Kawasaki STX-15F Manuel d'utilisateur

STX-15FJET SKI®WatercraftService Manual

3-46 FUEL SYSTEM (DFI)Vehicle-down Sensor (Service Code/Character-31/dOS)•Turn the ignition switch OFF.•Remove the needle adapter set, and apply silic

FUEL SYSTEM (DFI) 3-47Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)Fuel Injector Remo valWARNINGGasoline is extremely

3-48 FUEL SYSTEM (DFI)Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)•Replace the seals [A] with new ones.•Apply grease

FUEL SYSTEM (DFI) 3-49Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)•Remove connectors for injector [A].•Connect each t

3-50 FUEL SYSTEM (DFI)Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)Injector Voltage Inspection•Turn the ignition switc

FUEL SYSTEM (DFI) 3-51Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)Injector Fuel Line Inspection•Check the injector fu

3-52 FUEL SYSTEM (DFI)Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)1. Fuel Injector #12. Fuel Injector #23. Fuel Injec

FUEL SYSTEM (DFI) 3-53Ignition Coils (Service Code/Character-51, 52/COL1, COL2)Ignition Coil #1, #4: Service Code 51-COL1Ignition Coil #2, #3: Service

3-54 FUEL SYSTEM (DFI)Ignition Coils (Service Code/Character-51, 52/COL1, CO L2)1. Main Relay in Relay Assembly2. Joint Connector F3. Connector C4. Co

FUEL SYSTEM (DFI) 3-55Engine Overheating (Service Code/Character-71/HEAt)•If the service code is displayed, check the doubtful parts referring to the

GENERAL INFORMATION 1-11General InformationTable of ContentsSmart Learning Operation mode (SLO) (JT1500-A2 model ∼)...

3-56 FUEL SYSTEM (DFI)Low En gine Oil Pressure (Service Code/Character-72/OILP)•If the service code is displayed, check the doubtful parts referring t

FUEL SYSTEM (DFI) 3-57Oil Temperatu re Sensor (Service Code/Character-73/O ILC or 73/OILt)Service Code/CharacterJT1500-A1:73/OILCJT1500-A2 ∼:73/OILtOi

3-58 FUEL SYSTEM (DFI)Oil Temperature Sensor (Service Code/Character-73/OILC or 73/OILt)•Turn the ignition switch OFF.If the output voltage is out of

FUEL SYSTEM (DFI) 3-59Engine Oil Overheating (Service Code/Character-76/OILH)JT1500-A2 model ∼;•If the service code is displayed, check the doubtful p

3-60 FUEL SYSTEM (DFI)ECUCAUTIONNever drop the ECU, especially on a hard surface.Such a shock to the ECU can damage it.ECU R emoval•Remove:Seat (see H

FUEL SYSTEM (DFI) 3-61ECU•Check the ECU power source voltage with a tester [A].○Position the terminal in accordance with terminal numbersof ECU connec

3-62 FUEL SYSTEM (DFI)ECUECU Power Source Circuit1. Main Relay in Relay assembly2. Joint Connector F3. Connector C4. Connector D5. Ignition Switch6. S

FUEL SYSTEM (DFI) 3-63DFI Power SourceMain Fuse Inspection•Refer to the Electrical System chapter for the ECU FuseInspection.Relay Assembly RemovalCAU

3-64 FUEL SYSTEM (DFI)DFI Power SourceFuel Pump RelayRelay Coil Terminals [6] and [8]Relay Switch Terminals [5] and [7]Testing RelayTester range: 1 Ω

FUEL SYSTEM (DFI) 3-65Throttle Lever, Cable and CaseFree Play Inspection•Refer to Throttle Control System Inspection in the Peri-odic Maintenance chap

1-2 GENERAL INFORMATIONSmart Learning Operation mode (SLO) (JT1500-A2 model ∼)This watercraft is equipped with the Smart Learning Operation mode (SLO)

3-66 FUEL SYSTEM (DFI)Throttle Lever, Cable and Case•Disassemble the throttle case.○Remove the circlip [A], flat washers [B], pin [C], throttlelever [

FUEL SYSTEM (DFI) 3-67Throttle Lever, Cable and Case•Tighten:Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40kgf·m, 34 in·lb)•Swing the throttle

3-68 FUEL SYSTEM (DFI)Throttle Lever, Cable and Case•Remove the throttle case (see Throttle Case Removal).•Slide the rubber boot out of the place.•Uns

FUEL SYSTEM (DFI) 3-69Throttle Lever, Cable and Case•Tighten:Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40kgf·m, 34 in·lb)•Route the following

3-70 FUEL SYSTEM (DFI)Air FilterAir Filter Removal•Remove the seat (see Hull/Engine Hood chapter).•Remove the rear storage pocket.•Disconnect the foll

FUEL SYSTEM (DFI) 3-71Air FilterAir Filter Disassembly•Remove:Air Filter (see Air Filter Removal)Air Filter Bolts [A]•Remove:Bolts [A]Flame Arrester [

3-72 FUEL SYSTEM (DFI)Throttle Body AssyIdle Speed InspectionThe normal idle speed is controlled by the ECU (Elec-tronic Control Unit).Idle SpeedStand

FUEL SYSTEM (DFI) 3-73Throttle Body AssyISC (Idle Speed Controller) Removal/Installation•RemoveSeat (see Hull/Engine Hood chapter)Air Filter (see Air

3-74 FUEL SYSTEM (DFI)Throttle Body AssyISC Resistance Inspection•Remove:Air Filter (from the throttle body assy)ISC Connector [A] (disconnect)•Measur

FUEL SYSTEM (DFI) 3-75Inlet ManifoldInlet Manifol d Removal•Remove:Supply Fuel Hose [A] at Delivery PipeReturn Fuel Hose [B] at Delivery PipeDelivery

GENERAL INFORMATION 1-3Before ServicingBefore starting to perform an inspection service or carry out a disassembly and reassembly oper-ation on waterc

3-76 FUEL SYSTEM (DFI)Inlet Manifold•Remove the inlet manifold [A] with the throttle body assy[B].•Remove the throttle body assy from the inlet manifo

FUEL SYSTEM (DFI) 3-77Inlet Manifold•Replace the injector seals [A] with new ones.•Apply grease to the inside and outside of seals.•Tighten the delive

3-78 FUEL SYSTEM (DFI)Fuel LineFuel Pressure InspectionNOTE○Be sure the battery is fully c harged.•Be sure to place a piece of cloth under the fuel su

FUEL SYSTEM (DFI) 3-79Fuel LineIf the fuel pressure is much lower than specified, and ifinspection above checks out good, replace the fuel filterand m

3-80 FUEL SYSTEM (DFI)Fuel Line•Prepare a measuring cylinder [A].•Disconnect the fuel supply hose from the fuel deliverypipe, and set the measuring cy

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

3-82 FUEL SYSTEM (DFI)Fuel FilterFuel Filter RemovalNOTE○The fuel filter is designed to be used throughout thewatercraft’s life without any maintenanc

FUEL SYSTEM (DFI) 3-83Fuel FilterFuel Filter Installation•Route the hose correctly (see Cable, Wire, and HoseRouting section in Appendix chapter).•Ins

3-84 FUEL SYSTEM (DFI)Fuel PumpFuel Pump RemovalCAUTIONNever drop the fuel pump, especially on a hard sur-face. Such a shock to the pump can damage it

FUEL SYSTEM (DFI) 3-85Fuel PumpFuel Pump Installation•Press down the rubber holder [A] onto the fuel pump [B]so the stepped part [C] of the holder com

1-4 GENERAL INFORMATIONBefore Servicing•Obtain a standard garden hose [A] and a garden hoseadapter [B] as shown.C: Garden Hose Fitting of AdapterD: Fl

3-86 FUEL SYSTEM (DFI)Fuel Pump•Remove the front storage pocket (see Hull/Engine Hoodchapter).•Connect the hand tester (25 V DC) [A] to the fuel pumpl

FUEL SYSTEM (DFI) 3-87Fuel PumpFuel Pump Relay Removal•Refer to the Relay Assembly Removal in the DFI PowerSource section.Fuel Pump Relay Inspection•R

3-88 FUEL SYSTEM (DFI)Fuel TankFuel Tank Removal•Drain the fuel tank into a suitable container.WARNINGGasoline is extremely flammable and can be explo

FUEL SYSTEM (DFI) 3-89Fuel Tank•Remove the fuel tank [A] out of the hull as shown.Fuel Tank Installation•Be sure the float [A] in place before putting

3-90 FUEL SYSTEM (DFI)Fuel TankFuel Filler and Tube Removal•Open the front storage compartment cover.•Loosen the fuel filler tube clamp screws [A] and

ENGINE LUBRIC ATIO N SYSTEM 4-14Engine Lubrication SystemTable of ContentsExploded View...

