Kawasaki JET SKI STX-15F Service Manual
STX-15F
JET SKI
Service Manual
®
Watercraft
is a trademark of Kawasaki Heavy Industries, Ltd. registered in U.S.A., Japan,
Austria, Benelux, Sweden, Denmark, Switzerland, France, Canada, Finland, Norway, Greece, Italy,
U.K., Portugal, Thailand, and Taiwan.
KAWASAKI JET SKI®is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Engine Lubrication System 4 j
Exhaust System 5 j
Engine Top End 6 j
Engine Removal/Installation 7 j
Engine Bottom End 8 j
Cooling and Bilge Systems 9 j
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.
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
STX-15F
®
JET SKI
Service M
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 Department/Consumer Products and Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your JET SKI
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.
Watercraft
anual
®
watercraft dealer for the
© 2003 Kawasaki Heavy Industries, Ltd. Second Edition (1):Oct. 15, 2004 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center
AC
ATDC after top dead center
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) perminute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet Vvolt(s)
ggram(s) W watt(s)
h
L
alternating current
hour(s)
liter(s)
m
min
N
Ω ohm(s)
meter(s)
minute(s)
newton(s)
Read OW
NER’S MANUAL before operating.
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 REGULAR GRADE GASOLINE
ONLY.
A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted
on service station pumps.
Emission Control Information
To protect the environment in which we all live, Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental
Protection Agency.
Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this engine. The fuel, ignition and exhaust systems of this engine have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
Maintenance
Proper maintenance and repair are necessary to ensure that watercraft will continue to have
low emission levels. This Service Manual contains those maintenance and repair recommendations for this engine. Those items identified by the Periodic Maintenance Chart are necessary
to ensure compliance with the applicable standards.
Tampering with Emission Control System Prohibited
Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of
any device or element of design incorporated into any new engine for the purposes of emission
control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use
of the engine after such device or element of design has been removed or rendered inoperative
by any person.
Among those acts presumed to c onstitute tampering are the acts listed below:
Do not tamper with the original emission related parts.
* Digital Transistor Ignition System
* Fuel Pump
* Spark Plugs
* Throttle Body and Internal Parts
* Fuel Injectors
*ECU
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
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
by the Special Tool Manual. Genuine parts
provided as spare parts are listed in the Parts
Catalog.
®
watercraft are introduced
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
®
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and convenient operation.
Indicates a procedural step or work to be
•
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 fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
This model, JT1500A, is mounted with a four
-stroke engine.
When the JET SKI
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.
®
watercraft is submerged
GENERAL INFORMATION 1-1
General Information
Table of Contents
Smart Learning Operation mode (SLO) (JT1500-A2 model ∼)............................................... 1-2
Before Servicing ..................................................................................................................... 1-3
Model Identification................................................................................................................. 1-10
General Specifications............................................................................................................ 1-11
Unit Conversion Table ............................................................................................................ 1-13
1
1-2 GENERAL INFORMATION
Smart Learning Operation mode (SLO) (JT1500-A2 model ∼)
This watercraft is equipped with the Smart Learning Operation mode (SLO) and normal operation
mode (Full Power Operation, FPO). The SLO mode reduces the maximum watercraft speed by approximately 30 percent for a use by unskilled operators. To change the SLO mode to FPO mode, and
back again, push the “MODE” button for 7 seconds or more.
SLO mode is displayed on the meter as SLO.
NOTE
When shifted to the SLO mode, the initial display, as
○
shown when the ignition switch is turned on, is shown
together with a buzzer sound.
Then, “SLO” is shown blinking at every three seconds.
○
Under the SLO mode, all the meter displays and other
○
functions work in the same manner as the normal operation (Full Power Operation, FPO) mode.
Normal operation mode (Full Power Operation mode, FPO)
is shown by FPO display.
NOTE
When shifted to the normal operation mode (Full Power
○
Operation mode, FPO), the same initial display is first
shown and followed by “FPO” for two seconds. However, “FPO” is shown only once when shifted and is not
displayed thereafter.
When the ignition switch is turned off and on again, the
○
same mode when turned off is displayed again.
GENERAL INFORMATION 1-3
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 version 2.2 that runs on Windows personal computer (PC) will be available as a diagnostic tool for watercraft with Kawasaki DFI system.
