1200 STX-R Servicemanual
1200 STX-R Servicemanual
1200 STX-R Servicemanual
General Information Periodic Maintenance Fuel System Engine Lubrication System Exhaust System Engine Top End Engine Removal/Installation Engine Bottom End Cooling and Bilge Systems Drive System Pump and Impeller Steering Hull/Engine Hood Electrical System Storage Troubleshooting
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1200 STX-R
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your "JET SKI" watercraft dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
LIST OF ABBREVIATIONS
A ABDC AC ATDC BBDC BDC BTDC C DC F F ft g h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot,feet gram(s) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) perminute top dead center total indicator reading volt(s) watt(s) ohm(s)
Foreword
This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your "JET SKI" watercraft: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki "JET SKI" watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki "JET SKI" watercraft are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. procedures in Follow the take shortcuts. this manual carefully. Dont keep of Remember torepaircomplete recordsanymaintenance and with dates and new parts installed.
WARNING
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
NOTE
General Information
TABLE OF CONTENTS
Before Servicing ........................................................................................................................ Model Identification.................................................................................................................... General Specifications............................................................................................................... Torque and Locking Agent......................................................................................................... Special Tools, Sealant ............................................................................................................... Cable, Wire and Hose Routing .................................................................................................. Technical Information Engine ................................................................................................. Technical Information Igniter................................................................................................... Technical Information Electrical Parts..................................................................................... Unit Conversion Table ............................................................................................................... 1-2 1-6 1-7 1-9 1-12 1-14 1-24 1-30 1-33 1-34
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damage will occur. (2) Auxiliary Cooling An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjustments. If possible, always operate the watercraft in water rather than use an auxiliary cooling supply.
Loosen the clamp and remove the cap [A]. (see above). [B] to the hose Connect the garden hose a faucet. Do notfitting on the water until the engine is running and turn it Attach the garden hose to turn off immediately when the engine stops. The engine requires 2.4 L/min (2.5 qts/min) at 1800 rpm
and 7.0 L/min (7.4 qts/min) at 6000 r/min (rpm).
CAUTION
Insufficient cooling supply will cause the engine and/or exhaust system to overheat and severe damage will occur. Excessive cooling supply may kill the engine and flood the cylinders, causing hydraulic lock. Hydraulic lock will cause severe damage to the engine. If the engine dies while using an auxiliary cooling supply, the water must be shut off immediately. Always turn the boat on its left side. Rolling to the right side can cause water in the exhaust system to run into the engine, with possible engine damage.
(3) Dirt Before removal and disassembly, clean the "Jet Ski" watercraft. Any sand entering the engine, carburetor, or other parts will work as an abrasive and shorten the life of the watercraft. For the same reason, before installing a new part, clean off any dust or metal filings. (4) Battery Ground Remove the ground () lead from the battery before performing any disassembly operations on the watercraft. This prevents: (a)the possibility of accidentally turning the engine over while partially disassembled. (b)sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts. (5) Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, they should all be started in their holes and tightened to snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (6) Torque The torque values given in this Service Manual should always be adhered to. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (7) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. (8) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (9) High Flash-Point Solvent A high flash-point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (10)Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (11) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturers directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine cooling passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock N Seal (Blue).
(20)Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (21)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones.
L L L L
L L L L L S L S SS S S L L L L L L
L L L L
(Liquid
Gasket-Black):
M14 1.25:
1. Air Intake Cover 2. Exhaust Manifold 3. TPS 4. Detent 5. Exhaust Chamber 6. Air Temperature Sensor: The sensor end must be out of the damper. 7. Refer to DETAIL 1 (Page 1-16). 8. Clamp 9. Water Box Muffer 10. To Speed Sensor 11. Resonator 12. Bilge Filter 13. Inlet Cooling Hose 14. White Mark
15. Drain 16. Drain Hose for #3 Head 17. Drain Hose for #2 Head 18. 18. Refer to DETAIL 2 (Page 116). 19. Starte Relay Case 20. Fuse Case 21. Electric Case 22. Run the spark plug leads so as not to come in contact with the starter motor lead. 23. Refer to DETAIL 3, 4 (Page 116). 24. Regulator/Rectifier 25. Plate 26. Screw 27. Main Harness 28. Loosen the spark plug leads remaining.
29. Loosen the inlet cooling hose remaining. 30. Cut the plastic clamps so that its cutting eddges do not fase upward. 31. Holder 32. Fuel Filter 33. Main Fuel Hose 34. Reserve Fuel Hose 35. Fuel Tank 36. Oil Tank 37. Bypass Outlet 38. 30 39. Holizontal Line 40. Bypass Outlet Hose (Drain Hose for #1 Head) 41. Fuel Level Sensor Leads 42. Oil Level Sensor Leads
43. To Steering 44. Wire Leads of Start/Stop Switch and Meter 45. Connectors 46. Crossmember 47. Fuel Vent Hose 48. Throttle Cable 49. Return Fuel Hose 50. Loosen the fuel hoses remaining. 51. Choke Cable 52. Snpply Fuel Hose 53. Clamp the water temperature sensor lead with the throttle cable. 54. Water Temperature Sensor 55. Loosen the sensor lead remaining. 56. Refer to DETAIL 5 (Page 116).
Nikasil Plating : A film in which silicon carbide (SiC) is combined with nickel (Ni). The cylinders are made from aluminium alloy for excellent heat transmission. This keeps the surface temperature of the cylinder-bore lower than is possible with a conventional aluminium cylinder with a cast-iron sleeve. Assembly and maintenance are improved with independent cylinders.
Nikasil Plating
The Kawasaki JET SKI Watercraft Constant Velocity Carburetor (1) Development Goals 1) The carburetor must allow high performance with high flexibility to match the engines capabilities. 2) The carburetor must have high driveability from low to high engine speeds, responding closely to the operators input. 3) The carburetor must lower exhaust emissions for less harm to the environment. (2) Features 1) The watercraft CV carburetor has a variable venturi for smoother driveability through the entire speed range of the engine. It has a vacuum diaphragm which moves a slide in the venturi, and a needle jet and jet needle. The slide changes the venturi area according to the pressure in the venturi, and the needle and jet vary the amount of fuel allowed into the venturi. 2) The watercraft CV carburetor is a diaphragm-type carburetor (as opposed to a float bowl-type), and has all the performance features of the traditional watercraft carburetor: It can operate efficiently at any angle, it is durable, and corrosion resistant. (3) Construction and Function 1) In operation, air is drawn through the intake [1], venturi opening [2], and the throttle valve [3], and into the engines crankcase. The vacuum-actuated slide [4] projects into the venturi, and is pushed to narrow the venturi opening by the vacuum slide spring [5]. When the engine is running slowly and the amount of air down into the engine is very small, the slide [4] moves to minimize the venturi cross sectional area. This maintains the air velocity in the venturi. The bottom of the slide [4] has a hole [4-1] that goes through into the space above the diaphragm [4-2]. This hole allows the low pressure in the venturi to draw the slide, against the pressure of the spring [5], out of the venturi, enlarging the venturi area [2]. The wider the throttle opens, the lower the pressure in the venturi and the farther the slide moves, opening the venturi so that the engine can speed up. This mechanism maintains the air speed through the venturi at an even level. 2) The carburetor assembly has a built-in pulse-type fuel pump [6]. Fuel flows from the fuel tank to the joint [7] on the carburetor assembly and into the fuel pump. As the engine turns, pressure pulses from the crankcase travel through the pulse joint [8] and push the diaphragm [9] in the fuel pump back and forth, drawing fuel through the check valve in the joint [7] and pushing it past the needle valve [11], and into the regulator chamber [12]. The needle valve [11] serves the same purpose as
6) As the fuel in the regulator chamber [12] flows out, the pressure in the chamber drops and draws the regulator diaphragm [22] into contact with the collar [24] of the float arm [23], which in turn pulls the needle float valve [11] away from the valve seat [10]. Fuel can now flow into the regulator
4. Oil Pump
The oil pump output is determined by both engine speed and throttle opening, reducing both oil consumption and exhaust smoke. This type of pump is often used on 2-stroke motorcycles. The oil pump has 5 outlet ports. The oil is supplied to each carburetor through 3 outlet ports and to the balancers through 2 ports for optimum lubrication. The oil pump output of the JH1100A is determined
A. B. C. D. E. F. G. H.
Battery Starter Starter Relay Ignition Switch Starter Switch Stop Switch Heat Sensor Intake Air Temperature Sensor
I. J. K. L. M. N. O. P.
Pickup Coil Throttle Position Sensor Warning Monitor Power-Source ON/OFF Circuit Wave Shape Circuit DC-DC Converter Control Unit Ignition Coil #1
(4) Overheat Control To protect the engine against overheating, a new, more sensitive heat-sensor constantly monitors exhaust pipe temperature. When temperature exceeds 90 degrees C or more, the igniter gradually cuts engine speed to 3500 rpm where it stays until the temperature is lowered.
(5) Engine Over-Rev Cut-Off The igniter stops ignition when engine speed exceeds 7500 r/min (rpm), to protect the engine from damage. The ignition starts again when the engine speed drops below 7500 r/min (rpm). (6) Engine Tachometer Drive The electric tachometer is driven by the pulsing signals from the ignitor. (7) Power Source OFF Function Three minutes after the engine stops, the igniter shuts off the power source automatically. The power source turns on again when the starter switch turns on. (8) Output for Outer Load Function When the power source of unit turns on, the igniter puts out a voltage equivalent to the battery voltage on the terminal. This terminal is connected to Trim Switch and Multifunction meter.
2. Magneto
The exciter coil is eliminated by adopting DC-CDI. Rare earth metal magnets lighten the magneto and decrease the flywheel effect, improving acceleration response. Diameter Weight Flywheel effect JT1200A 106 mm (1.732 in.) 1.44 kg (3.18 lb) 16.1 kgcm JH1100A 131 mm (5.175 in.) 2.54 kg (5.60 lb) 43.0 kgcm
Units of Length:
km m mm 0.6214 3.281 0.03937 = = = mile ft in
Units of Torque:
Nm Nm Nm kgfm kgfm kgfm 0.1020 0.7376 8.851 9.807 7.233 86.80 = = = = = = kgfm ftlb inlb Nm ftlb inlb
Units of Mass:
kg g 2.205 0.03527 = = lb oz
Units of Volume:
L L L L L L mL mL mL 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in
Units of Pressure:
kPa kPa kPa kgf/cm kgf/cm cm Hg 0.01020 0.1450 0.7501 98.07 14.22 1.333 = = = = = = kgf/cm psi cmHg kPa psi kPa
Units of Speed:
km/h 0.6214 = mph
Units of Force:
N N kg kg 0.1020 0.2248 9.807 2.205 = = = = kg lb N lb
Units of Power:
kW kW PS PS 1.360 1.341 0.7355 0.9863 = = = = PS HP kW HP
Units of Temperature:
Periodic Maintenance
TABLE OF CONTENTS
Periodic Maintenance Chart ...................................................................................................... Specifications ............................................................................................................................ Periodic Maintenance Procedures............................................................................................. All Hoses, Hose Clamps, Nuts, Bolts, and Fasteners Check ................................................. Hose and Hose Connect Inspection .................................................................................... Rubber Strap Inspection ...................................................................................................... Fuel System:........................................................................................................................... Idle Speed Adjustment......................................................................................................... Carburetor Synchronization ................................................................................................. High Altitude Performance Adjustment ................................................................................ Carburetor Cable Adjustment .............................................................................................. Oil Pump Cable Adjustment................................................................................................. Choke Cable Adjustment ..................................................................................................... Fuel Filter Screen Cleaning ................................................................................................. Fuel Vent Check Valve Mounting ......................................................................................... Fuel Vent Check Valve Inspection ....................................................................................... Flame Arrester Cleaning ...................................................................................................... Fuel Filter Inspection............................................................................................................ Throttle Shaft Spring Inspection........................................................................................... Engine Bottom End................................................................................................................. Coupling Damper Inspection................................................................................................ Cooling and Bilge Systems..................................................................................................... Cooling System Flushing ..................................................................................................... Bilge System Flushing ......................................................................................................... Pump and Impeller.................................................................................................................. Impeller Inspection............................................................................................................... Steering .................................................................................................................................. Steering Cable Inspection.................................................................................................... Handlebar Pivot Lubrication................................................................................................. Electrical System .................................................................................................................... Battery Charging Condition Inspection ................................................................................ Spark Plug Inspection .......................................................................................................... Spark Plug Adjustment ........................................................................................................ Spark Plug Cleaning ............................................................................................................ General Lubrication ................................................................................................................ Lubrication ........................................................................................................................... All Nuts, Bolts and Fasteners Check ...................................................................................... Nuts, Bolts, and Fasteners Tightness Inspection................................................................. 2-2 2-3 2-4 2-4 2-4 2-4 2-5 2-5 2-6 2-7 2-7 2-8 2-8 2-9 2-10 2-10 2-11 2-11 2-11 2-11 2-11 2-12 2-12 2-13 2-13 2-13 2-14 2-14 2-14 2-15 2-15 2-15 2-15 2-16 2-16 2-16 2-19 2-19
210 210 210 211 211 212 212 213 213 214 215 216 216
- - -
NOTE
Check the fuel and oil filler tubes and exhaut tubes for
NOTE
signs of wear, deterioration, damage or leakage. Replace if necessary. Make sure the above tubes are secured with the metal gear clamps away from any parts.
following rubber straps for any deterioration or Check thePull on squeeze the straps and look for cracks. damage. Battery Straps [A] Fuel and Oil Tank Straps Water Box Muffler Straps If a strap is damage in any way, replace it.
The normal idle speed is the lowest stable speed. Turn the idle adjusting screw [A] as required to reach this setting.
Idle Speed : in water out of water 1,250 100 r/min (rpm) 1,800 100 r/min (rpm)
the [A] Make sureawayidle adjusting screwpipe is secured with the clamp [B] from the exhaust [C]. If the idle adjusting screw touches the exhaust pipe, resecure the idle adjusting screw with the clamp to the cable bracket [D].
