JET SKI Watercraft | Kawasaki STX-15F instruction

STX-15F

JET SKI® Watercraft

Service Manual

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Kawasaki STX-15F service manual JET SKI Watercraft

Contents

JET SKI Watercraft Page Quick Reference Guide Page JET SKI Watercraft List of Abbreviations Emission Control Information Fuel InformationExhaust Emission Control System Foreword Page Page General Information Smart Learning Operation mode SLO JT1500-A2 model ∼ Adjustments Kawasaki Diagnostic System KDS SoftwareBefore Servicing Auxiliary Cooling General Information Edges of Parts Battery GroundSolvent Arrangement and Cleaning of Removed Parts Cleaning Watercraft before DisassemblyReplacement Parts Storage of Removed Parts Tightening Torque Assembly Order Tightening SequenceForce Gasket, O-ring Press Liquid Gasket, Locking AgentBall Bearing Oil Seal, Grease Seal Electrical Wires Circlips, Cotter PinsLubrication Direction of Engine Rotation Model Identification General Specifications Engine Oil Items JT1500-A1 ∼ A2Electrical Equipment Units of Force Units of Power Units of Volume Units of PressureUnit Conversion Table Prefixes for Units Units of Length Units of MassPage Periodic Maintenance Periodic Maintenance Chart Fastener Torque Remarks Kgf·m Ft·lb Fuel System Torque and Locking AgentEngine Lubrication System Exhaust System Fastener Torque Remarks Kgf·mEngine Top End Engine Bottom End Engine Removal/InstallationCooling and Bilge Systems Pump and Impeller Steering Fastener Torque Remarks Kgf·m Ft·lbHull/Engine Hood Electrical System Threads dia. mm Torque Kgf·m Ft·lb General Fasteners stainless bolt and nut Standard Service Limit Fuel System Specifications Special Tools and Sealant Air Filter Drain Caps Inspection and Cleaning Periodic Maintenance Procedures Fuel SystemThrottle Control System Inspection Air Filter Inspection and Cleaning Periodic Maintenance ProceduresFuel Vent Check Valve Inspection Engine Lubrication System Fuel Pump Screen CleaningThrottle Shaft Spring Inspection Engine Oil Change Dry Oil Filter Replace Air Suction Valve Inspection Periodic Maintenance Procedures Engine Top EndValve Clearance Inspection Periodic Maintenance Inlet Valve Clearance Adjustment Chart Exhaust Valve Clearance Adjustment Chart Cooling and Bilge Systems Engine Bottom EndEngine Mounting Bolts Inspection and Tightness Coupling Damper Inspection Periodic Maintenance Bilge System Flushing Steering Periodic Maintenance Procedures Pump and ImpellerImpeller Inspection Steering Cable/Shift Cable Inspection Battery Terminals Inspection Battery Charging Condition InspectionHull/Engine Hood Electrical System Lubrication Spark Plug Cleaning and Inspection Steering Cable Ball Joint a at Steering Shaft Lubricate the following with a penetrating rust inhibitor B Hose and Hose Connect Inspection Nuts, Bolts, and Fasteners Tightness InspectionNut, Bolt and Fastener to be checked JT1500-A2 ∼ Rubber Strap Inspection Page Fuel System DFI Fuel System DFI Fuel System Diagram Exploded View Fastener Torque Remarks Kgf·m Ft·lb Fuel System DFI Fastener Torque Remarks Kgf·m Fuel System DFI Fastener Torque Remarks Kgf·m Ft·lb Digital Fuel Injection System Standard Fuel System DFI Special Tools and Sealant DFI Parts Location Fuel System DFI Dummy DFI System Part Name Terminal Names Terminal Numbers of ECU Connectors DFI Servicing Precautions For JT1500-A2 ∼ Silicone Sealant Kawasaki Bond 56019-120 -Seals Connector Dealer Mode User ModeSelf-Diagnosis Self-diagnosis Outline Possible Problems Fail-Safe Function Self-Diagnosis Service Code Character TableDisplayed on JT1500-A1 Self-Diagnosis Memory of Service Code Character Watercraft conditions when problem occurred Troubleshooting the DFI System Sample Diagnosis Sheet Troubleshooting the DFI System Throttle Sensor Removal/Adjustment Throttle Sensor Service Code/Character-11/tPS Input Voltage Inspection Be sure the battery is fully charged Input Voltage at ECU Standard 4.75 ∼ 5.25 V DC Output Voltage Inspection Resistance Inspection ECU Joint Connector E Throttle Sensor Inlet Air Pressure Sensor Installation Inlet Air Pressure Sensor Service Code/Character-12/bOStInlet Air Pressure Sensor Removal Input Voltage at Sensor Connector Standard 4.75 ∼ 5.25 V DC Joint Connector E Inlet Air Pressure Sensor Inlet Air Temperature Removal/Installation Inlet Air Temperature Sensor