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This quick reference guide will assist you in locating a desired topic or procedure.
Â¥Ben 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.
Â¥Refe to the sectional table of contents for the exact pages to locate the specific topic required.
Quick Reference Guide
General Information |
1 |
Fuel System |
2 |
Engine Lubrication System |
3 |
|
- |
Exhaust System |
4 |
Engine Top End |
5 |
|
- |
Engine Removal and Installation |
6 |
Engine Bottom End |
7 |
|
- |
Cooling and Bilge Systems |
8 |
Drive System |
9 |
Pump and Impeller |
10 |
Steering |
11 |
HullIEngine Hood |
12 |
Electrical System |
13 |
Storage |
14 |
|
- |
Appendix |
15 |
Supplement - 1997 - 1999 Models |
16 |
1 Supplement - 2000 - 2002 Models 1 7 
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Kawasaki
I I00 ZXi
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 DepartmentConsumer Products & Machinery CompanyIKawasaki 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 incorporatedafter 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.
>Kawasaki Heavy Industries, Ltd. 1996, 1999, 2001 |
http://www.ReadManuals.com |
Fourth Edition (1):Jul. 18,2001 (K) |
LIST OF ABBREVIATIONS
A |
ampere(s) |
ABDC |
after bottom dead center |
AC |
alternating .current |
ATDC |
after top dead center |
BBDC |
before bottom dead center |
BDC |
bottom dead center |
BTDC |
before top dead center |
C |
degree(s) Celsius |
DC |
direct current |
F |
farad(s) |
O F |
degree(s) Fahrenheit |
ft |
foot-feet |
g |
gram(s) |
h |
hour(s) |
L |
liter(s) |
Ib |
pound(s) |
rn |
meter(s) |
min |
minute(s) |
N |
newton(s) |
Pa |
pascal(s) |
PS |
horsepower |
psi |
pound(s) per square inch |
r |
revolution |
rPm |
revolution(s) perminute |
TDC |
top dead center |
TI R |
total indicator reading |
v |
volt(s) |
W |
watt(s) |
Q |
ohm(s) |
Read OWNER'SMANUAL before operating
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Foreword
This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information t o make it useful to the owner w h o desires t o perform his o w n basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order t o carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to d o the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to |
perform |
the work |
efficiently and t o |
avoid costly |
mistakes, |
read the |
text, thoroughly |
familiarize yourself wit h the procedures before starting work, and then d o the work carefully i n a clean area. Whenever special tools or equipment are specified, d o 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, w e recommend that all repairs and scheduled maintenance be performed in accordance wit h 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:
Â¥Follo the Periodic Maintenance Chart in the Service Manual.
Â¥B alert for problems and non-scheduled maintenance.
Â¥Us proper tools and genuine Kawasaki "JET SKI" watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki "JET SKI" watercraft are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
@Follow the procedures in this manual carefully. Don'ttake shortcuts.
@Remember t o keep complete records of maintenance and repair wit h dates and any new parts installed.
How to Use this Manual
-
In preparing this manual, w e divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.
The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its o w n comprehensive Table of Contents.
The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations.
If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you h o w frequently t o clean and gap the plug. Next, use the Quick Reference Guide t o locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter t o find the Spark Plug section.
Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in 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.
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This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
NOTE
o This note symbol indicates points of particular interest for more efficient and convenient operation.
*Indicates a procedural step or work to be done.
o 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.
