Manuals / Kawasaki / Marine Equipment / Jet Ski

Kawasaki STX-15F service manual Appendix

Models: STX-15F

1 438

Download 438 pages 44.44 Kb

Page 403

APPENDIX 16-1

	Appendix
	Table of Contents
Cable, Wire and Hose Routing	............................................................................................... 16-2
Troubleshooting Guide	16-32

16

Image 403

Kawasaki STX-15F service manual Appendix

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 ∼ Auxiliary Cooling Kawasaki Diagnostic System KDS SoftwareAdjustments Before ServicingGeneral Information Edges of Parts Battery GroundSolvent Storage of Removed Parts Cleaning Watercraft before DisassemblyArrangement and Cleaning of Removed Parts Replacement PartsGasket, O-ring Assembly Order Tightening SequenceTightening Torque ForceOil Seal, Grease Seal Liquid Gasket, Locking AgentPress Ball BearingDirection of Engine Rotation Circlips, Cotter PinsElectrical Wires LubricationModel Identification General Specifications Engine Oil Items JT1500-A1 ∼ A2Electrical Equipment Units of Mass Units of Volume Units of PressureUnits of Force Units of Power Unit Conversion Table Prefixes for Units Units of LengthPage 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 Pump and Impeller Engine Removal/InstallationEngine Bottom End Cooling and Bilge SystemsElectrical System Fastener Torque Remarks Kgf·m Ft·lbSteering Hull/Engine HoodThreads dia. mm Torque Kgf·m Ft·lb General Fasteners stainless bolt and nutStandard Service Limit Fuel System SpecificationsSpecial 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 Engine Oil Change Fuel Pump Screen CleaningEngine Lubrication System Throttle Shaft Spring InspectionDry 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 Coupling Damper Inspection Engine Bottom EndCooling and Bilge Systems Engine Mounting Bolts Inspection and TightnessPeriodic Maintenance Bilge System Flushing Steering Cable/Shift Cable Inspection Periodic Maintenance Procedures Pump and ImpellerSteering Impeller InspectionElectrical System Battery Charging Condition InspectionBattery Terminals Inspection Hull/Engine HoodLubrication Spark Plug Cleaning and InspectionSteering 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 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 Dealer Mode User ModeSelf-Diagnosis Self-diagnosis Outline JT1500-A1 Self-Diagnosis Service Code Character TablePossible Problems Fail-Safe Function Displayed onSelf-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 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 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 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 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 Power Supply Inspection ECU InstallationECU Removal ECU connector B in this chapter figure ECU Power Source Circuit Main Fuse Inspection DFI Power SourceRelay Assembly Removal Relay Assembly InspectionFuel Pump Relay Relay Coil Terminals 6 Relay Switch Terminals 5Free Play Inspection Throttle Cable AdjustmentThrottle Case Removal/Disassembly Throttle Lever, Cable and CaseThrottle Case Assembly/Installation Throttle Cable Removal Throttle Cable Installation Throttle Cable Inspection Throttle Case and Cable LubricationAir Filter Air Filter InstallationAir 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 Removal Fuel PumpJT1500-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 Oil Level Inspection Engine Oil and Oil FilterPreliminary Check Ordinary standard Check Oil Filter Replacement Oil Cooler Oil Cooler InstallationOil Cooler Removal Oil Cooler Assembly Oil Cooler DisassemblyOil Cooler Inspection Oil Separator Tank Removal Breather Case InstallationBreather Case and Oil Separator Tank Breather Case RemovalBlowby Gas System Inspection Oil Separator Tank InstallationOil 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 Removal Oil Pump InstallationOil Pump Inspection Oil Screen InstallationOil Screen Removal Oil Pump Sprocket Chain Removal Oil Pressure Relief Valve InspectionOil 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 Removal Exhaust ManifoldExhaust 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 Fastener Engine TOP ENDEngine TOP END Fastener Torque Remarks Kgf·m Cylinder Head Standard Service Limit CamshaftsValves Cylinder, Piston Standard Service LimitSpecial Tools and Sealant Engine TOP END Engine TOP END Air Suction Valve Removal Clean Air SystemAir Suction Valve Installation Clean Air System Hose InspectionCylinder Head Cover Cylinder Head Cover InstallationCylinder Head Cover Removal Camshaft Chain Tensioner Camshaft Chain Tensioner InstallationCamshaft 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 Valve Removal Valve InstallationValves Valve Clearance CheckValve-to-Guide Clearance Measurement Wobble Method Valve Guide InstallationValve Seat Repair Valve Seat InspectionSeat Cutter Operation Care Operating