Kawasaki ~eT4ILl77:

Watercraft
Service Manual
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 I.

QUICK R~FERENCE GUIDE

,,

GENERAL INFORMATION

FUEL SYSTEM

ENGINE LUBRICATION SYSTEM

EXHAUST SYSTEM

ENGINE TOP END

ENGINE REMOVAL AND INSTALLATION

ENGINE BOTTOM END

COOLING AND BILGE SYSTEMS

DRIVE SHAFT

PUMP AND IMPELLER

STEERING

HULL

ELECTRICAL SYSTEM

STORAGE

APPENDIX

This quick reference guide will assist you in

locating a, desired topic or procedure.
-Bend the pages back to match the black
tab of the desired chapter number with
the black tab on the edge at each table
of cOlltents page.
-Refer to the sectional table of contents for

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the exact pages to locate the specific topic
required:

.'

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 Kawasaki

Watercraft
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior
written permission of Quality Assurance Department/Consumer Products Group/Kawasaki Heavy Industries,
ltd., Japan.
No liability can be accepted for 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 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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© Kawasaki Heavy Industries, Ltd. 1988, 1989, 1992 Third Edition (3): Sap. 10, 1997 (KJ

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 LIST OF ABBREVIATIONS

A ampere{s) Ib pound(s)
ABDC after bottom dead center m meter{s)
AC alternating current N newton(s)
ATDC after top dead center P. pascal(s)
BBDC before bottom dead center Pa Pascal(s)
BDC bottom dead center PS horsepower
8TDC before top dead center psi pound(s) per square inch
'c degree(s} Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad (5) TDC top dead center
'F degree(s) Fahrenheit TIR total indicator reading
It foot, feet V volt(s)
9 gram(s) W wan(s}
h hourIs) !l ohmlsl
L Liter(s!

This w.arning may apply to any of the following

components or any assembly containing one or
more of these components:­

Brake Shoe~ or Pads

Clutch Friction Material
Gaskets
Insulators

SAFETY INSTRUCTIONS

-Operate if possible OUt of doors or in a well

Bro"h,ng ..be'l<>'
d",", " •• "go",,,., ver1tilated place.
to heallh .Preferably use hand tools or low speed tOOls
equipped. if necessary. with an appropriate dust
FOil"" ,alew
;nn'uC1,on, extraction facility. If high speed tools are used.
they should always be so equipped.
elf possible, dampen before cutting or drilling.
-Dampen dust and place it ir. properly closed
receptaclE! and dispose of it safely.

Read OWNER'S MANUAL before operating

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 •

Foreword
This manual is designed primarily for use by ..................................................................
trained mechanics in a properly equipped shop. How to Use this Manual
However, it contains enough detail and basic ............................................................................
information to make it useful to the owner
who desires to perform his own basic main­ In preparing this manual, we divided the
tenance and repair work. A basic knowledge product into its major systems. These systems
of mechanics, the proper use of tools, and became the manual's chapters. All information
workshop procedures must be understood in for a particular system from adjustment
order to carry out maintenance and repair through disassembly and inspection is located
satisfactorily. Whenever the owner has insuf­ in a single chapter.
ficient experience or doubts his ability to do The Quick Reference Guide shows you all of
the work, alt adjustments, maintenance, and the. product's systems and assists in locating
repair should be carried out only by qualified theIr chapters. Each chapter in turn has its
mechanics. own comprehensive Table of Contents.
In order to perform the work efficiently and The Periodic Maintenance Chart is located in
to avoid costly mistakes, read the text, thor­ the General Information chapter. The chart
oughly familiarize yourself with the procedures gives a time schedule for required maintenance
before starting work, and then do the work operations.
carefully in a clean area. Whenever special If you want spark plu.g information, for
tools o.r equipment are specified, do not use example, go to the Periodic Maintenance Chart
makeshIft tools or equipment. Precision meas­ first. The chart tells you how frequently to
urements can only be made if the proper instru­ clean and gap the plug. Next, use the Ouick
ments are used, and the use of substitute tools Reference Guide to locate the Electrical
may adversely affect safe operation. System chapter. Then, use the Table of
For the duration of your warranty period Contents on the first page of the chapter to
especially. we recommend that all repairs and find the Spark Plug section.
scheduled maintenance be performed in accord­ Whenever you see these WARNING and
ance with this service manual. Any owner CAUTION symbols, heed their instructions!
maintenance or repair procedure not performed Always follow safe operating and maintenance
in accordance with this manual may void the practices.
warranty.
To get the longest life out of your water­
craft:
I WARNING I
_Follow the Periodic Maintenance Chart in the oThis warning symbol identifies special instruc·
Service Manual. tions or procedures which, if not correctly
eBe alert for problems and non-scheduled followe~, could result in personal injury, or
maintenance. loss of life.
eUse proper tools and genuine Kawasaki water·
craft parts. Speciai tools, gauges, and testers
that are necessary when servicing KawasakI (C~UT(O]]
watercrafts are introduced by the Special Tool
Manual. Genuine parts provided as spare oThis caution symbol identifies special instruc.
parts are listed in the Parts Catalog. tions or procedures which, if not strictly ob·
e Follow the procedures in this manual carefully. served, could result in damage to Or destruc·
Don't take shortcuts. tion of equipment.
e Remember to keep complete records of main­
tenance and repair with dates and any new This manual contains five more symbols (in
parts installed. addition to WARNING and CAUTION) which

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will help you distinguish different types of
information.

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 •

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.
olndicates a procedural sub-step or how to do
the work of the procedural step it follows.
It also precedes the text of a WARNING,
CAUTION, or NOTE.
*Indicates a conditional step or what action to
take based on the results of the test or inspec­
t;on in the procedural step or sub-step
it follows.
?Indicates a conditional sub-step or what
action to take based upon the results of the
conditional step it follows.

In most chapters an exploded view illustra­

tion 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 Identification _ , .. 1-5
General Specification . 1-6
Periodic Maintenance Chart , .. 1-7
Torque and Locking Agent . 1-8
Cable Routing . 1-1Q

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 1-2 GENERAL INFORMATION

Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed des­
criptions have been included wherever necessary. Nevertheless, even a detailed account has limita­
tions, 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,

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

121 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,

A. Fitting Cap A.Gurden Hose

_Remove the fitting cap at the cooling hose fitting.

-Attach to the garden hose fitting and clamp the garden hose securely (see above).
_Attach the garden hose to a faucet. Donat turn on the water until the engine is running and turn it
off immediately when the engine stops. The engine requires 2:.4 Llmin (2.5 qts/min) at 1 800 rpm
(idle) and 7.0 Llmin (7.4 qts/min) at 6 000 rpm,

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olnsufficient cooling supply will cause the engine and/or exhaust system to overheat and severe
damage will occur. Excessive cooling supply may kill the engine and flood the cylinder, causing
hydraulic lock. Hydraulic lock will cause severe damage to the engine. If the engine dies while
using an auxiliary cooling supply, the water must be shut off immediately.

