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Kawasaki STX-15F service manual

Models: STX-15F

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Kawasaki STX-15F service manual

Contents

JET SKI Watercraft Page Quick Reference Guide Page JET SKI Watercraft List of Abbreviations Fuel Information Emission Control InformationExhaust Emission Control System Foreword Page Page General Information Smart Learning Operation mode SLO JT1500-A2 model ∼ Kawasaki Diagnostic System KDS Software AdjustmentsBefore Servicing Auxiliary CoolingGeneral Information Battery Ground Edges of PartsSolvent Cleaning Watercraft before Disassembly Arrangement and Cleaning of Removed PartsReplacement Parts Storage of Removed PartsAssembly Order Tightening Sequence Tightening TorqueForce Gasket, O-ringLiquid Gasket, Locking Agent PressBall Bearing Oil Seal, Grease SealCirclips, Cotter Pins Electrical WiresLubrication Direction of Engine RotationModel Identification General Specifications Items JT1500-A1 ∼ A2 Engine OilElectrical Equipment Units of Volume Units of Pressure Units of Force Units of PowerUnit Conversion Table Prefixes for Units Units of Length Units of MassPage Periodic Maintenance Periodic Maintenance Chart Torque and Locking Agent Fastener Torque Remarks Kgf·m Ft·lb Fuel SystemEngine Lubrication System Fastener Torque Remarks Kgf·m Exhaust SystemEngine Top End Engine Removal/Installation Engine Bottom EndCooling and Bilge Systems Pump and ImpellerFastener Torque Remarks Kgf·m Ft·lb SteeringHull/Engine Hood Electrical SystemGeneral Fasteners stainless bolt and nut Threads dia. mm Torque Kgf·m Ft·lbSpecifications Standard Service Limit Fuel SystemSpecial Tools and Sealant Periodic Maintenance Procedures Fuel System Air Filter Drain Caps Inspection and CleaningThrottle Control System Inspection Periodic Maintenance Procedures Air Filter Inspection and CleaningFuel Vent Check Valve Inspection Fuel Pump Screen Cleaning Engine Lubrication SystemThrottle Shaft Spring Inspection Engine Oil ChangeDry Oil Filter Replace Periodic Maintenance Procedures Engine Top End Air Suction Valve InspectionValve Clearance Inspection Periodic Maintenance Inlet Valve Clearance Adjustment Chart Exhaust Valve Clearance Adjustment Chart Engine Bottom End Cooling and Bilge SystemsEngine Mounting Bolts Inspection and Tightness Coupling Damper InspectionPeriodic Maintenance Bilge System Flushing Periodic Maintenance Procedures Pump and Impeller SteeringImpeller Inspection Steering Cable/Shift Cable InspectionBattery Charging Condition Inspection Battery Terminals InspectionHull/Engine Hood Electrical SystemSpark Plug Cleaning and Inspection LubricationSteering Cable Ball Joint a at Steering Shaft Lubricate the following with a penetrating rust inhibitor B Nuts, Bolts, and Fasteners Tightness Inspection Hose and Hose Connect 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 SystemFuel System DFI Special Tools and Sealant DFI Parts Location Fuel System DFI Dummy DFI System Part Name Terminal Numbers of ECU Connectors Terminal NamesDFI Servicing Precautions For JT1500-A2 ∼ Silicone Sealant Kawasaki Bond 56019-120 -Seals Connector User Mode Dealer ModeSelf-Diagnosis Self-diagnosis Outline Self-Diagnosis Service Code Character Table Possible Problems Fail-Safe FunctionDisplayed on JT1500-A1Memory of Service Code Character Self-DiagnosisTroubleshooting the DFI System Sample Diagnosis Sheet Watercraft conditions when problem occurredTroubleshooting the DFI System Throttle Sensor Service Code/Character-11/tPS Throttle Sensor Removal/AdjustmentBe sure the battery is fully charged Input Voltage InspectionInput 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 Service Code/Character-12/bOSt Inlet Air Pressure Sensor InstallationInlet 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/InstallationSensor Resistance Inspection Fuel System DFI Water Temperature Sensor Service Code/Character-14/AqUt Water Temperature Sensor