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1. 8 16 Lower Crankcase Check Valve 8 17 Crankshaft 8 8 19 Connecting Rod Bend Twist e tp cede nu Ee RE RR RR YR Me Ern DEM 8 19 Connecting Rod Big End Radial Clearance 2 44 1000101 8 19 Connecting Rod Big End Side Clearance eene 8 20 Crankshaft Main tert tea e teet beoe 8 20 GrankshattRUnOUt uec eere eee val va Ee cH E eoe oed 8 20 8 2 ENGINE BOTTOM END Exploded View PAS J wd JH020188W5 C ENGINE BOTTOM END 8 3 Exploded View Torque No Fastener Nem ftlb Remarks 1 Flywheel Bolt 123 127 12 5 13 0 90 94 L 2 Stator Mounting Bolts 7 8 0 8 69 in Ib L 3 Balancer Drive Gear Mounting Bolts 12 1 2 8 7 L 4 Grommet Mounting Screws 3 5 0 36 31 in Ib L 5 Pickup Coil Mounting Screws 3 5 0 36 31 in Ib L 6 Coupling 123 127 12 5 13 0 90 94 L 7 Magneto Cover Mounting Bolts 12 1 2 8 7 L 8 Grommet Cover Mounting Bolts 8 8 0 9 78 in lb L 9 Oil Level Gauge Bolt 3 9 0 4 35 in Ib L Tein L S G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket MO Apply molybde
2. ERREUR eH 11 6 Ii lena MEET 11 7 P mp Disassembly x de ue eno Nets ete tede eta m iu uoi ee oca e 11 8 P fnpSSerbly io cn sec cet np roce aque tent opes Beer dee 11 10 Pump and Impeller Inspection Renee 11 14 Impeller Cleararice eer ec e Rr ERE E A d EO en ass 11 14 11 2 PUMP AND IMPELLER Exploded View 2 S 8 S PUMP AND IMPELLER 11 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Steering Nozzle Pivot Nuts 19 1 9 14 2 Tilt Ring Pivot Bolts 19 1 9 14 L 3 Cable Joint Bolts 9 8 1 0 87 in lb L 4 Pump Case Mounting Bolts 9 8 1 0 87 L 5 Pump Outlet Mounting Bolts 19 1 9 14 L 6 Pump Cap Bolts 9 8 1 0 87 in lb L 7 Impeller 98 10 72 8 Pump Mounting Nuts 36 3 7 27 9 Bracket Mounting Nuts 36 3 7 27 10 Cover Mounting Bolts 7 8 0 8 69 in lb E 11 Grate Mounting Bolts 9 8 1 0 87 L 12 Cable Joint 39 4 0 29 L 13 Tilt Ring Mounting Bolts L 35 mm 1 38 in L 14 Tilt Ring Mounting Bolts L 32 mm 1 26 in L 15 Stop Screws 3 2 0 33 29 in lb L 16 Pump Mounting Bolts 36 3 7 27 L 17 Pump Bracket Mounting Bolts 36 3 7 27 L 18 Plug 12 1 2 104 in Ib L HG Apply high grade water resistance grease Chevron Black Pearl Grease EP NLG12 or equivalent L Ap
3. JH08009BN2 e Apply molybdenum disulfide oil to the connecting rod big end bearings and the side washers e With a high flash point solvent clean off the mating surfaces of the crankcase halves and wipe dry e Check that the dowel pins A are in place e Place the crankshaft assembly B in the upper crankcase half OFit each position ring C of the bearings and each raised rib D of the oil seals into the grooves in the crankcase OFit the pins E of the bearing and labyrinth packing into the holes of the crankcase Olnstall the rear balancer gear G aligning a mark F on the balancer gear G with a mark H on the balancer drive gear I At this time push the bearing toward bow side J OPour 20 mL 1 2 cu in of 2 stroke oil into rear balancer room K e Set the bearing L for the front balancer gear pushing it toward stern side M ENGINE BOTTOM END 8 15 Crankcase Apply liquid gasket to the mating surface A of the lower crankcase half OWipe off any excess liquid gasket at the portions B indi cated in the figure NOTE OFinish the application of the liquid gasket within 30 min utes OTighten the case bolts just after finishing the application of the liquid gasket Special Tool Kawasaki Bond Liquid Gasket Black 92104 1062 e Install the lower crankcase half on the upper half o JH08006BN2 C 229 255 TA ec
4. 2 14 Trim Cable L bfFiCationis rere ete eee nee nitet teats tenets 2 15 Handlebar Pivot 2 15 Electrical Syste M E 2 16 Battery Charging Condition Inspection 0 1 2 16 Spark Plug 2 16 Spark Plug Adis elit orenen entes 2 16 spark Plug Gleanilig ca lode tesa ESS kita 2 17 C 2 17 All Hoses Hose Clamp Nuts Bolts and Fasteners 2 19 Nuts Bolts and Fasteners Tightness 2 2 19 Hose and Hose Connect 2 20 Rubber Strap Inspection 2 21 2 2 PERIODIC MAINTENANCE Torque and Locking Agent The following table list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or silicone sealant Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads SS Apply silicone sealant to the threads S Tighten the fasteners following the specified sequence Initial Torque for Temporal Tightening Fastener n
5. Multifunction Meter Multifunction Meter 38 18 9 18 4osueg 23 3uy wrap 3 i 4 18 DKI 9 18 9 18 LDKI 38 U 38 u 0 5 18 98 FH MA 9 18 8 dei as S SS 8 sS saz Z2 403199uU09 w a w a 0 0 nd fid Ad A9 193103 98 R A8 M 8 amp X8 2105095 2 38 18 38 18 4 18 8 18 Use usm 9 8 LZR 8 9 9 10399uUu09 40sueg 342 8 38 M 38 serves D A 9 u 9 Ase aris B 14 60 ELECTRICAL SYSTEM Switches Switch Inspection e Using an ohmmeter check to see that only the con nections shown in the table have continuity about zero ohms x If the switch has an open or short repair it or replace it with new one Ignition Switch OFF Start Switch Stop amp Tether Switch 1 STOP euro CODE BK w FREE SET Trim Switch JN10013B 5 ELECTRICAL SYSTEM 14 61 Fuse Inspection e Remove the fuse plug A e Take out the fuse A Filii i t T e Inspect the fuse element x lf it blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater tha
6. way replace it FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded 3 2 Pop off Pressure Inspection 3 20 Specifications 3 6 Fuel Pump Removal Installation 3 20 Fuel System Diagram 3 7 High Altitude Performance Throttle Control Cable 3 8 Adjustment 3 20 Carburetor Cable Adjustment 3 8 Flame 222 2 3 21 Oil Pump Cable Adjustment 3 8 Removal rrenen 3 21 Throttle Case and Throttle Control 3 22 Cable Removal 3 8 Flame Arrester Cleaning 3 22 Throttle Case and Throttle Control Inlet Manifold Reed Valves 3 23 Cable Installation 3 9 Inlet Manifold Removal 3 23 Throttle Control Cable Lubrication 3 10 Inlet Manifold Installation 3 23 Throttle Control Cable Inspection 3 10 Reed Valve Inspection 3 24 Smart Steering Cable 3 11 Valve Holder Inspection 3 24 Cable Removal 3 11 Valve Stop Inspection 3 24 Cable Installation 3 11 Fuel Vent Check Valve 3 25 Choke Cable 3 12 Fuel Vent Check Valve Mounti
7. JC13000BS1 C 3 26 FUEL SYSTEM Fuel Tank Fuel Tank Removal e f the level of the fuel is above the filler neck siphon some fuel out to prevent spilling it Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the engine e Remove the oil and fuel inlet tubes e Remove or disconnect Straps A of Fuel and Oil Tanks Oil Tank B Crossmember Fuel Level Sensor Lead Connector C Fuel Hoses D Air Vent Hose E e Move the fuel tank A backward and pull out the fuel level sensor assembly B e Remove the fuel tank A out of the engine compartment FUEL SYSTEM 3 27 Fuel Tank Fuel Tank Installation e Connect them correctly see Cable Wire and Hose Rout ing in the Appendix chapter Fuel Hoses Air Vent Hose Fuel Level Sensor Lead Connector Other Wire and Harness Fuel Tank Cleaning e Remove the fuel tank see Fuel Tank Removal e Drain the tank into a suitable container Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or spark this includes any appliance with a pilot light
8. Special Tool Hand Tester 57001 1394 JN10023BS1 C JN10024BS2 C ELECTRICAL SYSTEM 14 51 Sensors Inlet Air Temperature Sensor Inspection e Remove the inlet air temperature sensor e Suspend the sensor A in a container of water e Suspend an accurate thermometer B in the water NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently e Using the hand tester measure the internal resistance of the sensor at the temperatures shown in the table If the hand tester does not show the specified values re place the sensor Inlet Air Temperature Sensor Resistance Water Temperature Sensor Resistance 10 C 50 F approx 3 74 20 C 68 F approx 2 47 JN10025BS2 50 C 122 F approx 0 833 kO 70 C 158 F approx 0 448 Special Tool Hand Tester 57001 1394 14 52 ELECTRICAL SYSTEM Multifunction Meter Display Function Inspection e Using the auxiliary wires connect the 12 V battery A to the meter unit B connector as follows OConnect the battery positive terminal to the terminal 1 OConnect the battery negative terminal to the terminal 5 1 Battery 2 Oil Level Sensor 3 Fuel Level Sensor 4 Ignition Switch 5 Ground 6 Diagnosis Signal
9. e Examine the pump case A x If there are deep scratches inside the pump case replace it 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedure Steering Steering Cable Inspection e Examine the steering cable x If the cable or cable housing is kinked or frayed replace the cable x If the seal A at either end of the cable is damaged in any way replace the cable e Be certain that the cable moves freely in both directions e Disconnect the cable joint A at each end of the cable OTake out the cable joint bolt B and disconnect the cable joint CAUTION Never lay the watercraft on the right side Water in the exhaust system may drain back into the engine causing serious damage OSlide the inner cable back and forth in the cable housing x If the cable does not move freely replace it Steering Cable Lubrication NOTE OThe steering cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced Trim Cable Inspection e Examine the trim cable xIf the cable or cable housing is kinked or frayed replace the cable with the motor box x If the seal at either end of the cable is damaged in any way replace the cable with the trim actuator e Check the boot A on the trim cable for hardening crack ing checking cuts abrasious and breaks x If boot is damaged in any way replace it PERIODIC MAINTENANCE 2
10. BK W BL R zl 5 m vs T Ignition I BK BL Coil L Spark Plug BK Y BK Y BK BL BK BK Bek gt BL R BL R G BK W R Y R Y Y R Y R BK BK BK gt BL BL 6 Y BK BK W BK W BK ir BK 1 BK p G R BK W Pu PU 9 9 Y BK Y BK R R W Crankshaft 6 Sensor a ae S BK Y f Y Y Electric Case R R BL R ll R BK BK R BK ll BK W Regulator BK Rectifier Y R Y R Battery eS BK Motor Unit Y G W BL Y BL Y BL W W R DO y BL R BL R DO BL R q u BK BL BK BK y R G R BK R BK R BK W BK W BK W BL Trim Angle Sensor Trim Motor Box W2R3704CW5 14 12 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Electric Starter System Starter Motor Brush Length Commutator Diameter Charging System Regulator Rectifier Output Voltage Charging Coil Output Voltage Charging Coil Resistance Yellow Yellow Ignition System Ignition Timing Ignition Coil Primary Winding Resistance Secondary Winding Resistance Spark Plug Type Gap Terminal Crankshaft Sensor Resistance Crankshaft Sensor Air Gap Clearance Between The Rotor Projection and Crankshaft
11. art 2 lt pA MU il manans Sp JHOSO1OBS1 e Apply a non permanent locking agent to the crankcase bolts and tighten them in the order num bered on the lower crankcase Torque Crankcase M8 Bolts 29 3 0 kgf m 22 16 Crankcase M6 Bolts 8 8 N m 0 9 kgf m 78 in Ib OThe tightening sequence numbers are marked on the lower crankcase half 8 16 ENGINE BOTTOM END Crankcase LE ASPERA SEL prae im URIS Ta JH08003BW2 Crankcase Check Valves Inspection e Split the crankcase e Inspect the check valves OThe check valve A allows oil flow in the direction of the arrow B Olnspect the normal oil flow by injecting C a high flash point solvent in a squirt can or syringe the following case replace the check valve 1 Oil will not pass through the check valve in the normal direction 2 Oil will pass through the check valve in both direction CAUTION Do not use compressed air on the valve since doing so would damage the valve spring Upper Crankcase Check Valve Removal Installation e Remove the front A and rear B check valves on the upper crankcase C with pliers e Note the following when installing OApply a non permanent locking agent to the check valves OPress the check valves until they are bottomed At this ti
12. e Install the handlebar spacer A between the handlebar cover and the switch case C with the screw B STEERING 12 11 Steering Remove Remove the handlebar see Handlebar Removal Remove the oil inlet tube A air inlet duct B to make services easier Disconnect Switch Case Lead Connectors Throttle Cable End at Throttle Case e Disconnect Steering Position Sensor Lead Connector A e Remove Fuel Vent Pipe A Throttle Cable Upper End B Switch Case Lead Connectors C e Unscrew the mounting bolts A and remove the lever B Remove the steering cover OUnscrew the steering cover mounting bolts A 12 12 STEERING Steering ORemove Rubber Cover A Steering Cover Mounting Bolts B ODisconnect the ignition switch lead connector and pull out the grommet A ORemove the steering cover B with the ignition switch lead Unscrew the mounting bolts A and remove the steering holder B with the steering shaft C e Remove Steering Shaft Mount Plate Bolts A Steering Shaft Mount Plate B e Remove Steering Nut A Steering Shaft B STEERING 12 13 Steering Installation Check the bushings for damage and wear x If the bushings are damaged or worn replace them e Grease Upper Bushing A Lower Bushing B Washers C e Position the lower bushing on the member e Install the steering shaft D on the st
13. Grip and Rear Duct Removal Installation A Take out the bolts A and remove the grip B and rear 2 duct C gt 9 e To split the upper duct and lower duct remove the mount es ing screws D e Installation is the reverse of removal OApply a non permanent locking agent to the grip mounting bolts Torque Grip Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib JMO7025BS2 C Stabilizer Removal e Before removing the stabilizer mark A the position of the stabilizer on the hall e Unscrew the bolts B and remove the stabilizer C 13 12 HULL ENGINE HOOD Fittings Stabilizer Installation e Install the stabilizer A on it s original position by setting it with the marks 5 2 mm 0 2 0 08 in B 65 3 mm 2 6 0 1 in C e Apply a non permanent locking agent to the stabilizer mounting bolts and tighten them Torque Stabilizer Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Storage Cover Assembly e When disassembling the lock A from the storage cover B assemble the storage cover as shown Storage Cover B Lock TA 7 NH 7 Spring C Shaft D OPush down the shaft D into the lock A JM07009BS2 C HULL ENGINE HOOD 13 13 Hull Replacement To replace the hull remove the various parts in the follow ing suggested order Seat Battery and Pad Exhaust Pipe and Expansion Chamber Carburetor KSS Actuator
14. e Flush the tank repeatedly with high flash point solvent un til itis clean It may be necessary to put a few marbles or pieces of clean gravel into the tank and shake it to knock loose any foreign matter in the bottom Clean the tank in a well ventilated area and take ample care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the tank A fire or explosion could result Fuel Filler and Tube Removal e Loosen the tube clamps A and remove the fuel tube B e Unscrew the fuel filler A and pull off it 3 28 FUEL SYSTEM Fuel Tank Fuel Filler and Tube Installation e Install the fuel filler so that its rib faces downward Rib A Up B Front C Down D Rear E JC11000BS1 C Fuel Filter Screen Cleaning e Refer to Fuel Filter Screen Cleaning in the Periodic Main tenance chapter Fuel Filter Inspection e Refer to Fuel Filter Inspection in the Periodic Maintenance chapter FUEL SYSTEM 3 29 Fuel Tap Removal e Take out the plug e Unscrew the set screw A and take out the fuel tap knob B e Unscrew the mounting screws A and take out the fuel tap Pull the fuel hoses A off the fuel tap B Installation e Connect the fuel hoses to the fuel tap correctly see Ca ble Wire and Hose Routing section in the Appendix chap ter e Apply a n
15. 14 26 ELECTRICAL SYSTEM Charging System Charging Coil Testing e Disconnect the 2 pin charging coil leads connector Yel low A e With the hand tester check the charging coil output in circuit according to the following table with the engine running at approximately 3 000 rpm WARNING To avoid electrical shock do not perform this test with the watercraft in the water CAUTION Do not run the engine over 15 seconds without cool ing water Charging Coil Output Test Connections Standard Meter to Meter to Value 250 V AC Yellow lead Yellow lead 32 48 V Meter Setting x lf the charging coil output voltage is correct check the regulator according to the regulator test procedure x If the charging coil output voltage is low check the charg ing coil resistance with the hand tester according to the following table Charging Coil Resistance Test Meter Setting Standard Meter to Meter to Value Yellow lead Yellow lead 0 64 0 96 Q xIf the coil has normal resistance but the voltage check shows the charging system to be defective then the permanent magnets in the flywheel have probably weak ened necessitation flywheel replacement Special Tool Hand Tester 57001 1394 ELECTRICAL SYSTEM 14 27 Charging System Regulator Rectifier Removal Installation e Open the rear electric case see Rear Electric Case Re moval Disassembly e
16. Exploded View Torque No Fast R k astener kgf m ft lb emarks 1 Grip Mounting Bolts 9 8 1 0 87 in lb L 2 Crossmember Mounting Bolts 7 8 0 8 69 in lb A JH1200 B1 Model B JH1200 B2 Model AD Apply synthetic rubber adhesive L Apply a non permanent locking agent SS Apply silicone sealant 13 6 HULL ENGINE HOOD Fittings Hatch Cover Removal Installation Open the hatch cover Open the connector cover A e Disconnect the connectors B of the multifunction meter leads e Remove Lower Hatch Cover Bracket Mounting Bolts A and Nuts OFor JH1200 B1 model the nuts on the inside of the hull will drop down when the mounting bolts are removed e Remove the hatch cover assembly B with the hatch cover bracket e Remove Damper Bracket Mounting Bolts A Upper Hatch Cover Bracket Bolts B e Pull out the rubber boot C with the multifunction meter leads Remove the hatch cover bracket D from the hatch cover To remove the duct cover A unscrew the mounting bolts B e To remove the windshield unscrew the mounting screws A HULL ENGINE HOOD 13 7 Fittings To remove the multifunction meter A and meter cover take off the meter bracket B OUnscrew the bolts C e To remove the rear view mirrors A mirror bracket B and rubber dampers C unscrew the mounting nuts D Hatch Cover Installation e Install
17. Table of Contents mxdeltee em i 9 2 Special 100l 4 42 reete tb devia vete ented Pe st dr E EE ede e odia 9 4 BGG VSS M ee O M 9 5 Breather Removal o tete reete eere nns EI aa d e B TER ge reda 9 5 Breather 9 5 Breather Cleaning and 22 eene 9 5 Filter Removallnstallation 9 5 Filter Cleaning and Inspection eoe ede ente anteire gs 9 5 Cooling and Bilge System HOSES 9 6 Hose REMOVAL ws PM 9 6 Hose Installatlon 35 2 aa ete ao ERR E ende ets 9 6 1056 Ins pectiolTs Ta ri Ere 9 6 Cooling and Bilge System Flushing iui perii eee ede teet pot ee au Ee da A ee 9 7 Cooling System FUSNIN xii oh Pete 9 7 Bilge System Flushing arisin C n 9 7 9 2 COOLING AND BILGE SYSTEM Exploded View 41902007845 COOLING AND BILGE SYSTEM 9 3 Exploded View Torque No Fastener mem kgfm 16 Remarks 1 Water Pipe Joints 7 8 or above 0 8 or above 69 in lb or above 55 2 Bypass Outlet Screws L 3 Breather Mounting Bolt L L Apply a non permanent
18. e Cut the sealant at the indicated area A in the figure and remove the pump bracket from the hull Pump Installation Strip off all the old sealant around the pump intake e Apply silicone sealant on the groove A for the pump bracket B to form a seal between the bracket and the hull e Install the pump bracket and wipe off any excess sealant and smooth the joint Torque Pump Bracket Mounting Nuts 36 N m 3 7 kgf m 27 ft lb e Fill the gap A between the bracket and the hull with sili cone sealant and wipe off any excess sealant and smooth the joint e Run the steering and trim cables through the pump bracket JK04001BS1 C 11 8 PUMP AND IMPELLER Pump and Impeller e Install the following on the pump bracket and the pump case Pipes A Pins B O rings C e Be sure trim seal D is in place e Grease the splines on the drive shaft with water resistant grease e Install the pump case E Torque Pump Mounting Nuts F 36 N m 3 7 27 41 JK04003BN2 Apply a non permanent locking agent to the grate mount ing bolts and install the grate A Torque Grate Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Be sure the trim seal B is in place e Apply a non permanent locking agent to the pump cover mounting bolts and install the pump cover Torque Pump Cover Mounting Bolts 7 8 N m 0 8 kgf m 69 in Ib Pump Disassembly e Unscrew the mo
19. e Install the starter motor and tighten the mounting bolts Torque Starter Motor Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib Starter Motor Disassembly e Mark A the front cover yoke and rear cover to ease reassembly e Take off the starter motor through bolts A and remove the front B and rear C covers and pull the armature out of the yoke D ELECTRICAL SYSTEM 14 21 Electric Starter System e Pull the positive brush A out of the brush holder plate B e Remove Nut A Insulating Bushing B Negative Brush Assembly C Insulating Plate D Starter Motor Assembly e Install the insulating plate A on the rear cover B so that its projection C faces the bottom side of the rear cover e Insert new O ring A on the positive brush assembly B e Slide the washer A on the armature B 14 22 ELECTRICAL SYSTEM Electric Starter System e Install the O rings A as shown JNOGOOS5BS1 Align A the recess on the brush holder plate B with the recess on the rear cover C e Put the armature D among the brushes e Install the yoke A to the rear cover B OAlign the projection C inside yoke with the recesses D on the plate and cover Position the yoke A and front cover B OAlign C the index mark made previously Brush Inspection e Measure the length A of each brush x If any is worn down to the service limit replace th
20. gt ae Kawasaki ULTRA150 JET SKI Watercraft Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Lubrication System Exhaust System Engine Top End Engine Removal Installation Engine Bottom End Cooling and Bilge System Drive System Pump and Impeller Hull Engine Hood Electrical System Storage Appendix ABDC AC ATDC BBDC BDC BTDC C DC F ft E LIST OF ABBREVIATIONS ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s perminute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating MAINTENANCE AND ADJUSTMENTS Maintenance replacement or repair of the
21. 08 14 69 122 in lb Ss Cylinder Base Nuts 49 7 8 5 0 0 8 36 69 5 Water Pipe Mounting Nuts 9 8 1 0 87 5 PERIODIC MAINTENANCE 2 3 Torque and Locking Agent Fastener Torque kgf m ft Ib Engine Removal Installation Engine Mounting Bolts Engine Damper Mounting Bolts Engine Mount Bolts Engine Bottom End Flywheel Bolt Stator Mounting Bolts Balancer Drive Gear Mounting Bolts Grommet Mounting Screws Crankshaft Sensor Mounting Screws Coupling Magneto Cover Mounting Bolts Grommet Cover Mounting Bolts Oil Level Gauge Bolt Crankcase Bolts 6 mm dia Crankcase Bolts 8 mm dia 3 7 1 6 3 5 90 94 69 in lb 8 7 31 in lb 31 in lb 90 94 8 7 78 in lb 35 in lb 78 in lb 22 ET nn Cooling And Bilge Systems Water Pipe Joint Bypass Outlet Screws Breather Mounting Bolt Drive System Coupling Drive Shaft Holder Mounting Bolts Coupling Cover Mounting Bolts Pump And Impeller Steering Nozzle Pivot Nuts Tilt Ring Pivot Bolts Cable Joint Bolts Pump Case Mounting Bolts Pump Outlet Mounting Bolts Pump Cap Bolts Impeller Pump Mounting Nuts Pump Bracket Mounting Nuts Pump Cover Mounting Bolts Grate Mounting Bolts Cable Joint Tilt Ring Mounting Bolts L 35 mm 1 38 in Tilt Ring Mounting Bolts L 32 mm 1 26 in Stop Screws Pump Mounting Bolts Pump Bracket Mounting Bolts 69 in lb or above 14 14 87 in lb 87 in lb 14 87 in
22. Inlet Manifold Mounting Nuts 9 8 N m 1 0 kgf m 87 in Ib e When the balance tube B and air inlet connecting elbows C were removed noting the following OApply a non permanent locking agent to the threads of the elbows and torque the elbows and then turn them inside 9010014881 so that they are parallel to the flange portion D of the inlet manifold Torque Air Inlet Connecting Elbows 7 8 14 N m 0 8 1 4 kgf m 69 121 in Ib 3 24 FUEL SYSTEM Inlet Manifold Reed Valves Reed Valve Inspection Check reed warp by measuring the clearance A between each reed B and the valve holder C x lf one of the clearance measurements exceeds the service limits replace the reed with a new one Check reed warp after installing a new reed x If the clearance is correct tight the mounting screws se curely Reed Warp Service Limit 0 2 mm 0 008 in e Check the mounting screw tightness e Visually inspect the reeds for cracks folds or other dam age lf there is any doubt as to the condition of a reed replace the reed reed becomes wavy replace the reed with a new one even if reed warp is less than the service limit Olnstall the reed and stop onto the reed valve holder align ing the chamfered corner of the reed with that of the reed stop Valve Holder Inspection Check the reed A contact areas of the valve holder for grooves scratches or other damage e Check
23. OA ede 15 2 Cooling SY SUS M Se east a eco 15 2 Bilge Syste nT recette dtd o Sox eed agis Mi eli 15 2 FEELS US VS P P EUM 15 2 see eed 15 3 tli d 15 3 IC ANON e dudes dcm sse 15 3 RR 15 4 Removal from hib deno esed 15 5 Else 15 5 General Inspection cse tee Rei Tees ee eere e elg ub dede e Dog 15 5 acsi ATETEA E TE 15 5 TEStRUN ann e CREER 15 6 15 2 STORAGE Preparation for Storage During the winter or whenever the watercraft will not be in use for a long period of time proper storage is essential It consists of checking and replacing missing or worn parts lubricating parts to ensure that they do not become rusted and in general preparing the watercraft so that when the time comes to use it again it will be in top condition Cooling System Clean the cooling system see Cooling System Flushing in the Periodic Maintenance chapter Bilge System Clean the bilge system see Bilge System Flushing the Periodic Maintenance chapter Before reconnecting the hoses to the plastic breather fitt
24. 7 Tachometer Pulse 8 Trim Angle Sensor 1 9 Speed Sensor 10 Speed Sensor Power Source 11 Trim Limit Switch 12 Trim Angle Sensor 2 Battery Voltage Range 10 16 V e Check that when the battery positive terminal 1 is con nected to the terminal 4 using the auxiliary wire all the LCD segments and LED warning light appear for sec onds e Check that when the terminals are disconnected all the LCD segments and LED warning light disappear x If the LCD segments and LED warning light will not ap pear replace the meter assembly 1 SET Button 2 MODE Button 3 Fuel Symbol 4 Fuel Level Gauge 5 Tachometer 6 Speedometer 7 Oil Level Gauge 8 Engine Oil Symbol 9 LED Warning Light 10 Trim Indicator 11 Clock Time Trip Hour Meter 12 Battery Symbol 13 Heat Symbol JN17016BS2 C JN17017BS1 C CAUTION Do not drop the meter unit Do not short the termi nals 9 10 and 10 5 If the multifunction meter displays incorrectly while the engine is running first disconnect the bat tery terminal lead and reconnect it again to recover the meter display Then check to see that the standard plugs and or plug caps are installed Install only the standard plugs and or plug caps The resistors are embed ded in both parts ELECTRICAL SYSTEM 14 53 Multifunction Meter Fuel Level Gauge Symbol Warning Light Inspection Connect the 12 V battery
25. 78 in lb Clamp Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib OKeep the magneto lead G loose when tightening the clamp mounting bolt E JHO05010BS1 JHO5011BS1 8 12 ENGINE BOTTOM END Stator e Install the stator and crankshaft sensor on the magneto cover ORun the pickup coil leads A to the left C under the stator leads B as shown OApply a non permanent locking agent to the stator mount ing bolts and put the washers Torque Stator Mounting Bolts 7 8 N m 0 8 kgf m 69 in Ib JHO6001BS1 OApply a non permanent locking agent to the crankshaft sensor mounting screws and install the crankshaft sensor A together with the ground lead B so that the stator leads C have to be pressed by the crankshaft sensor Torque Crankshaft Sensor Mounting Screws 3 5 N m 0 36 kgf m 31 in Ib NOTE OWhile pressing the crankshaft sensor outward torque the crankshaft sensor mounting screws JH06002BS1 Crankshaft Sensor Air Gap Clearance between the rotor projection and pickup core Standard 0 75 0 95 mm 0 030 0 037 in NOTE OWhen installing the crankshaft sensor A fix the crank slack and bite shaft sensor leads B between the stator leads C and 0 the inside wall 0 of the magneto cover bey NI OBe sure the stator and crankshaft sensor leads have no JHO6003BS1 ENGINE BOTTOM END 8 13
