Page 1

MODEL APPLICATION Year

Model

2007

JT1500B7F

2008

JT1500B8F

2009

JT1500E9F

2009

JT1500F9F

2010

JT1500EAF

2010

JT1500FAF

Beginning Hull No. US-KAW30001□607 US-KAW39001□607 US-KAW40001□708 US-KAW49001□708 US-KAW10001□809 US-KAW19001□809 US-KAW90001□809 US-KAW70001□910 US-KAW79001□910 US-KAW80001□910

□:This digit in the hull number changes from one machine to another.

Part No.99924-1377-04

Printed in Japan


ULTRA 250X ULTRA 260X ULTRA 260LX

®

JET SKI Watercraft Service Manual


Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.

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


ULTRA 250X ULTRA 260X ULTRA 260LX

®

JET SKI Watercraft Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/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.

© 2006 Kawasaki Heavy Industries, Ltd.

4th Edition (1):Nov. 26, 2009 (K)


LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L

ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

lb m min N Pa PS psi r rpm TDC TIR V W Ω

pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) perminute top dead center total indicator reading volt(s) watt(s) ohm(s)

COUNTRY AND AREA CODES AT AU CA CAL CH

Austria Australia Canada California Switzerland

DE EUR GB US WVTA

Germany Europe United Kingdom United States Whole Vehicle Type Approval


MAINTENANCE AND ADJUSTMENTS Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine Sl engine repair establishment or individual.

EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED PREMIUM GRADE GASOLINE ONLY. A minimum of 90 octane of the antiknock index is recommended. The antiknock index is posted on service station pumps. Emission Control Information To protect the environment in which we all live, Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this engine. The fuel, ignition and exhaust systems of this engine have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. Maintenance Proper maintenance and repair are necessary to ensure that watercraft will continue to have low emission levels. This Service Manual contains those maintenance and repair recommendations for this engine. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards. Tampering with Emission Control System Prohibited Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related parts. * Digital Transistor Ignition System * Fuel Pump * Spark Plugs * Throttle Body and Internal Parts * Fuel Injectors * ECU * Supercharger with intercooler & relief-valves


Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your JET SKI® watercraft: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki JET SKI® watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki JET SKI® watercraft are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

• • •

the procedures in this manual care• Follow fully. Don’t take shortcuts. to keep complete records of main• Remember tenance and repair with dates and any new parts installed.

How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.


NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. This model, JT1500B/E/F, is mounted with a four-stroke engine with supercharger. When the JET SKI® watercraft is submerged and swamped, the four-stroke engine needs special care and systematic procedure for recovery compared with the two-stroke engine. Therefore in this manual, such procedures, which are not shown in SMs for two-stroke engines, are explained thoroughly to cope with the cases. Refer to the section, After submerging in Chapter 9, Cooling and Bilge Systems for the summary and detailed procedures.


GENERAL INFORMATION 1-1

General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................

1 1-2 1-10 1-14 1-16


1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on watercraft, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following:

Kawasaki Diagnostic System (KDS) Software KDS software that runs on Windows personal computer (PC) will be available as a diagnostic tool for watercraft with Kawasaki DFI system. You need the following items to use the KDS. Item KDS Software Version 3.â–Ą (CD-ROM, Updated Version) KDS3 Adapter

Communication Cables KDS Adapter Cable

P/No. 57001-1650 57001-1648 and 57001-1724 or 57001-1725 57001-1649 and 57001-1688 or 57001–1745 57001-1696

The connectors for the communication cable and KDS adapter cable are located in the front. Connect the communication cable to the KDS connector (4-pin) [A] and the KDS adapter cable between the ignition switch (immobilizer amplifier) lead connectors (6-pin) [B].

Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting or presence of symptoms indicate that adjustments may be required. Whenever running of the engine is required during maintenance it is best to 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 adjustments. If possible, always operate the watercraft in water rather than use an auxiliary cooling supply.


