A downloadable Kawasaki Jet-Ski repair manual, also termed Kawasaki service manual or online factory service manual. 1998-2000 Kawasaki 900 STX JT900 900STX. A downloadable Kawasaki jet-ski repair manual, also termed Kawasaki watercraft factory service manual or Kawasaki wave-runner. 2001 2002 2003 Kawasaki 900 STX JT900.

1. Kawasaki Jet Ski Service Manual
2. 2000 Kawasaki Jet Ski 900 Stx Service Manual

Kawasaki Jet Ski Service Manual

. STX-15F JET SKI Watercraft ® Service Manual. 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. 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 latest information on product improvements incorporated after this publication.

Are you out of shape? Are you in condition? Are you good to go? It’s time for your checkup! Answer key for study island. Make your way into these quizzes and test your medical smarts!

ampere(s) ABDC after bottom dead center alternating current ATDC after top dead center BBDC before bottom dead center bottom dead center BTDC before top dead center °C degree(s) Celsius direct current farad(s) °F degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) Read OWNER’S MANUAL before operating. A minimum of 87 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. Follow the Periodic Maintenance Chart in the Service Manual.

Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki JET ® watercraft parts. Special tools, gauges, and testers that are necessary when servicing ® Kawasaki JET SKI watercraft are introduced by the Special Tool Manual. This model, JT1500A, 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.

General Information Smart Learning Operation mode (SLO) (JT1500-A2 model ). Before Servicing. Model Identification.

General Specifications. Unit Conversion Table. GENERAL INFORMATION 1-1 Table of Contents 1-10 1-11 1-13. 1-2 GENERAL INFORMATION Smart Learning Operation mode (SLO) (JT1500-A2 model ) This watercraft is equipped with the Smart Learning Operation mode (SLO) and normal operation mode (Full Power Operation, FPO). The SLO mode reduces the maximum watercraft speed by ap- proximately 30 percent for a use by unskilled operators. Kawasaki Diagnostic System (KDS) Software KDS software version 2.2 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. KDS Software Version 2.2 (CD-ROM). 1-4 GENERAL INFORMATION 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. ) is available as a garden hose adapter.

Before Servicing 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 Ground Before completing any service on the watercraft, discon- nect the battery wires from the battery to prevent the engine from accidentally turning over. 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. 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. 1-8 GENERAL INFORMATION 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.

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. 1-10 GENERAL INFORMATION Model Identification JT1500-A1 Left Side View JT1500-A1 Right Side View. General Specifications Items Engine Type Displacement Bore and Stroke Compression Ratio Maximum Horsepower Maximum Torque Ignition System Lubrication System Carburetion System Starting System Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Tuning Specifications Spark plug: Type Ignition Timing. 1-12 GENERAL INFORMATION General Specifications Items Overall Width Overall Height Dry Weight Fuel Tank Capacity Engine Oil Type Viscosity Capacity Electrical Equipment Battery Maximum Generator Output †: This information shown here represents results under controlled conditions, and the information may not be correct under other conditions.

Specifications subject to change without notice, and may not apply to every country. Unit Conversion Table Prefixes for Units Prefix Symbol mega kilo centi milli micro µ Units of Mass × 2.205 × 0.03527 Units of Volume × 0.2642 × 0.2200 × 1.057 × 0.8799 × 2.113 × 1.816 × 0.03381 × 0.02816 ×. Periodic Maintenance Periodic Maintenance Chart. Torque and Locking Agent. Special Tools and Sealant.

Periodic Maintenance Procedures. Throttle Control System Inspection. Air Filter Drain Caps Inspection and Cleaning. Air Filter Inspection and Cleaning. Fuel Vent Check Valve Inspection. 2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the watercraft in good running condition. The initial maintenance is vitally important and must not be neglected.

