JET SKI Watercraft
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Quick Reference Guide
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JET SKI Watercraft
List of Abbreviations
Exhaust Emission Control System
Fuel Information
Emission Control Information
Foreword
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General Information
Smart Learning Operation mode SLO JT1500-A2 model ∼
Auxiliary Cooling
Kawasaki Diagnostic System KDS Software
Adjustments
Before Servicing
General Information
Solvent
Battery Ground
Edges of Parts
Storage of Removed Parts
Cleaning Watercraft before Disassembly
Arrangement and Cleaning of Removed Parts
Replacement Parts
Gasket, O-ring
Assembly Order Tightening Sequence
Tightening Torque
Force
Oil Seal, Grease Seal
Liquid Gasket, Locking Agent
Press
Ball Bearing
Direction of Engine Rotation
Circlips, Cotter Pins
Electrical Wires
Lubrication
Model Identification
General Specifications
Electrical Equipment
Items JT1500-A1 ∼ A2
Engine Oil
Units of Mass
Units of Volume Units of Pressure
Units of Force Units of Power
Unit Conversion Table Prefixes for Units Units of Length
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Periodic Maintenance
Periodic Maintenance Chart
Engine Lubrication System
Torque and Locking Agent
Fastener Torque Remarks Kgf·m Ft·lb Fuel System
Engine Top End
Fastener Torque Remarks Kgf·m
Exhaust System
Pump and Impeller
Engine Removal/Installation
Engine Bottom End
Cooling and Bilge Systems
Electrical System
Fastener Torque Remarks Kgf·m Ft·lb
Steering
Hull/Engine Hood
Threads dia. mm Torque Kgf·m Ft·lb
General Fasteners stainless bolt and nut
Standard Service Limit Fuel System
Specifications
Special Tools and Sealant
Throttle Control System Inspection
Periodic Maintenance Procedures Fuel System
Air Filter Drain Caps Inspection and Cleaning
Fuel Vent Check Valve Inspection
Periodic Maintenance Procedures
Air Filter Inspection and Cleaning
Engine Oil Change
Fuel Pump Screen Cleaning
Engine Lubrication System
Throttle Shaft Spring Inspection
Dry
Oil Filter Replace
Valve Clearance Inspection
Periodic Maintenance Procedures Engine Top End
Air Suction Valve Inspection
Periodic Maintenance
Inlet Valve Clearance Adjustment Chart
Exhaust Valve Clearance Adjustment Chart
Coupling Damper Inspection
Engine Bottom End
Cooling and Bilge Systems
Engine Mounting Bolts Inspection and Tightness
Periodic Maintenance
Bilge System Flushing
Steering Cable/Shift Cable Inspection
Periodic Maintenance Procedures Pump and Impeller
Steering
Impeller Inspection
Electrical System
Battery Charging Condition Inspection
Battery Terminals Inspection
Hull/Engine Hood
Lubrication
Spark Plug Cleaning and Inspection
Steering 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 Inspection
Hose and Hose Connect Inspection
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
Digital Fuel Injection System
Standard
Fuel System DFI
Special Tools and Sealant
DFI Parts Location
Fuel System DFI
Dummy
DFI System
Part Name
Terminal Names
Terminal Numbers of ECU Connectors
DFI Servicing Precautions
For JT1500-A2 ∼
Silicone Sealant Kawasaki Bond 56019-120 -Seals Connector
Self-Diagnosis Self-diagnosis Outline
User Mode
Dealer Mode
JT1500-A1
Self-Diagnosis Service Code Character Table
Possible Problems Fail-Safe Function
Displayed on
Self-Diagnosis
Memory of Service Code Character
Watercraft conditions when problem occurred
Troubleshooting the DFI System Sample Diagnosis Sheet
Troubleshooting the DFI System
Throttle Sensor Removal/Adjustment
Throttle Sensor Service Code/Character-11/tPS
Input Voltage Inspection
Be sure the battery is fully charged
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 Removal
Inlet Air Pressure Sensor Service Code/Character-12/bOSt
Inlet 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/AIrt
Sensor Resistance Inspection
Fuel System DFI
Water Temperature Sensor Removal/Installation
Water Temperature Sensor Service Code/Character-14/AqUt
Output 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/CrAg
Crankshaft Sensor Removal/Installation
Camshaft Position Sensor Inspection
