly (see Cable, Wire, and Hose • Route Routing in Appendix chapter). • • • Throttle Cable Steering Cable Fuel Tank Vent Hose Start/Stop Switch Leads Buzzer Leads Multifunction Meter Leads Adjust the following.
3-70 FUEL SYSTEM (DFI) Air Filter Air Filter Removal the seat (see Hull/Engine Hood chapter). • Remove the rear storage pocket. • Remove the following from the air filter [A]. • Disconnect Air Suction Valve Hose [B] • Oil Separator Tank Hose [C] Remove the oil separator tank [D] (see Engine Lubrication System chapter). the clamp [A] on the inlet air duct [B]. • Loosen Remove the air filter mounting bolts [C]. • • Remove the air filter [A] out of the engine compartment.
FUEL SYSTEM (DFI) 3-71 Air Filter Air Filter Disassembly • Remove: Air Filter (see Air Filter Removal) Air Filter Bolts [A] • Remove: Bolts [A] Flame Arrester [B] Hose [C] Duct [D] Air Filter Bracket Mounting Bolts [E] Air Filter Bracket [F] • Remove the air screen [A] Air Filter Assembly inspect the seal [A] for damage. • Visually If necessary, replace it with a new one. the flame arrester [B], hose [C] and duct [D] as • Install shown. • Install the air screen [A] aligning the marks [B].
3-72 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection The normal idle speed is controlled by the ECU (Electronic 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 controls the air/fuel mixture automatically.
FUEL SYSTEM (DFI) 3-73 Throttle Body Assy ISC (Idle Speed Controller) Removal/Installation • Remove Seat (see Hull/Engine Hood chapter) Air Filter (see Air Filter Removal) Bands [A] ISC connector [B] Stepping Motor Mounting Screws [C] Stepping Motor [D] ISC Actuator Mounting Bolts [E] ISC Actuator [F] the mating surface of throttle body and ISC actuator • Clean (stepping motor). the O-ring [A] with a new one. • Replace Install the motor [B] and tighten the screws [C].
3-74 FUEL SYSTEM (DFI) Throttle Body Assy ISC Resistance Inspection • Remove: Air Filter (from the throttle body assy) ISC Connector [A] (disconnect) • Measure the ISC resistance with the hand tester. Special Tool - Kawasaki Hand Tester: 57001-1394 ISC [A] Rotor [B] ISC Resistance Connection: 1-2, 2-3, 4-5, 5-6 terminals Standard: Connection: Standard: about 30 Ω (at 20°C) 1-3, 4-6 terminals about 60 Ω (at 20°C) If the reading is out of the specified value, replace the steeping motor.
FUEL SYSTEM (DFI) 3-75 Inlet Manifold Inlet Manifold Removal • Remove: Supply Fuel Hose [A] at Delivery Pipe • • Return Fuel Hose [B] at Delivery Pipe Delivery Pipe Mounting Bolts [C], Collars and Clamps Remove the bands [D] and disconnect the following connectors.
3-76 FUEL SYSTEM (DFI) Inlet Manifold the inlet manifold [A] with the throttle body assy • Remove [B]. the throttle body assy from the inlet manifold (see • Remove Throttle Body Assy Removal). the inlet manifold plate bolts [A] and remove the • Unscrew plate [B] and gasket [C]. • Remove: Inlet Air Temperature Sensor [D] Inlet Manifold Drain Plug [E] Inlet Air Pressure Sensor Bolts [F] Inlet Air Pressure Sensor [G] Inlet Manifold Installation the inlet manifold plate gasket with a new one.
FUEL SYSTEM (DFI) 3-77 Inlet Manifold the injector seals [A] with new ones. • Replace grease to the inside and outside of seals. • Apply • Tighten the delivery pipe mounting bolts [B]. Torque - Delivery Pipe Mounting Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) the cable, wire and hose correctly (see Cable, Wire • Route and Hose Routing in Appendix chapter). ○For JT1500-A2 model ∼; Replace the double spring clamps with new ones.
3-78 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○Be sure the battery is fully charged. sure to place a piece of cloth under the fuel supply • Be hose [A] of the fuel delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
FUEL SYSTEM (DFI) 3-79 Fuel Line If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the fuel filter and measure the fuel pressure again. Remove the fuel pressure gauge and adapter. Run the fuel hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. ○For JT1500-A2 model ∼; Replace the double spring clamps with new ones. (see Fuel System Diagram) • • Fuel Flow Rate Inspection NOTE ○Be sure the battery is fully charged.
3-80 FUEL SYSTEM (DFI) Fuel Line a measuring cylinder [A]. • Prepare Disconnect supply hose from the fuel delivery • pipe, and setthethefuel measuring cylinder and fuel supply hose • [B] as shown. Close the fuel tank cap. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. the ignition switch ON. • Turn Push the start button for 3 seconds. • Measure the discharge for 3 seconds.
FUEL SYSTEM (DFI) 3-81 Fuel Vent Check Valve Fuel Vent Check Valve Mounting to Fuel Vent Check Valve Inspection in the Periodic • Refer Maintenance chapter. Fuel Vent Check Valve Inspection to Fuel Vent Check Valve Inspection in the Periodic • Refer Maintenance chapter.
3-82 FUEL SYSTEM (DFI) Fuel Filter Fuel Filter Removal NOTE ○The fuel filter is designed to be used throughout the watercraft’s life without any maintenance if it is used under normal conditions. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke.
FUEL SYSTEM (DFI) 3-83 Fuel Filter Fuel Filter Installation the hose correctly (see Cable, Wire, and Hose • Route Routing section in Appendix chapter). the fuel hoses to the fuel filter, noting its “IN” fitting • Install [A] and “OUT” fitting [B]. ○For JT1500-A2 model ∼; Replace the double spring clamps with new ones. (see Fuel System Diagram) Install the holder and apply a non-permanent locking agent to the mounting bolts and tighten them. Torque - Fuel Filter Mounting Bolts: 8.8 N·m (0.
3-84 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. JT1500-A1 model; Remove the front storage pocket (see Hull/Engine Hood chapter).
FUEL SYSTEM (DFI) 3-85 Fuel Pump Fuel Pump Installation down the rubber holder [A] onto the fuel pump [B] • Press 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]. NOTE ○Install the rubber holder onto the fuel pump so the rub- ber holder top surface [F] must be below the top surface [G] of the fuel pump to prevent any water from collecting on top of the pump.
3-86 FUEL SYSTEM (DFI) Fuel Pump the front storage pocket (see Hull/Engine Hood • Remove chapter). the hand tester (25 V DC) [A] to the fuel pump • Connect lead connector [B], using the needle adapter set [C]. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 the ignition switch ON and push the lanyard key un• Turn der the stop button. the start button, run the engine 5 ∼ 6 seconds at • Pushing idling to measure the power source voltage.
FUEL SYSTEM (DFI) 3-87 Fuel Pump Fuel Pump Relay Removal to the Relay Assembly Removal in the DFI Power • Refer Source section. Fuel Pump Relay Inspection to the Relay Assembly Inspection in the DFI Power • Refer Source section. 1. Relay Assembly 2. Joint Connector F 3. Connector C 4. Connector D 5. Joint Connector R 6. Main Fuse 20 A 7. Battery 8. ECU 9. Joint Connector P 10. Fuel Pump 11.
3-88 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal • Drain the fuel tank into a suitable container. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the engine (see Engine Removal/Installation • Remove chapter). • Remove the fuel pump (see Fuel Pump Removal).
FUEL SYSTEM (DFI) 3-89 Fuel Tank • Remove the fuel tank [A] out of the hull as shown. Fuel Tank Installation sure the float [A] in place before putting the fuel tank • Be into the hull. the following correctly (see Cable, Wire, and Hose • Route Routing section in Appendix chapter). Fuel Hoses Fuel Tank Vent Hose Fuel Level Sensor Leads Other Wire and Harness ○For JT1500-A2 model ∼; Replace the double spring clamps with new ones.
3-90 FUEL SYSTEM (DFI) Fuel Tank Fuel Filler and Tube Removal the front storage compartment cover. • Open the fuel filler tube clamp screws [A] and remove • Loosen the fuel filler tube [B]. the fuel filler cap [A]. • Remove Take out the • fuel filler [C].screws [B] in the filler flange and remove the Fuel Filler and Tube Installation the deck and filler on their mating surfaces with • Clean greaseless, high-flash point solvent.
ENGINE LUBRICATION SYSTEM 4-1 Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Engine Oil Flow Chart............................................................................................................. Specifications ......................................................................................................................... Special Tool and Sealant ..........
4-2 ENGINE LUBRICATION SYSTEM Exploded View
ENGINE LUBRICATION SYSTEM 4-3 Exploded View No.
4-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart A: Blowby Gas B: Supply Engine Oil Flow C: Return Engine Oil Flow D: Oil Sump 1. from Oil Pump Side Passage 2. Oil Cooler 3. to Main Oil Passage 4. Oil Passage Bolt 5. Oil Pressure Switch 6. Oil Filter 7. Oil Passage (to Oil Filter) 8. Oil Passage (to Main Oil Passage) 9. Oil Pipe (from Lower Crankcase to Upper Crankcase) 10. Oil Passage Plug 11. Oil Pipe (from Oil pump to Lower Crankcase) 12. Oil Pressure Relief Valve 13. Oil Pump 14.
ENGINE LUBRICATION SYSTEM 4-5 Engine Oil Flow Chart 21. Oil Separator Tank 22. to Air Filter 23. to Oil Pan 24. Joint 25. Camshaft Oil Passage 26. Camshaft Cap Oil Passage 27. Oil Passage (from Oil Pipe to Camshaft Cap) 28. Oil Pipe (from Cylinder to Cylinder Head) 29. Oil Passage (from Main Oil Passage to Oil Pipe) 30. Crankshaft Oil Passage 31. Oil Screen 32. Oil Sump (in Crank Room) 33. Oil Seal 34. Oil Hose (from Cylinder to Oil Pan) 35. Cylinder Oil Passage Joint 36. Cylinder 37.
4-6 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil Grade Viscosity Capacity Level Oil Pressure Measurement Oil pressure @3 000 r/min (rpm), oil temperature 74°C (165°F) Standard API SE, SF, or SG API SH or SJ with JASO MA SAE 10W-40 4.0 L (4.2 US qt, with or without the filter) 5.0 L (5.3 US qt, when engine is completely dry) Between upper and lower level lines (see text) 461 kPa (4.
ENGINE LUBRICATION SYSTEM 4-7 Special Tool and Sealant Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Kawasaki Bond (Silicone Sealant): 56019-120 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033 Kawasaki Bond (Silicone Sealant): 92104-0004 Oil Filter Wrench: 57001-1249
4-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Watercraft operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Oil Level Inspection This watercraft engine is equipped with a semi-dry sump. In the semi-dry sump engine, the oil level difference is very large between the level measured after just stopping and that after leaving for a long time.
ENGINE LUBRICATION SYSTEM 4-9 Engine Oil and Oil Filter CAUTION Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause.
4-10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter the seat (see Hull/Engine Hood chapter) • Remove Remove the dipstick [A], wipe it dry and insert it back to • the dipstick tube [B], and then remove it again to check the oil level. the oil level using the hot level mark on the dipstick • Check [A]. High Level Line when Hot [B] Low Level Line when Hot [C] If the oil level is too high, drain the excess oil thoroughly from the dipstick tube [A] using a commercially-available vacuum pump [B].
ENGINE LUBRICATION SYSTEM 4-11 Oil Cooler Oil Cooler Removal • Remove: Seat (see Hull/Engine Hood chapter) • • Air Filter with Inlet Duct (see Fuel System (DFI) chapter) Inlet Manifold (see Fuel System (DFI) chapter) Disconnect the oil pressure switch connector [A]. Loosen the clamp screws [B] and remove the oil cooler cooling hoses [C] from the oil cooler. the oil filter [A] with the oil filter wrench [B]. •○Remove Place a rag or cloth [C] under the oil filter to receive the remaining oil.
4-12 ENGINE LUBRICATION SYSTEM Oil Cooler engine oil to the thread [A] of the passage bolt and • Apply 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) the oil pressure switch connector securely. • Connect Install the cooling hoses (see Cable, Wire and Hose Rout• ing in Appendix chapter). Install the inlet manifold (see Fuel System (DFI) chapter).
ENGINE LUBRICATION SYSTEM 4-13 Oil Cooler Oil Cooler Inspection the engine to check for water and oil leaks. • Start 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, odorless, poisonous gas which can be lethal. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damage will occur.
4-14 ENGINE LUBRICATION SYSTEM Breather Case and Oil Separator Tank Breather Case Removal • Remove: Seat (see Hull/Engine Hood chapter) • Exhaust Manifold (see Exhaust System chapter) Clamp [A] Breather Hose [B] Breather Case Mounting Bolts [C] Pull the breather case [D] upward. Breather Case Installation If the breather pipe [A] removed, install the pipe as follow. ○Apply grease to the O-ring [B]. ○Install the O-ring to the short length pipe side [C] of the breather pipe.
ENGINE LUBRICATION SYSTEM 4-15 Breather Case and Oil Separator Tank • Remove: Breather Hose Clamp [A] Breather Hose [B] Oil Separator Tank [C] NOTE ○Hold the hose end to the upward. The oil will flow out if the hose lies at the bottom. Oil Separator Tank Installation installing the breather hoses, avoid sharp bending, • When kicking, flattening or twisting, and route the hoses according to Hose Routing section in Appendix chapter.