4-2 ENGINE LUBRICATION SYSTEMExploded View

ENGINE LUBRIC ATIO N SYSTEM 4-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Breather Plate Bolts 7.8 0.80 69 in·lb2 Oil Filler Cap 1.0 0.10

4-4 ENGINE LUBRICATION SYSTEMEngine Oil Flow ChartA: Blowby GasB: Supply Engine Oil FlowC: Return Engine Oil FlowD: Oil Sump1. from Oil Pump Side Pas-

ENGINE LUBRIC ATIO N SYSTEM 4-5Engine Oil Flow Chart21. Oil Separator Tank22. to Air Filter23. to Oil Pan24. Joint25. Camshaft Oil Passage26. Camshaft

GENERAL INFORMATION 1-5Before ServicingCAUTIONTurn the capsized boat clockwise so that the port side always faces downward. Turningcounterclockwise ca

4-6 ENGINE LUBRICATION SYSTEMSpecificationsItem StandardEngine OilGrade API SE, SF, or SGAPI SH or SJ with JASO MAViscosity SAE 10W-40Capacity 4.0 L (

ENGINE LUBRIC ATIO N SYSTEM 4-7SpecialToolandSealantOil Pressure G auge, 10 kgf/cm²:57001-164Oil Pressure Gauge Adapter, PT 1/8:57001-1033Oil Filter W

4-8 ENGINE LUBRICATION SYSTEMEngine Oil and Oil FilterWARNINGWatercraft operation with insufficient, deteriorated,or contaminated engine oil will caus

ENGINE LUBRICATION SYSTEM 4-9Engine Oil and O il FilterCAUTIONRacing the engine before the oil reaches every partcan cause engine seizure.If the engin

4-10 ENGINE LUBRICATION SYSTEMEngine Oil and Oil Filter•Remove the seat (see Hull/Engine Hood chapter)•Remove the dipstick [A], wipe it dry and insert

ENGINE LUBRICATION SYSTEM 4-11Oil CoolerOil Cooler Removal•Remove:Seat (see Hull/Engine Hood chapter)Air Filter with Inlet Duct (see Fuel System (DFI)

4-12 ENGINE LUBRICATION SYSTEMOil Cooler•Apply engine oil to the thread [A] of the passage bolt andO-ring [B] of the oil filter [C].•Tighten the oil f

ENGINE LUBRICATION SYSTEM 4-13Oil CoolerOil Cooler Inspection•Start the engine to check for water and oil leaks.If the water and oil leak, replace the

4-14 ENGINE LUBRICATION SYSTEMBreather Case and Oil Separator TankBreather Case Removal•Remove:Seat (see Hull/Engine Hood chapter)Exhaust Manifold (se

ENGINE LUBRICATION SYSTEM 4-15Breather Case and Oil Separator Tank•Remove:Breather Hose Clamp [A]Breather Hose [B]Oil Separator Tank [C]NOTE○Hold the

1-6 GENERAL INFORMATIONBefore ServicingCleaning Watercraft before DisassemblyClean the watercraft thoroughly before disassembly. Dirtor other foreign

4-16 ENGINE LUBRICATION SYSTEMOil PanOil Pan Removal•Remove:Engine Oil (drain, see Periodic Maintenance chapter)Engine (see Engine Removal/Installatio

ENGINE LUBRICATION SYSTEM 4-17Oil Pu mp Sprocket, Oil Pump and Oil Pressure Relief ValveOil Pump Sprocket Removal•Drain:Engine Oil (see Periodic Maint

4-18 ENGINE LUBRICATION SYSTEMOil Pump Sprocket, Oil Pu mp and Oil Pressure Relief Valve•Install the oil pump chain guide [A], collar [B], washer [C],

ENGINE LUBRICATION SYSTEM 4-19Oil Pu mp Sprocket, Oil Pump and Oil Pressure Relief Valve•Install:Oil Pump S procket (see Oil Pump Sprocket Installatio

4-20 ENGINE LUBRICATION SYSTEMOil Pump Sprocket, Oil Pu mp and Oil Pressure Relief ValveOil Pressure Relief Valve Inspection•Remove:Oil Pan (see Oil P

ENGINE LUBRICATION SYSTEM 4-21Oil Pressure Measuremen tOil Pressure Measurement•Remove:Seat (see Hull/Engine Hood chapter)Inlet Manifold (see Fuel Sys

4-22 ENGINE LUBRICATION SYSTEMOil Pressure Measuremen tWARNINGTake care against burns from hot engine oil thatwill drain through the oil passage when

ENGINE LUBRICATION SYSTEM 4-23Oil Pressure SwitchOil Pressure Switch Removal•Remove:Seat (see Hull/Engine Hood chapter)Inlet Manifold (see Fuel System

EXHAUST SYSTEM 5-15Exhaust SystemTable of ContentsExploded View...

GENERAL INFORMATION 1-7Before ServicingAssembly OrderIn most cases assembly order is the reverse of disassem-bly, however, if assembly order is provid

5-2 EXHAUST SYSTEMExploded View

EXHAUST SYSTEM 5-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Exhaust Manifold Mounting Nuts25 2.5 18S2 Exhaust Manifold Mounting Bolts 25 2.

5-4 EXHAUST SYSTEMExhaust ManifoldExhaust Manifold Removal•Remove:Oil Separator Tank [A] with the Oil Separator Hoses (seeLubrication system)Air Filte

EXHAUST SYSTEM 5-5Exhaust M an ifold•Take out the exhaust manifold with the exhaust pipe fromthe hull.•Disconnect the hose [A] from the exhaust pipe.E

5-6 EXHAUST SYSTEMExhaust ManifoldExhaust Manifold Clea ning and Inspection•Remove the exhaust manifold parts.•Clean the carbon deposits out of the ex

EXHAUST SYSTEM 5-7Exhaust PipeExhaust Pipe Removal•Remove:Exhaust Manifold with Exhaust Pipe (see Exhaust Man-ifold Removal)Exhaust Pipe Mounting Bolt

5-8 EXHAUST SYSTEMExhaust PipeExhaust Pipe Cleaning and Inspection•Remove the exhaust pipe parts.•Clean the carbon deposits out of the exhaust passage

EXHAUST SYSTEM 5-9Water Box MufflerWater Box Muffler Removal•Remove:Rear Storage PocketOil Separator Tank with Oil Separator Hoses (see theLubrication

5-10 EXHAUST SYSTEMWater Box Muffler•Be sure the dampers [A] on the left side water box muffler[B] are in place.•Make sure the two rings [A] are insta

ENGINE TOP END 6-16Engine Top EndTable of ContentsExploded View... 6-2Specifications ...

1-8 GENERAL INFORMATIONBefore ServicingLiquid Gasket, Locking AgentFor applications that require Liquid Gasket or a Lockingagent, clean the surfaces s

6-2 ENGINE TOP ENDExploded View

ENGINE TOP END 6-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb2 Cylinder Head Cover Bolts 9.8

6-4 ENGINE TOP ENDExploded View

ENGINE TOP END 6-5Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Exhaust Side Camshaft Chain Guide Bolts (Upper) 25 2.5 182 Exhaust Side Camsh

6-6 ENGINE TOP ENDSpecificationsItem Standard Service LimitCamshaftsCam Height:Exhaust 36.143 ∼ 36.257 mm (1.4229 ∼ 1.4274 in.) 36.04 mm (1.4189 in.)I

ENGINE TOP END 6-7SpecificationsItem Standard Service LimitInlet (Outer) 45.78 mm (1.802 in.) 44.2 mm (1.740 in.)Cylinder, PistonCylinder Inside Diame

6-8 ENGINE TOP ENDSpecial Tools and SealantCompression Gauge, 20 kgf/cm²:57001-221Valve Spring Compressor Assembly:57001-241Top Dead Center Finder:570

ENGINE TOP END 6-9Special Tools and SealantValve Seat Cutter, 45° - 30:57001-1187Valve Spring Compressor Adapter, 22:57001-1202Valve Guide Arbor, 5:57

