Kawasaki Ultra Lx Jt1500k Jet Ski Watercraft Shop Manual 2012 2015

ULTRA LX

®

JET SKi Watercraft 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 SKiÂŽ is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.

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

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JET SKi Watercraft Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your JET SKi® watercraft dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

© 2011 Kawasaki Heavy Industries, Ltd.

First Edition (0):Jul. 25, 2011

LIST OF ABBREVIATIONS A ABDC AC Ah ATDC BBDC BDC BTDC °C cmHg cu in DC DFI ECU F °F FPO ft g gal h HP IC in.

ISC

ampere(s) after bottom dead center alternating current ampere hour after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius centimeters of mercury Cubic inch(s) direct current Digital Fuel Injection Electronic Control Unit farad(s) degree(s) Fahrenheit Full Power Operation foot, feet gram(s) gallon(s) hour(s) horsepower(s) Integrated Circuit inch(s) Idle Speed Control

KDS km/h L lb LCD LED m min mph N oz Pa PS psi qt r rpm s SLO TDC TIR V W Ω

Kawasaki Diagnostic System kilometers per hour liter(s) pound(s) Liquid Crystal Display Light Emission Diode meter(s) minute(s) miles per hour newton(s) ounce(s) pascal(s) horsepower pound(s) per square inch quart(s) revolution revolution(s) per minute second(s) Smart Learning Operation top dead center total indicator reading volt(s) watt(s) ohm(s)

COUNTRY AND AREA CODES AU EUR

Australia Europe

US

United States

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

EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GRADE GASOLINE ONLY with an octane rating equal to or higher than that shown below.

Minimum Octane Rating:

Antiknock Index* 87 Research Octane Number (RON) 91

*: The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON).

Emission Control Information To protect the environment in which we all live, Kawasaki has incorporated an exhaust 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.

Evaporative Emission Control System The evaporative emission control system for this watercraft consists of low permeation fuel hoses.

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. * Fuel Pump * Spark Plugs * Fuel Injectors * ECU

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.

Follow the procedures in this manual carefully. 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.

DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE NOTICE is used to address practices not related to personal injury.

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 par○ ticular 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, JT1500K, is mounted with a four -stroke engine.

When the JET SKi® watercraft is submerged and swamped, the four-stroke engine needs special care and systematic procedure for 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 1-11 1-13

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

P/No. 57001-1747 57001-1650 57001-1725 57001-1745 57001-1696

KDS3 Kit KDS Software (CD-ROM) KDS3 Adapter Communication Cable KDS Adapter Cable

The connectors for the communication cable and KDS adapter cable are located in the front storage compartment cover. Connect the communication cable [A] between the KDS connector (4-pin) [B] and KDS3 Adapter. Connect the KDS adapter cable [C] between the ignition switch (immobilizer amplifier) lead connectors (6-pin) [D].

NOTE

â—‹Connect the cable (57001-1696) to the ignition switch side connector first and then connect the ECU side connector.

A. Communication Cable (57001-1745) B. KDS Adapter Cable (57001-1696)

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.

GENERAL INFORMATION 1-3 Before Servicing NOTICE Operating the engine without cooling water for more than 15 seconds, especially at high rpm, will cause severe engine and exhaust system damage. To avoid engine damage, do not run the engine without providing sufficient cooling water.

Auxiliary Cooling An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjustments. If possible, always operate the watercraft in water rather than use an auxiliary cooling supply. 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. 92005-3748) 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.

NOTICE Operating the engine without cooling water for more than 15 seconds, especially at high rpm, will cause severe engine and exhaust system damage. To avoid engine damage, do not run the engine without providing sufficient cooling water.

An excessive supply of cooling water may cause the engine to stop and flood the cylinders, creating the potential for hydraulic lock which causes severe engine damage. To prevent engine damage when using an auxiliary cooling supply, shut the water off immediately if the engine stops running.

1-4 GENERAL INFORMATION Before Servicing NOTICE Rolling to the right side can cause water in the exhaust system to run into the engine, with possible engine damage. To prevent engine damage, always turn the boat on its left side.