Removal/InstallationOutput Voltage at ECU Standard about 3 ∼ 4 V at 20C 68F ECU Joint Connector E Water Temperature Sensor Crankshaft Sensor Service Code/Character-21/CrAg Crankshaft Sensor Removal/InstallationCrankshaft Sensor Inspection Camshaft Position Sensor Service Code/Character-23/CAAg Camshaft Position Sensor Removal/InstallationCamshaft Position Sensor Inspection Vehicle-down Sensor Service Code/Character-31/dOS Vehicle-down Sensor InstallationVehicle-down Sensor Removal Vehicle-down Sensor Inspection Fuel System DFI Fuel Injector Installation Fuel Injector RemovalInjector Signal Test Audible InspectionInjector Resistance Inspection Injector Unit TestInjector Voltage Inspection Injector Fuel Line Inspection ECU Ignition Coils Service Code/Character-51, 52/COL1, COL2 Ignition Coil Removal/InstallationFuel System DFI Engine Overheating Service Code/Character-71/HEAt Possible Causes Action ChapterLow 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 Installation ECU Power Supply InspectionECU Removal ECU connector B in this chapter figure ECU Power Source Circuit DFI Power Source Relay Assembly RemovalRelay Assembly Inspection Main Fuse InspectionRelay Coil Terminals 6 Relay Switch Terminals 5 Fuel Pump RelayThrottle Cable Adjustment Throttle Case Removal/DisassemblyThrottle Lever, Cable and Case Free Play InspectionThrottle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Case and Cable Lubrication Throttle Cable InspectionAir Filter Installation Air FilterAir Filter Removal Air Filter Disassembly Air Filter AssemblyThrottle Body Assy ISC Idle Speed Controller Removal/Installation ISC Idle Speed Controller InspectionISC Resistance Inspection ISC aInlet Manifold Inlet Manifold RemovalInlet Manifold Installation Fuel System DFI Fuel Line Fuel Pressure InspectionFuel Flow Rate Inspection Amount of Fuel Flow Standard 67 mL or more for 3 seconds Fuel Vent Check Valve Fuel Vent Check Valve MountingFuel Filter Fuel Filter RemovalFuel Filter Installation Fuel Pump Fuel Pump RemovalJT1500-A2 ∼ model Fuel Pump Installation Power Source Voltage InspectionOperating Voltage Inspection Fuel Pump Relay Removal Fuel Pump Relay InspectionFuel Tank Fuel Tank RemovalFuel Tank Installation Fuel Tank CleaningFuel Filler and Tube Installation Fuel Filler and Tube RemovalEngine Lubrication System Exploded View Fastener Torque Remarks Kgf·m Ft·lb Engine Oil Flow Chart Passage Oil Pressure Measurement Special Tool and Sealant Engine Oil and Oil Filter Oil Level InspectionPreliminary Check Ordinary standard Check Oil Filter Replacement Oil Cooler Installation Oil CoolerOil Cooler Removal Oil Cooler Disassembly Oil Cooler AssemblyOil Cooler Inspection Breather Case Installation Breather Case and Oil Separator TankBreather Case Removal Oil Separator Tank RemovalOil Separator Tank Installation Blowby Gas System InspectionOil Pan Installation Oil PanOil Pan Removal Oil Pump Sprocket Installation Oil Pump Sprocket, Oil Pump and Oil Pressure Relief ValveOil Pump Sprocket Removal Oil Pump Installation Oil Pump RemovalOil Screen Installation Oil Pump InspectionOil Screen Removal Oil Pressure Relief Valve Inspection Oil Pump Sprocket Chain RemovalOil Pressure Measurement Oil Pressure MeasurementEngine Lubrication System Oil Pressure Switch Oil Pressure Switch RemovalOil Pressure Switch Installation Page Exhaust System Exploded View Fastener Torque Remarks Kgf·m Exhaust Manifold Exhaust Manifold RemovalExhaust Manifold Installation Exhaust Manifold Cleaning and Inspection Exhaust Pipe Installation Exhaust PipeExhaust Pipe Removal Exhaust Pipe Cleaning and Inspection Water Box Muffler Installation Water Box MufflerWater Box Muffler Removal Water Box Muffler Inspection Engine Top End Exploded View Engine TOP END FastenerEngine TOP END Fastener Torque Remarks Kgf·m Standard Service Limit Camshafts Cylinder HeadValves Standard Service Limit Cylinder, PistonSpecial Tools and Sealant Engine TOP END Engine TOP