GENERAL INFORMATION 1-3 Before Servicing a standard garden hose [A] and a garden hose • Obtain adapter [B] as shown. C: Garden Hose Fitting of Adapter D: Flushing Fitting of Adapter E: Thread: Rp 3/4

○Optional part (P/No. 92005-3746) is available as a garden hose adapter.

the front storage compartment cover. • Open Remove the flushing cap [A] on the brim of the storage • compartment.

a garden hose adapter [A] onto the flushing fitting • Screw [B]. a garden hose [C] to a garden hose adapter and • Attach secure the hose clamp [D].

the garden hose to a faucet. Do not turn on the water until the engine is running and turn it • Attach 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 cylinders, 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.


1-4 GENERAL INFORMATION 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 possible engine damage.

Battery Ground Before completing any service on the watercraft, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (–) wire 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.


GENERAL INFORMATION 1-5 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 decrease performance of the watercraft.

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

Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, 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 beyond 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.


1-6 GENERAL INFORMATION Before Servicing Assembly Order In most cases assembly order is the reverse of disassembly, 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 sequence 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 quarter 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 damage. 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 performance. 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


GENERAL INFORMATION 1-7 Before Servicing Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. 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 contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

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

Apply specified grease to the lip of seal before installing the seal.


1-8 GENERAL INFORMATION Before Servicing Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation When rotating the crankshaft, by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (counter-clockwise viewed from stern sinde).

Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires 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 thoroughly before using the meter. Incorrect values may lead to improper adjustments.


GENERAL INFORMATION 1-9 Before Servicing Harness Connector Apply grease [A] on all connectors of harness [B] for water resistance. Do not apply grease on the only connector of inlet air pressure sensor.


1-10 GENERAL INFORMATION Model Identification JT1500B7F Left Side View

JT1500B7F Right Side View

Hull Identification Number (HIN)

Engine Number


GENERAL INFORMATION 1-11 Model Identification JT1500B8F Left Side View

JT1500B8F Right Side View


1-12 GENERAL INFORMATION Model Identification JT1500E9F Left Side View

JT1500E9F Right Side View


GENERAL INFORMATION 1-13 Model Identification JT1500F9F Left Side View

JT1500F9F Right Side View


1-14 GENERAL INFORMATION General Specifications

Engine Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque

Ignition System Lubrication System Carburetion System Starting System Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Tuning Specifications Spark plug: Type Gap Ignition Timing Idle Speed Compression Pressure

Drive System Coupling Jet Pump: Type Thrust Steering

JT1500E9F ∼ EAF/F9F ∼ FAF

JT1500B7F ∼ B8F

Items

Digital transistor Forced lubrication (semi-dry sump) FI (fuel injection) MIKUNI AC 60 × 1 Electric starter

← ← ← 8.4 : 1 191 kW (260 PS) @7 750 r/min (rpm) 240 N·m (24.5 kgf·m, 177.0 ft·lb) @7 250 r/min (rpm) ← ← ← ←

Front (bow) to rear (stern), 1-2-3-4

1-2-4-3

15° BTDC 65° ABDC 260°

22.5° BTDC 67.5° ABDC 270°

73.5° BBDC 8.5° ATDC 262°

74.5° BBDC 9.5° ATDC 264°

NGK PMR9B 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.) 0° ATDC @1 300 r/min ∼ 8° BTDC @3 000 r/min (rpm) 1 300 ±100 r/min (rpm) -in water 1 300 ±100 r/min (rpm) -out of water 819 ∼ 1 268 kPa (8.3 ∼ 12.9 kgf/cm², 118 ∼ 184 psi) @380 r/min (rpm)

← ←

4-stroke, DOHC, 4-cylinder, water cooled 1 498 cm³ (91.4 cu in.) 83 × 69.2 mm (3.27 × 2.72 in.) 7.8 : 1 184 kW (250 PS) @7 750 r/min (rpm) 237 N·m (24.2 kgf·m, 174.8 ft·lb) @6 500 r/min (rpm)

