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Kawasaki STX-15F service manual Engine Removal/Installation

Models: STX-15F

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ENGINE REMOVAL/INSTALLATION 7-1

Engine Removal/Installation

	Table of Contents
Exploded View	7-2
Engine Removal/Installation	7-4
Engine Removal	7-4
Engine Damper Removal	7-5
Engine Damper Installation	7-6
Engine Installation	7-6

7

Image 215

Kawasaki STX-15F service manual Engine Removal/Installation

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 ∼ Auxiliary Cooling Kawasaki Diagnostic System KDS SoftwareAdjustments Before ServicingGeneral Information Solvent Battery GroundEdges of Parts Storage of Removed Parts Cleaning Watercraft before DisassemblyArrangement and Cleaning of Removed Parts Replacement PartsGasket, O-ring Assembly Order Tightening SequenceTightening Torque ForceOil Seal, Grease Seal Liquid Gasket, Locking AgentPress Ball BearingDirection of Engine Rotation Circlips, Cotter PinsElectrical Wires LubricationModel Identification General Specifications Electrical Equipment Items JT1500-A1 ∼ A2Engine Oil Units of Mass Units of Volume Units of PressureUnits of Force Units of Power Unit Conversion Table Prefixes for Units Units of LengthPage 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 Pump and Impeller Engine Removal/InstallationEngine Bottom End Cooling and Bilge SystemsElectrical System Fastener Torque Remarks Kgf·m Ft·lbSteering Hull/Engine HoodThreads dia. mm Torque Kgf·m Ft·lb General Fasteners stainless bolt and nutStandard Service Limit Fuel System SpecificationsSpecial 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 Engine Oil Change Fuel Pump Screen CleaningEngine Lubrication System Throttle Shaft Spring InspectionDry 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 Coupling Damper Inspection Engine Bottom EndCooling and Bilge Systems Engine Mounting Bolts Inspection and TightnessPeriodic Maintenance Bilge System Flushing Steering Cable/Shift Cable Inspection Periodic Maintenance Procedures Pump and ImpellerSteering Impeller InspectionElectrical System Battery Charging Condition InspectionBattery Terminals Inspection Hull/Engine HoodLubrication Spark Plug Cleaning and InspectionSteering 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 Digital Fuel Injection System StandardFuel System DFI Special Tools and Sealant DFI Parts Location Fuel System DFI Dummy DFI System Part Name Terminal Names Terminal Numbers of ECU ConnectorsDFI Servicing Precautions For JT1500-A2 ∼ Silicone Sealant Kawasaki Bond 56019-120 -Seals Connector Self-Diagnosis Self-diagnosis Outline User ModeDealer Mode JT1500-A1 Self-Diagnosis Service Code Character TablePossible Problems Fail-Safe Function Displayed onSelf-Diagnosis Memory of Service Code CharacterWatercraft conditions when problem occurred Troubleshooting the DFI System Sample Diagnosis SheetTroubleshooting the DFI System Throttle Sensor Removal/Adjustment Throttle Sensor Service Code/Character-11/tPSInput Voltage Inspection Be sure the battery is fully chargedInput 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 Removal/Installation Inlet Air Temperature Sensor Service Code/Character-13/AIrtSensor Resistance Inspection Fuel System DFI Water Temperature Sensor Removal/Installation Water Temperature Sensor Service Code/Character-14/AqUtOutput 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 Removal Fuel Injector InstallationAudible Inspection Injector Signal TestInjector Unit Test Injector Resistance InspectionInjector Voltage Inspection Injector Fuel Line Inspection ECU Ignition Coil Removal/Installation Ignition Coils Service Code/Character-51, 52/COL1, COL2Fuel System DFI Possible Causes Action Chapter Engine Overheating Service Code/Character-71/HEAtLow 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/OILHECU Removal ECU InstallationECU Power Supply Inspection ECU connector B in this chapter figure ECU Power Source Circuit Main Fuse Inspection DFI Power SourceRelay Assembly Removal Relay Assembly InspectionFuel Pump Relay Relay Coil Terminals 6 Relay Switch Terminals 5Free Play Inspection Throttle Cable AdjustmentThrottle Case Removal/Disassembly Throttle Lever, Cable and CaseThrottle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Cable Inspection Throttle Case and Cable LubricationAir Filter Removal Air Filter InstallationAir Filter Air Filter Assembly Air Filter DisassemblyThrottle Body