200 Series Jet Operators Manual
Contents
1. 44 N S 44 G Q NN OQ KODIAK JET OPERATOR S MANUAL MODEL NUMBERS FOR 100 SERIES KODIAK JETS Due to rearrangement of jet model numbers we are now using the following to improve the identity of each jet MODEL NO 157 STAGE IMPELLER 2NP STAGE IMPELLER IF USED 312 STAGE IMPELLER IF USED 130 3 Stage Jet Model 1 Pozzi Nozzle 1 Overlap Impeller 2 Standard Impeller 3 Coarse Impeller 102 102mm Diameter Nozzle 30 KODIAK MARINE ENGINE AND JETDRIVE LIMITED WARRANTY EFFECTIVE FEBRUARY 1 2002 KEM Equipment Inc the Company warranties each new KODIAK MARINE engine Jetdrive and factory installed accessories properly registered with KEM to be free from defects in material and workmanship The warranty shall commence after receipt of a properly completed Warranty Registration at the factory on the date of the first retail purchase and extends to original and subsequent purchasers However in no event shall the duration of this Warranty exceed two 2 years measured from the original retail sale date All subsequent purchasers must inform KEM in writing and with a payment of 50 00 transfer fee of the sale of the engine or jet to continue the warranty If notification is not received by KEM within 15 days of the resale the warranty will be null and void In t2. CD OPT A R OPT N D I I S N OQ OPT A R OPT K700621 TRANSOM SEAL 1 K700623 INS BUSHING 12 K700624 TRANSOM SPRING 1 KODIAK JET OPERATOR S MANUAL K700631 SPLASH GUARD OPT K700752A SIZE SMALL TILT TRIM POZZI NOZZLE OPT K700753A SIZE LARGE TILT TRIM POZZI NOZZLE OPT K700755A SIZE SMALL POZZI NOZZLE OPT K700756A SIZE LARGE POZZI NOZZLE OPT K701300 DRIVELINE 1 K701401 BAR MOUNT 1 K701402 FLEX MOUNT 2 K702319 MAIN INTAKE HOUSING 1 K702320 INSPECTION COVER 1 K702326 STATOR HOUSING 2 K702326A STATOR HOUSING ASSEMBLY OPT K702331 TRANSOM PLATE 1 K702603 SEAL PLATE 1 K703113 INTAKE GRATE 1 K703174 BUCKET 1 K703182 SUPPORT OPT K703358 TAIL PIPE HOUSING 1 K703376 HOUSING NOT SOLD SEP K703376A BEARING HOUSING ASSEMBLY 1 K703409 HOUSING 1 K704707 96MM STD NOZZLE A R K704708 108MM NOZZLE A R K704709 115MM NOZZLE A R K704710 DEFLECTOR A R K704711 DEFLECTOR A R 27 A R A R A R A R A R OPT OPT OPT OPT OPT A R A R A R A R A R K704712 A R K710107 0 K710116 4 K710117 0 K710117A 0 K710202 0 K710302 0 K710523 0 K710553 0 K720107 0 K720117 0 K720117A 0 K720202 0 K720302 0 K720402 2 K720403 2 K720523 0 K720555 A R K720556 2 K721102
3. Distributors dealers and service providers are not agents for KEM The company s obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective parts and does not authorize any person to create for it any obligation of liability in connection with this product nor does the company assume any obligation due to incorrect or defective installation by the dealer 31 11 All incidental and or consequential damages are excluded from this warranty Implied warranties are limited to the life of this warranty All implied warranties including merchantability fitness for a particular purpose or otherwise are disclaimed in their entirety after expirations of the appropriate two 2 year warranty period This warranty gives you specific rights and you may also have other rights which may vary from state to state 12 reserves the right to change or improve design of any product previously assembled without notice and without obligation 13 In the event that a warranty claim is required outside of the continental United States with the exception of Alaska and Hawaii there may be additional charges to the engine owner KEM will not warranty any engine or jet sold outside the continental United States with the exception of Alaska and Hawaii unless competent and trained personal are available to provide service to the engine or jet ENGINE AND JET IDENTIFICATION Engines and Jets are
4. 10 KODIAK JET OPERATOR S MANUAL Grease Quality To help achieve proper equipment performance and durability it is important that you use only grease of proper quality in your equipment Proper quality greases also provide maximum efficiency Use Shell Alvania EP2 or grease that meets KODIAK Jet specifications and NLGI grade 2 It is best not to mix different brands of lubricants because sometimes they are not compatible and deteriorate when mixed together Stay with one brand and weight to ensure compatibility Greasing the Spicer Shaft drive line Annually minimum Remove engine cover Inspect the driveline Ensure that there is grease smeared on the drive line Coat the driveline with grease on a periodic basis annually as a minimum apply only a minimal amount DO NOT BE EXCESSIVE Greasing the Universal Joint Spicer Every 50 hours minimum WARNING ONS Never grease a bearing with the equipment operating Remove engine cover 2 Clean the grease fitting on U joint 3 Ensure that grease gun fitting is clean and free of contaminants CAUTION Do not overfill Using too much grease may cause grease spattering on enclosure 4 Place the grease gun fitting and add grease apply only minimal pressure DO NOT OVERFILL 5 Remove the grease gun and clean grease fitting and associated surfaces Greasing the Thrust Bearing Every 25 hours minimum WARNING Never grease a bearing with the equipmen
