1100 ZXi Personal Water Craft

Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure. ¥Ben 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. ¥Refeto the sectional table of contents for the exact pages to locate the specific topic required.

General Information

1

Fuel System

2

Engine Lubrication System Exhaust System

– 3
4

Engine Top End Engine Removal and Installation

– 5
6

Engine Bottom End Cooling and Bilge Systems

– 7
8

Drive System

9

Pump and Impeller

10

Steering

11

HullIEngine Hood

12

Electrical System

13

Storage

– 14

Appendix
– – Supplement 1997
1 – – Supplement 2000

15
1999 Models 16 2002 Models 1 7

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Kawasaki

I I00 ZXi

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 DepartmentConsumer Products & Machinery CompanyIKawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your “JET SKI” watercraft dealer for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

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Fourth Edition (1):Jul. 18,2001 (K)

A ABDC AC ATDC BBDC BDC BTDC C DC F
OF
ft
g h L

LIST OF ABBREVIATIONS

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
rn min N Pa PS psi
r
rPm TDC TI R
v
W Q

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

Read OWNER’S MANUAL before operating

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Foreword

This manual is designed primarily for use b y trained mechanics in a properly equipped shop. However, it contains enough detail and basic information t o make it useful to the owner w h o desires t o perform his o w n basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order t o carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to d o 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 w i t h the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, d o 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, w e 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: ¥Follo the Periodic Maintenance Chart in the
Service Manual. ¥B alert for problems and non-scheduled mainte-
nance. Â¥Us proper tools and genuine Kawasaki “JET SKI”
watercraft parts. Special tools, gauges, and testers that are necessary w h e n 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 t o keep complete records of maintenance and repair w i t h dates and any new parts installed.

How to Use this Manual

p

~

~

–

In preparing this manual, w e 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 o w n 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 h o w frequently t o clean and gap the plug. Next, use the Quick Reference Guide t o 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.

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.

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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.
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GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing……………………………………………………………………………………….1…-.2.. Model Identificati:on…………………………………………………………………………………….1..-.5 Gen~eraSl pecifications ………………………………………………………………………………….1..-6 Torque and Locking Agent …………………………………………………………………………1..-..7. Periodic Maintenance Chart ………………………………………………………………………..1..-..9 Technical Informati,on …………………………………………………………………………………1..-110
Maintenance Free Battery ………………………………………………………………………1..-.10 (I) Construction………………………………………………………………………………….1..-10 (11,) Main Features ………………………………………………………………………………..1-10 (HI) Princip’leof Sealing Structure……………………………………………………….1..-.10 (IV) Filling the Battery with Electrolyte…………………………………………………1..-11 (V) Initial Charge………………………………………………………………………………1…-.1.2 (VI) Precautions ………………………………………………………………………………….1.-13
Accelerator Pump ………………………………………………………………………………….1..-.14 KawasakiAir Induction System (KAIS) ……………………………………………………..1-15 Kawasaki Automatic Trim System (KATS) ………………………………………………….1-16 Special Tools8S, ealant ……………………………………………………………………………….1..-..17 Cable, Wire and Hose Routing……………………………………………………………………… 1 -19
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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.
1 1I 1 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.
¥Loose the clamp and remove the cap [A]. ¥Connecthe garden hose [B] to the hose fitting (see above). ¥Attac 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/mh (2.5 qts/rnin) at 1800 rpm and 7.0 L/min (7.4 qts/rnin) at 6000 rpm. CAUTION
–
Insufficient cooling supply will cause the engine and/or exhaust system to overheat and severe damage will occur. Excessivecooling supply may kill the engine and flood the cylinders, causing hydraulic lock. Hydraulic lock will cause severe damage to the engine. If the engine dies while using an auxiliary cooling supply, (he water must be shut off immediately. Always turn the boat on its left side. Rolling to the right side can cause water in the exhaust system to run into the engine, with possible engine damage.
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GENERAL INFORMATION 1-3
Dirt Before removal and disassembly, clean the “Jet Ski” watercraft. Any sand entering the engine, carburetor,
or other pans will work as aln abrasive and shorten the life of the watercraft. For the same reason, before installing a new pan, clean off any dust or metal filings. Battery Ground
Remove the ground (-1 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. 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 t o 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. 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. 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 (particularllyfor the removal of screws held by a locking agent) in order to avoid damaging the screw heads. Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect youlr hands with gloves or a piece of thick cloth when lifting the engine or turning it over. High Flash-point Solvent
A high flash-point solvent is recommended t o 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-Rang
Do not reuse a gasket or 0 – r m g 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 slurfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine cooling passages and cause serious damage. An example of a nan- perma~nentlocking 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 b y 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.
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1-4 GENERAL INFORMATION

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 lubncative 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 lubncative quality and may contain abrasive foreign particles.
Don’t use lust 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 applica~tionfor 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 primav color and then the secondary color. For example, a yellow wire with thin red stripes is referred t o as a “yellow/redWwire; it would be a “red/yellown wire if the colors were reversed t o make red the main color.

Wire (cross-sect ion)
-Red
Wire Strands

Color Indicated on the t i r e

Colw ~ndicatedçnthçÃ^~rinsKiae

Ye1 low

(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 ilose 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 t o 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.

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JH1100-A1 Left Side View :

GENERAL INFORMATION 1-5

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1-6 GENERAL INFORMATION 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:
Steering Braking

Type Thrust

Performance: tMinimum turning radius tFuel consumption ?Cruising range

Dimensions: Length Width Height Dry weight Fuel tank capacity

Engine Oil: Type Oil tank capacity

Electrical Equipment: Battery Maximum generator out put

2-stroke, 3-cylinder, crankcase reed valve, water cooled
1 071 mL
80 x 71 mrn 5.8: 1 88.2kW (120 PS) @6 750 rimin (rpm) 129 N-m(13.2 kg-m, 95 .5ft-lb) @6 000 r/min(rpm)
Magneto CDI (Digital) Oil injection (break-in period: Oil injection and and fuel mixture 50 : 1) Keihin CDK-38-29 x 3 diaphragm type (33 mrn venturi)
Electric starter

– – NGK BR9ES
0.7 0.8mrn 17* BTDC @I 250 rimin (rpm)

27′ BTDC @3000 r/mm (rprn)

1 250 ±I0rimin (rpm) – in water

– – – 1 800 Â 100 r/min (rpm)- out of water
657 1040 kPa (6.7 10.6 kg/cm2, 95 151 psi)

Direct drive from engine Axial flow, single stage
3 570 N (364kg, 803 Ib)
Steerable nozzle
Water drag

4.0 m
46 L/h @full throttle
97.5 krn @full throttle 1 hour and 5 minutes

2 760 rnm
1 070 mm
999 mrn 265 kg 52 L including 7 L reserve

2-stroke, N.M.M.A. Certifiledfor Service TC-WU or TC-W3 3.3 L

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

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Torque and Locking Agent

GENERAL INFORMATION 1-7

The following table list the tightening torque for the major fasteners, and the parts 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.

Fastener
Fuel System: Carburetor Mounting Bolts Intake Manifold Mounting Nuts Air Intake Cover Bolts Arrester Case Stay Mounting Bolts Throttle Case Mounting Screws
Engine Lubrication System Air Bleeding Bolt
Oil Pump Mounting Bolts
Exhaust System Exhaust Pipe Mounting Bolts Water Pipe Joints Exhaust Manifold Mounting Nuts Expansion Chamber Mounting Bolts
Engin~eT o p End: Cylinder Head Nuts Water Pipe Joint Cylinder Base Nuts Cable Holder Mounting Bolts
Engine Removal/Installation: Engine Mounting Bolts: Engine Bed Mounting Bolts Engine Mount Bolts
Engine B o t t o m End: Flywheel Bolt Stator Mounting Bolts Coupling Magneto Cover Mounting Bolts Crankcase Bolts-6 mm Dia. Crankcase Bolts-8 mrn Dia. Magneto Cooling Cover Magneto Cover Stud
Cooling and Bilge Systems: Water Pipe Joint
Drive System: Coupling Cover Nuts Coupling Drive Shaft Holder Mounting Bolts

Torque

ft-lb
78 in-lb 87 in-lb 69 in-lb 78 in-lb 35 in-lb
43 in-lb 78 in-lb
36 8.5 14.5 36

Remarks

94 8.5 94
78 in-lb
78 in-lb 22
78 in-lb
–

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1-8 GENERAL INFORMATION

Fastener
Pump and Impeller: Steering Nozzle Pivot Bolts Pump Outlet Mounting Bolts Pump Cap Impeller Pump Mounting Bolts Pump Cover Mountilng Bolts Grate Mounting Bolts
Steering: Handlebar Clamp Bolts Steering Neck Mounting Bolts Steering Holder Mounting Bolts Steering Shaft Lock Nut Steering Cable Nuts Trim Cable Nut
HullJEngine Hood:
Bumper Bushings Bumper Mounting Nuts
Electrical System: Electric Case Bolts Electric Case Mounting Bolts Electric Case Connector Mounting Bolts CD1 Igniter Mounting Bolts Spark Plugs Starter Motor Mounting Bolts Ignition Coil Mou~ntingBolts Starter Relay Mounting Nuts Starter Lead Mounting Nut Battery Gro~undLead Mounting Bolt Flywheel Bolt Stator Mounting Bolts

Torque kg-m

ft-lb

Remarks

13-.5

35 in-lb

7 2

16.0

69

in-lb –

11.5 11.5
-11.5
29 36 29 29
–

69 I ~ I – I I ~ 69 in-lb 78 in-lb 69 in-lb
20 78 in-lb 69 in-lb 69 in-lb 69 in-lb 78 in-lb
94 8.5 ft-lb

The table below, relating tightening torque 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. All of the values are for
use with dry solvent-cleaned threads.

General Fasteners (stainless boll and nut)

Threads

I

dia. (mm)
6 8
10

I

N-m
-5.9 8.8 -16 22 -30 41

– — – –
Torque
kg-m
– 0.60 0.90
-1.6 2.2
– 3 1 4.2

–
– –ft-lb
52 78 in-lb 11.6 15.9
22 30

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– –
Periodic M a i n t e m n c e Chart
NOTE 0Complete the R e -Ride Checklist before each outing.

GENERAL INFORMATION 1-9

Frequency
– Description
Check all hose clamps, nuts, bolts, and fasteners

Initial 10
Hours
@

Torque cylinder head nuts

0

Lubricate throttle cable fitting and choke cable fitting at carburetor

Lubricate choke cable and throttle cable and

throttle cable fitting at throttle case.

1 Clean and gap spark plugs (replace if necessary)

1

1

Lubricate steering cable / trim cable ball joints and steermq nozzle / trim nozzle pivots

Lubricate handlebar pivot (disassemble)

Clean fuel filter screens

Inspectlreplace fuel filter
1 Adjust carburetor
1 Flush bilge line and filter 1 Flush cooling system (after each use in salt water)

Inspect/clean flame arrester

In~spectimpeller blade for damage (remove)

— – –
Inspect/replace coupling damper
1 Inspect steering cable / trim cables

1

1

Every 25
Hours
Â
Â

Every 1 00 Hours

,

Â

• I

1

a a
Â

a a

1

I

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1-10 GENERAL INFORMATION Technical Information

Maintenance Free Battery
A maintenance free battery is installed in this model The maintenance free battery is a seated type, and so the electrolyte level check and t o ~ p i n q – u pcannot be performed.

(I) Construction

.Sealing p l u g

“f’Tt Pole
(lead-calcium alloy) Negative plate (lead and lead-calcium alloy)
Special separator
Positive plate (lead and lead-calcium alloy)

(11) Main Features 1) Maintenance free………………………………….. It is not necessary to check the electrolyte level and top-up the electrolyte.
2) N o electrolyte leakage …………………………… As the electrolyte is retained firmly in the special separators, there is n o
free electrolyte in the battery.
3) Instant activation system……………………….. it can be used instantly after filling only the electrolyte without initial charge.
4) O n e – p w h motion ele~tro~lyftiellling………… it is possible t o fill the electrolyte by easy one-push motion. 5) S’afety construction ………………………………. If the battery internal pressure rises abnormally high, the safety valve
opens to release the gas inside the battery to restore the normal pressure
and prevent the battery from rupturing. After restoring the normal
pressure, the safety valve closes and the battery is sealed again.
Moreover, a ceramic filter is disposed o n top of the safety valve under the lid t o remove risk of ignition or explosion caused by fire from outside. 6) Compact and high performance.. …….. No presence of free electrolyte allows the battery made lower in height, thus resulting in enhanced volume efficiency. Moreover, gas bemg
absorbed inside the battery eliminates the need for a gas exhaust tube. 7) Strong chargefdischarge characteristics .. It can amply withstand deep charge/discharge cycles.

