99924-1325-06 JT1500A9F English Ebook
99924-1325-06 JT1500A9F English Ebook
99924-1325-06 JT1500A9F English Ebook
Service Manual
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
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/Consumer Products and Machinery
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. Sixth Edition (1):Jun. 30, 2008 (K)
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) perminute
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) Ω ohm(s)
L liter(s)
Maintenance, replacement, or repair of the emission control devices and systems may
be performed by any marine Sl engine repair establishment or individual.
Fuel Information
THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE
ONLY.
A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted
on service station pumps.
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.
Among those acts presumed to constitute tampering are the acts listed below:
and testers that are necessary when servic- This manual contains four more symbols (in
ing Kawasaki JET SKI® watercraft are intro- addition to WARNING and CAUTION) which will
duced by the Service Manual. Genuine parts help you distinguish different types of informa-
provided as spare parts are listed in the Parts tion.
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
General Information 1
Table of Contents
Smart Learning Operation mode (SLO) (JT1500-A2 Model ∼)............................................... 1-2
Before Servicing ..................................................................................................................... 1-3
Model Identification................................................................................................................. 1-10
General Specifications............................................................................................................ 1-11
Unit Conversion Table ............................................................................................................ 1-13
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.
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.
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds, especially
in high revolutionary speed or severe engine and exhaust system damage will occur.
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.
1-4 GENERAL INFORMATION
Before Servicing
• Screw
[B].
a garden hose adapter [A] onto the flushing fitting
• 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.
CAUTION
Insufficient cooling supply will cause the engine and/or exhaust system to overheat and
severe damage will occur. Excessive cooling supply may kill the engine and flood the cylin-
ders, causing hydraulic lock. Hydraulic lock will cause severe damage to the engine. If the
engine dies while using an auxiliary cooling supply, the water must be shut off immediately.
CAUTION
Always turn the boat on its left side. Rolling to the right side can cause water in the exhaust
system to run into the engine, with possible engine damage.
GENERAL INFORMATION 1-5
Before Servicing
CAUTION
Turn the capsized boat clockwise so that the port side always faces downward. Turning
counterclockwise can cause water in the exhaust system to run into the engine, with pos-
sible engine damage.
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.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
1-6 GENERAL INFORMATION
Before Servicing
Cleaning Watercraft before Disassembly
Clean the watercraft thoroughly before disassembly. Dirt
or other foreign materials entering into sealed areas during
watercraft disassembly can cause excessive wear and de-
crease performance of the watercraft.
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.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
GENERAL INFORMATION 1-7
Before Servicing
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.
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
1-8 GENERAL INFORMATION
Before Servicing
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.
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.
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.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
1-10 GENERAL INFORMATION
Model Identification
JT1500-A1 Left Side View
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
2
Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System
Vehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb
Bracket Mounting Bolts 8.8 0.90 78 in·lb 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 in·lb
Inlet Air Pressure Sensor Bolts 7.8 0.80 69 in·lb
Throttle Cable Holder Bolts 8.8 0.90 78 in·lb 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 in·lb
Crankshaft Sensor Screws 4.4 0.45 39 in·lb L
Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb 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 in·lb
ECU Mounting Bolts 8.8 0.90 78 in·lb L
Electrical Parts Bracket Screws 4.9 0.50 43 in·lb L
Throttle Sensor Mounting Screws 2.0 0.20 18 in·lb
ISC Actuator Mounting Bolts 4.9 0.50 43 in·lb
Oil Pressure Switch 15 1.5 11 SS
Fuel Filler Tube Clamp Screws 2.9 0.30 26 in·lb
Fuel Level Sensor Clamp Screw 2.9 0.30 26 in·lb
Fuel Filter Mounting Bolts 8.8 0.90 78 in·lb L
Fuel Pump Holder Clamp Screws 2.9 0.30 26 in·lb
Air Filter Mounting Bolts 9.8 1.0 87 in·lb L
Air Filter Bracket Mounting Bolts 7.8 0.80 69 in·lb L
Throttle Cable Locknut 7.8 0.80 69 in·lb
Throttle Case Mounting Screws 3.9 0.40 35 in·lb
Engine Lubrication System
Breather Plate Bolts 7.8 0.80 69 in·lb
Oil Filler Cap 1.0 0.10 8.7 in·lb
Oil Passage Plugs 20 2.0 14 L
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Oil Separator Tank Mounting Screws 4.9 0.50 43 in·lb L
Breather Case Mounting Bolts 7.8 0.80 69 in·lb
Breather Pipe Bolts 8.8 0.90 78 in·lb L
Oil Passage Joints 11 1.1 95 in·lb L
Oil Cooler Assembly Bolts 7.8 0.80 69 in·lb
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 in·lb S
Dipstick Tube Bolts 8.8 0.90 78 in·lb L, S
Oil Pump Sprocket Bolt (JT1500-A1 ∼ A2) 15 1.5 11 LN
Oil Pump Sprocket Bolt (JT1500A6F) 16 1.6 12 LN
Oil Pump Cover Bolts 7.8 0.80 69 in·lb
Oil Pressure Relief Valve 15 1.5 11 LN
Oil Pipe Bolts 7.8 0.80 69 in·lb
Oil Pump Chain Guide Bolt 7.8 0.80 69 in·lb
Chain Guide Spring Plate Bolt 7.8 0.80 69 in·lb
Oil Pump Body Plug 20 2.0 14 L
Oil Pump Body Bolts 7.8 0.80 69 in·lb
Oil Screen Bolts 7.8 0.80 69 in·lb
Water Hose Joints 20 2.0 14 L
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 in·lb L
Water Hose Joint 11 1.1 95 in·lb 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 (JT1500A8F
5.0 0.51 44 in·lb
∼)
Exhaust Tube Clamp Screws (JT1500A8F) 5.0 0.51 44 in·lb
Engine Top End
Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb
Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S
Camshaft Cap Bolts 12 1.2 104 in·lb 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
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Cylinder Head Bolts (M6) 12 1.2 104 in·lb S
Engine Hook Bolts 20 2.0 14
Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb L
Exhaust Side Camshaft Chain Guide Bolts 25 2.5 18
(Upper)
Exhaust Side Camshaft Chain Guide Bolts 12 1.2 104 in·lb
(Lower)
Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S
Inlet Side Camshaft Chain Guide Bolts 12 1.2 104 in·lb L
Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb L
Camshaft Chain Tensioner Cap Bolt 20 2.0 14
Camshaft Position Sensor Rotor Bolt 12 1.2 104 in·lb L
Water Hose Joint 11 1.1 95 in·lb L
Oil Passage Joint 11 1.1 95 in·lb 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 in·lb
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 in·lb L
Grommet Cover Bolts 9.8 1.0 87 in·lb L
Magneto Cover Bolts 20 2.0 14
Output Cover Bolts 7.8 0.80 69 in·lb
Output Shaft 245 25.0 180 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 in·lb S
Cooling and Bilge Systems
Bilge Breather Mounting Bolts – – – L
Water Hose Joint (L Shape Type) 11 1.1 95 in·lb L
Water Hose Joint (Straight Shape Type) 20 2.0 14 L
Water Hose Joint (Straight Shape Type) 11 1.1 95 in·lb L, see text
Cooling Hose Clamp Screws 2.5 0.25 22 in·lb
Flushing Cap (JT1500A8F ∼) 0.90 0.092 8.0 in·lb
Drive System
Coupling 39 4.0 29
Drive Shaft Holder Mounting Bolts 22 2.2 16 L
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Coupling Cover Bolts 8.8 0.90 78 in·lb 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 in·lb L
Pump Cap Bolts (JT1500A7F ∼) 3.9 0.40 35 in·lb L
Pump Cap Plug 3.9 0.40 35 in·lb
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 in·lb L
Pump Cover Mounting Bolts 7.8 0.80 69 in·lb L
Grate Mounting Bolts 9.8 1.0 87 in·lb L
Filter Cover Mounting Bolts 9.8 1.0 87 in·lb L
Steering
Handlebar Clamp Bolts 16 1.6 12 L
Start/stop Switch Case Mounting Screws 3.9 0.40 35 in·lb
Throttle Case Mounting Screws 3.9 0.40 35 in·lb
Steering Shaft Locknut 49 ∼ 59 5.0 ∼ 6.0 36 ∼ 43
Steering Shaft Nut 2.9 0.30 26 in·lb
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 in·lb L
Ball Joint 9.8 1.0 87 in·lb LN
Shift Cable End Nut 9.8 1.0 87 in·lb
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 in·lb L
Handrail Bolts 9.8 1.0 87 in·lb L
Lock Assembly Nut 4.9 0.50 43 in·lb
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
Seat Locknut – – – L
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Reboarding Step Bolts – – – L
Mirror Stay Bolts – – – L
Stabilizer Bolts 9.8 1.0 87 in·lb L
Air inlet Duct Bolts – – – L
Exhaust Outlet Bolts – – – L
Electrical System
Vehicle-Down Sensor Mounting Screws 1.5 0.15 13 in·lb
Electrical Parts Bracket Screws 4.9 0.50 43 in·lb L
Starter Relay Case Bolts 7.8 0.80 69 in·lb
Ignition Coil Mounting Bolts 8.8 0.90 78 in·lb L
Water Temperature Sensor 15 1.5 11 see text
Starter Relay Mounting Nut 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lb
Starter Cable Mounting Nut 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lb
Timing Rotor Bolt 20 2.0 14 L
Crankshaft Sensor Screws 4.4 0.45 39 in·lb L
Rubber Grommet Holder Screws 4.4 0.45 39 in·lb L
Crankshaft Sensor Cover Bolts 7.8 0.80 69 in·lb
Oil Temperature Sensor 15 1.5 11 see text
Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb L
Spark Plugs 13 1.3 113 in·lb
Regulator/rectifier Bolts 7.8 0.80 69 in·lb
Replay Assembly Bolt 2.5 0.25 22 in·lb L
ECU Mounting Bolts 8.8 0.90 78 in·lb L
Main Fuse Mounting Bracket Bolt 7.8 0.80 69 in·lb
Bracket Mounting Bolts 8.8 0.90 78 in·lb L
Multifunction Meter Mounting Bolts 3.9 0.40 35 in·lb L
Fuel Level Sensor Clamp Screw 2.9 0.30 26 in·lb
Start/stop Switch Case Mounting Screws 3.9 0.40 35 in·lb
Speed Sensor Mounting Bolts 3.9 0.40 35 in·lb L
Starter Motor Through Bolts 6.4 0.65 56 in·lb L, R
Starter Motor Mounting Bolts 8.8 0.90 78 in·lb L
Starter Motor Ground Bolt 7.8 0.80 69 in·lb
Starter Motor Terminal Nut 7.8 0.80 69 in·lb
Stator Coil Bolts 12 1.2 104 in·lb L
Grommet Holder Bolts 8.8 0.90 78 in·lb L
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
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)
N·m kgf·m ft·lb
6 5.9 ∼ 8.8 0.60 ∼ 0.90 52 ∼ 78 in·lb
8 16 ∼ 22 1.6 ∼ 2.2 12 ∼ 16
10 30 ∼ 41 3.1 ∼ 4.2 22 ∼ 30
PERIODIC MAINTENANCE 2-9
Specifications
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
• Remove the seat (see Hull/Engine Hood chapter).
• Inspect thetheairrear
Remove storage pocket.
• [B]. filter [A] for water inside with its drain caps
• Remove
chapter).
the front storage pocket (see Hull/Engine Hood
• 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.
PERIODIC MAINTENANCE 2-13
Periodic Maintenance Procedures
• Incooling
a well-ventilated area, start the engine while cooling the
system.
○Open the front storage compartment cover.