← ← ← 840 ∼ 1 298 kPa (8.6 ∼ 13.2 kgf/cm², 122 ∼ 188 psi) @350 r/min (rpm)

Direct drive from engine

Axial flow single stage 6 780 N (692 kgf, 1 524 lb)

← 7 051 N (719 kgf, 1 585 lb) ←

Steerable nozzle


GENERAL INFORMATION 1-15 General Specifications

Braking Performance †Minimum Turning Radius †Fuel Consumption †Cruising Range Dimensions Overall Length Overall Width Overall Height Dry Weight: JT1500B7F JT1500B8F Curb Mass Air Draft (1) Maximum Draft (2) Fuel Tank Capacity Engine Oil Type Viscosity Capacity Electrical Equipment Battery Maximum Generator Output

JT1500E9F ∼ EAF/F9F ∼ FAF

JT1500B7F ∼ B8F

Items Water drag

4.0 m (13.1 ft) ← ← 74.5 L/h (19.7 US gal/h) @full throttle 105 km (65.2 mile) @full throttle 59 minutes ← (3 person) 3 370 mm (132.7 in.) 1 195 mm (47.0 in.) 1 150 mm (45.3 in.)

← ← ←

416 kg (917 lb) 410 kg (904 lb) –––

––– ––– 482 kg (1 063 lb) ← ← ←

848 mm (33.4 in.) 370 mm (14.6 in.) 78 L (20.6 US gal) API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 5.0 L (5.3 US qt)

12 V 18 Ah 16 A @14 V

← ←

← ←

†: This information shown here represents results under controlled conditions, and the information may not be correct under other conditions. Specifications subject to change without notice, and may not apply to every country. (1) Vertical distance between the floating plane in the light craft condition and the highest point of the craft structure, namely the handle top. (2) Draft in the fully loaded craft condition. *The information shown here represents results under controlled conditions, and the information may not be correct under other condition.


1-16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Prefix mega kilo centi milli micro

Symbol M k c m µ

Units of Length

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass kg g

× ×

2.205 0.03527

= =

lb oz

km m mm

× × ×

0.6214 3.281 0.03937

= = =

mile ft in.

= = = = = =

kgf·m ft·lb in·lb N·m ft·lb in·lb

= = = = = =

kgf/cm² psi cmHg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Torque N·m N·m N·m kgf·m kgf·m kgf·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

Units of Pressure Units of Volume L

×

0.2642

=

L L L L L mL mL mL

× × × × × × × ×

0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

= = = = = = = =

gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

kPa kPa kPa kgf/cm² kgf/cm² cmHg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed km/h

×

0.6214

Units of Power Units of Force N N kg kg

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature

= = = =

kg lb N lb

kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863


PERIODIC MAINTENANCE 2-1

Periodic Maintenance Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Periodic Maintenance Procedures.......................................................................................... Fuel System......................................................................................................................... Throttle Control System Inspection................................................................................... Air Box Drain Cap Inspection and Cleaning...................................................................... Supercharger Drive Belt for Wear/Damage and Belt Tension Inspection ......................... Supercharger Gear Oil Level Inspection........................................................................... Fuel Vent Check Valve Inspection .................................................................................... Fuel Pump Screen Cleaning ............................................................................................. Throttle Shaft Spring Inspection........................................................................................ Engine Lubrication System .................................................................................................. Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Engine Top End ................................................................................................................... Air Suction Valve Inspection (JT1500B7F Model)............................................................. Valve Clearance Inspection .............................................................................................. Engine Mounting Bolts Inspection and Tightness ............................................................. Engine Bottom End.............................................................................................................. Coupling Damper Inspection............................................................................................. Cooling and Bilge Systems.................................................................................................. Cooling System Flushing .................................................................................................. Bilge System Flushing ...................................................................................................... Pump and Impeller............................................................................................................... Impeller Inspection............................................................................................................ Steering ............................................................................................................................... Steering Cable/Shift Cable Inspection .............................................................................. Handlebar Pivot Lubrication.............................................................................................. Hull/Engine Hood................................................................................................................. Drain Plug Inspection........................................................................................................ Electrical System ................................................................................................................. Battery Charging Condition Inspection ............................................................................. Battery Terminals Inspection............................................................................................. Spark Plug Inspection ....................................................................................................... Lubrication ........................................................................................................................... All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check ............................................... Nuts, Bolts, and Fasteners Tightness Inspection.............................................................. Hose and Hose Connect Inspection ................................................................................. Rubber Strap Inspection ................................................................................................... Fuel Hose Replacement ................................................................................................... Apply Corrosion Protection Coating to the Supercharger Rotors ..................................... Replace Grease Seal........................................................................................................

