Kawasaki STX-15F User 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

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.

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

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 constitute tampering are the acts listed below:

Do not tamper with the original emission related parts.

* Digital Transistor Ignition System

* Fuel Pump

* Spark Plugs

* Throttle Body and Internal Parts

* Fuel Injectors

*ECU

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 w ork 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 m ain-

•

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 m anual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa­tion.

NOTE

This note symbo l 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] o nto 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 s ervice 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 stripe 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 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.

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

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

ter

Initial 10

Hours

Every 25

Hours

•

•

•

•

Every 50

Hours

•

(or every

year)

•

(or every

year)

•

(or every

year)

Every 100

Hours

•

•

•

•

Refer-

ence

2-10

2-10

2-11

2-11

2-12

2-12

2-12

2-14

2-15

2-15

2-19

Inspect/replace coupling damper

Flush cooling system (after each use in
salt water)

Flush b ilge 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 cable ball
joints and stee
pivots

Check all hoses, hose clamps, nuts,
bolts, and fasteners

ble/shift cable

ring nozzle/reverse bucket

• •

•

•

•

•

•

•

•

•

•

•

•

•

•

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

(e): Emission Related Items

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 Cooler Assembly Bolts

Oil Pressure Switch

Oil Passage Bolt

Oil Filter 18 1.8 13 EO

Oil Cooler Positioning Bolt 20 2.0 14 S

Oil Pan Bolts 7.8 0.80 69 in·lb S

Dipstick Tube Bolts 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 G uide Bolts
(Upper)

Exhaust Side Camshaft Chain G uide 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 C over Bolts 8.8 0.90 78 in·lb L

Pump and Impeller

Steering Nozzle P ivot 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

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Starter Relay Mounting Nut 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lb
Starter Cable Mounting Nut 3.5 ∼ 4.5 0.35 ∼ 0.45 30 ∼ 40 in·lb

Timing Rotor Bolt 20 2.0 14 L

Crankshaft Sensor Screws 4.4 0.45 39 in·lb L

Rubber Grommet Holder Screws 4.4 0.45 39 in·lb L

Crankshaft Sensor Cover Bolts 7.8 0.80 69 in·lb

Oil Temperature Sensor 15 1.5 11 see text

Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb L

Spark Plugs 13 1.3 113 in ·lb

Regulator/rectifier Bolts 7.8 0.80 69 in·lb

Replay Assembly Bolts 2.5 0.25 22 in·lb L

ECU Mounting Bolts 8.8 0.90 78 in·lb L

Main Fuse Mounting Bracket Bolt 7.8 0.80 69 in·lb

Multifunction Meter Mounting Bolts

Fuel Level Sensor Clamp Screw

Start/stop Switch Case Mounting Screws 3.9 0.40 35 in·lb

Speed Sensor Mounting Bolts 3.9 0.40 35 in·lb L

Starter M otor Through Bolts 6.4 0.65 56 in·lb L, R

Starter M otor Mounting Bolts 8.8 0.90 78 in·lb L

Starter Motor Ground Bolt 7.8 0.80 69 in·lb

Starter Motor Terminal Nut 7.8 0.80 69 in·lb

Stator Coil Bolts 12 1.2 104 in·lb L

Grommet Holder Bolts 8.8 0.90 78 in·lb L

N·m kgf·m ft·lb

3.9 0.40 35 in·lb L

2.9 0.30 26 in·lb

Torque

Remarks

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

General Fasteners (stainless bolt and nut)

Threads dia. (mm)

N·m kgf·m ft·lb

6 5.9 ∼ 8.8 0.60 ∼ 0.90 52 ∼ 78 in·lb
8 16 ∼ 22 1.6 ∼ 2.2 12 ∼ 16

10 30 ∼ 41 3.1 ∼ 4.2 22 ∼ 30

Torque

2-8 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System

Throttle Lever Free Playabout 2 mm (0.08 in.) –––

Engine Lubrication
System

Engine Oil:

Type API SE, SF or SG

API SH or SJ with JASO MA

Viscosity SAE 10W-40 –––

Capacity 4.0 L (4.2 US qt, with or without the filter)

5.0 L (5.3 US qt, when engine is completely dry)

Engine Top End

Valve Clearance:

IN 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) –––
EX 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) –––

Electrical System

Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

–––

–––

–––

Special Tools and Sealant

PERIODIC MAINTENANCE 2-9

Oil Filter Wrench:
57001-1249

Shaft Wrench:
57001-1551

2-10 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Throttle Control System Inspection

Inspect the throttle lever free play [A].

•

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

Throttle Lever Free Play

Standard: about 2 mm (0.08 in.)

Check that the throttle lever moves smoothly from full

•

open to close, and the throttle closes quickly and com­pletely 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.
If the idle speed increase, check the throttle cable adjust­ment and the cable routing.

Remove the seat (see Hull/Engine Hood chapter).

•

Check throttle cable adjustment.

•

With the throttle lever released, the upper stop [A] on the

•

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: 7.8 N·m (0.80 kgf·m, 69

in·lb)

NOTE

Make sure that the throttle pivot arm stops against the

○

stopper on the throttle body with the throttle lever re­leased.

Air Filter Drain Caps Inspection and Cleaning

Remove the seat (see Hull/Engine Hood chapter).

•

Remove the rear storage pocket.

•

Inspect the air filter [A] for water inside with its drain caps

•

[B].
If there is water in the caps, remove both caps and dis­charge the water.

NOTE

Be sure to have a rag or cloth underneath for possible

○

oily water.

Periodic Maintenance Procedures

Air Filter Inspection and Cleaning

Remove:

•

Air Filter (see Fuel System (DFI) chapter)
Flame Arrester [A] (see Air Filter Disassembly in Fuel
System (DFI) chapter)

Clean the flame arrester [A].

•

Visually inspect the flame arrester for damage.

•

If necessary, replace it with a new one.

PERIODIC MAINTENANCE 2-11

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.

Remove the front storage pocket (see 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].

Blow through the fuel vent check valve from each end.

•

If the check valve will allow air to flow as shown, it is OK.

If air will flow through the check valve in both direction or

in neither direction, the check valve must be replaced.

2-12 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

The fuel vent check valve [C] must be mounted so that

•

the arrow [D] on its case is pointing toward the fuel tank.

Fuel Pump Screen Cleaning

Remove the fuel pump (see Fuel System chapter).

•

Wash the fuel pump screen [A] in non-flammable of high

•

-flash point solvent. Use a brush to remove any contami­nants trapped in the screens.

WARNING

Clean the fuel pump screen in a well-ventilated
area, and take ample care that there are no sparks
or flame anywhere near the working area; this
includes any appliance with a pilot light. Do not
use gasoline or a low flash-point solvent. A fire or
explosion could result.

Throttle Shaft Spring Inspection

Remove the seat (see Hull/Engine Hood chapter).

•

Check the throttle shaft spring [A] by pulling the throttle

•

lever.
If the springs are damaged or weak, replace the throttle
body.

Engine Lubrication System

Engine Oil Change

Level the watercraft port to starboard as well as fore to

•

aft.

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

Periodic Maintenance Procedures

In a w ell-ventilated area, start the engine while cooling the

•

cooling system.

Open the front storage compartment cover.

○

Remove the flushing cap (see Cooling System Flushing).

○

Screw a garden hose adapter [A] onto the flushing fitting

○

[B].

Attach a garden hose [C] to a garden hose adapter and

○

secure the hose clamp [D].

Warm up the engine and stop it.

•

CAUTION

The engine must be running before the water is

turned on and the water must be turned off before

the engine is stopped.

Do not run the engine without cooling water flow for

more than 15 seconds.

Remove the seat (see Hull/Engine Hood chapter).

•

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

•

CAUTION

PERIODIC MAINTENANCE 2-13

Be careful not to allow any dirt or foreign materials

to enter the engine.

Drain the oil thorough from the dipstick tube [A] using a

•

commercially-available vacuum pump [B].

WARNING

Do not discard the engine oil as the engine oil is

toxic substance and will pollute the environment.

Contact your local authority for approved disposal

methods.

Pour in the specified type and amount of oil through the

•

oil filler opening [A].

Engine Oil

Grade: API SE, SF or SG

API SH or SJ with JASO MA

Viscosity:

Amount:

SAE 10W-40

4.0 L (4.2 US qt, with or without the filter)

5.0 L (5.3 US qt, when engine is completely
dry)

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Depending on the atmospheric temperature of your riding

○

area, the engine oil viscosity should be changed accord­ing to the chart s hown.

Install the filler cap.

•

Torque - Oil Filler Cap: 1.0 N·m (0.10 kgf·m, 8.7 in·lb)

Check the oil level (see Engine Lubrication System chap-

•

ter).

Oil Filter Replace

Remove:

•

Seat (see Hull/Engine Hood chapter)

Drain the engine oil (see Engine Oil Change).

•

Place a reg or cloth under the oil filter to receive the re-

•

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

•

Special Tool - Oil Filter Wrench: 57001-1249

Replace the filter with a new one.

•

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 kg f·m, 13 ft·lb)

Pour in the specified type and amount of oil (see Engine

•

Oil Change).