Remove the carburetor (see Carburetor Removal in the Fuel System chapter). until there is a Turn out the idle adjusting screw [A]end and throttleclearance between the adjusting screw shaft
lever [B]. Turn in the idle adjusting screw until the adjusting screw end just touches the throttle shaft lever. Turn in the adjusting screw 3/4 turn from the point to keep the specified throttle valve [C] opening in the front carburetor [D]. Measure the distance from the bottom of the carburetor bore lower end to the valve edge shown as "H". Turn the synchronizing screw [E] so that the valve edge in the middle carburetor [F] keeps the same distance within 0.2 mm (0.008 in.) tolerance as that in the front carburetor. Turn the synchronizing screw [G] so that the valve edge in the rear carburetor [H] keeps the same distance within 0.2 mm (0.008 in.) tolerance as in the front carburetor. Install the carburetor. Adjust the throttle control and choke cables.
Be sure to inspect the remaining cable if whichever cable the carburetor the oil pump is adjusted. carburetor cable adjustment. Checkthe throttle lever released, the lower stop on the With
NOTE
throttle pivot arm [A] should rest against the idle adjust screw [B], and there should be slight slack in the throttle cable. When the throttle lever is fully applied (pulled), the upper stop on the pivot arm should be all the way up against the stop on the carburetor.
the lower stop on the pivot arm hits against the idle adjust screw with slight cable slack. Tighten the locknuts securely.
Check the oil pump cable adjustment (see Oil Pump Cable Adjustment).
If necessary, adjust the oil pump cable.
adjustment. Check carburetor cable carburetor cable. If necessary, adjust theadjustment. oil Check the pump cable is fully applied (pulled), check to When throttle lever see that there is a clearance [A] (approx. 0.6 mm, 0.0236 in.) between stop [B] on the oil pump pulley and the stopper pin [C] on the oil pump body. At this time, the oil pump pulley is fully opened.
If necessary, adjust the oil pump cable [A]. Hold the throttle lever fully applied (pulled). Turn the oil pump pulley till the stop on the pulley contacts to the stopper pin on the oil pump body. At this time, the oil pump pulley is fully open. And then give the oil pump cable tension by turning the upper locknut clockwise. Loosen the upper locknut [B] by turning counterclockwise 1/2 turn and then fix the oil pump cable by tightening the lower locknut [C] securely.
Torque - Oil Pump Cable Locknuts: 9.8 Nm (1.0 kgfm, 87 inlb)
choke cable adjustment. Check the choke knob is turned to the OFF position, the When choke butterfly valve in the carburetor should be completely open. The choke pivot arm [A] should stand all the way toward the port side of the boat with cable slack. When the choke knob is turned to the ON position, the choke butterfly valve in the carburetor should be completely closed. Check that the choke pivot arm stands all the way toward the starboard side of the boat without cable slack.
Loosen the locknuts [B] at the cable holder and turn the
choke knob to the OFF position. Check that the choke pivot arm stands all the way toward the port side of the boat with cable slack, and tighten the locknuts.
Turn the choke nob to the ON position. Check that the choke pivot arm stands all the way toward
the starboard side of the boat without cable slack.
Remove the storage pocket (see Storage Pocket Removal/Installation in the Hull/Engine Hood chapter). Unscrew the fuel filter assembly mounting screws [A].
fuel filter assembly Pull the the storage pocket. [A] out of the space after removing
Wash the fuel filter screens [A] intonon-flammable or high flash-point solvent. Use a brush remove any contaminants trapped in the screens.
WARNING
Clean the fuel screens in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent. A fire or explosion could result.
When installing the fuel filter assembly, note the following. Be sure the hoses are connected correctly with their fittings. Reserve Line [A] Main (ON) Line [B] Return Line [C] Fuel Vent Line [D]
Remove the check valve and blow through it from each end.
If the check valve will allow air to flow as shown, it is OK. If air will flow through the check valve in both direction or in neither direction, the check valve must be replaced.
WARNING
Eye protection should be worn when compressed air is used to dry parts. Do not direct air toward anyone. Use 172 kPa (1.75 kgf/cm, 25 psi) maximum nozzle pressure. flame Install thethe Fuelarrester (see Flame Arrester Installation Notes in System chapter).
in accordance Inspect and replace the fuel filter [A] whenever you with the Periodic Maintenance Chart, or find from outside any foreign material or water trapped in the fuel filter. Check the fuel filter body for cracks and damage. If necessary, replace the fuel filter.
Check the throttle shaft springs [A] by pulling the throttle lever.
If the springs are damaged or weak, replace the carburetors.
Start the engine and allow it to idle before turning on the water.
CAUTION
The engine must be running before the water is turned on or water may flow back through the exhaust pipe into the engine, resulting in the possibility of severe internal damage. the water adjust the that a Immediately turn oncomes outan the bypassflow so [A] on little trickle of water of outlet the right side of the hull.
Leave the engine idle for several minutes with the water running. off Leave the idling. Turn the the water.few times toengine the water out of the clear Rev engine a exhaust system.
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damage will occur. off Switchcap.the engine, remove the garden hose, install the fitting
the bilge (from the hull to the Connecthoses, turnfilter hoses on, and flush itbottom) about garden the water out for a minute. During this procedure, water will flow into the engine compartment. Do not allow a large amount of water to accumulate in the engine compartment. Remove the drain screws in the stern to drain the engine compartment. Connect the other hoses (from the hull bulkhead) to the garden hose, turn the water on, and flush it out for several minutes.
the to plastic breather fit Before reconnectingsmallhoses[A], the top of the breather ting make sure the hole on
NOTE
removed with abrasive paper or careful filing. Smooth leading edges are especially important to avoid cavitation.
directions. Be certain that the cable moves freely in bothcable. Disconnect the cable joint at each end of the
CAUTION
Never lay the watercraft on the right side. Water in the exhaust system may drain back into the engine causing serious damage.
Slide the inner cable [A] back and forth [B] in the cable
housing. If the cable does not move freely, replace it.
the bushings for damage and Checkbushings are damaged or worn,wear. them. If the replace Grease: Bushings [A]
CAUTION
Be sure to disconnect the negative terminal lead first.
NOTE
Remove the spark plugs (see Spark Plug Removal in the Electrical System). Examine the ceramic insulator [C] and electrodes if[A] [B]. If the insulator appears glazed or very white, or there
are gray metallic deposits on the electrodes, combustion chamber temperatures are too high. Refer to Troubleshooting. If the insulator appears dry and sooty the fuel/air mixture is overly rich (see Carburetor Adjustments in the Fuel System chapter). If the insulator and electrodes are wet and oily, an improper oil type or an excess oil output may be the cause. If the ceramic insulator is cracked, replace the plug. If the electrodes are badly worn or burned, replace the plug. Examine the spark plug threads. If the threads are damaged, replace the plug.
Measure the spark plug gap [D]. electrodes with a feeler Check the distance between the
gauge or a wire gauge.
Spark Plug Gap Standard: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in.)
If the gap is not within specifications, adjust it. Adjust the gap by carefully bending the side electrode with a tool designed for this purpose.
General Lubrication
As in all marine craft, adequate lubrication and corrosion protection is an absolute necessity to provide long, reliable service. Refer to the Periodic Maintenance Chart for the frequency of the following items:
Lubrication
a Lubricate the following with[A]penetrating rust inhibitor [B]. Throttle Control Cable Choke Cable [A]
NOTE
Fuel System
TABLE OF CONTENTS
Exploded View....................................... Specifications ........................................ Fuel System Diagram ............................ Throttle Control Cable ........................... Carburetor Cable Adjustment .......... Oil Pump Cable Adjustment............. Throttle Case and Throttle Control Cable Removal.............................. Throttle Case and Throttle Control Cable Installation........................... Throttle Control Cable Lubrication ... Throttle Control Cable Inspection .... Choke Cable.......................................... Choke Cable Adjustment ................. Choke Knob and Cable Removal..... Choke Knob and Cable Installation Notes............................................. Choke Cable Inspection................... Choke Cable Lubrication.................. Carburetor/Fuel Pump ........................... Idle Speed Adjustment..................... Synchronization ............................... Pilot Screw Removal/Installation...... Carburetor Removal......................... Carburetor Installation...................... Carburetor Disassembly .................. Carburetor Assembly ....................... Carburetor Cleaning and Inspection Float Arm Level Inspection and Adjustment .................................... 3-2 3-6 3-7 3-8 3-8 3-8 3-8 3-9 3-9 3-9 3-10 3-10 3-10 3-11 3-11 3-11 3-12 3-12 3-12 3-12 3-12 3-13 3-14 3-16 3-17 3-18 Fuel Pump Removal/Installation Note............................................... Flame Arrester....................................... Removal........................................... Installation........................................ Flame Arrester Cleaning .................. Intake Manifold, Reed Valves ................ Intake Manifold Removal ................. Intake Manifold Installation .............. Reed Valve Inspection ..................... Valve Holder Inspection ................... Valve Stop Inspection ...................... Fuel Tank ............................................... Fuel Tank Removal .......................... Fuel Tank Installation ....................... Fuel Tank Cleaning .......................... Fuel Filler and Tube Removal.......... Fuel Filler and Tube Installation Notes............................................. Fuel Filter Screen Cleaning ............. Fuel Filter Inspection........................ Fuel Vent Check Valve .......................... Fuel Vent Check Valve Mounting ..... Fuel Vent Check Valve Inspection ... Fuel Tap................................................. Removal........................................... Installation Notes ............................. Cleaning........................................... 3-18 3-19 3-19 3-20 3-21 3-22 3-22 3-22 3-23 3-23 3-24 3-25 3-25 3-26 3-27 3-27 3-28 3-28 3-28 3-29 3-29 3-29 3-30 3-30 3-30 3-31
1. Fuel Vent Pipe 2. Fuel Vent Check Valve: The fuel vent check valve must be mounted so that the arrow is pointing toward the fuel tank. 3. Arrow Mark 4. Fuel Vent Line 5. VENT 6. Fuel Filter/Pipe 7. ON 8. Main Line
9. Fuel Tap 10. Reserve Line 11. RESERVE 12. RETURN 13. Return Line 14. Supply Line 15. Fuel Filter 16. Carburetor 17. Pulse Line
Refer
Cut off the clamp [A] securing the idle adjusting screw [B]. Cut off the clamps [C] securing the water temperature [D] sensor lead. Loosen the adjuster locknuts of the carburetor and oil pump cables. [E] of holder [F] Take out the bolts controlthe cable port side toand move the holder with the cables to make the
service easier. from the Disconnect the carburetor cableand slide carburetor.from the cable Unscrew the adjuster locknuts the cable holder. Slide the cable tip [A] from the throttle shaft lever.
pump cable. Disconnect the oil pump cable from the oilthe cable from Unscrew the adjuster locknuts and slide
Take out the bolt [A] and washer [B], and disconnect the
oil pump cable end [C].
cable from case. Disconnect the throttleto separate the tip of the cable end Use a screw driver [A]
Slide the rubber boot out of the place. Unscrew the throttle cable fitting nut.
Remove: Handlebar
(see Handlebar Removal in the Steering Chapter.) Steering Cover (see Steering Removal in the Steering Chapter.) Grommet Mounting Plate Pull down the throttle control cable.
Apply a non-permanent locking agent to the oil pump caBe sure the cable portion indicated in the illustration is in
Torque - Oil Pump Cable Mounting Bolt: 4.9 Nm (0.5 kgfm, 43 inlb)
throttle Pulling the shown. cable [A], position the tips of the cable end [B] as
Route the following correctly (see Cable, Wire, and Hose Routing in the General Information chapter).
Throttle Cable Carburetor Cable Oil Pump Cable Choke Cable Idle Adjusting Screw Water Temperature Sensor Leads Adjust the following. Throttle Cable Carburetor Cable Oil Pump Cable Choke Cable (if necessary) Check that the throttle lever moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring. If the throttle lever does not return properly, check the throttle control cable routing, cable adjustments, and cable damage. Then lubricate the throttle control cable. Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If the idle speed increase, check the throttle control cable adjustment and the cable routing.
Refer to Choke Cable Adjustment in the Periodic MainteChoke Knob and Cable Removal
Disconnect the choke cable from the carburetor. Remove the plug. [A] and take out the choke knob Remove the set screw [B].
Pull out the choke knob cover [A] from the left side cover [B].
the cable Removechoke knobholder mounting screws [A]. out of the Pull the shaft [B] with cable holder hull.
Loosen the locknut [A] and unscrew the cable housing [B] from the holder [C]. Slide the tip [D] of the choke inner cable out of the pulley on the choke knob shaft.
Remove the pin and washer, and pull out the choke knob shaft from the cable holder.
[A] Choke Knob Shaft [B] Washer [C] Spring [D] Cable Holder [E] O-ring [F] Washer [G] Pin
indicated Grease the Holder area [A] the O-ring is installed. [B] Cable [C] O-ring [D] Washer [E] Pin [F] Choke Knob Shaft Route the choke cable according to the Cable Routing section in the General Information chapter. Adjust the choke cable (see Choke Cable Adjustment).
the Turn itinseatspilot screw [A] and count the amount of turns until thoroughly and then remove the screw. The purpose is to set the screw to its original position when installing. Spring [B] Washer [C] O-ring [D]
If the carburetor is tampered with or counting the amount of turns is not performed, set the pilot screw to the specified amount of turns.
Pilot Screw 1 1/4 1/2 turn open
Carburetor Removal
Remove or Disconnect: Air Intake Cover Assembly (see Flame Arrester Removal) Pulse Hose [A] Fuel (Supply) Hose [B] Fuel (Return) Hose [C] TPS Lead Connector [D]
clamps on the stay. Remove thethe inlet oil hoses [A] which lead to the carbuDisconnect retors, lifting the carburetor assembly [B]. Lift the carburetor assembly off the intake manifold.
Carburetor Installation
[A] Install new gasketspins under the carburetors. Be sure the dowel [B] are in place.
Connect the oilininlet hose correctly (see Cable, Wire and Hose Routing the General Information). the Installletter gaskets [A] on the carburetors [B] so that its UP [C] faces upward. Install the cases [D] on the carburetors noting its installing direction indicated in the figure. to the carburetor Apply a non-permanent locking agent following the semounting bolts [E] and torque them
quence shown.
Torque - Carburetor Mounting Bolts: 8.8 Nm (0.9 kgfm, 78 inlb)
Connect the fuel and pulse hoses correctly (see Cable, Wire and Hose Routing in the General Information). Adjust the throttle control and choke cables (see Throttle Control and Choke Cable Adjustment).
Carburetor Disassembly
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Remove the carburetor (see Carburetor Removal).off the Unscrew the carburetor cap screws [A] and take carburetor cap [B]. Remove: [C] Cap Spring
Vacuum Piston [D] and Diaphragm [E]
CAUTION
During carburetor disassembly, be careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm.
