Kawasaki Jet-ski 750sx 750ss 750xi Service Manual Repair 1992-1998 - PDF DOWNLOAD by www.heydownloads.com

This is the base manual for ALL 750 Watercraft. If you do not have the 750SX Standup model you will use your manual supplement first, then use this manual for anything not included in it.

JET SKIÂŽWatercraft Service Manual

Quick Reference Guide

Pump and Impeller

I 2 I 3 I 4 I 5 I 6 I 7 I 8 I 9 I 10 I

Handle Pole and Handlebar

111

Hull I Engine Hood

121

General Information Fuel System Engine Lubrication System Exhaust System Engine Top End Engine Removal and Installation Engine Bottom End Cooling and Bilge Systems Drive System

Electrical System

This quick reference guide will assist you in locating a desired topic or procedure . â&#x20AC;˘ Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page . â&#x20AC;˘ Refer to the sectional table of contents for the exact pages to locate the specific topic required .

Storage

1141

Appendix

115 1

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC "C DC F "F ft 9 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)

Ib m min N Pa PS psi rpm TDC TIR V W (1

pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

Read OWNER'S MANUAL before operating

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 substi tute 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 mainte-

How to Use This Manual In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section . Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

AWARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

nance .

• 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. • Follow the procedures in this manual carefully. Don't take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed.

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 o

This note symbol indicates points of particular interest for more efficient and convenient operation .

• Indicates a procedural step or work to be done.

o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1 .

General Information Table of Contents

Before Servicing ............................................... .................................. ,........................1-2 Model Identification ......................................... ...........................................................1-5 General Specifications ............................................................... .......... .. .....................1-6 Periodic Maintenance Chart ..................................................... ..................................1-7 Torque and Locking Agent ................................................. ........... .. .. ......................... 1-8 Special Tools. Sealant ............................................................................................... 1-10 Cable. Wire and Hose Routing ........... .. .. ................................ ..... .............................1 -12

1-2 GENERAL INFORMATION Before Servicing Before starting to service a watercraft, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Especially note the following: - (1) Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting or presence of symptoms indicate that adjustments may be required. Whenever running of the engine is required during maintenance it is best to have the watercraft in water.

CAUTION Do not run the engine without cooling water supply for more than 15 seconds 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) . • Connect the garden hose [B) to the hose fitting (see above) . • Attach the garden hose to a faucet Do not turn on the water until the engine is running and turn it off immediately when

the engine stops. The engine requires 2.4 Llmin (2.5 qts/min) at 1800 rpm and 7.0 Llmin (7.4 qts/min) at 6000 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 cylinder, 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 tum 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.

GENERAL INFORMATION 1-3

(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) n 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 turn ing 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 Stoddard solvent (generic name) . Always follow manufacturer and container directions regarding the use of any solvent. (10) Gasket, 0- Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket shou ld be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (11) Liquid Gasket, Non- Permanent Locking Agent Follow manufacturer's 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 avai lable in North America is Loctite Lock N' Seal (Blue). (12) Press A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (13) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. (14) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.

1-4 GENERAL INFORMATION

(15)

(16)

(17) (18)

(19)

When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal. until the face of the seal is even with the end of the hole. Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal. apply a little lubricant, preferably high temperature grease on the lips to reduce rubber to metal friction. Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them . When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) shou ld be applied to any rubbing surface which has lost its lubricative film . Old grease and dirty oil should be cleaned oft. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. Electrical Wires All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amou nt of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/ yellow" wire if the colors were reversed to make red the main color.

Wire (cross-section)

Name of Wire Color

/ /- _ Red Wire Strands

/<-""-.

Yellow/ Red Yellow Red

(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. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (22) Service Data Numbers of service data in this text have following meanings: "Standards": Show dimensions or performances which brand-new parts or systems have. "Service Limits": Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

GENERAL INFORMATION 1-5 Model Identification

JS750-A1

JS750-A2

JS750-A3

...--

.--; -~

[ '

. ,.lj'""",""-

JS750-A4

1-6 GENERAL INFORMATION General Specifications Items

JS750-A1,A2,Al,A4

Engine: Type Displacement Bore and stroke Compression ratio Maximum horsepower Maximum torque

Ignition system Lubrication system Carburetion system Starting system Tuning Specifications: Spark plug: Type Gap Ignition timing Carburetor: Idle speed Compression pressure

Drive System: Coupling Jet pump:

Type Thrust

Steering Braking Performance: tMinimum Turning Radius tOraft (Stationary) tFuel consumption tCruising range Dimensions: Length Width Height Dry weight Fuel tank capacity

2-stroke, vertical twin, crankcase reed valve, water cooled 743 mL 80.0 x 74.0 mm 7.0: 1 46.3 kW (63 PS) @6 000 rl min (rpm) (E) 44.1 kW@6 250 rlmin (rpm) 76.5 N-m (7.8 kg-m, 56.4 ft- Ib) @5 500 rlmin (rpm) (E) 73.5 N-m @5 500 rlmin (rpm) Magneto COl (Digital) Oil injection (break-in period: Oil injection and fuel mixture 50 : 1) Keihin CDK40-34 diaphragm type (38 mm venturi) Electric starter NGK BR8ES 0.7 - 0.8 mm 13" BTDC @1 250 rl min (rpm) - 16" BTDC @2 500 rl min (rpm) 1 250 Âą 100 rl min (rpm) - in water 1700 Âą100 rl min (rpm) - out of water 835 - 1 294 kPa (8.5 - 13.2 kg l cm', 121 - 187 psi) Direct drive from engine Axial flow. single stage 2451 N (250 kg, 551 Ib) Steerable nozzle Water drag 2.9 m 200mm 23 L/ h @full throttle 49 km @ full throttle 42 minutes, JS750-A2 : 58 km @50 minutes 2210 mm 700mm 680mm 144 kg 16 L including 2.3 L reserve, JS750-A2 : 19 L

Engine Oil: Type Oil tank capacity

2-stroke, NMMA Certified for Service TC-WII 2.6 L

Electrical Equipment; Battery Maximum generator out put

6 .6 A/14 V @6 000 rl min (rpm)

12V19Ah

t : This information shown here represents results under controlled conditions, and the information may not be correct under other conditions. Specifications are subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-7 Periodic Maintenance Chart NOTE

o Complete the Pre-Ride Checklist before each outing. Frequency Description Check all hose clamps, nuts, bolts, and fasteners Torque cylinder head nuts Lubricate throttle cable fitting and choke cable fitting at carburetor Lubricate choke cable and throttle case and cable Clean and gap spark plugs (replace if necessary) Check battery level and terminals Lubricate steering nozzle pivots Lubricate steering cable ball joints Clean fuel filter screens Adjust carburetor Flush bilge line and filter Flush cooling system (after each use in salt water) Inspect/ clean flame arrester Inspect impeller blade for damage (remove) Inspect/replace coupling damper Inspect carburetor throttle shaft spring (replace carburetor if necessary) Inspect steering cable

Initial

Every

100

Hours

• •

• • • • • • • • • • • • •

Every

• • • •

1-8 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non - permanent locking agent or silicone sealant. Letters used in the "Remarks" column mean: L : Apply a non-permanent locking agent to the threads. SS : Apply silicone sealant to the threads. S : Tighten the fasteners following the specified sequence .. Torque Remarks

Fastener N-m

kg-m

ft-Ib

7.8 7.8 7.8

0.8 0.8 0.8 -

69 in-Ib 69 in-Ib 69 in-Ib -

14.5 14.5 87 in-Ib 14.5 14.5 14.5

2.0 2.0 1.0 2.0 2.0 2.0 -

Engine Top End: Cylinder Head Nuts Water Pipe Joint Cylinder Base Nuts

29 9.8 34

3.0 1.0 3.5

22 87 in-Ib 25

Engine Removal / Installation: Engine Mounting Bolts Engine Bed Mounting Bolts Engine Mount Bolts

36 36 16

3.7 3.7 1.6

27 27 11.6

125 12 98 7.8 7.8 29 7.8 7.8

13.0 1.2 10.0 0.8 0.8 3.0 0.8 0.8

94 8.5

72 69 in-Ib 69 in - Ib 22 69 in-Ib 69 in-Ib

SS L L, S L, S L L L

9.8

1.0

87 in-Ib

39 22

4.0 2.2

29 16.0

L SS L

Fuel System: Carburetor Mounting Bolts Intake Manifold Mounting Nuts Air Intake Cover Bolts Fuel Tap Mounting Screws Choke Assembly Mounting Screws Intake Silencer Stand Mounting Bolts Exhaust System: Exhaust Pipe Mounting Bolts Front Muffler Mounting Bolts Water Pipe Joints Exhaust Manifold Mounting Nuts Expansion Chamber Mounting Bolts Muffler Bracket Mounting Bolts Water Box Muffler Bracket Mounting Bolts

Engine Bottom End: Flywheel Bolt Stator Mounting Bolts Coupling Magneto Cover Mounting Bolts Crankcase Bolts (6 mm Dia.) Crankcase Bolts (8 mm Dia.) Water Drain Valve Mounting Bolts Water Drain Valve Cover Bolts Magneto Cover Stud Cooling and Bilge Systems: Water Pipe Joint Drive System : Coupling Cover Nuts Coupling Drive Shaft Holder Mounting Bolts

20 20 9.8 20 20 20

L L L L L L L SS S L L L S SS

GENERAL IN FORMATION 1-9

Torque Remarks

Fastener Pump and Impeller: Water Pipe Joint Steering Nozzle Pivot Bolts Pump Outlet Mounting Bolts Pump Cap Bolts Impeller Pump Mounting Bolts Pump Cover Mounting Bolts Grate Mounting Bolts Handle Pole and Handlebar: Steering Support Bracket Mounting Bolts Steering Pivot Stud Handle Pole Pivot Shaft Handle Pole Pivot Shaft Nut Handlebar Clamp Bolts Handle Pole Bracket Bolts Hull/Engine Hood: Bumper Bushings Bumpers Mounting Nuts Mat Guard Mounting Nuts Electrical System: Electric Case Bolts Electric Case Mounting Bolts . Regulator/ Rectifier Mounting Bolts CDI Igniter Mounting Bolts Spark Plugs StarterÂˇ Motor Mounting Bolts Ignition Coil Mounting Bolts Temperature Sensor Mounting Bolts Starter Relay Mounting Nuts Starter Lead Mounting Nut Battery Ground Lead Mounting Bolt Flywheel Bolt Stator Mounting Bolts

N-m

kg-m

ft-Ib

9.8 9.8

1.0 1.0

87 in-Ib 87 in-Ib

98 22 6.9 9.8

10.0 2.2 0.7 1.0

SS L L L

72 16.0 61 in-Ib 87 in-Ib

L L L L

38 13 33 18 19

3.9 1.3 3.4 1.8 1.9

28 9.5 25 13.0 13.5

7.8 7.8 7.8 7.8 27 7.8 7.8 7.8 7.8 7.8 7.8 125 7.8

0.8 0.8 0.8 0.8 2.8 0.8 0.8 0.8 0.8 0.8 0.8 13.0 0.8

L L

L L L

69 69 69 69

in-Ib in-Ib in-Ib in-Ib 20 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 94 69 in-Ib

L L L L L L L

This table relating tightening torque of the stainless bo lt and the nut to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value.

General Fasteners (stainless bolt and nut) Threads dia.

Torque

(mm)

N-m

kg-m

ft-Ib

6 8 10

5.9-8.8 16-22 30-41

0.60-0.90 1.6-2.2 3.1 -4.2

52-78 in-Ib 11 .6- 15.9 22-30

1-10 GENERAL INFORMATION Special Tools, Sealant Compression Gauge: 57001 -221

Piston Ring Compressor Belt, <1>67 - <1>79: 57001 -1097

Piston Pin Puller Assembly: 57001 -910

Bearing Driver Set: 57001 -1129

Hand Tester (V. O. M): 57001-983

Compression Gauge Adapter. 57001 -1159

Oil Seal & Bearing Remover: 57001 -1058

Rotor Puller, M16/ M18/ M20/ M22 x 1.5: 57001-1216

Piston Ring Compressor Grip: 57001-1095

Impeller Wrench: 57001 -1228

GENERAL INFORMATION 1-11

Coupling Holder: 57001 -1230

Flywheel Holder: 57001 -1313

Drive Shaft Holder Adapter: 57001 -1231

Drive Shaft Holder: 57001 -1327

Coil Tester: 57001 -1242

Pressure Cable Luber. K56019-021

Rotor Pulier, M18 x 1.5: '57001-1258

Kawasaki Bond (Silicone Sealant): 56019-120

Watercraft Strap Tool: 57001 -1294

Kawasaki Bond (Liquid Gasket - Black): 92104-1003

1-12 GENERAL INFORMATION Cable, Wire and Hose Routing

1. Start/ Stop Switch Leads 2. Throttle Cable 3. Steering Cable 4. Fuel Vent Hose 5. Wiring Clamps S. Detent 7. Choke Cable 8. Water Box Muffler Damper 9. Magneto Case 10. Magneto Lead 11. Clamps 12. Starter Motor 13. To Electric Case

® --+-.,~ - t -'-- BOW

GENERAL INFORMATION 1 -13

11 14

Viewed from C

Viewed from B

Viewed from A

o 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Oil Tank Oil Inlet Hose Vent Hose Fuel Tank Detent Throttle Cable Carburetor

Choke Cable Battery Cable (-) Battery

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Battery Cable (+) Bilge Hose Bilge Breather

Clamp Start/ Stop Swi'tch Leads Electric Case

Magneto Leads Starter Motor Cable

Bypass Cooling Hose Water Box Muffler

21. 22 . 23. 24. 25. 26.

Inlet Cooling Hose Cooling Hose

Oil Outlet Hose Pulse Hose Temperature Sensor Temperature Sensor Leads

1-14 GENERAL INFORMATION

1. 2. 3. 4. 5.

OFF

â&#x20AC;¢

Clamp Start/Stop Switch Leads Bypass Cooling Hose Fuel Hoses Remote Control Cables

6. Supply Fuel Hose 7. Return Fuel Hose

8. Fuel Knob 9. Reel 10. Fuel Tap

FUEL SYSTEM 2-1

Fuel System Table of Contents

Exploded View .. ................... ... ....... .......... ........ ......... 2-2

Carburetor Cleaning and Inspection ............. 2 - 17

Specifications .................................... ........................ 2-4

Float Ann Level Inspection and Adjustment ....... ......................................... 2-17 Fuel Pump Removal/Installation Note .......... 2-18 Flame Arrester.................. ....... .................................2-19 Removal .........................................................2-19 Installation Notes .. ... .. ...... .... .......................... 2-19 Clean ing ........................................................ .2 -1 9 Intake Manifold, Reed Valves ... ......... .....................2-20 Removal ...... ..... ..... ........... ... ..... ...................... 2-20 Installation Notes ... .... ....................................2-20 Reed Valve Inspection .................... :.............. 2-20 Valve Holder Inspection .............................. ..2-21 Valve Stop Inspection .... ................................ 2-21 Fuel Tank .. .......... .......... ....... ....................................2-22 Fuel Tank Removal ........................................2-22 Fuel Tank Installation Notes ....... ............ ... .... 2-22 Fuel Tank Cleaning ............ .... .. .. .................... 2-22 Fuel Filler and Tube Removal. .......................2-23 Fuel Filler and Tube Installation Notes ..... .... 2-23 Fuel Filter Screen Cleaning ...........................2-23 Fuel Tap and Cables ...............................................2-24 Removal ....................... ....... .. ... ......................2;24 Installation Notes .............. .. ...........................2-24 Cleaning ............ ........... ............ ..................... .2-25

Fuel System Diagram .................................. .............. 2-5 Throttle Case and Cable ............................................ 2-6 Throttle Cable Adjustment ...................... ......... 2-6 Throttle Case RemovaI/Disassembly ......... ...... 2-6 Throttle Case Assembly/Installation Notes ..... 2-7 Throttle Cable Removal ..................... .... .......... 2-8 Throttle Cable Installation Notes ... ..................2-9 Throttle Case and Cable Lubrication ............... 2-9 Throttle Case Inspection .................... ...... .. ...... 2-9 Throttle Cable Inspection ....... ............ ....... .... 2 -1 0 Choke Cable .. .......................................... ................ 2-11 Adjustment ..................................................... 2-11 Removal ..... ... .................... ...... ............ ........... 2-11 Inspection .......................................... ........ .... 2-12 Lubrication .... ............................... .................. 2-12 Carburetor/ Fuel Pump ............................................2-13 Idle Speed Adjustment ........... .... .... ... .... ........ 2-13 Mixture Screw Adjustment ............................2-13 High Altitude Performance Adjustment ........ 2-13 Carburetor Removal .......... .......... ................... 2-14 Carburetor Installation Notes ......... ... ............ 2-15 Carburetor Disassembly .... ................. .... ..... ... 2-15 Carburetor Assembly Notes ........ ................... 2-16

2 - 2 FUEL SYSTEM Exploded View

1. Main Jet

2. Pilot Jet 3. Diaphragm Needle 4. Check V ave I Tl'· 78 . N'm (08 . k g.m, 69 in·lb) L : Apply G . A a non-permanent I k' · pply grease oc 109 agent SS· . . . · Apply silicone sealant

FUEL SYSTEM 2-3

2-4 FUEL SYSTEM Specifications Item Carburetor: Make, type Size Mixture screws: Low speed

High speed Main jet Pilot jet Idle speed:

in water out of water

Standard Keihin, CDK 40 - 34 Diaphragm 38 mm Venturi 7/ 8 turn open , JS750·A3-: 1Ya turn open 7/ 8 turn open, JS750·A3- : 3/4 turn open #140, JS750·A3-: #145 #75 1250 ±100 rpm 1700 ±100 rpm

Reed Valve: Reed warp

---

Fuel Tank: Capacity

16 L (including 2.3 L reserve)

Special Tool - Pressure Cable Luber: K56019~21 Watercraft Strap Tool: 57001·1294 (This Special Tool is available for the rubber strap removal and installation.) Sealant - Kawasaki Bond (Silicone Sealant): 56019·120

Service Limit

---

------ ---

------ -

0 .2mm ---

FUEL SYSTEM 2-5 Fuel System Diagram 1. 2. 3. 4.

Supply Return V ent Pulse

eD 4 R

.....

f~ ~

(OJ

C~)"". "-

)

::D

~ @@'~ I~ © © @

_@.

~ ....@ @@~ @ 0)(5)

@ ;C

2-6 FUEl SYSTEM Throttle Case and Cable

Throttle Cable Adjustment • Check throttle cable adj ustment. O With the throttle lever released, the stop on the shaft lever [AJ should rest against the idle adjust screw [BJ, and there shou ld be slight slack in the throttle cable.

O When the throttle lever is fully applied (pushed). the stop on the shaft lever should be all the way up against the stop on the carburetor.

THROTTLE CLOSED ( RELEASED )

THROTTLE OPEN (APPLIED)

.If necessary, adjust the throttle cable. • Loosen and tum the locknuts [AJ at the bracket until the stop on the shaft lever hits against the idle adjust screw with slight cab le slack .

• Tighten the locknuts securely.

Throttle Case Removal/Disassembly • Unscrew the mounting screws [AJ, remove the handlebar pad [BJ .

• Disconnect the throttle cable from th e carburetor (see Throttle Cable Removal).

• Remove the throttle case.

o Remove the throttle case bolts [AJ

and separate the case halves .

• Unscrew the socket bolts [AJ and remove the steel plate.

FUEL SYSTEM 2-7

eRemove the throttle cable (see Throttle Cable Removal). e Disassemble t he throttle case. o Remove the throttle bolt [A), lockwasher, and flat washer, and lift the th rottle case lever [B) and return spring [C) from the case. o Pull the throttle control lever out of the case. o Pull the control lever pivot bushings [D) out of the case. One is toward the outside and the other is to the inside. There is an O-ring

[E) between them. o Remove the lockbolt and take out the throttle limiter [F).

~ \,

o Throttle Case Assembly/Installation Notes e Be sure the rubber seal [A) is in place on the throttle lever pivot. *If there is any doubt as to the condition of the rubber coating on the

steel plate or the rubber seal on the throttle lever pivot, replace it with a new one. e Lubricate the throttle case and cable before assembly/ installation (see Throttle Case and Cable Lubrication) .

â&#x20AC;˘ Be certain that the return spring [AJ is correctly installed on the throttle lever. eApply a non-permanent locking agent to the throttle lever bolt and tighten it to the specified torque (see Exploded View). eApplya non-permanent locking agent to the throttle cable threads at the throttle case . â&#x20AC;˘ Swing the throttle control lever so that the carburetor throttle valve is

fullyopen. e Locate the throttle limiter at the throttle lever fu lly open.

Operation with an Improperly assembled throttle case could result in an unsafe riding condition.

eAdjust the throttle cable (see Throttle Cable Adjustment).

2-8 FUEL SYSTEM

Throttle Cable Removal • Disconnect the throttle cable from the carburetor. [AJ and slide the cable from the bracket. OSlide the cable lower end [BJ from the shaft lever.

o Loosen the adjuster locknuts

• Remove and disassemble the throttle case to free the upper end of the cable from the case (see Throttle Case Removal / Disassembly) . • Slide the rubber boot out [AJ of the place . • Pull the cable tip from the throttle lever catch [BJ. • Unscrew the throttle cable fitting nut [C].

• Remove the handle pole cover. • Unfasten the throttle cable from the cable holder [AJ .

• Pull the throttle cable from the handle pole. o Lubricate the cable passage in the handle pole with a penetrating rust

in hibitor.

o Reach under the front deck and pull the throttle cable from the handle pol e.

FUEL SYSTEM 2-9

Throttle Cable Installation Notes • Lubricate the outside of the new cable with a penetrating rust inhibitor to ease cable installation .

• Check throttle cable routing to be sure the cable does not bend sharply at the steering pivot nut. Check the cable at both extremes of handlebar movement. .Applya non-permanent locking agent to the throttle cable threads at the throttle case .

• Adjust the throttle cable (see Throttle Cable Adjustment).

Throttle Case and Cable Lubrication Whenever the throttle case is disassembled, and in accordance with

the Periodic Maintenance Chart, perform the following . • Apply water resistant grease [AJ to the tips of the throttle cable ends .

• Lubricate the cable by seeping oil between the cable and cable housing. Special Tool - Pressure Cable Luber: K56019-021 [AJ

Throttle Case Inspection .With the throttle cable disconnected form the throttle lever, the lever should move freely and return smoothly by spring tension. If the lever binds, disassemble the throttle case, and clean and lubricate the throttle case (see Throttle Case and Cable Lubrication) . • Examine the lever and case for cracks. Replace the case assembly if it is cracked.

2-10 FUEL SYSTEM

Throttle Cable Inspection â&#x20AC;˘ Examine the cable. *If the cable or cable housing is kinked [A] or frayed [B] , replace the cable. A

â&#x20AC;˘ Be certain that the throttle cable moves freely in both directions.

o Loosen the adjuster locknuts, and slide the cable from the pulley.

o Slide the inner cable back and forth in the cable housing. *If the cable does not move freely, replace it.

FUEL SYSTEM 2-11 Choke Cable

Adjustment .When the choke knob is turned counterclockwise, the choke butterfly va lve in the carburetor should be completely open. Check that the choke pivot arm [A] is up all the way with minimal cable slack. This

will fully open the choke butterfly va lve in the carburetor.

CHOKE.OPEN (TUR NED TO OFF)

elf necessary, adjust the choke cable. OTum the choke knob counterclockwise completely.

a Loosen the locknuts [A] and turn the nuts to allow a little cable slack. aTighten the locknuts.

Removal â&#x20AC;˘ Disconnect the choke cable from the carburetor. a Loosen the adjuster locknuts [A] and slide the cable from the bracket. a Slide the cable lower end [B] from the pivot arm .

â&#x20AC;˘ Remove the electric case (see Electric Case Removal in the Electrical System chapter). e Loosen the locknuts [A] and disconnect the cable tip [B].

CHOKE CLOSED (TURNED TO ON)

2-12 FUEL SYSTEM

Inspection • Examine the cable.

*If the cable or cable housing is kinked [A] or frayed [B], replace the cable.

.With the choke cable disconnected at the both ends, the cable should move freely within the cable housing.

* If the cable does not move freely, replace it.

Lubrication Whenever the choke cable removed, lubricate the choke cable as follows . • Apply water resistant grease to the tips of the choke cable ends . • Lubricate the choke cable by seeping oil between the cable and cable housing. Special Tool - Pressure Cable Luber: K56019-021 [A]

.Attached the choke cable to the carburetor and adjust the choke cable (see Choke Cable Adjustment).

FUEL SYSTEM 2-13 Carburetor/Fuel Pump

Idle Speed Adjustment The normal idle speed setting is the lowest at which the watercraft will run reliable while still producing enough thrust to circle back to the rider after spill. . Turn the idle adjusting screw [A] as required to reach this setting.

Idle Speed 1.250 ±100 rpm (in water) 1.700 ±100 rpm (out of water)

Mixture Screw Adjustment Since every carburetor is adjusted individually at the factory using a flow meter, specific mixture screw settings cannot be given. After adjustment. a cap [A] is installed over each mixture screw head [B] w ith the point straight down [C] to identify proper mixture screw settings for each until. DO NOT CHANGE THESE SETTINGS. If the carburetor is tampered with and these settings cannot be relocated, set the mixture screws to the following guide line .

• Pull out the mixture screw caps. e Ta set each screw, turn it in until seats lightly, and then back it out the specified number of turns. Mixture Screw

Turns out

Low Speed (lower) [A] High Speed (upper) [B]

7/8, JS750-A3- : 1Ys 7/8, JS750-A3- : 3/4

These guideline represent a "starting point" from wh ich additional fine tuning of.the carburetor may be necessary.

CAUTION Do not force the mixture screws into their seats. You could damage the screws or the carburetor. Operating the watercraft with the high speed screw at too lean a setting (screwed in clockwise too far) could cause serious engine damage.

High Altitude Performance Adjustment The normal carburetor settings are best for sea level. If the watercraft is used at the higher elevations, the lower atmospheric pressure makes the carburetion richer. To obtain the proper carburetor setting at higher elevations, turn in the high speed screw according to the following table.

2-14 FUEL SYSTEM

Altitude m (H)

Tum the high speed screw in the normal position

1000 (3300) 2000 (6600) 3000 (10000)

1/ 8 turn 1/ 4tum 3/8 turn

NOTE

o The adjustment of the low speed screw is not required on the actual usage.

Carburetor Removal • Remove: Strap [A] on Intake Silencer Air Intake Cover Mounting Bolts [B] Air Intake Cover with Intake Silencer [C]

.Disconnect: Throttle Cable [A] Choke Cable [B] Fuel Hoses [C] Pulse Hose [0]

• Remove the carburetor mounting bolts [AJ, and remove the arrester case [B] . • Lift the carbureto'r off the intake manifold.

FUEL SYSTEM 2-15

Carburetor Installation Notes .Connect the fuel hoses and pulse hose correctly (see Fuel System Diagram) . • Install a new gasket under the carburetor . • Apply a non- permanent locking agent to the carburetor mounting bolts. Torque - Carburetor Mounting Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

• Bend the tab portions of the double washer over the bolts . • Adjust the throttle and choke cables (see Throttle Cable Adjustment, Choke Cable Adjustmeni).

Carburetor Disassembly • Remove the carburetor (see Carburetor Removal). • Unscrew the carburetor cover screws [A] and take off the carburetor

cover [B].

• Unscrew the carburetor case screw [A] and separate the carburetor

case [B] from the carburetor body.

• Unscrew the float arm set screw [A] . • Remove: Float Arm [B] Spring Float Va lve Main Jet [C] Pilot Jet [0]

• Remove the mounting screws [A] and drop out the plate [B] and check valve [CJ.

2-16 FUEL SYSTEM

NOTE Olf the mixture screws need to be removed; check number of return rotations of mixture screws beforehand.

eTo remove the mixture screws, turn them counterclockwise until they

come out. Do not lose the spring [Aj , washer [Bj , and O-ring [C] on each screw.

Carburetor Assembly Notes elf the mixture screws were removed, install then, as shown. A. High Speed Screw B. Low Speed Screw

.Assemble the carburetor cover, as shown. A. Float Arm B. Spring C. Diaphragm Needle D. Main Jet E. Pilot Jet

NOTE OAfter 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 [Aj at the carburetor, and blow [Bj through it until fuel appears at the fuel return fitting on the carburetor, The fuel system in now full offuel.

AWARNING Gasoline is extremely flammable and can be explosive under certain condilions. Positon the starter interlock switch to the locked position. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparksj tJ:Iis includes any appliance with a pilot

light.

FUEL SYSTEM 2-17

Carburetor Cleaning and Inspection • Disassemble the carburetor (see Carburetor Disassembly).

AWARNING 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. 00 not direct air towards anyone. Use 172 kPa (1.75 kg/cm 2 1 25 psi) maximum nozzle pressure.

• Immerse all the metal parts in a carburetor cleaning solution . • Rinse the parts in water .

• When the parts are clean, dry them with compressed air. • Blowout the air and fuel passages with compressed air. • Inspect the check valve [AJ for damage or deterioration, and replace it if necessary. *If the gasket [BJ under the check valve appears damaged, it may leak and must be replaced.

• Check these rubber parts for damage. O-ring [A] Diaphragm [B] *It any of these parts are not in good condition, replace them .

• Check the plastic tip on the diaphragm valve needle. smooth, without any grooves, scratches. or tears. Diaphragm Needle [A] Diaphragm Needle Wear [BJ *11 the plastic tip is damaged, replace the needle.

It should be

Float Arm Level Inspection and Adjustment .Check the float arm level [A]. o Measure from the plastic tip [B] on the float arm to the carburetor case [C]. Float Arm Level 1.0 - 2.0 mm * If the float arm level is incorrect, bend the float arm very slightly to change the float arm level.

2-18 FUEL SYSTEM

Fuel Pump Removal/ Installation Note â&#x20AC;˘ Remove the carburetor .

â&#x20AC;˘ Remove the fuel pump body screws [A] , and take the fuel pump unit [ B] off the carburetor.

CAUTION The fuel pump should not be disassembled. H leakage is evident or internal damage is suspected, replace the fuel

pump unil [B].

FUEL SYSTEM 2-19 Flame Arrester

Removal • Remove: Clamp [A) on Duct (Loosen) Air Intake Cover Mounting Bolts [B] Air Intake Cover [C] Carburetor Mounting Bolts [0] Arrester Case [E) .

Installation Notes .When assembling the flame arrester, put the screen [A) between two expanders [B) .

• Install the arrester case so that the mark [A] points to the engine side . • Apply a non-permanent locking agent to the thread of the carburetor mounting bolts and the air intake cover bolts. Torque - Carburetor Mounting Bolts: 7.8 N-m (0.8 kg."" 69 in-Ib)

• Bend the tap portions of double washer over the carburetor mounting bolts.

Cleaning • Remove the flame arrester (see Flame Arrester Removal) . • Blow the flame arrester clean with compressed air. AWARNING Eye protection should be worn when compressed air is used to dry ports. Do nol direct air toward anyone. Use 172 kPa (1.75 kg/cm", 25 psI) maximum nozzle pressure .

• Install the flame arrester (see Flame Arrester Installation Notes).

2-20 FUEL SYSTEM Intake Manifold, Reed Valves

Removal • Remove: Air Intake Cover with Intake Silencer Carburetor (see Carburetor Removal) Oil Pump Outlet Hose [A] at Oil Injection Nozzle . • Remove the intake manifold mounting nuts [8] and remove the intake manifold.

epull out the gaskets [A] and the reed valves [6] .

,rrt l Installation Notes • Replace the gaskets with new ones. elnstall the reed valves so that the "up" mark [A] is up. elnstall the intake manifold.

Torque - Intake Manifold Mounting Nuts: 7.8 N-m (0.8 kg-m. 69 in-Ib)

.After installing the parts removed, bleed the oil pump if there are air bubbles in the outlet hose (see Engine Lubrication System chapter) .

Reed Valve Inspection e Check reed warp by measuring the clearance [A] between each reed [6] and the valve holder [C] . *If anyone of the clearance measurements exceeds the service limit, replace the reed valve assembly with a new one. Reed Warp

Service Limit:

0.2 mm

e Check the mounting screw tightness . • Visually inspect the reeds for cracks, folds, or other damage. *11 there is any doubt as to the condition of a reed, replace the reed valve assembly. If a reed becomes wavy, replace the reed valve assembly with a new one even if reed warp is less than there service limit

FUEL SYSTEM 2-21

Valve Holder Inspection .Check the reed [AJ contact areas of the valve holder for grooves, scratches, or other damage . â&#x20AC;˘ Check that the rubber coating [BJ on the valve holder does not show any signs of separation from the holder.

* If there is any doubt as to the condition of the rubber coating, replace the reed valve assembly with a new one.

Valve Stop Inspection â&#x20AC;˘ Check the valve stops [AJ for defonnation, 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.

2-22 FUEL SYSTEM Fuel Tank

Fuel Tank Removal elf the level of the fuel is above the inlet neck, siphon some fuel out to prevent spilling it.

AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Position the starter interlock switch to the locked postian. Do not smoke. Make sure the area is well ventilated and free from any source of ffame or sparks; this includes any appliance with a pilot

light. • Remove: Intake Silencer Exhaust Pipe and Exhaust Chamber (see the Exh aust System chapter) Intake Silencer Bracket [A] Breather [B] Fuel Tap Assembly [C] Rubber Strap [D] Oil Tank Clamp on Fuel Inlet Hose Fuel Tank [E]

Fuel Tank Installation Notes • Be sure the O - ring [A] is on the fuel tank . • Apply a non-permanent locking agent to the intake silencer bracket mounting bolts and tighten them securely.

Fuel Tank Cleaning • Remove the fuel tank (see Fuel Tank Removal). • Drain the tank into a suitable container.

AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Position the starter interlock switch to the locked position. 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. • Flush the tank repeatedly w ith high flash-point solvent until it is clean. It may be necessary to put a few marbles or pieces of clean gravel into the tank and shake it, to knock loose any foreign matter in the bottom.

AWARNING Clean the tank in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working areaj 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.

FUEL SYSTEM 2-23

Fuel Filler and Tube Removal • Remove the fuel tank (see Fuel Tank Removal) . • Loosen the clamp and twist the filler tube [AJ off the bottom of the filler.

.Take out the screws [AJ in the filler flange, cut the sealant [6). and pull the filler away from the hull.

Fuel Filler and Tube Installation Notes .Clean the hull and the filler on their mating surfaces with a graceless, high flash-point solvent. .

AWARNING 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. .Apply an even layer of silicone sealant to the mating surfaces of the

filler and hull.

Fuel Filter Screen Cleaning • Clean the fuel filler screens in accordance with the Periodic Maintenance Chart (see Genera l Information chapter) .

• Wash the fuel filler screens in non -flammable or high flash-point solvent.

Use a brush to remove any contaminants trapped in 'the

screens. AWARNING Clean the fuel filter screens in a well ventilated area, and take 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 solvenl A fire or explosion could resull

2-24 FUEL SYSTEM Fuel Tap and Cables

Removal • Remove:

Locknuts (Loosen) [A] Control Cables [B] Fuel Hoses [C] Mounting Screws [0] Electric Case (see the Electrical Cable Clamp Screws [E] Locknuts (Loosen) [F] Control Cables [G]

S~stem

chapter)

Installation Notes .Set the fuel knob and fuel tap in the "OFF" position, and install the cables. OAlign the 'OFF" mark [A] on the fuel tap with the projection [B] on the bracket. • Connect the fuel hoses and cables, as shown.

1. 2. 3. 4. 5. 6.

Fuel Knob Reel Control Cables Supply Fuel Hose Return Fuel Hose Fuel Tap

FUEL SYSTEM 2-25

Cleaning If the fuel tap becomes clogged with foreign matter, it must be cleaned . • Pull the luel lines off the carburetor . • Remove the luel tap assembly . • Use compressed air to blow through supply hose, while switching th e luel knob right and left between the " ON" and " RES " positions . • And use compressed air to blow through the return hose.

NOTE ODD not use too high air pressure (25 psi max.).

ENGINE LUBRICATION SYSTEM 3-1

Engine Lubrication System Table of Contents

Exploded View ................. ".,."., ,.. ,., .. ,. " .... ,...... ,.. ', .. ,.. .... .. ,... ....... .. ,....... .... "., ...,..... .. ,..3-2 Specifications" ,. ". ,.. ,. ,. ". ,. ".,. ,.. " .... ,. ' .. ...,..,.. ,........ ,........ .. ,....... ,............ .. ,........,.... ,.. ,..3-3 Oil Pump"".,.""."", ...,."."".,.".",.",., .. .", .....,..,.........,...... ,..,.... ,', ..,.,.. ..,.. ,', .. ,...,., .. ...,..3-4 Oil Pump Bleeding" "".". "'" ". " .. ,," "" " "" " .," ... " ..... "",, ".,," "." '" ""." .. " ... "., ,,3-4 Oil Pump Performance Test ".,," " " ."" '" ". " .,"." """"" ..... ,,.,, ".",,' "" ""'" ". "., ,,3-4 Oil Pump Removal" . ' ....,.."" ...... ....,..,... " ,........ ... ,.......,... " ...... ,.. " ... " .... " ......... ,.. 3-5 Oil Pump Installation ....,..,.... ,............,................ ,.... ,." .... "',." ....... ,",.,',.,', .. ", .... 3-5 Oil Tank ,................................... ," .................. " ......... ,.. ,........ ,.,'" '"'' "., .... "',., .. ," ... ",.,.3-6 Removal .. ,.. ".,."., ... " ...,.... ,................,..,.....,.. ...,..... ,."."., .. ,.,',.,", .. ,.,', .. ', .. ,.. ,."",.3-6 Installation Note " ...,' ,... "., ............. ' ..,..,... ,. ,........,.. " .......... ,.. ,' ,. " .. ,' ,.... ,...,....... ,.. 3-6 Cleaning., "., .... ,. ,., ..," ,.,., ''', .. " .. ,...,."., .. " ....,.. ,,..,... ,......... ... ,....,. ,.,'" " . " .......... , '" ,3-6

3-2 ENGINE LUBRle Exploded View ATION SYSTEM

L : Apply a no " -permanent lock'm9 agent.

(),

---/

ENGINE LUBRICATION SYSTEM 3-3 Specifications Item Engine Oil: Type Capacity Engine Oil Pump: Oil pump output@3000 r/ min (rpm), 2min.

Standard 2 -stroke, N M MA Certified for Service TC- WIT 2.6 L 5.9 - 7.2 mL

3-4 ENGINE LUBRICATION SYSTEM

Oil Pump Oil Pump Bleeding • Make sure that there is plenty of engine oil in the oil tank and that oil flow is no restricted. • Loosen the air bleeder screw [AJ on the oil pump a couple of turns wait until oil flows out, and then tighten the bleeder screw securely.

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 .

• Supply the cooling system with water (see A uxiliary Cooling in the General Information chapter) . • Start the engine, keep it at idling speed and check the oil flow through the transparent outlet hose. • Keep the engine running until the air bubble in the outlet hose disappear.

Oil Pump Performance Test If a drop in oil pump performance is suspected, check the rate at which the oil is being pumped. • Disconnect the oil pump outlet hose at the oil injection nozzle and run the hose [AJ into a measuring glass [8J.

CAUTION For this test use a 50 : 1 mixture of gasoline to oil instead the gasoline normally used.

• Supply the cooling system with water (see Auxiliary Cooling in the General Information chapter) . • Start the engine, and run it at a steady 3,000 rpm (use a tachometer). • Collect the oil that is being pumped for 2 minutes. If the quantity of oil collected is within the specification, the oil pump is operating properly. Oil Pump Output (3,000 rpm for 2 minutes) Standard: 5.9 - 7.2 mL * If the oil pump output is subnormal, inspect the oil pump, and the inlet and outlet hoses for oil leaks. *If oil leaks are not found , replace the oil pump.

NOTE OA check valve is built into the oil pump and can not be removed.

ENGINE LUBRICATION SYSTEM 3-5

Oil Pump Removal .Squeeze the inlet hose [A] to restrict oil flow and disconnect it from the oil pump . â&#x20AC;˘ Pull off the outlet hose [B], remove both mounting nuts [C] and take off the oil pump and the a-ring.

'2'

Oil Pump Installauon' .Be sure the a-ring [A] is in place and install the oil pump on the magneto cover. OWhen mounting the oil pump, note the position of the slot [B] in the flywheel bolt, and then turn the oil pump shaft [C] so that it will fit into the slot. .Connect both oil hose and bleed the air form the system (see Oil Pump Bleeding).

3-6 ENGINE LUBRICATION SYSTEM

Oil Tank

Removal • Remove: Engine Oil (Drain) Oil Inlet Hose [A] Rubber Strap [B] .Take out the oil tank [C]

Installation Note • Be sure the rubber damper [A] is in place.

Cleaning • Flush the tank repeatedly with high flash-point solvent until it is clean. AWARNING 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.

EXHAUST SYSTEM 4-1

Exhaust System Table of Contents

Exploded View .............. .... .............................................................. ........ ................... .4- 2 Expansion Chamber ........................................................... ................................ .... .....4-3 Removal ..............................................................................................................4-3 Installation Notes ....................... .... .. ...................................................................4-4 Expansion Chamber Cleaning and Inspection ................................................... 4-4 Exhaust Manifold :................................ .. .............................................. ...................... .4-5 Removal ....................... ....................................................................................... 4-5 Installation Notes ..... ...........................................................................................4-5 Exhaust Manifold Cleaning and Inspection .......................................................4-6 Water Box Muffler ............ .... .. .................................. .. ................................................ .4-7 Removal/ Installation ................................ ...........................................................4-7 Inspection ...........................................................................................................4-8

4-2 EXHAUST SYSTEM Exploded View

T1: T2: L : SS :

9.8 N-m (1.0 kg-m, 87 in-I b) 20 N-m (2.0 kg-m, 14.5 ft-Ib) Apply a non-permanent locking agent. Apply silicone sealant.

EXHAUST SYSTEM 4-3 Expansion Chamber Removal • Remove or disconnect: Cooling Hose [A] Bypass Hose [B] Clamp [C] (Loosen) Water Drain Knob [0] Intake Silencer

• Remove: Muffler Bracket Mounting Bolts [A] Exhaust Pipe Mounting Bolts [B]

• Remove the exhaust pipe, the front muffler and the expansion chamber as a set [A].

• Disassemble: Exhaust Pipe [A] Front Muffler [B] Expansion Chamber [C]

4-4 EXHAUST SYSTEM

Installation Notes .Assemble provisionally the exhaust pipe [A], the front muffler [B] and the expansion chamber [C] with the gaskets [0] .

• Install the above assembly provisionally on the exhaust manifold that is set on the engine with the gasket [A] . • Install provisionally the muffler bracket [B] between the cylinder and the front muffler. A

.Applya non-permanent locking agent to all the bolts and torque all the bolts in the following order. Torque - Exhaust Pipe Mounting Bolts: 20 N-m (2.0 kg-m, 14.5 It-Ib)

[A] Front Muffler Mounting Bolts: 20 N-m (2.0 kg-m, 14.5 It-Ib)

[B] expansion Chamber Mounting Bolts: 20 N-m (2.0 kg-m, 14.5 It-Ib) [C] Muffler Bracket Mounting Bolts (cylinder side): 20 N-m (2.0 kg-m, 14.51t-lb) [DJ Muffler Bracket Mounting Bolts (front muffler side): 20 N-m (2.0 kg-m, 14.51t-lb) [E]

Expansion Chamber Cleaning and Inspection • Remove the expansion chamber (see Expansion Chamber Removal) . • Scrape any carbon deposits out of the expansion chamber with a blunt, roundedged tool. Excessive deposits will cause the engine to run poorly. • Check the expansion chamber carefully for cracks. Also look for corrosion both inside and out.

EXHAUST SYSTEM 4-5 Exhaust Manifold

Removal • Remove the exhaust pipe, the front muffler and the expansion chamber as a set . • Disconnect the inlet cooling hose [A) from the lower part of the exhaust man ifold [B] .

• Remove the exhaust manifold mounting nuts [A] . • Take off the exhaust manifold off the cylinder.

Installation Notes .Install the exhaust manifold gaskets so that the arrows [A] point the up .

• The cooling hose clamp bolt [A] should face toward cylinder [B] .

4-6 EXHAUST SYSTEM

Water Box Muffler .Torque the exhaust manifold mounting nuts, following the specified tightening sequence. Torque - Exhaust Ma~ifold Mounting Nuts: 20 N-m (2.0 kg-m, 14.5 ft-Ib)

Exhaust Manifold Cleaning and Inspection • Remove the exhaust manifold parts . • Clean the carbon deposits out of the exhaust passages with a blunt, roundedged tool. .Flush foreign matter out of the water passages with fresh water . • Check the insides of the water passages for corrosion. Check the gasket surfaces 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.

EXHAUST SYSTEM 4-7

Water Box Muffler

Removal/Installation • Remove of disconnect: Electric Case Exhaust Pipe, Front Muffler and Expansion Chamber as a set Outlet Tube [A] Inlet Tube [B] M ufller Bracket [C]

• Rotating the water box muffler [A] as shown, remove the muffler out of the hull.

4-8 EXHAUST SYSTEM

Inspection • Remove the water box muffler. • Empty any water out of the water box. • Check the inlet spigot for damage caused by excessive 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 mixture needle adjustment (see Mixture Screw Adjustment in the Fuel System chapter) . • Check the seem around the center of the water box for leaks. * If there are leaks in the water box seam, they may be repaired with an epoxy putty, or the water box may be replaced . Exhaust leaks will fill the engine compartment with exhaust gasses which will cause the engine to run poorly.

ENGINE TOP END 5-1

Engine Top End Table of Contents

Exploded View ......................................................................................................... ... 5-2 Specifications .............................................................................................................. 5-3 Engine Top End ...........................................................................................................5-4 Disassembly and Assembly: ...................................................................................5-4 Disassembly .. ..................................................... .. ............................................... 5-4 Assembly Notes ................ .. ..................... .. ........... ............ ..................................5-5 Maintenance and Inspection: ....... ......... .. .......... ..... .. ....... .. ................ ..................... 5-7 Compression Measurement ...... .......................................................................... 5-7 Cylinder Head Warp Inspection ................................ _........................................ 5-7 Cylinder Wear Inspection ....................... ... .. .. ....... .......................................... .... 5-8 Piston Diameter Measurement .................... ..... ......... .......... ............................... 5-8 Piston/Cylinder Clearance ........ .......... .. .............................................................. 5-8 Boring and Honing ......................... .................................................................. .. 5-9 Piston Ring, Piston Ring Groove Inspection ................ ..................................... 5-9 Piston Ring End Gap ..........................................................................................5-9

5-2 ENGINE TOP END Exploded V ·Iew 87 in·lb) Tl : 9.8 N'm (l.\k~;, 22 ft.lb) T2' 29 N' m (3;0 g 25 ft.lb) .

N·m (3.5 kg-m,

T3 : 34 T one sealant. SS: Apply so Ie '1 o : Apply engine 01 •

ENGINE TOP END 5-3 Specifications Item Cylinder Head: Cylinder compression

Cylinder head warp Cylinder, Piston: Cylinder inside diameter Piston diameter (18 mm up from bottom of skirt) Piston/ cylinder clearance Oversize piston and rings Piston ring / groove clearance: Top (keystone) Second Piston ring groove width: Top (keystone) Second Piston ring thickness: Top (keystone) Second Piston ring end gap: Top Second

Standard

Service Limit

(Usable range) 835 - 1294 kPa (8.5 - 13.2 kg / em', 121 - 187 pis) (Open throttle) -- -

--0.05 mm

80.000 - 80.015 mm 79.900 - 79.915 mm 0.095 - 0.115 mm +0.5 mm and +1.0 mm -- 0.03 - 0.07 mm

--1 .22 - 1 .24 mm

--1.17 - 1.1 9 mm 0.25 - 0.40 mm 0.25 - 0.40 mm

Special Tools - Piston Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Bel~ 11>67 - 11>79: 57001-1097 Compression Gauge: 57001Âˇ221 Compression Gauge Adapter: 57001-1159

80.10 mm 79.75 mm ------0.17 mm --1.32 mm

--1.1 mm 0 .7 mm 0.7 mm

5-4 ENGINE TOP END Engine Top End Disassembly and Assembly:

Disassembly • Remove: Spark Plugs Intake Silencer Carburetor (see Carburetor Removal in the Fuel System chapter) Exhaust Pipe, Front Muffler and Expansion Chamber as a set (see Exhaust System chapter) .Remove the cylinder head nut [A], and take off the cylinder head

[8].

• Remove the cylinder base nuts [A], and lift off the cylinder [8] .

• Stuff clean rags into the crankcase opening to prevent dirt or foreign

objects from falling into the crankcase . • Remove the piston pin snap ring [A] with a pliers [8] .

• Remove the piston by pushing its pin out the side that the circlip was

removed. Use a piston pin puller assembly [AJ, if the pin is tight. Special Tool - Piston Pin Puller Assembly: 57001-910

.Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it.

ENGINE TOP END 5-5

Assembly Notes elf any parts in the piston assemblies require replacement, or if the cylinder is honed or 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 upwards as shown .

• When installing the piston rings by hand, first fit one end of the piston ring against the pin in the ring groove, spread 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 .

• Apply engine oil to the surface of each piston pin . • Mount the piston on the connecting rod with the arrow [A] on its crown pointing to the lett (exhaust) side [B) of the engine .

• When installing a piston pin snap ring, compress it only enough to install it and no more.

CAUTlON Do not reuse rings, as removal weakens and deforms them. They could fall out and score the cylinder wall . • Fit a new piston pin snap ring into the side of each piston so that the snap ring opening [A) does not coincide with the slits [B) of the piston pin hole.

• Set the new cylinder base gasket in place on the crankcase . • Apply engine oil to the surface of the pistons . • Compress the piston rings. Special Tool - Piston Ring Compressor Grip: 57001-1095 [A) Piston Ring Compressor Bel~ <1>67 - <1>79: 57001-1097

[B)

5-6 ENGINE TOP END

.Thoroughly oil the cylinder bores . • Slide the cylinder block down over the cra nkcase studs onto the crankcase.

CAUTION Do not force the cylinder block. Make sure the rings are in position . • Install the cylinder base nuts, and cross-tighten them. Torque - Cylinder Base Nuls: 34 N-m (3.5 kg-m, 25 H-Ib)

• Place a new cylinder head gasket on the cylinder head. OThe "U P" mark [AJ of the gasket must face upward and " EX" mark [ BJ must face toward the exhaust side of the engine.

fRONT

• Install the cylinder head. Torque - Cylinder Head Nut 29 N-m (3.0 kg-m, 22 H-Ib)

OThe tightening sequence numbers are marked on the cylinder head.

Exhaust Side

.Start the engine to check for fuel and oil leaks. exhaust leaks, and

excessive vibration. AWARNING 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 for more than 15 seconds without cooling water.

ENGINE TOP END 5-7

Maintenance and Inspection: Compression Measurement .Thoroughly warm up the engine, while checking that there is no compression leakage from around the spark plugs or the cylinder head gasket.

CAUTION Do not run the engine for more than 15 seconds without cooling water.

eStop the engine. â&#x20AC;˘ Remove the spark plugs and screw a compression gauge firmly into the spark plug hole. Special Tools - Compression Gauge: 57001-221 [AJ Compression Gauge Adapter: 57001-1159 [ BJ e Using the starter motor. turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. e Repeat the measurement for the other cylinder. Cylinder Compression (Usable Range) 835 - 1 .294 kPa (8.S - 13.2 kg/em'. 121 -187 psi) (open throttle) *If the cylinder compression is higher than the usable range. check the following . o Carbon buildup on the piston head and cylinder head - clean off any carbon on the piston head and cylinder head. OCylinder head gasket. cylinder base gaskets - use only the proper gaskets. The use of a gasket of incorrect thickness w ill change the

compression.

* If cylinder compression is lower than the usable range, check the following: o Gas leakage around the cylinder head - replace the damaged gasket and check the cylinder head for warp. o Piston / cylinder clearance. piston seizure. o Piston rings. piston ring grooves wear.

Cylinder Head Warp Inspection eLay a straightedge [AJ across the lower surface of the head [BJ at several different points, and measure warp 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

5-8 ENGINE TOP END

Cylinder Wear Inspection 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-ta-side and a front-ta-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure. A 10mm B.80mm C.35 mm

f â&#x20AC;˘

*If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder will have to be bored oversize and then honed.

Cylinder Inside Diameter Standard: 80.000 - 80.015 mm and less than 0.01 mm

difference between any two measurements Service Limit:

80.10 mm, or more than 0.05 mm difference between any two measurements

Piston Diameter Measurement eMeasure the outside diameter [AJ of the piston 18 mm up [BJ from the bottom of the piston at a ring angle to the direction of the piston pin.

Piston Diameter Standard: Service Limit:

79.900 - 79.915 mm 79.75 mm

Oif the measurement is less than the service limit, replace the piston.

NOTE OAbnormal 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 va lue maintained anytime a piston or the cylinder block are replaced with new parts, or whenever the cylinder is rebored and oversize pistons installed . â&#x20AC;˘ 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 . â&#x20AC;˘ Measure the piston diameter as just described, and subtract this value from the measurement. The difference is the piston clearance. PistonlCylinder Clearance 0.095 - 0.115 mm

.,..;

t_ )

10 ~

ENGINE TOP END 5-9

Boring and Honing When boring and honing a cylinder, note the following: o The are two sizes of oversize pistons available. Oversize Piston and Rings Oversize Pistons and Rings 0.5 mm Oversize

1 .0 mm Oversize o Before boring a cylinder, first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the Service Date Section, determine the rebore diameter. However, if the amount of boring necessary would make the inside diamet er grater than 1.0 mrn oversize, the cylinder block must be replaced. o Cylinder inside diameter must not vary more than 0.01 mm at any point. o Be wary of measurements taken immediately after boring since the heat affects cylinder diameter. o In the case of a rabored cylinder and oversize piston, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm and the service limit for the piston is the oversize piston original diameter minus 0.15 mm. If the exact figure for the rebored diameter is unknown. it can be roughly determined by measuring the diameter at the base of the cylinder.

Piston Ring, Piston Ring Groove Inspection .Visually inspect the piston ri ngs and the piston ring grooves. *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 w ith new rings.

Piston Ring End Gap â&#x20AC;˘ Place the piston ring inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low . â&#x20AC;˘ Measure the gap [AJ 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 rep laced.

Piston Ring End Gap Standard Top 0.25 - 0.40 mm Second 0.25 - 0.40 mm

Service Limit

0.70mm 0.70mm

ENGINE REMOVAL / INSTALLATION 6-1

Engine Removal/Installation Table of Contents

Exploded View ............. .............................. ...................................... ........................... 6-2 Engine Removal/Installation .. .. .............. ........... .....â&#x20AC;¢... .......... .. ............. ........................ 6-3 Removal ....... ............... ... ...................... ..................... ....................... ................... 6-3 . Installation Notes ...... ............ ....................... ... .................................................... 6-4

6-2 ENGINE REMOVAL / INSTALLATION Exploded View

T1: 16 N'm (1.6 kg-m. 11.6 ft·lb) T2: 36 N·m (3.7 kg-m. 27 ft·lb) L : Apply a non-permanent locking agent.

