STX 15 F

STX-15F
JET SKi Watercraft

Service Manual
Downloaded from www.Manualslib.com manuals search engine
is a trademark of Kawasaki Heavy Industries, Ltd. registered in U.S.A., Japan,
Austria, Benelux, Sweden, Denmark, Switzerland, France, Canada, Finland, Norway, Greece, Italy,
U.K., Portugal, Thailand, and Taiwan.
KAWASAKI JET SKi is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.

Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Engine Lubrication System 4 j
Exhaust System 5 j
Engine Top End 6 j
Engine Removal/Installation 7 j
Engine Bottom End 8 j
Cooling and Bilge Systems 9 j
Drive System 10 j
Pump and Impeller 11 j
Steering 12 j
Hull/Engine Hood 13 j
Electrical System 14 j
Storage 15 j
Appendix 16 j
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.

STX-15F
JET SKi Watercraft

Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your JET SKi watercraft dealer for the
latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
2003 Kawasaki Heavy Industries, Ltd. 9th Edition (1):May 20, 2011

LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) ohm(s)
L liter(s)
COUNTRY AND AREA CODES

AU Australia FR France
CA Canada US United States
EUR Europe

MAINTENANCE AND ADJUSTMENTS
Maintenance, replacement, or repair of the emission control devices and systems may
be performed by any marine Sl engine repair establishment or individual.
EMISSION CONTROL INFORMATION
Fuel Information
THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GRADE GASOLINE ONLY with
an octane rating equal to or higher than that shown below.
Minimum Octane Rating: Antiknock Index* 87
Research Octane Number (RON) 91
*: The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane
Number (MON).
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, 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.

* Digital Transistor Ignition System
* Fuel Pump
* Spark Plugs
* Throttle Body and Internal Parts
* Fuel Injectors
* ECU

Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
Follow the procedures in this manual care-
fully. Dont take shortcuts.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
Remember to keep complete records of main-
tenance and repair with dates and any new
sires to perform his own basic maintenance and parts installed.
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce- How to Use This Manual
dures must be understood in order to carry out
maintenance and repair satisfactorily. When- In this manual, the product is divided into
ever the owner has insufficient experience or its major systems and these systems make up
doubts his ability to do the work, all adjust- the manuals chapters. The Quick Reference
ments, maintenance, and repair should be car- Guide shows you all of the products system
ried out only by qualified mechanics. and assists in locating their chapters. Each
In order to perform the work efficiently and chapter in turn has its own comprehensive Ta-
to avoid costly mistakes, read the text, thor- ble of Contents.
oughly familiarize yourself with the procedures For example, if you want ignition coil informa-
before starting work, and then do the work care- tion, use the Quick Reference Guide to locate
fully in a clean area. Whenever special tools or the Electrical System chapter. Then, use the
equipment are specified, do not use makeshift Table of Contents on the first page of the chap-
tools or equipment. Precision measurements ter to find the Ignition Coil section.
can only be made if the proper instruments are Whenever you see symbols, heed their in-
used, and the use of substitute tools may ad- structions! Always follow safe operating and
versely affect safe operation. maintenance practices.
For the duration of the warranty period, DANGER
we recommend that all repairs and scheduled
DANGER indicates a hazardous situa-
maintenance be performed in accordance with
tion which, if not avoided, will result in
this service manual. Any owner maintenance or
death or serious injury.
repair procedure not performed in accordance
with this manual may void the warranty. WARNING
To get the longest life out of your JET SKi
watercraft: WARNING indicates a hazardous situa-
Follow the Periodic Maintenance Chart in the
Service Manual.
tion which, if not avoided, could result
in death or serious injury.
Be alert for problems and non-scheduled
maintenance. NOTICE
Use proper tools and genuine Kawasaki JET
SKi watercraft parts. Special tools, gauges,
NOTICE is used to address practices not
related to personal injury.
and testers that are necessary when servic-
ing Kawasaki JET SKi watercraft are intro- This manual contains four more symbols
duced by the Service Manual. Genuine parts which will help you distinguish different types
provided as spare parts are listed in the Parts of information.
Catalog.

NOTE
This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates
done.
a procedural step or work to be
Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or 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 locking
agent during assembly.
This model, JT1500A, is mounted with a four

-stroke engine.
When the JET SKi watercraft is submerged
and swamped, the four-stroke engine needs
special care and systematic procedure for re-
covery compared with the two-stroke engine.
Therefore in this manual, such procedures,
which are not shown in SMs for two-stroke
engines, are explained thoroughly to cope with
the cases.
Refer to the section, After submerging in
Chapter 9, Cooling and Bilge Systems for the
summary and detailed procedures.

GENERAL INFORMATION 1-1
General Information
Table of Contents
1
Smart Learning Operation mode (SLO) (JT1500-A2 Model )............................................... 1-2
Before Servicing ..................................................................................................................... 1-3
Model Identification................................................................................................................. 1-11
General Specifications............................................................................................................ 1-12
Unit Conversion Table ............................................................................................................ 1-14

1-2 GENERAL INFORMATION
Smart Learning Operation mode (SLO) (JT1500-A2 Model )
This watercraft is equipped with the Smart Learning Operation mode (SLO) and normal operation
mode (Full Power Operation, FPO). The SLO mode reduces the maximum watercraft speed by ap-
proximately 30 percent for a use by unskilled operators. To change the SLO mode to FPO mode, and
back again, push the MODE button for 7 seconds or more.
SLO mode is displayed on the meter as SLO.

NOTE
When shifted to the SLO mode, the initial display, as
shown when the ignition switch is turned on, is shown
together with a buzzer sound.
Then, SLO is shown blinking at every three seconds.
Under the SLO mode, all the meter displays and other
functions work in the same manner as the normal oper-
ation (Full Power Operation, FPO) mode.
Normal operation mode (Full Power Operation mode, FPO)

is shown by FPO display.
NOTE
When shifted to the normal operation mode (Full Power
Operation mode, FPO), the same initial display is first
shown and followed by FPO for two seconds. How-
ever, FPO is shown only once when shifted and is not
displayed thereafter.
When the ignition switch is turned off and on again, the
same mode when turned off is displayed again.

Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly oper-
ation on watercraft, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Kawasaki Diagnostic System (KDS) Software

KDS software that runs on Windows personal computer (PC) will be available as a diagnostic tool
for watercraft with Kawasaki DFI system.
You need the following items to use the KDS.
Item P/No.
KDS Software Version 3. (CD-ROM, Updated Version) 57001-1650
57001-1648 and 57001-1724
KDS3 Adapter or
57001-1725
Communication Cables 57001-1649 and 57001-1688
Relay Cable 57001-1535
The connectors for the communication cable and relay cable are located in the front of the battery.
Connect the communication cable to the KDS connector (4-pin) [A] and the relay cable between
the relay assembly [B] connectors (8-pin) [C].
Adjustments
Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever trou-
bleshooting or presence of symptoms indicate that adjustments may be required. Whenever running
of the engine is required during maintenance it is best to have the watercraft in water.
NOTICE
Operating the engine without cooling water for more than 15 seconds, especially at high
rpm, will cause severe engine and exhaust system damage. To avoid engine damage, do
not run the engine without providing sufficient cooling water.
Auxiliary Cooling
An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjust-
ments. If possible, always operate the watercraft in water rather than use an auxiliary cooling supply.

Before Servicing
Obtain a standard garden hose [A] and a garden hose

adapter [B] as shown.
C: Garden Hose Fitting of Adapter
D: Flushing Fitting of Adapter
E: Thread: Rp 3/4
Optional part (P/No. 92005-3746) is available as a garden
hose adapter.
Open the front storage compartment cover.

compartment.
Remove the flushing cap [A] on the brim of the storage
Screw
[B].
a garden hose adapter [A] onto the flushing fitting
Attach a garden hose [C] to a garden hose adapter and

secure the hose clamp [D].
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 rpm
and 7.0 L/min (7.4 qts/min) at 6 000 rpm.
NOTICE
Operating the engine without cooling water for more than 15 seconds, especially at high
rpm, will cause severe engine and exhaust system damage. To avoid engine damage, do
not run the engine without providing sufficient cooling water.
An excessive supply of cooling water may cause the engine to stop and flood the cylinders,
creating the potential for hydraulic lock which causes severe engine damage. To prevent
engine damage when using an auxiliary cooling supply, shut the water off immediately if
the engine stops running.
NOTICE
Rolling to the right side can cause water in the exhaust system to run into the engine, with
possible engine damage. To prevent engine damage, always turn the boat on its left side.

Before Servicing
NOTICE
Rolling the capsized watercraft counterclockwise (to its STARBOARD side) can cause wa-
ter in the exhaust system to run into the engine, with possible engine damage. Always turn
the capsized boat clockwise so that the PORT side always faces downward.
Battery Ground
Before completing any service on the watercraft, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable () first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative () ca-
ble to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Before Servicing
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Watercraft before Disassembly

Clean the watercraft thoroughly before disassembly. Dirt
or other foreign materials entering into sealed areas during
watercraft disassembly can cause excessive wear and de-
crease performance of the watercraft.
Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts

After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.

Before Servicing
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Before Servicing
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling
Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Before Servicing
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in-
stalling to prevent deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation

When rotating the crankshaft, by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (counter-clockwise
viewed from stern sinde).
Electrical Leads
A two-color lead is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads must be connected to those of the same color.

Before Servicing
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufactures instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.

Model Identification
JT1500-A1 Left Side View
JT1500-A1 Right Side View

General Specifications
Items JT1500-A1 A2, A6 AC

Engine
Type 4-stroke, DOHC, 4-cylinder, water cooled
Displacement 1 498 cm (91.4 cu in.)
Bore and Stroke 83 69.2 mm (3.27 2.72 in.)
Compression Ratio 10.6 : 1
Maximum Horsepower 118 kW (160 PS) @7 500 r/min (rpm)
(JT1500AC) (EU) 112 kW (152 PS) @7 500 r/min (rpm)
(CA, US)
Maximum Torque 152 Nm (15.5 kgfm, 112.1 ftlb) @7 250 r/min (rpm)
(JT1500AC) (EU) 144 Nm (14.7 kgfm, 106.2 ftlb) @7 250 r/min
(rpm)
(CA, US)
Ignition System Digital transistor
Lubrication System Forced lubrication (semi-dry sump)
Carburetion System FI (fuel injection) MIKUNI AC 60 1
Starting System Electric starter
Cylinder Numbering Method Front (bow) to rear (stern), 1-2-3-4
Firing Order 1-2-4-3
Valve Timing:
Inlet:
Open 22.5 BTDC
Close 67.5 ABDC
Duration 270
Exhaust:
Open 74.5 BBDC
Close 9.5 ATDC
Duration 264
Tuning Specifications
Spark plug:
Type NGK CR9EK
Gap 0.7 0.8 mm (0.028 0.031 in.)
Ignition Timing 3 ATDC @1 300 r/min 32 BTDC @3 000 r/min (rpm)
Idle Speed 1 300 100 r/min (rpm) -in water
1 300 100 r/min (rpm) -out of water
Compression Pressure 1 190 1 799 kPa (12.1 18.3 kgf/cm, 173 261 psi) @430
r/min (rpm)
Drive System
Coupling Direct drive from engine
Jet Pump:
Type Axial flow single stage
Thrust 4 250 N (434 kgf, 955 lb)
(JT1500AC) (EU) 4 130 N (421 kgf, 928 lb)
Steering Steerable nozzle
Braking Water drag
Performance
Minimum Turning Radius 4.0 m (13.1 ft)

General Specifications
Items JT1500-A1 A2, A6 AC

Fuel Consumption 43 L/h (11.4 US gal/h) @full throttle
Cruising Range 134 km (87 mile) @full throttle 1 hour and 26 minutes (3 person)
Dimensions
Overall Length 3 120 mm (122.8 in.)
Overall Width 1 180 mm (46.5 in.)
Overall Height 1 050 mm (41.3 in.)
Dry Mass (JT1500-A1 A8) 338 kg (745 lb)
Curb Mass (JT1500A9 ) 383 kg (845 lb)
Fuel Tank Capacity 62 L (16.4 US gal)
Engine Oil
Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 5.0 L (5.3 US qt)
Electrical Equipment
Battery 12 V 18 Ah
Maximum Generator Output 16 A @14 V
: 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.

Unit Conversion Table
Prefixes for Units Units of Length
km 0.6214 = mile
Prefix Symbol Power m 3.281 = ft
mega M 1 000 000 mm 0.03937 = in.
kilo k 1 000
centi c 0.01 Units of Torque
milli m 0.001 Nm 0.1020 = kgfm
micro 0.000001 Nm 0.7376 = ftlb
Nm 8.851 = inlb
kgfm 9.807 = Nm
Units of Mass kgfm 7.233 = ftlb
kg 2.205 = lb kgfm 86.80 = inlb
g 0.03527 = oz
Units of Pressure
Units of Volume kPa 0.01020 = kgf/cm
L 0.2642 = gal (US) kPa 0.1450 = psi
L 0.2200 = gal (IMP) kPa 0.7501 = cmHg
L 1.057 = qt (US) kgf/cm 98.07 = kPa
L 0.8799 = qt (IMP) kgf/cm 14.22 = psi
L 2.113 = pint (US) cmHg 1.333 = kPa
L 1.816 = pint (IMP)
mL 0.03381 = oz (US) Units of Speed
mL 0.02816 = oz (IMP) km/h 0.6214 = mph
mL 0.06102 = cu in
Units of Power
Units of Force kW 1.360 = PS
N 0.1020 = kg kW 1.341 = HP
N 0.2248 = lb PS 0.7355 = kW
kg 9.807 = N PS 0.9863 = HP
kg 2.205 = lb
Units of Temperature

PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-2
Torque and Locking Agent...................................................................................................... 2-4 2
Specifications ......................................................................................................................... 2-10
Special Tools ......................................................................................................................... 2-11
Periodic Maintenance Procedures.......................................................................................... 2-12
Fuel System......................................................................................................................... 2-12
Throttle Control System Inspection................................................................................... 2-12
Air Filter Drain Caps Inspection and Cleaning .................................................................. 2-12
Air Filter Inspection and Cleaning ..................................................................................... 2-13
Fuel Vent Check Valve Inspection .................................................................................... 2-13
Fuel Pump Screen Cleaning ............................................................................................. 2-14
Throttle Shaft Spring Inspection........................................................................................ 2-14
Engine Lubrication System .................................................................................................. 2-14
Engine Oil Change............................................................................................................ 2-14
Oil Filter Replace .............................................................................................................. 2-16
Engine Top End ................................................................................................................... 2-17
Air Suction Valve Inspection (JT1500-A1 A8 Models) ................................................... 2-17
Valve Clearance Inspection .............................................................................................. 2-17
Engine Mounting Bolts Inspection and Tightness ............................................................. 2-22
Engine Bottom End.............................................................................................................. 2-22
Coupling Damper Inspection............................................................................................. 2-22
Cooling and Bilge Systems.................................................................................................. 2-22
Cooling System Flushing .................................................................................................. 2-22
Bilge System Flushing ...................................................................................................... 2-24
Pump and Impeller............................................................................................................... 2-25
Impeller Inspection............................................................................................................ 2-25
Jet Pump Bearings/seals Lubrication, Inspection and Replacement ................................ 2-25
Steering ............................................................................................................................... 2-25
Steering Cable/Shift Cable Inspection .............................................................................. 2-25
Handlebar Pivot Lubrication.............................................................................................. 2-25
Hull/Engine Hood................................................................................................................. 2-26
Drain Plug Inspection........................................................................................................ 2-26
Electrical System ................................................................................................................. 2-26
Battery Charging Condition Inspection ............................................................................. 2-26
Battery Terminals Inspection............................................................................................. 2-26
Spark Plug Cleaning and Inspection................................................................................. 2-27
Lubrication ........................................................................................................................... 2-27
All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check ............................................... 2-30
Nuts, Bolts, and Fasteners Tightness Inspection.............................................................. 2-30
Hose and Hose Connect Inspection ................................................................................. 2-30
Rubber Strap Inspection ................................................................................................... 2-32
Fuel Hose Replacement ................................................................................................... 2-32

2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the watercraft in
good running condition. The initial maintenance is vitally important and must not be neglected.
Frequency Initial 10 Every 25 Every 50 Every 100 Refer-
Description Hours Hours Hours Hours ence
Inspect throttle control system (e) 2-11
Inspect/clean air filter drain caps 2-11
Inspect/clean air filter

(or every 2-12
year)
Inspect fuel vent check valve 2-12
Clean fuel pump screen (e) 2-13
Inspect throttle shaft spring (replace throttle
body if necessary) (e) 2-13
Replace engine oil

(or every 2-13
year)
Replace engine oil filter 2-15
Inspect air suction valve (JT1500-A1 A8
Models) 2-16
Inspect/adjust valve clearance (e) 2-16
Inspect/tighten engine mounting bolts

(or every 2-21
year)
Inspect/replace coupling damper 2-21
Flush cooling system (after each use in salt
water) 2-21
Flush bilge line and filter 2-23

Inspect impeller blades for damage (remove) 2-24
Initial 25 hours or one year whichever
Lubricate jet pump bearings and seals; inspect
comes first, then every 50 hours or every 2-24
and replace bearings/seals if necessary
year whichever comes first
Inspect steering cable/shift cable 2-24
Lubricate handlebar pivot (disassemble) 2-24
Inspect hull drain screws (replace if
necessary) 2-25
Inspect battery charging condition 2-25

Inspect battery terminals 2-25
Clean and gap spark plugs (replace if
necessary) (e) 2-26
Lubricate throttle cable fitting at throttle body 2-26

Lubricate throttle cable and throttle fitting at
throttle case 2-26
Lubricate steering cable/shift cable ball joints

and steering nozzle/reverse bucket pivots 2-26
Check all hoses, hose clamps, nuts, bolts,

and fasteners 2-29
Replace fuel hoses Every 5 years 2-31

Periodic Maintenance Chart
(e): Emission Related Items

Torque and Locking Agent
The following table list the tightening torque for the major fasteners, and the parts requiring use of
a non-permanent locking agent or silicone sealant.
Letters used in the Remarks column mean:
EO: Apply oil to the threads and seating surface.
L: Apply a non-permanent locking agent to the threads. (Medium Strength: Loctite 242 equivalent)
LN: Apply a non-permanent locking agent to the threads. (High Strength: Loctite 271 equivalent)
MO: Apply molybdenum disulfide grease oil solution. (mixture of the engine oil and molybdenum
disulfide grease in a weight ratio 10 : 1 )
R: Replacement Part
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant to the threads.
Torque
Fastener Remarks
Nm kgfm ftlb
Fuel System
Vehicle-down Sensor Mounting Screws 1.5 0.15 13 inlb
Bracket Mounting Bolts 8.8 0.90 78 inlb L
Inlet Manifold Mounting Bolts 25 2.5 18 L
Inlet Manifold Mounting Nuts 20 2.0 14
Delivery Pipe Mounting Bolts 7.8 0.80 69 inlb
Inlet Air Pressure Sensor Bolts 7.8 0.80 69 inlb
Throttle Cable Holder Bolts 8.8 0.90 78 inlb L
Inlet Air Temperature Sensor 20 2.0 14
Throttle Body Assy Mounting Bolts 20 2.0 14
Inlet Manifold Drain Plug 20 2.0 14
Inlet Manifold Plate Bolts 7.8 0.80 69 inlb
Crankshaft Sensor Screws 4.4 0.45 39 inlb L
Camshaft Position Sensor Bolt 9.8 1.0 87 inlb L
Oil Temperature Sensor 15 1.5 11 see text
Water Temperature Sensor 15 1.5 11 see text
Regulator/Rectifier Bolts 7.8 0.80 69 inlb
ECU Mounting Bolts 8.8 0.90 78 inlb L
Electrical Parts Bracket Screws 4.9 0.50 43 inlb L
Throttle Sensor Mounting Screws 2.0 0.20 18 inlb
ISC Actuator Mounting Bolts 4.9 0.50 43 inlb
Oil Pressure Switch 15 1.5 11 SS
Fuel Filler Tube Clamp Screws 2.9 0.30 26 inlb
Fuel Level Sensor Clamp Screw 2.9 0.30 26 inlb
Fuel Filter Mounting Bolts 8.8 0.90 78 inlb L
Fuel Pump Holder Clamp Screws 2.9 0.30 26 inlb
Air Filter Mounting Bolts 9.8 1.0 87 inlb L
Air Filter Bracket Mounting Bolts 7.8 0.80 69 inlb L
Throttle Cable Locknut 7.8 0.80 69 inlb
Throttle Case Mounting Screws 3.9 0.40 35 inlb
Engine Lubrication System
Breather Plate Bolts 7.8 0.80 69 inlb
Oil Filler Cap 1.0 0.10 8.7 inlb
Oil Passage Plugs 20 2.0 14 L

Torque
Fastener Remarks
Nm kgfm ftlb
Oil Separator Tank Mounting Screws 4.9 0.50 43 inlb L
Breather Case Mounting Bolts 7.8 0.80 69 inlb
Breather Pipe Bolts 8.8 0.90 78 inlb L
Oil Passage Joints 11 1.1 95 inlb L
Oil Cooler Assembly Bolts 7.8 0.80 69 inlb
Oil Pressure Switch 15 1.5 11 SS
Oil Passage Bolt 78 8.0 58 S
Oil Filter 18 1.8 13 EO
Oil Cooler Positioning Bolt 20 2.0 14 S
Oil Pan Bolts 7.8 0.80 69 inlb S
Dipstick Tube Bolts 8.8 0.90 78 inlb L, S
Oil Pump Sprocket Bolt (JT1500-A1 A2) 15 1.5 11 LN
Oil Pump Sprocket Bolt (JT1500A6) 16 1.6 12 LN
Oil Pump Cover Bolts 7.8 0.80 69 inlb
Oil Pressure Relief Valve 15 1.5 11 LN
Oil Pipe Bolts 7.8 0.80 69 inlb
Oil Pump Chain Guide Bolt 7.8 0.80 69 inlb
Chain Guide Spring Plate Bolt 7.8 0.80 69 inlb
Oil Pump Body Plug 20 2.0 14 L
Oil Pump Body Bolts 7.8 0.80 69 inlb
Oil Screen Bolts 7.8 0.80 69 inlb
Water Hose Joints (JT1500-A1 AA Early
20 2.0 14 L
Models)
Exhaust System
Exhaust Manifold Mounting Nuts 25 2.5 18 S
Exhaust Manifold Mounting Bolts 25 2.5 18 L, S
Bypass Nozzle L
Flushing Hose Joint 11 1.1 95 inlb L
Water Hose Joint 11 1.1 95 inlb L
Water Temperature Sensor 15 1.5 11 see chapter 3
Exhaust Pipe Mounting Plate Bolts 29 3.0 22 L
Exhaust Pipe Mounting Bolts 29 3.0 22
Exhaust Tube Clamp Screws (JT1500A8 ) 5.0 0.51 44 inlb
Exhaust Tube Clamp Screws (JT1500A8) 5.0 0.51 44 inlb
Engine Top End
Air Suction Valve Cover Bolts 9.8 1.0 87 inlb
Cylinder Head Cover Bolts 9.8 1.0 87 inlb
Upper Camshaft Chain Guide Bolts 12 1.2 104 inlb S
Camshaft Cap Bolts 12 1.2 104 inlb S
Cylinder Head Bolts (M7) 20 2.0 14 S
Cylinder Head Bolts (M11) 23 2.3 17 First, MO, S
Cylinder Head Bolts (M11) 59 6.0 43 Final, MO, S
Water Jacket Plugs 20 2.0 14 L

Torque
Fastener Remarks
Nm kgfm ftlb
Cylinder Head Bolts (M6) 12 1.2 104 inlb S
Engine Hook Bolts 20 2.0 14
Exhaust Side Camshaft Chain Guide Bolts 25 2.5 18
(Upper)
Exhaust Side Camshaft Chain Guide Bolts 12 1.2 104 inlb
(Lower)
Upper Camshaft Chain Guide Bolts 12 1.2 104 inlb S
Inlet Side Camshaft Chain Guide Bolts 12 1.2 104 inlb L
Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 inlb L
Camshaft Chain Tensioner Cap Bolt 20 2.0 14
Camshaft Position Sensor Rotor Bolt 12 1.2 104 inlb L
Water Hose Joint 11 1.1 95 inlb L
Oil Passage Joint 11 1.1 95 inlb L
Engine Removal/Installation
Engine Mounting Bolts 36 3.7 27 L
Engine Damper Mounting Bolts 16 1.6 12 L
Engine Bottom End
Crankshaft Sensor Cover Bolts 7.8 0.80 69 inlb
Engine Bracket Mounting Bolts 32 3.3 24 L
Timing Rotor Bolt 29 3.0 22 L
Connecting Rod Nuts MO, see text
Oil Passage Plugs 20 2.0 14 L
Stator Mounting Bolts 12 1.2 104 inlb L
Grommet Cover Bolts 9.8 1.0 87 inlb L
Magneto Cover Bolts 20 2.0 14
Output Cover Bolts 7.8 0.80 69 inlb
Output Shaft (JT1500-A1 A9 Early Models) 245 25.0 180 MO
Output Shaft (JT1500A9 Late Model ) 265 27.0 195 MO
Coupling 98 10 72
Crankcase Bolts (M10) 50 5.0 36 MO, S
Crankcase Bolts (M8) 29 3.0 22 MO, S
Crankcase Bolts (M8) 29 3.0 22 S
Crankcase Bolts (M6) 12 1.2 104 inlb S
Cooling and Bilge Systems
Bilge Breather Mounting Bolts L
Water Hose Joint (L Shape Type) 11 1.1 95 inlb L
Water Hose Joint (Straight Shape Type) 20 2.0 14 L
Water Hose Joint (Straight Shape Type) 11 1.1 95 inlb L, see text
Cooling Hose Clamp Screws 2.5 0.25 22 inlb
Flushing Cap (JT1500A8 ) 0.90 0.092 8.0 inlb
Drive System
Coupling 265 27.0 195

Torque
Fastener Remarks
Nm kgfm ftlb
Drive Shaft Holder Mounting Bolts 22 2.2 16 L
Coupling Cover Bolts 8.8 0.90 78 inlb L
Pump and Impeller
Steering Nozzle Pivot Bolts 19 1.9 14 L
Pump Mounting Bolts 36 3.7 27 L
Pump Outlet Mounting Bolts 19 1.9 14 L
Pump Cap Bolts 9.8 1.0 87 inlb L
Pump Cap Bolts (JT1500A7 ) 3.9 0.40 35 inlb L
Pump Cap Plug 3.9 0.40 35 inlb
Impeller 98 10 72
Pump Bracket Mounting Bolts (2) 19 1.9 14 LN, SS
Pump Bracket Mounting Bolts (4) 9.8 1.0 87 inlb L
Pump Cover Mounting Bolts 7.8 0.80 69 inlb L
Grate Mounting Bolts 9.8 1.0 87 inlb L
Filter Cover Mounting Bolts 9.8 1.0 87 inlb L
Steering
Handlebar Clamp Bolts 16 1.6 12 L
Start/stop Switch Case Mounting Screws 3.9 0.40 35 inlb
Throttle Case Mounting Screws 3.9 0.40 35 inlb
Steering Shaft Locknut 49 59 5.0 6.0 36 43
Steering Shaft Nut 2.9 0.30 26 inlb
Steering Holder Mounting Bolts 20 2.0 14.5 LN
Steering Neck Mounting Bolts 16 1.6 12 L
Steering Cable Joint Bolt 9.8 1.0 87 inlb L
Ball Joint 9.8 1.0 87 inlb LN
Shift Cable End Nut 9.8 1.0 87 inlb
Reverse Bucket Pivot Bolts 19 1.9 14 LN
Shift Cable Nut 39 4.0 29
Steering Cable Nut 39 4.0 29
Shift Lever Locknut 20 2.0 14.5
Hull/Engine Hood
Crossmember Bolts 7.8 0.80 69 inlb L
Handrail Bolts 9.8 1.0 87 inlb L
Lock Assembly Nut 4.9 0.50 43 inlb
Front Duct Bolts L
Damper Bolts L
Damper Bracket Bolts L
Front Storage Compartment Cover Bolts L
Hinge Bolts L
Front Storage Compartment Hook Bolts L
Steering Cover Bolts L
Meter Screen Bolts L
Seat Hook Bolts L

Torque
Fastener Remarks
Nm kgfm ftlb
Seat Locknut L
Reboarding Step Bolts L
Mirror Stay Bolts L
Stabilizer Bolts 9.8 1.0 87 inlb L
Air inlet Duct Bolts L
Exhaust Outlet Bolts L
Electrical System
Vehicle-Down Sensor Mounting Screws 1.5 0.15 13 inlb
Electrical Parts Bracket Screws 4.9 0.50 43 inlb L
Starter Relay Case Bolts 7.8 0.80 69 inlb
Ignition Coil Mounting Bolts 8.8 0.90 78 inlb L
Water Temperature Sensor 15 1.5 11 see text
Starter Relay Mounting Nut 3.5 4.5 0.35 0.45 30 40 inlb
Starter Cable Mounting Nut 3.5 4.5 0.35 0.45 30 40 inlb
Timing Rotor Bolt 20 2.0 14 L
Crankshaft Sensor Screws 4.4 0.45 39 inlb L
Rubber Grommet Holder Screws 4.4 0.45 39 inlb L
Crankshaft Sensor Cover Bolts 7.8 0.80 69 inlb
Oil Temperature Sensor 15 1.5 11 see text
Spark Plugs 13 1.3 113 inlb
Regulator/rectifier Bolts 7.8 0.80 69 inlb
Replay Assembly Bolt 2.5 0.25 22 inlb L
ECU Mounting Bolts 8.8 0.90 78 inlb L
Main Fuse Mounting Bracket Bolt 7.8 0.80 69 inlb
Bracket Mounting Bolts 8.8 0.90 78 inlb L
Multifunction Meter Mounting Bolts 3.9 0.40 35 inlb L
Fuel Level Sensor Clamp Screw 2.9 0.30 26 inlb
Start/stop Switch Case Mounting Screws 3.9 0.40 35 inlb
Speed Sensor Mounting Bolts 3.9 0.40 35 inlb L
Starter Motor Through Bolts 6.4 0.65 56 inlb L, R
Starter Motor Mounting Bolts 8.8 0.90 78 inlb L
Starter Motor Ground Bolt 7.8 0.80 69 inlb
Starter Motor Terminal Nut 7.8 0.80 69 inlb
Stator Coil Bolts 12 1.2 104 inlb L
Grommet Holder Bolts 8.8 0.90 78 inlb L

The next table, relating tightening torque 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)
Torque
Threads dia. (mm)
Nm kgfm ftlb
6 5.9 8.8 0.60 0.90 52 78 inlb
8 16 22 1.6 2.2 12 16
10 30 41 3.1 4.2 22 30

Specifications
Item Standard Service Limit

Fuel System
Throttle Lever Free
about 2 mm (0.08 in.)
Play
Engine Lubrication
System
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or
MA2
Capacity 4.0 L (4.2 US qt, when filter is not removed)
5.0 L (5.3 US qt, when engine is completely dry)
Engine Top End
Valve Clearance:
IN 0.15 0.24 mm (0.0059 0.0094 in.)
EX 0.22 0.31 mm (0.0087 0.0122 in.)
Electrical System
Spark Plug Gap 0.7 0.8 mm (0.028 0.031 in.)

Special Tools
Oil Filter Wrench: Shaft Wrench:
57001-1249 57001-1551

Periodic Maintenance Procedures
Fuel System
Throttle Control System Inspection
Inspect the throttle lever free play [A].
If the free play is incorrect, adjust the throttle cable.
Throttle Lever Free Play
Standard: about 2 mm (0.08 in.)
Check that the throttle lever moves smoothly from full

open to close, and the throttle closes quickly and com-
pletely in all steering positions by the return spring.
If the throttle lever does not return properly, check the
throttle cable routing, cable adjustments, and cable dam-
age. Then lubricate the throttle cable.
Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increase, check the throttle cable adjust-
ment and the cable routing.
Remove the seat (see Hull/Engine Hood chapter).

With the throttlecable
Check throttle adjustment.
throttle pivot arm [B] should
lever released, the upper stop [A] on the
rest against the stopper [C]
on the throttle body, and there should be slight slack in
the throttle cable.
When the throttle lever is fully applied (pulled), the lower
stop [D] on the pivot arm should be all the way up against
the stopper on the throttle body.
If necessary, adjust the throttle cable.

Loosen and turn the locknuts [A] at the bracket until the
upper stop on the pivot arm hits against the stopper on
the throttle body with slight cable slack.
Tighten the locknuts securely.
Torque - Throttle Cable Locknuts: 7.8 Nm (0.80 kgfm, 69
inlb)
NOTE
Make sure that the throttle pivot arm stops against the
stopper on the throttle body with the throttle lever re-
leased.
Air Filter Drain Caps Inspection and Cleaning
Inspect thetheairrear
Remove storage pocket.
[B]. filter [A] for water inside with its drain caps
If there is water in the caps, remove both caps and dis-

charge the water.
NOTE
Be sure to have a rag or cloth underneath for possible
oily water.

Air Filter Inspection and Cleaning
Remove:
Air Filter (see Fuel System (DFI) chapter)
Flame Arrester [A] (see Air Filter Disassembly in Fuel
System (DFI) chapter)
Clean the flame arrester [A].

If necessary,
Visually inspect the flame arrester for damage.
replace it with a new one.
Fuel Vent Check Valve Inspection

The fuel vent check valve is mounted in the fuel tank vent
hose to prevent fuel from spilling during riding. 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.
Remove
chapter).
the front storage pocket (see Hull/Engine Hood
Cut off the bands [A].

Pull out each end of the fuel vent check valve [B] from the
vent hoses [C].
Blow through the fuel vent check valve from each end.
If the check valve will allow air to flow as shown, it is OK.
If air will flow through the check valve in both direction or
in neither direction, the check valve must be replaced.

The fuel vent check valve [C] must be mounted so that

the arrow [D] on its case is pointing toward the fuel tank.
Fuel Pump Screen Cleaning

Remove the fuel pump (see Fuel System chapter).
-flash pointfuel
Wash the pump screen [A] in non-flammable of high
solvent. Use a brush to remove any contami-
nants trapped in the screens.
WARNING
Gasoline and low flash-point solvents are extremely
flammable and can be explosive under certain con-
ditions. To prevent a fire or explosion, clean the fuel
pump screen in a well-ventilated area with a high
flash-point solvent away from any ignition sources,
including any appliance with a pilot light.
Throttle Shaft Spring Inspection

lever. throttle shaft spring [A] by pulling the throttle
Check the
If the springs are damaged or weak, replace the throttle

body.

Engine Oil Change
Level
aft.
the watercraft port to starboard as well as fore to
Level Ground [A]

Side Bumper [B]
Parallel [C]

Incooling
a well-ventilated area, start the engine while cooling the
system.
Remove the flushing cap (see Cooling System Flushing).
Screw a garden hose adapter [A] onto the flushing fitting
[B].
Warm up the engine and stop it.
NOTICE
The engine must be running before the water is
turned on and the water must be turned off before
the engine is stopped.
Do not run the engine without cooling water flow for
more than 15 seconds.

Remove the oil filler cap [A] and the dipstick [B].
NOTICE
Dirt and other foreign materials can cause serious
engine damage. To prevent engine damage, do not
allow dirt or foreign materials to enter the engine.
Drain the oil thorough from the dipstick tube [A] using a
commercially-available vacuum pump [B].
WARNING
Used engine oil is toxic and pollutes the environ-
ment. To protect the environment, do not discard
used engine oil; always return it to an authorized
recycling center.
Pour in the specified type and amount of oil through the

oil filler opening [A].
Engine Oil
Grade: API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity: SAE 10W-40
Amount: 4.0 L (4.2 US qt, with or without the filter)
5.0 L (5.3 US qt, when engine is completely
dry)

Depending on the atmospheric temperature of your riding
area, the engine oil viscosity should be changed accord-
ing to the chart shown.
Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and clutch.
Install the filler cap.

Torque - Oil Filler Cap: 1.0 Nm (0.10 kgfm, 8.7 inlb)
Check
ter).
the oil level (see Engine Lubrication System chap-
Oil Filter Replace

Remove:
Seat (see Hull/Engine Hood chapter)
Place the
Drain engine oil (see Engine Oil Change).
maining oil. or cloth under the oil filter to receive the re-
a reg
Remove the oil filter [A] with the oil filter wrench [B].
Special Tool - Oil Filter Wrench: 57001-1249
Replace the filter with a new one.

Tighten the filter
Apply engine oil to the gasket [A] before installation.
with the oil filter wrench.
Torque - Oil Filter: 18 Nm (1.8 kgfm, 13 ftlb)
Pour in the specified type and amount of oil (see Engine
Oil Change).

Engine Top End
Air Suction Valve Inspection (JT1500-A1 A8
Models)
Remove
ter).
the air suction valve (see Engine Top End chap-
Visually inspect the reeds [A] for cracks, folds, warps,

heat damage, or other damage.
If there is any doubt as to the condition of the reed, replace
the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder, or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly with a high-flash point solvent.
NOTICE
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
Valve Clearance Inspection

NOTE
Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
Remove:
Cylinder Head Cover (see Engine Top End chapter)
Position the crankshaft at #1, #4 piston TDC as follows.
Using the shaft wrench [A], turn the crankshaft counter-

clockwise [B] and set the crankshaft at #1, 4 piston TDC.
Special Tool - Shaft Wrench: 57001-1551
D:\DOC
The timing marks [A] must be aligned with the cylinder

head upper surface [B] as shown.

Measure the valve clearance between the cam and the

valve lifter with a thickness gauge [A].
Valve Clearance
Standard:
IN 0.15 0.24 mm (0.0059 0.0094 in.)
EX 0.22 0.31 mm (0.0087 0.0122 in.)
When positioning #1 piston TDC at the end of the

compression stroke:
Inlet Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [ ]
Bow [A]

Camshaft Sprocket Position [B]
When positioning #4 piston TDC at the end of the

compression stroke:
Inlet Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [ ]
Bow [A]

Camshaft Sprocket Position [B]
If the valve clearance is not within the specified range,

first record the clearance, and then adjust it.
To change the valve clearance, remove the camshaft

chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.
NOTE
Mark and record the valve lifter and shim locations so
they can be reinstalled in their original positions.
If there is no clearance, select a shim which is several
sizes smaller and then measure the clearance.
To select a new shim which brings the valve clearance

within the specified range, refer to the Valve Clearance
Adjustment Charts.

Bisides the standard shims in the valve clearance adjust-
ment charts, the following additional shims maybe used.
Adjustment Shims
Part Number Thickness
92025-1982 2.425 mm
92025-1983 2.475 mm
92025-1984 2.525 mm
92025-1985 2.575 mm
92180-1058 2.375 mm
92180-1059 2.625 mm
92180-1194 2.675 mm
92180-1195 2.725 mm
92180-1196 2.775 mm
Clean the shim to remove any dust or oil.

Measure the thickness of the removed shim [A].

INLET VALVE CLEARANCE ADJUSTMENT CHART
1. Measure the clearance (when engine is cold).

2. Check present shim size.
3. Match clearance in vertical column with present shim
size in horizontal column.
4. Install the shim specified where the lines intersect.
This shim will give the proper clearance.
Example
Present shim is 2.60 mm.
Measured clearance is 0.35 mm.
Replace 2.60 mm shim with 2.75 mm shim.
5. Remeasure the valve clearance and readjust if nec-
essary.

EXHAUST VALVE CLEARANCE ADJUSTMENT CHART
1. Measure the clearance (when engine is cold).

2. Check present shim size.
3. Match clearance in vertical column with present shim
size in horizontal column.
4. Install the shim specified where the lines intersect.
This shim will give the proper clearance.
Example
Present shim is 2.65 mm.
Measured clearance is 0.42 mm.
Replace 2.65 mm shim with 2.80 mm shim.
5. Remeasure the valve clearance and readjust if nec-
essary.

Apply molybdenum disulfide oil to the valve lifters and ap-

ply engine oil to the shims, and install them.
Install the camshafts. Be sure to install the camshafts
properly (see Engine Top End chapter).
Remeasure any valve clearance that was adjusted.
Readjust if necessary.
NOTICE
Using shim stock under the shim may cause it to
pop out at high rpm and cause severe engine dam-
age. Do not put shim stock under the shim.
Grinding the shim may cause it to fracture, causing
severe engine damage. Do not grind the shim.
Engine Mounting Bolts Inspection and Tightness

Check the tightness of the engine mounting bolts [A].
If there are loose bolts, remove the bolts.
Apply a non-permanent locking agent to the engine
mounting bolts and tighten them.
Torque - Engine Mounting Bolts: 36 Nm (3.7 kgfm, 27 ftlb)
Engine Bottom End

Coupling Damper Inspection
Remove:
Engine (see Engine Removal/Installation chapter)
Remove the coupling damper [A] and inspect it for wear
[B] and deterioration.
If it is grooved or misshapen, replace it with a new damper.
If there is any doubt as to coupler condition, replace it.

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 right side of the hull.

Obtain a standard garden hose [A] and a garden hose

adapter [B] as shown.
Garden Hose Fitting of Adapter [C]
Flushing Fitting of Adapter [D]
Thread: Rp 3/4 [E]
NOTE
Optional part (P/No. 92005-3746) is available as a gar-
den hose adapter.

compartment.
Remove the flushing cap [A] on the brim of the storage
Screw
[B].
a garden hose adapter [A] onto the flushing fitting

Start
water.
the engine and allow it to idle before turning on the
NOTICE
If the water is turned on before the engine is run-
ning, water may flow back through the exhaust pipe
and into the engine, causing severe engine damage.
To prevent engine damage, be sure the engine is
running before turning the water on.
Immediately turn on the water and adjust the flow so that

a little trickle of water comes out of the bypass outlet [A]
on the right side of the hull.

Leave
running.
the engine idle for several minutes with the water
Turn off the water. Leave the engine idling.

Rev the engine a few times to clear the water out of the
exhaust system.
NOTICE
Operating the engine without cooling water for
more than 15 seconds, especially at high rpm, will
cause severe engine and exhaust system damage.
To avoid engine damage, do not run the engine
without providing sufficient cooling water.
Switch
adapter.
off the engine, remove the garden hose and the
Install the flushing cap securely.

Torque - Flushing Cap: 0.90 Nm (0.092 kgfm, 8.0 inlb)
(JT1500A8 Model )
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.
Disconnect both bilge hoses [A] at the plastic breather
fitting [B].
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 wa-
ter to accumulate in the engine compartment. Remove
the drain screws in the stern to drain the engine compart-
ment.
Connect the other hoses (from the hull bulkhead) to the
garden hose, turn the water on, and flush it out for several
minutes.
Before reconnecting the hoses to the plastic breather fit-

ting make sure the small hole [A], on top of the breather
fitting is clear.
Reconnect the bilge hoses.

Pump and Impeller
Impeller Inspection
Examine the impeller. [A]
If there is pitting, deep scratches, nicks or other damage,
replace the impeller.
NOTE
Minor nicks and gouges in the impeller blades can be
removed with abrasive paper or careful filing. Smooth
leading edges are especially important to avoid cavita-
tion.
Jet Pump Bearings/seals Lubrication, Inspection

and Replacement
See
ter.
Pump Disassembly in the Pump and Impeller chap-
Steering
Steering Cable/Shift Cable Inspection
Examine the steering cable or shift cable.
If each cables or cable housings are kinked or frayed,
replace the cables.
If the each seal [A] at either end of each cable is damaged
in any way, replace the cables.
Be certain that each cable moves freely in both directions.

Take out thethecable
Disconnect cable joints at each end of each cable.
joint bolt or ball joint and disconnect
the cable joint.
NOTICE
If the watercraft is laid on its right side, water in the
exhaust system may drain back into the engine a
cause serious damage. Never lay the watercraft on
the right side.
Slide the inner cable back [A] and forth [B] in each cable
housings.
If each cable does not move freely, replace it.
Handlebar Pivot Lubrication
Check the bushings for damage and wear.
If the bushings are damaged or worn, replace them.
Grease:
Bushings [A]

Steering Shaft [B]
Hull/Engine Hood
Drain Plug Inspection
Check the drain plugs [A] for cracks or damage and the
drain plug mounting screws [B] are tightened securely.
Check the seals [C] for damage.
If necessary, replace the drain plugs or seals.
Electrical System
Battery Charging Condition Inspection
Battery charging condition can be checked by measuring
battery terminal voltage.
Disconnect the battery terminal leads (see Battery Re-
moval in Electrical System chapter).
Be sure to disconnect the negative terminal lead first.
Measure the battery terminal voltage.
NOTE
Measure with a digital voltmeter [A] which can be read
one decimal place voltage.
If the reading is below the specified, refreshing charge
is required (see Refreshing Charge in Electrical System
chapter).
Battery Terminal Voltage
Standard: 12.6 V or more
Connect the battery leads, positive first.
Battery Terminals Inspection

Check the battery terminal screws [A] for tightness and
make sure terminal covers are in place.
WARNING
Loose battery leads 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 covers are installed over the termi-
nals.

Check that the battery terminals [B] are not corroded.

If necessary, remove the battery (see Electrical System
chapter) and clean the terminals and cable ends using a
solution of baking soda and water.
After attaching both cables, coat the terminals and cable
ends with grease to prevent corrosion.
Install the battery (see Electrical System chapter).
Spark Plug Cleaning and Inspection
Remove:
Spark Plug Caps
Remove the spark plugs using the 16 mm plug wrench
[A].
Owners Tool - Spark Plug Wrench, 16 mm: 92110-1145
Clean the spark plug, preferably in a sandblasting device,

and then clean off any abrasive particles. The plug may
also be cleaned using a high-flash point solvent and a wire
brush or other tool.
If the spark plug center electrode [A] and/or side elec-
trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug. Use the standard spark plug
or its equivalent.
Measure the gaps [D] with a wire-type thickness gauge.
If the gap is incorrect, carefully bend the side electrode
with a tool to obtain the correct gap.
Spark Plug Gap: 0.7 0.8 mm (0.028 0.031 in.)
Insert the spark plug vertically into the plug hole with the
spark plug installed in the plug wrench [A].
Owners Tool - Spark Plug Wrench, 16 mm: 92110-1145
Tighten:
Torque - Spark Plugs: 13 Nm (1.3 kgfm, 113 inlb)
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:

Lubricate the following with grease.

Pull the throttle lever and hold it.
Throttle Cable End at Throttle Lever [A]
Throttle Cable End [A] at Throttle Body
Remove the storage pocket (see Hull/Engine Hood chap-

ter).
Steering Cable Ball Joint [A] at Steering Shaft
Remove the storage pocket (see Hull/Engine Hood chap-

ter).
Shift Cable Ball Joint [A] at Reverse Lever
Shift Cable Ball Joint [A] at Reverse Bucket

Lubricate the following with a penetrating rust inhibitor [B].

Throttle Cable [A]
Steering Nozzle Pivots [A]

Reverse Bucket Pivots [B]
With the cable disconnected at both ends, the cable

should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.