Unscrew the jet needle holder bolt [A] and take off the holder spring and jet needle [B].
Unscrew the vacuum piston holder screws [A] and take off the vacuum piston holder [B].
Unscrew the carburetor cover screws [A] and take off the carburetor cover [B].
Unscrew the float arm set screw [A]. Remove: [B] and Pin Float Arm
Inlet Valve [C] Spring [D]
Carburetor Assembly
the vacuum piston holder [A]. Install the jet needle [B] and holder spring [C] in the vacInstall uum piston [D], and tighten the jet needle holder bolt [E]. Install:Spring [F] Cap Carburetor Cap [G]
After
the carburetor has been disassembled and cleaned, it should be primed before starting the engine to save the battery. Pull off the fuel return hose [A] at the carburetor, and blow [B] through it until fuel appears at the fuel return fitting [C] on the carburetor. The fuel system in now full of fuel.
Immerse all the metal parts in a carburetor cleaning solution. parts in Rinse the parts arewater. dry them with compressed air. When the Blow out the air andclean, fuel passages with Inspect the check valve [A] for damagecompressed air. or deterioration, and replace it if necessary.
If the gasket [B] under the check valve appears damaged, it may leak and must be replaced.
on the diaphragm valve needle. It Check the plastic tipwithout any grooves, scratches, or should be smooth, tears. Inlet Valve [A] Inlet Valve Wear [B] If the plastic tip is damaged, replace the needle.
float arm level Check thefrom the plastic [A]. [B] on the float arm to the Measure tip
1.0 ~ 2.0 mm (0.039 ~ 0.079 in.)
If the float arm level is incorrect, bend the float arm very slightly to changed the float arm level.
the carburetor. Remove the fuel pump body screws [A], and take the fuel Remove [B] off the carburetor. pump unit
CAUTION
The fuel pump should not be disassembled. If leakage is evident or internal damage is suspected, replace the fuel pump unit [B].
Note the following when installing the pump unit [A] to the carburetor assembly [B].
place them. Align the slot [D] on the pump body with the shaft [E] on the carburetor assembly.
Installation
duct.
installing duct [A] into arrester case Whenthe rib [C] the the case with the groove [D] on [B], align on the the
Tighten the clamp screws [A] within the range [B] indicated in the figure.
The #2 duct has no clamp.
a non-permanent agent Apply mounting bolts andlocking them. to the air intake cover torque
Torque - Air Intake Cover Mounting Bolts: 7.8 Nm (0.8 kgfm, 69 inlb)
Be careful not to drop the bolts into the hull bottom when
installing.
NOTE
Install the bracket [A] aligning the groove on the bracket with the project on the air intake cover [B].
Flame Arrester Cleaning
nance chapter.
Pull out the gaskets [A] and the reed valves [B].
Replace the gaskets with new ones. either obverse or As for the base gaskets [A], installation
As for the reed valve assemblies [B] and the gasket [C],
install them noting the direction of UP [D] letters. Align [E] the projections on the reed valve assemblies with the holes on the intake manifold. The projections on the reed valve assemblies must be upward.
Install the intake manifold [A]. Torque the mounting nuts, following the sequence indicated in the figure. the balance tube intake air connecting el When[C] were removed,[B] and the following. bows noting
Torque - Intake Manifold Mounting Nuts: kgfm, 87 inlb) 9.8 Nm (1.0
reed warp Checkreed [B] andby measuring the clearance [A] between each the valve holder [C]. If any one of the clearance measurements exceeds the service limits, replace the reed with a new one. Check reed warp after installing a new reed. If the clearance is correct, tight the mounting screws securely. screw tightness. Check the mountingreeds for cracks, folds, or other dam Visually inspect the age. If there is any doubt as to the condition of a reed, replace the reed. If a reed becomes wavy, replace the reed with a new one even if reed warp is less than the service limit. Install the reed and stop onto the reed valve holder, aligning the chamfered corner of the reed with that of the reed stop.
Reed Warp Service Limit: 0.2 mm (0.008 in.)
Check the reed [A] contact areas of the valve holder for grooves, scratches, or other damage. rubber valve holder Check that thesigns ofcoating [B] on thethe holder. does not show any separation from
If there is any doubt as to the condition of the rubber coating, replace the reed valve holder with a new one.
Check the valve stops [A] for deformation, cracks, or other damage.
If there is any doubt as to the condition of a stop, replace the reed valve assembly with a new one.
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). oil the oil level sensor (see Oil Remove thethe tank withLubrication System chapter).Tank Removal in Engine
level sensor lead connector [A]. Disconnect the fuel [B] and pull the fuel filler tube [C]. Unscrew the calmp
Remove the storage pocket (see Storage Pocket Removal/Installation in the Hull/Engine Hood chapter). the fuel assembly Unscrewthe clampfilter on the fuelmounting screws [A]. Loosen [B] level sensor [C].
the fuel filter assembly [A] fuel level sensor Pullof the space after removing andstorage pocket. [B] out the
in Be sure the O-ring [A] is(seeposition.Wire and Hose RoutConnect them correctly Cable, ing in the General Information). Fuel Hoses Fuel Vent Hose Fuel Level Sensor Lead Connector Other Wire and Harness.
WARNING
Clean the tank in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the tank. A fire or explosion could result.
the Take out[B]. screws [A] in the filler flange, and cut the sealant
Loosen the tube clamps [A] and pull the filler [B] from the hull.
WARNING
Clean the parts in a well ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent. A fire or explosion could result. an even layer silicone Apply of the filler andofhull. sealant to the mating surfaces
Refer to Fuel Filter Screen Cleaning in the Periodic MainFuel Filter Inspection
chapter.
Remove the fuel tap knob cover [A] from the right side cover [B].
Unscrew the mounting screws [A] and take out the fuel tap [B].
Pull the fuel hoses [A] off the fuel tap [B].
Installation Notes
Connect the fuel hoses to the fuel tap correctly (see Cable, Wire and Hose Routing section in the General Infor
mation chapter). Apply a non-permanent locking agent to the fuel tap mounting screws and tighten them securely.
Do not use too high air pressure (172 kPa, 1.8 kgf/m,
25 psi max.).
NOTE
3.83 mL (0.129 US oz) 10% 4.00 mL (0.135 US oz) 10% 3.83 mL (0.129 US oz) 10% 1.33 mL (0.045 US oz) 10% 1.33 mL (0.045 US oz) 10%
CAUTION
Use a 50 : 1 mixture of gasoline to oil in the fuel tank in place of the gasoline normally used. Do not turn on the water until the engine is running and turn it off immediately when the engine stops. the cooling system with water (see Supplythe General Information chapter). Auxiliary Cooling in the engine, keep is at idling speed and Startthrough the transparent outlet hoses. check the oil flow Keep the engine running until any air bubbles in the outlet hoses disappear.
If a drop in oil pump performance is suspected, check the rate at which the oil is being pumped. Cut off the clamp [A] securing the idle adjusting screw [B]. Take out the bolt [C] of the cable holder [D] and move the holder with the control cables to portside to make the service easier.
Disconnect the oil pump outlet hoses [A] at the pump body.
Plug the ends of the oil pump outlet hoses.connect them suitable transparent Reserve oil pump outlets. hoses and with the oil transparent hoses. Injecteachinto theinto a measuring glass. Run hose Reinstall the cable holder. If necessary, adjust control cables.
CAUTION
For this test use a 50:1 mixture of gasoline to oil instead the gasoline normally used.
If the oil pump output is subnormal, inspect the oil pump, and the inlet and output hoses for oil leaks. If oil leaks are not found, replace the oil pump.
the clamp the idle adjusting screw [B]. Cut offout the bolt[A] securingcable holder [D] and move Take [C] of the the holder with the control cables to port side to make the service easier.
cable [A] on the pulley [B]. Install the oil pumpthe oil pump cable mounting bolt. Put the washer on ble mounting bolt and torque it.
Apply a non-permanent locking agent to the oil pump caBe sure the cable portion indicated in the illustration is in
contact [C] with the pulley portion indicated in the illustration.
Torque - Oil Pump Cable Mounting Bolt: 4.9 Nm (0.5 kgfm, 43 inlb)
the oil pump cover. Install mounting the on the magnetothe position of the slot oil pump, note When
[A] in the front balancer shaft, and then turn oil pump shaft [B] so that it will fit into the slot. Apply a non-permanent locking agent to the oil pump mounting bolts and torque them.
Torque - Oil Pump Mounting Bolts: 8.8 Nm (0.9 kgfm, 78 inlb)
Route the oil hoses correctly (see Cable, Wire and Hose Routing in the General Information chapter).
To Carburetors [A] To Check Valves for Balancer Lubrication [B] Clamps [C] Bleed the air from the system (see Oil Pump Bleeding). Adjust the oil pump cable [D] (see Oil Pump Cable Adjustment in the Fuel System). Fix the idle adjusting screw correctly (see Cable, Wire and Hose Routing in the General Information chapter).
Drain the engine oil. [A] and pull off the oil hose [B]. Loosen the lower clamp
Remove the oil tank [A] with the oil level sensor out of the hull. Loosen the clamp [B] and pull up the oil level sensor [C].
Flush the tank repeatedly with high flash-point solvent until it is clean.
WARNING
Clean the tank in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the tank. A fire or explosion could result.
Take out the oil filter a[A]. or Wash the oil filter in non-flammable anyhigh flash-point solvent. Use a brush to remove contaminates
trapped in the filter.
WARNING
Clean the oil filter in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the filter. A fire or explosion could result.
Exhaust System
TABLE OF CONTENTS
Exploded View........................................................................................................................... Expansion Chamber .................................................................................................................. Removal............................................................................................................................... Installation............................................................................................................................ Exhaust Pipe/Exhaust Chamber Cleaning and Inspection .................................................. Exhaust Manifold ....................................................................................................................... Removal............................................................................................................................... Installation............................................................................................................................ Cleaning and Inspection ...................................................................................................... Water Box Muffler ...................................................................................................................... Removal............................................................................................................................... Installation............................................................................................................................ Inspection............................................................................................................................. Resonator .................................................................................................................................. Resonator Removal ............................................................................................................. Resonator Installation .......................................................................................................... 5-2 5-4 5-4 5-5 5-7 5-8 5-8 5-9 5-9 5-10 5-10 5-10 5-10 5-11 5-11 5-11
Remove the exhaust pipe [A] and expansion chamber [B] as a set.
Installation
Install the expansion chamber on the exhaust pipe. Be sure the dowel pin [A] is in place.
that its UP letter [C] faces upward. chamber mounting bolts and torque them.
Install the new gasket [B] on the expansion chamber so Apply a non-permanent locking agent to the expansion
Torque - Expansion Chamber Mounting Bolts: 29 Nm (3.0 kgfm, 22 ftlb)
water passage on the expansion Be sure thenot obstructed by foreign matter. chamber [B] hole [A] is
Torque - Exhaust Pipe Mounting Bolts - 8 mm (0.315 in.) Dia: 29 Nm (3.0 kgfm, 22 ftlb) [D] Exhaust Pipe Mounting Bolts - 10 mm (0.394 in.) Dia: 49 Nm (5.0 kgfm, 36 ftlb) [E]
exhaust tubes their fittings [B], When installing thepositions [C] are[A] on the fiting projecbe sure the clamp over tions [D].
Chamber
Cleaning
and
Remove the exhaust pipe and chamber. the carbon deposits out Clean blunt, roundedged tool. of the exhaust passages with a Flush foreign matter out of the water passages with fresh water. the insides of the Check the gasket surfaceswater passages for corrosion. Check for nicks or other damage.
If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly, replace the part.
the Unscrew [B]. mounting nuts [A] and remove the exhaust manifold
Tighten the exhaust manifold nuts [D] following the sequence shown.
Torque - Exhaust Manifold Nuts: 34 Nm (3.5 kgfm, 25 ftlb)
Remove the exhaust manifold parts. exhaust passages the carbon deposits out Clean blunt, roundedged tool. of the with a Flush foreign matter out of the water passages with fresh water. the insides of the Check the gasket surfaceswater passages for corrosion. Check for nicks or other damage.
If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly, replace the part.
Installation
dampers Be sure the place. [A] on the hull bottom and muffler body are in the clamp [B] securing the exhaust its Install position (see Cable, Wire and Hosetube, notingthe screw Routing in General Information chapter).
Inspection
Remove the water box muffler. of the water box. Empty water outspigot for damage caused by excessive Check the inlet heat.
If there is heat damage to the inlet spigot, check the cooling system for blockage (see Cooling System Cleaning and Inspection) and the carburetor for proper adjustment (see Fuel System chapter).
Resonator Installation
Align the projections [A] on the resonator [B] with the white mark [C] on the exhaust tubes [D]. the clamp screws Position the dampers [F] as[E] underneath. Wire and Position Hose Routing in the Generalshown (see Cable, Information chapter).
Cylinder head warp Cylinder, Piston: Cylinder inside diameter Piston diameter-26.9 mm (1.0591 in.) up from bottom of skirt Piston/cylinder clearance Piston ring/groove clearance: Top (keystone) Second (keystone) Piston ring groove width: Top (keystone) Second (keystone) Piston ring thickness: Top (keystone) Second (keystone) Piston ring end gap: Top Second
80.000 ~ 80.015 mm (3.1496 ~ 3.1502 in.) 79.865 ~ 79.880 mm (3.1443 ~ 3.1449 in.) 0.130 ~ 0.140 mm (0.0051 ~ 0.0055 in.) 0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in.) 0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in.)
Special Tools - Piston Pin Puller Assembly: 57001-910 Piston Pin Puller Adapter: 57001-1211 Compression Gauge: 57001-221 Compression Gauge Adapter, M14 1.25: 57001-1514
Remove the engine (see Engine Removal/Installation chapter). Remove: [A] Spark Plugs
Cylinder Head Nuts [B] and Washers [C] Spark Plug Holder [D] Reinforce [E] Cylinder Head [F] Cylinder Head Gasket [G] Front [H]
Remove the cylinder base nuts [A], and lift off the cylinders [B].
rags into the crankcase opening to prevent Stuff cleanobjects from falling into the crankcase. dirt or foreign Remove the piston pin snap ring [A] with a pliers [B].
pushing its Remove the piston byUse a pistonpin out the side that the circlip was removed. pin puller assembly, if the pin is tight.
