JET SKI Watercraft
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Quick Reference Guide
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JET SKI Watercraft
List of Abbreviations
Fuel Information
Emission Control Information
Exhaust Emission Control System
Foreword
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General Information
Smart Learning Operation mode SLO JT1500-A2 model ∼
Before Servicing
Kawasaki Diagnostic System KDS Software
Adjustments
Auxiliary Cooling
General Information
Battery Ground
Edges of Parts
Solvent
Replacement Parts
Cleaning Watercraft before Disassembly
Arrangement and Cleaning of Removed Parts
Storage of Removed Parts
Force
Assembly Order Tightening Sequence
Tightening Torque
Gasket, O-ring
Ball Bearing
Liquid Gasket, Locking Agent
Press
Oil Seal, Grease Seal
Lubrication
Circlips, Cotter Pins
Electrical Wires
Direction of Engine Rotation
Model Identification
General Specifications
Items JT1500-A1 ∼ A2
Engine Oil
Electrical Equipment
Unit Conversion Table Prefixes for Units Units of Length
Units of Volume Units of Pressure
Units of Force Units of Power
Units of Mass
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Periodic Maintenance
Periodic Maintenance Chart
Torque and Locking Agent
Fastener Torque Remarks Kgf·m Ft·lb Fuel System
Engine Lubrication System
Fastener Torque Remarks Kgf·m
Exhaust System
Engine Top End
Cooling and Bilge Systems
Engine Removal/Installation
Engine Bottom End
Pump and Impeller
Hull/Engine Hood
Fastener Torque Remarks Kgf·m Ft·lb
Steering
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 Cleaning
Throttle Control System Inspection
Periodic Maintenance Procedures
Air Filter Inspection and Cleaning
Fuel Vent Check Valve Inspection
Throttle Shaft Spring Inspection
Fuel Pump Screen Cleaning
Engine Lubrication System
Engine Oil Change
Dry
Oil Filter Replace
Periodic Maintenance Procedures Engine Top End
Air Suction Valve Inspection
Valve Clearance Inspection
Periodic Maintenance
Inlet Valve Clearance Adjustment Chart
Exhaust Valve Clearance Adjustment Chart
Engine Mounting Bolts Inspection and Tightness
Engine Bottom End
Cooling and Bilge Systems
Coupling Damper Inspection
Periodic Maintenance
Bilge System Flushing
Impeller Inspection
Periodic Maintenance Procedures Pump and Impeller
Steering
Steering Cable/Shift Cable Inspection
Hull/Engine Hood
Battery Charging Condition Inspection
Battery 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
Nuts, Bolts, and Fasteners Tightness Inspection
Hose and Hose Connect Inspection
Nut, Bolt and Fastener to be checked
JT1500-A2 ∼
Rubber Strap Inspection
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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 Mode
Self-Diagnosis Self-diagnosis Outline
Displayed on
Self-Diagnosis Service Code Character Table
Possible 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 Service Code/Character-12/bOSt
Inlet Air Pressure Sensor Installation
Inlet 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/Installation
Crankshaft Sensor Inspection
Camshaft Position Sensor Service Code/Character-23/CAAg
Camshaft Position Sensor Removal/Installation
Camshaft Position Sensor Inspection
Vehicle-down Sensor Service Code/Character-31/dOS
Vehicle-down Sensor Installation
Vehicle-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 Inspection
ECU Removal
ECU connector B in this chapter figure
ECU Power Source Circuit
Relay Assembly Inspection
DFI Power Source
Relay Assembly Removal
Main Fuse Inspection
Relay Coil Terminals 6 Relay Switch Terminals 5
Fuel Pump Relay
Throttle Lever, Cable and Case
Throttle Cable Adjustment
Throttle 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 Installation
Air Filter
Air 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 Removal
JT1500-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 Inspection
Preliminary Check
Ordinary standard Check
Oil Filter Replacement
Oil Cooler Installation
Oil Cooler
Oil Cooler Removal
Oil Cooler Disassembly
Oil Cooler Assembly
Oil Cooler Inspection
Breather Case Removal
Breather Case Installation
Breather Case and Oil Separator Tank
Oil Separator Tank Removal
Oil Separator Tank Installation
Blowby Gas System Inspection
Oil Pan Installation
Oil Pan
Oil Pan Removal
Oil Pump Sprocket Installation
Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve
Oil Pump Sprocket Removal
Oil Pump Installation
Oil Pump Removal
Oil Screen Installation
Oil Pump Inspection
Oil 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 Removal
Oil Pressure Switch Installation
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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 Pipe
Exhaust Pipe Removal
Exhaust Pipe Cleaning and Inspection
Water Box Muffler Installation
Water Box Muffler
Water 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 Head
Valves
Standard Service Limit
Cylinder, Piston
Special Tools and Sealant
Engine TOP END
Engine TOP END
Clean Air System Hose Inspection
Clean Air System
Air Suction Valve Installation
Air Suction Valve Removal
Cylinder Head Cover Installation
Cylinder Head Cover
Cylinder Head Cover Removal
Camshaft Chain Tensioner Installation
Camshaft Chain Tensioner
Camshaft 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 Installation
Valves
Valve Removal
Valve Guide Installation
Valve-to-Guide Clearance Measurement Wobble Method
Valve Seat Inspection
Valve Seat Repair
Operating Procedures
Seat Cutter Operation Care
Marks Stamped on the Cutter
Engine TOP END
Engine TOP END
Engine TOP END
Cylinder, Pistons
Cylinder Removal
