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Kawasaki STX-15F service manual Electrical Connectors Female Connectors a Male Connectors B

Models: STX-15F

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ELECTRICAL SYSTEM 14-19

Precautions

○Electrical Connectors

Female Connectors [A]

Male Connectors [B]

Image 345

Kawasaki STX-15F service manual Electrical Connectors Female Connectors a Male Connectors B

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 ∼ Adjustments Kawasaki Diagnostic System KDS SoftwareBefore Servicing Auxiliary CoolingGeneral Information Battery Ground Edges of PartsSolvent Arrangement and Cleaning of Removed Parts Cleaning Watercraft before DisassemblyReplacement Parts Storage of Removed PartsTightening Torque Assembly Order Tightening SequenceForce Gasket, O-ringPress Liquid Gasket, Locking AgentBall Bearing Oil Seal, Grease SealElectrical Wires Circlips, Cotter PinsLubrication Direction of Engine RotationModel Identification General Specifications Items JT1500-A1 ∼ A2 Engine OilElectrical Equipment Units of Force Units of Power Units of Volume Units of PressureUnit 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 Bottom End Engine Removal/InstallationCooling and Bilge Systems Pump and ImpellerSteering Fastener Torque Remarks Kgf·m Ft·lbHull/Engine Hood Electrical SystemThreads dia. mm Torque Kgf·m Ft·lb General Fasteners stainless bolt and nutStandard Service Limit Fuel System SpecificationsSpecial 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 Engine Lubrication System Fuel Pump Screen CleaningThrottle 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 Cooling and Bilge Systems Engine Bottom EndEngine Mounting Bolts Inspection and Tightness Coupling Damper InspectionPeriodic Maintenance Bilge System Flushing Steering Periodic Maintenance Procedures Pump and ImpellerImpeller Inspection Steering Cable/Shift Cable InspectionBattery Terminals Inspection Battery Charging Condition InspectionHull/Engine Hood Electrical SystemLubrication Spark Plug Cleaning and InspectionSteering 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 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 User Mode Dealer ModeSelf-Diagnosis Self-diagnosis Outline Possible Problems Fail-Safe Function Self-Diagnosis Service Code Character TableDisplayed on JT1500-A1Self-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 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 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 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 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 Installation ECU Power Supply InspectionECU Removal ECU connector B in this chapter figure ECU Power Source Circuit Relay Assembly Removal DFI Power SourceRelay Assembly Inspection Main Fuse InspectionFuel Pump Relay Relay Coil Terminals 6 Relay Switch Terminals 5Throttle Case Removal/Disassembly Throttle Cable AdjustmentThrottle Lever, Cable and Case Free Play InspectionThrottle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Cable Inspection Throttle Case and Cable LubricationAir Filter Installation Air FilterAir Filter Removal 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 Fuel Pump Fuel Pump RemovalJT1500-A2 ∼ model 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 Engine Oil and Oil Filter Oil Level InspectionPreliminary Check Ordinary standard Check Oil Filter Replacement Oil Cooler Installation Oil CoolerOil Cooler Removal Oil Cooler Assembly Oil Cooler DisassemblyOil Cooler Inspection Breather Case and Oil Separator Tank Breather Case InstallationBreather Case Removal Oil Separator Tank RemovalBlowby Gas System Inspection Oil Separator Tank InstallationOil 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 Removal Oil Pump InstallationOil Screen Installation Oil Pump InspectionOil Screen Removal Oil Pump Sprocket Chain Removal Oil Pressure Relief Valve InspectionOil 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 Removal Exhaust ManifoldExhaust 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 Fastener Engine TOP ENDEngine TOP END Fastener Torque Remarks Kgf·m Standard Service Limit Camshafts Cylinder HeadValves Cylinder, Piston Standard Service LimitSpecial Tools and Sealant Engine TOP END Engine TOP END Air Suction Valve Installation Clean Air SystemClean 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 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 Valves Valve InstallationValve Clearance Check Valve RemovalValve-to-Guide Clearance Measurement Wobble Method Valve Guide InstallationValve Seat Repair Valve Seat InspectionOperating Procedures Seat Cutter Operation CareMarks Stamped on the Cutter Engine