Periodic Maintenance Procedures

Engine Top End

Air Suction Valve Inspection

Remove the air suction valve (see Engine Top End chap-

•

ter).

Visually inspect the reeds [A] for cracks, folds, warps,

•

heat damage, or other damage.

If there is any doubt as to the condition of the reed, replace

the a ir suction valve as an assembly.

Check the reed contact areas [B] of the valve holder for

•

grooves, scratches, any signs of separation from the

holder, or heat damage.

If there is any doubt as to the condition of the reed contact

areas, replace the air suction valve as an assembly.

If any carbon or other foreign particles have accumulated

between the reed and the reed contact area, wash the

valve assembly with a high-flash point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this

could damage the rubber, requiring replacement of

the suction valve assembly.

PERIODIC MAINTENANCE 2-15

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (at room temperature).

Remove:

•

Seat (see Hull/Engine Hood chapter)
Cylinder Head Cover (see Engine Top End chapter)

Position the crankshaft at #1, #4 piston TDC as follows.

•

Using the shaft wrench [A], turn the crankshaft counter-

○

clockwise [B] and set the crankshaft at #1, 4 piston TDC.

Special Tool - Shaft Wrench: 57001-1551

The timing marks [A] must be aligned with the cylinder

○

head upper surface [B] as shown.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Measure the valve clearance between the cam and the

•

valve lifter with a thickness gauge [A].

Valve Clearance

Standard:

IN

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

EX

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

When positioning #1 piston TDC at the end of the

○

compression stroke:

Inlet Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [
Bow [A]
Camshaft Sprocket Position [B]

]

•

When positioning #4 piston TDC at the end of the

○

compression stroke:

Inlet Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [
Bow [A]
Camshaft Sprocket Position [B]

If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.

To change the valve clearance, remove the camshaft

•

chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.

Mark and record the valve lifter and shim locations so

○

they can be reinstalled in their original positions.
If there is no clearance, select a shim which is several

○

sizes smaller and then measure the clearance.

To select a new shim which brings the valve clearance

•

within the specified range, refer to the Valve Clearance
Adjustment Charts.

]

•

NOTE

Periodic Maintenance Procedures

INLET VALVE CLEARANCE ADJUSTMENT CH ART

PERIODIC MAINTENANCE 2-17

1. Measure the clearance (when engine is cold).

2. Check present shim size.

3. Match clearance in vertical column with present shim
size in horizontal column.

4. Install the shim specified where the lines intersect.
This shim will give the proper clearance.

Example

Present sh im is 2.60 mm.
Measured clearance is 0.35 mm.
Replace 2.60 mm shim with 2.75 mm shim.

5. Remeasure the valve clearance and readjust if nec­essary.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

EXHAUST VALVE CLEARANCE ADJUSTMENT CHART

1. Measure the clearance (when engine is cold).

2. Check present shim size.

3. Match clearance in vertical column with present shim
size in horizontal column.

4. Install the shim specified where the lines intersect.
This shim will give the proper clearance.

Example

Present sh im is 2.65 mm.
Measured clearance is 0.42 mm.
Replace 2.65 mm shim with 2.80 mm shim .

5. Remeasure the valve clearance and readjust if nec­essary.

Periodic Maintenance Procedures

Apply molybdenum disulfide oil to the valve lifters and ap-

•

ply engine oil to the shims, and install them.
Install the camshafts. Be sure to install the camshafts

•

properly (see Engine Top End chapter).
Remeasure any valve clearance that was adjusted.

•

Readjust if necessary.

•

CAUTION

Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex­tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.

Engine Mounting Bolts Inspection and Tightness

Check the tightness of the engine mounting bolts [A].

•

If there are loose bolts, remove the bolts.
Apply a non-permanent locking agent to the engine

•

mounting bolts and tighten them.

Torque - Engine Mounting Bolts: 36 N·m (3.7 kgf·m, 27 ft·lb)

PERIODIC MAINTENANCE 2-19

Engine Bottom End

Coupling Damper Inspection

Remove:

•

Seat (see Hull/Engine Hood chapter)
Engine (see Engine Removal/Installation chapter)

Remove the coupling damper [A] and inspect it for wear

•

[B] and deterioration.
If it is grooved or misshapen, replace it with a new damper.
If there is any doubt as to coupler condition, replace it.

Cooling and Bilge Systems

Cooling System Flushing

To prevent sand or salt deposits from accumulating in the
cooling system, it must be flushed occasionally. Flush the
system according to the Periodic Maintenance Chart, after
each use in salt water, or whenever there is reduced water
flow from the bypass outlet on the right side of the hull.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Obtain a standard garden hose [A] and a garden hose

•

adapter [B] as shown.

Garden Hose Fitting of Adapter [C]
Flushing Fitting of Adapter [D]
Thread: Rp 3/4 [E]

NOTE

Optional part (P/No. 92005-3746) is available as a gar-

○

den 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] o nto the flushing fitting

•

[B].
Attach a garden hose [C] to a garden hose adapter and

•

secure the hose clamp [D].

Start the engine and allow it to idle before turning on the

•

water.

CAUTION

The engine must be running before the water is
turned on or water may flow back through the
exhaust pipe into the engine, resulting in the pos­sibility of severe internal damage.

Immediately turn on the water and adjust the flow so that

•

a little trickle of water comes out of the bypass outlet [A]
on the right side of the hull.

Periodic Maintenance Procedures

Leave the engine idle for several minutes with the water

•

running.

Turn off the water. Leave the engine idling.

•

Rev the engine a few times to clear the water out of the

•

exhaust system.

CAUTION

Do not run the engine without cooling water supply

for more than 15 seconds, especially in high revolu-

tionary speed or severe engine and exhaust system

damage will occur.

Switch off the engine, remove the garden hose and the

•

adapter.

Install the flushing cap securely.

•

Bilge System Flushing

To prevent clogging, the bilge system should be flushed
out according to the Periodic Maintenance Chart, or when­ever you suspect it is blocked.

Disconnect both bilge hoses [A] at the plastic breather

•

fitting [B].

PERIODIC MAINTENANCE 2-21

Connect the bilge filter hoses (from the hull bottom) to the

•

garden hoses, turn the water on, and flush it out for about

a minute. During this procedure, water will flow into the

engine compartment. Do not allow a large amount of wa-

ter to accumulate in the engine compartment. Remove

the drain screws in the stern to drain the engine compart-

ment.

Connect the other hoses (from the hull bulkhead) to the

•

garden hose, turn the water on, and flush it out for several

minutes.

Before reconnecting the hoses to the plastic breather fit-

•

ting make sure the small hole [A], on top of the breather

fitting is clear.

Reconnect the bilge hoses.

•

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Pump and Impeller

Impeller Inspection

Examine the impeller. [A]

•

If there is pitting, deep scratches, nicks or other damage,
replace the impeller.

NOTE

Minor nicks and gouges in the impeller blades can be

○

removed with abrasive paper or careful filing. Smooth
leading edges are especially important to avoid cavita­tion.

Steering

Steering Cable/Shift Cable Inspection

Examine the steering cable or shift cable.

•

If each cables or cable housings are kinked or frayed,
replace the cables.
If the each seal [A] at either end of each cable is damaged
in any way, replace the cables.

Be certain that each cable moves freely in both directions.

•

Disconnect the cable joints at each end of each cable.

•

Take out the cable joint bolt or ball joint and disconnect

○

the cable joint.

CAUTION

Never lay the watercraft on the right side. Water in
the exhaust system may drain back into the engine
causing serious damage.

Slide the inner cable back [A] and forth [B] in each cable

○

housings.
If each cable does not move freely, replace it.

Handlebar Pivot Lubrication

Check the bushings for damage and wear.

•

If the bushings are damaged or worn, replace them.
Grease:

•

Bushings [A]

Periodic Maintenance Procedures

Steering Shaft [B]

Hull/Engine Hood

Drain Plug Inspection

Check the drain plugs [A] for cracks or damage and the

•

drain plug mounting screws [B] are tightened securely.

Check the seals [C] for damage.

•

If necessary, replace the drain plugs or seals.

PERIODIC MAINTENANCE 2-23

Electrical System

Battery Charging Co ndition Inspection

Battery charging condition can be checked by measuring
battery terminal voltage.

Disconnect the battery terminal leads (see Battery Re-

•

moval in Electrical System chapter).

CAUTION

Be sure to disconnect the negative terminal lead

first.

Measure the battery terminal voltage.

•

NOTE

Measure with a digital voltmeter [A] which c an be read

○

one decimal place voltage.

If the reading is below the specified, refreshing charge

is required (see Refreshing Charge in Electrical System

chapter).

Battery Terminal Voltage

Standard:

Connect the battery leads, positive first.

•

12.6 V or more

Battery Terminals Inspection

Check the battery terminal screws [A] for tightness and

•

make sure terminal covers are in place.

WARNING

Loose battery cables can create sparks which can

cause a fire or explosion resulting in injury or death.

Make sure the battery terminal screws are tightened

securely and the covers are installed over the termi-

nals.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check that the battery terminals [B] are not corroded.