26. Bumper Nut or Rivets All Cable Joint Balls Threads and Joint Bolts Electrical System Spark Plug Caps Starter Motor Mounting Bolts Battery Terminal Ground Cable Mounting Nut Hose and Hose Connect Inspection e Check the following hoses for leakage A hardening cracking B checking cuts abrasions breaks and bulges C And make sure the hoses are not kinked or pinched Fuel Hoses Fuel Vent Hose Oil Hoses Cooling Hoses Bilge Hoses x If a hose is damaged any way replace it immediately and check all the others for damage e Make sure the above hoses are routed properly and se cured with the clamps away from any moving parts and sharp edged portions A Plastic Clamp B Hose C Hose Fitting NOTE OThe majority of bilge hoses have no clamps at the hose ends A Metal Clamp B Hose C Hose Fitting NOTE OCheck the fuel and oil filler tubes and exhaust tubes for signs of wear deterioration damage or leakage Re place if necessary OMake sure the above tubes are secured with the metal gear clamps away from any parts 6003020281 JB02003BS1 JB02002BS1 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedure Rubber Strap Inspection Check the following rubber straps for any deterioration or damage Pull on squeeze the straps and look for cracks Battery Straps A Fuel and Oil Tanks Straps Water Box Muffler Straps lf a strap is damage
27. Oil Level Sensor Inspection e Disconnect the oil level sensor 2 pin connector Remove the oil level sensor out of the oil tank e Set the hand tester ohmmeter to the x 1 range Special Tool Hand Tester 57001 1394 e Connect the tester leads to the BK W and BL leads to check the switching operation of the float Meter Reading When the two floats are held downward A approx 4 When one float is held upward B approx 2 kQ When the two floats are held upward C approx 00 The meter should read as specified If it does not replace the oil level sensor Fuel Level Sensor Inspection Remove the fuel level sensor out of the fuel tank e Set the hand tester ohmmeter to the x 100 O range Special Tool Hand Tester 57001 1394 e Connect the tester leads to the W R and BK W leads e Take out the mounting screws A and remove the cover B e According the next figure test the fuel level sensor by sliding the float C meter should read as specified If it does not replace the fuel level sensor 31031 5 24613 530037230 0 88 E 221 3407930049300 19643 490379200 171 3 01599313327 14633 12143 4735058700 9643 47355955500 FUEL LEVEL JN10022BN2 ELECTRICAL SYSTEM 14 49 Sensors Throttle Sensor Removal Installation CAUTION Do not remove the throttle sensor B unneces
28. clean the Jet Ski watercraft Any sand entering the engine will shorten the life of the watercraft For the same reason before installing a new part clean off any dust or metal filings 4 Battery Ground Disconnect the ground wire from the battery before performing any disassembly operations on the Jet Ski watercraft This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the wires from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive wire to the positive terminal of the battery 5 Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation or assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assem bled in the same way It is preferable to mark and record the locations and routing whenever possible 6 Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque
29. e Water must flow freely through the filter but large debris must not x If the filter cannot be cleaned or if it is broken and allows debris to pass through replace it 9 6 COOLING AND BILGE SYSTEM Cooling and Bilge System Hoses Hose Removal e None of the bilge system hoses has a clamp To remove this hose remove the filter see Filter Removal The bilge system hoses may be simply pulled off their fittings e All the cooling system hoses are clamped at both ends Loosen the clamps and pull the hoses off Hose Installation e To install the bilge filter hose push the hose over the end of the filter e When installing the cooling system hoses be sure to use the same kind of clamp as the original Some of the clamps are metal for tighter clamping ability required when smooth fittings are used Plastic clamps are used where tight clamping is not required Hose Inspection e Check the hoses for hardening cracking checking cuts abrasions and breaks x If a hose is damaged in any way replace it immediately and check all the others for damage COOLING AND BILGE SYSTEM 9 7 Cooling and Bilge System Flushing Cooling System Flushing e Refer to Cooling System Flushing in the Periodic Mainte nance chapter Bilge System Flushing Refer to Bilge System Flushing in the Periodic Mainte nance chapter DRIVE SYSTEM 10 1 Drive System Table of Contents zxdeltee emi 10 2 Specifications weiss E 10
30. first confirm the following OBe sure that there is no punch mark A on the cylinder block B e The cylinder blocks and studs should be assembled and installed following the next combination Bow A Cylinder Block P N 11005 3744 Studs P N 92004 3736 Length 56 mm 2 20 in P N 92004 3735 e Install the water pipe A on the cylinder OPlace new water pipe gaskets B on each cylinder as shown OSet the clamp C on the water pipe as shown OTighten the water pipe nuts D following the sequence shown Bow E Torque Water Pipe Mounting Nuts 9 8 N m 1 0 kgf m 87 in Ib JF04018BS1 Cylinder Block P N 11005 3744 92004 3735 3 liest 92004 3736 JF04011BS1 C 1 JF04020BS2 C 6 10 ENGINE TOP END Engine Top End e Install the exhaust manifold A on the cylinder OPlace new gaskets B on the cylinders so that UP letter C faces upward as shown OTighten the exhaust manifold nuts D following the se quence shown Torque Exhaust Manifold Mounting Nuts 34 N m 3 5 kgf m 25 ft lb e Place a new cylinder head gasket on the cylinder head OAlign the tab A of head gasket B with that C of the cylinder block D OAlign the dowel pins on the cylinder block with the holes of the head gaskets Bow E e Install the cylinder head in this order 2 3 1 middle rear front OTemp
31. on the balancer drive gear B OAlign the maker mark C on the magneto flywheel with the key groove D on the gear B OApply a non permanent locking agent to the balancer drive gear mounting bolts E and tighten them following the sequence shown Torque Balancer Drive Gear Mounting Bolts 12 N m 1 2 kgf m 8 7 1 Stater Clutch Gear and Starter Idle Gear Removal e Remove Magneto Cover Magneto Flywheel A Starter Idle Gear B Starter Clutch Gear C Starter Clutch Gear and Starter Idle Gear Installation e Apply molybdenum disulfide oil to the starter idle gear shaft A e Grease slightly the needle bearing B and the inside of the starter clutch gear C as shown e Install the 3 mm 0 118 in thick spacer D on the cylinder side and the 2 5 mm 0 0984 in thick spacer E on the magneto side with each chamfer side facing the cylinder side Magneto Flywheel Installation e Using a high flash points solvents clean off any oil or dirt that may be on the flywheel bolt the crankshaft taper or in the tapered hole in the flywheel e Fit the woodruff key A securely in the crankshaft before installing the magneto flywheel e Install the magneto flywheel aligning a mark A on the balancer drive gear with a mark B on the balancer driven gear Torque Flywheel Bolt 123 127 N m 12 5 13 0 kgf m 90 94 ft Ib JHO5008BS1 8 10 ENGINE BOTTOM END Ma
32. or replacement of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related parts CDI Ignition System Flame Arrester Fuel Filter Screen Spark Plugs Carburetor and internal parts Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift t
33. the clearance is outside the range given remove the pump case and change the amount of shims 11 14 PUMP AND IMPELLER Pump and Impeller e Install the following on the pump A Pin B O ring C Pump Outlet D Trim Seal E OApply a non permanent locking agent to the pump outlet mounting bolts F Torque Pump Outlet Mounting Bolts 19 N m 1 9 kgf m 14 ft lb Pump and Impeller Inspection e Refer to Pump and Impeller Inspection in the Periodic Maintenance chapter Impeller Clearance e Impeller clearance is critical to proper performance If the pump case and impeller are not visibly damaged poor performance may be caused by too much impeller clear ance To check impeller clearance remove the grate and insert a feeler gauge A between the tip of the impeller blade B and the pump case C Impeller Clearance Standard 0 2 0 3 mm 0 008 0 012 in Service Limit 0 6 mm 0 024 in x If the clearance is less than the service limit do not adjust it xIf the clearance is greater than the service limit but the pump case has deep scratches replace the pump case x If the clearance is greater than the service limit and the pump case is in good condition adjust the impeller clear ance JKO4017BS2 C STEERING 12 1 Steering Table of Contents Exploded View EE 12 2 Cable ere ee 12 4 Steering Cable Adjustm
34. tract this value from the cylinder inside diameter measure ment The difference is the piston clearance Piston Cylinder Clearance 0 130 0 140 mm 0 005118 0 005512 in Piston Ring Piston Ring Groove Inspection e Visually inspect the piston rings and the piston ring grooves x If the rings are worn unevenly or damaged they must be replaced x If any piston ring groove is worn unevenly or damaged the piston must be replaced and fitted with new rings JF04023BS1 C JF04024BS1 C ENGINE TOP END 6 13 Engine Top End Piston Ring End Gap e Put the cylinder upside down Place the piston ring inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap A between the ends of the ring B with a thickness gauge x If the gap is wider than the service limit the ring is worn excessively and must be replace Top amp Second Piston Ring End Gap Standard 0 25 0 40 mm 0 00984 0 0157 in Service Limit 0 70 mm 0 028 in H JF02007B81 ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents Exploded View o deterrere rana Pe PR ERROR 7 2 Engine Removal 7 4 EP mE 7 4 o eco Leer cete a a e
35. will multiply the stress caused by the intermittent force on the piston and will result in not only rapid crankshaft bearing wear but also noise power loss vibration and shortened engine life A defective crankshaft should be always detected at an early stage and repaired immediately The following explanation concerns the most common crankshaft problems and the method for mea suring play runout and con rod alignment It does not cover crankshaft disassembly because of the highly specialized equipment that is required If crankshaft components become damaged or worn the entire crankshaft should be replaced as an assembly or rebuilt by a properly equipped shop Connecting Rod Bend Twist Set the crankshaft in an alignment jig or in V blocks 100mm surface plate Select an arbor of the same diameter as the connecting rod small end and at least 100 mm 3 9 in long and insert the arbor through the connecting rod small end e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 9 in length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the con necting rod or crankshaft must be replaced JH09000BS1 Connecting Rod Bend Standard Under 0 05 100 mm 0 00197 3 934 in Service Limit 0 2 100 mm 0 0079 3 934 in e With the crankshaft still in the align
36. 15 Periodic Maintenance Procedure e Be certain that the cable moves freely in both directions e Disconnect the cable joint A at each end of the cable OTake out the cable joint bolt B and disconnect the cable joint CAUTION Never lay the watercraft on the right side Water in the exhaust system may drain back into the engine causing serious damage OSlide the inner cable back and forth in the cable housing x lf the cable does not move freely replace the cable with the motor box Trim Cable Lubrication NOTE OThe trim cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced Handlebar Pivot Lubrication e Remove the steering shaft A see Steering chapter e Check the bushings B for damage and wear x If the bushings are damaged or worn replace them e Grease Bushings Washers C JR13001BS2 C 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedure Electrical System Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage e Disconnect the battery terminal cables see Battery Re moval in the Electrical System chapter CAUTION Be sure to disconnect the negative terminal lead first Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter A which can be read one decimal place voltage x If the reading is below th
37. 264 in JH1200 B1 B2 5 5 6 5 mm 0 217 0 254 in JH1200 B3 OFill the bearing side oil seal with high grade wa ter resistance grease D and install it so that the sides with the spring face outward OHigh grade water resistance grease the grease seal lips E Special Tool Bearing Driver Set 57001 1129 JK04065BS2 e Before installing the pump bearing blow any dirt or for eign particles out of the guide vane with compressed air e High grad water resistance grease A the collar B C e Insert the collar B and press the new ball bearing C into A x the vane guide D Special Tool Bearing Driver Set 57001 1129 JKO4031BS2 C e Molybdenum disulfide grease A the pump shaft B and high grade water resistance grease the O ring C e Push the pump shaft into the guide vane JK04086BS1 C 11 12 PUMP AND IMPELLER Pump and Impeller e Grease the pump shaft threads and screw on impeller Special Tools Impeller Holder 57001 1425 Impeller Wrench 57001 1228 Torque Impeller 98 N m 10 kgf m 72 ft lb e Install the dowel pins A on the guide vane B e Position the pump case C on the guide vane and bring the impeller blades so that it will contact D with the inside of the pump case e Measure the space X between the pump case and the guide vane at three places of 120 degree intervals e The maximum value measured at three places is as sum
38. A e Set the tester B to the DC 10 V range connect it to the 3 pin connector C of the main harness side Hand Tester Purple Lead Hand Tester Black White Lead e Turn the ignition switch on e Check the tester reading Overheat Diagnosis Output Voltage around DC 5 V When the engine is not in overheat mode x lf the tester reading does not show specified voltage re place the igniter is defective Special Tool Hand Tester 57001 1394 Spark Plug Removal e Pull off the spark plug caps e Unscrew the spark plugs OBe careful to avoid breaking the ceramic on the spark plugs JNOSO47BS2 C JN08048BS2 C ELECTRICAL SYSTEM 14 37 Ignition System Spark Plug Installation e Be sure the spark plug threads are clean and dry Torque the spark plugs Torque Spark Plugs 25 29 N m 2 5 3 0 kgf m 18 22 ft lb OBe careful to avoid breaking the ceramic on the spark plugs e Install the spark plug cap onto the spark plug securely OPush the cap onto the plug so that the distance between the lower end A of the cap and upper surface B of the plug hexagonal nut is 6 mm 0 24 in C NOTE OFor easier correct installation of the spark plug Push the cap onto the plug until the figures BR9ES D printed on the plug are half covered with the cap or the figures E of KGK R are completely covered Spark Plug Inspection ORefer to Spark Plug I
39. A of the choke inner cable out of the pulley on the choke knob shaft e Loosen the locknut B and unscrew the cable housing C from the holder D FUEL SYSTEM 3 13 Choke Cable e Remove the pin and washer and pull out the choke knob shaft from the cable holder A Choke Knob Shaft B Washer 8 Spring D Cable Holder E Pin F O ring 22 W B Choke Knob and Cable Installation e Route the choke cable according to the Cable Routing section in the Appendix chapter e Adjust the choke cable see Choke Cable Adjustment in the Periodic Maintenance chapter Inspection e Examine the cable x lf the cable or cable housing is kinked A or frayed B replace the cable e With the choke cable disconnected at the both ends the cable should move freely within the cable housing x If the cable does not move freely replace it Lubrication Whenever the choke cable removed lubricate the choke cable as follows e Apply grease to the tip of the choke cable end e Lubricate the choke cable A by seeping oil between the cable and cable housing e Attached the choke cable to the carburetor and adjust the choke cable see Choke Cable Adjustment in the Periodic Maintenance chapter 6604010251 3 14 FUEL SYSTEM Carburetor Fuel Pump Idle Speed Adjustment e Refer to Idle Speed Adjustment in the Periodic Mainte nance chapter Carburetor Synchronization e Refer to Carbu
40. Cable GENERAL INFORMATION 1 19 Technical Information Igniter 1 Block Diagram of Digital Igniter M N m f r A Battery B Starter C Starter Relay D Ignition Switch E Starter Switch F Stop Switch G Steering Position Sensor H Water Temperature Sensor Inlet Air Temperature Sensor J Crankshaft Sensor K Throttle Sensor 78060118484 L Warning Monitor M Power Source ON OFF Circuit N Wave Shape Circuit O DC DC Converter P Control Unit Q Ignition Coil 1 R Ignition Coil 2 S Ignition Coil 3 T Tachometer U Smart Steering Actuator V Outer Load I F Interface 1 20 GENERAL INFORMATION Technical Information Igniter 2 Functions of Digital Igniter 1 K TRIC The throttle sensor is installed on the throttle body The output signal is sent to the igniter which determines the optimum igniter timing The K TRIC system controls the independent timing maps for each cylinder based on engine speed and throttle opening for quick throttle response 2 Correction of Engine Acceleration The igniter features an acceleration function which advances the timing during rapid acceleration for improved throttle response When revs stabilise timing returns to normal 3 Inlet Air Temperature Correction The inlet air temperature sensor is installed in the engine room As the air temperature inside the hull rises the igniter compensate
41. Engine and Mounts Oil Tank and Filler Air Vent Ducts Electric Case Front Rear Fuse Assy and Brackets Water Box Muffler Drive Shaft and Shaft Holder Steering Cover Fuel Tap Choke Assembly Pump and Hoses Handlebar and Steering Crossmember Fuel Tank and Filler Steering Cable Tilt Cable with Tilt Motor Box Bilge and Cooling System Hose Bypass Hose and Outlet Main Harness Bumpers Seat Latch Hatch Cover and Brackets The following parts cannot be removed from the hull and must be replaced Decals Labels Mats Registration Number if any If the new hull is to be painted do that first Then install removed parts in the reverse order of their removal Finally install the labels decals mats and the registration numbers 13 14 HULL ENGINE HOOD Rubber Parts NOTE OThe rubber parts on the watercraft are fastened in place with various adhesives To replace a rubber part use a cement in the following table or an equivalent Read all warnings and cautions on any solvents and adhesives used Many of these products are flammable may be harmful to the skin and eyes and may give off harmful vapors Use these sol vents and adhesives only in a well ventilated area and never near an open flame For this Application Mats Engine Hood Gasket Hatch Cover Trim Seal Detents Type Synthetic Rubber Adhesive P N 92104 3701 Cyanoacrylate Cement Handlebar Grips CAUTION Be ve
42. Fuel System chapter x If necessary adjust the oil pump cable Oil Pump Cable Adjustment e Check carburetor cable adjustment e f necessary adjust the carburetor cable e Check oil pump cable adjustment OWhen the throttle lever is fully applied pulled check to see that there is a clearance A approx 0 6 mm 0 024 in between stop B on the oil pump pulley and the stopper pin C on the oil pump body At this time the oil pump pulley is fully opened x If necessary adjust the oil pump cable A OHold the throttle lever fully applied pulled OTurn the oil pump pulley till the stop on the pulley contacts to the stopper pin on the oil pump body At this time the oil pump pulley is fully open And then give the oil pump cable tension by turning the upper adjusting nut clockwise OLoosen the upper adjusting nut B by turning counter clockwise 1 2 turn and then fix the oil pump cable by tight ening the lower adjusting nut C securely Choke Cable Adjustment Check choke cable adjustment OWhen the choke knob is turned to the OFF position the choke butterfly valve in the carburetor should be com pletely open The choke pivot arm A should stand all the way toward the port side of the boat with cable slack OWhen the choke knob is turned to the ON position the choke butterfly valve in the carburetor should be com pletely closed Check that the choke pivot arm stands all the way toward the starboard
43. Rear View Mirror Installation eese nennen 13 9 Grossmember suds lates 13 9 Crossmember Installation pp 13 11 Grip and Rear Duct Removal lnstallatiom 9 13 11 Stabilizer Removal 2 esie Due Eae 13 11 Stabilizer Installation oie terere oet tete da tex eoe tte ee e Pee oes 13 12 Sigrage Cover Assembly ctu iX HER Ee Ld 13 12 FH ro rec ete resets 13 13 RUDDER Panes cc ciento mte ceci leer 13 14 Rubber Parts 13 14 Front Bumper meme 13 15 Rear Bumper 13 15 Side Bumper REMOVAl te eec pe ead de odes spe E e Side Bumper Installation 13 2 HULL ENGINE HOOD Exploded View HULL ENGINE HOOD 13 3 Exploded View Torque No Fastener ilb Remarks 1 Rear Mounting Plate Nuts 25 2 5 18 L 2 Stabilizer Mounting Bolts 9 8 1 0 87 in lb L AD Apply synthetic rubber adhesive L Apply a non permanent locking agent SS Apply silicone sealant 13 4 HULL ENGINE HOOD Exploded View HULL ENGINE HOOD 13 5
44. Sensor Core 12 V 18 Ah 12 0 mm 0 47 in 28 mm 1 10 in Battery voltage 14 5 0 5 V 32 48 V 93 000 r min rpm 0 64 0 96 O 15 BTDC 1 250 r min rpm 22 BTDC 3 500 r min rpm 0 33 0 43 O 5 44 7 36 BR9ES 0 7 0 8 mm 0 028 0 031 in Solid post 396 594 O 0 75 0 95 mm 0 030 0 037 in 6 5 mm 0 26 in 27 mm 1 06 in ELECTRICAL SYSTEM 14 13 Special Tools Hand Tester Needle Adapter Set 57001 1394 57001 1457 72 T571457ST 7571394ST Peak Voltage Adapter 57001 1415 875714155 14 14 ELECTRICAL SYSTEM Battery Removal e Disconnect the battery cables To prevent possible personal injury and damage to electrical components always disconnect the grounded cable first e Unhook the battery straps A Carefully lift the battery from the engine compartment Installation e Be sure the battery damper A is in position in the battery compartment e Place the battery so that its terminals face to bow side e Hook the battery straps e Connect the battery cables positive first OAfter attaching both cables coat the terminals and cable ends with grease to prevent corrosion OSlide the protective boot over each terminal Loose battery cables can create sparks which can cause a fire or explosion resulting in injury or death Make sure the battery terminal screws are tightened securely and the cove
45. TOP END Exploded View ENGINE TOP END 6 3 Exploded View Torque No Fastener Nem kgfm ftlb Remarks 1 Cylinder Head Nuts 29 7 8 3 0 0 8 22 69 in Ib S 2 Water Hose Joints 7 8 14 0 8 1 4 69 122 in lb 55 3 Cylinder Base Nuts 49 7 8 5 0 0 8 36 69 in Ib S 4 Water Hose Mounting Nuts 9 8 1 0 87 5 Initial torque for temporal tightening MO Apply molybdenum disulfide oil Mixture of the engine oil and molybdenum grease in a weight ratio 10 1 S Tighten the fasteners following the specified sequence SS Apply silicone sealant Kawasaki Bond 56019 120 6 4 ENGINE TOP END Specifications Item Standard Service Limit Cylinder Head Cylinder Compression Cylinder Head Warp Usable range 675 1 070 kPa 6 9 10 9 kgf cm 98 155 psi Open throttle 0 05 mm 0 0020 in Cylinder Piston Cylinder Inside Diameter Piston Diameter 26 9 mm 1 06 in up from bottom of skirt Piston Cylinder Clearance Piston Ring Groove Clearance Top keystone Second keystone Piston Ring Groove Width Top keystone Second keystone Piston Ring Thickness Top keystone Second keystone Piston Ring End Gap Top Second 80 000 80 015 mm 3 14961 3 15019 in 79 865 79 880 mm 3 14429 3 14488 in 0 130 0 140 mm 0 005118 0 005512 in 0 25 0 40 mm 0 00984 0 0157 in 0 25 0 40
46. Tools Piston Pin Puller Assembly 57001 910 Piston Pin Puller Adapter 57001 1211 e Do not confuse these pistons since each should be in stalled in the original cylinder to maintain the correct clear ance Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Assembly e f any parts in the piston assemblies require replacement or if the cylinder is replaced be sure to check the critical clearances of the new parts against the values given in Specifications e Install the piston rings so that the R mark A faces up ward as shown OWhen the piston rings are reinstalled to the piston ring grooves reinstall them as follows for fitting Second Piston Ring Second Piston Ring Groove Top Piston Ring Top Piston Ring Groove e When installing the piston rings by hand first fit one end of the piston ring against the pin in the ring groove spread the ring opening with the other hand and then slip the ring into the groove e Check to see that the pin A in each piston ring groove is between the ends of the piston ring e Using molybdenum disulfide oil lubricate the small end bearing and insert into the connecting rod eye e Using molybdenum disulfide oil lubricate the piston pin and the pin holes GE16060881 JF02005BS1 C JF02006BS1 C 6 8 ENGINE TOP END Engine Top End e Install each piston in the o
47. Torque rear mounting plate nuts 2 6 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Idle Speed in Water out of Water Main Jet Front Middle Rear Pilot Jet Front Middle Rear 1 250 100 r min rpm 1 800 100 r min rpm 165 155 for high altitude 165 155 for high altitude 165 155 for high altitude 48 45 for high altitude 48 45 for high altitude 48 45 for high altitude Electrical System Battery Terminal Voltage Spark Plug Gap 12 6 V or more 0 7 0 8 mm 0 028 0 031 PERIODIC MAINTENANCE 2 7 Periodic Maintenance Procedure Fuel System Idle Speed Adjustment The normal idle speed is the lowest stable speed e Turn the idle adjusting screw A as required to reach this setting Idle Speed 1 250 100 rpm in water 1 800 100 rpm out of water Carburetor Synchronization e Remove the carburetor see Fuel System chapter e Turn out the idle adjusting screw A until there is a clear ance between the adjusting screw end and throttle shaft lever B e Turn in the idle adjusting screw until the adjusting screw end just touches the throttle shaft lever e Turn in the adjusting screw 3 4 turn from the point to keep the specified throttle valve C opening in the front carbu retor D e Measure the distance from the bottom of the carburetor bore lower end to the valve edge shown as H e Turn the s
48. Valve Seat Size Arm Spring Load Pop Off Pressure Idle Speed In Water Out Of Water N8DC 1 6 mm 0 063 in 0 18 N 18 g 108 kPa 1 10 kgf cm 15 6 psi 1 250 100 r min rpm 1 800 100 r min rpm Item Standard Service Limit Carburetor Make Type Keihin CDCV 40 35 x 3 i Size 35 mm 1 378 in Venturi Main Jet Front 165 155 for high altitude Middle 165 155 for high altitude 165 155 for high altitude Pilot Jet Front 48 45 for high altitude Middle 48 45 for high altitude 48 45 for high altitude Pilot Screw 1 1 4 1 2 turn open Reed Valve Reed Warp 0 2 mm 0 008 in Fuel Tank Capacity 58 L 15 3 US gal including 7 L 1 85 US gal reserve Sealant Kawasaki Bond Silicone Sealant 56019 120 FUEL SYSTEM 3 7 Fuel System Diagram Sos SS C uf 4 lt Vent or Pulse JCO4005BH3 Nh i ea ek LXoL ES Fuel Vent Pipe Fuel Vent Check Valve The fuel vent check valve must be mounted so that the arrow is pointing toward the fuel tank Arrow Mark Fuel Vent Line Fuel Vent Pipe Fuel Filter Pipe ON Main Line Fuel Tap Reserve Line RESERVE RETURN Return Line Supply Line Fuel Filter Carburetor Pulse Line Fuel Tank 3 8 FUEL SYSTEM Throttle Control Cable Carburetor Cable Adjustm
49. a non permanent locking agent to the carburetor mounting bolts B and torque Torque Carburetor Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib JC07028BS1 3 16 FUEL SYSTEM Carburetor Fuel Pump Connect the fuel and pulse hoses correctly see Appendix chapter e Adjust the throttle control and choke cables see Throt tle Control and Choke Cable Adjustment in the Periodic Maintenance chapter Check the oil pump cable installation as follows OPull the throttle lever to ensure if the oil pump cable A makes the oil pump pulley B turn OMake sure the lower part C of the oil pump cable is in stalled the oil pump pulley securely x If necessary reinstall the oil pump cable to the pulley and adjust it see Oil Pump Cable Adjustment in the Fuel Sys tem chapter Carburetor Disassembly NOTE ODo not adjust the stop screw A OThe stop screw has been adjusted at the factory it is not necessary to adjust x If the stop screw is turned it will cause engine trouble Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal e Unscrew the carburetor cap screws A and take off the carburetor cap B e Remove Cap Spring C Vacuum P