All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check
Nuts, Bolts, 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
For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If 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.
If cotter pins are damaged, replace them with new ones.
Nut, Bolt and Fastener to be checked
Engine:
Oil Filter Cartridge
Engine Mounting Bolts (and bracket bolts)
Engine Damper Mounting Bolts
Cylinder Head Cover Bolts
Cylinder Head Bolts
Drive Shaft, Pump, and Impeller:
Drive Shaft Holder Mounting Bolts
Pump Mounting Bolts
Pump Cover Mounting Bolts
Pump Grate Mounting Bolts
Steering Nozzle Pivot Bolts
Reverse Bucket Pivot Bolts
Steering:
Handlebar Clamp Bolts
Steering Neck Mounting Bolts
Steering Holder Mounting Bolts
Steering Shaft Locknut
Steering Cable Nut
Steering Cable Joint Bolt
Shift (reverse) Cable Nut
Hull and Engine Hood:
Stabilizer Bolts
Handrail Bolts
Electrical System:
Spark Plugs
Battery Terminal
Hose and Hose Connect Inspection
Check the following hoses for leakage [A], hardening,
cracking [B], checking, cuts, abrasions, breaks and
bulges [C]. And make sure the hoses are not kinked or
pinched.
Fuel Hoses
Fuel Vent Hose
Oil Hoses
Cooling Hoses
Bilge Hoses
If a hose is damaged in any way, replace it immediately
and check all the others for damage.

Make sure the above hoses are routed properly and se-
cured with the clamps away from any moving parts and
sharp edged portions.
Plastic Clamp [A]
Hose [B]
Hose Fitting [C]
NOTE
The majority of bilge hoses have no clamps at the hose
ends.
Metal Clamp [A]

Hose [B]
Hose Fitting [C]
NOTE
Check the fuel and exhaust tubes for signs of wear, de-
terioration, damage or leakage. Replace if necessary.
Make sure the above tubes are secured with the metal
gear clamps away from any parts.
JT1500-A2 Model ;
Double Spring Clamp [A]
Hose [B]
Hose Fitting [C]
NOTE
Check the fuel hoses for signs of wear, deterioration,
damage or leakage. Replace if necessary.
Make sure the above hoses are secured with the double
spring clamps away from any parts.
NOTICE
Reusing the double spring clamps will cause fuel
leakage, creating the potential for a fire or explo-
sion. Do not reuse the double spring clamps on the
fuel line. Replace the double spring clamps with
new ones.
Replacement
follows.
procedure for the double spring clamp is as
Remove the double spring clamp with pliers and discon-

nect the fuel hose.
Install the fuel hose and insert the new double spring
clamp [A] with the clamp stopper [B].
Pull up the clamp stopper with pliers [C].
NOTE
Position the double spring clamp on the fuel hose cor-
rectly.

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 Tank Straps
Water Box Muffler Straps
If a strap is damage in any way, replace it.
Fuel Hose Replacement

WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. 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 double spring clamps and fuel hoses.

When installing
Replace the fuel hoses with new ones.
to Cable, Wire, the fuel hose, route the hose according
and Hose Routing section in Appendix
chapter.
When installing the fuel hose, avoid sharp bending, kink-
ing, flattening or twisting, and route the fuel hose with a
minimum of bending so that the fuel flow will not be ob-
structed.
Make sure the fuel hoses are routed properly and se-
cured with the double spring clamps away from any mov-
ing parts and sharp edged portions (see Hose and Hose
Connect Inspection).
Start the engine and check the fuel hose for leaks.

FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)

Table of Contents
Fuel System Diagram ........................ 3-3 Vehicle-down Sensor (Service
Exploded View................................... 3-4 Code/Character-31/dOS)................ 3-47
Specifications .................................... 3-10 Vehicle-down Sensor Removal .... 3-47
Special Tools and Sealants ............... 3-12 Vehicle-down Sensor Installation . 3-47 3
DFI Parts Location............................. 3-13 Vehicle-down Sensor Inspection.. 3-48
DFI System........................................ 3-16 Fuel Injectors (Service
DFI Servicing Precautions ................. 3-21 Code/Character-41, 42, 43,
Self-Diagnosis ................................... 3-24 44/InJ1, InJ2, InJ3, InJ4) ................ 3-50
Self-diagnosis Outline..................... 3-24 Fuel Injector Removal .................. 3-50
Service Code (Character) Table ..... 3-25 Fuel Injector Installation ............... 3-50
Troubleshooting the DFI System ....... 3-27 Audible Inspection........................ 3-51
Throttle Sensor (Service Injector Signal Test....................... 3-51
Code/Character-11/tPS) ................. 3-29 Injector Resistance Inspection ..... 3-52
Throttle Sensor Removal/Adjust- Injector Unit Test .......................... 3-52
ment .......................................... 3-29 Injector Voltage Inspection........... 3-53
Input Voltage Inspection............... 3-30 Injector Fuel Line Inspection ........ 3-54
Output Voltage Inspection............ 3-32 Ignition Coils (Service
Resistance Inspection.................. 3-33 Code/Character-51, 52/COL1,
Inlet Air Pressure Sensor (Service COL2) ............................................. 3-57
Code/Character-12/bOSt)............... 3-35 Ignition Coil Removal/Installation. 3-57
Inlet Air Pressure Sensor Input Voltage Inspection............... 3-57
Removal .................................... 3-35 Engine Overheating (Service
Inlet Air Pressure Sensor Code/Character-71/HEAt)............... 3-60
Installation ................................. 3-35 Low Engine Oil Pressure (Service
Input Voltage Inspection............... 3-35 Code/Character-72/OILP)............... 3-61
Output Voltage Inspection............ 3-36 Oil Temperature Sensor (Service
Inlet Air Temperature Sensor (Service Code/Character-73/OILC or
Code/Character-13/AIrt) ................. 3-39 73/OILt)........................................... 3-62
Inlet Air Temperature Sensor Oil Temperature Sensor
Removal/Installation.................. 3-39 Removal/Installation.................. 3-62
Output Voltage Inspection............ 3-39 Output Voltage Inspection............ 3-62
Sensor Resistance Inspection ..... 3-40 Sensor Resistance Inspection ..... 3-64
Water Temperature Sensor (Service Engine Oil Overheating (Service
Code/Character-14/AqUt) ............... 3-42 Code/Character-76/OILH)............... 3-65
Water Temperature Sensor ECU ................................................... 3-66
Removal/Installation.................. 3-42 ECU Removal .............................. 3-66
Output Voltage Inspection............ 3-42 ECU Installation ........................... 3-66
Sensor Resistance Inspection ..... 3-44 ECU Power Supply Inspection..... 3-66
Crankshaft Sensor (Service DFI Power Source ............................. 3-70
Code/Character-21/CrAg)............... 3-45 Main Fuse Inspection................... 3-70
Crankshaft Sensor Relay Assembly Removal ............ 3-70
Removal/Installation.................. 3-45 Relay Assembly Inspection.......... 3-70
Crankshaft Sensor Inspection...... 3-45 Throttle Lever, Cable and Case......... 3-72
Camshaft Position Sensor (Service Free Play Inspection .................... 3-72
Code/Character-23/CAA1).............. 3-46 Throttle Cable Adjustment ........... 3-72
Camshaft Position Sensor Throttle Case Removal/Disas-
Removal/Installation.................. 3-46 sembly....................................... 3-72
Camshaft Position Sensor Throttle Case Assembly/Installa-
Inspection.................................. 3-46 tion ............................................ 3-73
Throttle Cable Removal ............... 3-74

3-2 FUEL SYSTEM (DFI)
Throttle Cable Installation ............ 3-75 Inlet Manifold Installation ............. 3-84
Throttle Case and Cable Fuel Line............................................ 3-86
Lubrication................................. 3-76 Fuel Pressure Inspection ............. 3-86
Throttle Cable Inspection ............. 3-76 Fuel Flow Rate Inspection ........... 3-88
Air Filter ............................................. 3-77 Fuel Vent Check Valve ...................... 3-89
Air Filter Removal ........................ 3-77 Fuel Vent Check Valve Mounting . 3-89
Air Filter Installation ..................... 3-78 Fuel Vent Check Valve Inspection 3-89
Air Filter Disassembly .................. 3-78 Fuel Filter........................................... 3-90
Air Filter Assembly ....................... 3-79 Fuel Filter Removal...................... 3-90
Throttle Body Assy ............................ 3-80 Fuel Filter Installation................... 3-91
Idle Speed Inspection .................. 3-80 Fuel Pump ......................................... 3-92
High Altitude Performance Fuel Pump Removal .................... 3-92
Adjustment ................................ 3-80 Fuel Pump Installation ................. 3-93
Throttle Body Assy Removal........ 3-80 Power Source Voltage Inspection 3-94
Throttle Body Assy Installation..... 3-80 Operating Voltage Inspection....... 3-94
Throttle Body Assy Disassembly . 3-80 Fuel Pump Relay Removal .......... 3-95
Throttle Bore Cleaning ................. 3-81 Fuel Pump Relay Inspection ........ 3-95
ISC (Idle Speed Controller) Fuel Tank ........................................... 3-98
Removal/Installation.................. 3-81 Fuel Tank Removal ...................... 3-98
ISC (Idle Speed Controller) Fuel Tank Installation ................... 3-99
Inspection.................................. 3-81 Fuel Tank Cleaning ...................... 3-99
ISC Resistance Inspection........... 3-82 Fuel Filler and Tube Removal ...... 3-100
Inlet Manifold ..................................... 3-83 Fuel Filler and Tube Installation ... 3-100
Inlet Manifold Removal ................ 3-83 Fuel Tank Vent Hose Installation.. 3-101

Fuel System Diagram
1. Fuel Pump
2. Clamps (JT1500-A1 Model)
Double Spring Clamps (JT1500-A2 Model )
(Installation Procedure: Pull up the clamp stopper [A] with pliers [B].)
3. Main Line
4. Fuel Filter
5. Supply Line
6. Return Line
7. Delivery Pipe
8. Fuel Injectors
9. Fuel Tank

Exploded View

Exploded View
Torque
No. Fastener Remarks
Nm kgfm ftlb
1 Vehicle-down Sensor Mounting Screws 1.5 0.15 13 inlb
2 Bracket Mounting Bolts 8.8 0.90 78 inlb L
3 Inlet Manifold Mounting Bolts 25 2.5 18 L
4 Inlet Manifold Mounting Nuts 20 2.0 14
5 Delivery Pipe Mounting Bolts 7.8 0.80 69 inlb
6 Inlet Air Pressure Sensor Bolts 7.8 0.80 69 inlb
7 Throttle Cable Holder Bolts 8.8 0.90 78 inlb L
8 Inlet Air Temperature Sensor 20 2.0 14
9 Throttle Body Assy Mounting Bolts 20 2.0 14
10 Inlet Manifold Drain Plug 20 2.0 14
11 Inlet Manifold Plate Bolts 7.8 0.80 69 inlb
12 Crankshaft Sensor Screws 4.4 0.45 39 inlb L
13 Camshaft Position Sensor Bolt 9.8 1.0 87 inlb L
14 Water Temperature Sensor 15 1.5 11 see text
15 Oil Temperature Sensor 15 1.5 11 see text
16 Regulator/rectifier Bolts 7.8 0.80 69 inlb
17 ECU Mounting Bolts 8.8 0.90 78 inlb L
18 Electrical Parts Bracket Screws 4.9 0.50 43 inlb L
19 Throttle Sensor Mounting Screws 2.0 0.20 18 inlb
20 ISC Actuator Mounting Bolts 4.9 0.50 43 inlb
21. Ignition Coils
22. Fuel Injectors
23. Main Fuse 20 A
24. Relay Assembly (Main Relay/Fuel Pump Relay)
A: JT1500-A1 Model (Clamps)
B: JT1500-A2 Model (Double Spring Clamps)
C. JT1500-A1 A6 Model
D: JT1500A8 Model
DG Fill the hollow with the heat transfer grease (Heat Transfer Grease, SCH-20: 92137-1002 or
equivalent).
EO: Fill the hollow with the engine oil (10W-30).
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SO: Apply silicone oil to the O-ring.

Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Oil Pressure Switch 15 1.5 11 SS
2 Fuel Filler Tube Clamp Screws 2.9 0.30 26 inlb
3 Fuel Level Sensor Clamp Screw 2.9 0.30 26 inlb
4 Fuel Filter Mounting Bolts 8.8 0.90 78 inlb L
5 Fuel Pump Holder Clamp Screws 2.9 0.30 26 inlb
6. Meter Unit
7. Buzzer
8. Fuel Vent Check Valve
9. Fuel Level Sensor
10. Fuel Filter
11. Fuel Pump
A: JT1500-A1 Model
B: JT1500-A2 Model
C: JT1500-A1 A8, AB Late Model (AU and EUR Models)
SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).

Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Air Filter Mounting Bolts 9.8 1.0 87 inlb L
2 Air Filter Bracket Mounting Bolts 7.8 0.80 69 inlb L
3 Gromet Plate Bolts L
4 Throttle Cable Locknut 7.8 0.80 69 inlb
5 Throttle Case Mounting Screws 3.9 0.40 35 inlb
G: Apply grease.

Specifications
Item Standard
Digital Fuel Injection System
Idle Speed 1 300 100 r/min (rpm) -both in and out of water
Throttle Body Assy:
Throttle Valve Single throttle valve
Bore 60 mm (2.36 in.)
ECU (Electronic Control Unit):
Make Mitsubishi Electric
Type Digital memory type, with built in IC igniter, sealed with
resin
Operating range Engine speed range 100 8 100 r/min (rpm)
Fuel Pressure (High Pressure Line):
Engine Idling approx. 294 kPa (3.0 kgf/cm, 43 psi)
Fuel Pump:
Type Impeller type
Discharge 67 mL or more for 3 seconds
Throttle Sensor:
Input Voltage 4.75 5.25 V DC between R and BK/W leads
Output Voltage 1.08 1.18 V DC between G/W and BK/W leads (at idle
throttle opening)
Resistance 4 6 k
Inlet Air Pressure Sensor:
Input Voltage 4.75 5.25 V DC between R and BK/W leads
Output Voltage 3.75 4.25 V DC between G/R and BK/W leads at standard
atmospheric pressure
Inlet Air Temperature Sensor:
Output Voltage at ECU about 2.3 2.6 V @20C (68F)
Resistance 5.4 6.6 k at 0C (32F)
2.26 2.86 k at 20C (68F)
0.29 0.39 k at 80C (176F)
Water Temperature Sensor:
Resistance see Electrical System chapter
Output Voltage at ECU about 3 4 V @20C (68F)
Vehicle-down Sensor:
Detection Method Magnetic flux detection method
Detection Angle more than 110 130 for each bank
with sensor tilted 110 130 or more: 0.65 1.35 V
Output Voltage
with sensor arrow mark pointed up: 3.55 4.45 V
Fuel Injectors:
Type INP-281
Nozzle Type One spray type with 4 holes
Resistance about 11.7 12.3 at 20C (68F)
Oil Temperature Sensor:
Resistance same to water temperature sensor
Output Voltage at ECU about 3 4 V @20C (68F)

Specifications
Item Standard
Throttle Lever and Cables
Throttle Lever Free Play about 2 mm (0.08 in.)

Special Tools and Sealants
Oil Pressure Gauge, 5 kgf/cm: Sensor Harness Adapter:
57001-125 57001-1561
Hand Tester: Harness Adapter:

57001-1394 57001-1562
Needle Adapter Set: Liquid Gasket, TB1211:

57001-1457 56019-120
Fuel Pressure Gauge Adapter: Heat Transfer Grease, SCH-20:

57001-1463 92137-1002
Throttle Sensor Setting Adapter:

57001-1521

DFI Parts Location
1. Fuel Injector #1
2. Fuel Injector #2
3. Fuel Injector #3
4. Fuel Injector #4
5. Inlet Air Pressure Sensor
6. Inlet Air Temperature Sensor
7. Throttle Sensor
8. ISC (Idle Speed Controller)
9. Camshaft Position Sensor
10. Water Temperature Sensor
11. Crankshaft Sensor
12. Oil Pressure Switch
13. Oil Temperature Sensor

DFI Parts Location
14. Ignition Switch
15. Meter Unit
16. Buzzer
17. Fuel Pump
19. Vehicle-down Sensor
20. Ignition Coil #1, #4
22. Main Fuse 20 A
23. ECU (Electronic Control Unit)
24. Diagnosis Connector
26. Battery

DFI Parts Location
This page intentionally left blank.

DFI System
DFI System Wiring Diagram (JT1500-A1 A7 Models)

DFI System
Part Name
1. Fuel Injector #1
2. Fuel Injector #2
3. Fuel Injector #3
4. Fuel Injector #4
5. Joint Connector H
8. Joint Connector E
9. Joint Connector J
12. Joint Connector F
13. Connector C
15. Meter Unit (Diagnosis Signal)
16. Ignition Switch
17. Joint Connector Q
18. Start Switch
19. Joint Connector R
20. Main Fuse 20 A
21. Starter Motor
22. Battery 12 V 18 Ah
28. Throttle Sensor
31. Connector D
32. Ignition Coils
33. Joint Connector P
34. Fuel Pump
35. Joint Connector S
A: JT1500-A2 A7 Models

DFI System
DFI System Wiring Diagram (JT1500A8 Model )

DFI System
Part Name
1. Joint Connector Y
2. Joint Connector Z
3. Joint Connector X
4. Joint Connector W
5. Fuel Injector #4
6. Fuel Injector #3
7. Fuel Injector #2
8. Fuel Injector #1
14. Fuel Pump
15. Ignition Switch
20. Start Switch
21. Main Fuse 20A
22. Joint Connector T
23. Starter Motor
25. Joint Connector U
26. Meter Unit (Diagnosis Signal)
27. Ignition Coils
31. Throttle Sensor

DFI System
Terminal Numbers of ECU Connectors
Terminal Names
1. Tachometer Signal 24. Ground for External Diagnosis
2. ECU Main Relay System
3. Unused 25. Ground for Control System
4. SLO (Smart Learning Operation) Mode (JT1500-A2 26. External Diagnosis System
Model ) Signal
5. Oil Pressure Switch 27. Diagnosis Signal
6. Engine Stop Switch 28. Start Button
7. Inlet Air Temperature Sensor 29. Vehicle-down Sensor
8. Ground for Sensors 30. Power Supply to ECU
9. Ignition Switch (from Battery)
10. Steering Position Sensor 31. Unused
11. Unused 32. Ground for Control System
12. Power Supply to Sensors 33. Inlet Air Pressure Sensor
13. Cam Sensor (+) Signal 34. Throttle Sensor
14. Cam Sensor () Signal 35. Water Temperature Sensor
15. Crankshaft Sensor 36. External Diagnosis System
16. Unused Signal
17. Fuel Pump Relay 37. Oil Temperature Sensor
18. ISC (Idle Speed Controller) 38. Injector #2
21. ISC (Idle Speed Controller) 41. Ground for Power System
22. Ignition Coil #1,#4 42. Ground for Power System
23. Unused 43. Injector #1
44. Ignition Coil #2,#3

DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.
This DFI system is designed to be used with a 12 V sealed

battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
Do not reverse the battery cable connections. This will
damage the ECU.
To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is on, or while the engine is running.
Take care not to short the cables that are directly con-
nected to the battery positive (+) terminal to the engine
ground.
When charging, remove the battery from the vehicle. This
is to prevent ECU damage by excessive voltage.
Whenever the DFI electrical connections are to be discon-
nected, first turn off the ignition switch. Conversely, make
sure that all the DFI electrical connections are firmly re-
connected before starting the engine.
Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memo-
rizes service codes.
If a transceiver is installed on the vehicle, make sure that
the operation of the DFI system is not influenced by elec-
tric wave radiated from the antenna. Check operation of
the system with the engine at idle. Locate the antenna as
far as possible away from the ECU.
When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
Before removing the fuel system parts, blow the outer sur-
faces of these parts clean with compressed air.
When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
When installing the fuel hoses, avoid sharp bending, kink-
ing, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be ob-
structed.
Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
Install the hose clamps in the position shown, and se-

curely tighten the clamp bolts. Check the fuel system for
leaks after hose installation.
Fuel Hose [A]
Clamp [B]
Fuel Pipe [C]

For JT1500-A2 Model ;
Install the double spring clamp in the position as shown,
and securely pull up the clamp stopper with pliers. Check
the fuel system for leaks after hose installation.
Fuel Hose [B]
Double Spring Clamp [A]
Fuel Pipe [C]
NOTICE
Reusing the double spring clamps will cause fuel
leakage, creating the potential for a fire or explo-
sion. Do not reuse the double spring clamps on the
fuel line. Replace the double spring clamps with
new ones.
Replace the fuel hose if it has been sharply bent or kinked.
The high pressure inside the fuel line can cause fuel to
leak [A] or the hose to burst. Bend and twist the fuel hose
while examining it.
Replace the hose if any cracks [B] or bulges [C] are no-
ticed.
When checking the DFI parts, do not run the engine for
15 seconds or more without auxiliary cooling (see General
Information chapter).
NOTICE
Running the engine without auxiliary cooling for 15
seconds or more, even at idle speed, may damage
the rubber components in the Exhaust System. Do
not run the engine for more than 15 seconds with-
out auxiliary cooling water.
Execute the auxiliary cooling securely in case that fre-
quent engine running is required.
When checking the DFI parts, use a digital meter which

can be read two decimal place voltage or resistance.
The DFI part connectors have seals, including the ECU.
When measuring the input or output voltage with the
connector joined, use the needle adapter set. Insert the
needle adapter inside the seal until the needle adapter
reaches the terminal.
Digital Meter [A]
Special Tool - Needle Adapter Set: 57001-1457
NOTICE
If the needle adapter is inserted at an angle it may
create a short-circuit between the terminals and
damage the electrical system. To avoid a short
circuit, insert the needle adapter straight along the
terminal in the connector.

After measurement, remove the needle adapters and ap-
ply silicone sealant to the seals [A] of the connector [B]
for waterproofing.
Sealant - Liquid Gasket, TB1211: 56019-120
Always check battery condition before replacing the DFI

parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.
Do not directly connect a 12 V battery to a fuel injector.
Insert a resistor (5 7 ) or a bulb (12 V, 3 3.4 W) in
series between the battery and the injector.

Self-Diagnosis
Self-diagnosis Outline
The self-diagnosis system has two modes and can be
switched to another mode.
Push the SET button with MODE button at the
[A]
same time for 3 seconds or more.
Push either SET or MODE button for more than
[B]
one second or more.
User Mode
This is a standard mode and enters automatically after
ignition switch ON. The ECU notifies the rider of troubles
in DFI system and ignition system by flashing LED warn-
ing light [A], the FI indicator [B] and FI character [C] when
DFI system and ignition system parts are faulty, and initiates
fail-safe function. The buzzer sound goes on. In case of se-
rious troubles ECU stops the injection/ignition/starter motor
operation. The buzzer sound can be stopped by pushing
either SET or MODE button.
Dealer Mode
The LCD in the meter unit displays service code charac-
ter [A] to show the problem(s) which the DFI system and
ignition system has at the moment of diagnosis.
To enter the dealer mode push the SET button [B] with
MODE button [C] for 3 seconds or more.
Read the service code character in the LCD display. Re-
fer to the Service Code (Character) Table in the following
section.
To return the user mode push either SET or MODE
button for one second or more.
The service code character(s) will not be shown on the
LCD in the meter unit after the problems are solved.

Self-Diagnosis
Service Code (Character) Table
Service Service Code
Code Character
Possible Problems Fail-Safe Function
(used in (displayed on
ECU) Meter Unit)
Throttle sensor malfunction, The ECU locks ignition timing into
wiring open or short the ignition timing at closed throttle
11
position and sets the DFI in the D-J
method (see Note 1).
Inlet air pressure sensor The ECU sets the DFI in the -N
12
malfunction, wiring open or short method (see Note 2).
Inlet air temperature sensor The ECU sets the inlet air
13
malfunction, wiring open or short temperature at 40C.
Water temperature sensor The ECU sets the water
14
malfunction, wiring open or short temperature at 70C.
Crankshaft sensor malfunction,
21
wiring open or short
The ECU continues to ignite
Camshaft position sensor
23 cylinders in the same sequence
malfunction, wiring open or short
following the last good signal.
Vehicle-down sensor The ECU slows down the engine
31 malfunction, wiring open or speed less than 3 000 r/min (rpm)
short by stopping the ignition.
Injector #1 malfunction, wiring
41
open or short
42
open or short
43
open or short
44
open or short
The ECU shuts off the injectors
Ignition coil #1, #4 malfunction,
51 #1/#4 to stop fuel to the cylinders
#1/#4.
The ECU shuts off the injectors
Ignition coil #2, #3 malfunction,
52 #2/#3 to stop fuel to the cylinders
#2/#3.
The ECU slows down the engine
71 Engine overheat speed less than 3 000 r/min (rpm)
by stopping the ignition.
The ECU slows down the engine
72 Engine oil pressure too low speed less than 3 000 r/min (rpm)
(JT1500-A1) Oil temperature sensor The ECU sets the oil temperature
malfunction, wiring open or at 60C.
73 short The ECU slows down the engine
(JT1500-A2 ) speed less than 3 000 r/min (rpm)
(JT1500-A2 ) The ECU slows down the engine

76 Engine oil overheat speed less than 3 000 r/min (rpm)

Self-Diagnosis
Note:
(1) D-J Method: the DFI control method from medium to heavy engine load. When the engine load
is light like at idling or low speed, the ECU determines the injection quantity by calculating from
the throttle vacuum (vacuum sensor output voltage) and engine speed (crankshaft sensor output
voltage).
(2) -N Method: As the engine speed increases, and the engine load turns middle to heavy, the ECU
determines the injection quantity by calculating from the throttle opening (throttle sensor output
voltage) and the engine speed.
(3) If both throttle sensor system and inlet air pressure fails, the ECU locks ignition timing into the
ignition timing at closed throttle position and sets the DFI in the -N method.
(4) The ECU may be involved in these problems. If all the parts and circuits checked out good, be
sure to check the ECU for ground and power supply. If the ground and power supply are checked
good, replace the ECU.
Memory of Service Code (Character)

The service codes (characters) in the past are stored in the ECU. However, the characters cannot be
displayed in the meter. The past service codes can be confirmed by using the Kawasaki Diagnostic
System and they can be erased.

Troubleshooting the DFI System
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.): Year of initial registration:
Model: Engine No.: Hull No.:
Date problem occurred: Mileage:
Environment when problem occurred.
Weather fine, cloudy, rain, snow, always, other:
Temperature hot, warm, cold, very cold, always
Problem
frequency
chronic, often, once
Altitude normal, high (about 1 000 m or more)
Watercraft conditions when problem occurred.
Warning turn on immediately after ignition switch ON, and turn off after 1 2 seconds
LED light, FI (normal).
character, FI lights blink after ignition switch ON, and stay on (DFI problem)
mark unlights (LED light, meter unit, ECU or its wiring fault).
sometimes lights up (probably wiring fault).
Starting starter motor not rotating.
difficulty starter motor rotating but engine doesnt turn over.
starter motor and engine dont turn over.
no fuel flow ( no fuel in tank, no fuel pump sound).
engine flooded (do not crank engine with throttle opened, which promotes
engine flooding).
no spark.
other:
right after starting.
Engine stalls
when opening throttle lever.
when closing throttle lever.
when moving off.
when stopping the watercraft.
when cruising.
other:
Poor running at very low idle speed, very high idle speed, rough idle speed.
low speed battery voltage is low (charge the battery).
spark plug loose (tighten it).
spark plug dirty, broken, or gap maladjusted (remedy it).
backfiring.
afterfiring.
hesitation when acceleration.
engine oil viscosity too high.
engine overheating.
other:

Troubleshooting the DFI System
Poor running spark plug loose (tighten it).

or no power at spark plug dirty, broken, or gap maladjusted (remedy it).
high speed
spark plug incorrect (replace it).
knocking (fuel poor quality or incorrect).
engine overheating.
engine oil level too high.
engine oil viscosity too high.
other:

Throttle Sensor (Service Code/Character-11/tPS)
Throttle Sensor Removal/Adjustment
NOTICE
A shock to the throttle sensor can damage it. Do
not drop the throttle sensor.
Remove:
Air filter (see Air Filter Removal)
Use a Torx wrench [A] (T20, B = 3.86 mm (0.152 in.)) to

remove the throttle sensor mounting screws [C].
NOTE
In the engine compartment, there is not enough space
between the throttle sensor and hull to remove the Torx
screws. So use an L shape Torx wrench.
When installing the throttle sensor, note the following (In

the photo, the throttle sensor has been removed from the
throttle body for clarity).
Align [A] the projections [B] on the throttle sensor with the
throttle shaft [C] as shown when putting the throttle sensor
to the throttle body.
Turn the throttle sensor counterclockwise [A] a little and

temporarily tighten the throttle sensor mounting screws.

Adjust the throttle sensor positioning as follows.

Install the air filter temporarily.
After warming up the engine, check the idling speed.
Idle Speed
Standard: 1 300 100 r/min (rpm)
Stop the engine and turn the ignition switch OFF.
Disconnect the throttle sensor connector and connect the
throttle sensor setting adapter [A] between the harness
connector and throttle sensor connector.
Connect a digital meter to the sensor setting adapter
leads.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1521
Throttle Sensor Output Voltage

Connections to Sensor
Meter (+) G/W lead
Meter () BK/W lead
Start the engine with idle speed.

Turn [A] the throttle sensor and bring the sensor output
voltage within the standard range.
Output Voltage at Sensor
Standard: 1.08 1.18 V DC (at idle throttle opening)
Tighten the throttle sensor mounting screws.
Torque - Throttle Sensor Mounting Screws: 2.0 Nm (0.20
kgmf, 18 inlb)
Recheck the sensor output voltage is within the standard
range.
Stop the engine and turn the ignition switch OFF.
Remove the setting adapter and reconnect the throttle
sensor connector.
Input Voltage Inspection
NOTE
Be sure the battery is fully charged.
Turn the ignition switch OFF.
Remove the ECU (see ECU Removal). Do not disconnect
the ECU connector.
Connect a digital voltmeter [A] to the connector [B], using

the needle adapter set.
Throttle Sensor Input Voltage

Connections to ECU
Meter (+) R lead (terminal 12)
Meter () BK/W lead (terminal 8)

Turn the ignition switch ON and push the lanyard key un-
der the stop button.
Pushing the start button, run the engine 5 6 seconds at
idling to measure the sensor input voltage.
Wait 15 seconds before using the starter again.
Input Voltage at ECU
Standard: 4.75 5.25 V DC

If the reading of input voltage is less than the standard,
check the ECU for its ground, power supply and wiring
shorted. If the ground, power supply and wiring are good,
replace the ECU.
If the input voltage is within the standard range, check the
input voltage at the throttle sensor connector.
Remove the air filter temporarily (see Air Filter Removal).

setting adapter [A] between the harness connector and
throttle sensor connector.
Connect a digital meter to the setting adapter leads.
-1521
Throttle Sensor Input Voltage

Meter (+) R lead
Meter () BK/W lead
Install the air filter.

Input Voltage at Sensor

If the reading is out of the range, check the wiring (see
wiring diagram in this section).
If the reading is good, check the output voltage of the
sensor.

Output Voltage Inspection
Measure the output voltage at the ECU in the same way
as input voltage inspection. Note the following.
Digital Voltmeter [A]
Connector [B]

Connections to ECU
Meter (+) G/W lead (terminal 34)
Start the engine.

Check idle speed to ensure throttle opening is correct.
Idle Speed
Standard: 1 300 100 r/min (rpm)
Measure the sensor output voltage with the idle speed.

Output Voltage at ECU
NOTICE
If the output voltage is within the standard range, check

the ECU for a good ground, and power supply (see ECU
Power Supply Inspection). If the ground and power sup-
ply are good, replace the ECU.
If the output voltage is far out of the standard range (e.g.
when the wiring is open, the reading is 0 V), check the
output voltage at the sensor connector.


setting adapter [A] between the harness connector and
throttle sensor connector.
Connect a digital meter to the setting adapter leads.
-1521

Meter (+) G/W lead
Meter () BK/W lead
Measure the sensor output voltage with the idle speed.

NOTICE
After throttle sensor voltage inspection, remove the set-

ting adapter.
If the reading is out of the standard range, inspect the
throttle sensor resistance.
If the output voltage is normal, check the wiring for conti-
nuity (see next diagram).
Resistance Inspection
Remove:
Air Filter (see Air Filter Removal)
setting adapter
[A] to the throttle sensor [B].
-1521
Do not connect the harness connector.
Connect a digital meter [C] to the harness adapter leads.
Measure the throttle sensor resistance.
Throttle Sensor Resistance
Connections to
Harness Adapter: R lead [D] BK/BL lead [E]
Standard: 4 6 k
If the reading is out of the range, replace the throttle body
assy.
If the reading is within the range, but the problem still
exists, replace the ECU.

JT1500-A1 A7 Models

3. Throttle Sensor
JT1500A8 Model

4. Throttle Sensor

Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)
NOTICE
Inlet Air Pressure Sensor Removal

Turn the ignition switch off.
Remove:
Inlet Air Pressure Sensor Bolts [A]

Inlet Air Pressure Sensor Connector [B]
Inlet Air Pressure Sensor [C]
Inlet Air Pressure Sensor Installation

Apply silicone oil to the O-ring [A].
NOTICE
Do not apply silicone oil to the sensor end (sensing
part) [B] and the inside [C] of the sensor connector.
Tighten:
Torque - Inlet Air Pressure Sensor Bolts: 7.8 Nm (0.80
kgfm, 69 inlb)

NOTE
The inspection is the same as Input Voltage Inspection
of the throttle sensor.

the ECU the
Remove ECU (see ECU Removal). Do not disconnect
connector.
Connect a digital voltmeter [A] to the connector [B], with

Inlet Air Pressure Sensor Input Voltage

Connections to ECU
Meter (+) R lead (terminal 12)

If the reading is less than the standard, check the ECU for
its ground, power supply and wiring. If the ground, power
supply and wiring are good, replace the ECU.

If the reading is within the standard range, and check the
input voltage at the sensor connector.
Disconnect the inlet air pressure sensor connector and
connect the harness adapter [A] between the harness
connector and inlet air pressure sensor connector.
Connect a digital meter to the harness adapter leads.
[B] Inlet Air Pressure Sensor
Special Tool - Sensor Harness Adapter: 57001-1561
Inlet Air Pressure Sensor Input Voltage

Meter (+) R lead [C]
Meter () BK/W lead [D]
Input Voltage at Sensor Connector

If the reading is out of the standard range, check the
wiring (see Wiring Diagram in this section).
If the reading is good, the input voltage is normal. Check
the output voltage.
Measure the output voltage at the ECU in the same way
Inlet Air Pressure Sensor Output Voltage
Connections to ECU
Meter (+) G/R lead (terminal 33)

Usable Range: 3.75 4.25 V DC at the standard
atmospheric pressure (101.32 kPa, 76
cmHg absolute)
NOTE
The output voltage changes according to the local at-
mospheric pressure.
The vacuum sensor output voltage is based on a nearly
perfect vacuum in the small chamber of the sensor. So,
the sensor indicates absolute vacuum pressure.
If the output voltage is within the usable range, check
the ECU for its ground, power supply and wiring. If the
ground, power supply and wiring are good, replace the
ECU.

If the output voltage is far out of the usable range, check
the output voltage at the sensor connector [A].
Measure the output voltage at the sensor in the same way
[B] Inlet Air Pressure Sensor
Special Tool - Sensor Harness Adapter: 57001-1561
Inlet Air Pressure Sensor Output Voltage

Meter (+) G/R lead [C]
Meter () BK/W lead [D]
Output Voltage at Sensor Connector

Usable Range: 3.75 4.25 V DC at the standard
atmospheric pressure (101.32 kPa or
76 cmHg absolute)
If the output voltage is normal, check the wiring for conti-
nuity (see next diagram).
If the output voltage is out of the usable range, replace
the sensor.
Remove the sensor harness adapter.
Output Voltage Performance

(at Input Voltage: 4.75 5.25 V)
P: Vacuum Pressure
Vo: Output Voltage

JT1500-A1 A7 Models
1. ECU (Electronic Control Unit) 3. Joint Connector H

2. Joint Connector E 4. Inlet Air Pressure Sensor
JT1500A8 Model
1. ECU (Electronic Control Unit) 3. Joint Connector W

2. Joint Connector X 4. Inlet Air Pressure Sensor

Inlet Air Temperature Sensor (Service Code/Character-13/AIrt)
Inlet Air Temperature Sensor Removal/Installation
NOTICE
Remove the air filter (see Air Filter Removal).

Disconnect
ture sensor.
the connector [A] from the inlet air tempera-
Remove the inlet air temperature sensor [B] and washer.

Install the inlet air temperature sensor and washer [A].
Tighten:
Torque - Inlet Air Temperature Sensor: 20 Nm (2.0 kgfm,
14 ftlb)

NOTE
the ECU connector.
Connect a digital voltmeter to the ECU connector, using
needle adapter set.
Inlet Air Temperature Sensor Output Voltage

Connections to ECU Connector
Meter (+) R/BL lead (terminal 7)
idling to measure the sensor output voltage.
Standard: about 2.3 2.6 V at inlet air temperature
20C (68F)
NOTE
The output voltage changes according to the inlet air
temperature.

If the output voltage is out of the specified, check the ECU
for its ground, and power supply (see ECU Power Supply
Inspection). If the ground and power supply are good,
replace the ECU.
If the output voltage is far out of the specified, check the
wiring (see next diagram).
Remove the needle adapter set, and apply silicone
sealant to the seals of the ECU connector for waterproof-
ing.
If the wiring is good, check the sensor resistance.
Sensor Resistance Inspection
Remove the inlet air temperature sensor (see Inlet Air
Temperature Sensor Removal/Installation).
Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion and threaded portion are
submerged.
Suspend a thermometer [B] with the heat-sensitive por-
tion [C] located in almost the same depth with the sensor.
NOTE
The sensor and thermometer must not touch the con-
tainer side or bottom.
Place the container over a source of heat and gradually

raise the temperature of the oil while stirring the oil gently
for even temperature.
Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the table.
Inlet Air Temperature Sensor Resistance
Standard: 5.4 6.6 k at 0C (32F)
2.26 2.86 k at 20C (68F)
0.29 0.39 k at 80C (176F)
If the measurement is out of the range, replace the sensor.
If the measurement is within the specified, replace the
ECU.

JT1500-A1 A7 Models

JT1500A8 Model

2. Joint Connector

Water Temperature Sensor (Service Code/Character-14/AqUt)
Water Temperature Sensor Removal/Installation
NOTICE
Disconnect the sensor connector [A], and unscrew the

water temperature sensor [B].
Fill the hollow of the exhaust manifold [A] with the engine
oil (10W-30) [B] as shown, before installing the water tem-
perature sensor [C].
[D] 5 10 mm (0.2 0.4 in.)
Tighten:
Torque - Water Temperature Sensor: 15 Nm (1.5 kgfm, 11
ftlb)
NOTE
When filling the engine oil in the hollow of the exhaust
pipe, remove the exhaust pipe. Fill the engine oil and
install the water temperature sensor.
Do not overfill the engine oil or silicone grease, or fitting
boss could be damaged.
NOTE
the connector.

Connect a digital voltmeter [A] to the ECU connector [B],

with the needle adapter set.
Water Temperature Sensor Output Voltage

Connections to ECU
Meter (+) G/Y lead (terminal 35)
Standard: about 3 4 V at 20C (68F)
NOTE
The output voltage changes according to the coolant
temperature in the engine.

replace the ECU.
If the output voltage is far out of the specified (e.g. when
the wiring is open, the voltage is about 5 V), check the
If the wiring is good, check the water temperature sensor
resistance.
ing.

JT1500-A1 A7 Models

JT1500A8 Model

Remove the water temperature sensor (see Water Tem-
perature Sensor Removal/Installation).
Refer to the water temperature sensor inspection in the
Electrical System chapter.

Crankshaft Sensor (Service Code/Character-21/CrAg)
Crankshaft Sensor Removal/Installation
Refer to the Ignition System section in Electrical System
chapter.
Crankshaft Sensor Inspection
The crankshaft sensor has no power source, and when
the engine stops, the sensor generates no signals.
Crank the engine and measure the peak voltage of the
crankshaft sensor (see Electrical System chapter) in or-
der to check the sensor.
Check the wiring for continuity, using the following dia-
gram.
JT1500-A1 A7 Models

JT1500A8 Model


Camshaft Position Sensor (Service Code/Character-23/CAA1)
Camshaft Position Sensor Removal/Installation
The camshaft position sensor detects the position of the
camshaft, and distinguishes the cylinder.
Refer to the Ignition System section in Electric System
chapter.
Camshaft Position Sensor Inspection
The camshaft position sensor has no power source, and
when the engine stops, the camshaft position sensor gen-
erates no signal.
Crank the engine and measure the peak voltage of the
camshaft position sensor (see Electrical System chapter)
in order to check the sensor.
Check the wiring for continuity, using the following dia-
gram.
1. ECU

Vehicle-down Sensor (Service Code/Character-31/dOS)
This sensor has a weight [A] with two magnets inside, and
sends a signal to the ECU. But when the watercraft banks
110 130 or more to either side (in fact falls down), the
weight turns and shuts off the signal. The ECU senses this
change, and stops the fuel pump, the fuel injectors, and the
ignition system.
Hall IC [B]
Vehicle-down Sensor Connector [A]

Ground Terminal BK/W [B]
Output Terminal BL/W [C]
Power Source Terminal R/G [D]
Vehicle-down Sensor Removal

NOTICE
A shock to the down sensor can damage it. Do not
drop the down sensor.
Remove:
Front Storage Pocket (see Hull/Engine Hood chapter)
Bracket Mounting Bolts [A] and Washers
Remove:
Vehicle-down Sensor Connector [A]
Screws [B]
Vehicle-down Sensor [C]
Vehicle-down Sensor Installation

The UP mark [A] of the sensor should face upward.
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situ-
ations for an accident resulting in injury or death.
Ensure that the vehicle-down sensor is held in
place by the sensor brackets.
Tighten:
Torque - Vehicle-down Sensor Mounting Screws: 1.5 Nm
(0.15 kgfm, 13 inlb)

Vehicle-down Sensor Inspection
NOTE
Remove:
Fuel Tank (see Fuel Tank Removal)
Connect a digital volt meter [A] to the connector [B] of the

vehicle-down sensor lead with the needle adapter set [C].
Vehicle-down Sensor Power Source Voltage

Meter (+) R/G lead [D]
Meter () BK/W lead [E]
idling to measure the sensor power sours voltage.
Power Source Voltage at Sensor
Standard: 4.75 5.25 V

If there is no standard voltage, check the following:
Battery (see Electrical System chapter)
Main Fuse 20 A
Wiring for Vehicle-down Sensor Power Source (see next
diagram)
If the power source is normal, check the output voltage.

connector.the vehicle-down sensor. Do not disconnect the
Remove
Connect a digital volt meter [A] to the connector, with nee-

dle adapter set [B].
Vehicle-down Sensor Output Voltage

Meter (+) BL/W lead [D]
Meter () BK/W lead [E]
Hold the sensor vertically.

der the stop
button.
idling to measure button,
Pushing the start run the engine 5 6 seconds at
the sensor output voltage.
Tilt the sensor 110 130 or more [C] right or left, then
hold the sensor and measure the output voltage.
Standard: with sensor tilted 110 130 or more right
or left: 0.65 1.35 V
with sensor arrow mark pointed up: 3.55
4.45 V


sealant to the seals of the vehicle-down sensor connec-
tor for waterproofing.
If the output voltage is normal, the wiring is suspect.
Check the wiring.
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection). If the
ground and power supply are good, replace the ECU.
If the output voltage is out of the specified, replace the
vehicle-down sensor.
JT1500-A1 A7 Models

3. Connector C
JT1500A8 Model


Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)
Fuel Injector Removal
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do
not smoke. Turn the ignition switch OFF. Discon-
nect the battery () terminal. To avoid fuel spills,
draw it from the tank when the engine is cold. Be
prepared for fuel spillage; any spilled fuel must be
completely wiped up immediately.
Remove:
Fuel Hoses
Delivery Pipe Mounting Bolts [A], Collars [B] and Clamps
Remove the delivery pipe assembly from the cylinder
head.
Push the lock [A] and disconnect the injector connectors.

Remove the fuel injectors [B].
NOTICE
A shock to the fuel injector can damage it. Do not
drop the fuel injector.
Fuel Injector Installation

Replace the O-rings [A] of the injectors with new ones.
Insert the injectors
Apply grease to the O-rings.
whether they turn smoothly
into the delivery pipe and confirm
or not.

Replace the seals [A] with new ones.

Apply grease to the inside and outside of seals.
Install:
Delivery Pipe Assembly
Collars
Install the clamps [A] as shown.
Tighten:
Torque - Delivery Pipe Mounting Bolts: 7.8 Nm (0.80 kgfm,
69 inlb)
Install the fuel hoses (see Cable, Wire, and Hose Routing
section in Appendix chapter).
For JT1500-A2 Model ; Replace the double spring
clamps with new ones. (see Fuel System Diagram)
Audible Inspection
Start the engine.
the griptheendtiponto
Apply of a screwdriver [A] to the injector [B]. Put
your ear, and listen whether the injector
is clicking or not.
A sound scope can also be used.
Do the same for the other injector.
If all the injectors click at a regular intervals, the injectors
are good.
The click interval becomes shorter as the engine speed
rises.
If either injector doesnt click, perform the Injector Signal
Test for injector operation.
Injector Signal Test
Prepare four test lights set with male terminals as shown.
Rating of Bulb [A]: 12 V, 3 3.4 W
Terminal Width [B]: 1.8 mm (0.07 in.)
Terminal Thickness [C]: 0.8 mm (0.03 in.)
NOTICE
A larger terminal could damage the injector main
harness connector (female), leading to harness re-
pair or replacement. Do not use larger terminals
than specified above.

Remove connectors for injector [A].

nector [C]. test light set [B] to the injector harness con-
Connect each
Turn the ignition switch ON.

the testcranking
While
lights.
the engine with the starter motor, watch
If the test lights flicker at regular intervals, the injector

circuit in the ECU, and the wiring are good. Perform the
Injector Resistance Inspection.
Injector signals can be also confirmed by connecting the

hand tester ( 10 V AC) instead of the test light set to
the injector harness (female) connector. Crank the en-
gine with the starter motor, and check to see if the hand
oscillates at regular intervals.
Special Tool - Hand Tester: 57001-1394
If the test light doesnt flicker (or the test hand doesnt
oscillates), check the wiring and connectors again. If the
wiring is good, check the injector voltage.
Injector Resistance Inspection
Remove the delivery pipe assembly.
Measure thetheinjector
Disconnect connector from the injector [A].
resistance with the hand tester [B].
Injector Resistance
Standard: about 11.7 12.3 @20C (68F)
If the reading is out of the range, perform the Injector Unit
Test.
If the reading is normal, perform the Injector Unit Test
for confirmation.
Injector Unit Test
Use two leads [A] and the same test light set [B] as in
Injector Signal Test.
Rating of Bulb [C]: 12 V, 3 3.4 W
12 V Battery [D]
NOTICE
The bulb works as a current limiter to protect the
solenoid in the injector from excessive current. Be
sure to connect the bulb in series.
(could use more info on this to make it better)
Connect the test light set to the injector [E] as shown.

() terminalconnect
Open and [F] the end of the lead to the battery
repeatedly. The injector should click.
If the injector does not click, replace the injector.