6-10 ENGINE TOP ENDSpecial Tools and SealantPiston Base, 8:57001-1604Kawasaki Bond (Silicone Sealant):56019-120

ENGINE TOP END 6-11Clean Air SystemAir Suction Valve Removal•Remove:Seat (see Hull/Engine Hood chapter)Hoses [A]•Remove:Air Suction Valve Cover Bolts

GENERAL INFORMATION 1-9Before ServicingCirclips, Cotter PinsReplace circlips or cotter pins that were removed with n ewones. Take care not to open the

6-12 ENGINE TOP ENDCylinder Head CoverCylinder Head Cover Removal•Remove:Air Suction Valve Hoses [A]Spark Plug Caps [B]Breather Hoses [C]•Remove the c

ENGINE TOP END 6-13Camshaft Chain TensionerCamshaft Chain Tensioner RemovalCAUTIONThis is a non-return type camshaft chain tensioner[A]. The push rod

6-14 ENGINE TOP ENDCamshaft, Camshaft ChainCamshaft Removal•Remove:Seat (see Hull/Engine Hood chapter)Spark P lugs (see Periodic Maintenance chapter)C

ENGINE TOP END 6-15Camshaft, Camshaft ChainCamshaft Installation•Be sure to install the following parts.Pins [A]•Apply molybdenum disulfide oil soluti

6-16 ENGINE TOP ENDCamshaft, Camshaft Chain•Remove the spark plugs.•Using the shaft wrench [A], turn the crankshaft counter-clockwise [B] and set the

ENGINE TOP END 6-17Camshaft, Camshaft Chain•Remove:#1 Spark Plug (Front Side)•Install the piston top detector [A] in the hole of the plug.Special Tool

6-18 ENGINE TOP ENDCamshaft, Camshaft ChainCamshaft, Camshaft Cap Wear•Cut strips of plastigage (press gauge) to journal width.Place a strip on each j

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

6-20 ENGINE TOP ENDCylinder HeadCylinder Compression MeasurementNOTE○Use the battery which is fully charged.•Thoroughly warm up the engine, while chec

ENGINE TOP END 6-21Cylinder HeadThe following table should be consulted if the obtainable compression reading is not within the us-able range.Problem

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1-10 GENERAL INFORMATIONModel IdentificationJT1500-A1 Left Side ViewJT1500-A1 Right Side View

6-22 ENGINE TOP ENDCylinder Head•Remove:Engine Hook Bolts [A]Engine Hook [B]Cylinder Head Bolts [C]•Remove:Upper Dipstick Tube Bolts [A]Upper Exhaust

ENGINE TOP END 6-23Cylinder Head•Apply molybdenum disulfide oil solution [A] to both sidesof the M11 cylinder head bolt washers [B] and the threadof h

6-24 ENGINE TOP ENDValvesValve Clearance Check•Refer to Valve Clearance Inspection and Adjustment inthe Periodic Maintenance chapter.Valve Removal•Rem

ENGINE TOP END 6-25ValvesValve Guide Installation•Apply engine oil to the valve guide outer surface beforeinstallation.•Heat the area around the valve

6-26 ENGINE TOP ENDValvesValve Seat In spection•Remove the valve (see Valve Removal).•Check the valve seating surface [A] between the valve [B]and val

ENGINE TOP END 6-27ValvesSeat Cutter Operation Care1. This valve s eat cutter is developed to grind the valve forrepair. Therefore the cutter must not

6-28 ENGINE TOP ENDValves•Measure the outside diameter of the seating surface witha vernier caliper.If the outside diameter of the seating surface is

ENGINE TOP END 6-29ValvesIf the seat width is too wide, make the 60° or 55° [A] grinddescribed below.If the seat width is within the specified range,

6-30 ENGINE TOP ENDValves

ENGINE TOP END 6-31Cylinder, PistonsCylinder Removal•Drain the engine oil (see Periodic Maintenance chapter).•Remove:Engine (see Engine Removal/Instal

GENERAL INFORMATION 1-11General SpecificationsItems JT1500-A1 ∼ A2EngineType4-stroke, DOHC, 4-cylinder, water cooledDisplacement1498mL(91.4cuin.)Bore

6-32 ENGINE TOP ENDCylinder, Pistons•Carefully spread the ring opening with your thumbs andthen push up on the opposite side of the ring [A] to remove

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

6-34 ENGINE TOP ENDCylinder, PistonsCylinder Wear•Since there is a difference in cylinder wear in different di-rections, take a side-to-side and a fro

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

ENGINE REMOVAL/INSTALLAT ION 7-17Engine Removal/InstallationTable of ContentsExploded View...

7-2 ENGINE REMOVAL/INSTALLATIONExploded View

ENGINE REMOVAL/INSTALLATION 7-3Exploded ViewTorqueNo FastenerN·mkgf·m ft·lbRemarks1 Engine Mounting Bolts 36 3.7 27 L2 Engine Damper Mounting Bolts 16

7-4 ENGINE REMOVAL/INSTALLATIONEngine Removal/InstallationEngine Removal•Remove:Seat (see Hull/Engine Hood chapter)Oil Separator Tank (see Lubrication

ENGINE REMOVAL/INSTALLATION 7-5Engine Removal/Installation•Remove:Engine Mounting Bolts [A]•Slide the engine toward the front to disengage the cou-pli

1-12 GENERAL INFORMATIONGeneral SpecificationsItems JT1500-A1 ∼ A2Overall Width 1180mm(46.5in.)Overall Height 1050mm(41.3in.)Dry Weight338 kg (745 lb)

7-6 ENGINE REMOVAL/INSTALLATIONEngine Removal/InstallationEngine Damper Installatio n•Install the shim(s) of the same number.•Apply a non-permanent lo

ENGINE BOTTOM END 8-18Engine Bottom EndTable of ContentsExploded View...

8-2 ENGINE BOTTOM ENDExploded View

ENGINE BOTTOM END 8-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Crankshaft Sensor Cover Bolts 7.8 0.80 69 in·lb2 Engine Bracket Mounting B

8-4 ENGINE BOTTOM ENDSpecificationsItem Standard Service LimitCrankshaft, Connecting RodsConnecting Rod Bend–––0.2/100 mm(0.008/3.94 in.)Connecting Ro

ENGINE B OTTOM E ND 8-5SpecificationsItem Standard Service LimitCrankshaft Main Journal Diameter: 40.984 ∼ 41.000 mm(1.6135 ∼ 1.6142 in.)40.96 mm(1.61

8-6 ENGINE BOTTOM ENDSpecial Tools and SealantOil Seal & Bearing R emover:57001-1058Bearing Driver Set:57001-1129Coupling Holder #2:57001-1423Roto

ENGINE BOTTOM END 8-7Special Tools and SealantKawasaki Bond (Liquid G asket - Black):92104-1062

8-8 ENGINE BOTTOM ENDCouplingCoupling/Output Shaft Removal•Remove:Engine (see Engine Removal/Installation chapter)Crankshaft Sensor Cover (see Electri

ENGINE B OTTOM E ND 8-9Coupling•Using the rotor holder [A], remove the output shaft [B].Special Tool - Rotor Holder: 57001-1544Coupling/Output Shaft I

GENERAL INFORMATION 1-13Unit Conversion TablePrefixes for UnitsPrefix SymbolPowermega M × 1 000 000kilo k ×1000centi c ×0.01milli m × 0.001micro µ × 0

8-10 ENGINE BOTTOM ENDCoupling•Install:Pins [A]Gasket [B]•Position the magnet lead [C] as shown.•Apply grease to the oil seal lip.•Install the output

ENGINE BOTTOM END 8-11Coupling•Replace the oil seals with new ones.•Apply thin coat grease to the oil seal lips [A].•Pack grease [B] between the oil s

8-12 ENGINE BOTTOM ENDMagneto FlywheelMagneto Flywheel Removal•Remove:Engine (see Engine Removal/Installation chapter)Crankshaft Sensor Cover (see Ele

ENGINE BOTTOM END 8-13Magneto Flywheel•Apply grease to the boss outside [A] of the magneto fly-wheel [B].10 mm (0.39 in.) [C]•Install the magneto flyw

8-14 ENGINE BOTTOM ENDStatorStator Removal•Remove:Engine (see Engine Removal/Installation chapter)Magneto Cover (see Coupling/Output Shaft Removal)Gro

ENGINE BOTTOM END 8-15Crankcase SplittingCrankcase Splitting•Remove:Seat (see Hull/Engine Hood chapter)Engine (see Engine Removal/Installation chapter