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GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing.......................................................................................................... |
1-2 |
|
Model Identificati:on.................................................................................................... |
1-5 |
|
Gen~eralSpecifications ................................................................................................ |
1-6 |
|
Torque and Locking Agent ......................................................................................... |
1-7 |
|
Periodic Maintenance Chart ....................................................................................... |
1-9 |
|
Technical Informati,on ............................................................................................... |
1-110 |
|
Maintenance Free Battery .................................................................................... |
1-10 |
|
(I) Construction................................................................................................ |
1-10 |
|
(11,) |
Main Features |
1-10 |
|
||
(HI) |
Princip'leof Sealing Structure................................................................... |
1-10 |
(IV) Filling the Battery with Electrolyte ........................................................... |
1-11 |
|
(V) Initial Charge............................................................................................... |
1-12 |
|
(VI) |
Precautions ............................................................................................... |
1-13 |
Accelerator Pump ................................................................................................. |
1-14 |
|
Kawasaki Air Induction System (KAIS) ................................................................ |
1-15 |
|
Kawasaki Automatic Trim System (KATS) .......................................................... |
1-16 |
|
Special Tools8,Sealant ............................................................................................... |
1-17 |
|
Cable, Wire and Hose Routing................................................................................. |
1 -19 |
|
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1 - 2 GENERAL INFORMATION
Before Servicing
Before starting to service a watercraft, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
Especially note the following:
(1) |
Adjustments |
|
|
|
|
Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever trouble- |
|
|
|
shooting 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. |
|
1 |
Do not run the engine without cooling water supply for more than 15 seconds or severe engine and exhaust system 1 |
||
1 |
damage will occur. |
I |
|
(2) |
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. |
|
Â¥Loose the clamp and remove the cap [A].
Â¥Connec the garden hose [B] to the hose fitting (see above).
Â¥Attac 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/mh (2.5 qts/rnin) at 1800 rpm and 7.0 L/min (7.4 qts/rnin) at 6000 rpm.
CAUTION
-
Insufficient cooling supply will cause the engine and/or exhaust system to overheat and severe damage will occur. Excessivecooling 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, (he water must be shut off immediately.
Always turn the boat on its left side. Rolling to the right side can cause water in the exhaust system to run into the engine, with possible engine damage.
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GENERAL INFORMATION 1-3
Dirt
Before removal and disassembly, clean the "Jet Ski" watercraft. Any sand entering the engine, carburetor, or other pans will work as aln abrasive and shorten the life of the watercraft. For the same reason, before installing a new pan, clean off any dust or metal filings.
Battery Ground
Remove the ground (-1 lead from the battery before performing any disassembly operations on the watercraft. This prevents:
(a)the possibility of accidentally turning the engine over while partially disassembled.
(b)sparks at electrical connections which will occur when they are disconnected.
(c)damage to electrical parts.
Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, they should all be started in their holes and tightened to snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them,
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated.
Torque
The torque values given in this Service Manual should always be adhered to. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.
Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic faced mallet. Use an impact driver for screws (particularllyfor the removal of screws held by a locking agent) in order to avoid damaging the screw heads. Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect youlr hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
High Flash-point Solvent
A high flash-point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.
(10) Gasket, 0-Rang
Do not reuse a gasket or 0-rmg once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
(11) Liquid Gasket, Non-permanent Locking Agent
Follow manufacturer's directions forcleaning and preparing slurfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine cooling passages and cause serious damage. An example of a nan-perma~nentlocking agent commonly available in North America is Loctite Lock N'Seal (Blue)
(12) Press
A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly.
(13) Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft.
(14) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer'smarks, press it in with the marks facing out. Seals
should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
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1-4 GENERAL INFORMATION
Seal Guide
A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little lubricant, preferably high temperature grease on the lips to reduce rubber to metal friction.
Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.
Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubncative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubncative quality and may contain abrasive foreign particles.
Don'tuse lust any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an applica~tionfor which they are not intended.
(19) Electrical Wires
All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primav color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/redWwire; it would be a "red/yellown wire if the colors were reversed to make red the main color.
W i r e ( c r o s s - s e c t i o n ) |
C o l o r I n d i c a t e d o n t h e t i r e C o l w ~ n d i c a t e d à § n t h à § à ˆ ~ r i n s K i a e |
- R e d |
|
W i r e S t r a n d s |
|
Ye1 low |
|
(20) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or ilose their original function once removed.
(21) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion |
Crack |
Hardening |
Warp |
Bent |
Dent |
Scratch |
Wear |
Color change |
Deterioration |
Seizure |
|
(22) Service Data |
|
|
|
Numbers of service data in this text have following meanings- |
|
||
"Standards": Show dimensions or performances which brand-new parts or systems have. |
|||
"Service Limits". |
Indicate the usable limits. |
If the measurement shows excessive wear or deteriorated |
|
performance, replace the damaged parts.