ENGINE REMOVAL / INSTALLATION 6-3 Engine Removal/Installation Removal • Remove or disconnect (see the appropriate chapters) :

Air Intake Cover with Intake Silencer [A) Intake Silencer Stand Throttle Cable Choke Cable Fuel Hoses (Return and Supply) Exhaust Pipe, Front Muffler and Expansion Chamber as a set [B) Inlet Cooling Hose Spark Plug Caps Battery Ground Cable Electric Case Cap [C) Magneto Lead [D)

• Remove the engine bed mounting bolts [A) .

• Slide the engine toward the front to disengage the couplings, and then

lift the engine out of the hull. • Remove the engine mounting bolts [A]. and separate the engine bed and the engine.

6-4 ENGINE REMOVAL / INSTALLATION

Installation Notes • Be sure there are no foreign objects and parts inside of the hull. • Clean the bilge filter (see Filter Cleaning and Inspection in the Cooling and Bilge Systems chapter) . • Check the coupling damper for wear and damage (see Coupling Damper Inspection in the Engine Bottom End chapter) . • 'nstall the engine bed so that the small notches [AJ are on the magneto end of the engine as shown .

• Apply a non-permanent locking agent to the following mounting bolts, and torque them. Torque - Engine Mounting Bolls: 36 N-rn (3.7 kg-m, 27 ft-Ib) Engine Bed Mounting Bolls: 36 N-rn (3.7 kg-rn, 27 ft-Ib) .Check the gap between the engine bed and the dampers by rocking the engine. • ,f there is a gap, insert a suitable shim between the engine bed and the damper to achieve a good fit.

Shim Selection Shim No .

92025-370S 9202S-3706 92025-3707 92025-3708

Thickness to.3 mm to.S mm t1.0 mm t1.S mm

.After installing the engine in the hull, check the following. Throttle Cable Choke Cable Oil Pump Bleeding Fuel and Exhaust Leaks

AWARNING 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 onty for short periods wHhoulcoollng water. Stop the engine Immediately if the temperature warning buzzer goes on. Overheating will cause severe engine and exhaust system damage.

ENGINE BOTTOM END 7-1

Engine BoHom End Table of Contents

Exploded View .............................................................. ..............................................7-2 Specifications .............................. .................................... ............................................7-3 Coupling ................................................... ..................... ..............................................7-4 Removal .......................... ....... ........ ...... ................. .. ............................................7-4 Installation Notes ................ ........ .. ..... .. .. .................... .. .................... ...... .. ........... 7-4 Coupling Damper Inspection ................................................ ... ......... .. ............... 7-4 Magneto Flywheel .................................................................... ................... ............... 7-5 Remova l ......................... ....... ........................................ ...................................... 7-5 Installation Notes ............................... ..................... ............................................ 7-5 Stator ...........................................................................................................................7-6 Removal ..............................................................................................................7-6 Installation Notes ................................................................................................ 7-7 Water Drain Valve ................ ........................................................................................ 7-8 Removal ................................ ................................................................. .......... .. .7-8 Water Drain Valve Installation ............................................. ..................... .. ........ 7-8 Crankcase ............................................................................................â&#x20AC;˘. ... ............ .. .. .. .7-9 Splitting ....................................................................................................... ........7-9 Assembly Notes ............................................................................................... .. .7-9 Crankshaft Maintenance ...... .... ......................... ..................................... ...................7 -11 Connecting Rod Bend/ Twist ................................................................ .. .........7 -11 Connecting Rod Big End Radial Clearance .. ...................................................7 -12 Connecting Rod Big End Side Clearance ........ ............................................. ...7 -12 Crankshaft Main Bearing Wear .............. .. ................. ....................................... 7 -12 Crankshaft Runout ...................... ..................................................................... 7 -13 Crankshaft Assembly Specifications ........... .. .................................. .................7 -13

7-2 ENGINE 80 TTOM END Exploded V iew

T1 ' 7.8 N-m (0.8 kg - m ' 85 69 ft-Ib) in - Ib) . (1 2 kg-m, . T2: 12 N-m. 22 ft-Ib) T3' 29 N -m (3.0 kg -m, m 94 ft -Ib)

~~n~nt

T4: 125 N-m (13.0 locking agent. L . Apply a non - per m disulfide grease. . I molybdenu M: Appy G : Apply ~re~se. asket. . LG: Apply liquid gh flanged portion. I 0 11 to t e o55:: App Applyy 51'1'ICO ne sealant.

ENGINE BOTTOM END 7-3 Specifications Standard

Service Limit

0.04 mm 0.45 - 0.55 mm 0.038 - 0.049 mm 0.05 mm/ 100 mm 0.15 mm/ 100 mm

0.10 mm TIR 0.8mm 0.10 mm 0.2mm/ 100mm 0.2mm/ 100mm

Item Crankshaft, Connecting Rods: Crankshaft runout Connecting rod side clearance Connecting rod radial clearance Connecting rod bend Connecting rod twist

Special Tools - Flywheel Holder: 57001-1313 Coupling Holder: 57001-1230 Rotor Puller, M16/M18/M20/M22 x 1.5: Rotor Puller, M18 x 1.5: 57001 -1258

57001-1216

Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104-1003 Kawasaki Bond (Silicone Sealant): 56019-120

7-4 ENGINE BOTTOM END Coupling

Removal â&#x20AC;˘ Remove: Engine (see Engine Removal / Installation chapter) Coupling Damper

Magneto Cover â&#x20AC;˘ Holding the flywheel, unscrew the coupling. Special Tool - Flywheel Holder: 57001-1313 [AJ Coupling Holder: 57001-1230 [BJ

Installation Notes .Apply a thin coat of silicone sealant to the coupling threads. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

.Screw the coupling onto the crankshaft and tighten it Torque - Coupling: 98 N-m (10.0 kg-m, 72 H-Ib)

Coupling Damper Inspection .With the engine removed, remove the coupling damper and inspect it for wear [A] and deterioration. *If it is grooved or misshapen, replaced it with a new damper.

*If there is any doubt as to coupler condition, replace it.

ENGINE BOTTOM END 7-5 Magneto Flywheel

Removal .Remove the fuel tank (see Fuel System chapter). • Remove the oil pump.

• Remove the mounting bolts [AJ, and take off the magneto cover [6J .

NOTE

o The flywheel can be removed without removing

the fue/tank if the

rotor puller (57001-1258) is used.

• Holding the flywheel. remove the flywheel bolt. Special Tool - Flywheel Holder: 57001-1313 [AJ

• Pull the flywheel off the crankshaft. Special Tool - Rolor Puller, M16/M18/M20/M22 x 1.5: 57001-1216 [AJ or Rolor Puller, M18 x 1.5: 57001-1258

CAUTION 00 not strike the flywheel with a hammer as the magnets may be damaged.

Installation Notes .Using a high flash · points solvents. clean off any oil or dirt that may be on the flywheel bolt, the crankshaft taper, or in the tapered hole in the flywheel. .Fit the woodruff key [AJ securely in the crankshaft, before installing the magneto flywheel.

.Apply a thin coat of engine oil to the flanged portion of flywheel bolt. • Install the flywheel. Torque - Flywheel Boll: 125 N-m (13.0 kg-m, 94 H-Ib) .Check that the knock pins [AJ and the spring [BJ are in place and replace the O·ring if it is damaged . • Apply a non-permanent locking agent to the threads of the magneto cover mounting bolts, and tighten them securely.

7-6 ENGINE BOTTOM END

Stator Removal • Remove the electric case cap [Al. and disconnect the connectors

[B) .

• Remove: Intake Silencer Magneto Cover [A)

.Slide the pins out of the connectors. o Use a screw driver [A) to depress the pin latches.

• Unscrew the grommet cap [A] from the electric case cap.

• Pull the leads. one at a time. through the grommet and cap. o Lubricate the grommet with a penetrating rust inhibitor.

ENGINE BOTTOM END 7-7

• Unscrew the set screws [A] and bolts [8] , and remove the stator assembly.

Installation Notes .Coat the grommets [AJ with water resistant grease .

• Insert the connector pins onto the connector, as shown .

• While pushing the pickup coil bracket [A] as shown, install the pickup coil [8] .

7-8 ENGINE BOTTOM END

Water Drain Valve

Removal • Remove: Exhaust Pipe, Front Muffler and Expansion Chamber (see Exhaust System chapter) Exhaust Manifold (see Exhaust System chapter) Starter Motor (see Electrical System chapter) .Remove the mounting bolt [A], and take out the water drain valve [B] .

• Remove the valve cap and then remove the E-ring to disassemble the

control valve.

A. Reed Valve Assembly B. Gasket C. Reed Valve Cover D. Cover bolt E. Valve Cap

F. Control Valve G. E-Ring H. Spring I. Control Valve Housing J. Mounting bolt

Water Drain Valve Installation .Visually inspect the reed valves for cracks, folds, or other damage.

* If there is any doubt as to the condition of a reed, replace the reed valve assembly. • Applya non-permanent locking agent to the cover bolt threads. ,f

Torque - Waler Drain Valve Cover Bolls: 7.8 N-m (0.8 kg-m, 69 in-Ib)

.Clean the drain hole [A] and the valve cap . • Visually inspect the valve cap, replace it if necessary .

• Install the assembly on the lower crankcase half. OApplya non-permanent locking agent to the threads of the water drain valve mounting bolts. Torque - Waler Drain Valve Mounling Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

o Loosen

the locknut just until the water drain valve knob returns by spring tension . • After installing the water drain valve, check that the control valve fits

tightly [A] in the drain hole.

ENGINE BOTTOM END 7-9 Crankcase

Splitting • Remove the engine (see Engine Removal/Installation chapter). • Remove the following from the engin e. Exhaust Manifold Starter Motor Carburetor Intake Manifold Cylinder Head Cylinder Block Pistons

Water Drain Valve Oil Pump Coupling Magneto Flywheel Reduction Gear

NOTE OAlways remove the coupling before removing the magneto flywheel; or there won't be any way to hold the crankshaft while unscrewing

the coupling.

• Remove the 6 mm crankcase bolts [A] first and the 8 mm bolts [B] .

• Pry the point [A] indicated in the figure to split the crankcase halves apart, and then remove the lower crankcase half. • Lift the crankshaft assembly out of the upper crankcase half.

Assembly Notes .Visually inspect the crankshaft O-ring [AJ, and replace it if necessary . • Grease the inner surface of the collar [B].

7-10 ENGINE BOTTOM END

.Grease the lips of the oil seals . • Pack grease [A) between the rear oil seals (coupl ing side) .

• Install the oil seals as shown. A. Double Lips Seals B. Single Lip Seals

• Place the crankshaft assembly [A) in the upper crankcase half so that the position ring [B) on the crankshaft assembly fits into the groove [C) in the crankcase .

• Check that the knock pins [A) are in place. • With a high flash -point solvent, clean off the mating surfaces of the crankcases halves and wipe dry. • Apply liquid gasket to the mating surface of the lower crankcase half. • Install the lower crankcase half onto the upper half.

• Apply a non- permanent locking agent to the crankcase bolts, and tighten them. Torque - Crankcase M8 Bolts: 29 N-m (3.0 kg-m, 22 fI-lb) Crankcase M6 Bolls: 7.8 N-m (0.8 kg-m, 69 in-Ib)

151:;:---1 4

f--------:l

O The tightening sequence numbers are marked on the lower crankcase

half.

~'0

13CJ

u n

it::}----C:11

ENGINE BOTTOM END 7-11 Crankshaft Maintenance The crankshaft changes the reciprocating motor of the piston into rotating motion to drive the jet pump. Crankshaft trouble. such as excessive play or runout, will multiply the stress caused by the intermittent force on the piston and will result in not only rapid crankshaft bearing wear, but also noise, power loss, vibration, and shortened engine life. A defective crankshaft should always be detected at an early stage and repaired immediately. The following explanation concerns the most common crankshaft problems and the method for measuring play, runout, and con-rod alignment, it does not cover crankshaft disassembly because of the highly specialized equipment that is required. If crankshaft components become damaged or worn, the entire shaft should be replaced as an assembly, or rebuilt by a properly equipped shop.

Connecting Rod Bend/Twist o Set the crankshaft in an alignment jig or in V blocks on a surface plate. o Select an arbor of the same diameter as the connecting rod small end and at least 100 mm long, and insert the arbor through the connecting rod small end. o With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connect rod bend. *If connecting rod bend exceeds the service limit, the connecting rod or crankshaft must be replaced.

Connecting Rod Bend Standard: Under 0.05/100 mm Service limit: 0.2/100 mm

â&#x20AC;˘ Measure connecting rod twist. o With the crankshaft still in the alignment jig, hold the connecting rod horizontally and measure the amount that the arbor varies from being parallel with the crankshaft over a 100 length of the arbor to detennine the amount of connecting rod twist. *It connecting rod twist exceeds the service limit, the connecting rod or crankshaft must be replaced.

Connecting Rod Twist Standard: Under 0.15/100 mm Service limit: 0.2/100 mm

7-12 ENGINE BOTTOM END

Connecting Rod Big End Radial Clearance .Check big end radial clearance. O Set the crarikshaft in an alignment jig or on V blocks, and place a dial gauge against the connecting rod big end.

o Push

the connecting rod first towards the gauge and then in the

opposite direction. The difference between the two gauge readings in

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: 0.038 - 0.049 mm Service Limit: 0.10 mm

Connecting Rod Big End Side Clearance eMeasure big end side clearance [AJ . o Insert feeler gauges between the big end and either crank 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 Service Limit: 0.8 mm

Crankshaft Main Bearing Wear eWash the bearings in high flash-point solvent, blow them dry ( DO NOT SPIN THEM) , and lubricate them with engine oil. AWARNING 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", 2S psi) maximum nozzle pressure .

â&#x20AC;˘ Turn each bearing over by hand and see that it makes no noise, turns smoothly, and has no rough spots. If any of the bearings are defective, replace them.

ENGINE BOTTOM END 7-13

Crankshaft Runout â&#x20AC;˘ Check crankshaft alignment by measuring run out. O With the crankshaft on V blocks [AJ. rotate the crankshaft slowly and measure runout at each of the locations shown. If the run out at any point exceeds the service limit, the crankshaft must be either replaced or rebuilt.

Crankshaft Runout (Either location) Standard : Under 0.04 mm TIR Service limit: 0.10 mm TIR

Crankshaft Assembly Specifications If the crankshaft is disassembled, use th ese specifications during rebuilding.

O. 4S-- 0 . 5 5 mm

9 1 . 5 mm

COOLING AND BILGE SYSTEMS 8-1

Cooling and Bilge Systems Table of Contents

Exploded View ... .. ............. .................................................... .. .. ........ ........... .. .............8-2 Bilge System ................................................................................................................8-3 Breather Removal .................................................................... ........ ...................8-3 Breather Installation .......... ....................... ... ... .. .. .. ...............................................8-3 Breather Cleaning and Inspection .......... ... ... ........ ..............................................8-3 Filter Removal ....................... ....... ... ............... .. ...................................................8-3 Filter Cleaning and Inspection ...........................................................................8-3 Cooling and Bilge System Hoses .................................. .............................................8-4 Hose Removal ....... .............................. ........... .. ... ................................................8-4 Hose Installation ......... .... ......... ................... ........................... .............................8-4 Hose Inspection ............ ........... .. .................... .. ......................... ..........................8-4 Cooling and Bilge System Flushing ................................................ .......................... .8-5 Cooling System Flushing ................................................................................ .. .8-5 Bilge System Flushing ........................................................... .............................8-5

8-2 COOLING

Exploded View

AND BILGE SYSTEM!S_ _ _ _ _

_=====;=

N'm (1.0 kg·m, 87 in·lb) Tl : 9.8 ' one sealant. SS: Apply 51'1 Ie

()

COOLING AND BILGE SYSTEMS 8-3 Bilge System

Breather Removal • Pull the hoses off the breather. • Remove the electric case (see the Electrical System chapter) . • Unscrew the mounting bolt [A] , and remove the breather [B] from the bracket.

Breather Installation .Be sure the small hole [A] in the breather is open before installing it.

Breather Cleaning and Inspection • Check that the small hole in the top of the breather is open by blowing in one end of the breather and plugging the 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 well as it should.

Filter Removal • Remove the electric case (see the Electrical System) . • Remove the mounting screws [A] and take out the filter [B] .

Filter Cleaning and Inspection .Flush the filter thorough with fresh water and shake it dry . • Water must flow freely through the filter, but large debris must not. *If the filter cannot be cleaned, or if it is broken and allows debris to pass through, replace it.

8-4 COOLING AND BILGE SYSTEMS Cooling and Bilge System Hoses Hose Removal .None of the bilge system hoses has a clamp. To remove this hose, remove the filter (see Filter Removal). The bilge system hoses without clamps may be simply pulled off their finings . â&#x20AC;˘ AII the cooling system hoses are clamped at both ends. Loosen the clamps and pull the hoses off.

Hose Installation eTa install the bilge filter hose, push the hose over the end of the filter. â&#x20AC;˘ When installing the cooling system hoses, be sure to use the same kind of clamp as the original. Some of the clamps are metal for tighter clamping ability (required when smooth fitting are used). Plastic clamps are used where tight clamping is not required.

Hose Inspection .Check the hoses for hardening, cracking, checking, cuts, abrasions, and breaks. If a hose is damaged in any way, replace it immediately and check all the other for damage.

COOLING AND BILGE SYSTEMS 8-5 Cooling and Bilge System Flushing

Cooling System Flushing To prevent sand or salt deposits from accumulating in the cooling system, it must be flushed occasionally_ Flush the system according to the Periodic Maintenance Chart, after each use in salt water, or whenever there is reduced water flow from the bypass outlet on the left side of the hull. eRemove the fitting cap [Aj on the cylinder head.

eConnect a garden hose [Aj to the fitting .

• 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, resuUing in the possibility of severe internal damage . • Immediately turn on the water an adjust the flow so that little trickle of water comes out of the bypass outlet [AJ on the left side of the hull .

• Left the engine idle for several minutes with the water running. eTurn off the water. Leave the engine idling . • Rev the engine a few times to clear the water out of the exhaust system.

CAUTION Do not run the engine without cooling water flowing for more than 15 seconds. Overheating will cause severe engine and exhaust system damage . • Switch off the engine. remove the garden hose. install the fitting cap.

Bilge System Flushing To prevent clogging. the bilge system should be f lushed out accord ing to the Periodic Maintenance Chart. or whenever you suspect it is blocked. eDisconnect both bilge hoses at the plastic breather fitting [Aj .

8-6 COOLING AND BILGE SYSTEMS

.Connect the bilge filter hose (from the hull bottom) to the garden hoses, turn the water on, and flush it out for about 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

• Connect the other hoses (from the hull bulkhead) to the garden hose, turn the water on, and flush it out fot several minutes.

• Before reconnecting the hoses to the plastic breather fitting make sure the small hole [AJ, on top of the breather fitting is clear. • Reconnect the bilge hoses.

DIRECTION OF COOLING SYSTEM FLOW DIRECTION OF BILGE SYSTEM FLOW DIRECTION OF COMBINED EXHAUST AND COOLING WATER FLOW

DRIVE SYSTEM 9-1

Drive System Table of Contents

Exploded View ... .... ..... ..... ... .. ......................... ............................................................. 9- 2 Specifications ................... ............................. ......... .............. .......................................9-3 Drive Shaft/ Drive Shaft Holder ...................... ............. .. .. ....... ............... .. .............. .. .... 9-4 Drive Shaft Removal / Installation .................. ................... .................................. 9-4 Drive Shaft Holder Removal/ Disassembly .................. ....................................... 9-4 Drive Shaft Holder Assembly/ Installation ... ....................................................... 9-5 Drive Shaft Runout .............................................................................................9-5

9-2 DRIVE SYSTEM Exploded View

T1: 39 N-m (4.0 kg-m', 29 ft-Ib) T2 : 22 N-m (2.2 kg-m. 16.0 ft-Ib) L :Apply a non-permanent locking agent. G : Apply grease. 55: Apply silicone sealant.

DRIVE SYSTEM 9-3 Specifications Standard

Item Drive Shaft: Runout (Refer to Page5)

[AJ less than 0.1 mm [BJ less than 0.2 mm

Special Tools - Coupling Holder: 57001 -1230 Drive ShaH Holder: 57001-1327 Drive ShaH Holder Adapter: 57001 -1231 Bearing Driver Set: 57001-1129 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit 0.2mm 0.6mm

9-4 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft Removal/Installation • Remove the engine (see Engine Removal/Installation chapter). • Lifting the fuel tank [AJ , pull the drive shaft [BJ out of the hull.

.Clamp the drive shaft, and unscrew the coupling. Special Tools - Coupling Holder: 57001-1230 [AJ Drive Shall Holder: 57001-1327 [BJ Drive Shaft Holder Adapter: 57001-1231 [CJ

.When installing the drive shaft, be careful of the following items. OApplya thin coat to the coupling threads and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Coupling: 39 N-m (4,0.kg-m, 29 ft-Ib)

OApply grease to the grease seal lips and the drive shaft spline.

Drive Shaft Holder Removal/ Disassembly • Remove the drive shaft . • Unscrew the mounting bolts [A] and remove the drive shaft holder [BJ from the bulkhead.

• Disassemble the drive shaft holder. [AJ.

o Remove the circlip

® @

DRIVE SYSTEM 9-5

o Press the small grease seal, and t he large grease seals, bearing. and small grease seals come out of the holder.

Press

A Sl eeve B. Blocks

Drive Shaft Holder Assembly/lnstal/ation • Replace the grease seals w ith new ones. • Press the bearing and grease seals into the drive shaft holder, noting the following. o Inst all the parts in this order: Two Small Grease Seals [AJ One Bea ring [BJ Two l arg e Grease Seals [CJ

Special Tool - Bearing Driver Set: 57001-1129 o Install the seals so that the sides with the spring face outward.

o Fill the gaps between the seals w ith grease [DJ . • Install the ci rclip . • Grease to the bearing inner surface and grease seal lips .

• Install the drive shaft holder on the bulkhead so t hat the circlip side face toward the front. .Apply a non-permanent locking agent to the drive shaft holder mounting bolts, tighten them loosely . • Install the drive shaft. • After installing the engine, tighten the drive shaft holder mounting bolts to the specified torque to give proper coupling alignment.

Torque - Drive ShaH Holder Mounting Bolts: 22 N-m (2.2 kg-m, 16.0 H-Ib)

Drive Shaft Runout • Measure drive shaft runout by supporting the shaft on V blocks and setting a dial gauge again st the shaft at each point shown. .Turn t he 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 [ AJ Less than 0.2 mm [BJ Service Limit: 0.2 mm [AJ 0.6 mm [BJ

~;~±~:~

PUMP AND IMPELLER 10-1

Pump and Impeller Table of Contents

Exploded View .............................. .. .......................................................................... 10-2 Specifications .................................................................................... ........................ 10-3 Pump and Impeller ........... ................... ...................................................................... 10-4 Pump Removal ........ ................................................................... ...................... 10-4 Pump Installation ................................................. ................. .............. .............. 10-4 Pump Disassembly ................................ .. ............................................ ............. 10-5 Pump Assembly .......... ........................... ............................... .............. ....... .. .....10-7 Pump and Impeller Inspection ...... ......................................... .......................... 10-8 Impeller Clearance ............................................................................................10-9

10-2 PUMP AND IMPELLER Exploded View

Tl: T2: T3: T4:

6.9 N·m (0.7 kg·m, 61 in· lb) 9.8 N·m (1.0 kg·m, 87 in-Ib) 22 N·m (2.2 kg·m , 16.0 It·lb) 98 N-m (10.0 kg·m, 72 It-Ib) SS: Apply silicone sealant. G : Apply grease. L : Apply a non-permanent locking agent.

T2 tJ;)

PUMP AND IMPELLER 10-3 Specifications Standard

Item Jet Pump: Impeller Outside Diameter Pump Case Inside Diameter Impeller Clearance

139.5 - 139.6 mm 140.0 - 140.1 mm 0.2 - 0.3 mm

Special Tools - Impeller Wrench: 57001-1228 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set 57001-1129 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit 138.5 mm 141 .1 mm 0.6 mm

10-4 PUMP AND IMPELLER Pump and Impeller Pump Removal .Turn the craft on its left side . • Unscrew the mounting bolts [AJ, and remove the grate [B] and the pump cover [C] .

• Slip the steering cable connector [A] off the ball. • Loosen the clamp, and pull off the hoses [B] .

• Unscrew the pump mounting bolts [A] .

• Slide the pump to the rear to disengage the drive shaft, and remove it from the hull.

Pump Installation .Grease the splines on the drive shaft with water resistant grease, and be sure the O ~ r;ng is in place inside the pump shaft . • Be sure the trim seal [A] is in place.

PUMP AND IMPELLER 10-5

. When installing the pump case [AJ. be careful that the trim seal [B] ;s stayed in place. o If necessary, apply water or oil to the surface of the trim seal.

NOTE ONo need to apply silicone sealant between the pump (trim seal) and the hull.

• When installing the drive shaft [A] . fit the drive shaft into the spline of the impeller such that no clearance [B] exist between the shaft end and the spacer [C] (material: rubber).

(CLOSE f i T) ( CLOSE f i T)

.Apply a non-permanent locking agent to the pump mounting bolts

and torque them. Torque - Pump Mounting Bolts: 22 N-m (2.2 kg-m, 16.0 ft-Ib)

• Connect the hose and steering cable .

• Install the pump cover [A] and the pump grate [ B] . OApply a non -permanent locking agent to the following bolts and torque them. Torque - Pump Cover Mounting Boits: 6.9 N-m (0.7 kg-m, 61 in-Ib) Grale Mounling Bolts: 9.8 N-m (1 .0 kg-m, 87 in-Ib)

Pump Disassembly .Unscrew the mounting bolts [A] . and remove the steering nozzle [B].

10-6 PUMP AND IMPELLER

• Unscrew the mounting bolts [AJ, and remove the pump outlet [8J.

• Unscrew the cap bolts [AJ, and remove the pump cap [8J.

• Hold the shaft in a vise, taking care not to damage it. Remove the impeller from the pump shaft and then pull out the pump shaft. Special Tool - Impeller Wrench: 57001-1228 [AJ

• Pull outthe bushing [AJ.

• Remove the grease seals. Special Tool - Oil Seal & Bearing Remover: 57001-1058 [AJ

PUMP AND IMPELLER 10-7

• Remove the pump bearings. A. Pump Case B. Bearing C. Collar

o Press the rear pump bearing into the pump case as far as it will go. o Insert the collar and install the front pump bearing .

• Replace the grease seals with new ones, if necessary, and install them using the same special tool used for bearing installation. o Press each seal into the pump case so that the side with the spring faces outward. Fill the gap between the seal with grease. • Push the bushing into the pump case . • Visually inspect the pump shaft O~rings , and replace them if necessary. • Grease the pump shaft and insert it from rear of the pump case . • Screw on the impeller. Torque - Impeller: 98 N-m (10.0 kg-m, 721t-lbj

.Visually inspect impeller grease seal [AJ, and replace if necessary. o When installing the grease seal, pack grease inside it.

• Be sure the O-ring [A] in place on the pump cap. A

10-8 PUMP AND IMPELLER

• Install: Pump Cap Pump Outlet Steering Nozzle .Applya non-permanent locking agent to the thread of the following. Pump Cap Bolts Pump Outlet Mounting Bolts Steering Nozzle Pivot Bolts

Torque - Steering Nozzle Pivot Bolts: 9.8 N-m (1.0kg-m, 87 in-Ib)

Pump and Impeller Inspection • Examine the impeller. *If there is pitting [AJ, deep scratches [B] , nicks [C] or other damage, replace the impeller.

NOTE

o Minor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing. Smooth leading edges are especially

important to avoid cavitation.

o Measure the impeller outside diameter. *If the impeller is worn smaller than the service limit, replace it.

Impeller Outside Diameter Standard: 139.5 - 139.6 mm Service limit: 138.5 mm

• Examine the pump case [A] .

* If there are deep scratches inside the pump case, replace it.

o Measure the inside diameter of the pump case. If the pump case is worn beyond the service limit, replace it.

Pump Case Inside Diameter

Standard: Service limit:

140.0 - 140.1 mm 141.1 mm

PUMP AND IMPELLER 10-9

Impeller Clearance â&#x20AC;˘ Impeller clearance is critical to proper performance. If the pump case and impeller are not visibly damaged, poor performance may be caused by too much impeller clearance. eTo check impeller clearance, remove the grate and insert a feeler gauge [A J between the tip of the impelier blade [BJ and the pump case

[C] . Impeller Clearance Standard: 0.2 - 0.3 mm

Service limit:

0 .6 mm

*If impeller clearance is incorrect. determine if it is due damage (see Pump and Impelier Inspection).

to wear or

HANDLE POLE AND HANDLEBAR 11-1

Handle Pole and Handlebar Table of Contents

Exploded View ..................................... ................................ ..................................... 11-2 Steering Cable ............................. .................................... ... ................ ....................... 11 -3 Adjustment ..... ........ .. ....... .... ......... ........................ ........................................ ... .. 11 -3 Removal ............... ......... ........... ..................... ..... ................. ..............................11-3 Installation Notes ..................... .... ......................................................... ............ 11-5 Inspection ................................. ........... ... ....... ................................................... 11 -5 Lubrication ... ..... .................. ............... ................... .... ... ..................................... 11-6 Handlebar .... .............................. ...................................... ..... ....... .............................. 11 -7 Hand Grip Removal/Installation ..................... ................................................. 11-7 Handlebar Removal .... ..... .................. ....................................... ........................11-7 Handlebar Installation Notes ........................ ....................... ....... .............. ........11-8 Handlebar Steering Pivot Maintenance ........... .... ............ .. ..............................11-9 Handle Pole and Bracket .........................................................................................11-11 Removal ........................................ ......................................... ......................... 11-11 Installation Notes ...................... ...................................................................... 11-12

11-2 HA NDLE POLE Exploded View AND HANDLEBAR L : Appl y a non-perm

:~::~::--==================;;=-~--------------

: Apply T anent lock· T1 : 13 N 51 ,cone sealant 'ng agent. SS -m (13k . T2: 18 N-m (1 -8 g-m, 9.5 ft-Ib) T3 : 19 N-m (1 :9 ~!rm, 13.0 ft-Ib) T4: 38 N-m (39 g m, 13_5 ft-Ib) T5: 33 N-m (3· 4 ~g-m, 28 ft-Ib) . !rm, 25 ft-Ib)

HANDLE POLE AND HANDLEBAR 11-3 Steering Cable

Adjustment .Check steering cable adjustment.

o Lower the handle pole and center the handlebar in the straight-ahead position.

eCheck that the steering nozzle is centered [A] in the pump cavity.

elf necessary adjust the steering cable. the handle pole and loosen the locknut [A] on the steering cable. o Disconnect the ball joint by sliding the outer sleeve [B] away from the ball [C] slightly, and lifting the cable from the ball. o Turn the ball joint on the cable to adjust the steering. o Connect the ball joint and check cable adjustment again.

o Raise

a When adjustment is correct. tighten the steering cable locknut.

Removal â&#x20AC;˘ Remove: Handlebar Pad Handlebar Pole Cover [A]

â&#x20AC;˘ Disconnect the ball joint at each end of the steering cable. O Slide the outer sleeve [A] away from the ball slightly, and lift the cab le from the ball.

CAUTION Never lay the watercraft on the right side.

Water in the exhaust

system may drain back Into the engine, causing serious damage.

11-4 HANDLE POLE AND HANDLEBAR

.Loosen the locknut [A], and then remove the ball joint [B] and locknut from each cable end.

• Disconnect the steering cable from the cable holder on the handle

pole.

o Unbolt the cable holder [A] .

• Remove the pump cover (see Pump Removal in the Pump/Impeller chapter). • Disconnect the steering cable from the fining at the rear of the hull.. o Unscrew the large nut [A] while holding the fining [B] in the hull with a wrench.

O Slide off the snap ring [AJ. washer [B] , and O-ring [C] .

• Remove:

Fuel Tank Water Box Muffler .Pull the cable from cable detents in the engine compartment. • Remove the cable by carefully pulling rear section [A] of the cable through the hull.

HANDLE POLE AND HANDLEBAR 11 - 5

.Push the rear end of the inner cable [A].

• Lay the handle pole a little rearwards, and remove the cable by carefully pulling the front section of the cable [A] through the handle pole.

Installation Notes .The protective sheath [A] and tape [B] around the steering cable goes toward the front of the watercraft, to protect the cable where it enters

the handle pole. • Lubricate the outside of the new cable to ease cable installation.

Inspection • Examine the steering cable.

*If the cable or cable housing is kinked [A] or frayed [B] , replace the cable.

*If the seal [A] at either end of the cable is damaged in any way, replace the cable.

11-6 HANDLE POLE AND HANDLEBAR

â&#x20AC;˘ Be certain that the cab le moves freely in both directions. o Disconnect the ball joint at each end of the steering cable. O Slide the outer sleeve [AJ away from the ball slightly, and lift the cable from the ball.

CAUTION Never Jay the watercraft on the right side. Water in the exhaust system may drain back into the engine causing serious damage.

o Slide the inner cable back and forth in the cable housing .

If the cable does not move freely, replace it.

Lubrication NOTE

o The.

steering cable is sealed at each end and does not require

lubrication. If the seals are damaged, the cable must be replaced.

HANDLE POLE AND HANDLEBAR 11-7 Handlebar Hand Grip Removal/Installation .The hand grips are bonded to the handlebar. To remove them, cut the

grips lengthwise with a sharp knife and peel [A] them off the bar.

AWARNING 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 .

• Apply an adhesive to the inside of grip . • Slide the grip into position on the handlebar.

Handlebar Removal • Remove:

Handlebar Pad Mounting Screws [A] Handlebar Pad [B] Throttle Case Bolts [C] Throttle Cases [0] Switch Case Screws [E] Switch Cases [F]

11-8 HANDLE POLE AND HANDLEBAR

• Remove or disconn ect

Steering Cable Ball Joint [AJ Wiring Clamps Screw [BJ Wiring Clamps [C]

• Remove the cotter pin [AJ and take the nut [BJ off the steering pivot stud. • Remove the handlebar with the handlebar plate from the handle pole.

• Remove the pad, and take out the screws [AJ and separate the handlebar from the handlebar plate [BJ.

Handlebar Installadon Notes .Applya non-permanent locking agent to the handlebar clamp screws and torque them. Torque - Handlebar Clamp Screws: 18 N-m (1.8 kg-m,13 ft-Ib)

• Grease the steering pivot thoroughly, and tighten the nut to allow the handlebar turn smoothly without play. Use a new cotter pin .

• Apply a non-permanent locking agent to the following and tighten them securely.

Wiring Clamp Screw Switch Case Screws Throttle Case Bolts

HANDLE POLE AND HANDLEBAR 11-9

Handlebar Steering Pivot Maintenance elf the steering pivot feels loose or overtight, the pivot may need lubrication or the bushings may need to be replaced . • Remove or disconnect:

Handlebar Pad Wiring Clamps Screw [A] Handle Pole Float [B] Steering Cable Ban Joint [C] Coner Pin [0] Steering Pivot Nut [E] • Remove the handlebar with the handlebar plate from the handle pole.

.Take out the screws [A] . and remove the handle pole cover [8] .

• Take out the mounting bolts [A]. and remove the steering support bracket [8] .

• Separate the nylon bushings [A] from the support bracket and the handlebar plate.

11-10 HANDLE POLE AND HANDLEBAR

• Clean the steering pivot stud [A] and check the surface for corrosion

and wear. If the stud is corroded or noticeably worn, replace it.

• Remove the stud from the steering support bracket

NOTE

o The stud and nut are installed with

a locking agent If necessary, heat the nut and stud with a torch to make removal easier,

.Clean the threads in the support bracket thoroughly and install the new

stud with a locking agent and tighten it to the specified torque. Torque - Steering Pivot Stud: 38 N-m (3.9 kg-m, 28 fI-lb)

.Check the bushings [Al for damage and wear. If the bushings are damaged or worn, replace them .

• When reassembling the steering pivot, be sure to grease [Al the new bushings well.

.Tighten the steering pivot nut so that the steering action is smooth but nut loose.

NOTE

o The steering pivot nut usually needs to be readjusted aher the first few hours of u,se after lubricating the steering bushings. The squeezes out of the bushings a little, and the steering feels 100S8. • Apply a non-permanent locking agent to wiring clamp screw and tighten it securely.

HANDLE POLE AND HANDLEBAR 11-11 Handle Pole and Bracket

Removal • Remove: Fuel Tank Thronle Cable Handlebar Switch Case and Wiring Steering Cable Steering Support Bracket [AJ Pad [BJ

.Take out the bolts [AJ holding the bracket to the hull.

oG • Remove the bracket [AJ with the handle pole [8J .

• Take off the handle pole pivot nut [AJ . • Unscrew the pivot bolt [BJ, and lift the handle pole out of the bracket. Two nylon washers will fall out.

• Remove the handle pole spring.

11-12 HANDLE POLE AND HANDLEBAR

Installation Notes .Grease the nylon washers with water resistant g"rease . â&#x20AC;˘ Install the handle pole pivot bolt and tighten to the specified torque before putting on the nut. Be sure the handle pole moves up and down smoothly before continuing. If it does not, decrease the pivot bolt torque slightly. Torque - Handle Pole Pivot Bolt: 13 N-m (1.3 kg-m , 9.5 fI-lb) Handle Pole Pivot Nut : 33 N-m (3.4 kg-m, 25 fI-lb)

.Clean the mating surfaces of the bracket and hu ll. .Torque the handle pole bracket bolts. Torque - Handle Pole Bracket Bolts: 19 N-m (1.9 kg-m,13.5 fI-lb)

HUll/ENGINE HOOD 12-1

Hull/Engine Hood Table of Contents

Exploded View ............. .............................................................................................12-2 Pads .................... ........................................................................ ........ ..................... .. 12-4 Hull Replacement.. ....................................................................................................12-5 Rubber Parts ....................................................................................... ....................... 12-6 Bumper Removal ............................................................................................ ..12-7 Bumper Installation Note .................................................................................12-8

12-2 HULL/ENGINE HOOD Exploded View L : Apply a non-permanent locking agent. SS : Apply sil icone sealant.

HUll/ENGINE HOOD 12-3

.:r",,~ .... "

'.J

12-4 HULL/ENGINE HOOD Pads

CAUTION Do not remove the pads unless it is absolutely necessary. because

the screw holes in the hull or pad frame may be damaged by removal.

When installing the pads, be careful not to overtighten the self~tapping

screws .

â&#x20AC;˘ Remove: Rear Bumpers

Plugs [AJ Mounting Screws [ BJ Rivets [CJ

elf the handle pole pad [AJ is to be removed, remove the steering support bracket.

elf the control panel [AJ is to be removed, remove the following parts. Fuel Tap Knob [BJ Choke Knob [C] Engine Hood Latch [ DJ Mounting Screws [EJ

HULL/ENGINE HOOD 12-5 Hull Replacement eTa replace the hull. remove the following .

Battery and Pad Pump and Hoses

Handle Pole with Bracket Intake Silencer Carburetor Exhaust Pipe, Front Muffler, and Expansion Chamber

Electric Case Water Box Muffler Engine and Mounts

Oil Tank Fuel Tank Drive Shaft and Shaft Holder Control Cables Engine Hood Latch Bilge Breather Bilge and Cooling Hose Fuel Filler Bypass Hose and Outlet Cable Detents Fuel Hose Holder Bumpers The following parts cannot be removed from the hull and must replaced. Decals Labels Registration Number (if any) If the new hull is to be painted, do that first. Then install the parts removed in the reverse order of their removal. Finally, install the labels, decals, mats and the registration numbers.

12-6 HULL/ENGINE HOOD Rubber Parts NOTE

o The rubber parts on the watercraft are fastened in place with various adhesives. To replace a rubber parts, use a cement in the following

table, or an equivalent. AWARNING Read all warnings and cautions on any solvents and adhesives used. Many of these products are lIammable, 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 tryis Application:

Type

Mat Eng ine Hood Gasket Water Box Muffler Damper

Synthetic Rubber Adhesive PI N: 92104 -3701

Detents Handlebar Grips Handle Pole Bracket Damper

Cyanoacrylate cement

CAunON Be very careful that the part is positioned correctly when you apply the cement. It may be impossible to reposition the part.

AWARNING 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! "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.

Rubber Parts Location Mat [AJ

HULL/ENGINE HOOD 12-7

Engine Hood Gasket [BJ

Water Box Muffler Damper [C)

Handle Pole Bracket Damper [OJ

Detent [EJ

Bumper Removal The bumper are consists of five-piece, they are attached firmly to the

hu ll with nuts . â&#x20AC;˘ Unscrew the mounting nuts, and remove the following. Front Bumper [AJ Rear Bumpers [BJ Side Bumpers [C) .

12-8 HULL/ENGINE HOOD

Bumper Installation Note .Applya non-permanent locking agent to all the nuts and tighten them securely_

HUll/ENGINE HOOD 13-1

Electrical System Table of Contents

Wiring Diagram ............ .................................. ........ .13-2

Exploded View ................................................... .... .13-3 Specifications ............................ .............................. 13-5 Battery ......................................... ..................... ....... 13.6 Precautions ............................ ........ ............... .13-6

Removal ................................................. ........ 13-6 Installation ......................................................13-6 Battery Cleaning ... ......................................... 13-7 Electrolyte Level Inspection ...... ... ......... ......... 13-7 Condition ...................... ................................. 13-7 Initial Charging .............................................. 13-8 Ordinary Charging .......................... ............... 13-9 Test Charging .................. ... ..................... .... 13-10 Electric Starter System ..........................................13-11 Starter Relay: ................................. ................... 13-11 Removal .............................................. ......... 13-11 Installation Notes ......................... ... ...... .... ... 13-11 Inspection ......................... ........................... 13-12 Reduction Gear: ........ .... ............. ... ................. ... 13-12 Removal/Installation Notes ......................... 13-12 Inspection .. .................................................. 13-12 Starter Motor: .............................................. ..... 13-13 Removal ... ........... ........ .......... ... .................... 13-13 Installation Notes ........ ......... ........................ 13-13 Disassembly .................................. ............... 13-13 Assembly ......... .... .... .. .. ........ .. .............. ......... 13-14 Brush Inspection ............................. ... ......... 13-15 Brush Spring Inspection .............................. 13-15 Commutator Cleaning and Inspection .... .. ..13-15 Armature Inspection ... .................................13-16 Brush Plate Inspection ................................ 13-16 Brush and Lead Assembly Inspection ........ 13-16 Charging System .......... .... .. .. ................................. 13-17 Charging Coil Testing ..................................13-17 Regulator/ Rectifier Removal ....................... 13-18 Regulator/ Rectifier Installation Notes ......... 13-18 Regulator/Rectifier Inspection ..... ,.............. 13-18 Ignition System ................................... ........... ....... 13-19 Pickup Coil Inspection ......... ...... .... ..... ........ 13-19 Ignition Coil Removal. ................................. 13-19 Ignition Coil Installation Note ....... ..... ......... 13-19 Ignition Coil Inspection .. ........ ... ..... ......... ....13-20 COl Igniter Removal ....................................13-21 COl Igniter Installation Notes ...................... 13-21 IC Igniter Inspection ....................................13-21 Spark Plug Removal ... ... .. ... ..... ...... ..... ..... .... 13-22 Spark Plug Installation ................................13-22

Spark Plug Inspection ..... .... ....... ... .............. 13-22 Spark Plug Cleaning ...........................c•••••••• 13-22 Spark Plug Adjustment ....... .... ... ................. 13-23 Electric Case .......................................................... 13-24 Removal ............................ .......... ..... .13-24 Installation Notes ....... ........... ... .................... 13-24 Disassembly ............... ..................................13-25 Assembly Notes ........................................... 13.25 Switches and Sensors ......... ........... ....................... 13-26 Start/ Stop Switch Removal ........................ 13.26 Start/Stop Switch Installation Notes .......... 13-26 Start/Stop Switch Inspection ..................... 13-27 Temperature Sensor ................... .. .. ... .................... 13-28 Temperature Sensor Removal ..................... 13-28 Temperature Sensor Installation Notes ....... 13-29 Temperature Sensor Inspection .................. 13-29 Fuse ......... .................. ....... ... ........... ... ..... ...... ... ... ... 13-30 Inspection ................................................... .13-30

...

~ W, :::!,

(,Q

m rm iii' (') (,Q i 1 -I C

--- ... ----, r--+----{BR

5. Magneto 6. SOBrk Plug

7. 8. 9. 10 . 11. 12. 13.

(j)

CD CD

® CD

1. Start SW Itch 2. stop Switch 3. Temperature Sensor 4. COl Igniter

r Qn ,1t Ion Co I I Regulato r /Rectifier (lOA)

Fuse

Starter Relay Battery

starter Motor Case

Electric

wire COlor code

BK BR G

B l ack

Brown Green

Blue

Orange

Purple

Wh I

Red

(98051-3709C)C

::0 (') ~

C/)

-I m

ELECTRICAL SYSTEM 13-3 Exploded View

1. lOA Fuse 2. 3 . 4. 5.

COl Ignote'. Ignition COil Starter Relay Regulator I Rectifier

~i~lb) (0 8 kg·m, 20 Tl : 7.8 N·m. ft.lb) L . Apply a non p

~ '-fP"

13-4 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM 13-5 Specifications Standard

Item Battery: Type Specific gravity of electrolyte

12V19Ah ' 1.280 @20"C (6S"F)

Electric Starter System: Starter motor: Brush length Commutator diameter

12.5 mm 2Smm

Charging System: Regulator/ rectifier output voltage Charging coil output voltage Charging coil resistance: Brown +--+ Brown

Ignition System: Ignition timing Ignition coil : Primary winding resistance Secondary winding resistance Spark plug: Type Gap Pickup coil resistance Start/ Stop Switch : Start button : Released Depressed Stop button: Released Depressed

Special Tools - Hand Tesler (Y. O. M): 57001·983 Coil TeSler: 57001·1242

Service Limit

---

--6.5mm 27mm

Battery voltage - 14.5 ±05 V 20V

-----

0.7 - 1.1 0

---

13" BTDC @1,250 r/ min (rpm) 16" @2,500 r/ min (rpm)

---

0.08 - 0.10 3.5 - 4.7 kO

---- -

NGK BRSES 0.7 - 0.8 mm 396 - 594 0

--- ----

000 Almost 00

--- --

roO Almost 00

---- -

13-6 ElECTRICAL SYSTEM Battery

Precautions Following a few simple rules will greatly extend the life of the battery. O When the level of the electrolyte in the battery is low, add only distilled water to each cell, until the level is at the upper level line marked on the outside of the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery. o Never add sulphuric acid solution to the battery. This will make the electrolyte solution too strong and will ruin the battery within a very short time. O Avoid quick-charging the battery. A quick-charge will damage the battery plates. o Never let a good battery stand for more than 30 days without giving it a supplemental charge, and never let a discharged battery stand without charging it. If a battery stands for any length of time, it slowly self-discharges. Once it is discharged, the plates sulphate (turn white) , and the battery will no longer take a charge. o Keep the battery well-charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged the battery becomes, the more easily if freezes. O DON'T INSTALL THE BATTERY BACKWARDS. The negative side is grounded.

Removal .. WARNING Battery electrolyte contains sulphuric acid which is poisonous and causes severe burns. When installed in the battery, electrolyte generates hydrogen gat! which under certain conditions if flammable and explosive. Keep all flames and sparks (cigarettes, etc.) away and always wear eye protection when working on or near the battery.

• Disconnect the battery cables.

To prevent possible personal injury and damage to components, always disconnect the grounded cable first.

.Unhook the battery straps [AJ . • Carefully lift the battery from the engine compartment.

Installation .Be sure the battery damper [AJ is in position in the battery compartment. • Place the battery in position .

o Install the battery with positive (+ ) terminal toward the bow (forward). • Hook the battery straps . • Connect the battery cables, positive first.

OAfter attaching both cables, coat the terminals and cable ends with grease to prevent corrosion. o Slide the protective boot over each terminal.

ELECTRICAL SYSTEM 13-7

Battery Cleaning • Remove the battery from the hull (see Battery Removal) . • Clean off the battery using a baking soda~and-water solution. o Mix one heaping tablespoon of baking soda in one cup of water. o Be careful not to get any of the cleaning solution in the battery. OThe terminals must be especially clean . • Rinse the battery with clean water.

Electrolyte Level Inspection • Remove the battery . • Visually check the electrolyte level [A] in the battery. If the level of electrolyte in any cell is below the lower level line on the battery case, add distilled water only to that cell. • Install the battery.

...

.a.

~ ,

Condition • Before charging, check battery condition by testing the specific gravity of the electrolyte in each cell. o Draw a little fluid from the cell with a hydrometer[A] . o Read the level of the electrolyte [B] on the floating scale. This is the specific gravity of the electrolyte .

• Look for sediment [A] and white su llation [B] inside the cells.

·B

.See the Battery Troubleshooting Guide in Battery Test Charging.

* If the specific gravity is below 1.2BO the battery needs to be charged. NOTE

o The

specific gravity of the electrolyte varies with changes in temperature, so the specific gravity reading must be corrected for the

temperature of the electrolyte.

o Celsius: Add 0.007 points to reading for each

1(J'C above 2(J'C or subtract 0.007 points for each I(J'C below 2(J'C. o Fahrenheit: Add 0.004 points to reading for each 10"F above 68"F or subtract 0.004 points for each I(J'F below 68"F.

...

13-8 ELECTRICAL SYSTEM

* *

If the specific gravity of any of the cells is more than 0.050 away from any other reading , the battery will probably not accept a charge. It is generally best to replace a battery in this condition . . If the specific gravity of all the cells is 1 .280 or more the battery is fully charged .

Battery Charging RalelTlme Table (12 V 50 Ah) 1.280 1.28 ~ully Charged 1.24 -

:::

'> ~ ~

1 .201.1 6 - 1.1 40

'-'u

1.12 -

1.08

1.04

;;:

"c.

--- -- Sample

- -

at 3A charge rate

; ~~ i", .".. .. . ..

,'J-," . . . .

.. I· .· · . . l ' ...... .. _1 080 - :,: 21 - 26 -J . '._ .. - - --.-Totally discharged: ... . Hours " . .

:W-: . .:~:

1.00 at 2A c;harge rate

-- ~

15 10

at 4A charge ra te

25 15

at SA charge rate

. 30

Before being placed in service, a new battery should be given an initial charging . • Fill each cell to the upper level line on the battery case with fresh electrolyte at a temperature of 30"F (86"F) or less. Let the battery stand about 30 minutes before charging.

NOTE

o If the

electrolyte level drops, add electrolyte to the upper level line before charging.

• Leaving the caps off th e cells, connect the battery to a charger, set th e ch arging rate at1 / 1 0 the battery capacity, and charge it for 10 hours. For example, if th e battery is rated at 50 Ah, th e charging rate w ould be 5A. AWARNING 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.

37.5

Hours of Charging T ime at Rat es Shown

Initial Charging

ELECTRICAL SYSTEM 13-9

CAUTION Do not use a high rate battery ch.arger, as it typically employed at automotive service stations, unless the charger rate can be reduced to the level required. Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher-than normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting. If the temperature of the electrolyte rises above 45°C (115°F) during charging, reduce the charging rate to lowsr the temperature, and increase charging time proportionately .

• Turn the charger off, then disconnect it from the battery . • Check battery voltage. Battery voltage should be 12 - 13 V. • Check the specific gravity of each cell with a hydrometer (see Battery Condition).

*If the voltmeter or hydrometer readings are below those specified, additional charging is necessary before the battery can be installed.

Ordinary Charging .Remove the battery from the hull (see Battery Removal) . • Clean off the battery (see Battery Cleaning) . • If any of the cells are low, fill them to the LOWER level line with distilled water only. The electrolyte will expand during charging, and the level will rise . • Connect a charger to the battery BEFORE plugging it in or turning it on. AWARNING 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 .

• Set the charge rate and time according to the battery condition previouS:ly determined (see Battery Condition) , using the table.

CAUTION 00 not use a high rate battery charger, as is typically employed at automotive service stations, unless the charger rate can be reduced to the level required. Charging the battery at a rate higher than specHied may ruin the battery. Charging at high rate causes excess heat which can warp the plates and cause internal shorting. High ~than-normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting. H the temperature of the electrolyte rises above 45°C (115°F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately .

• Turn the charger off or unplug it, then disconnect it from the battery . • Check battery condition (see Battery Condition) . *If the battery condition indicates that it is not fully charged, additional charging time is necessary.

13-10 ELECTRICAL SYSTEM

Test Charging elf the battery is suspected of being defective, sulfated, or unable to take a charge, consult the Battery Troubleshooting Guide table. eTa test charge a battery, perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below.

Battery Troubleshooting Guide

Good Battery

Suspect Battery

Action

(+) chocolate color

white (sulphated); + plates

(-) gray

broken or corroded

Sediment

none, or small amount

sediment up to plates, causing short

Replace

Voltage

above 12V

below 12V

Test charge

Electrolyte Level

above plates

below top of plates

Fill and test charge

Plates

Specific Gravity

above 1 .200 in all cells; no two

below 1.100, or difference of more

cells more than 0.020 different

than 0.020 between two cells

Replace

Test charge

ELECTRICAL SYSTEM 13-11 Electric Starter System Starter Relay:

Removal .Open the electric case (see Electric Case Disassembly). • Disconnect the starter relay switch ground lead [A] .

• Remove the nuts [A] from the battery and starter terminals on the starter relay sw itch.

• Slide the starter relay switch from the electric case, being careful not to lose any of the inSUlating washers or grommets. • Disconnect the yellow/ red and red wire connectors.

Installation Notes • Coat the insulating washers and grommets with waterproof grease. • Be certain all insulating washers and grommets are in position .

• Connect the ground lead (black) to the regulator/ rectifier mounting bolt. • Connect the battery cable to the relay (+) terminal having red lead.

13-12 ELECTRICAL SYSTEM

Inspection

.Set ohmmeter to R x 1 n scale . • Connect meter leads to starter relay as shown. *If resistance is less than infinite, the starter relay switch is not returning and must be replaced .

• Set ohmmeter to R x 1n scale. • Connect meter leads to starter relay as shown. .Activate starter relay switch by connecting a 12 V battery as shown. *11 the starter relay switch clicks and the ohmmeter indicates zero resistance. the starter relay switch is good. *If the meter indicates high or infinite (IX» resistance, the starter relay switch is defective and must be replaced.

Reduction Gear:

Removal/Installation Notes • Before removing the reduction gear, remove the magneto flywheel (see Engine Bottom End chapter) . • When installing the reduction gear, apply a molybdenum disulfide grease [A] to both ends of its shaft.

Inspection • Rotate the pinion gear [A] cou nterclockwise. The gear must be rotate freely [B].

• Rotate the pinion gear clockwise all the way. The pinion gear will be advanced along the reduction gear shaft, and stopped against the stopper [AJ . • Release the pinion gear. The pinion gear must return to the initial position rapidly. *If the pinion gear does not function properly, replace it.

ELECTRICAL SYSTEM 13-13

Starter Motor:

Removal • Disconnect: Battery Ground Cable Exhaust Pipe, Front Muffler and Expansion Chamber as a set Inlet Cooling Hose [A] Starter Motor Cable [B] eRemove the starter mounting bolts [C] and pull off the starter motor.