END Clean Air System Air Suction Valve InstallationClean Air System Hose Inspection Air Suction Valve RemovalCylinder Head Cover Installation Cylinder Head CoverCylinder Head Cover Removal Camshaft Chain Tensioner Installation Camshaft Chain TensionerCamshaft Chain Tensioner Removal Camshaft, Camshaft Chain Camshaft RemovalCamshaft Installation Piston TDC Finding Special Tool TDC Measurement Tool Camshaft, Camshaft Cap Wear Camshaft RunoutCamshaft Chain Removal Cylinder Head Cylinder Compression MeasurementCylinder Head Removal Cylinder Head Installation Cylinder Head Warp Valve Installation ValvesValve Clearance Check Valve RemovalValve Guide Installation Valve-to-Guide Clearance Measurement Wobble MethodValve Seat Inspection Valve Seat RepairOperating Procedures Seat Cutter Operation CareMarks Stamped on the Cutter Engine TOP END Engine TOP END Engine TOP END Cylinder, Pistons Cylinder RemovalPiston Removal Piston/Cylinder Installation Oil ring rails have no top or bottomWith the Hand With the Special ToolsCylinder Wear Piston WearPiston Ring, Piston Ring Groove Wear Piston Ring Groove WidthPiston Ring Thickness Piston Ring End GapPage Engine Removal/Installation Exploded View Fastener Torque Remarks Kgf·m Engine Removal/Installation Engine RemovalEngine Damper Removal Engine Damper Installation Engine InstallationEngine Bottom End Exploded View Fastener Torque Remarks Kgf·m Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Big End Bearing Insert SelectionCrankshaft Main Journal Diameter 40.984 ∼ 41.000 mm 40.96 mm Special Tools and Sealant Kawasaki Bond Liquid Gasket Black Coupling Coupling/Output Shaft RemovalCoupling/Output Shaft Installation Output Cover Oil Seal Replacement Magneto Cover Bearing Replacement Oil Seal InspectionBall Bearing Lubrication Ball Bearing InspectionMagneto Flywheel Installation Magneto FlywheelMagneto Flywheel Removal InstallMagneto Cover see Coupling/Output Shaft Installation Stator Installation StatorStator Removal Crankcase Splitting Crankcase SplittingCrankcase Assembly Following the sequence numbers, tighten the M8 bolts Crankshaft and Connecting Rods Crankshaft InstallationCrankshaft Removal Connecting Rod Removal Connecting Rod InstallationEngine Bottom END Connecting Rod Bend Be careful not to overtighten the nutsConnecting Rod Twist Connecting Rod Big End Side ClearanceConnecting Rod Big End Bearing Insert/Crankpin Wear 92139-3709 Crankshaft Main Bearing Insert/Journal Wear Marking Position Crankshaft Side Clearance Crankshaft RunoutMeasure the crankshaft runout CrankshaftCooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Breather Installation Breather Cleaning and InspectionBilge System Breather RemovalFilter Installation Filter Cleaning and InspectionHose Installation Cooling and Bilge System HosesHose Removal Hose InspectionCooling and Bilge System Flushing Cooling and Bilge System Flow Diagram Cooling and Bilge Systems Water Pipe Installation Water PipeWater Pipe Removal Summary Procedures after Submerging After SubmergingCooling 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 ShaftDrive System Drive Shaft Removal/Installation Drive Shaft Holder Removal/DisassemblyDrive 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 ∼ Water Filter Cover Removal/Installation Impeller Outside Diameter MeasurementPump Inspection Impeller ClearancePage Steering Exploded View 36 ∼ Special Tool and Sealant Steering Cable Adjustment Steering CableSteering Cable Removal Special Tool Box Wrench Steering Cable Installation Steering Cable InspectionSteering Cable Lubrication Handlebar Handlebar RemovalHandlebar Installation Steering Steering Removal Steering Steering Steering Installation Torque the steering shaft locknut a Steering Shift Cable Adjustment Reverse SystemShift Cable Removal Steering Shift Cable Installation Shift Cable InspectionShift Cable Lubrication Reverse Bucket Removal/Installation Shift Lever Shaft