(Ill) Principle of Sealing Structure
A lead-acid battery operates under the following chemical reaction:

(*)

(-1

Discharge

(-1

(+)

PbOz

+ 2H2S04

Pb

+4-

PbS04 + 2H20 + PbS04

(Lead peroxide) Positive active
material

(Sulfuric acid) Electrolyte

(Spongy lead) Negative active
material

Charge

(Lead sulfate) (water) (Lead sulfate)

Positive active Electrolyte Negative active

material

material

Normally in an ordinary lead-acid battery when it comes to an end of a charge, where the lead sulfate being a discharge
product returns to lead peroxide and spongy lead, the charge current flowing thereafter is used exclusively t o decompose
electrolytically water from the electrolyte, thus resulting in generation of hydrogen gas from the negative plate and oxygen gas from the positive plate. The gases so generated are released out of the battery, causing the amount of electrolyte decreased t o require occasional water replenishment.
A maintenance free battery, however, is so designed that, when i t is overcharged, even i f the positive plate is fully charged, the negative plate remains not fully turned to spongy lead Therefore, even when the positive plate is overcharged generating oxygen gas, the negative plate is no fully charged, hence generating n o hydrogen gas
Moreover, the oxygen gas generated from the positive plate immediately reacts with the charged active material o n the negative plate, and returns to water, with the ultimate result of no water loss.

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Pb Negative active
material (charged state)

1/2 0 2

Oxygen generated

from positive plate

(PbO) Negative active
material

(pbo)

H2S04

Electrolyte

PbS04

Negative active

material

(charged state)

H20 Water

Thus, the negative plate is made als not to get fully charged. Even if the overcharge continues, the oxygen gas generated inside the battery is absorbed by the negative plate, a process called oxygen cycle, which theoretically prevents water toss,
and allows the battery to be sealed.

(IV) Filling t h e Battery with Electrolyte
Do not remove the aluminum seal sheet sealing the filler ports until just before use. Be sure to use the dedicated electrolyte contallner for correct electrolyte volume.
Â¥Chec to see that there is no peelinlg, tears or holes in the sealing sheet. Â¥Plac the battery on a level surface. Â¥Remov the sealing sheet [A]. OWhen removing, check to hear an air-sucking sound “Shoosh~”from
filler ports [B] NOTE
O A battery whose sealing sheet has any peeling, tears, holes, or from which the air-sucking sound was not heard requires a refreshing charge (initial charge).
¥Tak the electrolyte container out of the vinyl bag. ¥Detac the strip of caps [A] from the conta~iner.
NOTE O D o not discard the strip of caps because it is used as the battery
plugs later.
0 Do not peel back or pierce the sealed areas [Bl

 Plaice the elec;trolyte container u p[side down with the six sealed areas in line with the six battery filler ports.
Â¥Pus the container down strongly enough to break the sealls Now the electrolyte should start to flow into the battery
NOTE
0Do not tilt the container as the electrdyie flow may be interrupted.

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1-12 GENERAL INFORMATION

Â¥Mak sure air bubbles [A] are corning up from all six filler ports. 0Leave the container this way for 5 minutes or longer
NOTE
0Jf no air bubbles are coming up from a filter port, tap the bottom of the bottle two or three times Never remove the container from [he battery
CAUTION Fill until the container is completely emptied.

¥B certain that all the electrolyte has flowed out ¥Ta the bottom the same way as above if there is any electrolyte left
in the container ¥No pull the container gently out of the battery
Â¥Le the battery sit for 20 minutes. During this time, the electrolyte permeates the special separators and the gas generated by chemical reaction is released
Â¥Fi the strip of caps [A] tightly into the filler ports until the strip is at the same level as the top of the battery

NOTE

0 Do not hammer. Press down evenly with both hands.

I

CAUTION

I

Once you install the strip of caps after filling the battery, never remove it, nor add any water or electrolyte.

I

I

d

(V) Initial Charge While a maintenance free battery can be used after only filling with electrolyte, a battery may not be able to sufficiently
move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if a battery shows a terminal voltage of higher than 12.5 V after 10 minutes of filling (Note I ) , no initial charge is
necessary.

1

Condition requiring initial charge

At low temperatures (lower than O0C)

Battery has been stored in hiqh temperature and hurrnditv.

1 1

– Charging method
1.8 A x 2 3 hours

1

Seal has been removed, or broken – peeling, tear or hole.
(If you did not hear the air-sucking sound “Shooshl” as you removed the seal.)

Battery as old als 2 years or more after manufacture

Battery manufacturing date is printed on battery top.

Example) 12

10

– 93

37-

Day ~ Z t h Year Mfg. location

– 1.8 A x 15 20 hours

Note 1 ‘ Terminal voltage – To measure battery terminal voltage, use a digital voltmeter.

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GENERAL INFORMATION 1-13
(VI) Precautions 1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use Forcibly prvinq off the sealing plug to add water is very dianqerous Never dlo that 2) Refreshing charge
If an enginc wiH not start, it indicates tlie haltcry lias been discl’inrgcd. Give refresh charge for 5 to 10 hours with charge
current shown in the specification (see the Electrical System ch~apter) When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery
CAUTION
This battery is designed to sustain no unusual deterioration if refresh- charged according to the method specified above. However, the battery’s performance may be reduced noticeably ilf charged under conditions other than given above. Never remove the sealing pluq during refresh charqe. II by chance an excessive amount of gas is generated due to overcharging, the safety valve operates to keep the battery safe.
3) When you d o not use the watercraft for months Give a refresh charge before you store the watercraft and store it with the negative lead removed. Give a refresh charge once a month during storage
4) Battery life If the battery will not sta~rthe engine even after several refresh charges, the battery has exceeded its useful life Replace it (Provided, however, the vehicle’s starting system has no problem )
Keep the battery away from sparks and open flames dluring charging, since the battery gives ofl an explosive gas mixtu~reof hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. No lire should be drawn near the battery, or no terminals slhould have the tightenling loosened. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Gel medical attention if severe.
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1-14 GENERAL INFORMATIOlN
Accelerator Pump
When a throttle is opened quickly, the carburetor fuel mixture tends to momentarily become too lean This results from the fact that th~efuel is of greater weight than air, and when the throttle is opened suddenly the flow of fuel will tag behind the flow of the air, resulting in a lean mixture
To supply the additional fuel needed to overcome this condition, a small pump IS incorporated in the front carburetor
NOTE
OAfter the engme has started, do not repeatedly operate the throttle. The accelerator pump may foul the spark plugs with excess foe/

A. Inlet Check Valve 0 Spring C. Pump Chamber D Pump Diaphragm E Pump Rod
F Link Cam

G. Outlet Check Valve
H Dischange Nozzle I. Link Lever I3
J. Link Lever A K. Throttle Shaft
L. Link Shaft

When the throttle is suddenly opened, the pump rod linked to the
throttle shaft pushes the pump diaphragm forcing the fuel from the pump
chamber. The inlet check valve closes and the outlet check valve opens
allowing fuel to spray from the discharge nozzle

As the diaphragm relaxes, the inlet valve opens letting fuel from the regulator chamber refill the pump chamber The outlet check valve closes as accelerator pump pressure faffs stopping fuel from synphoning out (he discharge nozzle.

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GENERAL INFORMATION 1-15 Kawasaki Air Induction System (KAIS)
KAIS is a system to reduce the coefficient of friction or drag between the bottom surface of the hull and the water
This system features t w o small air outlets [A] at the end of each inner strake When in motion the fast flowing water will create a vacuum [ B ] and draw air out of the engine compartment [C] to form a n a~ir-bubble film between the hull and the water
Structure of air outlet

This aerating of the rear portion of the hull improves acceleration and top speed.

Â¥
0)
0n) ,
0

,
– —.- : w.ithout KAIS Time

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1-16 GENERAL INFORMATION
Kawasaki Automatic Trim System (KATS)
The Kawasaki Automatic Trim System (KATS) is designed for optimum low speed acceleration With the automatic trim switch [A] set to the “ON” position, the trim control unit senses engine rprn, then controls the trim motor
When the switch is pushed in after the ignition switch is turned on, the LED indicator light [ B ] in the trim indicator comes on and the steering nozzle goes all t h e way down When the engine speed exceeds 2.000 rprn, the nozzle goes up to its level position and stays there The nozzle goes down when the engine speed is lower than 2,000 rprn
You can (urn off the system either by pushing the switch in again or by operating the trim switch The red indicator light shows that the system is functioning If the engine is not started within three minutes after the switch is pushed in, the light goes off but the system stays o n

SENSING ENGINE RPh TU!M
MOTOR

CHECK PROCESS FOR KATS

1 TURN ON IGNITION-S/W and PUSH TRIM-S/W (DOWN) -+CHECK TRIM MOVE to FULL-DOWN and STOP (ENGINE: OFF, AUTO-TRIM-S/W OFF)

2 PUSH TRIM-S/W CUP) (ENGINE. OFF, AUTO-TRIM-S/W. OFF)

CHECK TRIM MOVE to FULL-UP and STOP

3. PUSH ON AUTO-TRIM-S/W (ENGINE: OFF)

CHECK AUTO LED LIGHT UP, TRIM MOVE to FULL-DOWN and STOP

4 PUSH OFF AUTO TRIM-S/W (ENGINE. OFF)

CHECK AUTO-LED LIGHT DOWN

5. PUSH ON AUTO TRIM-S/W (ENGINE: OFF)

CHECK AUTO-LED LIGHT UP

6 START ENGINE and KEEP over 2000 rpm (over 3 sec)

CHECK TRIM MOVE to LEVEL and STOP (MOTOR WORKING TIME is 1.5 sec)

7. KEEP under 2000 rpm (over 1 sec)

CHECK TRIM MOVE to FULL- DOWN and STOP

8. PUSH TRIM-S/W (UP)

CHECK AUTO-LED LIGHT DOWN, TRIM MOVE to FULL-UP and STOP

9. PUSH ON AUTO TRIM-S/W and KEEP over 2000’ rpm (over 3 sec)

CHECK AUTO-LED LIGHT UP. TRIM does not MOVE (STAYS FULL-UP)

10. PUSH TRIM-S/W (DOWN)

CHECK AUTO-LED LIGHT DOWN, TRIM MOVE t o FULL-DOWN and STOP

11. STOP ENGINE and TURN OFF IGNITION-S/W

(REFER to KATS TROUBLESHOOTING in the ELECTRICAL SYSTEM CHAPTER)

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Special Tools, Sea~lant
Compression Gauge: 57001 -221

GENERAL INFORMATION 1-17
Bearing Driver Set: 57001-1129

Piston Pin Puller Assembly: 57001-910

Compression Gauae Adapter, M14 x 1.25: 57001 -1159

Oil Seal & Bearing Remover: 57001-1058

Rotor Puller, M I6/M18/M20l/M22 x 1.5: 57001-1216

Piston Ring Compressor Grip: 57001-1095

Flywheel Puller, M35 X 1.5: 57001-1223

– Piston Ring Compressor Belt, a67 @79: 57001-1097

I
ImpellerWrench: 57001-1228

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1-18 GENERAL INFQRMATION
Coupling Hdder: 57OQq-1230

Hand Tester. 57001-1394

Drive Shaft Holder Adapter: 57001-1237

Kawasaki Bormd (Silicone Sealant): 56019-120

Driue Shaft Holder: 57QQl-1327

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

Flywheel Holder: 57001- 7 313

Box Wrench (27 mm): 57001-1451

3

Impeller Holder: 5700j -1393

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Cable, Wire and Hose Routina

GENERAL INFORMATION 1-19

Clamp the pulse as shown.

1. Front Carburetor

2. Middle Carburetor

3. Rear Carburetor

4. Oil Hose (To Front Carb.)

5. Oil Hose (To Middle Carb.)

6. Oil Hose (To Rear Carb.)

7. Pulse Hose (To Front Carb )

8. Pulse Hose (To Rear Carb.)

9. Clamp

10. Fuel Hose (Return)

11. Fuel Hose (Supply)

12. Baiance Tube

13. Intake Manifold

-14. Balance Tube Fitting
15. Oil Pump 16. Magneto Cover 17. Magneto Leads

Be careful so that the o i l hose clamp

BOW

does n o t touch the accelerator p u m p cam.

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1-20 GENERAL INFQRMATON
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GENERAL INFORMATION 1-21

I Bypass Outlet

11. To Jet Pump

2 Clamp 3. Water Temperature Sensor
4 Exhaust Pmpe

– 12. Exhaust Manifold
13. Cylinder Head
14.Cooling Hose [Cylinder Head

Exhaulst Pipe]

– 5 Bypass Cocalmg km?
6. Caolling~Hose coo ling^ Cower Chamber)

Run the cooling hose new the magneto cover so that

7. Magneto Coohng Cover

the hose daes not touch the chamber body and rnanifdd.