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GENERAL INFORMATION 1-5
JH1100-A1 Left Side View :
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1-6 GENERAL INFORMATION
-- -
General Specifications
Items
Engine:
TYpe |
|
2-stroke, 3-cylinder, crankcase reed valve, water cooled |
Displacement |
|
1 071 mL |
Bore and stroke |
|
80x 71 mrn |
Compression ratio |
5.8: 1 |
|
Maximum horsepower |
88.2kW (120 PS) @6 750 rimin (rpm) |
|
Maximum torque |
129 N-m(13.2 kg-m, 95.5ft-lb) @6 000 r/min(rpm) |
|
Ignition system |
|
Magneto CDI (Digital) |
Lubrication system |
Oil injection (break-in period: Oil injection and and fuel mixture 50 : 1) |
|
Carburetion system |
Keihin CDK-38-29 x 3 diaphragm type (33 mrn venturi) |
|
Starting system |
|
Electric starter |
Tuning Specifications: |
NGK BR9ES |
|
Spark plug: |
Type |
|
|
Gap |
0.7- 0.8mrn |
Ignition timing |
|
17* BTDC @I 250 rimin (rpm) - 27'BTDC @3000 r/mm (rprn) |
Carburetor: |
Idle speed |
1 250 ±I0 rimin (rpm) - in water |
|
|
1 800 Â 100 r/min (rpm)- out of water |
Compression pressure |
657 - 1040 kPa (6.7 - 10.6 kg/cm2, 95 - 151 psi) |
|
Drive System: |
|
|
Coupling |
|
Direct drive from engine |
Jet pump: |
Type |
Axial flow, single stage |
|
Thrust |
3 570 N (364kg, 803 Ib) |
Steering |
|
Steerable nozzle |
Braking |
|
Water drag |
Performance: |
|
|
tMinimum turning radius |
4.0 m |
|
tFuel consumption |
46 L/h @full throttle |
|
?Cruising range |
|
97.5 krn @full throttle 1 hour and 5 minutes |
Dimensions: |
|
|
Length |
|
2760 rnm |
Width |
|
1 070 mm |
Height |
|
999 mrn |
Dry weight |
|
265 kg |
Fuel tank capacity |
52 L including 7 L reserve |
|
Engine Oil: |
|
2-stroke, N.M.M.A. Certifiledfor Service TC-WU or TC-W3 |
Type |
|
|
Oil tank capacity |
3.3 L |
|
Electrical Equipment:
Battery
Maximum generator out put
t: This information shown here represents results under controlled conditions, and the informationmay not be correct under other conditions.
Specifications subject to change without notice, and may not apply to every country.
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GENERAL INFORMATION 1-7
Torque and Locking Agent
The following table list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or silicone sealant.
Letters used in the "Remarks" column mean
L Apply a non-permanentlocking agent to the threads
SS Apply silicone sealant to the threads
S Tighten the fasteners following the specified sequence.
Fastener |
Torque |
Remarks |
|
|
f t - l b |
Fuel System: |
|
|
Carburetor Mounting Bolts |
|
78 in-lb |
Intake Manifold Mounting Nuts |
|
87 in-lb |
Air Intake Cover Bolts |
|
69 in-lb |
Arrester Case Stay Mounting Bolts |
|
78 in-lb |
Throttle Case Mounting Screws |
|
35 in-lb |
Engine Lubrication System |
|
|
Air Bleeding Bolt |
|
43 in-lb |
Oil Pump Mounting Bolts |
|
78 in-lb |
Exhaust System |
|
|
Exhaust Pipe Mounting Bolts |
|
36 |
Water Pipe Joints |
|
8.5 |
Exhaust Manifold Mounting Nuts |
|
14.5 |
Expansion Chamber Mounting Bolts |
|
36 |
Engin~eT o p End: |
|
|
Cylinder Head Nuts |
|
|
Water Pipe Joint |
|
|
Cylinder Base Nuts |
|
|
Cable Holder Mounting Bolts |
|
|
Engine Removal/Installation: |
|
|
Engine Mounting Bolts: |
|
|
Engine Bed Mounting Bolts |
|
|
Engine Mount Bolts |
|
|
Engine B o t t o m End: |
|
|
Flywheel Bolt |
|
94 |
Stator Mounting Bolts |
|
8.5 |
Coupling |
|
94 |
Magneto Cover Mounting Bolts |
|
78 in-lb |
Crankcase Bolts-6 mm Dia. |
|