5. KODIAK JET OPERATOR S MANUAL POST DELIVERY INSPECTION Your KODIAK jet was inspected before leaving the factory However the pre operational inspection must be made before putting the jet into operation 1 Remove engine hatch cover and let compartment air out for ten minutes WARNING Ensure key is not in the ignition and no electrical equipment is energized prior to any engine check or operation Do not energize engine prior to performing the following steps m D Ensure that no electrical equipment is energized Check engine oil level remove dipstick wipe clean and recheck Inspect oil filter check for tightness snug Check coolant level ensure fluids are at the proper levels Check for oil coolant and fuel leaks Correct any leaks prior to proceeding any further Check charge and fluid level of battery Inspect connections for corrosion and clean as necessary Check air cleaner ensure that it is clean or replace as necessary Inspect the exterior of the heat exchanger clean if necessary Check alternator belt adjust if necessary Check engine for loose bolts nuts or any loose pieces Inspect the exterior of the jet clean if necessary Check for any water leakage Ensure thrust bearing is greased refer to page 11 greasing the thrust bearing Check jet for loose bolts nuts or any loose pieces Start bilge fan let fan run for ten minutes Replace engine cove
6. Prior to starting ensure no one is standing near the equipment Ensure all safety guards are in place prior to starting the engine Ensure all tools have been removed after repairs prior to starting engine OO ONS KODIAK JET OPERATOR S MANUAL HOW TO USE THIS MANUAL We wrote this manual especially for you We hope you use it to get to know your equipment and how to get the most out of it That is why we urge you to read this manual from cover to cover First you will become familiar with the various controls and instruments As you read further we will tell you how to take care of your equipment and what services need to be performed to keep it in excellent running condition The table of contents will assist you to quickly locate any subject in the manual The description and specification contained in this manual were in effect at the time it was approved for printing KODIAK reserves the right to discontinue models at anytime or to change specifications or design without notice and without incurring obligation PARTS AND SERVICE Replacement parts can be obtained through your local KODIAK dealers KODIAK dealers are equipped to perform major and minor repairs They are anxious to see that all of your maintenance and service needs are quickly and courteously completed A service manual can be purchased from your distributor or dealer This publication will provide the necessary servicing and overhaul information for your KODIAK
7. 505 ET 700120 23 50616150 UPS65 0 e a il K708313 CT Jm 18 LOLOELX SIS 82100434 1010243 51 2 95 sqnL adTA 1010143 515 L LLLOLLM 515 L 340 32948 8 6 80848 ENIAM O Q 02004 Ay L a 51880 1 3 50200 N9 L9OSHN 951872090 5020043 8518710830 0200 3 6butysng 0 00 3 4 cua 0Z002 2815043 2060643 51 2060243 915 2060 3 DIS 020043 7108 21 4812 9 BSEEOLA 211912499902 7797298521 0520150501 2650043 6092043 9 62 0900 7 61 204 misos BLSOSHN Aana 926204 e 1918 608 Kipa s e II 7 9 6010018 avd LIXIN TAS 54191905 4 N9 1905 0262043 ZOZOELY 51 2020243 ALS ZOZOLLY SIS L 19 0050027 X LPASZAXO 529190518 0150015 VOLEEOLY SLEOSLLESO 0 x 1 ma 6050044 l X 60511950 x N9190SHN 0 X 80 PZSOOLM 215044 cosooz3 ZSOELM 215 x 4 6250243 OLS AGY 05004 351 J 9IZISHN 6260012 3 2 6550142 23 15 2 B 15650013 7090213 OW 6150018 209001 35 xd pas SSSOZZA 2 7011742 7750047 x 20 661701183