8-16 ENGINE BOTTOM ENDCrankcase SplittingCrankcase AssemblyCAUTIONThe upper and lower crankcase halves are ma-chined at the factory in the assembled s

ENGINE BOTTOM END 8-17Crankcase Splitting•Install the oil pump sprocket chain [A] on the chain guide[B] of the lower crankcase [C].•Apply molybdenum d

8-18 ENGINE BOTTOM ENDCrankshaft and Connecting RodsCrankshaft Removal•Split the crankcase (see Crankcase Splitting).•Remove:Camshaft Chain [A]Oil Pum

ENGINE BOTTOM END 8-19Crankshaft and Connecting Rods•Install the crankshaft with the oil pump sprocket chain [A]and camshaft chain [B] hanging on them

8-20 ENGINE BOTTOM ENDCrankshaft and Connecting RodsCAUTIONTo minimize vibration, the connecting rods shouldhave the same weight mark.BigEndCap[A]Conn

ENGINE BOTTOM END 8-21Crankshaft and Connecting Rods•Apply small amount of molybdenum disulfide oil solutionto the threads [A] and seating surfaces [B

8-22 ENGINE BOTTOM ENDCrankshaft and Connecting RodsConnecting Rod Twist•On surface plate, set the big-end arbor [A] on V block [C].•Measure the diffe

ENGINE BOTTOM END 8-23Crankshaft and Connecting RodsIf any crankpin has worn past the service limit, replace thecrankshaft with a new one.If the measu

8-24 ENGINE BOTTOM ENDCrankshaft and Connecting RodsCrankshaft Main Bearing Insert/Journal Wear•Measure the bearing insert/journal [B] clearance with

ENGINE BOTTOM END 8-25Crankshaft and Connecting Rods•Measure the main bearing bore diameter, and mark [B]the upper crankcase half [A] in accordance wi

8-26 ENGINE BOTTOM ENDCrankshaft and Connecting RodsCrankshaft Side Clearance•Insert a thickness gauge [A] between the thrust washer[B] and the c rank

COOLING AND BILGE SYSTEMS 9-19Cooling and Bilge SystemsTable of ContentsExploded View...

9-2 COOLING AND BILGE SYSTEMSExploded View

COOLING AND BILGE SYSTEMS 9-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Water Hose Joint (L Shape Type)11 1.1 95 in·lbSS2 Water Hose Joint (

PERIODIC MAINTENANCE 2-12Periodic MaintenanceTable of ContentsPeriodic Maintenance Chart ...

9-4 COOLING AND BILGE SYSTEMSBilge SystemBreather Removal•Remove:Seat (see Hull/Engine Hood chapter)Rear Storage Pocket•Pull the hoses [A] off the bre

COOLING AND BILGE SYSTEMS 9-5Bilge SystemFollow the next procedures to remove the left side filter[D].•Remove the water box muffler [B] (see Exhaust S

9-6 COOLING AND BILGE SYSTEMSCooling and Bilge System H osesHose Removal•The majority of bilge hoses have no clamps at the hoseends. The majority of b

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

9-8 COOLING AND BILGE SYSTEMSCooling and Bilge System Flow Diagram

COOLING AND BILGE SYSTEMS 9-9Cooling and Bilge System Flow Diagram1. Cylinder Head2. Water Pipe3. Cylinder Head Gasket4. Cylinder5. Oil Cooler6. Outpu

9-10 COOLING AND BILGE SYSTEMSWater PipeWater Pipe Removal•Remove the inlet manifold (see Fuel System).•Disconnect the cooling hose [A] onto the water

COOLING AND BILGE SYSTEMS 9-11After SubmergingCAUTIONDo not operate the watercraft with water in the en-gine.Do not try to start the engine until it i

9-12 COOLING AND BILGE SYSTEMSAfter Submerging

COOLING AND BILGE SYSTEMS 9-13After SubmergingDetailed Procedures after S ubmerging1. Remove the seat (see Hull/Engine Hood chapter).2. Remove the dra

2-2 PERIODIC MAINTENANCEPeriodic Maintenance ChartThe scheduled maintenance must be done in accordance with this chart to keep the watercraft ingood r

9-14 COOLING AND BILGE SYSTEMSAfter Submerging13. Reconnect the primary ignition coil lead connectors,noting the #1,#4 [A] and the #2, #3 [B] coil con

COOLING AND BILGE SYSTEMS 9-15After Submerging18. If the fuel tank has water in it, it must be emptied bypump or siphon. Refill the tank with fresh fu

DRIVE SYSTEM 10-110Drive SystemTable of ContentsExploded View...

10-2 DRIVE SYSTEMExploded View

DRIVE SYSTEM 10-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Coupling39 4.0 292 Drive Shaft Holder Mounting Bolts 22 2.2 16 L3 Coupling Cover

10-4 DRIVE SYSTEMSpecificationItem Standard Service LimitDrive ShaftRunout (see P10-8) [A] Less than 0.1 mm (0.0039 in.)[B] Less than 0.2 mm (0.0079 i

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

10-6 DRIVE SYSTEMDrive Shaft/Drive Shaft H olderDrive Shaft Removal/Installatio n•Remove the engine (see Engine Removal/Installationchapter).•Pull the

DRIVE SYSTEM 10-7Drive Shaft/Drive Shaft Holder○Press the small grease seal, and the large grease seals,bearing, and small grease seals come out of th

PERIODIC MAINTENANCE 2-3Torque and Locking AgentThe following table list the tightening torque for the major fasteners, and the parts requiring use of

10-8 DRIVE SYSTEMDrive Shaft/Drive Shaft H olderDrive Shaft Runout•Measure drive shaft runout by supporting the shaft on Vblocks and setting a dial ga

PUMP AND IMPELLER 11-111Pump and ImpellerTable of ContentsExploded View...

11-2 PUMP AND IMPELLERExploded View

PUMP AND IMPELLER 11-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Pump Bracket Mounting Bolts (2)19 1.9 14L, SS2 Pump Bracket Mounting Bolts

11-4 PUMP AND IMPELLERSpecificationsItem Standard Service LimitJet PumpImpeller Outside Diameter 147.5 ∼ 147.7 mm (5.8071 ∼ 5.8149 in.) 146.5 mm (5.76

PUMP AND IMPELLER 11-5Special Tools and SealantOil Seal & Bearing Remover:57001-1058Bearing Driver Set:57001-1129Impeller Wrench:57001-1228Impelle

11-6 PUMP AND IMPELLERPump and ImpellerPump Removal•Turn the craft on its left side.•Disconnect the reverse cable ball joint at the rear end.•Unscrew

PUMP AND IMPELLER 11-7Pump and Impeller○Take out the pump bracket mounting bolts [A].○Cut the sealant at the indicated area [A] in the figure andremov

11-8 PUMP AND IMPELLERPump and Impeller•Be sure trim seal [A] is in place.•Grease the splines on the drive shaft with water resistantgrease.•Install t

PUMP AND IMPELLER 11-9Pump 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

2-4 PERIODIC MAINTENANCETorque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksOil Passage Joints 11 1.1 95 in·lb LOil Cooler Assembly Bolts7.8 0

11-10 PUMP AND IMPELLERPump and Impeller•Unscrew the pump cap bolts [A], and remove the pumpcap [B].•Pull out the impeller seal on the impeller.•Hold

PUMP AND IMPELLER 11-11Pump and Impeller•Remove the bearing by tapping evenly around the bearinginner race from the front end of the pump case [A].Spe

11-12 PUMP AND IMPELLERPump and Impeller•Before installing the pump bearing, blow any dirt or for-eign particles out of the pump case with compressed

PUMP AND IMPELLER 11-13Pump and ImpellerJT1500-A2 ∼;•Replace the grease seals with new ones, if necessary,and install them.Special Tool - Bearing Driv

11-14 PUMP AND IMPELLERPump and ImpellerJT1500-A1, A2 ∼;•Screw on the impeller and torque.Special Tools - Impeller Holder: 57001-1393Impeller Wrench:

PUMP AND IMPELLER 11-15Pump and ImpellerImpeller O utside Diameter Measurement•Measure the impeller outside diameter.If the impeller is worn smaller t

STEERING 12-112SteeringTable of ContentsExploded View...