Assy ISC Idle Speed Controller Inspection ISC Idle Speed Controller Removal/InstallationISC a ISC Resistance InspectionInlet Manifold Removal Inlet ManifoldInlet Manifold Installation Fuel System DFI Fuel Pressure Inspection Fuel LineFuel Flow Rate Inspection Amount of Fuel Flow Standard 67 mL or more for 3 seconds Fuel Vent Check Valve Mounting Fuel Vent Check ValveFuel Filter Removal Fuel FilterFuel Filter Installation JT1500-A2 ∼ model Fuel PumpFuel Pump Removal Power Source Voltage Inspection Fuel Pump InstallationOperating Voltage Inspection Fuel Pump Relay Inspection Fuel Pump Relay RemovalFuel Tank Removal Fuel TankFuel Tank Cleaning Fuel Tank InstallationFuel Filler and Tube Removal Fuel Filler and Tube InstallationEngine 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 Assembly Oil Cooler DisassemblyOil Cooler Inspection Oil Separator Tank Removal Breather Case InstallationBreather Case and Oil Separator Tank Breather Case RemovalBlowby Gas System Inspection Oil Separator Tank InstallationOil 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 Removal Oil Pump InstallationOil Screen Removal Oil Screen InstallationOil Pump Inspection Oil Pump Sprocket Chain Removal Oil Pressure Relief Valve InspectionOil Pressure Measurement Oil Pressure MeasurementEngine Lubrication System Oil Pressure Switch Installation Oil Pressure SwitchOil Pressure Switch Removal Page Exhaust System Exploded View Fastener Torque Remarks Kgf·m Exhaust Manifold Removal Exhaust ManifoldExhaust 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 Fastener Engine TOP ENDEngine TOP END Fastener Torque Remarks Kgf·m Valves Standard Service Limit CamshaftsCylinder Head Cylinder, Piston Standard Service LimitSpecial Tools and Sealant Engine TOP END Engine TOP END Air Suction Valve Removal Clean Air SystemAir Suction Valve Installation Clean Air System Hose InspectionCylinder Head Cover Removal Cylinder Head Cover InstallationCylinder Head Cover Camshaft Chain Tensioner Removal Camshaft Chain Tensioner InstallationCamshaft Chain Tensioner Camshaft Removal Camshaft, Camshaft ChainCamshaft Installation Piston TDC Finding Special Tool TDC Measurement Tool Camshaft Runout Camshaft, Camshaft Cap WearCamshaft Chain Removal Cylinder Compression Measurement Cylinder HeadCylinder Head Removal Cylinder Head Installation Cylinder Head Warp Valve Removal Valve InstallationValves Valve Clearance CheckValve-to-Guide Clearance Measurement Wobble Method Valve Guide InstallationValve Seat Repair Valve Seat InspectionMarks Stamped on the Cutter Operating ProceduresSeat Cutter Operation Care Engine TOP END Engine TOP END Engine TOP END Piston Removal Cylinder, PistonsCylinder Removal Oil ring rails have no top or bottom Piston/Cylinder InstallationWith the Special Tools With the HandPiston Ring Groove Width Cylinder WearPiston Wear Piston Ring, Piston Ring Groove WearPiston Ring End Gap Piston Ring ThicknessPage Engine Removal/Installation Exploded View Fastener Torque Remarks Kgf·m Engine Removal Engine Removal/InstallationEngine Damper Removal Engine Installation Engine Damper InstallationEngine Bottom End Exploded View Fastener Torque Remarks Kgf·m Connecting Rod Big End Bearing Insert Selection Standard Service Limit Crankshaft, Connecting RodsCrankshaft Main Journal Diameter 40.984 ∼ 41.000 mm 40.96 mm Special Tools and Sealant Kawasaki Bond Liquid Gasket Black Coupling/Output Shaft Removal CouplingCoupling/Output Shaft Installation Output Cover Oil Seal Replacement Ball Bearing Inspection Magneto Cover Bearing ReplacementOil Seal Inspection Ball Bearing LubricationMagneto Flywheel Removal Magneto Flywheel InstallationMagneto Flywheel InstallMagneto Cover see Coupling/Output Shaft Installation Stator Removal Stator InstallationStator Crankcase Splitting Crankcase SplittingCrankcase Assembly Following the sequence numbers, tighten the M8 bolts Crankshaft Removal Crankshaft and Connecting RodsCrankshaft Installation Connecting Rod Installation Connecting Rod RemovalEngine Bottom END Be careful not to overtighten the nuts Connecting Rod BendConnecting 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 Crankshaft Crankshaft Side ClearanceCrankshaft Runout Measure the crankshaft runoutCooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Breather Removal Breather InstallationBreather Cleaning and Inspection Bilge SystemFilter Cleaning and Inspection Filter InstallationHose Inspection Hose InstallationCooling