8. A R K721103 OPT K730107 2 K730117 4 K730117A 2 K730202 1 K730302 1 K730523 1 KM2054 1 DEFLECTOR WATER TUBE STUD 5 16NC x 1 3 4 STUD STUD STEERING SHAFT BUCKET SHAFT MAIN SHAFT SINGLE STAGE BEARING SLEEVE WATER TUBE STUD STUD STEERING SHAFT BUCKET SHAFT STATOR HOUSING INSULATOR STATOR HOUSING WEAR RING MAIN SHAFT 10 DEGREE PITCH IMPELLER BEARING SLEEVE 22 DEGREE PITCH IMPELLER 23 DEGREE PITCH IMPELLER WATER TUBE STUD STUD STEERING SHAFT BUCKET SHAFT MAIN SHAFT KODIAK STICKER 28 A R A R A R OPT A R A R A R OPT NHS0518F 44 NHS0518N 8 NHS0616N 2 SS HEX NUT 5 16 NC SS NYLOC NUT 5 16 NC SS HEX NUT 3 8 NC KODIAK JET OPERATOR S MANUAL NHS0624F NSH1216F ORB0734139 ORB0748158 ORB2484139 ORB2984139 ORB4475210 ORB7734139 OSB1750375 SSS0420038 WLS05 WLS06 WLS07 WPF3407506 WPS05 WPS06 WPS10 WPS10 THIN WPS12 WPS3108875 WPS3906907 55 3 8 SS 3 4 O RING WATER 211 O RING SHAFT 210 O RING SEAL FACE HOUSING 230 O RING LOC RING BEARING 234 O RING INSPECTION COVER 349 O RING STATOR HOUSING 265 OIL SEAL 1 3 4 SS SET SCREW LOCKWASHER 55 5 16 LOCKWASHER SS 3 8 LOCKWASHER SS 7 16 FIBRE WASHER WASHER SS PLAIN 5 16 WASHER SS PLAIN 3 8 WASHER SS PLAIN 5 8 WASHER 5 8 WASHER SS PLAIN BRASS FLAT WASHER WASHER 29 I N T N
9. 14 15 Adjustment Repaairl J 16 Clearing The Intake Grate a 16 Parts List Introduction J u J J 17 General 17 masita 18 25 Parts u ia A da gt za 26 28 Model Number Formart J J J J 29 Statement Of Limited Warranty 30 32 KODIAK JET OPERATOR S MANUAL INTRODUCTION We are pleased that you have selected a KODIAK jet to serve your needs KODIAK takes pride in the long tradition of quality products and great values that the name represents in the marine industry Every effort is made to maintain our reputation as the builder of the finest marine equipment of its kind The primary purpose of this document is to provide operating periodic maintenance and parts information for your new KODIAK jet KODIAK jets are tested and inspected before leaving the factory However certain checks should be made before putting your jet into regular operation Read and perform the Post Delivery Inspection prior to proceeding to any actual operation Please take a minute to fill out your warranty registration card SAFETY SUMMARY Anyon
10. Dealers failing to follow the parts return procedures will only slow down the processing of the claim 237 Warranty parts requiring return to KEM will be shipped to the dealer with a returned authorization form The papers are to be filled out completely and returned attached to the defective part Parts damaged due to improper packing will be returned to the sending dealer and the warranty claim rejected If a part is received from KEM an RGA number is included with the shipment This number must be affixed to the outside of the shipping container when the part is returned to KEM Return defective part with a copy of the claim inside the box so proper credit can be made ENGINE AND JETDRIVE RETURNS All engines and jetdrives being returned to KEM use the following procedure 1 2 3 4 Drain all lubricants and fluids If engine is in a running condition it should be fogged with rust preventative oil to prevent further damage Fasten the engine properly to the shipping skid Failure to follow these procedures could result in the rejection of a warranty claim CLAIM REJECTION Any warranty claim rejected will be returned to the dealer with the reason for rejection noted on the claim Claims may be rejected for the following reason 1 2 3 4 5 6 7 8 9 1 Invalid engine serial number Claim form not completed in its entirety No supporting invoices of documentation Work not covered by warranty Out of warra
11. airing from installation applications exhaust to engine fuel lines to the engine propping cooling to the engine or engine damage due to defective electrical hookups e Rust corrosion invasion effects of weather or electrolysis e Water invasion through exhaust e Detonation or operation with fuels oils or lubricants which are not suitable for use with this product Detonation causes poor fuel quality overloading of engine improper gear or propeller selection engine overheating excessive back pressure incorrect ignition timing excessive total timing e Reimbursement for haulout launch towing storage charges rental charges of any type inconvenience of any type loss of time or income expense of returning a KEM product to a service facility towing lodging loss or damage to personal property e Carburetor after the first five 5 hours of operation Fuel air and float adjustments are part of the installation Reasonable access must be provided to the product for warranty service Removal and or replacement of boat partitions or material because of boat design for necessary access to the product is not covered Warranty service must be requested by delivering the product for inspection to the retailer from whom the product was purchased or any convenient marine service center Proof of warranty must be provided at time of request for warranty service A properly completed warranty registration must be on file with KEM