Special Tool - Piston Pin Puller Assembly: 57001-910 Piston Pin Puller Adapter: 57001-1211
the ring opening your thumbs and Carefully spreadthe opposite side ofwith ring [A] to remove then push up on the it.
Assembly Notes
If any parts in theispiston assemblies require replacement, or if the cylinder replaced, be sure to check the critical
clearances of the new parts against the values given in Specifications. Install the piston rings so that the R mark [A] faces upward as shown. When the piston rings are reinstalled to the piston ring grooves reinstall them as follows for fitting. Top Piston Ring Top Piston Ring Groove Second Piston Ring Second Piston Ring Groove
the ring opening with the other hand and then slip the ring into the groove. Check to see that the pin [A] in each piston ring groove is between the ends of the piston ring. Using molybdenum disulfide oil, lubricate the small end bearing and insert into the connecting rod eye. Using molybdenum disulfide oil, lubricate the piston pin and the pin holes.
the Mount theirpistons on the connecting rods with the arrows [A] on crown pointing to the reed valves side [B] of engine.
pin snap When installing aitpistonno more. ring, compress it only enough to install and
CAUTION
Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. the side Fit a new piston pin snap ring into does notof each piston so that the snap ring opening [A] coincide with the slits [B] of the piston pin hole.
The tab [A] of gasket must faces forward [B] and align
the knock pin hole [C] of gasket with the knock pin on the cylinder.
CAUTION
Do not force the cylinder block. Make sure the rings are in position. nuts. Install the cylinder basecylinder base nuts in a cross patTemporarily torque the tern and torque them in the same order.
Initial Torque for Temporal Tightening Cylinder Base Nuts: 7.8 Nm (0.8 kgfm, 69 inlb) Torque - Cylinder Base Nuts: 49 Nm (5.0 kgfm, 36 ftlb)
on the Install the water pipe [A]gasketscylinder. the cylinder as [B] on Place new water pipe
shown. Set the clamp [C] on the water pipe as shown. Tighten the water pipe nuts [D] following the sequence shown. Front [E]
Torque - Water Pipe Mounting Nuts: 9.8 Nm (1.0 kgfm, 87 inlb)
[C] faces upward as shown. Tighten the exhaust manifold nuts [D] following the sequence shown.
Torque - Exhaust Manifold Mounting Nuts: 34 Nm (3.5 kgfm, 25 ftlb)
a head gasket on the Place thenew cylinderhead gasket [B] withcylinder head. that [C] of the Align tab [A] of cylinder block [D]. Align the dowel pins on the cylinder block with the holes of the head gaskets. Front [E]
Temporarily torque the cylinder head nuts in a cross pattern and torque them in the same order.
Initial Torque for Temporal Tightening Cylinder Head Nut: 7.8 Nm (0.8 kgfm, 69 inlb)
Start the engine to check for fuel and oil leaks, exhaust leaks, and excessive vibration.
WARNING
Do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas which can be lethal.
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damage will occur.
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damaged will occur. the engine. Stopall the spark plug caps from the spark plugs and push Pull the caps fully onto the spark plug cap holder (see Igniter Inspection in the Electrical System chapter).
compression is the highest reading obtainable. Repeat the measurement for the other two cylinders.
Cylinder Compression (Usable Range) 675 ~ 1070 kPa (6.9 ~ 10.9 kg/cm, 98 ~ 155 psi) (open throttle)
straightedge surface the Lay a[B] at several [A] across the lower measureofwarp head different points, and by inserting a thickness gauge between the straightedge and the head. If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged.
Cylinder Head Warp Service Limit: 0.05 mm (0.002 in.)
Inspect the inside of the cylinder for scratches and abnormal wear.
If the cylinder is damaged or badly worn, replace it with a new one. Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure. [A] 10 mm (0.3937 in.) [B] 90 mm (3.5433 in.) [C] 60 mm (2.3622 in.) If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder will have to be replaced with a new one.
Cylinder Inside Diameter Standard: 80.000 ~ 80.015 mm (3.1496 ~ 3.1502 in.) and less than 0.01 mm (0.0004 in.) difference between any two measurements Service Limit: 80.10 mm (3.1535 in.) , or more than 0.05 mm (0.002 in.) difference between any two measurements
Abnormal
NOTE
wear such as a marked diagonal pattern across the piston skirt may mean a bent connecting rod or a misaligned crankshaft.
Piston/Cylinder Clearance
The piston-to-cylinder clearance must be checked, and the standard value maintained anytime a piston or the cylinder block are replaced with new parts. The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measurements and then computing the difference between the two values. Measure the piston diameter as just described, and subtract this value from the cylinder inside diameter measurement. The difference is the piston clearance.
Piston/Cylinder Clearance 0.130 ~ 0.140 mm (0.0051 ~ 0.0055 in.)
If the rings are worn unevenly or damaged, they must be replaced. It the piston ring groove are worn unevenly or damaged, the piston must be replaced and fitted with new rings.
piston the cylinder, using the Place the the ringring inside in place. Set it close piston to locate squarely to the
bottom of the cylinder, where cylinder wear is low. Measure the gap [A] between the ends of the ring [B] with a thickness gauge. If the gap is wider than the service limit, the ring is worn excessively and must be replace.
Piston Ring End Gap Top Second 0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in.) 0.70 mm (0.0276 in.) 0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in.) 0.70 mm (0.0276 in.)
Engine Removal/Installation
TABLE OF CONTENTS
Exploded View........................................................................................................................... Engine Removal/Installation ...................................................................................................... Removal............................................................................................................................... Installation Notes ................................................................................................................. 7-2 7-4 7-4 7-6
Remove: Pipe [A] and Chamber [B] as a set (see Exhaust Exhaust
System chapter.) Air Intake Cover Assembly [C] (see Flame Arrester Removal in the Fuel System chapter) Carburetors (see Fuel System chapter)
and Take out the bolt [A][C]. washer [B], and disconnect the oil pump cable end
Unscrew the mounting bolts [A] and collars [B], and remove the coupling cover [C].
NOTE
Installation Notes
Be sure there are no foreign objects and parts inside of the hull. the bilge filter (see Filter Cleaning and Clean Cooling and Bilge Systems chapter). Inspection in the coupling damper wear and Check theDamper Inspectionfor the Enginedamage (see Coupling in Bottom End
chapter). Apply a non-permanent locking agent to the engine mount bolts [A] and torque them.
Torque - Engine Mount Bolts: 34 Nm (3.5 kgfm, 25 ftlb)
Check the gap between the engine mount and the dampers by rocking the engine. is a insert a suitable shim between If thereand gap,damper to achieve a good fit. the engine mount the
Shim Selection Shim No. 920253705 920253706 920253707 920253708 Thickness t 0.3 mm t 0.5 mm t 1.0 mm t 1.5mm
Apply a non-permanent locking agent to the engine mounting bolts and torque them.
Torque - Engine Mounting Bolts: 36 Nm (3.7 kgfm, 27 ftlb)
WARNING
Do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas which can be lethal.
CAUTION
Operate the engine only for short periods without cooling water.
0.8 mm (0.0315 in.) 0.087 mm (0.0034 in.) 0.2 mm/100 mm (0.0079 in./3.937 in.) 0.2 mm/100 mm (0.0079 in./3.937 in.)
Special Tools - Flywheel Puller Assy: 57001-1426 Rotor Holder: 57001-1428 Coupling Holder: 57001-1423 Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104-1003
Oil level is approx the middle line [C] of the gauge [D]
NOTE
under the state that the engine is mounted on the hull after pouring 200 mL (6.76 US oz).
Pour 20 mL (0.68 US oz) of 2-stroke oil [A] into the rear balancer room [B] after splitting the crankcase.
Hold the boss [B] of the front balancer gear [C] with the
rotor holder.
NOTE
CAUTION
Do not hold the teeth of the front balancer drive gear or magneto flywheel with the rotor holder. The gear teeth or the flywheel could be damaged.
Installation
Apply a non-permanent locking agent to the crankshaft threads. Screw the coupling onto the crankshaft and tighten it.
Coupling Damper Inspection
Torque - Coupling: 123 ~ 127 Nm (12.5 ~ 13.0 kgfm, 90.4 ~ 94.0 ftlb)
Refer
CAUTION
Do not hold the teeth of the front balancer drive gear or magneto flywheel with the rotor holder. The gear teeth or the flywheel could be damaged.
CAUTION
Do not hit the head of the flywheel puller assy. A loss in rotor magnetism may be caused.
[A]. Remove the snap ringclutch [B] compressing the friction Remove the oneway ring [C] from the balancer drive gear [D].
jections does not get out of the side plate. Remove the balancer drive gear mounting bolts [G] and take out the magneto flywheel [H].
Install the oneway clutch compressing the friction ring on the balancer drive gear.
When installing the oneway clutch, be careful that its rotating mark [A] faces toward the balancer gear [B] side. projections does not get out of the side plate. Replace the snap ring [C] with new one and install it.
Install the magnet flywheel [A] on the balancer drive gear [B].
the woodruff key groove [D] on the gear [B].
Align the maker mark [C] on the magneto flywheel [A] with Apply a non permanent locking agent to the balancer drive
Torque - Balancer Drive Gear Mounting Bolts: 12 Nm (1.2 kgfm, 8.5 ftlb)
gear mounting bolts [E] and tighten them following the sequence shown.
Magneto Flywheel [A] Torque Limiter [B] Starter Clutch Gear [C]
Both spacers are installed that the chamfer sides [F] face
toward cylinder side.
flash-points solvents, clean off any Using a highon the flywheel bolt, the crankshaft oil or dirt that may be taper, or
in the tapered hole in the flywheel. Fit the woodruff key [A] securely in the crankshaft, before installing the magneto flywheel.
Inspect the starter motor clutch. [A] by hand. The starter Turn the starter motor clutch gear
motor clutch gear should turn counterclockwise [C] freely, but should not turn clockwise [B]. If the clutch does not operate as it should or if it makes noise, disassemble the starter motor clutch, examine each part visually, and replace any worn or damaged parts.
NOTE
Remove: Engine
Magneto Cover [A]
Installation
NOTE
Apply
upward. Note the install direction for the cover [C] and clamp [D]. Apply a non-permanent locking agent to the grommet cover mounting bolts [E] and clamp mounting bolt [F].
Torque - Grommet Cover Mounting Bolts: 8.8 Nm (0.9 kgfm, 78 inlb) Clamp Mounting Bolts: 8.8 Nm (0.9 kgfm, 78 inlb)
Keep
the magneto lead [G] loose when tightening the clamp mounting bolt [E].
and pickup the magneto cover. Install the statorcoil leads [A] coil onleft [C] under the stator to the Run the pickup leads [B] as shown. Apply a non-permanent locking agent to the stator mounting bolts and put the washers.
mounting screws and install the pickup coil [A] together with the ground lead [B] so that the stator leads [C] have to be pressed by the pickup coil.
While pressing the pickup coil outward, torque the pickup coil mounting screws.
Pickup Coil Air Gap (Clearance between the rotor projection and pickup core) Standard: 0.75 ~ 0.95 mm (0.0295 ~ 0.0374 in.)
NOTE
When installing the pickup coil [A] ,fix the pickup leads
[B] between the stator leads [C] and the inside wall [D] of the magneto cover.
NOTE
Remove the engine (see Engine Removal/Installation chapter). the following from the engine. Remove Motor Starter
Intake Manifold Cylinder Head Cylinder Block Pistons Oil Pump Coupling Magneto Flywheel Balancer Gear Torque Limiter Starter Clutch Gear
Always remove the coupling before removing the magneto flywheel or there wont be any way to hold the crankshaft while unscrewing the coupling.
NOTE
(0.236 in.) crankcase bolts [A] first and Remove the 6 mmin.) bolts [B]. the 8 mm (0.315
crankcase half. Lift the crankshaft assembly out of the upper crankcase half.
Assembly
Install the oil seal [A] and the balancer drive gear [B] on the crankshaft [C] .
oil seal and install it noting the install direction indicated in the figure. Align a mark [E] on the balancer drive gear with a mark [F] on the crankshaft.
Visually inspect the crankshaft O-ring [A] and replace it if necessary. the inner surface of the collar it so Greasechamfer side [C] faces toward [B] and installdrive that its the balancer
gear. Slightly grease [D] the lips of the oil seals [E] and install them noting the install directions indicated in the figure. Attach the projections on the oil seal to the bearing.
Apply molybdenum disulfide oil to the connecting rod big end bearings and the side washers. clean off the With aofhigh flash-point solvent,and wipe dry. mating surfaces the crankcase halves
that the knock pins [A] in place. Checkthe crankshaft assemblyare in the upper crankcase Place [B] half.
ence [D] of the oil seals on the crankshaft assembly fit into the grooves in the crankcase. The pins [E] on the bearings and labyrinth packings on the crankshaft assembly fit into the grooves in the crankcase. Install the rear balancer gear [G], aligning a mark [F] on the balancer gear [G] with a mark [H] on the balancer drive gear [I]. At this time, push the bearing toward bow side [J]. Pour 20 mL (0.68 US oz) of 2 - stroke oil into rear balancer room [K]. Set the bearing [L] for the front blancer gear pushing it toward stern side [M].
Wipe off any excess liquid gasket at the portions [B] indi-
cated in the figure. Install the lower crankcase half on to the upper half.
Apply a non-permanent locking agent to the crankcase M6 bolts, and tighten them.
The
Torque - Crankcase M8 Bolts: 29 Nm (3.0 kgfm, 22 ftlb) Crankcase M6 Bolts: 8.8 Nm (0.9 kgfm, 78 inlb)
crankcase. Split thethe check valves. Inspect valve [A] allows oil flow in the direction of the The check arrow [B]. Inspect the normal oil flow by injecting [C] a high flash point solvent in a squirt can or syinge. In the following case, replace the check valves. 1. Oil will not pass through the check valve in the normal direction. 2. Oil will pass through the check valve in both direction.
CAUTION
Do not use compressed air on the valve since doing so would damage the valve spring
[A] and rear [B] Remove the fronthalf [C] with pliers.check valves on the upper crankcase following when installing. Note thenon-permanent locking agent to the check valves. Apply a
At this time, do not plug up the holes of the check valves with a locking agent. Install the check valves [A] [B] as shown.
Align the oil hose fitting of the front check valve [A] with
a rib [D] on the upper crankcase half. Align the oil hose fitting of the rear check valve [B] with a mark [E] on the upper crankcase half.