Description Inspect throttle control system (e) Inspect/clean air filter drain caps Inspect/clean air filter Inspect fuel vent check valve. Torque and Locking Agent 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: EO: Apply oil to the threads and seating surface. L: Apply a non-permanent locking agent to the threads. 2-4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Oil Passage Joints Oil Cooler Assembly Bolts Oil Pressure Switch Oil Passage Bolt Oil Filter Oil Cooler Positioning Bolt Oil Pan Bolts Dipstick Tube Bolts Oil Pump Sprocket Bolt Oil Pump Cover Bolts Oil Pressure Relief Valve Oil Pipe Bolts Chain Guide Spring Plate Bolt. Torque and Locking Agent Fastener Inlet Side Camshaft Chain Guide Bolts Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Position Sensor Rotor Bolt Water Hose Joint Oil Passage Joint Engine Removal/Installation Engine Mounting Bolts Engine Damper Mounting Bolts Engine Bottom End Crankshaft Sensor Cover Bolts Engine Bracket Mounting Bolts. 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Pump Cover Mounting Bolts Grate Mounting Bolts Filter Cover Mounting Bolts Steering Handlebar Clamp Bolts Start/stop Switch Case Mounting Screws Throttle Case Mounting Screws Steering Shaft Locknut Steering Shaft Nut Steering Holder Mounting Bolts Steering Neck Mounting Bolts Steering Cable Joint Bolt Ball Joint.

Torque and Locking Agent Fastener Starter Relay Mounting Nut Starter Cable Mounting Nut Timing Rotor Bolt Crankshaft Sensor Screws Rubber Grommet Holder Screws Crankshaft Sensor Cover Bolts Oil Temperature Sensor Camshaft Position Sensor Bolt Spark Plugs Regulator/rectifier Bolts Replay Assembly Bolts ECU Mounting Bolts Main Fuse Mounting Bracket Bolt Multifunction Meter Mounting Bolts. 2-8 PERIODIC MAINTENANCE Specifications Item Fuel System Throttle Lever Free Play about 2 mm (0.08 in.) Engine Lubrication System Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 4.0 L (4.2 US qt, with or without the filter) 5.0 L (5.3 US qt, when engine is completely dry) Engine Top End Valve Clearance. Special Tools and Sealant Oil Filter Wrench: PERIODIC MAINTENANCE 2-9 Shaft Wrench:. 2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Control System Inspection. Inspect the throttle lever free play A. If the free play is incorrect, adjust the throttle cable. Throttle Lever Free Play Standard: about 2 mm (0.08 in.).

Periodic Maintenance Procedures Air Filter Inspection and Cleaning. Remove: Air Filter (see Fuel System (DFI) chapter) Flame Arrester A (see Air Filter Disassembly in Fuel System (DFI) chapter). Clean the flame arrester A. Visually inspect the flame arrester for damage. If necessary, replace it with a new one. 2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures.

The fuel vent check valve C must be mounted so that the arrow D on its case is pointing toward the fuel tank. Fuel Pump Screen Cleaning. Remove the fuel pump (see Fuel System chapter). Periodic Maintenance Procedures. In a well-ventilated area, start the engine while cooling the cooling system.

○ Open the front storage compartment cover. ○ Remove the flushing cap (see Cooling System Flushing).

○ Screw a garden hose adapter A onto the flushing fitting B. 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed accord- ing to the chart shown.

Install the filler cap. Torque - Oil Filler Cap: 1.0 Nm (0.10 kgfm, 8.7 inlb). Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection. Remove the air suction valve (see Engine Top End chap- ter).

Visually inspect the reeds A for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly. 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Measure the valve clearance between the cam and the valve lifter with a thickness gauge A. Valve Clearance Standard: IN 0.15 0.24 mm (0.0059 EX 0.22 0.31 mm (0.0087 ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders. Periodic Maintenance Procedures INLET VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold).

Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures EXHAUST VALVE CLEARANCE ADJUSTMENT CHART 1.

Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. Periodic Maintenance Procedures.

Apply molybdenum disulfide oil to the valve lifters and ap- ply engine oil to the shims, and install them. Install the camshafts. Be sure to install the camshafts properly (see Engine Top End chapter).

Remeasure any valve clearance that was adjusted. 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Obtain a standard garden hose A and a garden hose adapter B as shown.