2-2 2-4 2-10 2-11 2-12 2-12 2-12 2-12 2-13 2-15 2-16 2-16 2-17 2-17 2-17 2-18 2-19 2-19 2-19 2-25 2-25 2-25 2-26 2-26 2-27 2-28 2-28 2-28 2-28 2-29 2-29 2-29 2-30 2-30 2-30 2-30 2-31 2-33 2-33 2-34 2-35 2-35 2-36 2-37

2


2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the watercraft in good running condition. The initial maintenance is vitally important and must not be neglected. Frequency Description

Initial 10 Hours

Every 25 Hours

• • •

Inspect throttle control system (e) Inspect/clean air box drain caps Inspect supercharger drive belt for wear/damage and belt tension

Clean fuel pump screen (e)

2-12 2-12 2-13

• •

2-16 2-16

• •

Replace engine oil

Check air suction valve Inspect/adjust valve clearance (e)

Inspect/tighten engine mounting bolts

• • •

2-18 2-19 2-19 2-25

(or every year)

Inspect/replace coupling damper

2-17 2-17

(or every year)

Replace engine oil filter

Flush bilge line and filter

2-15

(or every year)

Inspect throttle shaft spring (replace throttle body if necessary) (e)

Flush cooling system (after each use in salt water)

Every 100 Reference Hours

Inspect supercharger gear oil level (refill if necessary) Inspect fuel vent check valve

Every 50 Hours

• •

2-25 2-26 2-27

Inspect impeller blades for damage (remove)

• •

Inspect steering cable/shift cable

2-28 2-28

Lubricate handlebar pivot (disassemble) Inspect hull drain plugs (replace if necessary)

Inspect battery charging condition

• • • • •

2-30

2-32

Inspect battery terminals Inspect spark plugs (replace if necessary) (e) Lubricate throttle cable fitting at throttle body Lubricate throttle cable and throttle fitting at throttle case Lubricate steering cable/shift cable ball joints and steering nozzle/reverse bucket pivots

2-29

2-29

2-30 2-30 2-31 2-31


PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart Frequency Description Check all hoses, hose clamps, nuts, bolts, and fasteners Replace fuel hoses Apply corrosion protection coating to the supercharger rotors Replace grease seal (e): Emission Related Items

Initial 10 Hours

Every 25 Hours

Every 50 Hours

Every 100 Reference Hours

every 4 years Every storage or whenever the watercraft will not be in use for more than 30 days

(or every year)