Injector Voltage Inspection
Injector Power Source Voltage

Connector to Injector #1, #2, #3, #4
Meter (+) R/Y lead
Meter () Battery () Terminal
idling to measure the injector power source voltage.
Power Source Voltage at Injector Connector
Standard: Battery Voltage
If the power source voltage is less than standard, check
the wiring (see Wiring Diagram in this section), relay
(Main Relay Inspection) and ECU power source (see
ECU Power Supply Inspection).
Remove the ECU. Do not disconnect the connector.

the needle adapter set [C].
Injector Output Voltage

Connections to Injector #1
Meter (+) PU lead (terminal 43)
Meter (+) O lead (terminal 38)
Meter (+) BR lead (terminal 39)
Meter (+) BL/Y lead (terminal 40)
idling to measure the output voltage.
Output Voltage at Injector Connector
Standard: about 9 V or more
If the output voltage is out of the standard, replace the
ECU.

Injector Fuel Line Inspection
Check the injector fuel line for leakage as follows:
Connect a commercially available vacuum/pressure
pump [A] to the supply joint of the delivery pipe [B] with
the fuel hose [C] (both ends connected with the clamps
[D]) as shown.
Plug the return joint of the delivery pipe with a rubber plug
[E].
Tighten the clamp [F].
Apply soap and water solution to the areas [G] as shown.
Watching the pressure gauge, squeeze the pump lever
[H], and build up the pressure until the pressure reaches
the maximum pressure.
Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm, 44 psi)
NOTICE
During pressure testing, do not exceed the maxi-
mum pressure for which the system is designed.
Watch the gauge for at least 6 seconds.
If the pressure holds steady, the system is good.
If the pressure drops at once, or if bubbles are found in
the area, the line is leaking. Replace the delivery pipe,
injectors and related parts.
Repeat the leak test, and check the fuel line for no leak-
age.
Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in Appendix chapter).
clamps with new ones. (see Fuel System Diagram)

JT1500-A1 A7 Models
1. Fuel Injector #1 9. Connector D

2. Fuel Injector #2 10. Joint Connector R
3. Fuel Injector #3 11. Main Fuse 20 A
4. Fuel Injector #4 12. Battery 12 V 18 Ah
5. Joint Connector H 13. ECU (Electronic Control Unit)
6. Main Relay in Relay Assembly 14. Joint Connector P
7. Joint Connector F 15. Joint Connector S
8. Connector C

JT1500A8 Model
1. ECU (Electronic Control Unit) 7. Fuel Injector #1

2. Joint Connector Y 8. Main Relay in Relay Assembly
3. Joint Connector Z 9. Joint Connector P
4. Fuel Injector #4 10. Main Fuse 20 A
5. Fuel Injector #3 11. Battery 12 V 18 Ah
6. Fuel Injector #2 12. Joint Connector U

Ignition Coils (Service Code/Character-51, 52/COL1, COL2)
Ignition Coil #1, #4: Service Code 51-COL1
Ignition Coil #2, #3: Service Code 52-COL2
Ignition Coil Removal/Installation
NOTICE
A shock to the ignition coil can damage it. Do not
drop the ignition coil.
Refer to the Ignition System section in Electrical System

chapter.
NOTE
Remove:
Disconnect the ignition coil primary lead connector(s) [A].
Connect
[B].
the harness adapter [A] and a digital voltmeter
Special Tool - Harness Adapter: 57001-1562

idling to measure the input voltage.
Ignition Coil Input Voltage at Ignition Coil

Connections for Ignition Coil #1, #4
Meter (+) R/Y lead
Meter () Battery () terminal
Connections for Ignition Coil #2, #3
Meter (+) R/Y lead
Meter () Battery () terminal

If the reading is out of the standard, check the wiring (see
next wiring diagram).
If the reading is good, the input voltage is normal. Crank
the engine, and check the peak voltage of the ignition
coils (see Electrical System chapter) in order to check the
primary coils.

JT1500-A1 A7 Models
1. Main Relay in Relay Assembly

3. Connector C
4. Connector D
6. Main Fuse 20 A
7. Starter Motor
10. Ignition Coils

JT1500A8 Model

5. Main Fuse 20 A
6. Starter Motor
9. Ignition Coils

Engine Overheating (Service Code/Character-71/HEAt)
If the service code is displayed, check the doubtful parts referring to the following table.
Possible Causes Action (Chapter)
Water passage clogged, loosened or damaged Inspect (see 9 chapter)
Incorrect engine oil level Inspect (see 4 chapter)
Engine oil poor quality or incorrect Change (see 4 chapter)
Water temperature sensor broken Inspect (see 3 and 14 chapters)
Jet pump or impeller damaged Inspect (see 11 chapter)
Oil cooler clogged Clean (see 4 chapter)
Carbon build-up on combustion chamber Clean (see 6 chapter)

Low Engine Oil Pressure (Service Code/Character-72/OILP)
Possible Causes Action (Chapter)
Oil leak Inspect (see 4 chapter)
Engine oil level too low Inspect (see 4 chapter)
Engine oil viscosity too low Inspect (see 4 chapter)
Oil filter clogged Clean (see 4 chapter)
Oil pressure switch damaged Inspect (see 3 and 14 chapters)
Oil cooler clogged Inspect (see 4 chapter)
Camshaft bearing worn Inspect (see 6 chapter)
Crankshaft bearing worn Inspect (see 8 chapter)
Oil pressure relief valve stuck open Change (see 4 chapter)
Oil pump damaged Change (see 4 chapter)
Oil screen clogged Clean (see 4 chapter)
O-ring at the oil passage in the crankcase damaged Change (see 4 chapter)

Oil Temperature Sensor (Service Code/Character-73/OILC or 73/OILt)
Service Code/Character
JT1500-A1: 73/OILC
JT1500-A2 : 73/OILt
Oil Temperature Sensor Removal/Installation

NOTICE
Remove:
Oil Temperature Sensor [A]
Fill the hollow of the oil pan [A] with heat transfer grease
[B] to 80% volume as shown in the figure, before installing
the oil temperature sensor [C].
Heat Transfer Grease -
Heat Transfer Grease, SCH-20: 92137-1002 or
equivalent
NOTICE
Overfilling the grease may damage the fitting boss.
Do not overfill with grease.
Tighten:
Torque - Oil Temperature Sensor: 15 Nm (1.5 kgfm, 11
ftlb)

NOTE
Remove the ECU (see this chapter). Do not disconnect
the connector.
Connect a digital voltmeter [A] to the ECU connector [B],

with the needle adapter set.
Water Temperature Sensor Output Voltage

Connections to ECU
Meter (+) Y lead (terminal 37)
Standard: about 3 4 V at 20C (68F)
NOTE
The output voltage changes according to the oil temper-
ature in the engine.


replace the ECU.
If the output voltage is far out of the specified (e.g. when
the wiring is open, the voltage is about 5 V), check the
If the wiring is good, check the oil temperature sensor
resistance.
ing.
JT1500-A1 A7 Models

3. Joint Connector J
JT1500A8 Model



Remove the oil temperature sensor (see Oil Temperature
Sensor Removal/Installation).
Refer to the Oil Temperature Sensor Inspection in the
Electrical System chapter.

Engine Oil Overheating (Service Code/Character-76/OILH)
JT1500-A2 Model ;
Possible causes Action (Chapter)
Incorrect engine oil level Inspect (see 4 chapter)
Engine oil poor quality or incorrect Change (see 4 chapter)
Oil temperature sensor broken Inspect (see 3 and 14 chapters)
Oil cooler clogged Clean (see 4 chapter)
Oil pump malfunction Inspect (see 4 chapter)
Relief valve malfunction Inspect (see 4 chapter)
Water passage clogged, loosened or damaged Inspect (see 9 chapter)
Weeds or debris in jet pump Inspect (see 11 chapter)

ECU
NOTICE
A shock to the ECU can damage it. Do not drop the
ECU.
ECU Removal
Remove:
Bolts [A]
Disconnect the ECU lead connector [A].

ECU [B]
Remove:
ECU Installation
Connect the ECU connector and install it.
tighten them.
Apply a non-permanent locking agent to the bolts and
Torque - ECU Mounting Bolts: 8.8 Nm (0.90 kgfm, 78inlb)
ECU Power Supply Inspection

Visually inspect the terminals [A] of the ECU connectors.
If the connector is clogged with mud or dust, blow it off
with compressed air.
Replace the main harness if the terminals of the main har-
ness connector is cracked, bent, or otherwise damaged.
Replace the ECU if the terminals of the ECU connector is
cracked, bent, or otherwise damaged.
With the ECU connector [A] connected, check the follow-

ing ground lead for continuity with the ignition switch OFF,
using a tester and needle adapter set.
[B] Battery
[C] Tester
ECU Grounding Inspection

25, 32, 41, or 42 (BK)
Battery () Terminal: 0
Terminal
Engine Ground Battery () Terminal: 0
If no continuity, check the connector, the engine ground
lead, or main harness, and repair or replace them if nec-
essary.

ECU
Check the ECU power source voltage with a tester [A].

Position the terminal in accordance with terminal numbers
of ECU connector [B] in this chapter figure.
ECU Power Source Inspection
Tester Connections:
2 (R/G) Terminal Battery () Terminal
9 (R/W) Terminal Battery () Terminal
28 (Y/R) Terminal Battery () Terminal
30 (R/Y) Terminal Battery () Terminal
Terminal Voltage:
Ignition Switch OFF:
2 (R/G) Terminal Battery Voltage
9 (R/W) Terminal 0 V
28 (Y/R) Terminal 0 V
30 (R/Y) Terminal 0 V
Ignition Switch ON:
2 (R/G) Terminal Battery Voltage
9 (R/W) Terminal Battery Voltage
28 (Y/R) Terminal 0 V
30 (R/Y) Terminal 0 V
Ignition Switch ON and Start Button ON:
All Terminals Battery Voltage
Pushing the start button, run the engine 3 4 seconds.
If the tester does not read as specified, check the follow-
ing:
Power Source Wiring (see wiring diagram below)
Main Fuse 20 A (see Electrical System chapter)
ECU Main Relay (see DFI Power Source section)
Ignition Switch (see Electrical System chapter)
Start Switch (see Electrical System chapter)

ECU
ECU Power Source Circuit (JT1500-A1 A7 Models)
1. Main Relay in Relay assembly

3. Connector C
4. Connector D
5. Ignition Switch
6. Start Switch
8. Main Fuse 20 A

ECU
ECU Power Source Circuit (JT1500A8 Model )

4. Ignition Switch
7. Start Switch
8. Main Fuse 20 A
9. Joint Connector T

DFI Power Source
Main Fuse Inspection
Refer to the Fuse Inspection in the Electrical System
chapter.
Relay Assembly Removal
NOTICE
A shock to the relay can damage it. Do not drop the
relay.
Remove:
Seats (see Hull/Engine Hood chapter)
Bolt [A]
Relay Assembly [B]
Connector [C] (disconnect)
Band [D] (Cut)
Relay Assembly Inspection
Remove the relay assembly.
the relay the
Connect hand tester [A] and one 12 V battery [B] to
connector [C] as shown.
Main Relay
Relay Coil Terminals [3] and [4]
Relay Switch Terminals [1] and [2]
Testing Relay
Tester range: 1 range
Criteria: When battery is connected 0
When battery is disconnected
If the relay does not work as specified, replace the relay
assembly.

DFI Power Source
Fuel Pump Relay
Relay Coil Terminals [6] and [8]
Relay Switch Terminals [5] and [7]
Testing Relay
Tester range: 1 range
Criteria: When battery is connected 0
When battery is disconnected
If the relay does not work as specified, replace the relay
assembly.
Hand Tester [A]
Battery [B]

Throttle Lever, Cable and Case
Free Play Inspection
Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.
Throttle Cable Adjustment
Refer to the Throttle Control System in the Periodic Main-
tenance chapter.
Throttle Case Removal/Disassembly
Unscrew the mounting screws [A] and remove the han-
dlebar pad [B].
Remove the throttle case.
Unscrew the throttle case mounting screws [C] separate
the case halves [D].
Disconnect the throttle cable from the case.

Slide the rubber boots [A] and rubber cap [B] out of the
place.
Unscrew the throttle cable fitting nut [C].
Use a screw driver [A] to separate the tip [B] of the cable
end from the case body.

Disassemble the throttle case.

Remove the circlip [A], flat washers [B], pin [C], throttle
lever [D] and return spring [E] from the case [F].
Throttle Case Assembly/Installation

Insert the end of the return spring [A] in the throttle lever
hole [B] and set the spring in the throttle case [C] as
shown.
Install the control lever to the case.
Lubricate the throttle cable before assembly/installation.

ble end. resistant grease to the tips of the throttle ca-
Apply water
Pulling the throttle cable [A], position the tips [B] of the
cable end as shown.
Tighten the cable fitting nut.
Be sure the rubber cap [A] is in place on the throttle cable

fitting nut end.
Cover the cable fitting nut [B] with the rubber boot [C].

Tighten:
Torque - Throttle Case Mounting Screws: 3.9 Nm (0.40
kgfm, 35 inlb)
Swing
open.
the throttle lever so that the throttle valve is fully
WARNING
Operation with an improperly assembled throttle
case could result in an unsafe riding condition. Be
sure the throttle case is assembled correctly.
Adjust the throttle cable (see Throttle Cable Adjustment).

Throttle Cable Removal
Remove
ter).
the engine hood (see Hull/Engine Hood chap-
Remove the band [A] on the delivery pipe [B].
Disconnect the throttle cable from the body assy.

Slide out the rubber cap.
Unscrew the adjuster locknut [A] and slide the cable from
the bracket.
Slide the tip [A] of the cable lower end from the throttle
pivot arm.


dlebar pad [B].
Take out the inner pad.
Remove the throttle case (see Throttle Case Re-

moval/Disassembly).
Slide the rubber boot out of the place.
Remove the
Unscrew the throttle cable fitting nut.
Use a screw upper end of the cable from the case.
driver [A] to separate the cable tip [B] from
the throttle lever catch.
Remove the steering cover (see Steering Removal in

Steering chapter).
Unscrew the grommet mounting bolts [A] and pull out the
plate [B] and grommet [C].
Take the throttle cable [A] off the grommet [B].

Pull down the throttle cable.
Throttle Cable Installation

Lubricate the outside of the new cable with a penetrating
rust inhibitor to ease cable installation.
Slide the tip [A] of the cable lower end on the throttle pivot
arm [B].

Tighten:
kgfm, 35 inlb)
Route the following correctly (see Cable, Wire, and Hose
Routing in Appendix chapter).
Throttle Cable
Steering Cable
Fuel Tank Vent Hose
Start/Stop Switch Leads
Buzzer Leads
Multifunction Meter Leads
Adjust the following.
Throttle Cable
Check that the throttle lever moves smoothly from full
open to close, and the throttle closes quickly and com-
pletely in all steering positions by return spring.
If the throttle lever does not return properly, check the
throttle routing, cable adjustments, and cable damage.
Then lubricate the throttle cable.
Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increases, check the throttle cable ad-
justment and the cable routing.
Throttle Case and Cable Lubrication
Refer to the Lubrication in the Periodic Maintenance
chapter.
Throttle Cable Inspection
Refer to the Lubrication in the Periodic Maintenance
chapter.

Air Filter
Air Filter Removal
JT1500-A1 A8 Models
Remove the rear storage pocket.
Disconnect the following from the air filter [A].
Air Suction Valve Hose [B]
Oil Separator Tank Hose [C]
Remove the oil separator tank [D] (see Engine Lubrication
System chapter).
JT1500A9 Model
Disconnect the following from the air filter [A].
Oil Separator Tank Hose [B]
Remove the oil separator tank [C] (see Engine Lubrication
System chapter).
Loosen the clamp [A] on the inlet air duct [B].

Remove the air filter mounting bolts [C].

Air Filter
Remove the air filter [A] out of the engine compartment.
Air Filter Installation

Tighten:
Torque - Air Filter Mounting Bolts: 9.8 Nm (1.0 kgfm, 87
inlb)
Air Filter Disassembly

Remove:
Air Filter Bolts [A]
Remove:
Bolts [A]
Flame Arrester [B]
Hose [C]
Duct [D]
Air Filter Bracket Mounting Bolts [E]
Air Filter Bracket [F]
Remove the air screen [A].

Air Filter
Air Filter Assembly
Visually inspect the seal [A] for damage.
If necessary, replace it with a new one.
Install
shown.
the flame arrester [B], hose [C] and duct [D] as
Install the air screen [A] aligning the marks [B].
Apply a non-permanent locking agent to the air filter

bracket mounting bolts and tighten them.
Torque - Air Filter Bracket Mounting Bolts: 7.8 N m (0.80
kgfm, 69 inlb)

Throttle Body Assy
Idle Speed Inspection
The normal idle speed is controlled by the ECU (Elec-
tronic Control Unit).
Idle Speed
Standard: 1 300 100 r/min (rpm) -both in and out of
water
High Altitude Performance Adjustment

High altitude adjustment is not required as the ECU con-
trols the air/fuel mixture automatically.
Throttle Body Assy Removal
Remove:
Air Filter (from Throttle Body Assy)
Throttle Cable [A] (see Throttle Cable Removal)
Air Inlet Duct
ISC (Idle Speed Controller) Connector [B]
Throttle Sensor Connector [C]
Throttle Body Assy Mounting Bolts [D]
Throttle Body Assy [E]
Gasket
Throttle Body Assy Installation
Install a new gasket.
Tighten:
Torque - Throttle Body Assy Mounting Bolts: 20 Nm (2.0
kgfm, 14 ftlb)
Install the throttle cable and adjust the free play.
Route theharness
Bind the [A] and connector in the band [B].
(see Appendix chapter).
harness [C] and tighten the band [D] correctly
Throttle Body Assy Disassembly

NOTICE
Adjustment of the air screw, throttle link mecha-
nism and throttle body assy [A] could result in poor
performance, requiring replacement of the throttle
body assy. Do not remove, disassemble or adjust
the air screw, throttle link mechanism and throttle
body assy, they are precisely set at the manufac-
turer.

Throttle Body Assy
Throttle Bore Cleaning
Remove
Removal).
the throttle body assy (see Throttle Body Assy
Check the throttle bore [A] for carbon deposits by opening

the valve.
If any carbon accumulates, wipe the carbon off the throttle
bore and throttle valve, using a cotton pad.
NOTICE
Pressure and/or carburetor cleaner may damage
these surfaces. Do not apply pressure or use car-
buretor cleaner to clean these surfaces.
ISC (Idle Speed Controller) Removal/Installation
Remove
Bands [A]
ISC connector [B]
Stepping Motor Mounting Screws [C]
Stepping Motor [D]
ISC Actuator Mounting Bolts [E]
ISC Actuator [F]
Clean the mating surface of throttle body and ISC actuator

(stepping motor).
Replace the O-ring [A] with a new one.
Install the stepping
Install the motor [B] and tighten the screws [C].
ISC actuator [D] and tighten the bolts [E].
Torque - ISC Actuator Mounting Bolts: 4.9 Nm (0.50 kgfm,
43 inlb)
Route the harness and tighten the bands correctly (see
Appendix chapter).
After installing the ISC actuator, check the Smart Steering
System Operation in the water.
ISC (Idle Speed Controller) Inspection
Check
meter.
idle speed with a tachometer in the multifunction
With the engine idling, open and close the throttle lever.
Idle Speed
Standard: 1 300 100 r/min (rpm) -both in and out of
water
If the idle speed is within the standard, the ISC operates
properly.
If the idle speed is out of the specified range, inspect the
audible operation.

Throttle Body Assy
Run the engine and then stop the engine.

the ISC buzzing
Certain and humming sounds will be emitted from
[A] after the engine stop.
If the ISC sounds, inspect the ISC resistance.
If the ISC does not sound, replace the steeping motor.
ISC Resistance Inspection

Remove:
Air Filter (from the throttle body assy)
ISC Connector [A] (disconnect)
Measure the ISC resistance with the hand tester.

Special Tool - Kawasaki Hand Tester: 57001-1394
ISC [A]
Rotor [B]
ISC Resistance
Connection: 1-2, 2-3, 4-5, 5-6 terminals
Standard: about 30 (at 20C)
Connection: 1-3, 4-6 terminals
Standard: about 60 (at 20C)
If the reading is out of the specified value, replace the
steeping motor.

Inlet Manifold
Inlet Manifold Removal
Remove:
Supply Fuel Hose [A] at Delivery Pipe
Return Fuel Hose [B] at Delivery Pipe
Delivery Pipe Mounting Bolts [C], Collars and Clamps
Remove the bands [D] and disconnect the following con-
nectors.
Camshaft Position Sensor Connector [E]
Crankshaft Sensor Connector [F]
Disconnect:
Throttle Cable Lower End (see Throttle Cable Removal)
Throttle Sensor Connector [G] on Throttle Body Assy
ISC (Idle Speed Controller) Connector [H] on Throttle
Body Assy
Inlet Air Pressure Sensor Connector [I] on Inlet Manifold
Inlet Air Temperature Sensor Connector [J] on Inlet Man-
ifold
JT1500-A1 A8 Models [K]
JT1500A9 Model [L]
Unscrew
[B].
the inlet manifold mounting bolts [A] and nuts

Inlet Manifold
Remove
[B].
the inlet manifold [A] with the throttle body assy
Remove the throttle body assy from the inlet manifold (see
Throttle Body Assy Removal).
Unscrew the inlet manifold plate bolts [A] and remove the
plate [B] and gasket [C].
Remove:
Inlet Air Temperature Sensor [D]
Inlet Manifold Drain Plug [E]
Inlet Air Pressure Sensor Bolts [F]
Inlet Air Pressure Sensor [G]
Inlet Manifold Installation

Replace the inlet manifold plate gasket with a new one.
Tighten:
Torque - Inlet Manifold Plate Bolts: 7.8 Nm (0.80 kgfm, 69
inlb)
Inlet Manifold Drain Plug: 20 Nm (2.0 kgfm, 14
ftlb)
Inlet Air Temperature Sensor: 20 Nm (2.0 kgfm,
14 ftlb)
Apply silicone oil to the O-ring [A] on the inlet air pressure
sensor [B].
NOTE
Do not apply silicone oil to the inside of inlet air pressure
sensor connector.
Install the inlet air pressure sensor on the inlet manifold.

Tighten:
Torque - Inlet Air Pressure Sensor Bolts: 7.8 Nm (0.80
kgfm, 69 inlb)
Replace the inlet manifold gasket [A] with a new one and
install it as shown.
Apply a non-permanent locking agent to the inlet manifold
Torque - Inlet Manifold Mounting Bolts: 25 Nm (2.5 kgfm,
18 ftlb)
Inlet Manifold Mounting Nuts: 20 Nm (2.0 kgfm,
14 ftlb)

Inlet Manifold
Replace the injector seals [A] with new ones.

Apply grease to the inside and outside of seals.
Tighten the delivery pipe mounting bolts [B].
Torque - Delivery Pipe Mounting Bolts: 7.8 Nm (0.80 kgfm,
69 inlb)
Route the cable, wire and hose correctly (see Cable, Wire
and Hose Routing in Appendix chapter).
clamps with new ones (see Fuel System Diagram).

Fuel Line
Fuel Pressure Inspection
NOTE
Be sure to place a piece of cloth under the fuel supply
hose [A] of the fuel delivery pipe.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
Loosen
hose.
the clamp bolt [B] and pull out the fuel supply
[B]
For JT1500-A2 Model ; Loosen the double spring clamp
with pliers and pull out the fuel supply hose.

Fuel Line
Quickly install the fuel pressure gauge adapter [A] be-

tween the fuel supply pipe and the fuel supply hose.
Connect the pressure gauge [B] to the fuel pressure
gauge adapter.
Special Tools - Fuel Pressure Gauge Adapter: 57001-1463
Oil Pressure Gauge, 5 kgf/cm: 57001-125
WARNING
Fuel is extremely flammable and can be explosive
under certain conditions resulting in serious injury
or death.
Do not try to start the engine with the fuel hoses
disconnected.
Start the engine, and let it idle.

NOTE
Start the engine and inspect the fuel line leakage after
installing the special tools.
Measure the fuel pressure with the engine idling.

Fuel Pressure (idling)
Standard: approx. 294 kPa (3.0 kgf/cm, 43 psi)
NOTE
The gauge needle will fluctuate.
Read the pressure at
the average of the maximum and minimum indications.
If the fuel pressure is much higher than the specified,
check the following:
Fuel Hose from Gauge Adapter to Fuel Pump Return
Pipe for Sharp Bend, Kinking, or Clogging
Fuel Pump
If the fuel pressure is much lower than specified, check
the following:
Fuel Line Leakage
Fuel Injectors
Fuel Pump
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
If the fuel pressure is much lower than specified, and if
inspection above checks out good, replace the fuel filter
and measure the fuel pressure again.
Remove the fuel pressure gauge and adapter.
Run the fuel hoses in accordance with the Cable, Wire,
and Hose Routing section in the Appendix chapter.

Fuel Line
Fuel Flow Rate Inspection
NOTE
WARNING
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.

Open the the
Wait until engine cools down.
tank. fuel tank cap [A] to lower the pressure in the
Prepare a measuring cylinder [A].

pipe, and setthethefuel
Disconnect supply hose from the fuel delivery
measuring cylinder and fuel supply hose
[B] as shown.
Close the fuel tank cap.
WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.

Measure
Push the start button for 3 seconds.
the discharge for 3 seconds.
Amount of Fuel Flow
Standard: 67 mL or more for 3 seconds
If the fuel flow is much less than the specified, check the
following:
Fuel Hose from Fuel Pump Supply Pipe to Fuel Filter for
Sharp Bend, Kinking, or Clogging
Fuel Pump Operation
Fuel Pump Screen (see Fuel Pump Screen Cleaning in
the Periodic Maintenance chapter)
If above inspection checks out good, replace the fuel
pump, and measure the amount of fuel flow again.
After inspection, connect the fuel hose.
Start the engine and check for fuel leakage.

Fuel Vent Check Valve
Fuel Vent Check Valve Mounting
Refer to the Fuel Vent Check Valve Inspection in the Pe-
Fuel Vent Check Valve Inspection
Refer to the Fuel Vent Check Valve Inspection in the Pe-

Fuel Filter
Fuel Filter Removal
NOTE
The fuel filter is designed to be used throughout the
watercrafts life without any maintenance if it is used
under normal conditions.
WARNING
sive under certain conditions. To avoid a possi-
ble fire or explosion, pull the lanyard key off the
stop button. Do not smoke. Make sure the area is
light.
Remove:
Fuel Hoses [A]
Disconnect:
Spark Plug Caps [B]
Vehicle-down Sensor Lead Connector
Ignition Coil Primary Lead Connectors
Remove:
Bracket Mounting Bolts [A]
Remove:
Fuel Filter Mounting Bolts [A]
Holder [B]
Fuel Hoses [C]
Fuel Filter [D]

Fuel Filter
Fuel Filter Installation
Route the hose correctly (see Cable, Wire, and Hose
Routing section in Appendix chapter).
Install the fuel hoses to the fuel filter, noting its IN fitting
[A] and OUT fitting [B].
Install the holder and apply a non-permanent locking
agent to the mounting bolts and tighten them.
Torque - Fuel Filter Mounting Bolts: 8.8 Nm (0.90 kgfm, 78
inlb)

Fuel Pump
Fuel Pump Removal
NOTICE
A shock to the fuel pump can damage it. Do not
drop the fuel pump.
WARNING
light.
JT1500-A1 Model
Remove the front storage pocket (see Hull/Engine Hood
chapter).
Disconnect the fuel pump lead connector [A].
Loosen the clamp screws [B] and pull out the main [C]
and return [D] fuel hoses.
Cut off the clamp [E] and pull out the fuel vent hose [F].
Loosen the lower side clamp screw [G] on the rubber fuel
pump holder [H].
JT1500-A2 Model
Remove the front storage pocket (see Hull/Engine Hood
chapter).
Disconnect the fuel pump lead connector [A].
Loosen the double spring clamps [B] with priers and pull
out the main [C] and return [D] fuel hoses.
Cut off the clamp [E] and pull out the fuel vent hose [F].
Loosen the lower side clamp screw [G] on the rubber fuel
pump holder [H].
Pull the fuel pump [A] and rubber holder [B] through the
opening gained after removal of the front strage pocket.
Loose the upper side clamp screw [C] and remove the
rubber holder from the fuel pump.

Fuel Pump
Fuel Pump Installation
Press down the rubber holder [A] onto the fuel pump [B]
so the stepped part [C] of the holder completely contacts
the flanged part [D] of the pump.
Pressing down the rubber holder onto the fuel pump.
Set the upper side clamp (small diameter) onto the
groove (for clamp installation) of the rubber holder se-
curely, tighten the upper side clamp screw [E].
Torque - Fuel Pump Holder Clamp Screw: 2.9 Nm (0.30
kgfm, 26 inlb)
NOTE
Install the rubber holder onto the fuel pump so the rub-
ber holder top surface [F] must be below the top surface
[G] of the fuel pump to prevent any water from collect-
ing on top of the pump.
Install the O-ring [A] to the space between fuel pump [B]
and rubber holder [C] so it completely contacts the flanged
part [D] of the pump.
Insert the fuel pump with rubber holder and O-ring into the
tank so its fuel hose fittings face starboard side (see Ca-
ble, Wire, and Hose Routing in Appendix chapter). And
press down the pump so the O-ring [A] completely con-
tacts the top surface of the tank [E].
Set the lower side clamp (large diameter) onto the
groove (for clamp installation) of the rubber holder se-
curely, tighten the lower side clamp screw [F].
Torque - Fuel Pump Holder Clamp Screw: 2.9 Nm (0.30
kgfm, 26 inlb)
Check the position [A] of the lower side clamp [B] around
the entire circumference.

Fuel Pump
Install the following to the fuel pump.

Fuel Hoses
Fuel Tank Vent Hose
Fuel Pump Lead Connector
For JT1500-A2 Model; Replace the double spring clamps
with new ones (see Fuel System Diagram).
NOTE
The main fuel hose is larger than the return fuel hose.
Power Source Voltage Inspection
NOTE
Remove
chapter).
Connect the hand tester (25 V DC) [A] to the fuel pump
lead connector [B], using the needle adapter set [C].
Special Tools - Hand Tester: 57001-1394
Needle Adapter Set: 57001-1457
idling to measure the power source voltage.
Pump Power Source Voltage
Connections
Tester (+) W/R lead [D]
Tester () Battery () Terminal [E]
Power Source Voltage at Pump Lead Connector

If the reading is good, the power source voltage is normal.
Inspect the operating voltage.
If there is no battery voltage, check the following:
Main Fuse 20 A
Wiring for Fuel Pump Power Source (see Fuel Pump
Circuit in this chapter)
Operating Voltage Inspection
NOTE

Fuel Pump
Remove
chapter).
Connect the hand tester [A] to the connector [B], using

the needle adapter set [C].
idling to measure the operating voltage.
Pump Operating Voltage
Connections
Tester (+) W/R lead
Tester () BK lead
Operating Voltage
If the reading stays on battery voltage but the pump
doesnt work, replace the pump.
If there is no battery voltage at all, check the ECU for
its ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, check the fuel
pump wiring.
Fuel Pump Relay Removal
Refer to the Relay Assembly Removal in the DFI Power
Source section.
Fuel Pump Relay Inspection
Refer to the Relay Assembly Inspection in the DFI Power
Source section.

Fuel Pump
JT1500-A1 A7 Models
1. Relay Assembly (Main Relay/Fuel Pump Relay) 7. Battery 12 V 18 Ah

2. Joint Connector F 8. ECU (Electronic Control Unit)
3. Connector C 9. Joint Connector P
4. Connector D 10. Fuel Pump
5. Joint Connector R 11. Joint Connector S
6. Main Fuse 20 A

Fuel Pump
JT1500A8 Model
1. ECU (Electronic Control Unit) 5. Joint Connector P

2. Joint Connector Y 6. Main Fuse 20 A
3. Relay Assembly (Main Relay/Fuel Pump Relay) 7. Battery 12 V 18 Ah
4. Fuel Pump 8. Joint Connector U

Fuel Tank
Fuel Tank Removal
Drain the fuel tank into a suitable container.
WARNING
light.
Remove
chapter).
the engine (see Engine Removal/Installation
Remove the fuel pump (see Fuel Pump Removal).

Disconnect the following from the main harness.
Vehicle-down Sensor Lead Connector [A]
Ignition Coil Lead Connectors [B]
Remove the bracket [C] out of the engine compartment.
Remove the fuel filler tube [A] from the fuel tank [B].
Unhook the fuel tank straps [A].

Remove the fuel level sensor [B].

Fuel Tank
Remove the fuel tank [A] out of the hull as shown.
Fuel Tank Installation

Be sure the float [A] in place before putting the fuel tank
into the hull.
Route the following correctly (see Cable, Wire, and Hose
Routing section in Appendix chapter).
Fuel Hoses
Fuel Tank Vent Hose
Fuel Level Sensor Leads
Other Wire and Harness
Fuel Tank Cleaning
Remove the fuel tank (see Fuel Tank Removal).
Drain the tank into a suitable container.
WARNING
light.
Flush the tank repeatedly with high-flash-point solvent un-

til it is 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.
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area,
and take 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 to clean the tank.

Fuel Tank
Fuel Filler and Tube Removal
Loosen the fuel filler tube clamp screws [A] and remove
the fuel filler tube [B].
Remove the fuel filler cap [A].

fuel filler [C].screws [B] in the filler flange and remove the
Take out the
Fuel Filler and Tube Installation

Clean the deck and filler on their mating surfaces with
greaseless, high-flash point solvent.
WARNING
burns. Clean the parts in a well-ventilated area, and
take care that there is no spark or flame anywhere
near the working areas. Do not use gasoline or
low-flash point solvents to clean parts.
Replace the fuel filler gasket [A] with a new one.

If there is any doubt
Visually inspect the fuel filler cap gasket [B] for damage.
as to the condition of the fuel filler
gasket, replace the gasket with a new one.
Tighten the fuel filler tube clamp screws.
Torque - Fuel Filler Tube Clamp Screws: 2.9 Nm (0.30
kgfm, 26 inlb)

Fuel Tank
Put the clamp onto the tank as shown.

35 mm (1.38 in.) [A]
Fuel Tank Vent Hose Installation

Remove handlebar cover and pad and cut the tie-band
holding the leads and hoses over the clear tube.
Pull out the fuel tank vent hose [A] more than 150 mm (6
inches) off the clear tube upper end for corrugated tube
install [B].
Install the corrugated tube over the vent hose so the top
end of the vent hose protrudes 15 mm (0.6 inches) [C]
from the end of the corrugated tube.
Apply the new tie bands [D] at top and middle section and
wrap the lower and end of the corrugated tube with a vinyl
tape [E] together with the vent hose as shown.
Pull the vent hose down into the engine compartment so

that the vent hose is aligned straight with the steering
shaft without any loop or looseness.
Align the top end of the vent hose equal to or lower than
the height [A] of the steeling neck [B].
Apply the large tie band [C] firmly over the clear and the
corrugated tubes to hold them in place.
Install handlebar cover and pad removed.
NOTICE
The engine will malfunction if the fuel tank air vent
pipe end is obstructed by the handlebar pad and/or;
if the air vent hose is folded; and/or riding the wa-
tercraft with the air vent hose remaining clogged.
Be sure the fuel tank air vent pipe is installed cor-
rectly and securely.

ENGINE LUBRICATION SYSTEM 4-1

Table of Contents
Exploded View........................................................................................................................ 4-2
Engine Oil Flow Chart............................................................................................................. 4-4
Specifications ......................................................................................................................... 4-8
Special Tools and Sealants .................................................................................................... 4-9
Engine Oil and Oil Filter.......................................................................................................... 4-10
Oil Level Inspection........................................................................................................... 4-10 4
Engine Oil Change............................................................................................................ 4-12
Oil Filter Replacement ...................................................................................................... 4-12
Oil Cooler................................................................................................................................ 4-13
Oil Cooler Removal........................................................................................................... 4-13
Oil Cooler Installation........................................................................................................ 4-13
Oil Cooler Disassembly..................................................................................................... 4-14
Oil Cooler Assembly ......................................................................................................... 4-15
Oil Cooler Inspection......................................................................................................... 4-15
Breather Case and Oil Separator Tank................................................................................... 4-16
Breather Case Removal (JT1500-A1 A8 Models).......................................................... 4-16
Breather Case Installation (JT1500-A1 A8 Models)....................................................... 4-16
Oil Separator Tank Removal ............................................................................................. 4-16
Oil Separator Tank Installation .......................................................................................... 4-17
Blowby Gas System Inspection ........................................................................................ 4-17
Oil Pan.................................................................................................................................... 4-18
Oil Pan Removal ............................................................................................................... 4-18
Oil Pan Installation ............................................................................................................ 4-18
Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve ................................................. 4-19
Oil Pump Sprocket Removal............................................................................................. 4-19
Oil Pump Sprocket Installation.......................................................................................... 4-20
Oil Pump Removal (JT1500-A1 AB Models).................................................................. 4-22
Oil Pump Removal (JT1500AC Model)............................................................................. 4-22
Oil Pump Installation (JT1500-A1 AB Models)............................................................... 4-22
Oil Pump Installation (JT1500AC Model).......................................................................... 4-23
Oil Pump Inspection.......................................................................................................... 4-23
Oil Screen Removal .......................................................................................................... 4-23
Oil Screen Installation ....................................................................................................... 4-23
Oil Pressure Relief Valve Inspection................................................................................. 4-24
Oil Pump Sprocket Chain Removal .................................................................................. 4-25
Oil Pressure Measurement..................................................................................................... 4-26
Oil Pressure Measurement ............................................................................................... 4-26
Oil Pressure Switch ................................................................................................................ 4-28
Oil Pressure Switch Removal ........................................................................................... 4-28
Oil Pressure Switch Installation ........................................................................................ 4-28

4-2 ENGINE LUBRICATION SYSTEM
Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Breather Plate Bolts 7.8 0.80 69 inlb
2 Oil Filler Cap 1.0 0.10 8.7 inlb
3 Oil Passage Plugs 20 2.0 14 L
4 Oil Separator Tank Mounting Screws 4.9 0.50 43 inlb L
5 Breather Case Mounting Bolts 7.8 0.80 69 inlb
6 Breather Pipe Bolts 8.8 0.90 78 inlb L
7 Oil Passage Joints 11 1.1 95 inlb L
8 Oil Cooler Assembly Bolts 7.8 0.80 69 inlb
9 Oil Pressure Switch 15 1.5 11 SS
10 Oil Passage Bolt 78 8.0 58 S
11 Oil Filter 18 1.8 13 EO
12 Oil Cooler Positioning Bolt 20 2.0 14 S
13 Oil Pan Bolts 7.8 0.80 69 inlb S
14 Dipstick Tube Bolts 8.8 0.90 78 inlb L, S
Oil Pump Sprocket Bolt (JT1500-A1 A2) 15 1.5 11 LN
15
Oil Pump Sprocket Bolt (JT1500A6 ) 16 1.6 12 LN
16 Oil Pump Cover Bolts 7.8 0.80 69 inlb
17 Oil Pressure Relief Valve 15 1.5 11 LN
18 Oil Pipe Bolts 7.8 0.80 69 inlb
19 Oil Pump Chain Guide Bolt 7.8 0.80 69 inlb
20 Chain Guide Spring Plate Bolt 7.8 0.80 69 inlb
21 Oil Pump Body Plug 20 2.0 14 L
22 Oil Pump Body Bolts 7.8 0.80 69 inlb
23 Oil Screen Bolts 7.8 0.80 69 inlb
24 Water Hose Joints (JT1500-A1 AA) 20 2.0 14 L
25: JT1500-A1 A8 Models
26: JT1500-A1 AA Models
27: JT1500-A1 A6 Models
28: JT1500-A7 AB Models
D: Stepped side faces outward.
EO: Apply engine oil.
G: Apply grease.
LN: Apply a non-permanent locking agent (High Strength: Locktite 271 equivalent).
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide
grease in a weight ratio 10 : 1).
R: Replacement
S: Follow the specific tightening sequence.
SS: Apply silicone sealant (see text).

Engine Oil Flow Chart
JT1500-A1 A8 Models
A: Blowby Gas 6. Oil Filter 12. Oil Pressure Relief Valve

B: Supply Engine Oil Flow 7. Oil Passage (to Oil Filter) 13. Oil Pump
C: Return Engine Oil Flow 8. Oil Passage (to Main Oil 14. Oil Sump (in Oil Pan)
D: Oil Sump Passage) 15. Oil Pan
1. from Oil Pump Side Pas- 9. Oil Pipe (from Lower 16. Lower Crankcase
sage Crankcase to Upper 17. Upper Crankcase
2. Oil Cooler Crankcase) 18. Crankshaft
3. to Main Oil Passage 10. Oil Passage Plug 19. Breather Case
4. Oil Passage Bolt 11. Oil Pipe (from Oil pump to 20. Breather Hose
5. Oil Pressure Switch Lower Crankcase)

JT1500-A1 A8 Models
21. Oil Separator Tank 28. Oil Pipe (from Cylinder to 34. Oil Hose (from Cylinder
22. to Air Filter Cylinder Head) to Oil Pan)
23. to Oil Pan 29. Oil Passage (from Main 35. Cylinder Oil Passage
24. Joint Oil Passage to Oil Pipe) Joint
25. Camshaft Oil Passage 30. Crankshaft Oil Passage 36. Cylinder
26. Camshaft Cap Oil Pas- 31. Oil Screen 37. Main Oil Passage
sage 32. Oil Sump (in Crank 38. to Oil Pan Sump
27. Oil Passage (from Oil Room) 39. Oil Pipe
Pipe to Camshaft Cap) 33. Oil Seal

JT1500A9 Model
A: Blowby Gas 6. Oil Filter 12. Oil Pressure Relief Valve

B: Supply Engine Oil Flow 7. Oil Passage (to Oil Filter) 13. Oil Pump
C: Return Engine Oil Flow 8. Oil Passage (to Main Oil 14. Oil Sump (in Oil Pan)
D: Oil Sump Passage) 15. Oil Pan
1. from Oil Pump Side Pas- 9. Oil Pipe (from Lower 16. Lower Crankcase
sage Crankcase to Upper 17. Upper Crankcase
2. Oil Cooler Crankcase) 18. Crankshaft
3. to Main Oil Passage 10. Oil Passage Plug 19. Breather Hose Assy
4. Oil Passage Bolt 11. Oil Pipe (from Oil pump to (JT1500A9 AB Mod-
5. Oil Pressure Switch Lower Crankcase) els)

JT1500A9 Model
20. Oil Separator Tank 27. Oil Passage (from Main 33. Cylinder Oil Passage
21. to Air Filter Oil Passage to Oil Pipe) Joint
22. to Oil Pan 28. Crankshaft Oil Passage 34. Cylinder
23. Camshaft Oil Passage 29. Oil Screen 35. Main Oil Passage
24. Camshaft Cap Oil Pas- 30. Oil Sump (in Crank 36. to Oil Pan Sump
sage Room) 37. Oil Pipe
25. Oil Passage (from Oil 31. Oil Seal
Pipe to Camshaft Cap) 32. Oil Hose (from Cylinder
26. Oil Pipe (from Cylinder to to Oil Pan)
Cylinder Head)

Specifications
Item Standard
Engine Oil
Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Capacity 4.0 L (4.2 US qt, when filter is not removed)
5.0 L (5.3 US qt, when engine is completely dry)
Level Between upper and lower level lines (see text)
Oil Pressure Measurement
Oil pressure @3 000 r/min (rpm), 461 kPa (4.7 kgf/cm, 67 psi)
oil temperature 74C (165F)

Special Tools and Sealants
Oil Pressure Gauge, 10 kgf/cm: Liquid Gasket, TB1211:
57001-164 56019-120
Oil Pressure Gauge Adapter, PT 1/8: Liquid Gasket, TB1211F:

57001-1033 92104-0004
Oil Filter Wrench:

57001-1249

Engine Oil and Oil Filter
WARNING
Insufficient, deteriorated or contaminated engine
oil causes accelerated engine wear and may result
in sudden catastrophic engine failure that can lead
to an accident resulting in serious injury or death.
Change the engine oil according to the periodic
maintenance chart and check the oil level regularly
between oil changes
Oil Level Inspection

This watercraft engine is equipped with a semi-dry sump.
In the semi-dry sump engine, the oil level difference is very
large between the level measured after just stopping and
that after leaving for a long time.
It is necessary to check the specified amount of oil is in
the engine before starting the engine every day. At this
time use the cold mark of the level gauge. Then run the
engine to lubricate the engine parts sufficiently. After that
it is necessary to check the level by using hot mark of the
level gauge.
Preliminary Check
Whenever checking the engine oil level, keep the water-
craft level side to side and fore to aft as much as possible.
Level Ground [A]
Side Bumper [B]
Parallel [C]
Remove the dipstick [A], wipe it dry and insert it back to

the dipstick tube [B], and then remove it again to check
the oil level.
The oil level must be between the High [A] and Low [B]
level lines on the dipstick [C] (Use level lines when engine
is cold).
High Level Line when Cold [A]
Low Level Line when Cold [B]
Dipstick [C]
High Level Line when Hot [D]
Low Level Line when Hot [E]

NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not function
properly, the oil pressure warning light will light. If
this light stays on when the engine is running above
idle speed, stop the engine immediately and find the
cause.
If the oil level is too high, remove the excess oil using a
syring or some other suitable device.
If the oil level is too low, add the oil to the low level line
through the oil filter opening (see Periodic Maintenance
chapter). Use the same type and make of oil that is al-
ready in the engine.
NOTE
If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Ordinary (standard) Check

The preliminary is checked before the ordinary check.
Install the removed parts.
Launch the watercraft.
Start the engine for several minutes.
Ride the watercraft and run the engine at about 5 000 rpm
for 5 minutes.
Stop the engine and let it cool down for 10 minutes.
Steady the watercraft in calm water to prevent movement,

or on the ground, keep the watercraft level side to side
and fore to aft as much as possible.
NOTE
Since the trim and list of the watercraft will significantly
affect the oil level, be sure that the operator and/or
cargo are not aboard the watercraft when measuring
the oil level.
Also make the fuel tank [A] full if it is not full as shown
to keep the watercraft level.
Fuel Tank Filler Neck [B]
Fuel Full Level [C]
Fuel [D]
This measuring procedure with the watercraft afloat
should be followed when the oil level is found low and
to be added.

Remove the seat (see Hull/Engine Hood chapter)

the dipstick
Remove the dipstick [A], wipe it dry and insert it back to
tube [B], and then remove it again to check
the oil level.
Check
[A].
the oil level using the hot level mark on the dipstick
High Level Line when Hot [B]

Low Level Line when Hot [C]
If the oil level is too high, drain the excess oil thoroughly
from the dipstick tube [A] using a commercially-available
vacuum pump [B].
If the oil level is too low, add the oil to the high level line
through the oil filler opening (see Periodic Maintenance
chapter). Use the same type and make of oil that is al-
ready in the engine.
NOTE
If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Engine Oil Change

Refer to the Engine Oil Change in the Periodic Mainte-
nance chapter.
Oil Filter Replacement
Refer to the Oil Filter Replace in the Periodic Maintenance
chapter.

Oil Cooler
Oil Cooler Removal
Remove:
Air Filter with Inlet Duct (see Fuel System (DFI) chapter)
Inlet Manifold (see Fuel System (DFI) chapter)
Disconnect the oil pressure switch connector [A].
Loosen the clamp screws [B] and remove the oil cooler
cooling hoses [C] from the oil cooler.
Remove the oil filter [A] with the oil filter wrench [B].
Place a rag or cloth [C] under the oil filter to receive the
remaining oil.
Special Tool - Oil Filter Wrench: 57001-1249
Unscrew the oil cooler positioning bolt [A].