8. Expans~onChamber

9. Cooltng Hose [To Magneto Cooling Cover)

70. M e t Cooling Hose

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1-22 GENERAL INFORMATION
I . Throttle Laver 2. Throttie Cable 3. Clamp 4. Startistop Switch Leads 5. Sta~rt/StopSwitch 6. Protective Tube 7. To Fuel Knob 8. To Choke Knob 9. Grom~metPlate 10. Grommet 1I.Choke Cable 12. Trim Cable 13. Steering Cable ?4. Detent

BOW

BOW

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1 Detent 2. Fuel Hose (Supply) 3. Fuel Hose (Return) 4 Fuel Tap Assembly 5. Fuel Filter 6 Band 7. Clamp 8. Oil Inlet Hose
9. Oil Tank
10. Oil Filter
11 To Oil Pu~mp 12. Main Harness
13. Fuel Level Sensor

BOW

GENERAL INFORMATION 1-23

BOW BOW
5
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1-24 GENERAL INFORMATION
1 Oil Inlet Hose 2 . Detent 3 Oil Pump 4. Trim Motor Box
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FUEL SYSTEM 2-1

Fuel System
Table of Contents

Exploded View …………………………………………………. 2 – 2

Specifications …………………………………………………… 2 – 4

Fuel System Diagram ………………………………………… 2-5

Throttle Cable …………………………………………………… 2-6

Throttle Cable Adjustment ……………………………..2-6

Throttle Case and Cable Removal……………………2-6 Throttle Case and Cabl.e Installation Notes ………2-7

Throttle Case and Cable Lubrication ………………..2-7

Throttle Cable Inspection ………………………………. 2-8

Choke Cable …………………………………………………….2. -9

Choke Cablle Adjustment ………………………………..2-98

Choke Knob and Cable Removal

2-9

Choke Cable and Knob Installation Notes ……..2-10

Inspection …………………………………………………..2-180

Lubrication…………………………………………………. 2-101

Carburetor/Fuei Pump …………………………………….. 2-11

Idle Speed Adjustment …………………………………2-11

Mixture Screw Adjustment …………………………..2-W

High Al~titudePerforman. ce Adjustment ………….2-1i2

Synchronization………………………………………….. 2-12

Ca~rburetomrRemoval……………………………………..2-13

Ca’rburetorInstallation Notes ……………………….. 2-13

Carbureto’r Di,sassernbliy ……………………………….2-13

Carburetor Assembly No’tes………………………….2-14 Car.buretor Cleaning and Inspection ………………2-15 Float Arm Level In~spectionand Adjustment …..2-16 Fuel Pump RemovalfInstallation Note …………..2-16
Flame Arrester………………………………………………..2..-17
Removal…………………………………………………… 2-17 Installation Notes………………………………………… 2-17 Cleaning…………………………………………………….. 2-117 Intake Mani~fold,Reed Valves…………………………… 2 – 7 8 Removal…………………………………………………….. 2-18 Installation Notes…………………………………………2-18 Reed Valve Inspection…………………………………2. -18 Valve Holdier In~~pectio…n…………………………… 2 – 1 9 Valve Stop Inspection ………………………………….2-19 Fuel Tank ………………………………………………………. 2 – 2 0 Fuel Tank Rem. oval…………………………………….2..-20
Fuel Tank Ikistallation. Notes …………………………2-20
Fuel Tank Cleaning…………………….. ……………..2-21
Fuel Filler and Tube Removal ………………………. 2-211 Fuel Filler and Tube Installation Notes ………….. 2-21 Fuel Filter Screen Cleaning ………………………….. 2-22 Fuel Filter ‘Inspection…………………………………… 2-22

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2-2 FUEL SYSTEM
Exploded View
1. Main Jet
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FUEL SYSTEM 2-3
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2-4 FUEL SYSTEM Specifications

Carburetor Make, type Size Mixture screws: Low speed High speed Main jet: Fron~t Middle Rear Pilot jet Float arm level Idle speed: in water out of water
Reed Valve Reed warp
Fuel Tank Capacity

Item

Stan,dard Keihin, CDK 11 38-29
33 mrn Venturi 1 I/$ Â 1/4 turn open 1 Â 1/4 turn open
– – –
52 L (including 7 L reserve)

Special TOO~- Pressure Cable Luber: K56019-021 Sealant – Kawasaki Bond (Silicone Sealant): 56019-120

Service Limit

0.2 mrn

1

—

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Fuel System Dliagram

FUEL SYSTEM 2-5

BOW

Fuel Tao

N v e n t L i n e

Check valve
I
Accelerator

Car b u r e t o r
EnQ i n e

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2-6 FUEL SYSTEM Throttle Cable
Throttle Cable Adjustment
Â¥Chec throttle cable adjustment OWith the throttle lever released, the lower stop on the throttle pivot arm
[A] should rest against the idle adlust screw [B],and there should be
slight slack in the throttie cable OWhen the throttle lever is fully applied (pulled), the upper stop on the
pivot arm should be all the way up against the stop on the carburetor.

 ¥ I necessary, adjust the throttle cable [A] 0 Loosen and turn the locknuts [ E l at the cable holder until the lower
stop on the pivot arm hits against the idle adjust screw with slight cable slack. OTighten the locknuts securely

THROTTLE CLOSED (RELEASED)

THROTTLE OPEN
(APPLIED)

Throttle Case and Cable Removal
Â¥Disconnec the throttle cable from carburetor. *Remove’
Handlebar Pad Throttle Case Mounting Screws [ A ] StartIStop Switch Handlebar Steering Cover ¥Disconnecthe throttle cable from case.
Â¥Us a screw driver [A] to separate the tip of the cable end [B] from
the case body.

¥Tak out the bolts [A] and remove the grommet [B]. ¥Remov the throttle cable by carefully pulling the cable through the
hull,

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Throttle Case and Cable Installation Notes
Â¥Pullin the throttle cable [A], position the tips o f the cable end [B] as shown

FU’EL SYSTEM 2-7

¥Appl silicone sealant to the grommet [A]. ¥Rout the throttle cable correctly (see Cable Routing section in the
General Information chapter) ¥Adjusthe throttle cable (see Throttle Cable Adjustment)

Â¥Followin the sequence shown, torque the mounting screws.
Torque – Throttle Case Mounting Screws:
3.9 N-m (0.4 kg-m, 35 in-lb) [A]

1

CAUTION

1

1 Do not overtighten the mounting screws.

I

Throttle Case and Cable Lubrication
(Apply water resistant grease [A] to the tips of the throttle cable ends.

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2-8 FUEL SYSTEM m Lubricate the cable by seeping oil between the cable and cable
housing.
Throttk Cable Inspection

Examine the cable.

*If the cable or cable housing is kinked [A] or frayed f B ] , replace the
cable. ¥B certain that the throttle cable moves freely in both directions 0 Loosen the adjuster locknuts, and slide the cable from the pulley 0Slide the inner cable back and forth in the cable housing
irf the cablle does not move freely, replace it.
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Choke Cable Choke Cable Adjustment
Â¥Whe the choke knob is pushed in (off), the choke butterfly valve in the carburetor should be completely open. Check that the choke pivot arm [ A ] stands all the way toward the right side of the boat with minimum cable slack

FUEL SYSTEM 2-9

@Ifnecessary, adjust the choke cable [A] 0 Push the choke knob in completely 0Loosen and turn the locknuts [B] at the cable holder to allow a little
cable slack 0Tighten the locknuts securely

CHOKE OPEN (PUSHED IN)

CHOKE CLOSED
(PULLED OUT)

Choke Knob and Cable Removal
I Disconnect the choke cable from the carburetor. 0Loosen the set screw [A] 0Loosen the adjuster locknuts and slide the cable from the cable holder

Â¥Remov the steering cover. @Takeout the bolts [A] and remove the grommet [B].

Â¥Unscre the large nut [A] on the inside of the control panel.

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2-10 FUEL SYSTEM
Â¥Remov the choke cable by carefully pulling the cable through the hull

Choke Cable and Knob Insta//ationNotes
Â¥Appl silicone sealant to the grommet [A]. @Routethe choke cable according to the Cable Routing section in the
General Information chapter. ¥Adjusthe choke cable (see Choke Cable Adjustment).

Inspection
Â¥Examin the cable. If the cable or cable housing is kinked [A] or frayed [B], replace the
cable. ¥Wit 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 rt.

Lubrication
Whenever the choke cable removed, lubricate the choke cable as follows. ¥Appl water resistant grease to the tips of the choke cable ends.

Â¥Lubricat the choke cable by seeping oil between the cable and cable housing.

Special

– Pressure Cable Luber: K56019-021 [A]

Â¥Attache the choke cable to the carburetor and adjust the choke cable (see Choke Cable Adjustment).

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Carburetor/Fuel Pump
Do not open and close the throttle excessively when engine is running. The accelerator pump [A] can flood the engine, and cause

FUEIL SYSTEM 2-11

Idle Speed Adjustment
The normal idle speed setting is the fewest at which the watercraft will run reliable while still producing enough thrust to circlle back to the rider after spill ¥Tur the id~leadjusdng screw [All as required to reach this setting.

Idle Speed

1,250 Â100 rpm (in water)
1,800 ±I0 rpm (out 01 watei

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 ea~ch 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 lhne. ¥Pulout the mixture screw caps. ¥T set each screw, turn it in until seats lightly, and th~enback it out the
specified number of turns.

Mixture Screw
Low Speed (lower) [B] High Speed (upper) [C]

Turns out
1 1/8 ±
1 ±

These guidelines represent a “starting point” from which additional fine tuning of the carburetor may be necessary.

CAUTION
Do not force the mixture screws into their seals. You could damage the screws or the carburetor. Operalin~gthe watercraft with the high speed screw at loo lean a selling (screwed in clockwise too far) could cause serious engine damage.
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2-12 FUEL SYSTEM

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.
NOTE
QAdjustment of the tow speed screw is not required in actual usage
Synchonization
¥Remov the carburetor (see Carburetor Removal) ¥Tur out the idle adjusting screw [A] until there is a clearance between
the adjusting screw end and throttle shaft lever [B] ¥Tur in the idle adjusting screw until the adjusting screw end lust
touches the throttle shaft lever. ¥Tur in the adjusting screw 314 turn from the point to keep the
specified throttle valve [C] opening in the front carburetor [ D l .
Â¥Measur the distance from the bottom of the carburetor bore lower en~d to the valve edge shown as “H”.
@Turnthe synchronizing screw [El so that the valve edge in the middle
[fl carburetor keeps the same distance within k0.2 mrn tolerance as
that in thle front carburetor.
Â¥Tur the synchronizing screw [GI so that the valve edge in the rear
carburetor [HI keeps the same distance within k0.2 mm tolerance as in the front carburetor ¥Instalthe carburetor ¥Adjusthe throttle and choke cables

Altitude m (f)
1000 (3300) 2000 (6600) 3000 (1 0000)

Turn the high speed

screw in the

I

normal position

1/8 turn

I

1/4 turn

3/8 turn

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Carburetor Removal
Â¥Remove Air Intake Cover (see Flame Arrester Removal) Arrester Case (see Flame Arrester Removal) lisconnect Throttle Cable Choke Cable Return Hose [A] Inlet (Supply) Hose [El] Pulse Hose [ C ] Oil Hoses ift the carburetor off the intake manifold
Carburetor Jnstallation Notes
Â¥Connec the fuel hoses and pulse hose correctly (see Fuel System Diagram)
¥Instala new gasket under the carburetor as shown ¥Appl a non-permanent locking agent to the carburetor and air intake
cover bolts.
Torque – Carburetor Mounting Bolls: 8.8 N-m (0.9 kg-m, 78 in-lb) Air Intake Cover Bolls: 7.8 N-m (0.8 kg-m, 69 in-lb)
Â¥Adlus the throttle and choke cables (see Throttle and Choke Cable Adjustment)
Carburetor Disassembly
¥Remov the carburetor (see Carburetor Removal) ¥Unscre the carburetor cover screws [A] and take off the carburetor
cover [B]

FUEL SYSTEM 2-13
“UP” Mark Front

Â¥Unscre the carburetor case screw [A] and separate the carburetor case [ B ] from the carburetor body

¥Unscre the float arm set screw [A]. ¥Remove
Float Arm [B] Spring Float Valve Main Jet [C] Pilot Jet [Dl
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2-14 FUEL SYSTEM
Â¥Remov the mounting screws [A] and drop out the plates [ B ] and check valves [ C ] Carburetor Assembly Notes
¥I the mixture screws were removed, install then, as shown High Speed Screw [A] Low Speed Screw [B] ¥Assembl the carburetor cover, as shown. Float Arm [A] Sprw [El
Diaphragm Needle [C] Main Jet [Dl Pilot Jet [El
NOTE
0After 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 [Al at the carburetor, and blow [B] through it until fuel appears at the fuel return fitting on the carburetor The fuel system in now full of fuel.
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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.
Carburetor Cleaning and Inspection
Â¥Disassembl the carburetor (see Carburetor Disassembly).
Solvent is toxic and flammable. Avoid prolonged contact with skin and keep away from open flame. Use only i n a well-ventilated area.
Eye protection should be worn when colmpressed air is used lo dry
parts. Do not dilrect air toward anyone. Use 172 kPa (1.75 kg/cm2,
– >Immerse all the metal parts in a carburetor cleaning solution. @Rinsethe parts in water. Â¥Whe the parts are clean, dry them with compressed air. Â¥Blo out the air and fuel passages with compressed air. (Inspect the check valve [A] for damage or deterioration, and replace it i f necessary. If the gasket [B] under the check valve appears damaged, it may leak and must be replaced.
Â¥Chec these rubber parts for damage 0-nng [A] Diaphragm [B] i f any of these parts are not in good condition, replace them.