and Bilge System Hoses Hose RemovalCooling and Bilge System Flushing Cooling and Bilge System Flow Diagram Cooling and Bilge Systems Water Pipe Removal Water Pipe InstallationWater Pipe After Submerging Summary Procedures 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 Standard Service Limit Drive Shaft SpecificationDrive 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 JT1500-A1,A2 ∼ Pump AssemblySpecial Tool Bearing Driver Set Pump and Impeller JT1500-A1, A2 ∼ Impeller Clearance Water Filter Cover Removal/InstallationImpeller Outside Diameter Measurement Pump InspectionPage 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 Removal HandlebarHandlebar 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 Shift Lever Shaft Removal/Installation Reverse Bucket Removal/InstallationHull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Front Storage Compartment Cover Removal Seat InstallationFittings Seat RemovalFront Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Stay Removal Mirror InstallationMirror Removal Mirror Stay Installation Crossmember Removal Front Storage Pocket InstallationStorage Pocket Disassembly/Assembly Front Storage Pocket RemovalCrossmember Installation Exhaust Outlet Installation Handrail InstallationDrain Plug Housing Removal Drain Plug Housing InstallationReboarding Step Removal Stabilizer InstallationReboarding Step Installation Stabilizer RemovalHull Replacement Rubber Parts Location Rubber PartsHULL/ENGINE Hood Rivet Removal Rivet InstallationFront Bumper Installation Rear Bumper InstallationSide 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 Ignition System Standard Service Limit BatteryElectric Starter System Charging SystemElectrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Wiring Inspection Electrical WiringElectrolyte Filling BatteryInstallation RemovalElectrical System Initial Charge PrecautionsRefreshing Charge InterchangeCharging Condition Inspection Electrical System Starter Relay Inspection Starter Relay InstallationElectric Starter System Starter Relay RemovalStarter Motor Removal Starter Motor InstallationStarter Motor Assembly Starter Motor DisassemblyBrush Inspection Commutator Cleaning and InspectionBrush Plate and Terminal Bolt Inspection Armature InspectionBrush Lead Inspection Reduction Gear Inspection Reduction Gear Removal/InstallationElectrical System Magneto Output Voltage Regulator/Rectifier Removal/InstallationCharging System Regulator Inspection Regulator/Rectifier InspectionCharging System Circuit Electrical System Crankshaft Sensor Removal Crankshaft Sensor InstallationIgnition System Timing Rotor Removal Timing Rotor InstallationIgnition 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 Inspection Igniter Removal/InstallationIgnition Coil Primary Peak Voltage Standard 250 V or more Camshaft Position Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage CheckSpark Plug Removal Spark Plug InstallationSpark Plug Adjustment Spark Plug CleaningIgnition System Circuit Electrical System Steering Position Sensor and Magnet Removal Steering Position Sensor and Magnet InstallationKawasaki Smart Steering System Steering Position Sensor Clearance Inspection of Kawasaki Smart Steering SystemSteering Position Sensor Input Voltage Inspection Steering Position Sensor Output Voltage Inspection Steering Position Sensor Circuit Speed Sensor Inspection Speed Sensor Removal/InstallationSensors Fuel Level Sensor Inspection Throttle Sensor Removal/InstallationThrottle Sensor Inspection Water Temperature Sensor InspectionInlet Air Temperature Sensor Inspection Oil Temperature Sensor InspectionDisplay Function Inspection Multifunction MeterMODE/SET Button Inspection Speedometer Inspection Speed Sensor Electric Source Inspection Tachometer Inspection Battery Symbol/bAt Characters/LED InspectionBuzzer Inspection Electrical System Circuit Inspection Relay AssemblyRelay Assembly Circuit Inspection with the battery connected Switch Inspection SwitchesFuse Page Storage Engine Oil Preparation for StorageCooling System Bilge SystemEngine Engine Mounting Bolts BatteryDo not allow any soda solution to enter the battery Air FilterGeneral General Inspection Removal from StorageTest 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 Oil Pressure Warning Light Goes On OverheatingOver Cooling Abnormal Engine NoiseRuns Properly Engine Activates Slow Down ModeBattery Trouble Poor Performance through EngineModel Application