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Kawasaki STX-15F service manual

Models: STX-15F

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Kawasaki STX-15F service manual

Contents

JET SKI Watercraft Page Quick Reference Guide Page JET SKI Watercraft List of Abbreviations Emission Control Information Fuel InformationExhaust Emission Control System Foreword Page Page General Information Smart Learning Operation mode SLO JT1500-A2 model ∼ Before Servicing Kawasaki Diagnostic System KDS SoftwareAdjustments Auxiliary CoolingGeneral Information Edges of Parts Battery GroundSolvent Replacement Parts Cleaning Watercraft before DisassemblyArrangement and Cleaning of Removed Parts Storage of Removed PartsForce Assembly Order Tightening SequenceTightening Torque Gasket, O-ringBall Bearing Liquid Gasket, Locking AgentPress Oil Seal, Grease SealLubrication Circlips, Cotter PinsElectrical Wires Direction of Engine RotationModel Identification General Specifications Engine Oil Items JT1500-A1 ∼ A2Electrical Equipment Unit Conversion Table Prefixes for Units Units of Length Units of Volume Units of PressureUnits of Force Units of Power Units of MassPage Periodic Maintenance Periodic Maintenance Chart Fastener Torque Remarks Kgf·m Ft·lb Fuel System Torque and Locking AgentEngine Lubrication System Exhaust System Fastener Torque Remarks Kgf·mEngine Top End Cooling and Bilge Systems Engine Removal/InstallationEngine Bottom End Pump and ImpellerHull/Engine Hood Fastener Torque Remarks Kgf·m Ft·lbSteering Electrical SystemGeneral Fasteners stainless bolt and nut Threads dia. mm Torque Kgf·m Ft·lbSpecifications Standard Service Limit Fuel SystemSpecial Tools and Sealant Air Filter Drain Caps Inspection and Cleaning Periodic Maintenance Procedures Fuel SystemThrottle Control System Inspection Air Filter Inspection and Cleaning Periodic Maintenance ProceduresFuel Vent Check Valve Inspection Throttle Shaft Spring Inspection Fuel Pump Screen CleaningEngine Lubrication System Engine Oil ChangeDry Oil Filter Replace Air Suction Valve Inspection Periodic Maintenance Procedures Engine Top EndValve Clearance Inspection Periodic Maintenance Inlet Valve Clearance Adjustment Chart Exhaust Valve Clearance Adjustment Chart Engine Mounting Bolts Inspection and Tightness Engine Bottom EndCooling and Bilge Systems Coupling Damper InspectionPeriodic Maintenance Bilge System Flushing Impeller Inspection Periodic Maintenance Procedures Pump and ImpellerSteering Steering Cable/Shift Cable InspectionHull/Engine Hood Battery Charging Condition InspectionBattery Terminals Inspection Electrical SystemSpark Plug Cleaning and Inspection LubricationSteering Cable Ball Joint a at Steering Shaft Lubricate the following with a penetrating rust inhibitor B Hose and Hose Connect Inspection Nuts, Bolts, and Fasteners Tightness 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 SystemFuel System DFI Special Tools and Sealant DFI Parts Location Fuel System DFI Dummy DFI System Part Name Terminal Numbers of ECU Connectors Terminal NamesDFI Servicing Precautions For JT1500-A2 ∼ Silicone Sealant Kawasaki Bond 56019-120 -Seals Connector Dealer Mode User ModeSelf-Diagnosis Self-diagnosis Outline Displayed on Self-Diagnosis Service Code Character TablePossible Problems Fail-Safe Function JT1500-A1Memory of Service Code Character Self-DiagnosisTroubleshooting the DFI System Sample Diagnosis Sheet Watercraft conditions when problem occurredTroubleshooting the DFI System Throttle Sensor Service Code/Character-11/tPS Throttle Sensor Removal/AdjustmentBe sure the battery is fully charged Input Voltage InspectionInput 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 Installation Inlet Air Pressure Sensor Service Code/Character-12/bOStInlet 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/InstallationSensor Resistance Inspection Fuel System DFI Water Temperature Sensor Service Code/Character-14/AqUt Water Temperature