CAUTION Do nol tap the starter motor shaft or body. Tapping on the shaft or body could damage the motor.

Installation Notes eClean the starter motor lugs [A] and crankcase [B] where the starter · motor is grounded. eApply a small amount of engine oil to the O-ring -Apply a non-permanent locking agent to the starter motor mounting bolt threads. eConnect the battery ground cable.

Disassembly • Unscrew the retaining screws [A] and remove the both end covers .

• Pull the armature out the pinion gear end. eRemove the brush plate [A] from the leads [B] .

Yoke [C]

13-14 ELECTRICAL SYSTEM

.Remove the nut and terminal bolt [A) , and then remove the brush [B) and the plastic holder [C). Yoke [D)

Assembly â&#x20AC;˘ Install the terminal bolt as shown. Nut [A) Spring Washer [ B) Washer [C) Large Insulator [D) Small Insulator [E) Tenninal Bolt [F) O-ring [G) Plastic Holder [H)

.Install the brush plate as follows. o Install the brush plate [A) on the yoke fining the brush leads [B) into the notches [C) in the plate. Fit the brush plate tongue [D) into the yoke notch [E) .

o Insert the armature into the yoke. o Keeping the motor upright, install the brush springs [A) . Fit the spring on the spring post [B) halfway; the post must be positioned in the D-shaped end of the spring. Tum the other end of the spring a half turn clockwise [C), and fit the end in the brush groove [D). Push the spring onto the post to the stepped portion.

Brush [E)

OTo install the end covers on the yoke, align [A) the mark on the each end cover with the marks on the yoke.

ELECTRICAL SYSTEM 13-15

Brush Inspection • Measure the length of each brush.

* If any is worn down to the service limit, replace all the brushes. Starter Motor Brush Length Standard: 12.5 mm Service Limit: 6.5 mm

Brush Spring Inspection .Check that the brush springs are in place and will snap the brushes firmly into place. *If not. reinstall or rep lace the spring.

Commutator Cleaning and Inspection .Smooth the commutator surface [A] if necessary with fine emery cloth [B]. and clean out the grooves .

• Measure the diameter of the commutator. *Replace the starter motor with a new one if the commutator diameter

[A] is less than the service limit. Commutator Diameter Standard: 28 mm Service Limit: 27 mm

Armature Inspection • Using the x 1

n ohmmeter range, measure the resistance between any

two commutator segments [A].

* If there is a high resistance or no reading

(00) between any two segments, a winding is open and the starter motor must be replaced .

• Using the highest ohmmeter range, measure the resistance between

the commutator and the shaft [B] .

* If there is any reading at aU , the armature has a short and the starter motor must be replaced .

13-16 ELECTRICAL SYSTEM

good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.

Brush Plate Inspection â&#x20AC;˘ Using the x 10 ohmmeter range, measure the resistance between the

brush [A] an and the brush plate [B].

* If there is not close to zero ohms, the brush plate has an open and the brush plate must be replaced . â&#x20AC;˘ Using the highest ohmmeter range, measure the resistance between

the brush plate [B] and the brush holders [C].

* II there is any reading at ali, the brush holder has a short and the brush plate must be replaced.

Brush and Lead Assembly Inspection â&#x20AC;˘ Using the x 10 ohmmeter range, measure the resistance between the brushes. *11 there is high resistance or no reading (00), a lead is open and the brush and lead assembly must be replaced .

c;,i

ELECTRICAL SYSTEM 13-17 Charging System Charging Coil Testing • Remove the electric case connector [A]. eDisconnect the 3-pin connector [B] . • Temporarily connect the magneto leads except the charging coil leads (brown) .

• With a multimeter, check the charging coil output (in circuit) according to the following table with the engine running at approximately 3,000 rpm.

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. Take care not over-rev the engine while running it with no load.

Charging Coil Output Test Connections

Meter

Standard

Setting

Meter (+) to

Meter (-) to

Value

250 VAC

Brown lead

20 V

*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

Connections

Standard

Setting

Meter (+) to

Meter (-) to

Value

R x 10

Brown lead

0.7 - 1.1 0

* 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, necessitating flywheel replacement.

13-18 ELECTRICAL SYSTEM

Regulator/Rectifier Removal • Disconnect the battery ground cable . • Remove the electric case and open it. • Remove the regulator/ rectifier [AJ.

Regulator/Rectifier Installation Notes .Applya non-permanent locking agent to the following bolts. Torque - Regulator/RectHier Mounting Bolls: 7.8 N-m (0.8 kg-m, 69 In·lb) Electric Case Bolls: 7.8 N-m (0.8 kg-m, 69 In-Ib)

Regulator/Rectifier Inspection .With a multimeter set to the R x 1kO range, test the regulator/ rectifier according the following table.

Regulator/ Rectifier Resistance Test Tester ( +) Lead Connection Terminal

Red

Brown

Black

t8 - tID

t8 -110

15 - 80

18 - 110

18 -110

15 - 80

Brow n

1.0 - 6.0

30 - 160

18 - 110

Brow n

1.0 - 6.0

1.0-6.0

30 - 160

18 - 110

Black

2.0 - 12

1.0 - 6.0

1.0-6.0

Black

2.0 - 12

1.0 - 6.0

Red/ Purple (- )"

Red/ Purple

(.) : Tester (- ) Lead ConnectIon

*11 any of the values obtained do not agree with the above table, the regulator/ rectifier must be replaced.

ELECTRICAL SYSTEM 13-19 Ignition System

Pickup Coil Inspection • Remove the electric case connector [A]. • Disconnect the 4 ~ pin connector [B].

eSet the hand tester to the x 100 n range, zero it, and connect it to the pickup coil lead terminals (G 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.

Pic kup Coil Resistance

Standard:

396 - 594

Ignition Coil Removal .Open the electric case (see Electric Case Removal/Disassembly) . • Pull the spark plug caps [AJ, and slide off the protector tubes [B) .

• Unscrew the grommet caps and slide off the grommets. Lubricate the leads with a penetratinJ rust inhibitor.

• Disconnect the ignition coil primary lead connectors [A]. and unscrew the ignition coil [B) .

Ignition Coil Installation Note .Apply a non-permanent locking agent to the ignition coil mounting bolts and torque them. Torque - Ignition Coil Mounting Bolls: 7.8 N-m (0.8 kg-m. 69 in-Ib)

13-20 ELECTRICAL SYSTEM

Ignition Coil Inspection Measuring arcing distance: The most accurate test for determining 1he condition of the ignition coil is made by measuring qistance. • Remove the ignition coil. .Connect the ignition coil (with the spark plug cap left installed on the spark plug lead) to the tester, and measure the arcing distance.

Special Tool - Coil Tester: 57001-1242 [AJ

NOTE OSince a tester other than the Coil Tester may produce a different arcing distance, the Coil Tester is recommended for reliable results.

To avoid extremely high voltage shocks, do not touch the cool 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 or more

eTa determine which part is defective, measure the arcing distance again with the spark plug caps removed from the 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. Measuring coil resistance: If the Coil Tester is not available, the coil can be checked for a broken or badly shorted winding with a hand tester. However, a hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. • Disconnect the primary leads from th~ coil terminals. • Measure the primary winding resista'iice as follows [A]. o Connect the tester between the coil terminals. o Set the tester to the x 1 0 range, and read the tester. • Measure the secondary winding resistance as follows [8]. o Remove the plug caps by turning them counterclockwise. o Connect the tester between the spark plug leads. o Set the tester to the x 1 kO, and read the tester. * If the hand tester does not read as specified, replace the coil.

Winding Resistance Standard: Primary windings 0.08 - 0.1 0 Secondary windings 3.5 - 4.7 kO

* If the tester reads as specified, the ignition coil windings are probably good. However, if the ignitiOJ1 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 lor visible damage. *11 the spark plug lead is damaged, replace the coil.

? 9

I I

ELECTRICAL SYSTEM 13-21

COl Igniter Removal • Remove the electric case and open it.

• Remove the igniter [A] and disconnect the connectors.

COl Igniter Installation Note .Apply a non-permanent locking agent to the mounting bolts and torque them.

Torque - CDI'gniler Mounling Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

COl Igniter Inspection • Remove the COl igniter. • Set the hand tester to the x 1 kO range, zero it. and mark the measurements shown in the table *If the tester readings are not as specified, replace the COl igniter.

Special Tool - Hand Tesler (V. O. M): 57001-983

CAUTION Use only Hand Tester (special tool: multi~meter

57001-983) for this lest.

other than the Kawasaki Hand Tester may show different

readings. If a megger or a meter with a large-capacity baHery is used, the COl igniter will be damaged.

COl Igniter Internal Resistance Unit: kO Tester (+) Lead Connection

(-)

Lead Color

BK/ W

2-4

12-20

6-13

6 -13

10-20

2-4

BK / W

6-13

2-5

4-10

6-13

2-5

6-12

11-22

20-60

R/Y

20-60

40-100

BK/Y

10-30

2-4

4-10

11-22

12-23

6-12

40-110

14-28

20-60

130-400

100-200

00-200

60-200

20-60

6-13

2-5

4-10

10-30

25-60

30-300

10-30

6-13

2-5

4-10

6-13

2-5

4-10

100-200 100-200 100-200 130-400

(-) : Tester ( - ) Lead Connection

R/ Y

BK/Y

13-22 ELECTRICAL SYSTEM

Spark Plug Removal • Pull off the spark plug caps. • Unscrew the spark plugs. o Be careful to avoid breaking the ceramic on the spark plugs.

Spark Plug Installation • Be sure the spark plug threads are clean and dry . • Torque the spark plugs. Torque - Spark Plugs: 27 N-m (2.8 kg-m. 20 It-Ib) o Be careful to avoid breaking the ceramic on the spark plugs .

• Connect the spark plug caps.

Spark Plug Inspection • Remove the spark plugs (see Spark Plug Removal) . • Examine the ceramic insulator [ AJ and electrodes [BJ. *If the insulator appears glazed or very white. or if 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 Adjustm ents in the Fuel System chapter) . elf 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 w orn or burned, replace the plug . • Examine the spark plug threads [C]. *If the threads are damaged, replace the plug.

Spark Plug Cleaning • Clean the electrodes and the ceramic insulator around the center electrode with an abrasive blasting device.

o Be certain that all abrasive particles are removed from the plug . • Clean the entire plug in a high flash point solvent.

ELECTRICAL SYSTEM 13-23

Spark Plug Adjustment â&#x20AC;˘ Measure the spark plug gap. o Check the distance between the electrodes with a feeler gauge or a wire gauge.

Spark Plug Gap Standard:

0.7 - 0.8 mm

*If the gap in not within specifications, adjust it.

.Adjust the gap by carefully bending the side electrode with a tool designed for this purpose.

13-24 ELECTRICAL SYSTEM Electric Case

Removal • Remove or disconnect: Spark Plug Caps Bilge Hoses [A] Bypass Outlet Hoses [B] Starter Motor Cable [C] Battery Cable (+) [0] Electric Case Connector [E] 4-pin and 3 - pin Connectors [F]

• Remove the electric case mounting bolts [A] .

• Lift out the electric case [B].

Installation Notes .Apply a light coating of water resistance grease to the electric case connector O-ring [A] . • Apply a non-permanent locking agent to the electric case mounting bolts and torqu~ them.

Torque - Electric Case Mounting Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

ELECTRICAL SYSTEM 13-25

Disassembly • Remove the electric case (see Electric Case Removal). • Remove the electric case bolts [A] , and open the electric case.

• Remove the electric box components. o Before removing the igniter, remove the regulator/ rectifier mounting bolts [AJ.

Assembly Notes .Connect the battery cab le to the relay (+) terminal having red lead. • Run the charge wires of igniter and regulator through the electric case hole, before installing regulator . • Connect the ground leads (black) to the regulator/ rectifier mounting bolts . • Apply a non-permanent locki ng agent to all the removed bolts, and torque them. Torque - All Removed Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib) .Apply water resistance grease to the O-ring of electric case. 1. Fuse (lOA) 2. Spare Fuse 3. Starter Relay

4 . Temperature Sensor 5. Ignition Coil 6. CDI Igniter 7 . Regulatorl Rectifier

"/Y

o '/Y

13-26 ELECTRICAL SYSTEM

Switches Start/Stop Switch Removal • Remove or disconnect:

Start/ Stop Switch Connector (4-pin) [A] Handlebar Pad Wiring Ciamps [6]

• Carefully pull the start/ stop switch wiring up through the handle pole. • Unscrew the switch case mounting screws [AJ, and remove the switch case [6].

Start/Stop Switch Installation Notes .The switch case mounting clamp has an indexing dowel [A] . Position

the dowel in the handlebar hole [6] .

• Be certain the start/ stop switch wiring does not interfere with throttle cable or choke cable movement when the handlebar is moved.

ELECTRICAL SYSTEM 13-27

Start/Stop Switch Inspection â&#x20AC;˘ Examine the start/ stop switch case and wiring.

* If the switch case is broken or damaged in any w ay, replace the switch assembly. *If the wiring is damaged, repair it or replace the switch assembly.

eTest the start switch. o Set an ohmmeter to the R x 1

n scale.

o Connect the meter leads to the red/ blue and yellow/red start switch

leads. o Position the starter interlock switch to the right. o Check switch resistance with the start bunon released, and with the start button depressed .

Start Switch Resistance Start Button

Reading

Released

000

Depressed

Almost 0 0

* If either meter reading is incorrect. replace the start/stop switch. eTest the starter interlock switch. o Repeat the start switch test with the starter interlock switch to the left.

a Both meter readings should be 00 O. *If either reading is less than 00 0 , replace the start/stop switch .

eTest the stop switch.

a Set an ohmmeter to the R x 1 0

scale. o Connect the meter leads to the blue and white stop switch leads. o Check switch resistance with the stop button released , and with th e stop button depressed.

Stop Switch Resistance Stop Button

Reading

Released

000

Depressed

Almost 0 0

* If either meter reading is incorrect, replace the start/stop switch.

13-28 ELECTRICAL SYSTEM Temperature Sensor A temperature sensor is installed on the bypass hose. Whenever the cooling water temperature rises to 95°C (203°F) or higher, the contacts in the temperature sensor does and the igniter works to cut spark intermittently. The engine speed decreases to 3,500 rpm . If the watercraft slows down even with the throttle on and the engine running, return to shore immediately and check the cooling system for clogging.

.CAUTION H the watercraft slows down while running, return to the shore immediately. Overheating will cause severe engine and exhaust system damage. Do not operate the craft until the source of the problem is found and correct

Temperature Sensor Removal .Open the electric case (see Electric Case RemovaI/Disassembly) . • Disconnect the temperature sensor leads (B/Y and R/Y) . • Unscrew the grommet cap [AJ, and slide off the grommet [B] .

• Pull off the temperature sensor assembly [AJ out of the electric case .

• Slide off the rubber cap [AJ, and unscrew the temperature sensor

[B].

ElECTRICAL SYSTEM 13-29

Temperature Sensor Installation Notes eSe sure holder assembly [A] is in the position, as shown.

Temperature Sensor Inspection .Suspend the sensor [A] in a container of water so that the temperature sensing projection is submerged . â&#x20AC;˘ Suspend a thermometer in the water.

NOTE

o The sensor and thermometer must not touch the container sides or bottom. â&#x20AC;˘ Place the container over a source of heat and gradually rise the temperature of the water while stirring gently.

Temperatures Sensor Connections Rising temperature: From OFF to ON at 95"e (203"F) Falling temperature: From ON to OFF at 88"e (190"F) ON : less than 0 .5 n OFF: More than 1 M n

13-30 ELECTRICAL SYSTEM

Fuse Inspection • Remove the fuse plug [AJ .

• Pull the cap [AJ, and take out the fuse (10A) [B J.

• Inspect the fuse element.

* If it blow n out, replace the fuse. Before ,eplacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than th e fuse rating, check the wiring and related components for a short circu it.

CAUTION When replacing a fuse, be sure the new fuse matches the specified fuse rating for thai circuil. Installation of a fuse with a higher rating may cause damage to wiring and components.

Normal

Failed

STORAGE 14-1

Storage Table of Contents

Preparation for Storage ................................ ..... .......... .............................................. 14-2 Cooling System .................................. ............................................... ............... 14-2 Bilge System ....... ....................... ...... ........................................ ........... ..............14-2 Fuel System ......................................................................................................14-2 Engine ................. .. ........................ .. .............................................. .................... 14-3 Battery ......... ...................... ......... ... ...... .................... ... ...... .. ............................... 14-4 Lubrication .............................................. ............. ...... ....................................... 14-4 General ...................... .. .. ............. ........ .. ............................................................. 14-4 Removal from Storage .......... .. ..... .... ............................ .. .... .. ...... ...... ........... .. ... ... .. .. .. 14-5 Lubrication .................... ........... ......................................................................... 14-5 General Inspection ............................................... .... .. .. .. ..... ..... .............. .. ......... 14-5 Fuel System .............................................. ...... .. .. .... .................................... .. .... 14-5 Test Run ..... ....................................................... ......... .................. ..................... 14-6

14-2 STORAGE

Preparation for Storage During the winter, or whenever the watercraft will not be in use for a long period of t ime, proper storage is essential. It consists of checking and replacing missing or worn parts; lubricating parts to ensure that they do not become rested; and, in general, preparing the watercraft so that when the time comes to use it again, it will be in top condition.

Cooling System eClean the cooling system (see Cooling System Flushing in the Cooling and Bilge Systems chapter).

Bilge System eClean the bilge system (see Bilge System Flushing in the Cooling and Bilge Systems chapter). Before reconnecting the hoses to the plastic breather fitting, blow air through both hoses [AJ to force all water out of the bilge system.

Fuel System .. WARNING

Gasoline Is extremely flammable and can be explosive under certain conditions. Position the starter interlock switch to the left. 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.

â&#x20AC;˘ Drain the fuel tank. This should be done with a siphon or pump.

A. Siphon Hose

STORAGE 14-3

.Clean the filter screens (see Fuel Filter Screen Cleaning in the Fuel System chapter) . • Leave the fuel filler cap loose to prevent condensation in the tank .

• Start the engine and run it in 15 second periods until all fuel in the carburetor is used up. Wait 5 minutes between 15 second running periods.

CAUTION Do not run Ute engine with the watercraft out of the water for more than 15 seconds at a time. Overheating can cause severe engine and exhaust system damage.

• Remove the air intake cover [A] from the carburetor.

• Lift out the flame arrester and clean it, if necessary (see Flame Arrester Cleaning in the Fuel System chapter) . • Spraya penetrating rust inhibitor down the carburetor bore . • Install the flame arrester. • Reinstall the cover, apply a non -permanent locking agent to the threads of the air intake cover bolts and tighten securely.

Engine • Remove the spark plugs and 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 .

• Wh ile holding the stop button down turn the engine over several times with the start bunon to coat the cylinder wa lls with oil, then reinstall the spark plugs. • Remove the exhaust tube and pour three ounces of automobile antifreeze into the water box muffler. Replace the exhaust tube.

14-4 STORAGE

Battery • 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 00 not allow any soda solution to enter the battery .

• Check the electrolyte and fill to the upper level mark with distilled water, if necessary. • Check the specific gravity with a hydrometer and recharge if necessary. • Cover both battery terminals with grease .

• Store the battery in a cool. dry place.

Do not expose it to freezing

temperatures.

NOTE

o Check the battery at least every 30 days and recharge if necessary. A neglected battery will gradually lose its charge and begin to sulfate (plates turn white). Once this reaction has begun, the battery usually cannot be salvaged.

Lubrication • Carry out all recommended lubrication procedures (see Lubrication in

the Appendix chapter).

General .Wash the watercraft and dry it thoroughly, making sure to drain the engine compartment completely.

CAUTION Use only a mild detergent in water to wash the hull. Harsh solvents may attack the surface or smear the colors .

• Applya good grade of wax to all exterior hu ll surfaces . • Lightly spray all exposed metal parts with a penetrating rust inhibitor. • Block the seat up with 10 mm spacers to insure adequate venti lation, and prevent corrosion . • Cover the watercraft and store it in a clean, dry place.

STORAGE 14-5 Removal from Storage

Lubrication • Carry out all recommended lubrication procedures (see Lubrication in

the Appendix chapter) .

General Inspection .Check for binding or sticking throttle, choke, or steering mechanism. The throttle lever must return fully when released .

• Clean and gap spark plugs (see Spark Plug Cleaning and Spark Plug Adjustment in the Electrical System chapter) . • Check all rubber hoses for weathering, cracking, or looseness . • Turn the watercraft on its left side on protective pad, and remove the

jet pump cover. Check cooling hose for weathering , cracking or looseness. eReplace them if necessary. Replace the cover and tighten securely . • 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 .Check and clean or replace the fuel filter screens as necessary (see Fuel Filter Screen Cleaning in the Fuel System chapter) .

AWARNING Gasoline Is extremely flammable and can be explosive under certain

conditions. Position the starter interlock switch to the left. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparksj this includes any appliance with a pilot light.

.After refueling and before starting the engine, tilt the seat to the rear for several minutes to ventilate the engine compartment.

A concentration of gasoline fumes in the engine compartment can cause a fire or explosion .

• Check for fuel leaks. Repair if necessary. • Check the engine oil level. Fill the oil tank with the specified oil.

14-6 STORAGE

Test Run AWARNING

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 dealh .

â&#x20AC;˘ Start the engine and run it only for 15 seconds. Check for fuel. oil and exhaust leaks. Any leaks must be repaired .

CAUTION Never run the engine with the watercraft out of the water for more than 15 seconds. Overheating can cause severe engine and exhaust system damage. 00 not run the engine at maximum speed out of the water. Severe engine damage may result.

â&#x20AC;˘ Install the engine cover waking sure the engine cover latch is secure.

APPENDIX 15-1

Appendix Table of Contents

Lubrication ................................................................ ..... ..................... ..... ................. 15-2 Troubleshooting ................................................. ................... ............. ....................... 15-3 Unit Conversion Table ............................................................. ................................. 15-6

15-2 APPENDIX 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: â&#x20AC;˘ Lubri cate the following with a penetrating rust inhibitor. ThroHle Cable Choke Cable

Special Tool - Pressure Cable Luber: K56019-021 [A]

Steering Nozzle Pivots [B]

â&#x20AC;˘ Lubricate the following with a high quality waterproof grease. ThroHle Cable Ends [A]

ThroHle Case [B]

Choke Cable Ends [C]

APPENDIX 15-3

Steering Cabte Ball Joints [OJ

15-4 APPENDIX Troubleshooting

Ignition Spark Pre sent

1 Fault in fuel system 2

Ignition

System

r- 1 No Spark

Outside Carburetor

Faulty or fouled spark plug Faulty plug wire insulation Faulty COl igniter Faulty ignition coil Faulty magneto 6 Battery voltage low

r- 2 r- 3 r- 4 r- 5

Starting difficulty or failure to start

Lack of compression

Fuel feed line leaking or clogged

r- 2 - Pulse line leaking or clogged 3 Fuel filter screen clogged 4 Vent line clogged r' - 5 Faulty fuel pump

Fuel System (check that fuel tank contains

Inside

fuel)

CarburetQtl

r- 1

r--

Carburetor diaphragm damaged 2 Mixture screw not adjusted

t- 3 Water in carburetor 4 Float arm not adiusted

Battery/Starter System

1 Faulty magneto solenoid switch Battery voltage low

r- 2 r- 43 r'- 5

Starter motor brushes worn

Faulty reductl6n gear Faulty starter lockout switch

r- 1 Faulty crankshaft oil seal

l- 2

Crankcase joint leak 3 Worn piston and rings t- 4 Head ga,ket leak 5 Spark plug leak

Compression

Outside Carburetor

Engine starts but stops right away

Fuel System

Inside Carburetor

1 Misuse of choke Fuel filter screen clogged Fuel feed line leaking or clogged Pulse line leaking or clogged Vent line clogged '- 6 Faulty fuel pump

f- 2 l- 3 f- 4 f- 5

1 Water in carburetor

I-

2 Carburetor diaphragm damaged 3 Mixture screw not adjusted

L-

4 Float arm not adjusted

1 Faulty or fouled spark plug Electrical System

2 Poor wiring connection

3 Faulty magneto

APPENDIX 15-5

F ault 'In Carburetor

r - 1 Wrong mixture screw

f-- 2 Obstruction in fuel passage or outlet f-- 3 Diaphragm leaking or damaged L.- 4

Fuel mixture too lean

Other

Float arm not adjusted

Poor

fuel

supply

(fuel

filter screens,

hoses, or vent line clogged) , - 2 Carburetor mounting loose

'-- 3 Faulty fuel pump

Fuel System Fault in Carburetor

Engine mis-

Fuel mixture

fires, does not run

too rich

r-- 1 Diaphragm needle dirty or damaged

2 Float arm not adjusted

3 Choke not adjusted <- 4 Mixture screw not adjusted

Flame Arrester Clogged

smoothly

Ignition Timing Wrong

r-- 1 Reduced ignition coil output

Electrical System

I-- 2 High voltage insulation breakdown I-- 3 Spark plug fouled

Weak Spark

f-- 4 Spark plug gap wrong

Engine Lubrication System

Poor wiring connection, spark plug cap

6 Faulty COl igniter 7 Faulty magneto a aattery voltage low 1 Oil line clogged 2 Faulty oil pump

DUring normal

cruising

During sudden acceleration

Abnormal engine

sound Pinging

When the engine is idling while cold

I L

1 Slight piston seizure 2 Piston ring broken or sticking 3 Main bearing worn or damaged

Excessive clearance between connecting rod small end and piston pin, or between pin and piston <- 2 Excessive connecting rod big end clearance

r-- 1 t- 2 3 '-- 4

Ignition timing too advanced

Carbon accumulation in cylinder head Poor quality gasoline Spark plug wrong heat range

r-- 1 Exceuive piston clearance

l - 2 Piston rings worn I - 3 Piston worn L-

4 Connecting rod bent, twisted

15-6 APPENDIX

r-- 1 Spark plug gap or heat range wrong

Ignition System

I- 2

Ignition timing wrong

3 Reduced ignition coil output

'- 4 r-

Fuel System

Other

Low engine Power - This

trouble symptoms may not be clear

has more than one cause, and Overheating

connection

ignition

1 Insufficient fuel supply to carburetor

l- 2 Carburetor diaphragm damaged f- 3 Pulse line leaking or clogged I- 4 High speed nozzle clogged

trouble often

Loose wiri ng circuit

5 Throttle valve does not fully open 6 Fuel filter screen clogged 7 Faulty fuel pump 1 2 3 4

F lame arrester clogged Muffler or exhaust system clogged Water or foreign matter in gasoline or engine oil Exhaust gas leak in engine compartment

1 Ignition wrong

2 Carburetor not adjusted 3 Flame arrester or exhaust system clogged

4 Carbon accumulation in combustion chamber 5 Wrong type of gasoline or oil 6 Obstruction in oil pump hoses L- 7 Cooling water line leaking or clogged

Heavy Fuel Consumption

1 Carburetor not adjusted

2 Flame arrester clogged ' - 3 Muffler or exhaust system clogged 4 Worn cylinder. piston or piston ring ' - 5 Fuel feed line leaking ' - 6 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

Handlebars hard to turn

1 2 3 4 5

Handlebar pivot nut too tight Bushings damaged or cracked Handlebar plate or pivot bent No lub rican t on steering pivot Steering cable damaged or improperly routed

APPENDIX 15-7 Unit Conversion Table Prefixes for Units: Prefix

Symbol

Power

x 1 000000 x 1000 x 0.01 x 0.001 x 0.000001

mega kilo milli

k e m

micro

centi

Units of Length: km x 0.6214 m x 3.281 0.03937 mm x

mile It in

Units of Torque: N-m x 0.1020 N-m x 0.7376 N-m x 8.851

kg - m It-Ib in-Ib

Units of Mass: kg g

2.205 0.03527

x x

Units of Volume: L x 0.2642 L 0.2200 x L x 1.057 L x 0.8799 L 2.113 x L x 1.816 mL x 0.03381 mL x 0.02816 mL x 0.06102

kg-m kg-m kg-m

Units of Pressure: kPa x 0.01020 kPa x 0.1 450 kPa x 0 .7501

gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) 02 (US) 02 (imp)

= =

9.807 7.233 86.80

x x x

kg / em' kg /em' em Hg

N-m It-Ib in -Ib

kg/em' psi em Hg

98.07 14.22 1 .333

kPa psi kPa

0.6214

mph

cu in

Units of Speed: km/h

Units of Force: N x 0.1020 N x 0.2248 kg kg

kg Ib

9.807 2.205

x x

Units of Power: kW x 1 .360 kW x 1.341

N Ib

PS PS

x x

PS HP =

0 .7355 0.9863

kW HP

Units of Temperature:

9(OC+40) 5

OF -40

-20

I I

-40

°C

- 40

-4 jO

;I I;

-20 ! -17. 8

32 ; 40

: I I ;

0 ; 4.4

5(OF+40)

= °F

68 60

i !; I ;

26.7

9 104 100 ; 120

Ii I

48.9

140

160

I I:;

71. 1

of 176 212 ; 180 200 ; 220

:I I

248 284 240 ; 260 280 :

: I I ! I I ; I

100 93. 3

; 120 116

300

I; I ,I I i 140

138

320

160

°C

........,.

-1ÂŁâ&#x20AC;˘ .,;.-

Kawasaki

S~p;;NSport Xi

This is the supplemental manual for the 92-96 750 SS and 750 SS/Xi. For the 92-93 SS, use the 750 SX base manual for engine info not included. For the 94-96 750 SS/XI, use the 92-93 750 SS manual for anything not included except for the engine where you use the 750 SX base manual.

I apologize for any confusion the suppliments may cause. This is the way Kawasaki originally set up these manuals. I have attempted to organize and improve them as much as possible.

JET SKr Watercraft Service Manual Supplement

Quick Reference Guide

Pump and Impeller

I 2 I 3 I 4 I 5 I 6 I 7 I 8 I 9 I 10 I

Steering

111

Hull I Engine Hood

121

Electrical System

131

Storage

141

General Information Fuel System Engine Lubrication System Exhaust System Engine Top End Engine Removal and Installation Engine Bottom End Cooling and Bilge Systems Drive System

Appendix

1151

Supplement-1994 Models (JH750-A3/JH750-B2) 1 16 This quick reference guide will assist you in locating a desired topic or procedure. â&#x20AC;˘ Bend the pages back to match the black tab of the desired chapter number with the black t~b on the edge at each table of contents page. â&#x20AC;˘ Refer to the sectional table of contents for the exact pages to locate the specific topic required.

Supplement-1995 Models (JH750-A4/JH750-B3) 1171 Supplement-1996 Models (JH750-ElIJH7SO-F1) 1 181

Foreword This "JET SKI" SS/X4, Super Sport Xi watercraft Service Manual Supplement is designed to be used in conjunction with the "JET SKI" 750SX watercraft Service Manual (PIN 99924-1156-01). The maintenance and repair procedures described in this supplement are only those that are unique to the "JET SKI" SS/X4, Super Sport Xi watercraft. Most service operations for this model remain identical to those described in the base Service Manual. Complete and proper servicing of the "JET SKI" SS/X4, Super Sport Xi watercraft therefore requires both this supplement and the base Service Manual. The base Service Manual and this Supplement are designed primary for use by "J ET SKI" watercraft mechanics in a properly equipped shop. However, they contains enough detail and basic information to make them useful to the operator 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 operator 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, the mechanics should read the text, thoroughly familiarize himself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, makeshift tools or equipment should not be used. 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, especially, 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. â&#x20AC;˘ Use proper tools and genuine Kawasaki "JET SKI" watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki "J ET SKI" watercraft are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

.Follow the procedures in this manual carefully. Don't take shortcuts. â&#x20AC;˘ Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

AWARNING 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

o This note

symbol indicates points of particular interest for more efficient and convenient operation .

â&#x20AC;˘ Indicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

GENERAL INFORMATION 1-1

General Information Table of Contents

Before Servicing ....................................................................... .... ................. .. .. .......... 1-2 Model Identification ....................... .. ...... .................... ..................... .... ....... ... .............. 1-5 JH750-B1 ....................................... .... ............................................ ... ... ..................1-7 General Specifications ................................................................. ...................... ....... .. 1-8 JH750-B1 .................................................................................................... .. .. ..... .. 1-9 Periodic Maintenance Chart ........ ..................................................... .. ...................... 1-1 0 Torque and Locking Agent.. .. .......... ........................................................................ :1 -1 2 Special Tools, Sealant .... ... ........ .... ........ .............................................. ...................... 1-13 Cable, Wire and Hose Routing .......................................... ....................................... 1-15 JH750-B1 .................................................................. ,..... ,.................................... 1-19

1-2 GENERAL INFORMATION Before Servicing Before starting to service a watercraft, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting or presence of symptoms indicate that adjustments may be required. Whenever running of the engine is required during maintenance it is best to have the watercraft in water. CAUTION Do not run the engine without cooling water supply for more than 15 seconds or severe engine and exhaust system damage will occur.

• Loosen the clamp and remove the cap [AJ . • Connect the garden hose [BJ to the hose fitting (see above) . • Attach the garden hose to a faucet. Do not turn on the water until the engine is running and turn it 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 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 cylinder, 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 right side. Rolling to the left side can cause water in the exhaust system to run into the engine, with possible engine damage.

GENERAL INFORMATION 1-3

(3) Dirt - '-B'efore 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) n 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 Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (10) Gasket, 0- 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 manufacturer's 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). (12) Press A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (13) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. (14) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole .

1-4 GENERAL INFORMATION

(15) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal. apply a little lubricant, preferably high temperature grease on the lips to reduce rubber to metal friction . (16) Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms themÂˇ. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (17) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (18) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. (19) Electrical Wires All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color.

Wire (cross-section) L,/--

~-,

Name of Wire Color

Red Wire Strands Yellow/ Red Yellow Red

GENERAL INFORMATION 1-6 Model Identification JH750-A1 Left Side View:

JH750-A1 Right Side View :

1 -6 GENERAL INFORMATION

JH7S0-A2 Left Side View:

JH7S0-A2 Right Side View:

GENERAL INFORMATION 1-7

J H750- B1 Left Side View:

JH750-B1 Right Side View:

1-8 GENERAL INFORMATION General Specifications Items Engine: Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition system Lubrication System Carburetor Starting System Tuning Specifications: Spark Plug Gap Ignition Timing Carburetor Idle Speed Compression Pressure

JH750-A1.A2 2-stroke, vertical twin, crankcase reed valve, water cooled 743mL 80.0 x 74.0 mm 7.0: 1 50.7 kW (69 PS) @6 000 rl min (rpm) <E > 45.6 kW @6 250 rl min (rpm) 83.4 N-m (8.5 kg-m, 61.5 ft-Ib) @5 500 rlmin (rpm) <E> 74.0 N-m (7.5 kg-m, 54.6 ft-Ib) @5 500 rl min (rpm) Magneto CDI (Digital) Oil injection (break-in period: Oil injection and fuel mixture 50 : 1) Keihin CDK40-34 diaphragm type (38 mm venturi ) Electric Starter NGK BR8ES 0.7 - 0.8 mm 13' BTDC @1 250 rl min (rpm) - 16' @2 500 rl min (rpm ) 1250 Âą100 rl min (rpm) - in water 1 700 Âą1 00 rl min (rpm) - out of water 835 - 1 294 kPa (8.5 - 13.2 kgl cm' , 121 - 187 psi)

Drive System : Coupling Jet Pump: Type Thrust Steering Braking

Direct drive from engine Axial flow, single stage 2530 N (258 kg, 569 Ib) Steerable nozzle Water drag

Performance: tMinimum Turn ing Radius tFuel consumption tCruising range

3.3mm 24 L/ h @full throttle 92 km @full throttle 1 hour and 23 minutes

Dimension: Length Width Height Dry Weight Fuel Tank Capacity

2530 mm 1030 mm 945mm 170 kg 33 L including 6 L reserve

Engine Oil: Type Oil Tank Capacity

2-stroke, N.M.MA Certified for Service TC-WII 2.3 L

Electrical Equipment: Battery Maximum Generator Output

12V19Ah 6.6 A 14 V @6 000 rlmin (rpm )

= This information shown here represents results under controlled conditions, and information may not be correct under other conditions. Specification subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-9

Items Engine: Type Displacement Bore and stroke Compression ratio Maximum horsepower Maximum torque

Ignition system Lubrication system Carburetion system Starting system Tuning Specifications: Spark plug Type Gap Ignition timing Carburetor Idle Speed Compression pressure

JH7S0-Bl 2-stroke, vertical twin, crankcase reed valve, water cooled 743 mL 80.0 x 74.0 mm 7.0: 1 55.2 kW (75 PS) @6 500 rlm in (rpm) <E> 53 kW (72 PS)@6 500 rlmin (rpm) (Continuous maximum hosepower) 86.3 N-m (8.8 kg-m, 63.6 ft-Ib) @6 500 rlmin (rpm) <E> 83.4 N-m (8.5 kg-m, 61.4 ft-Ib) @5 750 rlmin (rpm)(Continuous maximum torque) Magneto CDI (Digital) Oil injection (break-in period: Oil injection and fuel mixture 50 : 1) Keihin CDK40-34 x 2 diaphragm type Electric starter NGK BR8ES 0.7 - 0.8 mm 13· BTDC @1 250 rlmin (rpm) - 16· BTDC @2 500 rlmin (rpm) 1 250 ± 100 r/m in (rpm) - in water 1 700 ±1 00 rlmin (rpm) - out of water 890 - 1 370 kPa (9.1 - 14.0 kglcm', 129 - 199 pis)(Open throttle)

Drive System: Coupling Jet pump: Type Thrust Steering Braking

Direct drive from engine Axial flow, single stage 2795 N (285 kg, 628 Ib) Steerable nozzle Water drag

Performance: tMinimum turning radius tFuel consumption tCruising range

3.3mm 28 L/h @full throttle 92 km @full throttle 1 hour and 11 minutes

Dimensions: Length Width Height Dry weight Fuel tank capacity

2530 mm 1 030 mm 945mm 176 kg 33 L including 6 L reserve

Engine Oil: Type Oil tank capacity

2-stroke, N.M.MA Certified for Service TC-WII 2.3 L

Electrical Equipment: Battery Maximum generator output t

12V19Ah 6.6 A/14 V @6 000 rlmin (rpm)

This information shown here represents results under controlled conditions, and information may not be correct under other conditions.

Specification subject to change without notice, and may not apply to every country. < E> : Other than US and Canadian models.

1-10 GENERAL INFORMATION Periodic Maintenance Chart NOTE

o Complete the Pre-Ride Checklist before each outing.

Frequency Description Check all hose clamps, nuts, bolts, and fasteners Torque cylinder head nuts Lubricate throttle cable fitting and choke cable fitting at carburetor Lubricate choke cable and throttle case and cable Clean and gap spark plugs (replace if necessary) Check battery level and terminals Lubricate steering nozzle pivots Lubricate steering cable ball joints Lubricate handlebar pivot (disassemble) Clean fuel filter screens Inspect fuel vent check valve Adjust carburetor Flush bilge line and filter Flush cooling system (after each use in salt water) Inspect/clean flame arrester Inspect impeller blade for damage (remove) Inspect/ replace coupling damper Inspect/ replace carburetor throttle shaft spring (replace carburetor if necessary) Inspect steering cable Inspect steering cable and trim cable (JH750-B1)

Initial 10 Hours

Every 25 Hours

• •

• • • • • • • • • • • • • •

•

Every 100 Hours

• • • • •

GENERAL INFORMATION 1-11 Torque and locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sea lant. Letters used in the "Remarks" column mean: L : Apply a non-permanent locking agent to the threads. SS : Apply silicone sealant to the threads. S : Tighten the fasteners following the specified sequence. Torque Fastener Fuel System: Carburetor Mounting Bolts Intake Manifold Mounting Nuts Air Intake Cover Bolts Fuel Tap Mounting Screws Choke Assembly Mounting Screws Intake Silencer Stand Mounting Bolts

Remarks N-m

kg-m

ft-Ib

78 7.8 7.8

0.8 0.8 0.8

69 in-Ib 69 in-Ib 69 in -Ib

L L L L L

Engine Lubrication System (JH750-Bl) Oil Pump Mounting Nuts Oil Hose Clamp Bolt

7.8 8.8

0.8 0.9

69 in-Ib 78 in-Ib

Exhaust System : Exhaust Pipe Mounting Bolts Joint Mounting Bolts Water Pipe Joints Exhaust Manifold Mounting Nuts Expansion Chamber Mounting Bolts Block Mounting Bolts Water Box Muffler Mounting Bolts Water Box Muffler Bottom Damper Bolts Water Box Muffler Bolts Output Pipe Mounting Bolts Water Box Muffler Bottom Plugs

49 9.8 9.8 20 7.8 7.8 7.8 7.8 7.8 7.8 7.8

5.0 1.0 1.0 2.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8

36 87 in-Ib 87 in-Ib 14.5 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib

L L SS S L L L L L L SS

Engine Top End: Cylinder Head Nuts Water Pipe Joint Cylinder Base Nuts Cable Holder Mounting Bolts (JH750-B1)

29 9.8 34 20

3.0 1.0 3.5 2.0

22 87 in -Ib 25 14.5

S SS

Engine Removal / Installation: Engine Mounting Bolts Engine Bed Mounting Bolts Engine Mount Bolts

36 36 16

3.7 3.7 1.6

27 27 11.6

125 12 98 7.8 7.8 29 7.8 7.8

13.0 1.2 10.0 0.8 0.8 3.0 0.8 0.8

94 8.5 72 69 in -Ib 69 in-Ib 22 69 in-Ib 69 in-Ib

SS L L, S L, S L L L

Cooling and Bilge Systems: Water Pipe Joint

9.8

1.0

87 in-Ib

Drive System: Coupling Cover Nuts Coupling Drive Shaft Holder Mounting Bolts

39 22

4.0 2.2

29 16.0

L SS L

Engine Bottom End: Flywheel Bolt Stator Mounting Bolts Coupling Magneto Cover Mounting Bolts Crankcase Bolts - 6 mm Dia . Crankcase Bolts - 8 mm Dia. Water Drain Valve Mounting Bolts Water Drain Valve Cover Bolts Magneto Cover Stud

1-12 GENERAL INFORMATION

Torque Fastener

Remarks

Pump and Impeller: Water Pipe Joint Steering Nozzle Pivot Bolts Tilt Nozzle Pivot Bolts (JH750-B1) Pump Outlet Mounting Bolts Pump Cap Bolts Impeller Pump Mounting Bolts Pump Cover Mounting Bolts Grate Mounting Bolts Steering: Handlebar Clamp Bolts Steering Neck Mounting Bolts Steering Holder Mounting Bolts Steering Shaft Nut Steering Shaft Lock Nut Steering Cable Nuts Trim Cable Nut (JH750-B1) Trim Adjuster Shaft Nut (J H750- B1) Hull/Engine Hood: Bumper Bushings Bumper Mounting Nuts Electrical System: Electric Case Bolts Electric Case Mounting Bolts Electric Case Connector Mounting Bolts (JH750-B1 ) Regulator/ Rectifier Mounting Bolts CDI Igniter Mounting Bolts Spark Plugs Starter Motor Mounting Bolts Ignition Coil Mounting Bolts Starter Relay Mounting Nuts Starter Lead Mounting Nut Battery Ground Lead Mounting Bolt Flywheel Bolt Stator Mounting Bolts

N-m

kg-m

ft-Ib

9.8 9.8 9.8

1.0 1.0 1.0

87 in-Ib 87 in-Ib 87 in-Ib

98 22 7.8 9.8

10.0 2.2 0.8 1.0

16.0 69 in-Ib 87 in-Ib

L L L

16 16 16 78 - 88 29 18 18

1.6 1.6 1.6 8-9 3.0 1.8 1.8

11 .5 11 .5 11 .5 58 - 65 22 13 13

L L

7.8 7.8 7.8

0.8 0.8 0.8

69 in-Ib 69 in-Ib 69 in -Ib

L L L

7.8 7.8 27 7.8 7.8 7.8 7.8 7.8 125 12

0.8 0.8 2.8 0.8 0.8 0.8 0.8 0.8 13.0 1.2

69 in-Ib 69 in-Ib 20 69 in -Ib 69 in-Ib 69 in -Ib 69 in-Ib 69 in -Ib 94 8.5 ft-Ib

L L

55 L L L L

L L

This table relating tightening torque of the stain less bolt and the nut to thread diameter, lists the basic torque for the bolts and nuts. Use this t<;lble for only the bolts and nuts which do not require a specific torque value. General Fasteners (stainless bolt and nut)

Threads

Torque

dia.(mm)

N-m

kg-m

ft-Ib

6 8 10

5.9 - 8.8 16 - 22 30 - 41

0.60 - 0.90 1.6 - 2.2 3.1 - 4.2

52 - 78 in- Ib 11.6 - 15.9 22 - 30

GENERAL INFORMATION 1-13 Special Tools, Sealant Compression Gauge: 57001 -221

Piston Ring Compressor Belt, <ll67 - <ll79: 57001-1097

Piston Pin Puller Assembly: 57001-910

Steering Stem Nut Wrench: 57001 -1100

Hand Tester: 57001-983

Bearing Driver Set: 57001 -1129

Oil Seal & Bearing Remover: 57001-1058

Compression Gauge Adapter, M14 x 1.25: 57001 -1159

Piston Ring Compressor Grip: 57001-1095

Impeller Wrench: 57001 -1228

1-14 GENERAL INFORMATION

Coupling Holder: 57001 -1230

Drive Shaft Holder: 57001 -1327

Drive Shaft Holder Adapter: 57001-1231

Rotor Holder: 57001 -1368

Coil Tester: 57001-1242

Pressure Cable Luber: K56019-021

Rotor Puller, M18 x 1 .5: 57001 -1258

Kawasaki Bond (Silicone Sealant): 56019-120

Watercraft Strap Tool: 57001-1294

Kawasaki Bond (Liquid Gasket - Black): 92104-1003

GENERAL INFORMATION 1-15 Cable, Wire and Hose Routing

1 . Fuel Vent Hose 2 . Clamp 3 . Throttle Cable

(

4. Grommet 5 . 6 . 7 . 8 . 9 . 10. 11 . 12. 13.

Start/ Stop Switch Leads LED Unit Leads LED Unit Engine Bed Cable Holder Detent Choke Cable Holder Steering Cable

6 5

BOW

f-- _ _

----------

f- --_________

10 -----+-"---~

!: ~Â¥c+=rT

~-----~

BOW

1-16 GENERAL INFORMATION

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

Fuel Tank Clamp Fuel Tap Main Fuel Hose (ON) Supply Fuel Hose Detent Bilge Breather

Battery (+1 Cable Battery Breather Hose Oil Inlet Hose Oi l Tank Electric Case Starter Motor Cable Battery (-) Cable

15. Carburetor 16. Reserve F~el Hose (RES) 17. Return Fuel Hose (RE-TURN)

18. 19. 20. 21.

Magneto Cover

Magneto Leads Stopper Starter Motor

.----

(

10 The magneto leads between clamps has to be loose enough so that it can absorb the engine movement.

2 2 19

Route the magneto leads so that the leads curve to the surface of the magneto cover.

1. Oil Tank 2. Clamp 3. Magneto Leads 4. Electric Case

Viewed from A

19)

(1)

iLl 11---

- --= ~--

(

l- -- ~ ,, I

5. 6. 7. 8. 9. 10. 11.

LED Unit Leads Fuel Level Sensor Leads Grommet Fuel Tank Fuel Tap Sediment Bowl Detent

12. 13. 14. 15. 16. 17. 18. 19. 20. 21 . 22.

Carburetor Starter Motor Cable Battery (-) Cable Battery Oil Inlet Hose Oil Level Sensor Leads Battery Breather Hose Air Duct Battery (+) Cable Spark Plug Magneto Leads

) )

m 2

m ::IJ

Âť r2

-----

::IJ

:; o 2

......, .....

1. 2. 3. 4. 5. 6. 7.

Oil Tank Oil Level Sensor Leads Clamp Battery (+) Cable To LED Unit LED Unit Leads Start/Stop Switch Leads

8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. To Start/Stop Switch Fuel Vent Hose Grommet Fuel Level Sensor Leads Detent Oil Inlet Hose Eng ine Bilge Filter Battery (- ) Cable Battery Breather Hose Magneto Leads

White Mark

BOW

Red Mark (Start/Stop Switch Leads)

::!

s:~

:lI

~ ,....

:lI

m Z m

CIO

......,

GENERAL INFORMATION 1-19 Cable, Wire and Hose Routing (JH750-B1)

1. Warning/I ndicator Light Leads 2. Fuel Vent Hose 3. Clamp 4. Throttle Cable 5. Grommet 6 .. Start/Stop Switch Leads 7. Warning/Indicator Light Display Panel 8. Steering Trim (Tilt) Cable 9. Choke Cable 10. Detent 11. Holder 12. Steering Cable

(

I:?BOW

BOW

c::>

1-20 GENERAL INFORMATION

1. Fuel Tank 2. Clamp 3. Fuel Tap 4. Main Fuel Hose (ON) 5. Supply Fuel Hose-A 6. Detent 7. Supply Fuel Hose-B 8. Bilge Breather

9. 10. 11. 12. 13. 14. 15. 16.

Battery (+) Cable Battery Breather Hose Oil Inlet Hose Oil Tank Electric Case Starter Motor Cable Batter (-) Cable Carburetor

17. Cooling Bypass Hose 18. Reserve Fuel Hose (RES) 19. Return Fuel Hose (RETURN) 20. Magneto Cover 21 . Magneto Leads 22. Stopper 23. Starter Motor

1 2

(

The magneto clamps has enough so absorb the ment.

leads between to be loose that it can engine move.ÂŁ;~~--

Clamp the magneto leads with other leads.

GENERAL INFORMATION 1 -21

1. Clamp 2. Carburetor 3. Intake Manifold 4. Pulse Hose 5. Oil Hose (to rear manifold) 6. Oil Hose (to front manifold) 7. Generator Cover 8. Stopper 9. Magneto leads

Run the oil hoses berear manifold. tween the front and

--~~~~t~i~~~~~~b~~~~~

FUEL SYSTEM 2-1

Fuel System Table of Contents

Exp loded View .......................................................... 2-2 JH750-B1 .............................................................2-4 Specifications ............................................................ 2-6 JH750-B1 ............................................................. 2-6 Fuel System Diagram ................................................ 2-7 JH750-B1 .................................... ......................... 2-6 Throttle Case and Cable ............................................2-8 Throttle Cable Adjustment ........ ... ..... ........ ... .... 2-8 Throttle Case Removal/ Disassembly ..................• Throttle Case Assembly/ Installation Notes ........• Throttle Cable Removal ... .... ............................2-8 Throttle Cable Installation Notes .................... 2-8 Throttle Case and Cable Lubrication ... ................ .. Throttle Case Inspection ..................................... : Throttle Cable Inspection ..................................... . Choke Cable .................................... ....... ................... 2-9 Choke Cable Adjustment ................................ 2-9 Choke Knob and Cable Remova l .................... 2-9 Choke Knob and Cable Installation Notes ... .2-10 Inspection ..................... .... ....... ............... ............ .

Lubrication ....................................................... . Carburetor/Fuel Pump ............................................ 2-11 Idle Speed Adjustment .................................. 2-11 Mixture Screw Adjustment ............................2-11 High Altitude Performance Adjustment.. ...... 2-11 Synchronization (JH750-B1) .......... ............. 2-12 Carburetor Remova l ..... ... ............ ........................... JH750-B1 ...................... .. ..... 2-12 Carburetor Install ation Notes ............................... ..

JH750- B1 ........................ .........................2-13 Carburetor Disassembly ....................................... • JH 750 - B1 .............. .. ................................. 2-13 Carburetor Assembly Notes ....... ................. . Carburetor Clean ing and Inspection ......... ., Float Arm Level Inspection and

Adjustment ... .. .. .... .. .. ..... ......................... .

Fuel Pump Removal/ Installation Note ............... : Flame Arrester ................................................................• Removal ........................... ................. .............. ...............• Installation Notes ......................................................... . Cleaning ...... .... ...............................................................• Flame Arrester (JH750- B1) ................................... 2- 15 Removal ......................................................... 2- 15 Installation Notes ........................................... 2-15 Intake Manifold, Reed Valves ....................................... : Removal ...................... ........ ... ..... ..........................• Installation Notes .................. ..... .. ..... ...................• Reed Valve Inspection .............. ............ ............ ..: Valve Holder Inspection ............ ........................ ...• Valve Stop Inspection ........................................ . Intake Manifold, Reed Valves (JH750-B1) ....... .... 2-16 Removal ......................................................... 2-16 Installation Notes ...........................................2-16 Sediment Bowl .................................. ...................... 2-17 Removal ......................................................... 2-17 Installation Notes ........................................... 2-17 Fuel Tank ................................................................. 2-18 Fuel Tank Removal ....... ....... .......................... 2-18 Fuel Tank Installation Notes ....................... ... 2-18 Fuel Tank Cleaning ..............................................• Fuel Filler and Tube Removal ... ........................... • Fuel Filler and Tube Installation Notes ............... : Fuel Filter Screen Cleaning ........................... 2-19 Fuel Vent Check Valve ................................... ......... 2-20 Fuel Vent Check Valve Mounting ........ ..... .. .. 2-20 Fuel Vent Check Valve Inspection ................ 2-20 Fuel Tap ................................................................... 2-21 Removal ........ .................................................2 -21 Installation Notes ...........................................2-21 Cleaning ........................................................ 2-21

2-2 FUEL SYSTEM

. (JH750-A1 .A2) Exploded View

1. Main Jet 2 Pilot Jet 3' Diaphragm Needle 4: Check Valve 69 in.lb) T1: 7.8 N-m (0.8 kg-m, t locking agent. L : Apply a non-permanen

G . Apply grease. SS; Apply silicone sealant.

11 111 11111 111111111

FUEL SYSTEM 2-3

~6Â®

Co @

'\, ,

6 '0

IIi

(?'~. f?r "~~i~~~~~~~

2-4 FUEL SYSTEM Exploded V'lew (JH750 . . -81)

1. MainJet . 32. Pilot . J et (first) 4'. PI!ot Jet (second ' m id range jet) Diaphragm N 5. Check V I eedle T1 ave N路m (0.8 k L :: 7.8 Apply an g路m, 69 in路lb) G . A on路perman ss: pply grease. ent locking agent . Apply silicone se aIant. .

3 L.

W\Q)~

FUEL SYSTEM 2-5

2-6 FUEL SYSTEM Specifications

JH750-A1.A2 Item

Standard

Carburetor: Make, type Size Mixture screws: Low speed High speed Maio jet Pilot jet Idle speed: in water out of water

Keihin, CDK 40 - 34 Diaphragm 38 mm Venturi 5/ 8 ± %turn open 1.0 ± %turn open # 155 #75 1 250 ±100 rpm 1700 ±100 rpm

Reed Valve: Reed warp

-- -

Fuel Tank: Capacity

33 L (including 6 L reserve)

Service Limit ---

--- ----

---------

0.2mm ---

Sealant - Pressure Cable Luber: K5601 9~21 Sealant - Kawasak.1Bond (Silicone Sealant): 56019·120

JH750-B1 Item

Standard

Carburetor: Make, type Size Mixture screws: Low speed High speed Main jet Pilot jet (first) Pilot jet (second, mid range jet) Idle speed: in water out of water

Keihin, CDK 40 - 34 x 2 (Diaphragm) 38 mm Venturi 1.0 ± %turn open 3/4 ± %turn open # 135 # 72 #45 1 250 ±1 00 rpm 1 700 ±1 00 rpm

Reed Valve: Reed warp

---

Fuel Tank: Capacity

33 L (including 6 L reserve)

Special Tool - Pressure Cable Luber: K56019~21 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit

- --- ------- --

---- -

--0.2 mm ---

FUEL SYSTEM 2-7 Fuel System Diagram

J H750-A 1.A2

1. 2. 3. 4. 5. 6.