○Remove the flushing cap (see Cooling System Flushing).
○Screw a garden hose adapter [A] onto the flushing fitting
[B].
○Attach a garden hose [C] to a garden hose adapter and
secure the hose clamp [D].
•Warm up the engine and stop it.
CAUTION
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.
• Drain the oil thorough from the dipstick tube [A] using a
commercially-available vacuum pump [B].
WARNING
Do not discard the engine oil as the engine oil is
toxic substance and will pollute the environment.
Contact your local authority for approved disposal
methods.
• Remove the oil filter [A] with the oil filter wrench [B].
Special Tool - Oil Filter Wrench: 57001-1249
• Remove:
Seat (see Hull/Engine Hood chapter)
Cylinder Head Cover (see Engine Top End chapter)
• Position the crankshaft at #1, #4 piston TDC as follows.
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.
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
EXHAUST VALVE CLEARANCE ADJUSTMENT CHART
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.
PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
• Screw
[B].
a garden hose adapter [A] onto the flushing fitting
• Start
water.
the engine and allow it to idle before turning on the
CAUTION
The engine must be running before the water is
turned on or water may flow back through the
exhaust pipe into the engine, resulting in the pos-
sibility of severe internal damage.
• Leave
running.
the engine idle for several minutes with the water
• Switch
adapter.
off the engine, remove the garden hose and the
• 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.
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.
○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]
PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
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).
CAUTION
Be sure to disconnect the negative terminal lead
first.
• Insert the spark plug vertically into the plug hole with the
spark plug installed in the plug wrench [A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1145
• Tighten:
Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 113 in·lb)
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:
PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
• 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.
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.
CAUTION
Do not reuse the double spring clamps on the fuel
line.
Reusing will cause fuel leakage.
Replace the double spring clamps with new ones.
• Replacement
follows.
procedure for the double spring clamp is as
Throttle Lever, Cable and Case......... 3-72 ISC Resistance Inspection........... 3-82
Free Play Inspection .................... 3-72 Inlet Manifold ..................................... 3-83
Throttle Cable Adjustment ........... 3-72 Inlet Manifold Removal ................ 3-83
Throttle Case Removal/Disas- Inlet Manifold Installation ............. 3-84
sembly....................................... 3-72 Fuel Line............................................ 3-86
Throttle Case Assembly/Installa- Fuel Pressure Inspection ............. 3-86
tion ............................................ 3-73 Fuel Flow Rate Inspection ........... 3-87
Throttle Cable Removal ............... 3-74 Fuel Vent Check Valve ...................... 3-89
Throttle Cable Installation ............ 3-75 Fuel Vent Check Valve Mounting . 3-89
Throttle Case and Cable Fuel Vent Check Valve Inspection 3-89
Lubrication................................. 3-76 Fuel Filter........................................... 3-90
Throttle Cable Inspection ............. 3-76 Fuel Filter Removal...................... 3-90
Air Filter ............................................. 3-77 Fuel Filter Installation................... 3-91
Air Filter Removal ........................ 3-77 Fuel Pump ......................................... 3-92
Air Filter Installation ..................... 3-78 Fuel Pump Removal .................... 3-92
Air Filter Disassembly .................. 3-78 Fuel Pump Installation ................. 3-93
Air Filter Assembly ....................... 3-79 Power Source Voltage Inspection 3-93
Throttle Body Assy ............................ 3-80 Operating Voltage Inspection....... 3-94
Idle Speed Inspection .................. 3-80 Fuel Pump Relay Removal .......... 3-95
High Altitude Performance Fuel Pump Relay Inspection ........ 3-95
Adjustment ................................ 3-80 Fuel Tank ........................................... 3-97
Throttle Body Assy Removal........ 3-80 Fuel Tank Removal ...................... 3-97
Throttle Body Assy Installation..... 3-80 Fuel Tank Installation ................... 3-98
Throttle Body Assy Disassembly . 3-80 Fuel Tank Cleaning ...................... 3-98
Throttle Bore Cleaning ................. 3-80 Fuel Filler and Tube Removal ...... 3-99
ISC (Idle Speed Controller) Fuel Filler and Tube Installation ... 3-99
Removal/Installation.................. 3-81 Fuel Tank Vent Hose Installation.. 3-100
ISC (Idle Speed Controller)
Inspection.................................. 3-81
FUEL SYSTEM (DFI) 3-3
Fuel System Diagram
1. Fuel Pump
2. Clamps (JT1500-A1 Model)
Double Spring Clamps (JT1500-A2 Model ∼)
(Installation Procedure: Pull up the clamp stopper [A] with pliers [B].)
3. Main Line
4. Fuel Filter
5. Supply Line
6. Return Line
7. Delivery Pipe
8. Fuel Injectors
9. Fuel Tank
3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Vehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb
2 Bracket Mounting Bolts 8.8 0.90 78 in·lb 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 in·lb
6 Inlet Air Pressure Sensor Bolts 7.8 0.80 69 in·lb
7 Throttle Cable Holder Bolts 8.8 0.90 78 in·lb 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 in·lb
12 Crankshaft Sensor Screws 4.4 0.45 39 in·lb L
13 Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb 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 in·lb
17 ECU Mounting Bolts 8.8 0.90 78 in·lb L
18 Electrical Parts Bracket Screws 4.9 0.50 43 in·lb L
19 Throttle Sensor Mounting Screws 2.0 0.20 18 in·lb
20 ISC Actuator Mounting Bolts 4.9 0.50 43 in·lb
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 ∼ A6F Model
D: JT1500A8F Model ∼
EO: Fill the hollow with the engine oil (10W-30).
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Fill the hollow with the specified silicone grease (Kawasaki Bond: 92137-1002).
SO: Apply silicone oil to the O-ring.
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Oil Pressure Switch 15 1.5 11 SS
2 Fuel Filler Tube Clamp Screws 2.9 0.30 26 in·lb
3 Fuel Level Sensor Clamp Screw 2.9 0.30 26 in·lb
4 Fuel Filter Mounting Bolts 8.8 0.90 78 in·lb L
5 Fuel Pump Holder Clamp Screws 2.9 0.30 26 in·lb
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 ∼ A8F Models
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
3-8 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-9
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Air Filter Mounting Bolts 9.8 1.0 87 in·lb L
2 Air Filter Bracket Mounting Bolts 7.8 0.80 69 in·lb L
3 Gromet Plate Bolts – – – L
4 Throttle Cable Locknut 7.8 0.80 69 in·lb
5 Throttle Case Mounting Screws 3.9 0.40 35 in·lb
G: Apply grease.
L: Apply a non-permanent locking agent.
3-10 FUEL SYSTEM (DFI)
Specifications
Item Standard
Digital Fuel Injection System
Idle Speed 1 300 ±100 r/min (rpm) -both in and out of water
Throttle Assy:
Type Single type
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/cm², 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 kΩ
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 @20°C (68°F)
Resistance 5.4 ∼ 6.6 kΩ at 0°C (32°F)
2.26 ∼ 2.86 kΩ at 20°C (68°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
Water Temperature Sensor:
Resistance see Electrical System chapter
Output Voltage at ECU about 3 ∼ 4 V @20°C (68°F)
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 Ω at 20°C (68°F)
Oil Temperature Sensor:
Resistance same to water temperature sensor
Output Voltage at ECU about 3 ∼ 4 V @20°C (68°F)
FUEL SYSTEM (DFI) 3-11
Specifications
Item Standard
Throttle Lever and Cables
Throttle Lever Free Play about 2 mm (0.08 in.)
3-12 FUEL SYSTEM (DFI)
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: Sensor Harness Adapter:
57001-125 57001-1561
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
19. ISC (Idle Speed Controller) 39. Injector #3
20. ISC (Idle Speed Controller) 40. Injector #4
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
FUEL SYSTEM (DFI) 3-21
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.
○When checking the DFI parts, do not run the engine for
15 seconds or more without auxiliary cooling (see General
Information chapter).
CAUTION
If running the engine without the auxiliary cooling
for 15 seconds or more (even at idle speed), the rub-
ber component relative to the Exhaust System may
be damaged.
CAUTION
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
FUEL SYSTEM (DFI) 3-23
DFI Servicing Precautions
○After measurement, remove the needle adapters and ap-
ply silicone sealant to the seals [A] of the connector [B]
for waterproofing.
Silicone Sealant (Kawasaki Bond): 56019-120
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.
FUEL SYSTEM (DFI) 3-25
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 α-N
12
malfunction, wiring open or short method (see Note 2).
Inlet air temperature sensor The ECU sets the inlet air temperature
13
malfunction, wiring open or short at 40°C.
Water temperature sensor The ECU sets the water temperature
14
malfunction, wiring open or short at 70°C.
Crankshaft sensor malfunction,
21 –
wiring open or short
The ECU continues to ignite cylinders
Camshaft position sensor
23 in the same sequence following the
malfunction, wiring open or short
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) by
short stopping the ignition.
Injector #1 malfunction, wiring
41 –
open or short
Injector #2 malfunction, wiring
42 –
open or short
Injector #3 malfunction, wiring
43 –
open or short
Injector #4 malfunction, wiring
44 –
open or short
Ignition coil #1, #4 malfunction, The ECU shuts off the injectors #1/#4
51
wiring open or short to stop fuel to the cylinders #1/#4.
Ignition coil #2, #3 malfunction, The ECU shuts off the injectors #2/#3
52
wiring open or short 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) by
stopping the ignition.
(JT1500-A1) Oil temperature sensor The ECU sets the oil temperature at
malfunction, wiring open or 60°C.
73 short The ECU slows down the engine
(JT1500-A2 ∼) speed less than 3 000 r/min (rpm) by
stopping the ignition.
• Remove:
Seat (see Hull/Engine Hood chapter)
Air filter (see Air Filter Removal)
○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 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
CAUTION
Never drop the throttle sensor can especially on a
hard surface. A shock to the sensor can damage it.
CAUTION
Never drop the throttle sensor, especially on a hard
surface. A shock to the sensor can damage it.
• Tighten:
Torque - Inlet Air Pressure Sensor Bolts: 7.8 N·m (0.80
kgf·m, 69 in·lb)
• 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
• 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 Sensor Connector
Standard: 4.75 ∼ 5.25 V DC
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.
FUEL SYSTEM (DFI) 3-37
Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)
If the output voltage is far out of the usable range, check
the output voltage at the sensor connector [A].
• Measure the output voltage at the sensor in the same way
as input voltage inspection. Note the following.
[B] Inlet Air Pressure Sensor
Special Tool - Sensor Harness Adapter: 57001-1561
• 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 output voltage.
○Wait 15 seconds before using the starter again.
Output Voltage at ECU
Standard: about 2.3 ∼ 2.6 V at inlet air temperature
20°C (68°F)
NOTE
○The output voltage changes according to the inlet air
temperature.
• 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 mm (0.2 in.)
• Tighten:
Torque - Water Temperature Sensor: 15 N·m (1.5 kgf·m, 11
ft·lb)
• 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 output voltage.
○Wait 15 seconds before using the starter again.
Output Voltage at ECU
Standard: about 3 ∼ 4 V at 20°C (68°F)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.
1. ECU
2. Camshaft Position Sensor
FUEL SYSTEM (DFI) 3-47
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]
• Remove:
Seat (see Hull/Engine Hood chapter)
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]
• Tighten:
Torque - Vehicle-down Sensor Mounting Screws: 1.5 N·m
(0.15 kgf·m, 13 in·lb)
3-48 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code/Character-31/dOS)
Vehicle-down Sensor Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Fuel Tank (see Fuel Tank Removal)
• 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 power sours voltage.
○Wait 15 seconds before using the starter again.