Sensor Removal/InstallationOutput Voltage at ECU Standard about 3 ∼ 4 V at 20C 68F ECU Joint Connector E Water Temperature Sensor Crankshaft Sensor Removal/Installation Crankshaft Sensor Service Code/Character-21/CrAgCrankshaft Sensor Inspection Camshaft Position Sensor Removal/Installation Camshaft Position Sensor Service Code/Character-23/CAAgCamshaft Position Sensor Inspection Vehicle-down Sensor Installation Vehicle-down Sensor Service Code/Character-31/dOSVehicle-down Sensor Removal Vehicle-down Sensor Inspection Fuel System DFI Fuel Injector Installation Fuel Injector RemovalInjector Signal Test Audible InspectionInjector Resistance Inspection Injector Unit TestInjector Voltage Inspection Injector Fuel Line Inspection ECU Ignition Coils Service Code/Character-51, 52/COL1, COL2 Ignition Coil Removal/InstallationFuel System DFI Engine Overheating Service Code/Character-71/HEAt Possible Causes Action ChapterLow 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 Power Supply Inspection ECU InstallationECU Removal ECU connector B in this chapter figure ECU Power Source Circuit Relay Assembly Inspection DFI Power SourceRelay Assembly Removal Main Fuse InspectionRelay Coil Terminals 6 Relay Switch Terminals 5 Fuel Pump RelayThrottle Lever, Cable and Case Throttle Cable AdjustmentThrottle Case Removal/Disassembly Free Play InspectionThrottle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Case and Cable Lubrication Throttle Cable InspectionAir Filter Air Filter InstallationAir Filter Removal Air Filter Disassembly Air Filter AssemblyThrottle Body Assy ISC Idle Speed Controller Removal/Installation ISC Idle Speed Controller InspectionISC Resistance Inspection ISC aInlet Manifold Inlet Manifold RemovalInlet Manifold Installation Fuel System DFI Fuel Line Fuel Pressure InspectionFuel Flow Rate Inspection Amount of Fuel Flow Standard 67 mL or more for 3 seconds Fuel Vent Check Valve Fuel Vent Check Valve MountingFuel Filter Fuel Filter RemovalFuel Filter Installation Fuel Pump Removal Fuel PumpJT1500-A2 ∼ model Fuel Pump Installation Power Source Voltage InspectionOperating Voltage Inspection Fuel Pump Relay Removal Fuel Pump Relay InspectionFuel Tank Fuel Tank RemovalFuel Tank Installation Fuel Tank CleaningFuel Filler and Tube Installation Fuel Filler and Tube RemovalEngine Lubrication System Exploded View Fastener Torque Remarks Kgf·m Ft·lb Engine Oil Flow Chart Passage Oil Pressure Measurement Special Tool and Sealant Oil Level Inspection Engine Oil and Oil FilterPreliminary Check Ordinary standard Check Oil Filter Replacement Oil Cooler Oil Cooler InstallationOil Cooler Removal Oil Cooler Disassembly Oil Cooler AssemblyOil Cooler Inspection Breather Case Removal Breather Case InstallationBreather Case and Oil Separator Tank Oil Separator Tank RemovalOil Separator Tank Installation Blowby Gas System InspectionOil Pan Oil Pan InstallationOil Pan Removal Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve Oil Pump Sprocket InstallationOil Pump Sprocket Removal Oil Pump Installation Oil Pump RemovalOil Pump Inspection Oil Screen InstallationOil Screen Removal Oil Pressure Relief Valve Inspection Oil Pump Sprocket Chain RemovalOil Pressure Measurement Oil Pressure MeasurementEngine Lubrication System Oil Pressure Switch Removal Oil Pressure SwitchOil Pressure Switch Installation Page Exhaust System Exploded View Fastener Torque Remarks Kgf·m Exhaust Manifold Exhaust Manifold RemovalExhaust Manifold Installation Exhaust Manifold Cleaning and Inspection Exhaust Pipe Exhaust Pipe InstallationExhaust Pipe Removal Exhaust Pipe Cleaning and Inspection Water Box Muffler Water Box Muffler InstallationWater Box Muffler Removal Water Box Muffler Inspection Engine Top End Exploded View Engine TOP END FastenerEngine TOP END Fastener Torque Remarks Kgf·m Cylinder Head Standard Service Limit CamshaftsValves Standard Service Limit Cylinder, PistonSpecial Tools and Sealant Engine TOP END