Vent Reserve Main Supply Return Pulse

JH750- B1

1. 2. 3. 4. 5. 4. 6.

Vent Reserve M ain Supply-A Return Supply- B Pulse

(

\ "

. / ' .. ~ /"

- ---5

2-8 FUEL SYSTEM Throttle Case and Cable Throttle Cable Adjustment .The adjustment procedure is the same as in the base manuaL

A. Idle Adjust Screw B. Throttle Shaft Lever C. Locknuts

TH RODlE CLOSED (RELEASED)

Throttle Cable Removal • Disconnect the thro.ttle cable from the carburetor. • Remove: Handlebar Pad Throttle Case Start/ Stop Switch Handlebar Steering Cover

.Take out the bolts [A) and remove the grommet [B) . • Remove the throttle cable by carefully pulling the cable through the hull.

Throttle Cable Installation Notes .Apply silicone sealant to the grommet [A) . • Route the throttle cable correctly (see Cable Routing section in the General Information chapter) .

• Adjust the throttle cable (see Throttle Cable Adjustment).

THRODlE OPEN (APPLIED )

FUEL SYSTEM 2-9 Choke Cable Choke Cable Adjustment

.The adjustment procedure is the same as in the base manual.

A Choke Pivot Arm B. Locknuts

CHOKE OPEN (TURNED TO OFF)

Choke Knob and Cable Removal • Disconnect the choke cable from the carburetor. • Remove the set screw and take out the choke knob.

• Remove the cable holder mounting screws [A] .

• Pull the choke knob shaft with cable holder out of the hull.

.Slide the tip [A] of the choke inner cable out of the pulley on the choke knob shaft . • Loosen the locknut [ B] and unscrew the cable housing [ C] from the holder [D] .

CHOKE CLOSED (TURNED TO ON)

2-10 FUEL SYSTEM

• Remove the E-ring and pull out the choke knob shaft from the cable holder.

NOTE

o When

pulling the choke knob shaft, two detent balls and two springs will fall out of the cable holder. Do not lose them.

A. Choke Knob Shaft B. Detent Sail C. Spring D. Cable Holder E. O- ring F. Washer G. E-ring

Choke Cable and Knob Installation Notes • Inspect the O-ring and replace it, if necessary . • Apply silicone sealant to the mating surface of the cable holder and the hull. • Route the choke cable according to the Cable Routing section in the General Information chapter .

• Adjust the choke cable (see Choke Cable Adjustment) .

FUEL SYSTEM 2-11 Carburetor/Fuel Pump

Idle Speed Adjustment The normal idle speed setting is the lowest at which the watercraft will run reliable while still producing enough thrust to circle back to the rider after spill. .Turn the idle adjusting screw [A] as required to reach this setting.

Idle Speed 1,250 ±100 rpm (in waler) 1,700 ±100 rpm (oul 01 waler)

Mixture Screw Adjustment Since every carburetor is adjusted individually at the factory using a flow meter, specific mixture screw settings cannot be given. After adjustment, a cap [A] is installed over each mixture screw head with the point straight down to identify proper mixture screw settings for each until. DO NOT CHANGE THESE SETIINGS. If the carburetor is tampered with and these settings cannot be relocated, set the mixture screws to the following guide line .

Lo . .,

• Pull out the mixture screw caps. eTa set each screw, turn it in until seats lightly, and then back it out the specified number of turns. Turns out Mixture Screw Low Speed (lower) [Bl High Speed (upper) [Cl

JH750·Al,A2

JH750·Bl

5/ 8 ±1 / 4 1.0±1/ 4.

1.0 ± 1/ 4

3/4 ±1 / 4

These guideline represent a "starting point" from which additional fine tuning of the carburetor may be necessary.

CAUTION Do not force the mixture screws into their seats. You could damage the screws or the carburetor. Operating the watercraft with the high speed screw at too lean a seHing (screwed in clockwise too tar) could cause serious engine damage.

High Altitude Performance Adjustment The normal carburetor settings are best for sea level. If the watercraft is used at the higher elevations, the lower atmospheric pressure makes the carburetion richer. To obtain the proper carburetor setting at higher elevations, tum in the high speed screw according to the following table.

NOTE

o The adjustment of the low speed screw is not required on the actual usage.

Altilude m (II) 1000 (3300) 2000 (6600) 3000 (10000)

Turn the high speed screw In the normal position

1/ 8 turn 1/ 4 tum 3/ 8 turn

2-12 FUel SYSTEM

Synchronization (JH750-B1) • Remove the carburetor (see Carburetor Removal) .Turn out the idle adjusting screw [AJ until there is a clearance between the adjusting screw end and throttle 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 [0]. • Measure the distance from the bottom of the carburetor bore lower end to the valve end shown as "Hit, .Turn the synchronizing screw [E] so that the valve end in the rear carburetor [F] keeps the same distance within ±O.2 mm tolerance as that in the front carburetor. .Install the carburetor. • Adjust the throttle and choke cables.

Carburetor Removal (JH750-B 1) • Remove:

Air Intake Cover (see Flame Arrester Removal) Arrester Case (see Flame Arrester Removal) • Disconnect: Throttle Cable [A] Choke Cable [B] Return Hose [C] Inlet (Supply) Hose [0] Pulse Hose [E] • Lift the carburetor off the intake manifold.

FUEL SYSTEM 2-13

Carburetor Installation Notes (JH750-B1) .Connect the fuel hoses and pulse hose correctly (see Fuel System Diagram) . • Install a new gasket under the carburetor. • Applya non-permanent locking agent to the carburetor and air intake

cover bolts. Torque - Carburetor Mounting Bolts: 7.8 N-m (0.8 kg-m, 69In-lb) Air Intake Cover Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib) • Bend the tab portions of the double washer over the carburetor mounting bolts . • Adjust the throttle and choke cables (see Throttle and Choke Cable Adjustment) .

Carburetor Disassembly (JH750-B 1) .Remove the carburetor (see Carburetor Removal). • Unscrew the carburetor cover screws [AJ and take off the carburetor cover [B]

• Unscrew the carburetor case screw [AJ and separate the carburetor

case [B] from the carburetor body.

• Unscrew the float arm set screw [AJ . • Remove: Float Arm [B] Spring Float Valve Main Jet [C] Pilot Jet (first) [ 0] Pilot jet (second, mid range jet) [E]

2-14 FUEL SYSTEM

.Remove the mounting screws [A] and drop out the plates [B] and check valves [C]

FUEL SYSTEM 2-15 Flame Arrester (JH750-B1) .

Removal • Remove: Air Intake Cover Mounting Bolts [AJ Air Intake Cover [BJ Carburetor Mounting Bolts [CJ Arrester Case [OJ

Installation Notes .When assembling the flame arrester, put the screen [AJ between two expanders [BJ

• Install the arrester case [AJ so that its shorter side [BJ from the intake to arrester case end faces the engine . • Applya non-permanent locking agent to the thread at the carburetor mounting bolts. Torque - Carburetor Mounting Bolts: 7,8 N·m (0,8 kg-m, 69 in·lb) • Bend the tab portions of double washer over the carburetor mounting bolts .

• Install the duct [AJ and cover [B], as shown. O Apply instant glue [C] to the outside of duct. o. Engine Side .Apply a non - permanent locking agent to the thread of the air intake cover bolts. Torque - Air Intake Cover Bolts: 7,8 N·m (0,8 N·m, 69 In·lb)

2-16 FUEL SYSTEM Intake Manifold, Reed Valves (JH750-B1)

Removal • Remove: Air Intake Cover Carburetor (see Carburetor Removal) Oil Pump Outlet Hoses [AJ at Oil Injection Nozzle • Remove the intake manifold mounting nut [8] and remove the intake manifold.

• Pull out the gaskets [AJ and the reed valves [BJ

Installation Notes A

• Replace the gaskets with new ones . • Install the reed valves so that the "UP" mark [AJ is up.

o • Torque the intake manifold mounting nuts, following the specified tightening sequence. Torque - Intake Manifold Mounting Nuts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

.After installing the parts removed, bleed the oil pump if there are air bubbles in the outlet hoses (see Engine Lubrication System chapter).

FUEL SYSTEM 2-17 Sediment Bowl The sediment bowl prevents water from entering the fuel tank. If there is water in the sediment bowl, drain it.

Removal .To remove only the sediment bowl [A], unscrew the ring nut [6] .

â&#x20AC;˘ To remove the entire assembly, remove the bolts [A] and pull the hoses [6].

Installation Note â&#x20AC;˘ Inspect the O-ring [A] and replace it, if necessary.

2-18 FUEl SYSTEM Fuel Tank

Fuel Tank Removal .If the level of the fuel is above the filler neck, siphon some fuel out to prevent spilling it. AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Push the starter interlock switch. Do not smoke. Make sure the area Is well ventllatPd and free from any source of flame or sparks; this includes any appliance with a pliot light. • Remove or disconnect: Engine Steering Cable Connector [A] Handle Return Spring [B] Fuel Level Sensor Connector Bypass Cooling Hose Steering Cable Holder [C] Sediment Bowl Assembly [0] Rubber Straps [E]

• Loosen the clamps [A] on the filler tube and remove the fuel tank .

• Remove the fuel level sensor [A] and the fuel filter assembly [ B] .

Fuel Tank Installation Notes • Be sure the O-ring [A] is in the position.

FUEL SYSTEM 2-19

Fuel Filter Screen Cleaning .Clean the fuel filter screens in accordance with the Periodic Maintenance Chart (see General Information chapter) .

• Open the hatch cover [A] and take out the storage case [B] .

• Disconnect the fuel vent hose [ A] .

• Unscrew the mounting screws [A] , and remove the fuel filter assembly

[B].

NOTE

o When

servicing, do not let fall the O-ring [A] and the mounting screws in the bottom of the hull.

• Wash the fuel filter screens in non-flammable or high flash-point solvent. Use a brush to remove any contaminants trapped in the screens.

..WARNING Clean the fuel filter screens in a well ventilated area, and take care that there are no sparks or flame anywhere near the working areaj this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent. A fire or explosion could result.

2-20 FUEL SYSTEM Fuel Vent Check Valve

Fuel Vent Check Valve Mounting The fuel vent check valve is mounting in the fuel tank vent hose to prevent fuel from spilling during riding. Air can flow into the tank to allow fuel to be drawn out by the fuel pump, but fuel cannot flow out the check valve. â&#x20AC;˘ The fuel vent check valve [A] must be mounted so that the arrows on its case are pointing toward the fuel tank.

Fuel Vent Check Valve Inspection

o p

â&#x20AC;˘ 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 directions or in neither direction, the check valve must be replaced.

)

FUEL SYSTEM 2-21 Fuel Tap

Removal • Unscrew the bracket mounting bolts [A] and remove the sediment

bowl assembly [B] .

• Unscrew the set screw and take out the fuel tap knob.

• Unscrew the mounting screws [A] and take out the fuel tap.

• Pull the fuel hoses off the fuel tap [A] .

Installation Notes .Apply an even layer of silicone sealant [A] to the mating surfaces of the tap and hull. Sealant - Kawasaki Bond (Silicone Sealant): 56019·120

.Connect the fuel hoses to th e fuel tap correctly (see Cable Routing section in the General Information chapter) . • Apply a non - permanent locking agent to the fuel tap mounting screws and tighten them securely.

Cleaning If the fuel tap becomes clogged with foreign matter, it must be cleaned .

• Remove the fuel tap [A]. • Use compressed air to blow [B] through the supply fuel hose fitting [ C], while switching the fuel tap right and left between the " ON" and " RES" positions. Do this until only blockage it forced out.

NOTE O Do not use too high air pressure (172 kPa, 1.8 kgl em', 25 psi max.).

ENGINE LUBRICATION SYSTEM 3-1

Engine Lubrication System Table of Contents

Exploded View ............... ........................................................... .. ....................... ......... 3-2 Specifications .. ....................................................................... .............. .... ..... ....... .......3-3 Oil Pump .................................. .. ................................ ........... ....................... ....................• Oil Pump Bleeding ......................................................... ...... ...................................• Oil Pump Performance Test ............................................................ .... ..... ...............• Oil Pump Removal ......................................... .........................................................• Oil Pump Installation ......................... ......... ............................... .............................• Oil Tank .................... .. ................. ............ .................................................................... 3-4 Removal ... ...........................................................................................................3-4 Installation Note ..........•. ... ................. .. .................. ............................ ................. 3-4 Cleaning ............................................ ................... ..... ........ ......... .. ... .. ......................•

3-2 EN GINE LUBRI Exploded View CATION SYSTEM

~:~::~========;= -----~==-

Tl: 7.8 N路m (0.8 k路 ermanent lock" -81 L : Apply a non-p g路m, 69 in-Ibl 路 J H750 1"9 agent.

r- - - I

I ~

ENGINE LUBRICATION SYSTEM 3-3 Specifications (JH750-A1.A2, JH750-B1) Item Engine Oil: Type Capacity Engine Oil Pump: Oil pump output @3000 r/ min (rpm). 2min.

Standard 2-stroke, NMMA Certified for Service TC-WII 2.3 L 5.9 - 7.2 mL

3-4 ENGINE LUBRICATION SYSTEM Oil Tank

Removal • Drain the engine oiL

.Loosen the clamp and pull the oil level sensor [A] out of the oil tank.

• Disconnect the oil pump inlet hose [A] . • Unscrew the mounting bolts [B] and remove the oil tank [C] .

Installation Note • Put the heat guard [A] on the water box muffler [B].

EXHAUST SYSTEM 4-1

Exhaust System Table of Contents

Exploded View .......................................................................................... ... ............... 4-2 Exhaust Pipe, Joint and Expansion Chamber ........................... ,............................... .4-3 Removal ........ ......................................................................................................4-3 Installation Notes ........................................ ... .. ...................................................4-4 JH750-B1 ................ ...... ............. ............................................. ......................4-5 Joint Disassembly ............................................................................................... 4 -6 Joint Assembly ...................... ........... ....... ...........................................................4-7 Expansion Chamber Cleaning and Inspection ........................................ ,............. : Exhaust Manifold ....................... ......................... ........................................................4-9 Removal ..................................... ............ ... ..... ............................... ......................4-9 Installation Notes ................................................................................... ............ .4-9 Exhaust Manifold Cleaning and Inspection .......................................................... : Water Box Muffler .....................................................................................................4-10 Removal ........................................... _..... ..................... .................................. ... .4-10 Inspection Notes ........................ ....................... .............................................. .4-10 Disassembly/Assembly Notes ........................... .............................................. .4-1 0

4-2 EXHAUST SYSTEM Exploded View

T1: T2: T3: T4: B :

7.8 N'm (0.8 kg-m, 69 in·lb) 9.8 N'm (1.0 kg-m, 87 i.,.lb) 20 N'm (2.0 kg-m, 14.5 ft·lb) 49 N'm (5.0 kg-m, 36 ft·lb) Apply a bonding agent. L : Apply a non-permanent locking agent SS: Apply silicone sealant.

T1eD

EXHAUST SYSTEM 4-3 Exhaust Pipe. Joint and Expansion Chamber

Removal • Disconnect:

Spark Plug Caps Battery (+) Cable Starter Motor Cable • Remove the electric case [AJ.

• Disconnect:

Cooling Hose (Joint - Water Box Muffler) [AJ Cooling Hose (Cylinder Head - Exhaust Pipe)[BJ Bypass Cooling Hose [C] Water Drain Knob [OJ

• Remove: Exha ust Pipe Mounting Bolts [AJ Electric Case Stand Mounting Bolts [BJ

4-4 EXHAUST SYSTEM

e Remove the expansion chamber mounting bolts [AJ, and loosen the clamp [B] on the connecting tube [C] .

â&#x20AC;˘ Remove the exhaust pipe and expansion chamber as a set [A] out of the engine compartment.

*11 there are any shims under the mount blocks [AJ, mark them so they may be put back in the same position.

Installation Notes .Whenever the connecting tube [Al is removed, install the connecting

tube so that the stepped edge [B] ring on the end of tube faces toward the front [C] of the watercraft.

elnstall the clamps. eAt this time, make sure that the groove inside the tube [A] fits over the projection

[8] on the expansion chamber.

EXHAUST SYSTEM 4-5

.Tighten the clamp of the engine side [AJ .

• Push the other end of the connecting tube [AJ completely over the water box muffler inlet [8] as shown.

X ,-

ill

v® •.

• Install the exhaust pipe gasket [AJ as shown .

• Apply a non-permanent locking agent to the following bolts and torque them. Torque - Exhaust Pipe Mounting Bolts: 49 N-m (5.0 kg-m, 36 fI-lb) Expansion Chamber Mounting Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

Installation Notes (JH750-B 1) . Apply a non~permanent locking agent on the thread in the range illustrated [AJ and torque the exhaust pipe mounting bolts [ BJ. Torque - Exhaust Pipe Mounting Bolts: 49 N-m (5.0 kg-m , 36 fI-lb)

4 -6 EXHAUST SYSTEM

Br-_ _-tl

Joint Disassembly • Unscrew the mounting bolts [AJ, and remove the joint [ B] .

• Remove: Clamps [A] Bands Outer Boot [B]

• Unscrew the screws [A] and take out the clamps [B] . • Remove the lower joint [C] .

• Remove: Race [A] Spring Seat [B] Spring [C] Inner Boot[D]

EXHAUST SYSTEM 4-7

Joint Assembly .Check the O-ring [AJ, ring [Bl and rubber boots [Cl for damage. *If any of these parts are not in good condition, replace them .

â&#x20AC;˘ Install the following onto the upper joint [Al. Inner Boot [Bl Spring [C] Spring Seat [Dl Race [El

.When connecting the upper [Al and lower [Bl joints, align the left end [C] of the recess in each joint with the line [Dl on the inner boot.

Li===;;z6====::\. ;

.Install the clamps [ AJ. OApplya non-permanent locking agent to the clamp screws.

o Keep the direction

of screws [Bl and lay the nut [Cl and the screws [ B] between the gap of the inner boot.

B ..

c .Push the outer boot over the joint with the arrow mark [A] upward.

4-8 EXHAUST SYSTEM

.Install the bands [AJ and clamps [BJ on the outer boot as shown being careful of the screw position.

o Lay the clamp worn between the gap [CJ of the bands as shown .

• Coat on the seal area [AJ of joints (upper and lower) with silicone sealant. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

.Wipe off any excess sealant.

• Install the gaskets. The "UP" mark of gasket must face upward.

A. "UP" mark B. Upper Gasket C. Lower Gasket

.Applya non·permanent locking agent to the joint mounting bolts and torque them.

Torque - Joint Mounting Bolts: 9.8 N-m (1.0 kg-m. 87 in-Ib)

EXHAUST SYSTEM 4-9 Exhaust Manifold

Removal • Remove the exhaust pipe and expansion chamber as a set [A] (see Exhaust Pipe, Joint and Expansion Chamber Removal) .

• Remove the exhaust manifold mounting nuts [A) .

• Disconnect the inlet cooling hose [AJ, and take off the exhaust manifold.

Installation Notes .Install the exhaust manifold gasket so that the arrows [AJ point the up .

• Torque the exhaust manifold mounting nuts, following the specified tightening sequence. Torque - Exhaust Manifold Mounting Nuts: 20 N-m (2.0 kg-m, 14.5 ft-Ib)

4-10 EXHAUST SYSTEM Water Box Muffler

Removal • Remove:

Battery Oil Tank Exhaust Pipe and Expansion Chamber Water Box Muffler Mounting Bolt [A]

• Loosen the clamp [A] and pull the exhaust tube [B] off the water box muffler. • Slide off the water box muffler toward the front.

Installation Notes .Apply a non-permanent locking agent to the water box muffler mou nting bolt. Torque - Water Box Muffler Mounting Bolls: 7.8 N-m (0.8 kg-m, 69In-lb)

Disassembly/Assembly Notes • Replace the O-rings. • Apply a thin coating of silicone sealant to the groove [A] in the bottom half matting surface, then install the O-ring [B]. This will insure a good·seal and prevent O-ring from getting out of place. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

• Be sure to lower the upper half straight down onto the bottom half during final assembly . • Apply a non-permanent locking agent to the following bolts and torque them.

Torque - Water Box Muffler Bolls: 7.8 N-m (0.8 kg-m, 69In-lb) [A] Outer Pipe Mounting Bolls: 7.8 N-m (0.8 kg-m, 69 In-Ib) [B]

EXHAUST SYSTEM 4-11

.Whenever the sub-assembly (exhaust pipes and spacer) are removed, note the following. OApply silicone sealant [A] on the inside of cylindrical wall. Sealant - Kawasaki Bond (Silicone Sealant): 56019Âˇ120

o Apply a non-permanent locking agent to the exhaust pipe mounting bolts [B], and then bend one of the tongues of plate [C], along the side of hexagonal head of bolt.

0 8e sure the O-rings [A] and the dampers [8] are in the position as shown. o Pay attention to the top of projection ot pipe exhaust be horizontal [8).

Spacer and Plate Location 1. Spacer 2. Plate

ENGINE TOP END 5-1

Engine Top End Table of Contents

Exploded View .................................................. .. ........................................................ 5-2 Specifications .................................................................................... .......................... 5-3 Engine Top End ...........................................................................................................5-4 Disassembly and Assembly .................................................................................... 5-4 Disassembly ............................................................................................................ . Assembly Notes .................................................................................................. 5-4 Disassembly and Assembly (JH750-B1) .............................................................. 5-4 Disassembly ... ................................. ................................ .................................... 5-4 Maintenance and Inspection ...................................................................................... . Compression Measurement ........ ..................... ........................ ............................... . Cylinder Head Warp Inspection .......................................................................... .. Cylinder Wear Inspection ............................. .............. ............................................ . Piston Diameter Measurement ................................................................................ Piston/Cylinder Clearance ...................................................................................... . Boring and Honing ................................................................................................. . Piston Ring. Piston Ring Groove Inspection ........................................................ .. Piston Ring End Gap ........................................................................... ..... .............. . â&#x20AC;˘

Base Manual

5-2 ENGINE TOP END Exploded View Tl: 9.8 N·m (1 .0 kg·m, 87 in·lb) T2: 29 N·m (3.0 kg·m, 22 ft·lb) T3: 34 N·m (3.5 kg·m, 25 ft·lb) T4: 20 N·m (2.0 kg·m, 14.5 ft·lb) SS : Apply silicone sealant. o : Apply engine oil. L : Apply a non·permanent locking agent.

~ T4 L: ~: .--- ----

I ,

I I

, /',

JH750·Bl "

I I I

' - - - -'

ENGINE TOP END 5-3 Specifications JH750-A1, A2

Item Cylinder Head: Cylinder compression

(Usable range) 835 - 1 294 kPa (8.5 - 13.2 kg / em', 121 - 187 pis) (Open throttle)

---

Cylinder head warp Cylinder, Piston: Cylinder inside diameter Piston diameter (18 mm up from bottom of skirt) Piston/cylinder clearance Oversize piston and rings 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 Special Tools -

Standard

80.000 - 80.015 mm 79.900 - 79.915 mm 0.095 - 0.115 mm + 0.5 mm and +1.0 mm

---

Service Limit

--0.05 mm

80.10 mm 79.75 mm

-----

- ----

-----

---

-- -

---

----0.7 mm 0.7 mm

---

0.25 - 0.40 mm 0.25 - 0.40 mm

Piston Pin Puller Assembly: 57001Âˇ910 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, <1>67 - <1>79: 57001-1097 Compression Gauge: 57001-221 Compression Gauge Adapter, M14 x 1.25: 57001-1159

JH750-B1

Item Cylinder Head: Cylinder compression Cylinder head warp Cylinder, Piston : Cylinder inside diameter Piston diameter (18 mm up from bottom of skirt) Piston/cylinder clearance Oversize piston and rings Piston ring/groove clearance: Top (keystone) Second (keystone) Piston ring groove width: Top (keystone) Second (keystone) Piston ring thickness: Top (keystone) Second (keystone) Top Piston ring end gap: Second Special Tools -

Standard (Usable range) 890 - 1370 kPa (9.1 - 14.0 kg /em', 129 - 199 pis) (Open throttle) ---

80.000 - 80.015 mm 79.900 - 79.915 mm 0.095 - 0.115 mm +0.5 mm and +1.0 mm

---------

----0.25 - 0.40 mm 0.25 - 0.40 mm

Piston Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, <1>67 - <1>79: 57001-1097 Compression Gauge: 57001-221 Compression Gauge Adapter, M14 x 1.25: 57001 -1159

Service Limit

--0.05 mm

80.10 mm 79.75 mm ---

-------

---

-----

--0.7 mm 0.7mm

5-4 ENGINE TOP END Engine Top End Disassembly and Assembly: Assembly Note .The assembly procedure is the same as in the base manual, except for

the following. o Both top and second rings are keystone type.

Top ring

----

~~ 11:", /

-" 7 "\

Second ring

~ Disassembly and Assembly: (J H750-B1) Disassembly .The disassembly procedure is the same as for the JH750-Al.A2, except for the following. OTo remove the cylinder, remove the cable holder [AJ.

ENGINE REMOVAL/INSTALLATION 6-1

Engine Removal/Installation Table of Contents

Exploded View ........................................................................................ ... ......... .. .. ....6-2 JH750-B1 ...............................................................................................................6-3 Engine Removal / Installation .................. ..... ................................................................6-4 Removal .................................. ............................................... ......... ....................6-4 JH750-B1 ........................................................................... ...........................6-5 Installation Notes .... ............................................................................................6-5

6-2 ENGINE REMOVAL/INSTALLATION Exploded View (JH750-A1.A2) T1: 16 N'm (1.6 kg-m, 11 .6 ft·lb) T2: 36 N·m (3.7 kg-m, 27 ft·lb) L : Apply a non-permanent locking agent

ENGINE REMOVAL/INSTALLATION 6-3 Exploded View (JH750-B1)

Tl: 16 N-m (1_6 kg-m, 11_6 ft-Ibl T2: 36 N-m (3_7 kg-m, 27 ft-Ibl

L : Apply a non-permanent locking agent.

T~ ® ~

@\----9

t-®

6-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation

Removal • Remove or disconnect: Battery Spark Plug Caps Electric Case Connector [AJ Starter Motor Cable [BJ Wiring Clamps [CJ

• Remove the electric case [AJ

• Remove (see the appropriate chapters): Exhaust Pipe and Expansion Chamber (as a set) Carburetor Coupling Cover

Oil inlet Hose

• Remove the engine bed mounting bolts [AJ .

• Slide the engine toward the front to disengage the couplings, and then

lift the engine out of the hull. • Remove the engine mounting bolts and separate the engine bed and

the engine.

ENGINE REMOVAL/INSTALLATION 6-5

Removal (JH750-B1) e The removal procedure is the same as for the JH750-A1.A2, except lor the following. aTo remove the engine, remove the cable bracket [AJ.

Installation Notes • Be sure there are no foreign objects and parts inside of the hull. eClean the bilge filter (see Filter Cleaning and Inspection in the Cooling and Bilge Systems chapter). eCheck the coupling damper for wear and damage (see Coupling Damper Inspection in the Engine Bottom End chapter). elnstall the engine bed so that the small notches [AJ are on the magneto end of the engine as shown.

. Install the engine in the hull, aligning the projection on the magneto cover [AJ with the arrow [BJ in the bottom of the hull.

.Apply a non -perma nent locking agent to the engine bed mounting bolts, and torque them. Torque - Engine Mounting Bolts: 36 N-m (3.7 kg-m, 27 fI-lb) Engine Bed Mounting Bolts: 36 N-m (3.7 kg-m, 27 fI-lb)

e Check the gap between the engine bed and the dampers by rocking the engine. elf there is a gap, insert a suitable shim between the engine bed and the damper to achieve a good fit.

Shim Selection Shim No.

92025-3705 92025-3706 92025-3707 92025-3708

Thickness 10.3 mm 10.5 mm t1 .0mm t1 .5 mm

eAfter installing the engine in the hull, check the following. Throttle Cable Choke Cable Oil Pump Bleeding Fuel and Exhaust Leaks

11 "''''

° 111:011 Il o:~Dl o

00I

° IIJ~:

6-6 ENGINE REMOVAL/INSTALLATION

AWARNING 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.

ENGINE BOTTOM END 7-1

Engine BoHom End Table of Contents

Exploded View ............................................................................................................7-2 Specifications ..............................................................................................................7-3 Coupling ................................................................................. .. ... .......... ....... ................... . Removal ...................... ............................................................................................• Installation Notes ... ................................................................................................. . Coupling Damper Inspection ................................................................... .............. . Magneto Flywheel ......................................................................................... .............7-4 Removal ..............................................................................................................7-4 Installation Notes ............... .................................................................................7-4 Stator ................................................................................................................................• Removal ................................................................................................................. .. Installation Notes ................... ... .. .............. ... .... .. .... ................................................. . Water Drain Valve ................................................................................................... .. ... 7-6 Removal ................................ ....... ......... ...... ............ .............. .... .. ..... ... ...... .......... .... * Installation ................... ........... ............................................................................. 7-6 Crankcase ............. ......... ...................................................................... .......... .................. . Splitting ...................................................................................................................• Assembly Notes ....................................................................................... ............... . Crankshaft Maintenance ..................................................................................... ............ . Connecting Rod Bend/ Twist ............................. .. ................................................. .. Connecting Rod Big End Radial Clearance .......................................................... .. Connecting Rod Big End Side Clearance ............................................................. .. Crankshaft Main Bearing Wear ............................................................................... Crankshaft Runout ................................................................................................... Crankshaft Assembly Specifications .... ................. ................................................. . JH750-B1 ..................... .. ...............................................................................7-7

• = Base Manual

OM END 2 ENGINE BOTT A2 JH750-B1) 7. w (JH750-A1. • Exploded Vie

69 ft-Ib) in·lb) T1 : 7.8 N·m 10.8kk g;:.8.5 T2 : 12 N-m 11.2 g. • 22 ft.lb) T3' 29 N·m 13.0 k~.m,;, 72 ft-Ib) T4: 98 N·m 110.0 k g. '78 in.lb) . 88 N·m 10.9 g·m, 94 ft-Ib) T5 : 125 N·m 113.0 locking agent. L6 . Apply a non-perm a disulfide grease. T M :. App Iy molybdenum

kg·";.~nt

G : Apply LG: Apply Iy o : App SS ; Apply

grease. sket. . liquid ~a flanged portion. all to t e T one sealant. 51 IC ~

~k ~~III''' A

JH750-81

-- - L_

: ~

' 0

I I

~----- -

@~ . G

@ LG

ENGINE BOTTOM END 7-3 Specifications (JH750-A1.A2, JH750-B1) Standard

Item Crankshaft, Connecting Rods: Crankshaft runout Connecting rod side clearance Connecting rod radial clearance Connecting rod bend Connecting rod twist

0.04 mm 0.45 - 0.55 mm 0.038 - 0.049 mm 0.05 mm/1 00 mm 0.15 mm/1 00 mm

Special Tool - Rotor Holder: 57001-1368 Rotor Puller, M18 x 1.5: 57001-1258 Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104-1003 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit 0.10 mm TIR 0.8 mm 0.10 mm 0.2 mm/1 00 mm 0.2 mm/1 00 mm

7-4 ENGINE BOTTOM END Magneto Flywheel (JH750-A1.A2, JH750-B1)

Removal • Remove:

Carburetor (see Fuel System chapter)(JH750-Bl only) Cable Holder [A](JH750-Bl only) Oil Tube Clamp [B](JH750-Bl only) Oil Pump Magneto Cover

• Holding the flywheel with the rotor holder [AJ remove the flywheel bolt.

NOTE a Place the wooden board [BJ to protect the hull bottom.

• Pull the flywheel off the crankshaft. Special Tool - Rotor Puller, M18 x 1.5: 57001·1258 [AJ Rotor Holder: 57001·1368 [BJ

NOTE aPlace the wooden board [CJ to protect the hull bottom.

Installation Notes • Using a high flash-points solvents. clean off any oil or dirt that may be on the flywheel bolt. the crankshaft taper. or in the tapered hole in the flywheel . • Fit the woodruff key [AJ securely in the crankshaft. before installing the magneto flywheel.

ENGINE BOTTOM END 7-5

.Applya thin coat of engine oil to the flanged portion of flywheel bolt. .Install the flywheel. Special Tool - Rotor Holder: 57001-1368 [AJ Torque - Flywheel Bolt: 125 N-m (13.0 kg-m, 94 ft-Ib)

o Use the universal joint [BJ to torque the flywheel bolt.

.Check that the knock pins [AJ and the spring [BJ are in place and replace the O-ring if it is damaged . â&#x20AC;˘ Applya non Âˇ permanent locking agent to the threads of the magneto cover mounting bolts, and tighten them securely.

7-6 ENGINE BOTTOM END Water Drain Valve '

Installation .Installation procedure is the same as in the base manual, except for the following. o Fully grease the drain knob shaft [AJ.

:::

ENGINE BOTTOM END 7-7 Crankshaft Maintenance (JH750-B1) Crankshaft Assembly Specifications (JH750-B1) If the crankshaft is disassemgbled, use these specifications dur during rebuilding.

.....,

..-'

,i , , i

.Jl.

r::; ~

l:f: :±t\W

I-'- ~

"t...:

(

~ '--,....,

..."Ii

"'4

] r[

f-T .

r' i

60. 3"-60 . 5mm 0.45-0.55mm

)

r- ~

~tr ·

I--i--

COOLING AND BILGE SYSTEMS 8-1

Cooling and Bilge Systems Table of Contents

Exploded View ....... .......... .. .. ... ...................................... ..............................................8-2 Bi lge System ...... ...... ................................................. .. ... .. .... ........................................8-3 Breather Removal ........... ................................. .... ................. ........ .. ....... ... ..........8-3 Breather Installation ............ .... ........ ........................ ....... .............. ...................... . Breather Cleaning and Inspection ............... ....... ..... ...... ...................... ... .......... ...... . Filter Removal ..... ............. .. ............. ......... ............................. .. ............................8-3 Filter Clean ing and Inspection ......................... ................ .............. ....... ...... ............ . Cooling and Bilge System Hoses .................................................................................. : Hose Removal ......... .................. .. ... .... .... .. ................................................................ Hose Installation ...... ....................... .............. .......... ....... ............................. ............ . Hose Inspection ....... ....... ...... .................................. ..................................... ... .... .... . Cooling and Bilge System Flushing .............................. .............. ............ .. .......... ....... 8-4 Cooling System Flushing .. .. .......................... ..................................................... 8-4 Bilge System Flushing ..... .. .......................... .. ........ .......... ...... .............. ......... ... .. .8-4

â&#x20AC;¢ = Base

Manual

8-2 COOLING AND BILGE SYSTEMS Exploded View

T1: 9.8 N·m (1.0 k!tm, 87 in·lb) SS: Apply silicone sealant.

COOLING AND BILGE SYSTEMS 8-3 Bilge System

Breather Removal • Pull the hoses [A] off the breather. • Unscrew the mounting bolt [B], and remove the breather [C].

Filter Remo val • Pull the hose [A] off the filter . • Unscrew the mounting screws [B], and remove the filter [C].

DIRECTION OF COOLING SYSTEM FLOW DIRECTION OF BILGE SYSTEM FLOW DI RECTION OF COMBINED EXHAUST AND COOLING WATER FLOW

8-4 COOLING AND BILGE SYSTEMS Cooling and Bilge System Flushing

Cooling System Flushing .The flushing procedure is the same as in the base manual. Refer to the following photographs. A. Fitting Cap B. Garden Hose C. Bypass Outlet

Bilge System Flushing .The flushing procedure is the same as in the base manual. Refer to the

following photograph. A. Breather Fitting

DRIVE SYSTEM 9-1

Drive System Table of Contents

Exploded View ..................... ....... ............................................ .................................... 9- 2 Specifications ........................ .................. ......................... ...........................................9-3 Drive Shaft/Drive Shaft Holder .......... ..... ......... ........ ................................................... 9-4 Drive Shaft Removal/Installation .................. ......... ............................................ 9-4 Drive Shaft Holder Removal / Disassembly .................................................. .. ... ......• Drive Shaft Holder Assembly/ Installation .............................................................. • Drive Shaft Runout ............................................................................................. 9-4 • = Base Manua l

9-2 DRIVE SYSTEM Exploded View

T1 : 39 N路m (4.0 kg-m. 29 ft路lb) T2: 22 N路m (2.2 kg-m. 16.0 ft路lb) L : Apply a non--permanent locking agent. G : Apply grease. SS : Apply silicone sealant.

DRIVE SYSTEM 9-3 Specifications Item Drive Shaft: Runout (Refer to Page 5)

Special Tools -

Standard [AJ less than 0.1 mm [BJ less than 0.2 mm

Coupling Holder: 57001-1230 Drive Shaft Holder: 57001 -1327 Drive Shaft Holder Adapler: 57001-1231 Bearing Driver Sel: 57001-1129

Special Tool - Pressure Cable Luber: K56019 021

Service Limit 0.2mm 0.6 mm

9-4 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft Removal/Installation • Remove the engine (see Engine Removal/Installation chapter) . • Pull the drive shaft [A] out of the hull .

• Clamp the drive shaft, and unscrew the coupling. Special Tools - Coupling Holder: 57001-1230 [A] Drive Shaft Holder: 57001-1327 [B] Drive Shaft Holder Adapter: 57001-1231 [C]

OApply grease to the grease seal lips and the drive shaft spline.

Drive Shaft Runout • Measure drive shaft runout by supporting the shaft on V blocks and setting a dial gauge against the shaft at each 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: Service Limit:

Less than 0.1 mm [A] Less than 0,2 mm [B] 0.2 mm [A] 0.6mm [B]

PUMP AND IMPELLER 10·1

Pump and Impeller Table of Contents

Exploded View .......................................................................................................... 10-2 JH750-B1 .............................................. ................... .... ........................................ 10-3 Specifications ..... .......................... ......................... ..... .. ................. ..... ..... ........... ... .. .. 10-4 Pump and Impeller .................................................... .. ............................................ .. 10-5 Pump Removal ........................................................................................................• Pump Installation ..... .............................................................................. .. ... ............ . Pump Disassembly .. ................................................................................................• Pump Assembly ..................... .. ....... ................... ... .............. .. ... .. .. .. ... ................ 10-5 Pump and Impeller Inspection ......... ..... .. ........ .. .............. .. ...................................... Impeller Clearance ......... ................ ....... .... .............. ........................... .......... .. ......... .

• = Base Manual

10-2 PUMP AND IMPELLER

Exploded View (JH750-A1.A2)

T1 : T2 T3: T4:

7.8 N-m (0.8 kg-m, 69 in-Ibl 9.8 N-m (1.0 kg-m, 87 in-Ibl 22 N-m (2.2 kg-m, 16.0 ft-Ibl 98 N-m (10.0 kg-m, 72 ft-Ibl

55: Apply silicone sealant. G : Apply grease. L :Applya non-permanent locking agent

c:::o@) CD

~ ~CD

(

~ L

@ Â® 0

PUMP AND IMPELLER 10-3 Exploded View (JH750-B1) • The nozzle trim is added on the JH750-Bl and the JH750-Bl has the five blade impelier (Material: Cast Stainless Steel).

Tl: T2: T3: T4: SS: G :

7.8 N·m (0.8 kg·m, 69 in·lb) 9.8 N-m (1.0 kg-m, 87 in-Ib) 22 N'm (2.2 kg·m, 16.0 ft·lb) 98 N-m (10.0 kg·m, 72 ft·lb) Apply silicone sealant. Apply grease. L : Apply a non-permanent locking agent.

@J ~ ~

~©

r (

~ 0

10-4 PUMP AND IMPELLER Specifications (JH750-A1.A2, JH750-B1) Item Jet Pump: Impeller Outside Diameter Pump Case Inside Diameter Impeller Clearance

Special Tools -

Sealanl -

Standard 139.5 - 139.6 mm 140.0 - 140.1 mm 0.2 - 0.3 mm

Impeller Wrench: 57001路1228 011 Seal & Bearing Remover: 57001路1058 Bearing Driver Set 57001路1129 Kawasaki Bond (Silicone Sealant): 57001路1120

Service Limit 138.5 mm 141.1 mm 0.6mm

PUMP AND IMPELLER 10-5 Pump and Impeller Pump Assembly â&#x20AC;˘ Pump assembly procedure is the same as in the base manual. Add the following information.

a Press the grease seal [A) into the impeller [8) , aligning the seal teeth [C] with the sleeve teeth [0) .

a To protect the seal teeth from damaging, insert a suitable collar [A) that is longer than no spline part including the spline starting area into

the impeller wrench [8). Special Tool - Impeller Wrench: 57001Âˇ1228

a Insert the grease seal [C] deeply into the impeller wrench, aligning the seal teeth with the wrench teeth.

a Push the above wrench assembly into the impeller [AJ, and then lightly press the wrench assembly to seat the grease seal into the impeller sleeve [8).

PRESS

CAUTION 00 not press the grease seal heavily. You could damage the grease seal.

STEERING 11-1

Steering Table of Contents

Exploded View ..........................................................................................................11 -2 JH750-B1 .. ........................ ... .... .............................. ............. ....... .. ........................11-3 Steering Cable ...........................................................................................................11 -4 Adjustment ........................................................................................................11-4 Trim Cable Adjustment (JH750-B1) ............................................................... 11-4 Removal ................................ ............................................................................ 11-4 JH750-B1 ........... .................... .................... ........ .........................................11-7 Installation Notes ..............................................................................................11-7 Trim Cable Removal/Installation Notes (JH750-B1) .... .. .............. .. ........ .... ... 11-7 Inspection .................... ...................................... ,..... .... ............................................ * Lubrication ............................................................................................................. Handlebar .................................................................................................................. 11 -8 Hand Grip Removal / Installation .............................................................................. Handlebar Removal .......................................................................................... 11-8 Handlebar Installation Notes .......... ............................ ......................................11-8 Steering ... .............................................................................. ................ .. ................ 11-10 Removal .......................................... ................................................................11 -1 0 I nstallation Notes .... ................. .... ... .. .. ............................................................11 -11 Trim Adjuster (JH750-B1) ........ .. ................................................................. .. .. ...... 11-14 Trim Adjuster Removal ...................................................................................11 -14 Installation Notes ............................................................................................11-15 â&#x20AC;˘ = Base Manual

11-2 STEERING Exploded View (JH750-A1. A2.) T1: T2: T3: T4: L :

16 N·m (1.6 kg-m, 11.5 ft·lb) 18 N·m (1.8 kg-m, 13.0 ft-Ib) 78 - 88 N-m (8 - 9 kg-m, 58 - 65 ft-Ibl 29 N-m (3.0 kg-m, 22 ft-Ib) Apply a non-permanent Locking agent. 55: Apply silicone sealant.

STEERING 11-3 Exploded View (JH7S0-B1)

T1: T2: T3: T4: L : SS:

16 N·m (1.6 kg·m, 11.5 It·lbl 18 N·m (1.8 kg·m, 13.0 It·lbl 78 - 88 N·m (8 - 9 kg·m, 58 - 65 It·lbl 29 N·m (3.0 kg·m, 22 ft·lbl Apply a non·permanent locking agent. Apply silicone sealant.

11-4 STEERING Steering Cable

Adjustment • Check the steering cable adjustment. o Center the handlebar in the straight-ahead position .

• Check that the steering nozzle is centered [A) in the pump cavity .

• If necessary adjust the steering cable.

o Loosen the locknut on the steering cable. o Disconnect the ball joint by sliding the outer sleeve [A)

away from the ball slightly, and lifting the cable from the ball. OTurn the ball joint on the cable to adjust the steering. o Connect the ball joint and check cable adjustment again. OWhen adjustment is correct, tighten the steering cable locknut.

Trim Cable Adjustment (JH750-B 1) • Check the trim cable adjustment. o Place the watercraft on the level ground.

....

o Disconnect the handle return spring [A]

STEERING 11-5

o Set the adjuster knob at the N-position (O"/level). o Put 30 em

- rule on the level part of pivot bolt mounting [Aj, which is at the top of steering nozzle, and lift the tip of the nozzle [Bj all the

way up.

o Check whether the rule is parallel to the ground.

NOTE

o The tip of nozzle has about 75 mm play structurally. O Do not place the rule on the bolt.

elf it is not parallel, adjust the trim cable. o For making the working space, disconnect the steering cable ball joint [Aj by sliding the outer sleeve away from the ball slightly, and lifting the cable from the ball. o Disconnect the trim cable ball joint [8] in the same way. OTurn the ball joint to adjust the trim cable. o Connect the ball and check cable adjustment again. o When adjustment is correct, tighten the cable locknut.

Removal â&#x20AC;˘ Disconnect the ball joint at each end of the steering cable.

o Slide the outer sleeve [Aj away from the ball slightly, and lift the cable from the ball.

CAUTION Never lay the watercraft on the left side. Water in the exhaust system may drain back into the engine, causing serious damage.

e Loosen

the ' locknut [AJ, and then remove the ball joint [B] and locknut from each cable end.

11-6 STEERI NG

• Disconnect the steering cable from the cable holder.

o Unhook the handle return spring. o Unscrew the mounting bolts [Aj, and remove the table holder [Bj

• Separate the cable [Aj form the cable holder [Bj .

• Remove the pump cover (see Pump Removal in the Pump/Impeller chapter) . • Disconnect the steering cable from the fitting at the rear of the hull.

o Unscrew the large nut [Aj while holding the fitting [Bj in the hull with a wrench.

OSlide off the snap ring [Aj, washer [B], and O-ring [Cj .

• Pull the cable from the cable detent in the engine compartment . • Pull out the steering cable toward the front.

STEERING 11-7

Removal (JH750-B 1) .The removal procedure is the same as in the JH750-Al.A2, except for the following. OTo remove the steering cable [AJ, push the trim cable [ B] , as shown.

Installation Notes • Lubricate the outside of the new cable to ease cable installation . • Slide a piece of rubber [A] or plastic tubing over the rear cable end to guide the cable through the hull.

•

Trim Cable Removal/Installation Notes (JH750-B1) . Trim cable removal is the same as steering cable removal. • During installation tighten the cable nuts. Torque - Cable Nut: 18 N-m (1.8 kg-m, 13.0 ft-Ib)

.Be sure to adjust the trim cable (see Trim Cable Adjustment) .

. . . --

11-8 STEERING Handlebar

Handlebar Removal • Remove the handle cover. • Unscrew the mounting bolts [A] and remove the pad [B] .

• Take out the throttle case clamp bolts and remove the throttle case [A] . • Take out the switch case clamp screws and remove the switch case

[B] .

• Take out the handle clamp bolts [A] and remove the handlebar [B].

Handlebar Installation Notes .Applya non-permanent locking agent to the handlebar clamp bolts . • Install the handlebar on the holders of the steering neck with clamp bolts .

• Align the punch mark [A] on the left side of the handlebar w ith the center of the gap [ B] between the left holder and clamp . • Tighten the front and then rear handlebar clamp bolts to the specified torque.

Torque - Handlebar Clamp Bolts: 16 N-m (1.6 kg-m.11.5 H-Ib)

STEERING 11-9

â&#x20AC;˘ Before installing the pad (front side) [AJ . set the handle cover [BJ on the pad as shown.

11-10 STEERING Steering

Removal • Remove the handlebar (see Handlebar Removal) . • Unscrew the mounting bolts [A] and remove the steering cover [8]. Sliding the cover towards front.

• Unscrew the mounting bolts [A] and remove the LED unit [8] .

• Unscrew the mounting bolts [A] and remove the bracket [A] and the steering neck [8] .

• Remove the cotter pin [A] and locknut [8] . • Take out the holder [C] .

• Holding the nut [ A] with the steering stem nut wrench [ 8 ]. remove the steering shaft nut [C] . Special Tool - Steering Stem Nut Wrench: 57001-1100

STEERING 11-11

• Remove: Duct Grommet [A] Vent Hose Throttle Cable Start/Stop Switch Leads LED Un it Leads

• Unscrew the mounting bolts [A] and remove the steering holder [B] . • Take out the nut and pull the steering shaft.

Installation Notes .Check the bushings for damage and wear.

* If the bushings are damaged or w orn, replace them . • Grease: Bushings [A] Steering Shaft [ B]

.Be sure the grommet [A] is installed around the washer [B].

ov C§:}-®

This side to be under

11-12 STEERING

elnstall the steering shaft [A] into the steering holder [B] and hand tighten the nut [C].

eClean the mating surfaces of the steering holder and hull. eCoat the steering holder bottom with silicone sealant [A], and fit the steering holder to the hull. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

.Applya non-permanent locking agent to the steering holder mounting bolts and torque them.

Torque - Steering Holder Mounting Bolts: 16 N-m (1.6 kg-m, 11.5 H-Ib)

eWith the steering cable connected, the nut [A] shou ld be loose enough so the spring tension allows the steering shaft to be selfÂˇturning.

eThe nut [A] should also be tight enough to eliminate all play in the steering shaft.

e Torque the steering shaft nut [A]. Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering ShaH Nut: 78 - 88 N-m (8 - 9 kg-m, 58 - 65 H-Ib)

STEERING 11-13

.Apply silicone sealant to the grommet [AJ and the air duct [ 6J.

11-14 STEERING Trim Adjuster (JH750-B1) Trim Adjuster Removal • Remove: Plug Adjuster Knob Mounting Bolt [A] Steering Cover (see Steering Removal) Locknut [B] and Plate Mounting Nuts [C]

• Disconnect the trim cable ball joint [A]

.Pull down the shaft [A] and spring [B] .

• Cut the sealant and remove the base plate [A] . • Unscrew the clamp bolt [B] and disconnect the trim cable [C].

STEERING 11-15

Installation Notes elnstall the bushings [A], noting the chamfer sides [B] as, shown. eGrease the shaft [ C] and apply a non-permanent locking agent to the M10 thread [ D] .

e App ly silicone sealant [A] to the mating surface of the plate and hull.

HULL/ENGINE HOOD 12-1

Hull/Engine Hood Table of Contents

Exploded View ......................................................................................... ................. 1 2 -2 Fittings .......................... ...... ........ ....................... ............... .. .. .... ................................. 12-4 Hatch Cover Removal/Installation ..................... .... .......................................... 12-4 Handrail Removal/Installation ..........................................................................12-4 Air Exhaust Duct Removal ................................................. ............................. 12-4 Air Exhaust Duct Installation Notes .................................. ...............................12-5 Hull Replacement ......................................................................................................12-6 Rubber Parts ..............................................................................................................12-7 Rubber Parts Location .......................................................... .... ........................ 12-7 Front Bumper Removal ....................................................................................12-8 Front Bumper Installation Notes ............ ........... ............................................... 12-8 Rear Bumper Removal ................. .. ........... ....................................................... 12-9 Rear Bumper Installation Notes ........ ............................................................... 12-9 Side Bumper Removal ...................................................................................... 12-9 Side Bumper Installation Notes ............................ ...... ................................... 12-10

12-2 HULL/ENGINE HOOD Exploded View

Iya non- pe rma nent locking agent L : App SS: Apply 51TIcone sealant.

HULL/ENGINE HOOD 12-3

L? ~ f

JH7S0-B1 @ _____ 1 ___ _ I I

I I I

~---------- -'

~ .,

~ ,I 55 Y

12-4 HULL/ENGINE HOOD Fittings

Hatch Cover Removal/Installation .Take out the bolts [A) and remove the hatch cover [B) . • Unscrew the mounting bolts [C) and remove hatch cover latch [D) . • To remove the cover hinge [E) , remove the mounting bolts [F) . • Installation is the reverse of removal. OApply silicone sealant [G) to the mating surface of the hinge and hull. Sealant - Kawasaki Bond (sillieone Sealant): 56019·120

Handrail Removal/Installation .Take out the bolts [A) and remove the handrail [B) . • When installing the handrail, apply silicone sealant [C) to the mating surface of the handrail and hull. Sealant - Kawasaki Bond (sillieone Sealant): 56019·120

Air Exhaust Duct Removal • Remove: Water Box Muffler (see the Exhaust System chapter) Cap [A) Duct Bracket Mounting Nuts [B) Bracket [C)

HULL/ENGINE HOOD 12-5

• Remove the duct [AJ out of the hull.

• Remove the battery breather hose [AJ.

Air Exhaust Duct Installation Notes • Be sure the damper [AJ is in the position . • Route the battery breather hose [ CJ correctly (see the Cable Routing section in the General Information chapter) . • Apply silicone sealant to the mating surface of the bracket [BJ and hull.

12-6 HULL/ENGINE HOOD Hull Replacement To replace the hull, remove the various parts in the following suggested order. Battery and Pad Oil Tank Electric Case Exhaust Pipe, and Expansion Chamber Water Box Muffler Air Duct

Carburetor Engine and Mounts Intake Silencer

Drive Shaft and Shaft Holder Sediment Bowl Fuel Tank and Filler Fuel Tap Choke Assembly Pump and Hoses Steering Cable Handlebar and Steering Bilge and Cooling System Hose Bypass Hose and Outlet Bumpers Engine Hood Latch Hatch Cover and Hinge

Handgrip The following parts cannot be removed from the hull and must be replaced. Decals Labels

Mats Registration Number (if any) If the new hull is to be painted, do that first. Then install the removed parts in the reverse order of their removal.

decals, mats and the registration numbers.

Final ly, install the labels,

HULL/ENGINE HOOD 12-7 Rubber Parts NOTE

o The rubber parts on the watercraft are fastened in place with various adhesives. To replace a rubber part use a cement in the following table, or an equivalent. .. 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.

Type

For th is Appl ication :

Mats Engine Hood Gasket Hatch Cover Trim Seal Hatch Cover Damper

Synthetic Rubber Adhesive PI N: 92104 -3701

Detents

Cyanoacrylate cement

Handlebar Grips

CAunON 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. H 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.

Rubber Parts Location Engine Hood Gasket [AJ

12-8 HUll/ENGINE HOOD

Hatch Cover Trim Seal [A) and Damper [B)

Detent [A)

Mat [A)

Front Bumper Removal â&#x20AC;˘ Unscrew the bushing [A) and the mounting nuts [B). and remove the front bumper [C).

Front Bumper Installation Notes .Applya non-permanent locking agent to the following. Front Bumper Mounting Nuts Bushing Nut

HULL/ENGINE HOOD 12-9

Rear Bumper Removal â&#x20AC;˘ Remove: Corner Bumper Mounting Nuts [A] Corner Bumpers [B] Rear Bumper Mounting Nuts [C] Rear Bumper [DJ

Rear Bumper Installation Notes .Applya non-permanent locking agent to the following. Corner Bumper Mounting Nuts Rear Bumper Mounting Nuts

Side Bumper Removal .Remove: Front Bumper (see Front Bumper Removal) Corner Bumper (see Rear Bumper Removal)

.Remove the trim strip [A] from the side bumper [B].

12-10 HULL/ENGINE HOOD

â&#x20AC;˘ Drill out the pop rivets with a drill bit of the correct size.