12-2 STEERINGExploded View

STEERING 12-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Handlebar Clamp Bolts16 1.6 12 L2 Start/stop Switch Case Mounting Screws 3.9 0.40 35

PERIODIC MAINTENANCE 2-5Torque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksInlet Side Camshaft C hain Guide Bolts 12 1.2 104 in·lb LCamshaft

12-4 STEERINGSpecialToolandSealantBox Wrench (27 mm):57001-1451Kawasaki Bond (Silicone Sealant):56019-120

STEERING 12-5Steering CableSteering Cable Adjustment•Check the steering cable adjustment.○Center the handlebar in the straight-ahead position.•Check t

12-6 STEERINGSteering Cable•Loosen the locknut [A] at the front end of the steeringcable, and slide back the outer sleeve of the ball joint andtake of

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

12-8 STEERINGHandlebarHandlebar Removal•Unscrew the mounting s crews [A] and remove the han-dlebar pad [B].•Remove the inner pad [A], pushing [B] the

STEERING 12-9HandlebarHandlebar Installation•Install the pad holder.○Apply a non-permanent locking agent to the pad holderbolts.•Install the handlebar

12-10 S TEERINGHandlebar•Install the bosses [A] on the pad holder to the holes [B]on the handlebar pad.•Align[A]theprojection[B]onthepadwiththegroove[

STEERING 12-11SteeringSteering Removal•Remove the handlebar and pad holder (see HandlebarRemoval).•Unscrew the set screw [A] and take out the cap [B].

12-12 S TEERINGSteering•Remove the front storage pocket (see Hull/Engine Hoodchapter).•Disconnect:Steering Position Sensor Lead Connector [A]Buzzer Co

STEERING 12-13Steering•Remove the cotter pin [A] and steering shaft locknut [B].•Take out the holder [C].•Unscrew the steering holder mounting bolts [

This quick reference guide will assistyou in locating a desired topic or pro-cedure.•Bend the pages back to match theblack tab of the desired chapter

2-6 PERIODIC MAINTENANCETorque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksPump Cover Mounting Bolts 7.9 0.80 69 in·lb LGrate Mounting Bolts9

12-14 S TEERINGSteeringSteering Installation•Replace the gasket [A] on the steering holder [B] with anew one.•Check the bushings for damage and wear b

STEERING 12-15Steering•Torque the steering shaft locknut [A].Torque - Steering Shaft Locknut: 49 ∼ 59 N·m (5.0 ∼ 6.0kgf·m, 36 ∼ 43 ft·lb)•Turning the

12-16 S TEERINGSteering•Be sure that the damper [A] is in position.•Apply a non-permanent locking agent to the grommetmounting plate.•Apply a non-perm

STEERING 12-17Reverse SystemShift Cable Adjustment•Check the shift cable adjustment.•When the shift lever is in the “F” position, the lower edge[A] of

12-18 S TEERINGReverse System•Pull the holder [A] off the cable bracket.•Remove the right side cover (see Hull/Engine Hood chap-ter).•Unscrew the bolt

STEERING 12-19Reverse System•Turn the water craft on its left side and remove the pumpcover (see Pump/Impeller chapter).CAUTIONNever lay the watercraf

12-20 S TEERINGReverse SystemReverse Bucket Removal/Installation•Disconnect the ball joint at rear end of the shift cable.•Remove the pump cover.•Unsc

HULL/ENGINE HOOD 13-113Hull/Engine HoodTable of ContentsExploded View...

13-2 HULL/ENGINE HOODExploded View

HULL/ENGINE HOOD 13-3Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Crossmember Bolts7.8 0.80 69 in·lb L2 Handrail Bolts 9.8 1.0 87 in·lb L3 Loc

PERIODIC MAINTENANCE 2-7Torque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksStarter Relay Mounting Nut 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lbStar

13-4 HULL/ENGINE HOODExploded View

HULL/ENGINE HOOD 13-5Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Stabilizer Bolts9.8 1.0 87 in·lb L2 Air Inlet Duct Bolts – – – L3Exhaust Out

13-6 HULL/ENGINE HOODFittingsSeat Removal•Pull [A] the latch handle [B].•Remove the s eat up [A] and to the rear [B].Seat Installation•Insert the seat

HULL/ENGINE HOOD 13-7Fittings•To remove the hinge assembly, remove the following.Damper Bolt [A]Hinge Bolts [B]Front Storage Compartment Cove r Disass

13-8 HULL/ENGINE HOODFittings•Drill out the rivets [A] with a drill bit [B] of the correct sizeand remove the front duct cover [C].Rivet Removal Drill

HULL/ENGINE HOOD 13-9FittingsMirror Re moval•Open the front storage compartment cover.•Unscrew the nuts [A] and washers [B] and remove themirrors [C]

13-10 H ULL/ENGINE HOODFittingsMirror Stay Installation•Be sure the dampers [A] are in position (both sides).•The right plate [A] on the inside of the

HULL/ENGINE H OOD 13-11FittingsFront Storage Pocket Removal•Remove the front storage pocket mounting screws [A].•Remove the front storage pocket [B].F

13-12 H ULL/ENGINE HOODFittings•Pull out the holder [A].•Unscrew the mounting bolts [D] and remove the cablebracket [C] with the cable [B].•To remove

HULL/ENGINE HOOD 13-13FittingsHandrail Re moval•Remove the seat (see this chapter).•Disconnect the bilge hoses from the breather fitting.•Unscrew the

2-8 PERIODIC MAINTENANCESpecificationsItem Standard Service LimitFuel SystemThrottle Lever Free Playabout 2 mm (0.08 in.) –––Engine LubricationSystemE

13-14 H ULL/ENGINE HOODFittingsStabilizer Removal•Unscrew the stabilizer bolts [A] and remove the stabilizer[B].Stabilizer Installation•Install the st

HULL/ENGINE HOOD 13-15Hull ReplacementTo replace the hull, remove the various parts in the follow-ing suggested order.Battery and PadExhaust Pipe and

13-16 H ULL/ENGINE HOODRubber PartsNOTE○The rubber parts on the watercraft are fastened in placewith various adhesives. To replace a rubber part, use

HULL/ENGINE HOOD 13-17Rubber PartsFront Storage Compartment Gasket [A]Front Storage Compartment Cover Trim Seal [B]Detent [A]Mats [A]Damper on Deck [A

13-18 H ULL/ENGINE HOODRubber PartsRivet Removal•Drill out the rivet with a drill bit [A] of the correct size.Rivet Removal Drill Bit Size5.0 m m (0.2

HULL/ENGINE HOOD 13-19Rubber PartsSide Bumper Removal•Take out the plugs [A].•Drill out the rivets [B] (see Rivet Removal).•Remove the corner bumper [

ELECTRICAL SYSTEM 14-114Electrical SystemTable of ContentsParts Location... 14-3Exploded View...

14-2 ELECTRICAL SYSTEMMODE/SET Button Inspection ... 14-58SLO (Smart Learning Operation)Mode Inspection (JT1500-A2model ∼) ...

ELECTRICAL SYSTEM 14-3Parts Location1. Bow2. Ignition Coil #2, #33. Ignition Coil #1, #44. Crankshaft Sensor5. Magneto6. Starter Motor7. Fuse Case8. R

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

14-4 ELECTRICAL SYSTEMParts Location13. Water Temperature Sensor14. Camshaft Position Sensor15. Oil Temperature Sensor16. Oil Pressure Switch17. Speed

ELECTRICAL SYSTEM 14-5Parts Location18. Fuel Level Sensor19. Steering Position Sensor20. Buzzer21. Multifunction Meter22. Starter Switch23. Engine Sto

14-6 ELECTRICAL SYSTEMExploded View

ELECTRICAL SYSTEM 14-7Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Vehicle-down Sensor Mounting Screws1.5 0.15 13 in·lb2 Electrical Parts Brac

14-8 ELECTRICAL SYSTEMExploded View

ELECTRICAL SYSTEM 14-9Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Multifunction Meter Mounting Bolts3.9 0.40 35 in·lb L2 Fuel Level Sensor Cl

14-10 ELECTRICAL SYSTEMExploded View

ELECTRICAL SYSTEM 14-11Exploded ViewTorqueNo. FastenerN·mkgf·m ft·lbRemarks1Starter Motor Through Bolts6.4 0.65 56 in·lb L, R2 Starter M otor Mounting

14-12 ELECTRICAL SYSTEMWiring DiagramJT1500-A1

ELECTRICAL SYSTEM 14-13Wiring DiagramJT1500-A1

2-10 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresFuel SystemThrottle Control System Inspection•Inspect the throttle lever free play [A].If the