Service Code/Character-13/AIrt Sensor Resistance Inspection Fuel System DFI Water Temperature Sensor Removal/Installation Water Temperature Sensor Service Code/Character-14/AqUt Output Voltage at ECU Standard about 3 ∼ 4 V at 20C 68F ECU Joint Connector E Water Temperature Sensor Crankshaft Sensor Removal/Installation Crankshaft Sensor Service Code/Character-21/CrAgCrankshaft Sensor Inspection Camshaft Position Sensor Removal/Installation Camshaft Position Sensor Service Code/Character-23/CAAgCamshaft Position Sensor Inspection Vehicle-down Sensor Installation Vehicle-down Sensor Service Code/Character-31/dOSVehicle-down Sensor Removal Vehicle-down Sensor Inspection Fuel System DFI Fuel Injector Removal Fuel Injector Installation Audible Inspection Injector Signal Test Injector Unit Test Injector Resistance Inspection Injector Voltage Inspection Injector Fuel Line Inspection ECU Ignition Coil Removal/Installation Ignition Coils Service Code/Character-51, 52/COL1, COL2 Fuel System DFI Possible Causes Action Chapter Engine Overheating Service Code/Character-71/HEAt Low Engine Oil Pressure Service Code/Character-72/OILP Oil Temperature Sensor Removal/Installation Sensor Resistance Inspection JT1500-A2 model ∼ Engine Oil Overheating Service Code/Character-76/OILH ECU Power Supply Inspection ECU InstallationECU Removal ECU connector B in this chapter figure ECU Power Source Circuit Relay Assembly Removal DFI Power SourceRelay Assembly Inspection Main Fuse Inspection Fuel Pump Relay Relay Coil Terminals 6 Relay Switch Terminals 5 Throttle Case Removal/Disassembly Throttle Cable AdjustmentThrottle Lever, Cable and Case Free Play Inspection Throttle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Cable Inspection Throttle Case and Cable Lubrication Air Filter Air Filter InstallationAir Filter Removal Air Filter Assembly Air Filter Disassembly Throttle Body Assy ISC Idle Speed Controller Inspection ISC Idle Speed Controller Removal/Installation ISC a ISC Resistance Inspection Inlet Manifold Removal Inlet Manifold Inlet Manifold Installation Fuel System DFI Fuel Pressure Inspection Fuel Line Fuel Flow Rate Inspection Amount of Fuel Flow Standard 67 mL or more for 3 seconds Fuel Vent Check Valve Mounting Fuel Vent Check Valve Fuel Filter Removal Fuel Filter Fuel Filter Installation Fuel Pump Removal Fuel PumpJT1500-A2 ∼ model Power Source Voltage Inspection Fuel Pump Installation Operating Voltage Inspection Fuel Pump Relay Inspection Fuel Pump Relay Removal Fuel Tank Removal Fuel Tank Fuel Tank Cleaning Fuel Tank Installation Fuel Filler and Tube Removal Fuel Filler and Tube Installation Engine Lubrication System Exploded View Fastener Torque Remarks Kgf·m Ft·lb Engine Oil Flow Chart Passage Oil Pressure Measurement Special Tool and Sealant Oil Level Inspection Engine Oil and Oil FilterPreliminary Check Ordinary standard Check Oil Filter Replacement Oil Cooler Oil Cooler InstallationOil Cooler Removal Oil Cooler Assembly Oil Cooler Disassembly Oil Cooler Inspection Breather Case and Oil Separator Tank Breather Case InstallationBreather Case Removal Oil Separator Tank Removal Blowby Gas System Inspection Oil Separator Tank Installation Oil Pan Oil Pan InstallationOil Pan Removal Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve Oil Pump Sprocket InstallationOil Pump Sprocket Removal Oil Pump Removal Oil Pump Installation Oil Pump Inspection Oil Screen InstallationOil Screen Removal Oil Pump Sprocket Chain Removal Oil Pressure Relief Valve Inspection Oil Pressure Measurement Oil Pressure Measurement Engine Lubrication System Oil Pressure Switch Removal Oil Pressure SwitchOil Pressure Switch Installation Page Exhaust System Exploded View Fastener Torque Remarks Kgf·m Exhaust Manifold Removal Exhaust Manifold Exhaust Manifold Installation Exhaust Manifold Cleaning and Inspection Exhaust Pipe Exhaust Pipe InstallationExhaust Pipe Removal Exhaust Pipe Cleaning and Inspection Water Box Muffler Water Box Muffler InstallationWater Box Muffler Removal Water Box Muffler Inspection Engine Top End Exploded View Fastener Engine TOP END Engine TOP END Fastener Torque Remarks Kgf·m Cylinder Head Standard Service Limit CamshaftsValves Cylinder, Piston Standard Service Limit Special Tools and Sealant Engine TOP END Engine TOP END Air Suction Valve Installation Clean Air SystemClean Air System Hose Inspection Air