•

If necessary, remove the battery (see Electrical System
chapter) and clean the terminals and cable ends using a
solution of baking soda and water.
After attaching both cables, coat the terminals and cable

•

ends with grease to prevent corrosion.
Install the battery (see Electrical System chapter).

•

Spark Plug C leaning and Inspection

Remove:

•

Seat (see Hull/Engine Hood chapter)
Spark Plug Caps

Remove the spark plugs using the 16 mm plug wrench

•

[A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1145

Clean the spark plug, preferably in a s andblasting device,

•

and then clean off any abrasive particles. The plug may
also be cleaned using a high-flash point solvent and a wire
brush or other tool.
If the spark plug center electrode [A] and/or side elec­trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug. Use the standard spark plug
or its equivalent.
Measure the gaps [D] with a wire-type thickness gauge.

•

If the gap is incorrect, carefully bend the side electrode
with a tool to obtain the correct gap.

Spark Plug Gap: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

Insertthesparkplugverticallyintotheplugholewiththe

•

spark plug installed in the plug wrench [A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1145

Tighten:

•

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 113 in·lb)

Lubrication

As in all marine craft, adequate lubrication and corrosion
protection is an absolute necessity to provide long, reliable
service. Refer to the Periodic Maintenance Chart for the
frequency of the following items:

Periodic Maintenance Procedures

Lubricate the following with grease.

•

Pull the throttle lever and hold it.

○

Throttle Cable End at Throttle Lever [A]

Throttle Cable End [A] at Throttle Body

PERIODIC MAINTENANCE 2-25

Remove the storage pocket (see Hull/Engine Hood chap-

○

ter).

Steering Cable Ball Joint [A] at Steering Shaft

Remove the storage pocket (see Hull/Engine Hood chap-

○

ter).

Shift Cable Ball Joint [A] at Reverse Lever

Shift Cable Ball Joint [A] at Reverse Bucket

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Lubricate the following with a penetrating rust inhibitor [B].

•

Throttle Cable [A]

Steering Nozzle Pivots [A]
Reverse Bucket Pivots [B]

With the cable disconnected at both ends, the cable

•

should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable

is frayed [B], or if the cable housing is kinked [C], replace

the cable.

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

All Hoses, Hose Clamps, Nuts, B olts and Fasteners Check

Nuts, Bolts, and Fasteners Tightness Inspection

Check the tightness of the bolts and nuts listed here. Also,

•

check to see that each cotter pin is in place and in good
condition.

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the spec­ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.

Nut, Bolt and Fastener to be checked

Engine:

Oil Filter Cartridge
Engine Mounting Bolts (and bracket bolts)
Engine Damper Mounting Bolts
Cylinder Head Cover Bolts
Cylinder Head Bolts

Drive Shaft, Pump, and Impeller:

Drive Shaft Holder Mounting Bolts
Pump Mounting Bolts
Pump Cover Mounting Bolts
Pump Grate Mounting Bolts
Steering Nozzle Pivot Bolts
Reverse Bucket Pivot Bolts

Steering:

Handlebar Clamp Bolts
Steering Neck Mounting Bolts
Steering Holder Mounting Bolts
Steering Shaft Locknut
Steering Cable Nut
Steering Cable Joint Bolt
Shift (reverse) Cable Nut

Hull and Engine Hood:

Stabilizer Mounting Bolts
Rear Grip Mounting Bolts

Electrical System:

Spark Plugs
Battery Terminal

Hose and Hose Connect Inspection

Check the following hoses for leakage [A], hardening,

•

cracking [B], checking, cuts, abrasions, breaks and
bulges [C]. And make sure the hoses are not kinked or
pinched.

Fuel Hoses
Fuel Vent Hose
Oil Hoses
Cooling Hoses

Bilge Hoses
If a hose is damaged in any way, replace it immediately
and check all the others for damage.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Make sure the above hoses are routed properly and se-

•

cured with the clamps away from any moving parts and
sharp edged portions.

Plastic Clamp [A]
Hose [B]
Hose Fitting [C]

NOTE

The majority of bilge hoses have no clamps at the hose

○

ends.

Metal Clamp [A]
Hose [B]
Hose Fitting [C]

NOTE

Check the fuel and exhaust tubes for signs of wear, de-

○

terioration, damage or leakage. Replace if necessary.
Make sure the above tubes are secured with the metal

○

gear clamps away from any parts.

JT1500-A2 ∼;

Double Spring Clamp [A]
Hose [B]
Hose Fitting [C]

NOTE

Check the fuel hoses for signs of wear, deterioration,

○

damage or leakage. Replace if necessary.
Make sure the above hoses are secured with the double

○

spring clamps away from any parts.

CAUTION

Do not reuse the double spring clamps on the fuel
line.
Reusing will cause fuel leakage.
Replace the double spring clamps with new ones.

Replacement procedure for the double spring clamp is as

•

follows.
Remove the double spring clamp with pliers and discon-

○

nect the fuel hose.
Install the fuel hose and insert the new double spring

○

clamp [A] with the clamp stopper [B].
Pull up the clamp stopper with pliers [C].

○

NOTE

Position the double spring clamp on the fuel hose cor-

○

rectly.

Periodic Maintenance Procedures

Rubber Strap Inspection

Check the following rubber straps for any deterioration or

•

damage. Pull on squeeze the straps and look for cracks.

Battery Straps [A]

Fuel Tank Straps

Water Box Muffler Straps
If a strap is damage in any way, replace it.

PERIODIC MAINTENANCE 2-29

Fuel System (DFI)

Table of Contents

Fuel System Diagram ........................ 3-3

Exploded View................................... 3-4

Specifications .................................... 3-10

Special Tools and Sealant ................. 3-12

DFI Parts Location............................. 3-13

DFI System........................................ 3-16

DFI Servicing Precautions ................. 3-19

Self-Diagnosis ................................... 3-22

Self-diagnosis Outline..................... 3-22

Service Code (Character) Table ..... 3-23

Troubleshooting the DFI System ....... 3-25

Throttle Sensor (Service

Code/Character-11/tPS) ................. 3-27

Throttle Sensor Removal/Adjust-

ment .......................................... 3-27

Input Voltage Inspection............... 3-28

Output Voltage Inspection............ 3-30

Resistance Inspection.................. 3-31

Inlet Air Pressure Sensor (Service

Code/Character-12/bOSt)............... 3-33

Inlet Air Pressure Sensor

Removal .................................... 3-33

Inlet Air Pressure Sensor

Installation ................................. 3-33

Input Voltage Inspection............... 3-33

Output Voltage Inspection............ 3-34

Inlet Air Temperature Sensor (Service

Code/Character-13/AIrt) ................. 3-36

Inlet Air Temperature

Removal/Installation.................. 3-36

Output Voltage Inspection............ 3-36

Sensor Resistance Inspection ..... 3-37

Water Temperature Sensor (Service

Code/Character-14/AqUt) ............... 3-39

Water Temperature Sensor

Removal/Installation.................. 3-39

Output Voltage Inspection............ 3-39

Sensor Resistance Inspection ..... 3-41

Crankshaft Sensor (Service

Code/Character-21/CrAg)............... 3-42

Crankshaft Sensor

Removal/Installation.................. 3-42

Crankshaft Sensor Inspection...... 3-42

Camshaft Position Sensor (Service

Code/Character-23/CAAg).............. 3-43

FUEL SYSTEM (DFI) 3-1

3

Camshaft Position Sensor

Removal/Installation.................. 3-43

Camshaft Position Sensor

Inspection .................................. 3-43

Vehicle-down Sensor (Service

Code/Character-31/dOS)................ 3-44

Vehicle-down Sensor Removal .... 3-44

Vehicle-down Sensor Installation . 3-44
Vehicle-down Sensor Inspection.. 3-45

Fuel Injectors (Service

Code/Character-41, 42, 43,

44/InJ1, InJ2, InJ3, InJ4) ................ 3-47

Fuel Injector Removal .................. 3-47

Fuel Injector Installation ............... 3-47

Audible Inspection........................ 3-48

Injector Signal Test....................... 3-48

Injector Resistance Inspection ..... 3-49

Injector Unit Test .......................... 3-49

Injector Voltage Inspection........... 3-50

Injector Fuel Line Inspection ........ 3-51

Ignition Coils (Service

Code/Character-51, 52/COL1,

COL2) ............................................. 3-53

Ignition Coil Removal/Installation. 3-53

Input Voltage Inspection............... 3-53

Engine Overheating (Service

Code/Character-71/HEAt)............... 3-55

Low Engine Oil Pressure (Service

Code/Character-72/OILP)............... 3-56

Oil Temperature Sensor (Service

Code/Character-73/OILC or

73/OILt)........................................... 3-57

Oil Temperature Sensor

Removal/Installation.................. 3-57

Output Voltage Inspection............ 3-57

Sensor Resistance Inspection ..... 3-58

Engine Oil Overheating (Service

Code/Character-76/OILH)............... 3-59

ECU................................................... 3-60

ECU Removal .............................. 3-60

ECU Installation ........................... 3-60

ECU Power Supply Inspection..... 3-60

DFI Power Source ............................. 3-63

Main Fuse Inspection................... 3-63

Relay Assembly Removal ............ 3-63

Relay Assembly Inspection.......... 3-63

3-2 FUEL SYSTEM (DFI)

