Kawasaki JET SKI ULTRA LX User manual

Category
Engine
Type
User manual

This manual is also suitable for

ULTRA 250X
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 Maintenance 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 250X
JET SKI
®
Watercraft
Service Manual
All rights reserved. No parts of this publication m ay 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 Q uality Assurance Division/Consumer Products and Machinery
Company/Kawasaki H eavy 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.
© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1):Dec. 15, 2006 (M)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(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) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
COUNTRY AND AREA CODES
AT Austria DE Germany
CA Canada GB United Kingdom
CA
L
Ca
lifornia
US Un
ited States
CH Switzerland
WVTA Whole Vehicle Type Approval
MAINTENANCE 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 ENGINE IS CERTIFIED TO OPERATE ON UNLEADED PREMIUM GRADE GASOLINE
ONLY.
A minimum of 90 octane of the antiknock index is recommended. The antiknock index is posted
on service station pumps.
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 levels. 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
* Supercharger with intercooler & relief-valves
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 mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of s ubstitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service m anual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your JET SKI
®
watercraft:
•
Follow the Periodic Maintenance Chart in the
Service Manual.
•
Be alert for problems and non-scheduled
maintenance.
•
Use proper tools and genuine Kawasaki JET
SKI
®
watercraft parts. Special tools, gauges,
and testers that are necessary when servicing
Kawasaki JET SKI
®
watercraft are introduced
by the Special Tool Manual. Genuine parts
provided as spare parts are listed in the Parts
Catalog.
•
Follow the procedures in this manual care-
fully. Don’t take shortcuts.
•
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its m ajor systems and these systems make 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 R eference Guide 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 differ ent types of informa-
tion.
NOTE
â—‹
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.
â—‹
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, JT1500B, is mounted with a four
-stroke engine with supercharger.
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 two-stroke
engines, are explained thoroughly to cope with
the cases.
Refer to 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 Specifications............................................................................................................ 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, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Kawasaki Diagnostic System (KDS) Software
KDS software version 2.4 that runs on Windows personal computer (PC) will be available as a di-
agnostic tool for watercraft with Kawasaki DFI system.
You need the following items to use the KDS.
Item P/No.
KDS Software Version 2.4 (CD-ROM) 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 Chart 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 will occur.
Auxiliary Cooling
An auxiliary cooling supply m ay be used if the watercraft cannot be operated in water during adjust-
ments. If possible, always operate the watercraft in water 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
â—‹
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].
•
Attach the garden hose to a faucet. Do not turn on the water until the engine is running and turn it
off immediately when the engine stops. The engine requires 2.4 L/min (2.5 qts/min) at 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
severe 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 downward. Turning
counterclockwise can cause water in the exhaust system to run into the engine, with pos-
sible engine damage.
Battery G round
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 (–) wire to the neg-
ative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible s harp 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 Disasse mbly
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 s ervice limit.
Replacement P arts
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 s everal 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 them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque 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 s eals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Be aring
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 removal
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 Engine 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 to 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
JT1500B7F Left Side View
JT1500B7F Right Side View
Hull Identification Number (HIN) Engine N umber
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Kawasaki JET SKI ULTRA LX User manual

Category
Engine
Type
User manual
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