Garden Hose Fitting of Adapter C Flushing Fitting of Adapter D Thread: Rp 3/4 E NOTE ○ Optional part (P/No. ) is available as a gar- den hose adapter. Periodic Maintenance Procedures. Leave 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. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolu. 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Pump and Impeller Impeller Inspection. Examine the impeller.

A If there is pitting, deep scratches, nicks or other damage, replace the impeller. NOTE ○ Minor nicks and gouges in the impeller blades can be removed with abrasive paper or careful filing. Periodic Maintenance Procedures Steering Shaft B Hull/Engine Hood Drain Plug Inspection. Check the drain plugs A for cracks or damage and the drain plug mounting screws B are tightened securely. Check the seals C for damage.

If necessary, replace the drain plugs or seals. Electrical System Battery Charging Condition Inspection Battery charging condition can be checked by measuring. 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Check that the battery terminals B are not corroded. If necessary, remove the battery (see Electrical System chapter) and clean the terminals and cable ends using a solution of baking soda and water.

Periodic Maintenance Procedures. Lubricate the following with grease. ○ Pull the throttle lever and hold it. Throttle Cable End at Throttle Lever A Throttle Cable End A at Throttle Body ○ Remove the storage pocket (see Hull/Engine Hood chap- ter). 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Lubricate the following with a penetrating rust inhibitor B.

Throttle Cable A Steering Nozzle Pivots A Reverse Bucket Pivots B. With the cable disconnected at both ends, the cable should move freely A within the cable housing. If cable movement is not free after lubricating, if the cable is frayed B, or if the cable housing is kinked C, replace the cable. Periodic Maintenance Procedures All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check Nuts, Bolts, and Fasteners Tightness Inspection.

Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. 2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures.

Make sure the above hoses are routed properly and se- cured with the clamps away from any moving parts and sharp edged portions. Plastic Clamp A Hose B Hose Fitting C NOTE ○ The majority of bilge hoses have no clamps at the hose ends.

Periodic Maintenance Procedures Rubber Strap Inspection. Check the following rubber straps for any deterioration or damage. Pull on squeeze the straps and look for cracks. Battery Straps A Fuel Tank Straps Water Box Muffler Straps If a strap is damage in any way, replace it. PERIODIC MAINTENANCE 2-29. Fuel System (DFI) Fuel System Diagram. Exploded View.

Special Tools and Sealant. DFI Parts Location. DFI Servicing Precautions. Self-diagnosis Outline. Service Code (Character) Table. Troubleshooting the DFI System.

Throttle Sensor (Service Code/Character-11/tPS). 3-2 FUEL SYSTEM (DFI) Throttle Lever, Cable and Case. Free Play Inspection. Throttle Cable Adjustment. Throttle Case Removal/Disas- sembly.

Throttle Case Assembly/Installa- tion. Throttle Cable Removal. Throttle Cable Installation. Throttle Case and Cable Lubrication.

Throttle Cable Inspection. Fuel System Diagram 1. Clamps (JT1500-A1 Model) Double Spring Clamps (JT1500-A2 Model ) (Installation Procedure: Pull up the clamp stopper A with pliers B.) 3.

Fuel Filter 5. Supply Line 6. Return Line 7. Delivery Pipe 8.

3-4 FUEL SYSTEM (DFI) Exploded View. EO: Fill the hollow with the engine oil (10W-30). G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts Si: Fill the hollow with the specified silicone grease (Kawasaki Bond: ).

SO: Apply silicone oil to the O-ring. FUEL SYSTEM (DFI) 3-5 Torque Nm. 3-6 FUEL SYSTEM (DFI) Exploded View. Fuel Level Sensor 9. Fuel Filter 10. Fuel Pump A: JT1500-A1 Model B: JT1500-A2 Model L: Apply a non-permanent locking agent.

R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120). FUEL SYSTEM (DFI) 3-7 Torque Nm kgfm ftlb 0.30 26 inlb. 3-8 FUEL SYSTEM (DFI) Exploded View.

