Kawasaki JET SKI ULTRA LX User manual

ULTRA LX

JET SKI

®

Watercraft

Service Manual

is a trademark of Kawasaki Heavy Industries, Ltd. registered in U.S.A., Japan,

Austria, Benelux, Sweden, Denmark, Switzerland, France, Canada, Finland, Norway, Greece, Italy,

U.K., Portugal, Thailand, and Taiwan.

KAWASAKI JET SKI

®

is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.

This quick reference guide will assist

you in locating a desired topic or pro-

cedure.

•Bend the pages back to match the

black tab of the desired chapter num-

ber with the black tab on the edge at

each table of contents page.

•Refer to the sectional table of contents

for the exact pages to locate the spe-

cific topic required.

Quick Reference Guide

General Information 1

j

Periodic Mainte nance 2

j

Fuel System (DFI) 3

j

Engine Lubrication System 4

j

Exhaust System 5

j

Engine Top End 6

j

Engine Removal/Installation 7

j

Engine Bottom End 8

j

Cooling and Bilge Systems 9

j

Drive System 10

j

Pump and Impeller 11

j

Steering 12

j

Hull/Engine Hood 13

j

Electrical System 14

j

Storage 15

j

Appendix 16

j

ULTRA LX

JET SKI

®

Watercraft

Service Manual

transmitted in any form or by any m eans, electronic mechanical photocopying, recording or otherwise,

without the prior written permission of Quality Assurance Division/Consumer Products and Machinery

Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible

care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation

to make such changes to products manufactured previously. See your JET SKI

®

watercraft dealer for the

latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time

of publication. Illustrations and photographs in this publication are intended for reference use only and may

not depict actual model component parts.

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center mmeter(s)

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

°C degree(s) Celsius r revolution

DC direct current rpm revolution(s) perminute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet Vvolt(s)

ggram(s) Wwatt(s)

h hour(s) Ω ohm(s)

Lliter(s)

COUNTRY AND AREA COD ES

AT Austria DE Germany

CA Canada GB United Kingdom

CAL California US United States

CH Switzerland WVTA Whole Vehicle Type Approval

MAINTE NANCE AND ADJUSTMENTS

Maintenance, replacement, or repair of the emission control devices and systems may

be performed by any marine Sl engine repair establishment or individual.

EMISSION CONTROL INFORMATION

Fuel Information

THIS ENG INE IS CERTIFIED TO OPE RATE ON UNLEADED REGULAR GR ADE GASOLINE

ONLY.

A minimum of 87 octane of the antiknock index is recommended. The antiknock i ndex is posted

on service station pum ps.

Emission Control Information

To protect the environment in which we all live, Kawasaki has incorporated an exhaust emis-

sion control system in compliance with applicable regulations of the United States Environmental

Protection Agency.

Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust

of this engine. The fuel, ignition and exhaust systems of this engine have been carefully de-

signed and constructed to ensure an efficient engine with low exhaust pollutant levels.

Maintenance

Proper maintenance and repair are necessary to ensure that watercraft will continue to have

low emission l evels. This Service Manual contains those maintenance and repair recommenda-

tions for this engine. Those items identified by the Periodic Maintenance Chart are necessary

to ensure compliance with the applicable standards.

Tampering with Emission Control System Prohibited

Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering

inoperative by any person other than for purposes of maintenance, repair, or replacement, of

any device or element of design incorporated into any new engine for the purposes of emission

control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use

of the engine after such device or element of design has been removed or rendered inoperative

by any person.

Among those acts presumed to constitute tampering are the acts listed below:

Do not tamper with the original emission related parts.

* Digital Transistor Ignition System

* Fuel Pump

* Spark Plugs

* Throttle Body and Internal Parts

* Fuel Injectors

*ECU

Foreword

This manual is designed primarily for use by

trained mechanics in a properly equipped shop.

However, it contains enough detail and basic in-

formation to make it useful to the owner who de-

sires to perform his own basic maintenance and

repair work. A basic knowledge of mechanics,

the proper use of tools, and workshop proce-

dures must be understood in order to carry out

maintenance and repair satisfactorily. When-

ever the owner has insufficient experience or

doubts his ability to do the work, all adjust-

ments, maintenance, and repair should be car-

ried out only by qualified mechanics.

In order to perform the work efficiently and

to avoid costly m istakes, read the text, thor-

oughly familiarize yourself with the procedures

before starting work, and then do the work ca

re-

fully in a clean area. Whenever special tools or

equipment are specified, do not use makeshift

tools or equipment. Precision measurem

ents

can only be m ade if the proper instruments are

used, and the use of substitute tools may ad-

versely affect safe operation.

For the duration of t he warranty period,

we recommend that all repairs and scheduled

maintenance be performed in

accordance with

this service manual. Any owner maintenance or

repair procedure not performed in accordance

with this manual may void

the warranty.