FUEL SYSTEM 2-15

Â¥Chec the plastic tip o n the diaphragm valve needlle smooth, without any grooves, scratches, or tears. Diaphragm Needle [A] Diaphragm Needle Wear [B] *If the plastic tip is damaged, replace the needle

It should be

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2-16 FUEL SYSTEM Float Arm Level inspection and Adjustment
Â¥Chec the float arm level [A] 0 Measure from the plastic tip [B]on the float arm to the carburetor case
LC1
– Float Arm Level 1.0 2.0 mm
*If the float arm level is incorrect, bend the float arm very slightly to
changed the float arm level
Fuel Pump Rernoval/Insta/lationNote
¥Remov the carburetor ¥Remov 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 internaldamage Is suspected, replace the fuel
pump unit [B].
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Flame Arrester
Removal Remove. Air Intake Cover Mounting Bolts [A] Air Intake Cover [B] Flame Arrester Carbulretor Mounting Bolts [C] Arrester Case [Dl

FUEL SYSTEM 2-17

Installation Notes
¥Fi the stay [A] to the case temporarily. ¥Torqu the bolt (cylinder head side) [B] and then torque the bolt
(arrester case side) [C]. ¥Inser the air intake cover into the arrester case [ D l . (Apply a non-permanent locking agent t o the following.
Torque – Slay Mounting Bolts: 7.0 N-m (0.8 kg-m, 69 in-lb) Carburetor Mounting Bolts: 8.8 N-m (0.9 kg-m, 78 in-lb) Air Intake Cover Bolts: 7.8 N-m (0.8 kg-m, 69 in-lb)
Cleaning
Â¥Remov the flame arrester [A] (see Flame Arrester Removal) Â ¥ B l o the flame arrester clean with compressed air.
should be worn when com~pressedair is used to dry
1 parts. Do no! direct air toward anyone. Use 172 kPa (1.75 kg/crn2,
25 ~ s iml aximum nozzle pressure. Â Install the flame arrester (see Flame Arrester Installation Notes)
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2-18 FUEL SYSTEM Intake Manifold. Reed Valves Removal
Â¥Remove Air Intake Cover Carburetor (see Carburetor Removal)
Â¥Remov the intake manifold mounting nut [A] and remove the intake manifold [Q].
Â¥Pulout the gaskets [A] and the reed valves [B] .
Installation Notes
Â¥Replac the gaskets with new ones. Â¥In~stathl e reed valves [A] and gaskets [B] so that the “UP” mark [C] is up.
Heed Vake Inspection
Â¥Chec reed warp by measuring the clearance [A] between each reed
[B] and the valve holder LC].
If any one of the clea~rancemeasurements exceeds the service limits,
replace the reed valve assembly with a new one. Reed Warp
Service Limit: 0.2 mm ¥Chec the mounting screw tightness. ¥Visuall inspect the reeds for cracks, folds, or other damage. If there is any doubt as to the condition of a reed, replacethe reed valve
assembly
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*If a reed becomes wavy relplace th~ereed valve assernbby w ~ t ha new one even i f reed warp 1s less than the serwe limit.

FUEL SYSTEM 2-19

Vahe Holder tnspection
@Check the reed [A], contact a’reas of the vallve holder for g6ooves, scratchmes, or o t k r damage.
.Check that the rubber coating [B] on1 the valve holder does not show any signs of separatikm from the holder.
if there is,any ‘doubt as to the condition of the rubber coating, repllace the peed valve assernb’lywith a new one.
V a h S o p fmpection
.Check the valve st~olps[A] for defomIaliafl~c,racks, or other damage. If there is any doubt as to th~eco~l~ditionf a stoptreplacethe reed valve
assembly with a n~ew’one.

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2-20 FUEL SYSTEM Fuel Tank Fuel Tank Removal
e l f the eve1of the fuel IS above the filler neck, slphon some fuel out to prevent s p i l h g it Gasoline is extremely flammable and can be explosive under certain conditions. Pull the lanyard key OHthe stop button. Do not smoke. Make sure the area is weli ventilated and free from any source of Itarne or sparks; this inchdes any appliance with a pilot light.
ORemove or dtsconnect: Engine Fuel Tank Straps [A] OLoosen t~heclamps [A] o n the filler tube.
ORemove the fuel Level sensor [A] and the f u d fdter assemb’ly [ B ] and remove The fuel tank,
Fue/ Tank InsWafion Notes
*Be sure the O-ring [A] IS ln the posit~on.
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Fuel Tank Cleaning a Remove the fuel tank (see Fuel Tank Removal).
Drain the tank ~ n t oa suftable contamer.
Gasoline is extremely flammabhe and can be explasive under certain conditions, Pull the lanyard key off the stqt button. Do not smoke. Make sure the area is well ventilated and tree from any source ot flame or spark; this includes any appliance with a pilo?light.
Flush the tank repeatedly with high flash-point solvent until it IS clean
It may be necessary to put a few marbles or p~ecesof clean gravel ~ n m
the tank and shake itoto knock loose any fore~gnmatter In the bottom
1 &-; Clean the lank in a well-ve11~i1at~area, and t a k i
1 ] here are no sparks or flame anywhere near the working area; this includes any appliance wkh a pilot light- Do not use gasoline or a low Flash- pointsolvenk to clean the tank. A fire or explosion could result,

FUEL SYSTEM 2-21

@loosenthe tube [A] damps and pull the filler from the hull,
Fuel Filler and Tube /nsta/fatimNotes
@Cleanthe hull and the f~lleron their mating surfaces with a greaseless, high flash-point s~lvent. Clean the parts In a well-venkilated area, and lake ample care that
there are no sparks or flame anywhere near the working area; this
includes any appliance with a p~tolt~gb~Dt.O mot use gasolkw o r a OW flash- point solwenl. A fire or explosion could result.
eApply an even layer of silicone sealant to the matmg surfaces of the
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Fuel Filter Screen C k a n ~ n g
@Cleanthe fuel Wer screens in acccardance with the Permd~cMainteDance Chart (see General Inform~ationchapter).
aClpen the hatch cover [A] and take out the storage case [B].
@Unscrewthe mountmg screws [A], and remove the h e ! filter assembly
PI.
@Wash the fuel filter screens in non-flammable or high flash-paint solvent Use a brush to remove any contamina~ntstrapped in the screens. 1fiber screens ina well-wentifated area, and take ample care that there are no sparks OK f~lameanywhere near the working area; this inclwdes m y appliance with a p b t Iighli. Do not use I
gasolineor a #owflash-pint s~lvent.& fire or explosioncould resulL
Fud Fiber Inspection
The watercraft is equpped with a hell filter [A] at the middle of the fuel line ta prevent dvt or other foreign material from entering the carburetor. @Lnspectand replace the fuel f&er in accordance with the Periodic
Maintenance Chart, or whenever you find from outs~deany h e i g n material or water trapped in the fuel filter.
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ENGINE LUBRICATION SYSTEM 3-1
Engine Lubrication System
Table of Contents
Expbded View …………………………………………………………………………………..3..-.2………. S p e ~ i f ~ i c a t i o n..s………………………………………………………………………………………3..-..3….. Oil Pump……………………………………………………………………………………………..3..-.4……..
011Pump Bleeding………………………………………………………………………………3..-.4….. 011Pump Performance Test …………………………………………………………………..3..-..5… Oil Pump Removal ……………………………………………………………………………..3…-.6….. Oil Pump Installation …………………………………………………………………………3..-.6……. 011Tank ……………………………………………………………………………………………….3..-.8……. Oil Tank Removal………………………………………………………………………………..3..-…8… Oil Tank C1leaning…………………………………………………………………………………..3..-..8 Oil Filter Cleaning ………………………………………………………………………………..3..-..8…
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3-2 ENGINE LUBRICATION SYSTEM
L : Apply a non-permanent locking agent.
G : Apply grease.
To Carburetors

1

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Specifications
Item
Engine Oil: Type Capacity Engine Oil Pump: Oil Pump output
0 3 OOOr/min (rpm), 2 rnrn’

ENGINE LUBRICATION SYSTEM 3-3
Standard
2-stroke. N M M A. Certified for Service TC-WU or TC-W3
3.3 L
– 101 123rnL

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3-4 ENGINE LUBRICATION SYSTEM Oil Pump 0i/Pump Bleeding
Â¥Mak sure that there is plenty of engine oil in the oil tank and that oil flow is not restricted.
Â¥Loose the air bleeder bolt [A] on the oil pump a couple of turns, wait until oil flows out, and then tighten the bleeder bolt securely
*lf the air bubbles remain through the transparent oil inlet hose, follow the next procedure
A: Pressure Bleeding ¥Prepar a container [A] which is soft enough to be squeezed by hand
and also a nozzle suitable for the oil pump bleed fitting. ¥Filthe container with about 100 rnl of the recommended engine oil.
(A)
 ¥ ~ e & o vthe air bleeder bollt [A].

Â¥Loose the oil tank cap. U q e c t oil [A] slowly through the oil pump bleed fitting by squeezing
the container with one continuo~usmotion Do not stop halfway. This amount of oil is sufficient to fill the line from the oil pump to the oil tank, so it can both remove air trapped in the oil pump and expel air
from the line.

!

CAUTION

I

interm~ittentlymay allow air to enter the oil line, causing obstruction o( oil flow and subsequent engine damage.

¥Reinstalthe air bleeder bolt. ¥Tighte ihe oil tan~kcap.

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ENGINE LUBRICATION SYSTEM 3-5
B: Vacuum Bleeding
Ã^Remow the air bleeder bolt [A1
@Attach a hand-operated vacuum pump [B] (like a Mityvac, P/N T96000-001) to the oil pump bleed fitting [C] and draw oil through
the injection pump. ¥Continu to draw oil through the qection system until no more air
bubbles come through the suction line ¥Replac the air bleeder bolt
Reservoir [ D l

Use a 50 :1 mixture of gasoline to oil in the fuel tank in place ot the
gasoline normally used.
Do not turn on the water until the engine is running and turn it off immediately when (he engine slops.
Â¥Suppl the cooling system with water (see Auxiliary Cooling in the General Information chapter)
Â¥Star the engine, keep it at idling speed and check the oil flow through
the transparent outlet hose. tKeep the engine running until any air bubbles in the outlet hoses
disappear.

Of/Pump Performance Test

If a drop in oil pump performance is suspected, check the rate at

which the oil is being pumped

ÃDisconnect the oil pump outlet hoses at the oil inlection nozzle and run

the hoses [A] into a measuring glass [B]

CAUTION

– —

–

For this test use a 50 :1 mixtureot gasoline to oil insteadthe gasoline normally used.

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3-6 ENGINE LUBRICATION SYSTEM

Â¥Suppl the cooling system with water (see Auxiliary Cooling in the General Information chapter).
¥Starthe engine, an~drun it at a steady 3,000 rpm (use a tachometer). ¥Collec 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:

10.1 12.3 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

0-4 check valve is built into the off pump and can not be removed

0/7Pump Removal
@Removethe mounting bolts [A] and take off the oil pump [B] and t,he O-ring.

0;)Pump Installation
Â¥Greas the hole of the connecting shaft, as shown. [A] Grease Hole [B] Oil Pump [C] Connecting Shaft
[Dl Flywheel Bolt
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ENGINE LUBRICATION SYSTEM 3-7
Â¥B sure the O-ring [A] is in place @Injectthe oil into the oil hoses, and then connect the hose to the oil
Pump ¥Instalthe oil pump on the magneto cover
0When mounting the oil pump, note the position of the slot [B] in the connecting shaft, and then turn oil pump shaft [C] so that it will fit into
the slot.
Torque – Oil Pump Mounting Bolts:
8.8 N-m (0.9 kg-m, 78 in-lb)
Â¥Rout the oil hoses correctly (see Cable, Wire and Hose Routing in the General Information chapter)
Â¥Blee the air from the system (see Oil Pump Bleeding)
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3-8 EMGINE LUBRICATION SYSTEM
Oil Tank 0/7 Tank Removal
Â¥Drai the engine oil. Â¥Loose the cla’mpand pull the oil level sensor [A] out of the oil tank. Â¥Tak out the straps.
Oil Tank Cleaning
Â¥Flus the tank repeatedly with high flash-point solvent until it is clean Clean Ifie tank in a well-ventillated 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. Oo not use gasoline or a low flash-point solvent to clean the lank. A fire or explosion could result.
0ifFilter Cleaning
Check the oil filter [A] for foreign particles every time you a~ddthe oil. If there are any foreign particles, the oil filter must be cleaned.
Â¥Tak out the oil filter out of the oil filter
@Washthe oil filter in a non-flammable or high flash-point solvent. Use a brush to remove any contaminates trapped in the filter
Clean the oil filter in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near Ihe working area; this
includes any appliancewith a pilot light. Do not use gasoline or a low
flash-point solvent to clean the filter. A fire or explosion could result.
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EXHAUST SYSTEM 4-1
Exhaust System
Table of Contents
Exploded View …………………………………………………………………………………..4..-..2……… Expansion Chamber ………………………………………………………………………………….4..-..3.
Removal ……………………………………………………………………………………………..4..-.3…. Installation…………………………………………………………………………………………4..-..3….. Expansion Chamber Cleaning and Inspection ……………………………………………4..-..4 Exhaust Manifold ………………………………………………………………………………….4…-.5…… Removal …………………………………………………………………………………………..4..-..5…… Installation ………………………………………………………………………………………..4..-…5….. Exhaust Manifold Cleaning and Inspection ……………………………………………….4..-..5 Water Box Muffler ………………………………………………………………………………..4..-.6…….. Removal …………………………………………………………………………………………4..-.6……… Installation …………………………………………………………………………………………..4…-.6… inspection ……………………………………………………………………………………….4…-.6……..
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4-2 EXHAUST SYSTEM Exploded View
TI : 12 N-m (1.2kg-m, 8.5 n-~b) T2 : 20 N-m (2.0 kg-m, 14.5 1t-lb) T3 :49 N-m (5.0 kg-m, 36 tt-lb) L : Apply a non-permanent locking
agent. SS: Apply silicone sealant.
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Expansion Chamber
Removal
0 Remove or disconnect’ Cooling Hose [ A ] Bypass Hose [ B ] Exhaust Pipe Mounting Bolts [C] Exhaust Pipe [ D l
– Magneto Cooling Hose [El
Cooling Hose (Chamber Hull) [ F ] Connecting Tube Clamps [GI Expansion Chamber Mounting Bolts [ H I Expansion Chamber [I]