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 GENERAL INFORMATION 1·3

(31 Dirt
Before removal and disassembly. clean the watercraft. Any sand entering the engine car­
buretor, or other parts will work as an abrasive and shorten the life of the watercraft. For the
same reason, before installing a new part, clean off any dust or metal filings.
(4) Battery Ground
Remove the ground (-I 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.
(e) damage to electrical parts.
(5) Tightening Sequence
Generally. when installing a part with several bolts, nuts, or screws, they should all be started
in their holes and tightened to a snug fit. Then tighten them evenly in a cross pattern. This is to
avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the
bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or
screws must be tightened in the order and method indicated.
(6) Torque
The torque values given in this Service Manual should always be adhered to. Either too little
or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.
(7) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in
order to avoid damaging the screw heads.
181 Edge,
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(9) High Flash-point Solvent
A high fla$h-point solvent is recommended to reduce fire danger, A commercial solvent com­
monly available in North America is Stoddard solvent (generic name). Always follow manufac­
turer and container directions regarding the use of any solvent.
(1OJ Gasket, O-ring
Do not reuse a gasket or O-ring once it has been in service_ The mating surfaces around the
gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
(11) Liquid Gasket, Non.permanent Locking Agent
Follow manufacturer's directions for cleaning and preparing surfaces where these compounds
will be used, Apply sparingly. Excessive amounts may block engine oil passages and cause
serious damage. An example of a non-permanent locking agent commonly available in North
America'is Loctite Lock'n Seal (Blue).
{12) Press
A part installed using a press or driver, such as a seal, should first be coated with oil on its
outer or inner circumference so that it will go into place smoothly.
{13) Bal! Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed
by a suitable driver. This prevents severe stress on the balls and races, and prevents races and
balls from being dented, Press a ball bearing until it stops at the stop in the hole or on the shaft.
(14) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages
seals.
When pressing in a seal which has manufacturer's marks, press it in with the marks facing out,
Seals should be pressed into place using a suitable driver, which contacts evenly with the side of
seal, until the face of the seal is even with the end of the hole.
(15) Seal Guide

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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 oil, preferably high temperature
grease on the lips to reduce rubber to metal friction.

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 1-4 GENERAL INFORMATION

(16) Circlip, Retaining Ring, Cotter Pin

Replace any circlips, cotter pins and retammq 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.
(17) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease {whichever is
more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and
may contain abrasive foreign particles.
Don't use just any oil or grease. Some oils and greases in particular should be used only in
certain applications and may be harmful if used in an application for which they are not intend
ed.
(18) Electrical Wires
All the electrical wires are either single-color or two-color and, with only a few exceptions,
must be connected to wires of the same color. On any of the two-color wires there is a greater
amount of one color and a lesser amount of a second color, so a two-color wire is identified by
first the primary color and then the secondary color. For example, a yellow wire with thin red
stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were
reversed to make red the main color.

Wire (cross-section) Name of Wire Color

Red

@; Wire strands
Yellow
Red
Yellow/red

(19) Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are
removed, These replacement parts will be damaged or lose their original function once removed.
(20) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or
other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(211 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 dete­
riorated performance, replace the damaged parts.
(22) Hull Supporting
In order to work safely on the Jet Mate without damaging the hull, prepare the suitable
stand, so that the supports fit into the tunnels in the hull. Be sure the stand does not touch the
stern.
[ ,)

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 GENERAL INFORII'IATION '-5

Model Identification

JB650-A1

_/
,

JB650-A2

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-
-------~--=;;.;..

JB65Q.A3

.
, •
V!M¥iSB!&'

JB65Q.A4

-0
. 0%
/
, .
_..:
•

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 1·6 GENERAL INFORMATION
............ - - - .
General Specifications

Engine:
Type I 2-stroke, vertical twin, crankcase reed valve, water cooled
Displacement 635 mL
Bore and Stroke 76.0 x 70.0 mm
Compression Ratio 7.2, ,
Maximum Horsepower 38.2 kW 152 PSI @6 000 r/m!n Irpml
Maximum Torque 64.7 N-m 16.6 kg·m. 47.7 ft-lb)@5 500 r/min (rpm)
Ignition 1 Magneto COl
Lubrication System Oil injection
I (break-in period: Oil injection and fuel mixture 50; 1)
Carburetor I Keihin COK34 diaphragm type (28 mm venturi)
-=_,S:.':::"_,":::in~g,-,-S'cyst~e_,mc-~ ~j E leetr i c Sta rteT
Turning Specifications: I
Spark Plug NGK BR7ES
Gap
Ignition Timing
1°,7
111'"
- 0.8 mm
BTDC @6 000 r/min (rpm), 2.0 mm @6 000 r/min (rpm)
Carburetor
Idle Speed ' 1 250 ± 100 ({min (rpm) : In water
, 800 ± 100 r/min (rpm) : Out of water
Compression Pressure
Driv-e~S'ch-aft~-;------~-I
Ccupling , Direct drive from engine
.
I 865 -1325 kPa (8.8 -13.5 kg/em;:, 125_-_'"'9:::2'-p:::s:::i)=-- _

Jet Pump: Type I Axial flow, single stage

Thrust , 2 260 N 1230 kg, 507 Ib)
Steering Steer~b\e n07Zle
Braking I Water drag
Performance:
I
toraft (Stationary) 1310 mm
+Fuel Consumption ' 19 LJh @fullthrottle
Maximum Capacity 13 persons, @ 3 persons or 218 kg (480 Ib)
-='c"M=;n'-im~u'-m'--T-="'-r:::n·:::'n"gc:R'-.=d=i::.u::.'--lc'2::: ...:1-'m'-----~ ~ _
Dimensions:
Length 'I 2710mm
Width 1 525 mm
Height
Dry Weight
1770 239 kg
mm

Fuel Tank Capacity 30 L including 4 L reserve

Engine Oil:
Type 2-stroke, N.M.M.A. Certified for Service TC-W
Oil Tank Capacity 5.5 L
Electrical Equipment:
Battery '2 V 50 Ah (20-hour rate)/40 Ah (5-hour rate)
Maximum Generator Output 8 A/14 V@5000r/min (rpm)
1

@::: US model
t ::: This information shown here represents results under controlled conditions, and the informa­
tion may not be correct under other conditions.

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Specification subject to change without notice, and may not apply to every country.

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 ._----------------------------------------_._--'.~~--"-'-

GENERAL INFORMATION '-7

........................- - - .
Periodic Maintenance Chart
........................................................................-...

NOTE
oComp/et8 the Pre-Ride Checklist before each outing.

Frequency Initial Every Every

10 25 100
Description Hours Hours Hours
Check all hose clamps, nuts, bolts, and fasteners • •
Torque cylinder head nuts • •
Grease both ends of throttle and choke cables • ..
Clean and gap spark plug (replace if necessary) •
Check battery level, and terminal •
Lubricate steering nOlzle and reverse bucket pivots •
Lubricate steering and shift cable ball joints •
Lubricate choke cable and throttle cable •
Inspect steering pivot (disassemble) •
Inspect/clean fuel filter screen •
Inspect engine oil vent check valve •
Adjust carburetor •
Flush cooling system (after each use in salt water) , •
InspecUclean flame arrestor •
Clean drive shaft •
Inspect impeller blade for damage (remove) •
Inspect/replace coupling damper •
Inspect carburetor throttle shaft spring
(replace carburetor if necessary)
•
Inspect steering and shift cables •
Inspect/c1ean fuel vent screen •
Inspect/clean anti-siphone valve •

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 1·8 GENERAL INFORMATION
..............................................................................
Torque and Locking Agent
..................... - '" - .
The following tables list the tightening torque for the major fasteners requiring use of a non-per­
manent locking agent or silicone sealant.

Letters used in the "Remarks" column mean:

L : Apply a non-permanent locking agent to the threads.
55 : Apply silicone sealant to the threads.
S : Tighten the fasteners following the specified sequence.