To get the longest l ife out of your JET SKI

®

watercraft :

•

Follow the Periodic Mai

ntenance Chart in the

Service Manual.

•

Be alert for problems and non-scheduled

maintenance.

•

Use proper tools and genuine Kawasaki JET

SKI

®

watercraft parts. Special tools, gauges,

and testers th

at are necessary when servic-

ing Kawasaki JET SKI

®

watercraft are intro-

duced by the Service Manual. G enuine parts

provided as

spare parts are listed in the Parts

Catalog.

•

Follow the procedures in this manual care-

fully. Don’t t ake shortcuts.

•

Remember to keep complete records of main-

tenance and repair w ith dates and any new

parts installed.

How to U se This Manual

In this manual, the product is divided into

its m ajor systems and these systems m ake up

the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system

and assists in locating their chapters. Each

chapter in turn has its own comprehensive Ta-

ble of Contents.

For example, if you want ignition coil informa-

tion, use the Quick Reference G uide to locate

the Electrical System chapter. Then, use the

Table of Contents on the first page of the chap-

ter to find the Ignition Coil section.

Whenever you see these WARNING and

CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance

practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This manual contains four more symbols (in

addition to WARNING and CAUTION) which will

help you distinguish different types of informa-

tion.

NOTE

○

This note symbol indicates points of par-

ticular interest for more efficient and con-

venient operation.

•

Indicates a procedural step or work to be

done.

○

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 inspec-

tion in the procedural step or sub-step it fol-

lows.

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 spec-

ified tightening torque, oil, grease or a locking

agent during assembly.

This model, JT1500C, is mounted with a four

-stroke engine.

When the JET SKI

®

watercraft is submerged

and swamped, the four-stroke engine needs

special care and systematic procedure for re-

covery compared with the two-stroke engine.

Therefore in this manual, such procedures,

which are not shown in SMs for tw o-stroke

engines, are explained thoroughly t o cope with

the cases.

Refer t o the section, After submerging in

Chapter 9, Cooling and Bilge Systems for the

summary and detailed procedures.

GENERAL INFORMATION 1-1

1

General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification........................................................................ ......................................... 1-10

General S pecifications............................................................................................................ 1-11

Unit Conversion Table ............................................................................................................ 1-13

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly oper-

ation on watercraft, read the precautions given below. To facilitate actual operations, notes, i llustra-

tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever

necessary. This section explains the items that require particular attention during t he removal and

reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Kawasaki Diagnostic System (KDS) Software

KDS software t hat runs on Windows personal computer (PC) will be available as a diagnostic tool

for watercraft with Kawasaki DFI system.

You need the following items to use the KDS.

Item P/No.

KDS Software Version 2.□ (CD-ROM, Updated Version) 57001-1503

Signal Converter 57001-1504

Communication Cable and Cable Adapter 57001-1470

KDS Adapter Cable 57001-1696

The connectors for the communication cable and KDS adapter cable are located in the front.

Connect the communication cable to the KDS connector (4-pin) [A] and the KDS adapter cable

between the ignition switch (immobilizer amplifier) lead connectors (6-pin) [B].

Adjustments

Adjustments shall be made in accordance with the Periodic Maintenance C hart or whenever trou-

bleshooting or presence of symptoms indicate that adjustments may be required. Whenever running

of the engine is required during maintenance it is best to have the watercraft in water.

CAUTION

Do not run the engine without cooling water supply for more than 15 seconds, especially

in high revolutionary speed or severe engine and exhaust system damage w ill occur.

Auxiliary Cooling

An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjust-

ments. If possible, always operate the watercraft in w ater rather than use an auxiliary cooling supply.

GENERAL INFORMATION 1-3

Before Servicing

•

Obtain a standard garden hose [A] and a garden hose

adapter [B] as shown.

C: Garden Hose Fitting of Adapter

D: Flushing Fitting of Adapter

E: Thread: Rp 3/4

○

Optional part (P/No. 92005-3746) is available as a garden

hose adapter.

•

Open the front storage compartment cover.

•

Remove the flushing cap [A] on the brim of the storage

compartment.

•

Screw a garden hose adapter [A] onto the flushing fitting

[B].

•

Attach a garden hose [C] to a garden hose adapter and

secure the hose clamp [D].

•

Att

ach the garden hose to a faucet. Do not turn on the water until the engine is running and turn it

off immediately when the engine stops. The engine requires 2.4 L/min (2.5 qts/min) at 1 800 rpm

and 7.0 L/min (7.4 qts/min) at 6 000 rpm.

CAUTION

Insufficient cooling supply will cause the engine and/or exhaust system to overheat and

se

vere damage will occur. Excessive cooling supply may kill the engine and flood the cylin-

ders, causing hydraulic lock. Hydraulic lock will cause severe damage to the engine. If the

engine dies while using an auxiliary cooling supply, the water must be shut off immediately.