12. and turn it slowly counterclockwise to the first stop When pressure has been completely released push down on cap and remove Allow the engine to cool down When engine has cooled down check the oil level add oil if necessary Check coolant level CAUTION Do not add coolant until engine has returned to a normal temperature Add coolant slowly until heat exchanger is full Ensure ignition switch is in OFF position Remove ignition key from ignition 0 Close fuel supply valve OO KODIAK JET OPERATOR S MANUAL DIAGNOSIS Detailed Jet Troubleshooting FAULT 1 Water leakage around thrust bearing on thrust face 2 High pitched whine rattle or vibration bearing 3 Excessive vibration bearings or universal 4 Poor acceleration performance running at impellers worn or progressively higher RPM s to maintain the same leading edges or too performance between impeller tips and stator housing 5 Instantaneous increase RPM s no change tachometer check performance etc 6 High RPM s noisy operation highly aerated clogged check water from jet necessary Foreign wrapped around shaft obstruction installed incorrectly may be caused by CAUSE 1 Damaged seal 2 Damaged thrust 3 Damaged joints 4 Damaged damaged much clearance b Damaged sender wiring 6 Intake screen And clear if material clear shaft Impeller s reversed
13. operation beyond the limits of the product All preparation cost for the removal of the engine Boat builders must give reasonable access to the engine for repair Tune ups adjustments cleaning of boat or fuel system components Failure due to poor fuel or lubricant quality of failure to perform the recommended maintenance All transportation or toll charges Damage or loss due to shipping and handling All engines are shipped FOB Any claims for damage are to be made directly to the freight company by the distributor dealer or customer Electrical components due to the reversing of polarity Damage due to water invasion or detonation Registering a product for pleasure use when being used for commercial 1 34 35 36
14. 0 IZSOOLX ecrverzauo 506 50616 K 20519 62 75 Pues UC 5 BH N AWL N DA Ta N wo O gt SS 159 MAIN 0517 OQ N m 1 NAN O LO S 59 12 12 KE 1 7 00 00 21 K700601 17006011 thick 23 Engine Hount Kit K703409 701467 SN NS K701401 627 WPS10 a 0 WPS06 O lt WPS 0 NHS0624F 91 506 Lock Washer 24 7200624 Transom Spring K70G623 ins bushing 401506 Fiber Washer ee 805 Washer 50 Bolt Hurt 790824 1 778 10227 25 KODIAK JET OPERATOR S MANUAL PART NUMBER 125HBL 12 12 125HBL 6 4 129HB 6 4 218P 12 B S0518147 B S0616175 BCS0518250 BHS0518100 BHS0518150 BHS0518200 BHS0616150 BHS0616275 BHS0616350 BHS1011175 BSM07C125 K700109 K700120 K700128 K700203 K700204 K700205 K700205A K700206 K700207 K700303 K700305 K700306 K700307 K700309 K700312 K700313 K700313A K700402 K700403 K700502 K700503 K70051
15. 2 K700515 K700517 K700518 K700519 K700521 K700522 K700524 3 K700525 K700551 K700552 K700553 K700554 K700601 K700601T DESCRIPTION HOSE BARB x 34 HOSE BARB 3 8 x 1 4 HOSE BARB 3 8 x 1 4 PLUG HEX HEAD SS STUD 5 16 x 1 1 2 LNG TAILPIPE NOZZ SS STUD 3 8NC x 1 3 4LNG INSP COVER C SUNK SS BOLT 5 16NC x 2 1 2LNG SS HEX BOLT 5 16NC x 1 LNG SS HEX BOLT 5 16NC x 1 1 2LNG SS HEX BOLT 5 16NC x 2LNG SS HEX BOLT 3 8NC x 1 1 2LNG SS HEX BOLT 3 8NC x 2 3 4LNG SS HEX BOLT 3 8NC x 3 1 2LNG SS HEX BOLT 5 8NC x 1 3 4LNG SKT HD CAP SCREW 7 16 x 1 1 4 FEET PLASTIC TUBING ZINC ANODE WATER TUBE SPRING NYLON BUSHING STEERING CRANK TAPER PIN TAPER PIN ASSEMBLY SHORT BUSHING PIVOT PIN REVERSE CRANK REVERSE CRANK ROLLER REVERSE YOKE BUSHING BUCKET ECCENTRIC REVERSE BUCKET PIVOT SLEEVE SPRING BRACKET BUCKET SPRING COTTER PIN INSULATOR 1 STAGE WEAR RING 1 STAGE MAIN SHAFT NUT OIL SEAL SPACER GREASE FITTING BEARING NOT SOLD SEP LOCATING RING SLINGER SEAL FACE HOUSING MECHANICAL SEAL COTTER PIN IMPELLER KEY SS END NUT WASHER STD OVERLAP IMPELLER CUTLESS BEARING BEARING SLEEVE IMPELLER FAIRING INTAKE GASKET STD THICK INTAKE GASKET 26 PT N gt O PS N 5 N O 4 wor OPT A R OPT N IS D I I S