Torque
Fastener Remarks
N·m kg·m ft·lb
Fuel System:
Fuel Tap Knob Set Screw - - - L
Carburetor Mounting Bolts - - - L
Intake Manifold Mounting Nuts 7.8 0.80 69 in-Ib
Air Intake Cover Bolts - - - L
Throttle and Choke Cable Clamp Bolts - - - L
Fuel Pump Mounting Bolts - - - L
Exhaust System:
Exhaust Pipe Bolts (8 mm Dia.~ 25 2.5 18.0
Exhaust Pipe Bolts {10 mm Oia.! 49 5.0 36
Water Pipe Joints 9.8 1.0 87 in~lb 55
Exhaust Manifold Mounting Nuts 20 2.0 14.5 5
Engine Top End:
Cylinder Head Nuts 29 3.0 22 5
Water Pipe Joint 9.8 1.0 87 in-Ib S5
Cylinder Base Nuts 34 3.5 25
Engine Removal/Installation:
Engine Mounting Bolts 36 3.7 27 L
Engine Mount Bolts 16 1.6 11.6
Engine Bed Mounting Bolts 22 2.2 16.0 L
Engine Bottom End:
Flywheel Bolt 98 10.0 72
Coupling 98 10.0 72
Magneto Cover Mounting Bolts - - I
- L
Crankcase Bolts 16 mm Dia.} 7.8 0.80 69 in-Ib L.S
Crankca~ Bolts (8 mm Dia.) 25 2.5 18.0 L,5
Water Drain Valve Mounting Bo(ts - - - L
Water Drain Valve Cover Bolts - - - L
Magneto Cover Stud I - - - L

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Cooling and Bilge Sys1em:
Water Pipe Joint 9.8 1.0 87 in-Ib 55

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 GENERAL INFORMATION '·9

Torque
Fastener Remarks
N·m kg·m ft-Ib
Drive Shaft: I
Coupling Cover Nuts - -. - l
39 4.0 29
Coupling
I
Drive Shaft Holder Mounting Bolts 22 2.2 16.0 l
Pump and Impeller:
Water Pipe Joints 9.8 1.0 87 in-Ib SS
Steering Nozlle Pivot Bolts 9.8 1.0 87 in-lb l
Pump Outlet Mounting Bolts - - - l
Pump Cap Bolts - - - l
Impeller 98 10.0 72
Pump Mounting Bo.!ts 22 2.2 16.0 l
Pump Cover Mounting Bolts 9.8
I 1.0 87 in-Ib l
Grate Mounting Bolts 9.8 1.0 87 in-lb I l
Steering:
Reverse Bucket Pivot Bofts 9.8 1.0 87 in-Ib l
Control Stick Mounting Bolt 22 I 2.2 16
Steering Shaft Clamp Bolt 22 2.2 16
Main Bracket Mounting 80lt 22 2.2 16
Cable Joint Arm Pivot Bolt 22 2.2 16
Electrical System:
Flywheel Bolt 98 10.0 72 l
Regulator/Rectifier Mounting Bolts 7.8 0.80 I 69 in-Ib l
COl Igniter Mounting Bolts 7.8 0.80 69 in·lb l
Spark Plugs 27 2.8 20
Grommet Cap Bolts 7.8 0.80 69 in·lb l
Starter Motor Mounting Bolts - - - l
Electric Case Bolts 7.8 0.80 69 in-Ib l
Electric Case Mounting Bolts 7.8 0.80 69 in-lb l

Thb table: relating tightening torque of the ~T.ainless

bolt and the nut to thread diameter, lists the basic
torque for the boJuand nuts. Use this table for only the
bolts and nut~ which do not reqUire a specific torque
value.

General Fastenen {stainless bolt and nut}

Torque
Threads
dia.(rr.m} N·m kg-m ft-Ib
6 5.9 -8.1:1 0.60 ­ 0.90 52 - 78 in-Ib
8 16 - 22 1.6 ­ 2.2 11.6 -15.9

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10 30 ­ 41 3.1-4.2 22 ­ 30

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 1·10 GENERAL INFORMATION
........................................- - - .
Cable Routing

1. Main Fuel Tap 5. Battery Ground Lead

2. Outside F'Jel Tap 6. Blower Fan Leads
3. Ground Leads (Green) 7. Battery (+) Cable
4. Bilge Pump Leads 8. Battery (-) Cable
9. Cable Box

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 GENERAL INFORMATION 1-11

c¢======?® To Battery (4-)

Terminal
L- =='1----"' Connect to the \-.
i starter m;;o~t=O.,'rlrT(;)"'nr:::==="if=:::7--~
termjna~.

1. Spark Plug Leads 5. Battery (+) Cable

2. Throttle Cable 6. Stator Leads
3. Choke Cable 7. Start/Stop and Ignition Switch Leads
4. Starter Motor Cable 8. Clamps

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 1-12 GENERAL INFORMATION

To starter I,ockout
switch ""
<1_ To warning buzzer
(j;
i To Ignition switch

To choke knob

1. Control Stick
2. Electric Case
3. Ignition Switch Leads
4. Choke Cable
5. Throttle Cable
6. Temperature Sensor Leads
7. Start/Stop Switch Leads
8. Magneto Leads

1. Cylinder
2. Drive Shaft
3. Bilge Pump
4. Inlet Cooling Hose
2
5. Bilge Pump leads
6. Clamps

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 FUEL SYSTEM 2·'

FUEL SYSTEM
Table of Contents

Exploded View. . . . . . . . . 2-2 Intake Manifold, Reed Valve .. , • , . 2-15

Specifications. . . . . . . . 2-4 Removal . . . . . . • __ _ . 2-15
Special Tools. . . . , , 2-4 Installation Notes •.• , , . 2-15
Sealant . 2-4 Reed Valve Inspection . 2-15
Fuel System Diagram . 2-4 Valve Holder Inspection _. ._ 2-16
Thronle Case and Cable . 2-5 Valve Stop Inspection . 2-16
Adjustment . 2-5 Fuel Tank _ . . . . . . . . .. . . 2-16
Removal . 2-5 Fuel Tank Removal _ 2-16
Installation.. . _ . 2-6 Fuel Tank Installation _ . 2·16
Lubrication. . . . . 2-6 Fuel Tank Cleaning. . . . 2-17
Inspection . 2-6 Fuel Filler and Tube Removal . 2-17
Choke Cable . 2·7 Fuel Filler and
Adjustment . 2-7 Tube lmtallation __ . _ _ 2-17
Removal . 2-7 Fuel Filter Screen Cleaning _ . 2-18
Installation .. , . 2-8 Fuel Tap _. 2- 18
Inspection . 2-8 Main Fuel Tap Removal/
LUbrication. . . . . . . . . . . . . 2-8 Installation_ _ .. _ _ 2-18
Fuel Pump. . . . .. . . 2-9 Anti-Siphon Valve Inspection ....• 2-18
Removal . 2-9 Outside Fuel Tap Removal/
Installation Note . 2-9 Installation _ . 2-19
Disassembly . 2·9 Fuel Vent Screen _ _ . , .•... 2-19
Assembly Notes . . . . . . 2-10 Cleaning _ . . _ _ 2-19
Carburetor . 2-10
Idle Speed Adjustment . 2-10
Mixture Screw Adjustment . 2-10
High Altitude
Performance Adjustment . 2-11
Carburemr Removal. . 2-11
Carburetor Installation . 2- 12
Carburetor Disassemb!y . 2-12
Carburetor Assembly . 2-13
Carburetor Cleaning and
Impection . 2-13
Float Arm Level Inspection
and Adjustment . 2-14
Flame Arrester . 2-14
Removal. . . . . . . . . . . .. . . 2-14
Install~tior1 . 2-14
Cleaning 2-15

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 2-2 FUEL SYSTEM

Exploded View
................
...................................................... ­.....
I '90 & After Models
©---~

I L ~

~
I

,
,,,
,
,,
, ,
!_---------------~

1. Main Jet
'90 & After Models
,
2. Pilot Jet
3. Diaphragm Needle
4. Check Valve

I'/A
)I~
co,
Ih'
i

beerdart
'~

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 FUEL SYSTEM 2-3

@
1

/
,
,,

G
. Apply grease. nt locking agent.
L .. Apply non-pennane 69 in-Ibl
. 78N-m (080 . kg-om,
Tl:.
SS : Apply SITcone
I sealant.

beerdart
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 2-4 FUEL SYSTEM
.............................................................................
Specifications Special Tool
., - , .
Pressure Cable Luber: K56019-o21
Carburetor
Type Keihin CDK34 Diaphragm
5il:e 28 mm Venturi
Mixture Screws See Page 2- 10
Main Jet 125
Pilot Jet 48
Slow Jet 58 ('89 model: 55)
Float Arm Level 1.5 ±O.5 mm

Sealant

Kawasaki Bond (Silicone Sealant): 56019-120

Fuel System Diagram

: CD

W 2

1. Main Fuel Tap

2. Fuel Filter Screen
3. Outside Fuel Tap
4. Carburetor
5. Fuel Pump
6. PUlse Line
7. Return Fuel Line

beerdart
8. Main Fuel Line
9. Fuel Line to Fuel Pump
10. Fuel Line to Carburetor

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 Throttle Cable
,
FUEL SYSTEM 2·5

Adjustment
eCheck throttle cable ~djustment.
OWith the throttle lever relea5ed, the stop on the throt­
tle sh.aft lever should rest .ag.ainst the idle adjust screw,
and there should be slight slack in the throttle cable.
oWhen the throttle lever is fully applied (SQueezed), the
stop on the throttle shaft lever should be all the w.ay
up .against the stop on the c.arburetor.