4-16 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Periodic Maintenance chapter) • • Engine (see Engine Removal/Installation chapter) Turn the engine to the side. Unscrew the dipstick tube bolts [A] and pull out the dipstick tube [B]. • Unscrew the oil pan bolts [A] and remove the oil pan [B]. Oil Pan Installation the oil pan bolts following the tightening sequence • Tighten [1 ∼ 17]. Torque - Oil Pan Bolts: 7.8 N·m (0.
ENGINE LUBRICATION SYSTEM 4-17 Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve Oil Pump Sprocket Removal • Drain: Engine Oil (see Periodic Maintenance chapter) Remove: • Engine (see Engine Removal/Installation chapter) Oil Pan (see Oil Pan Removal) Crankshaft Sensor Cover Bolts [A] Crankshaft Sensor Cover [B] • Unscrew the oil pump chain guide bolt [A], the spring plate bolt [A] and remove the spring • Unscrew plate [B], spring [C] and the oil pump chain guide [D].
4-18 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve the oil pump chain guide [A], collar [B], washer [C], • Install and bolt [D] as shown. the chain guide spring [A] and the spring plate [B]. •○Install Insert the tab [C] of the spring plate in the hole [D] of the crankcase. Torque - Chain Guide Spring Plate Bolt: 7.8 N·m (0.
ENGINE LUBRICATION SYSTEM 4-19 Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve • Install: Oil Pump Sprocket (see Oil Pump Sprocket Installation) Oil Pan (see Oil Pan Installation) Oil Pump Inspection the oil pump parts. • Remove Visually inspect the oil pump outer, inner rotors and cover. • If there is any damage or uneven wear, replace the rotors and cover.
4-20 ENGINE LUBRICATION SYSTEM Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Remove: Oil Pan (see Oil Pan Removal) Relief Valve [A] to see if the valve [A] slides smoothly when push• Check ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] force. NOTE ○Inspect the valve in its assembled state. Disassembly and assembly may change the valve performance.
ENGINE LUBRICATION SYSTEM 4-21 Oil Pressure Measurement Oil Pressure Measurement • Remove: Seat (see Hull/Engine Hood chapter) Inlet Manifold (see Fuel System (DFI) chapter) Oil Pressure Switch Connector [A] (disconnect) Oil Pressure Switch [B] the oil pressure gauge adapter [A] to the switch • Install hole. Special Tool - Oil Pressure Gauge Adapter, PT 1/8: 57001 -1033 • Install the oil pressure gauge [A] to the adapter. Special Tool - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 off a rag or cloth.
4-22 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement WARNING Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed.
ENGINE LUBRICATION SYSTEM 4-23 Oil Pressure Switch Oil Pressure Switch Removal • Remove: Seat (see Hull/Engine Hood chapter) • Inlet Manifold (see Fuel System (DFI) chapter) Disconnect: Switch Connector [A] a rag or cloth under the oil pressure switch [A] and • Place remove the oil pressure switch. ○Do not damage the connect part [B] of the switch. Oil Pressure Switch Installation silicone sealant to the threads of the oil pressure • Apply switch and tighten it.
EXHAUST SYSTEM 5-1 Exhaust System Table of Contents Exploded View........................................................................................................................ Exhaust Manifold .................................................................................................................... Exhaust Manifold Removal ............................................................................................... Exhaust Manifold Installation ........................................
5-2 EXHAUST SYSTEM Exploded View
EXHAUST SYSTEM 5-3 Exploded View No. 1 2 3 4 5 6 7 8 Fastener Exhaust Manifold Mounting Nuts Exhaust Manifold Mounting Bolts Bypass Nozzle Flushing Hose Joint Water Hose Joint Water Temperature Sensor Exhaust Pipe Mounting Plate Bolts Exhaust Pipe Mounting Bolts EO: Fill the hollow with the engine oil (10W-30). L: Apply a non-permanent locking agent. S: Follow the specific tightening sequence. SS: Apply silicone sealant. SY: Apply synthetic rubber adhesive. N·m 25 25 – 11 11 15 30 30 Torque kgf·m 2.5 2.
5-4 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Removal • Remove: Oil Separator Tank [A] with the Oil Separator Hoses (see • Lubrication system) Air Filter [B] (see Fuel System chapter) Disconnect: Spark Plug Caps [C] (see Periodic Maintenance chapter) Hoses [D] Water Temperature Sensor Connector [E] • Disconnect: Hoses [A] • Remove: Bolts [A] and Collars • Exhaust Pipe Mounting Plate [B] Loosen: Joint Tube Clamp Screws [C] the exhaust manifold mounting nuts [A] and bolts • Remove [B].
EXHAUST SYSTEM 5-5 Exhaust Manifold out the exhaust manifold with the exhaust pipe from • Take the hull. • Disconnect the hose [A] from the exhaust pipe. Exhaust Manifold Installation NOTE ○Unhook the rubber strap and remove the front exhaust tube from the water box muffler for easier installation of the exhaust manifold, and after connecting the water box muffler to the exhaust pipe, hook the rubber strap and install the tube. the exhaust manifold gasket [A] with a new one.
5-6 EXHAUST SYSTEM Exhaust Manifold Exhaust Manifold Cleaning and Inspection the exhaust manifold parts. • Remove the carbon deposits out of the exhaust passages • Clean with a blunt, roundedged tool. foreign matter out of the water passages with fresh • Flush water. the insides of the water passages for corrosion. • Check Check the gasket surfaces for nicks or other damage. If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly, replace the part.
EXHAUST SYSTEM 5-7 Exhaust Pipe Exhaust Pipe Removal • Remove: Exhaust Manifold with Exhaust Pipe (see Exhaust Manifold Removal) Exhaust Pipe Mounting Bolts [A] Exhaust Pipe [B] • Remove the joint tube [A] and the two rings. Exhaust Pipe Installation the two rings [A] in the ring grooves of the exhaust • Install pipe. If the two rings are damaged or warped, replace the rings.
5-8 EXHAUST SYSTEM Exhaust Pipe Exhaust Pipe Cleaning and Inspection the exhaust pipe parts. • Remove the carbon deposits out of the exhaust passages • Clean with a blunt, roundedged tool. foreign matter out of the water passages with fresh • Flush water. the insides of the water passage for corrosion. • Check Check gasket surface for nicks or other damage. • If there the is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly, replace the part.
EXHAUST SYSTEM 5-9 Water Box Muffler Water Box Muffler Removal • Remove: Rear Storage Pocket Oil Separator Tank with Oil Separator Hoses (see the Lubrication System chapter) Air Filter (see the Fuel System chapter) • Loosen: Joint Tube Clamp Screw (see Exhaust Manifold Removal) the front exhaust tube [A] by loosing the clamp • Remove screws [B]. the rubber strap [C] from the left water box muf• Unhook fler.
5-10 EXHAUST SYSTEM Water Box Muffler sure the dampers [A] on the left side water box muffler • Be [B] are in place. sure the two rings [A] are installed to the correct • Make position. If the rings are damaged or warped, replace the rings with new ones. the two rings [A] by putting the paper tape [B] around • Bind the rings. The paper tape can be burned out soon after firing. the joint tube to the exhaust pipe. • Install Install the water box muffler to the exhaust pipe.
ENGINE TOP END 6-1 Engine Top End Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Clean Air System............................... Air Suction Valve Removal........... Air Suction Valve Installation........ Air Suction Valve Check............... Clean Air System Hose Inspection.................................. Cylinder Head Cover ......................... Cylinder Head Cover Removal ....
6-2 ENGINE TOP END Exploded View
ENGINE TOP END 6-3 Exploded View No. 1 2 3 4 5 6 6 7 8 9 10 Fastener Air Suction Valve Cover Bolts Cylinder Head Cover Bolts Upper Camshaft Chain Guide Bolts Camshaft Cap Bolts Cylinder Head Bolts ( 7) Cylinder Head Bolts ( 11) Cylinder Head Bolts ( 11) Water Jacket Plugs Cylinder Head Bolts ( 6) Engine Hook Bolts Camshaft Position Sensor Bolt N·m 9.8 9.8 12 12 20 23 59 20 12 20 9.8 Torque kgf·m 1.0 1.0 1.2 1.2 2.0 2.3 6.0 2.0 1.2 2.0 1.
6-4 ENGINE TOP END Exploded View
ENGINE TOP END 6-5 Exploded View No. Fastener 1 2 3 4 5 6 7 8 9 Exhaust Side Camshaft Chain Guide Bolts (Upper) Exhaust Side Camshaft Chain Guide Bolts (Lower) Upper Camshaft Chain Guide Bolts Inlet Side Camshaft Chain Guide Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Position Sensor Rotor Bolt Water Hose Joint Oil Passage Joint N·m 25 12 12 12 9.8 20 12 11 11 Torque kgf·m 2.5 1.2 1.2 1.2 1.0 2.0 1.2 1.1 1.
6-6 ENGINE TOP END Specifications Item Camshafts Cam Height: Exhaust Inlet Camshaft Journal, Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp Valves Valve Clearance: Exhaust Inlet Valve Head Thickness: Exhaust Inlet Valve Stem Bend Valve Stem Diameter: Exhaust Inlet Valve Guide Inside Diameter: Exhaust Inlet Valve/valve Guide Clearance (Wobble Method): Exhaust Inlet Valve Seat Cutting Angle Valve Seating
ENGINE TOP END 6-7 Specifications Item Inlet (Outer) Cylinder, Piston Cylinder Inside Diameter Piston Diameter Piston/cylinder Clearance Piston Ring/groove Clearance: Top Second Piston Ring Groove Width: Top Second Piston Ring Thickness: Top Second Piston Ring End Gap: Top Second Valve Head Thickness Valve Head Thickness [A] Valve Stem Diameter [B] 45° [C] Standard 45.78 mm (1.802 in.) Service Limit 44.2 mm (1.740 in.) 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) 82.919 ∼ 82.934 mm (3.2645 ∼ 3.2651 in.) 0.
6-8 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: 57001-221 Valve Seat Cutter, 45° 57001-1116 35: Valve Spring Compressor Assembly: 57001-241 Valve Seat Cutter, 32° 57001-1120 30: Top Dead Center Finder: 57001-402 Valve Seat Cutter, 32° 57001-1121 35: Piston Pin Puller Assembly: 57001-910 Valve Seat Cutter, 60° 57001-1123 30: Piston Ring Compressor Grip: 57001-1095 Valve Seat Cutter Holder Bar: 57001-1128
ENGINE TOP END 6-9 Special Tools and Sealant Valve Seat Cutter, 45° 57001-1187 30: Valve Spring Compressor Adapter, 57001-1202 Valve Guide Arbor, 57001-1203 Valve Guide Reamer, 57001-1204 5: Valve Seat Cutter, 55° 57001-1247 22: 35: Compression Gauge Adapter, M10 × 1.
6-10 ENGINE TOP END Special Tools and Sealant Piston Base, 57001-1604 8: Kawasaki Bond (Silicone Sealant): 56019-120
ENGINE TOP END 6-11 Clean Air System Air Suction Valve Removal • Remove: Seat (see Hull/Engine Hood chapter) Hoses [A] • Remove: Air Suction Valve Cover Bolts [A] Air Suction Valve Covers [B] Air Suction Valve Assembly [C] Air Suction Valve Installation the valve assembly [A] so that its reeds [B] side • Install faces inside and it’s opening [C] side faces inlet side. • Install the air suction valve covers. Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.
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] the cylinder head cover bolts [A] and take off the • Remove cover [B]. Cylinder Head Cover Installation • Be sure to install the pins [A] and rubber gaskets [B]. the head cover gasket with a new one if dam• Replace aged. silicone sealant [A] to the cylinder head cover gas• Apply ket as shown.
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 position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain.
6-14 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Seat (see Hull/Engine Hood chapter) Spark Plugs (see Periodic Maintenance chapter) Cylinder Head Cover (see Cylinder Head Cover Removal) Air Filter (see Fuel System (DFI) chapter) • Position the crankshaft at #1, #4 piston TDC as follows. ○Using the shaft wrench [A], turn the crankshaft counter- clockwise [B] and set the crankshaft at #1, 4 piston TDC.
ENGINE TOP END 6-15 Camshaft, Camshaft Chain Camshaft Installation • BePinssure[A]to install the following parts. molybdenum disulfide oil solution to all cam parts • Apply and journals. NOTE ○The exhaust camshaft has a 320 EX mark [A] and the inlet camshaft has a 320 IN mark [B]. Be careful not to mix up these shafts. If the camshaft position sensor rotor is removed, install it as follows. ○Insert the pin [A] into the holes [B] in the camshaft and boss [C].
6-16 ENGINE TOP END Camshaft, Camshaft Chain the spark plugs. • Remove 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 the tension side (exhaust side) of the chain taut to • Pull install the chain. the camshaft chain with the camshaft sprockets • Engage so that the timing marks on the sprockets are positioned as shown.
ENGINE TOP END 6-17 Camshaft, Camshaft Chain • Remove: #1 Spark Plug (Front Side) • Install the piston top detector [A] in the hole of the plug. Special Tool - TDC Measurement Tool: 57001-1560 the gauge extender [B] into the detector. • Insert Using the shaft wrench, turn the crankshaft until the • gauge extender reaches its highest point. Special Tool - Shaft Wrench: 57001-1551 • Remove the extender and install it to the gauge.