16. ET OPERATOR S MANUAL PARTS LIST INTRODUCTION General Information This KODIAK Jet parts list has been prepared to assist the operator in identifying the jet parts for care maintenance and repair This section includes the illustrated parts breakdown with the part numbers showing Illustrations The illustrations show typical assemblies but do not attempt to show all styles of the parts in each case Some special optional parts will not be seen If you do not see a part on your KODIAK Jet contact your KODIAK dealer with the model and serial number of your unit and a complete description of the part Parts Information Each listing contains illustrations reference and part numbers of the individual parts used in each model 100 series jet to identify the correct part Starting on page 26 is a list of the reference numbers with part number description and quantity used per jet model NOTE The descriptions and specifications contained in this manual were in effect at the time the manual was released for printing KODIAK Marine reserves the right to discontinue models at any time or change specifications or design without notice and without incurring obligation 17 HHS0S18F BHS1011175 uLS0S gt 0 50616150 L Q0a4 lt 00207 NHS 616N K708385 o K700309 10 THIN 700306 WPS 221 704710 04711 704712 700312 NHS S LF 0 4 505
17. Faults 2 3 4 cause 6 also KODIAK JET OPERATOR S MANUAL PERIODIC MAINTENANCE This section is divided into two parts Section one is a series of operations on how to perform individual checks on specific components Section two is a series of procedures to be performed on the intervals outlined at the top of each procedure Routine Service To ensure that your equipment is always ready to use perform the following tasks 1 Make frequent checks of the inlets and lines 2 Keep equipment clean 3 Ensure that there is nothing binding on the steering mechanism 4 Ensure that there is no binding on the shift mechanism The habit of performing the Operational Procedures is your best method of ensuring that these items are checked on a periodic basis Lubricant Checking Lubrication 1 Check lubrication frequently at least daily 2 Ensure lubrication schedule is maintained 3 Add grease as required 4 Do overfill Adding Grease It is normal to add some grease approximately every 10 hours of operation The amount will vary with the severity of operations When adding or replacing grease be sure it meets the specification requirements listed Operating Parameters For most operations the equipment must be greased every 25 hours No break in period is specified We recommend checking the thrust bearing and shaft spline during every operational check This should ensure that your will not miss any abnormal situation
18. KODIAK MARINE 200 SERIES JET 5 MANUAL KODIAK MARINE by KEM Equipment Inc 10800 S W Herman Road Km 7645 Tualatin OR 97062 Phone 503 692 5012 Fax 503 692 1098 kempower hotmail com www kemequipment com TABLE OF CONTENTS Description Paqe Introduction uu 1 Safety Summary u 1 How To Use This Manual JJ Ul u u U 2 Parts And Service UI ia a S i ed 2 Post Deliverv Inspection J J J J 3 Operational Instruction l u u u u u 4 5 Cold Engine Starting siieu easta 6 Stopping The Engine Normal Conditions 6 Stopping The Engine Abnormal Conditions 7 Troubleshootihnd aa 8 ENGIN Givi ny hve a a dee 8 e a a TEE 8 DIAGNOSIS a B l Jas 9 Periodic Maintenancce J J u J 10 Routine SOV ICC i 10 EUD et b a 10 13 INSPECTIONS idi d kiwa as B
19. Lubricate all linkage points and thrust bearing Check for loose bolts nuts or any loose pieces 10 Inspect the mechanical shaft seal 11 Check sacrificial anodes located on tail pipe 12 Start bilge fan let fan run for ten minutes Replace engine cover O 15 KODIAK JET OPERATOR S MANUAL ADJUSTMENT REPAIR There are only two repair or adjustment procedures for the operator to perform One is the adjustment of the bucket if when necessary and the other is clearing a blocked intake While there are not common mechanical problems they can be when the equipment is operated in an environment that may cause materials to block the intake or cause the bucket to go out of adjustment Clearing The Intake Grate During operation in rivers or other shallow water environments it is possible to clog or cover the intake grate with leaves sticks weeds or other waterborne materials To clear the screen in this situation perform the following task 1 Back down the throttle immediately and shut off the engine this should allow the materials to fall away because of a lack of suction 2 If this does cure the problem ensure the engine is shut down 3 Remove the blockage manually preferably using a screen rake available option CAUTION Ensure pump inspection cover is above the waterline prior to opening the inspection cover 4 Open inspection cover and clear the intake grate 16 KODIAK J
