Engine TOP END | Kawasaki STX-15F specification

6-4 ENGINE TOP END

Exploded View

Image 182

Kawasaki STX-15F service manual Engine TOP END

Contents

JET SKI Watercraft Page Quick Reference Guide Page JET SKI Watercraft List of Abbreviations Exhaust Emission Control System Fuel InformationEmission Control Information Foreword Page Page General Information Smart Learning Operation mode SLO JT1500-A2 model ∼ Before Servicing Kawasaki Diagnostic System KDS SoftwareAdjustments Auxiliary Cooling General Information Solvent Battery GroundEdges of Parts 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 Electrical Equipment Items JT1500-A1 ∼ A2Engine Oil 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 Engine Lubrication System Torque and Locking AgentFastener Torque Remarks Kgf·m Ft·lb Fuel System Engine Top End Fastener Torque Remarks Kgf·mExhaust System 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 Throttle Control System Inspection Periodic Maintenance Procedures Fuel SystemAir Filter Drain Caps Inspection and Cleaning Fuel Vent Check Valve Inspection Periodic Maintenance ProceduresAir Filter Inspection and Cleaning Throttle Shaft Spring Inspection Fuel Pump Screen CleaningEngine Lubrication System Engine Oil Change Dry Oil Filter Replace Valve Clearance Inspection Periodic Maintenance Procedures Engine Top EndAir Suction Valve 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 Nut, Bolt and Fastener to be checked Nuts, Bolts, and Fasteners Tightness InspectionHose and Hose Connect Inspection 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 Self-Diagnosis Self-diagnosis Outline User ModeDealer Mode 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 Removal Inlet Air Pressure Sensor Service Code/Character-12/bOStInlet Air Pressure Sensor Installation 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 Inspection Crankshaft Sensor Service Code/Character-21/CrAgCrankshaft Sensor Removal/Installation Camshaft Position Sensor Inspection Camshaft Position Sensor Service Code/Character-23/CAAgCamshaft Position Sensor Removal/Installation Vehicle-down Sensor Removal Vehicle-down Sensor Service Code/Character-31/dOSVehicle-down Sensor Installation 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 Removal ECU InstallationECU Power Supply Inspection 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 Removal Air Filter InstallationAir Filter 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 JT1500-A2 ∼ model Fuel PumpFuel Pump Removal 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 Preliminary Check Engine Oil and Oil FilterOil Level Inspection Ordinary standard Check Oil Filter Replacement Oil Cooler Removal Oil Cooler InstallationOil Cooler 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 Removal Oil Pan InstallationOil Pan Oil Pump Sprocket Removal Oil Pump Sprocket InstallationOil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve Oil Pump Installation Oil Pump Removal Oil Screen Removal Oil Screen InstallationOil Pump Inspection Oil Pressure Relief Valve Inspection Oil Pump Sprocket Chain Removal Oil Pressure Measurement Oil Pressure Measurement Engine Lubrication System Oil Pressure Switch Installation Oil Pressure SwitchOil Pressure Switch Removal 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 Removal Exhaust Pipe InstallationExhaust Pipe Exhaust Pipe Cleaning and Inspection Water Box Muffler Removal Water Box Muffler InstallationWater Box Muffler Water Box Muffler Inspection Engine Top End Exploded View Engine TOP END Fastener Engine TOP END Fastener Torque Remarks Kgf·m Valves Standard Service Limit CamshaftsCylinder Head 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 Removal Cylinder Head Cover InstallationCylinder Head Cover Camshaft Chain Tensioner Removal Camshaft Chain Tensioner InstallationCamshaft Chain Tensioner 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 Marks Stamped on the Cutter Operating ProceduresSeat Cutter Operation Care Engine TOP END Engine TOP END Engine TOP END Piston Removal Cylinder, PistonsCylinder 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 Removal Magneto Flywheel InstallationMagneto Flywheel InstallMagneto Cover see Coupling/Output Shaft Installation Stator Removal Stator InstallationStator Crankcase Splitting Crankcase Splitting Crankcase Assembly Following the sequence numbers, tighten the M8 bolts Crankshaft Removal Crankshaft and Connecting RodsCrankshaft Installation Connecting Rod Removal Connecting Rod Installation Engine Bottom END Connecting Rod Bend Be careful not to overtighten the nuts Connecting Rod Big End Bearing Insert/Crankpin Wear Connecting Rod TwistConnecting Rod Big End Side Clearance 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 Removal Water Pipe InstallationWater Pipe 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/Drive Shaft Holder Drive Shaft Removal/InstallationDrive Shaft Holder Removal/Disassembly 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 Removal Steering Cable AdjustmentSteering Cable Special Tool Box Wrench Steering Cable Lubrication Steering Cable InstallationSteering Cable Inspection Handlebar Handlebar Removal Handlebar Installation Steering Steering Removal Steering Steering Steering Installation Torque the steering shaft locknut a Steering Shift Cable Removal Shift Cable AdjustmentReverse System Steering Shift Cable Lubrication Shift Cable InstallationShift Cable Inspection 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 Stay Removal Mirror InstallationMirror 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 Refreshing Charge InterchangeCharging Condition Inspection 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 Plate and Terminal Bolt Inspection Armature InspectionBrush Lead Inspection Reduction Gear Removal/Installation Reduction Gear Inspection Electrical System Magneto Output Voltage Regulator/Rectifier Removal/InstallationCharging System Regulator/Rectifier Inspection Regulator Inspection Charging System Circuit Electrical System Crankshaft Sensor Removal Crankshaft Sensor InstallationIgnition System Timing Rotor Installation Timing Rotor Removal Ignition Coil Removal Ignition Coil Installation Measuring coil resistance Ignition Coil InspectionMeasuring arcing distance Measuring spark plug lead resistance Camshaft Position Sensor InstallationCamshaft Position Sensor Removal 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 Steering Position Sensor and Magnet Removal Steering Position Sensor and Magnet InstallationKawasaki Smart Steering System 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 Speed Sensor Inspection Speed Sensor Removal/InstallationSensors 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 Poor Running at Low Speed Troubleshooting GuideEngine Doesn’t Start, Starting Difficulty 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