50. damper has a L mark B and the right rubber damper has a R mark Crossmember Removal Remove the seat e Disconnect the trim tether and starter switch connectors A e Remove Rear Handlebar Cover see Steering chapter Front Handlebar Cover see Steering chapter Handlebar Pad see Steering chapter Throttle Control Cable Upper End see Fuel System chapter e Pull down the throttle control cable A e Open the hatch cover e Remove Plug A Screw Fuel Tap Knob B Nuts C Right Side Cover D 13 10 HULL ENGINE HOOD Fittings e Remove Plug A Screw Choke Knob B Nuts C Left Side Cover D e Loosen the clamps e Remove Fuel Inlet Tube Upper End A Oil Inlet Tube Upper End B Front Air Vent Duct Upper End C e Cut the band A e Remove Fuel Tank Air Vent Hose Lower End B e Take out the bolts A and plates B e Unscrew the bolts A and remove the control unit B e Remove the crossmemeber C from the hall HULL ENGINE HOOD 13 11 Fittings Crossmember Installation e Apply grease to the busing e Install the busing A into the hole B of the crossmember e Apply a non permanent locking agent to the crossmem ber mounting bolts and torque them Torque Crossmember Mounting Bolts 7 8 N m 0 8 kgf m 69 in Ib e Run the throttle cable A into the tube of the steering bracket OBe sure the rubber boot B on the cable
51. determine which part is defective measure the arcing distance again with the spark plug caps removed from the ignition coil x If the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug caps JN08042BS2 C ELECTRICAL SYSTEM 14 31 Ignition System Measuring coil resistance If the Coil Tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester However a hand tester can not detect layer shorts and shorts resulting from insulation breakdown under high volt age e Disconnect the primary leads from the coil terminals e Measure the primary winding resistance as follows A OConnect the tester between the coil terminals OSet the tester to the x 1 O range and read the tester e Measure the secondary winding resistance as follows B ORemove the plug caps by turning them counterclockwise OConnect the tester between the spark plug leads OSet the tester to the x 1 kO and read the tester x If the hand tester does not read as specified replace the coil Winding Resistance Standard Primary windings 0 33 0 43 Secondary windings 5 44 7 36 Special Tool Hand Tester 57001 1394 x If the tester reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it sh
52. e Clean the bilge filter see Filter Cleaning and Inspection in the Cooling and Bilge Systems chapter e Check the coupling damper for wear and damage see Coupling Damper Inspection in the Engine Bottom End chapter e Apply a non permanent locking agent to the engine mount bolts A and torque them Torque Engine Mount Bolts 34 N m 3 5 kgf m 25 ft Ib J603008BS1 e Check the gap between the engine mount and the dampers by rocking the engine e f there is a gap insert a suitable shim between the engine mount and the damper to achieve a good fit Shim Selection Shim No Thickness 92025 3705 t 0 3 mm 92025 3706 t 0 5 mm 92025 3707 t 1 0 mm 92025 3708 t 1 5 mm e Apply a non permanent locking agent to the engine mounting bolts and torque them Torque Engine Mounting Bolts 36 N m 3 7 kgf m 27 16 e After installing the engine in the hull check the following Throttle Control Cable Choke Cable Oil Pump Bleeding Fuel and Exhaust Leaks 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Check the oil pump cable installation as follows OPull the throttle lever to ensure if the oil pump cable A makes the oil pump pulley B turn OMake sure the lower part C of the oil pump cable is in stalled the oil pump pulley securely x If necessary reinstall the oil pump cable to the pulley and adjust it see Oil Pump Cable Adjustment in the Periodic Maintenance chapter Do not ru
53. emission control devices and systems may be performed by any marine SI engine repair establishment or individual EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY A minimum of 87 octane of the antifknock index is recommended The antiknock index is posted on service station pumps Emission Control Information To protect the environment in which we all live Kawasaki has incorporated an exhaust emis sion control system in compliance with applicable regulations of the United States Environmental Protection Agency Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this engine The fuel ignition and exhaust systems of this engine have been carefully de signed and constructed to ensure an efficient engine with low exhaust pollutant levels Maintenance Proper maintenance and repair are necessary to ensure that watercraft will continue to have low emission levels This Service Manual contains those maintenance and repair recommenda tions for this engine Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards Tampering with Emission Control System Prohibited Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair
54. mm 0 00984 0 0157 in 80 10 mm 3 1535 in 79 72 mm 3 1386 in 0 7 mm 0 028 in 0 7 mm 0 028 in ENGINE TOP END 6 5 Special Tools Compression Gauge 20 kgf cm Piston Pin Puller Adapter 14 57001 221 57001 1211 875702215 T5712118T Piston Pin Puller Assembly Kawasaki Bond Silicone Sealant 57001 910 56019 120 7570910ST 875601205 Compression Gauge Adapter M14 x 1 25 57001 1159 6 6 ENGINE TOP END Engine Top End Disassembly and Assembly Disassembly e Remove the engine see Engine Removal Installation 2 chapter 6 Remove 40 lt gt B Spark Plugs A Cylinder Head Nuts B and Washers C Spark Plug Holder D Reinforce E Cylinder Head F Cylinder Head Gasket G Bow H JFO4018BS2 C e Remove Exhaust Manifold Mounting Nuts A Exhaust Manifold B Si e 1 wre TC ers AM 7 e Remove Water Pipe Mounting Nuts A Water Pipe B e Remove the cylinder base nuts A and lift off the cylin ders B ENGINE TOP END 6 7 Engine Top End Stuff clean rags into the crankcase opening to prevent dirt or foreign objects from falling into the crankcase Remove the piston pin snap ring A with pliers B Remove the piston by pushing its pin out the side that the circlip was removed Use a piston pin puller assembly if the pin is tight Special
55. screws A and take the fuel pump unit B off the carburetor CAUTION The fuel pump should not be disassembled If leakage is evident or internal damage is sus pected replace the fuel pump unit B e Note the following when installing the pump unit A to the carburetor assembly B OCheck the O rings C for damage and if necessary re place them OAlign the slot D on the pump body with the shaft E on the carburetor assembly High Altitude Performance Adjustment e Refer to High Altitude Performance Adjustment in the Pe riodic Maintenance chapter FUEL SYSTEM 3 21 Flame Arrester Removal Remove the bracket holding the air inlet cover Unscrew the air inlet cover mounting bolts A indicated in the figure pushing the air inlet cover B to the port side by hand NOTE OBe careful not to drop the removed bolts into the hull bottom when removing e Unscrew the remained mounting bolts and remove the air inlet cover Remove the flame arresters e Loosen the clamps A and take out the arrester case B e Another way to remove the flame arresters is the following procedures ORemove the bracket A holding the air inlet cover OLoosen the clamps B and pull out the air inlet cover as sembly C OTake out the air inlet cover mounting bolts D and sepa rate the air inlet cover E from the arrester case F OTake out the flame arresters G 102
56. side of the boat without cable slack lt 0 Choke Open Choke Closed Turned to OFF Turned to ON JC06008BS1 x If necessary adjust the choke cable A OLoosen the locknuts B at the cable holder and turn the choke knob to the OFF position OCheck that the choke pivot arm stands all the way toward the port side of the boat with cable slack and tighten the locknuts OTurn the choke nob to the ON position OCheck that the choke pivot arm stands all the way toward the starboard side of the boat without cable slack 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedure Fuel Filter Screen Cleaning e Remove Filler Tubes of Fuel and Oil Oil Tank Fuel Tank Strap Crossmember Cable Holder with Control Cables e Lift the front portion of the fuel tank e Disconnect Fuel Level Sensor Lead Connector Fuel Hoses Air Vent Hose e Pull out the fuel level sensor assembly A e Wash the fuel filter screens in non flammable or high flash point solvent Use a brush to remove any contaminants trapped in the screens WARNING Clean the fuel screens in a well ventilated area and take ample care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent A fire or explosion could result Fuel Filter Inspection e Inspect and replace the fuel filter A in accordance with the Periodic Mainten
57. the engine is running This is to prevent igniter damage Ignition Coil Primary Peak Voltage Check NOTE OBe sure the battery is fully charged Remove the front electric case and open it e Pull all the spark plug caps from the spark plugs and push the caps A fully onto the spark plug cap holder B NOTE OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head e Install a commercially available peak voltage adapter A into the hand tester B e Disconnect the ignition coil primary lead connector And the connector is reconnected mutually by using two aux iliary wires C e Connect the adapter between the ignition coil primary lead terminal D and the black lead terminal ground E of the electric case with the primary lead left connected Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Hand Tester 57001 1394 Hand Tester Range x DC 250 V Primary Lead Connections Adapter R Adapter BK 1 Coil G R lt gt 2 Coil G Y gt BK Ground 3 Coil G W lt gt sk 9 46 po sk IGNITION COIL 3 dirimi JN08044BS2 C 14 34 ELECTRICAL SYSTEM Ignition System To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn
58. the hatch cover rubber dampers OThe left damper A has a L mark B and the right damper has a R mark e Apply non permanent locking agent to the following parts Duct Cover Mounting Bolts Damper Bracket Mounting Bolts Hatch Cover Bracket Bolts e Insert the lower part A of the rubber boot into the hole B of the hull 13 8 HULL ENGINE HOOD Fittings Hatch Cover Bracket Removal Remove the hatch cover assembly see Hatch Cover Re moval Installation Take out the mounting bolts A and remove the hatch cover bracket B with damper C OPull out the rubber boot D with the multifunction meter leads e Remove Circlips A Discard Pins B Damper C e Unscrew the shaft A and nut B and remove the upper bracket C from the lower bracket D Hatch Cover Bracket Installation e Grease Bushings Shaft Nut e Insert the bushings A into the bracket e Set the upper bracket B and the lower bracket C Tighten the shaft D Tighten the nut E JM07004BS1 C e Apply a non permanent locking agent to the following Upper Bracket Mounting Bolts Lower Bracket Mounting Bolts HULL ENGINE HOOD 13 9 Fittings Rear View Mirror Removal Open the hatch cover Take out the nuts A and remove the rear view mirror B and rubber damper Rear View Mirror Installation e Install the rear view mirror and rubber A OThe left rubber
59. working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the tank A fire or explosion could result Oil Filter Cleaning e Tilt up the hatch cover e Take out the oil filter A Bow B e Wash the oil filter in a non flammable or high flash point solvent Use a brush to remove any contaminates trapped in the filter Clean the oil filter in a well ventilated area and take ample care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the filter A fire or explosion could result EXHAUST SYSTEM 5 1 Exhaust System Table of Contents Explode Views E 5 2 leere 5 4 Expansion Chamlber 55a Petre bee 5 5 Pi hae 5 5 ES fon ER cR E RU 5 5 Exhaust Pipe Exhaust Chamber Cleaning and Inspection 5 6 Exhaust Manifold tert te nde e nd a RR RO ade creada 5 7 eee ieu ere 5 7 Installation er tete agate veiut dea 5 7 Cleaning and Inspection exacte eei eese uci pee t p NR eM Ren RR eS 5 8 Water Box Re ente a em te
60. 0 psi L x 0 2200 gal imp kPa x 0 7501 cmHg L x 1 057 qt US kgf cm x 98 07 kPa L x 0 8799 qt imp kgf cm x 14 22 psi L x 2 113 pint US cm Hg x 1 333 kPa L x 1 816 pint imp mL x 0 03381 oz US mL x 0 02816 oz imp Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N x 0 1020 kg kW x 1 360 PS N x 0 2248 Ib kW x 1 341 HP kg x 9 807 N PS x 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature ega BO P 5 9 oF oF 4 32 68 104 176 212 248 284 40 20 0 20 40 60 i 80 100 120 140 160 180 200 1220 240 260 280 300 320 40 20 0 20 401 60 80 100 120 140 160 17 8 44 26 7 48 9 71 1 93 3 116 138 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Torque and Locking AGent eo tee Mea 2 2 Periodic Maintenance Chart pp 2 5 Specifications 2s c 2 6 dal 2 7 Fuel 2 7 idie Speed AdJIUSIUTIBDIE eios tbe 2 7 Carburetor Synchronization reise Lic Eee RERO TE RET MAE DH RR eR TERR 2 7 High Altitude Performance Adjustment nnns 2 8 Carburetor Cable Adjustme
61. 09003852 C 3 22 FUEL SYSTEM Flame Arrester Installation e Be sure the ribs A on the arrester case B fit the grooves C on the duct D Tighten the clamp screws E within the range F indi cated in the figure OThe 2 duct has no clamp e Apply a non permanent locking agent to the air inlet cover mounting bolts and torque them Torque Air Inlet Cover Mounting Bolts 7 8 N m 0 8 kgf m 69 in Ib NOTE OBe careful not to drop the bolts into the hull bottom when installing e Install the bracket A aligning the groove on the bracket with the project on the air inlet cover B Flame Arrester Cleaning e Refer to Flame Arrester Cleaning in the Periodic Mainte nance chapter FUEL SYSTEM 3 23 Inlet Manifold Reed Valves Inlet Manifold Removal lt 3 5 e Remove aa Air Inlet Cover Arrester Case Carburetor Remove the inlet manifold mounting nut A and remove the inlet manifold B e Pull out the gaskets A and the reed valves B Inlet Manifold Installation e Replace the gaskets with new ones OAs for the base gaskets A installation either obverse or reverse side is available OAs for the reed valve assemblies B and the gasket C install them noting the direction of UP D letters e Install the intake manifold A OTorque the mounting nuts following the sequence indi cated in the figure Torque
62. 2 7 Trim Cable Trim Cable Adjustment Check trim cable adjustment OTurn the ignition switch ON OPush the trim switch as the trim indicator shows the level position A OMeasure the distances from the pump outlet end to the steering nozzle end at the upper and lower locations as shown Both distances should be approximately equal The difference between the distance of A and B should be within 2 mm 0 08 in 1 Cable Joint Bolt 2 Joint 3 Trim Cable 4 Parallel 5 Steering Nozzle 6 Pump Outlet A Upper Distance B Lower Distance x If necessary adjust the trim cable OBe sure the trim indicator shows the level position OLoosen the locknut A on the trim cable OTake out the cable joint bolt B and disconnect the cable joint C from the trim ring OTurn the joint on the cable to adjust the trim angle OTemporarily tightening the cable joint bolt connect the joint with the trim ring and check trim cable adjustment OWhen adjustment is connect unscrew the cable joint bolt and apply a non permanent locking agent to it And tighten the cable joint bolt and steering cable nut securely Torque Cable Joint Bolt 9 8 N m 1 0 kgf m 87 in Ib Trim Cable with Trim Actuator Removal e Disconnect the cable joint at rear end of the trim cable OLoosen the locknut A on the trim cable OTake out the cable joint bolt B and disconnect the cable joint C from the trim ring Remove the cable
63. 3 in lb CAUTION Use a 50 1 mixture of gasoline to oil in the fuel tank in place of the gasoline normally used Do not turn on the water until the engine is running and turn it off immediately when the engine stops JD04014BS1 C e Supply the cooling system with water see Auxiliary Cool ing in the General Information chapter e Start the engine keep it at idling speed and check the oil flow through the transparent outlet hoses e Keep the engine running until any air bubbles in the outlet hoses disappear Oil Pump Performance Test If a drop in oil pump performance is suspected check the pump output at which the oil is being pumped e Take out the bolts A of the cable holder B and move the holder with the control cables to port side to make the service easier Exhaust Pipe C Bow D e Disconnect the oil pump outlet hoses A at the pump body Carburetors B e Plug the ends of the oil pump outlet hoses e Reserve suitable transparent hoses and connect them with the oil pump outlets e Inject oil into the transparent hoses e Run each hose into a measuring glass e Reinstall the cable holder If necessary adjust control cables JD04010BS1 C CAUTION For this test use a 50 1 mixture of gasoline to oil instead the gasoline normally used 4 6 ENGINE LUBRICATION SYSTEM Oil Pump e Supply the cooling system with water see Auxiliary Cool ing in the Ge
64. 4 SICUTI 10 5 Drive Shaft Drive Shaft 10 6 Drive Shaft Removal lnstallation mee 10 6 Drive Shaft Holder Removal Disassembly pp 10 6 Drive Shaft Holder Assembly Installation cenis ennt ennes 10 7 Drive RUhOUL ite ote rr e hoist bete te eret tte pont desc emat ahahaha tics 10 7 10 2 DRIVE SYSTEM Exploded View 2 Ma 70 O93 65 4402014885 C DRIVE SYSTEM 10 3 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Coupling 39 4 0 29 2 Drive Shaft Holder Mounting Bolts 22 2 2 16 L 3 Coupling Cover Mounting Bolts L G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease SS Apply silicone sealant Kawasaki Bond 56109 120 10 4 DRIVE SYSTEM Specifications Item Standard Service Limit Drive Shaft Runout See Page 10 8 A less than 0 1 mm 0 004 in 0 2 mm 0 008 in B less than 0 2 mm 0 008 in 0 6 mm 0 024 in DRIVE SYSTEM 10 5 Special Tools Bearing Driver Set Kawasaki Bond Silicone Sealant 57001 1129 56019 120 875711295 875601205 Coupling Holder 2 57001 1423 10 6 DRIVE SYSTEM Drive Shaft Drive Shaft Holder Drive Shaft Removal installation e Remove the engine see Engine Removal Installation chapter e Pull the drive shaft A out of the hull e Hold the dr
65. 4 65 Smart Steering System Steering Position Sensor Output Voltage Inspection e Measure the output voltage from the steering position sensor NOTE OBe sure the battery is fully charged OConnect a digital voltmeter A to the lead connector B of the steering position sensor using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Connections to steering Position Sensor Connector Meter Y W Terminal Meter gt BK Terminal OTurn the ignition switch ON OTurn the handlebar fully left or right OMeasure the output voltage Steering Position Sensor Output Voltage Standard approx 0V NOTE OWhen the handlebar is centered in straight ahead posi tion the output voltage standard value is battery voltage OTurn the ignition switch OFF x If the reading is out of the standard suspect the following Damaged Steering Position Sensor Open Sensor Circuit x If the reading is the standard but the Smart Steering sys tem does not operate suspect the igniter Smart Steering Actuator Removal e Disconnect the actuator connector A e Loosen the locknuts B at the bracket e Remove the actuator bracket mounting bolts C and pull the actuator D with the bracket out of the hull e Disconnect the smart steering cable end A from the pul ley B JL13002BS2 C 14 66 ELECTRICAL SYSTEM Smart Steering System e Unscrew the pulley mounting bolt A a
66. 5 9 5 9 InStall ation EN 5 9 INSPECHON re rt sleet Ant los Ark Aa ai A See ay 5 9 5 2 EXHAUST SYSTEM Exploded View JE020148W5 EXHAUST SYSTEM 5 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Cable Holder Mounting Bolts 8 8 0 9 78 L 2 Exhaust Pipe Mounting Bolts M10 49 5 0 36 L 3 Exhaust Pipe Mounting Bolts M8 29 3 0 22 L 4 Exhaust Manifold Mounting Nuts 34 3 5 25 5 5 Chamber Mounting Bolts 29 3 0 22 L 6 Water Hose Joints 7 8 14 0 8 1 4 69 122 in lb 55 L Apply non permanent locking agent S Follow the specific tightening sequence Si Fill the hollow with the specified silicone grease 92137 1002 SS Apply silicone sealant Kawasaki Bond 56019 120 5 4 EXHAUST SYSTEM Special Tool Kawasaki Bond Silicone Sealant 56019 120 875601205 EXHAUST SYSTEM 5 5 Expansion Chamber Removal Remove or disconnect Cable Holder A Lead Connector of Heat Sensor B Cooling Hose C Tube Clamp at Water Box Muffler D Exhaust Pipe Mounting Bolts E Remove the exhaust pipe A and expansion chamber B as a Set e Unscrew the mounting bolts A and separate the expan sion chamber B from the exhaust pipe C Installation e Install the expansion chamber on the exhaust pipe OBe sure the dowel pin A is in place Olnstall the new g
67. Crankcase Splitting e Remove the engine see Engine Removal Installation chapter e Remove the following from the engine Starter Motor Inlet Manifold Cylinder Head Cylinder Block and Pis tons Oil Pump Coupling Magneto Flywheel Balancer Gear Starter Idle Gear and Starter Clutch Gear NOTE OAlways remove the coupling before removing the mag neto flywheel or there won t be any way to hold the crankshaft while unscrewing the coupling e Remove the bearing cap A e Remove the 6 mm crankcase bolts A first and the 8 mm bolts B e Pry the point A indicated in the figure to split the crankcase halves apart and then remove the lower crankcase half e Lift the crankshaft assembly out of the upper crankcase half 8 14 ENGINE BOTTOM END Crankcase Assembly e Install the oil seal A and the balancer drive gear B on the crankshaft C OSlightly apply grease D to the lip of the oil seal and install it noting the install direction indicated in the figure OAlign a mark E on the balancer drive gear with a mark F on the crankshaft oN JHO8O002BS1 e Visually inspect the crankshaft O ring A and replace it if necessary e Grease the inner surface of the collar B and install it so that its chamfer side C faces toward the balancer drive gear e Slightly grease D the lips of the oil seals E and install them noting the install directions indicated in the figure
68. During the storage lubricate the following with penetrat ing rust inhibitor as well Steering Cable Joint Connector at Steering Nozzle Trim Cable Joint Connector at Steering Nozzle 15 4 STORAGE Preparation for Storage General e Wash the engine compartment with fresh water and re move the drain screw in the stern to drain the water Wipe up any water left in the compartment CAUTION Use only a mild detergent in water to wash the hull Harsh solvents may attack the surface or smear the colors e Apply a good grade of wax to all exterior hull surfaces e Lightly spray all exposed metal parts with a penetrating rust inhibitor e Remove the seat or block the seat up with 10 mm spacers to insure adequate ventilation and prevent corrosion Cover the watercraft and store it in a clean dry place STORAGE 15 5 Removal from Storage Lubrication Carry out all recommended lubrication procedures see Lubrication in the Periodic Maintenance chapter General Inspection Check for binding or sticking throttle choke or steering or trim mechanism The throttle lever must return fully when released e Clean and gap spark plugs see Spark Plug Cleaning and Spark Plug Adjustment in the Periodic Maintenance chap ter e Check all rubber hoses for weathering a cracking or looseness e Check that the drain screw in the stern is securely tight ened e Check the fire extinguisher for a full charge e Che
69. J04000BS2 C e Install the drive shaft holder on the bulkhead so that the circlip side face toward the front e Apply a non permanent locking agent to the drive shaft holder mounting bolts tighten them loosely e Install the drive shaft e After installing the engine tighten the drive shaft holder mounting bolts to the specified torque to give proper cou pling alignment Torque Drive Shaft Holder Mounting Bolts 22 N m 2 2 kgf m 16 ft Ib Drive Shaft Runout Measure drive shaft runout by supporting the shaft on V A blocks and setting a dial gauge against the shaft at each point shown e Turn the drive shaft slowly The difference between the highest and lowest dial gauge reading is the runout If any measurement exceeds the service limit replace the shaft A A Drive Shaft Runout Ju04020281 6 Standard A Less than 0 1 mm 0 004 in B Less than 0 2 mm 0 008 in Service Limit A 0 2 mm 0 008 in B 0 6 mm 0 024 in PUMP AND IMPELLER 11 1 Pump and Impeller Table of Contents Le 11 2 Specifications ies tere eite ele e ee gie esed aeta terere e e i ie e eri be 11 4 Special TOONS ED 11 5 Pump andilmpellet sc noo eroe ee Ea be Sepe enn 11 6 ette ette cree fee tege Ree even vets
70. Light Inspection 14 53 Charging System 14 26 Oil Level Gauge Symbol Warning Charging Coil Testing 14 26 Light Inspection 14 53 Regulator Rectifier Trim Indicator Inspection 14 54 Removal Installation 14 27 Speedometer Inspection 14 54 Regulator Rectifier Inspection 14 27 Speed Sensor Electric Source Ignition System 14 29 6 14 55 Crankshaft Sensor Inspection 14 29 Tachometer Inspection 14 56 Ignition Coil Remowval 14 29 Battery Symbol Warning Light Ignition Coil Installation 14 30 Inspection 14 56 Ignition Coil Inspection 14 30 Heat Symbol Warning Light Igniter Removal Installation 14 31 In Spector 14 57 Igniter Inspection 14 33 MODE SET Button Inspection 14 57 Spark Plug Removal 14 36 SWIICheS iere tM eet 14 60 Spark Plug Installation 14 37 Switch Inspection 14 60 Spark Plug Inspection 14 37 14 61 Spark Plug Adjustment 14 37 14 61 14 2 ELECTRICAL SYSTEM Smart Steering System 14 62 Steering Position Sensor and Mag
71. N m ft Ib marks Fuel System Flame Arrester Bracket Bolts L Fuel Filler Nut 4 9 0 5 43 Carburetor Mounting Bolts 8 8 0 9 78 in lb L Choke Knob Set Screw L Fuel Tap Set Screw L Oil Pump Cable Mounting Bolt 7 8 0 8 69 in Ib Fuel Filler Tube Clamps 2 9 0 3 26 in Ib Inlet Manifold Mounting Nuts 9 8 1 0 87 Air Inlet Cover Mounting Bolts 7 8 0 8 69 in Ib L Fuel Level Sensor Clamps 2 9 0 3 26 in Ib Cable Holder Mounting Bolts 8 8 0 9 78 in lb L Carburetor Cable Adjuster Locknuts 7 8 0 8 69 in Ib Choke Cable Adjuster Locknuts 7 8 0 8 69 in lb Throttle Case Mounting Screws 3 9 0 4 35 in Ib Air Inlet Connecting Elbows 7 8 14 08 14 69 121 in lb L Engine Lubrication System Oil Filler Nut 4 9 0 5 43 in lb Air Bleeder Screw 1 0 1 5 0 1 0 15 9 13 in lb Oil Filler Tube Clamps 2 9 0 3 26 Oil Pump Mounting Bolts 8 8 0 9 78 in lb L Oil Pump Cable Locknuts 7 8 0 8 69 in lb Oil Pump Cable End Mounting Bolt 4 9 0 5 43 L Exhaust System Exhaust Pipe Mounting Bolts 8 mm dia 29 3 0 22 L Exhaust Pipe Mounting Bolts 10 mm dia 49 5 0 36 L Cable Holder Mounting Bolts 8 8 0 9 78 in lb L Exhaust Manifold Mounting Nuts 34 35 25 5 Expansion Chamber Mounting Bolts 29 3 0 22 L Water Pipe Joints 7 8 14 0 8 1 4 69 122 in lb 55 Water Temperature Sensor 14 7 1 5 11 see text Engine Top End Cylinder Head Nuts 29 7 8 3 0 0 8 22 69 in Ib 5 Water Pipe Joint 7 8 14
72. Remove Regulator Rectifier Mounting Screw A Leads Connector B Regulator Rectifier C e Installation is the reverse of removal Regulator Rectifier Inspection e With the hand tester set to the R x 1 kO range test the regulator rectifier according the following table Special Tool Hand Tester 57001 1394 Regulator Rectifier Inspection Unit kO EN 2 20 3 30 Tester lead Connection If any of the values obtained do not agree with the above table the regulator rectifier must be replaced JNO7O13BS1 14 28 ELECTRICAL SYSTEM Charging System Charging System Circuit c ao Regulator Rectifier Joint Connector Main Fuse e mE JN07006BN5 ELECTRICAL SYSTEM 14 29 Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plugs ignition coils or spark plug leads while the engine is running or you could receive a severe electrical shock Crankshaft Sensor Inspection e Disconnect the 2 pin crankshaft sensor leads connector Blue A e Set the hand tester to the x 100 Q range zero it and connect it to the crankshaft sensor lead terminals G and BL in the connector x lf there is more resistance than the specified value the sensor has an open lead and must be replaced Much less than this resistance means the sensor is sho
73. Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 12 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious dam age 13 Press When using a press or driver to install a part such as a drive shaft holder bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 14 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 1 4 GENERAL INFORMATION Before Servicing 15 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the ma