6-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear strips of plastigage (press gauge) to journal width. • Cut Place a strip on each journal parallel to the camshaft in- • • stalled in the correct position. Measure each clearance between the camshaft journal and the camshaft cap using plastigage [A]. Tighten: Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Upper Camshaft Chain Guide Bolts: 12 N·m (1.
ENGINE TOP END 6-19 Camshaft, Camshaft Chain Camshaft Chain Removal the crankcase (see Engine Bottom End chapter). • Split the camshaft chain [A] from the crankshaft • Remove sprocket.
6-20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○Use the battery which is fully charged. warm up the engine, while checking that there • Thoroughly is no compression leakage from around the spark plugs or the cylinder head gasket. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damaged will occur. the engine.
ENGINE TOP END 6-21 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the usable range. Problem Cylinder compression is higher than usable range Cylinder compression is lower than usable range Diagnosis Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke). incorrect cylinder head gasket thickness.
6-22 ENGINE TOP END Cylinder Head • Remove: Engine Hook Bolts [A] Engine Hook [B] Cylinder Head Bolts [C] • Remove: Upper Dipstick Tube Bolts [A] Upper Exhaust Side Camshaft Chain Guide Bolt [B] M7 Cylinder Head Bolts [C] the M11 cylinder head bolts [A] and washers. • Remove Take off the cylinder head. • Cylinder Head Installation NOTE ○The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head.
ENGINE TOP END 6-23 Cylinder Head molybdenum disulfide oil solution [A] to both sides • Apply of the M11 cylinder head bolt washers [B] and the thread of head bolts [C]. the cylinder head. • Install First, tighten the M11 cylinder head bolts following the • tightening sequence [1 ∼ 10]. Torque - Cylinder Head Bolts (M11): First: 23 N·m (2.3 kgf·m, 17 ft·lb) Final: 59 N·m (6.0 kgf·m, 44 ft·lb) tighten the M7 cylinder head bolts following the • Next, tightening sequence [11 ∼ 12].
6-24 ENGINE TOP END Valves Valve Clearance Check to Valve Clearance Inspection and Adjustment in • Refer the Periodic Maintenance chapter. Valve Removal the cylinder head (see Cylinder Head Removal). • Remove Remove valve lifter and shim. •○Mark andthe record the valve lifter and shim locations so they can be installed in their original positions. the valve spring compressor assembly, remove the • Using valve.
ENGINE TOP END 6-25 Valves Valve Guide Installation engine oil to the valve guide outer surface before • Apply installation. the area around the valve guide hole to about 120 ∼ • Heat 150°C (248 ∼ 302°F). the valve guide in from the top of the head using the • Drive valve guide arbor. The flange stops the guide from going in too far. • Special Tool - Valve Guide Arbor, 5: 57001-1203 Ream the valve guide with valve guide reamer [A] even if the old guide is reused.
6-26 ENGINE TOP END Valves Valve Seat Inspection the valve (see Valve Removal). • Remove the valve seating surface [A] between the valve [B] • Check 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, repair the seat (see Valve Seat Repair). Valve Seating Surface Outside Diameter Standard: Exhaust 27.6 ∼ 27.8 mm (1.087 ∼ 1.094 in.) Inlet 32.6 ∼ 32.8 mm (1.283 ∼ 1.291 in.
ENGINE TOP END 6-27 Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
6-28 ENGINE TOP END Valves the outside diameter of the seating surface with • Measure a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range. Widened Width [A] of engagement by machining with 45° cutter Ground Volume [B] by 32° cutter 32° [C] Correct Width [D] Ground Volume [E] by 60° or 55° cutter 60° or 55° [F] the outside diameter of the seating surface with • Measure a vernier caliper.
ENGINE TOP END 6-29 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 the 60° or 55° grind, fit 60° or 55° cutter into the holder, and slide it into the valve guide. ○Turn the holder, while pressing down lightly.
6-30 ENGINE TOP END Valves
ENGINE TOP END 6-31 Cylinder, Pistons Cylinder Removal the engine oil (see Periodic Maintenance chapter). • Drain • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Head (see Cylinder Head Removal) Dipstick Tube Bolts [A] Dipstick Tube [B] • Remove: Breather Case Mounting Bolts [A] Clamp [B] Breather Case [C] (with Hose) Oil Hose [D] • Remove: Camshaft Chain Guide Bolts [A] Camshaft Chain Guide [B] Cylinder [C] Piston Removal the cylinder (see Cylinder Removal).
6-32 ENGINE TOP END Cylinder, Pistons spread the ring opening with your thumbs and • Carefully then push up on the opposite side of the ring [A] to remove it. the 3-piece oil ring with your thumbs in the same • Remove manner. Piston/Cylinder Installation NOTE ○If a new cylinder is used, use new piston rings. ○If new pistons and/or a new cylinder are installed, apply thin coat of molybdenum disulfide oil solution to the new pistons and cylinder bores.
ENGINE TOP END 6-33 Cylinder, Pistons piston ring openings must be positioned as shown in • The the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. [A] Top Ring [B] Second Ring [C] Oil Ring Steel Rails [D] Oil Ring Expander [E] Hollow (Exhaust Side) the cylinder gasket with a new one, and install • Replace the pins [A] and new cylinder gasket.
6-34 ENGINE TOP END Cylinder, Pistons Cylinder Wear there is a difference in cylinder wear in different di• Since rections, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) shown in the figure. If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. [A] 10 mm (0.39 in.) [B] 60 mm (2.36 in.) Cylinder Inside Diameter Standard: 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) Service Limit: 83.10 mm (3.272 in.
ENGINE TOP END 6-35 Cylinder, Pistons Piston Ring Thickness the piston ring thickness. •○Measure 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 Limit: Top [A] 0.80 mm (0.0315 in.) Second [B] 0.90 mm (0.0354 in.) If any of the measurements is less than the service limit on either of the rings, replace all the rings.
ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Engine Removal/Installation ................................................................................................... Engine Removal................................................................................................................ Engine Damper Removal.......................
7-2 ENGINE REMOVAL/INSTALLATION Exploded View
ENGINE REMOVAL/INSTALLATION 7-3 Exploded View No 1 2 Fastener Engine Mounting Bolts Engine Damper Mounting Bolts L: Apply a non-permanent locking agent. N·m 36 16 Torque kgf·m 3.7 1.
7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Remove: Seat (see Hull/Engine Hood chapter) • Oil Separator Tank (see Lubrication Sytem) Plug the hose end [A]. If the engine disassembles, drain the oil (see Engine Oil Change in Periodic Maintenance chapter).
ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Remove: Engine Mounting Bolts [A] the engine toward the front to disengage the cou• Slide pling [A]. the lifter [A], raise the front side of the engine a little • Using and lift the engine [B] out off the hull [C]. 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 the same position.
7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Damper Installation the shim(s) of the same number. • Install a non-permanent locking agent • Apply damper mount bolts, and tighten them. to the engine Torque - Engine Damper Mounting Bolts: kgf·m, 12 ft·lb) 16 N·m (1.6 Engine Installation sure there are no foreign objects and parts inside of • Be the hull. the bilge filter (see Filter Cleaning and Inspection • Clean in Cooling and Bilge Systems chapter).
ENGINE BOTTOM END 8-1 Engine Bottom End Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Coupling ............................................
8-2 ENGINE BOTTOM END Exploded View
ENGINE BOTTOM END 8-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fastener Crankshaft Sensor Cover Bolts Engine Bracket Mounting Bolts Timing Rotor Bolt Connecting Rod Nuts Oil Passage Plugs Stator Mounting Bolts Grommet Cover Bolts Magneto Cover Bolts Output Cover Bolts Output Shaft Coupling Crankcase Bolts (M10) Crankcase Bolts (M8) Crankcase Bolts (M8) Crankcase Bolts (M6) N·m 7.8 29 29 – 20 12 9.8 20 7.8 245 98 50 29 29 12 Torque kgf·m 0.80 3.0 3.0 – 2.0 1.2 1.0 2.0 0.80 25.0 10 5.0 3.0 3.
8-4 ENGINE BOTTOM END Specifications Item Crankshaft, Connecting Rods Connecting Rod Bend Standard ––– Connecting Rod Twist ––– Connecting Rod Big End Side Clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.041 ∼ 0.071 mm (0.0016 ∼ 0.0028 in.) 38.984 ∼ 39.000 mm (1.5348 ∼ 1.5354 in.) Connecting Rod Big end Bearing Insert/crankpin Clearance Crankpin Diameter: Marking: None ○ Connecting Rod Big End Bore Diameter: Marking None ○ Service Limit 0.2/100 mm (0.008/3.94 in.) 0.2/100 mm (0.008/3.94 in.) 0.
ENGINE BOTTOM END 8-5 Specifications Item Crankshaft Main Journal Diameter: Marking None 1 Crankcase Main Bearing Bore Diameter: Standard 40.984 ∼ 41.000 mm (1.6135 ∼ 1.6142 in.) Service Limit 40.96 mm (1.613 in.) 40.984 ∼ 40.992 mm (1.6135 ∼1.61385 in.) 40.993 ∼ 41.000 mm (1.61389 ∼ 1.6142 in.) 44.000 ∼ 44.016 mm (1.7323 ∼ 1.7329 in.) – – – 44.000 ∼ 44.008 mm (1.7323 ∼ 1.73259 in.) 44.009 ∼ 44.016 mm (1.73263 ∼ 1.7329 in.
8-6 ENGINE BOTTOM END Special Tools and Sealant Oil Seal & Bearing Remover: 57001-1058 Output Shaft Wrench, Hex 36: 57001-1550 Bearing Driver Set: 57001-1129 Grip: 57001-1591 Coupling Holder #2: 57001-1423 Flywheel & Pulley Holder: 57001-1605 Rotor Holder: 57001-1544 Rotor Puller: 57001-1623 Holder Attachment: 57001-1547 Kawasaki Bond (Silicone Sealant): 56019-120
ENGINE BOTTOM END 8-7 Special Tools and Sealant Kawasaki Bond (Liquid Gasket - Black): 92104-1062
8-8 ENGINE BOTTOM END Coupling Coupling/Output Shaft Removal • Remove: Engine (see Engine Removal/Installation chapter) • Crankshaft Sensor Cover (see Electrical System chapter) Holding the timing rotor, unscrew the coupling. Special Tools - Flywheel & Pulley Holder: 57001-1605 [A] Holder Attachment: 57001-1547 [B] Coupling Holder #2: 57001-1423 [C] If the coupling [A] and output shaft [B] removed together, holding the coupling, unscrew the output shaft with the output shaft wrench [C].
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 molybdenum disulfide oil solution to the seating sur• Apply face of the output shaft. • Using the rotor holder [A], install the output shaft [B]. Special Tool - Rotor Holder: 57001-1544 Torque - Output Shaft: 245 N·m (25.0 kgf·m, 180 ft·lb) silicone sealant [A] to the crankcase halves mating • Apply surfaces on the magneto cover.
8-10 ENGINE BOTTOM END Coupling • Install: Pins [A] Gasket [B] • Position the magnet lead [C] as shown. grease to the oil seal lip. • Apply Install output cover. •○Run thethemagneto lead [A] between the magneto cover [B] and the output cover [C] as shown. Torque - Output Cover Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) the coupling damper to the coupling. • Install Holding rotor, screw the coupling onto the out• put shafttheandtiming tighten it.
ENGINE BOTTOM END 8-11 Coupling the oil seals with new ones. • Replace thin coat grease to the oil seal lips [A]. • Apply grease [B] between the oil seal lip and housing of • Pack the oil seal (flywheel side oil seal [C]). in the oil seals until they are bottomed. •○Press Install the coupling oil seal [D] so that the manufacturer’s marks [E] face coupling side. ○Install the flywheel side oil seal so that the dust seal [F] side face out. Oil Seal Inspection the oil seal.
8-12 ENGINE BOTTOM END Magneto Flywheel Magneto Flywheel Removal • Remove: Engine (see Engine Removal/Installation chapter) Crankshaft Sensor Cover (see Electrical System chapter) Coupling (see Coupling/Output Shaft Removal) Magneto Cover (see Coupling/Output Shaft Removal) ○Using the rotor puller [A], pull off the flywheel [B]. Special Tool - Rotor Puller: 57001-1623 Grip: 57001-1591 [C] CAUTION Do not hit the head of the rotor puller. A loss in rotor magnetism may be caused.
ENGINE BOTTOM END 8-13 Magneto Flywheel grease to the boss outside [A] of the magneto fly• Apply wheel [B]. • 10 mm (0.39 in.) [C] Install the magneto flywheel. NOTE ○Confirm the magneto flywheel fit or not to the crankshaft before tightening it with specified torque. ○Install the output shaft and tighten it with 70 N·m (7.0 kgf·m, 52 ft·lb) of torque. ○Remove the output shaft. ○Check the tightening torque with rotor puller.
8-14 ENGINE BOTTOM END Stator Stator Removal • Remove: Engine (see Engine Removal/Installation chapter) Magneto Cover (see Coupling/Output Shaft Removal) Grommet Cover Mounting Bolts [A] Grommet Cover [B] Stator Mounting Bolts [C] with Washers Stator Assembly [D] Stator Installation water resistant grease to the outside of the grom• Apply met. a non-permanent locking agent to the grommet • Apply cover bolts. • Tighten: Torque - Grommet Cover Bolts: 9.8 N·m (1.