2-33 2–35 2–36 2–37


2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or silicone sealant. Letters used in the “Remarks” column mean: EO: Apply oil to the threads and seating surface. L: Apply a non-permanent locking agent (Medium Strength: Loctite 242 Equivalent). LN: Apply a non-permanent locking agent (High Strength: Loctite 271 Equivalent). MO: Apply molybdenum disulfide grease oil solution. R: Replacement Part S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant to the threads. Fastener Fuel System Vehicle-down Sensor Mounting Screws Bracket Mounting Bolts Inlet Manifold Mounting Bolts Inlet Manifold Mounting Nuts Delivery Pipe Mounting Bolts Inlet Air Pressure Sensor Bracket Bolts Inlet Air Temperature Sensor Throttle Body Assy Mounting Bolts Inlet Manifold Drain Plug Throttle Body Assy Damper Bolts Crankshaft Sensor Screws Camshaft Position Sensor Bolt Water Temperature Sensor Oil Temperature Sensor ECU Mounting Bolts Relay Bolts Throttle Sensor Mounting Screws ISC Actuator Mounting Bolts Fuse Bracket Bolt Harness Bolts Charging Temperature Sensor Fuel Filler Tube Clamp Screws Fuel Pump Holder Clamp Screws Oil Separator Tank Mounting Bolts Air Box Bracket Bolts Air Box Bolts Rear Supercharger Bolts Belt Tensioner Plate Bolts Idler Bolt Intake Pipe Bolts (IN/OUT) Gear Oil Level Gauge Front Supercharger Bolts Drain Bolt

N·m 1.5 8.8 25 20 7.8 8.8 20 20 20 20 4.4 9.8 15 15 3.0 2.5 2.0 4.9 2.5 8.8 15 2.9 2.9 8.8 8.8 8.8 45 45 30 7.8 19 45 19

Torque kgf·m 0.15 0.90 2.5 2.0 0.80 0.90 2.0 2.0 2.0 2.0 0.45 1.0 1.5 1.5 0.3 0.25 0.20 0.50 0.25 0.90 1.5 0.30 0.30 0.90 0.90 0.90 4.6 4.6 3.1 0.80 1.9 4.6 1.9

ft·lb 13 in·lb 78 in·lb 18 14 69 in·lb 78 in·lb 14 14 14 14 39 in·lb 87 in·lb 11 11 27 in·lb 22 in·lb 18 in·lb 43 in·lb 22 in·lb 78 in·lb 11 26 in·lb 26 in·lb 69 in·lb 69 in·lb 69 in·lb 33 33 22 69 in·lb 14 33 14

Remarks

L

L

L L see text see text L L

L L

L L L


PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Pulley Nut (JT1500E9F Late Model ∼/F9F Late Model ∼) Pulley Bolt (JT1500B7F ∼ B8F/E9F Early Model/F9F Early Model) Belt Cover Bolts Intercooler Plate Bolts Intercooler Bracket Bolts Intercooler Mounting Bolts Water Hose Joint Water Hose Joint Intercooler Cover Bolts Blow off Valve Bolts Throttle Cable Locknuts Pulley Plate Bolts Belt Tension Adjuster Pulley Nose Mounting Bolts Engine Lubrication System Breather Plate Bolts Oil Filler Cap Oil Passage Plugs Oil Separator Tank Mounting Bolts Breather Case Mounting Bolts Breather Pipe Bolts Oil Passage Joints Oil Cooler Assembly Bolts Oil Pressure Switch Oil Passage Bolt Oil Filter Oil Cooler Positioning Bolt Oil Pan Bolts Dipstick Tube Bolts Oil Pump Sprocket Bolt Oil Pump Cover Bolts Oil Pressure Relief Valve Oil Pipe Bolts Oil Pump Chain Guide Bolt Chain Guide Spring Plate Bolt Oil Pump Body Plug Oil Pump Body Bolts Oil Screen Bolts Water Hose Joints Exhaust System Exhaust Manifold Mounting Nuts

N·m

Torque kgf·m

ft·lb

22

2.2

16

19

1.9

14

4.9 8.8 7.8 30 11 20 10 7.8 20 15 3.0 15

0.50 0.90 0.80 3.1 1.1 2.0 1.0 0.80 2.0 1.5 0.31 1.5

43 in·lb 69 in·lb 69 in·lb 22 95 in·lb 14 89 in·lb 69 in·lb 14 11 27 in·lb 11

7.8 – 20 4.9 7.8 8.8 11 7.8 15 78 18 20 7.8 7.8 16 7.8 15 7.8 7.8 7.8 20 7.8 7.8 20