Throttle Lever, Cable and Case......... 3-65

Free Play Inspection .................... 3-65

Throttle Cable Adjustment ........... 3-65

Throttle Case Removal/Disas-

sembly....................................... 3-65

Throttle Case Assembly/Installa-

tion ............................................ 3-66

Throttle Cable Removal ............... 3-67

Throttle Cable Installation ............ 3-68

Throttle Case and Cable

Lubrication................................. 3-69

Throttle Cable Inspection ............. 3-69

Air Filter ............................................. 3-70

Air Filter Removal ........................ 3-70

Air Filter Installation ..................... 3-70

Air Filter Disassembly .................. 3-71

Air Filter Assembly ....................... 3-71

Throttle Body Assy ............................ 3-72

Idle Speed Inspection .................. 3-72

High Altitude Performance

Adjustment ................................ 3-72

Throttle Body Assy Removal ........ 3-72

Throttle Body Assy Installation..... 3-72

Throttle Body Assy Disassembly . 3-72

Throttle Bore Cleaning ................. 3-72

ISC (Idle Speed Controller)

Removal/Installation.................. 3-73

ISC (Idle Speed Controller)

Inspection .................................. 3-73

ISC Resistance Inspection........... 3-74

Inlet Manifold ..................................... 3-75

Inlet Manifold Removal ................ 3-75

Inlet Manifold Installation ............. 3-76

Fuel Line............................................ 3-78

Fuel Pressure Inspection ............. 3-78

Fuel Flow Rate Inspection ........... 3-79

Fuel Vent Check Valve ...................... 3-81

Fuel Vent Check Valve Mounting . 3-81
Fuel Vent Check Valve Inspection 3-81

Fuel Filter........................................... 3-82

Fuel Filter Removal...................... 3-82

Fuel Filter Installation................... 3-83

Fuel Pump ......................................... 3-84

Fuel Pump Removal .................... 3-84

Fuel Pump Installation ................. 3-85

Power Source Voltage Inspection 3-85

Operating Voltage Inspection....... 3-86

Fuel Pump Relay Removal .......... 3-87

Fuel Pump Relay Inspection ........ 3-87

Fuel Tank ........................................... 3-88

Fuel Tank Removal ...................... 3-88

Fuel Tank Installation ................... 3-89

Fuel Tank Cleaning ...................... 3-89

Fuel Filler and Tube Removal ...... 3-90

Fuel Filler and Tube Installation ... 3-90

Fuel System Diagram

FUEL SYSTEM (DFI) 3-3

1. Fuel Pump

2. Clamps (JT1500-A1 Model)

Double Spring Clamps (JT1500-A2 Model ∼)

(Installation Procedure: Pull up the clamp stopper [A] with pliers [B].)

3. Main Line

4. Fuel Filter

5. Supply Line

6. Return Line

7. Delivery Pipe

8. Fuel Injectors

9. Fuel Tank

3-4 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

1 Vehicle-down Sensor Mounting Screws 1.5 0.15 13 in·lb

2 Bracket Mounting Bolts – – – L

3 Inlet Manifold Mounting Bolts 25 2.5 18 L

4 Inlet Manifold Mounting Nuts 20 2.0 14

5 Delivery Pipe Mounting Bolts 7.8 0.80 69 in·lb

6 Inlet Air Pressure Sensor Bolts 7.8 0.80 69 in·lb

7 Throttle Cable Holder Bolts 8.8 0.90 78 in·lb L

8 Inlet Air Temperature Sensor 20 2.0 14

9 Throttle Body Assy Mounting Bolts 20 2.0 14

10 Inlet Manifold Drain Plug 20 2.0 14

11 Inlet Manifold Plate Bolts 7.8 0.80 69 in·lb

12

Crankshaft Sensor Screws

13 Camshaft Position Sensor Bolt 7.8 0.80 69 in·lb L

14 Water Temperature Sensor 15 1.5 11 see text

15 Oil Temperature Sensor 15 1.5 11 see text

16 Regulator/rectifier Bolts 7.8 0.80 69 in·lb

17 ECU Mounting Bolts 8.8 0.90 78 in·lb L

18

Throttle Sensor Mounting Screws

19 ISC Actuator Mounting Bolts 4.9 0.50 43 in·lb

N·m kgf·m ft·lb

4.4 0.45 39 in·lb L

2.0 0.20 18 in·lb

Torque

Remarks

20. Ignition Coils

21. Fuel Injectors

22. Main Fuse 20 A

23. Relay Assembly (Main Relay/Fuel Pump Relay)
A: JT1500-A1 Model (Clamps)

B: JT1500-A2 Model ∼(Double Spring Clamps)

EO: Fill the hollow with the engine oil (10W-30).

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Fill the hollow with the specified silicone grease (Kawasaki Bond: 92137-1002).

SO: Apply silicone oil to the O-ring.

3-6 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1 Oil Pressure Switch 15 1.5 11 SS

2 Fuel Filler Tube Clamp Screws 2.9 0.30 26 in·lb

3

Fuel Level Sensor Clamp Screw

4 Fuel Filter Mounting Bolts 8.8 0.90 78 in·lb L

5. Meter Unit

6. Buzzer

7. Fuel Vent Check Valve

8. Fuel Level Sensor

9. Fuel F ilter

10. Fuel Pump
A: JT1500-A1 Model

B: JT1500-A2 Model ∼

L: Apply a non-permanent locking agent.

R: Replacement Parts

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

N·m kgf·m ft·lb

2.9 0.30 26 in·lb

Torque

Remarks

3-8 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-9

No. Fastener

1 Air Filter Mounting Bolts 9.8 1.0 87 in·lb

2 Air Filter Bracket Mounting Bolts 7.8 0.80 69 in·lb L

3

Throttle Cable Locknut

4 Throttle Case Mounting Screws 3.9 0.40 34 in·lb

G: Apply grease.

L: Apply a non-permanent locking agent.

N·m kgf·m ft·lb

7.8 0.80 69 in·lb

Torque

Remarks

3-10 FUEL SYSTEM (DFI)

Specifications

Item Standard

Digital Fuel Injection System

Idle Speed 1 300 ±100 r/min (rpm) -both in and out of water

Throttle Assy:

Type

Bore 60 mm (2.36 i n.)

ECU (Electronic Control Unit):

Make Mitsubishi Electric

Type

Operating range Engine speed range 100 ∼ 8 100 r/min (rpm)

Fuel Pressure (High Pressure Line):

Engine Idling approx. 294 kPa (3.0 kgf/cm², 43 psi)

Fuel Pump:

Type Impeller type

Discharge 67 mL or more for 3 seconds

Throttle Sensor:

Input Voltage 4.75 ∼ 5.25 V DC between R and BK/W leads
Output Voltage 1.08 ∼ 1.18 V DC between G/W and BK/W leads (at idle

Resistance 4 ∼ 6kΩ

Inlet Air Pressure Sensor:

Input Voltage 4.75 ∼ 5.25 V DC between R and BK/W leads
Output Voltage 3.75 ∼ 4.25 V DC between G/R and BK/W leads at standard

Inlet Air Temperature Sensor:

Output Voltage at ECU about 2.3 ∼ 2.6 V @20°C (68°F)
Resistance 5.4 ∼ 6.6 kΩ at 0°C (32°F)

Water Temperature Sensor:

Resistance see Electrical System chapter

Output Voltage at ECU about 3 ∼ 4 V @20°C (68°F)

Vehicle-down Sensor:

Detection Method

Detection A

Output Voltage

Fuel Injectors:

Type INP-281

Nozzle Type One spray type with 4 holes

Resistance about 11.7 ∼ 12.3 Ω at 20°C (68°F)

Oil Temperature Sensor:

Resistance same to water temperature sensor

Output Voltage at ECU about 3 ∼ 4 V @20°C (68°F)

ngle

Single type

Digital memory type, with built in IC igniter, sealed with
resin

throttle opening)

atmospheric pressure

2.26 ∼ 2.86 kΩ at 20°C (68°F)

0.29 ∼ 0.39 kΩ at 80°C (176°F)

Magnetic flux detection method

more than 110 ∼ 130° for each bank
with sensor tilted 110 ∼ 130° or more: 0.65∼ 1.35 V

with sensor arrow mark pointed up: 3.55 ∼ 4.45 V

Specifications

Item Standard

Throttle Lever and Cables

Throttle Lever Free Play about 2 mm (0.08 in.)