THROLLED CLOSED THROTTLE OPEN

(RELEASED) (APPLIED)
A. Throttle Cable
B. Locknuts

eDis<l.'>semble the control stick.

~, Pivot Boft
Steering Case

1. Idle Adjust Screw

2. Throttle Shaft Lever
3. Stopper

elf necessary, adjust the throttle cable.

eLoo5en and turn the locknuts at the br.acket until the
stop on the throttle pivot arm hits .against the idle
.adjust ,crew with slight cable slack.
'&.
. ..
eTighten the locknuts ,ecurely.
A. Pivot Bolt B. Steering Case

Covers

A. LocknuH

beerdart
qemoval
eDisconnect the throttle cable from the urburetor. A. Covers B. Screws

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 2-6 FUEL SYSTEM

• Remove the cable clamp.

_Unscrew the throttle lever pivot screw.
-Disconnect the throttle cable from the thrott',e lever.

A. Apply Grease.

eLubricate the cable bv seeping oil between the cable

A. Throttle Cable C. Pivot Screw and cable housing.
B. Cable Clamp

Cable lubrication

~'
Installation
_Installation is the reverse of removal. Note the fol­
lowing.
elnstall the throttle cable clamp as shown.

1. Pressure Cable Luber: K56019-021

Inspection
eExamine the cable.
*!f the cable or cable housing is kinked fO frayed,
replace the cable.
A. Clamp

_Adjust the throttle C,lble.

,
CD

beerdart
Lubrication
eApply water resistant grease to the tips of the throttle
cable ends. 1. Kinked housing 2. FrJyed Cable

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 _Be certain that the throttle cable moves freely in both
directions.
oLoo5en the adjuster locknuts, and slide the cable from
the throttle shaft lever.
FUEL SYSTEM 2-7

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

A. Locknuts

oTighten the locknuts.

Removal
eOi5connect the choke cable from thr carbure!or.

Choke Cable

Adjustment
eWhen the choke knob is turned counterclockwise, the
choke butterfly valve in the carburetor should be com­
plelely open. Check that the choke piva[ arm is down
all the way with minimal cable slack. This will fully
open the chokr butterfly valve in the carburetor.

CHOKE OPEN CHOKE CLOSED

A. Choke Cable B. Locknuts

eRemove the choke knob and cap.