20. assigned a serial number history file is created for the engine or jet and all information regarding the engine or jet is put into the file The engine serial number is located on metal plate affixed to the engine jet serial number is located on the base of the jet The serial number of the engine or jet must be given in all communications concerning the engine or jet WARRANTY CLAIM POLICY Applicable engine warranty is to be followed in all warranty situations Under normal circumstances customers should bring any request for warranty to their selling dealer If the customer is in transit all efforts should be made by the dealer to remedy engine warranty problems the customer may have The dealer should always investigate the customers complaint and determine if a warranty situation does exist It is the dealer s responsibility to inform the user that minor adjustments tune ups detonation water ingestion from an outside source are not warrantable situations If it is determined that the situation is not warrantable the dealer should then resolve the problem in a professional and courteous manner TIME LIMIT FOR FILING CLAIMS Warranty claims must be filled out in their entirety and submitted within 30 days of the labor being performed PROCEDURE FOR DEFECTIVE PARTS RETURN Defective parts replaced under warranty are to be returned to KEM within 10 days of the labor being performed unless the dealer is notified otherwise
21. e involved in the operation of equipment shall be familiar with the material contained in the warnings cautions and notes These safety precautions are mandatory and are used to augment formal safety Coast Guard regulations Anyone operating this equipment should become thoroughly familiar with details of operations of the equipment Such knowledge constantly and properly practiced is the only method for ensuring safety and reliable and economical equipment operation Our approach to safety includes the use of warnings cautions and notes throughout the book WARNINGS Warnings are statements that call attention to a step which if not strictly followed could result in serious injury or death of personnel CAUTIONS Cautions are statements that call attention to a step which if not strictly followed could result in destruction of equipment NOTES Notes are essential statements which must be highlighted Please read and follow any and all specific warnings cautions and notes contained here and else where in the text Overall safety and equipment reliability depend on continuous observation of sound operating practices Always observe required scheduled maintenance activities as outlined Never attempt to correct problems or repairs for which you are not qualified Always STOP the engine before refueling Always STOP the engine prior to any inspection check or repair work Ensure that proper ventilation is maintained at all times
22. ergized prior to any jet check or operation Do not energize engine prior to performing the following steps Ensure that no electrical equipment is energized Check for leakage around seals Correct any leaks prior to proceeding further Check lubrication points Inspect connections for corrosion and clean as necessary Grease thrust bearing Clean surface of pump Check hose ensure that it is clean or replace as necessary Lubricate all linkage points and thrust bearing Check for loose bolts nuts or any loose pieces Check sacrificial anodes located on tail pipe 10 Start bilge fan let fan run for ten minutes Replace engine cover 14 KODIAK JET OPERATOR S MANUAL 50 HOUR INSPECTION Perform the following inspection on our Jet Pump at 50 hour intervals CAUTION Service equipment more frequently under severe dust environmental or operating conditions WARNING Ensure key is in ignition and no electrical equipment is energized prior to any engine check or operation Do not energize engine prior to performing the following steps Ensure that no electrical equipment is energized Check for leakage around seals Correct any leaks prior to proceeding further Check lubrication points Inspect connections for corrosion and clean as necessary Grease u joints Grease thrust bearing Clean surface of pump Check hose ensure that it is clean or replace as necessary