NOTICE Rolling the capsized watercraft counterclockwise (to its STARBOARD side) can cause water in the exhaust system to run into the engine, with possible engine damage. Always turn the capsized boat clockwise so that the PORT side always faces downward.

Battery Ground Before completing any service on the watercraft, 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.

GENERAL INFORMATION 1-5 Before Servicing Solvent Use a high-flash point solvent when cleaning parts. High -flash point solvent should be used according to directions of the solvent manufacturer.

Cleaning Watercraft before Disassembly Clean the watercraft thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during watercraft disassembly can cause excessive wear and 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.

1-6 GENERAL INFORMATION Before Servicing Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.

Assembly Order In most cases assembly order is the reverse of 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.

GENERAL INFORMATION 1-7 Before Servicing 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

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.

1-8 GENERAL INFORMATION Before Servicing Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when 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 side).

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.

GENERAL INFORMATION 1-9 Before Servicing 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.

Harness Connector Apply dielectric 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 JT1500KC Left Side View

JT1500KC Right Side View

Hull Identification Number (HIN)

Engine Number

GENERAL INFORMATION 1-11 General Specifications Items Engine Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower

JT1500KC

4-stroke, DOHC, 4-cylinder, water cooled 1 498 cm³ (91.4 cu in.)

83 × 69.2 mm (3.27 × 2.72 in.)

10.6:1 112 kW (152 PS) @7 500 r/min (rpm) (AU) 118 kW (160 PS) @7 500 r/min (rpm) (US) – – – Maximum Torque 144 N·m (14.7 kgf·m, 106 ft·lb) @7 250 r/min (rpm) (AU) 152 N·m (15.5 kgf·m, 112 ft·lb) @7 250 r/min (rpm) (US) – – – Ignition System Digital transistor Lubrication System Forced lubrication (semi-dry sump) Carburetion System FI (fuel injection) MIKUNI AC 60 × 1 Starting System Electric starter Cylinder Numbering Method Front (bow) to rear (stern), 1-2-3-4 Firing Order 1-2-4-3 Valve Timing: Intake: Open 22.5° BTDC Close 67.5° ABDC Duration 270° Exhaust: Open 74.5° BBDC Close 9.5° ATDC Duration 264° Tuning Specifications Spark plug: Type NGK CR9EK Terminal Threaded terminal Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

Ignition Timing 3° ATDC @1 300 r/min ∼ 32° BTDC @3 000 r/min (rpm) Idle Speed 1 300 ±100 r/min (rpm) -in water 1 300 ±100 r/min (rpm) -out of water Compression Pressure 1 190 ∼ 1 799 kPa (12.1 ∼ 18.3 kgf/cm², 173 ∼ 261 psi) @430 r/min (rpm) Drive System Coupling Direct drive from engine Jet Pump: Type Axial flow single stage Thrust: EUR Model 4 130 N (421.3 kgf, 928.4 lb) Other than EUR Models 4 250 N (433.5 kgf, 955.4 lb) Steering Steerable nozzle Braking Water drag

1-12 GENERAL INFORMATION General Specifications Items Performance †Minimum Turning Radius †Fuel Consumption †Cruising Range Dimensions Overall Length Overall Width Overall Height Curb Mass Fuel Tank Capacity Engine Oil Grade Viscosity Capacity Electrical Equipment Battery Maximum Generator Output

JT1500KC 4.0 m (13.1 ft) 45 L/h (11.9 US gal/h) @full throttle 133 km (82.6 mile) @full throttle 1 hour and 38 minutes (3 person) 3 370 mm (132.7 in.)

1 195 mm (47.0 in.)

1 150 mm (45.3 in.)

423 kg (932.7 lb) 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.

GENERAL INFORMATION 1-13 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 L L L L L mL mL mL

× × × × × × × × ×

0.2642 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 Caps Inspection and Cleaning....................................................................

Air Box Inspection and Cleaning.......................................................................................