TOP END Engine TOP END Engine TOP END Cylinder, Pistons Cylinder RemovalPiston Removal Oil ring rails have no top or bottom Piston/Cylinder InstallationWith the Special Tools With the HandPiston Wear Cylinder WearPiston Ring, Piston Ring Groove Wear Piston Ring Groove WidthPiston 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 Oil Seal Inspection Magneto Cover Bearing ReplacementBall 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 Installation Connecting Rod RemovalEngine Bottom END Be careful not to overtighten the nuts Connecting Rod BendConnecting 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 Runout Crankshaft Side ClearanceMeasure the crankshaft runout CrankshaftCooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Breather Cleaning and Inspection Breather InstallationBilge System Breather RemovalFilter Cleaning and Inspection Filter InstallationCooling and Bilge System Hoses Hose InstallationHose Removal Hose InspectionCooling and Bilge System Flushing Cooling and Bilge System Flow Diagram Cooling and Bilge Systems Water Pipe Installation Water PipeWater Pipe Removal 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 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 JT1500-A1,A2 ∼ Pump AssemblySpecial Tool Bearing Driver Set Pump and Impeller JT1500-A1, A2 ∼ Impeller Outside Diameter Measurement Water Filter Cover Removal/InstallationPump 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 Removal HandlebarHandlebar 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 Shift Lever Shaft Removal/Installation Reverse Bucket Removal/InstallationHull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Fittings Seat InstallationSeat Removal Front Storage Compartment Cover RemovalFront Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Installation Mirror RemovalMirror Stay Removal Mirror Stay Installation Storage Pocket Disassembly/Assembly Front Storage Pocket InstallationFront Storage Pocket Removal Crossmember RemovalCrossmember Installation Drain Plug Housing Removal Handrail InstallationDrain Plug Housing Installation Exhaust Outlet InstallationReboarding Step Installation Stabilizer InstallationStabilizer Removal Reboarding Step RemovalHull Replacement Rubber Parts Location Rubber PartsHULL/ENGINE Hood Front Bumper Installation Rivet InstallationRear Bumper Installation Rivet RemovalSide 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 Electric Starter System Standard Service Limit BatteryCharging System Ignition SystemElectrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Wiring Inspection Electrical WiringInstallation BatteryRemoval Electrolyte FillingElectrical System Initial Charge PrecautionsInterchange Charging Condition InspectionRefreshing Charge Electrical System Electric Starter System Starter Relay InstallationStarter Relay Removal Starter Relay InspectionStarter Motor Removal Starter Motor InstallationStarter Motor Assembly Starter Motor DisassemblyBrush Inspection Commutator Cleaning and InspectionArmature Inspection Brush Lead InspectionBrush Plate and Terminal Bolt Inspection Reduction Gear Inspection Reduction Gear Removal/InstallationElectrical System Regulator/Rectifier Removal/Installation Charging SystemMagneto Output Voltage Regulator Inspection Regulator/Rectifier InspectionCharging System Circuit Electrical System Crankshaft Sensor Installation Ignition SystemCrankshaft Sensor Removal Timing Rotor Removal Timing Rotor InstallationIgnition 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 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 Adjustment Spark Plug InstallationSpark Plug Cleaning Spark Plug RemovalIgnition System Circuit Electrical System Steering Position Sensor and Magnet Installation Kawasaki Smart Steering SystemSteering Position Sensor and Magnet Removal 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 Removal/Installation SensorsSpeed Sensor Inspection Fuel Level Sensor Inspection Throttle Sensor Removal/InstallationInlet Air Temperature Sensor Inspection Water Temperature Sensor InspectionOil Temperature Sensor Inspection Throttle 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 Cooling System Preparation for StorageBilge System Engine OilEngine Do not allow any soda solution to enter the battery BatteryAir Filter Engine Mounting BoltsGeneral 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 Troubleshooting Guide Engine Doesn’t Start, Starting DifficultyPoor Running at Low Speed Poor Running or No Power at High Speed Over Cooling OverheatingAbnormal Engine Noise Oil Pressure Warning Light Goes OnBattery Trouble Engine Activates Slow Down ModePoor Performance through Engine Runs ProperlyModel Application