NOTE
Split the crankcase. to remove the rear check valve [B]. Take out the plug [A]
and out of the lower Tap the front [A]with arear [B] check valvesand driver [D]. crankcase half suitable screw [C]
rear [B] check valves. Press the check valves until their flange portions are bottomed. At this time , do not plug up the holes of check valves with a locking agent. Apply a non-permanent locking agent to the plug [C] for the rear check valve, install it.
In case that the check valves were installed aslant, replace the check valves.
NOTE
connecting rod Measurecrankshaft still intwist.alignment jig, hold the conthe With the
necting rod horizontally and measure the amount that the arbor varies from being parallel with the crankshaft over a 100 mm (3.937 in.) length of the arbor to determine the amount of connecting rod twist. If connecting rod twist exceeds the service limit, the crankshaft must be replaced.
Connecting Rod Twist Standard: Under 0.15/100 mm (0.0059/3.937 in.) Service Limit: 0.2/100 mm (0.0079/3.937 in.)
Push the connecting rod first towards the gauge and then
in the opposite direction. The difference between the two gauge readings is the radial clearance. if the radial clearance exceeds the service limit, the crankshaft assembly must be replaced or disassembled and the crankpin, needle bearing, and connecting rod big end examined for wear.
Connecting Rod Big End Radial Clearance Standard: 0.025 ~ 0.037 mm (0.001 ~ 0.0015 in.) Service Limit: 0.087 mm (0.0034 in.)
end side clearance [A]. Measure biggauges between the big end and either crank Insert feeler
half to determine clearance. If the measured value exceeds the service limit, the crankshaft should be either replaced or rebuilt.
Connecting Rod Big End Side Clearance Standard: 0.45 ~ 0.55 mm (0.0177 ~ 0.0217 in.) Service limit: 0.8 mm (0.0315 in.)
bearings high flash-point solvent, blow them Wash theNOT SPINinTHEM), and lubricate them with endry (DO
CAUTION
Solvent is toxic and flammable. Avoid prolonged contact with skin and keep away from open flame. Use only in a well ventilated area. Eye protection should be worn when compressed air is used to dry parts. Do not direct air towards anyone. Use 172 kPa (1.75 kg/ cm, 25 psi) maximum nozzle pressure. by and see Turn each bearing overand handno rough that it makes no noise, turns smoothly, has sports. If any of the bearings are defective, replace the crankshaft.
Pull the hoses [A] off the breather. the Unscrew [C]. mounting bolts [B], breathers
Breather Installation
Be sure the small hole [A] in the breather is open before installing it. Apply a non-permanent locking agent to the breather mounting bolts and tighten them.
small hole the top of the breather is open Check that theone end ofinthe breather and plugging the by blowing in other. If the hole is plugged, clean it with compressed air. Do not open it with a pointed object (like a needle or a piece of wire), because the hole may be enlarged. If the hole is too large, the bilge system may not suck water out of the hull as it should.
Filter Removal/Installation
[A] off the filter. Pull the hose mounting screws [B], and remove the filter Unscrew the [C].
To remove the left side filter, remove the water box muffler.
Flush the filter thoroughly with fresh water and shake it dry. must Waternot. flow freely through the filter, but large debris must
If the filter cannot be cleaned, or if it is broken and allows debris to pass through, replace it.
NOTE
Hose Installation
install the To the filter. bilge filter hose, push the hose over the end of
NOTE
Hose Inspection
Refer to Hose and Hose Connect Inspection in the Periodic Maintenance chapter.
Drive System
TABLE OF CONTENTS
Exploded View........................................................................................................................... Specification .............................................................................................................................. Drive Shaft/Drive Shaft Holder .................................................................................................. Drive Shaft Removal/Installation.......................................................................................... Drive Shaft Holder Removal/Disassembly ........................................................................... Drive Shaft Holder Assembly/Installation............................................................................. Drive Shaft Runout............................................................................................................... 10-2 10-4 10-5 10-5 10-5 10-6 10-7
10
Special Tools - Coupling Holder: 570011423 Bearing Driver Set: 570011129 Sealant - Kawasaki Bond (Silicone Sealant): 56019120
Remove the engine (see Engine Removal/Installation chapter). Pull the drive shaft [A] out of the hull.
Apply a non-permanent locking agent to the drive shaft Apply grease to the grease seal lips and the drive shaft
spline.
Remove the drive shaft. bolts [A] and remove the drive mounting Unscrew the[B] from the bulkhead. shaft holder
Press the small grease seal, and the large grease seals,
bearing, and small grease seals come out of the holder. [A] Sleeve [B] Blocks [C] Press
seals with Replace the greaseand grease new ones. the drive shaft Press the bearing holder, noting the following. seals into
Two Small Grease Seals [A] One Bearing [B] Two Large Grease Seals [C] Front [D]
Install the seals so that the sides with the spring face out-
ward. Fill the gaps between the seals with grease [E]. Install the circlip. Grease to the bearing inner surface and grease seal lips.
runout by on V Measure drive shaft dial gaugesupporting the shaft each blocks and setting a against the shaft at
point shown. Turn the drive shaft slowly. The difference between the highest and lowest dial gauge reading is the runout. If any measurement exceeds the service limit, replace the shaft.
Drive Shaft Runout Standard: Less than 0.1 mm (0.0039 in.) [A] Less than 0.2 mm (0.0079 in.) [B] Service Limit: 0.2 mm (0.0079 in.) [A] 0.6 mm (0.0236 in.) [B]
11
Special Tools - Impeller Wrench: 570011228 Impeller Holder : 570011393 Oil Seal & Bearing Remover: 570011058 Bearing Driver Set: 570011129 Sealant - Kawasaki Bond (Silicone Sealant): 56019120
Unscrew the mounting bolts [A] and remove the grate [B].
the bolts take off Removethe clamp[A] and the inletthe steering cable joint. Loosen [B] on cooling hose, and pull of the hoses [C].
the pump bolts [A]. Unscrew pump [B] tomountingto disengage the drive shaft, Slide the the rear and remove it from the hull.
Cut the sealant at the indicated area [A] in the figure and
remove the pump bracket [B].
pump bracket hull. Install thenon-permanent [A] to theagent to the following locking Apply a bolts and torque them.
Torque - Pump Bracket Mounting Bolts (2) [B] : 19 Nm ( 1.9 kgfm, 14 ftlb) Pump Bracket Mounting Bolts (4) [C] : 9.8 Nm (1.0 kgfm, 87 inlb)
As for the pump bracket mounting bolts (2) in the hull, the
bolt heads should be wrapped in silicone sealant.
Grease the splines on the deive shaft with water resistant grease. Install athe pump case. locking agent to the pump mountApply non-permanent
ing bolts and torque them.
Torque - Pump Mounting Bolts: 36 Nm (3.7 kgfm, 27 ftlb)
Install the grate [A]. [B] are in the position. Be sure the trim seals
ing bolts and torque them.
Apply a non-permanent locking agent to the grate mountTorque - Grate Mounting Bolts: 9.8Nm (1.0 kgfm, 87inlb)
Coat the outside edge [A] of the seal [B] with silicone
sealant to form a seal between the hull and seal.
Install the pump cover.in the position. Be sure the seal [A] is
mounting bolts and torque them.
Pump Disassembly
Unscrew the mounting bolts [A], and remove the steering nozzle [B].
JT1200A2:
Unscrew the mounting bolts [A], and remove the pump outlet [B].
JT1200A2:
Unscrew the cap bolts [A], and remove the pump cap [B].
a metal rod [A] into Insertremove the bearing the pump cap [B] from the rear end, by tapping evenly around the bearing inner race from the rear end of the pump cap.
Pump Assembly
the cap blow any dirt or Before installingthe pumpbearing, with compressedforeign particles out of cap [A] air. Install new bearing into the cap as far as it will go.
Special Tool - Bearing Driver Set: 570011129 [B]
pump bearing, blow any dirt or Before installing thethe pump case with compressed foreign particles out of air. Install new bearing into the pump case [A] as far as it will go.
Special Tool - Bearing Driver Set: 570011129 [B]
Replace the grease seals with new ones, if necessary, and install them.
Press each seal [A] into the pump case so that the side
Special Tool - Bearing Driver Set: 570011129
with the spring faces outward. Fill [B] the gap between the seals, and between the seal and the bearing with grease. Install the circlip [C]. Push the bushing [D] into the pump case. Visually inspect into the pump shaft O-rings [E], and replace them if necessary . Grease the pump shaft and insert it from rear of the pump case.
Special Tools - Impeller Holder: 570011393 Impeller Wrench: 570011228 Torque - Impeller: 98 Nm (10 kgfm, 72 ftlb)
Visually inspect impeller seal [A], and replace it if necessary. Be sure the O-ring [A] is in place on the pump cap.
Examine the impeller [A]. If there is pitting, deep scratches, nicks or other damage,
Minor nicks and gouges in the impeller blades can be
NOTE
removed with abrasive paper or careful filing. Smooth leading edges are especially important to avoid cavitation.
If the impeller is worn smaller than the service limit, replace it.
Impeller Outside Diameter Standard: 147.5 ~ 147.7 mm (5.8071 ~ 5.8149 in.) Service Limit: 146.5 mm (5.7677 in.)
Examine the pump case [A]. the pump case, replace If there are deep scratches inside
it.
If the pump case is worn beyond the service limit, replace it.
Pump Case Inside Diameter Standard: 148.0 ~ 148.1 mm (5.8268 ~ 5.8307 in.) Service Limit: 149.1 mm (5.8701 in.)
Impeller Clearance
proper performance. the Impeller clearance is critical tonot visibly damaged, Ifpoor pump case and impeller are
performance may be caused by too much impeller clearance. To check impeller clearance, remove the grate and insert a feeler gauge [A] between the tip of the impeller blade [B] and the pump case [C].
Impeller Clearance Standard: 0.15 ~ 0.3 mm (0.0059 ~ 0.0118 in.) Service Limit: 0.6 mm (0.0236 in.)
If impeller clearance is incorrect, determine if it is due to wear or damage (see Pump and Impeller Inspection).
[A] and pull off Loosen the clampcover mounting the hose [B]. Remove the filter Take out the filter cover [D]. bolts [C]. Replace the gasket with a new one. Installation is the revers order of removal.
STEERING 12-1
Steering
TABLE OF CONTENTS
Exploded View........................................................................................................................... 12-2 Specifications ............................................................................................................................ 12-4 Steering Cable........................................................................................................................... 12-5 Steering Cable Adjustment .................................................................................................. 12-5 Steering Cable Removal ...................................................................................................... 12-5 Steering Cable Installation ................................................................................................... 12-7 Steering Cable Inspection.................................................................................................... 12-7 Steering Cable Lubrication................................................................................................... 12-7 Handlebar .................................................................................................................................. 12-8 Handlebar Removal ............................................................................................................. 12-8 Handlebar Installation Note.................................................................................................. 12-8 Steering ..................................................................................................................................... 12-10 Removal............................................................................................................................... 12-10 Installation Notes ................................................................................................................. 12-12
12
12-2 STEERING
Exploded View
STEERING 12-3
Exploded View
T1: 16 Nm (1.6 kgfm, 12 ftlb) T2: 39 Nm (4.0 kgfm, 29 ftlb) T3: 49 ~ 59 Nm (5.0 ~ 6.0 kgfm, 36 ~ 43 ftlb) T4: Hand-Tight L: Apply a non-permanent locking agent. G: Apply grease.
12-4 STEERING
Specifications
Special Tool - Box Wrench: 570011451 Sealant - Kawasaki Bond (Silicone Sealant): 56019120
STEERING 12-5
Steering Cable
Steering Cable Adjustment
adjustment. Check the steering cablethe straight-ahead position. Center the handlebar in
Check that the steering nozzle [A] is centered in the pump cavity.
adjust steering cable. If necessarylocknut the on the steering cable. [A] Loosen the joint [C] from the steering nozzle.
Take out the cable joint bolt [B] and disconnect the cable Turn the joint on the cable to adjust the steering. Temporarily tightening the cable joint bolt, connect the
joint with the nozzle and check cable adjustment again. When adjustment is correct, unscrew the cable joint bolt and apply a non-permanent locking agent to it. And tighten the cable joint bolt and the steering cable locknut securely.
Torque - Cable Joint Bolt: 9.8 Nm (1.0 kgfm, 87 inlb)
Remove the storage pocket (see Storage Pocket Removal/Installation in the Hull/Engine Hood chapter). the and remove Loosen fromlocknut [A],front end. the ball joint [B] and locknut the cable
12-6 STEERING
Steering Cable
the Unscrew[B]. mounting bolts [A], and remove the cable bracket Pull the holder [C] off the cableofbracket. front end. Remove the cable bracket out the cable
side and remove Turn the watercraft on its left the Pump/Impellerthe pump cover (see Pump Removal in chapter)
CAUTION
Never lay the watercraft on the right side. Water in the exhaust system may drain back into the engine, causing serious damage.
Loosen the locknut [A] at the rear end of the steering cable, and remove the joint bolt [B]. Remove the joint [C] and locknut from the cable end. Disconnect the steering cable from the fitting at the rear of the hull.
nut (steering cable nut).
Special Tool - Box Wrench: 570011451
Unscrew the large nut in the hull with a wrench. Special tool, box wrench [A] is useful to remove the large
Slide off the snap ring [A], washer [B], and O-ring [C].
Pull the steering cable from the cable detent in the engine compartment. Pull out the steering cable toward the front.
STEERING 12-7
Steering Cable
Steering Cable Installation
short Slide aend to piece of rubber or plastic tubing over the rear cable guide the cable through the hull. Lubricate the outside of the new cable to ease cable installation. Torque: cable Apply a non-permanent locking agent to thebolts. joint bolt and the steering cable bracket mounting
Torque - Steering Cable Nut: 39 Nm (4.0 kgfm, 29 ftlb)
Refer to Steering Cable Inspection in the Periodic MainSteering Cable Lubrication NOTE
12-8 STEERING
Handlebar
Handlebar Removal
Unscrew the mounting screws [A] and remove the handlebar pad [B]. Take out the inner pad.
Take out the throttle case clamp screws and remove the throttle case [A]. switch Take out the[B]. case clamp screws and remove the switch case
Take out the handle clamp bolts [A] and remove the handlebar [B].
the mounting Unscrewbracket [B]. bolts [A] and remove the handlebar pad
Apply a non-permanent locking agent to the handlebar clamp bolts. Install the handlebar on the holders of the steering neck with clamp bolts.