EXHAUST SYSTEM 4-3

installation
¥Instalthe expansion chamber [A] on the engine with the pins FBI ¥Appl a lion-permanent locking agent to the expansion chambei
mounting bolts Torque – ExpansionChamber Mounting Bolts:
49 N-rn (5.0 kg-m, 36 fl-lb)
 ¥ F i the gasket [A] so that ‘”UP” mark faces upward Â¥Instalthe exhaust pipe on the expansion chamber. 0Apply a non-permanent locking agent to the exhaust pipe mounting
bolts Torque – Exhaust Pipe Mounting Bolts: 49 N-m (5.0 kg-m, 36 ft-lb)
Â¥Instalthe exhaust pipe with the giasket and apply a non-permanent locking agent to the following bolts and torque them in the following order Torque – (1) Exhaust Pipe Mounting Bolts (Manifold Side): 49 N-rn (5.0 kg-m, 36 ff-lib) [B] (2) Exhaust Pipe Mounting Bolls (Chamber Side): 49 N-~II (5.0 kg-m, 36 ft- lb) [C] Downloaded from www.Manualslib.com manuals search engine

4-4 EXHAUST SYSTEM Expansion Chamber Cleaning and Inspection
¥Remov the expansion chamber (see Expansion Cha~mberRemoval). ¥Scrap any carbon deposits out of the expansion chamber with a
blunt, round-edged tool. Excessive deposits will cause the engine to run poorly. ¥Chec the expansion chamber carefully for cracks Also look for corrosion both inside and out.
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Exhaust Manifold
Removal
Â¥Remov or disconnect. Expansion Chamber (see Expansion Chamber Removal) Exhaust Manifold Mountmg Nuts [ A ] – Inlet Cooling Hose [B] Magneto Cooling Hose (Manifold Magneto Coolinlg Cover) [C] Exhaust Manifold

EXHAUST SYSTEM 4-5

Installation
Â¥Instalt h e exhaust manifold gasket and 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 H-lb)
Exhaust Manifold Cleaning and Inspection
¥Remov the exhaust manifold parts ¥Clea the carbon deposits out of the exhaust passages with a blunt,
roundedged tool ¥Flus foreign matter out of the water passages with fresh water ¥Chec the insides of the water passage for corrosion Check thegasket
surfaces for nicks or other damage * i f there is excessive corrosion or if the gasket surfaces are so badly
damaged that they will not seal properly, replace the part

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4-6 EXHAUST SYSTEM Water Box Mluffler Removal
Â¥Rerno’v the expan~sionchamber (see Expa#nsio’nChamber Remova’l). Â¥Loose the clamp [A] on the exhaust tube and pull off it.
Installation
Â¥B sure the damper [A] is in the position.
Inspection
¥Remov the water box muffler. ¥Empt any water out of the water box ¥Chec 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 Coolmg System Cleaning and Inspection) and the carburetor for proper mixture needle adjustment (see Mixture Screw Adjustment in the Fuel System chapter)
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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 an,d Inspecti’on:……………………………………………………………………5..-7
Compression Measurement…………………………………………………………………..5..-. 7 Cylinder Head Warp Inspectio’n……………………………………………………………..5..-7 Cylinder Wear In8spection…………………………………………………………………….5…-.7 Piston Diameter Measurement………………………………………………………………..5. -8 Piston/Cylinder Clearance………………………………………………………………….5..-..8 Boring an~dHoning …………………………………………………………………………………5-9 Piston Ring, Piston Ring Groove Inspection1…………………………………………….5. -9 ‘iston Ring End Gap …………………………………………………………………………….5..-9
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5-2 ENGINE TOP END Exploded View
Tt : 12 N-m (1.2 kg-m, 8.5 tt-lb) 12: 20 N-m (2.0 kg-mu114.5 ft-lb) T3 : 29 N-m (3.0 kpm, 22 ft-11b)
34 N-m (3.5 kg-m, 25 ft-lb)
Applry a nonl-permanent locking agent.
Apply silicone sealant.
Apply engine oil.
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ENGINE TOP END 5-3

Standard

Service Limit

Cylinder head warp

(‘Usable range)
– – 657 1040 kPa (6.7 10.6 kg/cm2″
– 95 151 psi) (Open throttle)
—

Cylinder, Piston: Cyhnder ~ n s ~ d~eameter F~stondiameter ( I 6 9 mm up from bottom of skil Piston/cyiinder clearance

— 80 000 80.015 mm

07.9183605-

79 880 rnrn
0.140 mm

Clversize piston and rmgs

+0.5 mm and +I .O mrn

P~stunrmg/gr~oveclearance Tap (keystone}
Second (keystone

—
—

P~stonring groove w ~ d h Top (keystone)

—

Second ( k e y s t ~ n ~ – – –

P~stonrung th~ckness:

Top (keystone)

—

P~stonrmg end gap,

Second (keystone TQP Second

—
– 0 2 5 0 4 0 m m – 0.25 0.40 rnrn

Special Tools – piston Pin Puller Assembly: 57003-910
– Piston Ring Compress~rGrip: 570011-1095
Piston Ring Compressor Belt, @W Q79: 57001-1097
C~mpressimGauge: 57001-221 Campressi~nGauge Adapter, M I 4 x 1.25: S D O I -1159

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5-4 ENGINE TOP END ,EngineTop End Disassembly and Assembly: Disassemb/y
@Pullthe bilge hoses out
a Remove:
Spark Ptugs Cable Holder Carburetor Expansion Chamber Exhaust Mantfold w ~ t hCoolmg Hose 8 Remove the engine. @Remove the cylinder head nut {A], and take off the cylinder head
PI.
@Removethe cylinder base nut [A], and I I o~ff the cylinder [ E l .
Stuff dean rags mto the crankcase opening to prevent dirt or foreign objects from falling Into the crankcase.
Remove the piston ptn snap ring [A] with a phers [B] #Remove the ptston by pushmg ~ t sp ~ nout the side that the ctrclip was
removed Use a pston pm pdler assembky [A], ~f the pm IS tight.
Speclat Tool – Plslon Pin Fuller Assembly: 57001-910
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mcarefully spread the ring opening with your thumbs and then push up on the opposlte s~deof the ring [A] to remove ~t

ENGINE TOP END 5-5

Assembly Notes
e i f any parts In the ptston assembhes require replacement#or ~f the cylinder IS honed or replaced, be sure to check the crlt~calclearances of the new parts agamst the values given In Specif~cat~ons
elnstall the plston rlngs so that the “R” mark [A] faces upward as
shown
OWhen ~nstalhngthe plston rfngs by hand, first fit one end of the p~stori ring agalnst the pln In the rlng groove, spread the rmg openmg w ~ t h the o t h e ~hand and then shp the ring into the groove
@Checkto see that the pm [A] In each piston rmg groove IS between the ends of the p~stonrmg.
OUs~ngengme oil, lubr~catethe small end bearlng and insert ~ n t othe connecting rod eye
&Using engine 011,lubr~catethe pkston p ~ annd the pm holes &Mount the piston on the connecting rod w ~ t hthe arrow [B] on ~ t s
crown pomt~ngto the left (exhaust) swde of the englne
Owhen m t a h n g a plston pin snap rmg, compress it only enlough to ~nstal~l t and no mole.
Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.
@ F I a~new p i s m pin snap rlng Into the side of each piston so that the snap rmg openmg [A] does not co~nc~dwebth the shts [B] of the piston p ~ nhole
@Setthe new cvl~nderbase gasket ln place on the crankcase. OThe “UP” mark [A] must face upward.

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5-6 ENGINE TOP END
OApply engvne od to the surface of the p ~ s l o n s ~ OCompress the p l s t ~ nmgs.
– Speciah Tool – Fistan Ring Compressor Grip: 57001-1095[A] Fiston Ring Ccmpressor Belt, @67 W 9 : 57001-I097 WI
mTharoughly 011 the q1rnder bores. @Slide the cylinder block down over the crankcase studs onto the
crankcase.
1 Do nab force the cylinder block. Make sure lhe rings are in posihn.
Olnstal! the cyhnder base nuts.
Torque – Cylinder Base Nuts: 34 N-m(3.5 kg-m, 25 Wb] OThe ttghening sequence numbers are marked on the cyhnder ORace a new c y h d e r head gasket an the cyl~nderhead. OThe “UP” mark [A] of tlhe gasket must face upward and arrow mark
l[E] must face forward.
Oinstal! the cylinder head Torque – Cylinder Head Nut: 29 N-m (3.0 kg-m, 22 fl-lb)
QThe ttghtenmg sequence nu~mbersare marked o n the cyltnder head.
mStart the engme lo heck for fluel and1 ail leaks, exhaust leaks, and
excessive vibration.
I1 1 Do not run the engine in a closed area. Exhaus! gases conmain carban monoxide, a colorless, o d o r l ~ ? ~posi~sonaus gas which can be lethal. maN Do not rum bhe engine without cooling water suplplyfor mare than 15 seconds or severe engine and exhaust syslern damage will occur,
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Maintenance and Inspection:
Cmmpressim Measurement

Thoroughby warm up the en~ifle,while checking tlhat there is no compressm

leakage from around the spark plugs or the cylmder head gasket.

1 1 1

Do not run the engine without cooling water supply far more than 15 seconds r ~ sr evere engine and exhaust system dimage will wcur.

1

9Stap the eflgme.

Remove the spark plugs and screw a comnressm gauge firmly into the spark plug

hole.
Special Tools – Campressbn Gauge: 57001-221 [A] Compression Gauge Adapter, MI4 x 1.25: 57OQl-$159
PI
6Us1ng the starter mator, turn the engine aver w ~ t hthe throttle fully open unt11the compressm gauge stops rismg; the compressfon IS the highest reading obtainable.
a Repeat the measurement for the other twa cyhnders.
– – – Cyhnder Compression(Usable Range] 657 1040 kPa (6.7 10.6 kg/cm2,95 151 psi) (open &rattle)
If the cyl~ndercompress~cm1s higher than the usable range, check the
foN0wmg. 0 Carbon buttdup on the p~skonhead and cylmder head – clean off any
carbon on the plstofl head and cylmder head OCylinder head gasket, cyhnder base gaskets – use only the proper
gaskets The use of a gasket of ~ncorrecth~cknesswdl change the cornpresslon If cyfmder cmpessmn IS lower than the usable range, check the fo~Iow1flg 0 Gas leakage around the cyltnder head – replace the damaged gasket and check the cyiinder head for warp. 0Piston/cyI~n~decrlearance, ptston seizure. O?rstofl rmgs<pston rmg grooves wear.

Cylinder Head Warp Inspection
Lay a stra~ghtedge[A] across the lower surface of the head {B] at several different pomts, and measure warp by lnseflirig a thickness qmge hetween the straightedge and the head.
If warp exceeds the sewlce limit, repair the mamg surface. Replacethe cyl~nderhead if the matxng surface is badly damaged.
Cylinder Head Warp
Service Limit: 0.05 mm

Cyhder Wear hpection
@Inspectthe 1n51deof the tyhnder for scratches and abnormal wear.
*If the cylinder is damaged or badiy worn, replace 11with a new m e . 6Smce there IS a d~fferencein cyhnder wear in dkfferent directloris, take
a SI&-to-slde and a front-to-back measurement a1 each of the 3 locanwms [total of 6 measurements) shown m the hgure.
[ A ] 10 mrm [B] 80 rnm
[C] 35 IYlm

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ENGINE TOP EN0 5-7

5-8 ENGINE TOP END

Â¥*a’Iny 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 measluremeats

Service Limit: 80.10 mm, or more than 0.05 mrn difference

between any two measurements

Piston Diameter Measurement
Â¥Measur the outside diameter [A] of the piston 16.9 rnrn up [B] from the bottom of the piston at a ring angle to the direction of the piston pin.