Suction Valve Removal Cylinder Head Cover Cylinder Head Cover InstallationCylinder Head Cover Removal Camshaft Chain Tensioner Camshaft Chain Tensioner InstallationCamshaft Chain Tensioner Removal Camshaft Removal Camshaft, Camshaft Chain Camshaft Installation Piston TDC Finding Special Tool TDC Measurement Tool Camshaft Runout Camshaft, Camshaft Cap Wear Camshaft Chain Removal Cylinder Compression Measurement Cylinder Head Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp Valves Valve InstallationValve Clearance Check Valve Removal Valve-to-Guide Clearance Measurement Wobble Method Valve Guide Installation Valve Seat Repair Valve Seat Inspection Seat Cutter Operation Care Operating ProceduresMarks Stamped on the Cutter Engine TOP END Engine TOP END Engine TOP END Cylinder Removal Cylinder, PistonsPiston Removal Oil ring rails have no top or bottom Piston/Cylinder Installation With the Special Tools With the Hand Piston Wear Cylinder WearPiston Ring, Piston Ring Groove Wear Piston Ring Groove Width Piston Ring End Gap Piston Ring ThicknessPage Engine Removal/Installation Exploded View Fastener Torque Remarks Kgf·m Engine Removal Engine Removal/Installation Engine Damper Removal Engine Installation Engine Damper Installation Engine Bottom End Exploded View Fastener Torque Remarks Kgf·m Connecting Rod Big End Bearing Insert Selection Standard Service Limit Crankshaft, Connecting Rods Crankshaft Main Journal Diameter 40.984 ∼ 41.000 mm 40.96 mm Special Tools and Sealant Kawasaki Bond Liquid Gasket Black Coupling/Output Shaft Removal Coupling Coupling/Output Shaft Installation Output Cover Oil Seal Replacement Oil Seal Inspection Magneto Cover Bearing ReplacementBall Bearing Lubrication Ball Bearing Inspection Magneto Flywheel Magneto Flywheel InstallationMagneto Flywheel Removal InstallMagneto Cover see Coupling/Output Shaft Installation Stator Stator InstallationStator Removal Crankcase Splitting Crankcase Splitting Crankcase Assembly Following the sequence numbers, tighten the M8 bolts Crankshaft Installation Crankshaft and Connecting RodsCrankshaft Removal Connecting Rod Installation Connecting Rod Removal Engine Bottom END Be careful not to overtighten the nuts Connecting Rod Bend Connecting Rod Big End Side Clearance Connecting Rod TwistConnecting Rod Big End Bearing Insert/Crankpin Wear 92139-3709 Crankshaft Main Bearing Insert/Journal Wear Marking Position Crankshaft Runout Crankshaft Side ClearanceMeasure the crankshaft runout Crankshaft Cooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Breather Cleaning and Inspection Breather InstallationBilge System Breather Removal Filter Cleaning and Inspection Filter Installation Cooling and Bilge System Hoses Hose InstallationHose Removal Hose Inspection Cooling and Bilge System Flushing Cooling and Bilge System Flow Diagram Cooling and Bilge Systems Water Pipe Water Pipe InstallationWater Pipe Removal After Submerging Summary Procedures after Submerging Cooling and Bilge Systems Detailed Procedures after Submerging Cooling and Bilge Systems Cooling and Bilge Systems Page Drive System Exploded View Fastener Torque Remarks Kgf·m Standard Service Limit Drive Shaft Specification Drive System Drive Shaft Holder Removal/Disassembly Drive Shaft Removal/InstallationDrive Shaft/Drive Shaft Holder Drive Shaft Holder Assembly/Installation Drive Shaft Runout Pump and Impeller Exploded View Fastener Torque Remarks Kgf·m Standard Service Limit Jet Pump Pump and Impeller Pump Removal Pump Installation Torque Pump Mounting Bolts 36 N·m 3.7 kgf·m, 27 ft·lb Pump Disassembly Special Tool Oil Seal & Bearing Remover 57001-1058 a JT1500-A1,A2 ∼ Pump Assembly Special Tool Bearing Driver Set Pump and Impeller JT1500-A1, A2 ∼ Impeller Outside Diameter Measurement Water Filter Cover Removal/InstallationPump Inspection Impeller ClearancePage Steering Exploded View 36 ∼ Special Tool and Sealant Steering Cable Steering Cable AdjustmentSteering Cable Removal Special Tool Box Wrench Steering Cable Inspection Steering Cable InstallationSteering Cable Lubrication Handlebar Removal Handlebar Handlebar Installation Steering Steering Removal Steering Steering Steering Installation Torque the steering shaft locknut a Steering Reverse System Shift Cable AdjustmentShift Cable Removal Steering Shift Cable Inspection Shift Cable InstallationShift Cable Lubrication Shift Lever