Piston 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 Wear
Piston Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
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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 Replacement
Oil Seal Inspection
Ball Bearing Inspection
Magneto Flywheel Installation
Magneto Flywheel
Magneto Flywheel Removal
InstallMagneto Cover see Coupling/Output Shaft Installation
Stator Installation
Stator
Stator Removal
Crankcase Splitting
Crankcase Splitting
Crankcase Assembly
Following the sequence numbers, tighten the M8 bolts
Crankshaft and Connecting Rods
Crankshaft Installation
Crankshaft 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 Clearance
Connecting Rod Big End Bearing Insert/Crankpin Wear
92139-3709
Crankshaft Main Bearing Insert/Journal Wear
Marking Position
Measure the crankshaft runout
Crankshaft Side Clearance
Crankshaft Runout
Crankshaft
Cooling and Bilge Systems
Exploded View
Fastener Torque Remarks Kgf·m
Bilge System
Breather Installation
Breather Cleaning and Inspection
Breather Removal
Filter Installation
Filter Cleaning and Inspection
Hose Removal
Hose Installation
Cooling and Bilge System Hoses
Hose Inspection
Cooling and Bilge System Flushing
Cooling and Bilge System Flow Diagram
Cooling and Bilge Systems
Water Pipe Installation
Water Pipe
Water Pipe Removal
Summary Procedures after Submerging
After Submerging
Cooling and Bilge Systems
Detailed Procedures after Submerging
Cooling and Bilge Systems
Cooling and Bilge Systems
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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/Disassembly
Drive 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/Installation
Impeller Outside Diameter Measurement
Impeller Clearance
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Steering
Exploded View
36 ∼
Special Tool and Sealant
Steering Cable Adjustment
Steering Cable
Steering Cable Removal
Special Tool Box Wrench
Steering Cable Installation
Steering Cable Inspection
Steering 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 System
Shift Cable Removal
Steering
Shift Cable Installation
Shift Cable Inspection
Shift 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 Installation
Fittings
Front Storage Compartment Cover Removal
Front Storage Compartment Cover Disassembly
Front Storage Compartment Cover Assembly
Mirror Installation
Mirror Removal
Mirror Stay Removal
Mirror Stay Installation
Front Storage Pocket Removal
Front Storage Pocket Installation
Storage Pocket Disassembly/Assembly
Crossmember Removal
Crossmember Installation
Drain Plug Housing Installation
Handrail Installation
Drain Plug Housing Removal
Exhaust Outlet Installation
Stabilizer Removal
Stabilizer Installation
Reboarding Step Installation
Reboarding Step Removal
Hull Replacement
Rubber Parts
Rubber Parts Location
HULL/ENGINE Hood
Rear Bumper Installation
Rivet Installation
Front Bumper Installation
Rivet Removal
Side Bumper Installation
Side Bumper Removal
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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 Battery
Electric Starter System
Ignition System
Electrical System
Precautions
Electrical Connectors Female Connectors a Male Connectors B
Electrical Wiring
Wiring Inspection
Removal
Battery
Installation
Electrolyte Filling
Electrical System
Precautions
Initial Charge
Interchange
Charging Condition Inspection
Refreshing Charge
Electrical System
Starter Relay Removal
Starter Relay Installation
Electric Starter System
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 Inspection
Brush Plate and Terminal Bolt Inspection
Reduction Gear Removal/Installation
Reduction Gear Inspection
Electrical System
Regulator/Rectifier Removal/Installation
Charging System
Magneto Output Voltage
Regulator/Rectifier Inspection
Regulator Inspection
Charging System Circuit
Electrical System
Crankshaft Sensor Installation
Ignition System
Crankshaft Sensor Removal
Timing Rotor Installation
Timing Rotor Removal
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Measuring arcing distance
Measuring coil resistance
Camshaft Position Sensor Installation
Camshaft Position Sensor Removal
Measuring 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 Installation
Spark Plug Adjustment
Spark Plug Removal
Ignition System Circuit
Electrical System
Steering Position Sensor and Magnet Installation
Kawasaki Smart Steering System
Steering 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
Sensors
Speed Sensor Inspection
Throttle Sensor Removal/Installation
Fuel Level Sensor Inspection
Oil Temperature Sensor Inspection
Water Temperature Sensor Inspection
Inlet 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
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Storage
Bilge System
Preparation for Storage
Cooling System
Engine Oil
Engine
Air Filter
Battery
Do not allow any soda solution to enter the battery
Engine Mounting Bolts
General
Removal from Storage
General Inspection
Test Run
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Appendix
Cable, Wire and Hose Routing
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
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Appendix
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Appendix
Appendix
Troubleshooting Guide
Engine Doesn’t Start, Starting Difficulty
Poor Running at Low Speed
Poor Running or No Power at High Speed
Abnormal Engine Noise
Overheating
Over Cooling
Oil Pressure Warning Light Goes On
Poor Performance through Engine
Engine Activates Slow Down Mode
Battery Trouble
Runs Properly
Model Application