Power Source Voltage at Sensor
Standard: 4.75 ∼ 5.25 V
• Remove:
Seat (see Hull/Engine Hood chapter)
Fuel Hoses
Delivery Pipe Mounting Bolts [A], Collars [B] and Clamps
• Remove the delivery pipe assembly from the cylinder
head.
• Install:
Delivery Pipe Assembly
Collars
• Install the clamps [A] as shown.
• Tighten:
Torque - Delivery Pipe Mounting Bolts: 7.8 N·m (0.80 kgf·m,
69 in·lb)
• 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.
• Apply the tip of a screwdriver [A] to the injector [B]. Put
the grip end onto 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 doesn’t 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.)
CAUTION
Do not use larger terminals than specified above. A
larger terminal could damage the injector main har-
ness connector (female), leading to harness repair
or replacement.
3-52 FUEL SYSTEM (DFI)
Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)
Injector Resistance
Standard: about 11.7 ∼ 12.3 Ω @20°C (68°F)
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]
CAUTION
Be sure to connect the bulb in series. The bulb
works as a current limiter to protect the solenoid
in the injector from excessive current.
• 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 injector power source voltage.
○Wait 15 seconds before using the starter again.
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).
• 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 output voltage.
○Wait 15 seconds before using the starter again.
Output Voltage at Injector Connector
Standard: about 9 V or more
If the output voltage is out of the standard, replace the
ECU.
3-54 FUEL SYSTEM (DFI)
Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4)
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/cm², 44 psi)
CAUTION
During pressure testing, do not exceed the maxi-
mum pressure for which the system is designed.
• Connect
[B].
the harness adapter [A] and a digital voltmeter
• 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)
FUEL SYSTEM (DFI) 3-61
Low Engine Oil Pressure (Service Code/Character-72/OILP)
• If the service code is displayed, check the doubtful parts referring to the following table.
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)
3-62 FUEL SYSTEM (DFI)
Oil Temperature Sensor (Service Code/Character-73/OILC or 73/OILt)
Service Code/Character
JT1500-A1: 73/OILC
JT1500-A2 ∼: 73/OILt
• Remove:
Engine (see Engine Removal/Installation chapter)
Oil Temperature Sensor [A]
• Fill the hollow of the oil pan [A] with the specified silicone
grease [B] as shown, before installing the oil temperature
sensor [C].
[D] 5 mm (0.2 in.)
Silicone Grease (Kawasaki Bond): 92137-1002
• Tighten:
Torque - Oil Temperature Sensor: 15 N·m (1.5 kgf·m, 11
ft·lb)
• 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 output voltage.
○Wait 15 seconds before using the starter again.
Output Voltage at ECU
Standard: about 3 ∼ 4 V at 20°C (68°F)
NOTE
○The output voltage changes according to the oil temper-
ature in the engine.
FUEL SYSTEM (DFI) 3-63
Oil Temperature Sensor (Service Code/Character-73/OILC or 73/OILt)
ECU Removal
• Remove:
Seat (see Hull/Engine Hood chapter)
Bolts [A]
ECU Installation
• Connect the ECU connector and install it.
• tighten them.
Apply a non-permanent locking agent to the bolts and
• 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.
Special Tool - Hand Tester: 57001-1394
Main Relay
Relay Coil Terminals [3] and [4]
Relay Switch Terminals [1] and [2]
Testing Relay
Tester range: 1 Ω range
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
If the relay does not work as specified, replace the relay
assembly.
FUEL SYSTEM (DFI) 3-71
DFI Power Source
Fuel Pump Relay
Relay Coil Terminals [6] and [8]
Relay Switch Terminals [5] and [7]
Testing Relay
Tester range: 1 Ω range
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
If the relay does not work as specified, replace the relay
assembly.
Hand Tester [A]
Battery [B]
3-72 FUEL SYSTEM (DFI)
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].
○Use a screw driver [A] to separate the tip [B] of the cable
end from the case body.
FUEL SYSTEM (DFI) 3-73
Throttle Lever, Cable and Case
• Pulling the throttle cable [A], position the tips [B] of the
cable end as shown.
• Tighten the cable fitting nut.
• Tighten:
Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40
kgf·m, 35 in·lb)
• 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.
○Slide the tip [A] of the cable lower end from the throttle
pivot arm.
• Tighten:
Torque - Throttle Case Mounting Screws: 3.9 N·m (0.40
kgf·m, 35 in·lb)
• 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.
FUEL SYSTEM (DFI) 3-77
Air Filter
Air Filter Removal
JT1500-A1 ∼ A8F Models
•Remove the seat (see Hull/Engine Hood chapter).
•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).
JT1500A9F Model
•Remove the seat (see Hull/Engine Hood chapter).
•Remove the rear storage pocket.
•Disconnect the following from the air filter [A].
Oil Separator Tank Hose [B]
•Remove the oil separator tank [C] (see Engine Lubrication
System chapter).
• Remove:
Bolts [A]
Flame Arrester [B]
Hose [C]
Duct [D]
Air Filter Bracket Mounting Bolts [E]
Air Filter Bracket [F]
○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.
• Unscrew
[B].
the inlet manifold mounting bolts [A] and nuts
3-84 FUEL SYSTEM (DFI)
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]
• 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.
• 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
mounting bolts and tighten them.
Torque - Inlet Manifold Mounting Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Inlet Manifold Mounting Nuts: 20 N·m (2.0 kgf·m,
14 ft·lb)
FUEL SYSTEM (DFI) 3-85
Inlet Manifold
• Loosen
hose.
the clamp bolt [B] and pull out the fuel supply
WARNING
Do not try to start the engine with the fuel hoses
disconnected.
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)
FUEL SYSTEM (DFI) 3-87
Fuel Line
If the fuel pressure is much lower than specified, and if
inspection above checks out good, replace the fuel filter
and measure the fuel pressure again.
•Remove the fuel pressure gauge and adapter.
•Run the fuel hoses in accordance with the Cable, Wire,
and Hose Routing section in the Appendix chapter.
○For JT1500-A2 model ∼; Replace the double spring
clamps with new ones (see Fuel System Diagram).
Fuel Flow Rate Inspection
NOTE
○Be sure the battery is fully charged.
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Pull the lanyard
key off the stop button. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke.
• Remove:
Front Storage Pocket (see Hull/Engine Hood chapter)
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 SYSTEM (DFI) 3-91
Fuel Filter
Fuel Filter Installation
• Route the hose correctly (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).
• 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 N·m (0.90 kgf·m, 78
in·lb)
3-92 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Removal
CAUTION
Never drop the fuel pump, especially on a hard sur-
face. Such a shock to the pump can damage it.
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Pull the lanyard
key off the stop button. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke.
JT1500-A1 Model
• Remove the front storage pocket (see Hull/Engine Hood
chapter).
• 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 SYSTEM (DFI) 3-93
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,
tighten the small diameter clamp [E].
Torque - Fuel Pump Holder Clamp Screw: 2.9 N·m (0.30
kgf·m, 26 in·lb)
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].
• Tighten the large diameter clamp [F] securely.
Torque - Fuel Pump Holder Clamp Screw: 2.9 N·m (0.30
kgf·m, 26 in·lb)
• Remove
chapter).
the front storage pocket (see Hull/Engine Hood
• 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
• 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 power source voltage.
○Wait 15 seconds before using the starter again.
Pump Power Source Voltage
Connections
Tester (+) → W/R lead [D]
Tester (–) → Battery (–) Terminal [E]
• Remove
chapter).
the engine (see Engine Removal/Installation
• Remove the fuel filler tube [A] from the fuel tank [B].
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Breather Plate Bolts 7.8 0.80 69 in·lb
2 Oil Filler Cap 1.0 0.10 8.7 in·lb
3 Oil Passage Plugs 20 2.0 14 L
4 Oil Separator Tank Mounting Screws 4.9 0.50 43 in·lb L
5 Breather Case Mounting Bolts 7.8 0.80 69 in·lb
6 Breather Pipe Bolts 8.8 0.90 78 in·lb L
7 Oil Passage Joints 11 1.1 95 in·lb L
8 Oil Cooler Assembly Bolts 7.8 0.80 69 in·lb
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 in·lb S
14 Dipstick Tube Bolts 8.8 0.90 78 in·lb L, S
Oil Pump Sprocket Bolt (JT1500-A1 ∼A2) 15 1.5 11 LN
15
Oil Pump Sprocket Bolt (JT1500A6F ∼) 16 1.6 12 LN
16 Oil Pump Cover Bolts 7.8 0.80 69 in·lb
17 Oil Pressure Relief Valve 15 1.5 11 LN
18 Oil Pipe Bolts 7.8 0.80 69 in·lb
19 Oil Pump Chain Guide Bolt 7.8 0.80 69 in·lb
20 Chain Guide Spring Plate Bolt 7.8 0.80 69 in·lb
21 Oil Pump Body Plug 20 2.0 14 L
22 Oil Pump Body Bolts 7.8 0.80 69 in·lb
23 Oil Screen Bolts 7.8 0.80 69 in·lb
24 Water Hose Joints 20 2.0 14 L
A: JT1500-A1 ∼ A8F Models
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LN: Apply a non-permanent locking agent (High Strength: Locktite 271 equivalent).
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).
4-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
JT1500-A1 ∼ A8F
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
4-6 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
JT1500A9F
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)
4-8 ENGINE LUBRICATION SYSTEM
Specifications
Item Standard
Engine Oil
Grade API SE, SF, or SG
API SH or SJ with JASO MA
API SH, SJ or SL with JASO MA (JT1500A7F ∼)
Viscosity SAE 10W-40
Capacity 4.0 L (4.2 US qt, with or without the filter)
5.0 L (5.3 US qt, when engine is completely dry)
Level Between upper and lower level lines (see text)
Oil Pressure Measurement
Oil pressure @3 000 r/min (rpm), 461 kPa (4.7 kgf/cm², 67 psi)
oil temperature 74°C (165°F)
ENGINE LUBRICATION SYSTEM 4-9
Special Tool and Sealant
Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant):
57001-164 56019-120
• 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]
ENGINE LUBRICATION SYSTEM 4-11
Engine Oil and Oil Filter
CAUTION
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not function
properly, the oil pressure warning light will light. If
this light stays on when the engine is running above
idle speed, stop the engine immediately and find the
cause.
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.
• Check
[A].
the oil level using the hot level mark on the dipstick
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.
•○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
• Place a rag or cloth [D] under the oil cooler to receive the
remaining oil.
• 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 N·m (8.0 kgf·m, 58 ft·lb)
Oil Cooler Positioning Bolt: 20 N·m (2.0 kgf·m, 14
ft·lb)
4-14 ENGINE LUBRICATION SYSTEM
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 N·m (1.8 kgf·m, 13 ft·lb)
CAUTION
Do not run the engine without cooling water supply
for more than 15 seconds, especially in high revolu-
tionary speed or severe engine and exhaust system
damage will occur.
4-16 ENGINE LUBRICATION SYSTEM
Breather Case and Oil Separator Tank
Breather Case Removal (JT1500-A1 ∼ A8F Models)
• Remove:
Seat (see Hull/Engine Hood chapter)
Exhaust Manifold (see Exhaust System chapter)
Clamp [A]
Breather Hose [B]
Breather Case Mounting Bolts [C]
• Pull the breather case [D] upward.
• 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.
○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.
4-18 ENGINE LUBRICATION SYSTEM
Oil Pan
Oil Pan Removal
• Drain:
Engine Oil (see Periodic Maintenance chapter)
• Remove:
Engine (see Engine Removal/Installation chapter)
• Unscrew
Turn the engine to the side.