FUEL SYSTEM (DFI) 3-11

3-12 FUEL SYSTEM (DFI)

Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm²:
57001-125

Hand Tester:
57001-1394

Needle Adapter Set:
57001-1457

Sensor Harness Adapter:
57001-1561

Harness Adapter:
57001-1562

Kawasaki Bond (Silicone Sealant):
56019-120

Fuel Pressure Gauge Adapter:
57001-1463

Throttle Sensor Setting Adapter:
57001-1521

Kawasaki Bond (Silicone Grease):
92137-1002

DFI Parts Location

1. Fuel Injector #1

2. Fuel Injector #2

3. Fuel Injector #3

4. Fuel Injector #4

5. Inlet Air Pressure Sensor

6. Inlet Air Temperature Sensor

7. Throttle Sensor

8. ISC (Idle Speed Controller)

9. Camshaft Position Sensor

10. Water Temperature Sensor

11. Crankshaft Sensor

12. Oil Pressure Switch

13. Oil Temperature Sensor

FUEL SYSTEM (DFI) 3-13

3-14 FUEL SYSTEM (DFI)

DFI Parts Location

14. Ignition Switch

15. Meter Unit

16. Buzzer

17. Fuel Pump

18. Fuel Level Sensor

19. Vehicle-down Sensor

20. Ignition Coil #1, #4

21. Ignition Coil #2, #3

22. Main Fuse 20 A

23. ECU (Electronic Control Unit)

24. Diagnosis Connector

25. Relay Assembly (Main Relay/Fuel Pump Relay)

26. Battery

DFI Parts Location

Dummy Page

FUEL SYSTEM (DFI) 3-15

3-16 FUEL SYSTEM (DFI)

DFI System

DFI System Wiring Diagram

DFI System

Part Name

1. Fuel Injector #1

2. Fuel Injector #2

3. Fuel Injector #3

4. Fuel Injector #4

5. Joint Connector H

6. Inlet Air Temperature Sensor

7. Inlet Air Pressure Sensor

8. Joint Connector E

9. Joint Connector J

10. Crankshaft Sensor

11. Relay Assembly (Main Relay/Fuel P ump Relay)

12. Joint Connector F

13. Connector C

14. Vehicle-down Sensor

15. Meter Unit (Diagnosis Signal)

16. Ignition Switch

17. Joint Connector Q

18. Start Switch

19. Joint Connector R

20. Main Fuse 20 A

21. Starter Motor

22. Battery

23. ECU (Electronic Control Unit)

24. Oil Pressure Switch

25. Camshaft Position Sensor

26. ISC (Idle Speed Controller)

27. Diagnosis Connector

28. Throttle Sensor

29. Water Temperature Sensor

30. Oil Temperature Sensor

31. Connector D

32. Ignition Coils

33. Joint Connector P

34. Fuel Pump

35. Joint Connector S

FUEL SYSTEM (DFI) 3-17

3-18 FUEL SYSTEM (DFI)

DFI System

Terminal Numbers of ECU Connectors

Terminal Names

1. Tachometer Signal

2. ECU Main Relay

3. Unused

4. SLO (Smart Learning Operation) Mode (JT1500-A2

Model ∼)

5. Oil Pressure Switch

6. Engine Stop Switch

7. Inlet Air Temperature Sensor

8. Ground for Sensors

9. Ignition Switch

10. Steering Position Sensor

11. Unused

12. Power Supply to Sensors

13. Cam Sensor (+) Signal

14. Cam Sensor (–) Signal

15. Crankshaft Sensor

16. Unused

17. Fuel Pump Relay

18. ISC (Idle Speed Controller)

19. ISC (Idle Speed Controller)

20. ISC (Idle Speed Controller)

21. ISC (Idle Speed Controller)

22. Ignition Coil #1,#4

23. Unused

24. Ground for External Diagnosis
System

25. Ground for Control System

26. External Diagnosis System
Signal

27. Diagnosis Signal

28. Start Button

29. Vehicle-down Sensor

30. Power Supply to ECU
(from Battery)

31. Unused

32. Ground for Control System

33. Inlet Air Pressure Sensor

34. Throttle Sensor

35. Water Temperature Sensor

36. External Diagnosis System
Signal

37. Oil Temperature Sensor

38. Injector #2

39. Injector #3

40. Injector #4

41. Ground for Power System

42. Ground for Power System

43. Injector #1

44. Ignition Coil #2,#3

DFI Servicing Precautions

There are a number of important precautions that should

be followed servicing the DFI system.

This DFI system is designed to be used with a 12 V sealed

○

battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
Do not reverse the battery cable connections. This will

○

damage the ECU.
To prevent damage to the DFI parts, do not disconnect the

○

battery cables or any other electrical connections when
the ignition switch is on, or while the engine is running.
Take care not to short the leads that are directly con-

○

nected to the battery positive (+) terminal to the engine
ground.
When charging, remove the battery from the vehicle. This

○

is to prevent ECU damage by excessive voltage.
Whenever the DFI electrical connections are to be discon-

○

nected, first turn off the ignition switch. Conversely, make
sure that all the DFI electrical connections are firmly re­connected before s tarting the engine.
Do not turn the ignition switch ON while any of the DFI

○

electrical connectors are disconnected. The ECU memo­rizes service codes.
If a transceiver is installed on the vehicle, make sure that

○

the operation of the DFI system is not influenced by elec­tric wave radiated from the antenna. Check operation of
the system with the engine at idle. Locate the antenna as
far as possible away from the ECU.
When any fuel hose is disconnected, do not turn on the

○

ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
Do not operate the fuel pump if the pump is completely

○

dry. This is to prevent pump seizure.
Before removing the fuel system parts, blow the outer sur-

○

faces of these parts clean with compressed air.
When any fuel hose is disconnected, fuel may spout out

○

by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
When installing the fuel hoses, avoid sharp bending, kink-

○

ing, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be ob­structed.
Route the hoses according to Cable, Wire, and Hose

○

Routing section in the Appendix chapter.

FUEL SYSTEM (DFI) 3-19

Install the hose clamps in the position shown, and se-

○

curely tighten the clamp bolts. Check the fuel system for
leaks after hose installation.

Fuel Hose [A]
Clamp [B]
Fuel Pipe [C]

3-20 FUEL SYSTEM (DFI)

DFI Servicing Precautions

For JT1500-A2 ∼;

Install the double spring clamp in the position as shown,

○

and securely pull up the clamp stopper with pliers. Check
the fuel system for leaks after hose installation.

Fuel Hose [B]
Double Spring Clamp [A]
Fuel Pipe [C]

CAUTION

Do not reuse the double spring clamps on the fuel
line. Reusing will cause fuel leakage.
Replace the double spring clamps with new ones.

Replace the fuel hose if it has been sharply bent or kinked.

○

The high pressure inside the fuel line can cause fuel to

○

leak [A] or the hose to burst. Bend and twist the fuel hose
while examining it.
Replace the hose if any cracks [B] or bulges [C] are no-

○

ticed.

When checking the DFI parts, do not run the engine for

○

15 seconds or more without auxiliary cooling (see General
Information chapter).

CAUTION

If running the engine without the auxiliary cooling
for 15 seconds or more (even at idle speed), the rub­ber component relative to the Exhaust System may
be damaged.

Execute the auxiliary cooling securely in case that fre-

○

quent engine running is required.

When checking the DFI parts, use a digital meter which

•

can be read two decimal place voltage or resistance.
The DFI part connectors have seals, including the ECU.

○

When measuring the input or output voltage with the
connector joined, use the needle adapter set. Insert the
needle adapter inside the seal until the needle adapter
reaches the terminal.

Digital Meter [A]

Special Tool - Needle Adapter Set: 57001-1457

CAUTION

Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.

DFI Servicing Precautions

After measurement, remove the needle adapters and ap-

○

ply silicone sealant to the seals [A] of the connector [B]
for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120) -Seals
of Connector

Always check battery condition before replacing the DFI

•

parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.
Do not directly connect a 12 V battery to a fuel injector.

•

Insert a resistor (5 ∼ 7 Ω) or a bulb (12 V, 3 ∼ 3.4 W) in

series between the battery and the injector.

FUEL SYSTEM (DFI) 3-21

3-22 FUEL SYSTEM (DFI)

Self-Diagnosis

Self-diagnosis Outline

The self-diagnosis system has two modes and can be

switched to another mode.

Pushthe“SET”buttonwith“MODE”buttonatthe

[A]

same time for 3 seconds or more.

Push either “SET” or “MODE” button for more than

[B]

one second or more.

User Mode

This is a standard mode and enters automatically after
ignition switch ON. The ECU notifies the rider of troubles
in DFI system and ignition system by flashing LED warn­ing light [A], the FI indicator [B] and “FI” character [C] when
DFI system and ignition system parts are faulty, and initiates
fail-safe function. The buzzer sound goes on. In case of se­rious troubles ECU stops the injection/ignition/starter motor
operation. The buzzer sound can be stopped by pushing
either “SET” or “MODE” button.

Dealer Mode

The LCD in the meter unit displays service code charac­ter [A] to show the problem(s) which the DFI system and
ignition system has at the moment of diagnosis.

To enter the dealer mode push the “SET” button [B] with

•

“MODE” button [C] for 3 seconds or more.

Read the service code character in the LCD display. Re-

•

fer to the “Service Code (Character) Table” in the following

section.

To return the user mode push either “SET” or “MODE”

•

button for one second or more.

The service code character(s) will not be shown on the

•

LCD in the meter unit after the problems are solved.