[C].
Unscrew the oil passage bolt [B] and remove the oil cooler
Place a rag or cloth [D] under the oil cooler to receive the
remaining oil.
Oil Cooler Installation

Replace the O-ring [A] with new one and apply grease to
new O-ring.
Fit the O-ring on the oil cooler [B] securely.
Install the oil cooler positioning bolt [A] and the oil pas-
sage bolt [B] temporarily.
Tighten the passage bolt first.
Next, tighten the positioning bolt.
Torque - Oil Passage Bolt: 78 Nm (8.0 kgfm, 58 ftlb)
Oil Cooler Positioning Bolt: 20 Nm (2.0 kgfm, 14
ftlb)

Oil Cooler
Apply engine oil to the thread [A] of the passage bolt and
O-ring [B] of the oil filter [C].
Tighten the oil filter (P/No. 16097-1072).
Torque - Oil Filter: 18 Nm (1.8 kgfm, 13 ftlb)
Connect the oil pressure switch connector securely.

ing in Appendix
Install the cooling hoses (see Cable, Wire and Hose Rout-
chapter).
Install the inlet manifold (see Fuel System (DFI) chapter).
Oil Cooler Disassembly
Remove:
Oil Cooler (see Oil Cooler Removal)
Water Hose Joints [A] (JT1500-A1 AA Models)
Oil Pressure Switch [B]
Oil Cooler Assembly Bolts [C]
Remove the O-ring [A].

bly bolts [B].cooler up side down, and remove the assem-
Turn the oil
Separate the oil cooler.

Inside Oil Cooler Cover [A]
O-rings [B]
Oil Cooler [C]
Outside Oil Cooler Cover [D]

Oil Cooler
Oil Cooler Assembly
Apply grease to new O-rings, and fit them on to each
groove of the coolers securely.
Apply a non-permanent locking agent to the joints and
tighten them.
Torque - Oil Cooler Assembly Bolts: 7.8 Nm (0.80 kgfm,
69 inlb)
Water Hose Joints: 20 Nm (2.0 kgfm, 14 ftlb)
JT1500-A1 AA Models
Install the oil cooler (see Oil Cooler Installation).
Oil Cooler Inspection
Start the engine to check for water and oil leaks.
If the water and oil leak, replace the O-rings.
DANGER
Exhaust gas contains carbon monoxide, a color-
less, odorless poisonous gas. Inhaling carbon
monoxide can cause serious brain injury or death.
DO NOT run the engine in enclosed areas. Operate
only in a well-ventilated area.
NOTICE

Breather Case and Oil Separator Tank
Breather Case Removal (JT1500-A1 A8 Models)
Remove:
Exhaust Manifold (see Exhaust System chapter)
Clamp [A]
Breather Hose [B]
Breather Case Mounting Bolts [C]
Pull the breather case [D] upward.
Breather Case Installation (JT1500-A1 A8

Models)
If the breather pipe [A] removed, install the pipe as follow.
Apply grease to the O-ring [B].
Install the O-ring to the short length pipe side [C] of the
breather pipe.
Install the breather pipe so that the short length pipe side
faces downward.
Apply a non-permanent locking agent to the threads of
breather pipe bolts and tighten them.
Torque - Breather Pipe Bolts: 8.8 Nm (0.90 kgfm, 78 inlb)
Apply
[D].
silicone sealant to the inside of the rubber grommet
Sealant - Liquid Gasket, TB1211F: 92104-0004

Tighten the breather case mounting bolts.
M6 55 Bolts [E]
M6 45 Bolt [F]
Torque - Breather Case Mounting Bolts: 7.8 Nm (0.80
kgfm, 69 inlb)
Install the breather hose clamp pinch head [G] as shown.
Oil Separator Tank Removal

Remove:
Breather Hose Clamps [A] (slide out)
Breather Hoses [B]
Mounting Screws
Braket
careful not to drop the nuts [C].
Be

Breather Case and Oil Separator Tank
Remove:
Breather Hose Clamp [A]
Breather Hose [B]
Oil Separator Tank [C]
NOTE
Hold the hose end to the upward. The oil will flow out if
the hose lies at the bottom.
Oil Separator Tank Installation

When installing the breather hoses, avoid sharp bending,
kicking, flattening or twisting, and route the hoses accord-
ing to Hose Routing section in Appendix chapter.
Apply a non-permanent locking agent to the oil separator
tank mounting screws.
Be careful not to drop the nuts.
Tighten:
Torque - Oil Separator Tank Mounting Screws: 4.9 Nm
(0.50 kgfm, 43 inlb)
Blowby Gas System Inspection

Be certain that all the hoses are routed without being flat-
tened or kinked, and are connected correctly.
If they are not, correct them.
Inspect the breather hoses [A], breather pipes and the
air filter drain caps for damage or signs of deterioration.
Squeeze the hoses. These hoses should not be hard and
brittle, nor should be soft or swollen.
Replace any damaged hoses.
Check that the hoses and caps are securely connected.
The air filter drain caps [A] is provided beneath the air filter
are housing catches the water or oil from the bottom of
the air filter housing. Usually water or oil does not collect
at the bottom of the housing. In the event that water is
drawn in through the duct, or if engine oil is blown back,
drain the housing.
Pull the air filter drain plugs to drain the water or breather
oil when changing engine oil.

Oil Pan
Oil Pan Removal
Drain:
Engine Oil (see Periodic Maintenance chapter)
Remove:
Unscrew
Turn the engine to the side.
stick tubethe dipstick tube bolts [A] and pull out the dip-
[B].
Unscrew the oil pan bolts [A] and remove the oil pan [B].
Oil Pan Installation

Tighten the oil pan bolts following the tightening sequence
[1 17].
Torque - Oil Pan Bolts: 7.8 Nm (0.80 kgfm, 69 inlb)
Apply grease to the O-ring [A] on the dipstick tube [B].

bolts. non-permanent locking agent to the dipstick tube
Apply a
Tighten all the dipstick tube bolts temporary.

First, tighten the oil pan side bolt. Next, tighten the cylin-
der head side bolts.
Torque - Dipstick Tube Bolts: 8.8 Nm (0.90 kgfm, 78 inlb)

Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve
Oil Pump Sprocket Removal
JT1500-A1 AB Models
Drain:
Remove:
Oil Pan (see Oil Pan Removal)
Crankshaft Sensor Cover Bolts [A]
Crankshaft Sensor Cover [B]
Unscrew the oil pump chain guide bolt [A].
JT1500-A1 A6 Models
Unscrew the spring plate bolt [A] and remove the spring
plate [B], spring [C] and the oil pump chain guide [D].
Remove:
Oil Pump Sprocket Bolt [E]
Washer
Pull out the oil pump sprocket [F] together with the oil
pump sprocket chain [G].
JT1500-A7 AB Models
Unscrew the spring plate bolt [A] and remove the spring
plate [B], spring [C] and the oil pump chain guide [D].
Remove:
Oil Pump Sprocket Bolt [E]
Washer [F]
Pull out the oil pump sprocket [G] together with the oil
pump sprocket chain [H].
JT1500AC Model
Drain:
Remove:
Oil Pump Sprocket Bolt [A]
Washer [B]

Remove the oil pump body bolts [A].
Pull out the oil pump body [A] and remove the oil pump
sprocket [B].
Oil Pump Sprocket Installation

JT1500-A1 A6 Models
Engage the oil pump chain [A] to the oil pump sprocket
[B].
Install the sprocket with the chain to the oil pump shaft
[C].
Apply a non-permanent locking agent (High Strength: 271
equivalent) to the sprocket bolt.
Tighten:
Torque - Oil Pump Sprocket Bolt: 15 Nm (1.5 kgfm, 11
ftlb)
(JT1500-A1~A2 Models)
Oil Pump Sprocket Bolt: 16 Nm (1.6 kgfm, 12
ftlb)
(JT1500A6 Model)
sprocket [B].
JT1500-A7 AB Models
Engage the oil pump chain [A] to the oil pump sprocket
[B].
Install the sprocket with the chain to the oil pump shaft [C]
so that the stepped side [D] faces outward.
Apply a non-permanent locking agent (High Strength: 271
equivalent) to the sprocket bolt.
Tighten:
Torque - Oil Pump Sprocket Bolt: 16 Nm (1.6 kgfm, 12
ftlb)
sprocket [B].

Install the oil pump chain guide [A], collar [B], washer [C],
and bolt [D] as shown.
Install the collar so that the flat surface of the collar faces
to crankcase.
Tighten:
Torque - Oil Pump Chain Guide Bolt: 7.8 Nm (0.80 kgfm,
69 inlb)
JT1500-A1 AB Models
Install the chain guide spring [A] and the spring plate [B].
Insert the tab [C] of the spring plate in the hole [D] of the
crankcase.
Tighten:
Torque - Chain Guide Spring Plate: 7.8 Nm (0.80 kgfm, 69
inlb)
Install:
Oil Pan (see Oil Pan Installation)
JT1500AC Model
Check that dowel pins [A] and oil pipe [B] are in place on
the crankcase.
Replace the O-ring [C] with a new one.
Engage the oil pump chain with the oil pump sprocket [A].
faces outward
Install the oil pump sprocket so that the 620 Mark [B]
on the oil pump body [C].
Tighten:
Install the oil pump body.

Torque - Oil Pump Body Bolts: 7.8 Nm (0.80 kgfm, 69 inlb)

Oil Pump Removal (JT1500-A1 AB Models)
Drain:
Remove:
Oil Pump Sprocket (see Oil Pump Sprocket Removal)
Oil Pump Cover Bolts [A]
Pull out the oil pump cover [B].
Pull out the oil pump shaft [A] with inner rotor [B].
Remove the outer rotor [C].
Oil Pump Removal (JT1500AC Model)

Drain:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Remove:
Engine (see Engine Removal in the Engine Removal/In-
stallation chapter)
Oil Pump Body (see Oil Pump Sprocket Removal)
Oil Pump Cover Bolts [A]
Pull out the oil pump cover [B] and oil pump shaft [C].
Remove:
O-ring [A]
Inner Rotor [B]
Outer Rotor [C]
Oil Pump Installation (JT1500-A1 AB Models)

Apply molybdenum disulfide oil solution to the outer and
the inner rotors out side.
Install the outer rotor [A] into the oil pump body.
Assemble the pin [B]disulfide
Apply molybdenum oil solution to the shaft.
shaft [D]. , inner rotor [C] onto the oil pump
Fit the pin into the slot of the inner rotor.

Insert the shaft assembly.
Fit the new
Be sure the dowel pin [E] is in place in the pump body.
Fit the oil pump
O-ring [F] to the groove of the pump body.
cover and tighten the cover bolts.
Torque - Oil Pump Cover Bolts: 7.8 Nm (0.80 kgfm, 69
inlb)
Install:
Oil Pump Sprocket (see Oil Pump Sprocket Installation)
Oil Pump Installation (JT1500AC Model)
Replace the O-ring with a new one.
the inner rotors out side.
Apply molybdenum disulfide oil solution to the outer and
Install the outer rotor [A] and inner rotor [B] into the oil
pump body.
Apply molybdenum disulfide oil solution to the shaft.
shaft [E]. the oil pump cover [C] , pin [D] onto the oil pump
Assemble
Fit the pin into the slot of the inner rotor.

Insert the shaft assembly.
Apply grease
Be sure the dowel pin [F] is in place in the oil pump body.
the groove of the
to the new O-ring [G] and fit the O-ring to
oil pump body.
Fit the oil pump cover and tighten the oil pump cover bolts.
Torque - Oil Pump Cover Bolts: 7.8 Nm (0.80 kgfm, 69
inlb)
Install:
Oil Pump Sprocket (see Oil Pump Sprocket Installation)
Oil Pump Inspection
Remove the oil pump parts.
If there is any damage
Visually inspect the oil pump outer, inner rotors and cover.
or uneven wear, replace the rotors
and cover.
Oil Screen Removal
Remove:
Oil Screen Bolts [A]
Pull out the soil screen [B] to the coupling side.
Oil Screen Installation

Clean the oil screen [A] with high-flash point solvent and
remove any particles stuck to it.
WARNING
burns. Clean the screen in a well-ventilated area,
and take 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 to clean the screen.
NOTE
While cleaning the screen, check for any metal particles
that might indicate internal engine damage.

Apply grease to the O-ring [A].

Tighten:the oil screen [B].
Install

Torque - Oil Screen Bolts [C]: 7.8 Nm (0.80 kgfm, 69 inlb)
Install:
Oil Pressure Relief Valve Inspection

Remove:
Relief Valve [A]
Check to see if the valve [A] slides smoothly when push-

ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] force.
NOTE
Inspect the valve in its assembled state.
Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high-flash point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
burns. Clean the relief valve in a well-ventilated
area, and take care that there is no spark or flame
anywhere near the working areas. Do not use
gasoline or low-flash point solvents to clean the
relief valve.
If cleaning does not solve the problem, replace the relief
valve as an assembly. The relief valve is precisely made
with no allowance for replacement of individual parts.
Apply a non-permanent locking agent to the relief valve.
Install the relief valve and tighten it.
Torque - Oil Pressure Relief Valve: 15 Nm (1.5 kgfm, 11 ft
lb)

Oil Pump Sprocket Chain Removal
Split the crankcase (see Engine Bottom End chapter).
Remove
chain [B].
the camshaft chain [A] and the oil pump sprocket

Remove:
Oil Pressure Switch Connector [A] (disconnect)
Oil Pressure Switch [B]
Install
hole.
the oil pressure gauge adapter [A] to the switch
Special Tool - Oil Pressure Gauge Adapter, PT 1/8: 57001

-1033
Install the oil pressure gauge [A] to the adapter.

Special Tool - Oil Pressure Gauge, 10 kgf/cm: 57001-164
Out off a rag or cloth.
Install:
Launch the watercraft.

Run the engine
Start the engine for several minutes.
pressure gauge.at the specified speed, and read the oil
If the oil pressure is significantly below the specification,
inspect the oil pump and relief valve.
If the oil pump and relief valve are not at fault, inspect the
rest of the lubrication system.
Oil Pressure
Standard: 461 kPa (4.7 kgf/cm, 67 psi) @3 000 r/min
(rpm), oil temperature 74C (165F)
Stop the engine.

Remove:
Raise the watercraft to the land.
Inlet Manifold
Oil Pressure Gauge and Adapter

WARNING
Hot oil can cause severe burns. Beware of hot en-
gine oil that will drain through the oil passage when
the gauge adapter is removed.
Install:
Oil Pressure Switch (see Oil Pressure Switch Installa-
tion)
Inlet Manifold

Oil Pressure Switch
Oil Pressure Switch Removal
Remove:
Disconnect:
Switch Connector [A]
Place a rag or cloth under the oil pressure switch [A] and
remove the oil pressure switch.
Do not damage the connect part [B] of the switch.
Oil Pressure Switch Installation

Apply silicone sealant to the threads of the oil pressure
switch and tighten it.
Torque - Oil Pressure Switch: 15 Nm (1.5 kgfm, 11 ftlb)
Connect the switch connector.

EXHAUST SYSTEM 5-1
Exhaust System
Table of Contents
Exploded View........................................................................................................................ 5-2
Exhaust Manifold .................................................................................................................... 5-4
Exhaust Manifold Removal ............................................................................................... 5-4
Exhaust Manifold Installation ............................................................................................ 5-5
Exhaust Manifold Cleaning and Inspection....................................................................... 5-6
Exhaust Pipe .......................................................................................................................... 5-7
Exhaust Pipe Removal...................................................................................................... 5-7
Exhaust Pipe Installation...................................................................................................
Exhaust Pipe Cleaning and Inspection .............................................................................
5-7
5-8
5
Water Box Muffler ................................................................................................................... 5-9
Water Box Muffler Removal .............................................................................................. 5-9
Water Box Muffler Installation ........................................................................................... 5-10
Water Box Muffler Inspection ............................................................................................ 5-11

5-2 EXHAUST SYSTEM
Exploded View

EXHAUST SYSTEM 5-3
Exploded View
Torque
Nm kgfm ftlb
1 Exhaust Manifold Mounting Nuts 25 2.5 18 S
2 Exhaust Manifold Mounting Bolts 25 2.5 18 L, S
3 Bypass Nozzle L
4 Flushing Hose Joint 11 1.1 95 inlb L
5 Water Hose Joint 11 1.1 95 inlb L
6 Water Temperature Sensor 15 1.5 11 see chapter 3
7 Exhaust Pipe Mounting Plate Bolts 29 3.0 22 L
8 Exhaust Pipe Mounting Bolts 29 3.0 22
9 Exhaust Tube Clamp Screws (JT1500A8 ) 5.0 0.51 44 inlb
10 Exhaust Tube Clamp Screws (JT1500A8) 5.0 0.51 44 inlb
B: JT1500-A1 AA Models
EO: Fill the hollow with the engine oil (10W-30).
SY: Apply synthetic rubber adhesive.

5-4 EXHAUST SYSTEM
Exhaust Manifold
Exhaust Manifold Removal
JT1500-A1 A8 Models
Remove:
Oil Separator Tank [A] with the Oil Separator Hoses (see
Engine Lubrication System chapter)
Air Filter [B] (see Fuel System chapter)
Disconnect:
Spark Plug Caps [C] (see Periodic Maintenance chapter)
Hoses [D]
Water Temperature Sensor Connector [E]
JT1500A9 Model
Remove:
Oil Separator Tank [A] with the Oil Separator Hoses (see
Engine Lubrication System chapter)
Air Filter [B] (see Fuel System chapter)
Disconnect:
Spark Plug Caps [C] (see Periodic Maintenance chapter)
Water Temperature Sensor Connector
Disconnect:
Hoses [A]
Remove:
Bolts [A] and Collars
Exhaust Pipe Mounting Plate [B]
Loosen:
Joint Tube Clamp Screws [C]
Remove
[B].
the exhaust manifold mounting nuts [A] and bolts
Remove the exhaust manifold from the engine.

EXHAUST SYSTEM 5-5
Exhaust Manifold
Disconnect the exhaust pipe [A] from the left water box
muffler [B] by pulling the exhaust manifold with the ex-
haust pipe toward the front [C].
Take out the exhaust manifold with the exhaust pipe from
the hull.
Disconnect the hose [A] from the exhaust pipe.
Exhaust Manifold Installation

NOTE
Unhook the rubber strap and remove the front exhaust
tube from the water box muffler for easier installation
of the exhaust manifold, and after connecting the water
box muffler to the exhaust pipe, hook the rubber strap
and install the tube.
Replace the exhaust manifold gasket [A] with a new one.

lars [C] asexhaust
Install the
shown.
manifold and the washers [B] and col-
Apply a non-permanent locking agent to the exhaust man-

ifold mounting bolts.
Tighten the exhaust manifold mounting nuts and bolts fol-

lowing the specified tightening sequence.
Torque - Exhaust Manifold Mounting Nuts: 25 Nm (2.5
kgfm, 18 ftlb)
Exhaust Manifold Mounting Bolts: 25 Nm (2.5
kgfm, 18 ftlb)
Apply a non-permanent locking agent to the exhaust pipe
mounting plate bolts and install the collars.
Tighten:
Torque - Exhaust Pipe Mounting Plate Bolts: 29 Nm (3.0
kgfm, 22 ftlb)
Connect the water box muffler to the exhaust pipe after
binding the two rings with the paper tape (see Exhaust
Pipe Installation).

5-6 EXHAUST SYSTEM
Exhaust Manifold
If the water temperature sensor is removed, see water
temperature sensor removal/installation in Fuel System
chapter.
Check the hose routing and clamp screw position (see
Cable, Wire and Hose Routing in Appendix chapter).
Exhaust Manifold Cleaning and Inspection
Remove the exhaust manifold parts.
with a blunt,carbon
Clean the deposits out of the exhaust passages
roundedged tool.
Flush
water.
foreign matter out of the water passages with fresh
Check the insides of the water passages for corrosion.

Check the gasket surfaces for nicks or other damage.
If there is excessive corrosion or if the gasket surfaces are
so badly damaged that they will not seal properly, replace
the part.

EXHAUST SYSTEM 5-7
Exhaust Pipe
Exhaust Pipe Removal
Remove:
Exhaust Manifold with Exhaust Pipe (see Exhaust Man-
ifold Removal)
Exhaust Pipe Mounting Bolts [A]
Exhaust Pipe [B]
Remove the joint tube [A] and the two rings.
Exhaust Pipe Installation

Install
pipe.
the two rings [A] in the ring grooves of the exhaust
If the two rings are damaged or warped, replace the rings.
Bind the two rings [A] securely by putting the paper tape
[B] around the rings so that it is easy to insert the water
box muffler into the exhaust pipe. The paper tape can be
burned out soon after firing.
Install the joint tube to the exhaust pipe.
Replace
shown.
the exhaust pipe gasket [A] with a new one as
Install the exhaust pipe [B] to the exhaust manifold [C]

and tighten the bolts [D].
Torque - Exhaust Pipe Mounting Bolts: 30 Nm (3.0 kgfm,
22 ftlb)
[E] Water Hose Joint
[F] 30

5-8 EXHAUST SYSTEM
Exhaust Pipe
Exhaust Pipe Cleaning and Inspection
Remove the exhaust pipe parts.
Clean the carbon deposits out of the exhaust passages
with a blunt, roundedged tool.
Flush
water.
foreign matter out of the water passages with fresh
Check the insides of the water passage for corrosion.

If there the
Check gasket surface for nicks or other damage.
is excessive corrosion or if the gasket surfaces are
so badly damaged that they will not seal properly, replace
the part.

EXHAUST SYSTEM 5-9
Water Box Muffler
Water Box Muffler Removal
NOTE
JT1500-A1 A8 Models have the water box mufflers
located at left and right, however JT1500A9 Model
has it only left side.
Remove:
Rear Storage Pocket
Oil Separator Tank with Oil Separator Hoses (see the
Lubrication System chapter)
Air Filter (see the Fuel System chapter)
Loosen:
Joint Tube Clamp Screw (see Exhaust Manifold Re-
moval)
Remove the front exhaust tube [A] by loosing the clamp

screws [B].
Unhook
fler.
the rubber strap [C] from the left water box muf-
Remove:
Hoses [A]
Exhaust Manifold [B] (see Exhaust Manifold Removal)
Remove the left water box muffler by pulling it to the rear.

NOTE
When removing the left water box muffler, remove the
water box muffler [A] from the deck with turning it with
the welding spot [B] and rivets [C].
Only left side water box muffler should be removed or
inspected.
Remove the joint tube from the exhaust pipe.

5-10 EXHAUST SYSTEM
Water Box Muffler
Water Box Muffler Installation
Be sure the dampers [A] on the hull bottom and muffler
body are in place.
Be sure the dampers [A] on the left side water box muffler
[B] are in place.
Make sure the two rings [A] are installed to the correct
position.
If the rings are damaged or warped, replace the rings with
new ones.
Bind the two rings [A] by putting the paper tape [B] around
the rings. The paper tape can be burned out soon after
firing.
Install the joint tube to the exhaust pipe.

Tighten theleftclamp
Install the water box muffler to the exhaust pipe.
its screw position, securing the front exhaust tube, noting
and check the hose routing and clamp
screw position (see Cable, Wire and Hose Routing in Ap-
pendix chapter).
Torque - Exhaust Tube Clamp Screws: 5.0 Nm (0.51 kgfm,
44 inlb)

EXHAUST SYSTEM 5-11
Water Box Muffler
Water Box Muffler Inspection
Remove the left water box muffler.
Empty water out of the water box.
Check
heat.
the inlet spigot for damage caused by excessive
If there is heat damage to the inlet spigot, check the cool-

ing system for blockage (see Cooling System Flushing in
the Periodic Maintenance chapter) and the fuel system for
proper adjustment (see Fuel System chapter).

ENGINE TOP END 6-1
Engine Top End

Table of Contents
Exploded View................................... 6-2 Cylinder Head.................................... 6-22
Specifications .................................... 6-6 Cylinder Compression
Special Tools and Sealant ................. 6-8 Measurement ............................ 6-22
Clean Air System............................... 6-11 Cylinder Head Removal ............... 6-23
Air Suction Valve Removal Cylinder Head Installation ............ 6-24
(JT1500-A1 A8 Models) ......... 6-11 Cylinder Head Warp..................... 6-25
Air Suction Valve Installation Valves ................................................ 6-26
(JT1500-A1 A8 Models) ......... 6-11 Valve Clearance Check................ 6-26
Air Suction Valve Check Valve Removal ............................. 6-26
(JT1500-A1 A8 Models) ......... 6-11 Valve Installation .......................... 6-26
Clean Air System Hose Inspection Valve Guide Removal .................. 6-26 6
(JT1500-A1 A8 Models) ......... 6-11 Valve Guide Installation ............... 6-27
Cylinder Head Cover ......................... 6-12 Valve-to-Guide Clearance
Cylinder Head Cover Removal .... 6-12 Measurement (Wobble
Cylinder Head Cover Installation . 6-12 Method) ..................................... 6-27
Camshaft Chain Tensioner ................ 6-14 Valve Seat Inspection .................. 6-28
Camshaft Chain Tensioner Valve Seat Repair ........................ 6-28
Removal .................................... 6-14 Cylinder, Pistons................................ 6-33
Camshaft Chain Tensioner Cylinder Removal......................... 6-33
Installation ................................. 6-14 Piston Removal............................ 6-33
Camshaft, Camshaft Chain ............... 6-15 Piston/Cylinder Installation........... 6-34
Camshaft Removal ...................... 6-15 Cylinder Wear .............................. 6-36
Camshaft Installation ................... 6-16 Piston Wear ................................. 6-36
Piston TDC Finding...................... 6-18 Piston Ring, Piston Ring Groove
Camshaft, Camshaft Cap Wear ... 6-20 Wear.......................................... 6-37
Camshaft Runout ......................... 6-20 Piston Ring Groove Width............ 6-37
Cam Wear.................................... 6-20 Piston Ring Thickness ................. 6-37
Camshaft Chain Removal ............ 6-21 Piston Ring End Gap ................... 6-38

6-2 ENGINE TOP END
Exploded View

ENGINE TOP END 6-3
Exploded View
Torque
Nm kgfm ftlb
1 Air Suction Valve Cover Bolts 9.8 1.0 87 inlb
2 Cylinder Head Cover Bolts 9.8 1.0 87 inlb
3 Upper Camshaft Chain Guide Bolts 12 1.2 104 inlb S
4 Camshaft Cap Bolts 12 1.2 104 inlb S
5 Cylinder Head Bolts ( 7) 20 2.0 14 S
Cylinder Head Bolts ( 11) 23 2.3 17 First, MO, S
6
Cylinder Head Bolts ( 11) 59 6.0 43 Final, MO, S
7 Water Jacket Plugs 20 2.0 14 L
8 Cylinder Head Bolts ( 6) 12 1.2 104 inlb S
9 Engine Hook Bolts 20 2.0 14
B: JT1500-A1 AB Models
SS: Apply silicone sealant.

6-4 ENGINE TOP END
Exploded View

ENGINE TOP END 6-5
Exploded View
Torque
Nm kgfm ftlb
1 Exhaust Side Camshaft Chain Guide Bolts (Upper) 25 2.5 18
2 Exhaust Side Camshaft Chain Guide Bolts (Lower) 12 1.2 104 inlb
3 Upper Camshaft Chain Guide Bolts 12 1.2 104 inlb S
4 Inlet Side Camshaft Chain Guide Bolt 12 1.2 104 inlb L
5 Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 inlb L
6 Camshaft Chain Tensioner Cap Bolt 20 2.0 14
7 Camshaft Position Sensor Rotor Bolt 12 1.2 104 inlb L
8 Water Hose Joint 11 1.1 95 inlb L
9 Oil Passage Joint 11 1.1 95 inlb L
10. Closed coil end faces downward.
11. A marking hollow faces exhaust side.
G: Apply grease.

6-6 ENGINE TOP END
Specifications

Camshafts
Cam Height:
Exhaust 36.143 36.257 mm (1.4229 1.4274 in.) 36.04 mm (1.4189 in.)
Inlet 36.440 36.554 mm (1.4346 1.4391 in.) 36.34 mm (1.431 in.)
Camshaft Journal, Camshaft 0.028 0.071 mm (0.0011 0.0028 in.) 0.16 mm (0.006 in.)
Cap Clearance
Camshaft Journal Diameter 23.950 23.972 mm (0.9429 0.9438 in.) 23.92 mm (0.942 in.)
Camshaft Bearing Inside 24.000 24.021 mm (0.9449 0.9457 in.) 24.08 mm (0.948 in.)
Diameter
Camshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.004 in.)
Cylinder Head
Cylinder Compression (usable range)
1 185 1 795 kPa (12.1 18.3 kgf/cm,
172 260 psi) @430 r/min. (rpm)
Cylinder Head Warp 0.05 mm (0.002 in.)
Valves
Valve Clearance:
Exhaust 0.22 0.31 mm (0.0087 0.0122 in.)
Inlet 0.15 0.24 mm (0.0059 0.0094 in.)
Valve Head Thickness:
Exhaust 0.8 mm (0.03 in.) 0.5 mm (0.02 in.)
Inlet 0.5 mm (0.02 in.) 0.25 mm (0.0098 in.)
Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm (0.002 in.)
Valve Stem Diameter:
Inlet 4.975 4.990 mm (0.1959 0.1965 in.) 4.96 mm (0.195 in.)
Valve Guide Inside Diameter:
Inlet 5.000 5.012 mm (0.1969 0.1973 in.) 5.07 mm (0.200 in.)
Valve/valve Guide Clearance
(Wobble Method):
Inlet 0.03 0.11 mm (0.0012 0.0043 in.) 0.29 mm (0.011 in.)
Valve Seat Cutting Angle 45, 32, 60, 55
Valve Seating Surface:
Outside Diameter:
Exhaust 27.6 27.8 mm (1.087 1.094 in.)
Inlet 32.6 32.8 mm (1.283 1.291 in.)
Width:
Exhaust 0.8 1.2 mm (0.03 0.047 in.)
Inlet 0.5 1.0 mm (0.02 0.039 in.)
Valve Spring Free Length:
Exhaust (Inner) 38.08 mm (1.499 in.) 36.7 mm (1.445 in.)
Exhaust (Outer) 45.97 mm (1.810 in.) 44.3 mm (1.744 in.)
Inlet (Inner) 37.97 mm (1.495 in.) 36.5 mm (1.437 in.)

ENGINE TOP END 6-7
Specifications

Inlet (Outer) 45.78 mm (1.802 in.) 44.2 mm (1.740 in.)
Cylinder, Piston
Cylinder Inside Diameter 82.994 83.006 mm (3.2675 3.2679 in.) 83.10 mm (3.272 in.)
Piston Diameter 82.919 82.934 mm (3.2645 3.2651 in.) 82.77 mm (3.259 in.)
Piston/cylinder Clearance 0.060 0.087 mm (0.0024 0.0034 in.)
Piston Ring/groove
Clearance:
Top 0.03 0.07 mm (0.0012 0.0028 in.) 0.17 mm (0.0067 in.)
Second 0.02 0.06 mm (0.0008 0.0024 in.) 0.16 mm (0.0063 in.)
Piston Ring Groove Width:
Top 0.92 0.94 mm (0.0362 0.0370 in.) 1.02 mm (0.0402 in.)
Second 1.01 1.03 mm (0.0398 0.0406 in.) 1.11 mm (0.0437 in.)
Piston Ring Thickness:
Top 0.87 0.89 mm (0.0343 0.0350 in.) 0.80 mm (0.0315 in.)
Second 0.97 0.99 mm (0.0382 0.0390 in.) 0.90 mm (0.0354 in.)
Piston Ring End Gap:
Top 0.25 0.40 mm (0.0098 0.0157 in.) 0.7 mm (0.0276 in.)
Second 0.40 0.55 mm (0.0157 0.0217 in.) 0.8 mm (0.0315 in.)
Valve Head Thickness Valve Stem Bend
Valve Head Thickness [A]

Valve Stem Diameter [B]
45 [C]

6-8 ENGINE TOP END
Special Tools and Sealant
Compression Gauge, 20 kgf/cm: Valve Seat Cutter, 45 - 35:
57001-221 57001-1116
Valve Spring Compressor Assembly: Valve Seat Cutter, 32 - 30:

57001-241 57001-1120
Top Dead Center Finder: Valve Seat Cutter, 32 - 35:

57001-402 57001-1121
Piston Pin Puller Assembly: Valve Seat Cutter, 60 - 30:

57001-910 57001-1123
Piston Ring Compressor Grip: Valve Seat Cutter Holder Bar:

57001-1095 57001-1128

ENGINE TOP END 6-9
Valve Seat Cutter, 45 - 30: Valve Seat Cutter, 55 - 35:
57001-1187 57001-1247
Valve Spring Compressor Adapter, 22: Compression Gauge Adapter, M10 1.0:
57001-1202 57001-1317
Valve Guide Arbor, 5: Piston Ring Compressor Belt, 80 91:

57001-1203 57001-1320
Valve Guide Reamer, 5: Shaft Wrench:

57001-1204 57001-1551
Valve Seat Cutter Holder, 5: TDC Measurement Tool:

57001-1208 57001-1560

6-10 ENGINE TOP END
Piston Base, 8: Liquid Gasket, TB1211:
57001-1604 56019-120

ENGINE TOP END 6-11
Clean Air System
Air Suction Valve Removal (JT1500-A1 A8
Models)
Remove:
Hoses [A]
Remove:
Air Suction Valve Cover Bolts [A]
Air Suction Valve Covers [B]
Air Suction Valve Assembly [C]
Air Suction Valve Installation (JT1500-A1 A8

Models)
Install the valve assembly [A] so that its reeds [B] side
faces inside and its opening [C] side faces inlet side.
Install the air suction valve covers.
Torque - Air Suction Valve Cover Bolts: 9.8 Nm (1.0 kgfm,
87 inlb)
Air Suction Valve Check (JT1500-A1 A8 Models)

Refer to Air Suction Valve Inspection in the Periodic Main-
tenance chapter.
Clean Air System Hose Inspection (JT1500-A1
A8 Models)
Be certain that all the hoses are routed without being flat-
tened or kinked, and are connected correctly to the air
filter housing, throttle body and air suction valve covers.
If they are not, correct them. Replace them if they are
damaged.

6-12 ENGINE TOP END
Cylinder Head Cover
Cylinder Head Cover Removal
JT1500-A1 A8 Models
Remove:
Air Suction Valve Hoses [A]
Spark Plug Caps [B]
Breather Hoses [C]
Remove the cylinder head cover bolts [A] and take off the
cover [B].
JT1500A9 Model
Remove:
Spark Plug Caps [A]
Breather Hoses [B]
Remove the cylinder head cover bolts [A] and take off the
cover [B].
Cylinder Head Cover Installation

Be sure to install the pins [A] and rubber gaskets [B].

ENGINE TOP END 6-13
Cylinder Head Cover
Replace
aged.
the head cover gasket with a new one if dam-
Apply silicone sealant [A] to the cylinder head cover gas-

ket as shown.
Install the washer with the metal side [A] faces upward.
Tighten:
Torque - Cylinder Head Cover Bolts [B]: 9.8 Nm (1.0 kgfm,
87 inlb)
Route the hoses correctly (see Appendix chapter).

6-14 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
NOTICE
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below.
The camshaft chain tensioner can be damaged
if not removed and reset, causing severe engine
damage. To prevent damaging the cam chain
tensioner, do not loosen the mounting bolts only
halfway. Retightening the mounting bolts from
this position could damage the tensioner and the
camshaft chain. Once the bolts are loosened, the
tensioner must be removed and reset as described
in "Camshaft Chain Tensioner installation".
Turning the crankshaft while the cam chain ten-
sioner is removed can upset the timing and damage
the valves. Do not turn the crankshaft when the
tensioner is removed.
Remove:
Cap Bolt [A]
Washer [B]
Spring [C]
Rod [D]
Remove the mounting bolts [E] and take off the camshaft
chain tensioner.
Camshaft Chain Tensioner Installation

Release the stopper [B] and push the push rod [C] into
the tensioner body [D] fully.
Install
ward.
the tensioner body so that the stopper faces down-
Apply a non-permanent locking agent to the tensioner

mounting bolts [A].
Tighten the tensioner mounting bolts.
Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8
Nm (1.0 kgfm, 87 inlb)
Install the spring [B], rod [C] and washer [D].
Tighten the cap bolt [E].
Torque - Camshaft Chain Tensioner Cap Bolt: 20 Nm (2.0
kgfm, 14 ftlb)

ENGINE TOP END 6-15
Camshaft, Camshaft Chain
Camshaft Removal
Remove:
Spark Plugs (see Electrical System in the Periodic Main-
tenance chapter)
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Position the crankshaft at #1, #4 piston TDC as follows.

clockwise [B] and set the crankshaft at #1, 4 piston TDC.
D:\DOC
head upper surface [B] as shown (JT1500-A1 A9 Early
Models).

head upper surface [B] as shown (JT1500A9 Late Model
).

6-16 ENGINE TOP END
Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Camshaft Cap Bolts [A]
Upper Camshaft Chain Guide [B]
Camshaft Cap [C]
Camshafts
Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.
NOTICE
A kinked cam chain could damage both the chain
and the sprocket on the crankshaft. The crankshaft
can be turned while the camshafts are removed, but
always pull the cam chain taut to avoid kinking the
chain on the crankshaft sprocket.
Camshaft Installation
BePinssure[A]to install the following parts.
Apply molybdenum disulfide oil solution to all cam parts

and journals.
NOTE
The exhaust camshaft has a 320 EX mark [A] and the
inlet camshaft has a 320 IN mark [B]. Be careful not to
mix up these shafts.
If the camshaft position sensor rotor is removed, install it

as follows.
Insert the pin [A] into the holes [B] in the camshaft and
boss [C].

ENGINE TOP END 6-17
Fit the projection [A] of the rotor [B] on the camshaft re-
cess [C].
Apply a non-permanent locking agent to the camshaft po-
sition sensor rotor bolt [D], and tighten it.
Torque - Camshaft Position Sensor Rotor Bolt: 12 Nm (1.2
kgfm, 104 inlb)
Remove:
Coupling Cover Bolts [A]
Clamps [B]
Coupling Cover [C]
Remove the spark plugs.

clockwise [B]
and set the crankshaft at #1, 4 piston TDC
(see Piston TDC Finding).
Pull the tension side (exhaust side) of the chain taut to

install the chain.
Engage the camshaft chain with the camshaft sprockets
so that the timing marks on the sprockets are positioned
as shown.
The timing marks must be aligned with the cylinder head
upper surface [A] (JT1500-A1 A9 Early Models).
EX mark [B]
#1 Pin [C]
#2 Pin [D]
IN mark [E]
#31 Pin [F]

6-18 ENGINE TOP END
The timing marks must be aligned with the cylinder head
upper surface [A] (JT1500A9 Late Model ).
EX mark (two punch marks) [B]
#1 Pin [C]
#2 Pin [D]
IN mark (one punch mark) [E]
#31 Pin [F]
#32 Pin [G]
Install the camshaft cap [A] and upper camshaft chain

guide [B]. While pushing the camshaft chain, tighten all
camshaft bolts and chain guide bolts.
Install the longer (white) bolts to the #10 and #14 position
shown by triangle marks.
First tighten the all camshaft cap and chain guide bolts
evenly to seat the camshaft in place, then tighten all bolts
following the specified tightening sequence.
Torque - Camshaft Cap Bolts: 12 Nm (1.2 kgfm, 104 inlb)
Upper Camshaft Chain Guide Bolts: 12 Nm (1.2
kgfm, 104 inlb)
Tighten the camshaft chain
Chain Tensioner installation).
tensioner (see Camshaft
Turn the crankshaft counterclockwise two turns.

Install the cylinder head cover (see Cylinder Head Cover
installation).
Piston TDC Finding
This job can be done when the engine is on the hull and
during camshaft installation.
Prepare a suitable wire for pointer.
Using the coupler cover bolt [A], hold the wire pointer [B].
Remove:
#1 Spark Plug (Front Side)
Install the piston top detector [A] in the hole of the plug.
Special Tool - TDC Measurement Tool: 57001-1560
Insert the gauge extender [B] into the detector.
gauge extender
Using the shaft wrench, turn the crankshaft until the
reaches its highest point.
Remove the extender and install it to the gauge.

ENGINE TOP END 6-19
Install the top dead center finder [A] and the gauge [B]
with the extender.
Special Tool - Top Dead Center Finder: 57001-402
Set the gauge at position that the needle on the gauge
rotates a few turns.
Set the gauge to read 0.
Turn the crankshaft counterclockwise until the needle will

stop fluctuating, then scribe a mark [A] on the coupling at
the tip of the wire pointer.
Turn the crankshaft clockwise until the needle will stop

fluctuating, then describe a mark [A] on the coupling at
the tip of the wire pointer.
Turn the crankshaft so that the wire pointer is halfway [A]

between the two described marks.
The crankshaft is now at TDC for #1 and #4 Cylinders.

6-20 ENGINE TOP END
Camshaft, Camshaft Cap Wear
Cut strips of plastigage (press gauge) to journal width.
Place a strip on each journal parallel to the camshaft in-
stalled in the correct position.
Measure each clearance between the camshaft journal
and the camshaft cap using plastigage [A].
Tighten:
Torque - Camshaft Cap Bolts: 12 Nm (1.2 kgfm, 104 inlb)
Upper Camshaft Chain Guide Bolts: 12 Nm (1.2
kgfm, 104 inlb)
NOTE
Do not turn the camshaft when the plastigage is be-
tween the journal and camshaft cap.
Camshaft Journal, Camshaft Cap Clearance

Standard: 0.028 0.071 mm (0.0011 0.0028 in.)
Service Limit: 0.16 mm (0.006 in.)
If any clearance exceeds the service limit, measure the

diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard: 23.950 23.972 mm (0.9429 0.9438 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again
If the clearance still remains out of the limit, replace the
cylinder head with camshaft cap.
Camshaft Runout
Remove the camshaft (see Camshaft Removal).
Set the camshaft on V blocks.
Measure
as shown.
runout with a dial gauge at the specified place
If the runout exceeds the service limit, replace the

camshaft.
Camshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.1 mm (0.004 in.)
Cam Wear
Remove the camshaft (see Camshaft Removal).
If the camstheareheight
Measure [A] of each cam with a micrometer.
worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust 36.143 36.257 mm (1.4229 1.4274 in.)
Inlet 36.440 36.554 mm (1.4346 1.4391 in.)
Service Limit:
Exhaust 36.04 mm (1.419 in.)
Inlet 36.34 mm (1.431 in.)

ENGINE TOP END 6-21
Camshaft Chain Removal
Split the crankcase (see Engine Bottom End chapter).
Remove
sprocket.
the camshaft chain [A] from the crankshaft

6-22 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
NOTE
Use the battery which is fully charged.
Thoroughly warm up the engine, while checking that there
is no compression leakage from around the spark plugs
or the cylinder head gasket.
NOTICE
Stop the engine.

chapter). the front storage pocket (see Hull/Engine Hood
Remove
Disconnect both two connection on the ignition coil pri-

mary lead connectors [A].
Remove:
Spark Plugs (see Electrical System in Periodic Mainte-
nance chapter)
Attach the compression gauge [A] and adapter [B] firmly

into the spark plug hole.
Using the starter motor, turn the engine with the throttle
fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
Special Tools - Compression Gauge, 20 kgf/cm: 57001-221
Compression Gauge Adapter, M10 1.0:
57001-1317
Cylinder Compression
Usable Range: 1 185 1 795 kPa (12.1 18.3 kgf/cm,
172 260 psi) @430 r/min (rpm)
Repeat the measurement for the other cylinders.

Maintenance
Install the spark plugs (see Electrical System in Periodic
chapter).
Tighten:
Torque - Spark Plugs: 13 Nm (1.3 kgfm, 113 inlb)
Reconnect the primary ignition coil lead connectors, not-

ing the #1,#4 [A] and the #2, #3 [B] coil connectors. the
#1, #4 coil connector has a red/yellow and a green/blue
leads from the main harness. The #2, #3 coil connec-
tor has a red/yellow and green/black leads from the main
harness.
NOTE
The service codes (COIL1 and COIL2) caused by this
procedure are stored in the ECU. If necessary, these
service codes can be erased by using the Kawasaki
Diagnostic System (KDS).

ENGINE TOP END 6-23
Cylinder Head
The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem Diagnosis Remedy (Action)
Cylinder Carbon accumulation on piston and in Remove the carbon deposits
compression is combustion chamber possibly due to and replace damaged parts if
higher than usable damaged valve stem oil seal and/or necessary.
range damaged piston oil rings (This may be
indicated by white exhaust smoke).
incorrect cylinder head gasket thickness. Replace the gasket with a
standard part.
Cylinder Gas leakage around cylinder head Replace damaged gasket and
compression is check cylinder head warp.
lower than usable Bad condition of valve seating Repair if necessary.
range
incorrect valve clearance Adjust the valve clearance.
incorrect piston/cylinder clearance Replace the piston and/or cylinder
Piston seizure Inspect the cylinder and
replace/repair the cylinder
and/or piston as necessary.
Bad condition of piston ring and/or piston Replace the piston and/or the
ring grooves piston rings.
Cylinder Head Removal

Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Unscrew the crankshaft sensor cover bolts [A] and re-
move the crankshaft sensor cover [B].
Drain the engine oil by one liter.
Turn the crankshaft clockwise and set the crankshaft at

#1, 4 piston TDC.
TDC Mark [A] for #1, 4 pistons
Timing Mark [B] (Crankcase halves mating surface)
Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Camshafts (see Camshaft Removal)

6-24 ENGINE TOP END
Cylinder Head
Remove:
Engine Hook Bolts [A]
Engine Hook [B]
Cylinder Head Bolts [C]
Remove:
Upper Dipstick Tube Bolts [A]
Upper Exhaust Side Camshaft Chain Guide Bolt [B]
M7 Cylinder Head Bolts [C]
Remove the M11 cylinder head bolts [A] and washers.

Take off the cylinder head.
Cylinder Head Installation

NOTE
The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.
Replace that the O-rings [A] of the oil pipe [B] and apply
molybdenum disulfide oil solution to them.
Verify that the oil pipe [A] is installed properly.

Install a new cylinder head gasket [B], and knock pins [C].

ENGINE TOP END 6-25
Cylinder Head
Apply molybdenum disulfide oil solution [A] to both sides

of the M11 cylinder head bolt washers [B] and the thread
of head bolts [C].
Install the cylinder head.

tightening sequence
First, tighten the M11 cylinder head bolts following the
[1 10].
Torque - Cylinder Head Bolts (M11):
First: 23 Nm (2.3 kgfm, 17 ftlb)
Final: 59 Nm (6.0 kgfm, 43 ftlb)
Next, tighten the M7 cylinder head bolts following the
tightening sequence [11 12].
Torque - Cylinder Head Bolts (M7): 20 Nm (2.0 kgfm, 14
ftlb)
Lastly, tighten the M6 cylinder head bolts following the
tightening sequence [13 14].
Torque - Cylinder Head Bolts (M6): 12 Nm (1.2 kgfm, 104
inlb)

O-ring
Install:
Upper Exhaust Side Camshaft Chain Guide Bolt [B]

Tighten:
Torque - Exhaust Side Camshaft Chain Guide Bolt (Upper):
25 Nm (2.5 kgfm, 18 ftlb)
Install the camshafts (see Camshaft Installation).
Cylinder Head Warp
Remove the cylinder head (see Cylinder Head Removal).
Lay a straightedge
Clean the cylinder head.
head at several positions.
across the lower surface of the cylinder
Measure the space between the straightedge [A] and the

head with a thickness gauge [B].
Cylinder Head Warp
Standard:
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).