Pop Rivet Removal Drill Bit Size 6.5mm

NOTE OStop drilling when the rivet head [Aj starts to turn with drill bit. o Tap the rivet out of the hull flange with a suitable punch and

hammer,

Side Bumper Installation Notes .Align the recess [Aj with the mounting hole for corner bumper.

) ~

.Secure the bumper to the hull flange with a pop rivet [Aj .

â&#x20AC;˘ Install the trim strip [Aj, pushing of the both sides of the strip as shown.

ELECTRICAL SYSTEM 13-1

Electrical System Table of Contents

Wiring Diagram ......................................................13-2 Exploded View ........................................................ 13-3 Specifications .................. ..... ...................................13-5 Battery................................ ............................... . Precautions ............................................................. Removal ................................................................• Installation .......... ................. ....... ........................ . Battery Cleaning ........ .............. ....... ....... ..... ......... Electrolyte Level Inspection .. ... .... ... .................... : Condition .......... ... ... ........... ... ...... ..........................• Initial Charging ......... .......................................... . Ordinary Charging .......... ... ................................. . Test Charging .......................................................• Electric Starter System ............... ...... ..... ......................... .. h_~~......... .

...·

Removal .............................................................. . Installation Notes ....... ..... .....................................• 1nspection .............. '.', ...................... ' .............. .... ,_" Reduction Gear: ................ ... ................................... . Removal / Installation Notes ................................. .. Inspection .......................................... ... ................ .. Starter Motor: ..... ........... ................................... . Removal .. ......................... . Installation Notes ............... ....... .... ...... ... ............ . Disassembly .......... .......................... ...................... .. Assemb ly ............ ..................................................• Brush Inspection ................................................ . Brush Spring Inspection ...................................... .. Commutator Cleaning and Inspection .. ... .......... .. Armature Inspection ... ... ..... ... ...............................• Brush Plate Inspection .........................................• Brush and Lead Assembly Inspection ................ : Charging System ...... .... .................................................• Charging Coil Testing .... ..................................... : Regulator/ Rectifier Removal ................................ • Regulator/ Rectifier Installation Notes ................ : Regulator/ Rectifier Inspection ........................... ..•

Ignition System ..... ..................................................13-6 Pickup Coil Inspection ............... .. .. ...................... .. Ignition Coil Removal ....................................... .. Ignition Coil Installation Note ............................ . Ign ition Coil Inspection .......................................• CDI Igniter Removal ..................... .............. . CDI Igniter Installation Notes .............................: CDI Igniter Inspection ........ ........................... 13-6 JH750-B1 ...............................................13-6 Spark Plug Removal ............................................. • Spark Plug Installation .................. ................. ..... : Spark Plug Inspection ......... ................................ : Spark Plug Cleanin g ........................................... : Spark Plug Adjustment.. ..................................... : Electric Case ............................................................13-7 Remova l ....... .... .. .... ..... ........................... 13- 7 Installation Notes ...........................................13-7 Disassembly ............. ...................................... 13-7 Assembly Notes ................... ............ .............. 13-7 Switches ...... .......................... ......................... . Start/ Stop Switch Removal. .......... ..................... : Start/Stop Switch Installation Notes ................. : Start/Stop Switch Inspection .................... . LED Fuel Gauge and Warning Unit .......... .............. 13-9 Oil Level Warning Light ................................. 13-9 Fuel Indicator/ Warning Light ............. ........... 13-9 Water Temperature Warning Light... .............13-9 LEO Unit Removal/Installation Notes ........ 13-10 LED Unitlnspection ... .............. ... .. .... .......... 13-10 Oil Level Sensor Inspection ........................ 13-10 Fuel Level Sensor Inspection ............. ......... 13-11 Temperatu re Sensor Removal ................... ........... • Temperature Sensor Installation Notes ....... . Temperatu re Sensor Inspection ........................... .. Fuse .............. ................................................ . Inspection ...... ........... . .. ......... .... ........... ......... . = Base Manual

~ _. ~, :t ::l

~ =QJ= ~ ==C ~t=QJ= ~t ==C

1. water Tempera t ur e Ind ic at or 2. Fu e l level

Indi c a to r 3. 011 l eve l Ind I cat or 4 . S top Switch s . s tort sw Itch

@ ~=>

(!)ma..n:::

(i])

CD (DIE I ~

- BR - R - BK

. .

<J <J

~~ ~

.. .

@Â©= R~ RC1J BK / Y ~ B

=lll==

CD ~ ~~~RU =UJ==

} =BKcfW _-

~ll

lJC-7~

W D<l-- BK t>D- R~PU D<l-- IR~ R--D<J- R

W BK R/B L Y/R

'" I ~

J-'

R~ -BK ~~

'"~ "-

R-D<I- R-

1'---

16 . COI I gnlte r 17. lgnlt Ion Co II 18. El ect ri c Case

water Tempe rature Sen so r

; - . - _. - ---

t>D---

15.

'--- BK '-- BR r'-- BR R-

!;lIre Co l or code Bl oc k BK BL Blue Brown BR Green G Of ange 0 P in k P Purple PU Red R Wh I te W Ye I I ow Y (980S I - 37158)C

\ ---

::II

-l

-< ~ m

14 . Spar k Plug

- >

~=>

(')

~ r-

9 . Fuse (lOA) atar/Reet I f ler etD 12. Fuel Leve I Sensor 13. 0 I I L eve I Sensor

(,!)coa...O:::

r\~

[

- R/Y --c[]- R/ Y

'" '" '"

III

3 -

7 . BatterY 8 . S tarter Relay

o,,>,,~

CO m C r_. m CO

6. Star ter Motor

JH 150A

ELECTRICAL SYSTEM 13-3 Exploded View

1. 2. 3. 4. 5. 6. 7. 8. 9. T1 :

T2: T3: T4: T5: T6:

Starter Relay COl Igniter 10 A Fuse Regulator/Rectifier Ignition Coil Temperatu re Sensor Fuel Level Sensor LED Unit Oil Level Sensor 7.8 N.m (0.8 kg.m, 69 in-Ibl 27 N-m (2.8 kg-m, 20 ft-Ibl 2.9 N·m (0.3 kg·m, 26 in-Ibl 98 N·m (10.0 kg-m, 72 ft-Ibl 12 N.m (1.2 kg-m, 8.5 ft.lbl 125 N-m (13,0 kg-m, 94 ft-Ibl

~M ~

t:j'@OC'--.

<::::;,

@--Yi

~ ~ Q:;, ~ ~ ~"

Apply a non-permanent locking agent. L G . Apply grease. M : Apply molybdenum disulf,'de grease.

~--------~~®

~....,

~ o ~ •

~",,®,-~G oJ.~ ~

TL'

~ ~'

"':,

.~,( ~ /'---...

T1 L

13-4 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM 13-5 Specifications Item

Standard

Battery: Type Specific gravity of electrolyte

12V19Ah 1.2S0 @20"C (6S"F)

Electric Starter System: Starter motor: Brush length Commutator diameter

12.5 mm 2S mm

Charging System: Regulator/ rectifier output voltage Charging coil output voltage Charging coil resistance: Brown .- -+ Brown

Ignition System : Ignition timing Ignition coil: Primary winding resistance Secondary winding resistance Spark plug: Type Gap Pickup coil resistance Pickup coil air gap (Clearance between the rotor projection and pickup core) Start/ Stop Switch: Start button : Released Depressed Stop button : Released Depressed Special Tools -

Hand Tester: 57001-983 Coil Tesler: 57001-1242

---

- --

6.5mm 27mm

Battery voltage - 14.5 Âą05 V 20 V 0.7 - 1.1

Service Limit

-------

13" BTDC @1,250 r/ min (rpm ) 16" @2,500 r/ min (rpm)

---

O.OS - 0.1 n 3.5 - 4.7 kn

-- ---

NGK BRSES 0.7 - O.S mm 396 - 594 n

-----

O.S - 1.0 mm

---

000

-----

Almost

000

Almost on

---

-- -

13-6 ELECTRICAL SYSTEM Ignition System CDllgniter Inspection .The inspection procedure is the same as in the base manual, except for the following.

COl Igniter Internal Resistance (JH7S0-A1 , A2) Unit: kO

Tester (+) Lead Connection Lead Color

BK/W

R(Y

BK(Y

BK/ BL

2-4

12 - 20

6 - 13

10 - 20

2-4

BK/W

6 - 13

2-5

2 - 5

4 - 10

6 - 13

2-5

4 - 10

6 - 12

11 - 22

12 - 23

6 - 12

20 - 60

42 - 110

14 - 28

20 - 60

R ( - )-

20 - 60

00 100 - 200 100 - 200 100 - 200 130-400

R/ Y

20 - 60

40 -100

60 - 200

20 - 60

BK/ Y

6 - 13

2-5

4 - 10

10 - 30

130-400 100 - 200 00 100 - 200 100 - 200

10 - 30

25 - 60

30 - 300

6 - 13

2-5

4 - 10

BK/ BL

6 - 13

2 - 5

2-5

4 - 10

30 - 300 30 - 300

(-r :Tester (-) Lead Connection COl Igniter Internal Resistance (JH750-B1) Unit : kO

Tester (+) Lead Connection 0

BK/ W

R/ Y

BK/ Y

BK/ BL

2-4

12 - 20

6 - 13

20 - 60

2-4

BK/W

6 - 13

2-5

8 - 25

6 - 13

2-5

2 - 5

8 - 25

6 - 12

11 - 22

15 - 45

6 - 12

20 - 60

40 - 110

30-150

20 - 60

Lead Color

R (-)-

20 - 60

00 100 - 200 100-200 100 - 200 130 - 400

R/ Y

BK/ Y

Â· 6 - 13

2 - 5

8 - 25

10 - 30

25 - 60

30 - 300

10 - 30

6 - 13

2 - 5

8 - 25

BK/ BL

6 - 13

2 - 5

8 - 25

(- r : Tester (-) Lead Connection

150 - 500 100 - 200 00 100 - 200 100 - 200

30 - 300 80 - 500

ELECTRICAL SYSTEM 13-7

Electric Case

Removal • Remove:

Battery (-) Cable Spark Plug Caps Battery (+) Cable [AJ Starter Motor Cable [BJ Electric Case Connector [C] Temperature Sensor Temperature Sensor Leads Connector StartlStop Switch Connector LED Unit Leads Connector • Unscrew the mounting bolts [AJ, and remove the electric case [BJ

Installation Notes .Apply water resistant grease to the O-ring [AJ of electric case connector .

• Apply a non-permanent locking agent to the electric case mounting bolts and torque them.

Torque - Electric Case Mounting Bolts: 7,8 N·m (0,8 kg·m, 69 in·lb)

Disassembly • • • o

Remove the electric case (see Electric Case Removal) . Remove the electric case bolts [AJ , and open the electric case . Remove the electric box compartments. Note wire routing and ground terminal location.

Assembly Notes .Connect the battery cable to the relay ( + ) terminal having red lead .

• Run the charge wires of igniter and regulator through the electric case hole, before installing regulator. . • Connect the ground leads (black) to the regulatorl rectifier mounting bolts . • Apply a non-permanent locking agent to all the removed bolts, and torque them. Torque - All Removed Bolts: 7,8 N·m (0,8 kg·m, 69 in·lb)

.Apply water resistance grease to the O-ring of electric case.

13-8 ELECTRICAL SYSTEM

To Magneto Grease O-ring

Plug

Fuse (lOA)

. ,

Grease (2 places)

Washer

Grommet

To Starter To Battery

..:....\ 3-pin Connector

\-:.~ '.Starter Relay Washer Washer

Spacer

1====~====:J To Front Cylinder 1:==]E=~J

To Rear Cylinder

};E=~==:ot=}TO Start/Stop Switch To Temperature Sensor

To LED Unit

BK/W Lead COl

Grease O-ring

larlitH,n Coil

Grease (6 Places) Cap

Joint

Grommet

ELECTRICAL SYSTEM 13-9 LED Fuel Gauge and Warner Unit The three kinds of red LED (Light Emitting Diode) go on only when the engine is running. When the engine is started, all warning and indicator lights go on for several seconds (self checking) , and then all

ÂŽ

lights go on according to each status.

A. Oil Level Warning Light B. Fuel Warning Light C. Fuel Indicator Lights

'aM

D. Water Temperature Warning Light

~rD ~~ I

ai/ Leve/ Warning Light When the oil level in the oil tank gets low, the warning light comes on to warn the riders .

Fue//ndicator/ Warning Light When the fuel tank is full, all indicator lights go on. As the fuel level in the tank goes down, the lights go off one by one from right (marked F) to left to show quantity of the fuel left in the tank. When the fuel has decreased to about 6 L, the warning light (marked E) goes on to warn the riders.

engine speed decreases to about 3 500 rpm . This prevents engine overheating damage and helps the riders get to shore if the cooling system is clogged with sand or debris from the water. If the cooling water cools to SS"C, the light comes off. Warning/Indicator Lights System Wiring Diagram

1. LED Unit 2. Oil Level Sensor 3. Fuel Level Sensor 4 . Temperature Sensor 5. COl Igniter 6. 12 V Battery 7. Regulator/ Rectifier S. Magneto 5

L-----~------~ 6

8 r---------------~

I-------------{ 7

13-10 ELECTRICAL SYSTEM

LED Unit Removal/Installation Notes • Remove or disconnect (see the Steering System chapter): Steering Cover LED Unit Mounting Bolts Grommet Wiring Connectors LED Unit .Installation is the reverse of removal. Note the following . • Check the waterproof rubber [A] and display panel [B] for damage. *If the rubber and panel are damaged, replace the unit.

LED Unit Inspection . There are the following troubles of LED unit. 1. All warning and indicator lights do not go on when the engine is running. 2. The self-checking procedure does not operate properly. 3. Some of the warning and indicator lights do not appear or do not go on. • Check the following for the above troubles. Battery power supplied to the unit Wiring broken or improperly connected Sensors damaged *11 all of the above check are good, replace the LED unit.

Oil Level Sensor Inspection • Disconnect the oil level sensor 2 -pin connector . • Loosen the clamp, and remove the oil level sensor [A] out of the oil tank [B].

• Set the hand tester (ohmmeter) to the x 1 n range, Special Tool - Hand Tester: 57001-983 • Connect the tester leads to the BL and B L leads to check the switching operation of the float. Meter Reading When sensor is held upright [A] When sensor is held upside down [B] 00 * The meter shou ld read as specified. If it does not, replace the oil level sensor.

ELECTRICAL SYSTEM 13-11

Fuel Level Sensor Inspection • Open the hatch cover.

• Disconnect the fuel level sensor 2-pin connector. • Loosen th e clamp, and remove the fuel level sensor [AJ out of the fuel tank [BJ.

• Set the hand tester (ohmmeter) to the x 1 kO range. Special Tool - Hand Tesler: 57001-983 .Connect the tester leads the PU and PU leads to check th e switching operation of the float.

Meter Reading 8.03 kO ±5% When sensor is held upright [AJ 0 - 500 When sensor is held upside down [ BJ *The meter should read as specified. If it does not replace the fuel level sensor.

h ll.tor

r " ---------------1 ,., , \ ." , ,! ,., ,, '.

....~_ _ o-rlll9

,.,

,uh, r 11119f!.t

-I1t-- - --fii'----L..dSWitCh But Pllte

S.,

;

,; ,

1. ,

•. 1 KII

L . _._. _,._. _.,_. _,_. _. ______J

Flolt

FUll Ln l l

FUll Level senIo r

i !

CirCUit

•

B20

STORAGE 14-1

Storage Table of Contents

Preparation for Storage ............................................................................... .. ............14-2 Cooling System ........................................................................................................ Bilge System ............ ..... .............. .. .. ................ .. ................................. ............... 14-2 Fuel System ........... .......... .......... .... .. .................................................... ............. 14-2 Engine ..... .................... ... .................... ............... ........ .......... ................................. .. .. Battery .................................... .... ...... .......... ........ ... ................................................... Lubrication ......................... ' ....................................................................................• General ............................................................................................. .. ..................... . Rem ova l from Storage .................. ....................... ................................. ...... .. ................... . Lubrication ........ ...... ...... ..... ........ ......................... " .... ..... ... ............. .. .... ...... ...... ....... .. General Inspection ..................................... .. ............................................................ Fuel System ........... ............... .. .................. .................................................. ... ..........• Test Run ........... .. ............................... .. ... ... ..... .................................. ... ................... .

•=

Base Manual

14-2 STORAGE Preparation for Storage

Bilge System .The cleaning procedure is the same as in the base manual. A. Blow through both hoses

Fuel System .The cleaning procedure is same as in the base manual, except for the following. o Drain the sediment bowl [A] to remove any water which may have settled in it.

APPENDIX 15-1

Appendix Table of Contents

Lubrication ... ....... .... .. ........ .. ......................... ....... ......... ..................... .. ...................... 15-2 Troubleshooting ... ............. ...................... ............................ ........................................ .. .. ' Unit Conversion Table .. ................................................................................. ..................•

• = Base

Manual

15-2 APPENDIX 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: â&#x20AC;˘ Lubricate the following with a penetrating rust inhibitor. Throttle Cable Choke Cable Special Tool - Pressure Cable Luber: K56019-021: [AJ

Steering Nozzle Pivots [BJ

â&#x20AC;˘ Lubricate the following with a high quality waterproof grease. Throttle Cable Ends [AJ

Throttle Case [BJ

Choke Cable Ends [C]

APPENDIX 15-3

Steering Cable Ball Joints [D)

SUPPLEMENT-1994 MODELS 16-1

Supplement-1994 Models (JH7S0-A3/JH7S0-B2) This "Supplement-1994 Models" chapter is designed to be used in conjunction with the front part of this manual (up to the end of the "Appendix" chapter). The maintenance and repair procedures described in this chapter are only those that are unique to the 1994 JH750- B3/JH750 - B2 watercraft, therefore requires mechanics to read both this chapter and the text in front of this chapter.

JH750-A3 General Information Table of Contents Model Identification ........................................................................................ ....................... 16-2 General Specifications .......................... ....... ...........................................................................16-3

16-2 SUPPLEMENT-1994 MODELS Model Identification JH750-A3 Left Side View:

JH750-A3 Right Side View:

SUPPLEMENT-1994 MODELS 16-3 General Specifications Items Engine: Type Displacement Bore and stroke Compression ratio Maximum Horsepower

Maximum torque

Ignition system Lubrication system Carburetion system Starting system Tuning Specifications: Spark plug Type Gap Ignition timing Carburetor Idle Speed Compression pressure Drive System: Coupling Jet pump: Type Thrust Steering Braking

Performance: tMinimum turning radius tFuel consumption tCruising range

JH750-A3 2-stroke, vertical twin, crankcase reed valve, water cooled 743 mL 80.0 x 74.0 mm 7.0: 1 51.5 kW (70 PS) @6 250 rl min (rpm) < E> 49.3 kW (67 PS) @6 250 rlmin (rpm) (Continuous maximum hosepower) 83.3 N-m (8.5 kg-m, 61.5 ft-Ib) @5 500 rl min (rpm) < E> 78.4 N-m (8.0 kg-m, 57.8 ft-Ib) @5 500 rl min (rpm) (Continuous maximum torque) Magneto CDI (Dig ital) Oil injection (break-in period: Oil injection and fuel mixture 50 : 1) Keihin CDK40-34 diaphragm type (38 mm venturi) Electric starter NGK BR8ES 0.7 - 0.8 mm 13' BTDC @1 250 rl min (rpm) - 16' @2 500 rl min (rpm) 1250 Âą100 rl min (rpm) - in water 1 700 Âą100 rlmin (rpm) - out of water 835 - 1 294 kPa (8.5 - 13.2 kglcm', 121 - 187 pis) Direct drive from engine Axial flow, single stage 2648 N (270 kg, 595 Ib) Steerable nozzle Water drag 3.3 m 27 L/ h @full throttle < E> 26 L/ h @full throttle 88 km @full throttle 1 hour and 14 minutes < E> 89 km @full throttle 1 hour and 16 minutes

Dimensions: Length Width Height Dry weight Fuel tank capacity

2530 mm 1 030 mm 945 mm 170 kg 33 L including 6 L reserve

Engine Oil: Type Oil tank capacity

2-stroke, N.M.MA Certified for Service TC-WII 2.3 L

Electrical Equipment: Battery Maximum Generator Output

6.6 A/14 V@6 000 rl min (rpm)

12 V 19 Ah

= This

information shown here represents results under controlled conditions, and information may not be correct under other conditions.

Specification subject to change without notice, and may not apply to every country.

16-4 SUPPLEMENT-1994 MODELS

JH7S0-A3 Fuel System Table of Contents Specifications ............ .. ........................................................................................................... 16-4

Specifications JH750-A3 Item

Standard

Carburetor: Make, type Size Mixture screws: Low speed High speed Main jet Pilot jet in water Idle speed: out of water

Keihin, CDK 40 - 34 Diaphragm 38 mm Venturi 7/ 8 ± %turn open 1.0 ± %turn open # 155 # 80 1 250 ±1 00 rpm 1 700 ±1 00 rpm

Reed Valve: Reed warp

---

Fuel Tank: Capacity

33 L (including 6 L reserve)

Special Tool - Pressure Cable Luber: K56019'{)21 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit

-------------

---

--0.2mm

- --

SUPPlEMENT-1994 MODElS 16-5

JH7S0-B2 General Information Table of Contents Model Identification ................................ .......................................................... ...... .. 16-6 General Specifications .............................................................................................. 16· 7 Cable, Wire and Hose Routing .................................................................................16-8 Technical Information ............................... " ............................................................16·11

16-6 SUPPLEMENT-1994 MODELS Model Identification JH750-B2 Left Side View:

JH750-B2 Right Side View:

SUPPLEMENT-1994 MODELS 16-7 General Specifications Items Engine: Type Displacement Bore and stroke Compression ratio

Maximum Horsepower

Maximum torque

Ignition system Lubrication system Carburet ion system Starting system Tuning Specifications : Spark plug Type Gap Ignition timing Carburetor Idle Speed Compression pressure

JH750-B2 2-stroke, vertical twin, crankcase reed valve, water cooled 743 mL 80.0 x 74.0 mm 7.0 : 1 55.2 kW (75 PS) @6 500 r/ min (rpm) < E> 53 kW (72 PS)@6 500 r/min (rpm) (Continuous maximum horsepower) 86.3 N-m (8.8 kg-m, 63.6 ft-Ib) @6 500 r/ min (rpm) < E> 83.4 N-m (8.5 kg-m, 61.4 ft-Ib) @5 750 r/ min (rpm) (Continuous maximum torque) Magneto CDI (Digital) Oil injection (break- in period : Oil injection and fuel mixture 50 : 1) Keihin CDK40-34 x 2 diaphragm type (38 mm venturi) Electric starter NGK BR8ES 0.7 - 0.8 mm 13" BTDC @1 250 r/ min (rpm) - 16"BTDC @2 500 r/ min (rpm) 1 250 Âą100 r/ min (rpm) - in water 1 700 Âą 100 r/ min (rpm) - out of water 890 - 1370 kPa (9 .1 - 14.0 kg/cm', 129 - 199 pis)(Open throttle)

Drive System: Coupling Jet pump: Type Thrust Steering Braking

Direct drive from engine Axial flow, single stage 2795 N (285 kg, 628 Ib) Steerable nozzle Water drag

Performance: tMinimum turning radius tFuel consumption tCruising range

3.3 m 28 L/ h @full throttle 92 km @full throttle 1 hour and 11 minutes

Dimensions: Length Width Height Dry weight Fuel tank capacity

2530 mm 1 030 mm 945 mm 176 kg 33 L including 6 L reserve

Engine Oil: Type Oil tank capacity

2-stroke, N.M.MA Certified for Service TC-WII 2.3 L

Electrical Equipment: Battery Maximum Generator Output

12 V 19 Ah 6.6 A/ 14 V @6 000 r/ min (rpm)

This information shown here represents results under controlled conditions, and information may not be correct under other conditions.

Specification subject to change without notice, and may not apply to every country. < E> : Other than US and Canadian models.

16-8 SUPPlEMENT-1994 MODElS Cable, Wire and Hose Routing

1. Warning/ Indicator light Leads 2. Fuel Vent Hose 3. Clamp

4. Throttle Cable 5. Grommet 6. Start/ Stop Switch leads

(

7. Warning / Indicator Light Display Panel

8. Trim Switch leads 9. Spark Plugs 10. 11 . 12. 13. 14. 15. 16. 17. 18. 19. 20.

Electric Case

Magneto leads Oil Tank Air Duct

Battery Breather Hose Oil Level Sensor Leads Oil Inlet Hose

BOW

Battery Battery( - ) Cable Carburetor Detent

@ ___....

L .. L:4=.c:.:t= .I ===-~::::::: ..__ --

.. ~

® \" \

5f~ ",

@ Red lead Connected to Battery (+)

"" ""

I [,

""®I BOW

-----/

J. 4. 5. 6. 7.

1. 2.

~--

Oil level Sensor Leads Clamp Battery{ +) Cable Band To L.E .D. Unit To Trim Switch/ Tacho Meter/Trim Indicator

Oil Tank

To Start/ Stop Switch Fuel level Sensor leads Trim Motor Box Trim Cable Detent

---- /-(j=J

13. Oil Inlet Hose 14. Engine

8. 9. 10. 11 . , 2.

~::~

17. Battery Breather Hose 18. Magneto Leads

15. Bilge Filter '6. Battery( - ) Cable

BOW

• to

...

(fl

C m

to to

-I

...•

m Z

r m ~

"tI "tI

(fl

16-10 SUPPLEM ENT-1994 M DOELS

1. Tachometer 2. Trim Meter

3. Bracket

4. Grommet Plate 5. Grommet

~8 / ~ 8

~\---

SUPPLEMENT-1994 MODELS 16-11 Technical Information Electric Trim Nozzle with Meter New Feature When the rider pushes the electric trim nozzle switch on the left handlebar, an electric motor lifts or lowers the jet pump nozzle. Pushing the trim switch down moves the jet pump nozzle down lowering the nose of the watercraft as it moves through the water.

Power Train

Function Trim Adjust Switch: Pushing on the switch moves the jet pump nozzle continuously up or down. Releasing the switch stops the jet pump nozzle movement. Motor : The motor turns a shaft connected to the motor clockwise or counterclockwise to move the slide lever back and forth on the shaft according to the position of the switch. Slide Lever: The slide lever turns the trim angle sensor through a pin on top of the slide lever. The slide lever is also attached to the trim cable which moves the trim nozzle. Sensor: The sensor in a rheostat (variable resistor) . The resistance of the coil wound in it varies according to the amount of pin movement. Controller: The controller acts as a motor relay to turn the motor on and off.

1. Trim Swilch

2. Motor 3. ShaH 4. Slide Lever

5. 6. 7. 8.

Trim Cable Trim Nozzle Trim Angle Sensor Trim Meter 9. Pin 10. Controller

16-12 SUPPLEMENT-1994 MODELS

11. 12. 13. 14. 15.

Trim Motor Box Steering Nozzle Steering Cable Pump Case Tachometer

!:sl;;

SUPPLEMENT-1994 MODELS 16-13

JH7S0-B2 Steering Table of Contents Exploded View ........................... ............ .............................................................................16-14 Steering Gable ....................................................................................................................... 16-15 Adjustment ........................ ........................ ................... ...................................16-15 Trim Gable Adjustment ....................................................................................................16-15 Trim Gable Remova l/ Installation Notes ...........................................................................16-16

16-14 SUPPLEMENT-1994 MODELS Exploded View T1: T2: T3: T4: L : 5S : B :

16 N-m (1.6 kg-m, 11.511-lb) 18 N-m (1.8 kg-m, 13.0 ft-Ib) 78 - 88 N-m (8 - 9 kg-m, 58 - 65 ft-Ib) 29 N-m (3.0 kg-m, 22 ft-Ib) Apply

a non~permanent locking agent.

Apply silicone sealant. Apply a bonding agent.

SUPPLEMENT-1994 MODELS 16-15 Steering Cable

Adjustment .Check the steering cable adjustment.

o Center the handlebar in the straight-ahead position .

â&#x20AC;˘ Check that the steering nozzle is centered [A] in the pump cavity.

elf necessary adjust the steering cable.

o Loosen the locknut on the steering cable. o Disconnect the ball joint by sliding the outer sleeve [A] away from the ball slightly, and lifting the cable from the ball. OTurn the ball joint on the cable to adjust the steering. o Connect the ball joint and check cable adjustment again. o When adjustment is correct, tighten the steering cable locknut.

Trim Cable Adjustment .Check the trim cable adjustment. o Place the watercraft on the level ground. o Star! the engine. o Keep pushing the "UP" [A] half of the switch until the trim meter needle [B] points the level position [C].

16-16 SUPPLEMENT-1994 MODELS

OCheck the steering nozzle position. It should be parallel to the ground. o Put 30 em - ru le on the level part of pivot bolt mounting [AJ. which is at the top of steering nozzle, and lift the tip of the nozzle [B] all the way up. o Check whether the rule is parallel to the ground .

• If it is not parallel. adjust the trim cable. o For making the working space, disconnect the steering cable ball joint [A] by sliding the outer sleeve away from the ball slightly, and lifting the cable from the ball. o Disconnect the trim cable ball joint [B] in the same way. OTurn the ball joint to adjust the trim cable. OConnect the ball and check cable adjust again . o When adjustment is correct. tighten the cable locknut.

Trim Cable Removal/Installation Notes .Remove the engine (see Engine Removal/Installation chapter). • Remove the engine damper mount bolts [A] and disconnect the electric leads [B] .

• • • •

Turn the craft on its right side. Remove the pump cover. Disconnect the trim cable ball joint. Unscrew the cable nut [A] while holding the fittings with a wrench .

• Slide off the E- ring [AJ. washer [B] and O-ring [C].

SUPPLEMENT-1994 MODELS 16-17

• Pull out the cable with the trim motor box [AJ,

• Unscrew the cable nut [A] and slide off the E-ring [8]. washer [C] and O-ring [D] . • Remove the trim motor box cover (E] .

• Remove the trim angle sensor [A] .

• Unscrew the mounting bolts [A] and remove the motor assembly

[8] .

• Disconnect the trim cable [A] from the lever [8].

16-18 SUPPLEMENT-1994 MODELS

â&#x20AC;˘ Install the trim cable, noting following. eTurn in the locknut [AJ to about 7 mm distance [BJ of the rod thread.

elnstall th e trim angle sensor [AJ on the bracket, aligning the slit [BJ with the pin [C] on the slide lever.

eApply a non-permanent locking agent to the motor assembly mounting bolts and the trim angle sensor mounting screws.

eAdjust the trim cable (see Trim Cable Adjustment).

SUPPLEMENT-1994 MODELS 16-19

JH7S0-B2 Electrical System Table of Contents Wiring Diagram ........ .............................................................................................................16-20 Exploded View ................................................................................. ..................................... 16-21 Specifications ..... ........... .................................................................... .......... ........................ 16-24 Ignition System ..................................................................................................................... 16-25 CO l Ign iter Inspection .................................... .................................................................. 16-25 Electric Case ......... ........ ........................................................... ................................ .............. 16-26 Trim Motor Box ... ................................ ..................................................... ........................... 16-27 Removal ...........................................................................................................................16-27 Disassembly ...................................................................................................................16-27 Assembly Notes .................................................................... ......................................... 16-28 Trim Motor Inspection ............................................................... .............. ....................... 16-29 Trim Angle Sensor Inspection ................... ....... .......... .......................... ........................... 16-29 Tachometer and Trim Meter ........................................... .... .. ................................................ 16-31 Removal ........ ...... ..............................................................................................................16-31 Installation Notes .......... .. ................................................................................................ 16-31 Switches ................................................................................................................................16-32 Trim Switch Inspection .................................. ..................................................................16-32

." •

-_c " 0_

li e e ell

' n

16-20 SUPPLEMENT-1994 MODELS

# #j" .

Wiring Diagram

tv 1/11

I/"~I/.

1/1

•c ~

•c u

? . c ~ ~

-, •

~ ~

;

· ·

, c

0 0

SUPPLEMENT-1994 MODELS 16-21 Exploded View 1. 2. 3. 4. 5. 6.

Starter Relay CDllgniler 10 A Fuse Regulalor/Reclltier IgnHion Coli Temperature Sensor

7. Fuel Level Sensor 8. Oil Level Sensor

T1 T2 T3 T4 T5 T6 L

: : : : : : :

7.8 N-m (0.8 kg-m, 69 in-Ib) 27 N-m (2.8 kg·m, 20 It-Ib) 2.9 N-m (0.3 kg-m, 26 in-Ib) 98 N-m (10.0 kg-m, 72 It-Ib) 12 N-m (1.2 kg .... , 8.5 It-Ib) 125 N·m (13.0 kg-m, 94 It·lb)

Apply a non-permanent locking agent.

G : Apply grease. M : Apply molybdenum disulfide grease.

1. 2. a 4' 5: 6. 7 8. 9:

Tachometer Trim Meter Relay L.E.D. Unit Motor Unit Shaft Slide Lever . Angle Sensor Trim Fuse (aOA).

10. Control Unit manent locking L : Appy I a non-per agent.

I grease. G : App y .. ne sealant. 55 : Apply soloco

SUPPlEMENT-1994 MODELS 16-23

11 12 13 l

: : : :

7.8 N-m (0.8 kg-m, 69 in-Ib) 12 N-m (1.2 kg-m, 8.5 H-Ib) 125 N-m (13.0 kg-m, 94 H-Ib) Apply a non~permanent locking agent G : Apply grease. M : Apply molybdenum disullide grease.

f\ c)0 G

""-..

7~ A

16-24 SUPPLEMENT-1994 MODELS Specifications Item

Standard

Battery: Type Specific gravity of electrolyte

12V19Ah 1 .2S0 @20"C (6S"F)

Electric Starter System : Starter motor: Brush length Commutator diameter

12.5 mm 2S mm

Charging System: Regu lator/ rectifier output voltage Charging coil output voltage Charging coil resistance: Brown

+-~

Brown

Ignition System: Ignition timing Ignition coil: Primary w inding resistance Secondary winding resistance Spark plug: Type Gap Pickup coil resistance Pickup coil air gap (Clearance between the rotor projection and pickup core) Start/ Stop Switch : Start button: Released Depressed Stop button : Released Depressed Special Tools -

Hand Tesler: 57001-983 Coil Tesler: 57001-1242

Service Limit ---

--6.5 mm 27 mm

Battery voltage - 14.5 Âą05 V 20V

- ----

0.7 - 1.1 0

---

13" BTDC @1,250 r/ min (rpm) 16"@2,500-r/ min (rpm)

---

O.OS - 0.1 0 3.5 - 4.7 kO

-- -- -

NGK BRSES 0.7 - O.S mm 396 - 5940

---

O.S - 1.0 mm

---

000 Almost 00

---

000 Almost 00

--- --

---

-- ---

SUPPLEMENT-1994 MODELS 16-25 Ignition System

COl Igniter Inspection .The inspection procedure is the same as in the base manual, except for the following. Unit: kO

CDllgniter Internal Resistance

Tester ( +) Lead Connection

(-)"

Lead Color

BK/W

RIY

BKIY

BKjBl

2-4

12,.,. 20

6 .... 13

6"", 13

20 - 60

2 - 4

2-4

2 - 4

B - 30

BK/W

6 ..... 13

2-5

2 - 5

8 - 25

3 - 20

6 .... 13

2-5

2 - 5

8 - 25

3 - 20

6 .... 12

6"'"' 12

11 ,.,. 22

15 .... 45

6 ...... 12

6"", 12

6 """ 12

8,.,. 30

20 ..... 60

20 ,.,. 60

20"'"' 60

30,.,. 150

20 '"'" 60 00

20 - 60

10,.,. 60

..... 22

40,.,. 110

00 100 '"'" 200 100 .... 200 100 ..... 200 130 ..... 400

RIY

BK/Y

6,.,. 13

2-5

8 - 25

3 - 20

10"", 30

10,... 30

25 .... 60

30 .... 300

10 ,.,.. 30

10 ..... 30

3 .... 150

6...., 13

2 - 5

2-5

8 - 25

3,.., 20

BK/BL

6 .... 13

2 - 5

2-5

8 -- 25

3 - 20

8 ...... 25

8 .... 25

20 ..... 60

20 - 60

10'"'" 30

8 '"'" 25

8 - 25

( - )": Tester (-) lead Connection

150-600 100 '"'" 200 00 100 """ 200 100 '"'" 200 100 '"'" 250

30 - 300 80 - 500

16-26 SUPPLEMENT-1994 MODELS

Electric Case

To Magneto

Nuts

(2 Places)

A To Starter

To Battery

SECT. A-! To Front Cylinder

Grease O- ring - , {"_)i:;!"{4l---Iiii:1=:II

Fuse (10 ~I--II-~=r

Coil

To Start/ Stop Switch

To To'''.",.,","O Sensor COl Igniter

To l.E .D. Unit

To Trim Meter

';ng G'oaso (7 Placos )

Cap

Joint

Grease (6 Places)

Grommet

SECT. B-B

SUPPLEMENT-1994 MODELS 16-27

Trim Motor Box Removal • Remove the trim cable with the motor box, and disconnect the cable

from the box (see Steering chapter).

Disassembly • Unscrew the bracket mounting bolts [A]and remove the following . Motor Unit [B] Motor Mount Plate [C] Shaft [D] Collar [E] Slide Lever [F]

• Disconnect the leads and remove the control unit [A].

16-28 SUPPLEMENT-1994 MODELS

Assembly Notes .Grease to inside of connector cap [A] .

• Insert the slide lever [A] into the shaft [B] in the any position .

• Align the projection [A] on the motor unit with the slit [B] on the bracket .

• Turn in the locknut [A] to about 7 mm distance [B] of the rod thread .

• Install the trim angle sensor [A] on the bracket, aligning the slit [B] with the pin [C] on the slide lever.

SUPPlEMENT-1994 MODElS 16-29

Trim Motor Inspection • Disconnect the motor unit leads [AJ (Green / White. Blue/ White. YeHow. Black) .

• Connect the motor unit leads to the battery, as shown. .Check the rotating direction of the motor unit by changing battery polarity. If the motor does not rotate, replace the motor unit with a new one.

CIRCUIT Dr AGRAW

r--- '- '- - .- .-.-. - --,, ;

lPM

~~FTATING SENSOR

,; , !

,;l._. _ _ ,_,_,_. ______ ,

BLlw y BK G/W

;::-

---- ®A

---- e®

ROTATING OIRECTlIIM 1 (IIlZZLE IXIIII)

ROTATING OIRECTlIIM X (IIlZZLE UP)

• Connect the motor unit leads to the battery and hand tester (ohmmeter), as shown . • Check that the resistance of rotating sensor turns from 0 0 into no reading (00) or from no reading (00) into 0 n. If the rotating sensor does not show the above result, replace the motor un it with a new one.

CIRCUIT DIAGRAW

,, .- _._._.- _._._._._.,

,.-,

BL/W

, y , ~FTAT'NG,: , BK SEIISOR ,,~ , G/W ,i.._._._.__ . ___ ____ .j, iN

D r-

---- ®e

- --- e®

ROTATING OIRECTlIIM 1 (IIlZZLE IXIIII)

ROTATING OrREClI1IM X (IIlZZLE UP)

Trim Ang/e Sensor Inspection • Using the x 100 () hand tester range, measure the resistance between BL/ R lead and W / R lead. . *11 the tester reading are not as specified, replace the sensor.

479

718

UNIT 1

(BL/R)~

Trim Angle Sensor Resistance Standard:

CIRCUIT (33Q) A

•

V"~

~.?

Special Tool - Hand Tester: 57001-983

UNIT 2

(W/R)

-A

·V . .

(33Q)

~ND

BK)

16-30 SUPPLEMENT-1994 MODELS

.Connect the tester leads to the BL/R and BK leads or to the W/R and BK leads . â&#x20AC;˘ Use the x 100 n, hand tester range . â&#x20AC;˘ Moving the sensor plate [A], check that the resistance is variable. *If the tester reading is not variable, replace the sensor.

ELECTRIC TRIM NOZZLE TROUBLESHOOTING GUIDE

Trim switch on <UP-DOWN>

Trim nozzle is not move.

Is engine running? (After engine is started, power source relay works.)

Is fuse brown?

Check 30A fuse.

Do shaft and slide lever move smoothly?

Is power source relay

operating?~

Check orange lead voltage (12 V).

Is trim switch good?

Is controller good?

Check red/white lead voltage (12 V).

Does motor rotate?

Is rotating sensor good?

Is trim meter good?

Is trim angle sensor good?

Electric Component Damaged by water.

SUPPlEMENT-1994 MODELS 16-31 Tachometer and Trim Meter

Removal • Remove the handlebar (see Steering chapter) . • Unscrew the mounting bolts [A] and remove the steering cover [8] .

• Unscrew the mounting bolts [A] and remove the L.E.D. unit [8] .

• Unscrew the screws [A] and remove the meter bracket [8] .

• Remove the grommet plate [A] and take out the grommet [8] . • Disconnect the electrical lead connectors and remove the tachometer and trim meter from the steering cover.

Installation Notes .Apply an even layer of silicone sealant to the mating surfaces of the

grommet plate [A] and hull.

16-32 SUPPLEMENT-1994 MODELS

Switches Trim Switch Inspection â&#x20AC;¢ Using a hand tester, check to see that only the connections shown in the table have continuity.

* If the switch has an open or short, replace

it with a new one.

Special Tool - Hand Tesler: 57001-983 Trim Switch Connections

RIW

UP < FREE>

DOWN

BUW

GIW

SUPPLEMENT-1995 MODELS 17-1

Supplement-1995 Models (JH750-A4/JH750-B3) This "Supplement-1995 Models" chapter is designed to be used in conjunction with the front part of this manual (up to 16-32) The maintenance and repair procedures described in this chapter are only those that are unique to the 1995 J H750-A4/ J H750- 83 watercraft. Most service operations for these models remain identical to those described in front of this chapter. Complete and proper servicing of the 1995 JH750-A4/JH750-83 watercraft, therefore requires mechanics to read both this chapter and the text in front of this chapter.

JH7S0-A4 Fuel System Table of Contents Exploded View Specifications

Exploded View

............................................................................................. ......... 17-1 .............................. ... .......... .............................. .............................. ... 17-2

17-2 SUPPlEMENT-1995 MODELS Specifications Item Carburetor : Make, type Size Mixture screws:

Main jet Pi lot jet Idle speed:

Low speed High speed

in water

out of water

Standard Keihin, CDK 40-34 Diaphragm 38 mm Ventruri 7/ 8 ±turn open 1 .0 ± % turn open #160 #78 1 250 ±1 00 rpm 1 700 ±1 00 rpm

Reed Valve: Reed warp

---

Fuel Tank: Capacity

33 L (including 6 L reserve)

Special Tool - Pressure Cable Luber: K56019'()21 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit -----

---

----------0.2 mm

---

SUPPLEMENT-1995 MODELS 17-3

JH7S0-A4 Engine Lubrication System Table of Contents .. ..... ................................................... 17·3

Exploded View ...

Exploded View An oil filter [1] is added between the oil pump and oil tank [2]. Install the oil filter so that its arrow mark points to the oil pump unit. And then, engine oil is supplied to the carburetor regulator room rather than the intake manifold.

Oc::;;

!?:)'o

~o~~

0. '---'

, ®

® ®

® 0

17-4 SUPPLEMENT-1995 MODELS

JH7S0-A4 Steering Table of Contents ........................ 17 -4

Exploded View ...................................................................................

Exploded View Structure of the steering nut has been changed.

T1: T2: T3: G: B: 1. 2.

39 - 49 N-m (5 - 6 kg-m, 29 - 36 ft-Ib) Hand-Tighten 16 N-m (1.6 kg-m,11.5 ft-Ib) Apply grease. Apply a bonding agent Lock Plate Steering Shaft Nut

/ o

~ [~Â®

SUPPlEMENT-1995 MODELS 17-5

JH7S0-A4

Electrical System Table of Contents Exploded View ................ . Wiring Diagram ..

.................... ...................... 17-5 ...................................................................................... 17-6

Exploded View The electric case features a spark plug cap holder [1] (grounding device) to prevent an accidental sparking during pumping out water out of the crankcase. L:

Apply a non-permanent locking agent.

...

7C-; '" :::r

-rn-

iil (}1 1. water Temp e ra tur e Indicator 3 3 o 0 2. Fu el Leve l I ndIcato r

C/)

all

Level

r- ,, -rn- ,, ~

Star

r--

r Bl-LU--Bl~

~EDa. a::

(

~E CD

l~ - , -BK

-".m

0.;

"'-' "--ell

R/W

YI R

:::z

c:...=o

r1 ~

® -C

13.

;:I '"

a II

Leve I

Sensor

Spark Plug

COl

Igniter

-0.

c :::r

o "

" :i'" '" :i

I gnition coil Electr Ie Case

'-BK~~ROR-

R-O<l--R-

-; :::r

in'

Wire Color Code

""":::r

Blac t Blue

G 0

Green Oran ge

P PU

Pin k

"n''"~

Purple

!!:

- . -- -------

li'"

8K 8l 8,

R W

!:::.

:::r'O "''0

"'"'"

\,---- -- - -- ---- -- -- -- -----.- - ---- -_.- .'\_ ._----- -- ... ---

ENGINE START SW ENG I NE STOP SW lAMYAiO BK W R/PU ~ YIR KEY ... - ..... -. SET 10 j-o 'IJI-, PU SH PUSH PULl 10

o '" 3.0

Starter Motor Batte r Y

m~ w

~~ IUt

ij; -

:::r

D<J- OK C>D-R/PU

0<1-> R IR R--Q:::]-

::t

SW Itch

15. water Temperature Sensor

~lot

StopSwlten

< 0. ~~

.g'" :i'" 0" ;:;:

16. 17 . lB.

C>D- W ----"

r===~~

l l ~~

]

OIPU

, I'

1L l

@ ©= 8K/Y~BK/W '/Y R/~~

r..3 mgw '5' --"

Indicato r

cii

starter Re I ay Fuse (IDA) Regulator/Rectifier Magneto 12 . Fue I Leve I Senso r

14,

:::J

@jlf----- ' /Y ---c[]-- '/Y

~BK/W o _- ~~J CDo.""

:~ =(

<J <J

6. 7. B, 9, 10 . 11.

mm m

~ ~

p P -LU-- p

:::I

-< '" iii"

,--- p

~ ....., :::!,

Brown

Red Wh I te Ye l l ow

(9 B051 - 3720A)C

:;.

"'" ~

if 3

0 '0

~. "

:::r

'"" :;. '" iii' -< " '"a.

0;' CC

... Q)

"tI "tI

m 2: -l ,

...

CD CD U'1

0 0

C/)

SUPPLEMENT-1995 MODELS 17-7

JH750-83 Engine Lubrication System Table of Contents ..... ........ ............ .................... 17-7

Exploded View ................ ........ ........... ......... .

Exploded View An oil filter [1] is added between the oil pump [2] and oil tank [3]. Install the oil filter so that its arrow mark points to the oil pump unit. And then, engine oil is supplied to the carburetor regulator room [5] rather than the intake manifold.

~ ~

()

~'"

-I -

'~- ~ - I I I ['1/ '"

r~ ~

0 0

, 速

速

速 0

~o 2

'---"

I I

速

17-8 SUPPLEMENT-1995 MODELS

JH7S0-B3 Steering Table of Contents Exploded View ........................................................................................................................17-8

Exploded View Structure of the steering nut has been changed.

T1: T2: T3: G: B: 1. 2.

39 - 49 N-m (5 - 6 kg-m, 29 - 36 H-Ib) Hand-Tighten 16 N-m (1.6 kg-m, 11.5 H-Ib) Apply grease. Apply a bonding agent Lock Plate Steering ShaH Nut

/ o

~®

[~®

SUPPLEMENT-1995 MODELS 17-9

JH7S0-83 Electrical System Table of Contents .......... 17 -9 .......... .... .. .. 17 -9

Trim Motor Box ........ .... .. ... .... .. ..... .. .... ... .. .. ....... .......... .. . Assembly Notes . ................ . .. .......... .

Trim Motor Box

Assembly Note .The assembly procedure is the same as in the JH750- B2. Add the following information. o Install the collars into the shaft, as shown . [A] [B] [C] [D]

Motor Unit Side Large Collar Small Collar Stepped Edge Side

® ®

SUPPLEMENT-1996 MODELS 18-1

Supplement-1996 Models (JH7S0-E1/JH7S0-F1 ) This "Supplement-1996 Models" chapter is designed to be used in conjunction with the front part of this manual (up to 17-9). The maintenance and repair procedures described in this chapter are only those that are unique to the 1996 JH750- E1 /J H750-F1 watercraft. Most service operations for these models remain identical to those described in front of this chapter. Complete and proper servicing of the 1996 JH750-E1/JH750-F1 water,craft, therefore requires mechanics to read both this chapter and the text in front of this chapter.

JH750-E1

General Information Table of Contents

Model Identification ................................ .. ... ................. .......................... ......... ....... 18-2 General Specifications .......................... ....................... ... .. .............. ... ... 18-3 Periodic Maintenance Chart ..... ....... ...... .. ... .. .................... ...... .................... .... 18-4

18-2 SUPPLEMENT-1996 MODELS Model Identification JH7S0-E1 Left Side View:

, ..

-.~"'. -'.- -",,",--oe '

JH750-E1 Right Side View:

--- .. _----

~,---.

" ""-"

SUPPlEMENT-1996 MODELS 18-3 General Specifications Items Engine: Type Displacement Bore and stroke Compression ratio Maximum Horsepower

Maximum torqu e

JH750-E1 2-stroke, vertica l twin, crankcase reed valve, water cooled 743 mL 80.0 x 74.0 mm 7.0 : 1 51.5 kW (70 PS) @6 250 rl min (rpm) < E> 49.3 kW (67 PS) @6 250 rl min (rpm) (Continuous maximum hose power) 83.3 N-m (8.5 kg-m, 61.5 ft-Ib) @5 500 rlmin (rpm) < E> 78.4 N-m (8.0 kg -m, 57.8 ft-Ib) @5 500 rl min (rpm) (Continuous maximum torque) Magneto COl (Digital) Oil injection (break-in period: Oil injection and fuel mixture 50 : 1) Keihin CDK40-34 diaphragm type (38 mm venturi) Electric starter NGK BR8ES 0.7 - 0.8 mm 13· BTDC @1 250 rl min (rpm) - 16· @2 500 rl min (rpm) 1250 ±100 rl min (rpm) - in water 1 700 ±100 rl min (rpm) - out of water 835 - 1 294 kPa (8.5 - 13.2 kgl cm', 121 - 187 pis) Direct drive from engine Axial flow, single stage 2648 N (270 kg, 595 Ib) Steerable nozzle Water drag 3.3m 27 L/ h @full throttle < E> 26 L/ h @full throttle 88 km @full throttle 1 hour and 14 minutes < E> 89 km @full throttle 1 hour and 16 minutes

Dimensions: Length Width Height Dry weight Fuel tank capacity

2530 mm 1030 mm 945 mm 182 kg 33 L including 6 L reserve

Engine Oil : Type Oil tank capacity

2-stroke, N.M.M.A. Certified for Service TC -WIT 2.3 L

Electrical Equipment: Battery Maximum Generator Output

6.6 A / 14 V @6 000 rl min (rpm)

12V19Ah

Th is information shown here represents results under controlled conditions, and information may not be correct under other conditions.

Specification subject to change without notice, and may not apply to every country. < E> : Other than US and Canadian models

18-4 SUPPLEMENT-1996 MODELS Periodic Maintenance Chart NOTE

o Complete the Pre-Ride Checklist before each outing. Frequency Description Check all hose clamps. nuts. bolts. and fasteners Torque cylinder head nuts Lubricate throttle cable fitting and choke cable fitting at carburetor Lubricate choke cable and throttle case and cable Clean and gap spark plugs (replace if necessary) Check battery level and terminals Lubricate steering nozzle pivots Lubricate steering cable ball joints Lubricate handlebar pivot (disassemble) Clean fuel filter screens Inspect/ replace fuel filter Inspect fuel vent check valve Adjust carburetor Flush bilge line and filter Flush cooling system (after each use in salt water) Inspect/ clean flame arrester I nspect impeller blade for damage (remove) Inspect/ replace coupling damper Inspect/ replace carburetor throttle shaft spring (replace carburetor it' necessary) Inspect steering cable

Initial

Every

100

Hours

• •

• • • • • • • • • • • • • • • •

• • • •

SUPPLEMEN T -1996 MODELS 18-5

JH7S0-E1 Fuel System Table of Contents Exploded View ....... .................................. ................ '" ... ...... ..... ................... ............. 18 - 5 Fuel System Diagram ..................................... ................... ..... ...... ............................. 18 -6 Fuel Tank .. ... ... .... ........................... ....................................... ....... ............... ..... .......... 18- 6 Fuel Filter Inspection ................................................... ........ .... ............................. 18- 6

Exploded View The JH750-E1 has a trigger type throttle. Th e fu el filter [AJ is added between the fuel tank and carburetor to keep the carburetor clean and free of jet- clogging debris.

Apply a non-permanent locking agent. 55: Apply silicone sealant.

(

Tl: 3.9 N-m (0.4 kg-m, 35 in-Ib):~

---=----1

<,~

~'>:i (

fflCJ

~,~~:

t::H-i-----fA

~~t~~ ~.",.,

~.",., @~~

)~~

18-6 SUPPLEMENT-1996 MODELS Fuel System Diagram

Re t urn Re serve Ma in

TO Steer I no

M in Rese r ve

Fue I Tao

Fuel Tank Fuel Filter Inspection The watercraft is equipped with a fuel filter [A] at the middle of the fuel line to prevent dirt or other foreign material from entering the

carburetor . â&#x20AC;˘ Inspect and replace the fuel filter in accordance with the Periodic Maintenance Chart, or whenever you find from outside any foreign material or water trapped in the fuel filter.

SUPPLEMENT-1996 MODELS 18-7

JH7S0-E1 Engine Lubrication System Table of Contents Oil Tank ......................... ..... .................................................... ................................... 18-7 Oil Filter Cleaning ........................... ............................................ .. ...... .............. .. .. 18-7

Oil Tank Oil Filter Cleaning Check the oil filter [AJ for foreign particles every time yo u add the oil. If there are any foreign particles, the oil filter must be cl eaned . â&#x20AC;˘ Take out the oil filter out of the oil filter. â&#x20AC;˘ Wash the oil filter in a non-flammable or high flash-point solvent. Use a brush to remove any 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.

18-8 SUPPLEMENT-1996 MODELS

JH750-E1 Pump and Impeller Table of Contents

Exploded View .................. ....................................................................................... 18-8

Exploded View The J H750-E1's iet pump has a three blade aluminum impeller to draw water well. T1: T2: T3: T4: SS: G: L:

7.8 N-m (0.8 kg-m, 69 in-Ib) 9.8 N-m (1.0 kg-m, 87 in-Ib) 22 N-m (2.2 kg-m, 16.0 It-Ib) 98 N-m (10.0 kg-m, 72 It-Ib) Apply sificone sealant Apply grease. Apply a non-permanent locking agent. T4

SUPPLEMENT-1996 MODELS 18-9

JH7S0-F1 General Information Table of Contents Model Identification ............ ..................... ............... .. .............................................. 18-10 General Specifications ........ .......................................................................... .. ........ 18-11 Periodic Maintenance Chart ...................................................................................18-12

18-10 SUPPLEMENT-1996 MODELS Model Identification JH750- Fl Left Side View:

JH750-Fl Right Side View:

.\"'1

, ...