78 in-lb |
Crankcase Bolts-8 mrn Dia. |
|
22 |
Magneto Cooling Cover |
|
78 in-lb |
Magneto Cover Stud |
|
- |
Cooling and Bilge Systems: |
|
|
Water Pipe Joint |
|
|
Drive System: |
|
|
Coupling Cover Nuts |
|
|
Coupling |
|
|
Drive Shaft Holder Mounting Bolts |
|
|
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1-8 GENERAL INFORMATION
Fastener |
Torque |
Remarks |
|
kg-m |
ft-lb |
Pump and Impeller: |
|
|
Steering Nozzle Pivot Bolts |
|
13.5 |
Pump Outlet Mounting Bolts |
|
- |
Pump Cap |
|
35 in-lb |
Impeller |
|
72 |
Pump Mounting Bolts |
|
16.0 |
Pump Cover Mountilng Bolts |
|
69 in-lb |
Grate Mounting Bolts |
|
- |
Steering: |
|
|
Handlebar Clamp Bolts |
|
11.5 |
Steering Neck Mounting Bolts |
|
11.5 |
Steering Holder Mounting Bolts |
|
11.5 |
Steering Shaft Lock Nut |
|
29 - 36 |
Steering Cable Nuts |
|
29 |
Trim Cable Nut |
|
29 |
HullJEngineHood: |
|
- |
Bumper Bushings |
|
|
Bumper Mounting Nuts |
|
- |
Electrical System: |
|
69 I ~ I - I I ~ |
Electric Case Bolts |
|
|
Electric Case Mounting Bolts |
|
69 in-lb |
Electric Case Connector Mounting Bolts |
|
78 in-lb |
CD1 Igniter Mounting Bolts |
|
69 in-lb |
Spark Plugs |
|
20 |
Starter Motor Mounting Bolts |
|
78 in-lb |
Ignition Coil Mou~ntingBolts |
|
69 in-lb |
Starter Relay Mounting Nuts |
|
69 in-lb |
Starter Lead Mounting Nut |
|
69 in-lb |
Battery Gro~undLead Mounting Bolt |
|
78 in-lb |
Flywheel Bolt |
|
94 |
Stator Mounting Bolts |
|
8.5 ft-lb |
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.
General Fasteners (stainless boll and nut)
|
|
|
|
- -- -- |
|
- |
|
Threads |
|
|
|
Torque |
|
|
|
I |
|
|
|
|
|
|
|
dia. (mm) |
|
N-m |
kg-m |
ft-lb |
|||
6 |
I |
5.9- 8.8 |
0.60- 0.90 |
52 - 78 in-lb |
|||
8 |
|
16 |
- 22 |
1.6 |
- 2.2 |
11.6 |
- 15.9 |
10 |
|
30 |
-41 |
3 1 |
- 4.2 |
22 |
- 30 |
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GENERAL INFORMATION 1-9
--
Periodic M a i n t e m n c e Chart
NOTE
0Complete the R e -Ride Checklist before each outing.
|
Frequency |
|
Initial |
Every |
|
Every |
|
|
|
|
10 |
25 |
|
100 |
|
|
- Description |
|
Hours |
Hours |
|
Hours |
|
|
Check all hose clamps, nuts, bolts, and fasteners |
|
@ |
 |
|
|
|
|
Torque cylinder head nuts |
|
0 |
 |
|
|
|
|
Lubricate throttle cable fitting and |
|
|
|
|
|
|
|
choke cable fitting at carburetor |
|
|
|
|
, |
|
|
Lubricate choke cable and throttle cable and |
|
|
|
|
||
|
|
|
 |
|
|
||
|
throttle cable fitting at throttle case. |
|
|
|
|
||
1 |
1 |
1 |
* |
I |
1 |
||
Clean and gap spark plugs (replace if necessary) |
|||||||
|
Lubricate steering cable / trim cable ball joints |
|
|
|
|
|
|
|
and steermq nozzle / trim nozzle pivots |
|
|
|
|
|
|
|
Lubricate handlebar pivot (disassemble) |
|
|
a |
|
|
|
|
Clean fuel filter screens |
|
|
a |
|
|
|
1 |
Inspectlreplace fuel filter |
|
|
|
|
 |
|
Adjust carburetor |
|
|
|
|
|
1
1
Flush bilge line and filter |
|
Flush cooling system (after each use in salt water) |
|
Inspect/clean flame arrester |
a |
In~spectimpeller blade for damage (remove) |
a |
--- - |
|
Inspect/replace coupling damper |
|
|
|
|
1 Inspect steering cable / trim cables |
1 |
1 |
1 |
I |
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1-10 GENERAL INFORMATION
Technical Information
Maintenance Free Battery
A maintenance free battery is installed in this model The maintenance free battery is a seated type, and so the electrolyte level check and t o ~ p i n q - u pcannot be performed.