6-26 ENGINE TOP END
Valves
Valve Clearance Check
Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.
Valve Removal
Remove the cylinder head (see Cylinder Head Removal).
Mark andthe
Remove valve lifter and shim.
record the valve lifter and shim locations so they
can be installed in their original positions.
Using
valve.
the valve spring compressor assembly, remove the
Special Tools - Valve Spring Compressor Assembly: 57001

-241 [A]
Valve Spring Compressor Adapter, 22:
57001-1202 [B]
Valve Installation
Replace the oil seal with a new one.
valve stem coat
Apply thin of molybdenum disulfide grease to the
before valve installation.
Install
wards.
the springs so that the closed coil end faces down-
Valve Spring Paint Color: EX-Red

IN-Blue
[A] Valve Stem
[B] Oil Seal
[C] Spring Seat
[D] Closed Coil End
[E] Valve Springs (Inner)
[F] Valve Springs (Outer)
[G] Retainer
[H] Split Keepers
Valve Guide Removal
Remove:
Valve (see Valve Removal)
Oil Seal
Spring Seat
Heat the area around the valve guide to 120 150C (248
302F), and hammer lightly on the valve guide arbor [A]
to remove the guide from the top of the head.
NOTICE
Heating the cylinder head with a torch will warp the
head. To prevent warping the cylinder head, soak it
in hot oil.
Special Tool - Valve Guide Arbor, 5: 57001-1203

ENGINE TOP END 6-27
Valves
Valve Guide Installation
Apply engine oil to the valve guide outer surface before
installation.
Heat the area around the valve guide hole to about 120
150C (248 302F).
Drive the valve guide in from the top of the head using the
valve guide arbor. The flange stops the guide from going
in too far.
Special Tool - Valve Guide Arbor, 5: 57001-1203
Ream the valve guide with valve guide reamer [A] even if
the old guide is reused.
Special Tool - Valve Guide Reamer, 5: 57001-1204
Valve-to-Guide Clearance Measurement (Wobble

Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve
guide clearance.
Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
NOTE
The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)

Standard:
Exhaust 0.09 0.17 mm (0.0035 0.0067 in.)
Inlet 0.03 0.11 mm (0.0012 0.0043 in.)
Service Limit:
Exhaust 0.35 mm (0.014 in.)
Inlet 0.29 mm (0.011 in.)

6-28 ENGINE TOP END
Valves
Valve Seat Inspection
Remove the valve (see Valve Removal).
Check the valve seating surface [A] between the valve [B]
and valve seat [C].
Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Valve Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust 27.6 27.8 mm (1.087 1.094 in.)
Inlet 32.6 32.8 mm (1.283 1.291 in.)
Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust 0.8 1.2 mm (0.03 0.047 in.)
Inlet 0.5 1.0 mm (0.02 0.039 in.)
Valve Seat Repair

Repair the valve seat with the valve seat cutters [A].
Valve Seat Cutter Holder, 5:
Special Tools-
57001-1208 [B]
Valve Seat Cutter Holder Bar:
57001-1128 [C]
[For Inlet Valve Seat]
Valve Seat Cutter, 45 - 35:
57001-1116
57001-1121
57001-1247
[For Exhaust Valve Seat]
57001-1187
57001-1120
57001-1123
If the manufacturers instructions are not available, use
the following procedure.

ENGINE TOP END 6-29
Valves
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60 ........................... Cutter angle [B]
37.5 ....................... Outer diameter of cutter [C]
Operating Procedures
Clean the seat area carefully.
Coat the seat with machinists dye.
Fit a 45 cutter into the holder and slide it into the valve
guide.
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
NOTICE
Overgrinding the seat will reduce valve clearance
by sinking the valve into the head. If the valve sinks
too far into the head, it will be impossible to ad-
just the clearance, and the cylinder head must be
replaced. Do not overgrind the seat.

6-30 ENGINE TOP END
Valves
Measure the outside diameter of the seating surface with

a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45 grind until the diameter is within the spec-
ified range.
Widened Width [A] of engagement by machining with
45 cutter
Ground Volume [B] by 32 cutter
32 [C]
Correct Width [D]
Ground Volume [E] by 60 or 55 cutter
60 or 55 [F]
Measure the outside diameter of the seating surface with

a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45 grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
Remove all pittings of flaws from 45 ground surface.
After grinding with 45 cutter, apply thin coat of machin-
ists dye to seating surface. This makes seating surface
distinct and 32 and 60 grinding operation easier.
When the valve guide is replaced, be sure to grind with
45 cutter for centering and good contact.
If the outside diameter [A] of the seating surface is too
large, make the 32 grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described be-
low.
Grind the seat at a 32 angle [B] until the seat outside
diameter is within the specified range.
To make the 32 grind, fit a 32 cutter into the holder, and
slide it into the valve guide.
Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
NOTICE
The 32 cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
After making the 32 grind, return to the seat outside di-
ameter measurement step above.
To measure the seat width, use a vernier caliper to mea-
sure the width of the 45 angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45 grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.

ENGINE TOP END 6-31
Valves
If the seat width is too wide, make the 60 or 55 [A] grind
described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
Grind the seat at a 60 or 55 angle until the seat width is
within the specified range.
To make the 60 or 55 grind, fit 60 or 55 cutter into the
holder, and slide it into the valve guide.
Turn the holder, while pressing down lightly.
After making the 60 or 55 grind, return to the seat width
measurement step above.
Correct Width [B]
Lap the valve to the seat, once the seat width and outside
diameter are within the ranges specified above.
Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
Repeat the process with a fine grinding compound.
[A] Lapper
[B] Valve Seat
[C] Valve
The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
Be sure to remove all grinding compound before assem-
bly.
When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Inspection in the Periodic
Maintenance chapter).

6-32 ENGINE TOP END
Valves

ENGINE TOP END 6-33
Cylinder, Pistons
Cylinder Removal
Drain the engine oil (see Periodic Maintenance chapter).
Remove:
Cylinder Head (see Cylinder Head Removal)
Dipstick Tube Bolts [A]
Dipstick Tube [B]
JT1500-A1 A8 Models
Remove:
Breather Case Mounting Bolts [A]
Clamp [B]
Breather Case (with Hose)
Oil Hose
JT1500A9 Model
Remove:
Clamp [A]
Oil Hose [B]
Remove:
Camshaft Chain Guide Bolts [A]
Camshaft Chain Guide [B]
Cylinder [C]
Piston Removal
Remove the cylinder (see Cylinder Removal).
ton pin snap ring
Place a clean cloth under the pistons and remove the pis-
[A] from the outside of each piston.
NOTICE
Snap rings are weakened and deform when re-
moved and may fall out, scoring the cylinder wall
and causing severe engine damage. Do not re-use
snap rings, always replace them.

6-34 ENGINE TOP END
Cylinder, Pistons
Remove the piston pins with a piston pin puller [A].

Special Tool - Piston Pin Puller Assembly: 57001-910
Remove the pistons.
Carefully spread the ring opening with your thumbs and

then push up on the opposite side of the ring [A] to remove
it.
Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston/Cylinder Installation
NOTE
If a new cylinder is used, use new piston rings.
If new pistons and/or a new cylinder are installed, apply
thin coat of molybdenum disulfide oil solution to the new
pistons and cylinder bores.
Install the oil ring expander [A] in the bottom piston ring
groove so the ends [B] butt together.
Install the oil ring steel rails, one above the expander and
one below it.
Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
Release the rail into the bottom piston ring groove.
NOTE
The oil ring rails have no top or bottom.
Do not mix up the top and second ring.
Install the
Install the top ring [A] so that the "R" mark [B] faces up.
second ring [C] so that the "RN" mark [D] faces
up.
Apply molybdenum disulfide oil solution to the piston
rings.

ENGINE TOP END 6-35
Cylinder, Pistons
NOTE
If a new piston is used, use new piston ring.
Install the piston with its dent mark facing exhaust side.
so that thepiston
Fit a new pin snap ring into the side of the piston
ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
Apply molybdenum disulfide oil solution to the piston pins
and piston journals.
When installing the piston pin snap ring, compress it only
enough to install it and no more.
NOTICE
Snap rings are weakened and deform when re-
moved and may fall out, scoring the cylinder wall
and causing severe engine damage. Do not re-use
snap rings, always replace them.
The piston ring openings must be positioned as shown in

the figure. The openings of the oil ring steel rails must be
about 30 40 of angle from the opening of the top ring.
[A] Top Ring
[B] Second Ring
[C] Oil Ring Steel Rails
[D] Oil Ring Expander
[E] Dent (Exhaust Side)
Replace the cylinder gasket with a new one, and install

the pins [A] and new cylinder gasket.
Exhaust Side [B]
Apply molybdenum disulfide oil solution to the cylinder
bore, external of pistons and piston rings.
Insert the piston in the cylinder by two methods.

With the Hand
Position the crankshaft at #2, #3 piston TDC.
Install the two cylinder head bolts [A] diagonally in the
crankcase.
Install the cylinder block [B].
Pistons [C]
insert the #2, #3 pistons, and then rotate the crank-
First
shaft at 90 angle.
Insert the piston rings with your thumbs or the thin ()
screw driver.

6-36 ENGINE TOP END
Cylinder, Pistons
With the Special Tools
Install the two cylinder head bolts [A] diagonally in the
crankcase.
Slip the piston bases [B] under the pistons to hold them
level.
Compress the piston rings using the piston ring compres-
sor grips [C] and piston ring compressor belts [D] with
chamfered side upward.
Special Tools - Piston Base, 8: 57001-1604
Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt, 80 91:
57001-1320
Push down vigorously the cylinder aligning the cylinder

bores with all the piston heads.
Install the cylinder so that its angle aligns the piston angle
after removing the piston ring compressor belts.
Cylinder Wear
Since there is a difference in cylinder wear in different di-
rections, take a side-to-side and a front-to-back measure-
ment at each of the two locations (total of four measure-
ments) shown in the figure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the cylinder.
[A] 10 mm (0.39 in.)
[B] 60 mm (2.36 in.)
Cylinder Inside Diameter
Standard: 82.994 83.006 mm (3.2675 3.2679 in.)
Piston Wear
Measure the outside diameter [A] of each piston 18 mm
(0.71 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is less than the service limit, replace
the piston.
Piston Diameter
Standard: 82.919 82.934 mm (3.2645 3.2651 in.)

ENGINE TOP END 6-37
Cylinder, Pistons
Piston Ring, Piston Ring Groove Wear
Check
ing.
for uneven groove wear by inspecting the ring seat-
The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top 0.03 0.07 mm (0.0012 0.0028 in.)
Second 0.02 0.06 mm (0.0008 0.0024 in.)
Service Limit:
Top 0.17 mm (0.0067 in.)
Second 0.16 mm (0.0063 in.)
Piston Ring Groove Width

Measure the piston ring groove width.
Use a vernier caliper at several points around the piston.
Standard:
Top [A] 0.92 0.94 mm (0.0362 0.0370 in.)
Second [B] 1.01 1.03 mm (0.0398 0.0406 in.)
Service Limit:
Top [A] 1.02 mm (0.0402 in.)
Second [B] 1.11 mm (0.0437 in.)
If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.
Piston Ring Thickness
Measure the piston ring thickness.
Use the micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top [A] 0.87 0.89 mm (0.0343 0.0350 in.)
Second [B] 0.97 0.99 mm (0.0382 0.0390 in.)
Service Limit:
Top [A] 0.80 mm (0.0315 in.)
Second [B] 0.90 mm (0.0354 in.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.

6-38 ENGINE TOP END
Cylinder, Pistons
Piston Ring End Gap
Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.
Measure the gap between the ends of the ring with a thick-
ness gauge [B].
Piston Ring End Gap
Standard:
Top 0.25 0.40 mm (0.0098 0.0157 in.)
Second 0.40 0.55 mm (0.0157 0.0217 in.)
Service Limit:
Top 0.7 mm (0.0276 in.)
Second 0.8 mm (0.0315 in.)
If the end gap of either ring is greater than the service
limit, replace all the rings.

ENGINE REMOVAL/INSTALLATION 7-1
Table of Contents
Exploded View........................................................................................................................ 7-2
Engine Removal/Installation ................................................................................................... 7-4
Engine Removal................................................................................................................ 7-4
Engine Damper Removal.................................................................................................. 7-5
Engine Damper Installation............................................................................................... 7-6
Engine Installation............................................................................................................. 7-6

7-2 ENGINE REMOVAL/INSTALLATION
Exploded View

Exploded View
Torque
No Fastener Remarks
Nm kgfm ftlb
1 Engine Mounting Bolts 36 3.7 27 L
2 Engine Damper Mounting Bolts 16 1.6 12 L

Engine Removal
Remove:
Oil Separator Tank (see Lubrication Sytem)
Plug the hose end [A].
If the engine disassembles, drain the oil (see Engine Oil
Change in Periodic Maintenance chapter).
Remove:
Exhaust Manifold (see Exhaust System chapter)
Bolts [A] and Ignition Coil Bracket
Remove:
Cooling Hoses [A]
The oil hose [B] is not necessary removal.
NOTE
If the oil is in the engine and the removed hose lies
down, the oil will flow out from hose end.
Remove:
Starter Motor Cables [A]
Cooling Hoses [B]
Disconnect:
Alternator Lead Connector [A]

Remove:
Engine Mounting Bolts [A]
Slide the engine toward the front to disengage the cou-

pling [A].
Using the lifter [A], raise the front side of the engine a little
and lift the engine [B] out off the hull [C].
Engine Damper Removal

Remove:
Engine Damper Mounting Bolts [A]
Engine Damper [B]
Shim [C] (0 2 pieces)
Bow [D]
Record the number of shims of four positions so they can
be put back in the same position.
NOTICE
Incorrect shims could cause drive shaft misalign-
ment. Install the shims to the same position.

Engine Damper Installation
Install the shim(s) of the same number.
Apply a non-permanent locking agent
damper mount bolts, and tighten them.
to the engine
Torque - Engine Damper Mounting Bolts: 16 Nm (1.6

kgfm, 12 ftlb)
Engine Installation
Be sure there are no foreign objects and parts inside of
the hull.
Clean the bilge filter (see Filter Cleaning and Inspection
in Cooling and Bilge Systems chapter).
Check the coupling damper for wear damage (see Cou-
pling Damper Inspection in Periodic Maintenance chap-
ter).
Install the inlet manifold (see Fuel System chapter).

mounting
Apply a non-permanent locking agent to the engine
bolts, and tighten them.
After installing the engine in the hull, check the following.

Throttle Cable
Fuel and Exhaust Leaks
DANGER
NOTICE

ENGINE BOTTOM END 8-1
Engine Bottom End

Table of Contents
Exploded View........................................................................................................................ 8-2
Specifications ......................................................................................................................... 8-4
Special Tools and Sealant ...................................................................................................... 8-7
Coupling ................................................................................................................................. 8-8
Coupling/Output Shaft Removal ....................................................................................... 8-8
Coupling/Output Shaft Installation .................................................................................... 8-9
Coupling Damper Inspection............................................................................................. 8-10
Output Cover Oil Seal Replacement................................................................................. 8-11
Oil Seal Inspection ............................................................................................................ 8-11
Magneto Cover Bearing Replacement.............................................................................. 8-11
Ball Bearing Lubrication .................................................................................................... 8-11
Ball Bearing Inspection ..................................................................................................... 8-12
Magneto Flywheel .................................................................................................................. 8-13
Magneto Flywheel Removal.............................................................................................. 8-13
Magneto Flywheel Installation........................................................................................... 8-13 8
Stator ...................................................................................................................................... 8-15
Stator Removal ................................................................................................................. 8-15
Stator Installation .............................................................................................................. 8-15
Crankcase Splitting................................................................................................................. 8-16
Crankcase Splitting ........................................................................................................... 8-16
Crankcase Assembly ........................................................................................................ 8-17
Crankshaft and Connecting Rods........................................................................................... 8-19
Crankshaft Removal ......................................................................................................... 8-19
Crankshaft Installation ...................................................................................................... 8-19
Connecting Rod Removal ................................................................................................. 8-20
Connecting Rod Installation .............................................................................................. 8-20
Connecting Rod Bend....................................................................................................... 8-24
Connecting Rod Twist ....................................................................................................... 8-24
Connecting Rod Big End Side Clearance ......................................................................... 8-24
Connecting Rod Big End Bearing Insert/Crankpin Wear .................................................. 8-25
Crankshaft Main Bearing Insert/Journal Wear .................................................................. 8-26
Crankshaft Side Clearance ............................................................................................... 8-29
Crankshaft Runout ............................................................................................................ 8-29

8-2 ENGINE BOTTOM END
Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Crankshaft Sensor Cover Bolts 7.8 0.80 69 inlb
2 Engine Bracket Mounting Bolts 32 3.3 24 L
3 Timing Rotor Bolt 29 3.0 22 L
4 Connecting Rod Nuts MO, see text
5 Oil Passage Plugs 20 2.0 14 L
6 Stator Mounting Bolts 12 1.2 104 inlb L
7 Grommet Cover Bolts 9.8 1.0 87 inlb L
8 Magneto Cover Bolts 20 2.0 14
9 Output Cover Bolts 7.8 0.80 69 inlb
Output Shaft (JT1500-A1 A9 Early Models) 245 25.0 180 MO
10
Output Shaft (JT1500A9 Late Model ) 265 27.0 195 MO
11 Coupling 98 10 72
12 Crankcase Bolts (M10) 50 5.0 36 MO, S
13 Crankcase Bolts (M8) 29 3.0 22 MO, S
14 Crankcase Bolts (M8) 29 3.0 22 S
15 Crankcase Bolts (M6) 12 1.2 104 inlb S
16. JT1500-A1 A6 Models
17. JT1500-A1 AB Models
18. JT1500-A1 AB Models (Engine No.; JTT50AE036455)
18. JT1500-AB AC Models (Engine No.; JTT50AE036456 )
D: Do not apply any grease or oil.
G: Apply grease.
LG: Apply liquid gasket (Liquid Gasket, TB1215B: 92104-1062).
R: Replacement Parts.
WG: Apply water resistant grease.

Specifications

Crankshaft, Connecting Rods
Connecting Rod Bend 0.2/100 mm
(0.008/3.94 in.)
Connecting Rod Twist 0.2/100 mm
(0.008/3.94 in.)
Connecting Rod Big End Side Clearance 0.13 0.38 mm 0.58 mm
(0.0051 0.0150 in.) (0.023 in.)
Connecting Rod Big end Bearing 0.041 0.071 mm 0.11 mm
Insert/crankpin Clearance (0.0016 0.0028 in.) (0.0043 in.)
Crankpin Diameter: 38.984 39.000 mm 38.97 mm
(1.5348 1.5354 in.) (1.534 in.)
Marking:
None 38.984 38.992 mm
(1.5348 1.5351 in.)
38.993 39.000 mm
(1.5352 1.5354 in.)
Connecting Rod Big End Bore Diameter: 42.000 42.016 mm
(1.6535 1.6542 in.)
Marking
None 42.000 42.008 mm
(1.6535 1.65386 in.)
42.009 42.016 mm
(1.65389 1.6542 in.)
Connecting Rod Big End Bearing Insert
Thickness:
Brown 1.475 1.480 mm
(0.05807 0.05827 in.)
Black 1.480 1.485 mm
(0.05827 0.05846 in.)
Blue 1.485 1.490 mm
(0.05846 0.05866 in.)
Connecting Rod Big End Bearing Insert Selection (TJ1500-A1 AB Models)
Con-rod Big Bearing Insert

Crankpin
End Bore
Diameter
Diameter Size Color Part Number
Marking
Marking
None Brown 92139-3710
None None
Black 92139-3709

None Blue 92139-3708

Specifications

Connecting Rod Big End Bearing Insert Selection (JT1500AC Model)
Connecting Bearing Insert

Rod Big Crankpin
End Inside Diameter
Diameter Marking Size Color Part Number
Marking
None Pink 92139-0724
None None
Yellow 92139-0723

None Green 92139-0722
Crankshaft Side Clearance 0.05 0.24 mm 0.44 mm

(0.0020 0.0094 in.) (0.017 in.)
Crankshaft Runout TIR 0.03 mm (0.0012 in.) or less TIR 0.07 mm
(0.0028 in.)
Crankshaft Main Bearing Insert/journal 0.030 0.054 mm 0.08 mm
Clearance (0.0012 0.0021 in.) (0.0032 in.)
Crankshaft Main Journal Diameter: 40.984 41.000 mm 40.96 mm
(1.6135 1.6142 in.) (1.613 in.)
Marking
None 40.984 40.992 mm
(1.6135 1.61385 in.)
1 40.993 41.000 mm
(1.61389 1.6142 in.)
Crankcase Main Bearing Bore Diameter: 44.000 44.016 mm
(1.7323 1.7329 in.)
Marking
44.000 44.008 mm
(1.7323 1.73259 in.)
None 44.009 44.016 mm
(1.73263 1.7329 in.)
Crankshaft Main Bearing Insert Thickness:
Brown 1.490 1.494 mm
(0.05866 0.05882 in.)
Black 1.494 1.498 mm
(0.05882 0.05898 in.)
1.498 1.502 mm
Blue (0.05898 0.05913 in.)

Specifications

Crankshaft Main Bearing Insert Selection (JT1500-A1 AB Models)
Crankcase Crankshaft Bearing Insert*

Main Bearing Main Journal
Bore Diameter Diameter Size Color Part Number Journal Nos.
Marking Marking
92139-3704 1, 5
1 Brown 92139-3713 3
92139-3707 2, 4
None 92139-3703 1, 5
Black 92139-3712 3
None 1
92139-3706 2, 4
92139-3702 1, 5
None None Blue 92139-3711 3
92139-3705 2, 4
*The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.
Crankshaft Main Bearing Insert Selection (JT1500AC Model)
Crankcase Crankshaft Bearing Insert*

Main Bearing Main Journal
Bore Diameter Diameter Size Color Part Number Journal Nos.
Marking Marking
92139-0727 1, 5
1 Pink 92139-0730 2, 4
92139-0733 3
None 92139-0726 1, 5
Yellow 92139-0729 2, 4
None 1
92139-0732 3
92139-0725 1, 5
None None Green 92139-0728 2, 4
92139-0731 3

Oil Seal & Bearing Remover: Output Shaft Wrench, Hex 36:
57001-1058 57001-1550
Bearing Driver Set: Grip:

57001-1129 57001-1591
Coupling Holder #2: Flywheel & Pulley Holder:

57001-1423 57001-1605
Rotor Holder: Rotor Puller:

57001-1544 57001-1623
Holder Attachment: Liquid Gasket, TB1215B:

57001-1547 92104-1062

Coupling
Coupling/Output Shaft Removal
Remove:
Crankshaft Sensor Cover (see Electrical System chap-
ter)
Holding the timing rotor, unscrew the coupling.
Special Tools - Flywheel & Pulley Holder: 57001-1605 [A]
Holder Attachment: 57001-1547 [B]
Coupling Holder #2: 57001-1423 [C]
If the coupling [A] and output shaft [B] removed together,

holding the coupling, unscrew the output shaft with the
output shaft wrench [C].
Collar [D]
Special Tool - Output Shaft Wrench, Hex 36: 57001-1550
Remove:
Output Cover Bolts [A]
Output Cover [B]
Remove:
Magneto Cover Bolts [C]
Magneto Cover

Coupling
Using the rotor holder [A], remove the output shaft [B].
Special Tool - Rotor Holder: 57001-1544
Coupling/Output Shaft Installation

Apply molybdenum disulfide oil solution to the seating sur-
face of the output shaft.
Using the rotor holder [A], install the output shaft [B].
Tighten:
(JT1500-A1 A9 Early Models)
Torque - Output Shaft: 245 Nm (25.0 kgfm, 180 ftlb)
(JT1500A9 Late Model )
Apply silicone sealant [A] to the crankcase halves mating

surfaces on the magneto cover.
Be sure to install the dowel pins [B].
Apply grease to the O-ring [A], and fit the O-ring onto the
groove of the magneto cover [B].
Install the magneto cover.
Be sure to install the washer [C] and the spring [D] into
the hole [E] of the bushing.
Tighten:
Torque - Magneto Cover Bolts: 20 Nm (2.0 kgfm, 14 ftlb)
Apply grease to the O-ring [A] and collar inside.

inward.the collar [B] so that the chamfer side [C] faces
Install

Coupling
Install:
Pins [A]
Gasket [B]
Position the magnet lead [C] as shown.
Apply grease to the oil seal lip.

Run thethemagneto
Install output cover.
lead [A] between the magneto cover [B]
and the output cover [C] as shown.
Tighten:
Torque - Output Cover Bolts: 7.8 Nm (0.80 kgfm, 69 inlb)
Install the coupling by using the old timing rotor as a hold-

ing tool.
Special Tools - Flywheel & Pulley Holder: 57001-1605 [A]
Holder Attachment: 57001-1547 [B]
Coupling Holder #2: 57001-1423
Torque - Coupling: 98 Nm (10 kgfm, 72 ftlb)
Then remove the timing rotor. This removed rotor
should be stored as a special tool by grinding the letter
or marking an adequate mark for verifying.
Then install one new timing rotor. Use the following as a
new part.
Model Name Part No.
JT1500-A1 A6 21007-3730
JT1500A7 21007-3746
Install:
Crankshaft Sensor Cover
Coupling Damper Inspection
Refer to the Coupling Damper Inspection in the Periodic

Coupling
Output Cover Oil Seal Replacement
Remove:
Output Cover (see Coupling/Output Shaft Removal)
Using the bearing driver [A], remove the oil seals as a set.
Special Tool - Bearing Driver Set: 57001-1129
Replace the oil seals with new ones.

Pack greasecoat[B]grease
Apply thin to the oil seal lips [A].
the oil seal (flywheel side oiltheseal
between oil seal lip and housing of
[C]).
Install the coupling oil seal [D] so thatbottomed.
Press in the oil seals until they are
the manufacturers
marks [E] face coupling side.
Install the flywheel side oil seal so that the dust seal [F]
side face out.
Oil Seal Inspection

Inspect the oil seal.
Replace it if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.
Magneto Cover Bearing Replacement
NOTICE
Removing the ball bearing may damage it. Do not
remove the ball bearing unless absolutely neces-
sary.
Remove:
Magneto Cover (see Coupling/Output Shaft Removal)
ball bearing
Using the oil seal and bearing remover [A], remove the
from the magneto cover [B].
When removing the ball bearing, hold the magneto cover.
Special Tool - Oil Seal and Bearing Remover: 57001-1058
Using a press and the bearing driver set [A], install the
new bearing until it stops at the bottom of its housing.
Ball Bearing Lubrication

NOTE
Since the bearings are packed with grease and sealed
on both sides, lubrication is not required.

Coupling
Ball Bearing Inspection
NOTE
It is not necessary to remove the bearings for inspec-
tion. If the bearing is removed, it will need to be re-
placed with a new one.
Spin [A] it by hand to check its condition.

If it is noisy, does not spin smoothly, or has any rough
spots, it must be replaced.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.

Magneto Flywheel
Magneto Flywheel Removal
Remove:
ter)
Coupling (see Coupling/Output Shaft Removal)
Using the rotor puller [A], pull off the flywheel [B].
Special Tool - Rotor Puller: 57001-1623
Grip: 57001-1591 [C]
NOTICE
Hitting the head of the rotor puller may cause a loss
in rotor magnetism. To prevent a loss in rotor mag-
netism, do not hit the head of the rotor puller.
Magneto Flywheel Installation

Using a high-flash points solvents, clean off any oil or dirt
that may be on the crankshaft taper, and in the tapered
hole in the magneto flywheel.
Install the O-ring [A] directly as shown.
This face [C] is magneto flywheel side.
Fit the woodruff key [B] securely in the crankshaft before
installing the magneto flywheel.
If the reduction gear [D] is removed, apply a molybdenum
disulfide grease to both ends of its shaft.
Install the reduction gear and the washer [E].

Magneto Flywheel
Apply grease to the boss outside [A] of the magneto fly-

wheel [B].
10 mm (0.39 in.) [C]
Install the magneto flywheel.
NOTE
Confirm the magneto flywheel fit or not to the crankshaft
before tightening it with specified torque.
Install the output shaft and tighten it with 70 Nm (7.0
kgfm, 52 ftlb) of torque.
Remove the output shaft.
Check the tightening torque with rotor puller.
Special Tool - Rotor Puller: 57001-1623
Grip: 57001-1591
If the magneto flywheel is not pulled out with 20 Nm (2.0
kgfm, 52 ftlb) of drawing torque, it is installed correctly.
If the magneto flywheel is pulled out with under 20 Nm
(2.0 kgfm, 52 ftlb) of drawing torque, clean off any oil dirt
or flaw of the crankshaft and magneto flywheel tapered
portion, and dry them with a clean cloth. Then, confirm
that it is not pulled out with above torque.
Tighten the output shaft while holding the magneto fly-
wheel steady with the rotor holder.
(JT1500-A1 A9 Early Models)
(JT1500A9 Late Model )
Install:
Magneto Cover (see Coupling/Output Shaft Installation)

Stator
Stator Removal
Remove:
Grommet Cover Mounting Bolts [A]
Grommet Cover [B]
Stator Mounting Bolts [C] with Washers
Stator Assembly [D]
Stator Installation
Apply
met.
water resistant grease to the outside of the grom-
Apply a non-permanent locking agent to the grommet

cover bolts.
Tighten:
Torque - Grommet Cover Bolts: 9.8 Nm (1.0 kgfm, 87 inlb)
Apply a non-permanent locking agent to the stator mount-

ing bolts and put the washers.
Tighten:
Torque - Stator Mounting Bolts: 12 Nm (1.2 kgfm, 104
inlb)
When installing the stator, fix the stator lead to the groove
of the magneto cover.
Be sure to the stator lead have no slack and bite.

Crankcase Splitting
Crankcase Splitting
Remove:
Engine (see Engine Removal/Installation chapter).
Drain the engine oil (see Periodic Maintenance chapter).
Set the engine on a clean surface and hold the engine
steady while parts are being removed.
Suitable Props [A]
Lower Crankcase Projections [B]
Remove:
ter)
Cylinder Head (see Engine Top End chapter)
Piston (see Engine Top End chapter)
Starter Motor (see Electrical System chapter)
Oil Pump Bodies (see Engine Lubrication System chap-
ter)
Magneto Flywheel (see Magneto Flywheel Removal)
Oil Filter (see Periodic Maintenance chapter)
Remove the crankcase bolts.

First loosen the M6 bolts [1 4].
Next loosen the M8 bolts [5 17].
Last loosen the M10 bolts [18 23].
Using the pry points [A], split the crankcase halves.

Lift off the lower crankcase half.

Crankcase Splitting
Crankcase Assembly
NOTICE
The upper and lower crankcase halves are ma-
chined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
With high-flash point solvent, clean off the mating sur-

faces of the crankcases halves and wipe dry.
Using compressed air, blow out the oil passages in the
crankcase halves.
Install:
Crankshaft [A] and Connecting Rods (see Crankshaft
Installation)
Camshaft Chain [B]
Oil Pump Sprocket Chain [C]
Dowel Pins [D]
Oil Passage Pipe [E] with O-ring
Oil Seal [F]
Before fitting the lower case on the upper case, check the
following.
Be sure to hang the camshaft and oil pump sprocket chain
on the crankshaft.
Check to see that the oil seal [A] is in the groove [B] of the
crankcase.
Apply liquid gasket [A] to the mating surface of the lower

crankcase half.
NOTE
Make the application finish within 30 minutes when
the liquid gasket to the mating surface of the lower
crankcase half is applied.
Moreover fit the case and tighten the case bolts just
after finishing the application of the liquid gasket.
Sealant - Liquid Gasket, TB1215B: 92104-1062
NOTICE
Do not apply liquid gasket around the crankshaft
main bearing inserts [B], and oil passage hole [C].

Crankcase Splitting
Install the oil pump sprocket chain [A] on the chain guide
[B] of the lower crankcase [C].
Apply molybdenum disulfide oil solution to the bolt seating

surfaces [A] on the lower crankcase for the M10 bolts [B]
and M8 [7 10] bolts [C].
Tighten the crankcase bolts.

Following the sequence numbers on the lower crankcase
half, tighten the M10 bolts [1 6].
Torque - Crankcase Bolts (M10): 50 Nm (5.0 kgfm, 36 ftlb)
Following the sequence numbers, tighten the M8 bolts [7
10].
19].
23].
Torque - Crankcase Bolts (M6): 12 Nm (1.2 kgfm, 104 inlb)
After
item.
tightening all crankcase bolts, check the following
Crankshaft turn freely.

Crankshaft and Connecting Rods
Crankshaft Removal
Split the crankcase (see Crankcase Splitting).
Remove:
Camshaft Chain [A]
Oil Pump Sprocket Chain [B]
Remove the crankshaft [C] with the oil seal [D].
Crankshaft Installation
NOTICE
If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with a plastigage
before assembling engine to be sure the correct
bearing inserts are installed.
Fit the crankshaft main bearing inserts on the upper [A]

and lower [B] crankcase halves.
#1, 5 Bearing Inserts (no Groove, same)
#2, 4 Bearing Inserts (Groove, same)
#3 Bearing Insert (no Groove)
NOTE
Be sure the bearing inserts are seated in the saddles,
and the tangs in the bearing inserts are aligned with the
notches in the saddles.
Apply molybdenum disulfide oil solution to the crankshaft

main bearing inserts.
Fit the thrust washers [A] to both sides of the upper

crankcase #3 main bearing [B].
Install the thrust washer so that the oil grooves [C] face
outward.

Install the crankshaft with the oil pump sprocket chain [A]
and camshaft chain [B] hanging on them.
Fit the oil seal [A] into the groove [B] of the crankcase.
Assemble the crankcase (see Crankcase Assembly).
Connecting Rod Removal

Split the crankcase (see Crankcase Splitting).
Remove the
Remove connecting rod nuts [A].
the crankshaft.
NOTE
Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.
Remove the connecting rods from the crankshaft.

Connecting Rod Installation
WARNING
Gasoline and low flash-point solvents are extremely
flammable and can be explosive under certain con-
ditions. To prevent a fire or explosion, clean the
crankshaft, bolts, nuts and connecting rods in a
well-ventilated area with a high flash-point solvent
away from any ignition sources, including any ap-
pliance with a pilot light.
After removing the connecting rods from the crankshaft,

clean them with high-flash point solvent.
Blow the crankshaft oil passages with compressed air to
remove any foreign particles or residue that may have
accumulated in the passages.

NOTICE
Using connecting rods with different weight marks
increases engine vibration. To minimize vibration,
the connecting rods should have the same weight
mark.
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark [D]
If the connecting rods, big end bearing inserts, or crank-
shaft are replaced with new ones, select the bearing insert
and check clearance with a plastigage before assembling
engine to be sure the correct bearing inserts are installed.
NOTICE
Connecting rod bolts are designed to stretch when
tightened; reusing them can lead to catastrophic
engine failure. Never reuse connecting rod bolts.
See the table below for correct bolt and nut usage.
Apply grease and oil to the following portions.

Apply molybdenum disulfide grease [A].
Do not apply grease and oil [B].
Apply molybdenum disulfide oil solution [C].
NOTICE
Do not apply grease to the inner surface of the lower
big end cap or to the outer surface of the lower bear-
ing insert.
Install the bearing insert as shown to prevent its outer

surface from scratch damage with connecting rod edge.
Connecting Rod Side Bearing Insert [A]
Dowel Pin [B]
Claw Side [C]
Cap Side Bearing Insert [D]
Connecting Rod Cap [E]
Replace
new ones.
the connecting rod big end bolts and nuts with
Be sure to clean the bolts, nuts, and connecting rods

thoroughly with high-flash point solvent, because the new
connecting rods, bolts, and nuts are treated with anti-rust
solution.
NOTICE
Immediately dry the bolts and nuts with com-
pressed air after cleaning.
Clean and dry the bolts and nuts completely.

JT1500-A1 AB Models (Engine No.;
JTT50AE036455)
Apply small amount of molybdenum disulfide oil solution
to the threads [A] and seating surfaces [B] of the connect-
ing rod nuts.
First, tighten the nuts to the specified torque. See the

table below.
Next, tighten the nuts by 120 more.
Mark [A] the connecting rod big end caps and nuts so that
nuts can be turned 120 [B] properly.
Tighten the hexagon nut by 2 corners.
Connecting Torque + Angle Nm
Bolt, Nut
Rod Assy (kgfm, ftlb)
New Use the bolts and nuts 21.6 (2.2, 16) + 120
attached to new con-rod.
Another new bolts and
nuts.
Used Replace the bolts and 21.6 (2.2, 16) + 120
nuts with new ones
NOTICE
Since the connecting rod bolts are designed to
stretch when tightened, overtightening the nuts
will excessively stretch the bolts, weakening them
so that they may break and cause severe engine
damage. Do not overtighten the nuts.
JT1500-AB AC Models (Engine No.; JTT50AE036456

)
(1) Bolt Length Measurement Method
Install new bolts and nuts in reused connecting rods.
Dent both bolt head and bolt tip with a punch.
Apply molybdenum disulfide oil solution to the threads [A]
and seating surfaces [B] of the connecting rod nuts.

Before tightening, use a point micrometer to measure the

length of new connecting rod bolts and record the values
to find the bolt stretch.
Connecting Rod [A]
Dent here with a punch [B].
Nuts [C]
Fit micrometer pins into dents [D].
Apply a small amount of molybdenum disulfide oil to the
following.
Threads of Nuts and Bolts
Seating Surfaces of Nuts and Connecting rods
Tighten the big end nuts until the bolt elongation reaches
the length specified in the table.
Check the length of the connecting rod bolts.
If the stretch is more than the usable range, the bolt has
stretched too much. An overelongated bolt may break in
use.
Bolt Length after Bolt Length before
= Bolt Stretch
tightening tightening
Connect- Usable Range of

ing Rod Bolt Nut Connecting Rod
Assy Bolt Stretch
Use the bolts
Attached to 0.20 0.29 mm
attached to
New new con-rod (0.0098 0.0134
new con-rod.
in.)
New New
Replace the Replace the 0.20 0.29 mm
Used bolts with new nuts with new (0.0098 0.0134
ones. ones. in.)
(2) Rotation Angle Method

If you dont have a point micrometer, you may tighten the
nuts using the Rotation Angle Method.
Install new bolts and nuts in reused connecting rod.
Apply molybdenum disulfide oil solution to the threads [A]
and seating surfaces [B] of the connecting rod nuts.
First, tighten the nuts to the specified torque. See the

table below.
Next, tighten the nuts 120 5.
Mark [A] the connecting rod big end caps and nuts so that
nuts can be turned 120 [B] properly.
Connecting Torque + Angle
Bolt Nut
Rod Assy Nm (kgfm, ftlb)
Use the bolts
Attached to
attached to 18 (1.8, 13) + 120
New new con-rod
new con-rod.
New New 18 (1.8, 13) + 120
Replace the Replace the
Used bolts with nuts with new 18 (1.8, 13) + 120
new ones ones

Connecting Rod Bend
Remove the connecting rod big end bearing inserts, and
reinstall the connecting rod big end caps.
Select an arbor [A] of the same diameter as the connect-
ing rod big end, and insert the arbor through the connect-
ing rod big end.
Select an arbor of the same diameter as the piston pin
at least 100 mm (3.94 in.) long, and insert the arbor [B]
through the connecting rod small end.
On a surface plate, set the big-end arbor on V blocks [C].
Measure the difference in the heights of the arbor above
the surface plate over a 100 mm (3.94 in.) distance-on
the arbor to determine the amount of connecting rod bend
with the connecting rod held vertically, and using a height
gauge.
If connecting rod bend exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Bend
Service Limit: 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist

On surface plate, set the big-end arbor [A] on V block [C].
above thethesurface
Measure difference in the heights of the arbor [B]
plate over a 100 mm (3.94 in.) dis-
tance-on the arbor to determine the amount of connect-
ing rod twist with the connecting rod held horizontally, and
using a height gauge.
If connecting rod twist exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Twist
Service Limit: 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Big End Side Clearance

Measure connecting rod big end side clearance [A].
Insert a thickness gauge [B] between the big end and ei-
ther crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard: 0.13 0.38 mm (0.0051 0.0150 in.)
If the clearance exceeds the service limit, replace the con-
necting rod with a new one and then check clearance
again. If clearance is too large after connecting rod re-
placement, the crankshaft also must be replaced.

Connecting Rod Big End Bearing Insert/Crankpin
Wear
Measure the bearing insert/crankpin [B] clearance with a
plastigage [A].
NOTE
Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).
Do not move the connecting rod and crankshaft during
clearance measurement.
Connecting Rod Big End Bearing Insert/Crankpin

Clearance
Standard: 0.041 0.071 mm (0.0016 0.00280 in.)
If clearance is within the standard, no bearing replace-

ment is required.
If clearance is between 0.072 mm (0.00284 in.) and
the service limit (0.11 mm, 0.0043 in.), replace the
bearing inserts [A] with inserts painted blue [B]. Check
insert/crankpin clearance with the plastigage. The clear-
ance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard: 38.984 39.000 mm (1.5348 1.5354 in.)
If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankpin Diameter Marks
None 38.984 38.992 mm (1.5348 1.5351 in.)
38.993 39.000 mm (1.5352 1.5354 in.)
: Crankpin Diameter Marks, mark or no mark.

Measure the connecting rod big end bore diameter, and

mark each connecting rod big end in accordance with the
bore diameter.
Big End Cap [A]
Connecting Rod [B]
Weight Mark [C]: A letter of the alphabet
Bore Diameter Mark (Around Weight Mark) [D]: or
no mark.
NOTE
Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).
The mark already on the big end should almost coincide
with the measurement.
Connecting Rod Big End Bore Diameter Marks

None 42.000 mm 42.008 mm (1.6535 1.65386 in.)
42.009 42.016 mm (1.65389 1.6542 in.)
Select the proper bearing insert in accordance with the

combination coding of the connecting rod and crankshaft.
Install the new inserts in the connecting rod and check
insert/crankpin clearance with the plastigage.
JT1500-A1 AB Models
Con-rod Big End Crankpin Bearing Insert
Bore Diameter Diameter
Marking Marking Size Color Part Number
None Brown 92139-3710

None None
Black 92139-3709

None Blue 92139-3708
JT1500AC Model
Connecting Rod Crankpin Bearing Insert
Big End Inside Diameter
Diameter Marking Marking Size Color Part Number
None Pink 92139-0724

None None
Yellow 92139-0723

None Green 92139-0722
Crankshaft Main Bearing Insert/Journal Wear

Measure the bearing insert/journal [B] clearance with a
plastigage [A].
NOTE
Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
Do not turn the crankshaft during clearance measure-
ment.
Journal clearance less than 0.025 mm (0.0010 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.

Crankshaft Main Bearing Insert/Journal Clearance
Standard: 0.030 0.054 mm (0.0012 0.0021 in.)
If clearance is within the standard, no bearing replace-
ment is required.
If clearance is between 0.055 mm (0.022 in.) and the ser-
vice limit (0.08 mm, 0.0032 in.), replace the bearing in-
serts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing seizure.
If clearance exceeds the service limit, measure the diam-
eter of the crankshaft main journal.
Crankshaft Main Journal Diameter

Standard: 40.984 41.000 mm (1.6135 1.6142 in.)
If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None 40.984 40.992 mm (1.6135 1.61385 in.)
1 40.993 41.000 mm (1.61389 1.6142 in.)
: Crankshaft Main Journal Diameter Marks, "1" mark or

no mark.
Measure the main bearing bore diameter, and mark [B]

the upper crankcase half [A] in accordance with the bore
diameter.
Crankcase main bearing bore diameter marks are ""
mark and no mark.
NOTE
Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Bore Diameter Marks

44.000 44.008 mm (1.7323 1.73259 in.)
None 44.009 44.016 mm (1.73263 1.7329 in.)

Marking Position
Select the proper bearing insert in accordance with the

combination coding of the crankcase and crankshaft.
Install the new inserts in the crankcase halves and check
insert/journal clearance with the plastigage.
1500-A1 AB Models
Crankcase Main Crankshaft Main Bearing Insert*
Bearing Bore Journal Diameter
Diameter Marking Marking Size Color Part Number Journal No.
92139-3704 1, 5
1 Brown 92139-3713 3
92139-3707 2, 4
92139-3703 1, 5
None
Black 92139-3712 3
None 1 92139-3706 2, 4
92139-3702 1, 5
None None Blue 92139-3711 3
92139-3705 2, 4
1500AC Model
Crankcase Main Crankshaft Main Bearing Insert*
Bearing Inside Journal Diameter
Diameter Marking Marking Size Color Part Number Journal No.
92139-0727 1, 5
1 Pink 92139-0730 2, 4
92139-0733 3
92139-0726 1, 5
None
Yellow 92139-0729 2, 4
None 1 92139-0732 3
92139-0725 1, 5
None None Green 92139-0728 2, 4
92139-0731 3

Crankshaft Side Clearance
Insert a thickness gauge [A] between the thrust washer
[B] and the crank web [C] at the No. 3 main journal to
determine clearance.
If the clearance exceeds the service limit, replace the
thrust washer as a set and check the width of the crank-
shaft #3 main journal.
Crankshaft Side Clearance
Standard: 0.05 0.24 mm (0.0020 0.0094 in.)
Measure the crankshaft #3 main journal width [A].

If the measurement exceeds the standard, replace the
crankshaft [B].
Crankshaft #3 Main Journal Width
Standard: 27.45 27.55 mm (1.0807 1.0846 in.)
Crankshaft Runout
Measure the crankshaft runout.
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard: TIR 0.03 mm (0.0012 in.) or less
Service Limit: TIR 0.07 mm (0.0028 in.)

COOLING AND BILGE SYSTEMS 9-1

Table of Contents
Exploded View........................................................................................................................ 9-2
Bilge System........................................................................................................................... 9-4
Breather Removal ............................................................................................................. 9-4
Breather Installation .......................................................................................................... 9-4
Breather Cleaning and Inspection..................................................................................... 9-4
Filter Removal................................................................................................................... 9-4
Filter Installation................................................................................................................ 9-5
Filter Cleaning and Inspection .......................................................................................... 9-5
Cooling and Bilge System Hoses ........................................................................................... 9-6
Hose Removal .................................................................................................................. 9-6
Hose Installation ............................................................................................................... 9-6
Hose Inspection ................................................................................................................ 9-6
Cooling and Bilge System Flushing........................................................................................ 9-7
Cooling System Flushing .................................................................................................. 9-7
Bilge System Flushing ...................................................................................................... 9-7
Cooling and Bilge System Flow Diagram ............................................................................... 9-8
Water Pipe.............................................................................................................................. 9-12 9
Water Pipe Removal ......................................................................................................... 9-12
Water Pipe Installation ...................................................................................................... 9-12
After Submerging.................................................................................................................... 9-13
Summary Procedures after Submerging........................................................................... 9-14
Detailed Procedures after Submerging............................................................................. 9-15

9-2 COOLING AND BILGE SYSTEMS
Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Water Hose Joint (L Shape Type) 11 1.1 95 inlb L
2 Water Hose Joint (Straight Shape Type) 20 2.0 14 L
3 Water Hose Joint (Straight Shape Type) 11 1.1 95 inlb L
4 Cooling Hose Clamp Screws 2.5 0.25 22 inlb
5 Flushing Cap (JT1500A8 ) 0.90 0.092 8.0 inlb
6. Cylinder Head
7. Water Pipe
8. Cylinder Head Gasket
9. Cylinder
10. Oil Cooler
11. Output Cover
12. Exhaust Pipe
13. Exhaust Pipe Gasket
14. Exhaust Manifold
15. Exhaust Manifold Gasket
16. Bypass Outlet Nozzle
17. Plastic Clamp
18. Flushing Fitting
19. Detent
20. Bypass Outlet
21. Left Water Box Muffler
22. Right Water Box Muffler
23. Tail Pipe
24. Cooling Water Filter Cover
25. Cooling Water Filter
26. Pump
27. Bilge Breather
28. Bilge Filter
29. Pump Outlet
30. Protective Tube
31. Metal Clamp
A: JT1500-A2 Model
B: JT1500A6 Model
C: JT1500-A1 A6 Models
CY: Apply cyanoacrylate cement.
D: JT1500A7 Model
E: JT1500-A1 A8 Models
G: Apply grease.

