Manuals / Kawasaki / Marine Equipment / Jet Ski

Kawasaki STX-15F service manual Electrical System

Models: STX-15F

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ELECTRICAL SYSTEM 14-63

Multifunction Meter

3.Buzzer

4.Multifunction Meter

5.Speed Sensor

6.20 A Main Fuse

7.Joint Connector R

8.Starter Motor

9.Battery

10.Joint Connector P

11.Ignition Switch

12.ECU (Electronic Control Unit)

A:JT1500-A2 model ∼

Image 389

Kawasaki STX-15F service manual Electrical System

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 ∼ Adjustments Kawasaki Diagnostic System KDS SoftwareBefore Servicing Auxiliary CoolingGeneral Information Solvent Battery GroundEdges of Parts 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 Electrical Equipment Items JT1500-A1 ∼ A2Engine Oil 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 Engine Lubrication System Torque and Locking AgentFastener Torque Remarks Kgf·m Ft·lb Fuel System Engine Top End Fastener Torque Remarks Kgf·mExhaust System 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 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 Lubrication System Fuel Pump Screen CleaningThrottle Shaft Spring Inspection Engine Oil ChangeDry 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 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 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 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 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 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 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 Breather Case and Oil Separator Tank Breather Case InstallationBreather Case Removal Oil Separator Tank 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 Installation Clean Air SystemClean Air System Hose Inspection Air Suction Valve RemovalCylinder 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 Valves Valve InstallationValve Clearance Check Valve RemovalValve-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 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 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 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 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 Outside Diameter Measurement Water Filter Cover Removal/InstallationPump Inspection 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 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 Fittings Seat InstallationSeat Removal Front Storage Compartment Cover RemovalFront Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Stay Removal Mirror InstallationMirror 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 PrecautionsRefreshing Charge InterchangeCharging Condition Inspection 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 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 Adjustment Spark Plug InstallationSpark Plug Cleaning Spark Plug RemovalIgnition 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/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 Poor Running at Low Speed Troubleshooting GuideEngine Doesn’t Start, Starting Difficulty 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