74. SYSTEM Electric Trim System JNi12014BW1 A Trim Actuator Assembly B 222 3 mm 8 74 0 12 in when the nozzle position is full up with limit switch ON Electronic Control Unit Inspection Electronic Control Unit has the following functions of con trolling the trim motor A G W Trim UP SW B BL W Trim DN SW C BL G Meter D BL Y Trim Motor UP E R BK Limit UP DN F BK W Limit DN G Plug H R BL Batt I BK Batt J BK BL Motor Box K W BL Limit UP L G Y Trim Motor UP JN12005BS2 C ELECTRICAL SYSTEM 14 41 Electric Trim System JN12006BN2 A Trim Switch H Igniter B Multifunction Meter I Ignition Switch C Motor Unit J Main Fuse D Trim Angle Sensor K Stop Switch E Trim Actuator L Start Switch F Trim Fuse M Electronic Control Unit G Starter Relay Electronic Control Unit Inspection e Unscrew the mounting bolts on the crossmember and dis connect the connectors of the electronic control unit e Using the auxiliary wires reconnect the connectors of the control unit to the connector of the main harness 14 42 ELECTRICAL SYSTEM Electric Trim System Check the electronic control unit OCheck the normal voltage and continuity according to the following table and see the causes for abnormal results 1 Normal Voltage and Continuity Ignition SW OFF Ignit
75. Steering Cable Cable Removal e Remove the flame arrester see this chapter e Unscrew the adjuster locknuts A and slide the cable B from the cable holder pulley side e Unscrew the adjuster locknuts A and slide the cable B from the cable holder carburetor side Cable Installation e Fit the actuator cable end A into the carburetor lever e Slide the cable B and screw the adjuster locknuts C into the holder as shown D 10 1 mm 0 40 0 04 in e Check the following after setting the cable end to the pul ley OThe pulley must not come into contact with one side of stopper when turning the pulley completely clockwise A Projection B Maintain clearance JL13006BS1 C OThe pulley must not come into contact with the other side of stopper when releasing the pulley completely A Maintain clearance B Projection e f the pulley contacts the projection check the cable ad justment and adjust as necessary 5 AA e HE 56 Pe 41130058581 3 12 FUEL SYSTEM Choke Cable Choke Cable Adjustment e Refer to Choke Cable Adjustment in the Periodic Mainte nance chapter Choke Knob and Cable Removal Disconnect the choke cable from the carburetor Remove the plug e Remove the set screw A and take out the choke knob B e Remove the cable holder mounting screws A e Pull the choke knob shaft B with cable holder out of the hull e Slide the tip
76. System Smart Steering Actuator see this chapter Steering Position Sensor Clearance see this chapter Steering Position Sensor Clearance e Check the clearance A between the steering position sensor B and the magnet C with a feeler gauge Steering Position Sensor Clearance Standard 0 5 1 5 mm 0 02 0 06 in xIf the clearance is the specified value inspect steering position sensor input voltage x If necessary adjust the steering nut 14 64 ELECTRICAL SYSTEM Smart Steering System Steering Position Sensor Input Voltage Inspection e Measure the input voltage to the steering position sensor NOTE OBe sure the battery is fully charged OConnect a digital voltmeter A to the lead connector B of the steering position sensor using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Connections to Steering Position Sensor Connector Meter R W Terminal Meter gt BK Terminal OTurn the ignition switch ON OCenter the handlebar in the straight ahead position OMeasure the input voltage Steering Position Sensor Input Voltage Standard Battery Voltage OTurn the ignition switch OFF x lf the reading is good inspect steering position sensor output voltage x If the reading is out of standard check the following Battery Voltage Main Fuse 10 A Power Source Wiring see Smart Steering System Cir cuit JL13000BS2 C ELECTRICAL SYSTEM 1
77. YSTEM 4 7 Oil Pump Oil Pump Installation e Be sure the O ring A is in place e Install the oil pump cable A on the pulley B OApply a non permanent locking agent to the oil pump ca ble mounting bolt and torque it Torque Oil Pump Cable End Mounting Bolt 4 9 N m 0 5 kgf m 43 in Ib OBe sure to run the cable C so that the cable end is in contact D with the guide of the pulley and the cable is along the groove of the pulley as shown JD04013BS1 C e Initially inject oil into the oil pump body and the hoses and connect the hoses with the oil pump as shown To 1 Carburetor A To 2 Carburetor B To 3 Carburetor C To Front Check Valve for Balancer Lubrication D To Rear Check Valve for Balancer Lubrication E JD04015BS1 C e Install the oil pump on the magneto cover OWhen mounting the oil pump note the position of the slot A in the front balancer shaft and then turn oil pump shaft B so that it will fit into the slot OApply a non permanent locking agent to the oil pump mounting bolts and torque them Torque Oil Pump Mounting Bolts 8 8 N m 0 9 78 in Ib e Check the oil pump cable installation as follows OPull the throttle lever to ensure if the oil pump cable A makes the oil pump pulley B turn OMake sure the lower part C of the oil pump cable is in stalled on the oil pump pulley securely x If necessary reinstall the oil pump cable on the pu
78. akdown e Spark plug fouled e Spark plug gap wrong e Poor wiring connection spark plug cap e Faulty CDI igniter 16 16 APPENDIX Troubleshooting e Faulty magneto e Battery voltage low Engine Lubrication System e Oil line clogged e Faulty oil pump Abnormal engine sound During normal cruising Slight piston seizure e Piston ring broken or sticking e Main bearing worn or damaged During sudden acceleration e Excessive clearance between connecting rod small end and piston pin or between pin and piston e Excessive connecting rod big end clearance Pinging Ignition timing too advanced e Carbon accumulation in cylinder head e Poor quality gasoline e Spark plug wrong heat range When the engine is idling while cold e Excessive piston clearance e Piston rings worn e Piston worn e Connecting rod bent twisted Low engine power This trouble often has more than one cause and trouble symptoms may not be clear Ignition System e Spark plug gap or heat range wrong e Ignition timing wrong e Reduced ignition coil output e Loose wiring connection in ignition circuit Fuel System e Insufficient fuel supply to carburetor e Carburetor diaphragm damaged e Pulse line leaking or clogged e High speed nozzle clogged e Throttle valve does not fully open e Fuel filter screen clogged e Faulty fuel pump APPENDIX 16 17 Troubleshooting Other e Flame arrester clogged e Muffler or exhaust system clogged e Water or fo
79. an 9 White mark bow side G Apply grease L Apply a non permanent locking agent 12 4 STEERING Steering Cable Steering Cable Adjustment e Check steering cable adjustment OCenter the handlebar in the straight ahead position e Check that the steering nozzle is centered A in the pump cavity x If necessary adjust the steering cable OLoosen the locknut A on the steering cable OTake out the cable joint bolt B and disconnect the cable joint C from the steering nozzle OTurn the joint on the cable to adjust the steering OTemporarily tightening the cable joint bolt connect the joint with the nozzle and check cable adjustment again OWhen adjustment is correct unscrew the cable joint bolt and apply a non permanent locking agent to it And tighten the cable joint bolt and the steering cable locknut securely Torque Cable Joint Bolt 9 8 N m 1 0 kgf m 87 in Ib Steering Cable Removal e Disconnect the cable joint at each end of the steering ca ble OTake out the cable joint bolt A and disconnect the cable joint B from the lever C CAUTION Never lay the watercraft on the right side Water in the exhaust system may drain back into the engine causing serious damage STEERING 12 5 Steering Cable OLoosen the locknut A on the steering cable OTake out the cable joint bolt B and disconnect the cable joint C from the steering nozzle ORemove the cab
80. ance Chart or whenever you find from outside any foreign material or water trapped in the fuel filter Fuel Vent Check Valve Mounting The fuel vent check valve is mounted in the fuel tank vent hose to prevent fuel from spilling during riding Air can flow into the tank to allow fuel to be drawn out by the fuel pump but fuel cannot flow out the check valve e The fuel vent check valve A must be mounted so that the arrow B on its body is pointing toward the fuel tank C 0 JC13003BS1 C PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedure Fuel Vent Check Valve Inspection e Remove the check valve and blow through it from each end x If the check valve will allow air to flow as shown it is OK x If air will flow through the check valve both direction or in neither direction the check valve must be replaced JC11001BS1 C Flame Arrester Cleaning e Remove the flame arrester A see Fuel System chapter e Blow the flame arrester clean with compressed air WARNING Eye protection should be worn when compressed air is used to dry parts Do not direct air toward anyone Use 172 kPa 1 75 kgf cm 25 psi maxi mum nozzle pressure e Install the flame arrester see Fuel System chapter Throttle Shaft Spring Inspection e Check the throttle shaft springs A by pulling the throttle lever x If the springs are damaged or weak replace the carbure tor
81. and maintenance are improved with independent cylinders Nikasil Plating Silicon Carbide HV 2500 Nickel HV550 STL TAT ae 47 f Aluminium Alloy GENERAL INFORMATION 1 13 Technical Information Engine 2 Balancer New counter balancers one at each end of the crankshaft decrease vibrations and make this the smoothest running Kawasaki triple ever produced When reassembling it is necessary to match the marks on the balancer gear and the balancer drive gear After engine reassembly the front and rear balancer oil chambers must be refilled with engine oil for lubricating the bearings and teeth since these chambers are isolated from crankcase chambers Front end 200 mL 12 2 cu in Rear end 20 mL 1 2 cu in Balancer Balancer 1 14 GENERAL INFORMATION Technical Information Engine 3 Carburetor and Throttle Sensor The JH1200 B1 has CDCV 40 carburetors with a Throttle Sensor A The CDCV 40 carburetors deliver sharp throttle response and smooth acceleration Throttle sensor ensures ideal ignition timing at all throttle openings delivering improved response harder acceleration and improved power feel at all rpm The throttle sensor signal goes to the igniter The igniter computes the optimum ignition timing K TRIC system Throttle Sensor The Kawasaki JET SKI Watercraft Constant Velocity Carburetor 1 Development Goals 1 The carburetor must allow high performance with high fle
82. and terminals in the same man ner as specified in the Display Function Inspection Connect the variable rheostat A to the terminal 3 as shown Check that the number of segments matches the resis tance value of the variable rheostat Resistance Value Q Display Segments 7 230 0 4 530 1 2 930 2 1 930 3 820 5 350 7 The LED warning light and fuel symbol flash at the same time e f any display function does not work replace the meter assembly Oil Level Gauge Symbol Warning Light Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e Connect the variable rheostat A to the terminal 2 as shown e Check that the number of segments matches the resis tance value of the variable rheostat Resistance Value Q Display Segments 2 000 0 The LED warning light and oil symbol flash at the same time e If any display function does not work replace the meter assembly JN17018BS2 C JN17019BS2 C 14 54 ELECTRICAL SYSTEM Multifunction Meter Trim Indicator Inspection Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection Connect the variable rheostat 1 A to the terminal 8 as shown Connect the variable rheostat 2 B to the terminal 12 as shown Check that the number of segme
83. ange measure the resis tance as shown A Terminal and Positive Brush B Rear Cover and Negative Brush OKeep the brush holder plate C in contact with the rear cover D as shown x If there is not close to zero ohms the brush lead has open Replace the positive brush assembly and or the negative brush subassembly Special Tool Hand Tester 57001 1394 8 11061051 8 11080851 14 24 ELECTRICAL SYSTEM Electric Starter System Rear Cover Assembly Inspection e Using the highest hand tester range measure the resis tance as shown A Terminal and Rear Cover x lf there is any reading the rear cover assembly have short Replace the rear cover assembly Starter Motor Clutch Inspection e Remove Magneto Cover Starter Idle Gear e Turn the starter motor clutch gear A by hand The starter motor clutch gear should turn counterclockwise C freely but should not turn clockwise B x If the clutch does not operate as it should or if it makes noise disassemble the starter motor clutch examine each part visually and replace any worn or damaged parts ELECTRICAL SYSTEM 14 25 Electric Starter System Electric Starter System Circuit 18 38 84 1030 Asay zeg 8 3 vase 1931838 0 7 d 5 34855 YORIMS VoL esnj JN06004BN5
84. arge While a sealed battery can be used after only filling with electrolyte a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below where an initial charge is required before use However if a battery shows a terminal voltage of 12 6 V or more using a digital volt meter after 10 minutes of filling no initial charge is necessary NOTE OTo measure battery terminal voltage use a digital voltmeter which can be read one decimal place voltage Condition requiring initial charge Charging method At low temperature lower than 0 C 1 8A x 2 3 hours Battery has been stored under high temperature and humidity Seal sheet has been removed or broken peeling tear or hole Battery two or more years old from date of manufacture Battery manufacturing date is printed on battery top Example R2 08 H V Mfg location Day Month Year 1 8A x 15 20 hours Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see this chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions in
85. arge Battery Charge is required PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedure Spark Plug Cleaning Clean the electrodes and the ceramic insulator around the center electrode with an abrasive blasting device OBe certain that all abrasive particles are removed from the plug Clean the entire plug in a high flash point solvent Lubrication As in all marine craft adequate lubrication and corrosion protection is an absolute necessity to provide long reliable service Refer to the Periodic Maintenance Chart for the frequency of the following items e Lubricate the following with a penetrating rust inhibitor Throttle Control Cable A Choke Cable A Smart Steering Cable A 6004010281 Steering Nozzle Pivots B Tilt Ring Pivots C e With the cable disconnected at both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 80904020152 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedure e Lubricate the following with grease Throttle Cable Ends A Kawasaki Smart Steering Cable Ends A Choke Pivot Arm A 13012 P PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedure Choke Cable End B All Hoses Hose Clamp Nuts Bolts and Fasteners Check Nuts Bo
86. asket B on the expansion chamber so that its UP letter C faces upward OApply a non permanent locking agent to the expansion chamber mounting bolts D and torque them Torque Expansion Chamber Mounting Bolts 29 N m 3 0 kgf m 22 ft lb b JE03005BS1 5 6 EXHAUST SYSTEM Expansion Chamber e Install the pipe and the chamber as a set on the manifold Olnstall the new gasket A on the exhaust manifold B so that its UP letter C faces upward OApply a non permanent locking agent to the exhaust pipe mounting bolts and torque them Torque Exhaust Pipe Mounting Bolts M10 D 49 N m 5 0 kgf m 36 ft Ib Exhaust Pipe Mounting Bolts M8 E 29 N m 3 0 kgf m 22 ft lb JE03002BS2 C e Fill the hollow of the exhaust pipe with the specified sil icone grease A if the water temperature sensor B is removed Tighten 556 Torque Water Temperature Sensor 14 7 N m 1 5 kgf m 11 16 JE03006BS1 Exhaust Pipe Exhaust Chamber Cleaning and Inspection e Remove the exhaust pipe and chamber e Clean the carbon deposits out of the exhaust passages with a blunt roundedged tool e Flush foreign matter out of the water passages with fresh water e Check the insides of the water passages for corrosion Check the gasket surfaces for nicks or other damage x If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal pro
87. attery Terminal To Starter Motor Terminal Red Mark Throttle Sensor 16 4 APPENDIX Cable Wire and Hose Routing uw TI E ie eS e Mw 7 ave 8 APPENDIX 16 5 Cable Wire and Hose Routing Water Box Muffler Exhaust Tube Clamp Bands Cut off the band as the cutting edge not facing up Water Pipe Joint Bypass Cooling Hose Bypass Outlet Detent Rubber Coupling Cover 10 Drain Hose 11 Band Clamp loosely the exhaust tube drain hoses and the inlet cooling hose 12 Inlet Cooling Hose 13 Note the clamp screw position on the exhaust tubes 14 Band Keep the inlet cooling hose loose 15 Approximately 50 16 Aligning Mark 17 Detent Plastic 18 Clamps 19 Horizontal Line 20 Bow 21 Viewed A 22 Viewed B 23 Viewed C 16 6 APPENDIX Cable Wire and Hose Routing VY EN MoS Zoo Oo ABS Se CAL I 4 Xy Qu N 5 4 Va 5569 N verd Ly AN ves 4 NS 25 aX AO Le ML q Sh eL SHELL mud 3 Dn is db ja AAN JB09062BW5 APPENDIX 16 7 Cable Wire and Hose Routing Front Check Valve Rear Check Valve To Fr
88. carburetor e Float arm not adjusted Battery Starter System e Faulty magneto solenoid switch e Battery voltage low e Starter motor brushes worn e Faulty starter clutch e Ignition switch turned OFF and or lanyard key not pushed under stop button Engine starts but stops right away Compression e Faulty crankshaft oil seal e Crankcase joint leak e Worn piston and rings e Head gasket leak e Spark plug leak Fuel System Outside Carburetor e Misuse of choke e Fuel filter screen clogged APPENDIX 16 15 Troubleshooting e Fuel feed line leaking or clogged e Pulse line leaking or clogged e Vent line clogged e Faulty fuel pump Inside Carburetor e Water in carburetor e Carburetor diaphragm damaged e Float arm not adjusted Electrical System e Faulty or fouled spark plug e Poor wiring connection e Faulty magneto Engine misfires does not run smoothly Fuel System Fuel mixture too lean Fault in Carburetor e Obstruction in fuel passage or outlet e Diaphragm leaking or damaged e Float arm not adjusted Other e Poor fuel supply fuel filter screens hoses or vent line clogged e Carburetor mounting loose e Faulty fuel pump Fuel mixture too rich Fault in Carburetor e Diaphragm needle dirty or damaged e Float arm not adjusted e Choke not adjusted Other e Flame arrester clogged Electrical System Other Ignition timing wrong Weak Spark e Reduced ignition coil output e High voltage insulation bre
89. ck the battery charge if necessary and clean the ter minals Install the battery see Battery Installation in the Electrical System chapter Fuel System e Check and clean or replace the fuel filter screens as nec essary see Fuel Filter Screen Cleaning in the Periodic Maintenance chapter Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from source of flame or spark this includes any appliance with a pilot light e After refueling and before starting the engine tilt the seat to the rear for several minutes to ventilate the engine com partment WARNING A concentration of gasoline fumes in the engine compartment can cause a fire or explosion e Check for fuel leaks Repair if necessary Check the engine oil level Fill the oil tank with the speci fied oil 15 6 STORAGE Removal from Storage Test Run WARNING Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death Start the engine and run it only for 15 seconds Check for fuel oil and exhaust leaks Any leaks must be repaired CAUTION Do not run the engine without cooling water supply for more than 15 seconds or severe engine and ex haust system
90. d key under the stop switch e Pushing the starter switch crank the engine 4 5 seconds to measure the crankshaft sensor peak voltage ODo not operate the starter for longer than 5 seconds Wait 15 seconds before using it again Repeat the measurements 5 or more times Crankshaft Sensor Peak Voltage Standard 2 V or more xIf the reading is less than the specified value check the crankshaft sensor see Crankshaft Sensor Inspection ELECTRICAL SYSTEM 14 35 Ignition System Throttle Sensor Input Voltage Check Remove the throttle sensor A lead connector e Set the tester B to the DC 10 V range and connect it to the connector C of the main harness Special Tool Hand Tester 57001 1394 Hand Tester Black Blue Lead Hand Tester Black Lead e Turn the ignition switch on e Check the throttle sensor input voltage Throttle Sensor Input Voltage Standard around DC 5 V NOTE OCheck the above process within three minutes is not the specified voltage check the igniter input voltage between Orange lead and Black White lead x lf there is battery voltage between the leads the igniter is defective e To check the throttle sensor output voltage see throttle sensor Inspection JN08045BS2 C Inlet Air Temperature Sensor Input Voltage Check e Disconnect the inlet air temperature sensor A connector e Set the tester B to the DC 10 V range and connect it t
91. damage will occur e Install the seat making sure it is locked APPENDIX 16 1 Appendix Table of Contents Cable Wire and Hose Routing ppp 16 2 Troubleshooting e 16 14 16 2 APPENDIX Cable Wire and Hose Routing 5 EU i MAA j JB09063BW5 APPENDIX 16 3 Cable Wire and Hose Routing Inlet Air Temperature Sensor Out off the end of the sensor from the holder Holder Connect the inlet air temperature sensor lead to the main harness Air Inlet Cover Exhaust Pipe Water Temperature Sensor Clamp Keep the water temperature sensor lead loose Magneto Cover Keep the magneto leads loose Connect the leads to the main harness Band Cylinder Head Front Electric Case Lead 1 Spark Plug Lead 2 Spark Plug Lead 3 Spark Plug Lead Front Electric Case Keep the spark plug leads loose Do not contact the spark plug leads and the battery cable Clamp spark plug lead The holder should be parallel with the battery front Starter Motor Cable Red Connect the rear electric case leads to the main harness Rear Electric Case Leads Connect the battery cable to the ground Rear Electric Case Connect the battery cable to the starter relay terminal Battery To B
92. dicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal ELECTRICAL SYSTEM 14 17 Battery 3 When you do not use the watercraft for months Give a refresh charge before you store the watercraft and store it with the negative lead re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the watercraft s starting system has no problem Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or ey
93. ditions are met engine speed averages more than 3 000 RPM for a spec ified time the throttle is released completely and the handlebars are held fully to the left or right Construction and Operation The main component parts for the Kawasaki Smart Steer ing system are the following Steering Position Sensor and Magnet Throttle Sensor Crankshaft Sensor IC Igniter Smart Steering Actuator The steering position sensor A is installed on the bottom side of the steering holder B Left and right sensors are built into the steering position sensor A The magnet C is installed on the mount plate D When the handlebar is fully turned in either direction the magnet C under the steering position sensor A signals the steering position sensor A to switch ON aPN JBO6010BS2 C GENERAL INFORMATION 1 9 Technical Information Kawasaki Smart Steering System Carburetor Type Kawasaki Smart Steering system provides thrust approx 2 800 rpm in water when the these three conditions are met INPUT OUTPUT Condition 1 Throttle is release The throttle opening angle of throttle sensor at idle Throttle Sensor Condition 2 The handlebar is fully turned in either Condition 1 gt direction The steering position sensor switches ON Condition 3 average engine speed for a period of u time before the system operates is 3 000 rpm eae Actuator or more The igniter calc
94. e carbon brushes Starter Motor Brush Length Standard 12 0 mm 0 47 in Service Limit 6 5 mm 0 26 in ELECTRICAL SYSTEM 14 23 Electric Starter System Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 hand tester range measure the resis tance between any two commutator segments A x lf there is a high resistance or no reading gt between two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced Special Tool Hand Tester 57001 1394 NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable within the hand tester If all other starter mo tor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Assembly Inspection e Using the x 1 O hand tester r
95. e specified refreshing charge is required see Refreshing Charge in the Electrical System chapter Battery Terminal Voltage Standard 12 6 V or more Connect the battery leads positive first Spark Plug Inspection e Remove the spark plugs see Spark Plug Removal in the Electrical System e Examine the ceramic insulator C and electrodes A B xIf the insulator appears glazed or very white or if there are gray metallic deposits on the electrodes combustion chamber temperatures are too high see Troubleshooting in the Appendix chapter x If the insulator appears dry and sooty the fuel air mixture is overly rich see Troubleshooting in the Appendix chap ter e f the insulator and electrodes are wet and oily im proper oil type or an excess oil output may be the cause x If the ceramic insulator is cracked replace the plug x lf the electrodes are badly worn or burned replace the plug e Examine the spark plug threads x lf the threads are damaged replace the plug Spark Plug Adjustment e Measure the spark plug gap D OCheck the distance between the electrodes with a feeler gauge or a wire gauge Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in xIf the gap is not within specifications adjust it e Adjustthe gap by carefully bending the side electrode with a tool designed for this purpose GP08070381 lt Terminal Voltage 5 0 25 50 75 100 Refreshing ch
96. ec em eee e Gate ee Rt ove cuero ad 7 5 7 2 ENGINE REMOVAL INSTALLATION Exploded View J802003BW5 ENGINE REMOVAL INSTALLATION 7 3 Exploded View Torque No Fastener Nm kgf m ft lb Remarks 1 Engine Mounting Bolts 36 3 7 27 L 2 Damper Mounting Bolts 16 1 6 12 3 Mount Bolts 34 3 5 25 L L Apply a non permanent locking agent 7 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Removal e Remove or disconnect Exhaust Pipe A and Chamber B as a set see Exhaust System chapter Air Inlet Cover C see Fuel System chapter Carburetors see Fuel System chapter Magneto Lead Connectors D Disconnect Oil Inlet Hose E Disconnect J503B012 P e Remove Spark Plugs A Cooling Hoses on Cylinder Heads B Coupling Cover B Engine Mounting Bolts A 003006852 C ENGINE REMOVAL INSTALLATION 7 5 Engine Removal Installation e Slide the engine toward the front to disengage the cou plings and then lift the engine A out of the hull OLift the engine by using the plates A NOTE OPerform the following services while the engine is lifted to make them easier Oil Pump Cable Disconnection Inlet Cooling Hose Disconnection Starter Motor Cable Disconnection e Remove the engine mount 4003007851 Installation e Be sure there are no foreign objects and parts inside of the hull
97. ed to be X max e Compare the X max value with that in the chart and choose the amount of shims X max mm Amount of Shims From 0 Less than 0 5 3 From 0 5 Less than 1 0 4 From 1 0 Less than 1 5 e Visually inspect the impeller seal A and replace if nec essary e Install the seal A on the impeller x If the pump cap bearing A was removed replace it with a new one e Press the bearing into the cap B until it is bottomed e Be sure the O ring C is in place on the pump cap e High grade water resistance grease the O ring JKO4033BS2 C JK04013BS1 C JK04014BS1 C PUMP AND IMPELLER 11 13 Pump and Impeller e Install the damper A over the pump shaft e Instal the following on the guide vane Dowel Pins B Shims C Pump Case D Pump Cap E Olnstall the shim s noting its tab F position OApply a non permanent locking agent to the following Torque Pump Case Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Pump Cap Bolts 9 8 1 0 kgf m 87 in Ib NOTE OBe sure the impeller rotates by 2 9 0 3 kgF m 26 in Ib or less after assembly JKO4015BS2 C OThe pump case can be installed in either direction A or B Tabs C e Use a feeler gauge A to measure the impeller B to pump case C clearance Impeller Clearance Standard 0 2 0 3 mm 0 008 0 012 in Service Limit 0 6 mm 0 024 in