• stick tubethe
[B].
dipstick tube bolts [A] and pull out the dip-
• Unscrew the oil pan bolts [A] and remove the oil pan [B].
• Unscrew the spring plate bolt [A] and remove the spring
plate [B], spring [C] and the oil pump chain guide [D].
• Unscrew the oil pump sprocket bolt [E].
• Pull out the oil pump sprocket [F] together with the oil
pump sprocket chain [G].
• Install
[C].
the sprocket with the chain to the oil pump shaft
• Install the oil pump chain guide [A], collar [B], washer [C],
and bolt [D] as shown.
• Tighten:
Torque - Oil Pump Chain Guide Bolt: 7.8 N·m (0.80 kgf·m,
69 ft·lb)
•○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 Bolt: 7.8 N·m (0.80
kgf·m, 69 in·lb)
• Install:
Oil Pan (see Oil Pan Installation)
• Pull out the oil pump shaft [A] with inner rotor [B].
• Remove the outer rotor [C].
ENGINE LUBRICATION SYSTEM 4-21
Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve
Oil Pump Installation
• 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
• Install:
Oil Pump Sprocket (see Oil Pump Sprocket Installation)
Oil Pan (see Oil Pan Installation)
Oil Pump Inspection
• Remove the oil pump parts.
• Visually inspect the oil pump outer, inner rotors and cover.
If there is any damage or uneven wear, replace the rotors
and cover.
Oil Screen Removal
• Remove:
Engine (see Engine Removal/Installation chapter)
Oil Pan (see Oil Pan Removal)
Oil Screen Bolts [A]
• Pull out the soil screen [B] to the coupling side.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
4-22 ENGINE LUBRICATION SYSTEM
Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve
• Install
hole.
the oil pressure gauge adapter [A] to the switch
• Install:
Oil Pressure Switch (see Oil Pressure Switch Installa-
tion)
Inlet Manifold
4-26 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
• Remove:
Seat (see Hull/Engine Hood chapter)
Inlet Manifold (see Fuel System (DFI) chapter)
• Disconnect:
Switch Connector [A]
• 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.
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
5
Exhaust Pipe .......................................................................................................................... 5-7
Exhaust Pipe Removal...................................................................................................... 5-7
Exhaust Pipe Installation................................................................................................... 5-7
Exhaust Pipe Cleaning and Inspection ............................................................................. 5-8
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
No. Fastener Remarks
N·m kgf·m ft·lb
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 in·lb L
5 Water Hose Joint 11 1.1 95 in·lb 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
Exhaust Tube Clamp Screws (JT1500A8F
9 5.0 0.51 44 in·lb
∼)
10 Exhaust Tube Clamp Screws (JT1500A8F) 5.0 0.51 44 in·lb
A: JT1500-A1 ∼ A8F Models
EO: Fill the hollow with the engine oil (10W-30).
L: Apply a non-permanent locking agent.
S: Follow the specific tightening sequence.
SY: Apply synthetic rubber adhesive.
5-4 EXHAUST SYSTEM
Exhaust Manifold
Exhaust Manifold Removal
JT1500-A1 ∼ A8F 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]
JT1500A9F 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
• 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.
• 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
• 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:
Hoses [A]
Exhaust Manifold [B] (see Exhaust Manifold Removal)
• 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.
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb
2 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
3 Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S
4 Camshaft Cap Bolts 12 1.2 104 in·lb 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 in·lb S
9 Engine Hook Bolts 20 2.0 14
10 Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb L
A: JT1500-A1 ∼ A8F Models
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide
grease in a weight ratio 10 : 1).
S: Follow the specific tightening sequence.
SS: Apply silicone sealant.
6-4 ENGINE TOP END
Exploded View
ENGINE TOP END 6-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Exhaust Side Camshaft Chain Guide Bolts (Upper) 25 2.5 18
2 Exhaust Side Camshaft Chain Guide Bolts (Lower) 12 1.2 104 in·lb
3 Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S
4 Inlet Side Camshaft Chain Guide Bolt 12 1.2 104 in·lb L
5 Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb L
6 Camshaft Chain Tensioner Cap Bolt 20 2.0 14
7 Camshaft Position Sensor Rotor Bolt 12 1.2 104 in·lb L
8 Water Hose Joint 11 1.1 95 in·lb L
9 Oil Passage Joint 11 1.1 95 in·lb L
10. Closed coil end faces downward.
11. A marking hollow faces exhaust side.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
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 Parts
S: Follow the specific tightening sequence.
6-6 ENGINE TOP END
Specifications
Valve Spring Compressor Adapter, 22: Compression Gauge Adapter, M10 × 1.0:
57001-1202 57001-1317
• Remove:
Air Suction Valve Cover Bolts [A]
Air Suction Valve Covers [B]
Air Suction Valve Assembly [C]
• Remove the cylinder head cover bolts [A] and take off the
cover [B].
JT1500A9F Model
• Remove:
Spark Plug Caps [A]
Breather Hoses [B]
• Remove the cylinder head cover bolts [A] and take off the
cover [B].
• Replace
aged.
the head cover gasket with a new one if dam-
• Install the washer with the metal side [A] faces upward.
• Tighten:
Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Route the hoses correctly (see Appendix chapter).
6-14 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
CAUTION
This is a non-return type camshaft chain tensioner
[A]. The push rod does not return to its original po-
sition once it moves out to take up camshaft chain
slack. Observe all the rules listed below:
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in "Camshaft Chain Ten-
sioner installation."
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing, and damage the valves.
• Remove:
Seat (see Hull/Engine Hood chapter)
Cap Bolt [A]
Washer [B]
Spring [C]
Rod [D]
• Remove the mounting bolts [E] and take off the camshaft
chain tensioner.
• 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.
CAUTION
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turn-
ing the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.
6-16 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Installation
• BePinssure[A]to install the following parts.
○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 N·m (1.2
kgf·m, 104 in·lb)
• Remove:
Coupling Cover Bolts [A]
Clamps [B]
Coupling Cover [C]
ENGINE TOP END 6-17
Camshaft, Camshaft Chain
• Remove:
#1 Spark Plug (Front Side)
• Install the piston top detector [A] in the hole of the plug.
Special Tool - TDC Measurement Tool: 57001-1560
• Insert the gauge extender [B] into the detector.
• gauge extender
Using the shaft wrench, turn the crankshaft until the
reaches its highest point.
Special Tool - Shaft Wrench: 57001-1551
• Remove the extender and install it to the gauge.
• 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”.
NOTE
○Do not turn the camshaft when the plastigage is be-
tween the journal and camshaft cap.
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.)
6-20 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Chain Removal
• Split the crankcase (see Engine Bottom End chapter).
• sprocket. the camshaft chain [A] from the crankshaft
Remove
ENGINE TOP END 6-21
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.
CAUTION
Do not run the engine without cooling water supply
for more than 15 seconds, especially in high revolu-
tionary speed or severe engine and exhaust system
damaged will occur.
Cylinder Compression
Usable Range: 1 185 ∼ 1 795 kPa (12.1 ∼ 18.3 kgf/cm²,
172 ∼ 260 psi) @430 r/min (rpm)
• 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]
• Replace that the O-rings [A] of the oil pipe [B] and apply
molybdenum disulfide oil solution to them.
• Using
valve.
the valve spring compressor assembly, remove the
Valve Installation
• Replace the oil seal with a new one.
• Apply thin coat of molybdenum disulfide grease to the
valve stem before valve installation.
• Install
wards.
the springs so that the closed coil end faces down-
NOTE
○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Operating Procedures
•Clean the seat area carefully.
•Coat the seat with machinist’s 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.
CAUTION
Do not grind the seat too much. Overgrinding 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 adjust the clearance, and the cylin-
der head must be replaced.
ENGINE TOP END 6-29
Valves
○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.
6-30 ENGINE TOP END
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).
ENGINE TOP END 6-31
Valves
6-32 ENGINE TOP END
Cylinder, Pistons
Cylinder Removal
• Drain the engine oil (see Periodic Maintenance chapter).
• Engine (see Engine Removal/Installation chapter)
Remove:
JT1500A9F 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).
• Place a clean cloth under the pistons and remove the pis-
ton pin snap ring [A] from the outside of each piston.
CAUTION
Do not reuse the snap rings, as removal weakens
and deforms them. They fall out and score the cylin-
der wall.
ENGINE TOP END 6-33
Cylinder, Pistons
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.
6-34 ENGINE TOP END
Cylinder, Pistons
NOTE
○If a new piston is used, use new piston ring.
• Install
side.
the piston with its marking hollow facing exhaust
• Fit a new piston pin snap ring into the side of the piston
so that the 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.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them.
They could fall out and score the cylinder wall.
•With
Insert the piston in the cylinder by two methods.
the Hand
• Position the crankshaft at #2, #3 piston TDC.
• crankcase.two cylinder head bolts [A] diagonally in the
Install the
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.)
Service Limit: 82.77 mm (3.259 in.)
6-36 ENGINE TOP END
Cylinder, Pistons
Piston Ring, Piston Ring Groove Wear
• Check
ing.
for uneven groove wear by inspecting the ring seat-
Engine Removal/Installation
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
7-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 7-3
Exploded View
Torque
No Fastener Remarks
N·m kgf·m ft·lb
1 Engine Mounting Bolts 36 3.7 27 L
2 Engine Damper Mounting Bolts 16 1.6 12 L
L: Apply a non-permanent locking agent.
7-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal
• Remove:
Seat (see Hull/Engine Hood chapter)
Oil Separator Tank (see Lubrication Sytem)
• Plug the hose end [A].
If the engine disassembles, drain the oil (see Engine Oil
Change in Periodic Maintenance chapter).
• Remove:
Air Filter (see Fuel System (DFI) chapter)
Inlet Manifold (see Fuel System (DFI) chapter)
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]
ENGINE REMOVAL/INSTALLATION 7-5
Engine Removal/Installation
• Remove:
Engine Mounting Bolts [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 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).
CAUTION
Do not run the engine without cooling water supply
for more than 15 seconds, especially in high revolu-
tionary speed or severe engine and exhaust system
damage will occur.
ENGINE BOTTOM END 8-1
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Crankshaft Sensor Cover Bolts 7.8 0.80 69 in·lb
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 in·lb L
7 Grommet Cover Bolts 9.8 1.0 87 in·lb L
8 Magneto Cover Bolts 20 2.0 14
9 Output Cover Bolts 7.8 0.80 69 in·lb
10 Output Shaft 245 25.0 180 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 in·lb S
A: JT1500-A1 ∼ A6F Models
D: Do not apply any grease or oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket (Kawasaki Bond: 92104-1062).
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 Parts.
S: Follow the specific tightening sequence.
SS: Apply silicone sealant.
WG: Apply water resistant grease.
8-4 ENGINE BOTTOM END
Specifications
• Remove:
Output Cover Bolts [A]
Output Cover [B]
• Remove:
Magneto Cover Bolts [C]
Magneto Cover
ENGINE BOTTOM END 8-9
Coupling
• Using the rotor holder [A], remove the output shaft [B].
Special Tool - Rotor Holder: 57001-1544
• 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 N·m (2.0 kgf·m, 14 ft·lb)
• Install:
Pins [A]
Gasket [B]
• Position the magnet lead [C] as shown.
• Install:
Crankshaft Sensor Cover
Engine (see Engine Removal/Installation chapter)
Coupling Damper Inspection
• Refer to the Coupling Damper Inspection in the Periodic
Maintenance chapter.
ENGINE BOTTOM END 8-11
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
• 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.
Special Tool - Bearing Driver Set: 57001-1129
○Using the rotor puller [A], pull off the flywheel [B].