(I)Construction
.Sealing p l u g
Pole
(lead-calcium alloy) "f'Tt
Negative plate
(lead and lead-calcium alloy)
Special separator
Positive plate
(lead and lead-calcium alloy)
(11) Main Features
1) Maintenance free.........................................
2)N o electrolyte leakage .................................
3)Instant activation system.............................
It is not necessary to check the electrolyte level and top-up the electrolyte. As the electrolyte is retained firmly in the special separators, there is n o free electrolyte in the battery.
it can be used instantly after filling only the electrolyte without initial charge.
4)One - pwh motion ele~tro~lytefillling............
5)S'afetyconstruction .....................................
6)Compact and high performance.. ........
7)Strong chargefdischarge characteristics ..
(Ill) Principle of Sealing Structure
it is possible to fill the electrolyte by easy one-push motion.
If the battery internal pressure rises abnormally high, the safety valve opens to release the gas inside the battery to restore the normal pressure and prevent the battery from rupturing. After restoring the normal pressure, the safety valve closes and the battery is sealed again. Moreover, a ceramic filter is disposed on top of the safety valve under the lid to remove risk of ignition or explosion caused by fire from outside.
No presence of free electrolyte allows the battery made lower in height, thus resulting in enhanced volume efficiency. Moreover, gas bemg absorbed inside the battery eliminates the need for a gas exhaust tube.
It can amply withstand deep charge/discharge cycles.
A lead-acid battery operates under the following chemical reaction:
( * ) |
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(-1 |
Discharge |
(-1 |
|
( + ) |
PbOz |
+ |
2H2S04 |
+ |
Pb |
+4- |
PbS04 + |
2H20 + |
PbS04 |
(Lead peroxide) |
|
(Sulfuric acid) |
|
(Spongy lead) |
Charge |
(Lead sulfate) |
(water) |
(Lead sulfate) |
Positive active |
|
Electrolyte |
|
Negative active |
|
Positive active |
Electrolyte |
Negative active |
material |
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material |
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material |
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material |
Normally in an ordinary lead-acid battery when it comes to an end of a charge, where the lead sulfate being a discharge product returns to lead peroxide and spongy lead, the charge current flowing thereafter is used exclusively to decompose electrolytically water from the electrolyte, thus resulting in generation of hydrogen gas from the negative plate and oxygen gas from the positive plate. The gases so generated are released out of the battery, causing the amount of electrolyte decreased to require occasional water replenishment.
A maintenance free battery, however, is so designed that, when i t is overcharged, even i f the positive plate is fully charged, the negative plate remains not fully turned to spongy lead Therefore, even when the positive plate is overcharged generating oxygen gas, the negative plate is no fully charged, hence generating no hydrogen gas
Moreover, the oxygen gas generated from the positive plate immediately reacts with the charged active material o n the negative plate, and returns to water, with the ultimate result of no water loss.
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Pb |
+ |
1/2 0 2 |
(PbO) |
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Negative active |
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Oxygen generated |
Negativeactive |
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material |
from positive plate |
material |
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(charged state) |
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(pbo) |
+ |
H2S04 |
PbS04 |
+ |
H20 |
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Electrolyte |
Negative active |
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Water |
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material |
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(charged state) |
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Thus, the negative plate is made als not to get fully charged. Even if the overcharge continues, the oxygen gas generated inside the battery is absorbed by the negative plate, a process called oxygen cycle, which theoretically prevents water toss, and allows the battery to be sealed.