Exploded View Fastener Air Filter Mounting Bolts Air Filter Bracket Mounting Bolts Throttle Cable Locknut Throttle Case Mounting Screws G: Apply grease. L: Apply a non-permanent locking agent. FUEL SYSTEM (DFI) 3-9 Torque Nm kgfm ftlb 87 inlb 0.80 69 inlb 0.80 69 inlb 0.40. 3-10 FUEL SYSTEM (DFI) Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Operating range Fuel Pressure (High Pressure Line): Engine Idling Fuel Pump: Type Discharge Throttle Sensor: Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor: Input Voltage.

FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Throttle Lever and Cables Throttle Lever Free Play about 2 mm (0.08 in.). Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Hand Tester: Needle Adapter Set: Fuel Pressure Gauge Adapter: Throttle Sensor Setting Adapter: Sensor Harness Adapter: Harness Adapter: Kawasaki Bond (Silicone Sealant): 56019-120 Kawasaki Bond (Silicone Grease):. DFI Parts Location 1. Fuel Injector #1 2. Fuel Injector #2 3.

Fuel Injector #3 4. Fuel Injector #4 5. Inlet Air Pressure Sensor 6. Inlet Air Temperature Sensor 7. Throttle Sensor 8.

ISC (Idle Speed Controller) 9. Camshaft Position Sensor 10. 3-14 FUEL SYSTEM (DFI) DFI Parts Location 14.

Ignition Switch 15. Meter Unit 16. Fuel Pump 18. Fuel Level Sensor 19.

Vehicle-down Sensor 20. Ignition Coil #1, #4 21. Ignition Coil #2, #3 22. Main Fuse 20 A 23. FUEL SYSTEM (DFI) 3-15 DFI Parts Location Dummy Page. 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram.

DFI System Part Name 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4.

Fuel Injector #4 5. Joint Connector H 6.

Inlet Air Temperature Sensor 7. Inlet Air Pressure Sensor 8. Joint Connector E 9. Joint Connector J 10. 3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1.

Tachometer Signal 2. ECU Main Relay 3. SLO (Smart Learning Operation) Mode (JT1500-A2 Model ) 5. Oil Pressure Switch 6. Engine Stop Switch 7.

Inlet Air Temperature Sensor 8. DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. 3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions For JT1500-A2; ○ Install the double spring clamp in the position as shown, and securely pull up the clamp stopper with pliers.

Check the fuel system for leaks after hose installation. Fuel Hose B Double Spring Clamp A Fuel Pipe C CAUTION.

○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals A of the connector B for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of Connector. Always check battery condition before replacing the DFI parts.

A fully charged battery is a must for conducting accurate tests of the DFI system. 3-22 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode. Push the “SET” button with “MODE” button at the same time for 3 seconds or more. Push either “SET” or “MODE” button for more than one second or more. Self-Diagnosis Service Code (Character) Table Service Service Code Code Character (used in (displayed on ECU) Meter Unit) Throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction.

The service codes (characters) in the past are stored in the ECU. However, the characters cannot be displayed in the meter.

The past service codes can be confirmed by using the Kawasaki Diagnostic System (see General Information chapter), and they can be erased. Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No.

(license plate No.): Model: Engine No.: Date problem occurred: Environment when problem occurred. □ □ Weather fine, cloudy, □ □ Temperature hot, warm, Problem □ □ chronic, frequency □ □. 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ Poor running spark plug loose (tighten it). Or no power at □ spark plug dirty, broken, or gap maladjusted (remedy it).

High speed □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect). Throttle Sensor (Service Code/Character-11/tPS) Throttle Sensor Removal/Adjustment CAUTION Never drop the throttle sensor A, especially on a hard surface.

Such a shock to the sensor can dam- age it. Remove: Seat (see Hull/Engine Hood chapter) Air filter (see air Filter Removal). 3-28 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS). Adjust the throttle sensor positioning as follows. ○ Install the air filter temporarily.

○ After warming up the engine, check the idling speed. Idle Speed Standard: 1 300 ±100 r/min (rpm) ○.

Throttle Sensor (Service Code/Character-11/tPS). Turn the ignition switch ON and push the lanyard key un- der the stop button.