You need the following items to use the KDS.
Item P/No.
KDS Software Version 2.2 (CD-ROM) 57001-1503
Signal Converter 57001-1504
Communication Cable and Cable Adapter
Relay Cable
The connectors for the communication cable and relay cable are located in the front of the battery.
Connect the communication cable to the KDS connector (4-pin) [A] and the relay cable between
the relay assembly [B] connectors (8-pin) [C].
57001-1470
57001-1535
Adjustments
Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting or presence of symptoms indicate that adjustments may be required. Whenever running
of the engine is required during maintenance it is best to have the watercraft in water.
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds, especially
in high revolutionary speed or severe engine and exhaust system damage will occur.
Auxiliary Cooling
An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjustments. If possible, always operate the watercraft in water rather than use an auxiliary cooling supply.
1-4 GENERAL INFORMATION
Before Servicing
Obtain a standard garden hose [A] and a garden hose
•
adapter [B] as shown.
C: Garden Hose Fitting of Adapter
D: Flushing Fitting of Adapter
E: Thread: Rp 3/4
Optional part (P/No. 92005-3746) is available as a garden
○
hose adapter.
Open the front storage compartment cover.
•
Remove the flushing cap [A] on the brim of the storage
•
compartment.
Screw a garden hose adapter [A] onto the flushing fitting
•
[B].
Attach a garden hose [C] to a garden hose adapter and
•
secure the hose clamp [D].
Attach the garden hose to a faucet. Do not turn on the water until the engine is running and turn it
•
off immediately when the engine stops. The engine requires 2.4 L/min (2.5 qts/min) at 1 800 rpm
and 7.0 L/min (7.4 qts/min) at 6 000 rpm.
CAUTION
Insufficient cooling supply will cause the engine and/or exhaust system to overheat and
severe damage will occur. Excessive cooling supply may kill the engine and flood the cylinders, causing hydraulic lock. Hydraulic lock will cause severe damage to the engine. If the
engine dies while using an auxiliary cooling supply, the water must be shut off immediately.
CAUTION
Always turn the boat on its left side. Rolling to the right side can cause water in the exhaust
system to run into the engine, with possible engine damage.
GENERAL INFORMATION 1-5
Before Servicing
CAUTION
Turn the capsized boat clockwise so that the port side always faces downward. Turning
counterclockwise can cause water in the exhaust system to run into the engine, with pos-
sible engine damage.
Battery Ground
Before completing any service on the watercraft, disconnect the battery wires from the battery to prevent the engine
from accidentally turning over. Disconnect the ground wire
(–) first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative (–) wire to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.
1-6 GENERAL INFORMATION
Before Servicing
Cleaning Watercraft before Disassembly
Clean the watercraft thoroughly before disassembly. Dirt
or other foreign materials entering into sealed areas during
watercraft disassembly can cause excessive wear and decrease performance of the watercraft.
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Before Servicing
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
GENERAL INFORMATION 1-7
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling
1-8 GENERAL INFORMATION
Before Servicing
Liquid Gasket, Locking Agent
For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil passages and cause serious damage.
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Before Servicing
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when installing to prevent deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.
GENERAL INFORMATION 1-9
Direction of Engine Rotation
When rotating the crankshaft, by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (counter-clockwise
viewed from stern sinde).
Electrical Wires
A two-color wire is identified first by the primary color and
then the s tripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
1-10 GENERAL INFORMATION
Model Identification
JT1500-A1 Left Side View
JT1500-A1 Right Side View
GENERAL INFORMATION 1-11
General Specifications
Items JT1500-A1 ∼ A2
Engine
Type
Displacement
Bore and Stroke 83 × 69.2 mm (3.27 × 2.72 in.)