ENGINE BOTTOM END 8-15 Crankcase Splitting Crankcase Splitting • Remove: Seat (see Hull/Engine Hood chapter) • • Engine (see Engine Removal/Installation chapter). Drain the engine oil (see Periodic Maintenance chapter). Set the engine on a clean surface and hold the engine steady while parts are being removed.
8-16 ENGINE BOTTOM END Crankcase Splitting Crankcase Assembly CAUTION The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. high-flash point solvent, clean off the mating sur• With faces of the crankcases halves and wipe dry. compressed air, blow out the oil passages in the • Using crankcase halves.
ENGINE BOTTOM END 8-17 Crankcase Splitting the oil pump sprocket chain [A] on the chain guide • Install [B] of the lower crankcase [C]. molybdenum disulfide oil solution to the bolt seating • Apply surfaces [A] on the lower crankcase for the M10 bolts [B] and M8 [7 ∼ 10] bolts [C]. the crankcase bolts. •○Tighten Following the sequence numbers on the lower crankcase half, tighten the M10 bolts [1 ∼ 6]. Torque - Crankcase Bolts (M10): 50 N·m (5.
8-18 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Removal the crankcase (see Crankcase Splitting). • Split • Remove: Camshaft Chain [A] • Oil Pump Sprocket Chain [B] Remove the crankshaft [C] with the oil seal [D]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed.
ENGINE BOTTOM END 8-19 Crankshaft and Connecting Rods the crankshaft with the oil pump sprocket chain [A] • Install and camshaft chain [B] hanging on them. the oil seal [A] into the groove [B] of the crankcase. • Fit Assemble the crankcase (see Crankcase Assembly). • Connecting Rod Removal the crankcase (see Crankcase Splitting). • Split Remove connecting rod nuts [A]. • Remove the the crankshaft.
8-20 ENGINE BOTTOM END Crankshaft and Connecting Rods CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed.
ENGINE BOTTOM END 8-21 Crankshaft and Connecting Rods small amount of molybdenum disulfide oil solution • Apply to the threads [A] and seating surfaces [B] of the connecting rod nuts. tighten the nuts to the specified torque. See the • First, table below. tighten the nuts by 120° more. •○Next, Mark [A] the connecting rod big end caps and nuts so that nuts can be turned 120° [B] properly. ○Tighten the hexagon nut by 2 corners.
8-22 ENGINE BOTTOM END Crankshaft and Connecting Rods Connecting Rod Twist surface plate, set the big-end arbor [A] on V block [C]. • On the difference in the heights of the arbor [B] • Measure above the surface plate over a 100 mm (3.94 in.) distance-on the arbor to determine the amount of connecting rod twist with the connecting rod held horizontally, and using a height gauge. If connecting rod twist exceeds the service limit, the connecting rod must be replaced. Connecting Rod Twist Service Limit: 0.
ENGINE BOTTOM END 8-23 Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankpin Diameter Marks None 38.984 ∼ 38.992 mm (1.5348 ∼ 1.5351 in.) ○ 38.993 ∼ 39.000 mm (1.5352 ∼ 1.5354 in.) ∆: Crankpin Diameter Marks, “○” mark or no mark.
8-24 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear the bearing insert/journal [B] clearance with a • Measure plastigage [A]. NOTE ○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○Do not turn the crankshaft during clearance measurement. ○Journal clearance less than 0.025 mm (0.0010 in.) can not be measured by plastigage, however, using genuine parts maintains the minimum standard clearance.
ENGINE BOTTOM END 8-25 Crankshaft and Connecting Rods the main bearing bore diameter, and mark [B] • Measure the upper crankcase half [A] in accordance with the bore diameter. ○Crankcase main bearing bore diameter marks are "○" mark and no mark. NOTE ○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○The mark already on the upper crankcase half should almost coincide with the measurement. Crankcase Main Bearing Bore Diameter Marks 44.000 ∼ 44.008 mm (1.7323 ∼ 1.73259 in.
8-26 ENGINE BOTTOM END Crankshaft and Connecting Rods Crankshaft Side Clearance a thickness gauge [A] between the thrust washer • Insert [B] and the crank web [C] at the No. 3 main journal to determine clearance. If the clearance exceeds the service limit, replace the thrust washer as a set and check the width of the crankshaft #3 main journal. Crankshaft Side Clearance Standard: 0.05 ∼ 0.24 mm (0.0020 ∼ 0.0094 in.) Service Limit: 0.44 mm (0.017 in.) the crankshaft #3 main journal width [A].
COOLING AND BILGE SYSTEMS 9-1 Cooling and Bilge Systems Table of Contents Exploded View........................................................................................................................ Bilge System........................................................................................................................... Breather Removal ............................................................................................................. Breather Installation ..................
9-2 COOLING AND BILGE SYSTEMS Exploded View
COOLING AND BILGE SYSTEMS 9-3 Exploded View No. Fastener 1 2 3 Water Hose Joint (L Shape Type) Water Hose Joint (Straight Shape Type) Water Hose Joint (Straight Shape Type) 4. Cylinder Head 5. Water Pipe 6. Metal Clamp 7. Cylinder Head Gasket 8. Cylinder 9. Oil Cooler 10. Output Cover 11. Exhaust Pipe 12. Exhaust Pipe Gasket 13. Exhaust Manifold 14. Exhaust Manifold Gasket 15. Bypass Outlet Nozzle 16. Plastic Clamp 17. Flushing Fitting 18. Flushing Cap 19. Detent 20. Bypass Outlet 21.
9-4 COOLING AND BILGE SYSTEMS Bilge System Breather Removal • Remove: Seat (see Hull/Engine Hood chapter) • • Rear Storage Pocket Pull the hoses [A] off the breather. Unscrew the mounting bolts [B], and remove the breathers [C]. Breather Installation sure the small hole [A] in the breather is open before • Be installing it. a non-permanent locking agent to the breather • Apply mounting bolts and tighten them.
COOLING AND BILGE SYSTEMS 9-5 Bilge System Follow the next procedures to remove the left side filter [D]. Remove the water box muffler [B] (see Exhaust System chapter). Pull the hose [C] off the filter. Unscrew the mounting screw [A] and remove the filter. • • • Filter Installation the projections [A] on the filters [B] with the holes • Align [C] on the brackets [D]. Filter Cleaning and Inspection the filter thoroughly with fresh water and shake it • Flush dry.
9-6 COOLING AND BILGE SYSTEMS Cooling and Bilge System Hoses Hose Removal majority of bilge hoses have no clamps at the hose • The 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. the cooling system hoses are clamped at both ends. • All Loosen the clamps and pull the hoses off. Hose Installation install the bilge filter hose, push the hose over the end • To of the filter.
COOLING AND BILGE SYSTEMS 9-7 Cooling and Bilge System Flushing Cooling System Flushing to Cooling System Flushing in the Periodic Mainte• Refer nance chapter. Bilge System Flushing to Bilge System Flushing in the Periodic Mainte• Refer nance chapter.
9-8 COOLING AND BILGE SYSTEMS Cooling and Bilge System Flow Diagram
COOLING AND BILGE SYSTEMS 9-9 Cooling and Bilge System Flow Diagram 1. Cylinder Head 2. Water Pipe 3. Cylinder Head Gasket 4. Cylinder 5. Oil Cooler 6. Output Cover 7. Exhaust Pipe 8. Exhaust Pipe Gasket 9. Exhaust Manifold 10. Exhaust Manifold Gasket 11. Flushing Fitting 12. Bypass Outlet 13. Left Water Box Muffler 14. Right Water Box Muffler 15. Tail Pipe 16. Cooling Water Filter Cover 17. Cooling Water Filter 18. Pump 19. Bilge Breather 20. Bilge Filter 21. Pump Outlet A.
9-10 COOLING AND BILGE SYSTEMS Water Pipe Water Pipe Removal the inlet manifold (see Fuel System). • Remove the cooling hose [A] onto the water pipe fitting. • Disconnect the mounting bolts [B] and remove the water • Unscrew pipe [C] from the cylinder head [D]. Water Pipe Installation grease to the O-rings [A] and install the water pipe • Apply with the mounting bolts. cooling hose [B] (cylinder head ∼ water box muffler) • Install to the water pipe fitting and secure the hose clamp [C].
COOLING AND BILGE SYSTEMS 9-11 After Submerging CAUTION Do not operate the watercraft with water in the engine. Do not try to start the engine until it is completely empty of water; internal engine parts could be severely and immediately damaged. If water gets into the engine, follow this procedure immediately! If water is left in the engine more than a few hours, it will destroy the crankshaft bearings and damage other internal engine parts.
9-12 COOLING AND BILGE SYSTEMS After Submerging
COOLING AND BILGE SYSTEMS 9-13 After Submerging Detailed Procedures after Submerging 1. Remove the seat (see Hull/Engine Hood chapter). 2. Remove the drain screws in the stern to drain water out of the engine compartment. 3. Remove the front storage pocket (see Hull/Engine Hood chapter). 4. Disconnect both two connectors [A] on the primary ignition leads located near the ignition coil. 5. Pull and remove all the spark plug caps. 6. Remove all spark plugs.
9-14 COOLING AND BILGE SYSTEMS After Submerging 13. Reconnect the primary ignition coil lead connectors, noting the #1,#4 [A] and the #2, #3 [B] coil connectors. The #1, #4 coil connector has a red/yellow and a green/blue leads from the main harness. The #2, #3 coil connector has a red/yellow and green/black leads from the main harness. NOTE ○The service codes (COIL1 and COIL2) caused by this procedure are stored in the ECU.
COOLING AND BILGE SYSTEMS 9-15 After Submerging 18. If the fuel tank has water in it, it must be emptied by pump or siphon. Refill the tank with fresh fuel. Do not dump contaminated fuel in places not designated for that purpose. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
DRIVE SYSTEM 10-1 Drive System Table of Contents Exploded View........................................................................................................................ Specification ........................................................................................................................... Special Tools and Sealant ...................................................................................................... Drive Shaft/Drive Shaft Holder ..............................
10-2 DRIVE SYSTEM Exploded View
DRIVE SYSTEM 10-3 Exploded View No. 1 2 3 Fastener Coupling Drive Shaft Holder Mounting Bolts Coupling Cover Bolts L: Apply M: Apply SS: Apply WG: Apply a non-permanent locking agent. molybdenum disulfide grease. silicone sealant. water resistance grease. N·m 39 22 8.8 Torque kgf·m 4.0 2.2 0.
10-4 DRIVE SYSTEM Specification Item Drive Shaft Runout (see P10-8) Standard [A] Less than 0.1 mm (0.0039 in.) [B] Less than 0.2 mm (0.0079 in.) Service Limit 0.2 mm (0.0079 in.) 0.6 mm (0.0236 in.
DRIVE SYSTEM 10-5 Special Tools and Sealant Bearing Driver Set: 57001-1129 Coupling Holder #2: 57001-1423 Kawasaki Bond (Silicone Sealant): 56019-120
10-6 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft Removal/Installation the engine (see Engine Removal/Installation • Remove 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] installing the drive shaft, be careful of the following • When items. ○Apply a non-permanent locking agent to the coupling threads and tighten it. Torque - Coupling: 39 N·m (4.
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 the grease seals with new ones. • Replace Press the bearing and grease seals into the drive shaft • holder, noting the following. ○Install the parts in this order.
10-8 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft Runout drive shaft runout by supporting the shaft on V • Measure blocks and setting a dial gauge against the shaft at each • point shown. Turn the drive shaft slowly. The difference between the highest and lowest dial gauge reading is the runout. If any measurement exceeds the service limit, replace the shaft. Drive Shaft Runout Standard: Less than 0.1 mm (0.0039 in.) [A] Less than 0.2 mm (0.0079 in.) [B] Service Limit: 0.2 mm (0.0079 in.
PUMP AND IMPELLER 11-1 Pump and Impeller Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Pump and Impeller ..................................
11-2 PUMP AND IMPELLER Exploded View
PUMP AND IMPELLER 11-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 Fastener Pump Bracket Mounting Bolts (2) Pump Bracket Mounting Bolts (4) Pump Mounting Bolts Grate Mounting Bolts Pump Cover Mounting Bolts Impeller Pump Cap Bolts Pump Outlet Mounting Bolts Steering Nozzle Pivot Bolts Pump Cap Plug Filter Cover Mounting Bolts Steering Cable Joint Bolt N·m 19 9.8 36 9.8 7.9 98 9.8 19 19 3.9 9.8 9.8 Torque kgf·m 1.9 1.0 3.7 1.0 0.80 10 1.0 1.9 1.9 0.40 1.0 1.
11-4 PUMP AND IMPELLER Specifications Item Standard Jet Pump Impeller Outside Diameter 147.5 ∼ 147.7 mm (5.8071 ∼ 5.8149 in.) Pump Case Inside Diameter 148.0 ∼ 148.1 mm (5.8268 ∼ 5.8307 in.) Impeller Clearance 0.15 ∼ 0.3 mm (0.0059 ∼ 0.0118 in.) Service Limit 146.5 mm (5.7677 in.) 149.1 mm (5.8701 in.) 0.6 mm (0.0236 in.