98. eering Position Switch Steering Position Sensor and Magnet Crankshaft Sensor Multifunction Meter Magneto Joint Connector Main Switch IC Igniter Battery Ignition Coils Spark Plugs Carburetor Cable Smart Steering Actuator lt 0 gt GENERAL INFORMATION 1 11 Technical Information Kawasaki Smart Steering System Carburetor Type Flow Chart of Kawasaki Smart Steering System Normal Operation is throttle fully released is handlebar fully turned Calculate Average rpm Is average rpm 3000 r min rpm or more before the handlebar fully turned Kawasaki Smart Steering System Operates 15 handlebar kept in Is throttie lever pulled in straight ahead position a third or more position JB08008B S 1 12 GENERAL INFORMATION Technical Information Engine 1 Cylinder This large displacement engine features independent Nikasil plated aluminium cylinders for light weight long wear and superb heat dispersion characteristics Comparison of Cylinders JH1200B Independent Linerless 3 cyl One Piece 3 with Iron Sleeves Nikasil Plating A film in which silicon carbide SiC is combined with nickel Ni The cylinders are made from aluminium alloy for excellent heat transmission This keeps the surface temperature of the cylinder bore lower than is possible with a conventional aluminium cylinder with a cast iron sleeve Assembly
99. eering holder E e Hand tighten the steering nut F and check that the steer ing shaft turns smoothly but there is no looseness be tween the shaft and holder e Apply a non permanent locking agent to the steering holder mounting bolts G and torque them Torque Steering Holder Mounting Bolts 16 N m 1 6 kgf m 11 5 ft Ib JLOG003BS2 C e Turning the steering shaft fully in left and right direction check whether the steering position sensor comes in con tact with the magnet e Check the clearance A between the steering position sensor B and the magnet C with feeler gauge Steering Position Sensor Clearance Standard 0 5 1 5 mm 0 02 0 06 in x If necessary adjust the steering shaft nut 14106004851 e Install the lever A over the steering shaft B OAlign the project C on the lever with the groove D on the shaft JLOG001BS1 HULL ENGINE HOOD 13 1 Hull Engine Hood Table of Contents Exploded Views E 13 2 gite f 13 6 Hatch Cover Removallnstallation eee 13 6 Hatch Cover Installation pt 13 7 Hatch Cover Bracket 1 21 enne nennen nennen nnne 13 8 Hatch Cover Bracket Installation nnn 13 8 Rear View Mirror 2 eser nsn 13 9
100. eering shaft fully to the left and right direc tion check whether the steering position sensor comes in contact with the magnet Check the clearance A between the steering position sensor B and the magnet C with a feeler gauge Steering Position Sensor Clearance Standard 0 5 1 5 mm 0 02 0 06 in x If necessary adjust the steering nut see Steering Instal lation in the Steering chapter Check the operation of the Smart Steering system Smart Steering System Inspection Inspect the smart steering system with the watercraft in the water e Center the handlebar in the straight ahead position Start the engine and allow it to idle for 4 seconds or more Turn the handlebar all the way to the left or right and check that the engine speed does not change i e the engine maintains and idle e Center the handlebar in the straight ahead position e Squeeze the throttle lever and rev the engine increase engine speed to approx 4 000 r min rpm or above for 4 seconds or more e Release the throttle lever e Within 1 second turn the handlebar all the way to the left or right and check that the engine speed increases to approx 2800 r min rpm e Center the handlebar in the straight ahead position and check that the engine speed decreases to an idle speed x If the Smart Steering system does not operate normally check the following Smart Steering Cable see Smart Steering Cable Adjust ment in the Fuel
101. el Removal Starter Clutch Gear and Starter Idle Gear Removal Stator Removal NOTE OOil level should be approx in the middle line C of the oil level gauge D under the state that the engine is mounted on the hull after pouring 200 mL 12 2 cu in e Fill 20 mL 1 2 cu in of 2 stroke oil A into the rear balancer room B after splitting the crankcase m SY JH13001BW2 ENGINE BOTTOM END 8 7 Coupling Removal e Remove Engine see Engine Removal Installation chapter Coupling Damper Magneto Cover Starter Idle Gear Holding the boss of the front balancer gear unscrew the coupling Special Tools Rotor Holder 57001 1428 A Coupling Holder 57001 1423 B NOTE OBe sure to hold the boss B of the front balancer gear C with the rotor holder A CAUTION Do not hold the teeth of the front balancer drive gear or magneto flywheel with the rotor holder The gear teeth or the flywheel could be damaged Installation e Apply a non permanent locking agent e Screw the coupling onto the crankshaft and tighten it Torque Coupling 123 127 N m 12 5 13 0 kgf m 90 94 ft Ib Coupling Damper Inspection e Refer to Coupling Damper Inspection in the Periodic Maintenance chapter 8 8 ENGINE BOTTOM END Magneto Flywheel Magneto Flywheel Removal e Remove Engine see Engine Removal Installation chapter Magneto Cover Starter Idle Gear Hold
102. en the clamp B and pull out the exhaust tube C OUnhook the rubber strap D Installation e Be sure the dampers A on the hull bottom and muffler body are in place e Install the clamps B of the exhaust tubes noting their screw positions OThe center lines of tube C and pipe D to be on the same line E 5 mm 0 2 in F View H G Rear View 4 05002852 C Inspection e Remove the water box muffler e Empty water out of the water box e Check the inlet spigot for damage caused by excessive heat x lf there is heat damage to the inlet spigot check the cool ing system for blockage see Cooling System Cleaning and Inspection and the carburetor for proper adjustment see Fuel System chapter ENGINE TOP END 6 1 Exploded View Specifications Special Tools Engine Top End Disassembly and Assembly Disassembly Assembly Maintenance and Inspection Engine Top End Table of Contents Compression ee enn en nne enne nnne nnns nen nnne nnns nnns Cylinder Head Warp Inspection Cylinder Wear Inspection Piston Diameter Measurement Piston Cylinder Clearance etoile Piston Ring Piston Ring Groove Inspection Piston Ring End Gap 6 2 6 4 6 5 6 6 6 11 6 11 6 11 6 12 6 12 6 12 6 12 6 13 6 2 ENGINE
103. ence Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a lock
104. ent 12 4 Steering Cable Removal tero eoe idet nee tede inden agen 12 4 Steering Gable Installation ruri euet E ERE Eee tee 12 6 Steering Cable Inspection cei e in ER TR MEE ena 12 6 Steering Cable Lubrication 12 6 rM 12 7 beet eto betae de tod bet apt adios 12 7 Trim Cable with Trim Actuator Removal pp 12 7 Trim Gable Installation RR eot a Po P Recibe 12 8 Trim Cable Inspection eee 12 8 Trim Cable L bfication edet etr t ree a d eee e pere eru et 12 8 GIS DAN host repete E ERN ere FERRE T SERERE ER TER eed 12 9 ail 12 9 accu uA 12 9 ila EE 12 11 REMOVE cits ack 12 11 12 2 STEERING Exploded View 41920078485 STEERING 12 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Handlebar Clamp Bolts 16 1 6 11 5 L 2 Steering Holder Mounting Bolts 16 1 6 11 5 L 3 Steering Cable Nut 39 4 0 29 4 Trim Cable Nut 39 4 0 29 5 Throttle Case Mounting Screws 3 9 0 4 35 in Ib 6 Switch Case Mounting Screws 3 9 0 4 35 T CabeJomBols 98 10 erme 8 98 10
105. ent e Refer to Carburetor Cable Adjustment in the Periodic Maintenance chapter Oil Pump Cable Adjustment e Refer to Oil Pump Cable Adjustment in the Periodic Main tenance chapter Throttle Case and Throttle Control Cable Removal e Loosen the adjuster locknuts of the carburetor and oil pump cables Take out the bolt A of the cable holder B and move the holder with the control cables to port side to make the service easier e Disconnect the carburetor cable from the carburetor OUnscrew the adjuster locknuts and slide the cable from the cable holder OSlide the cable tip A from the throttle shaft lever e Disconnect the oil pump cable from the oil pump cable OUnscrew the adjuster locknuts and slide the cable from the cable holder OTake out the bolt A and disconnect the oil pump cable end Remove the handlebar with the throttle case and the start stop switch case see Handlebar Removal in the Steering chapter e Disconnect the throttle cable from case OUse a screw driver A to separate the tip of the cable end B from the case body OSlide the rubber boot out of the place OUnscrew the throttle cable fitting nut e Pull down the throttle control cable JC05016BS1 FUEL SYSTEM 3 9 Throttle Control Cable Throttle Case and Throttle Control Cable Installation e Install the oil pump cable A on the pulley B OApply a non permanent locking agent to the oil pump ca ble m
106. er down strongly enough to break the seals Now the electrolyte should start to flow into the battery NOTE ODo not tilt the container as the electrolyte flow may be interrupted e Make sure air bubbles A are coming up from all six filler ports OLeave the container this way for 5 minutes or longer NOTE Olf no air bubbles are coming up from a filler port tap B the bottom of the container two or three times Never remove the container from the battery CAUTION Fill the electrolyte into the battery until the con tainer is completely emptied gp070004 tif 8 09000851 5 EE x 8 09000751 8 09000851 14 16 ELECTRICAL SYSTEM Battery e Be certain that all the electrolyte has flowed out Tap the bottom the same way as above if there is any electrolyte left in the container Now pull the container gently out of the battery Let the battery sit for 20 minutes During this time the electrolyte permeates the special separators and the gas generated by chemical reaction is released e Fit the seal cap A tightly into the filler ports until the seal cap is at the same level as the top of the battery NOTE ODo not hammer Press down evenly with both hands 8 09000951 C Once you installed the seal cap after filling the bat tery never remove it nor add any water or elec trolyte Initial Ch
107. es If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper watercraft electric system Therefore replace a sealed battery only on watercraft which was originally equipped with a sealed battery Be careful if a sealed battery is installed on watercraft which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection ORefer to Battery Charging Condition Inspection in the Pe riodic Maintenance chapter Refreshing Charge Remove the battery A see Battery Removal Refresh charge by following method according to the bat tery terminal voltage This battery is sealed type Never remove seal cap B even at charging Never add water Charge with current and time as stated below GP080705S1 Terminal Voltage 11 5 less than 12 6 V Standard Charge 1 8 A x 5 10 h see following chart Quick Charge 9 0Ax1 0h CAUTION If possible do not quick charge If the quick charge is done due to unavoidable circumstances do stan dard charge later on Terminal Voltage less than 11 5 V Charging Method 1 8Ax20h 14 18 ELECTRICAL SYSTEM Battery NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than five minutes at the increa
108. es connect the trim actuator termi nals to the main harness terminals as shown OConnect the hand tester to the trim actuator terminal as shown OMove the nozzle by pushing the trim switch OCheck that the meter readings are variable x If the meter readings are not variable the trim angle sen sor defective JN12012BS1 C e Inspect the limit switch function of the trim angle sensor OSet the nozzle full up position by pushing the trim switch ODisconnect the trim actuator connectors A P Ex OUsing the hand tester check to see the following connec tion When the nozzle is full up position x RIBK W around 0 Q B C OReconnect the trim actuator connectors A OSet the nozzle full down position by pushing the trim switch ODisconnect the trim actuator connectors JN12013BS1 C When the nozzle is full down position R BK BK W around 0 Q C R BK W B x lf the tester reading is not as specified the trim angle sensor is defective Special Tool Hand Tester 57001 1394 Inspect the amount of the trim cable stroke ODisconnect the trim cable end see Steering chapter OPushing the trim switch measure the amount of the trim cable between full up and full down positions Trim Cable Stroke Amount 16 mm 0 6 in x lf the stroke amount is not specified the trim actuator is defective 14 40 ELECTRICAL
109. ey see Smart Steering Actuator Removal in this chapter e Using auxiliary wires connect a 12 V battery A to the actuator connector B as follows OConnect the battery positive terminal to the R W terminal C OConnect the battery negative terminal to the BK terminal D e Check that when the battery negative terminal is con nected to the Y W terminal E using the auxiliary wire the actuator shaft F turns clockwise G x If the actuator shaft does not turn replace the actuator JN18001BS2 C 14 68 ELECTRICAL SYSTEM Smart Steering System 38 98 IE E 38 4osuas 33854842 lt s pay Le T lt 28 e o 3n1d x4edg 1199 uo131u31 gt o o c E o t o 38 8 4931u3 Asay peg 8 38 38 8 9 38 wa u 38 38 4 4 38 178 78 A 38 18 38 M k 38 4 4 38 14 19 4 38 18 38 M k 18 38 A 38 38 18 A 38 40 99UU09 3u1of 8 38 38 8 40329UuU0 yd 34 ug 18 u 38 0 08 98 JN18000BW5 49 1 o m u vol uey pea 7 M 208095 31504 gu aaays STORAGE 15 1 Storage Table of Contents Preparation Tor Storage
110. gent MO Apply molybdenum disulfide grease oil Mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 WG Apply water resistance grease 14 10 ELECTRICAL SYSTEM Wiring Diagram y TEA E uel Level Sensor BK Water G R G R Temperature R G R Speed Sensor Sensor BK W BK W BL BL Level Sensor Smart Steering Actuator R Y R Y 22 i CE Multifunction um p eY ay BK W sk TER R Y PU mmo 8 R R W R G BL R BL BK Connector BL R BL BK stearine Position RIN R G Sensor R BL R BL Main Fuse 10A oS R7 BK R BK ONG Trim Fuse 20 8 6 oo R BL R BK R R BL Ignition 5 ewe Switch 47 4 E 0 0 Stop Switch A Start Switch T Us o G W G W 7 BL W Trim Switch R W R W BL BLIY BK BL PEFR BL BK R G BK m c o e Trim Switch R W BK BL WG W Stop amp Ignition Switch Tether Switch Start Switch UP STOP BUTTON TETHER Y R Y R FREE FREE SET CHO FREE DOWN PUSH PuLL PUSH 213704 85 ELECTRICAL SYSTEM 14 11 Wiring Diagram Inlet Air Temperature Sensor Throttle i Sr Sensor Igniter i 8 gt
111. gneto Flywheel e Inspect the starter clutch OTurn the starter clutch gear A by hand The starter clutch gear should turn counterclockwise C freely but should not turn clockwise B x If the clutch does not operate as it should or if it makes noise disassemble the starter clutch examine each part visually and replace any worn or damaged parts NOTE OLeave the starter idle gear removed when inspecting ENGINE BOTTOM END 8 11 Stator Removal e Remove Engine Magneto Cover A e Remove Grommet Cover Mounting bolts A Grommet Cover B Stator Grommet Mounting Screws C Grommet D Gasket E Crankshaft Sensor Mounting Screws F Stator Mounting Bolts with Washers G Stator Assembly H Installation NOTE Olnstall the grommet and grommet cover before installing the stator assembly e Run the gasket through the stator lead e Install the grommet A on the grommet cover B OApply water resistant grease to the grommet OApply a non permanent locking agent to the grommet mounting screws C Torque Grommet Mounting Screws 3 5 N m 0 36 kgf m 31 in Ib e Install the grommet cover on the magneto cover Olnstall the new gasket A so that its UP letter B faces upward ONote the install direction for the cover C and clamp D OApply a non permanent locking agent to the grommet cover mounting bolts E and clamp mounting bolt F Torque Grommet Cover Mounting Bolts 8 8 N m 0 9 kgf m
112. he DC25 V range and connect it to the terminals 5 and 10 x If the voltage is less than 7 V replace the meter assembly Special Tool Hand Tester 57001 1394 JN17022BS2 C 14 56 ELECTRICAL SYSTEM Multifunction Meter Tachometer Inspection Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 7 OThe tachometer indicates approximately 3 000 rpm in case the input frequency would be approximately 66 Hz x If the tachometer does not work normally replace the me ter assembly Battery Symbol Warning Light Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e Check that the battery symbol warning light flash when the input voltage to the terminal A is lowered to 12 0 1 volts or less And check that the meter returns in the state of normality when the input voltage to the black lead terminal is raised to 12 5 V or more x If any display function does not work replace meter as sembly J LPL d 0 1 0 3 V DUTY 62 85 JN17023B83 JN17024BS2 C ELECTRICAL SYSTEM 14 57 Multifunction Meter Heat Symbol Warning Light Inspection Connect
113. ight 284 kg 626 Ib Fuel Tank Capacity 58 L 15 3 US gal including 7 L 1 8 US gal reserve Engine Oil Type 2 stroke N M M A Certified for Service TC W3 Oil Tank Capacity 4 7 L 1 2 US gal GENERAL INFORMATION 1 7 General Specifications Items JH1200 B1 B3 Electrical Equipment Battery 12 V 18 Ah Maximum Generator Out Put 5 0 A 14V 6 000 r min rpm This information shown here represents results under controlled conditions and the information may not be correct under other conditions Specifications subject to change without notice and may not apply to every country 1 8 GENERAL INFORMATION Technical Information Kawasaki Smart Steering System Carburetor Type Outline The Kawasaki Smart Steering system provides turning action under certain conditions when the throttle is re leased There must be thrust at the jet nozzle to initiate and complete turns This is supplemental steering system which assists operators in learning to negotiate turns and maneuver The Kawasaki Smart Steering system continuously de tects the operator s steering input as well as the boat s speed When the throttle is released while boat speed is high and a turn is initiated the smart steering system au tomatically increases engine speed to provide additional thrust The system does not work when the engine is off or the boat speed is low The Kawasaki Smart Steering system functions when all of these con
114. in lb 3 Oil Filler Tube Clamps 2 9 0 3 26 in Ib 4 Pump Mounting Bolts 8 8 0 9 78 in Ib L 5 Pump Cable Locknuts 7 8 0 8 69 in Ib 6 Pump Cable End Mounting Bolt 4 9 0 5 43 in lb L 87 L 8 Grommet Cover Mounting Bolts 78 in Ib L 10 Plate Bolt 78 11 To carburetor check valves 12 To front check valve on upper crankcase half 13 To rear check valve on upper crankcase half 14 Correct L Apply a non permanent locking agent G Apply grease 4 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type 2 stroke N M M A Certified for Service TC W3 Oil Tank Capacity 4 7 L 1 24 US gal Engine Oil Pump Oil pump output when oil pump pulley is fully opened 3 000 r min rpm 2 min per one line Output for 1 Carburetor 3 83 mL 0 234 cu in 10 Output for 2 Carburetor 4 00 mL 0 244 cu in 10 Output for 3 Carburetor 3 83 mL 0 234 cu in 10 Output for Front Balancer 1 33 mL 0 081 cu in 10 Output for Rear Balancer 1 33 mL 0 081 cu in 10 ENGINE LUBRICATION SYSTEM 4 5 Oil Pump Oil Pump Bleeding e Make sure that there is plenty of engine oil in the oil tank and that oil flow is not restricted e Place a container under the oil pump e Loosen the air bleeder screw A on the oil pump a cou ple of turns wait until oil flows out and then tighten the bleeder screw securely Torque Air Bleeder Screw 1 0 1 5 N m 0 1 0 15 kgf m 9 1
115. in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a part first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them 7 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 8 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads 9 Edges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over 10 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 11 Gasket O ring Replace a gasket or an O ring with a new part when disassembling
116. ing agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents i re 1 2 ldentificati N rr 1 5 General 1 6 Technical Information Kawasaki Smart Steering System Carburetor Type 1 8 Technical InformationsBrnglfiB Icone 1 12 Technical Information Propulsion System 1 18 Technical Information lgniter pe 1 19 Technical Information Electrical aede acre eere donna 1 22 Unit Coriversiobi Table 1 23 1 2 GENERAL INFORMATION Before Servicing Before starting to service a watercraft careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descrip tions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting or presence of symptoms indicate that adjustments may be required Whenever running of the engine is required during maintenance it is best to ha
117. ing blow air through both hoses A to force all water out of the bilge system Fuel System Gasoline is extremely flammable and can be explo sive under certain conditions Pull the lanyard key off the stop button Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Drain the fuel tank This should be done with a siphon or pump A Siphon Hose Clean the filter screens see Fuel Filter Screen Cleaning in the Periodic Maintenance chapter e Inspect replace the fuel filter see Fuel Filter Inspection in the Periodic Maintenance chapter e Leave the fuel filter cap loose to prevent condensation in the tank e Turn the ignition switch on e Push the lanyard key under the stop button and start the engine and run it in 15 second periods until all fuel in the carburetor is used up Wait 5 minutes between 15 second running periods e Pull the lanyard key off the stop button and turn the igni tion switch off CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damage will occur STORAGE 15 3 Preparation for Storage Remove the air inlet cover A from the carburetor e Lift out the flame arresters and clean them if necessary see Flame Arrester Cleaning in the Periodic Mainte na
118. ing the boss B of the front balancer gear C with the rotor holder A remove the flywheel bolt Special Tool Rotor Holder 57001 1428 A CAUTION Do not hold the teeth of the front balancer drive gear or magneto flywheel with the rotor holder The gear teeth or the flywheel could be damaged OUsing the special tool pull off the flywheel Special Tool Flywheel Puller Assembly M30 x 1 5 M33 x 1 5 57001 1426 A CAUTION Do not hit the head of the flywheel puller assy A loss in rotor magnetism may be caused Magneto Flywheel Disassembly e Remove the snap ring A e Compressing the friction ring C remove the oneway clutch B from the balancer drive gear D OWhen compressing the friction ring be careful that its pro jections E does not get out of the side plate F e Remove the balancer drive gear mounting bolts G and take out the magneto flywheel H Magneto Flywheel Assembly e Install the oneway clutch compressing the friction ring on the balancer drive gear OWhen installing the oneway clutch be careful that its ro tating mark A faces toward the balancer gear B side OWhen compressing the friction ring be careful that its projections does not get out of the side plate e Replace the snap ring C with new one and install it JH05004BS1 C JH05005BS1 ENGINE BOTTOM END 8 9 Magneto Flywheel e Install the magneto flywheel A
119. ion SW ON 1 R BL Ground BK 12 V Unit ON Unit Ful U Connections OFF P Full Up Full Down Full Down 2 R BK M T m BK W Discontinuity Discontinuity Continuity 3 R BK r TE E W BL Discontinuity Continuity Discontinuity SA BEASPIE Iaj 12 V 12V A 5 SES how ay 12 V OV A When the trim switch UP side is pushed B When the trim switch DOWN side is pushed 2 Causes for Abnormal Results Faulty Parts Faulty Parts Fuse Trim Angle Sensor Trim Switch e e e e ELECTRICAL SYSTEM 14 43 Electric Trim System ircul Electric Trim System C 40sueg waj 18 8 4 38 4 38 4 38 18 u 9 u yai Po 38 8 38 43 18 CKI 1 18 261 IUN 40708 1 4931u8 8 8 ase 1013009 18 8 18 8 w a 4103192uu0g K A 18 40398uu09 48120108485 4 8 4 18 4 18 8 9 4 9 e 1 y V k 107 8 u 3879 s vog 8789 7 asny Hi er paa 0777 T esn ule 1878 E d EM 38 18 38 18 ET 8 14 use uo139unj13 ny 14 44 ELECTRICAL SYSTEM Electric Case Front Electric Case Removal Disassembly Remove the battery e Remove or disconnect Lead C
120. iston D and Diaphragm E CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm e Unscrew the jet needle holder bolt A and take off the holder spring and jet needle B JCO7029BS1 FUEL SYSTEM 3 17 Carburetor Fuel Pump e Unscrew the vacuum piston holder screws A and take off the vacuum piston holder B e Unscrew the carburetor cover screws A and take off the carburetor cover B e Unscrew the float arm set screw A e Remove Float Arm B and Pin Inlet Valve C Spring D e Unscrew the check valve body screws A and take off the check valve body B Remove Main Jet A Pilot Jet B Screw C Valve Seat D 3 18 FUEL SYSTEM Carburetor Fuel Pump Carburetor Assembly e Install Valve Seat A and Screw B Main Jet C Pilot Jet D Gasket E e Apply a non permanent locking agent to the check valve body screws Check Valve Body F and Screws Spring G Float Arm and Inlet Valve I e Install the vacuum piston holder A e Install the jet needle B and holder spring C in the vac uum piston D and tighten the jet needle holder bolt E e Install Cap Spring F Carburetor Cap G 42070318851 NOTE OAfter the carburetor has been disassembled and cleaned it should be primed before starting the engine to save the battery Pu
121. it the crank shaft should be either replaced or rebuilt Connecting Rod Big End Side Clearance Standard 0 45 0 55 mm 0 01772 0 02165 in Service limit 0 8 mm 0 031 in Crankshaft Main Bearing Wear e Wash the bearings in a high flash point solvent blow them dry DO NOT SPIN THEM and lubricate them with en gine oil CAUTION Solvent is toxic and flammable Avoid prolonged contact with skin and keep away from open flame Use only in a well ventilated area Eye protection should be worn when compressed air is used to dry parts Do not direct air towards anyone Use 172 kPa 1 75 kgf cm 25 psi maximum nozzle pres sure e Turn each bearing over by hand and see that it makes no noise turns smoothly and has no rough spots xIf any of the bearings are defective replace them Crankshaft Runout e Check crankshaft alignment by measuring runout OWith the crankshaft on V blocks A rotate the crank shaft slowly and measure runout at each of the locations shown x lf the runout at any point exceeds the service limit the crankshaft must be either replaced or rebuilt Crankshaft Runout B Standard TIR under 0 04 mm 0 00157 in Service Limit TIR 0 10 mm 0 00394 in Crankshaft Runout C Standard TIR under 0 10 mm 0 00394 in Service Limit TIR 0 25 mm 0 00984 in JH09002BS1 C JH09012BS1 C COOLING AND BILGE SYSTEM 9 1 Cooling and Bilge System
122. it is very loose in vacuum piston holder replace the piston and or the holder e Check the plastic tip on the inlet valve It should be smooth without any grooves scratches or tears Inlet Valve A Inlet Valve Wear B x If the plastic tip is damaged replace inlet valve Float Arm Level Inspection and Adjustment e Check the float arm level A OMeasure from the plastic tip B on the float arm to the carburetor case C Float Arm Level 1 0 2 0 mm 0 04 0 08 in x If the float arm level is incorrect bend the float arm very slightly to changed the float arm level 40070178851 0070328 5 3 20 FUEL SYSTEM Carburetor Fuel Pump Pop off Pressure Inspection e Pull the fuel inlet and return hoses out of their fittings on the carburetor e Connect the hose of the gauge tester A to the fuel inlet fitting B e Press down the fuel return fitting C securely with a finger e Pump the tester until the inlet release pressure is reached seen by a sudden pressure drop Pop off Pressure Standard 108 kPa 1 10 kgf cm 15 6 psi NOTE OPressure inspection should be performed three times to obtain a correct reaching xIf the pop off pressure valve is not specified inspect the float arm level see this chapter CAUTION Do not stretch or cut the float arm spring Fuel Pump Removal Installation e Remove the carburetor e Remove the fuel pump body