Compression Ratio 10.6 : 1
Maximum Horsepower 118kW(160PS)@7500r/min(rpm)
Maximum Torque 152 N·m (15.5 kgf·m, 112.1 ft·lb) @7 250 r/min (rpm)
Ignition System Digital transistor
Lubrication System Forced lubrication (semi-dry sump)
Carburetion System FI (fuel injection) MIKUNI AC 60 × 1
Starting System Electric starter
Cylinder Numbering Method Front (bow) to rear (stern), 1-2-3-4
Firing Order 1-2-4-3
Valve Timing:
Inlet:
Open 22.5° BTDC
Close 67.5° ABDC
Duration 270°
Exhaust:
Open 74.5° BBDC
Close 9.5° ATDC
Duration
Tuning Specifications
Spark plug:
Type NGK CR9EK
Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
Ignition Timing 3° ATDC @1 300 r/min ∼ 32° BTDC @3 000 r/min (rpm)
Idle Speed 1 300 ±100 r/min (rpm) -in water
Compression Pressure 1190∼ 1799kPa(12.1∼ 18.3 kgf/cm², 173 ∼ 261 psi) @430
Drive System
Coupling Direct drive from engine
Jet Pump:
Type Axial flow single stage
Thrust 4 250 N (434 kgf, 955 lb)
Steering Steerable nozzle
Braking Water drag
Performance
†Minimum Turning Radius
†Fuel Consumption 43 L/h (11.4 US gal/h) @full throttle
†Cruising Range 134 km (87 mile) @full throttle 1 hour and 26 minutes (3 person)
Dimensions
Overall Length 3 120 mm (122.8 in.)
4-stroke, DOHC, 4-cylinder, water cooled
1498mL(91.4cuin.)
264°
1 300 ±100 r/min (rpm) -out of water
r/min (rpm)
4.0 m (13.1 ft)
1-12 GENERAL INFORMATION
General Specifications
Items JT1500-A1 ∼ A2
Overall Width 1180mm(46.5in.)
Overall Height 1050mm(41.3in.)
Dry Weight
Fuel Tank Capacity 62 L (16.4 US gal)
Engine Oil
Type API SE, SF or SG
Viscosity SAE 10W-40
Capacity 5.0 L (5.3 US qt)
Electrical Equipment
Battery 12 V 18 Ah
Maximum Generator Output 16 A @14 V
†: This information shown here represents resul ts 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.
338 kg (745 lb)
API SH or SJ with JASO MA
Unit Conversion Table
GENERAL INFORMATION 1-13
Prefixes for Units
Prefix Symbol
mega M × 1 000 000
kilo k ×1000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Power
Units of Mass
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume
L × 0.2642 = gal (US)
L × 0.2200 = gal (imp)
L × 1.057 = qt (US)
L × 0.8799 =
L×2.113=
L × 1.816 = pint (imp)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in
qt (imp)
pint (US)
Units of Length
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in.
Units of Torque
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Units of Pressure
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa
Units of Speed
km/h
× 0.6214 = mph
Units of Force
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units of Temperature
Units of Power
kW ×1.360=PS
kW ×1.341=HP
PS
PS × 0.9863 = HP
× 0.7355 = kW
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-2
Torque and Locking Agent...................................................................................................... 2-3
Specifications ......................................................................................................................... 2-8
Special Tools and Sealant ...................................................................................................... 2-9
Periodic Maintenance Procedures.......................................................................................... 2-10
Fuel System......................................................................................................................... 2-10
Throttle Control System Inspection ................................................................................... 2-10
Air Filter Drain Caps Inspection and Cleaning .................................................................. 2-10
Air Filter Inspection and Cleaning..................................................................................... 2-11
Fuel Vent Check Valve Inspection .................................................................................... 2-11
Fuel Pump Screen Cleaning ............................................................................................. 2-12
Throttle Shaft Spring Inspection........................................................................................ 2-12
Engine Lubrication System.................................................................................................. 2-12
Engine Oil Change............................................................................................................ 2-12
Oil Filter Replace .............................................................................................................. 2-14
Engine Top End ................................................................................................................... 2-15
Air Suction Valve Inspection ............................................................................................. 2-15
Valve Clearance Inspection .............................................................................................. 2-15
Engine Mounting Bolts Inspection and Tightness ............................................................. 2-19
Engine Bottom End.............................................................................................................. 2-19
Coupling Damper Inspection............................................................................................. 2-19
Cooling and Bilge Systems .................................................................................................. 2-19
Cooling System Flushing .................................................................................................. 2-19
Bilge System Flushing ...................................................................................................... 2-21
Pump and Impeller............................................................................................................... 2-22
Impeller Inspection............................................................................................................ 2-22
Steering ............................................................................................................................... 2-22
Steering Cable/Shift Cable Inspection .............................................................................. 2-22
Handlebar Pivot Lubrication.............................................................................................. 2-22
Hull/Engine Hood.................................................................................................................2-23
Drain Plug Inspection........................................................................................................ 2-23
Electrical System ................................................................................................................. 2-23
Battery Charging Condition Inspection ............................................................................. 2-23
Battery Terminals Inspection............................................................................................. 2-23
Spark Plug Cleaning and Inspection................................................................................. 2-24
Lubrication ........................................................................................................................... 2-24
All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check ............................................... 2-27
Nuts, Bolts, and Fasteners Tightness Inspection.............................................................. 2-27
Hose and Hose Connect Inspection ................................................................................. 2-27
Rubber Strap Inspection ................................................................................................... 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.