Camshaft Position Sensor Service Code/Character-23/CAAg
Camshaft Position Sensor Removal/Installation
Vehicle-down Sensor Removal
Vehicle-down Sensor Service Code/Character-31/dOS
Vehicle-down Sensor Installation
Vehicle-down Sensor Inspection
Fuel System DFI
Fuel Injector Removal
Fuel Injector Installation
Audible Inspection
Injector Signal Test
Injector Unit Test
Injector Resistance Inspection
Injector Voltage Inspection
Injector Fuel Line Inspection
ECU
Ignition Coil Removal/Installation
Ignition Coils Service Code/Character-51, 52/COL1, COL2
Fuel System DFI
Possible Causes Action Chapter
Engine Overheating Service Code/Character-71/HEAt
Low 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/OILH
ECU Removal
ECU Installation
ECU Power Supply Inspection
ECU connector B in this chapter figure
ECU Power Source Circuit
Main Fuse Inspection
DFI Power Source
Relay Assembly Removal
Relay Assembly Inspection
Fuel Pump Relay
Relay Coil Terminals 6 Relay Switch Terminals 5
Free Play Inspection
Throttle Cable Adjustment
Throttle Case Removal/Disassembly
Throttle Lever, Cable and Case
Throttle Case Assembly/Installation
Throttle Cable Removal
Throttle Cable Installation
Throttle Cable Inspection
Throttle Case and Cable Lubrication
Air Filter Removal
Air Filter Installation
Air Filter
Air Filter Assembly
Air Filter Disassembly
Throttle Body Assy
ISC Idle Speed Controller Inspection
ISC Idle Speed Controller Removal/Installation
ISC a
ISC Resistance Inspection
Inlet Manifold Removal
Inlet Manifold
Inlet Manifold Installation
Fuel System DFI
Fuel Pressure Inspection
Fuel Line
Fuel Flow Rate Inspection
Amount of Fuel Flow Standard 67 mL or more for 3 seconds
Fuel Vent Check Valve Mounting
Fuel Vent Check Valve
Fuel Filter Removal
Fuel Filter
Fuel Filter Installation
JT1500-A2 ∼ model
Fuel Pump
Fuel Pump Removal
Power Source Voltage Inspection
Fuel Pump Installation
Operating Voltage Inspection
Fuel Pump Relay Inspection
Fuel Pump Relay Removal
Fuel Tank Removal
Fuel Tank
Fuel Tank Cleaning
Fuel Tank Installation
Fuel Filler and Tube Removal
Fuel Filler and Tube Installation
Engine 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 Filter
Oil Level Inspection
Ordinary standard Check
Oil Filter Replacement
Oil Cooler Removal
Oil Cooler Installation
Oil Cooler
Oil Cooler Assembly
Oil Cooler Disassembly
Oil Cooler Inspection
Oil Separator Tank Removal
Breather Case Installation
Breather Case and Oil Separator Tank
Breather Case Removal
Blowby Gas System Inspection
Oil Separator Tank Installation
Oil Pan Removal
Oil Pan Installation
Oil Pan
Oil Pump Sprocket Removal
Oil Pump Sprocket Installation
Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve
Oil Pump Removal
Oil Pump Installation
Oil Screen Removal
Oil Screen Installation
Oil Pump Inspection
Oil Pump Sprocket Chain Removal
Oil Pressure Relief Valve Inspection
Oil Pressure Measurement
Oil Pressure Measurement
Engine Lubrication System
Oil Pressure Switch Installation
Oil Pressure Switch
Oil Pressure Switch Removal
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Exhaust System
Exploded View
Fastener Torque Remarks Kgf·m
Exhaust Manifold Removal
Exhaust Manifold
Exhaust Manifold Installation
Exhaust Manifold Cleaning and Inspection
Exhaust Pipe Removal
Exhaust Pipe Installation
Exhaust Pipe
Exhaust Pipe Cleaning and Inspection
Water Box Muffler Removal
Water Box Muffler Installation
Water Box Muffler
Water Box Muffler Inspection
Engine Top End
Exploded View
Fastener
Engine TOP END
Engine TOP END
Fastener Torque Remarks Kgf·m
Valves
Standard Service Limit Camshafts
Cylinder Head
Cylinder, Piston
Standard Service Limit
Special Tools and Sealant
Engine TOP END
Engine TOP END
Air Suction Valve Removal
Clean Air System
Air Suction Valve Installation
Clean Air System Hose Inspection
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Cylinder Head Cover
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Camshaft Chain Tensioner
Camshaft Removal
Camshaft, Camshaft Chain
Camshaft Installation
Piston TDC Finding
Special Tool TDC Measurement Tool
Camshaft Runout