Pushing the start button, run the engine 5 idling to measure the sensor input voltage. ○ Wait 15 seconds before using the starter again. Input Voltage at ECU Standard: 4.75 5.25 V DC. 3-30 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) Output Voltage Inspection. Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Voltmeter A Connector B Special Tool - Needle Adapter Set: Throttle Sensor Output Voltage Connections to ECU Meter (+) →.

Throttle Sensor (Service Code/Character-11/tPS). Disconnect the throttle sensor connector and connect the setting adapter A between the harness connector and throttle sensor connector.

Connect a digital meter to the setting adapter leads. Special Tool - Throttle Sensor Setting Adapter: -1521 Throttle Sensor Output Voltage Connections to Sensor. 3-32 FUEL SYSTEM (DFI) Throttle Sensor (Service Code/Character-11/tPS) 1. Joint Connector E 3.

Throttle Sensor. Inlet Air Pressure Sensor (Service Code/Character-12/bOSt) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal.

Turn the ignition switch off. Remove: Seat (see Hull/Engine Hood chapter) Inlet Air Pressure Sensor Bolts A Inlet Air Pressure Sensor Connector B Inlet Air Pressure Sensor C. 3-34 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code/Character-12/bOSt) If the reading is within the standard range, and check the input voltage at the sensor connector. Disconnect the inlet air pressure sensor connector and connect the harness adapter A between the harness connector and inlet air pressure sensor connector. Inlet Air Pressure Sensor (Service Code/Character-12/bOSt) If the output voltage is far out of the usable range, check the output voltage at the sensor connector A. Measure the output voltage at the sensor in the same way as input voltage inspection. Note the following.

2000 Kawasaki Jet Ski 900 Stx Service Manual

B Inlet Air Pressure Sensor Special Tool - Sensor Harness Adapter: Inlet Air Pressure Sensor Output Voltage. 3-36 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) Inlet Air Temperature Removal/Installation CAUTION Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it. Remove the air filter (see Air Filter Removal). (see next diagram).

Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of ECU Connectors If the wiring is good, check the sensor resistance. Sensor Resistance Inspection.

3-38 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code/Character-13/AIrt) 1. Joint Connector E 3. Joint Connector H 4.

Inlet Air Temperature Sensor. Water Temperature Sensor (Service Code/Character-14/AqUt) Water Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Disconnect the sensor connector A, and unscrew the water temperature sensor B. If the wiring is good, check the water temperature sensor resistance. Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of ECU Connectors 6 seconds. Water Temperature Sensor (Service Code/Character-14/AqUt) 1. Joint Connector E 3. Water Temperature Sensor Sensor Resistance Inspection.

Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation). Refer to Electrical System chapter for water temperature sensor inspection. FUEL SYSTEM (DFI) 3-41. 3-42 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code/Character-21/CrAg) Crankshaft Sensor Removal/Installation. See the Ignition System section in Electrical System chapter.

Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals. Camshaft Position Sensor (Service Code/Character-23/CAAg) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. See the Ignition system section in Electric System chap- ter. Camshaft Position Sensor Inspection ○ The camshaft position sensor have no power source, and when the engine stops, the camshaft position sensor gen- erates no signal. 3-44 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code/Character-31/dOS) This sensor has a weight A with two magnets inside, and sends a signal to the ECU. But when the watercraft banks 130° or more to either side (in fact falls down), the weight turns and shuts off the signal.

Vehicle-down Sensor (Service Code/Character-31/dOS) Vehicle-down Sensor Inspection NOTE ○ Be sure the battery is fully charged. Remove: Fuel Tank (see Fuel Tank Removal). Connect a digital volt meter A to the connector B of the vehicle-down sensor lead with the needle adapter set C.

Special Tool - Needle Adapter Set: Vehicle-down Sensor Power Source Voltage Connections to Sensor. Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect.

Check the wiring. Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Fuel Injector Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) cable ter- minal. Do not smoke.

Well-ventilated and free from any source of flame or sparks. 3-48 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4). Replace the seals A with new ones. Apply grease to the inside and outside of seals. Install: Delivery Pipe Assembly Collars. Install the clamps A as shown. Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4).

Remove connectors for injector A. Connect each test light set B to the injector harness con- nector C. Turn the ignition switch ON. While cranking the engine with the starter motor, watch the test lights. 3-50 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Injector Voltage Inspection. Turn the ignition switch OFF. Connect a digital voltmeter A to the connector B, with the needle adapter set.