Special Tool - Rotor Puller: 57001-1623
Grip: 57001-1591 [C]
CAUTION
Do not hit the head of the rotor puller. A loss in rotor
magnetism may be caused.
Stator Installation
• Apply
met.
water resistant grease to the outside of the grom-
○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.
8-16 ENGINE BOTTOM END
Crankcase Splitting
Crankcase Splitting
• Remove:
Seat (see Hull/Engine Hood chapter)
Engine (see Engine Removal/Installation chapter).
• Drain the engine oil (see Periodic Maintenance chapter).
• Set the engine on a clean surface and hold the engine
steady while parts are being removed.
Suitable Props [A]
Lower Crankcase Projections [B]
• Remove:
Crankshaft Sensor Cover (see Electrical System chap-
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)
• 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.
CAUTION
Do not apply liquid gasket around the crankshaft
main bearing inserts [B], and oil passage hole [C].
8-18 ENGINE BOTTOM END
Crankcase Splitting
• Install the oil pump sprocket chain [A] on the chain guide
[B] of the lower crankcase [C].
• After
item.
tightening all crankcase bolts, check the following
Crankshaft Installation
CAUTION
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.
• 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).
• Replace
new ones.
the connecting rod big end bolts and nuts with
CAUTION
Be careful not to overtighten the nuts.
Marking Position
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
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Water Hose Joint (L Shape Type) 11 1.1 95 in·lb L
2 Water Hose Joint (Straight Shape Type) 20 2.0 14 L
3 Water Hose Joint (Straight Shape Type) 11 1.1 95 in·lb L
4 Cooling Hose Clamp Screws 2.5 0.25 22 in·lb
5 Flushing Cap (JT1500A8F ∼) 0.90 0.092 8.0 in·lb
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: JT1500A6F Model ∼
C: JT1500-A1 ∼ A6F Models
CY: Apply cyanoacrylate cement.
D: JT1500A7F Model ∼
E: JT1500-A1 ∼ A8F Models
G: Apply grease.
L: Apply a non-permanent locking agent.
9-4 COOLING AND BILGE SYSTEMS
Bilge System
Breather Removal
• Remove:
Seat (see Hull/Engine Hood chapter)
Rear Storage Pocket
• Pull the hoses [A] off the breather.
• Unscrew the mounting bolts [B], and remove the
breathers [C].
Breather Installation
• Be sure the small hole [A] in the breather is open before
installing it.
• Apply a non-permanent locking agent to the breather
mounting bolts and tighten them.
Filter Installation
• Align the projections [A] on the filters [B] with the holes
[C] on the brackets [D].
• 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.
9-6 COOLING AND BILGE SYSTEMS
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.
WARNING
Do not lean over the engine when performing this
procedure. A water and gasoline mixture will be
forcibly ejected from the spark plug holes and could
get into your eyes. If you do get some in your eyes,
wash your eyes immediately with liberal amounts of
clean, fresh water. Consult a physician as soon as
possible.
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.
9-16 COOLING AND BILGE SYSTEMS
After Submerging
13. Reconnect the primary ignition coil lead connectors,
noting the #1,#4 [A] and the #2, #3 [B] coil 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
○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).
14. Start the engine by pressing the start button and run
less than 15 seconds.
CAUTION
Do not run the engine with the watercraft out of the
water for more than 15 seconds at a time. Overheat-
ing will cause severe engine and exhaust system
damage.
Never operate the engine at maximum speed out of
the water. Severe engine damage may occur.
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.
COOLING AND BILGE SYSTEMS 9-17
After Submerging
18. If the fuel tank has water in it, it must be emptied by
pump or siphon. Refill the tank with fresh fuel. Do not
dump contaminated fuel in places not designated for
that purpose.
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Pull the lanyard key
off the stop button. Do not smoke. Make sure the
area is well ventilated and free from any source of
flame or sparks; this includes any appliance with a
pilot light.
WARNING
Gasoline is toxic substance. Dispose of gasoline
properly. Contact your local authorities for ap-
proved disposal methods.
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 and Sealant ...................................................................................................... 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
No. Fastener Remarks
N·m kgf·m ft·lb
1 Coupling 39 4.0 29
2 Drive Shaft Holder Mounting Bolts 22 2.2 16 L
3 Coupling Cover Bolts 8.8 0.90 78 in·lb L
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
SS: Apply silicone sealant.
WG: Apply water resistance grease.
10-4 DRIVE SYSTEM
Specification
• When
items.
installing the drive shaft, be careful of the following
11
11-2 PUMP AND IMPELLER
Exploded View
PUMP AND IMPELLER 11-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Pump Bracket Mounting Bolts (2) 19 1.9 14 LN, SS
2 Pump Bracket Mounting Bolts (4) 9.8 1.0 87 in·lb L
3 Pump Mounting Bolts 36 3.7 27 L
4 Grate Mounting Bolts 9.8 1.0 87 in·lb L
5 Pump Cover Mounting Bolts 7.8 0.80 69 in·lb L
6 Impeller 98 10 72
7 Pump Cap Bolts 9.8 1.0 87 in·lb L
8 Pump Cap Bolts 3.9 0.40 35 in·lb 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 in·lb
12 Filter Cover Mounting Bolts 9.8 1.0 87 in·lb L
13 Steering Cable Joint Bolt 9.8 1.0 87 in·lb L
14 Water Hose Joint – – – L
15 Water Hose Joint – – – L
A: JT1500-A1 Model
B: JT1500-A2 Model ∼
C: JT1500A6F (France) ∼/A9F (Europe) Model ∼
D: JT1500-A1 ∼ A6F Models
E: JT1500A7F Model ∼
HG: Apply high grade water resistance grease (Chevron: Black Pearl Grease EP NLGI 2 or equiva-
lent).
L: Apply a non-permanent locking agent.
LN: Apply a non-permanent locking agent (High Strength: Loctite 271 equivalent).
M: Apply molybdenum disulfide grease.
SS: Apply silicone sealant.
11-4 PUMP AND IMPELLER
Specifications
• 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].
JT1500A7F Model ∼ [D]
○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.
• Liberally coat the outside edge of the pump bracket with
silicon sealant [A] to form a seal between the bracket and
the hull.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
11-8 PUMP AND IMPELLER
Pump and Impeller
• BeJT1500A7F
sure trim seal [A] is in place.
Model ∼ [B]
PUMP AND IMPELLER 11-9
Pump and Impeller
• Grease
grease.
the splines on the drive shaft with water resistant
○Coat the outside edge [A] of the seal [B] with silicone
sealant to form a seal between the hull and seal.
11-10 PUMP AND IMPELLER
Pump and Impeller
Pump Disassembly
• Unscrew the steering nozzle pivot bolts [A], and remove
the steering nozzle [B].
• Unscrew
cap [B].
the pump cap bolts [A], and remove the pump
PUMP AND IMPELLER 11-11
Pump and Impeller
JT1500A7F Model ∼
Special Tools - Impeller Holder: 57001-1695 [A]
Impeller Wrench: 57001-1228 [B]
JT1500-A1 Model
•Pull out the bushing [A].
11-12 PUMP AND IMPELLER
Pump and Impeller
JT1500-A2 Model ∼
• Press [A] the bussing [B] and the ball bearing [C]. They
come out of the pump case.
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
mounting bolts and tighten them.
Torque - Filter Cover Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
JT1500-A1 Model
•Install a new bearing into the pump case [A] as far as it
will go.
Special Tool - Bearing Driver Set: 57001-1129 [B]
11-14 PUMP AND IMPELLER
Pump and Impeller
JT1500-A2 Model ∼
• Replace the grease seals with new ones, if necessary,
and install them.
Special Tool - Bearing Driver Set: 57001-1129
○Press each seal [A] into the pump case [B] so that the side
with the spring faces outward.
○Fill the gap between the grease seals [C] with high grade
water resistance grease and apply it each greace seal lip
[D].
•Install the circlip [E].
•Install the bushing [F] into the pump case.
○Fill with high grade water resistance grease [G].
• Install
will go.
a new bearing into the pump case [A] as far as it
JT1500A7F Model ∼
•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.
• Push the pump shaft with bearing into the pump case
(JT1500A7F ∼).
11-16 PUMP AND IMPELLER
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 N·m (10 kgf·m, 72 ft·lb)
• Visually
sary.
inspect impeller seal [A], and replace it if neces-
• 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.
• BeJT1500A7F
sure the pump seal [A] is in place on the pump case.
Model ∼ [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.)
Service Limit: 146.5 mm (5.7677 in.)
Pump Inspection
• Examine the pump case [A].
If there are deep scratches inside the pump case, replace
it.
Steering
Table of Contents
Exploded View........................................................................................................................ 12-2
Special Tool and Sealant ........................................................................................................ 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 12
Reverse Bucket Removal/Installation ............................................................................... 12-20
Shift Lever Shaft Removal/Installation .............................................................................. 12-20
12-2 STEERING
Exploded View
STEERING 12-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Handlebar Clamp Bolts 16 1.6 12 L
2 Start/stop Switch Case Mounting Screws 3.9 0.40 35 in·lb
3 Throttle Case Mounting Screws 3.9 0.40 35 in·lb
4 Steering Shaft Locknut 49 ∼ 59 5.0 ∼ 6.0 36 ∼ 43
5 Steering Shaft Nut 2.9 0.30 26 in·lb
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 in·lb L
9 Ball Joint 9.8 1.0 87 in·lb LN
10 Shift Cable End Nut 9.8 1.0 87 in·lb
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: JT1500A7F Model ∼
G: Apply grease.
L: Apply a non-permanent locking agent.
LN: Apply a non-permanent locking agent (High Strength: Loctite 271 equivalent).
SS: Apply silicone sealant.
12-4 STEERING
Special Tool and Sealant
Box Wrench (27 mm): Kawasaki Bond (Silicone Sealant):
57001-1451 56019-120
• Check
cavity.
that the steering nozzle [A] is centered in the pump
•○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 N·m (1.0 kgf·m, 87
in·lb)
○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
• Turn the watercraft on its left side and remove the pump
cover (see Pump Removal in Pump/Impeller chapter).
CAUTION
Never lay the watercraft on the right side. Water in
the exhaust system may drain back into the engine,
causing serious damage.
• 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
• Slide off the snap ring [A], washer [B] and O-ring [C].
• Pull out the steering cable toward the rear.
STEERING 12-7
Steering Cable
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 N·m (4.0 kgf·m, 29 ft·lb)
• 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 N·m (1.0 kgf·m, 87
in·lb)
• Remove the inner pad [A], pushing [B] the buzzer [C].
• Unscrew the bolts [A] and remove the pad holder [B].
○Align the punch mark [A] on the left side of the handlebar
with the parting line [B].
○Tighten the front and then rear handlebar clamp bolts to
the specified torque.
Torque - Handlebar Clamp Bolts: 16 N·m (1.6 kgf·m, 12
ft·lb)
•○Install the fuel vent hose.
Refer to the Fuel Tank Vent Hose Installation in the Fuel
System chapter.
CAUTION
Be sure to install the fuel tank air vent pipe correctly
and securely. The engine will surely malfunction if
the fuel tank air vent pipe end gets clogged by the
handlebar pad and/or; if the air vent hose is folded;
and/or driving the watercraft with the air vent hose
remaining clogged.
• 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).
the front storage pocket (see Hull/Engine Hood
• 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].
• Remove the cotter pin [A] and steering shaft locknut [B].
• Take out the holder [C].
• Take out the air intake duct mounting bolts [A] and remove
the air intake duct [B] from the steering holder [C].
• Install the air intake duct [B] to the steering holder [C].
• mountingnon-permanent
Apply a
bolts [A].
locking agent to the air intake duct
• 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
mounting bolts and tighten them.