0.80 – 2.0 0.50 0.80 0.90 1.1 0.80 1.5 8.0 1.8 2.0 0.80 0.80 1.6 0.80 1.5 0.80 0.80 0.80 2.0 0.80 0.80 2.0

69 in·lb – 14 43 in·lb 69 in·lb 78 in·lb 95 in·lb 69 in·lb 11 58 13 14 69 in·lb 69 in·lb 12 69 in·lb 11 69 in·lb 69 in·lb 69 in·lb 14 69 in·lb 69 in·lb 14

30

3.1

22

Remarks

L L

L L

L

Hand-tighten L L

L SS S EO S S L, S LN LN

L

SS


2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Exhaust Manifold Mounting Bolts Bypass Nozzle Flushing Hose Joints Water Temperature Sensor Exhaust Pipe Mounting Bolt (L = 150 mm) Exhaust Pipe Mounting Bolts (L = 120 mm) Exhaust Pipe Mounting Bolts (L = 95 mm) Mark Plate Bolts Water Hose Joint Muffler Body Bolts Front Exhaust Tube Clamp Screws (JT1500B7F) Front Exhaust Tube Clamp Screws (JT1500B8F/E9F ∼ /F9F ∼ ) Water Hose Joint Rear Exhaust Tube Clamp Screws (JT1500B8F/E9F ∼ /F9F ∼ ) Engine Top End Air Suction Valve Cover Bolts Cylinder Head Cover Bolts Upper Camshaft Chain Guide Bolts Camshaft Cap Bolts Cylinder Head Bolts (M7) Cylinder Head Bolts (M11) Cylinder Head Bolts (M11) Water Jacket Plugs Cylinder Head Bolts (M6) Engine Hook Bolts Camshaft Position Sensor Bolt Water Hose Joints Cylinder Head Cover Plate Bolts Exhaust Side Camshaft Chain Guide Bolts (Upper) Exhaust Side Camshaft Chain Guide Bolts (Lower) Upper Camshaft Chain Guide Bolts Inlet Side Camshaft Chain Guide Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Position Sensor Rotor Bolt Water Hose Joint Oil Passage Joint Engine Removal/Installation Engine Mounting Bolts

N·m 30 – 11 15 45 35 35 5.0 20 35

Torque kgf·m 3.1 – 1.1 1.5 4.6 3.6 3.6 0.51 2.0 3.6

ft·lb 22 – 95 in·lb 11 33 26 26 44 in·lb 14 26

Remarks

LN L see chapter 3

see text L

2.9

0.30

26 in·lb

4.9

0.50

43 in·lb

11

1.1

95 in·lb

4.9

0.50

43 in·lb

9.8 9.8 12 12 20 23 69 20 12 20 9.8 20 7.8 25

1.0 1.0 1.2 1.2 2.0 2.3 7.0 2.0 1.2 2.0 1.0 2.0 0.80 2.5

87 in·lb 87 in·lb 104 in·lb 104 in·lb 14 17 51 14 104 in·lb 14 87 in·lb 14 69 in·lb 18