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 ...................................................................................................................

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............................................................................................................

Jet Pump Bearing and Seal 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 ...................................................................................................

2-2 2-3 2-8 2-9 2-10 2-10 2-10 2-11 2-11 2-11 2-12 2-12 2-13 2-13 2-14 2-15 2-15 2-18 2-19 2-19 2-19 2-19 2-20 2-21 2-21 2-21 2-21 2-21 2-22 2-22 2-22 2-23 2-23 2-23 2-23 2-24 2-27 2-27 2-27 2-29 2-29

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.

Description

Frequency Initial 10 Every 25 Every 50 Every 100 Reference Hours Hours Hours Hours

• • • •

Inspect throttle control system (e) Inspect/clean air box drain caps Inspect fuel vent check valve Clean fuel pump screen (e)

2-10 2-11 2-11 2-12

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

• •

Replace engine oil

2-13

(or every year)

Replace engine oil filter Inspect/adjust valve clearance (e)

•

Inspect/tighten engine mounting bolts

• •

Flush bilge line and filter

Initial 25 hours or one year whichever comes first, then every 50 hours or every year whichever comes first

•

Inspect steering cable/shift cable

•

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 Inspect all hoses, hose clamps, nuts, bolts, and fasteners Replace fuel hose (e): Emission Related Items

•

2-21 2-21 2-21 2-22

•

Inspect battery charging condition

2-19

2-20

•

Inspect hull drain plugs (replace if necessary)

2-15

2-19

Inspect impeller blades for damage (remove)

Lubricate handlebar pivot (disassemble)

2-14

2-18

•

Inspect/replace coupling damper

Jet pump bearings and seals; replace bearings/seals if necessary

• •

(or every year)

Flush cooling system (after each use in salt water)

2-12

2-22

• • • • •

2-23

•

2-24

•

2-27

Every 5 years

2-23 2-23 2-24 2-24

2-29

PERIODIC MAINTENANCE 2-3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean: AD: Apply adhesive.

EO: Apply engine oil.

G: Apply grease.

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 oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Part S: Follow the specified tightening sequence.

SS: Apply silicone sealant.

Fastener Fuel System (DFI) Air Box Mounting Bolts Air Box Bracket Mounting Bolts Air Box Flame Arrester Bolts Air Box Assembly Bolts Bracket Bolts Camshaft Position Sensor Bolt Crankshaft Sensor Screws Delivery Pipe Assy Mounting Bolts Delivery Pipe Fitting Delivery Pipe Plug ECU Mounting Bolts Fuel Filler Hose Clamp Screws Fuel Pump Rubber Holder Clamp Screws Intake Air Temperature Sensor Intake Manifold Drain Plug Intake Manifold Plate Bolts Intake Air Pressure Sensor Bolts ISC Actuator Mounting Bolts Intake Manifold Mounting Bolts Intake Manifold Mounting Nuts Oil Temperature Sensor Relay Mounting Bolts Throttle Position Sensor Mounting Screws Stepping Motor Mounting Screws Throttle Body Assy Mounting Bolts Throttle Cable Locknut Throttle Case Mounting Screw Vehicle-down Sensor Mounting Screws Water Temperature Sensor

N·m

Torque kgf·m

ft·lb

7.8 8.8 2.5 2.5 8.8 10 4.5 7.8 20 11 3.0 2.9 2.9 20 20 7.8 7.8 5.0 25 20 15 2.5 20 2.0 2.0 19.6 3.9 1.5 14.7

0.80 0.90 0.25 0.25 0.90 1.0 0.46 0.80 2.0 1.1 0.31 0.30 0.30 2.0 2.0 0.80 0.80 0.51 2.5 2.0 1.5 0.25 2.0 0.20 0.20 2.0 0.40 0.15 1.5

69 in·lb 78 in·lb 22 in·lb 22 in·lb 78 in·lb 89 in·lb 40 in·lb 69 in·lb 15 97 in·lb 27 in·lb 26 in·lb 26 in·lb 15 15 69 in·lb 69 in·lb 44 in·lb 18 15 11 22 in·lb 18 in·lb 18 in·lb 15 in·lb 14 35 in·lb 13 in·lb 11