123. ive shaft in a vice and unscrew the coupling Special Tool Coupling Holder A 57001 1423 e When installing the drive shaft be careful of the following items OApply a non permanent locking agent to the coupling threads and tighten it Torque Coupling 39 4 0 kgf m 29 ft Ib OApply grease to the grease seal lips and the drive shaft spline Drive Shaft Holder Removal Disassembly e Remove the drive shaft e Unscrew the mounting bolts A and remove the drive shaft holder B from the bulkhead e Disassemble the drive shaft holder ORemove the circlip A DRIVE SYSTEM 10 7 Drive Shaft Drive Shaft Holder OPress the small grease seal and the large grease seals bearing and small grease seals come out of the holder I A Sleeve B Blocks C Press lt JJ04004B 5 Drive Shaft Holder Assembly Installation e Replace the grease seals with new ones e Press the bearing and grease seals into the drive shaft holder noting the following Olnstall the parts in this order Two Small Grease Seals A D One Bearing B Two Large Grease Seals C ze J J Front D oA Special Tool Bearing Driver Set 57001 1129 Olnstall the seals so that the sides with the spring face out ward the gaps between the seals with grease E e Install the circlip e Grease to the bearing inner surface and grease seal lips ES J
124. joint and locknut on the cable JL04000BS1 C JL04001BS1 C 12 8 STEERING Trim Cable e Remove the pump see Pump Removal in the Pump Im peller chapter e Unscrew the large nut A in the hull with a wrench e Slide off the E ring A washer B and O ring C e Slide the fuel tank toward the right A to remove the trim actuator B with the cable OLoosen the upper clamps on the fuel and oil inlet tube and pull down the tubes OUnhook the straps for the fuel and oil tanks e Disconnect the connector of the trim actuator leads e Pull the cable from the cable detent in the engine com partment Pull out the trim cable with the trim actuator Trim Cable Installation e Torque Torque Trim Cable Nut 39 N m 4 0 kgf m 29 ft Ib Trim Cable Inspection e Refer to Trim Cable Inspection in the Periodic Mainte nance chapter Trim Cable Lubrication NOTE OThe trim cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced STEERING 12 9 Handlebar Removal Remove the clamp screws for the throttle case A and the switch case B e Unscrew the mounting screws C and remove the rear handlebar cover D e Unscrew the mounting screws A and remove the front handlebar cover B e Unscrew the mounting screws C and remove the han dlebar pad D Take out the handle clamp bolts A a
125. l insulating washers and grommets are in po sition e Connect the ground lead black to the ground mounting Screw e Connect the battery cable to the relay terminal having red lead Inspection e Set the hand tester to R x 1 O scale e Connect meter leads to starter relay as shown If resistance is less than infinite the starter relay switch is not returning and must be replaced e Set the hand tester to R x 1 O scale e Connect meter leads to starter relay as shown e Activate starter relay switch by connecting a 12 V battery as shown x If the starter relay switch clicks and the hand tester indi cates zero resistance the starter relay switch is good xIf the meter indicates high or infinite gt resistance the starter relay switch is defective and must be replaced Special Tool Hand Tester 57001 1394 JNOG016BS1 JNO06017BS1 JNOG018BS1 C 14 20 ELECTRICAL SYSTEM Electric Starter System Starter Motor Starter Motor Removal e Remove the engine see Engine Removal Installation chapter e Remove the mounting bolts A e Pull out the starter motor B Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Apply grease to the O ring A
126. lb 72 27 27 69 in lb 87 in lb 29 29 in lb 27 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Ree Nm fb marks L Steering Handlebar Clamp Bolts 16 1 6 11 5 L Smart Steering Actuator Bracket 8 8 0 9 78 in lb L Mounting Bolts Steering Holder Mounting Bolts 16 1 6 11 5 L Steering Cable Joint 9 8 1 0 87 in lb Steering Cable Nut 39 4 0 29 Trim Cable Nut 39 4 0 29 Throttle Case Mounting Screws 3 9 0 4 35 in Ib Switch Case Mounting Screws 3 9 0 4 35 in Ib Cable Joint Bolts 9 8 1 0 87 in lb L Cable Joint 9 8 1 0 87 in lb Hull Engine Hood Stabilizer Mounting Bolts 9 8 1 0 87 in lb L Crossmember Mounting Bolts 7 8 0 8 69 in lb Grip Mounting Bolts 9 8 1 0 87 in lb L Rear Mounting Plate Nuts 25 2 5 18 Electrical System Actuator Pulley Mounting Bolt 3 5 0 36 31 in lb L Actuator Mounting Bolt 8 8 0 9 78 in lb L Actuator Bracket Mounting Bolts 8 8 0 9 78 in lb L Meter Bracket Mounting Bolts 3 9 0 4 35 in Ib L Switch Case Mounting Screws 3 9 0 4 35 in Ib Spark Plugs 25 29 2 5 3 0 18 20 Speed Sensor Mounting Bolts 3 9 0 4 35 in Ib L Water Temperature Sensor 15 1 5 11 Starter Motor Mounting Bolts 8 8 0 9 78 in lb L Starter Relay Mounting Nuts 34 44 0 35 0 45 30 39 in lb Starter Motor Cable Nut 7 8 0 8 69 in Ib Fuse Case Mounting Bolts 7 8 0 8 69 in lb L Fuse Bracket Mounting Screws 4 4 0 45 39 in lb L The table below relating tightening torque
127. le bearing grease seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 19 Electrical Wires All the electrical wires are either one color or two color A two color wire is identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless in structed otherwise electrical wires must be connected to wires of the same color Two Color Electrical Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Yellow Red 20 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 21 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or dete riorated performance replace the damaged parts GENERAL INFORMATION 1 5 Model Identification JH1200 B1 Left Side View JH1200 B1 Right Side View 1 6 GENERAL INFORMATION General S
128. le joint and the locknut on the cable e Remove Rubber Cover A Loosen Steering Cover Bolts B Loosen Steering Cover Bolts A e Disconnect the steering cable from the holder OUnscrew the mounting bolts A and remove the holder OTake out the bolt A and separate the cable B from the cable holder C 12 6 STEERING Steering Cable e Remove the pump see Pump Removal in the Pump Im peller chapter OUnscrew the large nut A in the hull with a wrench OSlide off the E ring A washer B and O ring C e Pull the cable from the cable detent in the engine com partment e Pull out the steering cable toward the front Steering Cable Installation e Slide a short piece of rubber or plastic tubing over the rear cable end to guide the cable through the hull e Lubricate the outside of the new cable to ease cable in stallation e Torque Torque Steering Cable Nut 39 N m 4 0 kgf m 29 ft Ib e Apply a non permanent locking agent to the cable joint bolts and torque them Torque Cable Joint Bolts 9 8 1 0 kgf m 87 in Ib e Adjust the steering cable see Steering Cable Adjust ment Steering Cable Inspection e Refer to Steering Cable Inspection in the Periodic Main tenance chapter Steering Cable Lubrication NOTE OThe steering cable is sealed at each end and do not require lubrication If the seal is damaged the cable must be replaced STEERING 1
129. ll off the fuel return hose A at the carburetor and blow B through it until fuel appears at the fuel return fitting C on the carburetor The fuel system in now full of fuel Carburetor Cleaning and Inspection e Disassemble the carburetor see Carburetor Disassem bly WARNING Solvent is toxic and flammable Avoid prolonged contact with skin and keep away from open flame Use only in a well ventilated area Eye protection should be worn when compressed air is used to dry parts Do not direct air toward anyone Use 172 kPa 1 75 kgf cm 25 psi maximum nozzle pressure e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e When the parts are clean dry them with compressed air e Blow out the air and fuel passages with compressed air e Inspect the check valve A for damage or deterioration and replace it if necessary x If the gasket B under the check valve appears damaged it may leak and must be replaced FUEL SYSTEM 3 19 Carburetor Fuel Pump Check these rubber parts for damage O ring A Diaphragm B x lf any of these parts are not in good condition replace them Check the vacuum piston diaphragm A for damage x If it is not in good condition replace it Check that the vacuum piston B moves smoothly in the carburetor body The surface of the piston must not be excessively worn x If the vacuum piston does not move smoothly or if
130. lley and adjust it see Oil Pump Cable Adjustment in the Periodic Maintenance chapter 4 8 ENGINE LUBRICATION SYSTEM Oil Pump e Route the oil hoses correctly see Cable Wire and Hose Routing in the Appendix chapter To Carburetors A To Check Valves for Balancer Lubrication B Clamps C Bleed the air from the system see Oil Pump Bleeding e Adjust the oil pump cable D see Oil Pump Cable Adjust ment in the Periodic Maintenance chapter ENGINE LUBRICATION SYSTEM 4 9 Oil Tank Oil Tank Removal e Tilt up the hatch cover and remove the storage case e Loosen the lower clamp A and pull off the oil hose e Loosen the clamps B and remove the fuel tube C e Plug the fuel tank opening at once e Unhook the rubber straps D Bow E e Remove the seat e Disconnect the oil level sensor connector green A e Disconnect the oil pump inlet hose B from the oil tank e Plug the tank nipple and hose immediately Oln the photo the cable holder has been removed for clar ity e Remove the oil tank C from the front hatch e Remove the oil level sensor from the oil tank Bow D Oil Tank Installation e Initially inject oil into the oil inlet hose Oil Tank Cleaning e Remove the oil tank e Flush the tank repeatedly with a high flash point solvent until it is clean Clean the tank in a well ventilated area and take ample care that there are no sparks or flame any where near the
131. locking agent SS Apply silicone sealant Kawasaki Bond 56019 120 9 4 COOLING AND BILGE SYSTEM Special Tool Kawasaki Bond Silicone Sealant 56019 120 875601205 COOLING AND BILGE SYSTEM 9 5 Bilge System Breather Removal e Pull the hoses A off the breather Unscrew the mounting bolt B and remove the breather C Breather Installation e Be sure the small hole A in the breather is open before installing it e Apply a non permanent locking agent to the breather mounting bolt and tighten it Breather Cleaning and Inspection Check that the small hole in the top of the breather is open by blowing in one end of the breather and plugging the other x lf the hole is plugged clean it with compressed air Do not open it with a pointed object like a needle or a piece of wire because the hole may be enlarged If the hole is too large the bilge system may not suck water out of the hull as it should Filter Removal Installation e Pull the hose A off the filter e Unscrew the mounting nuts B and remove the filter as sembly Drill out the pop rivets holding the filter with a drill Pop Rivet Removal Drill Bit Size 5 0 mm 0 20 in e Installation is the reverse of removal Note the following OApply silicone sealant to the outer circumference of the plate mounting nuts Filter Cleaning and Inspection e Flush the filter thoroughly with fresh water and shake it dry
132. lts and Fasteners Tightness Inspection Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x lf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Engine Engine Bed Mounting Bolts Engine Mounting Bolts Engine Mount Bolts Air Inlet Cover Bolts Carburetor Mounting Bolts Inlet and Exhaust Manifold Nuts Exhaust Pipe Mounting Bolts Exhaust Chamber Mounting Bolts Cylinder Head Nuts Cylinder Base Nuts Drive Shaft Pump and Impeller Drive Shaft Coupling Drive Shaft Holder Mounting Bolts Pump Mounting Bolts Pump Cover Mounting Bolts Pump Grate Mounting Bolts Impeller Steering Nozzle Pivot Bolts 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedure Steering Handlebar Clamp Bolts Throttle Case Screws Switch Case Screws Steering Neck Mounting Bolts Steering Cover Mounting Bolts Handlebar Cover and Bracket Mounting Bolts Hull and Engine Hood Towing Eyes
133. maged or badly worn replace it with a new one e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the 3 locations total of 6 measurements shown in the figure 10 mm 0 4 in A 90 mm 3 5 in B 60 mm 2 4 in C x If any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder will have to be re placed with a new one Cylinder Inside Diameter Standard 80 000 80 015 mm 3 14961 3 15019 in and less than 0 01 mm difference between any two measurements Service Limit 80 10 mm 3 1535 or more than 0 05 mm 0 0020 in difference between any two measurements Piston Diameter Measurement e Measure the outside diameter A of the piston 26 9 mm 1 059 in up B from the bottom of the piston at a right angle to the direction of the piston pin Piston Diameter Standard 79 865 79 880 mm 3 14429 3 14488 in Service Limit 179 72 mm 3 1386 in OIf the measurement is less than the service limit replace the piston NOTE OAbnormal wear such as a marked diagonal pattern across the piston skirt may mean a bent connecting rod or a misaligned crankshaft Piston Cylinder Clearance The piston to cylinder clearance must be checked and the standard value maintained anytime a piston or the cylin der block are replaced with new parts e Measure the piston diameter as just described and sub
134. me do not plug up the holes of the check valves with a non permanent locking agent Olnstall the check valves A B as shown NOTE OAlign the oil hose fitting of the front check valve A with a rib D on the upper crankcase half OAlign the oil hose fitting of the rear check valve B with a mark E on the upper crankcase half ENGINE BOTTOM END 8 17 Crankcase JHOSOTIBW2 Lower Crankcase Check Valve Removal Installation e Split the crankcase e Take out the plug A to remove the rear check valve B from the lower crankcase e Tap the front A and rear B check valves out of the lower crankcase with a suitable screw C and driver D OPlace a rug E on the crankcase half to prevent it from damage 8 18 ENGINE BOTTOM END Crankcase e Apply a non permanent locking agent to the front check valve A and rear check valve B e Press the check valves until their flanges portions are bot tomed At this time do not plug up the holes of check valves with a locking agent e Apply a non permanent locking agent to the plug C for the rear check valve and install it CAUTION In case that the check valves were installed aslant replace the check valves JH08005BS1 ENGINE BOTTOM END 8 19 Crankshaft Maintenance The crankshaft changes reciprocating motion of the piston into rotating motion to drive the jet pump Crankshaft trouble such as excessive play or runout
135. ment jig measure con necting rod twist 100mm OHold the connecting rod horizontally and measure the amount that the arbor varies from being parallel with the crankshaft over a 100 mm 3 9 in length of the arbor to determine the amount of connecting rod twist x If connecting rod twist exceeds the service limit the con necting rod or crankshaft must be replaced Connecting Rod Twist 9004851 Standard Under 0 15 100 mm 0 00591 3 934 in Service Limit 0 2 100 mm 0 0079 3 934 in Connecting Rod Big End Radial Clearance e Check big end radial clearance OSet the crankshaft in an alignment jig or on V blocks and place a dial gauge against the connecting rod big end OPush the connecting rod first towards the gauge and then in the opposite direction The difference between the two gauge readings is the radial clearance x If the radial clearance exceeds the service limit replace or disassemble the crankshaft assy and examine the crankpin needle bearing and con rod big end for wear 6105005851 Connecting Rod Big End Radial Clearance Standard 0 025 0 037 mm 0 000984 0 001457 in Service limit 0 087 mm 0 00343 in 8 20 ENGINE BOTTOM END Crankshaft Maintenance Connecting Rod Big End Side Clearance e Measure big end side clearance A Olnsert a feeler gauge between the big end and either crank half to determine clearance x If the measured value exceeds the service lim
136. n the engine in a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas which can be lethal CAUTION Operate the engine only for short periods without cooling water ENGINE BOTTOM END 8 1 Engine Bottom End Table of Contents Exploded oh tte Date Ae a hens 8 2 t b a eh ire be esa tbe diede e 8 4 NIME 8 5 UDG SC 8 6 Ne rr 8 6 eosam UNE 8 7 inc T TEE Installationer ea a a a a a a ae Coupling Damper Inspectigom 9 Magneto Fly wie el E Magneto Flywheel Removal Magneto Flywheel Disassembly pp Magneto Flywheel Assembly pp 8 8 Stater Clutch Gear and Starter Idle Gear 8 9 Starter Clutch Gear and Starter Idle Gear 8 9 Magneto Flywheel Installatiom eene enne 8 9 DIATOMS 8 11 CIC 8 11 6 LE 8 11 8 13 oue FoR teeta Aa lee te M 8 13 jl nip RI 8 14 Crankcase Check Valves 8 16 Upper Crankcase Check Valve
137. n the fuse rat ing check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D eee CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 14 62 ELECTRICAL SYSTEM Smart Steering System Steering Position Sensor and Magnet Removal Remove Steering Refer to the steering removal in the Steering chapter e Remove the steering holder A with the steering shaft B fuel vent hose C start stop switch leads D and throttle cable E 1800 e Unscrew the mounting screws A and remove the steer ing position sensor B Unscrew the mounting screw A and remove the magnet B Steering Position Sensor and Magnet Installation e Move the steering shaft in the direction of A and B inspect the steering shaft for excessive play x If necessary adjust the steering nut or replace the bush ings see Steering Installation in the Steering chapter Apply a non permanent locking agent to the steering position sensor mounting screws and magnet mounting screw e Install the steering position sensor A to the steering holder and align the projection B on the magnet with the hole C on the steering shaft plate ELECTRICAL SYSTEM 14 63 Smart Steering System Turning the st
138. nce chapter e Spray a penetrating rust inhibitor down the carburetor bore e Install the flame arrester Reinstall the cover apply a non permanent locking agent to the threads of the air intake cover bolts and tighten securely Engine e Remove the spark plugs and push the plug caps fully onto the plug cap holder on the cylinder head e Pour one ounce of motor oil into each cylinder CAUTION Do not use too much oil or the crank seals may be damaged when the engine is next started Turn the ignition switch on e Push the lanyard key under the stop switch Turn the engine over several times with the start switch to coat the cylinder walls with oil e Pull the lanyard key off the stop switch and turn the igni tion switch off e Reinstall the spark plugs and caps Battery Give a refresh charge before you store the watercraft and store it with the negative lead removed Give a refresh charge once a month during storage e Remove the battery see Battery Removal in the Electrical System chapter Clean the exterior with a solution of baking soda and wa ter one heaping tablespoon of baking soda in one cup of water Rinse thoroughly with water Cover both battery terminals with grease Store the battery a cool dry place Do not expose it to freezing temperatures Lubrication e Carry out all recommended lubrication procedures see Lubrication in the Periodic Maintenance chapter e
139. nd remove the han dlebar Installation e Apply a non permanent locking agent to the handlebar clamp bolts e Temporarily fix the handlebar with the clamps e Align A the hole B on the handlebar with the hole C on the steering shaft holder e Install the handlebar A on the steering shaft B with clamps C OMount the lower V shaped part of the handlebar onto the holder of the steering shaft OTighten the lower clamp bolts first and then the upper clamp bolts to the specified torque There will be a gap D at the upper part of the clamp after tightening Torque Handlebar Clamp Bolts 16 N m 1 6 11 5 ft Ib e Route the cable wire and hose as shown 12 10 STEERING Handlebar FRONTSIDE VIEW m iu 2 se 1 A yf E Vi MO JL05001BN2 8 Approx 7 mm 0 28 in 1 Throttle Cable 2 Start Stop Switch Leads 9 BET Hose Length Approx 30 mm 10 Clamp Attaching the fuel vent pipe to the 4 Steering Shaft Holder steering holder fasten the throttle cable 5 Fuel Vent Pipe fuel vent hose start stop switch leads with 6 Fuel Vent Hose the clam 7 Clamp Fasten the fuel vent hose and pipe 11 Approx 7 mm 0 28 in with the clamp 12 Approx 2 5 mm 0 10 in e Be sure the fuel vent pipe A is installed on the top end of the fuel vent hose Position the fuel vent pipe on the right side of the steering shaft B
140. nd remove the pul ley B e Unscrew the actuator mounting bolts C and remove the bracket D Smart Steering Actuator Installation e Apply a non permanent locking agent to the actuator mounting bolts and install the actuator to the bracket Torque Actuator Mounting Bolts 8 8 N m 0 9 78 ft lb e Insert the pulley A into the actuator shaft so that UP mark B faces upward Projection D e Apply non permanent locking agent to the pulley mount ing bolt C and torque it Torque Pulley Mounting Bolt 3 5 N m 0 36 kgf m 31 in Ib CAUTION When tightening the pulley mounting bolt do not use a power wrench impact tool to prevent dam aging the D C servomotor Torque it to 3 5 N m 0 36 kgf m 31 in Ib e Install the smart steering cable to the bracket and pulley e Apply a non permanent locking agent to the actuator bracket mounting bolts and torque them Torque Actuator Bracket Mounting Bolts 8 8 N m 0 9 kgf m 78 e When reconnecting the actuator connector apply water resistance grease A to the O ring B and connector C e Adjust the smart steering cable see Smart Steering Ca ble Adjustment in the Fuel System chapter JL13001BS1 C ELECTRICAL SYSTEM 14 67 Smart Steering System Smart Steering Actuator Inspection Remove the smart steering actuator see this chapter e Unscrew the pulley mounting bolt and remove the pull
141. ne by one 4 The main system consists of the check valve 18 the main jet 19 the needle jet 20 and the jet needle 21 The jet needle 21 is fixed to the slide and moves with it As the slide moves powered by the diaphragm 4 2 the tapered jet needle 21 moves in and out of the needle jet 20 varying the clearance between them and thus the fuel flow out of the needle jet 5 When then engine is idling the throttle valve 3 is almost closed The low pressure in the inlet tract downstream of the throttle valve draws fuel through the pilot outlet 16 and the bypass outlets 15 from the regulator chamber 12 Even though the pressure in the venturi 2 is higher on the upstream side of the throttle valve almost no fuel flows through the needle jet 20 and into the regulator chamber 12 because of the check valve 18 Idling ENZ EZ EE lt z f ZA Nite 22277 Ls aE n 6 As the fuel in the regulator chamber 12 flows out the pressure in the chamber drops and draws the regulator diaphragm 22 into contact with the collar 24 of the float arm 23 which in turn pulls the needle float valve 11 away from the valve seat 10 Fuel can now flow into the regulator chamber 12 and press the diaphragm 22 away from the float arm 23 This allows the float arm 1 16 GENERAL INFORMATION Technical Information Engine spring 25 to push the arm to
142. neral Information chapter Hold the oil pump pulley fully opened Start the engine and run it at a steady 3000 rpm e Collect the oil that is being pumped for 2 minutes If the quantity of oil collected is within the specification the oil pump is operating properly Oil Pump Output pump pulley fully opened engine 3000 rpm for 2 min Standard Output for 1 Carburetor A 3 83 mL 0 234 cu in 10 Output for 2 Carburetor B 4 00 mL 0 244 cu in 10 Output for 3 Carburetor C 3 83 mL 0 234 10 Output for Front Balancer D 1 33 mL 0 081 cu in 10 Output for Rear Balancer E 1 33 mL 0 081 cu in 10 x If the oil pump output is subnormal inspect the oil pump and the inlet and output hoses for oil leaks x lf oil leaks are not found replace the oil pump Oil Pump Removal e Take out the bolts A of the cable holder B and move the holder with the control cables to port side to make the service easier Exhaust Pipe C Bow D e Disconnect the oil inlet hose at the oil pump body e Unscrew the oil pump mounting bolts A e Loosen the clamps B to let the oil outlet hoses C move freely e Pull up the oil pump body remaining connected with the hoses and cable e Disconnect the oil hoses C e Take out the bolt D and disconnect the oil pump cable from the oil pump body e Remove the oil pump E JD04015BS1 C JD04011BS1 C ENGINE LUBRICATION S
143. net Removal 14 62 Steering Position Sensor and Magnet Installation 14 62 Smart Steering System 14 63 Steering Position Sensor 1 14 63 Steering Position Sensor Input Voltage Inspection Steering Position Sensor Output Voltage Inspection Smart Steering Actuator Removal Smart Steering Actuator Installation Smart Steering Actuator ELECTRICAL SYSTEM 14 3 Dummy Page 14 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 14 5 Exploded View Torque No Fastener Nm ftlb Remarks 1 Spark Plug 25 29 2 5 3 0 18 22 2 Starter Relay Mounting Nuts 3 4 4 4 0 35 0 45 30 39 in lb 3 Water Temperature Sensor 15 1 5 11 4 Fuse Bracket Mounting Screws 4 4 0 4 39 in Ib L 5 Fuse Case Mounting Bolts 7 8 0 8 69 in Ib L 6 Rear Electric Case 7 Front Electric Case 8 Regulator Rectifier 9 Starter Relay 10 Igniter 11 Ignition Coil 12 Inlet Air Temperature Sensor AD Apply adhesive G Apply grease L Apply a non permanent locking agent 14 6 ELECTRICAL SYSTEM Exploded View JN020448W5 C ELECTRICAL SYSTEM 14 7 Exploded View No Fastener To
144. ng 3 25 Choke Cable Adjustment 3 12 Fuel Vent Check Valve Inspection 3 25 Choke Knob and Cable Removal 3 12 Fuel Vent Pipe Removal 3 25 Choke Knob and Cable Fuel Vent Pipe Installation 3 25 Installation 3 13 Fuel Tank tps 3 26 3 13 Fuel Tank 3 26 Lubrication 3 13 Fuel Tank Installation 3 27 Carburetor Fuel Pump 3 14 Fuel Tank Cleaning 3 27 Idle Speed Adjustment 3 14 Fuel Filler and Tube Removal 3 27 Carburetor Synchronization 3 14 Fuel Filler and Tube Installation 3 28 Pilot Screw Removal Installation 3 14 Fuel Filter Screen Cleaning 3 28 Carburetor Remowval 3 14 Fuel Filter 3 28 Carburetor Installation 3 15 coii ete eret 3 29 Carburetor Disassembly 3 16 M 3 29 Carburetor Assembly 3 18 Installation pp 3 29 Carburetor Cleaning and Cleaning eoe oce tote tactus 3 29 3 18 Float Arm Level Inspection Adjustment 3 19 3 2 FUEL SYSTEM Exploded View JC02014BW5 FUEL SYSTEM 3 3 Exploded View No Fastener Remark
145. nge with a suitable punch and hammer Side Bumper Installation e Align A the hole on the bumper with the mounting hole on the hull e Secure the bumper to the hull flange with a pop rivet A e Install the trim strip pushing on the both sides of the strip ELECTRICAL SYSTEM 14 1 Electrical System Table of Contents Exploded 14 4 Spark Plug Cleaning 14 37 Wiring 14 10 Electric Trim System 14 39 Specifications 14 12 Trim Actuator Inspection 14 39 Special Tools 14 13 Electronic Control Unit Inspection 14 40 Battery ine etr t A 14 14 Electronic Control Unit Inspection 14 41 Removal treten tps 14 14 Electric 14 44 Installation 14 14 Front Electric Case Electrolyte Filling 14 14 Removal Disassembly 14 44 Initial 14 16 Front Electric Case Precautions erts 14 16 Assembly Installation 14 44 14 17 Rear Electric Case Charging Condition Inspection 14 17 Removal Disassembly 14 45 Refreshing Charge 14 17 Rear Electric Case Electric Starter S
146. nspection in the Periodic Mainte nance chapter Spark Plug Adjustment ORefer to Spark Plug Adjustment in the Periodic Mainte nance chapter Spark Plug Cleaning ORefer to Spark Plug Cleaning in the Periodic Maintenance chapter it 4osueg 29 19311 g Usd usa 38 asa 38 98 401908uu095 34938 493145 dois yoring vol esnj 48080228485 14 38 ELECTRICAL SYSTEM Ignition System 0 use E EET E il Asya 9 9 w a A79 18 18 Le ud 38 1 HA Asa A a RRRA 3 08 4 18 S RA L acu i ES 18 4 98 5 38 gt 3n1d 44edS 1199 rorem Tante uo131u3 a gt 2 ow DR sozoeuuoy shares MOS t 20 lt 9 lt 2 2 SS x Josuag 105 6 ea13346441 aunzesadual 4osueg aly 39141 Ignition System ELECTRICAL SYSTEM 14 39 Electric Trim System Trim Actuator Inspection e Inspect the internal resistance of the trim angle sensor A ODisconnect the trim actuator connector B OUsing the hand tester measure the resistance between the W R terminal and the BL R terminal Trim Angle Sensor Resistance 479 718 O ODisconnect the trim actuator connectors A B OUsing the auxiliary wir
147. nt 2 tede tetas Mk te eX teat lees 2 8 Oil Pump oo ades cast oct on rape Sport Op Ae tet tnt oru re 2 9 Choke Cable Adjustment 2 9 Fuel Filter Screen Cleaning 2 10 Fuel Filter Inspectionm 2 10 Fuel Vent Check Valve Mounting deris 2 10 Fuel Vent Check Valve 2 11 Flare Arrester Cleaning oor doceo tour deir 2 11 Throttle Shaft Spring 1 00 2 11 Engine Bottom etit ts 2 11 Coupling Damper 2 11 Cooling Bilge System eer eei rettet entrant S E E Lee ERR ER ER ene 2 12 Cooling SySient edm coh aM d Ratones 2 12 Bilge System Flushing ei ret ifa n i t p e e etenim iae eate 2 13 Purip and Imbpeller 2 3 cr pea te Ee ENS qud be X NP MARO 2 13 Pump and Impeller Inspection RR HR 2 13 10 24 pue D EI T 2 14 steering Gable InSpectlOfi z ue ERIS IER 2 14 Steering Cable LUDricationi iie er et ce eer en p dnc 2 14 Trim Cable