Bilge System
Breather Removal
Remove:
Rear Storage Pocket
Pull the hoses [A] off the breather.
Unscrew the mounting bolts [B], and remove the
breathers [C].
Breather Installation
Be sure the small hole [A] in the breather is open before
installing it.
Apply a non-permanent locking agent to the breather
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.
If 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
Follow the next procedures to remove the right side filter
[A].
Remove the engine (see Engine Removal/Installation
chapter).
Pull the hose [B] off the filter.
Unscrew the mounting screw [C] and remove the filter.

Bilge System
Follow the next procedures to remove the left side filter
[D].
Remove the water box muffler [B] (see Exhaust System
chapter).
Pull the hose [C] off the filter.
Unscrew the mounting screw [A] and remove the filter.
Filter Installation
Align the projections [A] on the filters [B] with the holes
[C] on the brackets [D].
Filter Cleaning and Inspection

Flush
dry.
the filter thoroughly with fresh water and shake it
Water must flow freely through the filter, but large debris
must not.
If the filter cannot be cleaned, or if it is broken and allows
debris to pass through, replace it.

Cooling and Bilge System Hoses
Hose Removal
The majority of bilge hoses have no clamps at the hose
ends. The majority of bilge system hoses may be simply
pulled off their fittings.
NOTE
Some of the bilge system hoses have plastic clamps at
hose ends.
All the cooling system hoses are clamped at both ends.

Loosen the clamps and pull the hoses off.
Hose Installation
To install the bilge filter hose, push the hose over the end
of the filter.
NOTE
Some of the bilge system hoses have plastic clamps at
hose ends.
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
Refer to the Hose and Hose Connect Inspection in the
Periodic Maintenance chapter.

Cooling and Bilge System Flushing
Cooling System Flushing
Refer to the Cooling System Flushing in the Periodic
Bilge System Flushing
Refer to the Bilge System Flushing in the Periodic Main-
tenance chapter.

Cooling and Bilge System Flow Diagram
JT1500-A1 A8 Models

1. Cylinder Head
2. Water Pipe
4. Cylinder
5. Oil Cooler
6. Output Cover
7. Exhaust Pipe
9. Exhaust Manifold
12. Bypass Outlet
15. Tail Pipe
18. Pump
19. Bilge Breather
20. Bilge Filter
21. Pump Outlet
A. Direction of Cooling System Flow
B. Direction of Bilge System Flow
C. Direction of Combined Exhaust Gas and Cooling Water Flow
D: JT1500A7 Model

JT1500A9 Model

1. Cylinder Head
2. Water Pipe
4. Cylinder
5. Oil Cooler
6. Output Cover
7. Exhaust Pipe
9. Exhaust Manifold
12. Bypass Outlet
13. Water Box Muffler
14. Tail Pipe
17. Pump
18. Bilge Breather
19. Bilge Filter
20. Pump Outlet
A. Direction of Cooling System Flow
B. Direction of Bilge System Flow
C. Direction of Combined Exhaust Gas and Cooling Water Flow

Water Pipe
Water Pipe Removal
Remove the inlet manifold (see Fuel System).
Disconnect the cooling hose [A] onto the water hose joint.
Unscrew the mounting bolts [B] and remove the water
pipe [C] from the cylinder head [D].
Water Pipe Installation

Apply grease to the O-rings [A] and install the water pipe
with the mounting bolts.
toInstall cooling hose [B] (cylinder head water box muffler)
the water hose joint and secure the hose clamp [C].
Tighten:
Torque - Cooling Hose Clamp Screws: 2.5 Nm (0.25 kgfm,
22 inlb)

After Submerging
NOTICE
If water enters the engine it will cause severe dam-
age. Do not operate the watercraft with water in the
engine. Do not try to start the engine until it is com-
pletely empty of water. If water gets into the engine,
follow this procedure immediately! If water is left in
the engine more than a few hours, it will destroy the
crankshaft bearings and damage other internal en-
gine parts.
If the watercraft becomes swamped, water may enter the
engine through the throttle body. Water may also enter the
fuel tank.
The following procedures explain the necessary steps
you must provide.
Read the summary of the procedure first and then their
detailed procedures carefully.

After Submerging
Summary Procedures after Submerging

After Submerging
Detailed Procedures after Submerging
1. Remove the seat (see Hull/Engine Hood chapter).
2. Remove the drain screws in the stern to drain water
out of the engine compartment.
3. Remove the front storage pocket (see Hull/Engine
Hood chapter).
4. Disconnect both two connectors [A] on the primary
ignition leads located near the ignition coil.
5. Pull and remove all the spark plug caps.

6. Remove all spark plugs. (see Spark Plug Cleaning
and Inspection in Periodic Maintenance chapter)
7. Turn the ignition switch on, push the lanyard key un-
der the stop button, and push the start button.
8. If there is any water in the engine, it will be pumped
out of the spark plug holes [A]. Do not operate the
starter for longer than 5 seconds. Wait 15 seconds
before using it again. Be sure that all the water is out
of the engine.
WARNING
A water and gasoline mixture will be forcibly
ejected from the spark plug holes and could injure
your eyes. To prevent eye injury, do not lean over
the engine when performing this procedure. If gas
does get in your eyes, immediately wash them with
plenty of clean, fresh water and consult a physician
as soon as possible.
9. Remove the rear storage pocket, and check the air

filter [A] for water inside with its drain caps [B].
10. If you see water in the caps, remove both caps and
discharge the water. Be sure to have a rag or cloth
underneath for possible oily water. And proceed to
the next procedure (No.11).
NOTE
If you see water in the caps, there is a great possibility
that water has entered the inlet manifold. If there is no
water in the caps, then proceed to No.12.
11. Remove the drain plug [A] of the inlet manifold [B] and
discharge water, if any, into a rag or cloth. (If you do
not see water in the caps for the air filter mentioned
above, omit this procedure and proceed to the next
procedure, No.12).
12. Spray the spark plugs clean and install them with their
plug caps.

After Submerging
13. Reconnect the primary ignition coil lead connectors,
noting the #1,#4 [A] and the #2, #3 [B] coil connec-
tors. The #1, #4 coil connector has a red/yellow and
a green/blue leads from the main harness. The #2,
#3 coil connector has a red/yellow and green/black
leads from the main harness.
NOTE
14. Start the engine by pressing the start button and run
less than 15 seconds.
NOTICE
Running the engine with the watercraft out of the
water for more than 15 seconds at a time will cause
overheating resulting in engine and exhaust sys-
tem damage. To prevent engine and exhaust sys-
tem damage, do not run the engine with the water-
craft out of the water for more than 15 seconds at a
time. Never operate the engine at maximum speed
out of the water.
15. Remove the dipstick [A] and check for the water pres-
ence in the engine oil. (If there is water in it, oil looks
milky.)
16. If the oil looks milky, then change the oil and repeat
procedures 14 and 15 until the oil does not turn milky
any more.
17. If the engine does not start, there may be water in the
fuel system.

After Submerging
18. If the fuel tank has water in it, it must be emptied by
pump or siphon. Refill the tank with fresh fuel. Do not
dump contaminated fuel in places not designated for
that purpose.
WARNING
light.
WARNING
Gasoline is toxic and pollutes the environment. To
protect the environment, do not discard gasoline;
always return it to an authorized recycling center.
19. Continued trouble may require cleaning of the fuel line
to drain water.
20. Try to start the engine (procedure No.14) and proceed
to the procedures No.15 and 16.
21. Reinstall the seat and secure it.
22. Reinstall the drain screws in the stern.
23. Finally, run the watercraft IN WATER for at least 10
minutes to dry any remaining water and blow any for-
eign matter (like salt) out through the exhaust.

DRIVE SYSTEM 10-1
Drive System
Table of Contents
Exploded View........................................................................................................................ 10-2
Specification ........................................................................................................................... 10-4
Special Tools .......................................................................................................................... 10-5
Drive Shaft/Drive Shaft Holder ............................................................................................... 10-6
Drive Shaft Removal/Installation....................................................................................... 10-6
Drive Shaft Holder Removal/Disassembly ........................................................................ 10-6
Drive Shaft Holder Assembly/Installation.......................................................................... 10-7
Drive Shaft Runout............................................................................................................ 10-8
10

10-2 DRIVE SYSTEM
Exploded View

DRIVE SYSTEM 10-3
Exploded View
Torque
Nm kgfm ftlb
1 Coupling 265 27.0 195
2 Drive Shaft Holder Mounting Bolts 22 2.2 16 L
3 Coupling Cover Bolts 8.8 0.90 78 inlb L
WG: Apply water resistance grease.

10-4 DRIVE SYSTEM
Specification

Drive Shaft
Runout (see P10-8) [A] TIR 0.1 mm (0.0039 in.) or less TIR 0.2 mm (0.0079 in.)
[B] TIR 0.2 mm (0.0079 in.) or less TIR 0.6 mm (0.0236 in.)

DRIVE SYSTEM 10-5
Special Tools
Bearing Driver Set: Coupling Holder #2:
57001-1129 57001-1423

10-6 DRIVE SYSTEM
Drive Shaft/Drive Shaft Holder
Drive Shaft Removal/Installation
Remove
chapter).
Pull the drive shaft [A] out of the hull.
Hold the drive shaft in a vice, and unscrew the coupling.

Special Tool - Coupling Holder: 57001-1423 [A]
When
items.
installing the drive shaft, be careful of the following
Apply a non-permanent locking agent to the threads of

drive shaft and tighten the coupling.
Torque - Coupling: 265 Nm (27.0 kgfm, 195 ftlb)
Apply grease to the grease seal lips and the drive shaft
spline.
Drive Shaft Holder Removal/Disassembly
Remove the drive shaft.
shaft holderthe[B]mounting
Unscrew bolts [A] and remove the drive
from the bulkhead.
Disassemble the drive shaft holder.

Remove the circlip [A].

DRIVE SYSTEM 10-7
Press the small grease seal, and the large grease seals,
bearing, and small grease seals come out of the holder.
[A] Sleeve
[B] Blocks
[C] Press
Drive Shaft Holder Assembly/Installation

Replace the grease seals with new ones.
holder, noting
Press the bearing and grease seals into the drive shaft
the following.
Install the parts in this order.
Two Small Grease Seals [A]
One Bearing [B]
Two Large Grease Seals [C]
Front [D]
Install the seals so that the sides with the spring face out-
ward.
Fill the gaps between the seals with water resistance
grease [E].
Install the circlip [F].
Apply water resistance grease to the bearing inner sur-
face and grease seal lips.
Install the drive shaft holder on the bulkhead so that the

circlip side face toward the front.
Apply a non-permanent locking agent to the drive shaft
holder mounting bolts, tighten them loosely.
Install the drive shaft.
mounting bolts the
After installing engine, tighten the drive shaft holder
to the specified torque to give proper cou-
pling alignment.
Torque - Drive Shaft Holder Mounting Bolts: 22 Nm (2.2
kgfm, 16 ftlb)
Make sure the clearance [A] between the engine coupling
[B] and the drive shaft coupling [C] is 3 5 mm (0.12
0.20 in.).

10-8 DRIVE SYSTEM
Drive Shaft Runout
Measure drive shaft runout by supporting the shaft on V
blocks and setting a dial gauge against the shaft at each
point shown.
Turn the drive shaft slowly. The difference between the
highest and lowest dial gauge reading is the runout.
If any measurement exceeds the service limit, replace the
shaft.
Drive Shaft Runout
Standard: TIR 0.1 mm (0.0039 in.) or less [A]
TIR 0.2 mm (0.0079 in.) or less [B]
Service Limit: TIR 0.2 mm (0.0079 in.) [A]
TIR 0.6 mm (0.0236 in.) [B]

PUMP AND IMPELLER 11-1
Pump and Impeller

Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Special Tools and Sealant ...................................................................................................... 11-5
Pump and Impeller ................................................................................................................. 11-6
Pump Removal ................................................................................................................. 11-6
Pump Installation .............................................................................................................. 11-7
Pump Disassembly ........................................................................................................... 11-10
Pump Assembly ................................................................................................................ 11-13
Impeller Inspection............................................................................................................ 11-17
Impeller Outside Diameter Measurement ......................................................................... 11-17
Pump Inspection ............................................................................................................... 11-17
Impeller Clearance............................................................................................................ 11-18
Water Filter Cover Removal/Installation ........................................................................... 11-18
11

11-2 PUMP AND IMPELLER
Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Pump Bracket Mounting Bolts (2) 19 1.9 14 LN, SS
2 Pump Bracket Mounting Bolts (4) 9.8 1.0 87 inlb L
3 Pump Mounting Bolts 36 3.7 27 L
4 Grate Mounting Bolts 9.8 1.0 87 inlb L
5 Pump Cover Mounting Bolts 7.8 0.80 69 inlb L
6 Impeller 98 10 72
7 Pump Cap Bolts 9.8 1.0 87 inlb L
8 Pump Cap Bolts 3.9 0.40 35 inlb L
9 Pump Outlet Mounting Bolts 19 1.9 14 L
10 Steering Nozzle Pivot Bolts 19 1.9 14 L
11 Pump Cap Plug 3.9 0.40 35 inlb
12 Filter Cover Mounting Bolts 9.8 1.0 87 inlb L
13 Steering Cable Joint Bolt 9.8 1.0 87 inlb L
14 Water Hose Joint L
15 Water Hose Joint L
A: JT1500-A1 Model
B: JT1500-A2 AB Models
C: JT1500A6 (France) /A9 (Europe) Model
D: JT1500-A1 A6, AB Models
E: JT1500A7 AA Models
F: JT1500-A A6, AB, AC Models
G: JT1500AC Model
AG: Apply lithium grease (NLGI Grade No.2)
LN: Apply a non-permanent locking agent (High Strength: Loctite 271 equivalent).

Specifications

Jet Pump
Impeller Outside Diameter 147.5 147.7 mm (5.8071 5.8149 in.) 146.5 mm (5.7677 in.)
Pump Case Inside Diameter 148.0 148.1 mm (5.8268 5.8307 in.) 149.1 mm (5.8701 in.)
Impeller Clearance 0.15 0.3 mm (0.0059 0.0118 in.) 0.6 mm (0.0236 in.)

Oil Seal & Bearing Remover: Impeller Holder:
57001-1058 57001-1393
Bearing Driver Set: Impeller Holder :

57001-1129 57001-1695
Impeller Wrench: Liquid Gasket, TB1211:

57001-1228 56019-120

Pump and Impeller
Pump Removal
Turn the craft on its left side.
Disconnect the reverse cable ball joint at the rear end.
Unscrew the pump cover mounting bolts [A], and remove
the pump cover [B] with the reverse bracket [C].
Unscrew
grate [B].
the grate mounting bolts [A] and remove the
Remove
joint.
the joint bolts [A] and take off the steering cable
Loosen the clamps [B] on the inlet cooling hose, and pull
off the hoses [C].
JT1500A7 Model [D]
Unscrew the pump mounting bolts [A].

and remove it from
Slide the pump [B] to the rear to disengage the drive shaft,
the hull.

Pump and Impeller
To remove the pump bracket, perform the following pro-

cedures.
Take out the pump bracket mounting bolts [A] and washer
in the hull.
Take out the pump bracket mounting bolts [A].
Cut the sealant at the indicated area [A] in the figure and
remove the pump bracket [B].
Pump Installation
Strip off all the old sealant around the pump intake.
silicon sealant
Liberally coat the outside edge of the pump bracket with
[A] to form a seal between the bracket and
the hull.

Pump and Impeller
Install the pump bracket [A] to the hull.

Apply a non-permanent locking agent or a non-permanent
locking agent (High Strength: 271 equivalent) to the fol-
lowing bolts and tighten them.
Torque - Pump Bracket Mounting Bolts (2) [B]: 19 Nm (1.9
kgfm, 14 ftlb) (Loctite 271 equivalent)
Pump Bracket Mounting Bolts (4) [C]: 9.8 Nm (1.0
kgfm, 87 inlb)
As for the pump bracket mounting bolts (2) in the hull, the
bolt heads should be wrapped in silicone sealant.
BeJT1500A7
sure trim seal [A] is in place.
Model [B]

Pump and Impeller
Grease
grease.
the splines on the drive shaft with water resistant
Install the pump.

Apply a non-permanent locking agent to the pump mount-
ing bolts and tighten them.
Torque - Pump Mounting Bolts: 36 Nm (3.7 kgfm, 27 ftlb)
Install the grate [A].

Be sure the trim seals [B] are in the position.
Apply a non-permanent locking agent to the grate mount-
ing bolts and tighten them.
Torque - Grate Mounting Bolts: 9.8 Nm (1.0 kgfm, 87 inlb)
Be sure the seals [A] on the hull are in the position.
Coat the outside edge [A] of the seal [B] with silicone
sealant to form a seal between the hull and seal.

Pump and Impeller
Install the pump cover.

Be sure the seal [A] is in the position.
Apply a non-prmanent locking agent to the pump cover
Torque - Pump Cover Mounting Bolts: 7.8 Nm (0.80 kgfm,
69 inlb)
Pump Disassembly
Unscrew the steering nozzle pivot bolts [A], and remove
the steering nozzle [B].
Unscrew the pump outlet mounting bolts [A], and remove

the pump outlet [B].
Unscrew
cap [B].
the pump cap bolts [A], and remove the pump

Pump and Impeller
Pull out the impeller seal on the impeller.

Hold the shaft in the impeller holder, taking care not to
damage it.
Remove the impeller from the pump shaft.
JT1500-A1 A6, AB AC Models
Special Tools - Impeller Holder: 57001-1393 [A]
Impeller Wrench: 57001-1228 [B]
JT1500A7 AA Models
Special Tools - Impeller Holder: 57001-1695 [A]
Impeller Wrench: 57001-1228 [B]
JT1500-A1 Model
Pull out the bushing [A].

Pump and Impeller
Remove the circlip.

Remove the grease seals.
Special Tool - Oil Seal & Bearing Remover: 57001-1058 [A]
Remove the bearing by tapping evenly around the bearing

inner race from the front end of the pump case [A].
Special Tool - Bearing Driver Set: 57001-1129 [B]
JT1500-A2 Model
Press [A] the bussing [B] and the ball bearing [C]. They
come out of the pump case.
Remove the circlip.

Remove the grease seals.
Special Tool - Oil Seal & Bearing Remover: 57001-1058 [A]

Pump and Impeller
JT1500A7 Model
Remove the pump shaft bearing.
Using a hand press [A] push out the pump shaft [B] and
remove the bearing [C].

Insert a metal rod [A] into the pump cap [B] from the rear
end, remove the bearing by tapping evenly around the
bearing inner race from the rear end of the pump cap.
Pump Assembly
Before installing the pump bearing, blow any dirt or for-
eign particles out of the pump case with compressed air.
Before installing the pump bearing, remove the filter cover
[C], and check the filter inside or outside [A] on the pump
case [B] if the foreign particles do not cling to the filter.
Apply high grade water resistant grease to the O-ring [D].
Apply a non-permanent locking agent to the filter cover
Torque - Filter Cover Mounting Bolts: 9.8 Nm (1.0 kgfm,
87 inlb)
JT1500-A1 Model
Install a new bearing into the pump case [A] as far as it
will go.

Pump and Impeller
Replace the grease seals with new ones, if necessary,

and install them.
Press each seal [A] into the pump case so that the side
with the spring faces outward. Fill [B] the gap between
the seals, and between the seal and the bearing with high
grade water resistance grease.
13.6 13.8 mm (0.535 0.543 in.) [C]
6.5 6.7 mm (0.256 0.264 in.) [D]
Install the circlip [E].
Push the bushing [F] into the pump case.
Visually inspect into the pump shaft O-rings [G], and re-
place them if necessary .
Apply molybdenum disulfide grease to the pump shaft and
insert it from rear of the pump case.
JT1500-A2 Model
Replace the grease seals with new ones, if necessary,
and install them.
Press each seal [A] into the pump case [B] so that the side
with the spring faces outward.
Fill the gap between the grease seals [C] with high grade
water resistance grease and apply it each greace seal lip
[D].
Install the circlip [E].
Install the bushing [F] into the pump case.
Fill with high grade water resistance grease [G].
Install
will go.
a new bearing into the pump case [A] as far as it

Pump and Impeller
Visually inspect the pump shaft O-rings [A], and replace
if necessary.
Install the O-ring over the pump shaft [B].
Grease the O-ring with high grade water resistance
greace.
JT1500A7 AA Models
Install the pump shaft to the bearing.
Using a hand press [A], press the shaft until its step bot-
toms the new ball bearing [B] inner race.
Install the O-ring [D] over the pump shaft [E].
Grease the O-ring with high grade water resistance
grease.
Apply molybdenum disulfide greace [A] to the thread of

the pump shaft
Push the pump shaft [B] into the pump case (JT1500-A1
A6, AB AC Models).
Push the pump shaft with bearing into the pump case
(JT1500A7 AA Models).

Pump and Impeller
JT1500-A1 Model
Screw on the impeller and tighten.
Special Tools - Impeller Holder: 57001-1393
Impeller Wrench: 57001-1228
Torque - Impeller: 98 Nm (10 kgfm, 72 ftlb)
Visually
sary.
inspect impeller seal [A], and replace it if neces-
Install the seal on the impeller.

Before installing the cap bearing, blow any dirt or foreign
particles out of the pump cap [A] with compressed air.
Install new bearing into the cap as far as it will go.
Be sure the O-rings [A] are in place on the pump cap [B]
and plug [C].
Apply high grade water resistance grease to the O-rings.
Install the following.

Pump Cap
Pump Cap Plug
Pump Outlet
Steering Nozzle
Apply a non-permanent locking agent to the thread of the
following.
Pump Cap Bolts
Pump Outlet Mounting Bolts
Steering Nozzle Pivot Bolts
Tighten:
Torque - Pump Cap Plug: 3.9 Nm (0.40 kgfm, 35 inlb)
Pump Cap Bolts: 9.8 Nm (1.0 kgfm, 87 inlb)
Pump Cap Bolts: 3.9 Nm (0.40 kgfm, 35inlb)
JT1500A7 AA Models
Pump Outlet Mounting Bolts: 19 Nm (1.9 kgfm,
14 ftlb)
Steering Nozzle Pivot Bolts: 19 Nm (1.9 kgfm, 14
ftlb)

Pump and Impeller
BeJT1500A7
sure the pump seal [A] is in place on the pump case.
AA Models [B]
Impeller Inspection
Refer to Impeller Inspection in the Periodic Maintenance
chapter.
Impeller Outside Diameter Measurement
Measure the impeller outside diameter.
If the impeller is worn smaller than the service limit, re-
place it.
Impeller Outside Diameter
Standard: 147.5 147.7 mm (5.8071 5.8149 in.)
Pump Inspection
Examine the pump case [A].
If there are deep scratches inside the pump case, replace
it.
Measure the inside diameter of the pump case.

If the pump case is worn beyond the service limit, replace
it.
Pump Case Inside Diameter
Standard: 148.0 148.1 mm (5.8268 5.8307 in.)

Pump and Impeller
Impeller Clearance
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: 0.15 0.3 mm (0.0059 0.0118 in.)
If impeller clearance is incorrect, determine if it is due to
wear or damage (see Pump and Impeller Inspection).
Water Filter Cover Removal/Installation
Loosen the clamps [A] and pull off the hoses [B].
Take out the
Remove filter cover mounting bolts [C].
Replace the gasket
the filter cover [D].
Installation is the reverse
with a new one.
Apply a non-permanent locking order of removal.
mounting bolts and tighten them.agent to the filter cover
JT1500A7 AA Models [E]
Torque - Filter Cover Mounting Bolts: 9.8 Nm (1.0 kgfm,
87 inlb)

STEERING 12-1
Steering
Table of Contents
Exploded View........................................................................................................................ 12-2
Special Tools .......................................................................................................................... 12-4
Steering Cable........................................................................................................................ 12-5
Steering Cable Adjustment ............................................................................................... 12-5
Steering Cable Removal ................................................................................................... 12-5
Steering Cable Installation ................................................................................................ 12-7
Steering Cable Inspection................................................................................................. 12-7
Steering Cable Lubrication................................................................................................ 12-7
Handlebar ............................................................................................................................... 12-8
Handlebar Removal .......................................................................................................... 12-8
Handlebar Installation ...................................................................................................... 12-9
Steering .................................................................................................................................. 12-11
Steering Removal ............................................................................................................. 12-11
Steering Installation ......................................................................................................... 12-14
Reverse System ..................................................................................................................... 12-17
Shift Cable Adjustment ..................................................................................................... 12-17
Shift Cable Removal ......................................................................................................... 12-17
Shift Cable Installation ..................................................................................................... 12-19
Shift Cable Inspection ....................................................................................................... 12-19
Shift Cable Lubrication...................................................................................................... 12-19
Reverse Bucket Removal/Installation ............................................................................... 12-20
Shift Lever Shaft Removal/Installation .............................................................................. 12-20
12

12-2 STEERING
Exploded View

STEERING 12-3
Exploded View
Torque
Nm kgfm ftlb
1 Handlebar Clamp Bolts 16 1.6 12 L
2 Start/stop Switch Case Mounting Screws 3.9 0.40 35 inlb
3 Throttle Case Mounting Screws 3.9 0.40 35 inlb
4 Steering Shaft Locknut 49 59 5.0 6.0 36 43
5 Steering Shaft Nut 2.9 0.30 26 inlb
6 Steering Holder Mounting Bolts 20 2.0 14.5 LN
7 Steering Neck Mounting Bolts 16 1.6 12 L
8 Steering Cable Joint Bolt 9.8 1.0 87 inlb L
9 Ball Joint 9.8 1.0 87 inlb LN
10 Shift Cable End Nut 9.8 1.0 87 inlb
11 Reverse Bucket Pivot Bolts 19 1.9 14 LN
12 Shift Cable Nut 39 4.0 29
13 Steering Cable Nut 39 4.0 29
14 Shift Lever Locknut 20 2.0 14.5
15. Buzzer
16. Steering Position Sensor
17. Magnet
A: JT1500A7 Model
B: JT1500-A1 AA Models
G: Apply grease.
LN: Apply a non-permanent locking agent (High Strength: Loctite 271 equivalent).

12-4 STEERING
Special Tools
Box Wrench (27 mm): Nut Tightening Plate:
57001-1451 57001-1698

STEERING 12-5
Steering Cable
Steering Cable Adjustment
Check the steering cable adjustment.
Center the handlebar in the straight-ahead position.
Check
cavity.
that the steering nozzle [A] is centered in the pump
The same distance [B].
IfLoosen
necessary, adjust the steering cable.
the locknut [A] on the end of the steering cable
located to the right of the steering nozzle.
Take out the cable joint bolt [B] and disconnect the cable
joint [C] from the steering nozzle.
Center the handlebar in a straight ahead steering position.
Turn the joint on the cable to adjust the steering.
Temporarily tighten the cable joint bolt, and connect the
joint with the nozzle and check cable adjustment again.
When 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 - Steering Cable Joint Bolt: 9.8 Nm (1.0 kgfm, 87
inlb)
As an additional check, turn the handlebar all the way to
the left and right, and measure the distance between the
nozzle and the edge of the pump cavity. It should be equal
at both extremes.
Steering Cable Removal
Remove the screws [A] and remove the front storage
pocket [B].

12-6 STEERING
Steering Cable
Loosen the locknut [A] at the front end of the steering

cable, and slide back the outer sleeve of the ball joint and
take off the ball joint [B] and remove the locknut from the
cable front end.
Pull the holder [A] off the cable bracket.

if the cable
Slide the steering cable [B] off the cable bracket [C], and
is hard to remove, unscrew the cable bracket
mounting bolts [D], and remove the cable bracket.
Turn the watercraft on its left side and remove the pump
cover (see Pump Removal in Pump/Impeller chapter).
NOTICE
the right side.
Loosen the locknut [A] at the rear end of the steering ca-
ble, and remove the joint bolt [B].
Remove the joint [C] and locknut from the cable end.
Unscrew
a wrench.
the large nut (steering cable nut) in the hull with
Special tool, box wrench [A] is useful to remove the large

nut (steering cable nut).
Special Tool - Box Wrench: 57001-1451

STEERING 12-7
Steering Cable
Slide off the snap ring [A], washer [B] and O-ring [C].
Pull out the steering cable toward the rear.
Steering Cable Installation

Slide a short piece of rubber or plastic tubing over the front
cable end to guide the cable through the hull.
Lubricate
stallation.
the outside of the new cable to ease cable in-
Tighten:
Torque - Steering Cable Nut: 39 Nm (4.0 kgfm, 29 ftlb)
Apply a non-permanent locking agent to the cable joint
bolt and the steering cable bracket mounting bolts, if re-
moved.
Tighten:
Torque - Steering Cable Joint Bolt: 9.8 Nm (1.0 kgfm, 87
inlb)
Apply a water resistant grease to the joint ball [A].

ment). the steering cable (see Steering Cable Adjust-
Adjust
Steering Cable Inspection

Refer to the Steering Cable/Shift Cable Inspection in the
Steering Cable Lubrication
NOTE
The steering cable is sealed at each end and do not
require lubrication. If the seal is damaged, the cable
must be replaced.

12-8 STEERING
Handlebar
Handlebar Removal
dlebar pad [B].
Remove the inner pad [A], pushing [B] the buzzer [C].
Unscrew the bolts [A] and remove the pad holder [B].
Take out the throttle case mounting screws and remove

the throttle case [A].
Take out the switch case mounting screws and remove
the switch case [B].
Unhook the pipe [C].
Cut off the clamp [D].
Unscrew the handlebar clamp bolts [A] and remove the

handlebar clamps [B] and handlebar [C].

STEERING 12-9
Handlebar
Handlebar Installation
Install the pad holder.
Apply a non-permanent locking agent to the pad holder
bolts.
Install the handlebar on the holder of the steering neck.
Apply a non-permanent locking agent to the handlebar
clamp bolts.
Align the punch mark [A] on the left side of the handlebar
with the parting line [B].
Tighten the front and then rear handlebar clamp bolts to
the specified torque.
Torque - Handlebar Clamp Bolts: 16 Nm (1.6 kgfm, 12
ftlb)
Install the fuel vent hose.
Refer to the Fuel Tank Vent Hose Installation in the Fuel
System chapter.
NOTICE
The engine will malfunction if the fuel tank air vent
pipe end is obstructed by the handlebar pad and/or;
if the air vent hose is folded; and/or riding the wa-
tercraft with the air vent hose remaining clogged.
Be sure the fuel tank air vent pipe is installed cor-
rectly and securely.
Install the throttle case and switch case.

Tighten the screws.
kgfm, 3.5 inlb)
start/stop Switch Case Mounting Screws: 3.9 Nm
(0.40 kgfm, 3.5 inlb)
Route the cable, wire and hose correctly (see Appendix
chapter).
Install the inner pad [A] on the handlebar, putting the

buzzer [B] into the hollow [C] on the inner pad.

12-10 STEERING
Handlebar
Install the bosses [A] on the pad holder to the holes [B]
on the handlebar pad.
Align [A] the projection [B] on the pad with the groove [C]
on the pad.

STEERING 12-11
Steering
Steering Removal
Remove the handlebar and pad holder (see Handlebar
Removal).
Unscrew the set screw [A] and take out the cap [B].
Unscrew
[B].
the shift lever nut [A] and remove the shift lever
Remove the right stay [A] with the right mirror (see
Hull/Engine Hood chapter).
Unscrew the steering cover mounting bolts [B], [C] and lift
up the steering cover [D].

12-12 STEERING
Steering
Remove
chapter).
Disconnect:
Steering Position Sensor Lead Connector [A]
Buzzer Connector [B]
Multifunction Meter Lead Connectors [C]
Steering Cable Ball Joint at Upper End
Shift Cable Ball Joint at Upper End
Take out the grommet mounting plate [A] and pull the
grommet [B].
Pull out the multifunction meter leads [A] and buzzer lead
[B] from the grommet.
Remove the steering cover [C].
Unscrew the steering neck mounting bolts [A] and remove

the steering neck [B].

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

washers, and lift up the steering holder [B].
Take out the air intake duct mounting bolts [A] and remove
the air intake duct [B] from the steering holder [C].
Disconnect the switch case lead connector and pull the

leads [A] out of the hull.
Disconnect the pipe at the fuel vent hose upper end and
pull down the fuel vent hose [B].
Disconnect the throttle cable upper end at the throttle
case and pull down the throttle cable [C].
Remove the lock plate [A].

ing shaft [C].steering shaft nut [B] and pull down the steer-
Take out the
Remove the steering holder.

12-14 STEERING
Steering
Steering Installation
Replace
new one.
the gasket [A] on the steering holder [B] with a
Check the bushings for damage and wear before in-

stalling the steering holder.
If the bushings are damaged or worn, replace them.
Grease:
Bushings [A]
Steering Shaft [B]
Install the steering shaft nut [A] to the steering holder by

tightening the nut with hand, and then loosen it a fraction
of turn.
Using the special tool tighten the steering shaft nut with
the specified torque.
Torque - Steering Shaft Nut: 2.9 Nm (0.30 kgfm, 26 inlb)
Special Tool - Nut Tightening Plate: 57001-1698
If steering is too tight, turn the steering shaft nut counter-
clockwise to loosen.
If the steering is too loose, turn the steering shaft nut
clockwise to tighten.
Install the lock plate [A].

nut holethe
Loosen steering shaft nut [B] until the steering shaft
aligns with the one of the lock plate.
Tighten the lock plate bolts [C].
Steering Shaft [D]
Be sure that the steering shaft turns, freely. If not, adjust
the steering shaft again.
NOTE
The steering shaft must be turned smoothly when the
cable is connected.

STEERING 12-15
Steering
Install the air intake duct [B] to the steering holder [C].
Apply a non-permanent locking agent to the air intake duct
mounting bolts [A].
Tighten the steering shaft locknut [A].

Torque - Steering Shaft Locknut: 49 59 Nm (5.0 6.0
kgfm, 36 43 ftlb)
Turning the steering shaft fully in left and right direction,

check whether the steering position sensor comes in con-
tact with the magnet.
Check the clearance [A] between the steering position
sensor [B] and the magnet [C] with feeler gauge.
Steering Position Sensor Clearance
Standard: 0.5 1.5 mm (0.02 0.06 in.)
If necessary, adjust the clearance by turning the steering
shaft nut.
Insert a new cotter pin [A].

NOTE
When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
It should be within 30 degrees.
Loosen once and tighten again when the slot goes past
the nearest hole.
Bend the cotter pin [A] over the nut.

12-16 STEERING
Steering
Install the steering holder.

Loctite a271non-permanent
Apply locking agent (High Strength:
equivalent) to the steering holder mounting
bolts and tighten them.
Torque - Steering Holder Mounting Bolts: 20 Nm (2.0
kgfm, 14.5 inlb)
Install the steering neck [A] so that its arrow mark [B]
points toward the front.
Apply a non-permanent locking agent to the steering neck
Torque - Steering Neck Mounting Bolts: 16 Nm (1.6 kgfm,
12 ftlb)
Be sure that the damper [A] is in position.

mounting plate.
Apply a non-permanent locking agent to the steering
cover mounting bolts.
Install the steering cover mounting bolts [A] to the steering
cover [B].
Apply a non-permanent locking agent (High Strength:
Loctite 271 equivalent) to the shift lever nut.
Apply a water resistant grease to the joint balls of the shift
cable and shift link rod.
Adjust the shift cable and steering cable.

STEERING 12-17
Reverse System
Shift Cable Adjustment
Check the shift cable adjustment.
When the shift lever is in the F position, the lower edge
[A] of the bucket should be held above the top [B] of the
steering nozzle with slight play so it doesnt interfere with
the water flow from the jet pump.
When the shift lever is in the R position, the lower stop-
per [C] on the bucket should rest against the bottom [D]
of the pump cover.
If either position is incorrect, adjust the shift cable.

Put the shift lever in the R position.
Loosen the locknut [A] at the end of the shift cable.
Slide back the outer sleeve and take the ball joint [B] off
the ball.
Turn the ball joint on the cable to adjust the shift cable.
Connect the ball joint and check the cable adjustment
again.
When adjustment is correct, tighten the shift cable lock-
nut.
Shift Cable Removal
Take out the storage case screws [A] and remove the stor-
age case [B].
Loosen
[B].
the locknut [A] at the front end of the shift cable

12-18 STEERING
Reverse System
Pull the holder [A] off the cable bracket.
Remove
ter).
the right side cover (see Hull/Engine Hood chap-
Unscrew the bolts [A] and remove the cable bracket.

NOTE
The collors on the inside of the hull will drip down when
the bolts are removed.
Remove the ball joint [A] and cable bracket [B] from the
shift cable [C].
Cut off the band [A] holding the shift cable [B] and inlet
cooling hose [C] for the oil cooler.
Cut off the band [A] holding the shift cable [B].
Bow [C]

STEERING 12-19
Reverse System
Turn the water craft on its left side and remove the pump
cover (see Pump/Impeller chapter).
NOTICE
the right side.
Loosen the locknut [A] at the rear end of the shift cable,
and remove the ball joint [B] from the reverse bucket [C],
Disconnect
the hull.
the shift cable from the fitting at the middle of
Unscrew the large nut (shift cable nut) in the hull with a
wrench.
Special tool, box wrench [A] is useful to remove the large
nut (shift cable nut).
Special Tool - Box Wrench: 57001-1451
Pull the cable from the cable detente in the engine com-
partment.
Slide off the snap ring [A], washer [B] and O-ring [C].
Pull out the shift cable toward the rear.
Shift Cable Installation

Slide a short piece of rubber or plastic tubing over the front
cable end to guide the cable through the hull.
Lubricate
stallation.
the outside of the new cable to ease cable in-
Tighten the shift cable nut.

Torque - Shift Cable Nut: 39 Nm (4.0 kgfm, 29 ftlb)
Apply a non-permanent locking agent to the cable bracket
mounting bolt.
Apply a water resistant grease to the joint ball at each end
of shift cable.
Adjust the shift cable (see Shift Cable Adjustment).
Shift Cable Inspection
Refer to the Steering Cable/Shift Cable Inspection in the
Shift Cable Lubrication
NOTE
The shift cable is sealed at each end and do not require
lubrication. If the seal is damaged, the cable must be
replaced.

12-20 STEERING
Reverse System
Reverse Bucket Removal/Installation
Disconnect the ball joint at rear end of the shift cable.
Remove the pump cover.
Unscrew
bucket [B].
the pivot bolts [A] and remove the reverse
Installation is the reverse of removal. Note the following.

Loctite 271 equivalent) to the reverse bucket pivot bolts,
and tighten them.
Torque - Reverse Bucket Pivot Bolts: 19 Nm (1.9 kgfm, 14
ftlb)
After installation, check the shift cable adjustment.
Shift Lever Shaft Removal/Installation
Remove:
Steering Cover (see Steering Removal)
Steering Cable Ball Joint at Upper End (disconnect)
Unscrew the mounting bolts [A] on the inside of the hull
and remove the shift lever holder [B].
Assemble the shift lever holder, noting the following.

Shift Lever Shaft [A]
Grease:
Bushings [B]
Apply silicone sealant to the mating surface between the
shift lever holder bottom and steering holder upper sur-
face.
Loctite 271 equivalent) to the lever nut [C] and the shift
lever holder mounting bolts [E].
Tighten the shift lever locknut [D].
Torque - Shift Lever Locknut: 20 Nm (2.0 kgfm, 14.5 ftlb)

STEERING 12-21
Reverse System
Insert a new cotter pin [A].

NOTE
When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
It should be within 30 degrees.
Loosen once and tighten again when the slot goes past
the nearest hole.
Bend the cotter pin [A] over the nut.
Before connecting the shift and steering cables, apply a

water resistant grease to their joint balls.

HULL/ENGINE HOOD 13-1
Hull/Engine Hood
Table of Contents
Exploded View........................................................................................................................ 13-2
Fittings .................................................................................................................................... 13-8
Seat Removal (JT1500-A1 A2 Models) ......................................................................... 13-8
Seat Removal (JT1500A6 Model ).................................................................................. 13-8
Seat Installation (JT1500-A1 A2 Models) ...................................................................... 13-8
Seat Installation (JT1500A6 Model )............................................................................... 13-9
Front Storage Compartment Cover Removal ................................................................... 13-9
Front Storage Compartment Cover Disassembly ............................................................. 13-10
Front Storage Compartment Cover Assembly .................................................................. 13-11
Mirror Removal ................................................................................................................. 13-11
Mirror Installation .............................................................................................................. 13-11
Mirror Stay Removal ......................................................................................................... 13-12
Mirror Stay Installation ...................................................................................................... 13-12
Front Storage Pocket Removal......................................................................................... 13-13
Front Storage Pocket Installation...................................................................................... 13-13
Storage Pocket Disassembly/Assembly ........................................................................... 13-14
Crossmember Removal .................................................................................................... 13-14
Crossmember Installation ................................................................................................. 13-15
Handrail Removal ............................................................................................................. 13-15
Handrail Installation .......................................................................................................... 13-15
Drain Plug Housing Removal............................................................................................ 13-16
Drain Plug Housing Installation......................................................................................... 13-16
Exhaust Outlet Removal ................................................................................................... 13-16
Exhaust Outlet Installation ................................................................................................ 13-16
Stabilizer Removal ............................................................................................................ 13-16
Stabilizer Installation ......................................................................................................... 13-17 13
Reboarding Step Removal................................................................................................ 13-17
Reboarding Step Installation............................................................................................. 13-17
Hull Replacement ................................................................................................................... 13-18
Rubber Parts .......................................................................................................................... 13-19
Rubber Parts Location ...................................................................................................... 13-19
Rivet Removal................................................................................................................... 13-21
Rivet Installation................................................................................................................ 13-21
Front Bumper Removal..................................................................................................... 13-21
Front Bumper Installation.................................................................................................. 13-21
Rear Bumper Removal ..................................................................................................... 13-22
Rear Bumper Installation .................................................................................................. 13-22
Side Bumper Removal ...................................................................................................... 13-22
Side Bumper Installation ................................................................................................... 13-22

13-2 HULL/ENGINE HOOD
Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Crossmember Bolts 7.8 0.80 69 inlb L
2 Handrail Bolts 9.8 1.0 87 inlb L
3 Lock Assembly Nut 4.9 0.50 43 inlb
4 Front Duct Bolts L
5 Damper Bolts L
6 Damper Bracket Bolts L
7 Front Storage Compartment Cover Bolts L
8 Hinge Bolts L
9 Front Storage Compartment Hook Bolts L
10 Steering Cover Bolts L
11 Meter Screen Bolts L
12 Seat Hook Bolts L
13 Seat Locknut L
14 Reboarding Step Bolts L
15 Mirror Stay Bolts L
A: JT1500-A1 A2 Model
B: JT1500A6 Model
C: JT1500A7 Model
D: JT1500-A1 A8 Models
E: JT1500-A1 AA Models
F: JT1500-A1 AA, AB (other than AU) Models

Exploded View
JT1500-A1 A8 Models

Exploded View
Torque
Nm kgfm ftlb
1 Stabilizer Bolts 9.8 1.0 87 inlb L
2 Air Inlet Duct Bolts L
3 Exhaust Outlet Bolts L
A: JT1500A7 Model
B: JT1500A8 Model

Exploded View
JT1500A9 Model

Exploded View
Torque
Nm kgfm ftlb
1 Stabilizer Bolts 9.8 1.0 87 inlb L
2 Air Inlet Duct Bolts L
3 Exhaust Outlet Bolts L
A: JT1500A9 AA Models
B: JT1500A9 AB Models

Fittings
Seat Removal (JT1500-A1 A2 Models)
Pull [A] the latch handle [B].
Remove the seat up [A] and to the rear [B].
Seat Removal (JT1500A6 Model )

Pull the latch handle [A].
Remove the rear seat up [B] and to the rear [C].
Pull the latch handle [A] of the front seat [B].

Remove the front seat up [C] and rear [D].
Seat Installation (JT1500-A1 A2 Models)

Insert the seat hook [A] into the bracket [B] on the deck
and slide it all the way forward by pushing the rear of the
seat.
Push down on the rear of the seat to lock it.

Fittings
Seat Installation (JT1500A6 Model )
Insert the seat hook [A] into the bracket [B] on the deck
and slide it all the way forward by pushing the rear of the
front seat.
Push down on the rear of the front seat to lock it.
Install the rear seat [A] and push down [B] on the rear of
the rear seat to lock it.
Front Storage Compartment Cover Removal

Remove:
Damper Bracket Mounting Bolts [A]
Front Storage Compartment Cover Bracket Mounting
Bolts [B]
Front Storage Compartment Cover Assembly [C]
ToDamper
remove the hinge assembly, remove the following.
Bolt [A]
Hinge Bolts [B]

Fittings
Front Storage Compartment Cover Disassembly
Unscrew
[B].
the front duct bolts [A] and remove the front duct
Unscrew the lock assembly nut [A] and remove the lock
assembly [B].
Drill out the rivets [A] with a drill bit [B] of the correct size
and remove the front duct cover [C].
Rivet Removal Drill Bit Size
5.0 mm (0.2 in.)
NOTE
Stop drilling when the rivet head starts to turn with drill
bit.
Tap the rivet out with a suitable punch and hammer.

Fittings
Front Storage Compartment Cover Assembly
Secure the front duct cover to the front duct [A] with the
rivets using a riveter [B].
Be sure that the trim seals [A] are in position.
Tighten the lock assembly nut.

Torque - Lock Assembly Nut: 4.9 Nm (0.50 kgfm, 43 inlb)
Apply
bolts.
a non-permanent locking agent to the following
Air Duct Bolts

Hinge Bolts
Damper Bolts
Mirror Removal
mirrors [C]the(both
Unscrew nuts [A] and washers [B] and remove the
sides).
Mirror Installation
Be sure that the washer [A] are in position.

Fittings
Mirror Stay Removal
To remove the right mirror stay [A], remove the bolts [B].
NOTE
The plate [C] on the inside of the hull will drop down
when the last bolt is removed.
Remove the right mirror (see Mirror Removal).
To remove the left mirror stay, perform the next proce-

dures.
Loosen the clamp [A] and disconnect the flushing hose
[B].
Remove the flushing cap.

hull.
Pull up the flushing fitting [A] with the damper [B] from the
Unscrew the bolt [C] and remove the left mirror stay [D].
NOTE
The plate [E] on the inside of the hull will drop down
when the last bolt is removed.
Remove the left mirror (see Mirror Removal).

Mirror Stay Installation
Be sure the dampers [A] are in position (both sides).