– Piston Diameter

Standard:

79.865 79.880 rnm

Service Limit: 79.72 mrn

0 If the measurement is less than the service limit, replace the piston

NOTE
I
OAbnormal wear such as a marked diagonal pattern across the piston
skirt may mean a bent connecting rod or a misaligned crankshaft.

P/’ston/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 whenever the cylinder is rebored and oversize pistons installed ¥Th most accurate way to find the piston clearance is by making
separate piston and cylindet diameter measurements and then computing the difference between the two values. ¥Measur the piston diameter as just described, and subtract this value
from the cylinder inside diameter measurement The difference is the piston clearance.
– Piston/Cylinder Clearance 0.130 0.140 mm

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Boring and Honing
When boring and honing a cylinder, note the following OThere are two sizes of oversize pistons available Oversize pistons
require oversize rings Oversize Piston and Rings
0 5 m m Oversize 1 0 rnm Oversize 0Before 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 0Cylinder inside diameter must not vary more than 0 01 m m at any point 0Be wary of measurements taken immediately after boring since the heat affects cylinder diameter 0In 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 an 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
@Visuallyinspect the piston rings and the piston ring grooves
ik If the rings are worn unevenly or damaged, they must be replaced
*It the piston ring groove are worn unevenly or damaged, the piston must be replaced and fitted with new rings

ENGINE TOP END 5-9

Piston Ring End Gap
Â¥Plac 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¥Measur the gap [A] between the ends of the rmg [B] with a thickness gauge
*If the gap is wider than the service limit, the ring is worn excessively and must be replace

Piston Ring End Gap

TOP Second

–Standard
0.25 0.40 mrn
0.25 0.40 mrn

Service Limit
0.70 rnm 0.70 mm

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Engine Removalllnstallation
Table of Contents
Exploded View ……………………………………………………………………………………..6..-..2…… Engine Rem~val/~nsta~lat.i.o..n…………………………………………………………………6..-.3…..
Removal ……………………………………………………………………………………………6..-.3…… Instaliation ………………………………………………………………………………………..6..-..4……
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Ex~plodedView
T I : 16 N-III (? -6 kg*, 11-6ft-lb] T2 :36 N-rn~(3.7 kg-m, 27 fi-lb] T3 :44 N-rn~(4.5 kg-m, 33 fi-lb) L : &ply a non-permanent locking
agent.
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Removal
a Remove or disconnect:
Battery Spark Plug Cap Electr~cCase Connectar [A] Starter Motor Cable [B] Battery (-1 Cabbe [C] Whig Chmps
Expans~onChamber
Cable Holder [ D l
Carburetor
Couph~?gCover
011Inlet Hase
Intake Manifold Exhaust Manrfold Bilge Breather

ENGINE REMOVALLINSTALLATIQN 6-3

OSlide the engine t ~ w a r dthe front to disengage the coupl~ngsa, nd then lift [A] the engme aut of the hull.
@Remavethe engine mounting bolts and separate the engm bed and the engme.
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6-4 ENGINE REMQVAL/lNSTALLATIQN
Installatim
@Besure there are no foreign objects and pa& ~nsideof the hull .Clean the bilge filter (see Filter Cleaning and Inspection in the Cooling
and 51IgeSystems chapter).
@Check the coupiing damper for wear and damage (see Coupling
Damper h s p e c t m in the Engine Bottom End chapter) @Install the engine b d so that the small notches [A] are on the
magneto end of the engine as shown.
*Install the engme in the hullfl ahgning the prqectm-i [A] on the magneto coalmg cover with the prajection [B] bn the bottom of the hull.

@Apply a non-permanent Locking agent 10 the engine bed mounting
bolts, and torque them.
– Torque Engine Mounting Bolts 44 M-rn (4.5 kg-m, 33 ft-lb) Engine Bed Mounting Bofb: 36 N-m 43.7 kg-m, 27 fl-rb]

*Check the gap between the engine bed and the dampers by rockmg
the engine. .If 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 gzwi4707 92025-37W

Thickness t 0.3 mm t 0.5 mfn 11.0 mfn
t1.5m

.After installing the engme rn the hull, check the following.
Throttle Cable Choke Cable 011Pump Bleeding Fuel and Exhaust Leaks

Do not run lhe engine in a closed area. Exhaust gases contain carbon monoxide, a co~orless,odorless, poisonous gas whkh cam be lethal.
WON
Do no1run the engine wM~outc o o h g water supply for more man 15 secondsor severe engine and exhaust system darna~eWIHoccur.

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ENGiNE BOTTOM END 7-1
Engine Bottom End
Table of Contents
E X ~V~ieM w……~…………………………………………………………………………………………7-2 Specifications ……………………………………………………………………………………………7…-.3. Coupling ……………………………………………………………………………………………………..7..-4
Removal ………………………………………………………………………………………………..7..-..4 I n s t a l l a t i a n ……………………………………………………………………………………………7..-..4.. Coupling Damper Inspe~ct~ia.n…………………………………………………………………….7. – 4 Magneto Flywheell ………………………………………………………………………………………7…-5 Remavai …………………………………………………………………………………………………… 7-5 l n s t a l l a t ~ o n…………………………………………………………………………………………………7 – 5 Stator ………………………………………………………………………………………………………..7..-..6 Removal ………………………………………………………………………………………………..7..-..6 lnstal~latim…………………………………………………………………………………………..7…-.7… Crankcase ………………………………………………………………………………………………….7…-.8 Splittikg …………………………………………………………………………………………………7..-..8 Assembly …………………………………………………………………………………………………7..-8 Cralnlkshaft Maintmance ………………………………………………………………………………7. -10 Connecting Rod RendtTwist …………………………………………………………………..7..-10’ Connecting Rod Big End Radial Clearance………………………………………………..7. -11 Con~lnectingRod Big End Side Clearance …………………………………………………… 7-11 Crankshaft Main Bearmg Wear ……………………………………………………………….7..-.11 Crankshaft Runou.~…………………………………………………………………………………7..-12 Crankshaft Assemhfy Specificat~ons………………………………………………………….. 7-12
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7-2 ENGINE BOTTOM END Exploded View

T I : 7.8 N-m (0.8 kg-m, 69 In-Ib)
T2 : 12 N-m (1.2 kg-rn, 8.5 ft-lb) T3 : 29 N-m (3.0 kg-m, 22 ft-lb) T3 : 130 N-m (13.5 kg-m, 98 ft-lb) T5 : 8.8N-rn (0.9kg-m, 78 In-tb)

T6 : 125 N-rn (113.k0g-m, 94 ft-lb)
L : Apply a non-pemanenl locking agent.
M : Apply molybdenum disulfide
grease.

LG : Apply liquid gasket. 0 : Apply oil to the flanged
portion.
SS : Apply silicone sealant. G : Apply grease.

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Specifications

1

Item

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

Standard
1 0115 mm/I 00 mrn

Special Tools – Flywheel Puller, M35 X 1-5: 57001-1223 Rotor Puller, M16/M18/M20/M22x 1.5: 57001-1216
flywheel Holdelr: 57001-1313 Coupling Holde~r:57001-1230
Sealant – Kawasaki Bond (Liquid Gasket-Black): 92104-1003
Kawasaki Bond (Silicone Sealant): 56019-120

ENGINE BOTTOM END 7-3

Service Limit

1

1

0.2mmf 100 mrn

1

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7-4 ENGINE BOTTOM END
Coupling Removal
Â¥Remove Engine (see Engine Removal/Installation chapter) Coupling Damper Magneto Cover
Â¥Holdin the flywheel, unscrew the coupling Special Tools – Flywheel Holder: 57001-1313 [A] Coupling Holder: 57001-1230 [B] Installation
Â¥Appl a thin coat of silicone sealant to the couplin~gthreads Sealant – Kawasaki Bond (Silicone Sealant): 56019-120
Â¥Scre the coupling onto the crankshaft and tighten it.
Torque – Coupling: 125 N-m (13.0 kg-rn, 94 ft-lb)
Coupling Damper Inspection
Â¥Wit the engine removed, remove the coupling damper and inspect it for wear [A] and deterioration.
lf it is g8roovedor misshapen, replaced it with a new damper. If there is a~nydou~bat s to coupler condition, replace it.
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Magneto Flywheel

– ~

– —

R emo val
Â¥Remove Engine Magneto Cover
(Holding the flywheel, remove the flywheel bolt.
Special Tool – FlywheelHo~lder:57001-1313 [A]

@Pullthe flywheel off the cran~kshaft. 0 Prepare the bolt [A] as shown.

ENGINE BOTTOM END 7-5

~

~

p – p p p p p –

—

– – – – -~ —

OUsing the special tools, pull off the flywheel.
Special Tools – Rotor Puller. M16!M18/M20/M22 x 1.5: 57001-1216
[A1 Flywheel Pullelr, M3S X 1.5: 57001-1223 [B]

–

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7-6 ENGINE BOTTOM END

Removal

Â¥Remov the electric case connector [A], and disconnect the connec-

tors.

&

Â¥Remov Magneto Cover [A] (see Magneto Flywh~eeRl emoval)

Â¥Slid the pins out of the connectors.
0 Use a screw driver [A] to depress the pin latches

Â¥Unscre the grommet cap [A] from the electric case connector

Â¥Pulthe leads, one at a time, through the grommet and cap.
0 Lubricate the grommet with a penetrating rust inhibitor.

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ENGINE BOTTOM END 7-7

Installation
Â¥Coathe grommets [A] with water resistant grease
Â¥Inserthe connector pins onto the connector, as shown.

Â¥Whil pushing the pickup coi’lbracket [A] as shown, install the pickup coil [El],

Pickup Coil Air Gap

– (Clearance between the rotor projection and pickup core)

Standard:

0.8 1.0 mm

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7-8 ENGINE BOTTOM END
Crankcase Splitting
¥Remov the engine (see Engine Removal/Installation chapter) ¥Remov the following from the engine.
Starter Motor Cylinder Head Cylinder Block Pistons Oil Pump Coupling Magneto Flywheel Reduction Gear
NOTE
OAiways remove the coupling before removing the magneto flywheel, or there won’t be any way to hold the crankshaft white unscrewing the coupling

Remove the 6 mrn crankcase bolts [A] first and the 8 rnm bolts [B].

Â¥Ta [A] with a soft hammer to spirt the crankcase halves apart, and then remove the lower crankcase half.
Â¥Lifthe crankshaft assembly out of the upper crankcase half
Assembly
Â¥Visuall inspect the crankshaft O-ring [A], and replace i t if necessary.
Â¥Greas the inner surface of the collar [B].
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ENGINE BOTTOM END 7-9
@Installthe oil seals as shown Double Lips Seals [A] Single Lip Seals [ B ] ¥Plac the crankshaft assembly [A] in the upper crankcase half so that the position ring [B] on the crankshaft a,ssemblyfits into the groove
[C]in the crankcase.
¥Chec that the knock pins [A] are in place, ¥Wit a high flash-point solvent, clean off the mating surfaces of the
crankcase 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 ctankcase bolts, and tighten them
Torque – Crankcase M8 Bolts: 29 N-m (3.0 kg-rn, 22 (t-lb)
Crankcase M6 Bolts: 8.8 N-rn (0.9 kg-m, 78 in-tb) OThe tightening sequence numbers are marked on the lower crankcase
half
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7-10 ENGINE BOTTOM END
Crankshaft Maintenance
The crankshaft changes the reciprocating motion 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 intermtttent force on the piston and will result in not only rapid crankshaft bearingwear, 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 11srequired. If crankshaft components become damaged or worn, the entire cra~nkshaftshould be replaced as an assembly, or rebuilt by a properly equipped shop

Connecting RodBendf Twist
0Set the crankshaft in an alignment jig or in V blocks on a surface plate 0Select an arbor of the same diameter as the connecting rod small end
and at least 100 mrn long, and insert the arbor through the connecting rod smatt 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 a I OOmm lengtlh to determine the amount of connecting rod bend.
*if connecting rod bend exceeds the service limit, the connecting rod or crankshaft must be replaced.

Connecting Bend

Standard:

Under 0.05/100 rnm

Service Limit: 0.2/100 mm

Â¥Measur connecting rod twist. 0 With the crankshaft still in the alignment jig, hold the connecting rod
horizontally and measure the amount that the arbor valries from being parallel with the crankshaft over a 100 length of the arbor to determine the amount of connecting rod twist.
*If connectihg rod twist exceeds the service limit, the connecting rod or crankshaft must be replaced.

Connecting Rod Twist

Standard:

Under 0.15fl00 mm

Service Limit 0.2/100 mrn

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ENGINE*BOTTOM END 7-11

Connecting Rod Big End Radial Clearance
Â¥Chec big end radial cl~earance OSet the crankshaft in an alignment yg or on V blocks, and place a dial
gauge against the connecting rod big end. OPush the connecting rod ftrst towards the gauge and then in the
opposite direction The difference between the two gauge readings is the radial clearance
*lIf the radial clearance exceeds the service limit, the crankshaft assembly
must be replaced or disassembled and the crankpin, needle beanng,
and connecting rod big end examined for wear

– ConnectingRod Big End Radial Clearance

Standard:

0.018 0.030mm

Service Limit: 0.080 rnm

Connecting Rod Big End Side Clearance
e Measure big end side clearance [A].
OInset-t feeler gauges between the big end and either crank half to determine clearance.