PUMP AND IMPELLER 11-5 Special Tools and Sealant Oil Seal & Bearing Remover: 57001-1058 Impeller Holder: 57001-1393 Bearing Driver Set: 57001-1129 Kawasaki Bond (Silicone Sealant): 56019-120 Impeller Wrench: 57001-1228
11-6 PUMP AND IMPELLER Pump and Impeller Pump Removal the craft on its left side. • Turn the reverse cable ball joint at the rear end. • Disconnect the pump cover mounting bolts [A], and remove • Unscrew the pump cover [B] with the reverse bracket [C]. the grate mounting bolts [A] and remove the • Unscrew grate [B]. the joint bolts [A] and take off the steering cable • Remove joint. the clamps [B] on the inlet cooling hose, and pull • Loosen off the hoses [C]. the pump mounting bolts [A].
PUMP AND IMPELLER 11-7 Pump and Impeller ○Take out the pump bracket mounting bolts [A]. ○Cut the sealant at the indicated area [A] in the figure and remove the pump bracket [B]. Pump Installation off all the old sealant around the pump intake. • Strip Liberally coat the outside edge of the pump bracket with • silicon sealant [A] to form a seal between the bracket and the hull. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 the pump bracket [A] to the hull.
11-8 PUMP AND IMPELLER Pump and Impeller • Be sure trim seal [A] is in place. the splines on the drive shaft with water resistant • Grease grease. the pump. •○Install Apply a non-permanent locking agent to the pump mounting bolts and torque them. Torque - Pump Mounting Bolts: 36 N·m (3.7 kgf·m, 27 ft·lb) the grate [A]. •○Install Be sure the trim seals [B] are in the position. ○Apply a non-permanent locking agent to the grate mounting bolts and torque them. Torque - Grate Mounting Bolts: 9.8 N·m (1.
PUMP AND IMPELLER 11-9 Pump and Impeller • Be sure the seals [A] on the hull are in the position. ○Coat the outside edge [A] of the seal [B] with silicone sealant to form a seal between the hull and seal. the pump cover. •○Install Be sure the seal [A] is in the position. ○Apply a non-prmanent locking agent to the pump cover mounting bolts and torque them. Torque - Pump Cover Mounting Bolts: 7.8 N·m (0.
11-10 PUMP AND IMPELLER Pump and Impeller the pump cap bolts [A], and remove the pump • Unscrew cap [B]. out the impeller seal on the impeller. • Pull Hold the shaft in the impeller holder, taking care not to • damage it. Remove the impeller from the pump shaft and then pull out the pump shaft. Special Tools - Impeller Holder: 57001-1393 [A] Impeller Wrench: 57001-1228 [B] JT1500-A1; Pull out the bushing [A]. • the circlip. • Remove Remove the grease seals.
PUMP AND IMPELLER 11-11 Pump and Impeller the bearing by tapping evenly around the bearing • Remove inner race from the front end of the pump case [A]. Special Tool - Bearing Driver Set: 57001-1129 [B] JT1500-A2 ∼; Press [A] the bussing [B] and the ball bearing [C]. They come out of the pump case. • the circlip. • Remove Remove the grease seals.
11-12 PUMP AND IMPELLER Pump and Impeller installing the pump bearing, blow any dirt or for• Before eign particles out of the pump case with compressed air. installing the pump bearing, remove the filter cover • Before [C], and check the filter inside or outside [A] on the pump case [B] if the foreign particles do not cling to the filter. ○Apply high grade water resistant grease to the O-ring [D]. ○Apply a non-permanent locking agent to the filter cover mounting bolts and torque them.
PUMP AND IMPELLER 11-13 Pump and Impeller JT1500-A2 ∼; Replace the grease seals with new ones, if necessary, and install them. • Special Tool - Bearing Driver Set: 57001-1129 ○Press each seal [A] into the pump case [B] so that the side with the spring faces outward. ○Fill the gap between the grease seals [C] with high grade water resistance grease and apply it each greace seal lip [D]. Install the circlip [E]. Install the bushing [F] into the pump case. ○Fill with high grade water resistance grease [G].
11-14 PUMP AND IMPELLER Pump and Impeller JT1500-A1, A2 ∼; Screw on the impeller and torque. • Special Tools - Impeller Holder: 57001-1393 Impeller Wrench: 57001-1228 Torque - Impeller: 98 N·m (10 kgf·m, 72 ft·lb) inspect impeller seal [A], and replace it if neces• Visually sary. • Install the seal on the impeller. sure the O-rings [A] are in place on the pump cap [B] • Be and plug [C]. ○Apply high grade water resistance grease to the O-rings. the following.
PUMP AND IMPELLER 11-15 Pump and Impeller Impeller Outside Diameter Measurement the impeller outside diameter. • Measure If the impeller is worn smaller than the service limit, replace it. Impeller Outside Diameter Standard: 147.5 ∼ 147.7 mm (5.8071 ∼ 5.8149 in.) Service Limit: 146.5 mm (5.7677 in.) Pump Inspection the pump case [A]. • Examine If there are deep scratches inside the pump case, replace it. ○Measure the inside diameter of the pump case.
STEERING 12-1 Steering Table of Contents Exploded View........................................................................................................................ Special Tool and Sealant ........................................................................................................ Steering Cable........................................................................................................................ Steering Cable Adjustment .............................................
12-2 STEERING Exploded View
STEERING 12-3 Exploded View No. Fastener 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Handlebar Clamp Bolts Start/stop Switch Case Mounting Screws Throttle Case Mounting Screws Steering Shaft Locknut Steering Shaft Nut Steering Holder Mounting Bolts Steering Neck Mounting Bolts Steering Cable Joint Bolt Ball Joint Shift Cable End Nut Reverse Bucket Pivot Bolts Shift Cable Nut Steering Cable Nut Shift Lever Locknut 15. Buzzer 16. Steering Position Sensor 17. Magnet G: Apply grease.
12-4 STEERING Special Tool and Sealant Box Wrench (27 mm): 57001-1451 Kawasaki Bond (Silicone Sealant): 56019-120
STEERING 12-5 Steering Cable Steering Cable Adjustment the steering cable adjustment. •○Check Center the handlebar in the straight-ahead position. that the steering nozzle [A] is centered in the pump • Check cavity. ○The same distance [B]. necessary, adjust the steering cable. •○IfLoosen the locknut [A] on the end of the steering cable located to the right of the steering nozzle. ○Take out the cable joint bolt [B] and disconnect the cable joint [C] from the steering nozzle.
12-6 STEERING Steering Cable the locknut [A] at the front end of the steering • Loosen cable, and slide back the outer sleeve of the ball joint and take off the ball joint [B] and remove the locknut from the cable front end. the holder [A] off the cable bracket. • Pull Slide the steering cable [B] off the cable bracket [C], and • if the cable is hard to remove, unscrew the cable bracket mounting bolts [D], and remove the cable bracket.
STEERING 12-7 Steering Cable Steering Cable Installation a short piece of rubber or plastic tubing over the front • Slide cable end to guide the cable through the hull. the outside of the new cable to ease cable in• Lubricate stallation. • Torque: Torque - Steering Cable Nut: 39 N·m (4.0 kgf·m, 29 ft·lb) a non-permanent locking agent to the cable joint • Apply bolt and the steering cable bracket mounting bolts, if removed. Torque - Cable Joint Bolt: 9.8 N·m (1.
12-8 STEERING Handlebar Handlebar Removal the mounting screws [A] and remove the han• Unscrew dlebar pad [B]. • Remove the inner pad [A], pushing [B] the buzzer [C]. • Unscrew the bolts [A] and remove the pad holder [B]. out the throttle case clamp screws and remove the • Take throttle case [A]. out the switch case clamp screws and remove the • Take switch case [B]. the pipe [C]. • Unhook Cut off the clamp [D].
STEERING 12-9 Handlebar Handlebar Installation the pad holder. •○Install Apply a non-permanent locking agent to the pad holder bolts. Install the handlebar on the holder of the steering neck. ○Apply a non-permanent locking agent to the handlebar clamp bolts. • ○Align the punch mark [A] on the left side of the handlebar with the parting line [B]. ○Tighten the front and then rear handlebar clamp bolts to the specified torque. Torque - Handlebar Clamp Bolts: 16 N·m (1.
12-10 STEERING Handlebar the bosses [A] on the pad holder to the holes [B] • Install on the handlebar pad. [A] the projection [B] on the pad with the groove [C] • Align on the pad.
STEERING 12-11 Steering Steering Removal the handlebar and pad holder (see Handlebar • Remove Removal). • Unscrew the set screw [A] and take out the cap [B]. the shift lever nut [A] and remove the shift lever • Unscrew [B]. the right stay [A] with the right mirror (see • Remove Hull/Engine Hood chapter). the steering cover mounting bolts [B], [C] and lift • Unscrew up the steering cover [D].
12-12 STEERING Steering the front storage pocket (see Hull/Engine Hood • Remove chapter). • Disconnect: Steering Position Sensor Lead Connector [A] Buzzer Connector [B] Multifunction Meter Lead Connectors [C] Steering Cable Ball Joint at Upper End Shift Cable Ball Joint at Upper End out the grommet mounting plate [A] and pull the • Take grommet [B]. out the multifunction meter leads [A] and buzzer lead • Pull [B] from the grommet. • Remove the steering cover [C].
STEERING 12-13 Steering the cotter pin [A] and steering shaft locknut [B]. • Remove • Take out the holder [C]. the steering holder mounting bolts [A], nuts, and • Unscrew washers, and lift up the steering holder [B]. out the air intake duct mounting bolts [A] and remove • Take the air intake duct [B] from the steering holder [C]. the switch case lead connector and pull the • Disconnect leads [A] out of the hull. the pipe at the fuel vent hose upper end and • Disconnect pull down the fuel vent hose [B].
12-14 STEERING Steering Steering Installation the gasket [A] on the steering holder [B] with a • Replace new one. the bushings for damage and wear before in• Check stalling the steering holder. • If the bushings are damaged or worn, replace them. Grease: Bushings [A] Steering Shaft [B] the steering shaft and the steering shaft nut (Hand • Install -Tighten) [A] to the steering holder. ○If steering is too tight, turn the steering shaft nut counterclockwise to loosen.
STEERING 12-15 Steering • Torque the steering shaft locknut [A]. Torque - Steering Shaft Locknut: 49 ∼ 59 N·m (5.0 ∼ 6.0 kgf·m, 36 ∼ 43 ft·lb) the steering shaft fully in left and right direction, • Turning check whether the steering position sensor comes in con- • tact with the magnet. Check the clearance [A] between the steering position sensor [B] and the magnet [C] with feeler gauge. Steering Position Sensor Clearance Standard: 0.5 ∼ 1.5 mm (0.02 ∼ 0.06 in.
12-16 STEERING Steering • Be sure that the damper [A] is in position. a non-permanent locking agent to the grommet • Apply mounting plate. a non-permanent locking agent to the steering • Apply cover mounting bolts. the steering cover mounting bolts to the steering • Install cover. a non-permanent locking agent to the shift lever nut. • Apply Apply a water resistant grease to the joint balls of the shift • cable and shift link rod. • Adjust the shift cable and steering cable.
STEERING 12-17 Reverse System Shift Cable Adjustment the shift cable adjustment. • Check the shift lever is in the “F” position, the lower edge • When [A] of the bucket should be held above the top [B] of the • steering nozzle with slight play so it doesn’t interfere with the water flow from the jet pump. When the shift lever is in the “R” position, the lower stopper [C] on the bucket should rest against the bottom [D] of the pump cover.
12-18 STEERING Reverse System • Pull the holder [A] off the cable bracket. the right side cover (see Hull/Engine Hood chap• Remove ter). • Unscrew the bolts [A] and remove the cable bracket. NOTE ○The collors on the inside of the hull will drip down when the bolts are removed. the ball joint [A] and cable bracket [B] from the • Remove shift cable [C]. off the band [A] holding the shift cable [B] and inlet • Cut cooling hose [C] for the oil cooler. off the band [A] holding the shift cable [B].
STEERING 12-19 Reverse System the water craft on its left side and remove the pump • Turn cover (see Pump/Impeller chapter). CAUTION Never lay the watercraft on the right side. Water in the exhaust system may drain back into the engine, causing serious damage. the locknut [A] at the rear end of the shift cable, • Loosen and remove the ball joint [B] from the reverse bucket [C], the shift cable from the fitting at the middle of • Disconnect the hull.
12-20 STEERING Reverse System Reverse Bucket Removal/Installation the ball joint at rear end of the shift cable. • Disconnect the pump cover. • Remove the pivot bolts [A] and remove the reverse • Unscrew bucket [B]. is the reverse of removal. Note the following. •○Installation Apply a non-permanent locking agent to the reverse bucket pivot bolts, and torque them. Torque - Reverse Bucket Pivot Bolts: 19 N·m (1.9 kgf·m, 14 ft·lb) ○After installation, check the shift cable adjustment.
HULL/ENGINE HOOD 13-1 Hull/Engine Hood Table of Contents Exploded View........................................................................................................................ Fittings .................................................................................................................................... Seat Removal ................................................................................................................... Seat Installation ...............................