Fittings
The right plate [A] on the inside of the hull has a R mark
[B] and the left plate [C] has L mark [D].
Apply a non-permanent locking agent to the mirror stay
bolts and tighten them securely.
Install the damper [A] onto the hull.

NOTE
Apply a little oil to the damper to make installation easy.
Install the flushing fitting [A] into the damper [B].
Front Storage Pocket Removal

Remove the front storage pocket mounting screws [A].
Remove the front storage pocket [B].
Front Storage Pocket Installation

Installation is the reverse of removal.

Fittings
Storage Pocket Disassembly/Assembly
To remove the storage pocket cover [A], turn and pull out
the shaft [B] (both side).
When installing the shafts, put the shaft end [C] (both
side) into the hollow [D] on the storage pocket.
To remove the lock [A], turn and pull out the shaft [B] (both
side).
When installing the shafts, push the shaft end [C] (both
side) into the hollow [D] on the lock.
Crossmember Removal
Remove the front storage pocket (see Front Storage
Pocket Removal).
Disconnect the steering cable upper end [A].
Pull out the holder [A].

bracket [C]thewithmounting
Unscrew bolts [D] and remove the cable
the cable [B].
To remove the right side cover, pull the holder [A] off the
cable bracket.

Fittings
Unscrew the mounting nuts [A] and washers [B] and the
left [C] and right [D] covers.
Unscrew the crossmember bolts [E] and bracket [F], and
remove the crossmember [G].
Crossmember Installation
Apply a non-permanent locking agent to the crossmem-
ber bolts and tighten them.
Torque - Crossmember Bolts: 7.8 Nm (0.80 kgfm, 69 inlb)
Be sure that the dampers [A] are in position.
mounting
Apply a non-permanent locking agent to the cable bracket
Handrail Removal
Remove the seat (see this chapter).
Unscrew thethemounting
Disconnect bilge hoses from the breather fitting.
and remove the lock assembly
nut [A] and washer inside the hull,
[B].
mounting bolts [C], and remove inside
Holding the nuts and washers hull, unscrew the
the handrail [D].
Handrail Installation
When installing the lock assembly and handrail, align the
projection [A] and stud bolt [B] on the lock assembly with
holes [C] on the hull.

Fittings
Drain Plug Housing Removal
Unscrew
ing [B].
the screws [A] and remove the drain plug hous-
Drain Plug Housing Installation

Check the seal [A] for damage.
If necessary, replace new ones.
Install the new gasket [B] so that its OUT mark [C] faces
outwards.
Exhaust Outlet Removal

Unscrew the mounting bolts [A] and remove the holder [B]
and exhaust outlet [C].
The exhaust outlet is located at the left on the hull in
JT1500-A1 A8 Models, however it is located at right on
the hull in JT1500A9 Model .
Exhaust Outlet Installation

Apply a non-permanent locking agent to the mounting
Stabilizer Removal
Unscrew
[B].
the stabilizer bolts [A] and remove the stabilizer
The exhaust outlet is located at the left on the hull in

JT1500-A1 A8 Models, however it is located at right on

Fittings
Stabilizer Installation
Install the stabilizer as shown.
Stabilizer [A]
Chine Line [B]
105 3 mm (4.13 0.12 in.) [C]
20 2 mm (0.79 0.08 in.) [D]
Apply a non-permanent locking agent to the stabilizer bolt
and tighten them.
Torque - Stabilizer Bolts: 9.8 Nm (1.0 kgfm, 87 inlb)
Reboarding Step Removal

Unscrew the reboarding step bolts [A] and remove the
reboarding step [B].
Reboarding Step Installation

Apply a non-permanent locking agent to the reboarding
step bolts and tighten them securely.

Hull Replacement
To replace the hull, remove the various parts in the follow-
ing suggested order.
Battery and Pad
Exhaust Pipe and Expansion Chamber
Inlet Manifold
Engine and Mounts
Air Filter
Water Box Muffler
Drive Shaft and Shaft Holder
Pump and Hoses
Steering Cover
Handlebar and Steering
Steering Cable
Reverse Cable
Crossmember
Fuel Tank and Filler
Bilge and Cooling System Hose
Bypass Hose and Outlet
Bumpers
Engine Hood Latch
Front Storage Compartment Cover and Brackets
Handrail
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.

Rubber Parts
NOTE
The rubber parts on the watercraft are fastened in place
with various adhesives. To replace a rubber part, use a
cement in the following table, or an equivalent.
WARNING
Many solvents and adhesives are flammable, may
be harmful to the skin and eyes, and may emit harm-
ful vapors. Read all product warnings before use.
Use only in a well-ventilated area and never near an
open flame.
For this Application Type

Mats Synthetic Rubber
Engine Hood Gasket Adhesive
Front Storage Compartment Cover (P/N: 92104-3701)
Trim Seal
Detents Cyanoacrylate Cement
Handlebar Grips
NOTICE
When the cement cures it may be impossible to
reposition the part. Be very careful that the part is
positioned correctly when you apply the cement.
WARNING
Cyanoacrylate cement is harmful to the eyes and
makes skin immediately stick to anything touched.
To prevent contact with cyanoacrylate cement, al-
ways wear safety goggles and gloves. If there is
eye contact, do not try to wash it out -- immediately
contact a physician. In case of skin contact, do not
touch any other part of your body; allow the cement
to cure and it will eventually wear off.
Rubber Parts Location

Engine Hood Gasket [A]
Rear Storage Trim Seal [B]

Rubber Parts
Front Storage Compartment Gasket [A]
Front Storage Compartment Cover Trim Seal [B]
Detent [A]
Mats [A]
Damper on Deck [A] (starboard side only)

20 mm (0.79 in.) [B]
30 mm (1.18 in.) [C]

Rubber Parts
Rivet Removal
Drill out the rivet with a drill bit [A] of the correct size.
Rivet Removal Drill Bit Size
5.0 mm (0.2 in.)
NOTE
Stop drilling when the rivet head [B] starts to turn with
drill bit.
Tap the rivet out with a suitable punch and hammer.
Rivet Installation
Secure
[A].
the parts to the hull with the rivets using a riveter
Front Bumper Removal

Take out the plugs [A].
Take out the
Take out the mounting screw [B] and nuts [C].
[H] JT1500A7 mounting bolts [F], nuts [C] and washers [G].
Model
Remove the front bumper
Drill out the rivets [D] (see Rivet Removal).
[E].
Front Bumper Installation

Secure the front bumper to the hull flange with the rivets
(see Rivet Installation).

Rubber Parts
Rear Bumper Removal
Remove the corner bumpers [A] and trim strip [B].
Take out the plugs [C].
Drill out the rivets [D] (see Rivet Removal).
Remove the rear bumper [E].
Rear Bumper Installation

Secure the bumpers to the hull flange with the rivets (see
Rivet Installation).
Side Bumper Removal
Take out the plugs [A].
Removethe
Drill out rivets [B] (see Rivet Removal).
the corner bumper [C].
Remove the trim strip [A] from the side bumper [B].
Drill out the rivets [A] (see Rivet Removal).
Side Bumper Installation

Secure the side bumpers to the hull flange with the rivets
(see Rivet Installation).
Install the trim strip.

ELECTRICAL SYSTEM 14-1
Electrical System
Table of Contents
Parts Location.................................... 14-3 Camshaft Position Sensor
Exploded View................................... 14-6 Removal .................................... 14-45
Wiring Diagram.................................. 14-12 Camshaft Position Sensor
Specifications .................................... 14-18 Installation ................................. 14-46
Special Tools and Sealant ................. 14-19 Camshaft Position Sensor
Precautions........................................ 14-20 Inspection.................................. 14-46
Electrical Wiring................................. 14-22 Igniter Removal/Installation.......... 14-46
Wiring Inspection ......................... 14-22 Igniter Inspection.......................... 14-47
Battery ............................................... 14-23 Spark Plug Removal .................... 14-50
Battery Removal .......................... 14-23 Spark Plug Installation ................. 14-50
Battery Installation ....................... 14-23 Spark Plug Inspection .................. 14-50
Battery Activation ......................... 14-23 Spark Plug Adjustment ................ 14-50
Precautions .................................. 14-26 Spark Plug Cleaning .................... 14-50
Interchange .................................. 14-27 Kawasaki Smart Steering System ..... 14-54
Charging Condition Inspection..... 14-27 Steering Position Sensor and
Refreshing Charge....................... 14-27 Magnet Removal ....................... 14-54
Electric Starter System ...................... 14-29 Steering Position Sensor and
Starter Relay Removal................. 14-29 Magnet Installation .................... 14-54
Starter Relay Installation.............. 14-29 Inspection of Kawasaki Smart
Starter Relay Inspection............... 14-29 Steering System........................ 14-55
Starter Motor Removal................. 14-30 Steering Position Sensor
Starter Motor Installation.............. 14-30 Clearance.................................. 14-55
Starter Motor Disassembly........... 14-31 Steering Position Sensor Input
Starter Motor Assembly ............... 14-31 Voltage Inspection..................... 14-56
Brush Inspection .......................... 14-32 Steering Position Sensor Output
Commutator Cleaning and Voltage Inspection..................... 14-57
Inspection.................................. 14-32 Sensors ............................................. 14-60
Armature Inspection..................... 14-33 Speed Sensor Removal/Installa- 14
Brush Lead Inspection ................. 14-33 tion ............................................ 14-60
Brush Plate and Terminal Bolt Speed Sensor Inspection............. 14-60
Inspection.................................. 14-33 Fuel Level Sensor Inspection....... 14-61
Reduction Gear Removal/Installa- Throttle Sensor Removal/Installa-
tion ............................................ 14-34 tion ............................................ 14-61
Reduction Gear Inspection .......... 14-34 Throttle Sensor Inspection ........... 14-62
Charging System ............................... 14-36 Water Temperature Sensor
Magneto Output Voltage .............. 14-36 Inspection.................................. 14-62
Regulator/Rectifier Inlet Air Temperature Sensor
Removal/Installation.................. 14-37 Inspection.................................. 14-62
Regulator/Rectifier Inspection...... 14-37 Oil Temperature Sensor
Regulator Inspection .................... 14-37 Inspection.................................. 14-62
Ignition System .................................. 14-40 Multifunction Meter ............................ 14-63
Crankshaft Sensor Removal ........ 14-40 Display Function Inspection ......... 14-63
Crankshaft Sensor Installation ..... 14-40 MODE/SET Button Inspection ..... 14-64
Timing Rotor Removal ................. 14-41 SLO (Smart Learning Operation)
Timing Rotor Installation .............. 14-41 Mode Inspection (JT1500-A2
Crankshaft Sensor Inspection...... 14-41 Model ) .................................... 14-64
Ignition Coil Removal ................... 14-42 Fuel Level Gauge/Symbol/FUEL
Ignition Coil Installation ............... 14-43 Characters/Warning Light
Ignition Coil Inspection................. 14-44 Inspection.................................. 14-65
Speedometer Inspection .............. 14-65

14-2 ELECTRICAL SYSTEM
Speed Sensor Electric Source Removal....................................... 14-71

Inspection.................................. 14-66 Installation.................................... 14-71
Tachometer Inspection................. 14-67 Circuit Inspection ......................... 14-71
Battery Symbol/bAt Switches ............................................ 14-73
Characters/LED Inspection ....... 14-67 Switch Inspection ......................... 14-73
Buzzer Inspection ........................ 14-68 Fuse................................................... 14-74
Relay Assembly................................. 14-71 Fuse Inspection............................ 14-74

Parts Location
1. Bow
5. Magneto
6. Starter Motor
7. Fuse Case
8. Regulator/Rectifier
10. Starter Relay
11. Battery

Parts Location
17. Speed Sensor

Parts Location
20. Buzzer
21. Multifunction Meter
22. Starter Switch
23. Engine Stop Switch
24. Lanyard Key (Tether Code)
25. Ignition Switch

Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Vehicle-down Sensor Mounting Screws 1.5 0.15 13 inlb
2 Electrical Parts Bracket Screws 4.9 0.50 43 inlb L
3 Starter Relay Case Bolts 7.8 0.80 69 inlb
4 Ignition Coil Mounting Bolts 8.8 0.90 78 inlb L
5 Water Temperature Sensor 15 1.5 11 see text
6 Starter Relay Mounting Nuts 3.5 4.5 0.35 0.45 30 40 inlb
7 Starter Cable Mounting Nuts 3.5 4.5 0.35 0.45 30 40 inlb
8 Timing Rotor Bolt 20 2.0 14 L
9 Crankshaft Sensor Screws 4.4 0.45 39 inlb L
10 Rubber Grommet Holder Screws 4.4 0.45 39 inlb L
11 Crankshaft Sensor Cover Bolts 7.8 0.80 69 inlb
12 Oil Temperature Sensor 15 1.5 11 see text
14 Spark Plugs 13 1.3 113 inlb
15 Regulator/Rectifier Bolts 7.8 0.80 69 inlb
16 Relay Assembly Bolt 2.5 0.25 22 inlb L
17 ECU Mounting Bolts 8.8 0.90 78 inlb L
18 Main Fuse Mounting Bracket Bolt 7.8 0.80 69 inlb
19 Bracket Mounting Bolts 8.8 0.90 78 inlb L
20. Do not apply grease for inlet air pressure sensor lead connector.
21. Do not apply grease for inlet air temperature sensor lead connector.
A: JT1500A8 Model
DG: Fill the hollow with the heat transfer grease (Heat Transfer Grease, SCH-20: 92137-1002 or
equivalent).
EO: Fill the hollow with engine oil (10W-30).
G: Apply grease.

Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Multifunction Meter Mounting Bolts 3.9 0.40 35 inlb L
2 Fuel Level Sensor Clamp Screw 2.9 0.30 26 inlb
3 Start/stop Switch Case Mounting Screw 3.9 0.40 35 inlb
4 Speed Sensor Mounting Bolts 3.9 0.40 35 inlb L
7. Buzzer
A: JT1500-A1 AA Models

Exploded View

Exploded View
Torque
Nm kgfm ftlb
1 Starter Motor Through Bolts 6.4 0.65 56 inlb L, R
2 Starter Motor Mounting Bolts 8.8 0.90 78 inlb L
3 Starter Motor Ground Bolt 8.8 0.90 78 inlb
4 Starter Motor Terminal Nut 8.8 0.90 78 inlb
5 Stator Coil Bolts 12 1.2 104 inlb L
6 Grommet Holder Bolts 8.8 0.90 78 inlb L
7. Main Fuse 20 A
8. Harness Connector (to Regulator/Rectifier)
B: JT1500-A1 A8 Models
C: JT1500A8 AA Models
G: Apply grease.
R: Replacement parts.

Wiring Diagram
JT1500-A1 Model

Wiring Diagram
JT1500-A1 Model

Wiring Diagram
JT1500-A2 A7 Models

Wiring Diagram
JT1500-A2 A7 Models

Wiring Diagram
JT1500A8 Model

Wiring Diagram
JT1500A8 Model

Specifications

Battery
Type 12 V 18 Ah
Electric Starter System
Starter Motor:
Brush Length 12 mm (0.4724 in.) 6.5 mm (0.2559 in.)
Commutator Diameter 28 mm (1.1024 in.) 27 mm (1.063 in.)
Charging System
Regulator/rectifier Output Voltage Battery Voltage 14 15 V
Alternator Output Voltage 48 72 V
Stator Coil Resistance 0.432 0.648
Ignition System
Ignition Coil:
Primary Winding Resistance 1.53 2.07
Secondary Winding Resistance 12.50 16.91 k
Spark Plug:
Type NGK CR9EK
Gap 0.7 0.8 mm (0.0276 0.0315 in.)
Crankshaft Sensor Resistance 408 612

Hand Tester: Harness Adapter:
57001-1394 57001-1562
Peak Voltage Adapter: Flywheel & Pulley Holder:

57001-1415 57001-1605
Needle Adapter Set: Liquid Gasket, TB1211:

57001-1457 56019-120
Holder Attachment:
57001-1547

Precautions
There are a number of important precautions that should
be followed servicing electrical systems.
Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
To prevent damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the ignition switch is on, or while the engine is running.
Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor wind-
ings.
Do not use a meter illumination bulb rated for other than
voltage or wattage specified in the wiring diagram, as the
meter or gauge panel could be warped by excessive heat
radiated from the bulb.
Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they must be repaired or replaced, or
the new replacement will soon fail again
Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, etc. Poor
leads and bad connections will affect electrical system
operation.
Measure coil and winding resistance when the part is cold
(at room temperature).
Color Codes
BK: Black LG: Light Green
BL: Blue O: Orange
BR: Brown P: Pink
CH: Chocolate PU: Purple
DG: Dark Green R: Red
G: Green W: White
GY: Gray Y: Yellow
LB: Light Blue

Precautions
Electrical Connectors
Connectors [A]
Connectors [B]

Electrical Wiring
Wiring Inspection
Visually
etc.
inspect the wiring for signs of burning, fraying,
If any wiring is poor, replace the damaged wiring.

Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
Check the wiring for continuity.
Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
Connect the hand tester between the ends of the leads.
Set the tester to the 1 range, and read the tester.
If the tester does not read 0 , the lead is defective. Re-
place the lead or the wiring harness [B] if necessary.

Battery
Battery Removal
Disconnect the battery cables [A].
WARNING
Electrical components, including the battery, can
cause shocks and burns. To prevent injury and
damage to electrical components, always discon-
nect the grounded cable first.
Unhook the battery straps [B].

Carefully lift the battery from the engine compartment.
Battery Installation
Be sure the battery damper [A] is in position in the battery
compartment.
Hook the battery straps.
Connect the battery cable, positive first.
After attaching both cables, coat the terminals and cable
ends with grease to prevent corrosion.
Slide the protective boot over each terminal.
WARNING
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 covers are installed over the termi-
nals.
NOTICE
Reversing the battery connections may damage the
electrical system. To prevent damage, be sure the
battery connections are correct.
Battery Activation
Electrolyte Filling
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
JT1500A: YTX20L-BS
NOTICE
Each battery comes with its own specific elec-
trolyte container; using the wrong container may
overfill the battery with incorrect electrolyte, which
can shorten battery life and deteriorate battery per-
formance. Be sure to use the electrolyte container
with the same model name as the battery since the
electrolyte volume and specific gravity vary with
the battery type.

Battery
NOTICE
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
DANGER
Sulfuric acid in battery electrolyte can cause severe
burns. To prevent burns, wear protective clothing
and safety glasses when handling electrolyte. If
the electrolyte comes in contact with your skin or
eyes, wash the area with liberal amounts of water
and seek medical attention for more severe burns.
Place the battery on a level surface.

or holestoinseeit. that the sealing sheet has no peeling, tears,
Check
Remove the sealing sheet.

NOTE
The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
Remove the electrolyte container from the vinyl bag.

aside, thesestrip
Detach the of caps [A] from the container and set
will be used later to seal the battery.
NOTE
Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
Place the electrolyte container upside down with the six

sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
Do not tilt the electrolyte container.

Battery
Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.
NOTE
Be careful not to have the battery fall down.
Keep the container in place. Dont remove the container
from the battery, the battery requires all the electrolyte
from the container for proper operation.
NOTICE
Removal of the container before it is completely
empty can shorten the service life of the battery.
Do not remove the container until it is completely
empty.
After filling, let the battery sit for 20 60 minutes with the
electrolyte container kept in place, which is required for
the electrolyte to fully permeate into the plates.
Make sure that the container cells have emptied com-
pletely, and remove the container from the battery.
Place the strip of caps [A] loosely over the filler ports,
press down firmly with both hands to seat the strip of caps
into the battery (dont pound or hammer). When properly
installed, the strip of caps will be level with the top of the
battery.
NOTICE
Once the strip of caps is installed onto the battery,
never remove the caps, nor add water or electrolyte
to the battery.
NOTE
Charging the battery immediately after filling can
shorten service life.

Battery
Initial Charge
Newly activated sealed batteries require an initial charge.
Standard Charge: 1.8 A 5 10 hours
If using a recommended battery charger, follow the
chargers instructions for newly activated sealed battery.
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO2
Yuasa MB-2040/2060
Christie C10122S
If the above chargers are not available, use equivalent
one.
Let battery sit 30 minutes after initial charge, then check
voltage using a voltmeter. (Voltage immediately after
charging becomes temporarily high. For accurate mea-
suring, let the battery sit for given time.)
NOTE
Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. If voltage is not at least 12.8 V, repeat
charging cycle.
To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V the
battery is defective.
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 indicated on the battery.
NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the batterys 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.
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 watercrafts starting system has no
problem).

Battery
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri-
ous injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. 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. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medial at-
tention for more severe burns.
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 batterys life will be shortened.
Charging Condition Inspection

Refer to Battery Charging Condition Inspection in the Pe-
Refreshing Charge
Remove the battery [A] (see Battery Removal).
tery terminal voltage.
Refresh-charge by following method according to the bat-
NOTICE
The battery is a sealed type and never needs to have
water added. Never remove the strip cap, even dur-
ing charging, or you may damage the battery. Never
add water. Charge the battery with the current and
time as stated below.
Terminal Voltage: 11.5 less than 12.6 V

Standard Charge: 1.8 A 5 10 h (see following chart)
Quick Charge: 9.0 A 1.0 h
NOTICE
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: 1.8 A 20 h

Battery
NOTE
Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than five minutes at the increased voltage
then check if the battery is drawing current.
If the battery will accept current, decrease the voltage
and charge by the standard charging method described
on the battery case. If the battery will not accept current
after 5 minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Determine battery condition after refreshing charge.

Determine 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

Starter Relay Removal
Remove:
Rear Storage Pocket (see Hull/Engine Hood chapter)
Battery (see this chapter)
Disconnect the negative battery cable from the battery
terminal. (see Battery Removal).
Disconnect the starter relay lead connector [A].
Slide out the rubber caps [A].

on the start
Remove the nuts [B] from the battery and starter terminals
relay switch.
starter relay switch
Remove the starter relay case bolts [C] and slide the
from the relay case [D], being care-
ful not to lose any of the insulating washers or grommets.
Starter Relay Installation

Mount the starter relay switch [A] in the relay case [B].
Coat the insulating washers [C] and grommets [D] with
water resistant grease.
Be certain all insulating washers and grommets are in po-
sition.
Tighten the relay mounting nuts [E] securely.
Torque - Starter Relay Mounting Nuts: 4 Nm (0.40 kgfm,
35 inlb)
Replace the gasket [A] with a new one.

Be sure the grommet
Be sure the dowel pins [B] are in position.
Be sure the battery cable
[C] is installed on the relay case [D].
minal having red mark. is connected to the battery ter-
Tighten:
Torque - Starter Relay Case Bolts: 7.8 Nm (0.80 kgfm, 69
inlb)
Starter Cable Mounting Nuts: 3.5 4.5 Nm (0.35
0.45 kgfm, 30 40 inlb)
Starter Relay Inspection

Remove the starter relay (see Starter Relay Removal).
Connect meter
Set hand tester to R 1 range.
If resistance is less
leads to starter relay as shown.
than infinite, the starter relay switch is
not returning and must be replaced.

Set ohmmeter to R 1 range.

Activate starter
Connect meter leads to starter relay as shown.
as shown. relay switch by connecting a 12 V battery
If the starter relay switch clicks and the ohmmeter indi-
cates zero resistance, the starter relay switch is good.
If the meter indicates high or infinite () resistance, the
starter relay switch is defective and must be replaced.
Starter Motor Removal

Remove:
Inlet Manifold (see Fuel System chapter)
Side out the rubber caps [A] and remove the terminal nuts.
Remove the mounting bolts [A].

Pull out the starter motor [B].
Starter Motor Installation

NOTICE
Tapping the starter shaft or body could damage the
motor. Do not tap the starter motor shaft or body.
When installing the starter motor, clean the starter mo-

tor legs [A] and crankcase [B] where the starter motor is
grounded.
Apply grease to the O-rings [A].

Install the starter motor and tighten the mounting bolts.
Torque - Starter Motor Mounting Bolts: 8.8 Nm (0.90 kgfm,
78 inlb)

Starter Motor Disassembly
Remove the starter motor (see Starter Relay Removal).
Take off the starter motor through bolts [A] and remove
both end covers [B] and pull the armature out of the yoke
[C].
Remove the terminal locknut [A] and terminal bolt [B], and
then remove the brush with the brush plate [C] from the
yoke.
Starter Motor Assembly

Apply a thin coat of grease to the oil seal [A].
Fit the toothed washer [B] into the end cover.
Install the plate cover [A] and the positive brush assembly
[B] in the yoke [C].
Tighten the terminal nut [D] securely.
Holding the spring ends [A] with suitable plates [B], put
the armature among the brushes.

Install the O-rings [A] and the washers [B] as shown.
Fit the tongue [A] on the brush plate into the end cover
groove [B].
Align the lines [A] on the yoke with the lines [B] on the
both end covers.
Replace the starter motor through bolts [C] with new ones.
Tighten:
Torque - Starter Motor Through Bolts: 6.4 Nm (0.65 kgfm,
56 inlb)
Brush Inspection
Measure the length [A] of each brush.
If any is worn down to the service limit, replace the nega-
tive brush assembly [B] and the positive brush assembly
[C].
Starter Motor Brush Length
Standard: 12 mm (0.4724 in.)
Commutator Cleaning and Inspection

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 (1.1024 in.)
Service Limit: 27 mm (1.063 in.)
Armature Inspection
Using the 1 hand tester range, measure the resis-
tance between any two commutator segments [A].
If there is a high resistance or no reading () between any
two segments, a winding is open and the starter motor
must be replaced.
Using the highest hand tester range, measure the resis-
tance between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
NOTE
Even 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 Lead Inspection

Using the 1 hand tester range, measure the resis-
tance as shown.
[A] Terminal and Positive Brush
[B] Brush Plate and Negative Brush
If there is not close to zero ohms, the brush lead has an
open. Replace the positive brush assembly and/or the
negative brush assembly.
Brush Plate and Terminal Bolt Inspection

Using the highest hand tester range, measure the resis-
tance as shown.
[A] Terminal Bolt and Brush Plate
[B] Terminal Bolt and Yoke
If there is any reading, the negative brush assembly
and/or positive brush assembly have a short. Replace
the negative and positive brush assemblies.

Reduction Gear Removal/Installation
Before removing the reduction gear, remove the magneto
flywheel (see Engine Bottom End chapter).
When installing the reduction gear, apply a molybdenum
disulfide grease [A] to both ends of its shaft.
Reduction Gear Inspection

Rotate the pinion gear [A] counterclockwise.
must be rotated freely [B].
The gear
Rotate the pinion gear clockwise all the way. The pinion
gear will be advanced along the reduction gear shaft, and
stopped against the stopper [A].
Release the pinion gear. The pinion gear must return to
the initial position rapidly.
If the pinion gear does not function properly, replace it.

Electric Starter Circuit (JT1500-A1 A7 Models)
5. Starter Motor
1. Main Fuse 20 A
2. Ignition Switch
7. Starter Relay
3. Engine Starter Switch
(Ground)
Electric Starter Circuit (JT1500A8 Model )
1. Engine Starter Switch 6. Starter Relay

2. Main Fuse 20 A 7. Joint Connector U
3. Joint Connector T 8. Ignition Switch
4. Starter Motor 9. Joint Connector P
5. Battery 12 V 18 Ah 10. Joint Connector G

Charging System
Magneto Output Voltage
Remove:
Air Filter with Duct (see Fuel System chapter)
Disconnect the 3-pin stator coil leads connector [A].
With the hand tester [A] check the magneto output (in
circuit) according to the following table with the engine
running at approximately 3 000 rpm.
WARNING
Water is a high conductor of electricity and perform-
ing an electrical circuit inspection on water could
cause severe electrical shock to you. To prevent
shocks, do not inspect the electrical system while
the boat is in the water and do not touch the alter-
nator output leads while the engine is running.
NOTICE
Magneto Output Voltage

Connections
Meter Setting Standard Value
Meter (+) to Meter () to
250 V AC White lead White lead 48 72 V
If the magneto output voltage is correct, check the regu-
lator according to the regulator test procedure.
If the magneto output voltage is low, check the stator coil
resistance with a multimeter according to the following
table.
Stator Coil Resistance Test
Connections
Meter Setting Standard Value
Meter (+) to Meter () to
R1 White lead White lead 0.432 0.648
If 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.

Charging System
Regulator/Rectifier Removal/Installation
Unscrew the mounting bolts [A] and remove the regula-
tor/rectifier [B].
Disconnect the connector [C].
Apply grease to all around on the top surface of harness

connector [A] for waterproofing.
Tighten:
Torque - Regulator/rectifier Bolts: 7.8 Nm (0.80 kgfm, 69
inlb)
Regulator/Rectifier Inspection
With the hand tester set to the R 1 k range, test the
regulator/rectifier according the following table.
Regulator/Rectifier Inspection Unit: k

Tester (+) Lead Connection
Terminal +
+ 500 500 500 500
()* 2 20 500 500 500
2 20 500 500 500
2 20 500 500 500
2 40 2 20 2 20 2 20
()*: Tester () lead Connection
If any of the values obtained do not agree with the above
table, the regulator/rectifier must be replaced.
Regulator Inspection
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 6 W bulb in a socket with leads).
NOTICE
The test light works as an indicator and also as a
current limiter to protect the regulator/rectifier from
excessive current. Do not use an ammeter instead
of a test light.

Charging System
Do the 1st step regulator circuit test.

Connect the test light and the 12 V battery to the regula-
tor/rectifier as shown.
Check infinity () terminals respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
Do the 2nd step regulator circuit test.

Connect the test light and the 12 V battery in the same
manner as specified in the 1st step regulator circuit test.
Apply 12 V to the positive (+) terminal.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
Do the 3rd step regulator circuit test.

Connect the test light and the 12 V battery in the same
manner as specified in the 1st step regulator circuit test.
Momentarily apply 24 V to the positive (+) terminal by
adding a 12 V battery.
NOTICE
If more than 24 volts is applied or 24 volts applied
for more than a few seconds, the regulator/rectifier
may be damaged. To prevent damage to the regu-
lator/rectifier, do not apply more than 24 volts, and
do not apply 24 volts for more than a few seconds.
If the test light does not light when 24 V is applied momen-
tarily to the positive (+) terminal, the regulator/rectifier is
defective. Replace it.
If the regulator/rectifier passes all the tests described, it
may still be defective. If the charging system still does
not work properly after checking all the components and
the battery, test the regulator/rectifier by replacing it with
a known good unit.
Repeat the test for another regulator/rectifier.

Charging System
Charging System Circuit (JT1500-A1 A7 Models)
1. Load 5. Joint Connector S

2. Main Fuse 20 A (Ground)
3. Joint Connector R 6. Regulator/Rectifier
4. Battery 12 V 18 Ah 7. Magneto
Charging System Circuit (JT1500A8 Model )
1. Joint Connector P 5. Joint Connector U

2. Load 6. Regulator/Rectifier
3. Main Fuse 20 A 7. Magneto

Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plugs, ignition coils,
or spark plug high-tension leads while the engine
is running, or you could receive a severe electrical
shock.
NOTICE
Disconnecting the battery cables or any other elec-
trical connections when the ignition switch is on or
while the engine is running can damage the ECU
(Electronic Control Unit). Do not disconnect the
battery cables or any other electrical connections
when the ignition switch is on, or while the engine
is running.
Installing the battery cables backwards can damage
the diodes and ECU. Be sure to install the cables
properly.
Crankshaft Sensor Removal

Remove:
Crankshaft Sensor Cover Bolts [A]
Crankshaft Sensor Cover [B]
Unscrew:
Rubber Grommet Holder Screws [A]
Crankshaft Sensor Screws [B]
Push out the rubber grommet [C] with the holder [D].
Remove the crankshaft sensor [E].
Crankshaft Sensor Installation

Run the sensor lead through the cover hole.
Apply the
Install crankshaft sensor [A].
a non-permanent locking agent to the sensor
screws and tighten them.
Torque - Crankshaft Sensor Screws: 4.4 Nm (0.45 kgfm,
39 inlb)
Install the rubber grommet [B] in the sensor cover hole.
Run the sensor lead [C] as shown.
Apply water resistant grease to the grommet outside.
holder screws and tighten them.
Torque - Rubber Grommet Holder Screws: 4.4 Nm (0.45
kgfm, 39 inlb)

Ignition System
Apply grease to the O-ring and fit it in the groove of the

sensor cover.
Apply silicone sealant [A] to the crankcase halves mating
surface on the right and left sides of the crankshaft sensor
mount.
Install the crankshaft sensor cover.
Tighten:
Torque - Crankshaft Sensor Cover Bolts: 7.8 Nm (0.80
kgfm, 69 inlb)
Install
ter).
the Engine (see Engine Removal/Installation chap-
Timing Rotor Removal

Remove
chapter).
Remove the crankshaft sensor cover (see Crankshaft

Sensor Removal).
Remove the timing rotor [A].
Holding the timing rotor with the flywheel and pulley holder
[B] and unscrew the bolt [C].
Special Tools - Flywheel & Pulley Holder: 57001-1605
Flywheel and Pulley Holder Adapter: 57001
-1547 [D]
Timing Rotor Installation

Fit the rotor to the crankshaft.
Tightena non-permanent
Apply locking agent to the rotor bolt.
the rotor bolt.
Torque - Timing Rotor Bolt: 20 Nm (2.0 kgfm, 14 ftlb)
Install the crankshaft sensor cover (see Crankshaft Sen-
sor Installation).
Crankshaft Sensor Inspection
Remove:
(Blue) [A]. the 2-pin crankshaft sensor leads connector
Disconnect

Ignition System
connect
Set the hand tester to the 100 range, zero it, and
it to the crankshaft sensor lead terminals (G and
BL) in the connector.
If 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 shorted, and
must be replaced.
Crankshaft Sensor Resistance
Standard: 408 612
Ignition Coil Removal

Remove:
Spark Plug Caps (see Periodic Maintenance chapter)
Clamp [A] (JT1500-A1 Model)
Double Spring Clamp [A] (JT1500-A2 Model )
Fuel Supply Hose End [B]
Bracket Mounting Bolts [A].
Disconnect the ignition coil primary lead connectors [A]

and vehicle-down sensor lead connector [B].
Pull up the bracket [A] together with the ignition coils [B],
vehicle-down sensor [C], and fuel filter [D] installed.

Ignition System
Unscrew the nuts [A] and remove the bolts, collars [B] and
ignition coils [C].
Pull out the high tension lead [B] from the ignition coil [A].
Lubricate the leads with penetrating rust inhibitor.
Ignition Coil Installation

Connect
lows.
the high tension lead to each ignition coil as fol-
#1 High Tension Lead Length 340 mm (13.4 in.) [A]

#2 High Tension Lead Length 450 mm (17.7 in.) [B]
#3 High Tension Lead Length 540 mm (21.3 in.) [C]
#4 High Tension Lead Length 600 mm (23.6 in.) [D]
Each lead number is marked [E].
Apply a non-permanent locking agent to the ignition coil
mounting bolts.
Install the #1, 4 ignition coil [F] and #2, 3 ignition coil [G]
to the bracket [H] and tighten the bolts.
Torque - Ignition Coil Mounting Bolts: 8.8 Nm (0.90 kgfm,
78 inlb)
Apply a non-permanent locking
agent to the bracket
Torque - Bracket Mounting Bolts: 8.8 Nm (0.90 kgfm, 78

inlb)

Ignition System
Install the removal parts.

clamps with new ones (see Fuel System (DFI) chapter).
Ignition Coil Inspection
Measuring arcing distance
The most accurate test for determining the condition of
the ignition coil is made by measuring arcing distance.
Remove the ignition coil (see Ignition Coil Removal).
Connect the ignition coil [A] (with the spark plug cap left
installed on the spark plug lead) to the tester [B], and mea-
sure the arcing distance.
Auxiliary wire [C]
WARNING
To avoid extremely high voltage shocks, do not
touch the coil body or leads.
If the distance reading is less than the specified value, the
ignition coil or spark plug cap is defective.
3 Needle Arcing Distance
Standard: 7 mm (0.28 in.) or more
To determine which part is defective, measure the arcing

distance again with the spark plug leads removed from
the ignition coil (see Ignition Coil Removal).
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 lead.

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.
Disconnect the primary leads from the coil terminals.
Measure the primary winding resistance as follows [A].

Connect the tester between the coil terminals.
Set the tester to the 1 range, and read the tester.
Measure the secondary winding resistance as follows [B].
Remove the high tension leads (see Ignition Coil Re-
moval).
Connect the tester between the secondary lead terminals.
Set the tester to the 1 k, and read the tester.
If the hand tester does not read as specified, replace the
coil.
Winding Resistance
Standard: Primary windings 1.53 2.07
Secondary windings 12.50 16.91 k
If the tester reads are as specified, the ignition coil wind-
ings are probably good. However, if the ignition system
still does not perform as it should after all other compo-
nents have been checked, test replace the coil with one
known to be good.
Measuring high tension lead resistance
Check the high tension lead [A] for visible damage.
If the high tension lead is damaged, replace the high ten-
sion lead.
Measure the lead resistance with the hand tester [B].
Spark Plug Lead Resistance
Standard: 3.75 6.25 k
If the hand tester does not read as specified, replace the
lead
Camshaft Position Sensor Removal

Remove:
Disconnect
Cut off the clamp [A].
[B]. the camshaft position sensor lead connector

Ignition System
Remove:
Camshaft Position Sensor Bolt [A]
Camshaft Position Sensor [B]
Camshaft Position Sensor Installation

Apply grease or engine oil to the O-ring on the camshaft
position sensor.
Tighten:
Torque - Camshaft Position Sensor Bolt: 9.8 Nm (1.0
kgfm, 87 inlb)
Camshaft Position Sensor Inspection

Remove:
Camshaft Position Sensor Lead Connector [A] (discon-
nect)
Set the hand tester [B] to the 10 range and connect it
to the yellow and black leads in the connector.
If there is more resistance than the specified value, the
sensor coil has an open lead and must be replaced. Much
less than this resistance means the sensor coil is shorted,
and must be replaced.
Camshaft Position Sensor Resistance: 400 460
Using the highest resistance range of the tester, mea-

sure the resistance between the camshaft position sensor
leads and chassis ground.
Any tester reading less than infinity () indicates a short,
necessitating replacement of the camshaft position sen-
sor.
Igniter Removal/Installation
Refer
ter.
to the ECU Removal in the Fuel System (DFI) chap-

Ignition System
Igniter Inspection
The igniter is built in the ECU (Electronic Control Unit).
NOTICE
Disconnecting the battery cables or any other elec-
trical connections when the ignition switch is on or
while the engine is running can damage the igniter
in the ECU (Electronic Control Unit). Do not discon-
nect the battery cables or any other electrical con-
nections when the ignition switch is on, or while the
engine is running.
Ignition Coil Primary Peak Voltage Check
NOTE
Remove:
Pull all the spark plug caps from the spark plugs.
and ground
Install the new spark plugs [A] into each plug caps [B],
them onto the engine.
NOTE
Maintain the correct value of compression pressure for
the cylinder (Be sure to measure the voltage with the
spark plug installed to the cylinder head).
Remove:
[B]. the peak voltage adapter [A] into the hand tester
Install

Ignition System
Connect the peak voltage adapter [A] to the ignition coil

primary lead connector [D], using the harness adapter [C].
Hand Tester [B]
Ignition Coil [E]
Spark Plugs [F]
Harness Adapter: 57001-1562
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Hand Tester Range: DC 1 000 V
Primary Lead Connections

Adapter Adapter
(R, +) (BK, )
#1, 4 Ignition Coil: R BK/W (Ground)
#2, 3 Ignition Coil: R BK/W (Ground)
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
Turn the ignition switch on and push the lanyard key under
the stop button.
Pushing the starter button, crank the engine 4 5 seconds
to measure the primary peak voltage.
Do not operate the starter for longer than 5 seconds. Wait
15 seconds before using it again.
Repeat the measurements 5 or more times for one ignition
coil.
Ignition Coil Primary Peak Voltage
Standard: 250 V or more
Repeat the test for the other ignition coil.

If the reading is less than the specified value, see Igni-
tion System Troubleshooting table to determine whether
igniter is good or no good.

Ignition System
Crankshaft Sensor Peak Voltage Check
NOTE
Connect
[B].
the peak voltage adapter [A] to the hand tester
Special Tool - Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B
Connect the adapter the crankshaft sensor lead connec-
tor [C], using the needle adapter set [D].
Connections
Adapter Adapter
(R, +) (BK, )
Crankshaft Sensor: G BL
Hand Tester Range: DC 10 V
Turn the ignition switch on and push the lanyard key under
the stop button.
Pushing the starter button, crank the engine 4 5 seconds
to measure the crankshaft sensor peak voltage.
Do 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
If the reading is less than the specified value, check the
crankshaft sensor (see Crankshaft Sensor Inspection).
Camshaft Position Sensor Peak Voltage Inspection
Remove:
Set the digital meter [B] to the 10 V DC range.

Connect the peak voltage adapter [C] to the digital meter.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Connect the peak voltage adapter to the camshaft sensor
lead connector [D], using the needle adapter set [A].
Connections
Camshaft Sensor Lead Adapter Hand Tester
Black Red (+)
Yellow Black ()
Turn the ignition switch and engine stop switch on.

to measure
Pushing the starter button, turn the engine 4 5 seconds
the camshaft position sensor peak voltage.
Repeat the measurement 5 or more times.
Camshaft Position Sensor Peak Voltage
If the peak voltage is lower than the standard, inspect the
camshaft position sensor.
Ignition System
Spark Plug Removal
Refer to the Spark Plug Cleaning and Inspection in the
Spark Plug Installation
Spark Plug Inspection
Spark Plug Adjustment
Spark Plug Cleaning

Ignition System
Ignition System Circuit (JT1500-A1 A7 Models)
1. Joint Connector H 9. Ignition Switch 17. Camshaft Position Sensor

2. Joint Connector J 10. Joint Connector Q 18. Throttle Sensor
3. Joint Connector E 11. Engine Stop Switch 19. Connector D
4. Crankshaft Sensor 12. Joint Connector R 20. Ignition Coils
5. Relay Assembly (Main Re- 13. Main Fuse 20 A 21. Spark Plugs
lay/Fuel Pump Relay) 14. Starter Motor 22. Joint Connector P
6. Joint Connector F 15. Battery 12 V 18 Ah 23. Joint Connector S
7. Connector C 16. ECU (Electronic Control
8. Vehicle-down Sensor Unit)

Ignition System
Ignition System Circuit (JT1500A8 Model )
1. Joint Connector Y 7. Ignition Switch 15. Battery 12 V 18 Ah

2. Joint Connector X 8. Joint Connector P 16. Joint Connector U
3. Joint Connector W 9. Joint Connector Q 17. Spark Plugs
4. Crankshaft Sensor 10. Joint Connector S 18. Ignition Coils
5. Relay Assembly (Main Re- 11. Joint Connector R 19. Camshaft Position Sensor
lay/Fuel Pump Relay) 12. Engine Stop Switch 20. Throttle Sensor
6. Vehicle-down Sensor 13. Main Fuse 20A 21. ECU (Electronic Control
14. Starter Motor Unit)

Ignition System

Kawasaki Smart Steering System
Steering Position Sensor and Magnet Removal
Remove the steering holder (see Steering Removal in
Steering chapter).
Remove or disconnect:
Steering Position Sensor Lead Connector [A]
Leads Clamp on Steering Holder
Steering Position Sensor Mounting Screws [B]
Steering Position Sensor [C]
Unscrew
[B].
the mounting screw [A] and remove the magnet
Steering Position Sensor and Magnet Installation

Moving the steering shaft in the direction [A] and [B],
check the steering shaft for excessive play.
If necessary, adjust the steering shaft nut or replace the
bushings.
Apply a non-permanent locking agent to the steering

position sensor mounting screws and magnet mounting
screw.
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.

Turning the steering shaft fully in left and right direction,

check whether the steering position sensor comes in con-
tact with the magnet.
Standard: 0.5 1.5 mm (0.02 0.06 in.)
If necessary, adjust the steering shaft nut.
Check the operation of Kawasaki Smart Steering system.
Inspection of Kawasaki Smart Steering System

Inspect
the water.
the smart steering system with the watercraft in
Center the handlebar in the straight-ahead position .

r/min (rpm)theorthrottle
Squeeze lever and allow it to approx. 4 000
above for 4 seconds or more.
Release the throttle lever.
Within 1 second, turn the handlebar all the way to the left
or right and check the engine speed increases to approx.
2 800 r/min (rpm).
Center the handlebar in the straight-ahead position, and
check the engine speed decreases to an idle speed.
If the Kawasaki Smart Steering system does not operate
normally, check the steering position sensor clearance.
Standard: 0.5 1.5 mm (0.02 0.06 in.)
If the clearance is the specified value, inspect steering
position sensor input voltage.
If necessary, adjust the steering shaft nut.

Steering Position Sensor Input Voltage Inspection
Measure the input voltage to the steering position sensor.
NOTE
Connect a digital voltmeter [A] to the lead connector [B]
of the steering position sensor using the needle adapter
set [C].
Connections to Steering Position Sensor Connector

Meter (+) R/W Terminal
Meter () BK Terminal

Center the handlebar in the straight-ahead position.
Measure the input voltage.
Steering Position Sensor Input Voltage
If the reading is good, inspect steering position sensor
output voltage.
If the reading is out of the standard, check the following.
Battery Voltage
20 A Main Fuse
Power Source Wiring (see Steering Position Sensor Cir-
cuit)

Steering Position Sensor Output Voltage
Inspection
Measure
sensor.
the output voltage from the steering position
NOTE
Be sure the battery is fully charged
Connect a digital voltmeter [A] to the lead connector [B]
of the steering position sensor using the needle adapter
set [C].
Connections to Steering Position Sensor Connector

Meter (+) Y/BK Terminal
Meter () BK Terminal
Turn the handlebar fully left or right.
Measure the output voltage.
Steering Position Sensor Output Voltage
Standard: approx. 0 V
NOTE
When the handlebar is centered in straight-ahead posi-
tion the output voltage standard value is battery voltage.
If the reading is out of the standard, suspect the following.
Damaged Steering Position Sensor
Open Sensor Circuit
If the reading is the standard, but the Kawasaki Smart
Steering system does not operate, suspect the ECU and
idle speed control in the throttle body.

Steering Position Sensor Circuit (JT1500-A1 A7 Models)
4. Main Fuse 20 A
9. Ignition Switch

Steering Position Sensor Circuit (JT1500A8 Model )
4. Main Fuse 20 A
5. Joint Connector V
9. Ignition Switch

Sensors
Speed Sensor Removal/Installation
Unscrew the mounting bolts [A] and remove the speed
sensor assembly [B].
The speed sensor is located at the right on the hull in
JT1500-A1 A8 Models, however it is located at left on
Unscrew the cap [A].

Pull out the speed sensor connector and disconnect it.
When installing the speed sensor assembly, note the fol-

lowing.
Apply silicone sealant around the grommet [A] and lead
wires.
Speed Sensor Inspection

Remove the speed sensor.
shown. the battery and tester leads to the sensor as
Connect

Sensors
Rotate the waterwheel by hand slowly.

Measure the output voltage of the speed sensor.
G/R (+), BK/W () 0 battery voltage; twice a rotation
(Rotate it slowly.)
If the voltage does not rise from zero to battery voltage
twice a rotation, replace the sensor.
Measure
speeds.
the output voltage of the sensor at higher
Rotate the waterwheel in a fair speed by air.