Self-Diagnosis

Service Code (Character) Table

FUEL SYSTEM (DFI) 3-23

Service

Code

(used in

ECU)

11

12

13

14

21

23

31

41

42

43

44

51

52

71 Engine overheat

72 Engine oil pressure too low

73

Service Code

Character

(displayed on

Meter Unit)

(JT1500-A1)

(JT1500-A2 ∼)

Possible Problems Fail-Safe Function

Throttle sensor malfunction,
wiring open or short

Inlet air pressure sensor
malfunction, wiring open or short

Inlet air temperature sensor
malfunction, wiring open or short

Water temperature sensor
malfunction, wiring open or short

Crankshaft s ensor malfunction,
wiring open or short

Camshaft position sensor
malfunction, wiring open or short

Vehicle-down sensor
malfunction, wiring open or
short

Injector #1 malfunction, wiring
open or short

Injector #2 malfunction, wiring
open or short

Injector #3 malfunction, wiring
open or short

Injector #4 malfunction, wiring
open or short

Ignition coil #1, #4 malfunction,
wiring open or short

Ignition coil #2, #3 malfunction,
wiring open or short

Oil temperature sensor
malfunction, wiring open or
short

The ECU locks ignition timing into
the ignition timing at closed throttle
position and sets the DFI in the D-J
method (see Note 1).

The ECU sets the DFI in the α-N
method (see Note 2).

The ECU sets the inlet air temperature
at 40°C.

The ECU sets the water temperature
at 70°C.

–

The ECU continues to ignite cylinders
in the same sequence following the
last good signal.

The ECU slows down the engine
speed less than 3 000 r/min (rpm) by
stopping the ignition.

–

–

–

–

The ECU shuts off the injectors #1/#4
to stop fuel to the cylinders #1/#4.

The ECU shuts off the injectors #2/#3
to stop fuel to the cylinders #2/#3.

The ECU slows down the engine
speed less than 3 000 r/min (rpm) by
stopping the ignition.

The ECU slows down the engine
speed less than 3 000 r/min (rpm) by
stopping the ignition.

The ECU sets the oil temperature at
60°C.
The ECU slows down the engine
speed less than 3 000 r/min (rpm) by
stopping the ignition.

76

(JT1500-A2 ∼)

Engine oil overheat

The ECU slows down the engine
speed less than 3 000 r/min (rpm) by
stopping the ignition.

3-24 FUEL SYSTEM (DFI)

Self-Diagnosis

Note:

(1) D-J Method: the DFI control method from medium to heavy engine load. When the engine load

is light like at idling or low speed, the E CU determines the injection quantity by calculating from
the throttle vacuum (vacuum sensor output voltage) and engine speed (crankshaft sensor output
voltage).

(2) α-N Method: As the engine speed increases, and the engine load turns middle to heavy, the ECU

determines the injection quantity by calculating from the throttle opening (throttle sensor output
voltage) and the engine speed.

(3) If both throttle sensor system and inlet air pressure fails, the ECU locks ignition timing into the

ignition timing at closed throttle position and sets the DFI in the α-N method.

(4) The ECU may be involved in these problems. If all the parts and circuits checked out good, be

sure to check the ECU for ground and power supply. If the ground and power supply are checked
good, replace the ECU.

Memory of Service Code (Character)

The service codes (characters) in the past are stored in the ECU. However, the characters cannot be
displayed in the meter. The past service codes can be confirmed by using the Kawasaki Diagnostic
System (see General Information chapter), and they can be erased.

FUEL SYSTEM (DFI) 3-25

Troubleshooting the DFI System

Sample Diagnosis Sheet

Rider name:

Model: Engine No.: Hull No.:

Date problem occurred: Mileage:

Weather
Temperature □ hot, □ warm, □ cold, □ very cold, □ always

Problem
frequency

Altitude □ normal, □ high (about 1 000 m or more)

Warning
LED light, FI
character, FI
mark

Starting
difficulty

Registration No. (license plate No.): Year of initial registration:

Environment when problem occurred.

□

fine, □ cloudy, □ rain, □ snow, □ always, □ other:

□ chronic, □ often, □ once

Watercraft conditions when problem occurred.

□ turn on immediately after ignition switch ON, and turn off after 1 ∼ 2 seconds

(normal).

□ lights blink after ignition switch ON, and stay on (DFI problem)
□ unlights (LED light, meter unit, ECU or its wiring fault).
□

sometimes lights up (probably wiring fault).

□ starter motor not rotating.
□ starter motor rotating but engine doesn’t turn over.
□ starter motor and engine don’t turn over.
□

no fuel flow (□ no fuel in tank, □ no fuel pump sound).

□

engine flooded (do not crank engine with throttle opened, which promotes
engine flooding).

□ no spark.
□ other:
□ right after starting.

Engine stalls

□ when opening throttle lever.
□ when closing throttle lever.
□

when moving off.

□

when stopping the watercraft.

□ when cruising.
□ other:

Poor running at
low speed

□ very low idle speed, □ very high idle speed, □ rough idle speed.
□ battery voltage is low (charge the battery).
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ backfiring.
□

afterfiring.

□ hesitation when acceleration.
□ engine oil viscosity too high.
□ engine overheating.
□ other:

3-26 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Poor running
or no power at
high speed

□ spark plug loose (tighten it).
□

spark plug dirty, broken, or gap maladjusted (remedy it).

□ spark plug incorrect (replace it).
□ knocking (fuel poor quality or incorrect).
□ engine overheating.
□ engine oil level too high.
□ engine oil viscosity too high.
□ other:

Throttle Sensor (Service Code/Character-11/tPS)

Throttle Sensor Removal/Adjustment

CAUTION

Never drop the throttle sensor [A], especially on a
hard surface. Such a shock to the sensor can dam­age it.

Remove:

•

Seat (see Hull/Engine Hood chapter)
Air filter (see air Filter Removal)

Use a Torx wrench [A] (T20, B = 3.86 mm (0.152 in.)) to

•

remove the throttle sensor mounting screws [C].

NOTE

In the engine compartment, there is not enough space

○

between the throttle sensor and hull to remove the Torx
screws. S o use an L shape Torx wrench.

FUEL SYSTEM (DFI) 3-27

When installing the throttle sensor, note the following (In

•

the photo, the throttle sensor has been removed from the
throttle body for clarity).

Align [A] the projections [B] on the throttle sensor with the

○

throttle shaft [C] as shown when putting the throttle sensor
to the throttle body.

Turn the throttle sensor counterclockwise [A] a little and

○

temporarily tighten the throttle sensor mounting screws.

3-28 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code/Character-11/tPS)

Adjust the throttle sensor positioning as follows.

•

Install the air filter temporarily.

○

After warming up the engine, check the idling speed.

○

Idle Speed

Standard: 1 300 ±100 r/min (rpm)

Stop the engine and turn the ignition switch OFF.

○

Disconnect the throttle sensor connector and connect the

○

throttle sensor setting adapter [A] between the harness
connector and throttle sensor connector.
Connect a digital meter to the sensor setting adapter

○

leads.

Special Tool - Throttle Sensor Setting Adapter: 57001

-1521

Throttle Sensor Output Voltage

Connections to Sensor

Meter (+)→ G/W lead
Meter (–)→ BK/W lead

Start the engine with idle speed.

○

Turn [A] the throttle sensor and bring the sensor output

○

voltage within the standard range.

Output Voltage at Sensor

Standard: 1.08 ∼ 1.18 V DC (at id le throttle op ening)

Tighten the throttle sensor mounting screws.

○

Torque - Throttle Sensor Mounting Screws: 2.0 N·m (0.20

kgm·f, 18 in·lb)

Recheck the sensor output voltage is within the standard

○

range.
Stop the engine and turn the ignition switch OFF.

○

Remove the setting adapter and reconnect the throttle

○

sensor connector.

Input Voltage Inspection

NOTE

Be sure the battery is fully charged.

○

Turn the ignition switch OFF.

•

Remove the ECU (see ECU Removal). Do not disconnect

•

the ECU connector.

Connect a digital voltmeter [A] to the connector [B], using

•

the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

Throttle Sensor Input Voltage

Connections to ECU

Meter (+)→ R lead (terminal 12)

Meter (–)→ BK/W lead ( terminal 8)

Throttle Sensor (Service Code/Character-11/tPS)

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor input voltage.
Wait 15 seconds before using the starter again.

○

Input Voltage at ECU

Standard: 4.75 ∼ 5.25 V DC

Turn the ignition switch OFF.

•

If the reading of input voltage is less than the standard,
check the ECU for its ground, power supply and wiring
shorted. If the ground, power supply and wiring are good,
replace the ECU.
If the input voltage is within the standard range, check the
input voltage at the throttle sensor connector.
Remove the air filter temporarily (see Air Filter Removal).

•

Disconnect the throttle sensor connector and connect the

•

setting adapter [A] between the harness connector and
throttle sensor connector.
Connect a digital meter to the setting adapter leads.

•

Special Tool - Throttle Sensor Setting Adapter: 57001

-1521

FUEL SYSTEM (DFI) 3-29

Throttle Sensor Input Voltage

Connections to Sensor

Meter (+)→ Rlead

Meter (–)→ BK/W lead

Install the air filter.