13-2 HULL/ENGINE HOOD Exploded View
HULL/ENGINE HOOD 13-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fastener Crossmember Bolts Handrail Bolts Lock Assembly Nut Front Duct Bolts Damper Bolts Damper Bracket Bolts Front Storage Compartment Cover Bolts Hinge Bolts Front Storage Compartment Hook Bolts Steering Cover Bolts Meter Screen Bolts Seat Hook Bolts Seat Locknut Reboarding Step Bolts Mirror Stay Bolts CY: Apply cyanoacrylate cement. L: Apply a non-permanent locking agent. SY: Apply synthetic rubber adhesive. N·m 7.8 9.8 4.
13-4 HULL/ENGINE HOOD Exploded View
HULL/ENGINE HOOD 13-5 Exploded View No. 1 2 3 Fastener Stabilizer Bolts Air Inlet Duct Bolts Exhaust Outlet Bolts CY: Apply L: Apply SS: Apply SY: Apply cyanoacrylate cement. a non-permanent locking agent. silicone sealant. synthetic rubber adhesive. N·m 9.8 – – Torque kgf·m 1.
13-6 HULL/ENGINE HOOD Fittings Seat Removal • Pull [A] the latch handle [B]. • Remove the seat up [A] and to the rear [B]. Seat Installation the seat hook [A] into the bracket [B] on the deck • Insert 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.
HULL/ENGINE HOOD 13-7 Fittings remove the hinge assembly, remove the following. • ToDamper Bolt [A] Hinge Bolts [B] Front Storage Compartment Cover Disassembly the front duct bolts [A] and remove the front duct • Unscrew [B]. the lock assembly nut [A] and remove the lock • Unscrew assembly [B].
13-8 HULL/ENGINE HOOD Fittings out the rivets [A] with a drill bit [B] of the correct size • Drill and remove the front duct cover [C]. Rivet Removal Drill Bit Size 5.0 mm (0.2 in.) NOTE ○Stop drilling when the rivet head starts to turn with drill bit. ○Tap the rivet out with a suitable punch and hammer. Front Storage Compartment Cover Assembly the front duct cover to the front duct [A] with the • Secure rivets using a riveter [B]. • Be sure that the trim seals [A] are in position.
HULL/ENGINE HOOD 13-9 Fittings Mirror Removal the front storage compartment cover. • Open the nuts [A] and washers [B] and remove the • Unscrew mirrors [C] (both sides). Mirror Installation • Be sure that the washer [A] are in position. Mirror Stay Removal • To remove the right mirror stay [A], remove the bolts [B]. NOTE ○The plate [C] on the inside of the hull will drop down when the last bolt is removed. • Remove the right mirror (see Mirror Removal).
13-10 HULL/ENGINE HOOD Fittings Mirror Stay Installation • Be sure the dampers [A] are in position (both sides). right plate [A] on the inside of the hull has a R mark • The [B] and the left plate [C] has L mark [D]. a non-permanent locking agent to the mirror stay • Apply bolts and tighten them securely. • Install the damper [A] onto the hull. NOTE ○Apply a little oil to the damper to make installation easy. • Install the flushing fitting [A] into the damper [B].
HULL/ENGINE HOOD 13-11 Fittings Front Storage Pocket Removal the front storage pocket mounting screws [A]. • Remove • Remove the front storage pocket [B]. Front Storage Pocket Installation • Installation is the reverse of removal. Storage Pocket Disassembly/Assembly remove the storage pocket cover [A], turn and pull out • To the shaft [B] (both side). installing the shafts, put the shaft end [C] (both • When side) into the hollow [D] on the storage pocket.
13-12 HULL/ENGINE HOOD Fittings out the holder [A]. • Pull Unscrew bolts [D] and remove the cable • bracket [C]thewithmounting the cable [B]. remove the right side cover, pull the holder [A] off the • To cable bracket. the mounting nuts [A] and washers [B] and the • Unscrew left [C] and right [D] covers. the crossmember bolts [E] and bracket [F], and • Unscrew remove the crossmember [G]. Crossmember Installation a non-permanent locking agent to the crossmem• Apply ber bolts and torque them.
HULL/ENGINE HOOD 13-13 Fittings Handrail Removal the seat (see this chapter). • Remove the bilge hoses from the breather fitting. • Disconnect Unscrew the mounting nut [A] and washer inside the hull, • and remove the lock assembly [B]. Holding the nuts inside hull, unscrew the • mounting bolts [C],andandwashers remove the handrail [D]. Handrail Installation installing the lock assembly and handrail, align the • When projection [A] and stud bolt [B] on the lock assembly with holes [C] on the hull.
13-14 HULL/ENGINE HOOD Fittings Stabilizer Removal the stabilizer bolts [A] and remove the stabilizer • Unscrew [B]. Stabilizer Installation the stabilizer as shown. • Install Stabilizer [A] • Chine Line [B] 111 ±3 mm (4.37 ±0.12 in.) [C] 8 ±2 mm (0.31 ±0.08 in.) [D] Apply a non-permanent locking agent to the stabilizer bolt and torque them. Torque - Stabilizer Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Reboarding Step Removal the reboarding step bolts [A] and remove the • Unscrew reboarding step [B].
HULL/ENGINE HOOD 13-15 Hull Replacement To replace the hull, remove the various parts in the following suggested order.
13-16 HULL/ENGINE HOOD Rubber Parts NOTE ○The rubber parts on the watercraft are fastened in place with various adhesives. To replace a rubber part, use a cement in the following table, or an equivalent. WARNING Read all warnings and cautions on any solvents and adhesives used. Many of these products are flammable, may be harmful to the skin and eyes, and may give off harmful vapors. Use these solvents and adhesives only in a well-ventilated area and never near an open flame.
HULL/ENGINE HOOD 13-17 Rubber Parts Front Storage Compartment Gasket [A] Front Storage Compartment Cover Trim Seal [B] Detent [A] Mats [A] Damper on Deck [A] (starboard side only) 20 mm (0.79 in.) [B] 30 mm (1.18 in.
13-18 HULL/ENGINE HOOD Rubber Parts Rivet Removal • Drill out the rivet with a drill bit [A] of the correct size. Rivet Removal Drill Bit Size 5.0 mm (0.2 in.) NOTE ○Stop drilling when the rivet head [B] starts to turn with drill bit. ○Tap the rivet out with a suitable punch and hammer. Rivet Installation the parts to the hull with the rivets using a riveter • Secure [A]. Front Bumper Removal out the plugs [A]. • Take Take out the mounting screw [B] and nuts [C].
HULL/ENGINE HOOD 13-19 Rubber Parts Side Bumper Removal out the plugs [A]. • Take out the rivets [B] (see Rivet Removal). • Drill • Remove the corner bumper [C]. • Remove the trim strip [A] from the side bumper [B]. • Drill out the rivets [A] (see Rivet Removal). Side Bumper Installation the side bumpers to the hull flange with the rivets • Secure (see Rivet Installation). • Install the trim strip.
ELECTRICAL SYSTEM 14-1 Electrical System Table of Contents Parts Location.................................... Exploded View................................... Wiring Diagram.................................. Specifications .................................... Special Tools and Sealant ................. Precautions........................................ Electrical Wiring................................. Wiring Inspection ......................... Battery ...............................................
14-2 ELECTRICAL SYSTEM MODE/SET Button Inspection ..... SLO (Smart Learning Operation) Mode Inspection (JT1500-A2 model ∼) .................................... Fuel Level Gauge/Symbol/FUEL Characters/Warning Light Inspection.................................. Speedometer Inspection .............. Speed Sensor Electric Source Inspection.................................. Tachometer Inspection................. 14-58 14-58 14-59 14-59 14-60 14-61 Battery Symbol/bAt Characters/LED Inspection .......
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. Starter Relay 11. Battery 12.
14-4 ELECTRICAL SYSTEM Parts Location 13. Water Temperature Sensor 14. Camshaft Position Sensor 15. Oil Temperature Sensor 16. Oil Pressure Switch 17.
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.
14-6 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 14-7 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Torque N·m kgf·m 1.5 0.15 Vehicle-down Sensor Mounting Screws Electrical Parts Bracket Screws 4.9 0.50 Starter Relay Case Bolts 7.8 0.80 Ignition Coil Mounting Bolts 8.8 0.90 Water Temperature Sensor 15 1.5 3.5 ∼ 4.5 0.35 ∼ 0.45 Starter Relay Mounting Nuts 3.5 ∼ 4.5 0.35 ∼ 0.45 Starter Cable Mounting Nuts Timing Rotor Bolt 20 2.0 4.4 0.45 Crankshaft Sensor Screws 4.4 0.
14-8 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 14-9 Exploded View No. 1 2 3 4 Fastener Multifunction Meter Mounting Bolts Fuel Level Sensor Clamp Screw Start/stop Switch Case Mounting Screw Speed Sensor Mounting Bolts 5. Multifunction Meter 6. Fuel Level Sensor 7. Buzzer N·m 3.9 2.9 3.9 3.9 Torque kgf·m 0.40 0.30 0.40 0.
14-10 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 14-11 Exploded View No. 1 2 3 4 5 6 Fastener Starter Motor Through Bolts Starter Motor Mounting Bolts Starter Motor Ground Bolt Starter Motor Terminal Nut Stator Coil Bolts Grommet Holder Bolts 7. Fuse G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement parts. WG: Apply water resistant grease. N·m 6.4 8.8 8.8 8.8 12 8.8 Torque kgf·m 0.65 0.90 0.90 0.90 1.2 0.
14-12 ELECTRICAL SYSTEM Wiring Diagram JT1500-A1
ELECTRICAL SYSTEM 14-13 Wiring Diagram JT1500-A1
14-14 ELECTRICAL SYSTEM Wiring Diagram JT1500-A2 ∼
ELECTRICAL SYSTEM 14-15 Wiring Diagram JT1500-A2 ∼
14-16 ELECTRICAL SYSTEM Specifications Item Battery Type Electric Starter System Starter Motor: Brush Length Commutator Diameter Charging System Regulator/rectifier Output Voltage Alternator Output Voltage Stator Coil Resistance Ignition System Ignition Coil: Primary Winding Resistance Secondary Winding Resistance Spark Plug: Type Gap Crankshaft Sensor Resistance Standard 12 V 18 Ah 12 mm (0.4724 in.) 28 mm (1.1024 in.) Service Limit – – – 6.5 mm (0.2559 in.) 27 mm (1.063 in.
ELECTRICAL SYSTEM 14-17 Special Tools and Sealant Hand Tester: 57001-1394 Harness Adapter: 57001-1562 Peak Voltage Adapter: 57001-1415 Flywheel & Pulley Holder: 57001-1605 Needle Adapter Set: 57001-1457 Kawasaki Bond (Silicone Sealant): 56019-120 Holder Attachment: 57001-1547 Kawasaki Bond (Silicone Grease): 92137-1002
14-18 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be followed servicing electrical systems. ○Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
ELECTRICAL SYSTEM 14-19 Precautions ○Electrical Connectors Female Connectors [A] Male Connectors [B]
14-20 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection inspect the wiring for signs of burning, fraying, • Visually etc. If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
ELECTRICAL SYSTEM 14-21 Battery Removal • Disconnect the battery cables [A]. WARNING To prevent possible personal injury and damage to electrical components, always disconnect the grounded cable first. the battery straps [B]. • Unhook Carefully lift the battery from the engine compartment. • Installation sure the battery damper [A] is in position in the battery • Be compartment. the battery straps. • Hook Connect the battery cables, positive first.
14-22 ELECTRICAL SYSTEM Battery to see that there is no peeling, tears or holes in the • Check seal sheet on the top of the battery. the battery on a level surface. • Place • Remove the seal sheet [A]. CAUTION Do not remove the seal sheet sealing the filler ports [B] until just before use. NOTE ○A battery whose seal sheet has any peeling, tears, or holes, requires a refreshing charge (initial charge). the electrolyte container out of the vinyl bag. • Take Detach the strip of cap [A] from the container.
ELECTRICAL SYSTEM 14-23 Battery Initial Charge the strip [A] of caps loosely over the filler ports. • Place • 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 sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
14-24 ELECTRICAL SYSTEM Battery 3) When you do not use the watercraft for months: Give a refresh charge before you store the watercraft and store it with the negative lead removed. Give a refresh charge once a month during storage. 4) Battery life: If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the watercraft’s starting system has no problem).
ELECTRICAL SYSTEM 14-25 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, decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery.
14-26 ELECTRICAL SYSTEM Electric Starter System Starter Relay Removal • Remove: Seat (see Hull/Engine Hood chapter) • • Rear Storage Pocket (see Hull/Engine Hood chapter) Battery (see this chapter) Disconnect the negative battery cable from the battery terminal. (see Battery Removal). Disconnect the starter relay lead connector [A]. out the rubber caps [A]. • Slide Remove the nuts [B] from the battery and starter terminals • on the start relay switch.
ELECTRICAL SYSTEM 14-27 Electric Starter System ohmmeter to R × 1 Ω range. • Set meter leads to starter relay as shown. • Connect starter relay switch by connecting a 12 V battery • Activate as shown. If the starter relay switch clicks and the ohmmeter indicates zero resistance, the starter relay switch is good. If the meter indicates high or infinite (∞) resistance, the starter relay switch is defective and must be replaced.
14-28 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly the starter motor (see Starter Relay Removal). • Remove off the starter motor through bolts [A] and remove • Take both end covers [B] and pull the armature out of the yoke [C]. the terminal locknut [A] and terminal bolt [B], and • Remove then remove the brush with the brush plate [C] from the yoke. Starter Motor Assembly a thin coat of grease to the oil seal [A]. • Apply Fit the toothed washer [B] into the end cover.