Frequency
Description
Inspect throttle control system (e)
Inspect/clean air filter drain caps
Initial 10
Hours
Every 25
Hours
•
•
Every 50
Hours
Every 100
Hours
Refer-
ence
2-10
2-10
Inspect/clean air filter
Inspect fuel vent check valve
Clean fuel pump screen (e)
Inspect throttle shaft spring (replace
throttle body if necessary) (e)
Replace engine oil
Replace engine oil fil
Check air suction valve
Inspect/adjust valve clearance (e)
Inspect/tighten engine mounting bolts
Inspect/replace coupling damper
Flush cooling system (after each use in
salt water)
Flush bilge line and filter
Inspect impeller blades for damage
(remove)
Inspect steering ca
Lubricate handlebar pivot (disassemble)
Inspect hull drain screws (replace if
necessary)
Inspect battery charging condition
Inspect battery terminals
Clean and gap 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 c able ball
joints and stee
pivots
Check all hoses, hose clamps, nuts,
bolts, and fasteners
(e): Emission Related Items
ter
ble/shift cable
ring nozzle/reverse bucket
• •
•
(or every
year)
•
•
•
•
(or every
year)
•
•
•
•
(or every
year)
•
•
•
•
•
•
•
•
•
•
•
•
•
2-11
2-11
2-12
2-12
2-12
2-14
2-15
2-15
2-19
2-19
2-19
2-21
2-22
2-22
2-22
2-23
2-23
2-23
2-24
2-24
2-24
2-24
2-27
PERIODIC MAINTENANCE 2-3
Torque and Locking Agent
The following table list the tightening torque for the major fasteners, and the parts requiring use of
a non-permanent locking agent or silicone sealant.
Letters used in the “Remarks” column mean:
EO: Apply oil to the threads and seating surface.
L: Apply a non-permanent locking agent to the threads.
MO: Apply molybdenum disulfide grease oil solution.
R: Replacement Part
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant to the threads.
Fastener
Fuel System
Vehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb
Bracket Mounting Bolts – – – L
Inlet Manifold Mounting Bolts 25 2.5 18 L
Inlet Manifold Mounting Nuts 20 2.0 14
Delivery Pipe Mounting Bolts 7.8 0.80 69 in·lb
Inlet Air Pressure Sensor Bolts 7.8 0.80 69 in·lb
Throttle Cable Holder Bolts 8.8 0.90 78 in·lb L
Inlet Air Temperature Sensor 20 2.0 14
Throttle Body Assy Mounting Bolts 20 2.0 14
Inlet Manifold Drain Plug
Inlet Manifold Plate Bolts 7.8 0.80 69 in·lb
Crankshaft Sensor Screws 4.4 0.45 39 in·lb L
Camshaft Position Sensor Bolt 7.8 0.80 69 in·lb L
Oil Temperature Sensor 15 1.5 11 see text
Water Temperature Sensor 15 1.5 11 see text
Regulator/Rectifier Bolts 7.8 0.80 69 in·lb
ECU Mounting Bolts 8.8 0.90 78 in·lb L
Throttle Sensor Mounting Screws 2.0 0.20 18 in·lb
ISC Actuator Mounting Bolts 4.9 0.50 43 in·lb
Oil Pressure Switch
Fuel Filler Tube Clamp Screws
Fuel Level Sensor Clamp Screw
Fuel Filter Mounting Bolts 8.8 0.90 78 in·lb L
Air Filter Mounting Bolts 9.8 1.0 87 in·lb