ProceduresMarks Stamped on the Cutter Engine TOP END Engine TOP END Engine TOP END Cylinder Removal Cylinder, PistonsPiston Removal Oil ring rails have no top or bottom Piston/Cylinder InstallationWith the Special Tools With the HandPiston Ring Groove Width Cylinder WearPiston Wear Piston Ring, Piston Ring Groove WearPiston 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 Ball Bearing Inspection Magneto Cover Bearing ReplacementOil Seal Inspection Ball Bearing LubricationMagneto 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 Installation Connecting Rod RemovalEngine Bottom END Be careful not to overtighten the nuts Connecting Rod BendConnecting 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 Crankshaft Crankshaft Side ClearanceCrankshaft Runout Measure the crankshaft runoutCooling and Bilge Systems Exploded View Fastener Torque Remarks Kgf·m Breather Removal Breather InstallationBreather Cleaning and Inspection Bilge SystemFilter Cleaning and Inspection Filter InstallationHose Inspection Hose InstallationCooling and Bilge System Hoses Hose RemovalCooling and Bilge System Flushing Cooling and Bilge System Flow Diagram Cooling and Bilge Systems Water Pipe Water Pipe InstallationWater 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 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 JT1500-A1,A2 ∼ Pump AssemblySpecial Tool Bearing Driver Set Pump and Impeller JT1500-A1, A2 ∼ Impeller Clearance Water Filter Cover Removal/InstallationImpeller Outside Diameter Measurement Pump InspectionPage 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 Removal HandlebarHandlebar 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 Shift Lever Shaft Removal/Installation Reverse Bucket Removal/InstallationHull/Engine Hood Exploded View Fastener Torque Remarks Kgf·m HULL/ENGINE Hood HULL/ENGINE Hood Front Storage Compartment Cover Removal Seat InstallationFittings Seat RemovalFront Storage Compartment Cover Disassembly Front Storage Compartment Cover Assembly Mirror Removal Mirror InstallationMirror Stay Removal Mirror Stay Installation Crossmember Removal Front Storage Pocket InstallationStorage Pocket Disassembly/Assembly Front Storage Pocket RemovalCrossmember Installation Exhaust Outlet Installation Handrail InstallationDrain Plug Housing Removal Drain Plug Housing InstallationReboarding Step Removal Stabilizer InstallationReboarding Step Installation Stabilizer RemovalHull Replacement Rubber Parts Location Rubber PartsHULL/ENGINE Hood Rivet Removal Rivet InstallationFront Bumper Installation Rear Bumper InstallationSide 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 Ignition System Standard Service Limit BatteryElectric Starter System Charging SystemElectrical System Precautions Electrical Connectors Female Connectors a Male Connectors B Wiring Inspection Electrical WiringElectrolyte Filling BatteryInstallation RemovalElectrical System Initial Charge PrecautionsCharging Condition Inspection InterchangeRefreshing Charge Electrical System Starter Relay Inspection Starter Relay InstallationElectric Starter System Starter Relay RemovalStarter Motor Removal Starter Motor InstallationStarter Motor Assembly Starter Motor DisassemblyBrush Inspection Commutator Cleaning and InspectionBrush Lead Inspection Armature InspectionBrush Plate and Terminal Bolt Inspection Reduction Gear Inspection Reduction Gear Removal/InstallationElectrical System Charging System Regulator/Rectifier Removal/InstallationMagneto Output Voltage Regulator Inspection Regulator/Rectifier InspectionCharging System Circuit Electrical System Ignition System Crankshaft Sensor InstallationCrankshaft Sensor Removal Timing Rotor Removal Timing Rotor InstallationIgnition 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 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 Removal Spark Plug InstallationSpark Plug Adjustment Spark Plug CleaningIgnition System Circuit Electrical System Kawasaki Smart Steering System Steering Position Sensor and Magnet InstallationSteering 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 Sensors Speed Sensor Removal/InstallationSpeed Sensor Inspection Fuel Level Sensor Inspection Throttle Sensor Removal/InstallationThrottle Sensor Inspection Water Temperature Sensor InspectionInlet Air Temperature Sensor Inspection Oil Temperature 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 Engine Oil Preparation for StorageCooling System Bilge SystemEngine Engine Mounting Bolts BatteryDo not allow any soda solution to enter the battery Air FilterGeneral 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 Engine Doesn’t Start, Starting Difficulty Troubleshooting GuidePoor Running at Low Speed Poor Running or No Power at High Speed Oil Pressure Warning Light Goes On OverheatingOver Cooling Abnormal Engine NoiseRuns Properly Engine Activates Slow Down ModeBattery Trouble Poor Performance through EngineModel Application