Kawasaki STX-15F manual

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Kawasaki STX-15F service manual

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 ∼ Before Servicing Kawasaki Diagnostic System KDS SoftwareAdjustments Auxiliary Cooling General Information Edges of Parts Battery GroundSolvent Replacement Parts Cleaning Watercraft before DisassemblyArrangement and Cleaning of Removed Parts Storage of Removed Parts Force Assembly Order Tightening SequenceTightening Torque Gasket, O-ring Ball Bearing Liquid Gasket, Locking AgentPress Oil Seal, Grease Seal Lubrication Circlips, Cotter PinsElectrical Wires Direction of Engine Rotation Model Identification General Specifications Engine Oil Items JT1500-A1 ∼ A2Electrical Equipment Unit Conversion Table Prefixes for Units Units of Length Units of Volume Units of PressureUnits of Force Units of Power 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 Cooling and Bilge Systems Engine Removal/InstallationEngine Bottom End Pump and Impeller Hull/Engine Hood Fastener Torque Remarks Kgf·m Ft·lbSteering Electrical System General Fasteners stainless bolt and nut Threads dia. mm Torque Kgf·m Ft·lb Specifications Standard Service Limit Fuel System 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 Throttle Shaft Spring Inspection Fuel Pump Screen CleaningEngine Lubrication System 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 Engine Mounting Bolts Inspection and Tightness Engine Bottom EndCooling and Bilge Systems Coupling Damper Inspection Periodic Maintenance Bilge System Flushing Impeller Inspection Periodic Maintenance Procedures Pump and ImpellerSteering Steering Cable/Shift Cable Inspection Hull/Engine Hood Battery Charging Condition InspectionBattery Terminals Inspection Electrical System Spark Plug Cleaning and Inspection Lubrication 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 Standard Digital Fuel Injection System Fuel System DFI Special Tools and Sealant DFI Parts Location Fuel System DFI Dummy DFI System Part Name Terminal Numbers of ECU Connectors Terminal Names DFI Servicing Precautions For JT1500-A2 ∼ Silicone Sealant Kawasaki Bond 56019-120 -Seals Connector Dealer Mode User ModeSelf-Diagnosis Self-diagnosis Outline Displayed on Self-Diagnosis Service Code Character TablePossible Problems Fail-Safe Function JT1500-A1 Memory of Service Code Character Self-Diagnosis Troubleshooting the DFI System Sample Diagnosis Sheet Watercraft conditions when problem occurred Troubleshooting the DFI System Throttle Sensor Service Code/Character-11/tPS Throttle Sensor Removal/Adjustment Be sure the battery is fully charged Input Voltage Inspection 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 Sensor Service Code/Character-13/AIrt Inlet Air Temperature Removal/Installation Sensor Resistance Inspection Fuel System DFI Water Temperature Sensor Service Code/Character-14/AqUt Water Temperature Sensor Removal/Installation 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 Installation Fuel Injector Removal Injector Signal Test Audible Inspection Injector Resistance Inspection Injector Unit Test Injector Voltage Inspection Injector Fuel Line Inspection ECU Ignition Coils Service Code/Character-51, 52/COL1, COL2 Ignition Coil Removal/Installation Fuel System DFI Engine Overheating Service Code/Character-71/HEAt Possible Causes Action Chapter Low Engine Oil Pressure Service Code/Character-72/OILP Oil Temperature Sensor Removal/Installation Sensor Resistance Inspection Engine Oil Overheating Service Code/Character-76/OILH JT1500-A2 model ∼ ECU Power Supply Inspection ECU InstallationECU Removal ECU connector B in this chapter figure ECU Power Source Circuit Relay Assembly Inspection DFI Power SourceRelay Assembly Removal Main Fuse Inspection Relay Coil Terminals 6 Relay Switch Terminals 5 Fuel Pump Relay Throttle Lever, Cable and Case Throttle Cable AdjustmentThrottle Case Removal/Disassembly Free Play Inspection Throttle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Case and Cable Lubrication Throttle Cable Inspection Air Filter Air Filter InstallationAir Filter Removal Air Filter Disassembly