Air Filter Bracket Mounting Bolts 7.8 0.80 69 in·lb L
Throttle Cable Locknut
Throttle Case Mounting Screws
Engine Lubrication System
Breather Plate Bolts 7.8 0.80 69 in·lb
Oil Filler Cap 1.0 0.10 8.7 in·lb
Oil Passage Plugs 20 2.0 14 L
Oil Separator Tank Mounting Screws
Breather Case Mounting Bolts
Breather Pipe Bolts 8.8 0.90 78 in·lb
N·m kgf·m ft·lb
20 2.0 14
15 1.5 11
2.9 0.30 26 in·lb
2.9 0.30 26 in·lb
7.8 0.80 69 in·lb
3.9 0.40 35 in·lb
4.9 0.50 43 in·lb L
7.8 0.80 69 in·lb
Torque
Remarks
SS
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Oil Passage Joints 11 1.1 95 in·lb L
Oil C ooler Assembly Bolts
Oil Pressure Switch
Oil Passage Bolt
Oil Filter 18 1.8 13 EO
Oil C ooler Positioning Bolt 20 2.0 14 S
Oil Pan Bolts 7.8 0.80 69 in·lb S
Dipstick Tube Bolts 7.8 0.80 69 in·lb L, S
Oil Pump Sprocket Bolt 15 1.5 11 L
Oil Pump Cover Bolts 7.8 0.80 69 in·lb
Oil Pressure Relief Valve 15 1.5 11 L
Oil Pipe Bolts 7.8 0.80 69 in·lb
Chain Guide Spring Plate Bolt 7.8 0.80 69 in·lb
Oil Pump Body Plug
Oil Pump Body Bolts
Oil Screen Bolts
Water Pipe Joints 20 2.0 14 L
Exhaust System
Exhaust Manifold Mounting Nuts 25 2.5 18 S
Exhaust Manifold Mounting Bolts
Bypass Nozzle – – – L
Flushing Hose Joint 11 1.1 95 in·lb SS
Water Hose Joint 11 1.1 95 in·lb SS
Water Temperature Sensor 15 1.5 11 see chapter 3
Exhaust Pipe Mounting Plate Bolts 30 3.0 22 L
Exhaust Pipe Mounting Bolts 30 3.0 22
Engine Top End
Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb
Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S
Camshaft Cap Bolts 12 1.2 104 in·lb S
Cylinder Head Bolts (M7)
Cylinder Head Bolts (M11)
Cylinder Hea
Water Jacket Plugs 20 2.0 14 L
Cylinder Head Bolts (M6) 12 1.2 104 in·lb S
Engine Hook Bolts 20 2.0 14
Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb L
Exhaust Side Camshaft Chain Guide Bolts
(Upper)
Exhaust Side Camshaft Chain Guide Bolts
(Lower)
Upper Camshaft Chain Guide Bolts 12 1.2 104 in·lb S
dBolts(M11)
N·m kgf·m ft·lb
7.8 0.80 69 in·lb
15 1.5 11
78 8.0 58
20 2.0 14 L
7.8 0.80 69 in·lb
7.8 0.80 69 in·lb
25 2.5 18
20 2.0 14
23 2.3 17
59 6.0 43
25 2.5 18
12 1.2 104 in·lb
Torque
Remarks
SS
S
L, S
S
First, MO, S
Final, MO, S
Torque and Locking Agent
PERIODIC MAINTENANCE 2-5
Fastener
Inlet Side Camshaft Chain Guide Bolts 12 1.2 104 in·lb L
Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb L
Camshaft Chain Tensioner Cap Bolt 20 2.0 14
Camshaft Position Sensor Rotor Bolt 12 1.2 104 in·lb L
Water Hose Joint 11 1.1 95 in·lb SS
Oil Passage Joint 11 1.1 95 in·lb L
Engine Removal/Installation
Engine Mounting Bolts 36 3.7 27 L
Engine Damper Mounting Bolts 16 1.6 12 L
Engine Bottom End
Crankshaft Sensor Cover Bolts 7.8 0.80 69 in·lb
Engine Bracket Mounting Bolts 29 3.0 22 L
Timing Rotor Bolt 29 3.0 22 L