Torque - Steering Neck Mounting Bolts: 16 N·m (1.6 kgf·m,
12 ft·lb)
• Loosen
[B].
the locknut [A] at the front end of the shift cable
12-18 STEERING
Reverse System
• Remove
ter).
the right side cover (see Hull/Engine Hood chap-
• 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).
CAUTION
Never lay the watercraft on the right side. Water in
the exhaust system may drain back into the engine,
causing serious damage.
• 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.
Hull/Engine Hood
Table of Contents
Exploded View........................................................................................................................ 13-2
Fittings .................................................................................................................................... 13-8
Seat Removal (JT1500-A1 ∼ A2 Models) ......................................................................... 13-8
Seat Removal (JT1500A6F Model ∼)................................................................................ 13-8
Seat Installation (JT1500-A1 ∼ A2 Models) ...................................................................... 13-8
Seat Installation (JT1500A6F 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 13
Exhaust Outlet Removal ................................................................................................... 13-16
Exhaust Outlet Installation ................................................................................................ 13-16
Stabilizer Removal ............................................................................................................ 13-16
Stabilizer Installation ......................................................................................................... 13-17
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
HULL/ENGINE HOOD 13-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Crossmember Bolts 7.8 0.80 69 in·lb L
2 Handrail Bolts 9.8 1.0 87 in·lb L
3 Lock Assembly Nut 4.9 0.50 43 in·lb
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: JT1500A6F Model ∼
C: JT1500A7F Model ∼
D: JT1500-A1 ∼ A8F Models
CY: Apply cyanoacrylate cement.
L: Apply a non-permanent locking agent.
SY: Apply synthetic rubber adhesive.
13-4 HULL/ENGINE HOOD
Exploded View
JT1500-A1 ∼ A8F
HULL/ENGINE HOOD 13-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Stabilizer Bolts 9.8 1.0 87 in·lb L
2 Air Inlet Duct Bolts – – – L
3 Exhaust Outlet Bolts – – – L
A: JT1500A7F Model ∼
B: JT1500A8F Model
CY: Apply cyanoacrylate cement.
L: Apply a non-permanent locking agent.
SS: Apply silicone sealant.
SY: Apply synthetic rubber adhesive.
13-6 HULL/ENGINE HOOD
Exploded View
JT1500A9F
HULL/ENGINE HOOD 13-7
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Stabilizer Bolts 9.8 1.0 87 in·lb L
2 Air Inlet Duct Bolts – – – L
3 Exhaust Outlet Bolts – – – L
CY: Apply cyanoacrylate cement.
L: Apply a non-permanent locking agent.
SS: Apply silicone sealant.
SY: Apply synthetic rubber adhesive.
13-8 HULL/ENGINE HOOD
Fittings
Seat Removal (JT1500-A1 ∼ A2 Models)
• Pull [A] the latch handle [B].
• Install the rear seat [A] and push down [B] on the rear of
the rear seat to lock it.
• ToDamper
remove the hinge assembly, remove the following.
Bolt [A]
Hinge Bolts [B]
13-10 HULL/ENGINE HOOD
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.
HULL/ENGINE HOOD 13-11
Fittings
Front Storage Compartment Cover Assembly
• Secure the front duct cover to the front duct [A] with the
rivets using a riveter [B].
Mirror Installation
• Be sure that the washer [A] are in position.
13-12 HULL/ENGINE HOOD
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.
• 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.
• 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.
• 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].
• To remove the right side cover, pull the holder [A] off the
cable bracket.
HULL/ENGINE HOOD 13-15
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 N·m (0.80 kgf·m, 69 in·lb)
• Be sure that the dampers [A] are in position.
• mounting
Apply a non-permanent locking agent to the cable bracket
bolts and tighten them securely.
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.
13-16 HULL/ENGINE HOOD
Fittings
Drain Plug Housing Removal
• Unscrew
ing [B].
the screws [A] and remove the drain plug hous-
WARNING
Read all warnings and cautions on any solvents
and adhesives used. Many of these products are
flammable, may be harmful to the skin and eyes,
and may give off harmful vapors. Use these sol-
vents and adhesives only in a well-ventilated area
and never near an open flame.
CAUTION
Be very careful that the part is positioned correctly
when you apply the cement. It may be impossible
to reposition the part.
WARNING
Do not get any cyanoacrylate cement in your eyes
or on your skin. If you do get some in your eyes,
do not try to wash it out. Contact a physician im-
mediately! If you do get some on your fingers, do
not touch any other part of your body; your fingers
will stick to anything they touch. Allow the cement
to cure and it will eventually wear off.
Detent [A]
Mats [A]
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
• Remove the trim strip [A] from the side bumper [B].
Electrical System
Table of Contents
Parts Location.................................... 14-3 Crankshaft Sensor Inspection...... 14-40
Exploded View................................... 14-6 Ignition Coil Removal ................... 14-41
Wiring Diagram.................................. 14-12 Ignition Coil Installation ............... 14-42
Specifications .................................... 14-18 Ignition Coil Inspection................. 14-43
Special Tools and Sealant ................. 14-19 Camshaft Position Sensor
Precautions........................................ 14-20 Removal .................................... 14-44
Electrical Wiring................................. 14-22 Camshaft Position Sensor
Wiring Inspection ......................... 14-22 Installation ................................. 14-45
Battery ............................................... 14-23 Camshaft Position Sensor
Battery Removal .......................... 14-23 Inspection.................................. 14-45
Battery Installation ....................... 14-23 Igniter Removal/Installation.......... 14-45
Electrolyte Filling.......................... 14-23 Igniter Inspection.......................... 14-45
Initial Charge................................ 14-25 Spark Plug Removal .................... 14-48
Precautions .................................. 14-25 Spark Plug Installation ................. 14-48
Interchange .................................. 14-26 Spark Plug Inspection .................. 14-48
Charging Condition Inspection..... 14-26 Spark Plug Adjustment ................ 14-48
Refreshing Charge....................... 14-26 Spark Plug Cleaning .................... 14-48
Electric Starter System ...................... 14-28 Kawasaki Smart Steering System ..... 14-52
Starter Relay Removal................. 14-28 Steering Position Sensor and
Starter Relay Installation.............. 14-28 Magnet Removal ....................... 14-52
Starter Relay Inspection............... 14-28 Steering Position Sensor and
Starter Motor Removal................. 14-29 Magnet Installation .................... 14-52
Starter Motor Installation.............. 14-29 Inspection of Kawasaki Smart
Starter Motor Disassembly........... 14-30 Steering System........................ 14-53 14
Starter Motor Assembly ............... 14-30 Steering Position Sensor
Brush Inspection .......................... 14-31 Clearance.................................. 14-53
Commutator Cleaning and Steering Position Sensor Input
Inspection.................................. 14-31 Voltage Inspection..................... 14-54
Armature Inspection..................... 14-32 Steering Position Sensor Output
Brush Lead Inspection ................. 14-32 Voltage Inspection..................... 14-55
Brush Plate and Terminal Bolt Sensors ............................................. 14-58
Inspection.................................. 14-32 Speed Sensor Removal/Installa-
Reduction Gear Removal/Installa- tion ............................................ 14-58
tion ............................................ 14-33 Speed Sensor Inspection............. 14-58
Reduction Gear Inspection .......... 14-33 Fuel Level Sensor Inspection....... 14-59
Charging System ............................... 14-35 Throttle Sensor Removal/Installa-
Magneto Output Voltage .............. 14-35 tion ............................................ 14-59
Regulator/Rectifier Throttle Sensor Inspection ........... 14-60
Removal/Installation.................. 14-35 Water Temperature Sensor
Regulator/Rectifier Inspection...... 14-36 Inspection.................................. 14-60
Regulator Inspection .................... 14-36 Inlet Air Temperature Sensor
Ignition System .................................. 14-39 Inspection.................................. 14-60
Crankshaft Sensor Removal ........ 14-39 Oil Temperature Sensor
Crankshaft Sensor Installation ..... 14-39 Inspection.................................. 14-60
Timing Rotor Removal ................. 14-40 Multifunction Meter ............................ 14-61
Timing Rotor Installation .............. 14-40 Display Function Inspection ......... 14-61
14-2 ELECTRICAL SYSTEM
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Vehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb
2 Electrical Parts Bracket Screws 4.9 0.50 43 in·lb L
3 Starter Relay Case Bolts 7.8 0.80 69 in·lb
4 Ignition Coil Mounting Bolts 8.8 0.90 78 in·lb 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 in·lb
7 Starter Cable Mounting Nuts 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lb
8 Timing Rotor Bolt 20 2.0 14 L
9 Crankshaft Sensor Screws 4.4 0.45 39 in·lb L
10 Rubber Grommet Holder Screws 4.4 0.45 39 in·lb L
11 Crankshaft Sensor Cover Bolts 7.8 0.80 69 in·lb
12 Oil Temperature Sensor 15 1.5 11 see text
13 Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb L
14 Spark Plugs 13 1.3 113 in·lb
15 Regulator/Rectifier Bolts 7.8 0.80 69 in·lb
16 Relay Assembly Bolt 2.5 0.25 22 in·lb L
17 ECU Mounting Bolts 8.8 0.90 78 in·lb L
18 Main Fuse Mounting Bracket Bolt 7.8 0.80 69 in·lb
19 Bracket Mounting Bolts 8.8 0.90 78 in·lb 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: JT1500A8F Model ∼
EO: Fill the hollow of the exhaust manifold with engine oil (10W-30).
G: Apply grease.
L: Apply a non-permanent locking agent.
Si: Fill the hollow of the oil pan with the specified silicone grease (Kawasaki Bond: 92137-1002).
WG: Apply water resistant grease.
14-8 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 14-9
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Multifunction Meter Mounting Bolts 3.9 0.40 35 in·lb L
2 Fuel Level Sensor Clamp Screw 2.9 0.30 26 in·lb
3 Start/stop Switch Case Mounting Screw 3.9 0.40 35 in·lb
4 Speed Sensor Mounting Bolts 3.9 0.40 35 in·lb L
5. Multifunction Meter
6. Fuel Level Sensor
7. Buzzer
14-10 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 14-11
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Starter Motor Through Bolts 6.4 0.65 56 in·lb L, R
2 Starter Motor Mounting Bolts 8.8 0.90 78 in·lb L
3 Starter Motor Ground Bolt 8.8 0.90 78 in·lb
4 Starter Motor Terminal Nut 8.8 0.90 78 in·lb
5 Stator Coil Bolts 12 1.2 104 in·lb L
6 Grommet Holder Bolts 8.8 0.90 78 in·lb L
7. Main Fuse 20 A
8. Harness Connector (to Regulator/Rectifier)
A: JT1500-A1 ∼ A6F Models
B: JT1500A8F Model ∼
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement parts.
WG: Apply water resistant grease.
14-12 ELECTRICAL SYSTEM
Wiring Diagram
JT1500-A1
ELECTRICAL SYSTEM 14-13
Wiring Diagram
JT1500-A1
14-14 ELECTRICAL SYSTEM
Wiring Diagram
JT1500-A2 ∼ A7F
ELECTRICAL SYSTEM 14-15
Wiring Diagram
JT1500-A2 ∼ A7F
14-16 ELECTRICAL SYSTEM
Wiring Diagram
JT1500A8F ∼
ELECTRICAL SYSTEM 14-17
Wiring Diagram
JT1500A8F ∼
14-18 ELECTRICAL SYSTEM
Specifications
Connectors [B]
14-22 ELECTRICAL SYSTEM
Electrical Wiring
Wiring Inspection
• Visually
etc.
inspect the wiring for signs of burning, fraying,
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.
CAUTION
Do not reverse the battery connections.