/ '

~~~,J.
1. Choke Pi VOL Arm

-If necessary, adjust the chokr cable.

beerdart
cTurn Lhe choke knob counter clockwise completely.
cLoQsen the locknuts and turn ,he nuts to allow a ;. Chokr Knob C. Cap
little cable slack. B. Screw

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 2-8 FUEL SYSTEM
eRemove the choke knob shaft assembly.

A. Cat! B. Knob

.Adju~t the choke cable.

A. S<;rews

NOTE
oWhen pulling the choke knob shah, two detent balls
and ryvo springs will fall out of the cable holder. Do
not lose them. Inspection
-Examine the cabl.e.
*If the cable or cable housing is kinked or frayed,
replace the cable.

CD

1. Kinked Housing 2, Frayed'Cable

1. Choke Knob Shaft _With the choke cable disconnected at the both ends,
2. Detem Ball the cable should move freely within the cable housing.
3. Spring *lfthe cable does not move freely, ,eplace it.
..
4. Cable Holder

Lubrication
Whenever the choke cable removed, Lubricate the
choke cdble dS follow:;.
Installation -Apply water resistant grease to the tips of the choke

beerdart
_Installation is [he reverse of removal. Note the follow­ cable ends.
ing. _Lubricate the choke cable by seeping oil between the
elnstall the choke knob and cap as shown. cable and cable housing.

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 FUEL SYSTEM 2-9

A. Fuel Pump B. Mounting Screws

1. Pressure Cable Luber: K56019-021

_Attached the choke cable to the carburetor and adju,t

the choke cable (see Choke Cable Adjustment).

Installation Note
_Connect the fuel hoses as shown.

-
Fuel Pump

Removal
_Disconnect the c00'ing and bilge hoses off the bulk­
head.
_Remove- the bracket bolts.
_Disconnect the fuel hose~.

Disassembly
_ Remove the fuel pump.

0The fuel pump contains delicate diaphragm that are

easily damaged, and gaskets that must be replaad jf
the unit is disassembled. Therefore, the pump should
not be disassembled unless leakage is evident or inter­
nal damege ;, suspected. Have spare parts available
beforehand.

_Remove the fuel pump body screm.

A. Bracket Bolts B. Fuel Pump _carefully separate the pump assembly into its in­
dividual COlTlponents. There are three body castings,

beerdart
three gaskets, and two diaphragms. The assembly may
be stuck together, and care must be taken to ,woid
_Remove the fuel pump from the bracket. damaging the diaphragms and castings.

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 2·10 FUEL SYSTEM
Idle Speed
,'J'\ """
1,250 ±100 rpm (in water)
1,800 tl00 rpm (out of water)

,); Q
"
6
,
1
,'- " " ~
Mixture Screw Adjustment
Since every carburetor i'i adjusted individually at the
hcrory using a flow meter, specific mixture screw
;;ettings cannot be given. After adjustment, a cap is
imtalled over each mixture screw head with the point
straight down to identify proper mixture ~rew ,~ttings
, . for each unit. DO NOT CHANGE THESE SETTINGS.
If the carburetor is tampered with and these settings
1. Gasket 3. Check Valve cannot be relocated, set the mixtUre screws to the
2. Diaphragm following guide line.
ePull out the mix\ure screw caps.
eTo set each screw, turn it in until it seats lightly, and
then back it oUt the specified number of turns.

Assembly Notes
.Visually inspect the check valves, and replace them if
necessary.
_Use all new gaskets and repalce other parts as required .

............. " - .
Carburetor A. Mixture Screw C. Downward
B. Cap

Idle Speed Adjustment

_Turn the idle adjust screw as required to reach this
Turn~ Out
~tting. Mixture Screw
'89 I '90 & Later Model
Low Speed Screw 1 Ih , 1 I/S
High Speed Screw 'h I 'I,

These guideline represent a "starting point" from

which additional fine tuning of the carburetor may be
necessary.

(i:AUT(O~]
000 not force the mixture screw. into their seats. You
could damage the screws or the carburetor.

beerdart
oOperating the watercraft with the high speed screw at
too lean a setting (screwed in clockwise too far) could
A. Idle A.djust Screw cause serious engine damage.

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 FUEL SYSTEM 2·"

Fuel Hoses

A. High Spl.'l.'d Screw 8. low Speed Screw

A. Hoses

H;gh Alt;tude Performance Adjustment

The norl]lal carburetor sellings are best for sea level. Air Intake Cover
If the watercraft is used at the higher elevatiom, the Flame Arrester
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.

Altitude Turn the high speed screw in

m (ft) the normal position
1 000 (J 300) 1/8 turn
2 000 (6 600) 1/4 turn
3 000 (l 0 ODD) 3/8 turn

NOTE
oThe adjustment of the low speed screw;s not required
on the actual usage. B. Air Intake Cover
A. Bolts

Carburetor Removal eRemove the carburetor mounting bolts and remove the
eRemove the following. carburetor.
Throttle Cable
Choke Cable

beerdart
A. Throttle Cable B. Choke Cable

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A. Mounting Bolts
 2·12 FUEL SYSTEM

Carburetor Installation
elnstallation is the reverse of removal. Note the fol­
lowing.
-Apply a nan-permanent locking agent to the carburetor
mounting bolts, and tighten them securely.
eBend the tab portions of the double washer over the
bolt heads.
_Connect the fuel hoses, as shown,

A. Carburetor Case g. Screw

Float Arm
Main Jet
Pilot Jet

A. Return Line (To Fuel Tank)

B. Main Line (From Fuel Pump)

-Adjust the throttle and choke cables (see Trhottle

Cable Adjustment, Choke Cable Adjustment).

A. Float Arm C. Pilot let

B. Main Jet D. Sel Screw

Carburetor Disassembly Check Valve

_Remove the following.
Carburetor Cover

A. Screws C. Check Valve

B. Plate

A. Carburetor Cover a.Screws NOTE

beerdart
olf the mixture screws need to be removed, check
number of return rotations of mixture screWS' before­
Carbureror Case hand.

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 FUEL SYSTEM 2-13

·T~~ remove the mixture screws, turn them counter­ Carburetor Cleaning and Inspection
clockwise until [hey come out. Do not Ime the spring, -Disassemble the carburetor (see Carburetor Disas­
wa,her, and a-ring on each screw. sembly).

. I WARNING I
cSohent is toxic lind flammable. Avoid prolonged
contact with skin and keep away from open Rame_
Use only in a well·ventilated area. Eye protection
Carburetor Assembly should be worn when compressed air is used to dry
IIAssembly is the reverse of disassembly. Note the fol­
parts. Do not direct air towards anyone. Use 172 kPa
lowing.
(1.75 kg/cm 2 • 25 psi) maximum nozzle preSSure.
elf the mixture ,crews were removed, install them as
shown.
.Immerse all the menl parts in a carburetor cleaning
solution.
_Rinse the parrs in water.
_When the parts are clean, dry them with compressed
air.
_Blowout the air and fuel passages with compressed air .
• lnspect the check valve for damage or deterioration,
and replace it if necessary.
'*If the gasket under the check valve appean damaged, it
may leak and must be replaced .

.. ~ .. '

'®
A. High B. Law

_Place the float arm spring in its hole and install the
connol arm with the rounded projection seating
against the top of the spring.

Carburetor Cover Assembly A. Gasket C. Plate

8. Check Valve

_Check these rubber part, for damage.

a-rings
Diaphragm

beerdart
1. Float Arm 4. Main Jet
2. Spring 5. Pilot Jet
3. Diaphragm Needle A. a-rings 8. Diaphragm

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 2-14 FUEL SYSTEM

*If any of these parts are not In good condition, replace Float Arm Level
them. 1.0 - 2.0 mm
_Check the plastic tip on the diaphragm valve needle. It
should be smooth, without any grooycs, scratches, or
tear-so
*If the float arm level ~s incorrect, bend the float arm
very slightly to change the float arm level.

DiaDhragm Needle Wear

+---{C!J ...............................................- .
Flame Arrester
...... , ' .
Removal
_Remove the following.
Throttle Cable
Choke Cable
1. Diaphragm Needle 2. Diaphragm Needle 'Vear
Air Intake Cover

*rfthe plastic tip is damaged, replace the needle.

Float .Arm Leve/lnspection and Adjustment

-Check the float arm level.
oMeasure from the plaHic tip on the float arm to the
case, as shown. A. Air Intake Cover C. Throttle Cable
B. Bolts D. Choke Cable

Float Arm Level Measurement _Lift out the flame arrester.

Installation
-Flame arrester jmtallation is the reverse of re'T'IOval.
Note the followin~.

beerdart
_Insul! the flame arrester witn the flat face downward
('89 model only).
1. Float Arm Level 3. Carburetor Case -Apply a non-permanent locking agent to the air intake
2. Plastic Tip cover bolts.

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 FUEL SYSTEM 2·15

Flame Arrester Instillation _Pullout the reed valves and gaskets.

"if UP

e:--======='2}

Cleaning
_Remove the flame arrester. A. Reed Valves B. Gaskets
_Blow the flame arrester clean with compressed air.

I WARNING I