Air Filter Assembly Throttle Body Assy ISC Idle Speed Controller Removal/Installation ISC Idle Speed Controller Inspection ISC Resistance Inspection ISC a Inlet Manifold Inlet Manifold Removal Inlet Manifold Installation Fuel System DFI Fuel Line Fuel Pressure Inspection Fuel Flow Rate Inspection Amount of Fuel Flow Standard 67 mL or more for 3 seconds Fuel Vent Check Valve Fuel Vent Check Valve Mounting Fuel Filter Fuel Filter Removal Fuel Filter Installation Fuel Pump Removal Fuel PumpJT1500-A2 ∼ model Fuel Pump Installation Power Source Voltage Inspection Operating Voltage Inspection Fuel Pump Relay Removal Fuel Pump Relay Inspection Fuel Tank Fuel Tank Removal Fuel Tank Installation Fuel Tank Cleaning Fuel Filler and Tube Installation Fuel Filler and Tube Removal 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 Disassembly Oil Cooler Assembly Oil Cooler Inspection Breather Case Removal Breather Case InstallationBreather Case and Oil Separator Tank Oil Separator Tank Removal Oil Separator Tank Installation Blowby Gas System Inspection 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 Installation Oil Pump Removal Oil Pump Inspection Oil Screen InstallationOil Screen Removal Oil Pressure Relief Valve Inspection Oil Pump Sprocket Chain Removal 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 Exhaust Manifold Removal 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 Engine TOP END Fastener Engine TOP END Fastener Torque Remarks Kgf·m Cylinder Head Standard Service Limit CamshaftsValves Standard Service Limit Cylinder, Piston Special Tools and Sealant Engine TOP END Engine TOP END Clean Air System Hose Inspection Clean Air SystemAir Suction Valve Installation 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, Camshaft Chain Camshaft Removal Camshaft Installation Piston TDC Finding Special Tool TDC Measurement Tool Camshaft, Camshaft Cap Wear Camshaft Runout Camshaft Chain Removal Cylinder Head Cylinder Compression Measurement Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp Valve Clearance Check Valve InstallationValves Valve Removal Valve Guide Installation Valve-to-Guide Clearance Measurement Wobble Method Valve Seat Inspection Valve Seat Repair Seat Cutter Operation Care Operating ProceduresMarks Stamped on the Cutter Engine TOP END Engine TOP END Engine TOP END Cylinder Removal Cylinder, PistonsPiston Removal Piston/Cylinder Installation Oil ring rails have no top or bottom With the Hand With the Special Tools Piston Ring, Piston Ring Groove Wear Cylinder WearPiston Wear Piston Ring Groove Width Piston Ring Thickness Piston Ring End GapPage Engine Removal/Installation Exploded View Fastener Torque Remarks Kgf·m Engine Removal/Installation Engine Removal Engine Damper Removal Engine Damper Installation Engine Installation Engine Bottom End Exploded View Fastener Torque Remarks Kgf·m Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Big End Bearing Insert Selection Crankshaft Main Journal Diameter 40.984 ∼ 41.000 mm 40.96 mm Special Tools and Sealant Kawasaki Bond Liquid Gasket Black Coupling Coupling/Output Shaft Removal Coupling/Output Shaft Installation Output Cover Oil Seal Replacement Ball Bearing Lubrication Magneto Cover Bearing ReplacementOil Seal Inspection 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 Removal Connecting Rod Installation Engine Bottom END Connecting Rod Bend Be careful not to overtighten the nuts 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 Measure the crankshaft runout Crankshaft Side ClearanceCrankshaft Runout Crankshaft Cooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Bilge System Breather InstallationBreather Cleaning and Inspection Breather Removal Filter Installation Filter Cleaning and Inspection Hose Removal Hose InstallationCooling and Bilge System Hoses Hose Inspection Cooling and Bilge System Flushing Cooling and Bilge System Flow Diagram Cooling and Bilge Systems Water Pipe Water Pipe InstallationWater Pipe Removal Summary Procedures after Submerging 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 Specification Standard Service Limit Drive Shaft 