23. he case of commercial use this warranty shall be in effect for one year 360 days from the date of start up but longer than 450 days from the first date of retail purchase Replacement engines are warranted for 90 days from date of sale The company obligation is limited to repairing or replacing those parts defective in material and workmanship only At its option it may replace such part with a part of equal quality as shall be necessary to remedy any malfunction resulting from a defect in material or workmanship as covered in this warranty KEM will make all necessary repairs under this warranty free of charge at the KEM factory Optionally KEM may provide for the repair or replacement of any defective part at the selling dealership or a service center of KEM s choice KEM will make payment reimbursements for labor to replace such part as previously provided in the then current flat rate manual A no exception 100 deductible will apply to each warranty claim during the second year of the warranty period KEM distributors or service center must be advised of any warranty related problem prior to the expiration of the warranty This warranty will not apply to e Use of an accessories or parts not manufactured or sold by KEM Equipment Inc e Neglect failure to follow maintenance schedules accident abnormal operations misuse negligence improperly maintained improperly operated or installed racing or engine modification Problems
24. n NEUTRAL position Check jet for loose bolts nuts or any loose pieces Start bilge fan let run for ten minutes Replace engine cover Check bucket area ensure that there is nothing to impede movement Turn steering wheel ensure that there is nothing to impede movement Cycle bucket at least once up and down ensure that there is no binding KODIAK JET OPERATOR S MANUAL NORMAL START cold starting see page 6 CAUTION Ensure that jet drive is in NEUTRAL position 1 Advance throttle lever slightly 2 Turn ignition key switch to START position release when engine starts 3 After engine starts return throttle lever to idle position CAUTION If the engine stalls or falters in starting wait three or four seconds before re engaging starter This prevents possible damage to the starter or engine NOTE The starter shall not be operated for periods longer than 30 seconds Wait at least two minutes between cranking periods to protect the starter from overheating KODIAK JET OPERATOR S MANUAL Cold Engine Starting CAUTION Ensure that jet drive is NEUTRAL position Pump throttle lever one or two times one or two cycles in forward position Advance throttle lever slightly as in normal start Turn ignition key switch to START position release when engine starts After engine starts adjust throttle lever so that tachometer reads 900 1 000 RPM for engine warm up When engine warms up return throt
25. nderside of the tailpipe 2 Ensure that the anode is cleaned to a bright condition 3 Replace the anode when it is approximately 50 of its original size Ensure that area is clean dry and free of contaminants 12 KODIAK JET OPERATOR S MANUAL Inspecting the Mechanical Shaft Seal Every 50 hours semi annually minimum This check should be run on the first run up after installation and then on a periodic basis This shall be not less than once at the beginning of each season after 50 hours of continuous operation and prior to any lay up storage WARNING Ensure key is in ignition and no electrical equipment is energized prior to any jet check operation Do not energize engine prior to performing the following steps WARNING Never perform this inspection with the boat in the water Remove engine cover Remove inspection cover from jet unit Visually inspect seal area for fishing line or other debris Close inspection cover return boat to water and with engine cover open observe area below main jet drive bearing for leaks If a leak is present contact your nearest KODIAK dealer 43 KODIAK JET OPERATOR S MANUAL INSPECTIONS 25 Hour Inspection Perform the following inspection on your Jet Pump at 25 hour intervals CAUTION Service equipment more frequently under severe dust environmental or operating conditions WARNING Ensure key is not in ignition and no electrical equipment is en
26. nty period Returned part meets specifications Additional work done over that required to satisfy the warranty Job time over that of the flat rate Failure customer induced by bad fuel overrev insufficient water poor maintenance 0 Haul out and or lift out or removal of boat from water WARRANTY EXCLUSIONS The following services and expenses will not be reimbursed under the terms of the warranty 233 15 Carburetors are warranted for the first five hours of engine operation only 17 18 Use of replacement parts not manufactured or sold by KEM You must use KODIAK parts only Replacement of complete assemblies when the defective part could have been replaced to correct the problem Starter motors and or armatures o field coil assemblies which are returned or damaged because of excessive cranking or water Parts testing within specifications Parts will be returned and labor claim refused All sublet or outside repairs which are deemed reasonable claimed by the dealer will be reimbursed at dealer s actual cost Copies of the original invoice must accompany the claim Engine damage caused by Non KODIAK parts will not be allowed All incidental and or commercial damages not allowed by the warranty will be disallowed Expenses related to replacement of lubricant anti freeze or special additives will not be considered under the warranty Repairs due to neglect misuse accident improper application installation or