CAUTION

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.

1-4 GENERAL INFORMATION

Before Servicing

CAUTION

Turn the capsized boat clockwise so that the port side always faces dow nward. Turning

counterclockwise can cause water i n the exhaust system to run into the engine, with pos-

sible engine damage.

Battery Ground

Before completing any service on the watercraft, discon-

nect the battery wires from the battery to prevent the engine

from accidentally turning over. Disconnect the ground wire

(–) first and then the positive (+). When completed with the

service, first connect the positive (+) wire to the positive (+)

terminal of the battery then the negative (–) w ire to the neg-

ative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury

from possible sharp edges on the parts.

Solvent

Use a high flush point solvent when cleaning parts. High

flush point solvent should be used according to directions

of the solvent manufacturer.

GENERAL INFORMATION 1-5

Before Servicing

Cleaning Watercraft before Disassembly

Clean the watercraft thoroughly before disassembly. Dirt

or other foreign materials entering into sealed areas during

watercraft disassembly can cause excessive wear and de-

crease performance of the watercraft.

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the

parts according to the order the parts were disassembled

and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been

cleaned, store the parts in a clean area. Put a clean cloth

or plastic sheet over the parts to protect from any foreign

materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious ac-

cident. Visually inspect removed parts for corrosion, discol-

oration, or other damage. Refer to the appropriate sections

of this manual for service limits on individual parts. Replace

the parts if any damage has been found or if the part is be-

yond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or

recommended by KAWASAKI. Gaskets, O-rings, Oil seals,

Grease seals, circlips or cotter pins must be replaced with

new ones whenever disassembled.

1-6 GENERAL INFORMATION

Before Servicing

Assembly Order

In most cases assembly order is the reverse of disassem-

bly, however, if assembly order is provided in this Service

Manual, follow the procedures given.

Tightening Sequence

Generally, when installing a part with several bolts, nuts,

or screws, start them all in their holes and tighten them to

a snug fit. Then tighten them according to the specified se-

quence to prevent case warpage or deformation which can

lead to malfunction. Conversely when loosening the bolts,

nuts, or screws, first loosen all of t hem by about a quar-

ter turn and then remove them. If t he specified tightening

sequence is not indicated, tighten the fasteners alternating

diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw m ay

lead to serious damage. Tighten fasteners to the specified

torque using a good quality tor

que wrench.

Force

Use common sense during disassembly and assembly,

excessive force can cause expensive or hard to repair dam-

age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets

and O-rings after disassembly can reduce sealing per-

formance. Remove old gaskets and clean the sealing

surfaces thoroughly so that no gasket material or other

material remains. Install new gaskets and replace used

O-rings when re-assembling

GENERAL INFORMATION 1-7

Before Servicing

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a Locking

agent, clean the surfaces so that no oil residue remains be-

fore applying liquid gasket or locking agent. Do not apply

them excessively. Excessive application can clog oil pas-

sages and cause serious damage.

Press

For items such as bearings or oil seals that must be

pressed into place, apply small amount of oil to the con-

tact area. Be sure to m aintain proper alignment and use

smooth movements when installing.

Ball Bearing

Do not remove pressed ball or needle unless removal is

absolutely necessary. Replace with new ones whenever

removed. Press bearings with the manufacturer and size

marks facing out. Press the bearing into place by putting

pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between

the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless r emoval

is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing

out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing

the seal.

1-8 GENERAL INFORMATION

Before Servicing

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new

ones. Take care not to open the clip excessively when in-

stalling to prevent deformation.

Lubrication

It is important to lubricate rotating or sliding parts during

assembly to minimize wear during initial operation. Lubri-

cation points are called out throughout this manual, apply

the specific oil or grease as specified.

Direction of E ngine Rotation

When rotating the crankshaft

, by hand, the free play

amount of rotating direction will affect the adjustment. Ro-

tate the crankshaft to positive direction (counter-clockwise

viewed from stern sinde).

Electrical Wires

A two-color wire is identified first by the primary color and

then the stripe color. Unless instructed otherwise, electrical

wires must be connected t o those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate

measurement. Read the manufacture’s instructions thor-

oughly before using the meter. Incorrect values may lead

to improper adjustments.

GENERAL INFORMATION 1-9

Before Servicing

Harness Connector

Apply grease [A] on all connectors of harness [ B] for water

resistance. Do not apply grease on the only connector of

inlet air pressure sensor.

1-10 GENERAL INFORMATION

Model Identification

JT1500C7F Left Side View

JT1500C7F Right Side View

Hull Identification Number (HIN) Engine Number

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Kawasaki JET SKI ULTRA LX User manual

Kawasaki JET SKI ULTRA LX User manual

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