â&#x20AC;¢.

SUPPLEMENT-1996 MODELS 18-11 General Specifications Items Engine: Type Displacement Bore and stroke Compression ratio Maximum Horsepower

Maximum torque

Ignition system Lubrication system Carburetion system Starting system Tuning Specifications: Spark plug Type Gap Ignition timing Carburetor Idle Speed Compression pressure

JH750-F1 2-stroke, vertical twin, crankcase reed valve, water cooled 743 mL 80.0 x 74.0 mm 7.2 : 1 58.8 kW (80 PS) @6 500 rl min (rpm) < E> 55.2 kW (75 PS)@6 500 rlmin (rpm) (Continuous maximum horsepower) 91.2 N-m (9.3 kg-m, 67.3 ft-Ib) @6 500 rl min (rpm) < E> 86.3 N-m (8.8 kg -m, 63.6 ft-Ib) @5 750 rl min (rpm) (Continuous maximum torque) Magneto CDI (Digital) Oil injection (break-in period: Oil injection and fuel mixture 50 : 1) Keihin CDK40-31 x 2 diaphragm type (35 mm venturi) Electric starter NGK BR8ES 0.7 - 0.8 mm 13" BTDC @1 250 rl min (rpm) - 16"BTDC @2 500 rl min (rpm) 1 250 Âą100 rl min (rpm) - in water 1 700 Âą100 rl min (rpm) - out of water 890 - 1370 kPa (9.1 - 14.0 kglcm', 129 - 199 pis)(Open throttle)

Drive System: Coupling Jet pump: Type Thrust Steering Braking

Direct drive from engine Axial flow, single stage 2 795 N (285 kg, 628 Ib) Steerable nozzle Water drag

Performance: tMinimum turning radius tFuel consumption tCruising range

3.3 m 28 L/ h @full throttle 92 km @full throttle 1 hour and 11 minutes

Dimensions: Length Width Height Dry weight Fuel tank capacity

2530 mm 1 030 mm 945 mm 188 kg 33 L including 6 L reserve

Engine Oil: Type Oil tank capacity

2-stroke, N.M .M.A. Certified for Service TC-WIT 2.3 L

Electrical Equipment: Battery Maximum Generator Output

6.6 A/ 14 V @6 000 rl min (rpm)

12V19Ah

= This

information shown here represents results under controlled conditions, and information may not be correct under other conditions.

Specification subject to change without notice, and may not apply to every country. < E> : Other than US and Canadian models.

18-12 SUPPLEMENT-1996 MODELS Periodic Maintenance Chart NOTE

o Complete the Pre -Ride Checklist before each outing. Frequency Description Check all hose clamps, nuts, bolts, and fasteners Torque cylinder head nuts Lubricate throttle cable fitting and choke cable fitting at carburetor Lubricate choke cable and throttle case and cable Clean and gap spark plugs (replace if necessary) Check battery level and terminals Lubricate steering nozzle pivots Lubricate steering cable ball joints Lubricate handlebar pivot (disassemble) Clean fuel filter screens Inspect/ replace fuel filter Inspect fuel vent check valve Adjust carburetor Flush bi lge line and filter Flush cooling system (after each use in salt w ater) Inspect/ clean flame arrester Inspect impeller blade for damage (remove) Inspect/ replace coupling damper Inspect/ replace carburetor throttle shaft spring (replace carburetor if necessary) Inspect steering cable and trim cable

Initial

Every

100

Hours

• •

• • • • • • • • • • • • • • • •

• • • •

SUPPLEMENT-1996 MODELS 18-13

JH750-F1 Fuel System Table of Contents Exploded Vi ew ...... ................................................................ .. ... .. .......................... 18-13 Specifications .. .. ......................................... ............... ..... ... .... .. ............ ........ .. .......... 18-1 4 Fuel System Diagram .... ............................ ............. ............... .. ..... ...........................18-14 Fuel Tank ..... .... ..................... .... .............. ... .... ........... .... .. ....... .. .. .. ............................ 18-1 4 Fuel Filter Inspection ............... ............. ...................... ... .. ...................................18-14

Exploded View The JH750-E1 has a trigger type throttle. Th e luel Ii Iter [AJ is added between th e luel tank and carburetor to keep the ca rbu retor clean and free of jet-clogging debris.

Apply a non-permanent

locking agent. 55: Apply silicone sealant. T1 : 3.9 N·m (0.4 kg-m, 35 in·lb)

---=----:

( I

®-

1<:::::, ,

®~ - q

00'

(

<:?f:$

Jll

~,"'~I

_-=:I

() ~~! :ICJ

~~t~~

18-14 SUPPlEMENT-1996 MODELS Specifications Item

Standard

Carburetor: Make, type Size Mixture screws: Low speed High speed Main jet Pilot jet Id le speed: in water out of water

Keihin, CDK40-31 x 2 (Diaphragm) 35 mm Venturi 3/ 4 ± ~ turn open 3/ 4 ± ~ turn open # 135 #72 1 250 ±1 00 rpm 1 700 ±1 00 rpm

Reed Valve: Reed warp

---

Fuel Tank: Capacity

33 L (including 6 L reserve)

Service Limit ---

-- ------- ----- -

0.2 mm

---

Fuel System Diagram

= = =

= TO S t eer InQ

Fuel TaD

Fuel Tank

Fuel Filter Inspection The water craft is equipped with a fuel filter [A] at the middle of the fuel line to prevent dirt or other foreign material from entering the carburetor. .Inspect and replace the fuel filter in accordance with the Periodic Maintenance Chart, or whenever you find from outside any foreign material or water trapped in the fuel filter.

SUPPLEMENT-1996 MODELS 18-15

JH750-F1 Engine Lubrication System Table of Contents Oil Tank .. ..................................................• .•.. ... . Oil Filter Cleaning ................................. .. ..

Oil Tank

Oil Filter Cleaning Check the oil filter [AJ for foreign particles every time you add the oil. If there are any foreign particles, the oil filter must be cleaned . • Take out the oil filter out of the oil filter. eWash the oil fi lter in a non-flammable or high flash-point solvent. Use a brush to remove any contaminates trapped in the filter.

AWARNING

Clean the oil filter in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working areaj 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.

.... ..... ................................18-15 ........ ........ .................. .... .18-15

18-16 SUPPLEMENT-1996 MODELS

JH750-F1 Pump and Impeller Table of Contents

Ex ploded View .. ...... ...... ..... .............. .... .. .. ........ ......... ......................................... ..... 18-16

Exploded View The JH750- E1 's jet pump has a three blade aluminum impelier to draw w ater well. 11: T2: T3: T4: 55: G: L:

7.8 N-m (0,8 kg-m. 69 in-Ib) 9.8 N·m (1 .0 kg-m. 87 In-Ib) 22 N-m (2.2 kg-m, 16.0 H·lb) 98 N-m (10.0 kg-m. 72 H-Ib) Apply silicone sealant Apply grease. Apply a non-permanenllocking agent

SUPPLEMENT-1996 MODELS 18-17

JH750-F1 Electrical System Table of Contents

Wiring Diagram ....................................................................................................... 18-18 Exploded View ........................................................................................................18-19 Trim Motor Box ....................................................................................................... 18-20 Trim Angle Sensor Inspection ............................................................................18-20 Trim Control Unit Inspection ........... ................................................ ................... 18-21

•

\.. .. ~ ...................: ...j

••

~i!~WJl

Wiring Diagram

-:==

•••• o ••••••••••••• ••••••••• ••••• •• •••••••• • • ••• •

l UL---'

""' le'Fl""'19"""18""'1- ~

, o

.,-

I I

o ~

c c

-L _~--t1-rrF~~~B]:"

18-18 SUPPLEMENT-1996 MODELS

•

• :

" <:

SUPPLEMENT-1996 MODELS 18-19 Exploded View

The new trim motor box does not incorporate a fuse. On the '96 model, the electric case incorporates two blade fuses [A] for easier access. A limit switch is added in the electrical tilt system to stop the motor when the slide lever exceed predetermined angle.

1. Starter Relay 2. CDllgniler 3. Regulator/RectHier 4. Ignition Coil 5. Temperature Sensor 6. Motor Unit 7. ShaH 8. Slide Lever 9. Trim Angle Sensor 10. Trim Control Unit

T1: 7.8 NÂˇm (0.8 kg-m. 69 in-Ib) T2: 27 N-m (2.8 kg-m. 20 H-Ib) T3: 2.9 N-m (0.3 kg-m. 26 in-Ib) L: Apply a non-permanent locking agent. G: Apply grease. M: Apply molybdenum disulfide

grease.

18-20 SUPPlEMENT-1996 MODELS Trim Motor Box

Trim Angle Sensor Inspection .Check the sensor resistance (UN IT 1 - UNIT 2). o Using the hand tester, measure the resistance between the BL/ R and W / R lead. Trim Angle Sensor Resistance 479 718 Standard:

( 33 0 )

UNIT1:H ( Bl ( ' )

n (UNIT t

- UNIT 2)

UN IT2

Special Tool - Hand Tester: 57001·1394

(W/R)

*It the tester reading is not as specified, replace the sensor.

~ ~GND(")

( 1<120)

• Check the resistance ratios.

R (UN IT 1 [BL/ RJ - GND [BKJ)

Resistance Ratio

R (UNIT 2 [W/ RJ - GND [BKJ) aTurn the sensor plate [DJ within three ranges [AJ . [BJ. [CJ. as shown.

CAUTION Do not tUrn the sensor plate beyond 58 degrees to the left and 32 degrees to the right from the center line [E], or the trim angle sensor could be damaged.

o Using the hand tester, measure the following resistances within three ranges, BL/R - BK (UNIT 1) W / R - BK (UNIT 2) Special Tool - Hand Tester: 57001·1394

Resistance Ratios

Trim Meter

0.02 - 0.1

1.2 - 1.6

2.5 - 4.5

DOWN

LEVEL

If the resistance ratios are not as specified, replace the sensor.

• Check the trim limit switch. a Turn the sensor plate [C] within two ranges [AJ. [BJ. as shown.

CAUTION 00 nol turn the sensor plate beyond 58 degrees to the left and 32 degrees to the right from the center line [EJ J or the trim angle sensor could be damaged.

,,'

---~-~"~.

SUPPLEMENT-1996 MODELS 18-21

.Using the hand tester, check to see that only the connections shown in the table continuity (about zero ohms). Special Tool - Hand Tesler: 57001-1394

°1 .~

elf the limit switch has an open or short, replace it with new one. R

DnOYC tDD~.:.:.·-·· D (:~iR) '-, >"0

UP (Switch 1 ) [AJ

....

DOWN (Switch 2) [BJ

(W/ R)

'C>

SW-1

(810

UP 5 I DE

UNIT 2

GND

( BK )

0'.).,

~ CO Id( R)

SW- 2 ( W)

OOWN S ID E

Trim Control Unit Inspection .With the hand tester, test the trim control unit [AJ according to the following table. Special Tool - Hand Tester: 57001-1394

CAUTION 00 not run the engine without cooling water supply for more than 15 seconds or-severe engine and exhaust system damage will occur.

(1) Normal Voltage and Continuity. Engine stopped

Connections (1 ) R - BK (2) BL/ W (male) - BK

(3)

BL/ W (male) - BL/ W (female)

(4) G/ W (female) - BK (5) G/ W (female) - G/ W (male)

Engine Running (Unit ON)

(Unit OFF)

" LEVEL

"UP

"DOWN

12 V

Continuity

Discontinuity

Continuity

Discontinuity

Continuity

Discontinuity

Continuity

Discontinuity

Continuity

Discontinuity

Continuity

Discontinuity

Continuity

(6)

GY - BK

2-4V

2 - 4V

(7)

0- BK

12 V

(8) R/ BK - BK/ W

Discontinuity

Continuity

Discontinuity

(9) R/ BK - W

Discontinuity

Continuity

• Trim Meter indicates:

18-22 SUPPLEMENT-1996 MODELS

(2) Causes for Abnormal Results Faulty Parts Trim Control Unit

• • • • • • •

(3)

(4) (&)

(6) (7)

(8) (9)

Igniter

• • • • •

(1 ) (2)

Harness

• • • •

Battery

Fuse

•

TRIW SW I TCH

Bl/w

'~p-."\.

G/W

UP :

BK i

lIWIT :QH

)

G/w

G/O ~----'

Bl/o

----'_ __

- L_

TRill UGH SENSOR

Bl/O

In°O'i':~. ~

R/W

------~/

-"-_, '; 0

I '77l

FUSE

f->C~ ' I t- t 2V BATTERY

TRIW CONTROL UNIT

.--=GY

Kawasaki This is the supplemental manual for the 1998 750 Xi. Use the 750 SX base manual for the engine and anything not included in this supplement.

JET SKI@ Watercraft Service Manual

Quick Reference Guide General Information Fuel System Engine Lubrication System Exhaust System Engine Top End Engine Removal and Installation Engine Bottom End Cooling and Bilge Systems Drive System Pump and Impeller Steering

Hull I Engine Hood Electrical System Storage Appendix

.JEw~ ~~

KaVlasaki

IIVmel'craN

Xi Sport

JET SKI®Watercraft Service Manual

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 Group/ Kawasaki Heavy Industries, ltd., Japan. No liability can be accepted for nny inaccurncies 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.

First Edition (1) : June. 17, 1997 (C)

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC Â°C DC F

of It 9 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)

Ib m min

N Pa PS psi

pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution

rpm TDC TIR V

revolution(s) perminute top dead center total indicator reading volt(s) watt(s) ohm(s)

Read OWNER'S MANUAL before operating

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 texl. 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. .Se 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 part provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don't take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to Use this Manual In preparing this manual, we divided the product into its major systems, These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to loCate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

AWARNING 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

o This note symbol indicates points of particular interest for more efficient and convenient operation . â&#x20AC;˘ Indicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

GENERAL INFORMATION 1-1

General Information Table of Contents

Before Servicing ...................................................................................... ................... 1 -2 Model Identification .................................................................................................... 1 -5 General Specifications .............................................................................................. 1 -6 Periodic Maintenance Chart ...................................... ............... ... .............................. 1 -7 Torque and Locking Agent.. ....... ................ ..... ... . .. .... ......... ... .. .......... .. .. .................. 1-8 Special Tools. Sealant .............................................................. ............................... 1-10 Cable. Wire and Hose Routing ................... .......... ...................................... .............. 1 -12

1-2 GENERAL INFORMATION Before Servicing Before starting to service a watercraft careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever trouble shooting or presence of symptoms indicate that adjustments may be required. Whenever running of the engine is required during maintenance it is best to have the watercraft in water.

CAUTION Do not run the engine without cooling water supply for more than 15 seconds or severe engine and exhaust system damage will occur.

the engine stops. The engine requires 2.4 Li min (2.5 qtsi min) at 1800 rpm and 7.0 Li min (7.4 qtsi min) at 6000 rpm.

CAUTION Insufficient cooling supply will cause the engine andlor exhaust system to overheat and severe damage will occur. Excessive cooling supply may kill the engine and flood the cylinder, 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 right side. Roiling to the left side can cause water in the exhaust system to run into the engine, with possible engine damage.

GENERAL INFORMATION 1-3

(3) Dirt Before removal and disassembly, clean the "Jet Ski" watercraft. Any sand entering the engine, carburetor, or other parts wi ll 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 va lues 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) n 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 manufacturer's 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). (12) Press A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (13) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. (14) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.

1-4 GENERAL INFORMATION

(15) Seal Gu ide A seal gu ide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little lubricant preferably high temperature grease on the lips to reduce rubber to metal friction. (16) Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them on ly enough to install them and no more. (17) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (18) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. (19) Electrical Wires All the electrical w ires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color.

Wire (cross-section)

Name of Wire Color

//__ Red Wire Strands Yellow/Red Yellow Red

(20) Replacement Parts When there is a replacement instruction, rep lace these parts w ith 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 fo llowing conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (22) Service Data Numbers of service data in this text have following meanings: "Standards": Show dimensions or performances which brand-new parts or systems have. "Service Limits": Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

GENERA L INFORMATION 1-5 Model Identification JH750- G1 Left Side View:

JH750- G1 Right S IOd e View:

1-6 GENERAL INFORMATION General Specifications Items

JH750-G1

Engine: Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition System Lubrication System Carburetor Starting System

2-stroke, vertical twin, crankcase reed valve, water cooled 743 mL 80.0 x 74.0 mm 7.2: 1 58.8 kW (80 PS) @6 500 rlmin (rpm) 92.1 N-m (9.3 kg-m, 67.3 fI-lb) @6 000 rlmin (rpm) Magneto COl (Digital) Oil injection (break-in period: Oil injection and fuel mixture 50 : 1) Keihin CDK40-31 x 2 diaphragm type (35 mm venturi) Electric Starter

Tuning Specifications: Spark Plug(Terminal Profile) Gap Ignition Timing Carburetor Idle Speed Compression Pressure Drive System: Coupling Jet Pump: Type Thrust Steering Braking

Performance: tMinimum Turning Radius tFuel Consumption tCruising Range

NGK BR8ES(Solid) 0.7 - 0.8 mm 13" BTDC @1 250 rlmin (rpm) - 20.2" @4 000 rlmin (rpm) 1 250 ÂąiOO rlmin (rpm) - in water 1700 Âą100r/min (rpm) - out of water 890 - 1 370 kPa (9.1 - 1,4.0 kglcm', 129 - 199 psi) Direct drive from engine Axial flow, single stage 2900 N (296 kg, 653 Ib) Steerable nozzle Water drag 3.3 m

31 Llh @full throttle 92 km @full throttle 1 hour and 4 minutes

Dimension: Overall Length Overall Width Overa II Heig ht Dry Weight Fuel Tank Capacity

2530 mm 1030 mm 945mm 185 kg 33 L including 6 L reserve

Engine Oil: Type Oil Tank Capacity

2-stroke, N.M.MA Certified for Service TC-WII 2.3 L

Electrical Equipment: Battery Maximum Generator Output

12V19Ah 6.6 A 14 V @6 000 rlmin (rpm)

This information shown here represents results under controlled conditions, and information may not be correct under other conditions.

Specification subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-7 Periodic Maintenance Chart

NOTE

o Complete the Pre-Ride Checklist before each outing.

Initial

Every

100

Hours

• •

• • • • • • • • • •

Inspect/replace fuel filter Inspect fuel vent check valve Adjust carburetor Flush bilge line and filter Flush cooling system (after each use in salt water) Inspect/clea n flame arrester Inspect impeller blade for damage (remove) Inspect/replace coupling damper Inspect/replace carburetor throttle shaft spring (replace carburetor if necessary) Inspect steering cable

• • • • •

Every

•

• • • •

1-8 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torqu e for the major fasteners requiring use of a non -permanent locking agent or silicone sealant. Letters used in the " Remarks" column mean : L : Apply a non -permanent locking agent to the threads. SS : Apply silicone sealant to the threads. S : Tighten the fasteners following the specified sequence. Torque Fastener

Remarks N-m

kg-m

ft-Ib

7.8 7.8 7.8

0.8 0.8 0.8

69 in - Ib 69 in-Ib 69 in -Ib

Engine Lubrication System Oil Pump Mounting Nuts

7.8

0.8

69 in - Ib

Exhaust System: Exhaust Pipe Mounting Bolts Joint Mounting Bolts Water Pipe Joints Exhaust Manifold Mounting Nuts Expansion Chamber Mounting Bolts Block Mounting Bolts Water Box MuHler Mounting Bolts Water Box Muffler Bottom Damper Bolts Water Box MuHler Bolts Output Pipe Mounting Bolts Water Box M uHler 80ttom Plugs

49 9.8 9.8 20 7.8 7.8 7.8 7.8 7.8 7.8 7.8

5.0 1.0 1.0 2.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8

36 87 in -Ib 87 in -Ib 14.5 69 in -Ib 69 in - Ib 69 in -Ib 69 in -Ib 69 in - Ib 69 in - Ib 69 in-Ib

L L SS S L L L L L L SS

Engine Top End: Cylinder Head Nuts Water Pipe Joint Cylinder Base Nuts Cable Holder Mounting Bolts

29 9.8 34 20

3.0 1.0 3.5 2.0

22 87 in -Ib 25 14.5

S SS

Engine Removal / Installation: Engine Mounting Bolts Engine Bed Mounting Bolts Engine Mount Bolts

49 36 16

5.0 3.7 1.6

L L L

125 12 98 7.8 7.8 29 7.8 7.8

13.0 1.2 10.0 0.8 0.8 3.0 0.8 0.8

Fuel System: Carburetor Mounting Bolts Intake Manifold Mounting Nuts Air Intake Cover Bolts Fuel Tap Mounting Screws Choke Assembly Mounting Screws

Engine Bottom End: Flywheel Bolt Stator Mounting Bolts Coupling Magneto Cover Mounting Bolts Crankcase Bolts - 6 mm Dia. Crankcase Bolts - 8 mm Dia. Water Drain Valve Mounting Bolts Water Drain Valve Cover Bolts Magneto Cover Stud

27 11 .6

L L L

94 8.5

SS L L,S L, S L L L

87 in-Ib

SS L SS L

69 in-Ib 69 in - Ib 22 69 in -Ib 69 in-Ib

Cooling and Bilge Systems: Water Pipe Joint

9.8

Drive System: Coupling Cover Nuts Coupling Drive Shaft Holder Mounting Bolts

39 22

4.0 2.2

29 16.0

1.0

GENERAL INFORMATION 1-9

Torque Fastener

Remarks N-m

kg-m

ft-Ib

9.8 9.8

1.0 1.0

Pump and Impeller: Water Pipe Joint Steering Nozzle Pivot 80lts Pump Outlet Mounting Bolts Pump Cap Bolts Impeller Pump Mounting Bolts Pump Cover Mounting Bolts Grate Mounting Bolts

87 in-Ib 87 in-Ib -

SS L L L

98 25 7.8 7.8

10.0 2.5 0.8 0.8

72 18.0 69 in-Ib 69 in-Ib

L L L

Steering: Handlebar Clamp Bolts Steering Neck Mounting Bolts Steering Holder Mounting Bolts Steering Shaft Lock Nut Steering Cable Nuts

16 16 16 29 18

1.6 1.6 1.6 3.0 1.8

11.5 11.5 11.5 22 13

L L

7.8 7.8 7.8 7.8 7.8 27 7.8 7.8 7.8 7.8 7.8 125 12

0.8 0.8 0.8 0.8 0.8 2.8 0.8 0.8 0.8 0.8 0.8 13.0 1.2

Hull/Engine Hood: Bumper Bushings Bumper Mounting Nuts Electrical System: Electric Case Bolts Electric Case Mounting Bolts Electric Case Connector Mounting Bolts Regulator/Rectifier Mounting Bolts CDI Igniter Mounting Bolts Spark Plugs Starter Motor Mounting Bolts Ignition Coil Mounting Bolts Starter Relay Mounting Nuts Starter Lead Mounting Nut Battery Ground Lead Mounting Bolt Flywheel Bolt Stator Mounting Bolts

69 69 69 69 69

in-Ib in-Ib in-Ib in-Ib in-Ib 20 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 69 in-Ib 94 8.5 ft-Ib

L L L L L L L

L L

This table relating tightening torque of the stainless bolt and the nut to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. General Fasteners (stainless bolt and nut)

Torque

Threads dia.(mm)

N-m

kg-m

ft-Ib

6 8 10

5.9 - 8.8 16 - 22 30 - 41

0.60 - 0.90 1.6 - 2.2 3.1 - 4.2

52 - 78 in -Ib 11.6 - 15.9 22 - 30

1-10 GENERAL INFORMATION Special Tools, Sealant Compression Gauge: 57001 -221

Bearing Driver Set: 57001 -1129

Piston Pin Puller Assembly: 57001 -910

Compression Gauge Adapter, M14 x 1.25: 57001-1159

o o o Oil Seal & Bearing Remover: 57001-1058

Impeller Wrench: 57001 -1228

Piston Ring Compressor Grip: 57001 -1095

Coupling Holder: 57001-1230

Piston Ring Compressor Belt, 4>67 - 4>79: 57001-1097

Drive Shaft Holder Adapter' 57001 -1231

GENERAL INFORMATION 1 -11

Rotor Puller, M18 x 1.5; 57001 -1258

Pressure Cable Luber; K56019-021

Watercraft Strap Tool; 57001 -1 294

Kawasaki Bond (Silicone Sealant): 56019-120

Drive Shaft Holder; 57001 -1327

Kawasaki Bond (Liquid Gasket- Black) : 92104-1003

Rotor Holder; 57001 -1368

Hand Tester; 57001-1394

1-12 GENERAL INFORMATION Cable, Wire and Hose Routing 1. 2. 3. 4. 5. 6. 7. 8. 9.

Warning/Indicator light Leads Fuel Vent Hose Clamp Throttle Cable Grommet Start/Stop Switch Leads Warning/Indicator Light Display Panel Choke Cable Detent 10. Holder 11 . Steering Cable 3

f!Jl ___~_\v

f- .. _

"--

r __ ___

.. ---1----">..

BOW

GENERAL INFORMATION 1Âˇ13

1. 2. 3. 4. 5.

9. Battery (+) Cable 10. Battery Breather Hose

Fuel Tank Clamp FuelTap Main Fu el Hose (ON) Supply Fuel Hose-A

17. Cooling Bypass Hose 1 B. Reserve Fuel Hose(RES) 19. Return Fuel Hose (RETURN)

11 . Oil Inlet Hose 12. Oil Tank 1 3. Electric Case

6 . Detent

14. Starter Motor Cable

7. Supply Fuel Hose-B 8. Bilge Breather

15. Battery (-) Cable

20. Magneto Cover

21 . Magneto Leads 22. Stopper 23. Starter Motor 24. Fuel Filter

16. Carburetor

--.

BOW

16 14

The magneto leads between clamps has to be loose enough so that it can absorb the engine mo vement.

Clamp the magneto leads with other leads.

BOW

1-14 GENERAL INFORMATION

1. Oil Tank 2. Fuel Filter 3. Supply Fu el Hose

to Carbu retor 4. Return Fuel Hose

5. Supply Fuel Hose to Filter 6. Sediment Bowl 7. Main Fuel Hose 8. Fuel Tap 9. Vent Hose to Bracket

10. Vent Hose to Sediment Bowl 11 . Reserve Fuel Hose 12. Cooling Bypass Hose

13. Oil Hose to Pump 14. Battery Breather Hose

GENERAL INFORMATION 1-15

View from Top

1. Oil Tank 2. Clamp (Band) 3. Magneto Leads

Electric Case

5. Spark Plug 6. Oil Level Sensor Leads

7. Battery Breather Hose 8. Battery 9. Fuel Filter 10. Battery (+) Cable 11 . Battery (-) Cable

... BOW

-----=:--

FUEL SYSTEM 2-1

Fuel System Table of Contents

Exp loded View.

Specifications ...

..... 2 -2

....... ... ... ......

.......... 2-4

Fu el System Diagram ................ .2-5 Throttle Case and Cable.. ..................... 2-6 Throttle Cable Adjustment ...... .... ... ... 2-6 Throttl e Case and Cable Removal......... .......... 2-6 Throttle Cable and Case Installation Note ....... .. ..2-7 Throttle Cable Installation Notes ... ........... .... 2-8 Throttle Case and Cable Lubrication .................... 2-8 Throttle Cable Inspection .......... ............ ...... ..... ... 2-8 ..... .... .... ...... ....... ..... 2 -10 Choke Cable.. Choke Cable Adjustment ...................... ......... 2 -10 Choke Knob and Cable Removal. ..................... 2-10 Choke Cable and Knob Installation Notes ....... .2-11 Inspection ...... ......... .......... 2-11 Lubrication ..... ........ .... .... ....... ... ................... 2 -11 Carburetor/Fuel Pump .......................................... 2-12 Idle Speed Adjustment..... ......... 2-12 Mixture Screw Ad justment ...................... .... .. ... 2- 12 High A ltitude Performance Adjustment. .. ..... .2-12 Synchronization. ... .... ..... ........... .......... 2-13 Carburetor Removal ... ................ ............. ...... .. .2- 13 Carburetor Installation Notes . .... 2-14 Carburetor Disassembly................. .2-14 Carburetor Assemb ly Notes ................ ... ..... 2 -15

Carburetor Cleaning and Inspection .

..... 2-16

Float Arm Level Inspection and Adjustment .. ... 2 -17 Fuel Pump Remova l/ Installation Note .............. 2-17

Flame Arrester ............. ... ............. .... ........................2-18 Removal.... .... ........ ... ................................ 2-18 Installation Notes ................................................2-18 Cleaning ..............................................................2-19 Intake Manifold. Reed Va lves ................................. 2-20 Removal......................... ............................... 2-20 Installation Notes ................................... ........... .. 2-20 Reed Valve Inspection ........................................ 2-20 Valve Holder Inspection .....................................2-21 Va lve Stop Inspection ............... ........ .......... ....... 2-21 Sediment Bowl ........................................................ 2-22 Removal .............................................................. 2-22 Installation Note .................................................2-22 Fuel Tank ....... ................................. .............. .... ....... 2 -23 Fuel Tank Removal ............. ... .... ... .... .......... ... ..... 2-23 Fuel Tank Installation Notes .............................. 2-23 Fuel Tank Cleaning .............. ........ ....... .............. 2-24 Fuel Filler and Tube Removal ...... ......................2-24 Fuel Filler and Tube Installation Notes ........ ...... 2-24 Fuel Filler Screen Cleaning ......... ....... ................ 2-25 Fuel Vent Check Valve ............................................ 2-26 Fu el Vent Check Valve Mounting ......................2-26 Fuel Vent Check Va lve Inspection .............. ..... ..2-26 Fuel Tap ...................................................................2 -27 Removal ................................................ .............. 2-27 Installation Notes ..................................... .......... 2-27 Cleaning .. ......................... ......................... ....... .2-27

2-2 FUEL SYSTEM Exploded View 1. Main Jet 2 . Pilot Jet

3. Check Valve 4. Diaphragm Needle T1 7.8 N·m (08 L .: A . kg·m, 69 in·lb) . pplya non-perman t I . G . Apply en ockong agent SS :

grease.

Tl L .

. Apply SIlicone sealant.

,•I

FUEL SYSTEM 2-3

'o~_

•.,' :v _ _ ~

'1,

6 , -0

00 ' II i

®I~ (

o~~ '---

fI,:

~:)

---

~~ \J

o 0 '0

I )

2-4 FUEl SYSTEM Specifications Standard

Item Carburetor: Make, type Size ~ixture

screws: Low speed High speed

Main jet Pilot jet Idle speed:

in water out of water

Keihin, CDK 40 - 31 x 2(Diaphragm) 35 mm Venturi 3/4 ±% turn open 3/4 ±\\ turn open # 135 #72 1 250 ± 1 00 rpm 1 700 ±100 rpm

Reed Valve: Reed warp

---

Fuel Tank: Capacity

33 L (including 6 L reserve)

Sealant - Pressure Cable luber: K56019-021 Sealant- Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit -------

-----------

0.201m ---

FUEL SYSTEM 2-5 Fuel System Diagram

Enolne

Return

a II

Pump

Fuel Te.nk

Reserve Main

",.~r.-v----<f),----"i)jJ To Ce.rb

To steerlnQ

o or

Ma n e

rye

Sed Iment

Bowl Fuel

Tap

2-6 FUEL SYSTEM Throttle Case and Cable

Throttle Cable Adjustment e Check throttle cable adjustment. OWith the throttle lever released; the stop on the shaft lever (A] should

rest against the idle adjust screw [8], and there should be slight slack

in the throttle cab le. OWhen the throttle lever is fully applied (pushed), the stop on the shaft lever should be all the way up against the stop on the carburetor.

elf necessary, adjust the throttle cable . • Loosen and turn the locknuts [C] at the bracket until the stop on the shaft lever hits against the idle adjust screw with slight cable slack.

.Tighten the locknuts securely.

Throttle Case and Cable Removal • Disconnect the throttle cable from the ca rburetor. • Remove:

Handlebar Pad Throttle Case

Start/Stop Switch Handlebar Steering Cover

• Disconnect the throttle cable from the case.

eUse the screw driver [A] to separate the tip of the cable end [8] from the case body.

eTake out the bolts (A] and remove the grommet [8] . • Remove the throttle cable by carefully pulling the cable through the hull.

THROTIlE CLOSED ( RELEASED)

THROTTLE OPEN (APPLIED)

FUEL SYSTEM 2-7

Throttle Case and Cable Installation Notes .Pulling the throttle cable [AJ. position the tip of the cable end [BJ. as

shown .

• Apply silicone sealant to the grommet [AJ . • Route the throttle cable correctly (see Cable Routing section in the General Information chapter) . • AdJust the throttle cable (see Throttle Cable Adjustment).

Throttle Case and Cable Lubrication .Apply water resistant grease [AJ to the tips of the throttle cable ends .

• Lubricate the cable by seeping oil between the cable and cable

housing. Special Tool - Pressure Cable Luber: K56019-021 [AJ

2-8 FUEL SYSTEM

Throttle Cable Inspection • Examine the cable.

*If the cable or cab le housing is kinked [AJ or frayed [b], replace the cab le.

• Be certain that the thrott le cable moves freely in both directions.

o Loosen the adjuster locknuts. and slide the cable from

the pulley. OSlide the inner cable back and forth in the cable housing. If the cable does not move freely, replace it.

FUEL SYSTEM 2-9 BLANK

2-10 FUEL SYSTEM Choke Cable

Choke Cable Adjustment .When the choke knob is turned counterclockwise, the choke butterfly valve in the carburetor should be completely open. Check that the choke pivot arm (AJ is up all the way w ith minimal cable slack. This will fully open the choke butterfly valve in the carburetor. elf necessary, adjust the choke cable. Olurn the choke knob counterclockwise completely. o loosen the locknuts [8] and turn the nuts to allow a little cable slack. o Tighten the locknuts. CHOKE OPEN (TURNED TO OFF)

Choke Knob and Cable Removal • Disconnect the choke cable from the carburetor. • Remove the set screw and take out the choke knob . • Remove the cable holder mounting screws [A].

• Pull the choke knob shaft with cable holder out of the hull.

.Slide the tip [A] of the choke inner cable out of the pulley on the choke knob shaft . • Loosen the locknut [B] and unscrew the cable housing [C] from the holder [D].

CHOKE CLOSED (TU RNED TO ON)

FUEL SYSTEM 2-11

• Remove the E-ring and pull out the choke knob shaft from the cable holder.

NOTE

o When

pulling the choke knob shaft, two detent balls and two

springs will fall out of the cable holder. Do not lose them.

A. Choke Knob Shaft B. Detent Ball C. Spring D. Cable Holder E. O- ring

F. Washer G. E- ring

Choke Cable and Knob Installation Notes .Inspect the O-ring and replace it, if necessary .

• Apply silicone sealant to the mating surface of the cable holder and the hull. • Route the choke cable according to the Cable Routing section in the General Information chapter .

• Adjust the choke cable (see Choke Cable Adjustment).

Inspection • Examine the cable.

* If the cable or cable housing is kinked [AJ or frayed [BJ, replace the cable . • With the choke cable disconnected at the both ends, the cable should move freely w ithin the cable housing.

* If the cable does not move freely. replace it.

Lubrication Whenever the choke cable removed. lubricate the choke cable as follows .

• Apply water resistant grease to the tips of the choke cable ends. • Lubricate the choke cable by seeping oil between the cable and cable housing.

Special Tool - Pressure Cable Luber: K56019-021 [AJ .Attacked the choke cable to the carburetor and adjust the choke ca ble

(see Choke Cable Adjustment).

2-12 FUEL SYSTEM

Carburetor/Fuel Pump

Idle Speed Adjustment The normal idle speed setting is the lowest at which the watercraft will run reliable while still producing enough thrust to circle back to the rider after spill. .Turn the idle adjusting screw [AJ as required to reach this setting.

Idle Speed

1,250 ±100 rpm (In water) 1,700 ±100 rpm (out of water)

r L

• Pull out the mixture screw caps. eTa set each screw, turn it in until seats lightly, and then back it out the specified number of turns. Turns out Mixture Screw

JH750-G1

Low Speed (lower) [B] High Speed (uppe,) [C]

3/4 3/4

± ±

1/4 1/4

These guideline represent a "starting point" from which additional fine tuning of the carburetor may be necessary. .-

...

CAlITlON Do not force the mixture screws into their seats. You could damage the screws or the carburetor. Operating the watercraft with the high speed screw at too lean a setting (screwed in clockwise too far) could cause serious engine damage.

NOTE

o The adjustment of the low speed screw is not required on the actual usage.

Altitude m (ft) 1000 (3300) 2000 (6600) 3000 (10000)

Turn the high speed screw in the normal position 1/8 turn 1/4 turn 3/8 turn

FUEL SYSTEM 2-13

Synchronization • Remove the carburetor (see Carburetor Removal)

.Turn out the idle adjusting screw [AJ until there is a clearance between the adjusting screw end and throttle shaft lever [BJ

.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 va lve [C] opening in the front carb uretor [0] . • Measure the distance from the bottom of the carburetor bore lower end to the valve end shown as "H" . • Turn the synchronizing screw [E] so that the valve end in the rear carburetor [F] keeps tim Silrne distflllGP. within ±O.2 mill tolernnce (lS that in the front carburetor . • Install the carburetor . • Adjust the throttle and choke cables.

~ ('I

Carburetor Removal • Remove: Air Intake Cover (see Flame Arrester Removal) Arrester Case (see Flame Arrester Removal) • Disconnect: Throttle Cable [A] Choke Cable [B] Return Hose [C] Inlet (Supply) Hose [D] Pulse Hose [E] Oil Hoses • Lift the carburetor off the intake manifold.

2-14 FUEL SYSTEM

Carburetor Installation Notes .Connect the fuel hoses. pulse hose and oil hoses correctly (see Fuel System Diagram) . • Install a new gasket under the carburetor.

.Applya non -permanent locking agent to the carburetor and air intak e cover bolts. Torque - Carburetor Mounting Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib) Air Intake Cover Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

• Bend the tab portions of the double washer over the carburetor mounting bolts . • Adjust the throttle and choke cables (sec Throttle nnd Choke Cnble Adjustment).

Carburetor Disassemblv .Remove the carburetor (see Carburetor Removal) . • Unscrew the carburetor cover screws [A] and take off the carburetor

cover [BJ

• Unscrew the carburetor case screw {A] and separate the carburetor case [BJ from the carburetor body.

• Unscrew the float arm set screw [AJ . • Remove: Float Arm [BJ Spring Float Valve Main Jet [C] Pilot Jet [DJ

FUEL SYSTEM 2-15

.Remove the mounting screws [A] and drop out the plate [8] and check valve [C].

Carburetor Assembly Notes elf the mixture screws were removed, install then, as shown.

A. High Speed Screw B. Low Speed Screw

.Assemble the carburetor cover, as shown.

A. Float Arm 8. Spring C. Diaphragm Needle D. Main Jet E. Pilot Jet

\?~ ~

.~~~ NOTE CAfter 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 on the carburetor. system in now full of fuel.

The fuel

2-16 FUEL SYSTEM

AWARNING Gasoline Is extremely flammable and can be explosIve under curtain 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 wilh 8 pilei light.

Carburetor Cleaning and Inspection • Disassemble the

carburet~r

(see Carburetor Disassembly).

AWARNING Solvent Is toxic and flammable. Avoid prolonged contact with skin

and keep away from open flame. Use only In a sell ventilated area. Eye protection should be worn when compressed air is used to dry parts. Do not direct air toward anyone. Use 172 kPa (1.75 kg/cm 2 , 25 spl) maximum nozzle pressure . • • • • •

Immerse all the metal parts in a carburetor cleaning solution . Rinse the parts in water . When the parts are clean, dry then with compressed air . Blowout the air and fuel passages with compressed air . Inspect the check valve [A] for damage or deterioration, and replace it if necessary. If the gasket [BJ under the check valve appears damaged, it may leak and must be replaced .

• Check these runner parts for damage. O-ring [AJ Diaphragm [BJ If any of these parts are not in good condition, replace them .

• Check the plastic tip on the diaphragm valve needle. smooth, without any grooves, scratches, or tears. Diaphragm Needle [AJ Diaphragm Needle Wear [BJ

If the plastic tip is damaged, replace the needle.

It should be

FUEL SYSTEM 2-17

Float Arm Level Inspection and Adjustment • Check the float arm level [A]. o Measure from the plastic tip [8] on the float arm to the carburetor case

[C]. Float Arm Level 1.0 - 2.0 mm

* If the float arm level is incorrect bend the float arm very slightly to change the float arm level.

Fuel Pump Removal/Installation Note • Remove the carburetor . • Remove the fuel pump body screws [A], and take the fuel pump unit [B] off the carburetor.

CAUTION The fuel pump should not be disassembled. If leakage is evident or Internal damage Is suspected, replace the fuel pump unit [B].

2-18 FUEl SYSTEM Flame Arrester

Removal • Remove: Air Intake Cover Mounting Bolts [A] Air Intake Cover [B] Carburetor Mounting Bolts [C] Arrester Case [D]

Installation Notes .When assembling the flame arrester, put the screen [A] between two expanders [ B]

• Install th e arrester case [A] so that its shorter side [BJ from the intake to arrester case end faces the engine . • Apply a non -permanent locking agent to the thread at the carburetor mounting bolts.

Torque - Carburetor Mounting Bolts: 7.8 N-m (0.8 kg-m, 69In-lb)

• Bend the tab portions of double wash er over the carburetor mounting bolts .

• Install the duct [A] and cover [B], as shown. OApply instant glue [C] to the outside of duct. D. Engine Side .Apply a non -permanent locking agent to the thread of the air intake

cover bolts. Torque - Air Intake Cover Bolts: 7.8 N-m (0.8 N-m, 69 In-Ib)

FUEL SYSTEM 2-19

Cleaning • Remove the flame arrester (see Flame Arrester Removal) . • Blow the flame arrester clean with compressed air.

AWARNING Eye protection should be worn when compressed air is used to dry porls. Do nol direct air toward anyone. Use 172 kPa (1.75 kg/cm 2 , 25 psi) maximum nozzle pressure .

• Install the flame arrester (see Flame Arrester Installation Notes).

2-20 FUEL SYSTEM Intake Manifold. Reed Valves

Removal .Remove: Air Intake Cover Carburetor (see Carburetor Removal) .Remove the intake manifold mounting nut [AJ and remove the intake

manifold .

• Pull out the gaskets [A] and the reed val ves [B].

Installation Notes

• Replace the gaskets with new ones. • Install the reed valves so that the "up" mark [A] is up.

r./(5-Tl/ 0 ' - .

o~o b[Jt]d .Torque the intake manifold mounting nuts, following the specified tightening seq uence. Torque - fnlake Manifold Mounting Nuts: 7.8 N-m (0.8 kg-m, 69 in-I b)

.After installing the parts removed, bleed the oil pump if there are air bubbles in the outlet hoses (see Engine Lubrication System chapter).

o~ 5

(§)

Reed Valve Inspection • Check reed warp by measuring the clearance [A] between each reed

[B] and the va lve holder [C].

* If anyone of the clearance measurements exceeds the service limits, replace the reed valve assembly with a new one.

c Reed Warp Service Limit:

0.2 mm

• Check the mounting screw tightness . • Visually inspect the reeds for cracks, folds. or other damage. *If there is any doubt as to the condition of a reed, replace the reed valve

assembly.

FUEL SYSTEM 2-21

* If a reed becomes wavy, replace the reed valve assembly with a new one even if reed warp is less than there service limit.

Valve Holder Inspection .Check the reed [A] contact areas of the valve holder for grooves, scratches, or other damage. . .Check that the rubber coating [B) on the valve holder does not show any signs of separation from the holder. If there is any doubt as to the condition of the rubber coating. replace the reed valve assembly with a new one.

Valve Stop Inspection .Check the va lve 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.

2-22 FUEL SYSTEM Sediment Bowl The sediment bowl prevents water from entering the fuel tank. If there is water in the sediment bowl, drain it.

Removal eTa remove only the sediment bowl {A], unscrew the ring nut [8].

eTa remove the entire assembly, remove the bolts [A] and pull the

hoses [BJ.

Installation Note â&#x20AC;˘ Inspect the O-ring [A] and replace it, if necessary.

FUEL SYSTEM 2-23 Fuel Tank Fuel Tank Removal elf the level of the fuel is above the filler neck, sip hon some fuel out to

prevent spilling it.

•..WARNING Gasoline Is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop buHon. Do not smoke. Make sure the area Is well venlllated and free from any source of flame or sparks;thls Includes any appliance wIth a pilot light.

• Remove or disconnect: Engine Steering Cable Connector [AJ Fuel Level Sensor Connector

Bypass Cooling Hose Steering Cable Holder [CJ Sediment Bowl Assembly [DJ Rubber Straps [EJ

• Loosen the clamp [AJ on the filler tube and remove the fuel tank.

• Remove tho fuel level sensor [AJ and the fuel filter assembly [BJ.

Fuel Tank Installation Notes .Be sure the O-ring [AJ is in the position.

2-24 FUEL SYSTEM

Fuel Tank Cleaning • Remove the fuel tank (see Fuel Tank Removal) . • Drain the tank into a suitable container.

AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop buHon. Do not smoke.

Make sure Ihe area is well ventilated and free from any source of flame or sparksj this includes any appliance with a pilot light.

• Flush the tank repeatedly with high flash-point solvent until it is clean. It may be necessary to put a few marbles or pieces of clean gravel into the tank and shake it, to knock loose any foreign matter in the bottom.

AWARNING 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. 00 not use gasoline or a low flash- point solvent to clean the tank. A fire or explosion could result.

Fuel Filter and Tube Removal .Take out the screws (A] in the filler flange, and cut the sealant [8].

• Loosen the tune clamps [A] and pull the tube [8].

Fuel Fi/ler and Tube /nsta/la(ion Notes .Clean the full and the filler on their mating surfaces with a graceless, high flash -point solvent.

AWARNING 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.

.Apply an even layer of silicone sealant to the mating surface of the filler and hull.

FUEL SYSTEM 2-25

Fuel Filter Screen Cleaning • Clean the fuel filter screens in accordance with the Periodic Maintenance Chart (see General Information chapter) . • Open the hatch cover and take out the storage case . • Disconnect the fuel vent hose [A).

• Unscrew the mounting screws [AJ, and remove the fuel filter assembly [ 8).

NOTE

o When

servicing. do not let fall the O-ring [A] and the mounting

screws in the bottom of the hull.

.Wash the fuel filter screens in non -flammable or high flash-point solvent. Use a brush to remove any contaminants trapped in the

screens.

AWARNING Clean the fuel tllter screens In a well ventilated area, and take care that there are no sparks or lIame anywhere near the working area; this includes any appliance wilh a pilot light. Do nol use gasoline or a low flash-point solvent. A lire or explosion could result.

Fuel Filter Inspection The watercraft is equipped with a fuel filter [A] at the middle of the fuel line to prevent dirt or other foreign material from entering the ca rburetor . • Inspect and replace the fuel filter in accordance with the periodic Maintenance Chart, or whenever you find from outside any foreign material or water trapped in the fuel filter.

2-26 FUEL SYSTEM Fuel Vent Check Valve

Fuel Vent Check Valve Mounting The fuel vent check valve is mounting in the fuel tank ven t hose to prevent fuel from spilling during riding. Air can flow in to the tank to allow fuel to be drawn out by the fuel pump, but fuel cannot flow out the check valve . â&#x20AC;˘ The fuel vent check valve [A] must be mounted so that th e arrows on its case are pointing toward the fuel tank.

Fuel Vent Check Valve Inspection â&#x20AC;˘ 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 directions or in neither direction, the check valve must be replaced.

FUEL SYSTEM 2-27 Fuel Tap

Removal .Unscrew the bracket mounting bolts [A] and remove the sediment bowl assembly [6] .

• Unscrew the set screw and take out the fuel tap -knob . • Unscrew the mounting screws [A] and take -out the fuel tap .

• Pull the fuel hoses off the fuel tap [A].

Installation Notes .Apply an even layer of silicone sealant [A] to the mating surfaces of the tap and hull. Special Tool - Pressure Cable Luber: K56019-021

• Connect the fuel hoses to the fuel tap correctly (see Cable Routing section in the General Information chapter) . • Applya non -permanent locking agent to the fuel tap mounting screws and tighten them securely.

Cleaning If the fuel tap becomes clogged with foreign matter, it must be cleaned . • Remove the fuel tap [A] . • Use compressed air to blow [8] through the supply fuel hose fitting [el. while switching the fuel tap right and left between the "ON" and "RES" positions. Do this until only blockage it forced out.

NOTE ODo not use too high air pressure (172 kPa, 1.8 kglem', 25 psi max.).

ENGINE LUBRICATION SYSTEM 3-1

Engine Lubrication System Table of Contents

Exploded View ....... .................................... .. ....................................... 3-2 Specifications ......... ................................. .................... ............. ......... ..... 3-3 Oil Pump .. .......... .... ...................................................... .......... ................................... 3-4 Oil Pump Bleeding ..................................................... ........................................ 3-4 Oil Pump Performance Test ................................. ...... ..... ..... ............................. 3-4 Oil Pump Removal .......................... ....................... ... .......................................... 3-5 Oil 'Pump Installation ......... ........................ ....................... ................. 3-5 Oil Tank ....... ..... ................................................. ... ... ... ... ... ......................................... 3-6 Remova l.. ........ ........................... ............ ... ..... ... .... ...................... 3-6 Installation Note .... ....... ......... ........................... .. ...... ........... .. .... .3-6 Oil Tank Cleaning ... ................. ... .. ... ...... .... .. .............................. .. 3-6 Oil Filter Cleaning .. ............................ ..................................... .......... 3-6

3-2 ENGINE LUBRICATION SYSTEM Exploded View (08 kg-m, 69 in-Ib) nt locking agent. L: Apply a non-permane

T1: 7.8 N-m.

, T 1\ / '"

"- ~ --------; I

I I

ENGINE LUBRICATION SYSTEM 3-3 Specifications Standard

Item Engine Oil: Type Capacity Engine Oil Pump: Oil pump output @3000 r/min (rpm), 2min .

2-stroke, NMMA Certified for Service TC -Wll 2.3 L 5.9 - 7.2 mL

3-4 ENGINE LUBRICATION SYSTEM

Oil Pump Oil Pump Bleeding .Make sure that there is plenty of engine oil in the oil tank and that oil flow is no restricted . • Loosen the air bleeder screw [A] on the oil pump a couple of turns wait until oil flows out, and then tighten the bleeder screw securely.

CAUTION Use a 50 : 1 mixture of gasoline to 011 In the fuel lank In place of the gasoline normally used. 00 not turn on the water until the engine is running and turn iI off Immediately when the engine stops .

• Supply the cooling system with water (see Auxiliary Cooling in the

General Information chapter) . • Start the engine. keep it at idling speed and check the oil flow through the transparent outlet hose. • Keep the engine running until the air bubble in the outlet hose disappear.

Oil Pump Performance Test If a drop in oil pump performance is suspected, check the rate at which the oil is being pumped. • Disconnect the oil pump outlet hoses at the oil injection nozzle and run the hoses [A] into a measuring glass [6].

CAUTION For this test use a 50 : 1 mixture of gasoline to 011 Instead the gasoline normally used .

011 Pump Output (3,000 rpm lor 2 minutes) Siandard:

5.9 - 7.2 mL

*If the oil pump output is subnormal. inspect the oil pump, and the inlet and outlet hoses for oil leaks. * If oil leaks are not found, replace the oil pump.

NOTE OA check valve is built into the oil pump and can not be removed.

ENGINE LUBRICATION SYSTEM 3-5

Oil Pump Removal .Squeeze the inlet hose [AJ to restrict oil flow and disconnect it from the oil pump . â&#x20AC;˘ Pull off the outlet hoses [B], remove both mounting nuts [C] and take off the oil pump and the O -ring.

Oil Pump Installation .8e sure th e O-ring [AJ is in place and inslall the oil pump on the magneto cover. OWhen mounting the oil pump, note the position of the slot [8] in the flywheel bolt. and then turn the oil pump shaft [C] so that it will fit into the slot. â&#x20AC;˘ Connect both oil hose and bleed the air form the system (see Oil Pump Bleeding).

3-6 ENGINE LUBRICATION SYSTEM Oil Tank Removal • Drain the engine oil.

• Loosen the clamp and pull the oil level sensor [A] out of the oil tank.

• Disconnect the oil pump inlet hose [A]. .Unscrew the mounting bolts [B] and remove the oil tank [ C] .

Installation Note .Put the heat guard [A] on the water box muffler.

Oil Tank Cleaning .Flush the tank repeatedly with high flash-point solvent until it is clean .

AWARNING Clean the lank In a well~ventllaled 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·polnt solvent to clean the tank. A fire or explosion could result.

Oil Filter Cleaning Check the oil filter [A] for foreign particles every time you add the oil. If there are any foreign particles, the oil filter must be cleaned . • Take out the oil filter Qut of the oil filter . • Wash the oil filter in a non-flammable or high flash - point solvent. Use a brush to remove any contaminates trapped in the filter.

'.WARNING Clean the all filter In a well-ventilated area, and take ample care that

there are no sparks or flame anywhere near the working area;lhls Includes any appliance with a pilot light. Do not UBe gasoline or a low flash-point solvent to clean the filter. A fire or exposilion could result.

EXHAUST SYSTEM 4-1

Exhaust System Table of Contents

Exploded View .......... ..................................................................................................4-2 Exhaust Pipe, Joint and Expansion Chamber ........... .................................................4-3 Removal ............ ... ..... .. .. ..... .........................................4-3 Installation Notes .......... ..... . ................................................................... ...... .4-4 Joint Disassembly... ....... ........................... ...................................... ..4-6 Joint Assembly..... ........................................ ............ .... ... ... ......... ..4-7 Expansion Chamber Cleaning and Inspection ................................................ .4-8 Exhaust Manifold .. .. ............. ................................................... 4-9 Removal...... .... ...................... .............. ...... .... ...... ............ 4-9 Installation Notes ................ ........................................................4-9 Exhaust Manifold Cleaning and Inspection . . ....................................4-10 Water Box Muffler..... ................ ................................................... 4-11 Removal.... ..... ....................... ... ... ............. . . .. 4-11 Installation Notes...... . ............ . ..................................... .4-11 Disassemblyl Assembly Notes. ............................. .4-11 Inspection ........................ . ................................................................. ..4-11

4-2 EXHAUST SYSTEM Exploded View T1 T2 T3

78 N-m (08 kg-m. 69 In-Ib) 9.8 N-m (1 0 kg -m. 87 In -Ib) 20 N -m (20 kg -m. 14 5 ft-Ib)

49 N-m (50 kg -m. 36 ft-Ib) A I a bonding agent

~ A~~I~ a non - permanent locking agent

55' Apply silicone sealant

~855

@ Q

9~~

EXHAUST SYSTEM 4-3 Exhaust Pipe, Joint and Expansion Chamber

Removal • Disconnect:

Spark Plug Caps Battery (+) Cable Starter Motor Cable • Remove the electric case [A] .