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 Pump Assembly JT1500-A1,A2 ∼ Special Tool Bearing Driver Set Pump and Impeller JT1500-A1, A2 ∼ Pump Inspection Water Filter Cover Removal/InstallationImpeller Outside Diameter Measurement 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 Handlebar Removal 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 Reverse Bucket Removal/Installation Shift Lever Shaft Removal/Installation Hull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Seat Removal Seat InstallationFittings Front Storage Compartment Cover Removal Front Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Removal Mirror InstallationMirror Stay Removal Mirror Stay Installation Front Storage Pocket Removal Front Storage Pocket InstallationStorage Pocket Disassembly/Assembly Crossmember Removal Crossmember Installation Drain Plug Housing Installation Handrail InstallationDrain Plug Housing Removal Exhaust Outlet Installation Stabilizer Removal Stabilizer InstallationReboarding Step Installation Reboarding Step Removal Hull Replacement Rubber Parts Rubber Parts Location HULL/ENGINE Hood Rear Bumper Installation Rivet InstallationFront Bumper Installation Rivet Removal Side Bumper Installation Side Bumper RemovalPage 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 Charging System Standard Service Limit BatteryElectric Starter System Ignition System Electrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Electrical Wiring Wiring Inspection Removal BatteryInstallation Electrolyte Filling Electrical System Precautions Initial Charge Charging Condition Inspection InterchangeRefreshing Charge Electrical System Starter Relay Removal Starter Relay InstallationElectric Starter System Starter Relay Inspection Starter Motor Installation Starter Motor Removal Starter Motor Disassembly Starter Motor Assembly Commutator Cleaning and Inspection Brush Inspection Brush Lead Inspection Armature InspectionBrush Plate and Terminal Bolt Inspection Reduction Gear Removal/Installation Reduction Gear Inspection Electrical System Charging System Regulator/Rectifier Removal/InstallationMagneto Output Voltage Regulator/Rectifier Inspection Regulator Inspection Charging System Circuit Electrical System Ignition System Crankshaft Sensor InstallationCrankshaft Sensor Removal Timing Rotor Installation Timing Rotor Removal 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 Removal/Installation Igniter Inspection Ignition Coil Primary Peak Voltage Standard 250 V or more Crankshaft Sensor Peak Voltage Check Camshaft Position Sensor Peak Voltage Inspection Spark Plug Cleaning Spark Plug InstallationSpark Plug Adjustment Spark Plug Removal Ignition System Circuit Electrical System Kawasaki Smart Steering System Steering Position Sensor and Magnet InstallationSteering Position Sensor and Magnet Removal Inspection of Kawasaki Smart Steering System Steering Position Sensor Clearance Steering Position Sensor Input Voltage Inspection Steering Position Sensor Output Voltage Inspection Steering Position Sensor Circuit Sensors Speed Sensor Removal/InstallationSpeed Sensor Inspection Throttle Sensor Removal/Installation Fuel Level Sensor Inspection Oil Temperature Sensor Inspection Water Temperature Sensor InspectionInlet Air Temperature Sensor Inspection Throttle Sensor Inspection Multifunction Meter Display Function Inspection MODE/SET Button Inspection Speedometer Inspection Speed Sensor Electric Source Inspection Battery Symbol/bAt Characters/LED Inspection Tachometer Inspection Buzzer Inspection Electrical System Relay Assembly Circuit Inspection Relay Assembly Circuit Inspection with the battery connected Switches Switch Inspection Fuse Page Storage Bilge System Preparation for StorageCooling System Engine Oil Engine Air Filter BatteryDo not allow any soda solution to enter the battery Engine Mounting Bolts General Removal from Storage General Inspection 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 Abnormal Engine Noise OverheatingOver Cooling Oil Pressure Warning Light Goes On Poor Performance through Engine Engine Activates Slow Down ModeBattery Trouble Runs Properly Model Application