Kawasaki STX-15F guide

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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 Cooling General Information Battery Ground Edges of PartsSolvent Cleaning Watercraft before Disassembly Arrangement and Cleaning of Removed PartsReplacement Parts Storage of Removed Parts Assembly Order Tightening Sequence Tightening TorqueForce Gasket, O-ring Liquid Gasket, Locking Agent PressBall Bearing Oil Seal, Grease Seal Circlips, Cotter Pins Electrical WiresLubrication Direction of Engine Rotation Model 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 Impeller Fastener Torque Remarks Kgf·m Ft·lb SteeringHull/Engine Hood 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 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 Change Dry 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 Inspection Periodic Maintenance Bilge System Flushing Periodic Maintenance Procedures Pump and Impeller SteeringImpeller Inspection Steering Cable/Shift Cable Inspection Battery Charging Condition Inspection Battery Terminals InspectionHull/Engine Hood 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 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 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 User Mode Dealer ModeSelf-Diagnosis Self-diagnosis Outline Self-Diagnosis Service Code Character Table Possible Problems Fail-Safe FunctionDisplayed on 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 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/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 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 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 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 Inspection Relay Coil Terminals 6 Relay Switch Terminals 5 Fuel Pump Relay Throttle Cable Adjustment Throttle Case Removal/DisassemblyThrottle Lever, Cable and Case Free Play Inspection Throttle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Case and Cable Lubrication Throttle Cable Inspection Air Filter Installation Air FilterAir 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 Fuel Pump RemovalJT1500-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 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 Assembly Oil Cooler Inspection Breather Case Installation Breather Case and Oil Separator TankBreather Case Removal Oil Separator Tank Removal Oil Separator Tank Installation Blowby Gas System Inspection Oil 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 Removal Oil Screen Installation Oil Pump InspectionOil Screen Removal Oil Pressure Relief Valve Inspection Oil Pump Sprocket Chain Removal Oil Pressure Measurement Oil Pressure Measurement Engine 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 Removal Exhaust 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 Fastener Engine TOP END Fastener Torque Remarks Kgf·m Standard Service Limit Camshafts Cylinder HeadValves Standard Service Limit Cylinder, Piston Special Tools and Sealant Engine TOP END Engine TOP END Clean Air System Air Suction Valve InstallationClean Air System Hose Inspection Air Suction Valve Removal Cylinder Head Cover Installation Cylinder Head CoverCylinder Head Cover Removal Camshaft Chain Tensioner Installation Camshaft Chain TensionerCamshaft 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 Installation ValvesValve Clearance Check Valve Removal Valve Guide Installation Valve-to-Guide Clearance Measurement Wobble Method Valve Seat Inspection Valve Seat Repair Operating 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 bottom With the Hand With the Special Tools Cylinder Wear Piston WearPiston Ring, Piston Ring Groove 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 Magneto Cover Bearing Replacement Oil Seal InspectionBall Bearing Lubrication Ball Bearing Inspection Magneto Flywheel Installation Magneto FlywheelMagneto Flywheel Removal InstallMagneto Cover see Coupling/Output Shaft Installation Stator Installation StatorStator Removal Crankcase Splitting Crankcase Splitting Crankcase Assembly Following the sequence numbers, tighten the M8 bolts Crankshaft and Connecting Rods Crankshaft InstallationCrankshaft Removal Connecting Rod Removal Connecting Rod Installation Engine Bottom END Connecting Rod Bend Be careful not to overtighten the nuts Connecting 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 Crankshaft Cooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Breather Installation Breather Cleaning and InspectionBilge System Breather Removal Filter Installation Filter Cleaning and Inspection Hose Installation Cooling and Bilge System HosesHose Removal Hose Inspection Cooling 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 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 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 Removal Handlebar 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/Installation Hull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Seat Installation FittingsSeat Removal Front Storage Compartment Cover Removal Front 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 Removal Crossmember Installation Handrail Installation Drain Plug Housing RemovalDrain Plug Housing Installation Exhaust Outlet Installation Stabilizer Installation Reboarding Step InstallationStabilizer Removal Reboarding Step Removal Hull Replacement Rubber Parts Rubber Parts Location HULL/ENGINE Hood Rivet Installation Front Bumper InstallationRear 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 Standard Service Limit Battery Electric Starter SystemCharging System Ignition System Electrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Electrical Wiring Wiring Inspection Battery InstallationRemoval Electrolyte Filling Electrical System Precautions Initial Charge Interchange Charging Condition InspectionRefreshing Charge Electrical System Starter Relay Installation Electric Starter SystemStarter Relay Removal Starter Relay Inspection Starter Motor Installation Starter Motor Removal Starter Motor Disassembly Starter Motor Assembly Commutator Cleaning and Inspection Brush Inspection Armature Inspection Brush Lead InspectionBrush Plate and Terminal Bolt Inspection Reduction Gear Removal/Installation Reduction Gear Inspection Electrical System Regulator/Rectifier Removal/Installation Charging SystemMagneto Output Voltage Regulator/Rectifier Inspection Regulator Inspection Charging System Circuit Electrical System Crankshaft Sensor Installation Ignition SystemCrankshaft Sensor Removal Timing Rotor Installation Timing Rotor Removal Ignition 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 Inspection Ignition Coil Primary Peak Voltage Standard 250 V or more Crankshaft Sensor Peak Voltage Check Camshaft Position Sensor Peak Voltage Inspection Spark Plug Installation Spark Plug AdjustmentSpark Plug Cleaning Spark Plug Removal Ignition 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 Clearance Steering 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 Inspection Water Temperature Sensor Inspection Inlet Air Temperature Sensor InspectionOil 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 Preparation for Storage Cooling SystemBilge System Engine Oil Engine Battery Do not allow any soda solution to enter the batteryAir Filter 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 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 On Engine Activates Slow Down Mode Battery TroublePoor Performance through Engine Runs Properly Model Application