G/R (+), BK/W () approx. 5 V
If the sensor voltage does not reach 5 volts when spun
with compressed air, replace the sensor.
Fuel Level Sensor Inspection

Loosen the the
Disconnect fuel level sensor 2-pin connector.
of the fuel tank. and remove the fuel level sensor out
clamp,
Set the hand tester (ohmmeter) to the 1 k range.

Connect the tester leads the W/R and BK/W leads to
check the switching operation of the float.
Meter Reading
When sensor is held upright [A]: approx. 8.03 k
When sensor is held upside down [B]: approx. 0
The meter should read as specified. If it does not, replace
the fuel level sensor.
Throttle Sensor Removal/Installation

Refer to the Throttle Sensor Removal/Adjustment in the
Fuel System chapter.

Sensors
Throttle Sensor Inspection
Refer to the Throttle Sensor Section in the Fuel System
chapter.
Water Temperature Sensor Inspection
Remove the water temperature sensor (see Feul (DFI)
System chapter).
Suspend the sensor [A] in a container of water so that the
temperature-sensing projection is submerged.
Suspend an accurate thermometer [B] in the water.
NOTE

raise the temperature of the water while stirring the water
gently.
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.
Water Temperature Sensor Resistance
Water Temperature Sensor Resistance
20C (68F) approx. 293 k
50C (122F) approx. 78.5 k
90C (194F) approx. 18.1 k
100C (212F) approx. 13.2 k
Inlet Air Temperature Sensor Inspection

Refer to the Inlet Air Temperature Sensor Section in the
Fuel System chapter.
Oil Temperature Sensor Inspection
Remove the oil temperature sensor (see Feul (DFI) Sys-
tem chapter).
Suspend the sensor [A] in a container of water so that the
temperature-sensing projection is submerged.
Suspend an accurate thermometer [B] in the water.
NOTE

raise the temperature of the water while stirring the water
gently.
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.
Oil Temperature Sensor Resistance
Oil Temperature Sensor Resistance
20C (68F) approx. 293 k
50C (122F) approx. 78.5 k
90C (194F) approx. 18.1 k
100C (212F) approx. 13.2 k

Multifunction Meter
Display Function Inspection
Using the auxiliary wires, connect the 12 V battery [A] to
the meter unit [B] connector as follows.
JT1500-A2 Model [C]
JT1500-A1 Model [D]
Connect the battery positive terminal to the terminal [1].
Connect the battery negative terminal to the terminal [2].
[1] R Battery (+)
[2] BK, Ground ()
[3] R/BL, Speed Sensor
[4] R/W Ignition Switch (+)
[5] W/R, Fuel Level Sensor
[6] BL/BK, Diagnosis Signal
[7] GY, Tachometer Pulse
[8] G/R, Speed Sensor Pulse
[9] BK/W, Buzzer ()
[10] R/BK, Buzzer (+)
[11] Y/BL, SLO (Smart Learning Operation) Mode
Battery Voltage Range: 10 16 V
When the positive terminal (+) of battery is connected

to the terminal [4] completely, inspect that every LCD
segment and LED warning light will be lit for several
seconds just after disappearance of demonstrative fig-
ure-expression.
Check that when the terminals are disconnected , all the
LCD segments and LED warning light disappear.
If the LCD segments and LED warning light will not ap-
pear, replace the meter assembly.
[1] MODE Button
[2] SET Button
[3] Fuel Indicator
[4] Fuel Level Gauge
[5] Tachometer
[6] Speedometer
[7] LED Warning Light
[8] Engine Oil Pressure Indicator
[9] FI Indicator
[10] Low Battery Voltage Indicator
[11] Engine Cooling Water Temperature Indicator
[12] Multifunction Display
NOTICE
Do not drop the meter unit. Do not short the termi-
nals.
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.

Multifunction Meter
MODE/SET Button Inspection
Check that when the MODE button is pushed and held
continuously, the display rotates through the four modes.
Indicate the clock mode.

Check that when the SET button is pushed for more than
two seconds, the meter display turns to the clock set
mode.
If the display function does not work, replace the meter
assembly.
Indicate the time mode.

two seconds,when
Check that the SET button is pushed for more than
the meter display turns to 00:00.
assembly.
Indicate the trip mode.

two seconds,when
Check that the SET button is pushed for more than
the meter display turns to 000.0.
assembly.
SLO (Smart Learning Operation) Mode Inspection
(JT1500-A2 Model )
Confirmation of the SLO mode shift.
To change the normal operation mode to SLO mode, push
the MODE button for 7 seconds or more.
The same initial display as shown when ignition switch
turned on is shown together with two times buzzer sound.
Then SLO (1 second) and normal display
(Clock/Time/Trip/Hour) (3 seconds) are shown blinking al-
ternately.
Confirmation of the normal operation mode shift.

To change the SLO mode to normal operation mode, push
the MODE button for 7 seconds or more.
The same initial display is first shown and followed by
FPO [A] for 2 seconds.
However FPO is shown only once when shifted and not
displayed thereafter.
assembly.

Multifunction Meter
Fuel Level Gauge/Symbol/FUEL Characters/Warn-
ing Light Inspection
Connect the 12 V battery and terminals in the same man-
ner as specified in the Display Function Inspection.
Connect
shown.
the variable rheostat [A] to the terminal [5] as
JT1500-A2 Model [B]

JT1500-A1 Model [C]
Check that the number of segments matches the resis-
tance value of the variable rheostat.
Resistance Value () Display Segments
8030 0*
2930 1 2
1330 3 4
510 5 6
0 7 8
*: The LED warning light, fuel symbol and FUEL char-
acters flash at the same time.
Ifassembly.
any display function does not work, replace the meter
Speedometer Inspection
The speed equivalent to the input frequency is indicated in
the oscillator [A] if the square wave (illustrated as shown)
would be input into the terminal [8].
JT1500-A2 Model [B]
JT1500-A1 Model [C]
Indicates approximately 60 mph in case the input fre-
quency would be approximately 265 Hz.
Indicates approximately 60 km/h in case the input fre-
quency would be approximately 165 Hz.

Multifunction Meter
Ifchecked
the oscillator is not available, the speedometer can be
as follows.
Install the meter unit.
Turn on the ignition switch.
Rotate the waterwheel by hand.
Check that the speedometer shows the speed.
If the speedometer does not work, check the speed sen-
sor electric source voltage and speed sensor.
Speed Sensor Electric Source Inspection

Set the hand tester [A] to the DC 25 V range and connect
it to the terminals [3] and [2].
If the voltage is less than 7 V, replace the meter assembly.

Multifunction Meter
Tachometer Inspection
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].
JT1500-A2 Model [B]
JT1500-A1 Model [C]
The tachometer indicates approximately 3 000 r/min
(rpm) in case the input frequency would be approxi-
mately 100 Hz.
If the tachometer does not work normally, replace the me-
ter assembly.
Battery Symbol/bAt Characters/LED Inspection

Check that the battery symbol/bAt characters/LED flash
when the input voltage to the terminal [A] is lowered to
12 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.
If any display function does not work, replace meter as-
sembly.

Multifunction Meter
Buzzer Inspection
Make sure that the buzzer sounds correctly when turning
the ignition switch key to the ON position and warning
the trouble after connecting the buzzer between [9] and
[10].
If the output voltage between [9] and [10] is out of the
range during the buzzer sound, replace the meter assy.
Output Voltage
7 14 V for normal sound, 2 4 V for low sound.
Hand tester [A]

Multifunction Meter
Multifunction Meter Circuit (JT1500-A1 A7 Models)
3. Buzzer
5. Speed Sensor
6. Main Fuse 20 A
8. Starter Motor
11. Ignition Switch

Multifunction Meter
Multifunction Meter Circuit (JT1500A8 Model )
3. Buzzer
5. Speed Sensor
6. Main Fuse 20 A
7. Joint Connector V
8. Starter Motor
11. Ignition Switch

Relay Assembly
Removal
Relay Assembly Connector [A]
Remove:
Clamp [B]
Bolt [C]
Relay Assembly [D]
Installation
Apply a non-permanent locking agent to the relay assem-
bly mounting bolt and tighten it securely.
Route the relay assembly leads correctly (see Cable, Wire
and Harness Routing in Appendix chapter).
Circuit Inspection
Remove the relay assembly.
by connecting the hand
Check conductivity of the following numbered terminals
tester and one 12 V battery to the
relay assembly as shown.
If the tester does not read as specified, replace the relay
assembly.

Relay Assembly
Relay Assembly Circuit Inspection (with the battery disconnected)
Tester Connection Tester Reading ()
3-4
ECU Main Relay [A]
1-2 Not *
7-8
Fuel Pump Relay [B]
5-6 Not *
(*): The actual reading varies with the hand tester used.
Relay Assembly Circuit Inspection (with the battery connected)

Battery Connection
Tester Connection Tester Reading ()
(+) ()
ECU Main Relay [A] 1-2 3-4 0
Fuel Pump Relay [B] 5-6 7-8 0
(+): Apply positive lead.
(): Apply negative lead.

Switches
Switch Inspection
Using a hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).
For the switch housing and the ignition switch, refer to the
tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Ignition Switch
Start Switch
Stop Switch
Tether Switch
Engine Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition

Fuse
Fuse Inspection
Remove:
Seat
Fuse Case [A]
Take out the fuse [A].
Inspect the fuse element.

If it blown out, replace the fuse. Before replacing a blown
fuse, always check the amperage in the affected circuit.
If the amperage is equal to or greater than the fuse rat-
ing, check the wiring and related components for a short
circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTICE
Installation of a fuse with a higher rating may cause
damage to wiring and components. When replacing
a fuse, be sure the new fuse matches the specified
fuse rating for that circuit.

STORAGE 15-1
Storage
Table of Contents
Preparation for Storage .......................................................................................................... 15-2
Cooling System................................................................................................................. 15-2
Discharging water in the exhaust system ......................................................................... 15-2
Bilge System ..................................................................................................................... 15-3
Engine Oil ......................................................................................................................... 15-3
Fuel System ...................................................................................................................... 15-3
Engine............................................................................................................................... 15-4
Air Filter............................................................................................................................. 15-4
Battery............................................................................................................................... 15-5
Engine Mounting Bolts ...................................................................................................... 15-5
Lubrication ........................................................................................................................ 15-5
General ............................................................................................................................. 15-5
Removal from Storage............................................................................................................ 15-6
Lubrication ........................................................................................................................ 15-6
General Inspection............................................................................................................ 15-6
Fuel System ...................................................................................................................... 15-6
Test Run............................................................................................................................ 15-7
15

15-2 STORAGE
Preparation for Storage
During the winter, or whenever the watercraft will not be
in use for a long period of time, proper storage is essential.
It consists of checking and replacing missing or worn parts;
lubricating parts to ensure that they do not become rusted;
and, in general, preparing the watercraft so that when the
time comes to use it again, it will be in top condition.
NOTE
Personal watercraft is not meant to be left in the water
for extended periods. Continuous exposure to water
over a long period of time will cause the hull paint to
bubble and peel. It also causes electrolytic erosion of
the metal parts of the pump, decreasing its service life.
Larger boats which are left in the water must be hauled
out periodically, so the bottom of the hull can be scraped
and repainted with anti-fouling paint. They also usually
have a sacrificial anode to reduce electrolytic erosion of
metal parts in contact with the water.
Cooling System
Clean the cooling system (see Cooling System Flushing
in the Periodic Maintenance chapter).
When storing the watercraft in an area where the temper-
ature drops below freezing, perform the following.
Discharging water in the exhaust system
NOTICE
Water in the exhaust system could freeze during
cold weather and damage the exhaust pipe. Dis-
charge water from the exhaust system after flush-
ing the cooling system.
After flushing, remove the cooling water hose [C] from

the fitting [B] on the engine output cover [A] at the rear
of the engine. Lead the hose to the lowest level in the
engine room so that water remaining in the exhaust pipe
[D] drains out.
Air Filter Box [E]
Connect the hose to fitting on the output cover and tighten
the clamp securely.
NOTICE
If the hose comes off during operation, cooling wa-
ter could swamp the boat.
Connect the hose securely to the fitting.
If you are not confident you can perform storage
procedures, ask your Kawasaki JET SKi watercraft
dealer for this service.

STORAGE 15-3
Bilge System
Clean the bilge system (see Bilge System Flushing in the
Periodic Maintenance chapter). Before reconnecting the
hoses to the plastic breather fitting, blow air through both
hoses [A] to force all water out of the bilge system.
Engine Oil
Change the engine oil (see Engine Lubrication System in
Periodic Maintenance chapter).
Fuel System
WARNING
light.
Drain
pump.
the fuel tank. This should be done with a siphon or
[A] Siphon Hose

NOTE
Lift the stern upward a little so that fuel and water in the
bottom of the fuel tank may flow toward the fuel filter to
completely drain the fuel tank.
Remove the fuel pump (see the Fuel System chapter).

riodic Maintenance
Clean the fuel pump screen [A] (see Fuel System in Pe-
chapter).
gal U.S.).
Refill the fuel tank with fresh fuel approximately 10 L (2.6
Turn the ignition switch on.

enginetheandlanyard
Push key under the stop button, and start the
run it in 15 second periods until all fuel in the
fuel system is with fresh fuel. Wait 5 minutes between 15
seconds running periods.
NOTICE
Pull the lanyard key off the stop button and turn the igni-
tion switch off.
Drain the fuel tank.
the tank.the fuel filler cap loose to prevent condensation in
Leave

15-4 STORAGE
Engine
Remove
chapter).
Disconnect both two connection on the ignition coil pri-

mary lead connectors [A].
Remove the spark plugs (see Electrical System in Peri-
odic Maintenance chapter).
Spray fogging oil directly into each cylinder.
Push theignition
Turn the switch on.
engine over severalkeytimes
lanyard under the stop button. Turn the
with the start button to coat the
cylinder walls with oil.
WARNING
An air/oil mist may be forcibly ejected from the
spark plug holes and could get into your eyes. Do
not lean over the engine when performing this pro-
cedure. If you do get oil in your eyes, wash them
immediately with liberal amounts of clean, fresh
water and consult a physician as soon as possible.
Pull the lanyard key off the stop button and turn the igni-
tion switch off.
Spray the spark plugs with fogging oil, and reinstall the
spark plugs and caps (see Electrical System in Periodic
Maintenance chapter).
Reconnect the primary ignition coil lead connectors, not-

ing the #1,#4 [A] and the #2, #3 [B] coil connectors. The
#1, #4 coil connector has a red/yellow and a green/blue
leads from the main harness. The #2, #3 coil connec-
tor has a red/yellow and green/black leads from the main
harness.
NOTE
Air Filter
Remove the air filter (see Fuel (DFI) System chapter).
ter).
Disassemble the air filter (see Fuel (DFI) System chap-
Wash and dry the flame arrester [A].

chapter). and install the air filter (see Fuel (DFI) System
Assemble

STORAGE 15-5
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.
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.
NOTICE
Do not allow any soda solution to enter the battery.
Coat both battery terminals with grease.

freezingthetemperatures.
Store battery in a cool, dry place. Do not expose it to
Engine Mounting Bolts

Tighten all engine mounting
moval/Installation chapter).
bolts (see Engine Re-
Lubrication
Carry out all recommended lubrication procedures (see
Lubrication in Periodic Maintenance chapter).
General
Wash the engine compartment with fresh water and re-
move the drain screw in the stern to drain the water. Wipe
up any water left in the compartment.
NOTICE
Harsh solvents may attack the surface or smear the
colors of the hull. Use only a mild detergent in water
to wash the hull.
Apply a good grade of wax to all exterior hull surfaces.

Lightly spray all exposed metal parts with a penetrating
rust inhibitor.
Remove the seat, or block the seat up with 10 mm (0.39
in.) spacers to insure adequate ventilation, and prevent
corrosion.
Cover the watercraft and store it in a clean, dry place.

15-6 STORAGE
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, steering or shift
mechanism. The throttle lever must return fully when
released.
Clean and gap spark plugs (see Electrical System in Pe-
riodic Maintenance chapter).
Check all rubber hoses for weathering a cracking, or
looseness.
Check that the drain screw in the stern is securely tight-
ened.
Check the fire extinguisher for a full charge.
Check the battery, charge if necessary, and clean the ter-
minals. Install the battery (see Battery Installation in Elec-
trical System chapter).
Fuel System
Check and clean or replace the fuel pump screens as nec-
essary (see Fuel System in Periodic Maintenance chap-
ter).
WARNING
light.
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. To pre-
vent a fire or explosion, remove the seat to vent the
engine compartment.
Check for fuel leaks. Repair if necessary.

oil. the engine oil level. Fill the oil with the specified
Check

STORAGE 15-7
Removal from Storage
Test Run
DANGER
Start the engine and run it only for 15 seconds. Check for
fuel, oil and exhaust leaks. Any leaks must be repaired.
NOTICE
Install the seat making sure it is locked.

APPENDIX 16-1
Appendix
Table of Contents
Cable, Wire and Hose Routing ............................................................................................... 16-2
Troubleshooting Guide ........................................................................................................... 16-46
16

16-2 APPENDIX
Cable, Wire and Hose Routing
JT1500-A1 A8 Models

APPENDIX 16-3
1. Crossmember
2. Cylinder Head Cover
3. Throttle Cable
4. Delivery Pipe
5. Fix the throttle cable to the delivery pipe with the band.
6. Inlet Manifold
7. Horizontal Plane
8. Position the clamp pinch head below the horizontal plane.
9. Throttle Body Assy
10. Air Filter
11. Clamps
12. Cooling Hose (Cylinder Left Water Box Muffler)
13. Oil Pan
14. Position the clamp pinch head as shown.
15. Oil Separator Tank Hose (Tank Oil Pan)
16. Cooling Hose (Pump Output Cover)
17. Output Cover
18. Exhaust Pipe
19. Cooling Hose (Output Cover Exhaust Pipe)
20. Bands
21. Oil Separator Tank
22. Cooling Hose (Left Water Box Muffler Cylinder)
23. Return Oil Hose (Cylinder Oil Pan)
24. Air Filter Drain Caps
25. White Mark
26. Oil Separator Tank Hose (Tank Air Filter)
27. Deck (Port Side)
28. Oil Separator Tank Hose (Cylinder Head Cover Tank)
29. Plate
30. Air Suction Valve Hose
32. Flushing Hose
33. Bypass Outlet Hose
34. Breather Hose (Cylinder Head Breather Case)
35. Run the flushing hose under the crossmember. Fix the flushing hose with the band at the left
end hole so that the hose does not touch the crossmember.
36. Flushing Cap

16-4 APPENDIX
JT1500A9 Model

APPENDIX 16-5
1. Crossmember
3. Throttle Cable
4. Delivery Pipe
5. Fix the throttle cable to the delivery pipe with the band.
6. Inlet Manifold
7. Horizontal Plane
8. Position the clamp pinch head below the horizontal plane.
10. Air Filter
11. Clamps
12. Cooling Hose (Cylinder Left Water Box Muffler)
13. Oil Pan
14. Position the clamp pinch head as shown.
15. Oil Separator Tank Hose (Tank Oil Pan)
17. Output Cover
18. Exhaust Pipe
20. Bands
21. Oil Separator Tank
22. Cooling Hose (Water Box Muffler Cylinder)
24. Air Filter Drain Caps
25. White Mark
26. Oil Separator Tank Hose (Tank Air Filter)
27. Deck (Port Side)
28. Oil Separator Tank Hose (Cylinder Head Cover Tank)
29. Plate
31. Flushing Hose
33. Breather Hose (Cylinder Head Breather Case) (JT1500A9 AB Models)
34. Run the flushing hose under the crossmember. Fix the flushing hose with the band at the left
end hole so that the hose does not touch the crossmember.
35. Flushing Cap

16-6 APPENDIX

APPENDIX 16-7
1. Oil Cooler
2. Cylinder Head
3. Water Pipe
4. Cylinder
5. Oil Filter
6. Oil Pan
7. Battery () Cable
8. Starter Motor
9. Starter Motor Cable
10. Cooling Hose (Cylinder Head Left Water Box Muffler)
11. Fix the No.10 cooling hose, battery () cable and starter motor cable with the band.
12. Output Cover
13. Water Hose Joint (Inlet)
14. Water Hose joint (Outlet)
16. Protective Tube
17. JT1500A9 Model

16-8 APPENDIX
JT1500-A1 A8 Models

APPENDIX 16-9
1. Clamps
2. Breather Hose (Cylinder Head Breather Case)
3. Clamp Detail
4. Position the clamp pinch heads as shown.
5. Air Suction Valve
7. Inlet Water Pipe Joint on the Cylinder (Cooling Water from Left Water Box Muffler)
8. Cylinder
10. Output Cover
11. Protective Tube
13. Breather Hose (Cylinder Breather Case)
14. Breather Case
15. Oil Pan
16. Front Pinch Head
17. Rear Pinch Head
18. Position the clamp so that its pinch heads do not touch the oil separator tank hose.
19. To Air Fillter

16-10 APPENDIX
JT1500A9 Model

APPENDIX 16-11
1. Clamps
2. Breather Hose (Cylinder Head Crankcase) (JT1500A9 AB Models)
3. Clamp Detail (JT1500A9 AB Models)
4. Position the clamp pinch heads as shown. (JT1500A9 AB Models)
5. Inlet Water Pipe Joint on the Cylinder (Cooling Water from Water Box Muffler)
6. Cylinder
8. Output Cover
9. Protective Tube
11. Oil Pan
12. Front Pinch Head
13. Rear Pinch Head
14. Position the clamp so that its pinch heads do not touch the oil separator tank hose.
15. To Air Fillter
16. Clamp (JT1500A9 AB Models)

16-12 APPENDIX
JT1500-A1 A8 Models

APPENDIX 16-13
Refer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapter.
Install the clamp as shown, noting its screw head direction.
1. Bypass Outlet
2. Clamps
3. Holder
4. Bypass Outlet Hose: Run the bypass outlet hose between the fuel tank and the straps as shown.
5. Cooling Hose (Oil Cooler Exhaust Manifold): Run the cooling hose between the fuel tank and
the straps as shown.
6. Cooling Hose (Pump Oil Cooler)
7. Oil Cooler
8. Water Pipe on the Cylinder Head
9. Position the clamp screw head as shown.
10. Cooling Hose (Cylinder Head Water Pipe Joint under the Left Water Box Muffler)
11. Protective Tube
13. Output Cover
15. Oil Pan
16. Bands
18. Position the clamp so that its screw head faces downward and outside.
19. Position the clamp so that its screw head faces backward.
20. Pump
21. Drain
24. Cooling Hose (Left Water Box Muffler Hull)
25. Fix the No.26 and No.27 cooling hoses with the band.
27. Cooling Hose (Left Water Box Muffler Cylinder): Run the No.27 cooling hose under the No.26
cooling hose as shown.
28. Exhaust Pipe
29. Position the clamp so that its screw head faces inside.
31. Cooling Hose (Oil Cooler Exhaust Manifold)
32. Fuel Tank
33. Fuel Tank Strap
34. Shift Cable
35. Fix the No. 6 cooling hose and the shift cable with the band.
36. Protective Tube (JT1500A6 Model )

16-14 APPENDIX
JT1500A9 Model

APPENDIX 16-15
Refer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapter.
Install the clamp as shown, noting its screw head direction.
1. Bypass Outlet
2. Clamps
3. Holder
4. Bypass Outlet Hose: Run the bypass outlet hose between the fuel tank and the straps as shown.
5. Cooling Hose (Oil Cooler Exhaust Manifold): Run the cooling hose between the fuel tank and
the straps as shown.
6. Cooling Hose (Pump Oil Cooler)
7. Oil Cooler
8. Water Pipe on the Cylinder Head
9. Position the clamp screw head as shown.
10. Cooling Hose (Cylinder Head Water Pipe Joint under the Water Box Muffler)
11. Protective Tube
13. Output Cover
15. Oil Pan
16. Bands
17. Position the clamp so that its screw head faces downward and outside.
18. Pump
19. Drain
22. Cooling Hose (Water Box Muffler Hull)
23. Fix the No.26 and No.27 cooling hoses with the band.
25. Cooling Hose (Water Box Muffler Cylinder): Run the No.27 cooling hose under the No.26
cooling hose as shown.
26. Exhaust Pipe
27. Position the clamp so that its screw head faces inside.
29. Cooling Hose (Oil Cooler Exhaust Manifold)
30. Fuel Tank
31. Fuel Tank Strap
32. Shift Cable
33. Fix the No. 6 cooling hose and the shift cable with the band.
34. Protective Tube

16-16 APPENDIX
JT1500-A1 A8 Models

APPENDIX 16-17
1. Exhaust Manifold
2. Exhaust Pipe
3. Water Hose Joint (Cooling Hose from the Output Cover)
4. 30
5. Water Hose Joint (Cooling Hose from the Oil Cooler)
6. Upper Water Hose Joint
7. Water Hose Joint (Left Water Box Muffler Cylinder)
8. Water Hose Joint (Left Water Box Muffler Drain)
9. Lower Water Hose Joint
10. 45
11. Dampers
13. Position the clamp so that their screw heads face forward.
14. To Tail Pipe
15. White Marks
16. F Mark
17. R Mark
18. Exhaust Tubes

16-18 APPENDIX
JT1500A9 Model

APPENDIX 16-19
1. Exhaust Manifold
2. Exhaust Pipe
3. Water Hose Joint (Cooling Hose from the Output Cover)
4. 30
5. Water Hose Joint (Cooling Hose from the Oil Cooler)
6. Upper Water Hose Joint
7. Water Hose Joint (Water Box Muffler Cylinder)
8. Water Hose Joint (Water Box Muffler Drain)
9. Lower Water Hose Joint
10. 45
11. Dampers
13. Position the clamp so that their screw heads face forward.
14. To Tail Pipe
15. Arrow Mark
16. Exhaust Tube

16-20 APPENDIX
JT1500-A1 A8 Models

APPENDIX 16-21
1. Right Rear Duct
2. Right Bilge Hose
3. Left Bilge Hose
4. Left Rear Duct
6. Position the left rear duct inside the left bilge hose as shown.
7. Position the right rear duct under the right bilge hose as shown.
9. Right Bilge Breather
10. Left Bilge Breather
11. Left Bilge Filter
12. Right Bilge Filter

16-22 APPENDIX
JT1500A9 Model

APPENDIX 16-23
1. Right Rear Duct
2. Right Bilge Hose
3. Left Bilge Hose
4. Left Rear Duct
6. Position the left rear duct inside the left bilge hose as shown.
7. Position the right rear duct under the right bilge hose as shown.
8. Right Bilge Breather
9. Left Bilge Breather
10. Left Bilge Filter
11. Right Bilge Filter

16-24 APPENDIX
JT1500-A1 A8 Models

APPENDIX 16-25
1. Position the clamp screw so that its head faces forward (JT1500-A1 Model).
Position the double spring clamp so that its pinch head faces forward (JT1500-A2 Model ).
2. Delivery Pipe Joints
3. Delivery Pipe
5. Protective Tube
7. Position the clamp screw so that its head faces backward (JT1500-A1 Model).
Position the double spring clamp so that its pinch head faces backward (JT1500-A2 Model ).
8. #4 Spark Plug Cap
10. Fix the #2 and #3 high tension leads with the clamp.
16. Clamp (JT1500-A1 Model)
Double Spring Clamp (JT1500-A2 Model )
17. Fuel Filter
18. Bracket
20. Ignition Coils
21. #4 High Tension Lead
25. O-ring
26. Holder
27. Fuel Pump
28. Return Fuel Hose
29. Main Fuel Hose
30. Supply Fuel Hose
31. 20
32. Position the black/white lead upward (both ignition coils).
33. Position the red lead downward (both ignition coils).
34. Clamp

16-26 APPENDIX
JT1500A9 Model

APPENDIX 16-27
1. Position the double spring clamp so that its pinch head faces forward.
2. Delivery Pipe Joints
3. Delivery Pipe
5. Protective Tube
7. Position the double spring clamp so that its pinch head faces backward.
15. Double Spring Clamp
16. Fuel Filter
17. Bracket
19. Ignition Coils
24. O-ring
25. Holder
26. Fuel Pump
27. Return Fuel Hose
28. Main Fuel Hose
29. Supply Fuel Hose
30. 20
31. Position the black/white lead upward (both ignition coils).
32. Position the red lead downward (both ignition coils).
33. Clamp

16-28 APPENDIX
JT1500-A1 A8 Models

APPENDIX 16-29
1. Air Suction Valve Hose (to Air Filter)
2. Air Suction Valve
3. Air Suction Valve Cover (Rear)
4. Water Temperature Sensor Leads
5. Exhaust Manifold
6. Air Suction Valve Hose Fitting
7. Air Suction Valve Cover (Front)
8. Breather Hose
10. Crankshaft Sensor Leads
11. Fix the crankshaft sensor lead and the oil temperature sensor lead to the dipstick pipe with the
band.
12. Dipstick Pipe
13. Inlet Manifold
14. Clamp the engine harness and the crankshaft sensor lead connector.
15. Engine Harness
17. Run the inlet air pressure sensor leads under the delivery pipe.
18. Delivery Pipe
19. Oil Temperature Sensor Leads
20. Throttle Sensor Connector
21. Injectors
23. Oil Filter
24. Oil Cooler
26. ISC (Idle Speed Controller) Connector
27. Camshaft Position Sensor Connector
28. ECU (Electronic Control Unit) Connector
29. Clamp the water temperature sensor and camshaft position sensor leads.
31. Fix the engine harness to the ISC with the band.
32. Crankshaft Sensor Lead Connector
33. Fix the camshaft position sensor connector and water temperature sensor leads with the band.
35. Run the oil pressure switch lead between the cylinder and inlet manifold.

16-30 APPENDIX
JT1500A9 Model

APPENDIX 16-31
1. Water Temperature Sensor Leads
2. Exhaust Manifold
3. Breather Hose (JT1500A9 AB Models)
6. Fix the crankshaft sensor lead and the oil temperature sensor lead to the dipstick pipe with the
band.
7. Dipstick Pipe
8. Inlet Manifold
9. Clamp the engine harness and the crankshaft sensor lead connector.
10. Engine Harness
12. Run the inlet air pressure sensor leads under the delivery pipe.
13. Delivery Pipe
14. Oil Temperature Sensor Leads
15. Throttle Sensor Connector
16. Injectors
18. Oil Filter
19. Oil Cooler
21. ISC (Idle Speed Controller) Connector
22. Camshaft Position Sensor Connector
23. ECU (Electronic Control Unit) Connector
24. Clamp the water temperature sensor and camshaft position sensor leads.
26. Fix the engine harness to the ISC with the band.
27. Crankshaft Sensor Lead Connector
28. Fix the camshaft position sensor connector and water temperature sensor leads with the band.
30. Run the oil pressure switch lead between the cylinder and inlet manifold.

16-32 APPENDIX

APPENDIX 16-33
2. Grommet
3. Crankshaft Sensor Cover (Reverse Side)
5. Magneto Cover (Reverse Side)
6. Magneto Leads
7. Plate for fixing the magneto leads: Do not place the leads between the plate and magneto cover.
8. Run the magneto leads along the hollow of the magneto cover.
9. Crankcase
10. Coupling
11. Output Cover
12. Run the magneto leads between the magneto cover and output cover. Do not pinch the leads.

16-34 APPENDIX

APPENDIX 16-35
1. Band
2. Main Harness
3. Rivet
4. Washer
5. See wire routing at bow.
6. See wire routing at stern.
7. Clamps
8. Speed Sensor Leads
9. Water Box Muffler Strap
11. 16 Pin (Gray) and 6 Pin (White) Connectors (JT1500-A1 A7 Models)
12. To Engine (JT1500A8 Model )
13. JT1500A9 Model

16-36 APPENDIX

APPENDIX 16-37
1. Crossmember
2. Steering Position Sensor Leads
3. Holder and Clamp
4. Fuel Vent Hose
5. Throttle Cable
6. Band
7. Ignition Switch Lead
8. Ignition Switch Lead Connector (Black)
9. Steering Position Sensor Lead Connector (White)
10. Fuel Level Sensor Lead Connector (Black)
11. Main Harness
12. Fuel Pump
13. Fuel Pump Lead Connector (White)
14. Steering Cable
15. Fuel Filter
17. Ignition Coil Lead Connectors (Gray)
18. Vehicle-down Sensor Lead Connector (White)
19. Fuel Tank
21. #2, #3 Ignition Coils
22. #1, #4 Ignition Coils
24. Clamp
25. Fuel Tank Filler Tube
26. 35 mm (1.38 in.)

16-38 APPENDIX

APPENDIX 16-39
1. Multifunction Meter Lead Connector (Blue and Yellow: JT1500-A1 Model), (Blue and White:
JT1500-A2 Model )
2. Buzzer Lead Connector (Blue)
3. Start/Stop Switch Lead Connector (White)
4. Fuel Tank
5. Holders and Bands
6. Main Harness
7. Shift Cable
8. Fuse Case
9. Regulator/Rectifier
10. 16 Pin (Gray) and 6 Pin (White) Connectors (JT1500-A1 A7 Models)
12. Starter Relay Case
13. Starter Relay Lead Connector (Black)
14. Battery (+) Cable Connector (Gray: JT1500-A1 Model), (White: JT1500-A2 Model )
15. Battery (+) Cable
16. Speed Sensor Lead Connector (Black)
17. Speed Sensor Lead
18. Right Water Box Muffler Strap
19. Clamp
20. Battery () Cable Connector (Black)
21. Magneto Lead Connector (Black)
22. Battery () Cable
23. Starter Motor
24. Starter Motor Cable
25. Relay Assembly
26. To Engine (JT1500A8 Model )
27. JT1500A9 Model
28. White Tape
29. JT1500A9 Late Model

16-40 APPENDIX

APPENDIX 16-41
1. Regulator/rectifier
3. Main Harness
4. Clamp
5. Electrical Parts Bracket
6. To Starter Motor
7. To Battery
8. Relay Assembly
9. Red Mark
10. Starter Relay
11. Right Side Deck
12. Main Harness

16-42 APPENDIX

APPENDIX 16-43
1. Fuel Vent Pipe: Hook the pipe at the handlebar.
2. Throttle Cable
3. Buzzer Leads (Run the leads through the protective tube.)
4. Protective Tube
5. Band
6. Clamp
7. Start/Stop Switch Leads
8. Grommet on Steering Holder
9. Multifunction Meter Leads
10. Fuel Vent Hose
11. Steering Holder
12. Holder
14. Steering Shaft
15. Reverse Side of Steering Holder
16. Protective Tube (small diameter)
17. Clamps
18. Buzzer
19. Buzzer Leads
20. White Tape
21. 50 mm (1.97 in.)
22. JT1500A9 Model

16-44 APPENDIX

APPENDIX 16-45
1. 80 mm (3.15 in.)
2. 100 mm (1.18 in.)
3. 180 mm (7.09 in.)
4. 40 mm (1.57 in.)
5. 105 mm (4.13 in.)
6. 90 mm (3.54 in.)
7. 50 mm (1.97 in.)
8. 130 mm (5.12 in.)
9. Detent
10. Holder

16-46 APPENDIX
Troubleshooting Guide
NOTE Spark plug cap shorted or not in good con-
This is not an exhaustive list, giving every tact
possible cause for each problem listed. It IC igniter in ECU trouble
is meant simply as a rough guide to assist Camshaft position sensor trouble
the troubleshooting for some of the more Crankshaft sensor trouble
common difficulties. Wiring shorted or open
Fuse blown
Engine Doesnt Start, Starting
Fuel/air mixture incorrect
Difficulty
Air passage clogged
Starter motor not rotating
Air filter poorly sealed
Starter motor trouble (brushes worn)
Fuel injector trouble
Battery voltage low
Water or foreign matter in fuel
Starter relay not contacting or operating
Throttle sensor trouble
Start button not contacting
Fuel pressure may be low
Wiring open or shorted
Fuel pump trouble
Ignition switch trouble
Inlet air pressure sensor trouble
Engine stop switch trouble
Inlet air temperature sensor trouble
Fuse blown
Water temperature sensor trouble
Starter motor rotating but engine doesnt
Crankshaft sensor trouble
turn over
Compression Low
Reduction gear trouble
Spark plug loose
Vehicle-down sensor (DFI) coming off
Cylinder head not sufficiently tightened
Engine wont turn over
down
Valve seizure
No valve clearance
Valve lifter seizure
Cylinder, piston worn
Cylinder, piston seizure
Piston ring bad (worn, weak, broken, or
Crankshaft seizure
sticking)
Connecting rod small end seizure
Piston ring/groove clearance excessive
Connecting rod big end seizure
Cylinder head gasket damaged
Camshaft seizure
Cylinder head warped
No fuel flow
Valve spring broken or weak
No fuel in tank
Valve not seating properly (valve bent,
Fuel tank air vent obstructed
worn, or carbon accumulation on the
Fuel pump screen and/or fuel filter clogged
seating surface)
Fuel injector trouble
Fuel line clogged
Engine flooded Poor Running at Low Speed
Clean spark plug and adjust plug gap Spark weak
Starting technique faulty (When flooded, do Battery voltage low
not crank the engine with the throttle fully Spark plug dirty, broken, or maladjusted
opened. This promotes engine flood be- Ignition coil shorted or not in good contact
cause more fuel is supplied automatically Ignition coil trouble
by DFI.) Spark plug incorrect
No spark; spark weak Spark plug cap trouble
Ignition coil faulty Spark plug cap shorted or not in good con-
Vehicle-down sensor (DFI) coming off tact
Vehicle-down sensor trouble IC igniter in ECU trouble
Ignition switch turned OFF and/or lanyard Camshaft position sensor trouble
key not pushed under stop button Crankshaft sensor trouble
Battery voltage low Fuel/air mixture incorrect
Spark plug dirty, broken, or gap malad- Air passage clogged
justed Air filter poorly sealed
Ignition coil shorted or not in good contact Fuel tank air vent obstructed
Ignition coil trouble Fuel pump trouble
Spark plug incorrect Inlet air duct loose
Spark plug cap trouble Fuel pump screen and/or fuel filter clogged
Throttle body assy loose
Throttle body assy gasket damage

APPENDIX 16-47
Fuel line clogged Fuel injector trouble
Inlet air pressure sensor trouble Throttle sensor malfunction
Inlet air temperature sensor trouble Water temperature sensor trouble
Engine stalls easily Inlet air pressure sensor trouble
Fuel pump trouble Surge
Fuel injector trouble Unstable fuel pressure
Throttle sensor trouble Fuel injector trouble
Camshaft position sensor trouble Water temperature sensor trouble
Fuel pressure too low or too high Backfiring when deceleration
Inlet air pressure sensor trouble Spark plug dirty, broken or gap maladjusted
Water temperature sensor trouble Too low fuel pressure
Inlet air temperature sensor trouble Fuel pump trouble
Fuel line clogged Throttle sensor trouble
Crankshaft sensor trouble Inlet air temperature sensor trouble
Ignition coil trouble Water temperature sensor trouble
Compression low Inlet air pressure sensor trouble
Spark plug loose Air suction valve trouble
Cylinder head not sufficiently tightened After fire
down Crankshaft sensor trouble
No valve clearance Spark plug burned or gap maladjusted
Cylinder, piston worn Inlet air temperature sensor trouble
Piston ring bad (worn, weak, broken, or Water temperature sensor trouble
sticking) Inlet air pressure sensor trouble
Piston ring/groove clearance excessive Fuel injector trouble
Cylinder head warped Run-on (dieseling)
Cylinder head gasket damaged Ignition switch trouble
Valve spring broken or weak Engine switch trouble
Valve not seating properly (valve bent, Fuel injector trouble
worn, or carbon accumulation on the Loose terminal of battery () lead or ECU
seating surface) ground lead
Hesitation Carbon accumulating on valve seating sur-
Too low fuel pressure face
Clogged fuel line Engine overheating
Fuel pump trouble Other
Fuel injector trouble IC igniter in ECU trouble
Inlet air temperature sensor trouble Engine oil viscosity too high
Throttle sensor trouble Air suction valve trouble
Water temperature sensor trouble Engine overheating
Inlet air pressure sensor trouble Intermittent any DFI fault and its recovery
Loose injector connectors
Crankshaft sensor trouble Poor Running or No Power at High
Ignition coil trouble Speed
Loose terminal of battery () cable or engine Firing incorrect
ground cable Spark plug dirty, broken, or maladjusted
Poor acceleration Ignition coil shorted or not in good contact
Too low fuel pressure Ignition coil trouble
Water or foreign matter in fuel Spark plug incorrect
Clogged fuel filter or pump screen Spark plug cap trouble
Fuel pump trouble Spark plug cap shorted not in good contact
Fuel injector trouble Camshaft position trouble
Inlet air temperature sensor trouble IC igniter in ECU trouble
Water temperature sensor trouble Crankshaft sensor trouble
Ignition coil trouble Fuel/air mixture incorrect
Engine oil level to high Air filter poorly sealed
Spark plug dirty, broken or gap maladjusted Air filter O-ring damaged
Stumble Inlet air duct loose
Too low fuel pressure Water or foreign matter in fuel

16-48 APPENDIX
Fuel to injector insufficient (DFI) Engine oil viscosity too high
Fuel tank air vent obstructed Lubrication inadequate
Fuel line clogged Engine oil level too low
Fuel pump trouble (DFI) Engine oil poor quality or incorrect
Injector clogged Oil cooler incorrect
Throttle body assy loose Oil cooler clogged
Throttle body assy gasket damaged Sensor incorrect
Fuel line clogged Water temperature sensor broken
Fuel pump operates intermittently
Inlet air temperature sensor trouble Over Cooling
Throttle sensor trouble Sensor incorrect
Inlet air pressure sensor trouble Water temperature sensor broken
Compression low
Spark plug loose Abnormal Engine Noise
Cylinder head not sufficiently tightened Knocking
down IC igniter in ECU trouble
No valve clearance Carbon built up in combustion chamber
Cylinder, piston worn Fuel poor quality or incorrect
Piston ring bad (worn, weak, broken, or Spark plug incorrect
sticking) Overheating
Piston ring/groove clearance excessive Piston slap
Cylinder head gasket damaged Cylinder/piston clearance excessive
Cylinder head warped Cylinder, piston worn
Valve spring broken or weak Connecting rod bent
Valve not seating properly (valve bent, Piston pin, piston pin hole worn
worn, or carbon accumulation on the Valve noise
seating surface.) Valve clearance incorrect
Knocking Valve spring broken or weak
Carbon built up in combustion chamber Camshaft bearing worn
Fuel poor quality or incorrect Valve lifter worn
Spark plug incorrect Other noise
IC igniter in ECU trouble Connecting rod small end clearance exces-
Camshaft position sensor trouble sive
Crankshaft sensor trouble Connecting rod big end clearance exces-
Ignition coil trouble sive
Inlet air temperature sensor trouble Piston ring/groove clearance excessive
Miscellaneous Piston ring worn, broken, or stuck
Throttle valve wont fully open Piston ring groove worn
Engine overheating Piston seizure, damage
Engine oil level too high Cylinder head gasket leaking
Engine oil viscosity too high Crankshaft runout excessive
Air suction valve trouble Engine mount loose
Camshaft cam worn Crankshaft bearing worn
Camshaft chain tensioner trouble
Overheating Camshaft chain, sprocket, guide worn
Firing incorrect Air suction valve damaged
Spark plug dirty, broken, or maladjusted Magneto flywheel loose
Spark plug incorrect
IC igniter in ECU trouble Oil Pressure Warning Light Goes On
Fuel/air mixture incorrect Oil pump damaged
Inlet air duct loose Oil screen clogged
Air filter poorly sealed Oil filter clogged
Air filter O-ring damaged Engine oil level too low
Compression high Engine oil viscosity too low
Carbon built up in combustion chamber Camshaft bearing worn
Engine load faulty Crankshaft bearing worn
Engine oil level too high

APPENDIX 16-49
Oil pressure switch damaged Engine Activates Slow Down Mode
Wiring faulty Cooling water temperature gets high
O-ring at the oil passage in the crankcase Weeds or debris in jet pump
damaged Cooling water line clogged
Low oil pressure
Battery Trouble Low oil level
Battery discharged Improper engine oil quality
Charge insufficient Water temperature sensors malfunction,
Battery faulty (too low terminal voltage) wiring open or short
Battery lead making poor contact Vehicle-down sensor malfunction, wiring
Magneto trouble open or short
Wiring faulty Oil temperature sensor gets high
Regulator/rectifier trouble Low oil level
Battery overcharged Oil pump malfunction
Magneto trouble Relief valve malfunction
Regulator/rectifier trouble Weeds or debris in jet pump
Battery faulty Cooling water line clogged
Oil temperature sensor malfunction,
Poor Performance through Engine wiring open or short
Runs Properly
Jet pump
Intake area obstructed
Impeller or pump case damaged
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
Steering maladjusted
Bushing damaged or cracked
Steering shaft bent
No lubricant on steering pivot
Steering cable damaged or improperly
routed

MODEL APPLICATION
Year Model Beginning Hull No.
2004 JT1500-A1 KAW60001304
2005 JT1500-A2 US-KAW50001405
2006 JT1500A6 US-KAW40001506
2007 JT1500A7 US-KAW20001607
2008 JT1500A8 US-KAW30001708
US-KAW50001809
2009 JT1500A9
US-KAW59001809
US-KAW20001910
2010 JT1500AA
US-KAW29001910
US-KAW10001011
2011 JT1500AB
US-KAW19001011
US-KAW10001112
2012 JT1500AC
US-KAW19001112
:This digit in the hull number changes from one machine to another.
Part No.99924-1325-09 Printed in Japan

STX 15 F

Uploaded by

Copyright:

Available Formats

STX 15 F

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

STX 15 F

Uploaded by

Copyright:

Available Formats

STX-15F

JET SKi Watercraft

Downloaded from www.Manualslib.com manuals search engine

This quick reference guide will assist

Downloaded from www.Manualslib.com manuals search engine

JET SKi Watercraft

Downloaded from www.Manualslib.com manuals search engine

COUNTRY AND AREA CODES

Downloaded from www.Manualslib.com manuals search engine

EMISSION CONTROL INFORMATION

Emission Control Information

Exhaust Emission Control System

Tampering with Emission Control System Prohibited

Do not tamper with the original emission related parts.

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Indicates a procedural sub-step or how to do

This model, JT1500A, is mounted with a four

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

SLO mode is displayed on the meter as SLO.

Normal operation mode (Full Power Operation mode, FPO)

Downloaded from www.Manualslib.com manuals search engine

Kawasaki Diagnostic System (KDS) Software

Downloaded from www.Manualslib.com manuals search engine

Obtain a standard garden hose [A] and a garden hose

Open the front storage compartment cover.

Attach a garden hose [C] to a garden hose adapter and

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Cleaning Watercraft before Disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Liquid Gasket, Locking Agent

Oil Seal, Grease Seal

Downloaded from www.Manualslib.com manuals search engine

Circlips, Cotter Pins

Direction of Engine Rotation

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

JT1500-A1 Right Side View

Downloaded from www.Manualslib.com manuals search engine

Items JT1500-A1 A2, A6 AC

Downloaded from www.Manualslib.com manuals search engine

Items JT1500-A1 A2, A6 AC

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Inspect/clean air filter

Replace engine oil

Inspect/adjust valve clearance (e) 2-16

Inspect/tighten engine mounting bolts

Flush bilge line and filter 2-23

Inspect battery charging condition 2-25

Lubricate throttle cable fitting at throttle body 2-26

Lubricate steering cable/shift cable ball joints

Check all hoses, hose clamps, nuts, bolts,