Remarks

L L L (1) L L L L L L

L

L

2-4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Engine Lubrication System Breather Plate Bolts Dipstick Tube Bolts Oil Catch Cover Bolts Oil Cooler Assembly Bolts Oil Cooler Positioning Bolt Oil Filler Cap Oil Filter Oil Pan Bolts Oil Passage Bolt Oil Passage Joints Oil Passage Plug (R1/4) Oil Passage Plug (R3/8) Oil Pressure Relief Valve Oil Pressure Switch Oil Pump Body Bolts Oil Pump Body Plug Oil Pump Cover Bolts Oil Pump Sprocket Bolt Oil Screen Bolts Oil Separator Tank Mounting Nuts Exhaust System Exhaust Manifold Mounting Bolts Exhaust Manifold Mounting Nuts Exhaust Pipe Mounting Bolts Exhaust Pipe Mounting Plate Bolts Front Exhaust Hose Clamp Screws Rear Exhaust Hose Clamp Screws Water Hose Joints Engine Top End Camshaft Cap Bolts (L = 40 mm) Camshaft Cap Bolts (L = 50 mm) Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Position Sensor Rotor Bolt Cylinder Head Bolts (M11, Final) Cylinder Head Bolts (M11, First) Cylinder Head Bolts (M6) Cylinder Head Bolts (M7) Cylinder Head Cover Bolts Breather Plate Bolts Engine Hook Bolts

N·m

Torque kgf·m

ft·lb

7.8 8.8 7.8 7.8 20

0.80 0.90 0.80 0.80 2.0

69 in·lb 78 in·lb 69 in·lb 69 in·lb 15

–

–

–

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

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

13 15 58 97 in·lb 69 in·lb 15 11 11 69 in·lb 15 69 in·lb 12 69 in·lb 43 in·lb

25 25 45 30 5.0 5.0 11

2.5 2.5 4.6 3.1 0.51 0.51 1.1

18 18 33 22 44 in·lb 44 in·lb 97 in·lb

L, S S

12 12 20 10 12 60 23 12 20 10 7.8 20

1.2 1.2 2.0 1.0 1.2 6.1 2.3 1.2 2.0 1.0 0.80 2.0

106 in·lb 106 in·lb 15 89 in·lb 106 in·lb 44 17 106 in·lb 15 89 in·lb 69 in·lb 15

S S

Remarks

L, S

S Hand -tighten EO, R S S L L L LN L L LN L

L

L

L LN MO, S MO, S S S

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Exhaust Side Camshaft Chain Guide Bolt (Lower) Exhaust Side Camshaft Chain Guide Bolt (Upper) Harness Clamp Mounting Bolts Intake Side Camshaft Chain Guide Bolt Oil Passage Joints Spark Plugs Upper Camshaft Chain Guide Bolts Water Hose Joint Water Jacket Plugs Engine Removal/Installation Engine Damper Mounting Bolts Engine Mounting Bolts Engine Bottom End Alternator Cover Bolts (L = 40 mm) Alternator Cover Bolts (L = 60 mm) Connecting Rod Nuts Coupling Coupling Cover Bolts Crankcase Bolts (M6) Crankcase Bolts (M8, L = 45 mm) Crankcase Bolt (M8, L = 55 mm) Crankcase Bolts (M8, L = 85 mm) Crankcase Bolts (M10) Engine Bracket Mounting Bolts Oil Passage Plug (R1/4) Oil Passage Plugs (R3/8) Output Cover Bolts Output Shaft Oil Catch Cover Bolts Stator Coil Grommet Holder Plate Bolts Stator Coil Mounting Bolts Cooling and Bilge Systems Flushing Cap Water Pipe Mounting Bolts Water Hose Clamp Screws Water Hose Clamp Screw Water Hose Clamp Screws Water Hose Joints Water Hose Joint (Water Pipe) Drive System Coupling Drive Shaft Holder Mounting Bolts