Engine TOP END Clean Air System Hose Inspection Clean Air SystemAir Suction Valve Installation Air Suction Valve RemovalCylinder Head Cover Cylinder Head Cover InstallationCylinder Head Cover Removal Camshaft Chain Tensioner Camshaft Chain Tensioner InstallationCamshaft Chain Tensioner Removal Camshaft, Camshaft Chain Camshaft RemovalCamshaft Installation Piston TDC Finding Special Tool TDC Measurement Tool Camshaft, Camshaft Cap Wear Camshaft RunoutCamshaft Chain Removal Cylinder Head Cylinder Compression MeasurementCylinder Head Removal Cylinder Head Installation Cylinder Head Warp Valve Clearance Check Valve InstallationValves Valve RemovalValve Guide Installation Valve-to-Guide Clearance Measurement Wobble MethodValve Seat Inspection Valve Seat RepairSeat Cutter Operation Care Operating ProceduresMarks Stamped on the Cutter Engine TOP END Engine TOP END Engine TOP END Cylinder Removal Cylinder, PistonsPiston Removal Piston/Cylinder Installation Oil ring rails have no top or bottomWith the Hand With the Special ToolsPiston Ring, Piston Ring Groove Wear Cylinder WearPiston Wear Piston Ring Groove WidthPiston Ring Thickness Piston Ring End GapPage Engine Removal/Installation Exploded View Fastener Torque Remarks Kgf·m Engine Removal/Installation Engine RemovalEngine Damper Removal Engine Damper Installation Engine InstallationEngine Bottom End Exploded View Fastener Torque Remarks Kgf·m Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Big End Bearing Insert SelectionCrankshaft Main Journal Diameter 40.984 ∼ 41.000 mm 40.96 mm Special Tools and Sealant Kawasaki Bond Liquid Gasket Black Coupling Coupling/Output Shaft RemovalCoupling/Output Shaft Installation Output Cover Oil Seal Replacement Ball Bearing Lubrication Magneto Cover Bearing ReplacementOil Seal Inspection Ball Bearing InspectionMagneto Flywheel Magneto Flywheel InstallationMagneto Flywheel Removal InstallMagneto Cover see Coupling/Output Shaft Installation Stator Stator InstallationStator Removal Crankcase Splitting Crankcase SplittingCrankcase Assembly Following the sequence numbers, tighten the M8 bolts Crankshaft Installation Crankshaft and Connecting RodsCrankshaft Removal Connecting Rod Removal Connecting Rod InstallationEngine Bottom END Connecting Rod Bend Be careful not to overtighten the nutsConnecting Rod Big End Side Clearance Connecting Rod TwistConnecting Rod Big End Bearing Insert/Crankpin Wear 92139-3709 Crankshaft Main Bearing Insert/Journal Wear Marking Position Measure the crankshaft runout Crankshaft Side ClearanceCrankshaft Runout CrankshaftCooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Bilge System Breather InstallationBreather Cleaning and Inspection Breather RemovalFilter Installation Filter Cleaning and InspectionHose Removal Hose InstallationCooling and Bilge System Hoses Hose InspectionCooling and Bilge System Flushing Cooling and Bilge System Flow Diagram Cooling and Bilge Systems Water Pipe Water Pipe InstallationWater Pipe Removal Summary Procedures after Submerging 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 Specification Standard Service Limit Drive ShaftDrive System Drive Shaft Holder Removal/Disassembly Drive Shaft Removal/InstallationDrive 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/InstallationImpeller Outside Diameter Measurement Impeller ClearancePage Steering Exploded View 36 ∼ Special Tool and Sealant Steering Cable Steering Cable AdjustmentSteering Cable Removal Special Tool Box Wrench Steering Cable Inspection Steering Cable InstallationSteering Cable Lubrication Handlebar Handlebar RemovalHandlebar Installation Steering Steering Removal Steering Steering Steering Installation Torque the steering shaft locknut a Steering Reverse System Shift Cable AdjustmentShift Cable Removal Steering Shift Cable Inspection Shift Cable InstallationShift Cable Lubrication Reverse Bucket Removal/Installation Shift Lever Shaft