Shaft Removal/Installation Reverse Bucket Removal/Installation Hull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Fittings Seat InstallationSeat Removal Front Storage Compartment Cover Removal Front Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Removal Mirror InstallationMirror Stay Removal Mirror Stay Installation Storage Pocket Disassembly/Assembly Front Storage Pocket InstallationFront Storage Pocket Removal Crossmember Removal Crossmember Installation Drain Plug Housing Removal Handrail InstallationDrain Plug Housing Installation Exhaust Outlet Installation Reboarding Step Installation Stabilizer InstallationStabilizer Removal Reboarding Step Removal Hull Replacement Rubber Parts Location Rubber Parts HULL/ENGINE Hood Front Bumper Installation Rivet InstallationRear Bumper Installation Rivet Removal Side Bumper Removal Side Bumper InstallationPage Electrical System Electrical System Parts Location Electrical System Electrical System Exploded View 30 ∼ 40 in·lb Starter Cable Mounting Nuts Electrical System Fastener Torque Remarks Kgf·m Electrical System Electrical System Wiring Diagram Electrical System JT1500-A2 ∼ Electrical System Electric Starter System Standard Service Limit BatteryCharging System Ignition System Electrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Wiring Inspection Electrical Wiring Installation BatteryRemoval Electrolyte Filling Electrical System Initial Charge Precautions Charging Condition Inspection InterchangeRefreshing Charge Electrical System Electric Starter System Starter Relay InstallationStarter Relay Removal Starter Relay Inspection Starter Motor Removal Starter Motor Installation Starter Motor Assembly Starter Motor Disassembly Brush Inspection Commutator Cleaning and Inspection Brush Lead Inspection Armature InspectionBrush Plate and Terminal Bolt Inspection Reduction Gear Inspection Reduction Gear Removal/Installation Electrical System Charging System Regulator/Rectifier Removal/InstallationMagneto Output Voltage Regulator Inspection Regulator/Rectifier Inspection Charging System Circuit Electrical System Ignition System Crankshaft Sensor InstallationCrankshaft Sensor Removal Timing Rotor Removal Timing Rotor Installation Ignition Coil Removal Ignition Coil Installation Measuring arcing distance Ignition Coil InspectionMeasuring coil resistance Camshaft Position Sensor Removal Camshaft Position Sensor InstallationMeasuring spark plug lead resistance Igniter Inspection Igniter Removal/Installation Ignition Coil Primary Peak Voltage Standard 250 V or more Camshaft Position Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Check Spark Plug Adjustment Spark Plug InstallationSpark Plug Cleaning Spark Plug Removal Ignition System Circuit Electrical System Kawasaki Smart Steering System Steering Position Sensor and Magnet InstallationSteering Position Sensor and Magnet Removal Steering Position Sensor Clearance Inspection of Kawasaki Smart Steering System Steering Position Sensor Input Voltage Inspection Steering Position Sensor Output Voltage Inspection Steering Position Sensor Circuit Sensors Speed Sensor Removal/InstallationSpeed Sensor Inspection Fuel Level Sensor Inspection Throttle Sensor Removal/Installation Inlet Air Temperature Sensor Inspection Water Temperature Sensor InspectionOil Temperature Sensor Inspection Throttle Sensor Inspection Display Function Inspection Multifunction Meter MODE/SET Button Inspection Speedometer Inspection Speed Sensor Electric Source Inspection Tachometer Inspection Battery Symbol/bAt Characters/LED Inspection Buzzer Inspection Electrical System Circuit Inspection Relay Assembly Relay Assembly Circuit Inspection with the battery connected Switch Inspection Switches Fuse Page Storage Cooling System Preparation for StorageBilge System Engine Oil Engine Do not allow any soda solution to enter the battery BatteryAir Filter Engine Mounting Bolts General General Inspection Removal from Storage Test Run Page Appendix Cable, Wire and Hose Routing Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Engine Doesn’t Start, Starting Difficulty Troubleshooting GuidePoor Running at Low Speed Poor Running or No Power at High Speed Over Cooling OverheatingAbnormal Engine Noise Oil Pressure Warning Light Goes On Battery Trouble Engine Activates Slow Down ModePoor Performance through Engine Runs Properly Model Application