N·m 12 25 8.8 12 11 13 12 11 19.6

Torque kgf·m 1.2 2.5 0.90 1.2 1.1 1.3 1.2 1.1 2.0

ft·lb 106 in·lb 18 78 in·lb 106 in·lb 97 in·lb 115 in·lb 106 in·lb 97 in·lb 14

15.7 36.3

1.6 3.7

12 27

20 20 see text 110 8.8 12 30 30 30 50 32 7.8 20 7.8 265 7.8 8.8 12

2.0 2.0 ← 11.2 0.90 1.2 3.1 3.1 3.1 5.1 3.3 0.80 2.0 0.80 27.0 0.80 0.90 1.2

15 15 ← 81 78 in·lb 106 in·lb 22 22 22 37 24 69 in·lb 15 69 in·lb 195 69 in·lb 78 in·lb 106 in·lb

0.90 7.8 2.5 3.0 4.0 11 20

0.092 0.80 0.25 0.31 0.41 1.1 2.0

8.0 in·lb 69 in·lb 22 in·lb 27 in·lb 35 in·lb 97 in·lb 15

L L

265 22

27.0 2.2

195 16

L

Remarks

L L L S L L L L

MO, R L S S S MO, S MO, S L L L MO L L

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Pump and Impeller Filter Cover Mounting Bolts Grate Mounting Bolts Impeller Pump Bracket Mounting Bolts (M6) Pump Bracket Mounting Bolts (M8) Pump Cap Bolts Pump Cover Mounting Bolts Pump Mounting Bolts Pump Outlet Mounting Bolts Pump Shaft Nut Steering Cable Joint Bolt Steering Nozzle Pivot Bolts Steering Adjustable Steering Holder Nut Handlebar Clamp Bolts Reverse Bucket Pivot Bolts Start/Stop Switch Case Mounting Screws Shift Cable End Nut Shift Cable Nut Steering Cable Bracket Bolts Steering Cable Joint Bolt Steering Cable Nut Steering Holder Mounting Nuts Steering Neck Mounting Bolts Steering Shaft Locknut Steering Shaft Nut Throttle Case Mounting Screws Hull/Engine Hood Bracket Bolts Front Hatch Mounting Screws Handrail Mounting Screws Handrail Plate Nuts Latch Handle Screws Seat Lock Ratchet Pins Stabilizer Bolts Electrical System Bracket Bolts Camshaft Position Sensor Bolt Crankshaft Sensor Cover Bolts Crankshaft Sensor Screws ECU Mounting Bolts Ignition Coil Mounting Bolts

N·m

Torque kgf·m

ft·lb

9.8 9.8 147 9.8 19 3.9 7.8 36 19 98 9.8 19

1.0 1.0 15.0 1.0 1.9 0.40 0.80 3.7 1.9 10 1.0 1.9

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

4.9 0.50 15.7 1.6 19 1.9 3.9 0.40 9.8 1.0 39.2 4.0 9.8 1.0 9.8 1.0 39.2 4.0 19.6 2.0 15.7 1.6 29.4 ∼ 34.3 3.0 ∼ 3.5 2.9 0.30 3.9 0.40

43 in·lb 12 14 35 in·lb 87 in·lb 29 87 in·lb 87 in·lb 29 14 12 22 ∼ 25 26 in·lb 35 in·lb