148. nts matches the resis tance value of the variable rheostat Variable Rheostat 1 Variable Rheostat 2 Display Resistance Value Q Resistance Value Q Segment 33 100 1 100 330 Connect the terminal 11 to the 5 terminal GND e If any display function does not work replace the meter assembly JN17020BS2 C Speedometer Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e The speed equivalentto the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the terminal 9 Olndicates approximately 60 mph in case the input fre quency would be approximately 337 Hz Olndicates approximately 60 km h in case the input fre quency would be approximately 209 Hz DUTY 50 20 48170218853 ELECTRICAL SYSTEM 14 55 Multifunction Meter e f the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit OTurn on the ignition switch ORotate the waterwheel by hand OCheck that the speedometer shows the speed x If the speedometer does not work check the speed sen sor electric source voltage and speed sensor Speed Sensor Electric Source Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection e Set the hand tester A to t
149. num disulfide oil to the flanged portion Mixture of the engine oil and molybde num disulfide grease in a weight ratio 10 1 S Tighten the fasteners following the specified sequence P1 Pour 200 mL 12 2 cu in of 2 stroke oil P2 Pour 20 mL 1 2 cu in of 2 stroke oil WG Apply water resistance grease 8 4 ENGINE BOTTOM END Specifications Item Standard Service Limit Crankshaft Connecting Rods Crankshaft Runout Runout B TIR under 0 04 mm 0 00157 in TIR 0 10 mm 0 00394 in Runout C TIR under 0 10 mm 0 00394 in TIR 0 25 mm 0 00984 in Connecting Rod Side Clearance 0 45 0 55 mm 0 8 mm 0 031 in 0 01772 0 02165 in Connecting Rod Radial Clearance 0 025 0 037 mm 0 087 mm 0 00343 in 0 000984 0 001457 in Connecting Rod Bent 0 05 mm 100 mm 0 2 mm 100 mm 0 00197 3 934 in 0 0079 3 934 in Connecting Rod Twist 0 15 mm 100 mm 0 2 mm 100 mm 0 00591 3 934 in 0 0079 3 934 in ENGINE BOTTOM END 8 5 Special Tool Coupling Holder 2 Rotor Holder 57001 1423 57001 1428 Flywheel Puller Assembly M30 x 1 5 M33 x 1 5 Kawasaki Bond Liquid Gasket Black 57001 1426 92104 1062 8 6 ENGINE BOTTOM END Oil Filling Oil Filling e Take out the plug A on the magneto cover and fill 200 mL 12 2 cu in of 2 stroke oil B into the front balancer room inside the magneto cover after the following ser vice procedures Coupling Removal Magneto Flywhe
150. o the sensor connector C of the main harness side Special Tool Hand Tester 57001 1394 Connections Tester Positive Blue Red Tester Negative Black White e Turn the ignition switch on e Check the tester reading Inlet Air Temperature Sensor Input Voltage around DC 5 V NOTE OCheck the above process within three minutes x lf the tester reading does not show specified voltage check the igniter input voltage between Orange lead and Black White lead x lf there is battery voltage between the leads igniter is defective JNOSO46BS2 C 14 36 ELECTRICAL SYSTEM Ignition System Water Temperature Sensor Input Voltage Check e Disconnect the water temperature sensor A lead con nector e Set the tester B to the DC 10 V range and connect it to the sensor connector C of the main harness side Connections Tester Positive gt Red Yellow Lead Tester Negative Black White Lead e Turn the ignition switch on e Check the tester reading Water Temperature Sensor Input Voltage around DC 5V NOTE OCheck the above process within three minutes x If the tester reading does not show specified voltage check the igniter input voltage between Orange lead and Black White lead x If there is battery voltage between the leads the igniter is defective Special Tool Hand Tester 57001 1394 Overheat Diagnosis Output Voltage Check e Disconnect the 3 pin connector of the multifunction meter
151. on permanent locking agent to the fuel tap mounting screws and tighten them securely Cleaning If the fuel tap becomes clogged with foreign matter it must be cleaned Remove the fuel tap A Use compressed air to blow B through the supply fuel hose fitting C while switching the fuel tap right and left between the ON and RES positions Do this until only blockage is forced out NOTE not use too high air pressure 172 kPa 1 8 kgf cm 25 psi max ENGINE LUBRICATION SYSTEM 4 1 Engine Lubrication System Table of Contents Exploded E 4 2 EE 4 4 roni eec 4 5 enl m m 4 5 Oil Pump Performance 8 4 5 Oil Pump Removal TRE ER ETE 4 6 Oil P mp Installation a vU ede eb 4 7 eru 4 9 REMOVAL be ete o epa 4 9 Oil Tank Installation erret 4 9 lt 4 9 Oil Filter Er 4 9 4 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 4 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Oil Filler Nut 4 9 0 5 43 in Ib 2 Air Bleeder Screw 1 0 1 5 0 1 0 15 9 13
152. onnector A Clamps B Spark Plug Caps C e Remove or disconnect Clamps A Straps B Remove the front electric case assembly out of the hull out the clamps and open the case Remove the electric components ONote wire routing and ground terminal location Front Electric Case Assembly Installation e Install the plate aligning the hole on the plate with the projection on the lower case turn the two pages and see the illustration e Install the seal A on the lower case B e Install the gasket C on the seal aligning the recess in the gasket with the projection on the lower case e Align A the projection on the lower case with the recess on the upper case Seal and Gasket B e Use compressed air to blow A the male connector B of the front electric case lead when connecting CAUTION Water remained in the connector could cause the electrical leak ELECTRICAL SYSTEM 14 45 Electric Case Rear Electric Case Removal Disassembly e Remove the battery e Remove or disconnect Strap A Starter Motor Cable B Lead Connector C e Take out the clamps and open the case e Remove the electric components ONote wire routing and ground terminal location Rear Electric Case Assembly Installation e Be sure the seal B is in position e Align A the projection on the lower case with the recess on the upper case e Use compressed air to blow the male connec
153. ont Check Valve To Rear Check Valve To 1 Carburetor Check Valve To 2 Carburetor Check Valve To 3 Carburetor Check Valve Oil Pump Magneto Cover Clamp the oil hoses which lead to the carburetors Clamp the oil hoses which lead to the check valves on the upper crankcase Clamp Clamp the rear check valve hose Upper Crankcase Carburetors To oil pump Band Clamp the carburetor check valve oil hoses 1 2 and 3 Insert the band to the hole as shown Clamp the carburetor check valve oil hoses 1 2 and 3 Do not contact the oil hose to the smart steering lever and movable parts of the carburetor Smart Steering Lever Band Clamp the carburetor check valve oil hoses 2 and 3 Band Clamp the carburetor check valve oil hose 3 16 8 APPENDIX Cable Wire and Hose Routing VIEWED FROM BOW VIEWED FROM STERN APPENDIX 16 9 Cable Wire and Hose Routing gt Start Stop Switch Leads Throttle Cable Steering Shaft Handlebar Cable Holder Oil Pump Cable Choke Cable Carburetor Cable Idle Adjust Screw Carburetor Pump Oil Pump Pulley Be sure the cable portion indicated in the figure is in contact with the pulley portion indicated in the figure Pulse Hose White marked side shall be installed to engine side Band Throttle Sensor Fuel Hose Return Fitting Fuel Hose Suppl
154. ools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your JET SKI watercraft Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki JET SKI watercraft parts Special tools gauges and testers that are necessary when servicing Kawasaki JET SKI watercraft are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Refer
155. orarily torque the cylinder head nuts in a cross pat tern and torque them in the same order Initial Torque for Temporal Tightening Cylinder Head Nut 7 8 N m 0 8 kgf m 69 in Ib Torque Cylinder Head Nut 29 3 0 kgf m 22 16 Start the engine to check for fuel and oil leaks exhaust leaks and excessive vibration WARNING Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas which can be lethal CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damage will occur JF04022BS1 ENGINE TOP END 6 11 Engine Top End Maintenance and Inspection Compression Measurement Thoroughly warm up the engine while checking that there is no compression leakage from around the spark plugs or the cylinder head gasket CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damaged will occur Stop the engine Remove the spark plugs and screw a compression gauge firmly into the spark plug hole left side view Special Tools Compression Gauge 57001 221 A Compression Gauge Adapter M14 x 1 25 57001 1159 B e Using the starter motor turn the engine over with the throt tle f
156. ould after all other components have been checked test replace the coil with one known to be good e Check the spark plug lead for visible damage x If the spark plug lead is damaged replace the coil Igniter Removal Installation e Remove the front electric case and open it e Remove the igniter A and disconnect the connectors e Installation is the reverse of removal BK W BK JN08043BS1 14 32 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition Malfunctioned engine Ignition system wiring Repair or replace and connector inspection Good Good Good Voltage is less than Ignition coil primary peak voltage inspection the specified value Good Voltage is OK Voltage is zero Peak voltage measurement or almost zero is repeated 5 or more times No Yes Defective ignition coil Inspect Inspect 1 Adapter connection is 1 Lower resistance in a incorrect or adapter is hand tester Use defective KAWASAKI Hand Tester Replace Battery voltage 2 Battery voltage Crankshaft sensor peak voltage 3 Crankshaft sensor peak voltage No good Replace bad parts Igniter is defective Replace bad parts or inspect them with KAWASAKI Hand Tester JN08023B S ELECTRICAL SYSTEM 14 33 Ignition System Igniter Inspection CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while
157. ounting bolt and torque it Torque Oil Pump Cable End Mounting Bolt 4 9 N m 0 5 kgf m 43 OBe sure the cable portion indicated in the illustration is in contact C with the pulley portion indicated in the illustra tion JD04000BS1 C e Pulling the throttle cable A position the tips of the cable uu end B as shown B JC05006BS1 e Route the following correctly see Appendix chapter Throttle Cable Carburetor Cable Oil Pump Cable Choke Cable e Adjust the following Throttle Cable Carburetor Cable Oil Pump Cable Choke Cable if necessary Torque Carburetor Cable Adjuster Locknuts 7 8 N m 0 8 kgf m 69 in Ib Carburetor Cable Adjuster Locknuts 7 8 N m 0 8 kgf m 69 in Ib 3 10 FUEL SYSTEM Throttle Control Cable Throttle Control Cable Lubrication e Apply grease to the tips of the throttle A carburetor B cable ends e Lubricate the cable A by seeping oil between the cable and cable housing 6604010251 Throttle Control Cable Inspection e Examine the cable the cable or cable housing is kinked A or frayed B replace the cable e Be certain that the throttle control cable moves freely in both directions OLoosen the adjuster locknuts and slide the cable from the pulley OSlide the inner cable back and forth in the cable housing x If the cable does not move freely replace it FUEL SYSTEM 3 11 Smart
158. pecifications Items Engine Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition System Lubrication System Carburetion System Starting System Tuning Specifications Spark Plug Type Gap Terminal Ignition Timing Carburetor Idle Speed Compression Pressure Drive System JH1200 B1 B3 2 stroke 3 cylinder crankcase reed valve water cooled 1 176 mL 71 8 cu in 80 x 78 mm 3 15 x 3 07 in 5 8 1 106 6 kW 145 PS 96 750 r min rpm 153 5 15 6 kgf m 112 8 ft lb 96 000 r min rpm DC CDI Digital Superlube Oil injection break in period Oil injection and fuel mixture 50 1 Keihin CDCV 40 35 x 3 Electric starter NGK BR9ES 0 7 0 8 mm 0 028 0 031 in Solid post 15 BTDC 1 250 r min 22 BTDC 3 500 r min rpm 1 250 100 r min rpm in water 1 800 100 r min rpm out of water 675 1 070 kPa 6 9 10 9 kgf cm 98 155 psi 440 r min rpm Coupling Direct drive from engine Jet Pump Type Mixed flow single stage Thrust 4 020 N 410 kgf 904 Ib Steering Steerable nozzle Braking Water drag Performance TMinimum Turning Radius TFuel Consumption TCruising Range 4 0 m 13 1 ft 50 5 L h 13 3 US gal h full throttle 119 km 75 mile full throttle 1 hour and 9 minutes Dimensions Overall Length 2 890 mm 113 8 in Overall Width 1 129 mm 44 4 in Overall Height 1 028 mm 40 5 in Dry We
159. perly replace the part EXHAUST SYSTEM 5 7 Exhaust Manifold Removal e Remove the exhaust pipe and the exhaust chamber as a set e Remove the carburetor assembly A remaining con nected the fuel hoses oil hoses and control cables and place it on the hull bottom as shown e Remove the balance tube A to make the service easier Unscrew the mounting nuts A and remove the exhaust manifold B Installation e Install the exhaust manifold A on the cylinder OPlace the new gaskets B on the cylinders so that UP letter C faces upward as shown OTighten the exhaust manifold mounting nuts D following the sequence shown Torque Exhaust Manifold Mounting Nuts 34 N m 3 5 kgf m 25 ft Ib JE04004BS2 5 8 EXHAUST SYSTEM Exhaust Manifold Cleaning and Inspection e Remove the exhaust manifold parts e Clean the carbon deposits out of the exhaust passages with a blunt roundedged tool e Flush foreign matter out of the water passages with fresh water e Check the insides of the water passages for corrosion Check the gasket surfaces for nicks or other damage x If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly replace the part EXHAUST SYSTEM 5 9 Water Box Muffler Removal e Remove the engine see Engine Removal Installation chapter e Removal the water box muffler A out of the hull OLoos
160. ply a non permanent locking agent M Apply molybdenum disulfide grease SS Apply silicone sealant Kawasaki Bond 56019 120 11 4 PUMP AND IMPELLER Specifications Item Standard Service Limit Jet Pump Impeller Clearance 0 2 0 3 mm 0 008 0 012 in 0 6 mm 0 024 in PUMP AND IMPELLER 11 5 Special Tools Oil Seal amp Bearing Remover Impeller Holder 2 57001 1058 57001 1425 ST571058ST Bearing Driver Set Kawasaki Bond Silicone Sealant 57001 1129 56019 120 875711295 875601205 Impeller Wrench 57001 1228 11 6 PUMP AND IMPELLER Pump and Impeller Pump Removal e Turn the craft on its left side e Unscrew the mounting bolts A and remove the pump cover B e Remove the bolts A and take off the cable joints B e Unscrew the pump mounting bolts A e Slide the pump to the rear to disengage the drive shaft and remove it from the hull To remove the pump bracket remove the following e Pull out the inlet cooling hose A and the bilge hose B from each fitting in the hull Take out the pump bracket mounting nuts A and washers B in the hull JK04000BS1 C PUMP AND IMPELLER 11 7 Pump and Impeller Remove the grate A from the hull e Remove Steering and Trim Cable Joints Steering and Trim Cable Nuts A E rings Washers and O rings of Steering and Trim Ca ble
161. put voltage with the throttle fully open Throttle Sensor Output Voltage Standard 3 57 3 94 V When throttle is fully opened x lf it is not within the specified voltage adjust the sensor see Throttle Sensor Adjustment x If the sensor cannot be adjusted replace sensor 14 50 ELECTRICAL SYSTEM Sensors Throttle Sensor Adjustment Check the throttle sensor output voltage see Throttle Sensor Inspection x If the output voltage is out of the range adjust it as follows e Loosen the sensor mounting screws A e Adjust B the position of the sensor until the output volt age is within the specified range Water Temperature Sensor Inspection Remove the water temperature sensor e Suspend the sensor A in a container of water so that the temperature sensing projection is submerged e Suspend an accurate thermometer B in the water NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently e Using the hand tester measure the internal resistance of the sensor at the temperatures shown in the table x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance 20 C 68 F approx 2 759 50 C 122 F approx 635 90 C 194 F approx 121 9 100 C 212 F approx 85 3
162. reign matter in gasoline or engine oil e Exhaust gas leak in engine compartment Overheating Ignition wrong e Carburetor not adjusted e Flame arrester or exhaust system clogged e Carbon accumulation in combustion chamber e Wrong type of gasoline or oil e Obstruction in oil pump hoses e Cooling water line leaking or clogged Heavy Fuel Consumption e Carburetor not adjusted e Flame arrester clogged e Muffler or exhaust system clogged e Worn cylinder piston or piston ring e Fuel feed line leaking e Carburetor diaphragm needle dirty or damaged Poor performance though engine runs properly Jet Pump e Inlet area obstructed e Impeller or pump case damaged e Excessive clearance between impeller and pump case Poor steering control Since faulty steering is dangerous this problem should be examined by an authorized Jet Ski dealer Handlebar hard to turn e Steering maladjusted e Bushings damaged or cracked e Steering shaft bent e No lubricant on steering pivot e Steering cable damaged or improperly routed MODEL APPLICATION Year Model Beginning Hull No 2003 JH1200 B1 KAW40001 203 2004 JH1200 B2 KAW20001 304 2005 JH1200 B3 US KAW10001 405 This digit in the hull number changes from one machine to another Part No 99924 1308 03
163. retor Synchronization in the Periodic Main tenance chapter Pilot Screw Removal Installation e Turn in the pilot screw A and count the amount of turns until it seats thoroughly and then remove the screw The purpose is to set the screw to its original position when installing Spring B Washer C O ring D x If the carburetor is tampered with or counting the amount of turns is not performed set the pilot screw to the speci fied amount of turns Pilot Screw 1 1 4 1 2 turn open Carburetor Removal e Remove or Disconnect Air Inlet Cover Arrester Case Pulse Hose A Fuel Supply Hose B Fuel Return Hose C Throttle Sensor Lead Connector D Kea 96559 TPA JCO7027BS1 FUEL SYSTEM 3 15 Carburetor Fuel Pump Carburetor Cable E Choke Cable F Carburetor Mounting Bolts G Remove the clamps on the stay e Disconnect the inlet oil hoses A and clamps B which lead to the carburetors lifting the carburetor assembly C e Remove the smart steering cable D from the carburetor e Lift the carburetor assembly off the inlet manifold Carburetor Installation e Install new gaskets A under the carburetors OBe sure the dowel pins B are in place Olnstallation either obverse or reverse side is available e Connect the oil inlet hose see Appendix chapter e Install the cases A on the carburetors noting the direction indicated in the figure e Apply
164. riginal cylinder to maintain the correct clearance e Mount the pistons on the connecting rods with the arrows A on their crown pointing to the reed valves side B of engine e When installing a piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Fit a new piston pin snap ring into the side of each piston so that the snap ring opening A does not coincide with the slit B of the piston pin hole e Set the new cylinder base gasket in place on the crankcase OThe tab A of gasket must faces forward B and align the dowel pin hole C of gasket with the dowel pin on the cylinder e Apply molybdenum disulfide oil Small End Bearings Piston Pins and Piston Pin Holes Pistons and Cylinder Bores e Slide the cylinder block down over the crankcase studs onto the crankcase compressing the piston rings CAUTION Do not force the cylinder block Make sure the rings are in place e Install the cylinder base nuts OTemporarily torque the cylinder base nuts in a cross pat tern and torque them in the same order Initial Torque for Temporal Tightening Cylinder Base Nuts 7 8 N m 0 8 kgf m 69 in Ib Torque Cylinder Base Nuts 49 N m 5 0 kgf m 36 ft Ib ENGINE TOP END 6 9 Engine Top End e If the cylinder blocks and studs are replaced
165. rks facing out 16 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while the Jet Ski watercraft is driven leading to a major problem 17 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives therefore make sure to wipe it off and apply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their original function once they are removed There fore always replace these parts with new ones every time they are removed Although the pre viously mentioned gasket O ring ball bearing need
166. rque Remarks N m kgf m ft Ib 1 Meter Bracket Bolts 3 9 0 4 35 in lb L 2 Trim Cable Nut 39 4 0 29 3 Fuel Level Sensor Assembly Clamps 2 9 0 3 26 in lb 4 Start Stop Switch Case Mounting Screws 3 9 0 4 35 5 Speed Sensor Mounting Bolts 3 9 0 4 35 in Ib L 6 Smart Steering Actuator Pulley Mounting Bolt 3 5 0 36 31 in Ib L 7 Smart Steering Actuator Mounting Bolts 8 8 0 9 78 in lb L 8 Smart Steering Actuator Bracket Mounting Bolts 8 8 0 9 78 in lb L 9 Multifunction Meter 10 Oil Level Sensor 11 Fuel Level Sensor Assembly 12 Speed Sensor 13 Trim Actuator AD Apply adhesive G Apply grease L Apply a non permanent locking agent SS Apply silicone sealant WG Apply water resistance grease 14 8 ELECTRICAL SYSTEM Exploded View JN020458W5 C ELECTRICAL SYSTEM 14 9 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Gauge Bolt 3 9 0 4 35 in Ib L 2 Magneto Cover Mounting Bolts 12 1 2 8 7 L 3 Grommet Cover Mounting Bolts 8 8 0 9 78 in lb L 4 Grommet Clamp Mounting Bolt 8 8 0 9 78 in Ib L 5 Grommet Mounting Screws 3 5 0 36 31 in Ib L 6 Coil Mounting Screws 3 5 0 36 31 in Ib L 7 Stator Mounting Bolts 69 in Ib L 8 Flywheel Bolt 123 127 12 5 13 0 90 94 L 9 Balancer Drive Gear Mounting Bolt 12 1 2 73 in 11 Starter Motor Cable Nut 69 in Ib G AD Apply adhesive G Apply grease L Apply a non permanent locking a
167. rs are installed over the termi nals CAUTION Do not reverse the battery connections Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for JH1200 B1 YTX20L BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance 6 08070151 ELECTRICAL SYSTEM 14 15 Battery Check to see that there is no peeling tears or holes in the seal sheet on the top of the battery Place the battery on a level surface Remove the seal sheet A CAUTION Do not remove the seal sheet sealing the filler ports B until just before use NOTE OA battery whose seal sheet has any peeling tears or holes requires a refreshing charge initial charge e Take the electrolyte container out of the plastic bag e Detach the seal cap A from the container NOTE ODo not discard the seal cap because it is used as the battery plugs later ODo not peel back or pierce the seals B on the container e Place the electrolyte container upside down aligning the six seals with the six battery filler ports e Push the contain
168. rted and must be replaced Crankshaft Sensor Resistance Standard 396 5940 Special Tool Hand Tester 57001 1394 Ignition Coil Removal e Open the front electric case see Front Electric Case Re moval Disassembly e Pull the spark plug caps A and slide off the protector tubes B e Unscrew the grommet caps A and slide off the grommets B Lubricate the leads with penetrating rust inhibitor e Disconnect the ignition coil primary lead connectors A and unscrew the ignition coil mounting screws B e Remove the ignition coils C JN08040BS1 JN08041BS1 14 30 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation e Fix the each coil and connect the primary lead connectors as follows 1 Coil Black Connector 2 Coil Green Connector 3 Coil White Connector Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance Remove the ignition coil Connect the ignition coil A with the spark plug cap left installed on the spark plug lead to the tester B and mea sure the arcing distance WARNING To avoid extremely high voltage shocks do not touch the coil or lead x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing Distance Standard 7mm 0 3 in or more e To
169. ry careful that the part is positioned correctly when you apply the cement It may be impossible to reposition the part WARNING Do not get any cyanoacrylate cement in your eyes or on your skin If you do get some in your eyes do not try to wash it out Contact a physician im mediately If you do get some on your fingers do not touch any other part of your body your fingers will stick to anything they touch Allow the cement to cure and it will eventually wear off Rubber Parts Location Engine Hood Gasket A HULL ENGINE HOOD 13 15 Rubber Parts Trim Seal A Detent A Mats A Front Bumper Removal Installation e Pull out the plugs A e Unscrew the screws A and remove the front bumper B e Installation is the reverse of removal Rear Bumper Removal Installation e Take out the rear bumper mounting nuts A e Remove the rear bumper B e Installation is the reverse of removal 13 16 HULL ENGINE HOOD Rubber Parts Side Bumper Removal Remove the front bumper see Front Bumper Removal e Pull out the plugs A and unscrew the screws B e Remove the corner bumper C e Pull the trim strip A from the side bumper B e Drill out the pop rivets with a drill bit of the correct size Pop Rivet Removal Drill Bit Size 5 0 mm 0 2 in NOTE OStop drilling when the rivet head A starts to turn with drill bit OTap the rivet out of the hull fla
170. s Engine Bottom End Coupling Damper Inspection e With the engine removed remove the coupling damper and inspect it for wear A and deterioration xlf it is grooved or misshapen replaced it with a new damper x lf there is any doubt as to coupler condition replace it 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedure Cooling and Bilge System Cooling System Flushing To prevent sand or salt deposits from accumulating in the cooling system it must be flushed occasionally Flush the system according to the Periodic Maintenance Chart after each use in salt water or whenever there is reduced water flow from the bypass outlet on the left side of the hull e Remove the fitting cap A on the cylinder head Connect a garden hose B to the fitting Start the engine and allow it to idle before turning on the water CAUTION The engine must be running before the water is turned on or water may flow back through the exhaust pipe into the engine resulting in the pos sibility of severe internal damage e Immediately turn on the water an adjust the flow so that a little trickle of water comes out of the bypass outlet A on the right side of the hull e Left the engine idle for several minutes with the water running e Turn off the water Leave the engine idling e Rev the engine a few times to clear the water out of the exhaust system CAUTION Do not run the engine without cooling wa
171. s N m kgf m ft Ib Flame Arrester Bracket Bolts L Air Inlet Cover Mounting Bolts 7 8 0 8 69 in Ib L Carburetor Mounting Bolts 8 8 0 9 78 in lb L Inlet Manifold Mounting Nuts 9 8 1 0 87 Air Inlet Connecting Elbows 7 8 14 0 8 1 4 69 121 in lb L Main Jet Pilot Jet Inlet Valve Check Valve Jet Needle Pilot Screw Throttle Sensor Apply a non permanent locking agent O1 jo Ni gt 3 4 FUEL SYSTEM Exploded View lo Ef 0 0 JC02015BW5 FUEL SYSTEM 3 5 Exploded View Torque No Fastener Nm kgfm ft lb Remarks 1 Choke Knob Set Screw L 2 Fuel Filler Nut 4 9 0 5 43 in Ib 3 Fuel Filler Tube Clamps 2 9 0 3 26 in Ib 4 Choke Cable Adjuster Locknuts 7 8 0 8 69 in Ib 5 Case Mounting Screws 3 9 0 4 35 6 Tap Set Screw L 7 Oil Pump Cable Mounting Bolt 7 8 0 8 69 in lb 8 Carburetor Cable Adjuster Locknuts 7 8 0 8 69 in lb 9 Fuel Level Sensor Clamps 2 9 0 3 26 in lb 10 Throttle Cable 11 Choke Knob Shaft O ring 12 Fuel Tube 13 Buffer Pipe 14 Fuel Vent Hose 15 Fuel Vent Check Valve 16 Fuel Vent Pipe 17 Rubber Holder 18 Fuel Level Sensor Assembly G Apply grease L Apply a non permanent locking agent 3 6 FUEL SYSTEM Specifications Jet Needle Mark Inlet Valve System