• Disconnect:

Cooling Hose (Joint - Water Box Muffler)[AJ Cooling Hose (Cylinder Head - Exhaust Pipe)[B] Bypass Cooling Hose [C] Water Drain Knob [OJ

• Remove: Exhaust Pipe Mounting Bolts [AJ Electric Case Stand Mounting Bolts [BJ

4-4 EXHAUST SYSTEM

.Remove the expansion chamber mounting bolts [A], and loosen the clamp [B] on the connecting tube [C] .

â&#x20AC;˘ Remove the exhaust pipe and expansion chamber as a set [A] out of the engine compartment.

If there are any shims under the mount blocks [AJ , mark them so they may be put back in the same position.

Installation Notes .Whenever the connecting tube [A] is removed, install the connecting tube so that the stepped edge [B] ring on the end of tube faces toward the front [C] of the watercraft .

â&#x20AC;˘ Install the clamps. eAt this time, make sure that the groove inside the tube [A] fits over the projection [8] on the expansion chamber.

EXHAUST SYSTEM 4-5

eTighten the clamp of the engine side [AJ.

epush the other end of the connecting tube [AJ completely over the water box muffler inlet [8] as shown.

elnstal l the exhaust pipe gasket [AJ as shown.

Installation Notes .Apply a non-permanent locking agent on the thread in the range illustrated [AJ and torque the exhaust pipe mounting bolts [8]. Torque - Exhaust Pipe Mounting Bolls: 49 N-m (5.0 kg-m, 36 H-Ib)

.App ly a non-permanent locki ng agent to the expansion chamber mounting bolts [C] and torque them. Torque - Expansion chamber Mounting Bolts: 7.8 N-m (0.8 kg-m, 69 in-Ib)

B;--_-l'l

4-6 EXHAUST SYSTEM

Joint Disassembly • Unscrew the mounting bolts [AJ, and remove the joint [8) .

• Remove: Clamps [AJ

Bands Outer Boot [BJ

• Unscrew the screws [AJ and take out the clamps [BJ . • Remove the lower joint [C].

• Remove: Race [A] Spring Seat [B] Spring [C] Inner Boot[DJ

Joint Assembly .Check the O-ring [AJ, ring [B] and rubber boots [C] for damage.

* If any of these parts are not in good condition, replace them .

EXHAUST SYSTEM 4-7

.Install the following onto the upper joint [A]. Inner Boot [B] Spring [C] Spring Seat [D] Race [E]

.When connecting the upper [A] and lower [B] joints, align the left end [C] of the recess in each joint with the line [D] on the inner boot.

.Install the clamps [A]. OApplya non -permanent locking agent to the clamp screws.

o Keep the direction of screws

[B] and lay the nut [C] and the screws [B] between the gap of the inner boot.

.Push the outer boot over the joint with the arrow mark [A] upward .

â&#x20AC;˘ Install the bands [A] and clamps [B] on the outer boot as shown being careful of the screw position.

o Lay the clamp worn between the gap [C] of the bands as shown.

~3MÂŽ

4 -8 EXHAUST SYSTEM

.Coat on the seal area [A] of joints (upper and lower) with silicone sealant. Sealant -

Kawasaki Bond (Silicone Sealant): 56019-120

.Wipe off any excess sealant.

. Install the gaskets. The "UP" mark of gasket must face upward. A. "UP" mark B. Upper Gasket C. Lower Gasket

.Applya non-permanent locking agent to the joint mounting bolts and torque them.

Torque - Joint Mounting Bolts: 9.8 N-m (1 .0 kg-m, 87 In-Ib)

Expansion Chamber Cleaning and Inspection .Remove the expansion chamber . â&#x20AC;˘ Scrape any carbon deposits out of th~ expansion chamber with a blunt, roundedged tool. Excessive deposits will cause the engine to run poorly . â&#x20AC;˘ Check the expansion chamber carefully for cracks. Also look for

corrosion both inside and out.

EXHAUST SYSTEM 4-9 Exhaust Manifold

Removal .Remove the exhaust pipe and expansion chamber as a set [A] (see Exhaust Pipe, Joint and Expansion Chamber Removal) .

• Remove the exhaust manifold mounting nuts [A] .

• Disconnect the inlet cooling hose [AJ, and take off the exhaust manifold.

Installation Notes .Install the exhaust manifold gasket so that the arrows [AJ point the up .

• Torque the exhaust manifold mounting nuts, following the specified tightening sequence. Torque - Exhaust Manifold Mounting Nuts: 20 N-m (2.0 kg·m, 14.5 II-Ib)

4-10 EXHAUST SYSTEM

Exhaust Manifold Cleaning and Inspection • Remove the exhaust manifold parts. • Clean the carbon deposits out of the exhaust passages with a blunt, roundedged tool. • Flush foreign matter out of the water passages with fresh water . • Check the insides of the water passages for corrosion . Check the gasket surfaces for nicks. or other damage. there is excessive corrosion or if the gasket surfaces are so badly damaged that they w ill not seal properly. replace the part.

*11

EXHAUST SYSTEM 4-11

Water Box Muffler Removal • Remove: Battery Oil Tank Exhaust Pipe and Expansion Chamber Water Box Muffler Mounting Bolt [AJ

• Loosen the clamp [A) and pull the exhaust tube [BJ off the water box muffler . • Slide off the water box muffler toward the front.

Installation Notes .Apply a non - permanent locking agent to the water box muffler mounting bolt. Torque - Water Box Muftler Mounting Bolts: 7.8 N·m (0.8 kg-m. 69In·lb)

Disassembly/Assembly Notes • Replace the O-rings. .Applya thin coating of silicone sealant to the groove [AJ in the bottom half matting surface. then install the O-ring [8]. This will insure a good seal and prevent O-ring from getting out of place. Sealant -

Pressure Cable Luber: 56019-120

• Be sure to lower the upper half straight down onto the bottom half during final assembly . • Apply a non-permanent locking agent to the following bolts and torque them. Torque - Water Box Muffler BoilS: 7.8 N·m (0.8 kg·m . 69 In-Ib) [AJ Outer Pipe Mounting BoilS: 7.8 N-m (0.8 kg·m. 69 In-Ib) [BJ

4-12 EXHAUST SYSTEM

.Whenever the subÂˇassembly (exhaust pipes and spacer) are removed, note the following. OApply silicone sealant [A] on the inside of cylindrical wall.

Special Tool - Pressure Cable Luber: KS6019-021

OApply a non-permanent locking agent to the exhaust pipe mounting bolts [8J. and then bend one of the tongues of plate [CJ. along the side of hexagonal head of bolt.

o Be sure the O-rings [A] and the dampers [8] are in the position as shown. OPay attention to the top of projection of pipe exhaust be horizontal [8].

EXHAUST SYSTEM 4-13

Inspection • Remove the water box muffler . • Empty any water out of the water box . • Check the inlet spigot for damage caused by excessive 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 mixture needle adjustment (see Mixture Screw Adjustment in the Fuel System chapter) . • Check the seem around the center of the water box for leaks. If there are leaks in the water box seam, they may be repaired with an epoxy putty, or the water box may be replaced. Exhaust leaks will fill the engine compartment with exhaust gasses which will cause the engine to run poorly.

ENGINE TOP END 5-1

Engine Top End Table of Contents

Exploded View ............................................................................................................5-2 Specifications ............................................................................................................. 5-3 Engine Top End ........................................................................................................... 5-4 Disassembly and Assembly: ................................................................................... 5-4 Disassembly ........................................................ ... ... .......................................... 5-4 Assembly Notes ................................ .............. ..... ............................................... 5-5 Maintenance and Inspection: ...................................... ........................................... 5-7 Compression Measurement.. .............................................................................. 5-7 Cylinder Head Warp Inspection .........................................................................5-7 Cylinder Wear Inspection ..................................................................... ........ .. .5-8 Piston Diameter Measurement .................. ........ .................................................. 5-8 Piston/Cylinder Clearance ................ ... ..................................................... .......... 5-8 Boring and Honing .............................................................................................5-9 Piston Ring, Piston Ring' Groove Inspection ....................................................5-9 Piston Ring End Gap ..........................................................................................5-9

5-2 ENGINE TOP END Exploded View T1: T2: T3: T4: SS: 0:

9.8 N-m (1.0 kg-m, 87 in-Ib) 29 N -m (3.0 kg-m, 22 ft - Ib) 34 N-m (3.5 kg -m, 25 ft - Ib) 20 N-m (2.0 kg-m, 14.5 ft-Ib) Apply silicone sealant. Apply engine oil. Apply a non-permanent locking agent.

ENGINE TOP END 5-3 Specifications Item Cylinder Head: Cylinder compression

Standard (Usable range)

890 - 1370 kPa (9.1 - 14.0 kg / em'. 129 - 199 pis) (Open throttle) Cylinder head warp Cylinder. Piston: Cylinder inside diameter Piston diameter (18 mm up from bottom of skirt) Piston / cylinder clearance Oversize piston and rings 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 Special Tools -

Service Limit

---

80.000 - 80.D15 mm 79.900 - 79.915 mm 0.095 - 0.115 mm +0.5 mm and +1.0 mm ---

-- 0.05 mm

80.10 mm 79.75 mm ---

-----

---

-- -

---

- -- -- --

-------

0.25 - 0.40 mm 0.25 - 0.40 mm

Piston Pin Puller Assembly: 57001·910 Piston Ring Compressor Grip: 57001·1095 Piston Ring Compressor Belt, <1>67 - <1>79: 57001·1097 Compression Gauge: 57001·221 Compression Gauge Adapter, M14 x 1.25: 57001·1159

- -0.7 mm 0.7 mm

5-4 ENGINE TOP END Engine Top End Disassembly and Assembly:

Disassembly • Remove: Spark Plugs Intake Silencer

Cable Holder [A] Carburetor ( see Carburetor Removal in the Fuel System chapter) Exhaust Pipe, Front Muffler and Expansion Chamber as a set (see Exhaust System chapter)

.Remove the cylinder head nut [AJ, and take off the cylinder head [B] .

• Remove the cylinder base nuts [A], and lift off the cylinder [B] .

• Stuff clean rags into the crankcase opening to prevent dirt or foreign objects from falling into the crankcase .

• Remove the piston pin snap ring [A] with a pliers [BJ.

.Remove the piston by pushing its pin out the side that the circlip was

removed. Use a piston pin puller assembly [A], if the pin is tight. Special Tool - Piston Pin Puller Assembly: 57001-910

ENGINE TOP END 5-5

• Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [AJ to remove it.

Assembly Notes elf any parts in the piston assemblies require replacement, or if the cylinder is honed or 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 upwards as

shown .

Second ring

.When installing the piston rings by hand, first fit one end of the piston ring against the pin in the ring groove, spread the ring opening with the other hand and then slip the ring into the groove . • Check to see that the pin [AJ in each piston ring groove is between the ends of the piston ring .

• Apply engine oil to the surface of each piston pin . • Mount the piston on the connecting rod with the arrow [A] on its crown pointing to the left (exhaust) side [B] of the engine .

• When installing a piston pin snap ring, compress it only enough to install it and no more.

CAUTION Do not reuse rings, as removal weakens and deforms them. They could fall out and score the cylinder wall . • Fit a new piston pin snap ring into the side of each piston so that the snap ring opening [A] does not coincide with the slits [B] of the piston pin hole.

5-6 ENGINE TOP END

.Set the new cylinder base gasket in place on the crankcase . • Apply engine oil to the surface of the pistons. • Compress the piston rings. Special Tool - Piston Ring Compressor Grip: 57001-1095 [AJ Piston Ring Compressor Belt, <1>67 - <1>79: 57001-1097 [BJ

. Thoroughly oil the cylinder bores. • Slide the cylinder block down over the crankcase studs onto the

crankcase.

CAUTION Do not force the cylinder block. Make sure the rings are in position . • Install the cylinder base nuts, and cross-tighten them. Torque - Cylinder Base Nuts: 34 N-m (3.5 kg-m, 25 fI-lb)

• Place a new cylinder head gasket on the cylinder head. OThe "UP" mark [AJ of the gasket must face upward and "EX" mark [BJ must face toward the exhaust side of the engine.

®'_~,

FRONT

• Install the cylinder head. Torque - Cylinder Head Nut: 29 N-m (3.0 kg-m, 22 fI-lb) OThe tightening sequence numbers are marked on the cylinder head.

Exhaust Side

• Start the engine to check for fuel .and oil leaks. exhaust leaks. and excessive vibration .

AWARNING 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 for more than 15 seconds without cooling water.

ENGINE TOP END 5-7

Maintenance and Inspection:

Compression Measurement .Thoroughly warm up the engine. whi le checking that there is no compression leakage from around the spark plugs or the cylinder head gasket.

CAUTION Do not run the engine for more than 15 seconds without cooling

water. • Stop the engine. • Remove the spark plugs and screw a compression gauge firmly into the spark plug hole. Special Tools -

Compression Gauge: 57001-221 [AJ Compression Gauge Adapter, M14 x 1.25:

57001~1159

[BJ • Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. • Repeat the measurement for the other cylinder. Cylinder Compression (Usable Range) 890 - 1,370 kPa (9.1 - 14.0 kg/em', 129 - 199 psi) (open throHte)

*If the cylinder compression is higher than the usable range, check the following. o Carbon buildup on the piston head and cylinder head - clean off any carbon on the piston head and cylinder head. o Cylinder head gasket, cylinder base gaskets - use only the proper gaskets. The use of a gasket of incorrect thickness will change the compression. If cylinder compression is lower than the usable range, check the following : o Gas leakage around the cylinder head - replace th e damaged gasket and check the cylinder head for warp. o Piston /cylinder clearance, piston seizure. o Piston rings, piston ring grooves wear.

Cylinder Head Warp Inspection .Lay a straightedge [AJ across the lower surface of the head [BJ at several different points, and measure warp 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

5-8 ENGINE TOP END

Cylinder Wear Inspection • Inspect the in side 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-la-side and a front -la-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure. A.l0 mm B.80mm c. 35 mm

'--\1

1. ®

J}-

*If any of the cylinder inside diameter measurements exceeds the service

limit. the cylinder will have to be bored oversize and then honed. Cylinder Inside Diameter Standard: 80.000 - 80.015 mm and less than 0.01 mm difference between any two measurements Service Limn: BO.l0 mm, or more than 0.05 mm difference between any two measurements

Piston Diameter Measurement eMeasure the outside diameter [A] of the piston 18 mm up [B] from the bottom of the piston at a ring angle to the direction of the piston pin. Piston Diameter Standard: Service Limit:

79.900 - 79.915 mm 79.75 mm

o if the measurement is less than the service limit, replace the piston. NOTE OAbnormal 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, or wheneyer the cylinder is rebored and oversize pistons installed . • Th e 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 va lues . • Measure the piston diameter as just described, and subtract this value from the measurement. The difference is the piston clearance. Piston/Cylinder Clearance 0.095 - 0.115 mm

]®

ENGINE TOP END 5-9

Boring and Honing When boring and honing a cylinder, note the following: OThe are two sizes of oversize pistons available. Oversize Piston and Rings Oversize Pistons and Rings 0.5 mm Oversize 1 .0 mm Oversize o Before boring a cylinder, first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the Service Date Section, determine the rebore diameter. However, if the amount of boring necessary would make the inside diameter grater than 1.0 mm oversize, the cylinder block must be replaced. o Cylinder inside diameter must not vary more than 0.01 mm at any point. o Be wary of measurements taken immediately after boring since the heat affects cylinder diameter. o In the case of a rebored cylinder and oversize piston, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm and the service limit for the piston is the oversize piston original diameter minus 0.15 mm. If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder.

Piston Ring. Piston Ring Groove Inspection .Visually inspect the piston rings and the piston ring grooves. *If the rings are worn unevenly or damaged, they must t;.e replaced . *It the piston ring groove are worn unevenly or damaged, the piston must be replaced and fitted with new rings.

eMeasure the gap [AJ between the

ends of the ring [BJ with a

th ickness gauge.

* If the gap is w ider than the service limit, the ring is worn excessively and must be replaced. Piston Ring End Gap Standard 0.25 - 0.40 mm Top 0.25 - 0.40 mm Second

Service Limit

0.70mm O.70mm

ENGINE REMOVAL/INSTALLATION 6-1

Engine Removal/Installation Table of Contents

Exploded View .. ..... .. ........................................................................................... ........ 6-2 Engine Removal/Installation ................. .................... ..................................................6-3 Removal ..............................................................................................................6-3 Installation Notes .. ...... ... ....................................... ... .................. .. ............... ........ 6-4

6-2 ENGINE REMOVAL / INSTALLATION Exploded View T1: T2: T3: L:

16 N-m (1 .6 kg -m, 11.6 ft-Ib) 36 N-m (3.7 kg -m, 27 ft -Ib) 49 N-m (5.0 kg -m, 36 ft-Ib) Apply a non - permanent locking ag ent.

ENGINE REMOVAL/INSTALLATION 6-3 Engine Removal/Installation

Removal • Remove or disconnect:

Battery Spark Plug Caps Electric Case Connector (AJ

Starter Motor Cable [B] Wiring Clamps [C]

• Remove the electric case [AJ

• Remove (see the appropriate chapters): Exhaust Pipe and Expansion Chamber (as a set)

Cable Holder [A] Carburetor Coupling Cover

Oil inlet Hose

• Remove the engine bed mounting bolts [A] .

• Slide the engine toward the front to disengage the couplings, and then lift the engine out of the hull. .Remove the engine mounting bolts and separate the engine bed and the engine.

6-4 ENGINE REMOVAL / INSTALLATION

Installation Notes • Be sure there are no foreign objects and parts inside of the hull . • Clean the bilge filter (see Filter Cleaning and In spection in the Cooling

and Bilge Systems chapter) . • Check the coupling damper for wear and damage (see Coupling Damper Inspection in the Engine Bottom End chapter) .

• Install the engine bed so that the small notches [AJ are on the magneto end of the engine as shown. .Apply a non-permanent locking agent to the engine mounting bolts and torque them . Torque - EngIne Mounting Bolts: 49 N-m(S.O kg-m, 36 ft-Ib)

• Install the engine in the hull. aligning the projection on the magneto cover [AJ with the arrow [BJ in the bottom of the hull.

• Check the gap between the engine bed and the dampers by rocking the engine.

elf there is a gap, insert a suitable shim between the engine bed and the damper to achieve a good fit. Shim Selection

Thickness Shim No. 92025-3705 to.3 mm to.5 mm 92025-3706 92025-3707 11.0 mm 92025-3708 t1.5 mm .Apply a non-permanent locking agent to the engine bed mounting bolts. and torque them.

Torque - Engine Bed Mounting Boils: 36 N-m (3.7 kg-m, 27 "-Ib)

.After installing the engine in the hull, check the following. Throttle Cable Choke Cable Oil Pump Bleeding Fuel and Exhaust Leaks AWARNING Do not run the engine In a closed area. Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas which can be leth.l.

CAUTION Operate the engine only for short periods without cooling water.

o [II: oJI

®-

" om

110

:5:

0 1

0II 0I

11i~'

11 0 ':1 I

ENGINE BOTTOM END 7-1

Engine BoHom End Table of Contents

Exploded View ............................................................................................................7-2 Specifications .............................................. ................................................................7-3 Coupling ......................................................................................................................7-4 Removal ............................................................................... ....... .... ........................7-4 Installation Notes ................................ ............................. .... ........ ...........................7-4 Coupling Damper Inspection ..................................... .... .......................................7-4 Magneto Flywheel ......................................................................................................7-5 Removal .................................................................................................................7-5 Installation Notes ....................................................... ............................................7-5 Stator ...........................................................................................................................7-7 Removal .................................................................................................................7 -7 Installation Notes ........................................................................... ..... .................... 7-8 Water Drain Valve ......................................................................................................7-9 Removal ....................................... ...........................................................................7-9 Installation ............................................ .. ... ... ......................................... 7-9 Crankcase ..................................................................................................................7 -10 Splittinl1 .................................................................................................................7 -10 Assembly Notes ....................................................................................................7 -10 Crankshaft Maintenance ..........................................................................................7 -12 Connecting Rod Bend/Twist .............................. .... .............................................7-12 Connecting Rod Big End Radial Clearance .........................................................7 -13 Connecting Rod Big End Side Clearance ............................................................7 -13 Crankshaft Main Bearing Wear ...................................................... ....................7 -13 Crankshaft Runout .............. ..................................................................................7 -14 Crankshaft Assembly Specifications ....................................................................7-14

7-2 ENGINE BOTTOM END Exploded View T1: T2:

7.8 N-m (0.8 kg-m, 69 in -Ib) 12 N-m (1.2 kg -m, 8.5 ft-Ib)

T3: T4: T5:

29 N-m (30 kg-m, 22 ft-Ib) 98 N-m (100 kg-m, 72 ft-Ib) 125 N-m (130 kg-m, 94 ft-Ib)

Apply a non-permanent lockrng agent Apply molybdenum disulfide grease. Apply grease. A pply liquid gasket. Apply oil to the flanged portion. Apply silicone sealant.

M: G: LG: 0: SS:

(@cf/;f)) ~

ENGINE BOTTOM END 7-3 Specifications Item Crankshaft. Connecting Rods: Crankshaft runout Connecting rod side clearance Connecting rod radial clearance Connecting rod bend Connecting rod twist

Standard

0.04 mm 0.45 - 0.55 mm 0.038 - 0.049 mm 0.05 mm/ 100 mm 0.15 mm/100 mm

Special Tool - Rotor Puller, M18 x 1.5: 57001-1258 Rotor Holder: 57001-1368 Sealant -

Kawasaki Bond (Liquid Gasket - Black): 92104-1003 Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit

0.10 mm TIR 0.8mm 0.10 mm 0.2 mm/ 1 00 mm 0.2 mm/1 00 mm

7-4 ENGINE BOTTOM END Coupling

Removal • Remove: Engine (see Engine Removal/Installation chapter) Coupling Damper

Magneto Cover • Holding the flywheel, unscrew the coupling. Special Tools -

Rolor Holder: 57001-1368 [A] Kawasaki Bond (Silicone Sealanl): 56019-120

Installation Notes .Applya thin coat of silicone sealant to the coupling threads. Sealanl - Kawasaki Bond (Silicone Sealant): 56019-120 [B]

• Screw the coupling onto the crankshaft and tighten it Torque - Coupling: 98 N-m (10.0 kg-m. 72 tt-Ib)

Coupling Damper Inspection .With the engine removed, remove the coupling damper and inspect it for wear [A] and deterioration.

* If it is grooved or misshapen, replaced it w ith a new damper. * If there is any doubt as to coupler condition, replace it.

ENGINE BOTTOM END 7-5 Magneto Flywheel

Removal • Remove: Carburetor (see Fuel System chapter)

Cable Holder [A] Oil Tube Clamp Oil Pump Magneto Cover

• Holding the flywheel with the rotor holder [A] remove the flywheel bolt.

NOTE

a Place the wooden board [B]to protect the hull bottom.

• Pull the flywheel off the crankshaft. Special Tool - Rotor Puller, M18 x 1.5: 57001-1258 [A] Rolor Holder: 57001-1368 [B]

NOTE

a Place the wooden board [C]

to protect the hull bottom.

Installation Notes .Using a high flash-points solvents, clean off any oil or dirt that may be on the flywheel bolt, the crankshaft taper, or in the tapered hole in

the flywheel. • Fit the woodruff key [A] securely in the crankshaft, before installing the magneto flywheel.

7-6 ENGINE BOTTOM END

.Applya thin coat of engine oil to the flanged portion of flywheel bolt. .Install the flywheel. Special Tool - Rotor Holder: 57001-1368 [A] Torque - Flywheel Boll: 125 N-m (13.0 kg-m, 94 ft-Ib)

o Use the universal joint

[B] to torque the flywheel bolt.

.Check that the knock pins [A] and the spring [B] are in place and replace the O-ring if it is damaged . â&#x20AC;˘ Apply a non-permanent locking agent to the threads of the magneto cover mounting bolts, and tighten them securely.

ENGINE BOTTOM END 7-7

Stator

Removal .Remove the electric case cap [A] , and disconnect the connectors

[8].

• Remove: Magneto Cover [AJ (see Magneto Flywheel Removal)

.Slide the pins out of the connectors. o Use a screw driver [A] to depress the pin latches .

• Unscrew the grommet cap [A] from the electric case cap .

• Pull the leads, one at a time, through the grommet and cap. o Lubricate the grommet with a penetrating rust inhibitor.

7-8 ENGINE BOTTOM END

.Unscrew the set screws [A] and bolts [B]. and remove the stator assembly.

Installation Notes .Coat the grommets [A] with water resistant grease .

â&#x20AC;˘ Insert the connector pins onto the connector, as shown.

jJgfQ ~BL ~BR ~\ti ~ ~'ill

.While pushing the pickup coil bracket [A] as shown. install the pickup coil [B] .

ENGINE BOTTOM END 7-9 Water Drain Valve

Removal • Remove: Exhaust pipe and expansion chamber as a set (see Exhaust System chapter) Exhaust Manifold (see Exhaust System chapter) Starter Motor (see Electrical System chapter) • Remove the mounting bolt [A], and take out the water drain valve

[BJ.

• Remove the valve cap and then remove the E-ring to disassemble the control valve.

A Reed Valve Assembly B. Gasket C. Reed Valve Cover D. Cover bolt E. Valve Cap

F. Control Valve G. E-Ring H. Spring L Control Valve Housing J. Mounting bolt

Installation • Visually inspect the reed valves for cracks, folds, or other damage.

* If there is any doubt as to the condition of a reed, replace the reed valve assembly . • Apply a non-permanent locking agent to the cover bolt threads. Torque - Water Drain Valve Cover Bolts: 7.8 N-m (0.8 kg-m, 69 In-Ib)

.Clean the drain hole [A] and the valve cap . • Visually inspect the valve cap, replace it if necessary.

elnstall the assembly on the lower crankcase half. OApplya non-permanent locking agent to the threads of the water drain valve mounting bolts. Torque - Water Drain Valve Mounting 801ts: 7.8 N-m (0.8 kg-m, 69In-lb) o Loosen the locknut just until the water drain valve knob returns by spring tension. eAfter installing the water drain valve, check that the control va lve fits tightly [AJ in the drain hole.

o Fully grease the drain knob shaft [AJ.

I V::: -~ 3

7-10 ENGINE BOTTOM END Crankcase

Splitting • Remove the engine (see Engine Removal/ Installation chapter) . • Remove the following from the engine. Exhaust Manifold Starter Motor Carburetor Intake Manifold Cylinder Head Cylinder Block

Pistons Water Drain Valve

Oil Pump Coupling Magneto Flywheel Reduction Gear

NOTE OAlways remove the coupling before removing the magneto flywheel. or there won't be any way to hold the crankshaft while unscrewing

the coupling.

• Remove the 6 mm crankcase bolts [A] first and the 8 mm bolts [B] .

• Pry the point [AJ indicated in the figure to sp lit the crankcase halves apart, and then remove the lower crankcase half. • Lift the crankshaft assembly out of the upper crankcase half.

Assembly Notes .Visually inspect the crankshaft O-ring [AJ. and replace it if necessary.

• Grease the inner surface of the coliar [B].

ENGINE BOTTOM END 7-11

• Grease the lips of the oil seals . • Pack grease [A) between the rear oil seals (coupling side) .

• Install the oil seals as shown. A. Double lips Seals B. Single Lip Seals

-'1 8

o "

• Place the crankshaft assembly [A] in the upper crankcase half so that the position ring [8] on the crankshaft assembly fits into the groove [C) in the crankcase .

• Check that the knock pins [A) are in place . • With a high flash·point solvent, clean off the mating surfaces of the crankcases halves and wipe dry . • Apply liquid gasket to the mating surface of the lower crankcase half . • Install the lower crankcase half onto the upper half .

• Apply a non -permanent locking agent to the crankcase bolts, and tighten them. Torque - Crankcase MS Bolts: 29 N-m (3.0 kg-m, 22 ft-Ib) Crankcase M6 Bolts: 7.S N-m (O.S kg-m, 69 In-Ib)

OThe tightening sequence numbers are marked on the lower crankcase half.

15 1:;:--- 1 4

Tb:! ~

\s1

Irijh'O 1l

H[~ I,

'-=.,

7-12 ENGINE BOTTOM END Crankshaft Maintenance The crankshaft changes the reciprocating motor of the piston into rotating motion to drive the jet pump. Crankshaft trouble, such as excessive play or runout. will multiply the stress caused by the intermittent force on the piston and will result in not only rapid crankshaft bearing wear, but also noise, power loss, vibration, and shortened engine life. A defective crankshaft should always be detected at an early stage and repaired immediately. The following explanation concerns the most common crankshaft problems and the method for measuring play, runout, and con-rod alignment, it does not cover crankshaft disassembly because of the highly specialized equipment that is required. If crankshaft components become damaged or worn, the entire shaft should be replaced as an assembly, or rebuilt by a properly equipped shop.

Connecting Rod Bend/Twist o Set the crankshaft in an alignment j ig or in V blocks on a surface plate. o Select an arbor of the same diameter as the connecting rod small end and at least 100 mm long, and insert the arbor through the connecting rod smali end. OWith the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over aÂˇ 100 mm length to determine the amount of connect rod bend.

*If connecting rod bend exceeds the service limit, the connecting rod or crankshaft must be replaced.

Connecting Rod Bend Standard: Under 0.051100 mm Service Limit: 0.21100 mm

â&#x20AC;˘ Measure connecting rod twist. OWith the crankshaft stili in the alignment jig, hold the connecting rod horizontally and measure the amount that the arbor varies from being parallel with the crankshaft over a 100 length of the arbor to determine the amount of connecting rod twist. *If connecting rod twist exceeds the service limit, the connecting rod or crankshaft must be replaced.

Connecting Rod Twist Standard: Under 0.151100 mm Service Limit: 0.21100 mm

ENGINE BOTTOM END 7-13

Connecting Rod Big End Radial Clearance • Check big end radial clearance. o Set the crankshaft in an alignment jig or on V b locks, and place a dial gauge against the connecting rod big end. o Push the connecting rod first towards the gauge and then in the opposite direction. The difference between the two gauge readings in 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. Connecling Rod Big End Radial Clearance SIBndBrd: 0.038 - 0.049 mm Service Limit: 0.10 mm

Connecting Rod Big End Side Clearance • Measure big end side clearance [A]. o Insert feeler gauges between the big end and either crank 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 0.45 - 0.55 mm SIBndBrd: Service Llmll: 0.8 mm

Crankshaft Main Bearing Wear .Wash Ihe bearings in high flash-point solvenl, blow Ihem dry (DO NOT SPIN THEM), and lubrieale them with engine oil. AWARNING

•

Solvent Is toxic and flammable. Avoid prolonged contact with skin and keep away from open flame. Use only in a well-ventilated area. Eye proteclion should be worn when compressed air Is used to dry parts. Do not direct air towards anyone. Use 172 kPa (1.75 kg/cm 2 , 25 psi) maximum nozzle pressure . • Turn each bearing over by hand and see that it makes no noise, turns smoothly, and has no rough spots.

If any of the bearings are defective, replace them.

7-14 ENGINE BOTTOM END

Crankshaft Runout .Check crankshaft alignment by measuring runout. OWith the crankshaft on V blocks [AJ. rotate the crankshaft slowly and measure runout at each of the locations shown.

* If the runout at any point exceeds the service limit the crankshaft must be either replaced or rebuilt. Crankshaft Runout (Either Location) Standard: Under 0.04 mm TIR 0.10 mm TIR Service LImit:

Crankshaft Assembly Specifications If the crankshaft is disassembled, use these specifications during rebuilding.

'-'-' j- ' - ' -

Il'

c ;,.. - - ~ . ~ - - -- -- .-.-.-.-.- . ~ . - ,- ,- . - . -.-- - . ---- ---. - .

1,,1.

4 .... 0. 6mm

; u

0.45""0. 55mm

)

60. 3 ..... 60 . 5mm

COOLING AND BILGE SYSTEMS 8-1

Cooling and Bilge Systems Table of Contents

Exploded View .......... ..................................................................................................8 -2 Bilge System ....................................... .............. .. .. ...... ...... ...........................................8-3 Breather Removal ............................................................................................... 8-3 Breather Installation .................... ............ ....... ........... .......................................... 8-3 Breather Cleaning and Inspection .............. .. ......................................................8-3 Filter Removal ......... ..........................................................................................8-3 Filter Cleaning and Inspection ..................................... .. ... .. ...............................8-3 Cooling and Bilge System Hoses ...............................................................................8-4 Hose Removal ............................................... ...................................... .. .............. 8-4 Hose Installation .................................................................................................8-4 Hose Inspection ........ ... ...................................................................................... 8-4 Cooling and Bilge System Flushing ...........................................................................8-5 Cooling System Flushing ............. ................. .. ...................................................8-5 Bilge System Flushing ................................................ .. ................................... 8-5

8-2 CO OLING AND B Exploded View ILGE SYSTEMS

_ N -m (1 0 T1 -_ 98 55: Apply silic - kg -m, 87 in-Ib) one sealant.

â&#x20AC;¢

COOLING AND BILGE SYSTEMS 8-3 Bilge System

Breather Removal • Pull the hoses [AJ off the breather. .Unscrew the mounting bolt [BJ. and remove the breather [C].

Breather Installation • Be sure the small hole [A] in the breather is open before installing it.

Breather Cleaning and Inspection • Check that the small hole in the top of the breather is open by blowing in one end of the breather and plugging the 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 well as it should.

Filter Removal .Pull the hose [AJ off the filter . • Unscrew the mounting screws [8], and remove the filter [Cl

Filter Cleaning and Inspection • Flush the filter thorough with fresh water and shake it dry . • Water must flow freely through the filter, but large debris must not. If the filter cannot be cleaned, or if it is broken and allows debris to pass through, replace it.

8-4 COOLING AND BILGE SYSTEMS Cooling and Bilge System Hoses

Hose Removal • None of the bilge system hoses has a clamp. To remove this hose, remove the filter (see Filter Removal) . The bilge system hoses wi thout clamps may be simply pulled off their fittings . • AII the cooling system hoses are clamped at both ends. Loosen the clamps and pull the hoses off.

Hose Installation eTo install the bilge filter hose, push the hose over the end of the filter. • When installing the cooling system hoses, be sure to use the same kind of clamp as the original. Some of the clamps are metal for tighter clamping ability (required when smooth fitting are used). Plastic clamps are used where tight clamping is not required.

Hose Inspection • Check the hoses for hardening. cracking. checking. cuts. abrasions, and breaks. If a hose is damaged in any way. replace it immediately and check all the other for damage.

COOLING AND BILGE SYSTEMS 8-5 Cooling and Bilge System Flushing

Cooling System Flushing To prevent sand or salt deposits from accumulating in the cooling system, it must be flushed occasionally. Flush the system according to the Periodic Maintenance Chart. after each use in salt water, or whenever there is reduced water flow from the bypass outlet on the left side of the hull. • Remove the fitting cap [A] on the cylinder head.

eConnect a garden hose [AJ to the fitting .

• Start the engine and allow it to idle before turning on the water.

CAUTION The engine must be running before the waler Is turned on or water may flow back through the exhaust pipe Into the engine, resulting In the possibility of severe internal damage.

.Immediately turn on the water an adjust the flow so that little trickle of water comes out of the bypass outlet [AJ on the left side of the hull.

• Left the engine idle for several minutes with the water funning . • Turn off the water. Leave the engine idling. • Rev the engine a few times to clear the water out of the exhaust system.

CAUTION Do not run the engine without cooling water flowing for more than 15 seconds. Overheating will cause severe engine and exhaust system damage.

• Switch off the engine, remove the garden hose, install the fitting cap.

Bilge System Flushing To prevent clogging, the bilge system should be flushed out according to the Periodic Maintenance Chart. or whenever you suspect it is blocked. e Disconnect both bilge hoses at the plastic breather fitting [AJ .

r•

8-6 COOLING AND BILGE SYSTEMS

.Connect the other hoses (from the hull bulkhead) to the garden hose. turn the water on, and flush it out for several minutes .

• Before reconnecting the hoses to the plastic breather fitting make sure

the small hole [AJ. on top of the breather fitting is clear . • Reconnect the bilge hoses.

DIRECTION OF COOLING SYSTEM FLOW DIRECTION OF BILGE SYSTEM FLOW DIRECTION OF COMBINED EXHAUST AND COOLING WATER FLOW

DRIVE SYSTEM 9-1

Drive System Table of Contents

Exploded View ...................... ......................................................................................9-2 Specifications ..............................................................................................................9-3 Drive Shaft/Drive Shaft Holder ................................................................................... 9-4 Drive Shaft Removal/Installation ............... ........................................................9-4 Drive Shaft Holder Removal/Disassembly ................ .. .......................................9-4 Drive Shaft Holder Assembly/Installation ............. ............................................ .9-5 Drive Shaft Runout .. ..... ..... .................................................................................9-5

9-2 DR IVE SYSTEM Exploded V'lew T1: 39 N-m

::::~~~~::::::::::::::::::::::::::::::::========;;;;;;;;;;;;;;=---------

T2: 22 N-m ~~.~ ~g-m, 29 ft-Ib) L: Apply a no~ g-m, 16.0 ft-Ib) : Ap I -permanent I . ss. P y grease. ocklng agent. G . Apply silicone sealant.

DRIVE SYSTEM 9-3 Specifications ,

Item

Standard

Service limit

Drive Shaft: Runout (Refer to Page 5)

Special Tools -

[A) less than 0.1 mm [B] less than 0.2 mm

Coupling Holder: 57001,1230 Drive Shaft Holder: 57001-1327 Drive Shall Holder Adapter: 57001-1231 Bearing Driver Sel: 57001 -1129

Sealanl - Kawasaki Bond (Silicone Sealant): 56019-120

0.2 mm 0.6 mm

9-4 DRIVE SYSTEM Drive Shaft/Drive Shaft Holder Drive Shaft R emo val/Installation .Remove the engine (see Engine Removal/ Installation chapter) . • Pull the drive shaft [AJ out of the hull.

.Clamp the drive shaft and unscrew the coupling. Special Tools -

Coupling Holder: 57001-1230 [AJ Drive Shaft Holder: 57001-1327 [BJ Drive Shaft Holder Adapter: 57001-1231 [CJ

.When installing the drive shaft. be careful of the following items. OApplya thin coat to the coupling threads and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Coupling: 39 N-m (4.0 kg-m, 29 ft-Ib)

OApply grease to the grease seal lips and the drive shaft spline.

Drive Shaft Holder Removal/Disassembly • Remove the drive shaft . • Unscrew the mounting bolts [A] and remove the drive shaft holder [BJ from the bulkhead .

• Disassemble the drive shaft holder.

o Remove the ci rclip [AJ.

DRIVE SYSTEM 9-5

o Press

the small grease seal, and the large grease seals, bearing, and small grease sea ls come out of the holder.

Press

A. Sleeve B. Blocks

Drive Shaft Holder Assembly/ Installation • Replace the grease seals with new ones. • Press the bearing and grease seals into the drive shaft holder, noting

the following .

o Install the parts in this order. Two Small Grease Seals [A] One Bearing [B] Two Large Grease Seals [C] Special Tool - Bearing Driver Set: 57001-1129

o Install the sea ls so that the sides with the spring face outward . O Fil1 the gaps between the seals with grease [D] . • Install the circlip . • Grease to the bearing inner surface and grease seal lips .

• Install the drive shaft holder on th e bulkh ead so that the circlip side face toward the front.

.Apply a non -permanent locking agent to the drive shaft holder mounting bolts, tighten them loosely_

• Install the drive shaft . • After installing the engine. tighten the drive shaft holder mounting bolts to the specified torque to give proper coupling alignment.

Torque - Drive Shah Holder Mounting Bolts: 22 N-m (2.2 kg-m, 16.0 h-Ib)

Drive Shaft Runout • Measure drive shaft runout by supporting the shaft on V blocks and setting a dial gauge against the shaft at each 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: Service Limit:

Less than 0.1 mm [A] Less than 0.2 mm [B] 0.2 mm [A] 0.6 mm [B]

;;jff$!!~

PUMP AND IMPELLER 10-1

Pump and Impeller Table of Contents

Exploded View ... .... .................................................. ................................................. 10-2 Specifications ............................................................................................................10-3 Pump and Impeller ....................................................................................................10-4 Pump Remova l ........................................................... .. ........ ................................ 10-4 Pump Installation .......................................................................................... ..... ... 10-4 Pump Disassembly ............................................ .. .... .. ...........................................10-5 Pump Assembly .................... .. ......... ....... ... ........... .. .. ....................... ...... ........ ....... 10-7 Pump and Impeller Inspection ........................ : ................ .. ......... ...................... ... 10-9 Impeller Clearance ................................................................................................ 10-9

10-2 PUMP AND IMPElLER Exploded View

T1: T2: T3: T4: SS: G: L:

7.8 N-m (0.8 kg-m, 69 in-Ib) 9.8 N-m (1.0 kg-m, 87 in -Ib) 25 N-m (2.5 kg-m, 18.0 ft-Ib) 98 N-m (10.0 kg-m, 72 ft-Ib) Apply silicone sealant. Apply grease. Apply a non-permanent locking agent.

PUMP AND IMPEllER 10-3 Specifications Item Jet Pump: Impeller Outside Diameter Pump Case Inside Diameter Impeller Clearance Special Tools -

Standard 139.5 - 139.7 mm 140.0 - 140.1 mm 0.15 - 0.3 mm

Impeller Wrench: 57001 Âˇ1228 Oil Seal & Bearing Remover: 57001 -1058 Bearing Driver Sel: 57001-1129 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit 138.5 mm 141.1 mm 0.6 mm

10-4 PUMP AND IMPElLER Pump and Impeller Pump Removal .Turn the craft on its right side . • Unscrew the mourning bolts [AJ, and remove the grate [8] and the

pump cover [C] .

• Slip the cable connector [A] off the ball. .Loosen the clamp, and pull off the hoses [8].

• Unscrew the pump mounting bolts [AJ . • Slide the pump to the rear to disengage the drive shaft, and remove it . from the hulL

.To remove the pump bracket [A], culthe sealant [B] althe intake area.

Pump Installation .Strip off all the old sealant around the pump intake . • Liberally coat the outside edge of the pump bracket [A] with silicone sealant to form a seal between the bracket and the hull .

• Install the pump bracket, and wipe off any excess sealant and smooth the joint.

PUMP AND IMPElLER 10-5

.Grease the splines on the drive shaft with water resistant grease, and be sure the O-ring is in place inside the pump shaft. • Be sure the trim seal [A] is in place .

• Put into the bolts [A] and washers [B] through the pump case [e]. and be careful that the trim seD I [0] is stayed in place before installing the pump case . . o If necessary, apply water or oil to the surface of the trim seal.

NOTE

o No need to apply silicone sealant between the pump (trim seal) and the hull.

• Apply a non-permanent locking agent to the pump mounting bolts and torque them. Torque - Pump MounUng Bolls: 25 N-m (2.5 kg-m. 18.0 ft-Ib)

• Connect the hose and steering cable .

• Install the pump cover [A] and the pump gratdB]. OApply a non-permanent locking agent to the following bolts and torque them. Torque - Pump Cover MounUng Bolts: 7.8 N-m (0.8 kg-m, 69 In-Ib) Grate MounUng Bolls: 7.8 N-m (0.8 kg-m, 69In-lb)

Pump Disassembly • Unscrew the mounting bolts [AJ, and remove the steering nozzle [B].

•

10-6 PUMP AND IMPElLER

• Unscrew the mounting bolts [AJ. and remove the pump outlet [8].

• Unscrew the cap bolts [AJ. and remove the pump cap [8J .

• Hold the shaft in a vise, taking care not to damage it. Remove the impeller from the pump shaft and then pullout the pump shaft. Special Tool - Impeller Wrench: 5700t-1228 [AJ

.Pull out the bushing [AJ .

• Remove the grease seals. Special Tool - 011 Seal & Bearing Remover: 57001-1228 [AJ

PUMP AND IMPELLER 10-7

• Remove the pump bearin gs. A. Pump Case S. Bearing C. Collar

Pump Assembly • Before installing the pump bearings, blow any dirt or foreign particles out of the pump case with compressed air . • Install new bearings. Special Tool - Bearing Driver Set: 57001-1129 [AJ o Press the rear pump bearing into the pump case as far as it will go. o Insert the co llar and install the front pump bearing.

• Replace the grease seals with new ones, if necessary, and install them using the same special tool used for bearing installation. o Press each seal into the pump case so that the side with the spring faces outward. Fill the gap between the seal with grease . • Push the bushing into the pump case . • Visually inspect the pump shaft O-rings, and replace them if necessary. • Grease the pump shaft and insert it from rear of the pump case . • Screw on the impeller. Torque - Impeller: 98 N-m (10.0 kg-m, 72 ft-Ib)

.Visually inspect impeller grease seal [A], and replace if necessary .

• When installing the grease seal, follow the next procedure. o Press the grease seal [AJ into the impeller [6], aligning the seal teeth [CJ with the sleeve teeth [D].

10-8 PUMP AND IMPELLER

OTo protect the seal teeth from damaging. insert a suitable collar [AJ

that is longer than no spline part including the spline starting area into

the impeller wrench [BJ.

®-{

Special Tool - Impeller Wrench: 57001-1228

o Insert the grease seal

[CJ deeply into the impeller wrench. aligning the

seal teeth with the wrench teeth.

@H~ OPush the above wrench assembly into the impeller [AJ. and then lightly press the wrench assembly to seat the grease seal into the impeller sleeve [BJ.

PRESS

CAunON Do not press the grease seal heavily. You could damage the grease seal.

• Be sure the O-ring [AJ in place on the pump cap .

• Install: Pump Cap Pump Outlet Steering Nozzle .Applya non-permanent locking agent to the thread of the following.

Pump Cap Bolts Pump Outlet Mounting Bolts Steering Nozzle Pivot Bolts

Torque - Steering Nozzle Pivot Bolls: 9.8 N-m (1.0kg-m. 87 in-Ib)

PUMP AND IMPElLER 10-9

Pump and Impeller Inspection â&#x20AC;˘ Examine the impeller. *11 there is pitting [A], deep scratches [8], nicks [e] or other damage, replace the impeller.

NOTE

o Minor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing. Smooth leading edges are especially

important to avoid cavitation.

o Measure the impeller outside diameter.

* If the impeller is worn smaller th.an the service limit, replace it. Impeller Outside Diameter Standard: 139.5 - 139.6 mm Service Limit: 138.5 mm

.Examine the pump case [A]. If there are deep scratches inside the pump case, replace it.

o Measure the inside diameter of the pump case.

*If

the pump case is worn beyond the service limit, replace it.

Pump Case Inside Diameter Standard: 140.0 - 140.1 mm Service Limit: 141.1 mm

Impeller Clearance .Impeller clearance is critical to proper performance. If the pump case and impeller are not visibly damaged, poor performance may be caused by too much impeller clearance. eTo check impeller clearance, remove the grate and insert a feeler gauge [A ] between the tip 01 the impelier blade [8] and the pump case

[C]. Impeller Clearance Siandard: 0.2 - 0.3 mm Service Limit: 0.6 mm

* If impeller clearance is incorrect, determine if it is due damage (see Pump and Impeller Inspection) .

to wear or

STEERING 11-1

Steering Table of Contents

Exploded View...................... ......... ,............................................................ 11 -2 Steering Cable ...................... .. .............................................. 11 -3 .. ........................... .......................... ........... 11 -3 Adjustment. ............. . Removal .............................................................................................................11-3 Installation Notes ............................... .......................................... " ...................... 11-5 Handlebar ... .. ................................................................................. ,...........................11-6 Handlebar Removal.. ... .. ...................... ............................................. 11 -6 Handlebar Insta llation Notes ................................................................................11-6 Steering .............. " ...................... ......... ............ .......... ....... ... ,................... " .............. 11 -8 Removal...... .............. .. ...... .. ................... .......................................... 11-8 ................... 11 -9 Installation Notes ...

11-2 STEERING Exploded View Tl :16 N-m (1.6 kg-m, 1'.5ft-lb) 13.0 ft - Ib) T2: 18 N -m (1.8 kg -m, T3 : Hand-Tighten 22 ft-Ib) T4:

29 N-m (30 . kg-m, ermanent Lac king agent. A Iya non-p l: pp 51TIe one sealant. 55Â· Apply rG ~

STEERING 11-3 Steering Cable

Adjustment .Check the steering cable adjustment. o Center the handlebar in the straight ahead position .

• Check that the steering nozzle is centered [AJ in the pump cavity.

elf necessary adjust the steering cable.

o Loosen the locknut on the steering cable. o Disconnect the ball joint by sliding the outer sleeve [A]

away from the

ball stightly, and lifting the cable from the ball. OTurn the ball joint on the cable to adjust the steering. OConnect the ball joint and check cable adjustment again.

OWhen adjustment is correct, tighten the steering cable locknut.

Removal • Disconnect the ball joint at each end of the steering cable.

o Slide the outer sleeve [AJ away from the ball slightly, and lift the cable from the ball. CAUTION Never lay the watercraft on the left side. Water In the exhaust system may drain back into the engine, causing serious damage .

• Loosen ihe locknut [AJ, and then remove the ball joint [BJ and locknut from each cable end.

11-4 STEERING

• Disconnect the steering cable from the cable holder.

o Unscrew the mounting bolts [A], and remove the cable holder [8] .

• Separate the cable [A] from the cable holder [8J .

• Remove the pump cover (see Pump Removal in the Pump/Impeller chapter) . • Disconnect the steering cable from the fitting at the rear of the hull.

o Unscrew the large nut [A] while holding the fitting [B] in the hull with a wrench.

OSlide off the E-ring [A], washer [BJ, and O-ring [eJ .

• Pull the cable from the cable detent in the engine compartment.

• Pull out the steering cab le toward the front.

STEERING 11-5

Installation Notes • Lubricate th e outside of the new cable to ease cable installation . • Slide a piece of rubber [A] or plastic tubing over the rear cable end to

guide the ca ble through the hull.

11-6 STEERING Handlebar

Handlebar Removal • Remove the handlebar cover . • Unscrew the mounting bolts [A] and remove the pad [8].

.Take out the throttle case clamp screws and remove the throttle case

[A] . • Take out the switch case · clamp screws and remove the switch case

[8] .

• Take out the handle clamp bolts [A] and remove the handlebar [8].

Handlebar Installation Notes .Applya non-permanent locking agent to the handlebar clamp bolts . • Install the handlebar on the holders of the steering neck with clamp bolts .

• Align the punch mark [A] on the handlebar w ith the right holder front top . • Tighten the front and then rear handlebar clamp bolts to the specified torque.

Torque - Handlebar Clamp Bolts: 16 N-m (1.6 kg-m, 11.S H-Ib)

STEERING 11-7

eBefore installing the pad (front side)[Al. set handlebar cover [B) on the pad as shown.

11-8 STEERING Steering

Removal • Remove the handlebar (see Handlebar Removal) . • Unscrew the mounting bolts [A] and remove the steering cover (6).

sliding the cover towi'lrr:ls front.

• Unscrew the mounting bolts [AJ and remove the LED unit [BJ .

• Unscrew the mounting bolts [AJ and remove the bracket [BJand the steering neck [C] .

• Remove the cotter pin [AJ and locknut [BJ . • Take out the holder [CJ .

• Remove the lock plate [AJ and unscrew the steering shaft nut [BJ . • Pull out the steering shaft.

STEERING 11-9

• Remove: Duct Grommet [AJ Vent Hose Throttle Cable Start/Stop Switch Leads LED Unit Leads

• Unscrew the mounting bolts [AJ and remove the steering holder [BJ . • Take out the nut and pull the steering shaft.

Installation Notes • Check the bushings for damage and wear.

* If the bushings are damaged or worn, replace them . • Grease: Bushings [AJ Steering Shaft [BJ

• Be sure the grommet [AJ is installed around the washer [BJ.

(ffc1

11-10 STEERING

.Install the steering shaft [A] into the steering holder [B] and hand tighten the nut [C] .

â&#x20AC;˘ Clean the mating surface of the steering holder and hull. .Coat the steering holder bottom with silicone sealant [A], and fit the steering holder to the hull. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

.Applya non-permanent locking agent to the steering holder mounting bolts and torque them. Torque - Steering Holder Mounting Bolls: 16 N-m (1.6 kg-m, 11.5 ft-Ib)

.Apply silicone sealant to the grommet [A] and the air duct [8].

HULL/ENGINE HOOD 12-1

Hull/Engine Hood Table of Contents

Exploded View ......................................................................................................12 -2 Fittings.................. ............. . ................................ .... ......... 12-4 Hatch Cover Removal/ Insta llation .................... 12-4 Handrail Removal / Installation ......................................................................... 12-4 Air Exhaust Duct Removal.. ... ...................... .......................... ........... 12-4 Air Exhaust Duct Installation Notes ................................................................. 12-5 Stabilizer Installation . ............. ........... ....... . ...............................................12-5 Hull Replacement..... ......... .. ................................ ............................12-6 Rubber Parts....... ................. ............................. . ......................... ................ 12-7 Rubber Parts Location ........................ ................................................12-7 Front Bumper Removal.. ... ..... . .. ... ... ........... .... ................ 12-8 Front Bumper Installation Notes ........... ...................................................... 12-8 Rear Bumper Removal ... ....................................................................12-9 Rear Bumper Installation Notes .......................................................................12-9 Side Bumper Removal.. ...... ...... ..... .. ............ ....... ................................ 12-9 Side Bumper Installation Notes .............. ................ .. ............ .. .......... 12-10

12-2 HUL L/ENGINE Exploded V. HOOD lew

" sealan~.nt locking agent.

L "A SS: APPlY a non-perman .

pply silicone

HUll/ENGINE HO 01) â&#x20AC;¢ 12-3

12-4 HULL/ENGINE HOOD Fittings

Hatch Cover Removal/Installation .Take out the bolts [A] and remove the hatch cover [8] . • Unscrew the mounting screw [CJ and remove hatch cover latch [DJ. eTa remove the cover hinge (El , remove the mounting bolts [F) . • Installation is the reverse of removal.

OApply silicone sealant [GJ to the mating surface of the hinge and hull. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Handrail Removal/Installation .Take out the bolts [AJ and remove the handrail [BJ. . .When installing the handrail, apply silicone sealant [C] to the mating surface of the handrail and hull.

®~tr'"

~. ~

/ ~

/4"':. - - L~.. )" .

'$"

• Remove: Water Box Muffler (see the Exhaust System chapter) Cap [AJ Duct Bracket Mounting Nuts [BJ Bracket [C]

)l~ ? ,

S.alant - Kawasaki Bond (Silicone Sealant): 56019-120

Air Exhaust Duct Removal

"''''''...... ~:;! ~/ 1/, /~.;7

HULL/ENGINE HOOD 12-5

.Remove the duct [AJ out of the hull.

• Remove the battery breather hose [Aj.

Air Exhaust Duct Installation Notes .Be sure the damper [AJ is in the position . • Route the battery breather hose [CJ correctly (see the Cable Routing s~ction

in the General Information chapter) .

• App ly silicone sealant to the mating surface of the bracket [BJ and hull.

Stabilizer Installation .Strip all the old sealant off the mating surfaces between the hull and stabilizer. .Apply silicone sealant [AJ to the mating surface of the stabilizer, as shown. Sealant -

Kawasaki Bond (Silicone Sealant): 56019-120

.Applya non-permanent locking agent to the mounting bolts.

o Install the stabilizer to the hull.