• l f 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 mrn

Service Limit: 0.8 mrn

Crankshaft Main Bearing Wear
Â¥Was the bearings in high flash-point solvent, blow them dry (DO NOT SPIN THEM), and lubricate them with engine oil

CAUTION

I

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/cm2,

25 psi) maximum nozzle pressure.

I

Â¥Tur each bearing over by hand and see that it makes n o noise, turns smoothly, and has no rough spots.
if if any of the bearings are defective, replace them.

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7-12 ENGINE BOTTOM END

Crankshaft Runouf
@Checkcrankshaft ahgnment by measuring runout 0W1ththe crankshaft on V blocks [A], rotate the crankshaft slowly and
measure runout at each o f the locat~onsshown
*If the runout at any pomt exceeds the sewce hm11,the crankshaft must
be either replaced or rebu~h

Crankshaft Runou! (Either Location)

Standard:

Under 0.04 rnm TIR

Service Limit: 0.10 rnm TiR

Crankshaft Assembly Specificatiom
If the crankshaft IS dtsassembled, use these spec~f~cat~odnws n g
rebuddmg

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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 Instaliation ……………………………………………………………………………….8…-.3. Breather Cieaning and Inspection………………………………………………………….8…-.3… Filter Removal ……………………………………………………………………………………….8…-.3. Filter Clearing and Inspection………………………………………………………………….8..-.3. Cooling and Bilge System Hoses………………………………………………………………….8..-.4 Hose Removal………………………………………………………………………………………..8..-.4. Hose 1nstaNatic.m …………………………………………………………………………………….8..-..4 Hose lnspecti~on………………………………………………………………………………….8..-..4…. Coding and Bilge System Flushing ……………………………………………………………..8..-.5. Cooling System Flushing …………………………………………………………………………8..-.5 ‘BilgeSy3tet-n Rushing ……………………………………………………………………………..8…-5
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8-2 COOLING AND BILGE SYSTEIMS
Exploded View T I : 7 2 W m (1.2 kg-m, 8.5 R-Rb] L : Apply a non-permanent !aching agent.
SS: Apply silkone seajant.
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6ilge System

COOLING AND BILGE SYSTEMS 8-3

Breather Rwnovai
*Pull the hoses [A] off fhe breather

Unscrew the mountmg bolt [B]#and remove the breather [C].

A] in the b~eafhwIS open before mnstalltn~g~ t . *Apply a non-permanent Iockmg agent to the bmather mauntnng bolt
and t~ghten~ t .

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8-4 COOLING AND BILGE SYSTEMS – —
Cooling and Bilge System iioses
Hose Rernova/
@Noneof the bilge system hoses has a clamp To remove t h ~ shose, remove the f~lter(see F~lterRemoval). The bilge system hoses may be simply pulled off their fitt~ngs.
@All the coohng system hoses are clamped at both ends. Loosen the clamps and pull the hoses ojf.
Hose /nsta//ation
@Toinstall the bdge filter hose, push the hase over the end of the fher @Whenmstalling the caoling system hosesbe sure to use the same k m l
of clamp as the original. Some of the clamps are metal for t~ghter clamping a M t y (required when smooth fittings are used) Plastkc damps are used where t ~ g hct lamping IS not requtred.
Hose Inspection
@Check the hoses for hardening, crack~ngc~hecking, cuts, abrasions, and breaks.
If a hose is damaged In any way, replace I! mrnediately and check all the others for damage.
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Coolin,g and Bilge System Flushing

COOLING AND BILGE SYSTEMS 8-5

Cookng 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, 0 1 whenever
there is reduced1water flow from the bypass outlet on the left side of the
hull #Remove the fitting cap [A] on the cylinder head

Â¥Connec a garden hose [A] to the fitting.

Start the engine and allow it to idle before turning on the water.

1

CAUTION

1

The engine must be running before the water is turned on or water
may flow back through the exhaust pipe into the engine, resulting in
the possibility of severe internal damage.

Â¥Immediatel turn on the water an adjust the fllow so that a little trickle of water comes out of the bypass outlet [A] on the left side of the hull.

Â¥Lef the engine idle for several minutes with the water running. #Turn off the water Leave the engine idling #Rev the engine a few times to clear the water out of the exhaust
system.

1

CAUTION

Do not run the engine without cooling water supply for more than 15 seconds or severe engine and exhaust system damage will occur.

Switch off the engine, remove the g~ardenhose, install the fitt~nqcap.

M g e System Flushing
To prevent clogging, the bilge system should be flushed out accord-
ing to the Periodic Maintenance Chart, or whenever you suspect it is
blocked @Disconnectboth bilge hoses at the plastic breather fitting [A].

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8-6 COOLING AND BILGE SYSTEMS
Â¥Connec the bilge fitter 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.
Â¥Connecthe other hoses (from the hull bulkhead) to the garden hose, turn the water on, and flush it out for several minutes.
Â¥Befor reconnecting the hoses to the plastic breather fitting make sure the small hole [A], o n top of the breather fitting is clear
Â¥Reconnec the bilge hoses.
DIRECTION OF COOLING SYSTEM FLOW
0DIRECTION OF BILGE SYSTEM FLOW
@.J DIRECTION OF COMBINED EXHAUST A N D COOLING WATER FLOW
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DRIVE SYSTEM 9-1
Drive System
Table of Contents
Exploded View ………………………………………………………………………………………….9…-.2 Specifications ……………………………………………………………………………………………9..-.3. Drive Shaft/Drive Shaft Holder………………………………………………………………………..9-4
Drive Shah Remnval/tnstallatinn ……………………………………………………………….9-4 Drive Shaft Holder Rernoval/Disassem~bly…………………………………………………..3 – 4 Drive Shaft Holder A<wrnbly/lInstallation ……………………………………………………..9-5 Drive Shaft Runout…………………………………………………………………………………… 9-5
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9-2 DRIVE SYSTEM
Exploded View
T I : 39 N-m (4.0kg-m, 29 It-lb) T2 : 22 N-m (2.2kg-m, lI6.0fi-Ib) L : Apply a non-permanent locking agent. G : Apply grease.
ss: Apply silicone sealant.
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S ~ e c icf ations

Item
Drive Shaft: Runout (Refer to Page 6)

Standard
[A] less tha~n0.1 mrn [B] less than 0.2 mrn

Special Tools –

Coupling Holder: 57001-1230
Drive Shaft Holder: 57001-1327 Drive Shaft Holder Adapter: 57001-1231
Bearing Driver Set: 57001-1129

Sealant – Kawasaki Bond (Silicone Seallant): 560119-120

DRIVE SYSTEM 9-3
Service Limit 0.2 rnm 0.6 mrn

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9-4 DRIVE SYSTEM
Drive Shlaft/Drive Shaft Holder Drive Shaft RemovalIInsta//a/ion
¥Remov the engilne (see Engine Removal/Installation chapter). ¥Pulthe drive shaft [A] out of the hull.
Â¥Clam the drive shaft, and unscrew the coupling. Special Tools – Coupling Holder: 57001-1230 [A] Drive Shaft H~ollder:57001-1327 [B] Drive ShaH Holder Adapter: 57001-1231 [C] Â¥Whe installing the drive shaft, be careful of the following items. 0Apply a thin coat to the coupling threads and tighten it.
Sealant – Kawasaki Bond (Silicone Sealant): 56019-120 Torque – Couplling: 39 Him (4.0 kg-m, 29 It-lb) CApply grease to the grease seal lips and the drive shaft spline
Drive Shaft Holder Removaf/Disassernbly
Â¥Remov the drive shaft. Â¥Unscre the rnountin’g bolts [A] and remove the drive shaft holder
[B] from the bulkhead.
 Disassemble the drive shaft holder. 0Remove the circlip [A].
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–

0Press the small grease seal, and the large grease seals, bearing, and small grease seals come out of the holder

I

[A] Sleeve
[B] Blocks

DRIVE S Y S T E M 9-5
Press

Drive Shaft Holder Assembly/Installation
(Replace the grease seals with new ones ¥Pres the bearing and grease seals into the drive shaft holder, noting
the following 0Install the parts in this order
T w o Small Grease Seals [A] One Bearing [B] Two Large Grease Seals [C] Special Tool – Bearing Driver Set: 57001-1129
0Install the seals so that the sides with the spring face outward
0 Fill the gaps between the seals with grease [Dl.
¥Instalthe circlip ¥Greas to the bearing inner surface and grease seal lips

Â¥Instal the drive shaft holder on the bulkhead so that the circlip side face toward the front.
Â¥Appl a non-permanent locking agent to the drive shaft holder mounting bolts, tighten them loosely
Â¥Instalthe drive shaft (After installing the engine, tighten the drive shaft holder mounting
bolts to the specified torque to give proper coupling alignment.
Torque – Drive Shaft Holder Mounting Bolts: 22 N-m (2.2 kg-m, 16.0 ft-lb)

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.
Â¥Tur the drive shaft slowly The difference between the highest and lowest dial gauge reading is the runout
Â¥*’Iany measurement exceeds the service limit, replace the shaft.

Drive Shaft Runoul

Standard:

Less than 0.1 mm [ A ]

Less than 0.2 mrn [B]

Service Limit: 0.2 rnm [ A ] 0.6 rnm [B]

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9-6 DRIVE SYSTEM
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PUMP AND IIMPELLER 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 lnstallatio~n.,……………………………………………………………………………………1. 0 ‘ 5

Pump Disassembly …………………………………………………………………………………..10-86

Pump Assembly ………………………………………………………………………………………. 10-7

Pump and Impeller Inspection ………………………………………………………………….. 10-9

Impeller Clearance …………………………………………………………………………………. 10-10

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10-2 PUMP AND IMPELLER
3.9 N-m (0.4 kg-m, 35 in-lb) 19 N-m (1.9 kg-m, 13.5 tt-lb) 22 N-m(2.2 kg-m, 16.0 It-lb) 98 N-~B(1I 0.0 kg-m, 72 Wb) 7.8 N-FD(0.0 kg-m, 69 in-lb) Apply a non-permanent locking
agent. Apply grease. Apply silicone sealant.
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PUMP AND IMPELLER 10-3

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

Standard
– 147.5 147.7 mrn
– 148.0 148.1 mrn
– 0.15 0.3mrn

Special Toots – Impeller Wrench 57001-1228
Impeller Holder: 57001-1393 Oil Seal & Bearing Remover 57001-1058 Bearing Driver Set: 57001-1129
Sealant – Kawasaki Bond (Silkme Sealant): 56019-120

Service Limit
146.5 rnm 149.1 rnm 0.6mrn

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10-4 P U M P AND IMPELLER Pump and Impeller Pump Removal
@Turnthe craft on its left side. ¥Unscre the mounting bolts [A], and remove the pump cover [B].
¥Sli the cable connectors [A] off the ball ¥Loose the clamp, and pull off the hoses [B] ¥Unscre the pump mounting bolts [A]. ¥Slidthe pump to the rear to disengage the drive shaft, and remove ii
from the hull.
¥T remove the pump bracket, remove the following. ¥Remov the nut [A] and washer [B] in the hull
Â¥Remov the grate.
Â¥Unscre the pump bracket mounting bolts [A] Downloaded from www.Manualslib.com manuals search engine

PUMP AND IMPELLER 10-5
Pump installation
Â¥Stri 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 hulll. ¥Instalthe pump bracket, and wipe off any excess sealant and smooth
the joint.
(A)
@Besure trim seal [A] is in place. ¥Greas the splines on the drive shaft with water resistant grease, and
be sure the O-ring is in place inside the pump shaft.
a Installl the pump case [A]. Torque – Pump Mounting Bolls: 22 N-m (2.2 kg-m, 16 ft-lb)
@ Instdl the pump cover. OApply a non-permanent locking agent to the pump cover mounting
bollts and torque them. Torque – Pump Cower Mounting Bolls: 7.8 N-m (0.8 kg-m, 69 in-lb) Â¥T install the grate to the hull, be sure the trim seal [A] is in the position. eApplly a non permanent locking agent to the grate mounting bolts and tighten them with washers.
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10-6 PUMP AND IMPELLER Pump Disassembly
Â¥Unscre the mounting bolts [A], and remove tho steering nozzle [B] and tilt ring [C].
@Unscrewthe cap bolts [AJ,and remove the pump cap [ B ] ¥Hol the shaft in the impeller holder, taking care not to damage it Remove the impeller from the pump shaft and then pull out the pump shaft
Special Tools – Impeller Holder: 57001-1393 [A] Impeller Wrench: 57001-1228 [B] Downloaded from www.Manualslib.com manuals search engine

Â¥Pulout the bushing [A].