172. s the igniter shuts off the power source automatically The power source turns on again when the starter switch turns on 8 Output for Outer Load Function When the power source of unit turns on the igniter puts out a voltage equivalent to the battery voltage on the terminal This terminal is connected to Trim Switch and Multifunction meter 1 22 GENERAL INFORMATION Technical Information Electrical Parts 1 Engine Starter The more compact starter features a 1 way clutch with back torque limiter to prevent starter damage caused by kick back during starting 2 Magneto The exciter coil is eliminated by adopting DC CDI Rare earth metal magnets lighten the magneto and decrease the flywheel effect improving acceleration response py JH1200B JH1100A Diameter mm 106 4 17 in 131 5 16 in Weight kg 1 44 3 18 Ib 2 54 5 60 Ib Flywheel effect Kg am GENERAL INFORMATION 1 23 Unit Conversion Table Prefixes for Units Units of Length km x 0 6214 mile Prefix Symbol Power m x 3 281 ft mega M x 1 000 000 mm x 0 03937 in kilo k x 1000 centi 0 01 milli m x 0 001 Units of Torque micro u x 0 000001 N m x 0 1020 N m x 0 7376 ft lb N m x 8 851 in Ib 9 807 N m Units of Mass kgf m x 7 233 ft Ib kg x 2 205 Ib kgf m x 86 80 in Ib g x 0 03527 OZ Units of Pressure Units of Volume kPa x 0 01020 kgf cm L x 0 2642 gal US kPa x 0 145
173. s by advancing ignition timing to avoid power fade Inlet Air Temperature Correction Resistance Temperature Characteristic Temperature 30 0 50 100 C Ignition Timing Correction for Air Inlet Temperature Resistance Advanced Angle Correction Low 29 Air Inlet Temperature deg C x10 JB06014B P GENERAL INFORMATION 1 21 Technical Information Igniter 4 Overheat Control To protect the engine against overheating a new more sensitive heat sensor constantly monitors exhaust pipe temperature When temperature exceeds 90 degrees C or more the igniter gradually cuts engine speed to 3 500 rpm where it stays until the temperature is lowered Overheat Control Resistance Temperature characteristic Temperature 50 100 150 200 Water Temperature 100 Exhaust Pipe Resistance 10 020551 C VK x 10 Ignition Control Condition at Over heat Switch ON High 3500 rpm Low Time from Switch ON t sec ih120112 tif Engine Speed 5 Engine Over Rev Cut Off The igniter stops ignition when engine speed exceeds 7 500 rpm to protect the engine from dam age The ignition starts again when the engine speed drops below 7 500 rpm 6 Engine Tachometer Drive The electric tachometer is driven by the pulsing signals from the ignitor 7 Power Source OFF Function Three minutes after the engine stop
174. sar ily e Remove the carburetor see Fuel System e Unscrew the mounting screws A and remove the throttle sensor B e Be sure to adjust the throttle sensor when installing see Throttle Sensor Adjustment Throttle Sensor Inspection e Start the engine and warm it up thoroughly CAUTION Do not run the engine without cooling water supply for more than 15 seconds or severe engine and ex haust system damage will occur e Check Idle Speed see Periodic Maintenance chapter Battery Charging Condition see this chapter e Turn the ignition switch off e Remove the throttle sensor lead connector e Connect the adapter A between the connectors B Special Tool Throttle Sensor Setting Adapter 57001 1400 e Connect the hand tester to the adapter Hand Tester Y Lead C Wire Color of TS Hand Tester BK Lead D Wire Color of TS e Start the engine CAUTION Do not run the engine without cooling water supply for more than 15 seconds or severe engine and ex haust system damage will occur e Check the sensor output voltage with the engine idling Throttle Sensor Output Voltage Standard 0 73 0 83 V When engine is idling x lf it is not within the specified voltage adjust the throttle sensor position see Throttle Sensor Adjustment x lf it is specified voltage go to next test e Stop the engine e Turn on the ignition switch e Check the sensor out
175. sed voltage then check if the battery is drawing current Olf the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 minutes replace the battery Battery A Battery Charger B Standard Value C Battery Standard Charge Time Chart h 12 10 Charge Time 11 5 12 0 12 5 13 0 Battery Terminal Voltage v e Determine battery condition after refreshing charge ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below Criteria Judgement 12 6 V or more Good 12 0 less than 12 6 V Charge insufficient Recharge less than 12 0 V Unserviceable Replace JN05002BS1 ELECTRICAL SYSTEM 14 19 Electric Starter System Starter Relay Removal Open the rear electric case see Rear Electric Case Re moval Disassembly e Remove Starter Relay Connector A Ground Lead Mounting Screw B Regulator Mounting Plate C e Remove the nuts D from the starter terminals on the starter relay switch e Slide the starter relay switch from the electric case being careful not to lose any of the insulating washers or grom mets e Disconnect the wire connectors Installation e Coat the insulating washers A and grommets B with waterproof grease e Be certain al
176. t connects to both the carburetor cable which leads to the carburetor and the oil pump cable which leads to the oil pump Since the throttle lever controls both the carburetor and the oil pump simultaneously it is important that each cable be adjusted to its designed base position so that the oil and fuel air mixture reach the engine in the correct proportion at all throttle openings Cable stretch creates excess play at the throttle lever and alters the base positions of the cables at the carburetor and the oil pump necessitating periodic adjustment NOTE OBe sure to inspect the remaining cable if whichever ca ble the carburetor the oil pump is adjusted e Check carburetor cable adjustment OWith the throttle lever released the lower stop on the throttle pivot arm A should rest against the idle adjust screw B and there should be slight slack in the throttle cable OWhen the throttle lever is fully applied pulled the upper stop on the pivot arm should be all the way up against the stop on the carburetor Throttle Closed Released Throttle Open Applied JC05014BS1 PERIODIC MAINTENANCE 2 9 Periodic Maintenance Procedure e f necessary adjust the carburetor cable A OLoosen and turn the locknuts B at the cable holder until the lower stop on the pivot arm hits against the idle adjust screw with slight cable slack OTighten the locknuts securely e Check the oil pump cable adjustment see
177. tandard point to the center of the detent Detents Bulkhead Main Harness Detent for Fuel Filter Detent for Inlet Air Temperature Sensor 100 mm 3 94 Detent for Main Harness Speed Sensor Connectors Detent for Speed Sensor Lead Tube Holder for Multifunction Meter Leads Run the main harness over the crossmember 700 mm 27 6 in from the standard point to the center of the detent 900 mm 35 4 in from the standard point to the center of the detent 1100 mm 43 31 in from the standard point to the center of the detent 1950 mm 76 77 in from the standard point to the center of the detent Smart Steering Actuator To Left Side To Left Side Detent Rear Electric Case Front Electric Case Fuse Box 470 mm 18 5 in 400 mm 15 7 in Detent Detents 60 mm 2 4 in 16 14 APPENDIX Troubleshooting Starting difficulty or failure to start Ignition System Ignition Spark Present Fault in fuel system Lack of compression No Spark Faulty or fouled spark plug Faulty plug wire insulation Faulty CDI igniter Faulty ignition coil Faulty magneto Battery voltage low Fuel System check that fuel tank contains fuel Outside Carburetor e Fuel feed line leaking or clogged e Pulse line leaking or clogged e Fuel filter screen clogged e Vent line clogged e Faulty fuel pump Inside Carburetor e Carburetor diaphragm damaged e Water in
178. ter supply for more than 15 seconds especially in high revolu tionary speed or severe engine and exhaust system damage will occur e Switch off the engine remove the garden hose install the fitting cap PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedure Bilge System Flushing To prevent clogging the bilge system should be flushed out according to the Periodic Maintenance Chart or when ever you suspect it is blocked e Disconnect both bilge hoses at the plastic breather fitting A e Connect the bilge filter hoses from the hull bottom to the garden hoses turn the water on and flush it out for about a minute During this procedure water will flow into the engine compartment Do not allow a large amount of water to accumulate in the engine compartment e Connect the other hoses from the hull bulkhead to the garden hose turn the water on and flush it out for several minutes e Before reconnecting the hoses to the plastic breather fit ting make sure the small hole A on top of the breather fitting is clear e Reconnect the bilge hoses Pump and Impeller Pump and Impeller Inspection e Examine the impeller A x lf there is pitting deep scratches nicks or other damage replace the impeller NOTE OMinor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing Smooth leading edges are especially important to avoid cavita tion
179. that the rubber coating B on the valve holder does not show any signs of separation from the holder x If there is any doubt as to the condition of the rubber coat ing replace the reed valve holder with a new one Valve Stop Inspection e Checkthe valve stops A for deformation cracks or other damage x If there is any doubt as to the condition of a stop replace the reed valve assembly with a new one JC10006BS1 C FUEL SYSTEM 3 25 Fuel Vent Check Valve Fuel Vent Check Valve Mounting e Refer to Fuel Vent Check Valve Mounting in the Periodic Maintenance chapter Fuel Vent Check Valve Inspection e Refer to Fuel Vent Check Valve Inspection in the Periodic Maintenance chapter Fuel Vent Pipe Removal e Cut off the clamp A at lower end of the fuel vent hose e Unscrew the lower side clamp B and pull the fuel vent pipe C with the rubber holder D Fuel Vent Pipe Installation e Install the rubber holder A on the fuel vent pipe B so the flanged part C of the pipe completely contacts the stepped part D of the holder e Pressing down the rubber holder A tighten the small diameter clamp B Torque Small Diameter Clamp 2 9 N m 0 3 kgf m 26 in Ib e Insert the fuel vent pipe with rubber holder on the fuel tank and tighten the large diameter clamp Torque Large Diameter Clamp 2 9 0 3 kgf m 26 in Ib e Set the two clamp screws A so they do not hit the oil tank B
180. the 12 V battery and terminals in the same man ner as specified in the Display Function Inspection Check that the heat symbol warning light flash when the equivalent to the input frequency is indicated in the oscil lator A if the square ware illustrated as shown would be input into terminal 6 e Check that the meter returns in the state of normality when the terminal for input frequency is opened x lf any display function does not work replace meter as sembly GND 50Hz 50 JN17025B83 MODE SET Button Inspection e Check that when the MODE button is pushed and held continuously the display rotates through the four modes 5 Clock Time Trip Hour 771 e Indicate the clock mode e Check that when the SET button is pushed for more than two seconds the meter display turns to the clock set mode xIf the display function does not work replace the meter assembly e Indicate the time mode e Check that when the SET button is pushed for more than two seconds the meter display turns to 00 00 xIf the display function does not work replace the meter assembly 14 58 ELECTRICAL SYSTEM Multifunction Meter e Indicate the trip mode Check that when the SET button is pushed for more than two seconds the meter display turns to 000 0 x lf the display function does not work replace the meter assembly ELECTRICAL SYSTEM 14 59 JN17003BW5
181. the ignition switch and push the lanyard key under the stop button e Pushing the starter button crank the engine 4 5 seconds to measure the primary peak voltage ODo not operate the starter for longer than 5 seconds Wait 15 seconds before using it again e Repeat the measurements 5 or more times for one ignition coil Ignition Coil Primary Peak Voltage Standard 140 V or more Repeat the test for the other ignition coil x If the reading is less than the specified value see Igniter Unit Troubleshooting table to determine whether Igniter is good or no good Crankshaft Sensor Peak Voltage Check NOTE OBe sure the battery is fully charged e Disconnect the crankshaft sensor lead connector e Pull all the spark plug caps from the spark plugs and push the caps A fully onto the spark plug cap holder B NOTE OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head e Connect a commercially available peak voltage adapter B to the hand tester A Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B e Insert the adapter probes into the connector C of the magneto cover side for the crankshaft sensor as shown Special Tool Hand Tester 57001 1394 Connections Adapter R Adapter BK Crankshaft Sensor G BL Hand Tester Range x DC 10 V Turn the ignition switch on and push the lanyar
182. through into the space above the diaphragm 4 2 This hole allows the low pressure in the venturi to draw the slide against the pressure of the spring 5 out of the venturi enlarging the venturi area 2 The wider the throttle opens the lower the pressure in the venturi and the farther the slide moves opening the venturi so that the engine can speed up This mechanism maintains the air speed through the venturi at an even level 2 The carburetor assembly has a built in pulse type fuel pump 6 Fuel flows from the fuel tank to the joint 7 on the carburetor assembly and into the fuel pump As the engine turns pressure GENERAL INFORMATION 1 15 Technical Information Engine pulses from the crankcase travel through the pulse joint 8 and push the diaphragm 9 in the fuel pump back and forth drawing fuel through the check valve in the joint 7 and pushing it past the needle valve 11 and into the regulator chamber 12 The needle valve 11 serves the same purpose as the float valve in a float bowl type carburetor If the pump supplies more fuel than the engine can use the excess fuel escapes back to the fuel tank through the leak jet 13 3 The carburetor slow system provides fuel to the engine at low speeds The slow system consists of a slow jet 14 various bypass outlets 15 the pilot outlet 16 and the pilot screw 17 As the throttle valve opens fuel flows through the pilot outlet 16 and then the bypass outlets 15 o
183. to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads General Fasteners stainless bolt and nut Threads dia mm TET re E 59 88 0 60 0 90 52 78 inb 16 22 16 22 11 6 15 9 30 41 31 42 22 30 PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart F mE ene Initial 10 Hours Every 25 Hours Every 100 Hours Clean fuel filter screen C Inspect Inspect fuel vent check vent check valve Inspect fuel vent check valve e Inspect throttle valve return springs replace NEN NENNEN carburetor if necessary Inspect clean flame arrester 31 Flush cooling system after each use in salt water Flush bilge line and filter Inspect impeller blade for damage remove Inspect steering cable and trim cable Lubricate handlebar pivot disassemble Inspect battery Clean and gap spark plugs replace if necessary Lubricate carburetor cable fitting smart steering cable fitting and choke cable fitting at carburetor Lubricate smart steering cable choke cable and smart steering cable fitting throttle control cable and throttle cable fitting at throttle case Check all hoses hose clamps nuts bolt and fasteners
184. tor of the rear electric case lead 14 46 ELECTRICAL SYSTEM Electric Case 48090165884 C A Apply grease N Seal B Grommet O Regulator Rectifier C Grommet Starter Relay D Lower Electric Case Q Regulator Rectifier Mounting Plate E 1 Ignition Coil R Red Mark F 2 Ignition Coil S To Battery Terminal G 3 Ignition Coil T To Starter Motor Terminal H Align the projection with the hole U Spacer I Igniter V Washer J BK Lead W Route the leads downward K Upper Electric Case X Front Electric Case L Clamp Y Rear Electric Case M Gasket ELECTRICAL SYSTEM 14 47 Sensors Speed Sensor Inspection e Disconnect the speed sensor connectors A see Wiring Diagram e Connect the battery and tester leads to the sensor as shown Rotate the waterwheel by hand slowly e Measure the output voltage of a speed sensor GIR BK W 0 10 twice a rotation Rotate it slowly x lf the voltage does not rise from zero to about 10 volts twice a rotation replace the sensor e Measure the output voltage of the sensor at higher speeds ORotate the waterwheel in a fair speed by air G R BK W approx 5V x If the sensor voltage does not reach 5 volts when spun with compressed air replace the sensor Special Tool Hand Tester 57001 1394 Battery Hand Tester 14 48 ELECTRICAL SYSTEM Sensors
185. ts The oil is supplied to each carburetor through 3 outlet ports and to the balancers through 2 ports for optimum lubrication Oil Pump Plunger Differential Sub Pluger Plunger Spring Inlet Pump Shaft Outlet Stroke Length Control Plunger Point of Contact Plunger Stroke Pump Lever Plunger Control Cam Plunger Tip Miminum Throttle Opening Maximum Throttle Opening Plunger Cam Face ie Upstroke Direction of Rotation Downstroke 1 18 GENERAL INFORMATION Technical Information Propulsion System 1 Pump Two kinds of pump are used in PWC for propulsion The JH1200 B1 has a mixed flow pump The mixed flow pump is compact with high capacity and it delivers more efficient propulsion for improved acceleration and performance Pump 1 Axial Flow Pump 2 Mixed Flow Pump 1 Impeller 1 Impeller 2 SingleType Pump Case 2 Separate Type Pump Case 3 Part of Impeller 4 Part of Guide Vane JH1100A JH1200B 48060138 5 Impeller Pump Case Clearance STD 0 2 0 3 mm 0 008 0 012 in 2 Trim Actuator The JH1200 B1 has a trim cable driven by the gear system shown below An input signal revolves the motor which revolves the sun gear through a worm gear and the output gear pulls and pushes the trim cable This trim system has a quicker response time than the conventional system Trim Actuator 1 Motor 2 Output Gear 3 Trim
186. ulates the average Condition n 121 gt engine speed based the data sent from the crankshaft sensor 7 Crankshaft Corner ing Sensor Thrust Condition 3 gt JBOGOQ9BS2 C The IC igniter will send digital signals for the most ade quate actions to the Kawasaki Smart Steering actuator if three conditions mentioned above are completed The Smart Steering cable A will be pulled if the actuator B with a built in servo motor C receives signals Engine speed will be increased up to approximately 2 800 rpm by opening the throttle valves This will provide enough thrusts to allow your personal watercraft to turn Carburetor D Pulley E SS Le P K 4806012852 C How To Release Kawasaki Smart Steering System IN WATER OUT OF WATER Engine Speed approx approx When the Kawasaki 2 800 rpm 6 500 rpm Smart Steering system operates How To Release Keep the Keep the Kawasaki Smart handlebar in the handlebar in the Steering System straight ahead straight ahead position or pull position or pull the the throttle lever throttle lever in a in a third or more third or more 1 10 GENERAL INFORMATION Technical Information Kawasaki Smart Steering System Carburetor Type Kawasaki Smart Steering System Circuit BK BK gt BK W R B W ONO JH06007BW3 Throttle Sensor St
187. ully open until the compression gauge stops rising the compression is the highest reading obtainable e Repeat the measurement for the other two cylinders Cylinder Compression Usable Range 675 1 070 kPa 6 9 10 9 kgf cm 98 155 psi open throttle the cylinder compression is higher than the usable range check the following OCarbon buildup on the piston head and cylinder head clean off any carbon on the piston head and cylinder head OCylinder head gasket cylinder base gaskets use only the proper gaskets The use of a gasket of incorrect thickness will change the compression x lf cylinder compression is lower than the usable range check the following OGas leakage around the cylinder head replace the dam aged gasket and check the cylinder head for warp OPiston cylinder clearance piston seizure OPiston rings piston ring grooves wear Cylinder Head Warp Inspection e Lay a straightedge A across the lower surface of the head B at several different points and measure warp by inserting a thickness gauge between the straightedge and the head x If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 0020 in 6 12 ENGINE TOP END Engine Top End Cylinder Wear Inspection e Inspect the inside of the cylinder for scratches and abnor mal wear x If the cylinder is da
188. unting bolts A and remove the steering nozzle B and tilt ring PUMP AND IMPELLER 11 9 Pump and Impeller e Unscrew the mounting bolts A and remove the pump outlet B e Unscrew the guide vane mounting bolts A and remove the guide vane B Unscrew the cap bolts A and remove the pump cap B s j e Forcefully put the impeller holder A into the pump shaft B in the pump case to hold sufficiently the shaft in the impeller holder e Remove the impeller from the pump shaft and then pull out the pump shaft the bushing and the ball bearing Special Tools Impeller Holder A 57001 1425 Impeller Wrench C 57001 1228 JK04005BS2 C 11 10 PUMP AND IMPELLER Pump and Impeller e Pull out the pump shaft A from the vane guide B JK04006BS1 C e Press A the collar B and the ball bearing C They come out of the vane guide e Remove the circlip and the grease seals Special Tool Oil Seal amp Bearing Remover A 57001 1058 Pump Assembly e Install the O ring A over the pump shaft B JK04008BS1 C PUMP AND IMPELLER 11 11 Pump and Impeller e Press the new oil seals A into the guide vane B and install the circlip C as shown OBe sure there are no foreign objects inside the vane guide and over the grease seals Oil seal outside surface between the vene guide surface distance F 6 5 6 7 mm 0 256 0
189. ve the watercraft in water CAUTION Do not run the engine without cooling water supply for more than 15 seconds especially in high revolutionary speed or severe engine and exhaust system damage will occur 2 Auxiliary Cooling An auxiliary cooling supply may be used if the watercraft cannot be operated in water during ad justments If possible always operate the watercraft in water rather than use an auxiliary cooling 2 e Loosen the clamp remove the A Connect the garden hose B to the hose fitting see above e Attach the garden hose to a faucet Do not turn on the water until the engine is running and turn it off immediately when the engine stops The engine requires 2 4 L min 2 5 qts min at 1 800 r min rpm and 7 0 L min 7 4 qts min at 6 000 r min rpm CAUTION Insufficient cooling supply will cause the engine and or exhaust system to overheat and severe damage will occur Excessive cooling supply may kill the engine and flood the cylin ders causing hydraulic lock Hydraulic lock will cause severe damage to the engine If the engine dies while using an auxiliary cooling supply the water must be shut off immediately Always turn the boat on its left side Rolling to the right side can cause water in the exhaust system to run into the engine with possible engine damage JB02004BW1 GENERAL INFORMATION 1 3 Before Servicing 3 Dirt Before removal and disassembly
190. ward the float valve needle 11 pressing it into the seat 10 shutting off the fuel flow When the throttle valve 3 opens the engine runs at mid range or higher speeds The pressure in the venturi 2 drops as the air flow speed through it rises This pressure drop allows the check valve 18 to open and fuel flows through the main jet 19 the needle jet 20 past the jet needle 21 and into the venturi 2 on its way into the engine The low pressure in the venturi 2 also acts on the diaphragm 4 2 which pulls the slide 4 increasing the area of the venturi The diaphragm 4 2 moves the slide until the pressure of the vacuum slide spring 5 is high enough to overcome the force of the diaphragm As the slide moves it pulls the jet needle 21 out of the needle jet 20 increasing the clearance between the two and allowing more fuel to join the air going to the engine The parts on the carburetor are designed to balance the air to fuel ratio for the best fuel economy power driveability and lowest exhaust emissions 7 Full Open 2 Eng PULSE eS _ ES zd E LL GENERAL INFORMATION 1 17 Technical Information Engine 4 Oil Pump The oil pump output is determined by both engine speed and throttle opening reducing both oil consumption and exhaust smoke This type of pump is often used on 2 stroke motorcycles The oil pump has 5 outlet por
191. xibility to match the engine s capabilities 2 The carburetor must have high driveability from low to high engine speeds responding closely to the operator s input 3 The carburetor must lower exhaust emissions for less harm to the environment 2 Features 1 The watercraft CV carburetor has a variable venturi for smoother driveability through the entire speed range of the engine It has a vacuum diaphragm which moves a slide in the venturi and a needle jet and jet needle The slide changes the venturi area according to the pressure in the venturi and the needle and jet vary the amount of fuel allowed into the venturi 2 The watercraft CV carburetor is a diaphragm type carburetor as opposed to a float bowl type and has all the performance features of the traditional watercraft carburetor It can operate efficiently at any angle it is durable corrosion resistant and salt water proof 3 Construction and Function 1 In operation air is drawn through the intake 1 venturi opening 2 and the throttle valve 3 and into the engine s crankcase The vacuum actuated slide 4 projects into the venturi and is pushed to narrow the venturi opening by the vacuum slide spring 5 When the engine is running slowly and the amount of air down into the engine is very small the slide 4 moves to minimize the venturi cross sectional area This maintains the air velocity in the venturi The bottom of the slide 4 has a hole 4 1 that goes
192. y Fitting Fuel Tap Detent Rubber Fuel Filter RESERVE ON RETURN VENT Fuel Vent Check Valve The arrow toward the fuel tank Fuel Level Sensor Assembly Vent Tube Vent Pipe Band Install the band after hanging the pipe to the steering shaft 30 mm 1 18 in Insert length of vent pipe 2 5 mm 0 098 in 7 mm 0 28 in 7 mm 0 28 in Viewed A Detent Plastic White Mark Band Clamp the cable holder Apply a cyanoacrylate cement 16 10 APPENDIX Cable Wire and Hose Routing 4809065 45 APPENDIX 16 11 Cable Wire and Hose Routing Drain Plug Band Drain Tube Clamp Bracket Gasket Drain Plug BOW Main Harness Tube To the oil level gauge To the smart steering actuator To the water temperature sensor Detents Meter Leads Clamp the meter connector cover upside Meter Connector Cover Bulkhead Stern Side UP mark Smart Steering Actuator Locknut Adjust Nut Smart Steering Cable Carburetor Cable Lever 16 12 APPENDIX Cable Wire and Hose Routing APPENDIX 16 13 Cable Wire and Hose Routing Standard Point Transom 570 mm 22 4 in from the s
193. ynchronizing screw E so that the valve edge in the middle carburetor F keeps the same distance within 0 2 mm 0 008 in tolerance as that in the front carbu retor e Turn the synchronizing screw G so that the valve edge in the rear carburetor H keeps the same distance within 0 2 mm 0 008 in tolerance as in the front carburetor e Install the carburetor e Adjust the throttle control and choke cables e Adjust the idle adjusting screw JC07013BS1 C 10207014852 C 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedure High Altitude Performance Adjustment The normal carburetor settings are best for sea level If the watercraft is used at the higher elevations the lower atmospheric pressure makes the carburetions richer To obtain the proper carburetor setting at higher elevations change the main and slow jets according to the table Sea Level 1 000 2 000 2 000 000 Altitude 1 000 0 m 3 300 6 m 6 000 9 3 300 ft STD 600 ft STD 800 ft STD Main jet 165 165 155 P No 92063 3720 92063 3720 92063 3723 Pilot jet 48 48 45 slow jet P No 16158 3724 16158 3724 16158 3725 Carburetor Cable Adjustment The throttle control cable is actually an assembly of three cables the throttle cable the carburetor cable and the oil pump cable The throttle cable runs from the throttle lever to the cable assembly junction where i
194. ystem 14 19 Assembly Installation 14 45 Starter Relay 14 19 14 47 14 19 Speed Sensor Inspection 14 47 14 19 Oil Level Sensor Inspection 14 48 14 19 Fuel Level Sensor Inspection 14 48 Starter 14 20 Throttle Sensor Removal Installa Starter Motor Remowval 14 20 Starter Motor Installation 14 20 Throttle Sensor Inspection Starter Motor Disassembly 14 20 Throttle Sensor Adjustment Starter Motor Assembly 14 21 Water Temperature Sensor Brush Inspection 14 22 Commutator Cleaning Inlet Air Temperature Sensor 14 23 Armature Inspection 14 23 Multifunction Meter Brush Assembly Inspection 14 23 Display Function Inspection Rear Cover Assembly Inspection 14 24 Fuel Level Gauge Symbol Warn Starter Motor Clutch Inspection 14 24 ing

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