27. r Check bucket area ensure that there is nothing to impede movement Turn steering wheel ensure that there is nothing to impede movement Cycle bucket at least once up and down ensure that there is no binding bucket should cycle up and down using several fingers on the shifter KODIAK JET OPERATOR S MANUAL 1 OPERATIONAL INSTRUCTION Remove engine cover and air out for ten minutes WARNING Ensure key is not in the ignition and no electrical equipment is energized prior to any engine check or operation Do not energize engine prior to performing the following steps that electrical equipment is energized Check engine oil level remove dipstick wipe clean and recheck Inspect oil filter check for tightness snug Check coolant level ensure fluids are at the proper levels Check fluid level Check for oil coolant and fuel leaks Correct any leaks prior to proceeding further Check charge and fluid level of battery Inspect connections for corrosion and clean as necessary Check air cleaner ensure that it is clean or replace as necessary Inspect the exterior of the heat exchanger clean if necessary Check alternator belt adjust if necessary Check engine for loose bolts nuts or any loose pieces Inspect the exterior of the jet clean if necessary Check for any water leakage CAUTION Ensure that jet drive is i
28. t operating 1 Remove engine cover 2 Clean the grease fitting on thrust bearing 3 Ensure that the grease gun fitting is clean and free of contaminants CAUTION Do not overfill Using too much grease overfilling may cause premature seal failure on the bearing 11 KODIAK JET OPERATOR S MANUAL 4 Place grease gun fitting and add grease fitting and add grease apply only minimal pressure DO NOT OVERFILL 5 Remove the grease gun and clean grease fitting and associated surfaces Inspecting the Sacrificial Anodes zinc Every 25 hours minimum This check should be accomplished upon receipt and every 25 hours thereafter This shall be not less than once at the beginning of each season after 25 hours of continuous operation and prior to any lay up storage The zinc anode is specifically designed to protect your jet unit from spurious and induced cathodic degradation corrosion In order to perform its task efficiently you must keep the anode clean and bright an anode that has a powdery residue cannot perform efficiently WARNING Never perform this inspection with the equipment running This inspection would be most easily accomplished with the boat on the trailer or out of the water since it is a little difficult to view the underside of the tailpipe with the unit in the water CAUTION Do not lubricate or coat with any material Coating will interfere with catholic protection 1 Inspect the zinc anode on the u
29. tle lever to idle position gi NOTE The starter shall not be operated for periods longer than 30 seconds Wait at least two minutes between cranking periods to protect the starter from overheating Stopping The Engine Normal Conditions CAUTION Ensure that jet drive is in NEUTRAL position Place gear shift or bucket control lever in NEUTRAL position If the engine has been running at high RPM let it fun at fast idle 900 1 000 RPM for three to four minutes When engine has cooled down or returned to a normal operating temperature place throttle lever in idle position Turn ignition switch to OFF position Remove ignition key from engine Close fuel supply valve DOB B Ms KODIAK JET OPERATOR S MANUAL Stopping The Engine Abnormal Conditions CAUTION Ensure that jet drive is in NEUTRAL position 1 Place bucket control lever in NEURAL position 2 Turn ignition switch to OFF position WARNING Engine may continue to run after ignition switch is turned off If this happens turn the ignition switch immediately ON and allow the engine to idle until it has cooled enough to stop 3 Ifthe engine is overheated due to a loss of coolant it is best to stop the engine immediately If necessary by applying the load i e put the boat in gear WARNING Do not run engine out of water Damage to engine and jet will occur WARNING Avoid injury when checking a hot engine Cover heat exchanger with a thick cloth
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