oEye protection should be worn w~en compressed air is Installation
used to dry parts. Do not direct air towar-:l anyone. _Replace the gaskets with new one,.
Use 112 kPa (1.75 kg/cm~, 25 psi) maximum nOlzle -Install the reed valves so that the small hole is at the
pressure. bottom.

Intake Manifold, ~eed Valves

Removal
• Remove the carburetor.
_Disconnect the oil pump outlet hose at the oil injection
nozzle.
_Remove the intake manifold. A. Small Hole

-Tighten the intake manifold mounting nuts to the

specified torque.
_After installing the parts removed, bleed the oil pump
if there are air bUbbles in the outlet hme (see Engine
Lubrication System chapter).

Reed Valve Inspection

beerdart
_Check reed warp by measuring the clearance between
each reed and the valve holder.
*If anyone of the clearance measurements exceed, the
5ervice limit, replace the reed valve assembly with a
A. Intake Manifold B. Mountin.!:' NUB new onc.

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 2·16 FUEL SYSTEM

Reed Warp Valve Stop Inspection

Service limit 02mm _Check the valve stops for deformation, cracks, or other
damage.
*If there is any doubt as !O the condition of a sloP,
Reed Warp (exaggerated for illustration) replace the reed valve assemblv with a new one.

'1 )

Fuel Tank
.~. . .
Fuel Tank Removal
-Disconnect the fuel hoses.

1. Clearance 3. Reed Valve Holder

2. Reed

_Check the mounting screw tightnes'i.

• Visually ill~pect the reeds for cracks, folds, or other
damage.
*If there is any doubt as to the condition of a reed,
replace the reed valve assembly,
*If a reed become, wa~y, replace the reed valve
assembly with a new one even if reed warp is less than
ther serviCe limit.

A. FLJel Hoses

Valve Holder Inspection _If the level of the fuel is above the inlet neck, siphon
_Check the reed contact areas of the valve holder for some fuel out!O prevent spilling it.
grooves, scratches, or other damage.
_Check that the rubber coating on the valve holder does
not show any signs of separation from the holder. I WARNING I
*If there is any doubt as to the Condition of the rubber
coating, replace the reed valve assembly with a new oGaitOline is extremely flammable and can be explosive
one. under certain conditions. Push 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.

-Unhook the rubber strap.

_Loosen the clamp on the fuel inlet hose and vent hose
and remove the fuei tank from the hull.

Fuel Tank Installation

_Fuel tank installation is the reverse of removal. Note

beerdart
the following.
A. Reed C. Rubber Coating -Be sure the rubber dampers are in place before putting
B. Valve Stop the tank into the hull.

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 FUEL SYSTEM 2-17

A. Rubber Dampers A. Filler Tube B. Clamp

-Take out the screws in the filler flange, cut the sealant,
and pull the filler away from the hull.

Fuel Tank Cleaning

_Remove the fuel tank.
_Drain the tank into a suitable container.

I WARNING I
DGaBOline i3 extremely flammable and can be explolive
under certain conditioM. Push the STOP button. Do
not smoke. Make sure die area is well ventilated and
free from any source of flame or sparks; this includes
any appliance with a pilot light.

A. Screws B. Sealant
_Flush the tank repeatedly with high flash-point~olvenl
until it is clean. It may be necessary to put a few
marbles or pieces of clean gravel into the tank and
shake it, to knock loose any foreign matter in the
bottom.

[WARNING I
oClean the tank in a well-ventilated area, and take ample
Fuel Filler and Tube Installation
care that thare are no sparks or flame anywhere near _Clean the hull and the filler on their mating surfaces
the working area; this includes any appliance with a with a greaseless, high flash-point solvent.
pilot light. 00 not use gIIsoline or a low f1ash·point
solvent to clean the tank. A fire or expiation could
result. I WARNING)

oClean the parts in II well-ventilated area, and take

ample care that there are no sparks or flame anywhere
near the working area; this includes any appliance with
a pilot light. Do not use gasoline or a low flam-point
solvent. A fire or explosion could result.

_Apply an even Layer of silicone ~ealam to the mating

beerdart
Fuel Filler and TUbe Removal surfaces of the filler and hull.
_Remove the fuel tank. _Push the filler tube onto the bottom of the filler.
_Remove the fuel filler tube. _Slide the clamp into position, and tighten it securely.

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 2-18 FUEL SYSTEM

Fuel Filter Screen Cleaning 4nti-Siphon Valve Inspection

_Clean the fuel filter screens in accordance with the The anti-siphon valve Is bult into the main fuel tap.
Periodic M.aimenance Chart. If the fuel hme were to break between the valve and the
-Remove the main fuel tap. carburetor, rhe anti-siphon valve would prevent fuel flow
• Wash the fuel filter screens in non·flammable or high from the fuel tank .
flash-point solvent. Use a brush 10 remove any con­ eTo check anti-siphon valve operation fill the fuel tank
taminants trapped in the screens. with fuel
oRun the engine a few seconds.
oHold a suitable container under the end of the fuel
I WARNINQ hose and then disconnect the fuel hose from the fuel
pump inlet.
oClean t!"le fuel filter screens in II well ventilated area,
and take care that there are no sparks or flame any'
where near the working area; this ineludes any
I WARNING I
appliance with a pilot light. 00 not use gasoline or II oGasohne is extremelv flammable and can be explosive
low flash-point sol..ent. A fire or explosion could under certain conditions. Push the STOP button. Do
result. not smoke. Mal(,e sure the area is well ventilated and
free from any JOl1rce of flame or spart<s; this includes
any appliance with a nilot li9ht.

Fuel Tap
A. Disconnect this hose.
Main Fuel Tap Removal/Installation
_Disconnect the fuel hoses. u-rf the fuel flow stops, the anti-siphon valve is OK.
_Unscrew the mounting screws, 'l'rlf there is a constant flow of fuel from the removed
hose, inspect the internal parts of the anti-siphon valve.
-Inspect the a.nti-siphon valve.
cUnscrew thr flltlng nut, and remove the jpring and
plunger.

A. Mounting Screw5

beerdart
.When installing the fuel tap, be c<ireful not to over­
tighten the mounting ~crews_ A. O-Ring C. Spring
('Connect the furl hose. (see Fuel System Diagram). B. Plun~er

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 FUEL SYSTEM 2-19
*If there ii any dirt or flJreigrr matter in the ant:-s;phor.
valvc, clean the valve parts ir, a high flash-pain: SOlVent,
""f anv ()frhere parts are damaged, replace tne main rue'
twassembly.

Outside Fuel Tap Remova!/lnstallatiof1

eD;,l'onnect the fue! hos6
_Remove the fuel tap knob.

A.O.Ring

oln~talJ the h.e' tap with the inlet hose fining upward.

• ~.

A. Set Screw 9. Knob

.Pu!1 (Jut the cap, ~nd lIn~crew the fuel tap nut.
_Remove rhe oLBide fuel tap.
A. Inlet Hose Fitting
....... , .
Fuel Vent Screen
•
Cleaning

---
_Clean the fuel vent ,creen in accodance with thr Peri­
odic Maintenance Chart.
_Unscrew the cap and remove the fuel ven! screen.
.....
,

A. Fucl Tap NUl

beerdart
elnnal"ation is the r~\lerse of removal. Note ,he fol­
lowing.
oCheck the O·rings for damage. A. Cap B. Screen

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 2·20 FUEL SYSTEM

_Blow the fuel vent screen clean with compressed air.

OEye protection should be worn when compressed air it

used to dry part,. Do not direct air toward anyone.
Use 172 kPa (1.75 kg/cm~. 25 Pli) maximum nOlzle
pressure.

beerdart
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 ---------------_._----­
ENGINE LUBRICATION SYSTEM J·1

ENGINE LUBRICA"r10N SYSTEM

Table of Contents

Exploded View . 3·2

SpecHications - 3·J
Oil Pump , . 3-3
Oil Pump Bleeding " ......... . . 3·J
Oil Pump Performance Test ' . 3-3
Oil Pump Removal ' . J-4
Oil Pump Installation , . 3-4

Oil Tank. . 3-4

Oil Tank. Removal . J·4
Oil Tank Cleaning . 3-4

Oil Tank Vent Check Valve , '" . J·5

Oil Tank Vent Check Valve Mounting ' ' . 3·5
Oil Tank Vent Check Valve Inspection . J·5

beerdart
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 3-2 ENGINE LUBRICATION SYSTEM

Exploded View

L : Apply non-permanent IOt:king agent.

beerdart
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 ENGINE LUBRICATION SYSTEM 3-3

Specifications

Item Standard Service Limit

Engine Lubrication System:
Engine oil: 2-stroke, N.M.M_A. --­
Certified for Service TC-W
Capacity 5.5 L --­
Engine oil pump:
Oil pump output 5.9 ­ 7.2 mL --­
@3000r/min (rpm), 2 min.

OJ] Pump Performance Test

Oil Pump If a drop in oil Pump Performance is suspected, check
the rate at which the uil is being pumpted .
• Disconnec! the oil pump outlet hose at the oil injection
nozzle and run the ho~ into a measuring glass.