Special Tool - Needle Adapter Set: Injector Power Source Voltage Connector to Injector #1, #2, #3, #4 Meter (+) →. Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) Injector Fuel Line Inspection. Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump A to the supply joint of the delivery pipe B with the fuel hose C (both ends connected with the clamps D) as shown. 3-52 FUEL SYSTEM (DFI) Fuel Injectors (Service Code/Character-41, 42, 43, 44/InJ1, InJ2, InJ3, InJ4) 1. Fuel Injector #1 2. Fuel Injector #2 3. Fuel Injector #3 4.

Fuel Injector #4 5. Joint Connector H 6. Main Relay in Relay Assembly 7.

Ignition Coils (Service Code/Character-51, 52/COL1, COL2) Ignition Coil #1, #4: Service Code 51-COL1 Ignition Coil #2, #3: Service Code 52-COL2 Ignition Coil Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can dam- age it. 3-54 FUEL SYSTEM (DFI) Ignition Coils (Service Code/Character-51, 52/COL1, COL2) 1. Main Relay in Relay Assembly 2.

Joint Connector F 3. Connector C 4. Connector D 5.

Joint Connector R 6. Main Fuse 20 A 7. Starter Motor 8. Engine Overheating (Service Code/Character-71/HEAt). If the service code is displayed, check the doubtful parts referring to the following table. Possible Causes Water passage clogged, loosened or damaged Incorrect engine oil level Engine oil poor quality or incorrect Water temperature sensor broken Jet pump or impeller damaged Oil cooler clogged Carbon build-up on combustion chamber.

3-56 FUEL SYSTEM (DFI) Low Engine Oil Pressure (Service Code/Character-72/OILP). If the service code is displayed, check the doubtful parts referring to the following table. Possible Causes Oil leak Engine oil level too low Engine oil viscosity too low Oil filter clogged Oil pressure switch damaged Oil cooler clogged. Fill the hollow of the oil pan A with the specified silicone grease B as shown, before installing the oil temperature sensor C. D 5 mm (0.2 in.) Silicone Grease-Kawasaki Bond:. Tighten: Torque - Oil Temperature Sensor: 15 Nm (1.5 kgfm, 11 ftlb).

If the wiring is good, check the oil temperature sensor resistance. Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120) -Seals of ECU Connectors 1. Joint Connector E 3. Joint Connector J 4. Engine Oil Overheating (Service Code/Character-76/OILH) JT1500-A2 model;. If the service code is displayed, check the doubtful parts referring to the following table. Possible causes Incorrect engine oil level Engine oil poor quality or incorrect Oil temperature sensor broken Oil cooler clogged Oil pump malfunction Relief valve malfunction.

3-60 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal.

Remove: Seat (see Hull/Engine Hood chapter) Bolts A. Disconnect the ECU lead connector A. Check the ECU power source voltage with a tester A. ○ Position the terminal in accordance with terminal numbers of ECU connector B in this chapter figure. ECU Power Source Inspection Tester Connections: 2 (R/G) Terminal – Battery (−) Terminal 9 (R/W) Terminal –.

3-62 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. Main Relay in Relay assembly 2. Joint Connector F 3. Connector C 4.

Connector D 5. Ignition Switch 6. Start Switch 7. Joint Connector R 8. Main Fuse 20 A 9. DFI Power Source Main Fuse Inspection.

Refer to the Electrical System chapter for the ECU Fuse Inspection. Relay Assembly Removal CAUTION Never drop the relay, especially on a hard surface.

Such a shock to the relay can damage it. 3-64 FUEL SYSTEM (DFI) DFI Power Source Fuel Pump Relay Relay Coil Terminals 6 and 8 Relay Switch Terminals 5 and 7 Testing Relay Tester range: 1 Ω range Criteria: When battery is connected → 0 Ω When battery is disconnected → ∞ Ω If the relay does not work as specified, replace the relay assembly. Throttle Lever, Cable and Case Free Play Inspection. Refer to Throttle Control System Inspection in the Peri- odic Maintenance chapter. Throttle Cable Adjustment. Refer to Throttle Cable Adjustment in the Periodic Main- tenance chapter. Throttle Case Removal/Disassembly.