STEERING 12-9
Handlebar
the punch [A] Alignthe parting mark[B]. on the left side of the handlebar with line Tighten the front and then rear handlebar clamp bolts to the specified torque.
Torque - Handlebar Clamp Bolts: 16 Nm (1.6 kgfm, 12 ftlb)
pipe Be sure the[B]. [A] is installed on the top end of the fuel vent hose
inner pad Install thefrontward. [A] so that its raised letters FRONT [B] faces
Align [A] the handlebar clamp bolt heads with the hollows on the inner pad.
12-10 STEERING
Steering
Removal
Unscrew the mounting bolts [A] [B] and lift up the steering cover.
Unscrew the mounting bolts [A] and remove the steering neck [B].
STEERING 12-11
Steering
Remove the cotter pin [A] and locknut [B]. Take out the holder [C].
mounting Unscrew the holder [B].bolts [A], nut washers, and remove the steering
out the Take [B] frommounting bolts [A] and remove the air intake duct the steering holder [C].
Disconnect the start/stop switch lead connector and pull the leads [A] out of the hull. pipe at Disconnect thefuel vent the fuel vent hose upper end and pull down the hose [B]. Disconnect the throttle cable upper end at the throttle case and pull down the throttle cable [C].
12-12 STEERING
Steering
lock plate Remove the nut [B] and[A]. down the steering shaft [C]. Take out the pull
Installation Notes
the bushings for damage and Checkbushings are damaged or worn,wear. them. If the replace Grease: [A] Bushings
agent Apply a non-permanent locking them. to the steering holder mounting bolts and torque
Torque - Steering Holder Mounting Bolts: kgfm, 12 inlb) 16 Nm (1.6
Install the steering shaft nut (Hand-Tighten) [A]. counterIf steering is too tight, turn the steering shaft nut
NOTE
clockwise to loosen. If steering is too loose, turn the steering shaft nut clockwise to tighten.
STEERING 12-13
Steering
NOTE
inside the steering cover Be sure the plate [A] iscover mounting bolts [C]. [B] when installing the steering
Hull/Engine Hood
TABLE OF CONTENTS
Exploded View........................................................................................................................... Fittings ....................................................................................................................................... Front Storage Compartment Cover Removal ...................................................................... Front Storage Compartment Cover Installation ................................................................... Storage Pocket Removal/Installation ................................................................................... Storage Pocket Disassembly/Assembly .............................................................................. Crossmember Removal/Installation ..................................................................................... Handrail Removal/Installation .............................................................................................. Drain Plug Housing Removal/Installation............................................................................. Exhaust Outlet Removal/Installation .................................................................................... Stabilizer Removal ............................................................................................................... Stabilizer Installation ............................................................................................................ Hull Replacement ...................................................................................................................... Rubber Parts ............................................................................................................................. Rubber Parts Location ......................................................................................................... Front Bumper Removal/Installation...................................................................................... Rear Bumper Removal/Installation ...................................................................................... Side Bumper Removal ......................................................................................................... Side Bumper Installation ...................................................................................................... 13-2 13-6 13-6 13-6 13-6 13-7 13-8 13-9 13-9 13-9 13-10 13-10 13-12 13-13 13-13 13-14 13-15 13-15 13-16
13
Front Storage Compartment Cover Bracket Mounting Bolts [B] Front Storage Compartment Cover Assembly [C]
the inner cover To remove and bolts [C]. [A], unscrew the mounting screws [B]
the hinge To removeLower End assembly [A], remove the following. Damper (Disconnect) Hinge Mounting Bolts [B]
non-permanent Apply abolts and screws.locking agent to the all the removed
Disconnect the ignition switch lead connector from the main harness. in the hull. Remove the ignition switch nut [A]removing the storage The right photo is taken after
pocket.
Ignition Switch Nut [A] 36 mm (1.4 in) [B] Remove the storage pocket with the ignition switch. Installation is the reverse of removal.
To remove the storage pocket cover [A], turn and pull out the shaft [B] (both side). installing the shafts, put the shaft end Wheninto the hollow [D] on the storage pocket. [C] (both side)
To remove the rock [A], turn and pull out the shaft [B] (both side). installing the push the Wheninto the hollow shafts, the rock. shaft end [C] (both side) [D] on
Pull out the holder [A]. bolts [B] and remove the cable the mounting Unscrew[C] with the cable [D]. bracket
Remove: Knob and Cover (see Fuel Tap Removal in the Fuel Tap
Fuel System chapter). Choke Knob and Cover (see Choke Knob and Cable Removal in the Fuel System chapter). oil tank Remove thechapter). (see Oil Tank Removal in Engine Lubrication nuts Unscrew the mounting[C]. [A] and washers [B], and remove the side covers Unscrew the mounting bolts [D] and bracket [E], and remove the crossmember [F]. When installing the crossmember to the hull, note the following.
Apply a non-permanent locking agent to the crossmember mounting bolts and torque them.
lock assembly and handrail, align the When installing thestud bolt [B] on the lock assembly with projection [A] and holes [C] on the hull.
Unscrew the screws and remove the drain plug housing [A]. is the reverse of removal. Installation seal [B] for damage. Note the following. Check the
If necessary, replace new ones. Install the new gasket [C] so that its OUT mark [D] faces outwards.
Unscrew the mounting bolts [A] and remove the holder [B] and exhaust outlet [C]. of removal. Note Installation is the reverse locking agent to the following. the mounting Apply a non-permanent
bolts [A] and tighten them securely.
Unscrew the mounting bolts [A] and remove the stabilizer [B].
Unscrew the mounting bolts [A] and remove the stabilizer base [B].
Stabilizer Installation
Insert [C] the collars [A] into the holes [B] of stabilizer base as shown.
Reverse Side of Stabilizer Base [D]
Install the stabilizer base and stabilizer as shown. Stabilizer Base [A]
Stabilizer [B] Hull [C] 16.5 2 mm (0.65 0.08 in.) [D] Apply a non-permanent locking agent to the following and torque them.
Torque - Stabilizer Base Mounting Bolts: 9.8 Nm (1.0 kgfm, 87 inlb) Stabilizer Mounting Bolts: 9.8 Nm (1.0 kgfm, 87 inlb)
WARNING
Read all warnings and cautions on any solvents and adhesives used. Many of these products are flammable, may be harmful to the skin and eyes, and may give off harmful vapors. Use these solvents and adhesives only in a well-ventilated area and never near an open flame.
For this Application: Mats Engine Hood Gasket Front Storage Compartment Cover Trim Seal Detents Handlebar Grips Type Synthetic Rubber Adhesive (P/N: 92104-3701) Cyanoacrylate Cement
CAUTION
Be very careful that the part is positioned correctly when you apply the cement. It may be impossible to reposition the part.
WARNING
Do not get any cyanoacrylate cement in your eyes or on your skin. If you do get some in your eyes, do not try to wash it out. Contact a physician immediately! If you do get some on your fingers, do not touch any other part of your body; your fingers will stick to anything they touch. Allow the cement to cure and it will eventually wear off.
Detent [A]
Mats [A]
out the mounting nuts [A]. Takeout the pop rivets [B] with a drill bit of the correct size. Drill
Pop Rivet Removal Drill Bit Size 5.0 mm (0.1969 in.)
Stop drilling when the rivet head starts to turn with drill
NOTE
bit. Tap the rivet out of the hull flange with a suitable punch and hammer.
Remove the front bumper [C]. noting following. When installing the front bumper, with a pop rivet. Secure the bumper to the hull flange
Stop drilling when the rivet head starts to turn with drill
bit. Tap the rivet out of the hull flange with a suitable punch and hammer.
NOTE
Remove the rear bumper [D]. noting following. When installing the rear bumper, with a pop rivet. Secure the bumper to the hull flange
Side Bumper Removal
Drill out the pop rivets [A] with a drill bit of the correct size.
Pop Rivet Removal Drill Bit Size 5.0 mm (0.1969 in.)
Stop drilling when the rivet head [A] starts to turn with
NOTE
drill bit. Tap the rivet out of the hull flange with a suitable punch and hammer.
Remove the corner bumper [B]. Remove the trim strip [A] from the side bumper [B].
Drill out the pop rivets with a drill bit of the correct size.
Pop Rivet Removal Drill Bit Size 5.0 mm (0.1969 in)
Stop drilling when the rivet head [A] starts to turn with Tap the rivet out of the hull flange with a suitable punch
and hammer. drill bit.
NOTE
Align [A] the hole on the bumper with the mounting hole on the hull.
[A] the bumper to the with Securethe trim strip pushing onhull flangesides a riveter. Install the both of the strip.
Electrical System
TABLE OF CONTENTS
Exploded View....................................... Wiring Diagram...................................... Specifications ........................................ Battery ................................................... Removal........................................... Installation........................................ Electrolyte Filling.............................. Initial Charge.................................... Precautions ...................................... Interchange ...................................... Charging Condition Inspection......... Refreshing Charge........................... Electric Starter System .......................... Starter Relay:...................................... Removal........................................... Installation........................................ Inspection......................................... Starter Motor:...................................... Starter Motor Removal..................... Starter Motor Installation.................. Starter Motor Disassembly............... Starter Motor Assembly ................... Brush Inspection .............................. Commutator Cleaning and Inspection...................................... Armature Inspection......................... Brush Assembly Inspection.............. Left-hand End Cover Assembly Inspection...................................... Starter Clutch Inspection.................. Charging System ................................... Charging Coil Testing....................... Regulator/Rectifier Removal/Installation...................... Regulator/Rectifier Inspection.......... Ignition System ...................................... Pickup Coil Inspection...................... Ignition Coil Removal ....................... Ignition Coil Installation Notes.......... Ignition Coil Inspection..................... Igniter Removal/Installation.............. Igniter Inspection.............................. 14-4 14-10 14-12 14-13 14-13 14-13 14-13 14-15 14-15 14-16 14-16 14-17 14-19 14-19 14-19 14-19 14-19 14-20 14-20 14-20 14-21 14-21 14-23 14-23 14-24 14-24 14-24 14-24 14-26 14-26 14-27 14-27 14-28 14-28 14-28 14-29 14-29 14-30 14-32 Spark Plug Removal ........................ Spark Plug Installation ..................... Spark Plug Inspection ...................... Spark Plug Adjustment .................... Spark Plug Cleaning ........................ Electric Case ......................................... Electric Case Removal/Disassembly................... Electric Case Assembly/Installation . Sensors ................................................. Speed Sensor Removal/Installation. Speed Sensor Inspection................. Oil Level Sensor Inspection ............. Fuel Level Sensor Inspection........... Throttle Position Sensor Removal/Installation...................... Throttle Position Sensor Inspection . Throttle Position Sensor Adjustment Water Temperature Sensor Inspection...................................... Intake Air Temperature Sensor Inspection...................................... Multifunction Meter ................................ Display Function Inspection ............. Fuel Level Gauge/Symbol/FUEL Characters/Warning Light Inspection...................................... Oil Level Gauge/Symbol/OIL Characters/Warning Light Inspection...................................... Speedometer Inspection .................. Speed Sensor Electric Source Inspection...................................... Tachometer Inspection..................... Battery Symbol/bAt Characters/Warning Light Inspection...................................... Heat Symbol/HEAt Characters/Warning Light Inspection...................................... MODE/SET Button Inspection ......... Switches ................................................ 14-36 14-36 14-36 14-36 14-37 14-38 14-38 14-38 14-40 14-40 14-41 14-42 14-42 14-43 14-43 14-44 14-44 14-45 14-46 14-46 14-47 14-47 14-48 14-49 14-50 14-51 14-52 14-52 14-54
14
12 mm (0.4724 in.) 28 mm (1.1024 in.) Battery voltage -14.5 0.5 V 32 ~ 48 V @3 000 r/min (rpm) 0.64 ~ 0.96 15 BTDC @1 250 r/min (rpm) ~ 22 BTDC @3 500 r/min (rpm) 0.33 ~ 0.43 5.44 ~ 7.36 k NGK BR9ES 0.7 ~ 0.8 mm (0.0276 ~ 0.0315 in.) Solid post 396 ~ 594 0.75 ~ 0.95 mm (0.0295 ~ 0.0374 in.)
Special Tool - Hand Tester: 570011394 Throttle Sensor Setting Adapter: 570011400
WARNING
To prevent possible personal injury and damage to electrical components, always disconnect the grounded cable first.
Unhook the battery straps [B]. engine compartment. Carefully lift the battery from the
Installation
Be sure the battery damper [A] is in position in the battery compartment. battery straps. Hook thethe battery cables, positive first. Connect After attaching both cables, coat the terminals and cable
ends with grease to prevent corrosion. Slide the protective boot over each terminal.
WARNING
Loose battery cables can create sparks which can cause a fire or explosion resulting in injury or death. Make sure the battery terminal screws are tightened securely and the covers are installed over the terminals.
CAUTION
Do not reverse the battery connections.
Electrolyte Filling
Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These
names must be the same.
Battery Model Name for JT1200-A1: YTX20L-BS
CAUTION
Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type. This is to prevent overfilling of the electrolyte, shorting the battery life, and deterioration of the battery performance.
CAUTION
Do not remove the seal sheet sealing the filler ports [B] until just before use.
NOTE
Do not discard the seal cap because it is used as the battery plugs later. Do not peel back or pierce the seals [B] on the container.
NOTE
electrolyte Place thewith the six container upside down aligning the six seals battery filler ports. Push the container down strongly enough to break the seals. Now the electrolyte should start to flow into the battery.
NOTE
Make sure air bubbles [A] are coming up from all six filler ports.
Leave the container this way for 5 minutes or longer.
NOTE
the bottom of the container two or three times. Never remove the container from the battery.
generated by chemical reaction is released. Fit the seal cap [A] tightly into the filler ports until the seal cap is at the same level as the top of the battery.
NOTE
Initial Charge
While a sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if a battery shows a terminal voltage of 12.6 V or more, using a digital volt meter, after 10 minutes of filling, no initial charge is necessary.
To measure battery terminal voltage, use a digital voltmeter which can be read one decimal place
voltage. Condition requiring initial charge At low temperature (lower than 0C) Battery has been stored under high temperature and humidity. Seal sheet has been removed, or broken peeling, tear or hole. Battery two or more years old from date of manufacture. Battery manufacturing date is printed on battery top. Example) R2 08 H V Mfg. location Day Month Year Charging method 1.8 A 2 ~ 3 hours
NOTE
1.8 A 15 ~ 20 hours
Precautions
1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see this chapter). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.