12

1.2

104 in·lb

12 12 9.8 20 12 20 11

1.2 1.2 1.0 2.0 1.2 2.0 1.1

104 in·lb 104 in·lb 87 in·lb 14 104 in·lb 14 95 in·lb

S L L

36

3.7

27

L

L

S S S First, MO, S Final, MO, S L S L L

L L L


PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Engine Damper Mounting Bolts Engine Bottom End Crankshaft Sensor Cover Bolts Engine Bracket Mounting Bolts Timing Rotor Bolt Connecting Rod Nuts Oil Passage Plugs Stator Mounting Bolts Grommet Cover Bolts Magneto Cover Bolts Output Cover Bolts Output Shaft (JT1500B7F ∼ B8F/E9F Early Model/F9F Early Model) Output Shaft (JT1500E9F Late Model ∼ /F9F Late Model ∼ ) Coupling (JT1500B7F ∼ B8F) Coupling (JT1500E9F ∼ /F9F ∼ ) Crankcase Bolts (M10) Crankcase Bolts (M8) Crankcase Bolts (M8) Crankcase Bolts (M6) Cooling and Bilge Systems Water Hose Joint (L Shape Type) Water Hose Joint (Straight Shape Type) Cooling Hose Clamp Screws Intercooler Bracket Bolts Intercooler Mounting Bolts Intercooler Cover Bolts Intercooler Plate Bolts Drive System Coupling (JT1500B7F ∼ B8F) Coupling (JT1500E9F ∼ /F9F ∼ ) Drive Shaft Holder Mounting Bolts Pump and Impeller Pump Bracket Mounting Bolts (2) Pump Bracket Mounting Bolts (4) Pump Mounting Bolts Grate Mounting Bolts Pump Cover Mounting Bolts Impeller (JT1500B7F ∼ B8F) Impeller (JT1500E9F ∼ /F9F ∼ ) Pump Cap Bolts Pump Outlet Mounting Bolts

N·m 16

Torque kgf·m 1.6

ft·lb 12

Remarks L

7.8 32 20 – 20 12 9.8 20 7.8

0.80 3.3 2.0 – 2.0 1.2 1.0 2.0 0.80

69 in·lb 24 14 – 14 104 in·lb 87 in·lb 14 69 in·lb

245

25.0

180

MO

265

27.0

195

MO

110 110 50 29 29 12

11 11 5.0 3.0 3.0 1.2

81 81 36 22 22 104 in·lb

L MO, S MO, S S S

11 20 2.5 7.8 30 10 8.8

1.1 2.0 0.25 0.80 3.1 1.0 0.90

95 in·lb 14 22 in·lb 69 in·lb 22 89 in·lb 69 in·lb

39 265 22

4.0 27 2.2

29 195 16

19 9.8 36 9.8 7.8 98 147 3.9 19

1.9 1.0 3.7 1.0 0.80 10 15 0.4 1.9

14 87 in·lb 27 87 in·lb 69 in·lb 72 108 35 in·lb 14

L L MO, see text L L L

L L

L

L LN, SS L L L L

L L


2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Steering Nozzle Pivot Bolts Filter Cover Mounting Bolts Steering Cable Joint Bolt Steering Handlebar Clamp Bolts Adjustable Steering Holder Nut Steering Neck Mounting Bolts Steering Shaft Locknut Steering Holder Mounting Nuts Throttle Case Mounting Screws Start/stop Switch Case Mounting Screws Shift Cable Nut Steering Cable Nut Steering Shaft Nut Steering Cable Joint Bolt Ball Joint Shift Cable End Nut Reverse Bucket Pivot Bolts Steering Cable Braket Bolts (JT1500B7F ∼ B8F) Steering Cable Braket Bolts (JT1500E9F ∼ /F9F ∼ ) Hull/Engine Hood Stabilizer Bolts Front Bumper Bolts Exhaust Outlet Bolts Handrail Plate Nuts Side Cover Nuts Front Duct Bolts Damper Bracket Bolts Seat Lock Bolts Front Storage Compartment Cover Bolts Steering Cover Bolts Meter Screen Bolts Bracket Bolts Reboarding Step Bolts Hinge Shaft Nut Electrical System Vehicle-down Sensor Mounting Screws Bracket Bolts Starter Relay Case Bolts Water Temperature Sensor Starter Relay Mounting Nuts