ELECTRICAL SYSTEM 14-29 Electric Starter System • Install the O-rings [A] and the washers [B] as shown. the tongue [A] on the brush plate into the end cover • Fit groove [B]. the lines [A] on the yoke with the lines [B] on the • Align both end covers. the starter motor through bolts [C] with new ones. • Replace Tighten: • Torque - Starter Motor Through Bolts: 6.4 N·m (0.65 kgf·m, 56 in·lb) Brush Inspection the length [A] of each brush.
14-30 ELECTRICAL SYSTEM Electric Starter System the diameter [A] of the commutator [B]. • Measure Replace the starter motor with a new one if the commutator diameter is less than the service limit. Commutator Diameter Standard: 28 mm (1.1024 in.) Service Limit: 27 mm (1.063 in.) Armature Inspection the × 1 Ω hand tester range, measure the resis• Using tance between any two commutator segments [A].
ELECTRICAL SYSTEM 14-31 Electric Starter System Reduction Gear Removal/Installation removing the reduction gear, remove the magneto • Before flywheel (see Engine Bottom End chapter). installing the reduction gear, apply a molybdenum • When disulfide grease [A] to both ends of its shaft. Reduction Gear Inspection the pinion gear [A] counterclockwise. • Rotate must be rotated freely [B]. The gear the pinion gear clockwise all the way.
14-32 ELECTRICAL SYSTEM Electric Starter System 3. Engine Starter Switch 4. Joint Connector R 5. Starter Motor 6. Battery 12 V 18 Ah 7. Starter Relay 8.
ELECTRICAL SYSTEM 14-33 Charging System Magneto Output Voltage • Remove: Seat (see Hull/Engine Hood chapter) • Air Filter with Duct (see Fuel System chapter) Disconnect the 3-pin stator coil leads connector [A]. the hand tester [A] check the magneto output (in • With circuit) according to the following table with the engine running at approximately 3 000 rpm. WARNING To avoid electrical shock, do not perform this test with the watercraft in the water.
14-34 ELECTRICAL SYSTEM Charging System • Tighten: Torque - Regulator/rectifier Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) installing the bracket, apply a non-permanent lock• When ing agent to the bracket mounting screws and tighten them securely. Regulator/Rectifier Inspection the hand tester set to the R × 1 kΩ range, test the • With regulator/rectifier according the following table.
ELECTRICAL SYSTEM 14-35 Charging System the 2nd step regulator circuit test. •○Do 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 test light turns on, the regulator/rectifier is defective. Replace it. ○If the test light does not turn on, continue the test. the 3rd step regulator circuit test.
14-36 ELECTRICAL SYSTEM Charging System 1. Load 2. Main Fuse 20 A 3. Joint Connector R 4. Battery 12 V 18 Ah 5. Joint Connector S (Ground) 6. Regulator/Rectifier 7.
ELECTRICAL SYSTEM 14-37 Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent ECU (Electronic Control Unit) damage. Do not install the battery backwards.
14-38 ELECTRICAL SYSTEM Ignition System grease to the O-ring and fit it in the groove of the • Apply sensor cover. silicone sealant [A] to the crankcase halves mating • Apply surface on the right and left sides of the crankshaft sensor mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the crankshaft sensor cover. Torque - Crankshaft Sensor Cover Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb) the Engine (see Engine Removal/Installation chap• Install ter).
ELECTRICAL SYSTEM 14-39 Ignition System Ignition Coil Removal • Remove: Seat (see Hull/Engine Hood chapter) Front Storage Pocket (see Hull/Engine Hood chapter) Spark Plug Caps (see Periodic Maintenance chapter) Clamp [A] (JT1200-A1 model) Double Spring Clamp [A] (JT1200-A2 model ∼) Fuel Supply Hose End [B] Bolts [A] (see Electric Case Removal/Disassem• Bracket bly). the ignition coil primary lead connectors [A] • Disconnect and vehicle-down sensor lead connector [B].
14-40 ELECTRICAL SYSTEM Ignition System out the spark plug lead [B] from the ignition coil [A]. • Pull Lubricate the leads with penetrating rust inhibitor. Ignition Coil Installation the spark plug lead to each ignition coil as fol• Connect 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 Length 600 mm (23.6 in.
ELECTRICAL SYSTEM 14-41 Ignition System Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance. Remove the ignition coil (see Ignition Coil Removal). Connect the ignition coil [A] (with the spark plug cap left installed on the spark plug lead) to the tester [B], and measure the arcing distance. Auxiliary Wires [C] • • WARNING To avoid extremely high voltage shocks, do not touch the coil or lead.
14-42 ELECTRICAL SYSTEM Ignition System Measuring spark plug lead resistance Check the spark plug lead [A] for visible damage. If the spark plug lead is damaged, replace the spark plug lead. Measure the lead resistance with the hand tester [B]. • • Spark Plug Lead Resistance Standard: 3.75 ∼ 6.25 kΩ If the hand tester does not read as specified, replace the lead Camshaft Position Sensor Removal • Remove: Seat (see Hull/Engine Hood chapter) Cut off the clamp [A].
ELECTRICAL SYSTEM 14-43 Ignition System Camshaft Position Sensor Inspection • Remove: Seat (see Hull/Engine Hood chapter) • Camshaft Position Sensor Lead Connector [A] (disconnect) Set the hand tester [B] to the × 10 Ω range and connect it to the yellow and black leads in the connector. Special Tool - Hand Tester: 57001-1394 If there is more resistance than the specified value, the sensor coil has an open lead and must be replaced.
14-44 ELECTRICAL SYSTEM Ignition System • Remove: Front Storage Pocket (see Hull/Engine Hood chapter) the peak voltage adapter [A] into the hand tester • Install [B]. the peak voltage adapter [A] to the ignition coil • Connect primary lead connector [D], using the harness adapter [C].
ELECTRICAL SYSTEM 14-45 Ignition System Crankshaft Sensor Peak Voltage Check NOTE ○Be sure the battery is fully charged. the peak voltage adapter [A] to the hand tester • Connect [B]. Special Tool - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B the adapter the crankshaft sensor lead connec• Connect tor [C], using the needle adapter set [D].
14-46 ELECTRICAL SYSTEM Ignition System Spark Plug Removal to Spark Plug Inspection in the Periodic Mainte• Refer nance chapter. Spark Plug Installation to Spark Plug Inspection in the Periodic Mainte• Refer nance chapter. Spark Plug Inspection to Spark Plug Inspection in the Periodic Mainte• Refer nance chapter. Spark Plug Adjustment to Spark Plug Adjustment in the Periodic Mainte• Refer nance chapter. Spark Plug Cleaning to Spark Plug Cleaning in the Periodic Maintenance • Refer chapter.
ELECTRICAL SYSTEM 14-47 Ignition System Ignition System Circuit 1. Joint Connector H 2. Joint Connector J 3. Joint Connector E 4. Crankshaft Sensor 5. Relay Assembly (Main Relay/Fuel Pump Relay) 6. Joint Connector F 7. Connector C 8. Vehicle-down Sensor 9. Ignition Switch 10. Joint Connector Q 11. Engine Stop Switch 12. Joint Connector R 13. Main Fuse 20 A 14. Starter Motor 15. Battery 12 V 18 Ah 16. ECU (Electric Control Unit) 17. Camshaft Position Sensor 18. Throttle Sensor 19. Connector D 20.
14-48 ELECTRICAL SYSTEM Ignition System
ELECTRICAL SYSTEM 14-49 Kawasaki Smart Steering System Steering Position Sensor and Magnet Removal the steering holder (see Steering Removal in • Remove Steering chapter). or disconnect: • Remove Steering Position Sensor Lead Connector [A] Leads Clamp on Steering Holder Steering Position Sensor Mounting Screws [B] Steering Position Sensor [C] the mounting screw [A] and remove the magnet • Unscrew [B].
14-50 ELECTRICAL SYSTEM Kawasaki Smart Steering System the steering shaft fully in left and right direction, • Turning check whether the steering position sensor comes in contact with the magnet. the clearance [A] between the steering position • Check sensor [B] and the magnet [C] with feeler gauge. Steering Position Sensor Clearance Standard: 0.5 ∼ 1.5 mm (0.02 ∼ 0.06 in.) • If necessary, adjust the steering shaft nut. Check the operation of Kawasaki Smart Steering system.
ELECTRICAL SYSTEM 14-51 Kawasaki Smart Steering System Steering Position Sensor Input Voltage Inspection • Measure the input voltage to the steering position sensor. NOTE ○Be sure the battery is fully charged. ○Connect a digital voltmeter [A] to the lead connector [B] of the steering position sensor using the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Connections to Steering Position Sensor Connector Meter (+) → R/W Terminal Meter (–) → BK Terminal ○Turn the ignition switch ON.
14-52 ELECTRICAL SYSTEM Kawasaki Smart Steering System Steering Position Sensor Output Voltage Inspection the output voltage from the steering position • Measure sensor. NOTE ○Be sure the battery is fully charged ○Connect a digital voltmeter [A] to the lead connector [B] of the steering position sensor using the needle adapter set [C].
ELECTRICAL SYSTEM 14-53 Kawasaki Smart Steering System Steering Position Sensor Circuit 1. Joint Connector Q 2. Multifunction Meter 3. Steering Position Sensor 4. 20 A Main Fuse 5. Joint Connector R 6. Battery 7. Joint Connector S 8. Joint Connector P 9. Ignition Switch 10.
14-54 ELECTRICAL SYSTEM Sensors Speed Sensor Removal/Installation the mounting bolts [A] and remove the speed • Unscrew sensor assembly [B]. the cap [A]. • Unscrew Pull out the speed sensor connector and disconnect it. • installing the speed sensor assembly, note the fol• When lowing. ○Apply silicone sealant around the grommet [A] and lead wires. Speed Sensor Inspection the speed sensor. • Remove Connect • shown.
ELECTRICAL SYSTEM 14-55 Sensors the waterwheel by hand slowly. • Rotate • Measure the output voltage of the speed sensor. G/R (+), BK/W (–) → 0 ∼ battery voltage; twice a rotation (Rotate it slowly.) If the voltage does not rise from zero to battery voltage twice a rotation, replace the sensor. • Measure speeds. the output voltage of the sensor at higher ○Rotate the waterwheel in a fair speed by air. G/R (+), BK/W (–) → approx.
14-56 ELECTRICAL SYSTEM Sensors Throttle Sensor Inspection to Throttle Sensor Section in the Fuel System chap• Refer ter. Water Temperature Sensor Inspection the water temperature sensor (see Feul (DFI) • Remove System chapter). the sensor [A] in a container of water so that the • Suspend temperature-sensing projection is submerged. • Suspend an accurate thermometer [B] in the water. NOTE ○The sensor and thermometer must not touch the container side or bottom.
ELECTRICAL SYSTEM 14-57 Multifunction Meter Display Function Inspection the auxiliary wires, connect the 12 V battery [A] to • Using the meter unit [B] connector as follows. JT1500-A2 model ∼ [C] JT1500-A1 model [D] ○Connect the battery positive terminal to the terminal [1]. ○Connect the battery negative terminal to the terminal [2].
14-58 ELECTRICAL SYSTEM Multifunction Meter MODE/SET Button Inspection that when the MODE button is pushed and held • Check continuously, the display rotates through the four modes. the clock mode. • Indicate that when the SET button is pushed for more than • Check two seconds, the meter display turns to the clock set mode. If the display function does not work, replace the meter assembly. the time mode.
ELECTRICAL SYSTEM 14-59 Multifunction Meter Fuel Level Gauge/Symbol/FUEL Characters/Warning Light Inspection the 12 V battery and terminals in the same man• Connect ner as specified in the “Display Function Inspection”. the variable rheostat [A] to the terminal [5] as • Connect shown. • JT1500-A2 model ∼ [B] JT1500-A1 model [C] Check that the number of segments matches the resistance value of the variable rheostat.
14-60 ELECTRICAL SYSTEM Multifunction Meter the oscillator is not available, the speedometer can be • Ifchecked as follows. ○Install the meter unit. ○Turn on the ignition switch. ○Rotate the waterwheel by hand. ○Check that the speedometer shows the speed. If the speedometer does not work, check the speed sensor electric source voltage and speed sensor. Speed Sensor Electric Source Inspection the 12 V battery and terminals in the same man• Connect ner as specified in the “Display Function Inspection”.
ELECTRICAL SYSTEM 14-61 Multifunction Meter Tachometer Inspection the 12 V battery and terminals in the same man• Connect ner as specified in the “Display Function Inspection”. revolutions per minute (rpm) equivalent to the input • The frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the terminal [7].
14-62 ELECTRICAL SYSTEM Multifunction Meter Buzzer Inspection sure that the buzzer sounds correctly when turning • Make the ignition switch key to the “ON” position and warning • the trouble after connecting the buzzer between [9] and [10]. If the output voltage between [9] and [10] is out of the range during the buzzer sound, replace the meter assy. Output Voltage 7 ∼ 14 V for normal sound, 2 ∼ 4 V for low sound. Hand tester [A] Multifunction Meter Circuit 1. Joint Connector Q 2.