14-14 ELECTRICAL SYSTEMWiring DiagramJT1500-A2 ∼

ELECTRICAL SYSTEM 14-15Wiring DiagramJT1500-A2 ∼

14-16 ELECTRICAL SYSTEMSpecificationsItem Standard Service LimitBatteryType 12 V 18 Ah –––Electric Starter SystemStarter Motor:Brush Length 12 mm (0.4

ELECTRICAL SYSTEM 14-17Special Tools and SealantHand Tester:57001-1394Peak Voltage Adapter:57001-1415Needle Adapter Set:57001-1457Holder Attachment:57

14-18 ELECTRICAL SYSTEMPrecautionsThere are a number of important precautions that shouldbe followed servicing electrical systems.○Do not reverse the

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

14-20 ELECTRICAL SYSTEMElectrical WiringWiring Inspection•Visually inspect the wiring for signs of burning, fraying,etc.If any wiring is poor, replace

ELECTRICAL SYSTEM 14-21BatteryRemoval•Disconnect the battery cables [A].WARNINGTo prevent possible personal injury and damageto electrical components,

14-22 ELECTRICAL SYSTEMBattery•Check to see that there is no peeling, tears or holes in theseal sheet on the top of the battery.•Place the battery on

ELECTRICAL SYSTEM 14-23BatteryInitial C harge•Place the strip [A] of caps loosely over the filler ports.•Newly activated sealed batteries require an i

PERIODIC MAINTENANCE 2-11Periodic Maintenance ProceduresAir Filter Inspection and Cleaning•Remove:Air Filter (see Fuel System (DFI) c hapter)Flame Arr

14-24 ELECTRICAL SYSTEMBattery3) When you do not use the watercraft for months:Give a refresh charge before you store the watercraft and store it with

ELECTRICAL SYSTEM 14-25BatteryNOTE○Increase the charging voltage to a m aximum voltage of25 V if the battery will not accept current initially. Charge

14-26 ELECTRICAL SYSTEMElectric Starter SystemStarter Relay Removal•Remove:Seat (see Hull/Engine Hood chapter)Rear Storage Pocket (see Hull/Engine Hoo

ELECTRICAL SYSTEM 14-27Electric Starter S ystem•Set ohmmeter to R × 1 Ω range.•Connect meter leads to starter relay as shown.•Activate starter relay s

14-28 ELECTRICAL SYSTEMElectric Starter SystemStarter Motor Disassembly•Remove the starter motor (see Starter Relay Removal).•Take off the starter mot

ELECTRICAL SYSTEM 14-29Electric Starter S ystem•Install the O-rings [A] and the washers [B] as shown.•Fit the tongue [A] on the brush plate into the e

14-30 ELECTRICAL SYSTEMElectric Starter System•Measure the diameter [A] of the commutator [B].Replace the starter motor with a new one if the commu-ta

ELECTRICAL SYSTEM 14-31Electric Starter S ystemReduction Gear Removal/Installation•Before removing the reduction gear, remove the magnetoflywheel (see

14-32 ELECTRICAL SYSTEMElectric Starter System3. Engine Starter Switch4. Joint Connector R5. Starter Motor6. Battery 12 V 18 Ah7. Starter Relay8. Join

ELECTRICAL SYSTEM 14-33Charging SystemMagneto Output Voltage•Remove:Seat (see Hull/Engine Hood chapter)Air Filter with Duct (see Fuel System chapter)•

2-12 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•The fuel vent check valve [C] must be mounted so thatthe arrow [D] on its case is pointing to

14-34 ELECTRICAL SYSTEMCharging System•Tighten:Torque - Regulator/rectifier Bolts: 7.8 N·m (0.80 kgf·m, 69in·lb)•When installing the bracket, apply a

ELECTRICAL SYSTEM 14-35Charging System•Do the 2nd step regulator circuit test.○Connect the test light and the 12 V battery in the samemanner as specif

14-36 ELECTRICAL SYSTEMCharging System1. Load2. Main Fuse 20 A3. Joint Connector R4. Battery 12 V 18 Ah5. Joint Connector S(Ground)6. Regulator/Rectif

ELECTRICAL SYSTEM 14-37Ignition SystemWARNINGThe ignition system produces extremely high volt-age. Do not touch the spark plugs, ignition coils, orspa

14-38 ELECTRICAL SYSTEMIgnition System•Apply grease to the O-ring and fit it in the groove of thesensor cover.•Apply silicone sealant [A] to the crank

ELECTRICAL SYSTEM 14-39Ignition SystemIgnition Coil Removal•Remove:Seat (see Hull/Engine Hood chapter)Front Storage Pocket (see Hull/Engine Hood chapt

14-40 ELECTRICAL SYSTEMIgnition System•Pull out the spark plug lead [B] from the ignition coil [A].Lubricate the leads with penetrating rust inhibitor

ELECTRICAL SYSTEM 14-41Ignition SystemIgnition Coil InspectionMeasuring arcing distanceThe most accurate test for determining the condition ofthe igni

14-42 ELECTRICAL SYSTEMIgnition SystemMeasuring spark plug lead resistance•Check the spark plug lead [A] for visible damage.If the spark plug lead is

ELECTRICAL SYSTEM 14-43Ignition SystemCamshaft Position Senso r Inspection•Remove:Seat (see Hull/Engine Hood chapter)Camshaft Position Sensor Lead Con

PERIODIC MAINTENANCE 2-13Periodic Maintenance Procedures•In a well-ventilated area, start the engine while cooling thecooling system.○Open the front s

14-44 ELECTRICAL SYSTEMIgnition System•Remove:Front Storage Pocket (see Hull/Engine Hood chapter)•Install the peak voltage adapter [A] into the hand t

ELECTRICAL SYSTEM 14-45Ignition SystemCrankshaft Sensor Peak Voltage CheckNOTE○Be sure the battery is fully c harged.•Connect the peak voltage adapter

14-46 ELECTRICAL SYSTEMIgnition SystemSpark Plug Removal•Refer to Spark Plug Inspection in the Periodic Mainte-nance chapter.Spark Plug Installation•R

ELECTRICAL SYSTEM 14-47Ignition SystemIgnition System Circuit1. Joint Connector H2. Joint Connector J3. Joint Connector E4. Crankshaft Sensor5. Relay

14-48 ELECTRICAL SYSTEMIgnition System

ELECTRICAL SYSTEM 14-49Kawasaki Smart Steering SystemSteering Position Sensor and Magnet Removal•Remove the steering holder (see Steering Removal inSt

14-50 ELECTRICAL SYSTEMKawasaki Smart Steering System•Turning the steering shaft fully in left and right direction,check whether the steering position

ELECTRICAL SYSTEM 14-51Kawasaki Smart Steering SystemSteering Position Sensor Input Voltage Inspection•Measure the input voltage to the steering posit

14-52 ELECTRICAL SYSTEMKawasaki Smart Steering SystemSteering Position Sensor Output Voltage Inspection•Measure the output voltage from the steering p

ELECTRICAL SYSTEM 14-53Kawasaki Smart Steering SystemSteering P osition Sensor Circuit1. Joint Connector Q2. Multifunction Meter3. Steering Position S

2-14 PERIODIC MAINTENANCEPeriodic Maintenance Procedures○Depending on the atmospheric temperature of your ridingarea, the engine oil viscosity should

14-54 ELECTRICAL SYSTEMSensorsSpeed Sensor Removal/Installation•Unscrew the mounting bolts [A] and remove the speedsensor assembly [B].•Unscrew the ca

ELECTRICAL SYSTEM 14-55Sensors•Rotate the waterwheel by hand slowly.•Measure the output voltage of the speed sensor.G/R (+), BK/W (–) → 0 ∼ battery vo

14-56 ELECTRICAL SYSTEMSensorsThrottle Sensor Inspection•Refer to Throttle Sensor Section in the Fuel System chap-ter.Water Temperature Sensor Inspect

ELECTRICAL SYSTEM 14-57Multifunction MeterDisplay Function Inspe c tion•Using the auxiliary wires, connect the 12 V battery [A] tothe meter unit [B] c

14-58 ELECTRICAL SYSTEMMultifunction MeterMODE/SET Button Inspection•Check that when the MODE button is pushed and heldcontinuously, the display rotat