WARNING
Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medial attention if severe.
Interchange
A sealed battery can fully display its performance only when combined with a proper watercraft electric system. Therefore, replace a sealed battery only on watercraft which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on watercraft which had an ordinary battery as original equipment, the sealed batterys life will be shortened. riodic Maintenance chapter.
WARNING
This battery is sealed type. Never remove seal cap [B] even at charging. Never add water. Charge with current and time as stated below.
Terminal Voltage: 11.5 ~ less than 12.6 V 1.8 A 5 ~ 10 h Standard Charge: (see following chart) 9.0 A 1.0 h Quick Charge:
CAUTION
If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do standard charge later on.
Terminal Voltage : less than 11.5 V 1.8 A 20 h Charging Method:
NOTE
25V if the battery will not accept current initially. Charge for no more than five minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current, decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery. Battery [A] Battery Charger [B] Standard Value [C]
after refreshing charge. Determine battery condition the battery 30 minutes after Determine the condition of completion of the charge by measuring the terminal voltage according to the table below.
Criteria 12.6 V or more 12.0 ~ less than 12.6 V less than 12.0 V Judgement Good Charge insufficient Recharge Unserviceable Replace
Disconnect the battery cables (see Battery Removal in this chapter). Disconnect the starter relay wire connector [A]. terminals Remove the nuts [B] from the battery and starter on the starte relay switch. mounting bolts [C] Remove the the relay case [D], and slide the starter relay switch from being careful not to lose
any of the insulating washers or grommets.
Installation
the starter relay switch in Mountthe insulating washers andthe relay case. watergrommets with Coat
Be certain all insulating washers and grommets are in position. Tighten the terminal nuts securely.
proof grease.
the gasket [A] new Replace the dowel pins withare in one. Be sure [B] position. Be sure the grommet [C] is installed on the relay case [D]. Be sure the battery cable is connected to the battery ter minal having red mark.
Inspection
1 Set ohmmeter to R to scale. as shown. Connect meter leads starter relay If resistance is less than infinite, the starter relay switch is not returning and must be replaced.
Starter Motor:
Starter Motor Removal
Remove the engine (see Engine Removal/Installation chapter). the mounting bolts Removethe starter motor [B].[A]. Pull out
Apply grease to the O-ring [A]. the mounting bolts. Install the starter motor and tighten
thin to the Apply a platecoat of greasewasher oil seal [A]. right-hand [B] and the [C] into the Set the end cover.
the springs and holding the brush leads with suit Pressclips [A] as shown. able Put the armature [B] among the brushes.
the groove [A] Align [B] on the yoke.in the left-hand end cover and the mark
Brush Inspection
brushes.
the [A] of each Measureworn lengthto the servicebrush.replace the carbon If any is down limit,
Starter Motor Brush Length Standard: 12 mm (0.4724 in.) Service Limit: 6.5 mm (0.2559 in.)
the if necessary Smoothcloth commutator surface [A]grooves. with fine emery [B], and clean out the
the diameter [A] . Measure the starter motor of theacommutatorthe commuReplace with new one if tator diameter is less than the service limit.
Commutator Diameter Standard: 28 mm (1.1024 in.) Service Limit: 27 mm (1.063 in.)
NOTE
good, it may be defective in some manner not readily detectable within the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
the 1 Using as shown. hand tester range, measure the resistance [A] Terminal and Positive Brush [B] Left-hand End Cover and Negative Brush If there is not close to zero ohms, the brush lead has an open. Replace the positive brush assembly and/or the negative brush subassembly.
the highest Using as shown. hand tester range, measure the resistance [A] Terminal and Left-hand End Cover If there is any reading, the left-hand end cover assembly have a short. Replace the left-hand end cover assembly.
Torque Limiter Turn the starter clutch gear [A] by hand. The starter clutch gear should turn counterclockwise [C] freely, but should not turn clockwise [B]. If the clutch does not operate as it should or if it makes noise, disassemble the starter clutch, examine each part visually, and replace any worn or damaged parts.
a multimeter, check the cir With according to the followingcharging coil output (inruncuit) table with the engine ning at approximately 3,000 rpm.
WARNING
To avoid electrical shock, do not perform this test with the watercraft in the water.
CAUTION
Do not run the engine over 15 seconds without cooling water.
Charging Coil Output Test Meter Setting 250 VAC Connections Meter (+) to Yellow lead Meter () to Yellow lead Standard Value 32 ~ 48V
If the charging coil output voltage is correct, check the regulator according to the regulator test procedure. If the charging coil output voltage is low, check the charging coil resistance with a multimeter according to the following table.
Charging Coil Resistance Test Meter Setting R1 Connections Meter (+) to Yellow lead Meter () to Yellow lead Standard Value 0.64 ~ 0.96
If the coil has normal resistance, but the voltage check shows the charging system to be defective, then the permanent magnets in the flywheel have probably weakened, necessitation flywheel replacement.
Disconnect the battery cables (see Battery Removal in this chapter). the bracket mounting screws [A] on Unscrewthe bracket with the electrical parts. the hull and remove
Disconnect the wire connector [A]. remove the regulaand Unscrew the mounting bolts [B] [D]. tor/rectifier [C] from the bracket
bracket, apply a When instaling thebracket mounting non permanent locking agent to the screws and tighten them securely.
Regulator/Rectifier Inspection
range, With the hand tester set to the R 1 k table. test the regulator/rectifier according the following
Special Tool - Hand Tester: 57001-1394 Regulator/Rectifier Inspection Tester (+) Lead Connection Terminal + ()* ~ ~ + 2 ~ 20 2 ~ 20 3 ~ 30 ~ 2 ~ 20 ~ 2 ~ 20 Unit: k
()*: Tester () lead Connection If any of the values obtained do not agree with the above table, the regulator/rectifier must be replaced.
Disconnect the 2-pin pickup coil leads connector (Blue) [A]. Set the tester to range, connect handthe pickup the 100terminals (Gzero it, and it to coil lead and BL) in
the connector. If there is more resistance than the specified value, the coil has an open lead and must be replaced. Much less than this resistance means the coil is shorted, and must be replaced.
Pickup Coil Resistance Standard: 396 ~ 594
Open the electric case (see Electric Case Removal/Disassembly). Pull the spark plug caps [A], and slide off the protector tubes [B].
Unscrew the grommet caps [A] and slide off the grommets [B]. Lubricate the leads with penetrating rust inhibitor.
Disconnect the ignition coil primary lead connectors [A], and unscrew the ignition coil mounting screws [B]. Remove the ignition coils [C].
the each Fix follows. coil and connect the primary lead connectors as
WARNING
To avoid extremely high voltage shocks, do not touch the coil or lead. If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective.
3 Needle Arcing Distance Standard: 7 mm (0.28 in.) or more
part is defective, measure the arcing To determine whichthe spark plug caps removed from the distance again with ignition coil. If the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing distance is now normal, the trouble is with the spark plug caps.
Winding Resistance Standard: Primary windings 0.33 ~ 0.43 Secondary windings 5.44 ~ 7.36 k
If the tester reads as specified, the ignition coil windings are probably good. However, if the ignition system still does not perform as it should after all other components have been checked, test replace the coil with one known to be good. Check the spark plug lead for visible damage. If the spark plug lead is damaged, replace the coil.
Igniter Removal/Installation
Remove the electric case and open it (see Electric Case Removal/Disassembly). Disconnect the connectors [A] and unscrew the mouting screws [B]. the electric Remove theisigniter [C] from removal. case. Installation the reverse of
Remove the electric case and open it (see Electric Case Removal/Disassembly). all the spark from Pullcaps [A] fullyplug capsspark the spark plugs and push the onto the plug cap holder [B].
Maintain the correct value of compression pressure for
NOTE
the cylinder ( Be sure to measure the voltage with the spark plug installed to the cylinder head).
NOTE
commercially available peak voltage adapter [A] Install a hand tester [B]. into the [A] to the Connect the adapterthe needle ignition coil primary lead connector [D], using adapter ser [C].
Special Tool - Needle Adapter Set: 570011457 Recommended Tool: Peak Voltage Adapter Type: KEK-54-9-B Brand: KOWA SEIKI Special Tool - Hand Tester: 57001-1394 Hand Tester Range: DC 250 V Primary Lead Connections: Adapter (R, +) #1 Coil: G/R #2 Coil: G/Y #3 Coil: G/W Adapter (BK, ) BK (Ground) BK (Ground) BK (Ground)
15 seconds before using it again. Repeat the measurements 5 or more times for one ignition coil.
Ignition Coil Primary Peak Voltage Standard: 140 V or more
Repeat the test for the other ignition coil.value, see IgniIf the reading is less than the specified
tion System Troubleshooting table to determine whether Igniter is good or no good. Pickup Coil Peak Voltage Check:
the coil lead connector. Disconnectsparkpickupcaps from the spark plugs and push Pull all the plug the caps [A] fully onto the spark plug cap holder [B].
NOTE
NOTE
adapter connector [C] Insert thecover sideprobes into thecoil as shown. of the magneto for the pickup
Special Tool - Hand Tester: 57001-1394 Connections: Pickup Coil: Adapter (R, +) G Adapter (BK, ) BL
the Turnstop ignition switch on and push the lanyard key under the button. Pushing the starter button, crank the engine 4 ~ 5 seconds to measure the pickup coil peak voltage.
If the reading is less than the specified value, check the pickup coil (see Pickup Coil Inspection). TPS (Throttle Position Sensor) Input Voltage Check: Remove the TPS [A] lead connector. Set the tester [B] to the DC 10 V range, and connect it to the connector [C] of the main harness.
Special Tool - Hand Tester: 57001-1394 Hand Tester (+) Black/Blue Lead Hand Tester () Black Lead
NOTE
Special Tool - Hand Tester: 57001-1394 Connections: Tester Positive Blue/Red Tester Negative Black/White
NOTE
NOTE
Overheat Diagnosis Output Voltage: around DC 5 V (When the engine is not in overheat mode)
If the tester reading does not show specified voltage, igniter is defective.
Pull off the spark plug caps. Unscrew the spark plugs the ceramic on the spark Be careful to avoid breaking
plugs.
the spark plug Be surethe spark plugs.threads are clean and dry. Torque
the spark plug Installthe cap onto thecap onto the spark plug securely. plug so that the distance between Push the lower end [A] of the cap and the upper surface [B] of the plug hexagonal nut is 6 mm (0.24 in.) [C].
For
NOTE
easier correct installation of the spark plug cap, push the cap onto the plug until the figures BR9ES [D] printed on plug are half covered with the cap or the figures NGK [E] of NGK/R are completely covered.
[A] aligning Install the plateon the lowerthe holes on the plate with the projections [B] case. case [D]. Install the seal [C] on the lowerseal aligning the recess Install the gasket [E] on the [F] in the gasket with the projection [G] on the lower case.
[A] Apply grease. [B] Grommet [C] Grommet Cap [D] Lower Electric Case [E] #1 Ignition Coil [F] #2 Ignition Coil [G] #3 Ignition Coil
[H] Align the projection with the hole. [I] Igniter [J] BK Lead [K] Upper Electric Case [L] Clamp [M] Gasket [N] Seal
Unscrew the mounting bolts [A] and remove the speed sensor assembly [B].
Pull out the speed sensor connector [A] and disconnect it.
Remove the speed sensor.tester leads to the sensor as Connect the battery and shown.
Rotate the waterwheel by handa slowly. sensor. the speed MeasureBK/Woutput voltageV;oftwice a rotation (Rotate G/R (+), () 0 ~ 10
it slowly.) If the voltage does not rise from zero to about 10 volts twice a rotation, replace the sensor.
Measure speeds.
If the sensor voltage does not reach 5 volts when spun with compressed air, replace the sensor.
Disconnect the oil level sensor 2pin connector. the sensor out of the oil Removehandoil level(ohmmeter) to the 1tank.range. k Set the tester
BK/W and Connect the tester leads to the the float. BL leads to check the switching operation of
Meter Reading When the two floats are held downward [A]: approx. 4 k When one float is held upward [B]: approx. 2 k When the two floats are held upward [C]: approx. 0 Special Tool - Hand Tester: 57001-1394
The meter should read as specified. If it does not, replace the oil level sensor.
cover. Open the front storage compartmentpin connector. level sensor 2 Disconnect the fuel and remove the fuel level sensor out Loosen the clamp, of the fuel tank. Set the hand tester (ohmmeter) to the 1 k range. leads the W/R Connect the tester operation of the and BK/W leads to check the switching float.
Meter Reading When sensor is held upright [A]: approx. 8.03 k When sensor is held upside down [B]: approx. 0 Special Tool - Hand Tester: 57001-1394
The meter should read as specified. If it does not, replace the fuel level sensor.
tester to Connect the hand Y Leadthe adapter. of TPS) Hand Tester (+) [C] (Wire Color
Hand Tester () BK Lead [D] (Wire Color of TPS) Start the engine.
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds or severe engine and exhaust system damage will occur.
If it is not within the specified voltage, adjust the throttle position sensor position (see Throttle Position Sensor Adjustment). If it is specified voltage, go to next test. Stop the engine. Turn on the ignition switch. Check the sensor output voltage with the throttle fully open.
Throttle Position Sensor Output Voltage Standard: 3.57 ~ 3.94 V (When throttle is fully opened.)
If it is not within the specified voltage, adjustment the sensor (see Throttle Position Sensor Adjustment). If the sensor cannot be adjusted, replace sensor.
Check the throttle position sensor output voltage (see Throttle Position Sensor Inspection).
If the output voltage is out of the range, adjust it as follows. Loosen the sensor mounting screws [A]. Adjust [B] the position of the sensor until the output voltage is within the specified range.
Remove the water temperature sensor. water so that the Suspend the sensor [A] in a container of temperature-sensing projection is submerged. Suspend an accurate thermometer [B] in the water.
The sensor and thermometer must not touch the container side or bottom. the container over a of heat and gradually Placethe temperature of thesourcewhile stirring the water raise water
NOTE
gently. Using the hand tester, measure the internal resistance of the sensor at the temperatures shown in the table. If the hand tester does not show the specified values, replace the sensor.