(IV) Filling the Battery with Electrolyte
Do not remove the aluminum seal sheet sealing the filler ports until just before use.
Be sure to use the dedicated electrolyte contallner for correct electrolyte volume.
Â¥Chec |
to see that there is no peelinlg, tears or holes in the sealing sheet. |
Â¥Plac |
the battery on a level surface. |
Â¥Remov the sealing sheet [A].
OWhen removing, check to hear an air-sucking sound "Shoosh~"from filler ports [B]
NOTE
O A battery whose sealing sheet has any peeling, tears, holes, or from which the air-sucking sound was not heard requires a refreshing charge (initial charge).
¥Tak the electrolyte container out of the vinyl bag. ¥Detac the strip of caps [A] from the conta~iner.
NOTE
O D o not discard the strip of caps because it is used as the battery plugs later.
0 Do not peel back or pierce the sealed areas [Bl
 Plaice the elec;trolyte container u p[side down with the six sealed areas in line with the six battery filler ports.
Â¥Pus the container down strongly enough to break the sealls Now the electrolyte should start to flow into the battery
NOTE
0Do not tilt the container as the electrdyie flow may be interrupted.
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1-12 |
GENERAL INFORMATION |
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Â¥Mak |
sure air bubbles [A] are corning up from all six filler ports. |
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0Leave the container this way for 5 minutes or longer |
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NOTE |
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0Jf no air bubbles are coming up from a filter port, tap the bottom of |
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the bottle two or three times Never remove the container from [he |
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battery |
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CAUTION |
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Fill until the container is completely emptied. |
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Â¥B |
certain that all the electrolyte has flowed out |
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Â¥Ta |
the bottom the same way as above if there is any electrolyte left |
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in the container |
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Â¥No |
pull the container gently out of the battery |
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Â¥Le |
the battery sit for 20 minutes. During this time, the electrolyte |
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permeates the special separators and the gas generated by chemical |
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reaction is released |
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Â¥Fi |
the strip of caps [A] tightly into the filler ports until the strip is at |
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the same level as the top of the battery |
I |
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NOTE |
I |
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0 Do not hammer. Press down evenly with both hands. |
d |
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I |
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CAUTION |
I |
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Once you install the strip of caps after filling the battery, never remove it, nor add any water or electrolyte.
(V) Initial Charge
While a maintenance free battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if a battery shows a terminal voltage of higher than 12.5 V after 10 minutes of filling (Note I ) , no initial charge is necessary.
1 |
Condition requiring initial charge |
1 |
Charging method |
||
At low temperatures (lower than O0C) |
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1 |
1.8 A x 2 - 3 hours |
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Battery has been stored in hiqh temperature and hurrnditv. |
1 |
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Seal has been removed, or broken - peeling, tear or hole. |
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1.8 A x 15 - 20 hours |
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(If you did not hear the air-sucking sound "Shooshl" as you removed the seal.) |
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Battery as old als 2 years or more after manufacture |
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Battery manufacturing date is printed on battery top. |
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Example) 12 |
10 |
-93 |
37- |
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Day |
~ Z t h |
Year |
Mfg. location |
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Note 1 'Terminal voltage - To measure battery terminal voltage, use a digital voltmeter.
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GENERAL INFORMATION 1-13
(VI) Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use Forcibly prvinq off the sealing plug to add water is very dianqerous Never dlo that
2)Refreshing charge
If an enginc wiH not start, it indicates tlie haltcry lias been discl'inrgcd. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see the Electrical System ch~apter)
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'sperformance may be reduced noticeably ilf charged under conditions other than given above. Never remove the sealing pluq during refresh charqe.
II by chance an excessive amount of gas is generated due to overcharging, the safety valve operates to keep the battery safe.
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 removed. Give a refresh charge once a month during storage
4)Battery life
If |
the battery will not sta~rtthe engine even after several refresh charges, the battery has exceeded its useful life Replace |
it |
(Provided, however, the vehicle'sstarting system has no problem ) |
Keep the battery away from sparks and open flames dluring charging, since the battery gives ofl an explosive gas mixtu~reof hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedureprevents sparks at the battery terminals which could ignite any battery gases.
No lire should be drawn near the battery, or no terminals slhould have the tightenling loosened.