Connecting Rod Nuts
Oil Passage Plugs
Stator Mounting Bolts 12 1.2 104 in·lb L
Grommet Cover Bolts 9.8 1.0 87 in·lb L
Magneto Cover Bolts 20 2.0 14
Output Cover Bolts 7.8 0.80 69 in·lb
Output Shaft 245 25 180 MO
Coupling 98 10 72
Crankcase Bolts (M10) 50 5.0 36 MO, S
Crankcase Bolts (M8) 29 3.0 22 MO, S
Crankcase Bolts (M8) 29 3.0 22 S
Crankcase Bolts (M6)
Cooling and Bilge Systems
Breather Mounting Bolt – – – L
Water Hose Joint (L Shape Type) 11 1.1 95 in·lb SS
Water Hose Joint (Straight Shape Type) 20 2.0 14 SS
Water Hose Joint (Straight Shape Type) 11 1.1 95 in·lb SS, see text
Drive System
Coupling
Drive Shaft Holder Mounting Bolts
Coupling Cover Bolts 8.8 0.90 78 in·lb L
Pump and Impeller
Steering Nozzle Pivot Bolts 19 1.9 14 L
Pump Mounting Bolts 36 3.7 27 L
Pump Outlet Mounting Bolts 19 1.9 14 L
Pump Cap Bolts 9.8 1.0 87 in·lb L
Pump Cap Plug 3.9 0.40 35 in·lb
Impeller 98 10 72
Pump Bracket Mounting Bolts (2) 19 1.9 14 L, SS
Pump Bracket Mounting Bolts (4) 9.8 1.0 87 in·lb L
N·m kgf·m ft·lb
– – –
20 2.0 14 L
12 1.2 104 in·lb
39 4.0 29 L
22 2.2 16 L
Torque
Remarks
MO, see text
S
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Pump Cover Mounting Bolts 7.9 0.80 69 in·lb L
Grate Mounting Bolts
Filter Cover Mounting Bolts
Steering
Handlebar Clamp Bolts 16 1.6 12 L
Start/stop Switch Case Mounting Screws 3.9 0.40 35 in·lb
Throttle Case Mounting Screws 3.9 0.40 35 in·lb
Steering Shaft Locknut 49 ∼ 59 5.0 ∼ 6.0 36 ∼ 43
Steering Shaft Nut – – – Hand-Tight
Steering Holder Mounting Bolts 20 2.0 14.5 L
Steering Neck Mounting Bolts 16 1.6 12 L
Steering Cable Joint Bolt 9.8 1.0 87 in·lb L
Ball Joint 9.8 1.0 87 in·lb L
Shift Cable End Nut 9.8 1.0 87 in·lb
Reverse Bucket Pivot Bolts 19 1.9 14 L
Shift Cable Nut
Steering Cable Nut 39 4.0 29
Shift Lever Locknut 20 2.0 14.5
Hull/Engine Hood
Crossmember Bolts 7.8 0.80 69 in·lb L
Handrail Bolts 9.8 1.0 87 in·lb L
Lock Assembly Nut 4.9 0.50 43 in·lb
Front Duct Bolts – – – L
Damper Bolts – – – L
Damper Bracket Bolts – – – L
Front Storage Compartment Cover Bolts – – – L
Hinge Bolts – – – L
Front Storage Co
Steering Cover Bolts – – – L
Meter Screen Bolts – – – L
Seat Hook Bolts – – – L
Seat Locknut – – – L
Reboarding Step Bolts – – – L
Mirror Stay Bolts – – – L
Stabilizer Bolts 9.8 1.0 87 in·lb L
Air inlet Duct Bolts – – – L
Exhaust Outlet Bolts – – – L
Electrical System
Vehicle-Down Sensor Mounting Screws 1.5 0.15 13 in·lb
Electrical Parts Bracket Screws 4.9 0.50 43 in·lb L
Starter Relay Case Bolts 7.8 0.80 69 in·lb
Ignition Coil Mounting Bolts 8.8 0.90 78 in·lb L
Water Temperature Sensor 15 1.5 11 see text
mpartment Hook Bolts
N·m kgf·m ft·lb
9.8 1.0 87 in·lb L
9.8 1.0 87 in·lb L
39 4.0 29
– – – L
Torque
Remarks
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