Removal/InstallationHull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Seat Removal Seat InstallationFittings Front Storage Compartment Cover RemovalFront Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Removal Mirror InstallationMirror Stay Removal Mirror Stay Installation Front Storage Pocket Removal Front Storage Pocket InstallationStorage Pocket Disassembly/Assembly Crossmember RemovalCrossmember Installation Drain Plug Housing Installation Handrail InstallationDrain Plug Housing Removal Exhaust Outlet InstallationStabilizer Removal Stabilizer InstallationReboarding Step Installation Reboarding Step RemovalHull Replacement Rubber Parts Rubber Parts LocationHULL/ENGINE Hood Rear Bumper Installation Rivet InstallationFront Bumper Installation Rivet RemovalSide 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 Charging System Standard Service Limit BatteryElectric Starter System Ignition SystemElectrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Electrical Wiring Wiring InspectionRemoval BatteryInstallation Electrolyte FillingElectrical System Precautions Initial ChargeCharging Condition Inspection InterchangeRefreshing Charge Electrical System Starter Relay Removal Starter Relay InstallationElectric Starter System Starter Relay InspectionStarter Motor Installation Starter Motor RemovalStarter Motor Disassembly Starter Motor AssemblyCommutator Cleaning and Inspection Brush InspectionBrush Lead Inspection Armature InspectionBrush Plate and Terminal Bolt Inspection Reduction Gear Removal/Installation Reduction Gear InspectionElectrical System Charging System Regulator/Rectifier Removal/InstallationMagneto Output Voltage Regulator/Rectifier Inspection Regulator InspectionCharging System Circuit Electrical System Ignition System Crankshaft Sensor InstallationCrankshaft Sensor Removal Timing Rotor Installation Timing Rotor RemovalIgnition Coil Removal Ignition Coil Installation Measuring arcing distance Ignition Coil InspectionMeasuring coil resistance Camshaft Position Sensor Removal Camshaft Position Sensor InstallationMeasuring spark plug lead resistance Igniter Removal/Installation Igniter InspectionIgnition Coil Primary Peak Voltage Standard 250 V or more Crankshaft Sensor Peak Voltage Check Camshaft Position Sensor Peak Voltage InspectionSpark Plug Cleaning Spark Plug InstallationSpark Plug Adjustment Spark Plug RemovalIgnition System Circuit Electrical System Kawasaki Smart Steering System Steering Position Sensor and Magnet InstallationSteering Position Sensor and Magnet Removal Inspection of Kawasaki Smart Steering System Steering Position Sensor ClearanceSteering Position Sensor Input Voltage Inspection Steering Position Sensor Output Voltage Inspection Steering Position Sensor Circuit Sensors Speed Sensor Removal/InstallationSpeed Sensor Inspection Throttle Sensor Removal/Installation Fuel Level Sensor InspectionOil Temperature Sensor Inspection Water Temperature Sensor InspectionInlet Air Temperature Sensor Inspection Throttle Sensor InspectionMultifunction Meter Display Function InspectionMODE/SET Button Inspection Speedometer Inspection Speed Sensor Electric Source Inspection Battery Symbol/bAt Characters/LED Inspection Tachometer InspectionBuzzer Inspection Electrical System Relay Assembly Circuit InspectionRelay Assembly Circuit Inspection with the battery connected Switches Switch InspectionFuse Page Storage Bilge System Preparation for StorageCooling System Engine OilEngine Air Filter BatteryDo not allow any soda solution to enter the battery Engine Mounting BoltsGeneral Removal from Storage General InspectionTest 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 Engine Doesn’t Start, Starting Difficulty Troubleshooting GuidePoor Running at Low Speed Poor Running or No Power at High Speed Abnormal Engine Noise OverheatingOver Cooling Oil Pressure Warning Light Goes OnPoor Performance through Engine Engine Activates Slow Down ModeBattery Trouble Runs ProperlyModel Application