•

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor input voltage.
Wait 15 seconds before using the starter again.

○

Input Voltage at Sensor

Standard: 4.75 ∼ 5.25 V DC

Turn the ignition switch OFF.

•

If the reading is out of the range, check the wiring (see
wiring diagram in this section).
If the reading is good, check the output voltage of the
sensor.

3-30 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code/Character-11/tPS)

Output Voltage Inspection

Measure the output voltage at the ECU in the same way

•

as input voltage inspection. Note the following.

Digital Voltmeter [A]
Connector [B]

Special Tool - Needle Adapter Set: 57001-1457

Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → G/W lead (terminal 34)

Meter (–) → BK/W lead (terminal 8)

Start the engine.

•

Check idle speed to ensure throttle opening is correct.

•

Idle Speed

Standard: 1 300 ±100 r/min (rpm)

Measure the sensor output voltage with the idle speed.

•

Output Voltage at ECU

Standard: 1.08 ∼ 1.18 V DC (at idle throttle opening)

CAUTION

Never drop the throttle sensor can especially on a
hard surface. A shock to the sensor can damage it.

If the output voltage is within the standard range, check
the ECU for a good ground, and power supply (see ECU
Power Supply Inspection). If the ground and power sup­ply are good, replace the ECU.
If the output voltage is far out of the standard range (e.g.
when the wiring is open, the reading is 0 V), check the
output voltage at the sensor connector.

Throttle Sensor (Service Code/Character-11/tPS)

Disconnect the throttle sensor connector and connect the

•

setting adapter [A] between the harness connector and
throttle sensor connector.
Connect a digital meter to the setting adapter leads.

•

Special Tool - Throttle Sensor Setting Adapter: 57001

-1521

Throttle Sensor Output Voltage

Connections to Sensor

Meter (+) → G/W lead

Meter (–) → BK/W lead

Measure the sensor output voltage with the idle speed.

•

Output Voltage at Sensor

Standard: 1.08 ∼ 1.18 V DC (at idle throttle opening)

CAUTION

Never drop the throttle sensor, especially on a hard
surface. A shock to the sensor can damage it.

FUEL SYSTEM (DFI) 3-31

After throttle sensor voltage inspection, remove the set-

•

ting adapter.
If the reading is out of the standard range, inspect the
throttle sensor resistance.
If the output voltage is normal, check the wiring for conti­nuity (see next diagram).

Resistance Inspection

Turn the ignition switch OFF.

•

Remove:

•

Air Filter (see Air Filter Removal)

Disconnect the throttle sensor connector and connect the

•

setting adapter [A] to the throttle sensor [B].

Special Tool - Throttle Sensor Setting Adapter: 57001

-1521

Do not connect the harness connector.

○

Connect a digital meter [C] to the harness adapter leads.

•

Measure the throttle s ensor resistance.

•

Throttle Sensor Resistance

Connections to

Harness Adapter: R lead [D] ←→ BK/BLlead[E]

Standard: 4 ∼ 6kΩ

If the reading is out of the range, replace the throttle body
assy.
If the reading is within the range, but the problem still
exists, replace the ECU.

3-32 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code/Character-11/tPS)

1. ECU

2. Joint Connector E

3. Throttle Sensor

FUEL SYSTEM (DFI) 3-33

Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)

CAUTION

Never drop the sensor, especially on a hard surface.
Such a shock to the part can damage it.

Inlet Air Pressure Sensor Removal

Turn the ignition switch off.

•

Remove:

•

Seat (see Hull/Engine Hood chapter)
Inlet Air Pressure Sensor Bolts [A]
Inlet Air Pressure Sensor Connector [B]
Inlet Air Pressure Sensor [C]

Inlet Air Pressure Sensor Installation

Apply silicone oil to the O-ring [A].

•

CAUTION

Do not apply silicone oil to the sensor end (sensing
part) [B] and the inside [C] of the sensor connector.

Tighten:

•

Torque - Inlet Air Pressure Sensor Bolts: 7.8 N·m (0.80

kgf·m, 69 in·lb)

Input Voltage Inspection

NOTE

Be sure the battery is fully charged.

○

The inspection is the same as “Input Voltage Inspection”

○

of the throttle sensor.

Turn the ignition switch OFF.

•

Remove the ECU (see ECU Removal). Do not disconnect

•

the ECU connector.

Connect a digital voltmeter [A] to the connector [B], with

•

the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

Inlet Air Pressure Sensor Input Voltage

Connections to ECU

Meter (+)→ R lead (terminal 12)

Meter (–) → BK/W lead (terminal 8)

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor input voltage.
Wait 15 seconds before using the starter again.

○

Input Voltage at ECU

Standard: 4.75 ∼ 5.25 V DC

Turn the ignition switch OFF.

•

If the reading is less than the standard, check the ECU for
its ground, power supply and wiring. If the ground, power
supply and wiring are good, replace the ECU.

3-34 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)

If the reading is within the standard range, and check the
input voltage at the sensor connector.
Disconnect the inlet air pressure sensor connector and

•

connect the harness adapter [A] between the harness
connector and inlet air pressure sensor connector.
Connect a digital meter to the harness adapter leads.

•

[B] Inlet Air Pressure Sensor

Special Tool - Sensor Harness Adapter: 57001-1561

Inlet Air Pressure Sensor Input Voltage

Connections to Sensor

Meter (+) → Rlead[C]

Meter (–) → BK/W lead [D]

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor input voltage.
Wait 15 seconds before using the starter again.

○

Input Voltage at Sensor Connector

Standard: 4.75 ∼ 5.25 V DC

Turn the ignition switch OFF.

•

If the reading is out of the standard range, check the
wiring (see Wiring Diagram in this section).
If the reading is good, the input voltage is normal. Check
the output voltage.

Output Voltage Inspection

Measure the output voltage at the ECU in the same way

•

as input voltage inspection. Note the following.

Inlet Air Pressure Sensor Output Voltage

Connections to ECU

Meter (+) → G/R lead (terminal 33)

Meter (–) → BK/W lead (terminal 8)

Output Voltage at ECU

Usable Range:

The output voltage changes according to the local at-

○

mospheric pressure.
The vacuum sensor output voltage is based on a nearly

○

perfect vacuum in the small chamber of the sensor. So,
the sensor indicates absolute vacuum pressure.

3.75 ∼ 4.25 V DC at the standard

atmospheric pressure (101.32 kPa, 76
cmHg absolute)

NOTE

If the output voltage is within the usable range, check
the ECU for its ground, power supply and wiring. If the
ground, power supply and wiring are good, replace the
ECU.

FUEL SYSTEM (DFI) 3-35

Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)

If the output voltage is far out of the u sable range, check
the output voltage at the sensor connector [A].
Measure the output voltage at the sensor in the same way

•

as input voltage inspection. Note the following.

[B] Inlet Air Pressure Sensor

Special Tool - Sensor Harness Adapter: 57001-1561

Inlet Air Pressure Sensor Output Voltage

Connections to Sensor

Meter (+) → G/R lead [C]

Meter (–) → BK/W lead [D]

Output Voltage at Sensor Connector

Usable Range:

If the output voltage is normal, check the wiring for conti­nuity (see next diagram).
If the output voltage is out of the usable range, replace
the sensor.
Turn the ignition switch OFF.

•

Remove the sensor harness adapter.

•

3.75 ∼ 4.25 V DC at the standard

atmospheric pressure (101.32 kPa or
76 cmHg absolute)

Output Voltage Performance

(at Input Voltage: 4.75 ∼ 5.25 V)

P: Vacuum Pressure
Vo: Output Voltage

1. ECU

2. Joint Connector E

3. Joint Connector H

4. Inlet Air Pressure Sensor

3-36 FUEL SYSTEM (DFI)

Inlet Air Temperature Sensor (Service Code/Character-13/AIrt)

Inlet Air Temperature Removal/Installation

CAUTION

Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.

Remove the air filter (see Air Filter Removal).

•

Disconnect the connector [A] from the inlet air tempera-

•

ture sensor.
Remove the inlet air temperature sensor [B] and washer.

•

Install the inlet air temperature sensor and washer [A].

•

Tighten:

•

Torque - Inlet Air Temperature Sensor: 20 N·m (2.0 kgf·m,

14 ft·lb)

Output Voltage Inspection

NOTE

Be sure the battery is fully charged.

○

Remove the ECU (see ECU Removal). Do not disconnect

•

the ECU connector.
Connect a digital voltmeter to the ECU connector, using

•

needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

Inlet Air Temperature Sensor Output Voltage

Connections to ECU Connector

Meter (+) → R/BL lead (terminal 7)

Meter (–) → BK/W lead (terminal 8)

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor output voltage.
Wait 15 seconds before using the starter again.

○

Output Voltage at ECU

Standard:

about 2.3 ∼ 2.6 V at inlet air temperature

20°C (68°F)

NOTE

The output voltage changes according to the inlet air

○

temperature.

Turn the ignition switch OFF.