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. Gel medical attention if severe.
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1-14 GENERAL INFORMATIOlN
Accelerator Pump
When a throttle is opened quickly, the carburetor fuel mixture tends to momentarily become too lean This results from the fact that th~efuel is of greater weight than air, and when the throttle is opened suddenly the flow of fuel will tag behind the flow of the air, resulting in a lean mixture
To supply the additional fuel needed to overcome this condition, a small pump IS incorporated in the front carburetor
NOTE
OAfter the engme has started, do not repeatedly operate the throttle. The accelerator pump may foul the spark plugs with excess foe/
A. Inlet Check Valve |
G. Outlet Check Valve |
0 Spring |
H Dischange Nozzle |
C. Pump Chamber |
I. Link Lever I3 |
D Pump Diaphragm |
J. Link Lever A |
E Pump Rod |
K. Throttle Shaft |
F Link Cam |
L. Link Shaft |
When the throttle is suddenly opened, the pump rod linked to the throttle shaft pushes the pump diaphragm forcing the fuel from the pump chamber. The inlet check valve closes and the outlet check valve opens allowing fuel to spray from the discharge nozzle
As the diaphragm relaxes, the inlet valve opens letting fuel from the regulator chamber refill the pump chamber The outlet check valve closes as accelerator pump pressure faffs stopping fuel from synphoning out (he discharge nozzle.
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GENERAL INFORMATION 1-15
Kawasaki Air Induction System (KAIS)
KAIS is a system to reduce the coefficient of friction or drag between the bottom surface of the hull and the water
This system features t w o small air outlets [A] at the end of each inner strake When in motion the fast flowing water will create a vacuum [ B ] and draw air out of the engine compartment [C] to form a n a~ir-bubble film between the hull and the water
Structure of air outlet
This aerating of the rear portion of the hull improves acceleration and top speed.
0) |
, |
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Â¥ |
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0) |
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n |
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, |
---.-: without. |
KAIS |
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0 |
Time |
- |
|
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1-16 GENERAL INFORMATION
Kawasaki Automatic Trim System (KATS)
The Kawasaki Automatic Trim System (KATS) is designed for optimum low speed acceleration With the automatic trim switch [A] set to the "ON" position, the trim control unit senses engine rprn, then controls the trim motor
When the switch is pushed in after the ignition switch is turned on, the LED indicator light [B ] in the trim indicator comes on and the steering nozzle goes all t h e way down When the engine speed exceeds 2.000 rprn, the nozzle goes up to its level position and stays there The nozzle goes down when the engine speed is lower than 2,000 rprn
You can (urn off the system either by pushing the switch in again or by operating the trim switch The red indicator light shows that the system is functioning If the engine is not started within three minutes after the switch is pushed in, the light goes off but the system stays on
SENSING ENGINE RPh
TU!M
MOTOR
CHECK PROCESS FOR KATS
1 TURN ON IGNITION-S/W and PUSH TRIM-S/W (DOWN) -+CHECK TRIM MOVE to FULL-DOWN and STOP (ENGINE: OFF, AUTO-TRIM-S/W OFF)
2PUSH TRIM-S/W CUP)
(ENGINE. OFF, AUTO-TRIM-S/W. OFF)
3.PUSH ON AUTO-TRIM-S/W (ENGINE: OFF)
4PUSH OFF AUTO TRIM-S/W (ENGINE. OFF)
CHECK TRIM MOVE to FULL-UP and STOP