Unscrew the mounting screws A and remove the han- dlebar pad B. 3-66 FUEL SYSTEM (DFI) Throttle Lever, Cable and Case. Disassemble the throttle case. ○ Remove the circlip A, flat washers B, pin C, throttle lever D and return spring E from the case F. Throttle Case Assembly/Installation.

Insert the end of the return spring A in the throttle lever hole B and set the spring in the throttle case C as shown. Throttle Lever, Cable and Case.

Tighten: Torque - Throttle Case Mounting Screws: 3.9 Nm (0.40 kgfm, 34 inlb). Swing the throttle lever so that the throttle valve is fully open. WARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition. 3-68 FUEL SYSTEM (DFI) Throttle Lever, Cable and Case.

Remove the throttle case (see Throttle Case Removal). Slide the rubber boot out of the place. Unscrew the throttle cable fitting nut. Remove the upper end of the cable from the case. Throttle Lever, Cable and Case.

Tighten: Torque - Throttle Case Mounting Screws: 3.9 Nm (0.40 kgfm, 34 inlb). Route the following correctly (see Cable, Wire, and Hose Routing in Appendix chapter).

Throttle Cable Steering Cable Fuel Tank Vent Hose Start/Stop Switch Leads Buzzer Leads Multifunction Meter Leads. 3-70 FUEL SYSTEM (DFI) Air Filter Air Filter Removal. Remove the seat (see Hull/Engine Hood chapter). Remove the rear storage pocket. Disconnect the following from the air filter A. Air Suction Valve Hose B Oil Separator Tank Hose C. Air Filter Air Filter Disassembly.

Remove: Air Filter (see Air Filter Removal) Air Filter Bolts A. Remove: Bolts A Flame Arrester B Hose C Duct D Air Filter Bracket Mounting Bolts E Air Filter Bracket F. Remove the air screen A Air Filter Assembly. 3-72 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection The normal idle speed is controlled by the ECU (Elec- tronic Control Unit).

Idle Speed Standard: 1 300 ±100 r/min (rpm) -both in and out of water High Altitude Performance Adjustment High altitude adjustment is not required as the ECU con- trols the air/fuel mixture automatically. Throttle Body Assy ISC (Idle Speed Controller) Removal/Installation. Remove Seat (see Hull/Engine Hood chapter) Air Filter (see Air Filter Removal) Bands A ISC connector B Stepping Motor Mounting Screws C Stepping Motor D ISC Actuator Mounting Bolts E ISC Actuator F. Remove: Air Filter (from the throttle body assy) ISC Connector A (disconnect). Measure the ISC resistance with the hand tester. Special Tool - Kawasaki Hand Tester: ISC A Rotor B ISC Resistance Connection: 1-2, 2-3, 4-5, 5-6 terminals Standard: about 30 Ω.

Inlet Manifold Inlet Manifold Removal. Remove: Supply Fuel Hose A at Delivery Pipe Return Fuel Hose B at Delivery Pipe Delivery Pipe Mounting Bolts C, Collars and Clamps. Remove the bands D and disconnect the following con- nectors.

Camshaft Position Sensor Connector E Crankshaft Sensor Connector F. 3-76 FUEL SYSTEM (DFI) Inlet Manifold. Remove the inlet manifold A with the throttle body assy B. Remove the throttle body assy from the inlet manifold (see Throttle Body Assy Removal). Unscrew the inlet manifold plate bolts A and remove the plate B and gasket C. Inlet Manifold. Replace the injector seals A with new ones.

Apply grease to the inside and outside of seals. Tighten the delivery pipe mounting bolts B. Torque - Delivery Pipe Mounting Bolts: 7.8 Nm (0.80 kgfm, 69 inlb).

3-78 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. Be sure to place a piece of cloth under the fuel supply hose A of the fuel delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. Fuel Line If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the fuel filter and measure the fuel pressure again. Remove the fuel pressure gauge and adapter. Run the fuel hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. 3-80 FUEL SYSTEM (DFI) Fuel Line.