•

FUEL SYSTEM (DFI) 3-37

Inlet Air Temperature S ensor (Service Code/Character-13/AIrt)

If the output voltage is out of the specified, check the ECU
for its ground, and power supply (see ECU Power Supply
Inspection). If the ground and power supply are good,
replace the ECU.
If the output voltage is far out of the specified, check the
wiring (see next diagram).
Remove the needle adapter set, and apply silicone

•

sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120) -Seals
of ECU Connectors

If the wiring is good, check the sensor resistance.

Sensor Resistance Inspection

Remove the inlet air temperature sensor (see Inlet Air

•

Temperature Sensor Removal).
Suspend the sensor [A] in a container of machine oil so

•

that the heat-sensitive portion and threaded portion are
submerged.
Suspend a thermometer [B] with the heat-sensitive por-

•

tion [C] located in almost the same depth with the sensor.

NOTE

The sensor and thermometer must not touch the con-

○

tainer side or bottom.

Place the container over a source of heat and gradually

•

raise the temperature of the oil while stirring the oil gently
for even temperat
Using a digital meter, measure the internal resistance

•

of the sensor across the terminals at the temperatures
shown in the table.

Inlet Air Temperature Sensor Resistance

Standard: 5.4 ∼ 6.6 kΩ at 0°C (32°F)

If the measurement is out of the range, replace the sensor.
If the measurement is within the specified, replace the
ECU.

ure.

2.26 ∼ 2.86 kΩ at 20°C (68°F)

0.29 ∼ 0.39 kΩ at 80°C (176°F)

3-38 FUEL SYSTEM (DFI)

Inlet Air Temperature Sensor (Service Code/Character-13/AIrt)

1. ECU

2. Joint Connector E

3. Joint Connector H

4. Inlet Air Temperature Sensor

FUEL SYSTEM (DFI) 3-39

Water Temperature Sensor (Service Code/Character-14/AqUt)

Water Temperature Sensor Removal/Installation

CAUTION

Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.

Disconnect the sensor connector [A], and unscrew the

•

water temperature sensor [B].

When installing the water temperature sensor, remove the

•

exhaust manifold for the engine oil filling in the hollow of
the exhaust manifold.

Fill the hollow of the exhaust manifold [A] with the engine

•

oil (10W-30) [B] as shown, before installing the water tem­perature sensor [C].

[D] 5 mm (0.2 in.)

Tighten:

•

Torque - Water Temperature Sensor: 15 N·m (1.5 kgf·m, 11

ft·lb)

Output Voltage Inspection

NOTE

Be sure the battery is fully charged.

○

Remove the ECU (see ECU Removal). Do not disconnect

•

the connector.

3-40 FUEL SYSTEM (DFI)

Water Temperature Sensor (Service Code/Character-14/AqUt)

Connect a digital voltmeter [A] to the ECU connector [B],

•

with the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

Water Temperature Sensor Output Voltage

Connections to ECU

Meter (+) → G/Y lead (terminal 35)

Meter (–) → BK/W lead (terminal 8)

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor output voltage.
Wait 15 seconds before using the starter again.

○

Output Voltage at ECU

Standard: about 3 ∼ 4 V at 20°C (68°F)

NOTE

The output voltage changes according to the coolant

○

temperature in the engine.

Turn the ignition switch OFF.

•

If the output voltage is out of the specified, check the ECU
for its ground, and power supply (see ECU Power Supply
Inspection). If the ground and power supply are good,
replace the ECU.
If the output voltage is far out of the specified (e.g. when
the wiring is open, the voltage is about 5 V), check the
wiring (see next diagram).
If the wiring is good, check the water temperature sensor
resistance.
Remove the needle adapter set, and apply silicone

•

sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120) -Seals
of ECU Connectors

FUEL SYSTEM (DFI) 3-41

Water Temperature Sensor (Service Code/Character-14/AqUt)

1. ECU

2. Joint Connector E

3. Water Temperature Sensor

Sensor Resistance Inspection

Remove the water temperature sensor (see Water Tem-

•

perature Sensor Removal/Installation).
Refer to Electrical System chapter for water temperature

•

sensor inspection.

3-42 FUEL SYSTEM (DFI)

Crankshaft Sensor (Service Code/Character-21/CrAg)

Crankshaft Sensor Removal/Installation

See the Ignition System section in Electrical System

•

chapter.

Crankshaft Sensor Inspection

The crankshaft have no power source, and when the en-

○

gine stops, the crankshaft generates no signals.
Crank the engine and measure the peak voltage of the

•

crankshaft sensor (see Electrical System chapter) in or­der to check the sensor.
Check the wiring for continuity, using the following dia-

•

gram.

1. ECU

2. Joint Connector E

3. Joint Connector H

4. Crankshaft Sensor

FUEL SYSTEM (DFI) 3-43

Camshaft Position Sensor (Service Code/Character-23/CAAg)

Camshaft Position Sensor Removal/Installation

The camshaft position sensor detects the position of the

camshaft, and distinguishes the cylinder.

See the Ignition system section in Electric System chap-

•

ter.

Camshaft Position Sensor Inspection

The camshaft position sensor have no power source, and

○

when the engine stops, the camshaft position sensor gen­erates no signal.
Crank the engine and measure the peak voltage of the

•

camshaft position sensor (see Electrical System chapter)
in order to check the sensor.
Check the wiring for continuity, using the following dia-

•

gram.

1. ECU

2. Camshaft Position Sensor

3-44 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code/Character-31/dOS)

This sensor has a weight [A] with two magnets inside, and

sends a signal to the ECU. But when the watercraft banks

110 ∼ 130° or more to either side (in fact falls down), the

weight turns and shuts off the signal. The ECU senses this
change, and stops the fuel pump, the fuel injectors, and the
ignition system.

Hall IC [B]

Vehicle-down Sensor Connector [A]
Ground Terminal BK/W [B]
Output Terminal BL/W [C]
Power Source Terminal R/G [D]

Vehicle-down Sensor Removal

CAUTION

Never drop the down-sensor, especially on a hard
surface. Such a shock to the sensor can damage it.

Remove:

•

Seat (see Hull/Engine Hood chapter)
Front Storage Pocket (see Hull/Engine Hood chapter)
Bracket Bolts [A] and Washers

Remove:

•

Vehicle-down Sensor Connector [A]
Screws [B]
Vehicle-down Sensor [C]

Vehicle-down Sensor Installation

The UP mark [A] of the sensor should face upward.

•

WARNING

Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situ­ations, like leaning over in a turn, with the potential
for an accident resulting in injury or death. Ensure
that the down sensor is held in place by the sensor
brackets.

Tighten:

•

Torque - Vehicle-down Sensor Mounting Screws: 1.5 N·m

(0.15 kgf·m, 13 in·lb)

FUEL SYSTEM (DFI) 3-45

Vehicle-down Sensor (Service Code/Character-31/dOS)

Vehicle-down Sensor Inspection

NOTE

Be sure the battery is fully charged.

○

Remove:

•

Fuel Tank (see Fuel Tank Removal)

Connect a digital volt meter [A] to the connector [B] of the

•

vehicle-down sensor lead with the needle adapter set [C].

Special Tool - Needle Adapter Set: 57001-1457

Vehicle-down Sensor Power Source Voltage

Connections to Sensor

Meter (+) → R/G lead [D]

Meter (–) → BK/W lead [E]

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor power sours voltage.
Wait 15 seconds before using the starter again.

○

Power Source Voltage at Sensor

Standard:

Turn the ignition switch OFF.

•

If there is no standard voltage, check the following:

Battery (see Electrical System chapter)
MainFuse20A
Wiring for Vehicle-down Sensor Power Source (see next
diagram)

If the power source is normal, check the output voltage.

Turn the ignition switch OFF.

•

Remove the vehicle-down sensor. Do not disconnect the

•

connector.
Connect a digital volt meter [A] to the connector, with nee-

•

dle adapter set [B].

Special Tool - Needle Adapter Set: 57001-1457

Vehicle-down Sensor Output Voltage

Connections to Sensor

Meter (+) → BL/W lead [D]

Meter (–) → BK/W lead [E]

Hold the sensor vertically.

•

Turn the ignition switch ON and push the lanyard key un-

•

der the stop button.

Pushing the start button, run the engine 5 ∼ 6 seconds at

•

idling to measure the sensor output voltage.

Tilt the sensor 110 ∼ 130° or more [C] right or left, then

○

hold the sensor and measure the output voltage.
Wait 15 seconds before using the starter again.

○

4.75 ∼ 5.25 V

Output Voltage at Sensor

Standard: with sensor tilted 110 ∼ 130° or more righ t

or left: 0.65 ∼ 1.35 V

with sensor arrow mark pointed up: 3.55

∼ 4.45 V

3-46 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code/Character-31/dOS)

Turn the ignition switch OFF.

•

Remove the needle adapter set, and apply silicone

•

sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of
Vehicle-down Sensor Connector

If the output voltage is normal, the wiring is suspect.
Check the wiring.
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection). If the
ground and power supply are good, replace the ECU.
If the output voltage is out of the specified, replace the
vehicle-down sensor.

1. ECU

2. Joint Connector E

3. Connector C

4. Vehicle-down Sensor