ELECTRICAL SYSTEM 14-59Multifunction MeterFuel Level Gauge/Symbol/FUEL Characters/WarningLight Inspection•Connect the 12 V battery and terminals in th

14-60 ELECTRICAL SYSTEMMultifunction Meter•If the oscillator is not available, the speedometer can bechecked as follows.○Install the meter unit.○Turn

ELECTRICAL SYSTEM 14-61Multifunction MeterTachometer Inspection•Connect the 12 V battery and terminals in the same man-ner as specified in the “Displa

14-62 ELECTRICAL SYSTEMMultifunction MeterBuzzer Inspection•Make sure that the buzzer sounds correctly when turningthe ignition switch key to the “ON”

ELECTRICAL SYSTEM 14-63Multifunction Meter3. Buzzer4. Multifunction Meter5. Speed Sensor6. 20 A Main Fuse7. Joint Connector R8. Starter M otor9. Batte

PERIODIC MAINTENANCE 2-15Periodic Maintenance ProceduresEngine Top EndAir Suction Valve Inspection•Remove the air suction valve (see Engine Top End ch

14-64 ELECTRICAL SYSTEMRelay AssemblyRemoval•Remove the seat (see Hull/Engine Hood chapter).•Remove the rear storage pocket.•Remove:Relay Assembly Con

ELECTRICAL SYSTEM 14-65Relay AssemblyRelay Assembly Circuit Inspection (with the battery disconnected)Tester Connection Tester Reading (Ω)3-4 ∞ECU Mai

14-66 ELECTRICAL SYSTEMSwitchesSwitch Inspection•Using a hand tester, check to see that only the con-nections shown in the table have continuity (abou

ELECTRICAL SYSTEM 14-67FuseInspection•Remove:SeatFuse Case [A]•Take out the fuse [A].•Inspect the fuse element.If it blown out, replace the fuse. Befo

STORAGE 15-115StorageTable of ContentsPreparation for Storage ...

15-2 STORAGEPreparation for StorageDuring the winter, or whenever the watercraft will not bein use for a long period of time, proper storage is essent

STORAGE 15-3Preparation for Storage•Remove the fuel pump (see the Fuel System chapter).•Clean the fuel pump screen [A] (see Fuel System in Pe-riodic M

15-4 STORAGEPreparation for Storage•Reconnect the primary ignition coil lead connectors, not-ing the #1,#4 [A] and the #2, #3 [B] c oil c onnectors. T

STORAGE 15-5Preparation for StorageGeneral•Wash the engine compartment with fresh water and re-move the drain screw in the stern to drain the water. W

2-16 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Measure the valve clearance between the cam and thevalve lifter with a thickness gauge [A].Va

15-6 STORAGERemoval from StorageLubrication•Carry out all recommended lubrication procedures (seethe Periodic Maintenance chapter).General Inspection•

STORAGE 15-7Removal from StorageTest RunWARNINGDo not run the engine in a closed area. Exhaustgases contain carbon monoxide, a colorless, odor-less, p

APPENDIX 16-116AppendixTable of ContentsCable, Wire and Hose Routing ...

16-2 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-3Cable, Wire and Hose Routing1. Crossmember2. Cylinder Head Cover3. Throttle Cable4. Delivery Pipe5. Fix the throttle cable to the deliver

16-4 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-5Cable, Wire and Hose Routing1. Oil Cooler2. Cylinder Head3. Water Pipe4. Cylinder5. Oil Filter6. Oil Pan7. Battery (−) Cable8. Starter M

16-6 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-7Cable, Wire and Hose Routing1. Clamp2. Breather Hose (Cylinder Head ∼ Breather Case)3. Clamp Detail4. Position the clamp pinch heads as s

PERIODIC MAINTENANCE 2-17Periodic Maintenance ProceduresINLET VALVE C L EARANCE ADJUSTMENT CHART1. Measure the clearance (when engine is cold).2. Chec

16-8 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-9Cable, Wire and Hose RoutingRefer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapter.Install the clamp as sho

16-10 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-11Cable, Wire and Hose Routing1. Exhaust Manifold2. Exhaust Pipe3. Water Hose Point (Cooling Hose from the Output Cover)4. 30°5. Water Hos

16-12 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-13Cable, Wire and Hose Routing1. Right Rear Duct2. Right Bilge Hose3. Left Bilge Hose4. Left Rear Duct5. Left Water Box Muffler6. Position

16-14 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-15Cable, Wire and Hose Routing1. Position the clamp screw so that its head faces forward (JT1500-A1).Position the double spring clamp so t

16-16 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-17Cable, Wire and Hose Routing1. Air Suction Valve Hose (to Air Filter)2. Air Suction Valve3. Air Suction Valve Cover (Rear)4. Water Tempe

2-18 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresEXHAUST VALVE CLEARANCE ADJUSTMENT CHART1. Measure the clearance (when engine is cold).2. Chec

16-18 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-19Cable, Wire and Hose Routing1. Crankshaft Sensor Leads2. Grommet3. Crankshaft Sensor Cover (Reverse Side)4. Crankshaft Sensor5. Magneto

16-20 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-21Cable, Wire and Hose Routing1. Band2. Main Harness3. Rivet4. Washer5. See wire routing at bow.6. See wire routing at stern.7. Clamp8. Sp

16-22 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-23Cable, Wire and Hose Routing1. Crossmember2. Steering Position Sensor Leads3. Holder and Clamp4. Fuel Vent Hose5. Throttle Cable6. Band7

16-24 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-25Cable, Wire and Hose Routing1. Multifunction Meter Lead Connector (Blue and Yellow: JT1500-A1), (Blue and White: JT1500-A2 ∼)2. Buzzer L

16-26 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-27Cable, Wire and Hose Routing1. Regulator/rectifier2. ECU (Electronic Control Unit)3. Main Harness4. Clamp5. Electrical Parts Bracket6. T

PERIODIC MAINTENANCE 2-19Periodic Maintenance Procedures•Apply molybdenum disulfide oil to the valve lifters and ap-ply engine oil to the shims, and i

16-28 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-29Cable, Wire and Hose Routing1. Fuel Vent Pipe: Hook the pipe at the handlebar.2. Throttle Cable3. Buzzer Leads (Run the leads through th

16-30 APPENDIXCable, Wire and Hose Routing

APPENDIX 16-31Cable, Wire and Hose Routing1. 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 (

16-32 APPENDIXTroubleshooting GuideNOTE○This is not an exhaustive list, giving everypossible cause for each problem listed. Itis meant simply as a rou

APPENDIX 16-33Troubleshooting GuideFuel line cloggedInlet air pressure sensor troubleInlet air temperature sensor troubleEngine stalls easilyFuel pump

16-34 APPENDIXTroubleshooting GuideFuel to injector insufficient (DFI)Fuel tank air vent obstructedFuel line cloggedFuel pump trouble (DFI)Injector cl

APPENDIX 16-35Troubleshooting GuideOil pressure switch damagedWiring faultyO-ring at the oil passage in the crankcasedamagedBattery TroubleBattery dis

MODEL APPLICATIONYear Model Beginning Hull No.2004 JT1500-A1 KAW60001□3042005 JT1500-A2US-KAW50001□405□:This digit in the hull number changes from one

2-20 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Obtain a standard garden hose [A] and a garden hoseadapter [B] as shown.Garden Hose Fitting o

PERIODIC MAINTENANCE 2-21Periodic Maintenance Procedures•Leave the engine idle for several minutes with the waterrunning.•Turn off the water. Leave th

2-22 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresPump and ImpellerImpeller Inspection•Examine the impeller. [A]If there i s pitting, deep scrat

PERIODIC MAINTENANCE 2-23Periodic Maintenance ProceduresSteering Shaft [B]Hull/Engine HoodDrain Plug Inspection•Check the drain plugs [A] for cracks o

2-24 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Check that the battery terminals [B] are not corroded.If necessary, remove the battery (see E

PERIODIC MAINTENANCE 2-25Periodic Maintenance Procedures•Lubricate the following with grease.○Pull the throttle lever and hold it.Throttle Cable End a

STX-15FJET SKI®WatercraftService ManualAll rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, ortransmitte

2-26 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Lubricate the following with a penetrating rust inhibitor [B].Throttle Cable [A]Steering Nozz

PERIODIC MAINTENANCE 2-27Periodic Maintenance ProceduresAll Hoses, Hose Clamps, Nuts, Bolts and Fasteners CheckNuts, Bolts, and Fasteners Tightness In

2-28 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Make sure the above hoses are routed properly and se-cured with the clamps away from any movi

PERIODIC MAINTENANCE 2-29Periodic Maintenance ProceduresRubber Strap Inspection•Check the following rubber straps for any deterioration ordamage. Pull

FUEL SYSTEM (DFI) 3-13Fuel System (DFI)Table of ContentsFuel System Diagram ... 3-3Exploded View...