Prepare a measuring cylinder A. Disconnect the fuel supply hose from the fuel delivery pipe, and set the measuring cylinder and fuel supply hose B as shown.

Close the fuel tank cap. WARNING Wipe off spilled out fuel immediately. Fuel Vent Check Valve Fuel Vent Check Valve Mounting. Refer to Fuel Vent Check Valve Inspection in the Periodic Maintenance chapter.

Fuel Vent Check Valve Inspection. Refer to Fuel Vent Check Valve Inspection in the Periodic Maintenance chapter. FUEL SYSTEM (DFI) 3-81. 3-82 FUEL SYSTEM (DFI) Fuel Filter Fuel Filter Removal NOTE ○ The fuel filter is designed to be used throughout the watercraft’s life without any maintenance if it is used under normal conditions. WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.

Fuel Filter Fuel Filter Installation. Route the hose correctly (see Cable, Wire, and Hose Routing section in Appendix chapter). Install the fuel hoses to the fuel filter, noting its “IN” fitting A and “OUT” fitting B.

○ For JT1500-A2 model. 3-84 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Pull the lanyard key off the stop button. Fuel Pump Fuel Pump Installation. Press down the rubber holder A onto the fuel pump B so the stepped part C of the holder completely contacts the flanged part D of the pump.

Pressing down the rubber holder onto the fuel pump, tighten the small diameter clamp E. 3-86 FUEL SYSTEM (DFI) Fuel Pump. Remove the front storage pocket (see Hull/Engine Hood chapter). Connect the hand tester (25 V DC) A to the fuel pump lead connector B, using the needle adapter set C.

Special Tools - Hand Tester: Needle Adapter Set:. Fuel Pump Fuel Pump Relay Removal. Refer to the Relay Assembly Removal in the DFI Power Source section. Fuel Pump Relay Inspection. Refer to the Relay Assembly Inspection in the DFI Power Source section.

Relay Assembly 2. Joint Connector F 3. 3-88 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal.

Drain the fuel tank into a suitable container. WARNING Gasoline is extremely flammable and can be explo- sive 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.

Fuel Tank. Remove the fuel tank A out of the hull as shown. Fuel Tank Installation. Be sure the float A in place before putting the fuel tank into the hull. Route the following correctly (see Cable, Wire, and Hose Routing section in Appendix chapter). 3-90 FUEL SYSTEM (DFI) Fuel Tank Fuel Filler and Tube Removal. Open the front storage compartment cover.

Loosen the fuel filler tube clamp screws A and remove the fuel filler tube B. Remove the fuel filler cap A. Engine Lubrication System Exploded View. Engine Oil Flow Chart. Special Tool and Sealant.

Engine Oil and Oil Filter. Oil Level Inspection. Engine Oil Change. Oil Filter Replacement. Oil Cooler Removal. Oil Cooler Installation.

Oil Cooler Disassembly. Oil Cooler Assembly. 4-2 ENGINE LUBRICATION SYSTEM Exploded View.

Exploded View Fastener Breather Plate Bolts Oil Filler Cap Oil Passage Plugs Oil Separator Tank Mounting Screws Breather Case Mounting Bolts Breather Pipe Bolts Oil Passage Joints Oil Cooler Assembly Bolts Oil Pressure Switch 10 Oil Passage Bolt 11 Oil Filter 12 Oil Cooler Positioning Bolt 13 Oil Pan Bolts 14 Dipstick Tube Bolts. 4-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart A: Blowby Gas B: Supply Engine Oil Flow C: Return Engine Oil Flow D: Oil Sump 1. From Oil Pump Side Pas- sage 2. Oil Cooler 3. To Main Oil Passage 4. Oil Passage Bolt 5.

Engine Oil Flow Chart 21. Oil Separator Tank 22. To Air Filter 23. To Oil Pan 24.

Camshaft Oil Passage 26. Camshaft Cap Oil Pas- sage 27. Oil Passage (from Oil Pipe to Camshaft Cap) ENGINE LUBRICATION SYSTEM 4-5 28.