12-6 HUll/ENGINE HOOD Hull Replacement To replace the hull, remove the various parts in the following

suggested order. Battery and Pad Oil Tank Electric Case Exhaust Pipe, and Expansion Chamber Water Box Muffler Air Duct

Carburetor Engine and Mounts Intake Silencer Drive Shaft and Shaft Holder Sediment Bowl Fuel Tank and Fill er Fuel Tap Choke Assembly Pump and Hoses Steering Cable Handlebar and Steering Bilge and Cooling System Hose Bypass Hose and Outlet Bumpers Engine Hood Latch Ha~ch Cover and Hinge Handgrip

The following parts ca':lnot be removed from the hull and must be replaced . Decals Labels Mats Registration Number (if any) If the new hull is to be painted, do that first. Then install the removed parts in the reverse order of their removaL Finally, install the labels. decals, mats and the registration numbers.

HUll/ENGINE HOOD 12-7

Rubber Parts NOTE

o The rubber parts on the watercraft are fastened in place with

various adhesives. To replace a rubber part. use a cement in the following

table, or an equivalent.

Ilame.

For this Applica tio n:

Type

Mats Engine Hood Gasket Hatch Cover Trim Seal Hatch Cover Damper

Synthetic Rubber Adhesive

Detents Handlebar Grips

Cya noacrylate cement

PIN: 92104-3701

CAUTION Be very careful that the part is positioned correctly when you apply the cement. It may be Impossible to reposition the part.

AWARNING 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 lingers will stick to anything they touch. Allow the cement to cure and II will eventually wear oH.

Rubber Parts Location Engine Hood Gasket [AJ

12-8 HULL/ENGINE HOOD

Hatch Cover Trim Seal [AJ and Damper [BJ

Detent [AJ

Mat [AJ

Front Bumper Removal â&#x20AC;˘ Unscrew the bushing [AJ and the mounting nuts [BJ, and remove the front bumper [C].

Front Bumper Installation Notes .Applya non-permanent locking agent to the following. Front Bumper Mounting Nuts Bushing Nut

HUll/ENGINE HOOD 12-9

Rear Bumper Removal .Remove: Corner Bumper Mounting Nuts [A] Corner Bumpers [8] Rear Bumper Mounting Nuts [C] Rear Bumper [D]

Rear Bumper Installation Notes .Applya non-permanent locking agent to the following. Corner Bumper Mounting Nuts Rear Bumper Mounting Nuts

Side Bumper Removal â&#x20AC;˘ Remove: Front Bumper (see Front Bumper Removal) Corner Bumper (see Rear Bumper Removal) â&#x20AC;˘ Remove the trim strip [A] from the side bumper [B].

12-10 HULL/ENGINE HOOD

• Drill out the pop rivets with a drill bit of the correct size. Pop Rivet Removal Drill Bit Size 6.5mm A

NOTE OStop drilling when the rivet head [A] starts to turn with drill bit.

o Tap

the rivet out of the hull flange with a suitable punch and

hammer.

Side Bumper Installation Notes .Align the recess [A] with the mounting hole for corner bumper .

• Secure the bumper to the hull flange w ith a pop rivet [A] .

• Install the trim strip [AJ, pushing of the both sides of the strip as shown.

ELECTRICAL SYSTEM 13-1

Electrical System Table of Contents

Wiring Diagram .....................................................13 -2 Exploded View. ........................................ 13 -3 Specificotions.. ................................... 13-5 Battery ... .......... ....... ... 13-6

Precautions .

. .. .............. ................... 13 -6

Removal. .......... ..13-6 Installation. .............................................13 -6 ... .. 13 -7 Battery Cleaning Electrolyte Level Inspection .... ................... 13 -7 Condition .............. . .13-7 Initial Charging .. ........... ... .. ..... .... .. . .... 13-8 Ordinary Charging ................. 13 -9 Test Charging ................. . ............. 13- 10 Electric Starter System .............. . ..... .. ............ 13-11 Starter Relay: ..... .... ....... . ............... 13 -11 Removal.. .............. . .13-11 Installation Notes .. .. ............. . ... 13-11 Inspection .... . ........... ..13-12 Reduction Gear ................ . .. 13 - 12 ....... 13 -12 Removal/Installation Notes Inspection .... ....................... 13-12 Starter Motor: ................................ ... .13-13 Removal ................................... .... ............. 13 -13 Installation Notes ..................... . .... 13-13 Disossembly ......... ...... ......... ........ ............. .13-13 I\ssembly ........ .. .. .............. .. ...1 3 -14 Brush Inspection .... .. ..................... .. .13-15 Brush Spring Inspection.. ..... 13 - 15 Commutator Cleaning and Inspection ....... 13-15 Armature Inspection .. .. ...... ............ 13 - 15 Brush Plate Inspection. .. .... 13 -16 Brush and Lead Assemb ly Inspection .13-16 Charging System ..................... .. ... 1 3-17 Charging Coil Testing.. .......... .. ... 13-17 Regulator/ Rectifier Inspection .......... .. ... 13 -18 DC-DC Converter Inspection. ..... 13 - 18 Ignition Systcm. . .................... .. .......... 13-19 Pickup Coil Inspection .............................. 13 -19 Ignition Coil Removal ................................ 13 -19 Ignition Coil Installation Note ...... 13 -19

Ignition Coil Inspection ............................... 13-19 COl Igniter Inspection ................................. 13-21 Spork Plug Removal .................................... 13-22 Spark Plug Installation ................................ 13-22 Spark Plug Inspection ................................. 13-22 Spark Plug Cleaning .................................... 1;3-23 Spark Plug Adjustment .... 13-23 Electric Case ...... . ............................... 13-24 Removal . .. ................. 13-24 Installation Notes .......................................13-24 Disassembly ................................... 13-24 Assembly Notes ................................... .. ..... 13-24 Switches .............................................................. 13-26 Start/Stop Switch Removal ........................ 13-26 Start/Stop Switch Installation Notes .......... 13-26 Start/Stop Switch Inspection ..................... 13-27 Temperature Sensor .............................. ................ 13-28 Temperature Sensor Removal ..................... 13·28 Temperature Sensor Installation Notes ....... 13-29 Temperature Sensor Inspection .................. 13-29 L.E.D. Fuel Gouge and Warning Unit.. ................. 13-30 Oil Level Warning Light.. ............................. 13-30 Fuel Indicator/Warning Light... ................... 13-30 Water Temperature Warning Light.. ............ 13-30 L.E.D. Unit Removal / Installation Notes ...... 13-31 L.E.D. Unit Inspection ................................. 13-31 Oil Level Sensor Inspection ........................ 13-31 Fuel Level Sensor Inspection .. .................... 13·32 Fuse .....................................................................13·33 Inspection ........................................ ........... 13-33

....

(.oJ ~ ... N, :j'

~:ffi= ~

==L=J

Fue I Leve \ Sensor

----r-----,

'L -f11--' L BL-lU--BL----L--J 01\

Lelle l

sensor

~ , <Zl

1. 2. 3.

Q-" ] , , "=ill=" BK

T.moera~re

Water I ndicator Fuel Level Indicato r all Le\lel Indicator

"Y-Q]-R/Yl

m::;....'""'" ~I

EnQ l ne Stop

Sw i tch

EnQlne Start

Sw i tch

lonlter

" 1:;~i,,,,

Set

I Push

:,:

Starter ~otor

Bott e r V

-_ · Z __". '" ' ' ' '

" , """"

=. " = .. "''''' "''' ''''

1/'

----~Y7I

Wire COlor Code ~

' ..

I 10 fo, ,

Put I 0-0

£n9 1n8 Start SwItCh

~'ljRu~~r1l==].llq, ~~~J ljJ==C.J).,~.::, 0 ,_~-""j ~ , : . : : , = ~ Y ( R .~ ,,= " dD l . Re la v starter:;em

C/) ~

EnQlne Stop Switch Lanyard ~ key 1/11

,~~

(')

Push

'flLO

~I!I

C/)

nil

l:"d'~ "6'-BR -00- BR

:c r-

~~~

mmm l!..!l_ _"""

~ii!

Ion I t I on Co I I

(')

<)-oBK ;

~ " """ """"" "'~" ""~ ~~

soaek PluOS

iir

m rm

tr.4aoneto

'"Raoulotor

==_-""" =-_= =""" ,. --= __ =" === -•••

, . ====,,~ ;

BK BL BR G GY 0 P pU R W Y V

Bla ck ~Iue

Brown Green Gr IlV

Orange Pink purple

Rea wn I te Yellow

VIOlet

Electr i c Case

,, ,, , ,

___ J

ELECTRICAL SYSTEM 13-3 Exploded View 1. Starter Relay 2. CDI Igniter 3. 10 A Fuse 4. Regulator/ Rectifier

5. Ignition Coil 6. Temperature Sensor 7. Fuel Level Sensor

8. L.E.D. Unit 9, Oil Level Sensor

10. DC - DC Converter T1 : 7.8 N-m (0.8 kg -m, 69 in-Ib) T2 : 27 N-m (2.8 kg-m, 20 ft -Ib) T3 : 2.9 N -m (0.3 kg-m, 26 in -Ib) T4 : 98 N-m (10.0 kg-m, 72 ft-Ib) T5: 12N-m(1.2kg-m,8.5ft- lb) T6 : 125 N -m (13.0 kg-m , 94 ft -Ib) L : Apply a non-permanent locking agent. G : Apply grease. M : Apply mol ybden um disulfide grease. Apply oil to flanged portion.

o :

~~)~~ ~~

()

. 8

13-4 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM 13-5 Specifications Item

Standard

Battery: Type Specific gravity of electrolyte

12 V 19 Ah 1 .2BO @20"C (68"F)

Electric Starter System: Starter motor: Brush length Commutator diameter

12.5 mm 2B mm

Charging System: Regulator/rectifier output voltage

Service Limit -----

6.5mm 27mm

Charging coil output voltage

Battery voltage - 14.5 Âą05 V 20 V

---

Charging coil resistance: Brown "- -+ Brown

0.7 - 1.1 0

---

13" BTDC @1,250 r/min (rpm) 20.2" @4,000 r/min (rpm)

---

O.OB - 0.1 0 3.5 - 4.7 kO

---

Ignition System: Ignition timing

---

Ignition coil: Primary winding resistance

Secondary winding resistance Spark plug: Type(Terminal Profile) Gap Pickup coil resistance Pickup coil air gap (Clearance between the rotor projection and pickup core) Special Tool - Hand Tester: 57001-1394

---

NGK BRBES(Solid) 0.7 - O.B mm 396 - 5940

---

0.8 - 1.0 mm

---

-----

13-6 ELECTRICAL SYSTEM Battery Precautions Following a few simple rules wil l greatly extend the life of the battery. OWhen the level of the electrolyte in the battery is low, add only distilled water to each cell, until the level is at the upper level line marked on the outside of the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery. o Never add sulphuric acid solution to the battery_ This will make the electrolyte solution too strong and will ruin the battery within a very

short time. OAvoid quick-charging the battery. A quick -charge will damage the battery plates. o Never let a good battery stand for more than 30 days without giving it a supplemental charge, and never let a discharged battery stand without charging it. If a battery stands for any length of time, it slowly self-discharges. Once it is discharged, the plates sulphate (turn white), and the battery will no longer take a charge. o Keep the battery well-charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged the battery becomes, the more easily if freezes. ODON'T INSTALL THE BATTERY BACKWARDS. The negative side is grounded.

Removal .. WARNING Battery electrolyte contains sulphuric acid which is poisonous and causes severe burns. When Installed in the battery, electrolyte generates hydrogen gas which under certain conditions if flammable and explosive. Keep all flames and sparks (cigarettes, etc.) away and always wear eye protection when working on or near the battery. • Disconnect the battery cables.

components, always disconnect the grounded cable first.

• Unhook the battery straps [AJ . • Carefully lift the battery from the engine compartment.

Installation • Be sure the battery damper [A] is in position in the battery compartment. • Place the battery in position. o Install the battery with positive (+) terminal toward the bow (forward). • Hook the battery straps. • Connect the battery cables, positive first. o After attaching both cables, coat the terminals and cable ends with grease to prevent corrosion . o Slide the protective boot over each terminal.

ELECTRICAL SYSTEM 13-7

Battery Cleaning .Remove the battery from the hull (see Battery Removal) . • Clean off the battery using a baking soda-and-water solution. o Mix one heaping tablespoon of baking soda in one cup of water. o Be careful not to get any of the cleaning solution in the battery_ OThe terminals must be especially clean. • Rinse the battery with clean water.

Electrolyte Level Inspection • Remove the battery.

eVisually check the electrolyte level [AJ in the battery. If the level of electrolyte in any cell is below the lower level line on the

battery case, add distilled water only to that cell.

elnstall the battery.

Condition • Before charging, check battery condition by testing the specific gravity of the electrolyte in each cell.

o Draw a little fluid from the cell with a hydrometer[AJ. o Read the level of the electrolyte [BJ on the floating scale. This is the specific gravity of the electrolyte.

eLook for sediment [AJ and white sulfation [BJ inside the cells .

• See the Battery Troubleshooting Guide in Battery Test Charging.

* If the specific gravity is below 1.280 the battery needs to be charged. NOTE

o The

specific gravity of the electrolyte varies with changes in temperature, so the specific gravity reading must be corrected for the temperature of the electrolyte. o Celsius: Add 0.007 points to reading for each 10'C above 20"C or subtract 0.007 points for each 10' C below 20·C. o Fahrenheit: Add 0.004 points to reading for each 10°F above 68"F or subtract 0.004 points for each 10°F below 68"F.

13-8 ELECTRICAL SYSTEM

* If the specific gravity of any of the cells is more than 0.050 away from any other reading, the battery will probably not accept a charge. It is generally best to replace a battery in this condition . *If the specific gravity of all the cells is 1.280 or more the battery is fully

charged.

BaHery Charging RalelTime Table (12 V 50 Ah)

1.280 1.28 _ _ Fully Charged ~ .;: ~

(,;)

'"·u"

"Cl.

1.24 1.20 1.16 1.140 -------1 .12 Sample 1.08

-- -

:.~~

... .1 .......... ·.·.1

...... Hours

1.00 at 2A ,harge rate

at 3A charge rate

. 10

at 4A charge rate

.. ·· . . . . . . .

. I· .. .... I· . . . . . . . ... 1.080· .. ·21 ',:,> - 26 .··i<··· · · · · · · · · ·'.:-· Totally discharged:

1.04

at SA charge rate

···.i:?7.~·.···· 25 20 15 10

"1"

. 30

Before being placed in service, a new battery should be given an initial charging . • Fill each cell to the upper level line on the battery case with fresh electrolyte at a teroperature of 30°F (86°F) or less. Let the battery stand about 30 minutes before charging.

NOTE

o If the electrolyte level drops,

add electrolyte to the upper level line

before charging. • Leaving the caps off the celis, connect the battery to a charger, set the charging rate at 1/10 the battery capacity. and charge it for 10 hours. For example, if the battery is rated at 50 Ah, the charging rate would be5A

.. 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 19n1le any battery gases.

37.5

Hours of Charging Time at Rates Shown

Initial Charging

ELECTRICAL SYSTEM 13-9

CAUTION Do not use a high rate battery charger, as It typically employed at automotive service stations, unless the charger rate can be reduced to the level required. Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause Internal shorting. Higher-than normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause Internal shorting. If the temperature of the electrolyte rises above 45°C (115°F) during charging, reduce the charging rale to lower the temperature, and increase charging time proporlionately .

• Turn the charger off, then disconnect it from the battery .

• Check battery voltage. Battery voltage should be 12 - 13 V. • Check the specific gravity of each cell with a hydrometer (see Battery Condition). If the voltmeter or hydrometer readings are below those specified,

additional charging is necessary before the battery can be installed.

the level will rise . • Connect a charger to the battery BEFORE plugging it in or turning it

on. ..WARNING Keep the baHery 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, c~nnecllhe battery to the charger before turning on the charger. This procedure prevenls sparks at the battery terminals which could ignite any battery gases . • Set the charge rate and time according to the battery condition previously determined (see Battery Condition), using the table.

CAUTION Do not use a high rate battery charger, as Is typically employed at automotive service stations, unless the charger rate can be reduced to the level required. Charging the battery at a rate higher than specified may ruin the battery. Charging at high rate causes excess heat which can warp the plates and cause internal shorting. High-lhan-normal charging rates also cause the plates to shed active material. DepOSits will accumulate, and can cause Internal shorting. If the temperature of the electrotyte rises above 4S' C (llS'F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately . • Turn the charger off or unplug it then disconnect it from the battery.

• Check battery condition (see Battery Condition).

* If the battery condition indicates that it is not fully charged, additional charging time is necessary.

13-10 ELECTRICAL SYSTEM

Test Charging elf the battery is suspected of being defective. sulfated, or unable to take a charge, consult the Battery Troubleshooting Guide table.

eTo test charge a battery. perform the ordinary charging procedure and monitor the battery vo1taae and other signs as mentioned below.

BaHery Troubleshooting Guide Good Battery

Suspect Battery

Action

(+) chocolate color

white (sulphated); + plates

( - ) gray

broken or corroded

Sediment

none, or small amount

sediment up to plates, causing short

Replace

Voltage

above 12V

below 12V

Test charge

Electrolyte Level

above plates

below top of plates

Fill and test charge

above 1 .200 in all cells; no two

below 1 .100, or difference of more

cells more than 0.020 different

than 0.020 between two cells

Plates

Specific Gravity

Replace

Test charge

ELECTRICAL SYSTEM 13-11 Electric Starter System Starter Relay: Removal eOpen the electric case (see Electric Case Disassembly) . • Disconnect the starter relay switch ground lead [A].

• Remove the nuts [A] from the battery and starter terminals on the starter relay switch .

• Slide the starter relay switch from the electric case, being careful not to lose any of the insulating washers or grommets . • Disconnect the yellow/red and red wire connectors.

Installation Notes • Coat the insulating washers and grommets with waterproof grease. • Be certain all insulating washers and grommets are in position .

• Connect the ground lead (black) to the ground mounting bolt. .Connect the battery cable to the relay (+) terminal having red lead.

•

13-12 ELECTRICAL SYSTEM

Inspection

• Set ohmmeter to R x 10 scale. • Connect meter leads to starter relay as shown. *If resistance is less than infinite, the starter relay switch is not returning and must be replaced .

• Set ohmmeter to R x 1 n scale. • Connect meter leads to starter relay as shown . • Activate starter relay switch by connecting a 12 V battery as shown. If the starter relay switch clicks and the ohmmeter indicates zero resistance, the starter relay switch is good. *11 the meter indicates high or infinite (00) resistance, the starter relay switch is defective and must be replaced.

Reduction Gear:

Inspection • Rotate the pinion gear [A] counterclockwise. The gear must be rotate freely [B].

• Rotate the pinion gear clockwise all the way. The pinion gear will be advanced along the reduction gear shaft, and stopped against the stopper [A] . • Release the pinion gear. The pinion gear must return to the initial position rapidly. *If the pinion gear does not function properly, replace it.

ELECTRICAL SYSTEM 13-13

Starter Motor: Removal • Disconnect:

Battery Ground Cable Exhaust Pipe and Expansion Chamber as a set

Inlet Cooling Hose [A] Starter Motor Cable [B] • Remove the starter mounting bolts [C] and pull off the starter motor.

CAUTION 00 not tap the starter motor shaft or body. Tapping on the shaft or body could damage the motor.

Installation Notes . eClean the starter motor lugs [A] and crankcase [B] where the starter motor is grounded . • Apply a small amount of engine oil to the O-ring

.Applya non-permanent locking agent to the starter motor mounting bolt threads . • Connect the battery ground cable.

Disassembly • Unscrew the retaining screws [A] and remove the both end covers .

• Pull the armature out the pinion gear end.

eRemove the brush plate [A] from the leads [6]. Yoke [C]

13-14 ELECTRICAL SYSTEM

.Remove the nut and terminal bolt [A], and then remove the brush [B] and the plastic holder [el Yoke [0]

Assembly .Install the terminal bolt as shown.

Nut [A] Spring Washer [B] Washer [e] Large Insulator [0] Small Insulator [E] Terminal Bolt [F] O' ring [G] Plastic Holder [H]

â&#x20AC;˘ Install the brush plate as follows. on the yoke fitting the brush leads [B] into the notches [C] in the plate. Fit the brush plate tongue [0] into the yoke notch[E].

o Install the brush plate [A]

o Insert the armature into the yoke. o Keeping the motor upright, install the brush springs [A]. Fit the spring

on the spring post [8] halfway; the post must be positioned in the D-shaped end of the spring. Turn the other end of the spring a half turn clockwise [el. and fit the end in the brush groove [0]. Push the spring onto the post to the stepped portion.

Brush [E]

OTo install the end covers on the yoke, align [A] the mark on the each end cover with the marks on the yoke.

ElECTRICAL SYSTEM 13-15

Brush Inspection • Measure the length of each brush.

* If any is worn down to the service limit, replace all the brushes. Starter Motor Brush Length Standard: 12.5 mm Service Llmil: 6.5 mm

Brush Spring Inspection • Check that the brush springs are in place and will snap the brushes firmly into place. If not, reinstall or replace the spring.

Commutator Cleaning and Inspection .Smooth the commutator surface [A] if necessary with fine emery cloth [8]. and clean out the grooves .

• Measure the diameter of the commutator.

Replace the starter motor with a new one if the commutator diameter [AJ is less than the service limit.

Commutator Diameter Standard: 28 mm Service Limit: 27 mm

Armature I nspeclion • Using the x 1 Q ohmmeter range, measure the resistance between any two commutator segments [AJ. If there is a high resistance or no reading (00) between any two segments, a winding is open and the starter motor must be replaced. • Using the highest ohmmeter range, measure the resistance between the commutator and the shaft [8] . If there is any reading at all, the armature has a short and the starter motor must be replaced.

13-16 ELECTRICAL SYSTEM

Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with an ohmmeter. 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.

Brush Plate Inspection â&#x20AC;˘ Using the )( 10 ohmmeter range, measure the resistance between the brush [A] an and the brush plate [B].

* If thera is not close to zero ohms, the brush plate has an open and the brush plate must be replaced. â&#x20AC;˘ Using the highest ohmmeter range, measure the resistance between the brush plate [B] and the brush holders [e]. If there is any reading at aU, the brush holder has a short and the brush plate must be replaced.

Brush and Lead Assembly Inspection â&#x20AC;˘ Using the x 1 n ohmmeter range, measure the resistance between the brushes.

* If there is high resistance or no reading (00), a lead is open and the brush and lead assembly must be replaced.

ELECTRICAL SYSTEM 13-17 Charging System

Charging Coil Testing • Remove the electric case connector [A] . • Disconnect the 3-pin connector [B] . • Temporarily connect the magneto leads except the charging coil leads (brown).

eWith a multimeter, check the charging coi l output (in circuit) according to the following table with the engine running at approximately

3,000 rpm .

To avoid electrical shock, do not perform this test with the watercraft in the water.

CAlJTION 00 not run the engine over 15 seconds without cooling water. Take care not over-rev the engine while running it with no load.

Charging Coil Output Test

Meter

Connections

Standard

Setting

Meter (+) to

Meter ( - ) to

Value

250 VAC

Brown lead

20V

*If

the charging coit 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

Connections

Standard

Setting

Meter (+) to

Meter (-) to

Value

R x 10

Brown lead

0.7-1.10

* 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. necessitating flywheel replacement.

13-18 ElECTRICAL SYSTEM

Regulator/Rectifier Inspection • Disconnect t he battery ground cable. • Remove the electric case and open it. • Remove the regulator/rectifier {AJ .

• With the hand tester to the R x 1 kG range, test the regulator/rectifier according the foHowing table.

Regulator/Rectifier Resistance Test

Tester (+) Lead Connection

( -)

Terminal

Red

Red/Purple

Brown

Black

Red

18 - 110

15 - 80

18-110

18 - 110

15 - 80

Brown

1.0 - 6.0

30 - 160

18-110

Brown

1.0 - 6.0

30 - 160

18-110

Black

2.0 - 12

1.0 - 6.0

Red/ Purple

(-r: Tester (-) Lead Connection .Any of the values obtained do not agree with the above table, the regulator/rectifier must be replaced.

DC-DC Converter Inspection .With the hand tester set to the R x 1 kG range, test the DC-DC converter according the following table.

* If any of the values obtained do not agree w ith the above table, the DC~

DC converter must be replaced.

DC-DC Converter Resistance Test Tester (+) Lead Connection

( -)

Terminal

Purple

3 - 18

1.8 - 13

0-0.6

Red/ Yellow

5.5 - 40

8.5 - 60

5.5 - 40

White/Red

1.8 - 13

5.5 - 40

1.8 - 13

Black/Blue

0-0.6

3 - 18

1.8 - 13

Red/Yellow Wh iteiRed

( -). : Tester ( -) Lead Connection

Black/Blue

ElECTRICAL SYSTEM 13-19 Ignition System

Pickup Coil Inspection • Remove the electric case connector [AJ. • Disconnect the 4-pin connector [8J.

.Set the hand tester to the x 1000 range, zero it, and con nect it to the pickup coil lead terminals (G 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 Coli Reslslance

Siandard:

396 - 594 0

Ignition Coil Removal eOpen the electric case (see Electric Case Removal / Disassembly). • Puilihe spark plug caps [AJ, and slide off Ihe prolector tubes [BJ.

.Unscrew the grommet caps and slide off the grommets. Lubricate the leads with a penetrating rust inhibitor .

• Remove the regu lator/rectifier. • Disconnect the ignition coil primary lead connectors [AJ, and unscrew the ignition coil [BJ.

Ignition Coil Installation Note .Apply a non -permanent locking agent to the ignition coil mounting bolts and torque them. Torque - Ignition Coli Mounting Bolts: 7.8 N-m (0.8 kg-m, 69 In-I b)

13-20 ELECTRICAL SYSTEM

Ignition Coil Inspection Measuring arcing distance: The most accurate test for determining the condition of the ignition coil is made by measuring distance . • Remove the ignition coil. .Connect the ignition coil (with the spark plug cap left installed on the spark plug lead) to the tester [A], and measure the arcing distance.

NOTE OSince a tester other than the Coil Tester may produce a different

arcing distance. the Coil Tester is recommended for reliable results.

To avoid extremely high voltage shocks, do nol touch the cool or lead.

*If the distance reading is less than the specified value. the ignition coil or spark plug cap is defective. 3 Needle Arcing Olslance Standard: 7 mm or more

eTa determine which part is defective, measure the arcing distance again with the spark plug caps removed from the 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.

Measuring coil resistance: If the Coil Tester is flat available, the coil can be checked for a broken or badly shorted winding with a hand lester. However. a hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage . • Disconnect the primary leads from the coillerminals . • Measure the primary winding resistance as follows [A) . o Connect the tester between the coil termina ls.

o Set the tester to the x 1 0

range, and read the tester . • Measure Ihe secondary winding resistance as follows [8] . o Remove the plug caps by turning them counterclockwise. o Connect the tesler between the spark plug leads. o Set the tester to the x 1 kO, and read the tester. * If the hand lesler does not read as specified. replace the coi l. Winding Resistance Standard: Primary windings 0.08 - 0.1 Q Secondary windings 3.5 - 4.7 kO *If the tester reads as specified, the ignition coil windings are probably good. However, if the ignition system still does not perform as it shou ld after all other components have been checked, test replace the coil with one known to be good . • Check the spark plug lead lor visible damage. *If the spark plug lead is damaged. replace the coil.

ElECTRICAL SYSTEM 13-21

CDI Igniter Inspection â&#x20AC;˘ Remove the CO l igniter .

â&#x20AC;˘ Set the hand tester to the x 1 kO range, zero it, and mark the measurements shown in the table *11 the tester readings are not as specified, replace the COl igniter.

Special Tool - Hand Tester: 57001-1394

CAUTION .::c..:..._ Use only Hand Tester (special tool:

_ __ _ _ _---j

57001-1394) lor this lest.

multi-meier other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large~apacity baHery is used, the COl

Igniter will be damaged.

COl Igniter Internal Resistance

Unit: kO

Tester (+) Lead Connection Lead Color

1 (R)

2(Y/R)

3(R)

4(Y/ R)

5(BL)

6(G)

7(0)

B(BK/ W)

9 (R/Y)

1 (R)

0-0.6

2(V/R)

20 - 400

0-0.6

13 - 100

22 - 400

3(R)

0-0.6

20 - 400

0-0.6

20 - 400

13 - 100

22 - 400

4(Y/R) ~-- -----

(-)

--~-

-.~-~

13 - 100

f--

16-150 45 - 1000

16 - 150 45 - 1000

5(Bl)

5.5 - 40

6(G)

9.5 - 80

3.4 - 19

35 - 1000

3.4 - 19

9.5 - 80

7(0)

8.5 - 70

3 - 18

5 - 35

3 - 18

11 - 90

8(BK/W)

5.5 - 40

0-- 0.6

3.4 - 19

35 - 500

5.5 - 45

9(A/V)

10(BK/Y)

5.5 - 40

0-0.6

3.4 - 19

35 - 500

0-0.6

5.5 - 45

11(W)

12(8K)

5.5 - 40

0-0.6

3.4 - 19

35 - 500

0-0.6

5.5 - 45

13(BK/Bl)

5.5 - 40

0-0.6

3.4 - 19

35 - 500

0-0.6

5.5 - 45

14(W/R)

17 - 200

8 - 60

12 - 100 45 - 1000

8 - 60

12 - 100

15(R/Y)

11 - 90

4.8 - 30

7.5 - 60 40 - 1000

4.8 - 30

13 - 100

16 (PU)

150 - 00

100 - 00

100 - 00 100 - 00

100 - 00

100 -

17(BK/ Bl)

5.5 - 40

5.5 -- 40

0-0.6

(-): Tester (-) Lead Connection

3.4-19

35 - 500

0-0.6

5.5 - 45

3.4 - 19

35 - 600

0-0.6

5.6 - 45

13-22 ELECTRICAL SYSTEM

---------------------------------------------Tester ( + ) Lead Connection

Lead Color 10(BK/Y)

(-)

11 (W)

12(BK)

13(BK/ Bl) 14 (W/R)

l(R )

2(Y/R)

13 - 100

3(R)

4(Y/R)

13 - 100

5(Bl)

0-0.6

6(G)

3.4 - 19 9 .5 - 80 3.4 - 19 3.4 - 19

17(BK/B l)

20 - 400

12 - 100

13 - 100

20 - 400

12 - 100

13 - 100

4.2 - 26

3 - 18

0-0.6

8.5 - 70

5 - 40

3.4 - 19

4 - 100 13 - laO 13 - 100

7 - 50

16 (PU )

4 - 100 13 - 100 13 - 100 00

15 (R/Y)

0-0.6

7(0)

3 - 18

10 - 90

3 - 18

9 - 70

6 - 45

3 - 18

8( 8K /W )

0-0.6

7 _ 50

0-0.6

0 -0.6

4.2 - 26

3 - 18

0-0.6

9(R/ Y)

10(8K/Y)

7 - 50

0 -0.6

0- 0.6

4.2 - 26

3 - 18

0-0.6

11 (W)

12(BK)

0-0.6

7 - 50

0-0.6

4.2 - 26

3 - 18

0-0.6

13(8K/ 8l)

0-0.6

7 - 50

0-0.6

4.2 - 26

3 - 18

0-0.6

14(W/ R)

8 - 60

8 - 200

8 - 60

11 - 90

8 - 60

15(R/Y)

4.8 - 30

4.4 - 28

11 - 90

4.8 - 30

16(PU)

100 - 00

17 ( 8K / 8l)

0-0.6

3 - 18

4.8 - 30 4.8 - 30

00 - 00 100 - 00 100 - 00 150 - 00 7 - 50

0-0.6

4 .2 - 26

(-)": Tester (-) Lead Connection

Spark Plug Removal • Pull off the spark plug caps. • Unscrew the spark plugs .

o Be careful to avoid breaking the ceramic on the spark plugs.

Spark Plug Installation • Be sure the spark plug threads are clean and dry. • Torque the spark plugs. Torque - Spark Plugs: 27 N-m (2.8 kg-m, 20 ft-Ib) o Be careful to avoid breaking the ceramic on the spark plugs. • Connect the spark plug caps.

Spark Plug Inspection • Remove the spark plugs (see Spark Plug Removal) . • Examine the ceramic insulator [A] and electrodes [8] . *If the insulator appears g lazed or very white. or if there are gray metalli c

deposits on the electrodes. combustion chamber temperatures are too high. Refer to Troubleshooting. the insulator appears dry and sooty the fuel/air mixture is overly rich (see Carburetor Adjustments in the Fuel System chapter). elf 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, repla ce the plug.

*If *

*11 the electrodes are badly worn or burned, replaced the plug. • Examine the spark plug threads [C]. If the threads are damaged, replace the plug.

ELECTRICAL SYSTEM 13-23

Spark Plug Cleaning .Clean the electrodes and the ceramic insulator around the center electrode with an abrasive blasting device. o Be certain that abrasive particles are removed from the plug . â&#x20AC;˘ Clean the entire plug in a high flash point solvent.

Spark Plug Adjustment â&#x20AC;˘ Measure the spark plug gap . . o Check the dist;:mce betweell the electrodes w ith wire gauge. Spark Plug Gap Standard:

i'I

feeler grluge or

i'I

0.7 - 0.8 mm

* If the gap in not within specifications adjust it. .Adjust the gap by carefully bending the side electrode with a tool designed for this purpose.

13-24 ELECTRICAL SYSTEM Electric Case

Removal • Remove: Battery (-) Cable Spark Plug Caps Battery (+) Cable [AJ Starter Motor Cable [BJ Electric Case Connector [CJ Temperature Sensor Temperature Sensor Leads Connector

Start/Stop Switch Connector L.E.D. Unit Leads Connector

• Unscrew the mounting bolts [AJ, and remove the electric case [8]

Installation Notes .Apply water resistant grease to the

O~ring

[AJ of electric case

connector . • Applya non-permanent locking agent to the electric case mounting bolts and torque them. Torque - Electric Case Mounting Bolts: 7.8 N-m (O.S kg-m, 69 In-Ib)

Disassembly • • • o

Remove the electric case (see Electric Case Removal). Remove the electric case bolts [A]. and open the electric case. Remove the electric box compartments. Note wire routing and ground terminal location .

Assembly Notes .Connect the battery cab le to the relay (+) terminal having red lead. • Run the charge wires of igniter and regulator through the electric case hole, before installing regulator . • Connect the ground leads (black) to the regulator/rectifier mounting bolts . • Apply a non-permanent locking agent to all the removed bolts, and torque them. Torque - All Removed Bolls: 7.8 N-m (0.8 kg-m, 69 in-Ib)

.Apply water resistance grease to the O-ring of electric case.

Q-rlno

Ion I t I on Co I I

gg~~~rter

APPly grease (2 places).

Fuse ASSy

SECT. A-A

washer

Nu ts

IIIIW'\sr

~18oneto

Ground

SECT. B-B

, I\~

SK/W Lead

Fuse ASSy

Grommet

Ull 1J3-----'I

V~;--

To Fue I Leve I Indicator

To water Temperature Sensor

To start; stop Sw I tc~

Rear , -_ _ To

- - - - ' I Cy I I nder

To Front Cylinder ,,-

places).

' ====:=1 Clamp

APply orease

APply orease (7 places).

Battery

To starter Motor 1____ To

- '\....

O-~Ino \ Cap

~'--';""=I-<--~-

£\: " - --

Read Mark

t11

r-.J

w ,

-l

(J)

» r-

-l :0

m m r-

13-26 ELECTRICAL SYSTEM

Switches

Start/Stop Switch Removal • Remove or disconnect:

Start/Stop Switch Connector (4-pin) [A]

• Remove: Steering Cover (see the Steering chapter)

Grommet Mount Plate [Ii] Grommet [B]

.Carefu lly pull the start/stop switch w iring up through the steering holder . • Unscrew the switch case mounting screws [A], and remove the switch case [B].

, 'jilil/ll

~IUJJJlJJJ

Start/Stop Switch Installation Notes .The switch case mounting clamp has an indexing dowel [A]. Position the dowel in the handlebar hole [B] .

• Be certain the start/stop switch wiring does not interfere w ith throttle

cable or choke cable movement when the handlebar is moved.

ELECTRICAL SYSTEM 13-27

Start/Stop Switch Inspection â&#x20AC;˘ Examine the start/stop switch case and wiring.

* If the switch case is broken or damaged in any way, replace the switch assembly.

*If the wiring is damaged, repair it or replace the switch assembly. eTest the start switch.

o Set the hand tester to the

R x 1 0 scale. o Connect the meter leads to the red/p urple and yellow/red start switch leads. o Check switch resistance with the start button released, and with the

start button depressed. Start Switch Resistance Start Button

Reading

Released

000

Depressed

Almost 00

* If either meter reading is incorrect replace the start/stop switch .

â&#x20AC;˘ o o o

Test the stop switch. Set the hand tester to the A x 1 n scale. Connect the meter leads to the black and white stop switch leads. Check switch resistance with the stop button released, and with the stop button depressed. Slop Swilch Resistance

Stop Button

Reading

Released

000

Depressed

Almost 0 0

*If

either meter reading is incorrect, replace the start/stop switch.

13-28 ELECTRICAL SYSTEM Temperature Sensor A temperature sensor is installed on the bypass hose. Whenever the cooling water temperature rises to 95°C (203 F) or higher, the contacts in the temperature sensor does and the igniter works to cut spark G

intermittently. The engine speed decreases to 3,500 rpm. If the watercraft slows down even with the throttle on and the engine running, return to shore immediately and check the cooling system for clogging.

CAUTION H the watercraft slows down while running, return to the shore Immediately. Overheallng will cause severe engine and exhaust system damage. 00 not operate the craft until the source of the problem Is found and correct.

Temperature Sensor Removal .Open the electric case (see Electric Case Removal/Disassembly) . • Disconnect the temperature sensor leads (BK/Y and R/Y) . • Unscrew the grommet cap [A]. and slide off the grommet [B] .

• Pull off the bypass hoses and unscrew the mounting bolt [A] and remove the temperature sensor [8] .

• Remove the sensor [A] from the holder [B].

ELECTRICAL SYSTEM 13-29

Temperature Sensor Inspection .Suspend the sensor [A] in a conta iner of water so that the temperature sensing projection is submerged . • Suspend a thermometer in the water.

NOTE

o The sensor and thermometer must not touch the container sides or bottom . • Place the container over a source of heat and gradually rise the temperature of the water whi le stirring gently. Temperatures Sensor Connections

Rising temperature: Failing temperature:

From OFF to ON at 95°C (203°F) From ON to OFF at SSoC (190°F)

13-30 ELECTRICAL SYSTEM L.E.D. Fuel Gauge and Warner Unit The three kinds of red LED. (Light Emitting Diode) go on on ly when the engine is running. When the engine is started, all warning and indicator lights go on for several seconds (self checking), and then all lights go on according to each status.

A. B. C. D.

ÂŽ /

Oil Level Warning Light Fuel Warning Light Fuel Indicator Lights Water Temperature Warning Light

b ~

~(D ~~

.l j

\..

Oil Level Warning Light When the oil level in the oil tank gets low, the warning light comes on to warn the riders.

Fuel Indicator/Warning Light When the fuel tank is full, all indicator lights go on. As the fuel level in the tank goes down, the lights go off one by one from right (marked F) to left to show quantity of the fuel left in the tank. When the fuel has decreased to about 6 L, the warning light (marked E) goes on to warn the riders.

Water Temperature Warning Light If the cooling water temperature gets too high, the warning light comes on to warn the riders. The cooling water temperature warning light triggered when cooling water at the sensor should exceeds 95~C. At the same time, the igniter works to cut spark intermittently so that the engine speed decreases to about 3 500 rpm. This prevents engine overheating damage and helps the riders get to shore if the cooling system is clogged with sand or debris from the water. If the cooling water cools to SS"C, the light comes off. Warning/Indicator Lights System Wiring Diagram

1. 2. 3. 4. 5. 6. 7. S.

LED. Unit Oil Level Sensor Fuel Level Sensor Temperature Sensor CDI Igniter 12 V Battery Regulator/Rectifier Magneto

L---~--~--~6

3 "\-----~

B"\---------~

F-----------( 7

ELECTRICAL SYSTEM 13-31

LED. Unit Removal/Installation Notes • Remove or disconnect (see the Steering System chapter): Steering Cover

L.E.D. Unit Mounting Bolts Grommet Wiring Connectors

L.E.D. Unit • Installation is the reverse of removal. Note the fo llowing. eCheck the waterproof rubber [A] and display panel [B] for damage.

* If the rubber and panel are damaged, replace the unit. LED. Unit Inspection

eThere are the following troubles of L.E.D. unit. 1. All warning and indicator lights do not go on when the engine is running. 2. The self-checking procedure does not operate properly.

3. Some of the warning and indicator lights do not appear or do not go on .

e Check the following for the above troubles. Battery power supplied to the unit

Wiring broken or improperly connected Sensors damaged

*If

all of the above check are good, replace the L.E.D. unit.

Oil Level Sensor Inspection • Disconnect the oil level sensor 2-pin connector. • Loosen the clamp, and remove the oil leve.1 sensor [A] out of the oil

tank [B].

1~~ eSet the hand tester (ohmmeter) to the x 10 range, Special Tool - Hand Tester: 57001·983

eConnect the tester leads to the BL and BL leads to check the switching operation of the float.

Meter Reading When sensor is held upright [A] When sensor is held upside down [B]

00 00

*The meter shou ld read as specified. If it does not replace the oil level sensor.

13-32 ElECTRICAL SYSTEM

Fuel Level Sensor Inspection • Open the hatch cover . • Disconnect the fuel level sensor 2-pin connector . • Loosen the clamp, and remove the fuel level sensor [A] out of the fuel

tank [B] .

• Set the hand tester (ohmmeter) to the x 1kn range. Speelal Tool - Hand Tesler: 57001-983

.Connect the tester leads the PU and PU leads to check the switching operation of the float. Meter Reading When sensor is held upright [A] 8.03 kn ±5% When sensor is held upside down [B] 0 - 50n *The meter should read as specified. If it does not, replace the fuel level sensor.

111111.(

- ._.

,., '.2

.. )

.. 1

,w,

;

I I

SW4:. "

, , _ __---, .. ..

610 g

'" t .•

I i

6.11" 1

, :

'-- ._ ___ ___ _____ _ _ __...1 Circuit

ELECTRICAL SYSTEM 13-33

Fuse Inspection .Remove the fuse plug [A] .

â&#x20AC;˘ Pull the cap [AJ, and take out the fuse (10A) [EI] .

â&#x20AC;˘ Inspect the fuse element.

* If it blown out, replace the fuse.

Before replacing a blown 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.

CAUTION When replacing a fuse, be sure the new fuse malches the specified fuse rating for that circuit. Installation of a fuse with 8 higher rating may cause damage to wiring and components.

Normal

Failed

STORAGE 14-1

Storage Table of Contents

Preparation for Storage ...................... .. .......... ........ .................................................. .14-2 Cooling System ..................................................................................................... 14-2 Bilge System ...... '" ................................................................................................ 14-2 Fuel System .................................. ............ .................................................... ... .....14-2 Engine ........................................ ....... .. ....................................................... ...........14-3 Battery ... ................................................................... .............................................14-4 Lubrication ............................................................................................................ 14-4 General ............................ ......................................................................................14-4 Removal from Storage .............................................................................................. 14-5 Lubrication ......................................... .... .............. .................. ............................... 14-5 General Inspection ................................................................................................ 14-5 Fuel System .............................. ............................................................................ 14-5 Test Run ............................................... ....... .......................................................... 14-6

14-2 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 rested; and, in general, preparing the watercraft so that when the time comes to u.se it again, it wi ll be in top condition.

Cooling System eClean the cooling system (see Cooling System Flushing in the Cooling and Bilge Systems chapter).

Bilge System eClean the bilge system (see Bilge System Flushing in the Cooling and Bilge Systems chapter). Before reconnecting the hoses to the plastic breather fitting. blow air through both hoses [A] to force all water out of the bilge system.

Fuel System AWARNING Gasoline Is extremely flammable and can be explosive under certain conditions. Pull the lanyard key off the stop buOoo. 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.

â&#x20AC;˘ Drain the sediment bowl [A] to remove any water which may have settled in it.

STORAGE 14-3

• Drain the fuel tank. This should be done with a siphon or pump. A. Siphon Hose

.Clean the filter screens (see Fuel Filter Screen Cleaning in the Fuel System chapter). • Leave the fuel filler cap loose to prevent condensation in the tank .

• Start the engine and run it in 15 second periods until all fuel in the carburetor is used up. Wait 5 minutes between 15 second running periods.

CAUTION Do not run the engine with the watercraft oul of the water for more than 15 seconds at a time. Overheating can cause severe engine and exhaust system damage.

• Remove the air intake cover [A] from the carburetor. • Lift out the flame arrester and clean it, if necessary (see Flame Arrester Cleaning in the Fuel System chapter) . • Spraya penetrating rust inhibitor down the carburetor bore . • Install the flame arrester. • Reinstall the cover, apply a non -permanent locking agent to the threads of the air intake cover bolts and tighten securely.

Engine • Remove the spark plugs and 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.

• Pull the lanyard key off the stop button. Turn the engine over several times with the start button to coat the cylinder walls with oiL Then reinstall the spark plugs.

14-4 STORAGE

Battery .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.

• Check the electrolyte and fill to the upper level mark w ith distilled water, if necessary. • Check the specific gravity with a hydrometer and recharge if necessary. • Cover both battery terminals with grease. • Store the battery in a cool, dry place. Do not expose it to freezing temperatures.

NOTE

o Check the battery at least every 30 days and recharge

if necessary. A neglected battery will gradually lose its charge and begin to sulfate

(plates turn white). Once this reaction has begun. the battery usually cannot be salvaged.

Lubrication • Carry out all recommended lubrication procedures (see Lubrication in the Appendix chapter).

General .Wash the watercraft and dry it thoroughly, making sure to drain the engine compartment completely.

CAUTION Use only a mild detergent In water to wash the hull. Harsh solvents may aHack the surface or smear the colors . • Apply a good grade of wax to all exterior hull surfaces . • Lightly spray all exposed metal parts with a penetrating rust inhibitor. • Block the seat up with 10 mm spacers to insure adequate ventilation, and prevent corrosion. • Cover the watercraft and store it in a clean, dry place.

STORAGE 14-5 Removal from Storage

Lubrication • Carry out aU recommended lubrication procedures (see Lubrication in the Appendix chapter).

General Inspection .Check for binding or sticking throttle, choke, or steering mechanism. The throttle I~ver must return fully when released. eClean and gap spark plugs (see Spark Plug Cleaning and Spark Plug Adjustment in the Electrical System chapter) . • Check aU rubber hoses for weathering, cracking , or looseness .

• Turn the watercraft on its left side on protective pad, and remove the jet pump cover. Check cooling hose for weathering, cracking or looseness . • Replace them if necessary. Replace the cover and tighten securely . • 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 .Check and clean or replace the fuel filter screens as necessary (see Fuel Filter Screen Cleaning in the Fuel System chapter).

AWARNING. 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

.After refueling and before starting the engine, tilt the seat to the rear for several minutes to ventilate the engine compartment.

A concentration of gasoline fumes In the engine compartment can cause a lire or explosion . • Check for fuel leaks. Repair if necessary . • Check the engine oil level. Fill the oil tank with the specified oil.

14-6 STORAGE

Test Run AWARNING 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 . â&#x20AC;˘ Start the engine and run it only for 15 seconds. Check for fuel, oil and exhaust leaks. Any leaks must be repaired.

CAUTION Never run the engine with the watercraft out of the water for more than 15 seconds. Overheating can cause severe engine and exhaust system damage. Do not run the engine at maximum speed out of the waler. Severe engine damage may result. â&#x20AC;˘ Install the seat making sure it is locked.

APPENDIX 15-1

Appendix Table of Contents

Lubrication ................. ........ .. ..................................................................................... 15-2 Troubleshooting ....... .................... ......................................... ............... ..................... 15-3 Unit Conversion Table ............................................................... ............................... 15-6

@] I

15-2 APPENDIX

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: • Lubricate the following with a penetrating rust inhibitor. ThroHle Cable

Choke Cable Special Tool - Pressure Cable luber: k56019·021 [AJ

Steering Nozzle Pivots rS]

• Lubricate the following with a high quality waterproof grease. ThroHle Cable Ends [A J

Choke Cable Ends [BJ

APPENDIX 15-3

Steering Cable Ball Joint. [C ]

15-4 APPENDIX Troubleshooting

Ignition Spark Present

1 Fault in fuel system 2 Lack of compression

Ignition System

No Spark

Outside Carburetor

Starting difficulty or failure to start

-Fuel System (check that fuel tank contains fuel)

Inside Carburetor

Battery/Starter System

1 Faulty or fouled spark plug

f- 2 Faulty plug wire insulation f- 3 Faulty CDI igniter 4 Faulty ignition coil 5 Faulty magneto 6 Battery voltage low

2 3 4 5

Fuel feed line leaking or clogged Pulse line leaking or clogged Fuel filter Screen clogged Vent line clogged Faulty fuel pump

r- 1 Carburetor diaphragm damaged

f- 2

Mixture screw not adjusted I- 3 Water in carburetor '- 4 Float arm not adjusted

r2 f- 3 f- 4 5

Faulty magneto solenoid switch Battery voltage low Starter motor brushes worn Faulty reduction gear Faulty starter lockout switch

1 Faulty crankshaft oil seal f- 2 Crankcase joint leak 3 Worn piston and rings f- 4 Head gasket leak ' - 5 Spark plug leak

Compression

Outside Carburetor Engine starts but stops right away

Fuel System

Inside Carburetor

Electrical System

[

1 Misuse of choke

2 Fuel filter screen clogged 3 Fuel feed line leaking or clogged 4 Pulse line leaking or clogged 5 Vent line clogged 6 Faulty fuel pump

Water in carburetor 2 Carburetor diaphragm damaged 3 Mixture screw not adjusted 4 Float arm not adjusted

1 Faulty or fouled spark plug 2 Poor wiring connection 3 Faulty magneto

APPENDIX 15-5

Fault in Carburetor

Wrong mixture screw 2 Obstruction in fuel passage or outlet

3 Diaphragm leaking or damaged 4 Float arm not adjusted

Poor fuel supply (fuel filter screens, hoses, or vent line clogged) 2 Carburetor mounting loose

Fuel mixture too lean

ather

fFuel System Fault in Caraburetor

1 Diaphragm needle dirty or damaged 2 Float arm not adjusted 3 Choke not adjusted 4 Mixture screw not adjusted

Fuel mixture too rich

Engine misfires, does

3 Faulty fuel pump

Flame Arrester Clogged

not run

smoothly

Ignition Timing

Wrong

rElectrical System Weak Spark

fff-

1 Red uced ignition coil output 2 High vo ltage insulation breakdown

3 Spark plug fouled 4 Spark plug gap wrong

5 Poor wiring connection, spark plug cap

ff-

6 Faulty CDI igniter 7 Faulty magneto 8 Battery voltage low 1 Oil line clogged 2 Faulty oil pump

Enaine Lubrication System

During normal

cruising

L During sudden acceleration

1 Slight piston seizure 2 Piston ring broken or sticking 3 Main bearing worn or damaged

r2-

Abnormal engine sound Pinging

When the engine is

idling while cold

Excessive clearance between connecting rod small end and piston pin, or between pin and piston Excessive connecting rod big end clearance

1 Ignition timing too advanced 2 Carbon accumulation in cylinder head 3 Poor quality gasoline

4 Spark plug wrong heat range

1 2 3 4

Excessive piston clearance Piston rings worn Piston worn Connecting rod bent, twisted

15-6 APPENDIX

Ignition System

1 2 3 4

Spark plug gap or heat range wrong Ignition timing wrong Reduced ignition coil output Loose wiring connection in ignition

circuit

Fuel System

1 Insufficient fuel supply to carburetor

2 3 4 5 6 7

Carburetor diaphragm damaged Pulse Line leaking or clogged High speed nozzle clogged Throttle valve does not fully open . Fuel filter screen clogged Faulty fuel pump

r- 1 Flame arrester clogged

ather Low engine Power - This troub le often has more than one cause, and trouble symptoms may not be clear

I- 2 Muffler or exhaust system clogged 3 Water or foreign matter in gasoline or engine oil " - 4 Exhaust gas leak in engine compartment

r- 1 Ignition wrong

r- 2

Overheating

Carburetor not adjusted Flame arrester or exhaust system clogged Carbon accumulation in combustion chamber 5 Wrong type of gasoline or oil 6 Obstruction in oil pump hoses ' - 7 Cooling water line leaking or clogged

r- 3 r- 4 rr-

Heavy Fuel Consumption

1 Carburetor not adjusted 2 Flame arrester clogged

3 Muffler or exhaust system clogged 4 Worn cylinder, piston or piston ring

5 Fuel feed line leaking 6 Carburetor diaphragm needle dirty or

damaged

Poor performance

in_e_r_u_n_s_ _ _ _ _~~~~ _~th~0~U~g~h~e_ng_ properly Jet Pump _ _ _ _ _ _ _--{E;1 .

Intake area obstructed

Impeller or pump case damaged Excessive clearance between impeller and pump case

Poor steering control

Handlebar hard Since faulty steering is dangerous, this problem should be examined by an authorized Jet Ski dealer

to turn

1 Steering maladjusted 2 Bushings damaged or cracked 3 Steering shaft bent 4 No lubricant on steering pivot 5 Steering cab le damaged or improperly routed

APPENDIX 15-7 Unit Conversion Table Prefixes for Units: Prefix

Symbol

Power

x 1 000000 x 1000 x 0.01 x 0.001 x 0.000001

mega kilo milli

k e m

micro

centi

Units of Mass: kg x 2.205 9 x 0.03527

Ib oz

Units of Volume: L x 0.2642 0.2200 L x L x 1.057 0.8799 L x L x 2.113 1.816 L x mL x 0.03381 mL x 0.02816 0.06102 mL x

gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

0.1020 0.2248

kg Ib

kg kg

x x

9.807 2.205

N Ib

mile It in

Units of Torque: N-m x 0.1020 N-m 0.7376 x N-m x 8.851

kg-m It-Ib in - Ib

kg-m kg-m kg-m

N-m It-Ib in-Ib

9.807 7.233 86.80

x x

Units of Pressure: x 0.01020 kPa x 0.1450 kPa 0.7501 kPa x kg/em' kg/em' em Hg

Units of Force: N N

Units of Length: km x 0 .6214 m x 3.281 mm x 0.03937

x x x

kg/crT)' psi em Hg kPa psi kPa

98.07 14.22 1.333

Units of Speed: x 0.6214 km/h

mph

Units of Power: 1.360 kW x 1.341 kW x

PS HP

x x

PS PS

kW HP

0.7355 0.9863

Units of Temperature:

9(OC+40)

-40

°C

5(OF+40)

OF -40

- 40

-4 -20 ;0

I I

-20 ! -17.8

32 20

,i 40I i

4.4

104 100; 120

68 60 ; 80

I ! I

26. 7

I! I

48.9

140

- 40

of 284 248 240; 260 280 ; 300

176 212 160 ! 180 200 ; 220

71.1

°C

; I

I , 100

I !,

93.3

I i I ; I

; 120 116

; 140 138

I I

320

160

°C