3-2 FUEL SYSTEM (DFI)Throttle Lever, Cable and Case... 3-65Free Play Inspection ... 3-65Throttle Cable Adjustment ... 3

FUEL SYSTEM (DFI) 3-3Fuel System Diagram1. Fuel Pump2. Clamps (JT1500-A1 Model)Double Spring Clamps (JT1500-A2 Model ∼)(Installation Procedure: Pull u

3-4 FUEL SYSTEM (DFI)Exploded View

FUEL SYSTEM (DFI) 3-5Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Vehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb2 Bracket Mounting Bo

LIST OF ABBREVIATIONSA ampere(s) lb pound(s)ABDC after bottom dead centermmeter(s)ACalternating currentminminute(s)ATDC after top dead centerNnewton(s

3-6 FUEL SYSTEM (DFI)Exploded View

FUEL SYSTEM (DFI) 3-7Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Oil Pressure Switch 15 1.5 11 SS2 Fuel Filler Tube Clamp Screws 2.9 0.30 2

3-8 FUEL SYSTEM (DFI)Exploded View

FUEL SYSTEM (DFI) 3-9Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Air Filter Mounting Bolts 9.8 1.0 87 in·lb2 Air Filter Bracket Mounting Bo

3-10 FUEL SYSTEM (DFI)SpecificationsItem StandardDigital Fuel Injection SystemIdle Speed 1 300 ±100 r/min (rpm) -both in and out of waterThrottle Assy

FUEL SYSTEM (DFI) 3-11SpecificationsItem StandardThrottle Lever and CablesThrottle Lever Free Play about 2 mm (0.08 in.)

3-12 FUEL SYSTEM (DFI)Special Tools and SealantOil Pressure Gauge, 5 kgf/cm²:57001-125Hand Tester:57001-1394Needle Adapter Set:57001-1457Fuel Pressure

FUEL SYSTEM (DFI) 3-13DFI Parts Location1. Fuel Injector #12. Fuel Injector #23. Fuel Injector #34. Fuel Injector #45. Inlet Air Pressure Sensor6. Inl

3-14 FUEL SYSTEM (DFI)DFI Parts Location14. Ignition Switch15. Meter Unit16. Buzzer17. Fuel Pump18. Fuel Level Sensor19. Vehicle-down Sensor20. Igniti

FUEL SYSTEM (DFI) 3-15DFI Parts LocationDummy Page

MAINTENANCE AND ADJUSTMENTSMaintenance, replacement, or repair of the emission control devices and systems maybe performed by any marine Sl engine rep

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

FUEL SYSTEM (DFI) 3-17DFI SystemPart Name1. Fuel Injector #12. Fuel Injector #23. Fuel Injector #34. Fuel Injector #45. Joint Connector H6. Inlet Air

3-18 FUEL SYSTEM (DFI)DFI SystemTerminal Nu mbers of ECU ConnectorsTerminal Names1. Tachometer Signal2. ECU Main Relay3. Unused4. SLO (Smart Learning

FUEL SYSTEM (DFI) 3-19DFI Servicing PrecautionsThere are a number of important precautions that shouldbe followed servicing the DFI system.○This DFI s

3-20 FUEL SYSTEM (DFI)DFI Servicing PrecautionsFor JT1500-A2 ∼;○Install the double spring clamp in the position as shown,and securely pull up the clam

FUEL SYSTEM (DFI) 3-21DFI Servicing Precautions○After measurement, remove the needle adapters and ap-ply silicone sealant to the seals [A] of the conn

3-22 FUEL SYSTEM (DFI)Self-DiagnosisSelf-diagnosis OutlineThe self-diagnosis system has two modes and can beswitched to another mode.[A]Pushthe“SET”bu

FUEL SYSTEM (DFI) 3-23Self-DiagnosisService Code (Character) TableServiceCode(used inECU)Service CodeCharacter(displayed onMeter Unit)Possible Problem

3-24 FUEL SYSTEM (DFI)Self-DiagnosisNote:(1) D-J Method: the DFI control method from medium to heavy engine load. When the engine loadis light like at

FUEL SYSTEM (DFI) 3-25Troubleshooting the DFI SystemSample Diagnosis SheetRider name:Registration No. (license plate No.): Year of initial registratio

ForewordThis manual is designed primarily for use bytrained mechanics in a properly equipped shop.However, it contains enough detail and basic in-form

3-26 FUEL SYSTEM (DFI)Troubleshooting the DFI System□ spark plug loose (tighten it).□spark plug dirty, broken, or gap maladjusted (remedy it).□ spark

FUEL SYSTEM (DFI) 3-27Throttle Sensor (Service Code/Character-11/tPS)Throttle Sensor Removal/AdjustmentCAUTIONNever drop the throttle sensor [A], espe

3-28 FUEL SYSTEM (DFI)Throttle Sensor (Service Code/Character-11/tPS)•Adjust the throttle sensor positioning as follows.○Install the air filter tempor

FUEL SYSTEM (DFI) 3-29Throttle Sensor (Service Code/Character-11/tPS)•Turn the ignition switch ON and push the lanyard key un-der the stop button.•Pus

3-30 FUEL SYSTEM (DFI)Throttle Sensor (Service Code/Character-11/tPS)Output Voltage Inspection•Measure the output voltage at the ECU in the same wayas

FUEL SYSTEM (DFI) 3-31Throttle Sensor (Service Code/Character-11/tPS)•Disconnect the throttle sensor connector and connect thesetting adapter [A] betw

3-32 FUEL SYSTEM (DFI)Throttle Sensor (Service Code/Character-11/tPS)1. ECU2. Joint Connector E3. Throttle Sensor

FUEL SYSTEM (DFI) 3-33Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)CAUTIONNever drop the sensor, especially on a hard surface.Such a shoc

3-34 FUEL SYSTEM (DFI)Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)If the reading is within the standard range, and check theinput voltag

FUEL SYSTEM (DFI) 3-35Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)If the output voltage is far out of the usable range, checkthe output

NOTE○This note symbol indicates points of par-ticular inte rest for more efficient and con-venient opera tion.•Indicates a procedural step or work to

3-36 FUEL SYSTEM (DFI)Inlet Air Temperature Sensor (Service Code/Character-13/AIrt)Inlet Air Temperature Removal/InstallationCAUTIONNever drop the sen

FUEL SYSTEM (DFI) 3-37Inlet Air Temperature Sensor (Service Code/Character-13/AIrt)If the output voltage is out of the specified, check the ECUfor its

3-38 FUEL SYSTEM (DFI)Inlet Air Temperature Sensor (Service Code/Character-13/AIrt)1. ECU2. Joint Connector E3. Joint Connector H4. Inlet Air Temperat

FUEL SYSTEM (DFI) 3-39Water Temperature Sensor (Service Code/Character-14/AqUt)Water Temperature Sensor Removal/InstallationCAUTIONNever drop the sens

3-40 FUEL SYSTEM (DFI)Water Temperature Sensor (Service Code/Character-14/AqUt)•Connect a digital voltmeter [A] to the ECU c onnector [B],with the nee

FUEL SYSTEM (DFI) 3-41Water Temperature Sensor (Service Code/Character-14/AqUt)1. ECU2. Joint Connector E3. Water Temperature S ensorSensor Resistance

3-42 FUEL SYSTEM (DFI)Crankshaft Sensor (Service Code/Character-21/CrAg)Crankshaft Sensor Removal/Installation•See the Ignition System section in Elec

FUEL SYSTEM (DFI) 3-43Camshaft Position Sensor (Service Code/Character-23/CAAg)Camshaft Position Sensor Removal/InstallationThe camshaft position sens

3-44 FUEL SYSTEM (DFI)Vehicle-down Sensor (Service Code/Character-31/dOS)This sensor has a weight [A] with two magnets inside, andsends a signal to th

FUEL SYSTEM (DFI) 3-45Vehicle-down Sensor (Service Code/Character-31/dOS)Vehicle-down Sensor Inspe ctionNOTE○Be sure the battery is fully c harged.•Re