Oil Pump Bleeding
_Mak.e sure that there is p'P;nty of engine oil in tne oil
tank and that oil flow is not reSTricted.
_ Loosen the air bleeder screw on the oil pump a couple
of turns wait until oil flo'N5 out, and then tighten the o For this ten use a 50 : 1 mixture of gasolien to ojl
bleeder screw securely, instead the guoUen normally used.

A. BJe~der Screw
A. Measuring Glass B. Ou tlet Hasp.

(i:AUTl~
-Supply me cooling system with water (see Auxiliary
OUse a 50 : 1 mixwe of gasoline to oil In the fuel tlllllk Cooling in the Gener.ll InformalivrJ chapter).
in place at the gasoline normally used. _Start the engine, and run it a.t a steady 3,000 rpm (use
cDo not turn on the water until the engine is running a tachometer).
and turn it off the immediately when the engine stops. _ColleCt the oil that is being pumped for 2 minutes. If
the quantity of oil wHeeted is within the specificatinn,
-SClpply the waling system with water (see Auxiliary the oil pump is operating properly.
Cooling in the Generallnforrnation chapter).

beerdart
-Start the engine, "eep it at idling speed and check the
oil flow through the tramparent outlet hose.
Oil Pump Output (3,000 rpm for 2 minUles)
_Keep the engine running In[il the air bubble in tnc nut·
let hose disappear. Standard: 5.9 -7.2 mL

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 3-4 ENGINE LUBRICATION SYSTEM

*If the oil pump output i, subnormal, inspect the oil _Connect both oil Hoses and bleed the air from the
pump, and the inlet and outlet hoses for oil leaks. system (see Oil Pump Bleeding).
*If oil leaks are n01 found, replilce the oil pump.

NOTE
oA check valve is built into the oil pump and can nor be
removed.

Oil Tank
Oil Pump Removal
_Squeeze the inlet hose to restrict oil flow and
disconnect it from [head pump . Oil Tank Removal
• Pull off the QUllet hsoe, remove both mounting nuts _Remove the following.
and take off the oil pump and the a·ring. Engine Hood
Engine Oil (Drain)
Oil Inlet Hose
Oil Tank Bracket

A. Inlet Hose C. Mounting Nuts

B. Outlet Hose

A. Oil Tank C. Oil Tank Bracket

B. Oil Inlet Hose D. Mounting Bolts
Oil Pump Instal/ation
-Be sure the O-ring is in place and in;tall the oil pump
on the magneto eover.
(~When mounting the oil pump, note the position of the Oil Tank Cleaning
slot in the flywheel bolt, and then turn the oil pump _Flush the tank repeatedly with high flash.point solvent
shaft so that it will fit inw the slot. until it is clean.

I WARNING I
OClaan the tank in a well-ventilated area, and take ample
C<lre that there are no sparks or flame anywhere near
the working area; this includes any a1ppliimce with a
pilot light. Do not use gasoline or a low f1ash·point
solvent to clean the tank. A fire or expiation could
result.

beerdart
A. Sial C. O.Ring
B. Pump Shaft

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 ENGINE LUBRICATION SYSTEM 3-5

Oil Tank Vent Check Valve

Oil Tank Vent Check Valve Mounting

The oil tank vent check valve is mounted in the oil
tank vent hose to prevent oil from ~pilling during riding.
Air can flow into the tank to allow oil to be drawn out
by the oil pump, but oil can nor flow out the check
valve.
_The oil tank vent check valve must be mounted so that
,he arrows on its case arc pointing toward the oil tank.

I (~)

A. Check Valve

Oil Tank Vent Check Valve Inspection

-Remove the check valve ilnd blow through it from each
end .
• It' the check valve will allow air to flow as shown, iT is
OK.
*If air will flow through the check valve in both direc­
tions or in neigher direction, the check valve must be
replilced.

-0
G

I .

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 EXHAUST SYSTEM 4-1

EXHAUST SYSTEM
Table of Contents

Exploded View . 4-2

Exhaust Pipe and Manifold . 4-3
Exhaust Pipe and Manifold Removal. . 4-3
Exhaust Pipe and Manifold Installation " . 4-3
Exhaust Pipe and Manifold Cleaning and Inspection _ _ . 4-4
Water Box Muffler . 4-4
Water Box Muffler Removal . 4-4
Water Box Muffler Installation Note ' . 4-4
Water Box Muffler Inspection _.. 4-4

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 -
--~-..,

r I
® I
I
I
I

( I
I
I
II

I
1_­
A,j,)<j, :I
I
I
I
I

: Muffler :
I ,

,,
,

,
, I

.. I
,I
,I
I

I
"

r - --l
I
I ,I
I I
I I
A ply non -pe rmanent locking agent. I I
L: p .. sealant. I ----'f­
SS: Apply SlhCOn~ -m 87 in.lb) I

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T" 9 8 N·m (1.0 9 "45 ft.lb)
. . Okg-m. I ,I
T2' 20 N-m (2. • 36 fNbl i
T3; 49 N·m (5.0 tc;g·m, L _ I
~

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 EXHAUST SYSTEM 4-3

Exhaust Pipe and Manifold Installation

Exhaust Pipe and Manifold _!mtallation is the reYerse of remoYal. Note the fol­
lowing.
_Install the exhaust manifold gasket so that the hole in
Exhaust Pipe and Manifold Removal the center of the gasket is up.
-Remoye the following.
Engine Hood (see Frame chapter)
Cooling Hose
Bypass Hosc
Water Drain Knob

A. Hole

-Tighten the exhaust manifold mounting nuts to the

speCified torque (see Exploded View), following the
specified tightening sequence.

A. Cooling Hose D. Clamp Exhaust Manifold Mounting NUt! Tightening Order

B. Bypass Hose E. Bolts
C. Water Drain Knob

"Loosen The clamp and remoyc the exhaust pipe

bolts.
-RemMe the exhaust pipe.
-Disconnect the inlet cooling hose. 2
-Remoyc thc exhaust manifold.

_Install the exhaust pipe ga~k.et a~ ~hown.

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A. Inlet Cooling Hose C. Mounting Nuts
B. Exhaust Manifold A. Gask.et

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 4-4 EXHAUST SYSTEM

-instalilhe da.mper with the "INSIDE" mark facing in.

A. Clamps B. Rubber Straps

C. Water Box Muffler

eR~move the water box muffler.

A. "INSIDE" mark

eTighten the exhaust pipe bolts to the specified torque

(s~t: Exploded View).
Water Box Muffler Installation Note
elnstall the tube clamps as shown being careful of the
screw position and the screw head direction.

Exhaust Pipe and Manifold Cleaning

iJnd Inspection
_Clean the carbon deposits out of the e'l.haust passages
with il blunt, roundedged tooL
• Flush foreign matter out of the water passages with
fresh water. (j)
_Check the insides of the water passages for corrosion. .. ...
Check the gasket surfaces for flicks or Other damage.
*If there is ex"Cessive corrosion or if the gasket surfaces
are 50 badly damaged that they will not seal properly,
replace the p,ut.
• Check the stainless pipe carefully for cracks, especially
in the welds. Also look for corrosion both inside and
out.
*If there are large cracks in the stainless pipe walls or
welds, or if it i5 very corroded, replace the stainles~
pipe.
eCheck the rubber parts for cracks, tears, hardening, or
general deterioration.
*If the rubber part~ show damage or if they leak, replace
them.
,. Clamps

............................................................................
Water Box Muffler Water Box Muffler Inspection
.... , - . eRemove the water box muffler .
eEmpty any water out of the water box.
Water Box Muffler Removal eCheck the water box carefully for crads, especiallY in

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e Remove the engine hood, the welds. AI~o look for corrosion.
e Loosen the clamps. *If there are cracks in the water box walls or welds, or if
e Unhook the rubber straps. it is very corroded, replace the water box.

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 ENGINE TOP END 5-'

ENGINE TOP END

Table of Contents
Exploded View _. . . . . . . . . . . . . . . . . .. . 5-2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Special Tools ,............................ 5-3
Engine Top End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Disassembly and Assembly. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 5-4
Engine Top End Disassembly , . .. . . . . . 5-4
Engine Top End Assembly... . . . .. . .. .. . . . . . . .. .. . . .. . 5-5
Maintenance and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Compression Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
CyHnder Head Warp. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 5-7
Cylinder Wear Inspection _. . . . . . . . . . . . 5-7
Piston Diameter Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Piston/Cylinder Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
80ring and Honing _.. _. .. . . . . . .. . .. . . .. .. .. . 5-8
Piston Ring, Piston Ring Groove Inspection. . . . . . . . . . . . . . . . . . 5-8
Piston Ring End Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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 5-2 ENGINE TOP END

Exploded View

o o

o /
o

I
@

o : Apply engine oil.

55: Apply silicone sealant.
T1: 29 N-m (3.0 kg-m, 22 h-Ibl
T2: 34 N-m (3.5 kg-m, 25 h·lb)

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T3; 9.8 N-m (1.0 kg-m. 87 in-Ibl