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 for JT1500-A: YTX20L-BS
CAUTION
Be sure to use the electrolyte container with the
same model name as the battery since the elec-
trolyte volume and specific gravity vary with the
battery type. This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora-
tion of the battery performance.
14-24 ELECTRICAL SYSTEM
Battery
NOTE
○A battery whose seal sheet has any peeling, tears, or
holes, requires a refreshing charge (initial charge).
NOTE
○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 12.6 volts repeat the
charging cycle and load test. If still below 12.6 volts 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.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
14-26 ELECTRICAL SYSTEM
Battery
3) When you do not use the watercraft for months:
Give a refresh charge before you store the watercraft and store it with the negative lead re-
moved. Give a refresh charge once a month during storage.
4) Battery life:
If the battery will not start the engine even after several refresh charges, the battery has ex-
ceeded its useful life. Replace it (Provided, however, the watercraft’s starting system has no
problem).
WARNING
Keep the battery away from sparks and open flames during charging, since the battery
gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,
connect the battery to the charger before turning on the charger.
This procedure prevents sparks at the battery terminals which could ignite any battery
gases.
No fire should be drawn near the battery, or no terminals should have the tightening loos-
ened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medial attention if severe.
Interchange
A sealed battery can fully display its performance only when combined with a proper watercraft
electric system. Therefore, replace a sealed battery only on watercraft which was originally equipped
with a sealed battery.
Be careful, if a sealed battery is installed on watercraft which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
WARNING
This battery is sealed type. Never remove the
strip of cap [B] even at charging. Never add water.
Charge with current and time as stated below.
CAUTION
If possible, do not quick charge. If the quick charge
is done due to unavoidable circumstances, do stan-
dard charge later on.
• Remove the terminal locknut [A] and terminal bolt [B], and
then remove the brush with the brush plate [C] from the
yoke.
• 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.
ELECTRICAL SYSTEM 14-31
Electric Starter System
• 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 N·m (0.65 kgf·m,
56 in·lb)
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.)
Service Limit: 6.5 mm (0.2559 in.)
Armature Inspection
• Using the × 1 Ω hand tester range, measure the resis-
tance between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394
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.
• 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.
14-34 ELECTRICAL SYSTEM
Electric Starter System
Electric Starter Circuit (JT1500-A1 ∼ A7F Models)
5. Starter Motor
1. Main Fuse 20 A
6. Battery 12 V 18 Ah
2. Ignition Switch
7. Starter Relay
3. Engine Starter Switch
8. Joint Connector S
4. Joint Connector R
(Ground)
Electric Starter Circuit (JT1500A8F Model ∼)
• 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
To avoid electrical shock, do not perform this test
with the watercraft in the water.
CAUTION
Do not run the engine over 15 seconds without cool-
ing water.
Regulator/Rectifier Inspection
• With the hand tester set to the R × 1 kΩ range, test the
regulator/rectifier according the following table.
Special Tool - Hand Tester: 57001-1394
CAUTION
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
ECU (Electronic Control Unit) damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and ECU.
• 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].
• connect
Set the hand tester to the × 100 Ω 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 Ω
• Pull up the bracket [A] together with the ignition coils [B],
vehicle-down sensor [C], and fuel filter [D] installed.
14-42 ELECTRICAL SYSTEM
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.
• Remove:
Camshaft Position Sensor Bolt [A]
Camshaft Position Sensor [B]
Igniter Inspection
○The igniter is built in the ECU (Electronic Control Unit).
CAUTION
Do not disconnect the battery leads or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
igniter in the ECU damage.
Ignition Coil Primary Peak Voltage Check
NOTE
○Be sure the battery is fully charged.
• Remove:
Seat (see Hull/Engine Hood chapter)
14-46 ELECTRICAL SYSTEM
Ignition System
• 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:
Front Storage Pocket (see Hull/Engine Hood chapter)
• [B]. the peak voltage adapter [A] into the hand tester
Install
• 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
Connections
Adapter Adapter
(R, +) (BK, –)
Crankshaft Sensor: G ←→ BL
• 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
Standard: 2.5 V or more
If the reading is less than the specified value, check the
crankshaft sensor (see Crankshaft Sensor Inspection).
Camshaft Position Sensor Peak Voltage Inspection
•Remove:
Seat (see Hull/Engine Hood chapter)
14-48 ELECTRICAL SYSTEM
Ignition System
Connections
Camshaft Sensor Lead Adapter Hand Tester
Black ← Red → (+)
Yellow ← Black → (−)
• Unscrew
[B].
the mounting screw [A] and remove the magnet
NOTE
○Be sure the battery is fully charged
○Connect a digital voltmeter [A] to the lead connector [B]
of the steering position sensor using the needle adapter
set [C].
Special Tool - Needle Adapter Set: 57001-1457
NOTE
○When the handlebar is centered in straight-ahead posi-
tion the output voltage standard value is battery voltage.
○Turn the ignition switch OFF.
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.
14-56 ELECTRICAL SYSTEM
Kawasaki Smart Steering System
Steering Position Sensor Circuit (JT1500-A1 ∼ A7F Models)
1. Joint Connector Q
2. Multifunction Meter
3. Steering Position Sensor
4. Main Fuse 20 A
5. Joint Connector R
6. Battery 12 V 18 Ah
7. Joint Connector S
8. Joint Connector P
9. Ignition Switch
10. ECU (Electronic Control Unit)
ELECTRICAL SYSTEM 14-57
Kawasaki Smart Steering System
Steering Position Sensor Circuit (JT1500A8F Model ∼)
1. Joint Connector R
2. Multifunction Meter
3. Steering Position Sensor
4. Main Fuse 20 A
5. Joint Connector V
6. Battery 12 V 18 Ah
7. Joint Connector U
8. ECU (Electronic Control Unit)
9. Ignition Switch
10. Joint Connector P
11. Joint Connector Q
14-58 ELECTRICAL SYSTEM
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 ∼ A8F models, however it is located at left on
the hull in JT1500A9F model.
• Measure
speeds.
the output voltage of the sensor at higher
CAUTION
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.
14-62 ELECTRICAL SYSTEM
Multifunction Meter
MODE/SET Button Inspection
• Check that when the MODE button is pushed and held
continuously, the display rotates through the four modes.
• Ifassembly.
any display function does not work, replace the meter
Speedometer Inspection
• Connect the 12 V battery and terminals in the same man-
ner as specified in the “Display Function 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.
14-64 ELECTRICAL SYSTEM
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.
1. Joint Connector Q
2. Fuel Level Sensor
3. Buzzer
4. Multifunction Meter
5. Speed Sensor
6. Main Fuse 20 A
7. Joint Connector R
8. Starter Motor
9. Battery 12 V 18 Ah
10. Joint Connector P
11. Ignition Switch
12. ECU (Electronic Control Unit)
A: JT1500-A2 ∼ A7F Models
14-68 ELECTRICAL SYSTEM
Multifunction Meter
Multifunction Meter Circuit (JT1500A8F Model ∼)
1. Joint Connector R
2. Fuel Level Sensor
3. Buzzer
4. Multifunction Meter
5. Speed Sensor
6. Main Fuse 20 A
7. Joint Connector V
8. Starter Motor
9. Battery 12 V 18 Ah
10. ECU (Electronic Control Unit)
11. Ignition Switch
12. Joint Connector P
13. Joint Connector Q
ELECTRICAL SYSTEM 14-69
Relay Assembly
Removal
• Remove the seat (see Hull/Engine Hood chapter).
• Remove:the rear storage pocket.
Remove
• Relay Assembly Connector [A]
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.
• Check conductivity of the following numbered terminals
by connecting the hand tester and one 12 V battery to the
relay assembly as shown.
If the tester does not read as specified, replace the relay
assembly.
14-70 ELECTRICAL SYSTEM
Relay Assembly
Relay Assembly Circuit Inspection (with the battery disconnected)
Tester Connection Tester Reading (Ω)
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.
Start Switch
Stop Switch
Tether Switch
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
CAUTION
Discharge water from the exhaust system after
flushing the cooling system.
Water remaining in the exhaust system during cold
weather could freeze and damage the exhaust pipe.
Engine Oil
• Change the engine oil (see Engine Lubrication System in
Periodic Maintenance chapter).
Fuel System
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Pull the lanyard key
off the stop button. Do not smoke. Make sure the
area is well ventilated and free from any source of
flame or sparks; this includes any appliance with a
pilot light.
• Drain
pump.
the fuel tank. This should be done with a siphon or
• 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
Preparation for Storage
Engine
• Remove
chapter).
the front storage pocket (see Hull/Engine Hood
• 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).
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.
CAUTION
Use only a mild detergent in water to wash the hull.
Harsh solvents may attack the surface or smear the
colors.
• 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.
• Start the engine and run it only for 15 seconds. Check for
fuel, oil and exhaust leaks. Any leaks must be repaired.
CAUTION
Do not run the engine without cooling water supply
for more than 15 seconds at a time or severe engine
and exhaust system damage will occur.
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 ∼ A8F
APPENDIX 16-3
Cable, Wire and Hose Routing
1. Crossmember
2. Cylinder Head Cover
3. Throttle Cable
4. Delivery Pipe
5. Fix the throttle cable to the delivery pipe with the band.
6. Inlet Manifold
7. Horizontal Plane
8. Position the clamp pinch head below the horizontal plane.
9. Throttle Body Assy
10. Air Filter
11. 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
31. Exhaust Manifold
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
Cable, Wire and Hose Routing
JT1500A9F
APPENDIX 16-5
Cable, Wire and Hose Routing
1. Crossmember
2. Cylinder Head Cover
3. Throttle Cable
4. Delivery Pipe
5. Fix the throttle cable to the delivery pipe with the band.
6. Inlet Manifold
7. Horizontal Plane
8. Position the clamp pinch head below the horizontal plane.
9. Throttle Body Assy
10. Air Filter
11. 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 (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. Exhaust Manifold
31. Flushing Hose
32. Bypass Outlet Hose
33. Breather Hose (Cylinder Head ∼ Breather Case)
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
Cable, Wire and Hose Routing
APPENDIX 16-7
Cable, Wire and Hose Routing
1. Oil Cooler
2. Cylinder Head
3. Water Pipe
4. Cylinder
5. Oil Filter
6. Oil Pan
7. Battery (−) Cable
8. Starter Motor
9. Starter Motor Cable
10. Cooling Hose (Cylinder Head ∼ Left Water Box Muffler)
11. Fix the No.10 cooling hose, battery (−) cable and starter motor cable with the band.
12. Output Cover
13. Water Hose Joint (Inlet)
14. Water Hose joint (Outlet)
15. Return Oil Hose (Cylinder ∼ Oil Pan)
16. Protective Tube
17. JT1500A9F Model
16-8 APPENDIX
Cable, Wire and Hose Routing
JT1500-A1 ∼ A8F
APPENDIX 16-9
Cable, Wire and Hose Routing
1. Clamps
2. Breather Hose (Cylinder Head ∼ Breather Case)
3. Clamp Detail
4. Position the clamp pinch heads as shown.
5. Air Suction Valve
6. Air Suction Valve Hose
7. Inlet Water Pipe Joint on the Cylinder (Cooling Water from Left Water Box Muffler)
8. Cylinder
9. Cylinder Head Cover
10. Output Cover
11. Protective Tube
12. Return Oil Hose (Cylinder ∼ Oil Pan)
13. Breather Hose (Cylinder ∼ Breather Case)
14. Breather Case
15. Oil Pan
16. Front Pinch Head
17. 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
Cable, Wire and Hose Routing
JT1500A9F
APPENDIX 16-11
Cable, Wire and Hose Routing
1. Clamps
2. Breather Hose (Cylinder Head ∼ Crankcase)
3. Clamp Detail
4. Position the clamp pinch heads as shown.
5. Inlet Water Pipe Joint on the Cylinder (Cooling Water from Water Box Muffler)
6. Cylinder
7. Cylinder Head Cover
8. Output Cover
9. Protective Tube
10. Return Oil Hose (Cylinder ∼ Oil Pan)
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
16-12 APPENDIX
Cable, Wire and Hose Routing
JT1500-A1 ∼ A8F
APPENDIX 16-13
Cable, Wire and Hose Routing
Refer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapter.