Removal/InstallationHull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Seat Installation FittingsSeat Removal Front Storage Compartment Cover RemovalFront Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Installation Mirror RemovalMirror Stay Removal Mirror Stay Installation Front Storage Pocket Installation Storage Pocket Disassembly/AssemblyFront Storage Pocket Removal Crossmember RemovalCrossmember Installation Handrail Installation Drain Plug Housing RemovalDrain Plug Housing Installation Exhaust Outlet InstallationStabilizer Installation Reboarding Step InstallationStabilizer Removal Reboarding Step RemovalHull Replacement Rubber Parts Rubber Parts LocationHULL/ENGINE Hood Rivet Installation Front Bumper InstallationRear Bumper Installation Rivet RemovalSide 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 Standard Service Limit Battery Electric Starter SystemCharging System Ignition SystemElectrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Electrical Wiring Wiring InspectionBattery InstallationRemoval Electrolyte FillingElectrical System Precautions Initial ChargeInterchange Charging Condition InspectionRefreshing Charge Electrical System Starter Relay Installation Electric Starter SystemStarter Relay Removal Starter Relay InspectionStarter Motor Installation Starter Motor RemovalStarter Motor Disassembly Starter Motor AssemblyCommutator Cleaning and Inspection Brush InspectionArmature Inspection Brush Lead InspectionBrush Plate and Terminal Bolt Inspection Reduction Gear Removal/Installation Reduction Gear InspectionElectrical System Regulator/Rectifier Removal/Installation Charging SystemMagneto Output Voltage Regulator/Rectifier Inspection Regulator InspectionCharging System Circuit Electrical System Crankshaft Sensor Installation Ignition SystemCrankshaft Sensor Removal Timing Rotor Installation Timing Rotor RemovalIgnition Coil Removal Ignition Coil Installation Ignition Coil Inspection Measuring arcing distanceMeasuring coil resistance Camshaft Position Sensor Installation Camshaft Position Sensor RemovalMeasuring spark plug lead resistance Igniter Removal/Installation Igniter InspectionIgnition Coil Primary Peak Voltage Standard 250 V or more Crankshaft Sensor Peak Voltage Check Camshaft Position Sensor Peak Voltage InspectionSpark Plug Installation Spark Plug AdjustmentSpark Plug Cleaning Spark Plug RemovalIgnition System Circuit Electrical System Steering Position Sensor and Magnet Installation Kawasaki Smart Steering SystemSteering Position Sensor and Magnet Removal Inspection of Kawasaki Smart Steering System Steering Position Sensor ClearanceSteering Position Sensor Input Voltage Inspection Steering Position Sensor Output Voltage Inspection Steering Position Sensor Circuit Speed Sensor Removal/Installation SensorsSpeed Sensor Inspection Throttle Sensor Removal/Installation Fuel Level Sensor InspectionWater Temperature Sensor Inspection Inlet Air Temperature Sensor InspectionOil Temperature Sensor Inspection Throttle Sensor InspectionMultifunction Meter Display Function InspectionMODE/SET Button Inspection Speedometer Inspection Speed Sensor Electric Source Inspection Battery Symbol/bAt Characters/LED Inspection Tachometer InspectionBuzzer Inspection Electrical System Relay Assembly Circuit InspectionRelay Assembly Circuit Inspection with the battery connected Switches Switch InspectionFuse Page Storage Preparation for Storage Cooling SystemBilge System Engine OilEngine Battery Do not allow any soda solution to enter the batteryAir Filter Engine Mounting BoltsGeneral Removal from Storage General InspectionTest 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 Troubleshooting Guide Engine Doesn’t Start, Starting DifficultyPoor Running at Low Speed Poor Running or No Power at High Speed Overheating Over CoolingAbnormal Engine Noise Oil Pressure Warning Light Goes OnEngine Activates Slow Down Mode Battery TroublePoor Performance through Engine Runs ProperlyModel Application