PUMP AND IMPELLER 10-7

Â¥Remov the grease seals. Special Tool – Oil Seal & Bearing Remover: 57001-1058 [A] Pump Assembly
Â¥Befor installing the pump bearings, blow any dirt or foreign particles out of the pump case with compressed air.
Unstalt new bearings.
Special Tool – Bearing Driver Set: 57001-1129
0 Press the rear pump bearing into the pump case as far as it will go. 0Insert the collar and install the front pump bearing.
Â¥Replac the grease seals with new ones, if necessary, and install them using the same special tool used for bearing installation.
0Press each seal into the pump case so that the side with the spring faces outward. Fill the gap between the seal with grease.
¥Pus the bushing into the pump case. ¥Visuall inspect the pump shaft 0-rings, and replace them if necessary. @Greasethe pump shaft and insert it from rear of the pump case. ¥Scre on the impeller.
Torque – Impeller: 9B N-m(10.0 kg-m, 72 ft-lb)

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10-8 PUMP AND IMPELLER
Â¥Whe installing the grease seal, follow this procedure.
0 Press the grease seal [A] into the impeller [B], aligning the seal teeth
[C]with the sleeve teeth [Dl.

OTo protect the seal teeth from damage, insert a suitablle collar [A] that is longer than the non-splined length including the spline starting area into the impeller wrench [B].
– Special Tool Impeller Wrench: S 7 W -1228
0 Insert the grease seal fC] deeply into the impeller wrench, aligningthe seal teeth with the wrench teeth.
OPush the above wrench assembly into the impeller [A], and then lightly press the wrench assembly to seat the grease seal into the impeller sleeve [B] . CAUTION
Do not press the grease seal heavily. You could damage the grease
seal.

PRESS
0

Â¥B sure the O-ring [A] is in place on the pump cap
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Â¥Instal Pump Cap Pump Outlet Steering Nozzle
Â¥Appl a non-permanent locking agent to the thread of the following. Pump Cap Bolts Pump Outlet Mounting Bollts Steering Nozzle Pivot Bolts
Torque – Steering Nozzle Pivot Bolts: 9.8 N-m (1.0kg-m, 87 in-lb)

PUMP AND IMPELLER 10-9

Pump and Impeller Inspection
Examine the impeller.
*If there is pitting [A], deep scratches [BL nicks [C] or other damage,
repllace the impeller
NOTE
0Minor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing. Smooth leading edges are especially important lo avoid cavitatmn

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

Impeller Outside Diameter

Standard:

147.5 – 147.7 mrn

Service Limit: 146.5 mm

Â¥Examin the pump case [A]. Â¥*’Ithere are deep scratches inside the pumlp case, replace it

0Measure the inside diameter of the pump case. *If the pump case is worn beyond the service limit, replace it

– Pump Case Inside Diameter

Standard:

148.0 148.1 mm

Service Limit: 149.1 mm

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10-10 PUMP AND IMPELLER

/mpe//er Clearance
@Impeller clearance is critical t o proper performance. If the pump case
and impeller are not visibly damaged, poor performance may be caused by too much impeller clearance. ¥T check impeller clearance, remove the grate and insert a feeler gauge
[ A ] between the tip of the impeller blade [B] and the pump case

– Impeller Clearance

Standard:

0.15 0.3 m m

Servke Limit: 0.6 mm

*If impeller clearance is incorrect, determine if it is due to wear or damage (see Pump and Impeller Inspection).

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STEERING 11-1
Steering
Table of Contents
Explloded View …………………………………………………………………………………………..1..1-2 Steering Cable/Trim Cable…………………………………………………………………………….11-3
Steering Ca.ble Adjustment ……………………………………………………………………….1.1-3 Trim Cable Adjustment …………………………………………………………………………….1. 1-3 Steering Cable Remloval………………………………………………………………………….1..’1-4 Steering Cable Installation………………………………………………………………………1…1-5 Trim Cable Removal ……………………………………………………………………………….1..1-5 Trim Cable Installation ……………………………………………………………………………..1.1-7 Steering Cable and Trim Cable Inspection ………………………………………………….11-8 Steering and Trim Cable Lubrication …………………………………………………………1.1-8 Handlebar …………………………………………………………………………………………………..1. 1-9 Rem~ova.l…………………………………………………………………………………………………11-9 Installation……………………………………………………………………………………………..1..1-9 Steeriing …………………………………………………………………………………………………..1..1’-11 Removal ……………………………………………………………………………………………..1…1- 11 Installation…………………………………………………………………………………………….1. 1- 12
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11-2 STEERING Exploded View
T I : 3.9N-rn(0.4 kg-rn, 35 in-lb) T2: 16 N – m (1.6 kg-rn, 11.5 ft-lb)
– T3: 39 N-m (4.0 kg-m, 2Q ft.lb)
14 : 39 49 N-m (5-6 kg-m, 29-36 ft-lb) T5 : Hand-Tighten
L : Apply a non-permanent locking agent.
G : Apply grease. B : Apply a bonding agent.
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Steering Cableflrirn Cable Steering Cable Adjustment
Â¥Chec steennq cable adjustment 0Center the handlebar in th~estraight-ahead posit~on
Â¥Chec that the steering nozzle IS centered [A] in the pump cavity.

STEERING 11-3

Â¥I necessary adjust the steering cable 0 Loosen the locknut on the steering cable. 0 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 p i n t on the cable to adjust the steering 0Connect the ball pint and check cable adjustment again 0When1adjustment is correct, tighten the steering cable locknut.
Trim Cable Adjustment
Â¥Chec trim cable adjustmemt. 0Turn the ignition switch ON 0Adjust the trim switch [ A ] until the trim meter needle [B] points the
level position [C]

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11-4 STEERING
Â¥Measur the distance from the pump outlet end to steering nozzle end at the upper and lower locations as shown.
 Check the both distances [A] are salme.
 ¥ I necessary adjust the till cable. 0 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 tilt angle. 0Connect the ball joint and check cable adjustment again. OWhen adjustment is correct, tighten the tilt cable locknut

Turn the ignition switch OFF.

Steering Cable Removal
¥Remov the battery and battery case. ¥Disconnec the ball joint at each end of the steering cable. 0Slide the outer sleeve [A] away from th~eball slightly, and lift the cable
from the ball.
CAUTION
1 1 Never lay the watercrati on the right side. Water in the exhaust system may drain back into the engine, causing serious damage.
0Loosen the locknut [q,and then remove the ball j,oint [B] and
locknut from each cable end.
Â¥Disconnecthe steering cable from the holder. 0Unscrew the mounting bolts [A], and remove the holder [BJ
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STEERING 11-5
¥Remov the pump (see Pump Removal in the Pump/lmpeller chapter). ¥Disconnec the steering cable from th~efitting at the rear of the hull. 0Un1screwthe large nut [A] while holdingthe fitting [B] in the hull with
a wrench.
0Slide off the E-ring [A], washer [B], and O-ring [C]. ¥Pulthe cable from the cable detent in thle engine compartment. ¥Pulout the steering cable toward the front.
Steering Cable instailation
Â¥Lubricat the outside of the new cable to ease cable instaillation.
– Â¥Torque
Torque Steering Cable Nut: 39 N-m (4.0 kg-m,29 ft- lb)
@Adjustthe steering cable (see Steering Cable Adjustment).
Trim Cable Removal
Â¥Remove Arrester Case Battery and Battery Case Trim Motor Box Mounting Bolts [A] Downloaded from www.Manualslib.com manuals search engine

11-6 STEERING
¥Tur the craft on its left sisde. ¥Remov the pump cover. ¥Disconnecthe trim cable ball joint. ¥Unscre the cable nut [A] while holding the fittings [B] with a
wrench.
Â¥Slid off the E-nng [A], washer [B]and 0-ring [ C ] .
Â¥Pulout the cable with the trim motor box [A].
Â¥Unscre the cable nut [A] and slide off the E-iring [B], washer [C] and ‘O-ring [Dl.
@Remove the trim motor box cover.
ÂRemove the trim angle sensor [A].
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STEERING 11-7
@Disconnectthe trim cable [A] from the lever [B] Trim Cable Installation ¥Tur in the locknut [A] to about 7 mrn distance [B] of the rod thread.
@Apply a non-perrnanent locking agent to the motor assembly mounting bolts and the trim angle sensor mounting screws.
Â¥Positio the rubber boot [A] over the trim cable seal and tighten the clamps securely.
@Adjustthe trim cable (see Trim Cable Adjustment).
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11-8 STEERING
Steering Cable and T r h Cabk Inspection e Examine the steering cable and trim cable.
If the cable or cable hous~ngis kinked or frayed replace the cable
Lf the seal [A] at either end of the cabk is damaged in any way, replace the cable.
@Check the rubber boot [A] on the t111cable for hardening, cracking, checking, cuts, abrasions, and breaks.
If a boot IS damaged in any way, replace 11immediately.
Be certain that the cabbe moves freely I~Iboth d~rections 0 Disconnect the ball joint at each end of the cable OSIide the outer sleeve [A] away from the ball slightly, and 11tthe cable
from the balk
1 1 Never lay the watercraft on the right side. Water in the exhaust
I system may drain back inlo the engine causing serious damage.
OSlide the inner cable back and forth in the cable housing. *If the cable does Rat move freely, replace it.
Steering and Trim Cab/eLubrication NOTE
0The steering and trim cables are sealed at each end and do not
require lubricatiot~. If the seals are damaged, the cable must be repJaced,
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Handlebar

STEERING 11-9

@Takeout the throttle case clamp scpews and remove the throttle case [A1
@Takeout the switch case clamp screws m d remove the switch case [Bl.

/nsta//atj~n
Apply a non-permanent Iacktng agent ta the handlebar clamp bolts. @Installthe haodebar on the holders of the steering neck with clamp
bolts.
Align the punch mark [A] on the left side of the handlebar with the center of the gap [RJ between the left holder and clamp.
@Tightenthe front and then rear handlebar clamp bolts to the specisfied torque. Torque – Handlebar Clamp Bolts: 16 N-m (1.6 kgm, 11.5 8-lb)
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11-10 STEERING
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Remaval
Wiemove the handlebar (see Handlebar Remoital),
*Unscrew the mounting bolts [A],[I31 andl take out the steering cover.

STEERING 11-11

Disconnect. Steering ‘Cable Connector Retwn Spring
Unscrew the ~rnountingbolts [A] and ternmoutehe steering nle& [ H I .
ORemove the cotter pin [A] and locknut [B] @Take out the holder LC]

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I 1-d2 STEERING
a Remove:
Grommet [A] Vent Hase Throttle Cable Choke Cable Start/Stop Switch Leads Fuel Tap Control Cables
O h s c r e w the mountmg bolts [A] and remove the steermg holder [B] /nsta//aYbn OCheck the bushings for damage and wear.
*If the bushmgs are damaged or worn, replace them. 0 Grease
Bushings [A] Steermg Shaft [B] .Be sure the grommet [A] IS installed alround the washer [B] Downloaded from www.Manualslib.com manuals search engine

¥Clea the mating surfaces of the steering holder and hull ¥Coa the steering holder bottom with silicone sealant [A], and fit the
steering holder to the hull
Sealant – Kawasaki Bond (Silicone Sealant): 56019-120
Â¥Appl a non-permanent locking agent to the steering holder mounting bolts and torque them Torque – Steering Holder Mounting Bolls: 16 N-m (1.6 kg-rn, 11.5 ft-lb)
Â¥Instal the steering shaft [ A ] into the steering holder [B] and hand
tighten the nut [C].

STEERING 11-13

Â¥Appl silicone sealant [A] around the grommets, as shown

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HULL/ENGINE HOOD 12-1
HullIEngine Hood
Table of Contents
Exploded View ……………………………………………………………………………………………1. 2-2 Fittings ……………………………………………………………………………………………………….1. 2-4
Hatch Cover Rernoval/Installation …………………………………………………………….. 12-4 Rear View Mi.rror Rernoval/Installation………………………………………………………. 12-4 H d l Replacelment………………………………………………………………………………………..1.2-5 R.ubber Parts……………………………………………………………………………………………….12-6 Rubber parts Location ……………………………………………………………………………..1. 2-6 Front Bumper Remaval/Installation …………………………………………………………… 12-7 Rear Bumper Rem~oval/Insta~llatio..n…………………………………………………………..12-7 Side Bum8perRemoval ……………………………………………………………………………… 12-8 Side Bumper Installation ………………………………………………………………………….. 12-8 Air Intake Du~ctInstalliationl……………………………………………………………………….’.I 2-9 Kawasaki Air Induction System (KAIS) Inspection……………………………………..1. 2-9
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12-2 HULL/ENGINE HOOD
Exploded View L : Apply a nowpermanent locking
agent. SS : Apply silicone sealant.
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HULL/ENGINE HOOD 12-3
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12-4 HULL/ENGINE HOOD
Â¥Tak out the bolt [A] and remove the hatch cover [B] Rear View Mirror Removal//nsta/lation
Â¥Remov the steering cover mounting bolts [A], [ B”) Â¥Li,ftin the steering cover [A], unscrew the mirror mounting bolts
PI.
Â¥Remov the mirrors.
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Hull Replacement
To replace the hull, remove the various parts in the following
suggested order Battery and Pad Air Intake Ducts Oil Tank Electric Case Exhaust Pipe, and Expansion Chamber Carburetor and Fuel Filter Engine and Mounts Walter Box Muffler Drive Shaft and Shaft Holder Steering Cover Fuel Tank and Filler Fuel Tap Choke Assembly Pump and Hoses Steering Cable Tilt 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 ( i f any)
If the new hull is to be painted, do that first

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