Camshaft, Camshaft Cap Wear
Camshaft Chain Removal
Cylinder Compression Measurement
Cylinder Head
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Warp
Valve Removal
Valve Installation
Valves
Valve Clearance Check
Valve-to-Guide Clearance Measurement Wobble Method
Valve Guide Installation
Valve Seat Repair
Valve Seat Inspection
Marks Stamped on the Cutter
Operating Procedures
Seat Cutter Operation Care
Engine TOP END
Engine TOP END
Engine TOP END
Piston Removal
Cylinder, Pistons
Cylinder Removal
Oil ring rails have no top or bottom
Piston/Cylinder Installation
With the Special Tools
With the Hand
Piston Ring Groove Width
Cylinder Wear
Piston Wear
Piston Ring, Piston Ring Groove Wear
Piston Ring End Gap
Piston Ring Thickness
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Engine Removal/Installation
Exploded View
Fastener Torque Remarks Kgf·m
Engine Removal
Engine Removal/Installation
Engine Damper Removal
Engine Installation
Engine Damper Installation
Engine Bottom End
Exploded View
Fastener Torque Remarks Kgf·m
Connecting Rod Big End Bearing Insert Selection
Standard Service Limit Crankshaft, Connecting Rods
Crankshaft Main Journal Diameter 40.984 ∼ 41.000 mm 40.96 mm
Special Tools and Sealant
Kawasaki Bond Liquid Gasket Black
Coupling/Output Shaft Removal
Coupling
Coupling/Output Shaft Installation
Output Cover Oil Seal Replacement
Ball Bearing Inspection
Magneto Cover Bearing Replacement
Oil Seal Inspection
Ball Bearing Lubrication
Magneto Flywheel Removal
Magneto Flywheel Installation
Magneto Flywheel
InstallMagneto Cover see Coupling/Output Shaft Installation
Stator Removal
Stator Installation
Stator
Crankcase Splitting
Crankcase Splitting
Crankcase Assembly
Following the sequence numbers, tighten the M8 bolts
Crankshaft Removal
Crankshaft and Connecting Rods
Crankshaft Installation
Connecting Rod Installation
Connecting Rod Removal
Engine Bottom END
Be careful not to overtighten the nuts
Connecting Rod Bend
Connecting Rod Big End Bearing Insert/Crankpin Wear
Connecting Rod Twist
Connecting Rod Big End Side Clearance
92139-3709
Crankshaft Main Bearing Insert/Journal Wear
Marking Position
Crankshaft
Crankshaft Side Clearance
Crankshaft Runout
Measure the crankshaft runout
Cooling and Bilge Systems
Exploded View
Fastener Torque Remarks Kgf·m
Breather Removal
Breather Installation
Breather Cleaning and Inspection
Bilge System
Filter Cleaning and Inspection
Filter Installation
Hose Inspection
Hose Installation
Cooling and Bilge System Hoses
Hose Removal
Cooling and Bilge System Flushing
Cooling and Bilge System Flow Diagram
Cooling and Bilge Systems
Water Pipe Removal
Water Pipe Installation
Water Pipe
After Submerging
Summary Procedures 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
Standard Service Limit Drive Shaft
Specification
Drive System
Drive Shaft/Drive Shaft Holder
Drive Shaft Removal/Installation
Drive 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 Assembly
Special Tool Bearing Driver Set
Pump and Impeller
JT1500-A1, A2 ∼
Impeller Clearance
Water Filter Cover Removal/Installation
Impeller Outside Diameter Measurement
Pump Inspection
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Steering
Exploded View
36 ∼
Special Tool and Sealant
Steering Cable Removal
Steering Cable Adjustment
Steering Cable
Special Tool Box Wrench
Steering Cable Lubrication
Steering Cable Installation
Steering Cable Inspection
Handlebar Removal
Handlebar
Handlebar Installation
Steering
Steering Removal
Steering
Steering
Steering Installation
Torque the steering shaft locknut a
Steering
Shift Cable Removal
Shift Cable Adjustment
Reverse System
Steering
Shift Cable Lubrication
Shift Cable Installation
Shift Cable Inspection
Shift Lever Shaft Removal/Installation
Reverse Bucket Removal/Installation
Hull/Engine Hood
Exploded View
Fastener Torque Remarks Kgf·m
HULL/ENGINE Hood
HULL/ENGINE Hood
Front Storage Compartment Cover Removal
Seat Installation
Fittings
Seat Removal
Front Storage Compartment Cover Disassembly
Front Storage Compartment Cover Assembly
Mirror Stay Removal
Mirror Installation