Torque kgf·m 1.9 1.0 1.0

ft·lb 14 87 in·lb 87 in·lb

16 4.9 16 49 ∼ 59 20 3.9 3.9 39 39 2.9 9.8 9.8 9.8 19 –

1.6 0.50 1.6 5.0 ∼ 6.0 2.0 0.40 0.40 4.0 4.0 0.30 1.0 1.0 1.0 1.9 –

12 43 in·lb 12 36 ∼ 43 14.5 35 in·lb 35 in·lb 29 29 26 in·lb 87 in·lb 87 in·lb 87 in·lb 14 –

9.8

1.0

87 in·lb

L

9.8 – – 9.8 – – – – – – – 8.8 – 15.7

1.0 – – 1.0 – – – – – – – 0.90 – 1.60

87 in·lb – – 87 in·lb – – – – – – – 78 in·lb – 11.6

LN L L L L L L L L L LN L L

N·m 19 9.8 9.8

1.5 8.8 7.8 15 3.5 ∼ 4.5

0.15 13 in·lb 0.90 78 in·lb 0.80 69 in·lb 1.5 11 0.35 ∼ 0.45 30 ∼ 40 in·lb

Remarks L L L L L L

see text L L L L

L see text


PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Starter Cable Mounting Nuts Oil Temperature Sensor Camshaft Position Sensor Bolt Regulator/Rectifier Bolts Relay Bolts ECU Mounting Bolts Fuse Bracket Bolt Charging Temperature Sensor Multifunction Meter Mounting Bolts (JT1500B7F ∼ B8F) Multifunction Meter Mounting Bolts (JT1500E9F ∼ /F9F ∼ ) Start/stop Switch Case Mounting Screw Speed Sensor Mounting Bolts Starter Motor Through Bolts Starter Motor Mounting Bolts Starter Motor Ground Bolt Starter Motor Terminal Nut Stator Coil Bolts Grommet Holder Bolts Ignition Coil Mounting Bolts Timing Rotor Bolt Crankshaft Sensor Screws Rubber Grommet Holder Screws Crankshaft Sensor Cover Bolts Spark Plugs

N·m 3.5 ∼ 4.5 15 9.8 7.8 2.5 3.0 2.5 15 3.9

Torque kgf·m ft·lb 0.35 ∼ 0.45 30 ∼ 40 in·lb 1.5 11 1.0 87 in·lb 0.80 69 in·lb 0.25 22 in·lb 0.3 27 in·lb 0.25 22 in·lb 1.5 11 0.40 35 in·lb

9.8

1.0

87 in·lb

3.9 3.9 6.4 8.8 8.8 8.8 12 8.8 8.8 20 4.4 4.4 7.8 13

0.40 0.40 0.65 0.90 0.90 0.90 1.2 0.90 0.90 2.0 0.45 0.45 0.80 1.3

35 in·lb 35 in·lb 56 in·lb 78 in·lb 78 in·lb 78 in·lb 104 in·lb 78 in·lb 78 in·lb 14 39 in·lb 39 in·lb 69 in·lb 113 in·lb

Remarks

see text L L L L

L L, R L

L L L L L L

The next table, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

General Fasteners (stainless bolt and nut) Threads dia. (mm) 6 8 10

N·m 5.9 ∼ 8.8 16 ∼ 22 30 ∼ 41

Torque kgf·m 0.60 ∼ 0.90 1.6 ∼ 2.2 3.1 ∼ 4.2

ft·lb 52 ∼ 78 in·lb 12 ∼ 16 22 ∼ 30


2-10 PERIODIC MAINTENANCE Specifications Item Standard Fuel System Throttle Lever Free Play about 2 mm (0.08 in.) Engine Lubrication System Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 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) Engine Top End Valve Clearance: IN 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) EX 0.32 ∼ 0.41 mm (0.0126 ∼ 0.0161 in.) Electrical System Spark Plug Gap 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.)

Service Limit – – –

– – – – – – – – –

– – – – – – – – –


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2007 Kawasaki JT1500B7F Service Repair Manual  
2007 Kawasaki JT1500B7F Service Repair Manual  
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