8.8 2.0 4.0 9.8 2.0 27 15.7

0.90 0.20 0.41 1.0 0.20 2.8 1.6

78 in·lb 18 in·lb 35 in·lb 87 in·lb 18 in·lb 20 12

8.8 10 7.8 4.5 3.0 8.8

0.90 1.0 0.80 0.46 0.31 0.90

78 89 69 40 27 78

in·lb in·lb in·lb in·lb in·lb in·lb

Remarks

L L M L LN, SS L L L L L L

L, S LN

L L

L

L AD L L LN L L L L L

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Meter Unit Mounting Bolts Oil Temperature Sensor Regulator/Rectifier Bolts Relay Mounting Bolts Rubber Grommet Holder Screws Spark Plugs Speed Sensor Mounting Screws Starter Motor Ground Bolt Starter Motor Mounting Bolts Starter Motor Terminal Nut Starter Motor Through Bolts Starter Relay Terminal Bolts Stator Coil Bolts Stator Coil Grommet Holder Plate Bolts Timing Rotor Bolt Vehicle-down Sensor Mounting Screws Water Temperature Sensor Water Temperature Sensor (for Meter Unit)

N·m 9.8 15 7.8 2.5 4.5 13 3.9 8.8 8.8 8.8 6.4 5.5 12 8.8 20 1.5 14.7 8.8

Torque kgf·m 1.0 1.5 0.80 0.25 0.46 1.3 0.40 0.90 0.90 0.90 0.65 0.56 1.2 0.90 2.0 0.15 1.5 0.90

ft·lb 87 in·lb 11 69 in·lb 22 in·lb 40 in·lb 115 in·lb 35 in·lb 78 in·lb 78 in·lb 78 in·lb 57 in·lb 49 in·lb 106 in·lb 78 in·lb 15 13 in·lb 11 78 in·lb

Remarks L

L L L L L L, R L L L

The table below, 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.

Basic Torque for General Fasteners (stainless bolt and nut) Threads Diameter (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

2-8 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, when filter is not removed) 4.2 L (4.4 US qt, when filter is removed) 5.0 L (5.3 US qt, when engine is completely dry) Engine Top End Valve Clearance: Intake 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

Electrical System Spark Plug: Type NGK CR9EK Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.)

Service Limit – – –

– – – – – – – – –

– – – – – –

– – – – – –

PERIODIC MAINTENANCE 2-9 Special Tools Oil Filter Wrench: 57001-1249

Shaft Wrench: 57001-1551

2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Control System Inspection

• Check the throttle lever free play [A].

Throttle Lever Free Play Standard: About 2 mm (0.08 in.)

If the free play is incorrect, check the throttle cable.

that the throttle lever moves smoothly from full • Check open to close, and the throttle closes quickly and com-

•

pletely in all steering positions by the return spring.

If the throttle lever does not return properly, check the throttle cable routing, cable adjustments, and cable 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.

NOTICE Operating the engine without cooling water for more than 15 seconds, especially at high rpm, will cause severe engine and exhaust system damage.

To avoid engine damage, do not run the engine without providing sufficient cooling water.

If the idle speed increase, check the throttle cable adjustment and the cable routing. the seats (see Seat Removal in the Hull/Engine • Remove Hood chapter). throttle cable adjustment.

• Check the throttle lever released, the upper stop [A] on the • With throttle pivot arm [B] should rest against the stopper [C]

• • •

on the throttle body, and there should be slight slack in the throttle cable.

When the throttle lever is fully applied (pulled), the lower stop [D] on the pivot arm should be all the way up against the stopper on the throttle body.

If necessary, adjust the throttle cable.

Loosen and turn the locknuts [A] at the bracket until the upper stop on the pivot arm hits against the stopper on the throttle body with slight cable slack.

Tighten the locknuts securely.

Torque - Throttle Cable Locknuts: 19.6 N·m (2.0 kgf·m, 14 ft·lb)

NOTE

○Make sure that the throttle pivot arm stops against the stopper on the throttle body with the throttle lever released.

PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Air Box Drain Caps Inspection and Cleaning

the seats (see Seat Removal in the Hull/Engine • Remove Hood chapter). the handrail plate (see Handrail Plate Removal • Remove in the Hull/Engine Hood chapter). the air box [A] for water inside with its drain caps • Inspect [B].

If there is water in the caps, remove the caps and discharge the water.

NOTE

○Be sure to have a rag or cloth underneath for possible oily water.