Mirror Removal
Mirror Stay Installation
Crossmember Removal
Front Storage Pocket Installation
Storage Pocket Disassembly/Assembly
Front Storage Pocket Removal
Crossmember Installation
Exhaust Outlet Installation
Handrail Installation
Drain Plug Housing Removal
Drain Plug Housing Installation
Reboarding Step Removal
Stabilizer Installation
Reboarding Step Installation
Stabilizer Removal
Hull Replacement
Rubber Parts Location
Rubber Parts
HULL/ENGINE Hood
Rivet Removal
Rivet Installation
Front Bumper Installation
Rear Bumper Installation
Side Bumper Removal
Side Bumper Installation
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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
Ignition System
Standard Service Limit Battery
Electric Starter System
Charging System
Electrical System
Precautions
Electrical Connectors Female Connectors a Male Connectors B
Wiring Inspection
Electrical Wiring
Electrolyte Filling
Battery
Installation
Removal
Electrical System
Initial Charge
Precautions
Refreshing Charge
Interchange
Charging Condition Inspection
Electrical System
Starter Relay Inspection
Starter Relay Installation
Electric Starter System
Starter Relay Removal
Starter Motor Removal
Starter Motor Installation
Starter Motor Assembly
Starter Motor Disassembly
Brush Inspection
Commutator Cleaning and Inspection
Brush Plate and Terminal Bolt Inspection
Armature Inspection
Brush Lead Inspection
Reduction Gear Inspection
Reduction Gear Removal/Installation
Electrical System
Magneto Output Voltage
Regulator/Rectifier Removal/Installation
Charging System
Regulator Inspection
Regulator/Rectifier Inspection
Charging System Circuit
Electrical System
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Ignition System
Timing Rotor Removal
Timing Rotor Installation
Ignition Coil Removal
Ignition Coil Installation
Measuring coil resistance
Ignition Coil Inspection
Measuring arcing distance
Measuring spark plug lead resistance
Camshaft Position Sensor Installation
Camshaft Position Sensor Removal
Igniter Inspection
Igniter Removal/Installation
Ignition Coil Primary Peak Voltage Standard 250 V or more
Camshaft Position Sensor Peak Voltage Inspection
Crankshaft Sensor Peak Voltage Check
Spark Plug Removal
Spark Plug Installation
Spark Plug Adjustment
Spark Plug Cleaning
Ignition System Circuit
Electrical System
Steering Position Sensor and Magnet Removal
Steering Position Sensor and Magnet Installation
Kawasaki Smart Steering System
Steering Position Sensor Clearance
Inspection of Kawasaki Smart Steering System
Steering Position Sensor Input Voltage Inspection
Steering Position Sensor Output Voltage Inspection
Steering Position Sensor Circuit
Speed Sensor Inspection
Speed Sensor Removal/Installation
Sensors
Fuel Level Sensor Inspection
Throttle Sensor Removal/Installation
Throttle Sensor Inspection
Water Temperature Sensor Inspection
Inlet Air Temperature Sensor Inspection
Oil Temperature Sensor Inspection
Display Function Inspection
Multifunction Meter
MODE/SET Button Inspection
Speedometer Inspection
Speed Sensor Electric Source Inspection
Tachometer Inspection
Battery Symbol/bAt Characters/LED Inspection
Buzzer Inspection
Electrical System
Circuit Inspection
Relay Assembly
Relay Assembly Circuit Inspection with the battery connected
Switch Inspection
Switches
Fuse
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Storage
Engine Oil
Preparation for Storage
Cooling System
Bilge System
Engine
Engine Mounting Bolts
Battery
Do not allow any soda solution to enter the battery
Air Filter
General
General Inspection
Removal from Storage
Test Run
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Appendix
Cable, Wire and Hose Routing
Appendix
Appendix
Appendix
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Appendix
Poor Running at Low Speed
Troubleshooting Guide
Engine Doesn’t Start, Starting Difficulty
Poor Running or No Power at High Speed
Oil Pressure Warning Light Goes On
Overheating
Over Cooling
Abnormal Engine Noise
Runs Properly
Engine Activates Slow Down Mode
Battery Trouble
Poor Performance through Engine
Model Application