Water Temperature Sensor Resistance Water Temperature 20 C (68 F) 50 C (122 F) 90 C (194 F) 100 C (212 F) Sensor Resistance approx. 2759 k approx. 635 k approx. 121.9 k approx. 85.3 k
Remove the intake air temperature sensor. the sensor Suspend an accurate[A] in a container of water. thermometer [B] in the water. Suspend
The sensor and thermometer must not touch the container side or bottom. the container over a of heat and gradually Placethe temperature of thesourcewhile stirring the water raise water
NOTE
gently. Using the hand tester, measure the internal resistance of the sensor at the temperatures shown in the table. If the hand tester does not show the specified values, replace the sensor.
Intake Air Temperature Sensor Resistance Water Temperature 10 C (50 F) 20 C (68 F) 50 C (122 F) 70 C (158 F) Sensor Resistance approx. 3.74 k approx. 2.47 k approx. 0.833 k approx. 0.448 k
Connect the battery positive terminal to the terminal [1]. Connect the battery negative terminal to the terminal [5].
[1] R/BK, Battery (+) [2] BL, Oil Level Sensor [3] W/R, Fuel Level Sensor [4] R, Ignition Switch (+) [5] BK/W, Ground () [6] R/Y, Water Temperature Sensor [7] GY, Tachometer Pulse [8] G/R, Speed Sensor [9] R/W, Speed Sensor Power Source (+)
Battery Voltage Range: 10 ~ 16 V Check that when the battery positive terminal is connected to the terminal [4] using the auxiliary wire, all the LCD segments and LED warning light appear for seconds. Check that when the terminals are disconnected , all the LCD segments and LED warning light disappear. If the LCD segments and LED warning light will not appear, replace the meter assembly.
[1] SET Button [2] MODE Button [3] Fuel Symbol [4] Fuel Level Gauge [5] Tachometer [6] Speedometer [7] Oil Level Gauge [8] Engine Oil Symbol [9] LED Warning Light [10] Battery Symbol [11] Clock/Time/Trip/Hour Meter [12] [12] Heat Symbol
CAUTION
Do not drop the meter unit. Do not short the terminals. If the multifunction meter displays incorrectly while the engine is running, first disconnect the () battery terminal lead and reconnect it again to recover the meter display. Then, check to see that the standard plugs and/or plug caps are installed. Install only the standard plugs and/or plug caps. The resistors are embedded in both parts.
the same man Connect the 12 Vinbattery and terminals inInspection. ner as specified the Display Function Connect the variable rheostat [A] to the terminal [3] as shown. that number of Checkvalue thethe variable segments matches the resistance of rheostat.
Resistance Value () 8030 2930 1330 510 0 Display Segments 0* 1 ~ 2 3 ~ 4 5 ~ 6 7 ~ 8
*: The LED warning light, fuel symbol and FUEL characters flash at the same time.
If any display function does not work, replace the meter assembly.
Oil Level Gauge/Symbol/OIL Characters/Warning Light Inspection
the same man Connect the 12 Vinbattery and terminals inInspection. ner as specified the Display Function Connect the variable rheostat [A] to the terminal [2] as shown. that number of Checkvalue thethe variable segments matches the resistance of rheostat.
Resistance Value () 4000 2000 0 Display Segments 1* 2 3
*: The LED warning light oil symbol, OIL characters and one segment flash at the same time.
If any display function does not work, replace the meter assembly.
If the speedometer does not work, check the speed sensor electric source voltage and speed sensor.
the same man Connect the 12 Vinbattery and terminals inInspection. ner as specified the Display Function the Check thatwhen battery symbol/bAt characters/warning light flash the input voltage to the terminal [A] is lowered to 12 0.1 volts or less. And check that the meter returns in the state of normality when the input voltage to the black lead terminal is raised to 12.5 V or more. If any display function does not work, replace meter assembly.
the same man Connect the 12 Vinbattery and terminals inInspection. ner as specified the Display Function that light Checkwhenthe heat symbol/HEAt characters/warning[6] is flash the water temperature sensor terminal
connected to the ground terminal [5] using auxiliary wire [A] as shown. Check that the heat symbol/HEAt characters/warning light disapper when the terminals are disconnected. If any display function does not work, replace meter assembly.
the MODE button is Check that whendisplay rotates throughpushed and held continuously, the the four modes.
clock mode. Indicate thewhen the SET button is pushed for more than Check that two seconds, the meter display turns to the clock set mode. If the display function does not work, replace the meter assembly. time mode. Indicate thewhen the SET button is pushed for more than Check that two seconds, the meter display turns to 00:00. If the display function does not work, replace the meter assembly.
Start Switch
Stop Switch
Tether Switch
Inspect the fuse element. fuse. Before replacing a blown If it blown out, replace the
fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Housing [A] Fuse Element [B] Terminals [C] Blown Element [D]
CAUTION
When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components.
STORAGE 15-1
Storage
TABLE OF CONTENTS
Preparation for Storage ............................................................................................................. Cooling System.................................................................................................................... Bilge System ........................................................................................................................ Fuel System ......................................................................................................................... Engine.................................................................................................................................. Battery.................................................................................................................................. Lubrication ........................................................................................................................... General ................................................................................................................................ Removal from Storage............................................................................................................... Lubrication ........................................................................................................................... General Inspection............................................................................................................... Fuel System ......................................................................................................................... Test Run............................................................................................................................... 15-2 15-2 15-2 15-2 15-3 15-4 15-4 15-4 15-5 15-5 15-5 15-5 15-6
15
15-2 STORAGE
Preparation for Storage
During the winter, or whenever the watercraft will not be in use for a long period of time, proper storage is essential. It consists of checking and replacing missing or worn parts; lubricating parts to ensure that they do not become rusted; and, in general, preparing the watercraft so that when the time comes to use it again, it will be in top condition.
Cooling System
the cooling (see Cooling System Clean Cooling andsystemSystems chapter). Flushing in the Bilge
Bilge System
Bilge System Flushing in the Clean the bilge system (seechapter). Before reconnecting Cooling and Bilge Systems the hoses to the plastic breather fitting, blow air through both hoses [A] to force all water out of the bilge system.
Fuel System
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Drain the fuel tank. This should be done with a siphon or pump.
[A] Siphon Hose the fuel filter screen (see Clean the Periodic MaintenanceFuel Filter Screen Cleaning in chapter).
STORAGE 15-3
Preparation for Storage
Inspect/replace the fue filter (see Fuel Filter Inspection in the Periodic Maintenance chapter). Turn the ignition switch on. the stop button, and start the Push the lanyarditkey under periods until all fuel in engine and run in 15 second
the carburetor is used up. Wait 5 minutes between 15 seconds running periods. Pull the lanyard key off the stop button and turn the ignition switch off. Leave the fuel filler cap loose to prevent condensation in the tank.
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damage will occur. from the carbu Remove the air intake cover assemblythe Fuel System retor (see Flame Arrester Removal in
chapter). Lift out the flame arresters [A] and clean them, if necessary (see Flame Arrester Cleaning in the Periodic Maintenance chapter). Spray a penetrating rust inhibitor down the carburetor bore. Install the flame arrester. Reinstall the air intake cover assembly (see Flame Arrester Installation in the Fuel System chapter).
Engine
the and push Remove cap spark plugsthe cylinderthe plug caps fully onto the plug holder on head. Pour one ounce of motor oil into each cylinder.
CAUTION
Do not use too much oil, or the crank seals may be damaged when the engine is next started. on. Turn the ignition switchunder the stop button. Turn the Push the lanyard key with the start button to coat the engine over several times
cylinder walls with oil. Pull the lanyard key off the stop button and turn the ignition switch off. Reinstall the spark plugs and caps.
15-4 STORAGE
Preparation for Storage
Battery
watercraft and Give aitrefresh charge before you store the Give a refresh store with the negative lead removed.
charge once a month during storage. Remove the battery (see Battery Removal in the Electrical System chapter). Clean the exterior with a solution of baking soda and water (one heaping tablespoon of baking soda in one cup of water). Rinse thoroughly with water.
CAUTION
Do not allow any soda solution to enter the battery. both battery Coverthe battery in terminals with grease.not expose it to Store a cool, freezing temperatures. dry place. Do
Lubrication
Carry out all recommended lubrication procedures (see General Lubrication in the Periodic Maintenance chapter).
General
the engine compartment fresh water and re Wash the drain screw in the sternwithdrain the water. Wipe move to up any water left in the compartment.
CAUTION
Use only a mild detergent in water to wash the hull. Harsh solvents may attack the surface or smear the colors. good grade of wax to all exterior hull Apply aspray all exposed metal parts with a surfaces. penetrating Lightly rust inhibitor. Remove the seat, or block the seat up with 10 mm (0.39 in.) spacers to insure adequate ventilation, and prevent
STORAGE 15-5
Removal from Storage
Lubrication
Carry out all recommended lubrication procedures (see General Lubrication in the Periodic Maintenance chapter).
General Inspection
or sticking steering Check for bindingthrottle leverthrottle, choke orwhen remechanism. The must return fully leased. Clean and gap spark plugs (see Spark Plug Cleaning and Spark Plug Adjustment in the Periodic Maintenance chapter). Check all rubber hoses for weathering a cracking, or looseness. Check that the drain screw in the stern is securely tightened. Check the fire extinguisher for a full charge. Check the battery, charge if necessary, and clean the terminals. Install the battery (see Battery Installation in the Electrical System chapter).
Fuel System
as nec Check and clean or replace the fuel filter screensPeriodic essary (see Fuel Filter Screen Cleaning in the Maintenance chapter).
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop button. Do not smoke. Make sure the area is well ventilated and free from source of flame or spark; this includes any appliance with a pilot light. and before starting the engine, tilt the seat After refuelingseveral minutes to ventilate the engine comto the rear for partment.
WARNING
A concentration of gasoline fumes in the engine compartment can cause a fire or explosion. for Repair if necessary. Check the fuel leaks. level. Fill the oil tank with the speci Check engine oil fied oil.
15-6 STORAGE
Removal from Storage
Test Run
WARNING
Do not run the engine in a closed area. Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the engine and Check for Start oil and exhaust run it only for 15 seconds. repaired. fuel, leaks. Any leaks must be
CAUTION
Do not run the engine without cooling water supply for more than 15 seconds or severe engine and exhaust system damage will occur.
TROUBLESHOOTING 16-1
Troubleshooting
TABLE OF CONTENTS
Troubleshooting ......................................................................................................................... 16-2
16
16-2 TROUBLESHOOTING
Troubleshooting
Starting difficulty or failure to start Ignition System Ignition Spark Present Fault in fuel system Lack of compression No Spark Faulty or fouled spark plug Faulty plug wire insulation Faulty CDI igniter Faulty ignition coil Faulty magneto Battery voltage low Fuel System (check that fuel tank contains fuel) Outside Carburetor Fuel feed line leaking or clogged Pluse line leaking or clogged Fuel filter screen clogged Vent line clogged Faulty fuel pump Inside Carburetor Carburetor diaphragm damaged Water in carburetor Float arm not adjusted
Battery/Starter System solenoid Faulty magneto low switch Battery voltage Starter motor brushes worn Faulty starter motor clutch Ignition switch turned OFF and/or lanyard key not pushed under stop button
Engine starts but stops right away Compression Faulty crankshaft oil seal Crankcase joint leak Worn piston and rings Head gasket leak Spark plug leak Fuel System Outside Carburetor Misuse of choke Fuel filter screen clogged Fuel feed line leaking or clogged Pulse line leaking or clogged Vent line clogged Faulty fuel pump Inside Carburetor Water in carburetor Carburetor diaphragm damaged Float arm not adjusted Electrical System Faulty or fouled spark plug Poor wiring connection Faulty magneto
TROUBLESHOOTING 16-3
Troubleshooting
Engine misfires, does not run smoothly Fuel System Fuel mixture too lean Fault in Carburetor Obstruction in fuel passage or outlet Diaphragm leaking or damaged Float arm not adjusted Other Poor fuel supply (fuel filter screens, hoses, or vent line clogged) Carburetor mounting loose Faulty fuel pump Fuel mixture too rich Fault in Carburetor Diaphragm needle dirty or damaged Float arm not adjusted Choke not adjusted Other Flame arrester clogged
Electrical System Other Ignition timing wrong Weak Spark Reduced ignition coil output High voltage insulation breakdown Spark plug fouled Spark plug gap wrong Poor wiring connection, spark plug cap Faulty CDI igniter Faulty magneto Battery voltage low Engine Lubrication System Oil line clogged Faulty oil pump
Abnormal engine sound During normal cruising Slight piston seizure Piston ring broken or sticking Main bearing worn or damaged
During sudden acceleration between Excessive clearancepiston connecting rod small end and piston pin, or between pin and Excessive connecting rod big end clearance Pinging Ignition timing too advanced head Carbon accumulation in cylinder gasoline Poor qualitywrong heat range Spark plug When the engine is idling while cold Excessive piston clearance Piston rings worn Piston worn rod bent, twisted Connecting
16-4 TROUBLESHOOTING
Troubleshooting
Low engine power (This trouble often has more than one cause, and trouble symptoms may not be clear) Ignition System Spark plug gap or heat range wrong Ignition timing wrong Reduced ignition coil output Loose wiring connection in ignition circuit
Fuel System to carburetor Insufficient fuel supply damaged Carburetor diaphragm Pulse line leaking or clogged Main jet clogged Throttle valve does not fully open Fuel filter screen clogged Faulty fuel pump Other Flame arrester clogged clogged or exhaust system Muffleror foreign matter in gasoline or engine oil Water Exhaust gas leak in engine compartment Overheating Ignition wrong adjusted Carburetor not or exhaust system clogged Flame arrester accumulation in combustion chamber Carbontype of gasoline or oil Wrong Obstruction in oil pump hoses Cooling water line leaking or clogged Heavy Fuel Consumption Carburetor not adjusted Flame arrester clogged clogged or exhaust system Mufflercylinder, piston or piston ring Worn Fuel feed line leaking Carburetor diaphragm needle dirty or damaged
Poor performance though engine runs properly Jet Pump Intake area obstructed Impeller or pump case damaged Excessive clearance between impeller and pump case Poor steering control (Since faulty steering is dangerous, this problem should be examined by an authorized Jet Ski dealer) Handlebar hard to turn Steering maladjusted Bushings damaged or cracked Steering shaft bent No lubricant on steering pivot Steering cable damaged or improperly routed
MODEL APPLICATION
Year 2002 2003 Model JT1200-A1 JT1200-A2 Beginning Hull No. KAW50001202 KAW10001203
:This digit in the hull number changes from one machine to another.
Part No.
99924-1287-02
Printed in Japan