CHECK AUTO LED LIGHT UP, TRIM MOVE to FULL-DOWN and STOP
CHECK AUTO-LED LIGHT DOWN
5.PUSH ON AUTO TRIM-S/W (ENGINE: OFF)
6 START ENGINE and KEEP over 2000 rpm (over 3 sec)
7.KEEP under 2000 rpm (over 1 sec)
8.PUSH TRIM-S/W (UP)
CHECK AUTO-LED LIGHT UP
CHECK TRIM MOVE to LEVEL and STOP (MOTOR WORKING TIME is 1.5 sec)
CHECK TRIM MOVE to FULL-DOWN and STOP
CHECK AUTO-LED LIGHT DOWN, TRIM MOVE to FULL-UP and STOP
9.PUSH ON AUTO TRIM-S/W and KEEP over 2000'rpm (over 3 sec)
10.PUSH TRIM-S/W (DOWN)
11.STOP ENGINE and TURN OFF IGNITION-S/W
CHECK AUTO-LED LIGHT UP. TRIM does not MOVE (STAYS FULL-UP)
CHECK AUTO-LED LIGHT DOWN, TRIM MOVE to FULL-DOWN and STOP
(REFER to KATS TROUBLESHOOTING in the ELECTRICAL SYSTEM CHAPTER)
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Special Tools, Sea~lant
Compression Gauge: 57001-221
Piston Pin Puller Assembly: 57001-910
Oil Seal & Bearing Remover: 57001-1058
Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt, a67 - @79: 57001-1097
GENERAL INFORMATION 1-17
Bearing Driver Set: 57001-1129
Compression Gauae Adapter, M14 x 1.25: 57001-1159
Rotor Puller, M I6/M18/M20l/M22 x 1.5: 57001-1216
Flywheel Puller, M35 X 1.5: 57001-1223
I
ImpellerWrench: 57001-1228
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1-18 GENERAL INFQRMATION
Coupling Hdder: 57OQq-1230 |
Hand Tester. 57001-1394 |
Drive Shaft Holder Adapter: 57001-1237 |
Kawasaki Bormd (Silicone Sealant): 56019-120 |
Driue Shaft Holder: 57QQl-1327 |
Kawasaki Bond (Liquid Gasket- Black): 92104-1003 |
Flywheel Holder: 57001- 7 313 |
Box Wrench (27 mm): 57001-1451 |
3
Impeller Holder: 5700j -1393
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GENERAL INFORMATION 1-19
Cable, Wire and Hose Routina
1. Front Carburetor
2. Middle Carburetor
3. Rear Carburetor
4. Oil Hose (To Front Carb.)
5. Oil Hose (To Middle Carb.)
6. Oil Hose (To Rear Carb.)
7. Pulse Hose (To Front Carb )
8. Pulse Hose (To Rear Carb.)
9. Clamp
10. Fuel Hose (Return)
11. Fuel Hose (Supply)
12. Baiance Tube
13. Intake Manifold
14. Balance Tube Fitting
15. Oil Pump
16. Magneto Cover
17. Magneto Leads
Be careful so that the o i l hose clamp |
|
- |
does n o t touch the accelerator pump |
cam. |
|
Clamp the pulse as shown.
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1-20 GENERAL INFQRMAT\ON
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GENERAL INFORMATION 1-21
I |
Bypass Outlet |
11. To Jet Pump |
2 |
Clamp |
12. Exhaust Manifold |
3. |
Water Temperature Sensor |
13. Cylinder Head |
4 |
Exhaust Pmpe |
14.Cooling Hose [Cylinder Head - Exhaulst Pipe] |
5 Bypass Cocalmg km?
6. Caolling~Hose coo ling^ Cower - Chamber)
7. Magneto Coohng Cover
8. Expans~onChamber
9. Cooltng Hose [To Magneto Cooling Cover)
70. M e t Cooling Hose
Run the cooling hose new the magneto cover so that the hose daes not touch the chamber body and rnanifdd.
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1-22 GENERAL INFORMATION
I . Throttle Laver
2.Throttie Cable
3.Clamp
4. |
Startistop Switch Leads |
BOW |
5. |
Sta~rt/StopSwitch |
|
6. |
Protective Tube |
|
7. |
To Fuel Knob |
|
8. |
To Choke Knob |
|
9. |
Grom~metPlate |
|
10. Grommet
1I.Choke Cable
12. Trim Cable
13. Steering Cable
?4. Detent
BOW
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GENERAL INFORMATION 1-23
1 Detent
2.Fuel Hose (Supply)
3.Fuel Hose (Return)
4 |
Fuel Tap Assembly |
BOW |
5. |
Fuel Filter |
|
6Band
7.Clamp
8.Oil Inlet Hose
9.Oil Tank
10. Oil Filter
11 To Oil Pu~mp
12.Main Harness
13.Fuel Level Sensor
BOW
BOW
5
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1-24 GENERAL INFORMATION
1Oil Inlet Hose
2. Detent
3Oil Pump
4.Trim Motor Box
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