Air Box Inspection and Cleaning

• Remove: Air Box (see Air Box Removal in the Fuel System (DFI) chapter) Flame Arrester [A] (see Air Box Disassembly in the Fuel System (DFI) chapter)

the flame arrester [A].

• Clean Visually inspect the flame arrester for damage.

• If necessary, replace it with a new one.

Fuel Vent Check Valve Inspection The fuel vent check valve is mounted in the fuel tank vent hose to prevent fuel from spilling during riding. Air can flow into the tank to allow fuel to be drawn out by the fuel pump, but fuel cannot flow out the check valve. the center access cover (see Center Access • Remove Cover Removal/Installation in the Hull/Engine Hood

• •

chapter).

Cut off the bands [A].

Pull out each end of the fuel vent check valve [B] from the vent hoses [C].

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures through the fuel vent check valve from each end.

• Blow 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.

fuel vent check valve [A] must be mounted so that • The the arrow [B] on its case is pointing toward the fuel tank.

Fuel Pump Screen Cleaning

the fuel pump (see Fuel Pump Removal in the • Remove Fuel System (DFI) chapter). the fuel pump screen [A] in non-flammable of high • Wash -flash point solvent. Use a soft brush to remove any contaminants trapped in the screens.

WARNING Gasoline and low flash-point solvents are extremely flammable and can be explosive under certain conditions. To prevent a fire or explosion, clean the fuel pump screen in a well-ventilated area with a high flash-point solvent away from any ignition sources, including any appliance with a pilot light.

Throttle Shaft Spring Inspection

• Remove: Seats (see Seat Removal in the Hull/Engine Hood chap•

ter) Check the throttle shaft spring [A] by pulling the throttle lever.

If the spring is damaged or weak, replace the throttle body.

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change

the watercraft port to starboard as well as fore to • Level aft.

Level Ground [A] Side Bumper [B] Parallel [C]

a well-ventilated area, start the engine while cooling the • Incooling system.

○Obtain

a standard garden hose and a garden hose adapter (see Cooling System Flushing). ○Open the front storage compartment cover. ○Remove the flushing cap [A]. ○Screw a garden hose adapter [B] onto the flushing fitting [C]. ○Attach a garden hose [D] to a garden hose adapter and secure the hose clamp [E].

Warm up the engine and stop it.

Remove the garden hose and garden hose adapter.

• •

NOTICE The engine must be running before the water is turned on and the water must be turned off before the engine is stopped.

Do not run the engine without cooling water flow for more than 15 seconds. the seats (see Seat Removal in the Hull/Engine • Remove Hood chapter).

• Remove the oil filler cap [A] and the dipstick [B].

NOTICE Dirt and other foreign materials can cause serious engine damage. To prevent engine damage, do not allow dirt or foreign materials to enter the engine.

the oil thoroughly from the dipstick tube [A] using a • Drain commercially-available vacuum pump [B].

WARNING Used engine oil is toxic and pollutes the environment. To protect the environment, do not discard used engine oil; always return it to an authorized recycling center.

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures in the specified type and amount of oil through the • Pour oil filler opening [A].

Engine Oil Grade:

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity: SAE 10W-40 Amount:

4.0 L (4.2 US qt, when filter is not removed) 4.2 L (4.4 US qt, when filter is removed) 5.0 L (5.3 US qt, when engine is completely dry)

NOTE

○Do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for the engine. ○Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. the filler cap.

• Install Check the oil level (see Oil Level Inspection in the Engine • Lubrication System chapter).

Oil Filter Replacement

• Remove: Intake Manifold (see Intake Manifold Removal in the Fuel • • •

System (DFI) chapter) Drain the engine oil (see Engine Oil Change).

Place a rag or cloth under the oil filter to receive the remaining oil.

Remove the oil filter [A] with the oil filter wrench [B].

Special Tool - Oil Filter Wrench: 57001-1249

the filter with a new one.

• Replace Apply engine oil to the gasket [A] before installation.

• Tighten the filter with the oil filter wrench.

• Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

in the specified type and amount of oil (see Engine • Pour Oil Change).

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