ELECTRICAL SYSTEM 14-63 Multifunction Meter 3. Buzzer 4. Multifunction Meter 5. Speed Sensor 6. 20 A Main Fuse 7. Joint Connector R 8. Starter Motor 9. Battery 10. Joint Connector P 11. Ignition Switch 12.
14-64 ELECTRICAL SYSTEM Relay Assembly Removal the seat (see Hull/Engine Hood chapter). • Remove the rear storage pocket. • Remove • Remove: Relay Assembly Connector [A] Clamp [B] Bolt [C] Relay Assembly [D] Installation a non-permanent locking agent to the relay assem• Apply bly mounting bolt and tighten it securely. the relay assembly leads correctly (see Cable, Wire • Route and Harness Routing in Appendix chapter). Circuit Inspection the relay assembly.
ELECTRICAL SYSTEM 14-65 Relay Assembly Relay Assembly Circuit Inspection (with the battery disconnected) ECU Main Relay [A] Fuel Pump Relay [B] Tester Connection 3-4 1-2 7-8 5-6 Tester Reading (Ω) ∞ Not ∞* ∞ Not ∞* (*): The actual reading varies with the hand tester used. Relay Assembly Circuit Inspection (with the battery connected) ECU Main Relay [A] Fuel Pump Relay [B] (+): Apply positive lead. (–): Apply negative lead.
14-66 ELECTRICAL SYSTEM Switches Switch Inspection a hand tester, check to see that only the con• Using 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, repair it or replace it with a new one.
ELECTRICAL SYSTEM 14-67 Fuse Inspection • Remove: Seat Fuse Case [A] • Take out the fuse [A]. the fuse element. • Inspect 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 rating, check the wiring and related components for a short circuit.
STORAGE 15-1 Storage Table of Contents Preparation for Storage .......................................................................................................... Cooling System................................................................................................................. Bilge System ..................................................................................................................... Engine Oil .......................................................................
15-2 STORAGE Preparation for Storage During the winter, or whenever the watercraft will not be in use for a long period of time, proper storage is essential. It consists of checking and replacing missing or worn parts; lubricating parts to ensure that they do not become rusted; and, in general, preparing the watercraft so that when the time comes to use it again, it will be in top condition. NOTE ○Personal watercraft is not meant to be left in the water for extended periods.
STORAGE 15-3 Preparation for Storage the fuel pump (see the Fuel System chapter). • Remove the fuel pump screen [A] (see Fuel System in Pe• Clean riodic Maintenance chapter). the fuel tank with fresh fuel approximately 10 L (2.6 • Refill gal U.S.). the ignition switch on. • Turn Push key under the stop button, and start the • enginetheandlanyard run it in 15 second periods until all fuel in the fuel system is with fresh fuel. Wait 5 minutes between 15 seconds running periods.
15-4 STORAGE Preparation for Storage the primary ignition coil lead connectors, not• Reconnect 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 connector has a red/yellow and green/black leads from the main harness. NOTE ○The service codes (COIL1 and COIL2) caused by this procedure are stored in the ECU.
STORAGE 15-5 Preparation for Storage General the engine compartment with fresh water and re• Wash move the drain screw in the stern to drain the water. Wipe up any water left in the compartment. CAUTION Use only a mild detergent in water to wash the hull. Harsh solvents may attack the surface or smear the colors. a good grade of wax to all exterior hull surfaces. • Apply Lightly spray all exposed metal parts with a penetrating • rust inhibitor. the seat, or block the seat up with 10 mm (0.39 • Remove in.
15-6 STORAGE Removal from Storage Lubrication out all recommended lubrication procedures (see • Carry the Periodic Maintenance chapter). General Inspection for binding or sticking throttle, steering or shift • Check mechanism. The throttle lever must return fully when • • • • • released. Clean and gap spark plugs (see Electrical System in Periodic Maintenance chapter). Check all rubber hoses for weathering a cracking, or looseness. Check that the drain screw in the stern is securely tightened.
STORAGE 15-7 Removal from Storage Test Run WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the engine and run it only for 15 seconds. Check for • Start fuel, oil and exhaust leaks. Any leaks must be repaired.
APPENDIX 16-1 Appendix Table of Contents Cable, Wire and Hose Routing ............................................................................................... Troubleshooting Guide ...........................................................................................................
16-2 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-3 Cable, Wire and Hose Routing 1. Crossmember 2. Cylinder Head Cover 3. Throttle Cable 4. Delivery Pipe 5. Fix the throttle cable to the delivery pipe with the band. 6. Inlet Manifold 7. Horizontal Plane 8. Position the clamp pinch head below the horizontal plane. 9. Throttle Body Assy 10. Air Filter 11. Clamp 12. Cooling Hose (Cylinder ∼ Left Water Box Muffler) 13. Oil Pan 14. Position the clamp pinch head as shown. 15. Oil Separator Tank Hose (Tank ∼ Oil Pan) 16.
16-4 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-5 Cable, Wire and Hose Routing 1. Oil Cooler 2. Cylinder Head 3. Water Pipe 4. Cylinder 5. Oil Filter 6. Oil Pan 7. Battery (−) Cable 8. Starter Motor 9. Starter Motor Cable 10. Cooling Hose (Cylinder Head ∼ Left Water Box Muffler) 11. Fix the No.10 cooling hose, battery (−) cable and starter motor cable with the band. 12. Output Cover 13. Water Hose Joint (Inlet) 14. Water Hose joint (Outlet) 15. Return Oil Hose (Cylinder ∼ Oil Pan) 16.
16-6 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-7 Cable, Wire and Hose Routing 1. Clamp 2. Breather Hose (Cylinder Head ∼ Breather Case) 3. Clamp Detail 4. Position the clamp pinch heads as shown. 5. Air Suction Valve 6. Air Suction Valve Hose 7. Inlet Water Pipe Joint on the Cylinder (Cooling Water from Left Water Box Muffler) 8. Cylinder 9. Cylinder Head Cover 10. Output Cover 11. Protective Tube 12. Return Oil Hose (Cylinder ∼ Oil Pan) 13. Breather Hose (Cylinder ∼ Breather Case) 14. Breather Case 15. Oil Pan 16. Front Pinch Head 17.
16-8 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-9 Cable, Wire and Hose Routing Refer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapter. Install the clamp as shown, noting its screw head direction. 1. Bypass Outlet 2. Clamp 3. Holder 4. Bypass Outlet Hose: Run the bypass outlet hose between the fuel tank and the straps as shown. 5. Cooling Hose (Oil Cooler ∼ Exhaust Manifold): Run the cooling hose between the fuel tank and the straps as shown. 6. Cooling Hose (Pump ∼ Oil Cooler) 7. Oil Cooler 8.
16-10 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-11 Cable, Wire and Hose Routing 1. Exhaust Manifold 2. Exhaust Pipe 3. Water Hose Point (Cooling Hose from the Output Cover) 4. 30° 5. Water Hose Joint (Cooling Hose from the Oil Cooler) 6. Upper Water Hose Joint 7. Cooling Hose Fitting (Left Water Box Muffler ∼ Cylinder) 8. Cooling Hose Fitting (Left Water Box Muffler ∼ Drain) 9. Lower Water Hose Joint 10. 45° 11. Dampers 12. Left Water Box Muffler 13. Position the clamp so that their screw heads face forward. 14. To Tail Pipe 15.
16-12 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-13 Cable, Wire and Hose Routing 1. Right Rear Duct 2. Right Bilge Hose 3. Left Bilge Hose 4. Left Rear Duct 5. Left Water Box Muffler 6. Position the left rear duct inside the left bilge hose as shown. 7. Position the right rear duct under the right bilge hose as shown. 8. Right Water Box Muffler 9. Right Bilge Breather 10. Left Bilge Breather 11. Left Bilge Filter 12.
16-14 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-15 Cable, Wire and Hose Routing 1. Position the clamp screw so that its head faces forward (JT1500-A1). Position the double spring clamp so that its pinch head faces forward (JT1500-A2 ∼). 2. Delivery Pipe Joints 3. Delivery Pipe 4. Inlet Air Pressure Sensor 5. Protective Tube 6. Throttle Body Assy 7. Position the clamp screw so that its head faces backward (JT1500-A1). Position the double spring clamp so that its pinch head faces backward (JT1500-A2 ∼). 8. #4 Spark Plug Cap 9.
16-16 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-17 Cable, Wire and Hose Routing 1. Air Suction Valve Hose (to Air Filter) 2. Air Suction Valve 3. Air Suction Valve Cover (Rear) 4. Water Temperature Sensor Leads 5. Exhaust Manifold 6. Air Suction Valve Hose Fitting 7. Air Suction Valve Cover (Front) 8. Breather Hose 9. Cylinder Head Cover 10. Crankshaft Sensor Leads 11. Fix the crankshaft sensor leads and the oil temperature sensor leads to the dipstick pipe with the band. 12. Dipstick Pipe 13. Inlet Manifold 14.
16-18 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-19 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 the magneto leads along the hollow of the magneto cover. 9. Crankcase 10. Coupling 11. Output Cover 12. Run the magneto leads between the magneto cover and output cover. Do not pinch the leads.
16-20 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-21 Cable, Wire and Hose Routing 1. Band 2. Main Harness 3. Rivet 4. Washer 5. See wire routing at bow. 6. See wire routing at stern. 7. Clamp 8. Speed Sensor Leads 9. Water Box Muffler Strap 10.
16-22 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-23 Cable, Wire and Hose Routing 1. Crossmember 2. Steering Position Sensor Leads 3. Holder and Clamp 4. Fuel Vent Hose 5. Throttle Cable 6. Band 7. Ignition Switch Lead 8. Ignition Switch Lead Connector (Black) 9. Steering Position Sensor Lead Connector (White) 10. Fuel Level Sensor Lead Connector (Black) 11. Main Harness 12. Fuel Pump 13. Fuel Pump Lead Connector (White) 14. Steering Cable 15. Fuel Filter 16. Vehicle-down Sensor 17. Ignition Coil Lead Connectors (Gray) 18.
16-24 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-25 Cable, Wire and Hose Routing 1. Multifunction Meter Lead Connector (Blue and Yellow: JT1500-A1), (Blue and White: JT1500 -A2 ∼) 2. Buzzer Lead Connector (Blue) 3. Start/Stop Switch Lead Connector (White) 4. Fuel Tank 5. Holders and Bands 6. Main Harness 7. Shift Cable 8. Fuse Case 9. Regulator/Rectifier 10. 16 Pin (Gray) and 6 Pin (White) Connectors 11. ECU (Electronic Control Unit) 12. Starter Relay Case 13. Starter Relay Lead Connector (Black) 14.
16-26 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-27 Cable, Wire and Hose Routing 1. Regulator/rectifier 2. ECU (Electronic Control Unit) 3. Main Harness 4. Clamp 5. Electrical Parts Bracket 6. To Starter Motor 7. To Battery 8. Relay Assembly 9. Red Mark 10. Starter Relay 11. Right Side Deck 12.
16-28 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-29 Cable, Wire and Hose Routing 1. Fuel Vent Pipe: Hook the pipe at the handlebar. 2. Throttle Cable 3. Buzzer Leads (Run the leads through the protective tube.) 4. Protective Tube 5. Band 6. Clamp 7. Start/Stop Switch Leads 8. Grommet on Steering Holder 9. Multifunction Meter Leads 10. Fuel Vent Hose 11. Steering Holder 12. Holder 13. Steering Position Sensor 14. Steering Shaft 15.
16-30 APPENDIX Cable, Wire and Hose Routing
APPENDIX 16-31 Cable, Wire and Hose Routing 1. 80 mm (3.15 in.) 2. 100 mm (1.18 in.) 3. 180 mm (7.09 in.) 4. 40 mm (1.57 in.) 5. 105 mm (4.13 in.) 6. 90 mm (3.54 in.) 7. 50 mm (1.97 in.) 8. 130 mm (5.12 in.) 9. Detent 10.
16-32 APPENDIX Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX 16-33 Troubleshooting Guide Fuel line clogged Inlet air pressure sensor trouble Inlet air temperature sensor trouble Engine stalls easily Fuel pump trouble Fuel injector trouble Throttle sensor trouble Camshaft position sensor trouble Fuel pressure too low or too high Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Fuel line clogged Crankshaft sensor trouble Ignition coil trouble Compression low Spark plug loose Cylinder head not sufficiently
16-34 APPENDIX Troubleshooting Guide Fuel to injector insufficient (DFI) Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble (DFI) Injector clogged Throttle body assy loose Throttle body assy gasket damaged Fuel line clogged Fuel pump operates intermittently Inlet air temperature sensor trouble Throttle sensor trouble Inlet air pressure sensor trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, w
APPENDIX 16-35 Troubleshooting Guide Oil pressure switch damaged Wiring faulty O-ring at the oil passage in the crankcase damaged Battery Trouble Battery discharged Charge insufficient Battery faulty (too low terminal voltage) Battery lead making poor contact Magneto trouble Wiring faulty Regulator/rectifier trouble Battery overcharged Magneto trouble Regulator/rectifier trouble Battery faulty Poor Performance through Engine Runs Properly Jet pump Intake area obstructed Impeller or pump case damaged Exces
MODEL APPLICATION Year 2004 2005 Model JT1500-A1 JT1500-A2 Beginning Hull No. KAW60001□304 US-KAW50001□405 □:This digit in the hull number changes from one machine to another. Part No.