Install the clamp as shown, noting its screw head direction.
1. Bypass Outlet
2. 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
12. Cooling Hose (Output Cover ∼ Exhaust Pipe)
13. Output Cover
14. Cooling Hose (Pump ∼ Output Cover)
15. Oil Pan
16. Bands
17. Right Water Box Muffler
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
22. Cooling Hose (Pump ∼ Output Cover)
23. Left Water Box Muffler
24. Cooling Hose (Left Water Box Muffler ∼ Hull)
25. Fix the No.26 and No.27 cooling hoses with the band.
26. Cooling Hose (Output Cover ∼ Exhaust Pipe)
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.
30. Exhaust Manifold
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 (JT1500A6F Model ∼)
16-14 APPENDIX
Cable, Wire and Hose Routing
JT1500A9F
APPENDIX 16-15
Cable, Wire and Hose Routing
Refer to the Exploded View and Flow Diagram in the Cooling and Bilge Systems chapter.
Install the clamp as shown, noting its screw head direction.
1. Bypass Outlet
2. 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
12. Cooling Hose (Output Cover ∼ Exhaust Pipe)
13. Output Cover
14. Cooling Hose (Pump ∼ Output Cover)
15. Oil Pan
16. Bands
17. Position the clamp so that its screw head faces downward and outside.
18. Pump
19. Drain
20. Cooling Hose (Pump ∼ Output Cover)
21. Water Box Muffler
22. Cooling Hose (Water Box Muffler ∼ Hull)
23. Fix the No.26 and No.27 cooling hoses with the band.
24. Cooling Hose (Output Cover ∼ Exhaust Pipe)
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.
28. Exhaust Manifold
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
Cable, Wire and Hose Routing
JT1500-A1 ∼ A8F
APPENDIX 16-17
Cable, Wire and Hose Routing
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
12. Left Water Box Muffler
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
19. Right Water Box Muffler
16-18 APPENDIX
Cable, Wire and Hose Routing
JT1500A9F
APPENDIX 16-19
Cable, Wire and Hose Routing
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
12. Water Box Muffler
13. Position the clamp so that their screw heads face forward.
14. To Tail Pipe
15. Arrow Mark
16. Exhaust Tube
16-20 APPENDIX
Cable, Wire and Hose Routing
JT1500-A1 ∼ A8F
APPENDIX 16-21
Cable, Wire and Hose Routing
1. Right Rear Duct
2. Right Bilge Hose
3. Left Bilge Hose
4. Left Rear Duct
5. Left Water Box Muffler
6. Position the left rear duct inside the left bilge hose as shown.
7. Position the right rear duct under the right bilge hose as shown.
8. Right Water Box Muffler
9. Right Bilge Breather
10. Left Bilge Breather
11. Left Bilge Filter
12. Right Bilge Filter
16-22 APPENDIX
Cable, Wire and Hose Routing
JT1500A9F
APPENDIX 16-23
Cable, Wire and Hose Routing
1. Right Rear Duct
2. Right Bilge Hose
3. Left Bilge Hose
4. Left Rear Duct
5. Water Box Muffler
6. Position the left rear duct inside the left bilge hose as shown.
7. Position the right rear duct under the right bilge hose as shown.
8. Right Bilge Breather
9. Left Bilge Breather
10. Left Bilge Filter
11. Right Bilge Filter
16-24 APPENDIX
Cable, Wire and Hose Routing
JT1500-A1 ∼ A8F
APPENDIX 16-25
Cable, Wire and Hose Routing
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
4. Inlet Air Pressure Sensor
5. Protective Tube
6. Throttle Body Assy
7. Position the clamp screw so that its head faces backward (JT1500-A1 model).
Position the double spring clamp so that its pinch head faces backward (JT1500-A2 model ∼).
8. #4 Spark Plug Cap
9. #3 Spark Plug Cap
10. Fix the #2 and #3 high tension leads with the clamp.
11. Fix the #3 and #4 high tension leads with the clamp.
12. #2 Spark Plug Cap
13. Air Suction Valve Hose
14. #1 Spark Plug Cap
15. Fix the #1 and #2 high tension leads with the clamp.
16. Clamp (JT1500-A1 model)
Double Spring Clamp (JT1500-A2 model ∼)
17. Fuel Filter
18. Bracket
19. Vehicle-down Sensor
20. Ignition Coils
21. #4 High Tension Lead
22. #3 High Tension Lead
23. #2 High Tension Lead
24. #1 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
Cable, Wire and Hose Routing
JT1500A9F
APPENDIX 16-27
Cable, Wire and Hose Routing
1. Position the double spring clamp so that its pinch head faces forward.
2. Delivery Pipe Joints
3. Delivery Pipe
4. Inlet Air Pressure Sensor
5. Protective Tube
6. Throttle Body Assy
7. Position the double spring clamp so that its pinch head faces backward.
8. #4 Spark Plug Cap
9. #3 Spark Plug Cap
10. Fix the #2 and #3 high tension leads with the clamp.
11. Fix the #3 and #4 high tension leads with the clamp.
12. #2 Spark Plug Cap
13. #1 Spark Plug Cap
14. Fix the #1 and #2 high tension leads with the clamp.
15. Double Spring Clamp
16. Fuel Filter
17. Bracket
18. Vehicle-down Sensor
19. Ignition Coils
20. #4 High Tension Lead
21. #3 High Tension Lead
22. #2 High Tension Lead
23. #1 High Tension Lead
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
Cable, Wire and Hose Routing
JT1500-A1 ∼ A8F
APPENDIX 16-29
Cable, Wire and Hose Routing
1. Air Suction Valve Hose (to Air Filter)
2. Air Suction Valve
3. Air Suction Valve Cover (Rear)
4. Water Temperature Sensor Leads
5. Exhaust Manifold
6. Air Suction Valve Hose Fitting
7. Air Suction Valve Cover (Front)
8. Breather Hose
9. Cylinder Head Cover
10. Crankshaft Sensor Leads
11. Fix the crankshaft sensor 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
16. Inlet Air Pressure Sensor
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
22. Oil Pressure Switch
23. Oil Filter
24. Oil Cooler
25. Oil Temperature Sensor
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.
30. ISC (Idle Speed Controller)
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.
34. Inlet Air Temperature Sensor
35. Run the oil pressure switch lead between the cylinder and inlet manifold.
16-30 APPENDIX
Cable, Wire and Hose Routing
JT1500A9F
APPENDIX 16-31
Cable, Wire and Hose Routing
1. Water Temperature Sensor Leads
2. Exhaust Manifold
3. Breather Hose
4. Cylinder Head Cover
5. Crankshaft Sensor Leads
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
11. Inlet Air Pressure Sensor
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
17. Oil Pressure Switch
18. Oil Filter
19. Oil Cooler
20. Oil Temperature Sensor
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.
25. ISC (Idle Speed Controller)
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.
29. Inlet Air Temperature Sensor
30. Run the oil pressure switch lead between the cylinder and inlet manifold.
16-32 APPENDIX
Cable, Wire and Hose Routing
APPENDIX 16-33
Cable, Wire and Hose Routing
1. Crankshaft Sensor Leads
2. Grommet
3. Crankshaft Sensor Cover (Reverse Side)
4. Crankshaft Sensor
5. Magneto Cover (Reverse Side)
6. Magneto Leads
7. Plate for fixing the magneto leads: Do not place the leads between the plate and magneto cover.
8. Run the magneto leads along the hollow of the magneto cover.
9. Crankcase
10. Coupling
11. Output Cover
12. Run the magneto leads between the magneto cover and output cover. Do not pinch the leads.
16-34 APPENDIX
Cable, Wire and Hose Routing
APPENDIX 16-35
Cable, Wire and Hose Routing
1. Band
2. Main Harness
3. Rivet
4. Washer
5. See wire routing at bow.
6. See wire routing at stern.
7. Clamps
8. Speed Sensor Leads
9. Water Box Muffler Strap
10. Water Box Muffler
11. 16 Pin (Gray) and 6 Pin (White) Connectors (JT1500-A1 ∼ A7F Models)
12. To Engine (JT1500A8F Model ∼)
13. JT1500A9F Model
16-36 APPENDIX
Cable, Wire and Hose Routing
APPENDIX 16-37
Cable, Wire and Hose Routing
1. Crossmember
2. Steering Position Sensor Leads
3. Holder and Clamp
4. Fuel Vent Hose
5. Throttle Cable
6. Band
7. Ignition Switch Lead
8. Ignition Switch Lead Connector (Black)
9. Steering Position Sensor Lead Connector (White)
10. Fuel Level Sensor Lead Connector (Black)
11. Main Harness
12. Fuel Pump
13. Fuel Pump Lead Connector (White)
14. Steering Cable
15. Fuel Filter
16. Vehicle-down Sensor
17. Ignition Coil Lead Connectors (Gray)
18. Vehicle-down Sensor Lead Connector (White)
19. Fuel Tank
20. Bypass Outlet Hose
21. #2, #3 Ignition Coils
22. #1, #4 Ignition Coils
23. Fuel Level Sensor
16-38 APPENDIX
Cable, Wire and Hose Routing
APPENDIX 16-39
Cable, Wire and Hose Routing
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 ∼ A7F Models)
11. ECU (Electronic Control Unit)
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 (JT1500A8F Model ∼)
27. JT1500A9F Model
16-40 APPENDIX
Cable, Wire and Hose Routing
APPENDIX 16-41
Cable, Wire and Hose Routing
1. Regulator/rectifier
2. ECU (Electronic Control Unit)
3. Main Harness
4. Clamp
5. Electrical Parts Bracket
6. To Starter Motor
7. To Battery
8. Relay Assembly
9. Red Mark
10. Starter Relay
11. Right Side Deck
12. Main Harness
16-42 APPENDIX
Cable, Wire and Hose Routing
APPENDIX 16-43
Cable, Wire and Hose Routing
1. Fuel Vent Pipe: Hook the pipe at the handlebar.
2. Throttle Cable
3. Buzzer Leads (Run the leads through the protective tube.)
4. Protective Tube
5. Band
6. Clamp
7. Start/Stop Switch Leads
8. Grommet on Steering Holder
9. Multifunction Meter Leads
10. Fuel Vent Hose
11. Steering Holder
12. Holder
13. Steering Position Sensor
14. Steering Shaft
15. Reverse Side of Steering Holder
16. Protective Tube (small diameter)
17. Clamps
16-44 APPENDIX
Cable, Wire and Hose Routing
APPENDIX 16-45
Cable, Wire and Hose Routing
1. 80 mm (3.15 in.)
2. 100 mm (1.18 in.)
3. 180 mm (7.09 in.)
4. 40 mm (1.57 in.)
5. 105 mm (4.13 in.)
6. 90 mm (3.54 in.)
7. 50 mm (1.97 in.)
8. 130 mm (5.12 in.)
9. Detent
10. 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 Doesn’t 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 doesn’t
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 won’t 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
Troubleshooting Guide
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
Troubleshooting Guide
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 won’t 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
Troubleshooting Guide
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
□:This digit in the hull number changes from one machine to another.