B

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 ENGINE TOP END 5-3

Specifications

Cylinder Compression:
Item
---l-
I
Standard
(usable rangel
665 - 1,325 kPa 16.6 - 13.5 kg/em',
Service limit

125 - 192 psi) (open throttlel

---
I 0.05 mm
Cylinder head warp - --
I
Cylinder Block, Piston:
I
Cylinder inside diameter I 76.050 - 76.065 mm 76.10mm
Piston diameter I
('8 mm up from bottom of skirt) I 75.961 -75.976 mm 75.81 mm
Piston!cylinder clearance 0.064 - 0.094 mm ---
Oversize piston and rings +0.5 mm and +1,0 mm , --­
Piston ring/groove clearance
Top (keystone) --- I
---
Second (keystone) -­- --­
Piston ring groove width
Top (keystone) -­
-­ --­
Second (keystone) --­ --­
Piston ring thickness
Top (keystone) --­ --­
Second (keystone) --­ --­
Piston ring end gap
Top 0.2 ­ O.4mm 0.7 mm
Second 0.2 - 0.4 mm 0.7 mm
J

Adapter: 57001-1159
Special Tools

Compression Gauge: 57001-221

Piston AingCompressor Anembly: 57001·1094

Pi~ton Pin Puller Astemblv: 570(11-910

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e
o

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 5-4 ENGINE TOP END

Engine Top End

Disassembly and Assembly:

Engine Top End Disassembly
_Remove the following.
Engine Hood
Exhaust Pipe
Exhaust Manifold
Carburetor
_Remove the <:ylinder head.

A. Pliers B. Snap Ring

• Remove the piston by pushing its pin OUT the side that
the eire lip was removed. U5e a piston pin puller
il.5scmbly (special tool), jf the pin is tight.

A. Cylinder Head B. Head Nuts

eRemove the cylinder,

A. Piston Pin Puller Assembly: 57001 ·910

_Carefully spread the ring opening with your rhumbs

and then push up on the opposite side of the ring to
remove it.

A, Cylinder a,Base Nuts

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_Stuff clean rags into the crankcase opening to prc~'em
dirt or foreign objects from falling into the crankcase .
• Remove the piston pin snap ring. A. Piston Ring

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 ENGINE TOP END 5-5

Engine Top End Assemblv

aAssl.'mbly is the reverse of disassembly. Note the foi­
lowing.
_If any parts in the piston assemblies require replace­
ment, or if the cylinder is honed or replaced, be sure
to check the critical clearances of the ntw parts agains~
the values given in Specifications.
alnstal! the piston rings so that the correct side faces
upwards J.s ~hown.

Piston Rings

A. Left Side B. Arrows

_------L N Mar~ (on Top)
Top ring
\

= --~'-­
~
_0
is I ~_/
-When installing a piston pin snap ring, compress it
only enough to in'itall it and no more.

=
/
Second ring

.-r1 000 not reuse rings, as removal weaken, and deforms

them.
well.
They could fall out and score the cylinder

_When installing the piston rings by hand, first fit one _Fit a new piston pin snap ring into the side of each
end of the piston ring against the pin in the ring piston so that the snap ring opening does not coincide
groove, ,>pread the ring opening with the other hand with the slits of the piston pin hole.
and then ,lip the ring into the groove.
_Check to see that the pin in each piston ring groove is
belween the ends of the piston ring.

Piston Ring Position

cp

A. Slits B. Ring Opening

1. Pin

_Set the new cylinder base gasket in place on the crank·

_Apply engine oii to the surface of each piston pin. case.

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_Mount the piston on the connecting rod with the arrow _Apply engine oil to the surface of the pistons.
on its crown pointing to the left (exhaust) side of the _Compress the piston rings using the piston ring com­
engine. pressor as,emblies (special tool).

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 5-6 ENGINE TOP END

Cylinder Head Nun Tightening Order

A. Pi$TOn Ring Compressor As.!rembly: 57001·1094

o E/lhaun Side

eStan the t:ngir,c to check ror fuel and oillC'aki, (:;"(haust

• [horoughly oil the cylinder bores.
leaks, and excessj\'l' vibration.
-Slide the cylinder block clawn over the crankcase studs
onto the crankcase.
I WARNING I
000 n01 run the engine in a closed area. Exhaust gases
contain carbon monoxide, a colorless, odorless, poison·
000 not force the cylinder block. Make sure the ring,
ous gas which can be lethal.
afe in position.

-Install the cylinder base rl'Jts, and cross-tighlen them

to the specified torque (,1"1" Exploded View).
OOperate the engine only for short periods without
-Place a new cylinder head gasket on the cylinder head,
coating water, Stop the engine immediately if the
oThe "UP" mark of the gasket mu~t face upward and temperature! warning buzzer goes on. Overhuting will
"EX" mark must face toward the exhau~t side of the
cause severe engine and exhaust system damage.
engine.

Maintenance and Inspection:

Compression Measurement
.Thoroughly warm up the engine, while cheddng that
there is no compression leakage from around the ,park
plugs or the cylinder head gasket.

cOperat(! the engine only for short periods without

cooling water. Stop the engine immediately if the
temperature warning buzzlI!r goes on. Overheating wilt
cause severe engine and exhaust system damage.
A. Head Gasket C. "EX" Mark
B. "UP" Mark eStop the engine.
eRemove the spark plugs and screw a compression gauge
(special tool) firmly into the spark plug hofe,
eUsing tht' staner motor, turn the engine over with the
_!nstall the cylinder head and tighten the cylinder head throttle fully open until the compression gauge stops

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nUlS to the specified torque (see Exploded View). rising; the compression is the highest reading obtain·
0The tightening sequence numbers are marked on the able.
cylinder head. e Repe<l-t the measurement for the other cylinder.

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 ENGINE TOP END 5-7

Cylinder Compreuion (Usable Range)

8ti5 - 1,325 kPa
(8.6 - 13.5 kg'cm1 , 125 -192 psi)
{open throttle I

A. Straightedge B. Thickness Gauge

A.. Compression Gauge: 570Cl-221

B.'\daprer: 57001·1159

Cylinder Wear Inspection

*Jf the cylinder wmprcssion is higher than the uoable .In,rcect the inside of :he cylinder for scratche! and
range, check the following_ abnormal wear.
cCarbon buildup on the piston head anc cylinoer head *ff the cylinder is damlged or badlv worn, lepl<'l::e it
- clean off any ~arbon on t'1e piston head and with a new one.
cylinder head. _Since there is d difference in cylinder wear in different
::-Cylinder head gasket, cylinder base gaskeH - use directions take a side-to·side and a frDnt·to-back
only the proper gasket" The use of a ga,ket of mezsurement at each of the 3 locarions (total of 6
incorrect thickness wilt change the compression. measuremenH) shown in the figure .
• If cylinder wmpres!ion is lower than the uwble range, *If any of the cylinder inside diam~ter mea,uremenls
check the following: exceeds the ser,ice limit, lhe ,-ylindcr will have to be
,::.:Gas leakage around the cylinder head - rel"laCl~ tre bored o,ersiz£: and then honed.
damag~u gd,~et ald cheek the cyrmder he~d for
warp.
oPi~tor/cylindcr clearance" piston seizure.
l~ Piston rings, piston ring grooves wear. Cylinder Inside Diiuneter Measurement

1 m
IOD
CD

Cylinder Head Warp Inspection

.Lay a straigrtcdge across the lower SUrface of the head
J [
\1
at several cifferent points, and measure warp by
inserthg a thicknns gauge between the >udightedgc
and the head.
• ,f warp c:'\ceeds the sNvicl?' limir, repair the maling
surfac~. Replace the cylinde, heac if the mating "
surface is badly damaged. -- m
1 ~- ­
1:\ i ~

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Cylinder Head Warp 1. 10 mm 3. 25 mm
Service Limit: 0.05 mm 2. 75 mm

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 5-8 ENGINE TOP END

Cylinder Inside Diameter Piston/Cylinder Clearance

Standard: 76.050 - 16.065 mm and less than The pi,ton-lu-cylinder clearance must be checked, and
0.01 mm diHerence between any two the standard vahle maintained anytime a pi,ton or the
cylinder block are replaced with new part" or whenever
measurements
the cylinder is rebored and ovenitc pistons installed.
Service Limit: 76.10 mm, or more than 0.05 mm
eThe mo.;t accurate W~',' to find the piston clearancf' i,
difference between any two mell1Ure­
b,. maling separate piston and cvlinder diameter
ment. measuremenIs and then computing the difference
between the two values,
-Measure the piston diameter as just described, and
subtract thi5 value from the measurement. The
difference is the piston clearance,

Piston/Cylinder ClearanOll
Piston Diameter Measurement
eMc.asurc-. the uUl"it!e diameter ot the pi-;tun 18 mm up 0.084 - 0.094 mm
from the bonom (Jr' the pi~lorl <It d ring angl.c 10 the
direcLiuli ul the pistun pin.

Piston Diameter Measurement

Boring and Honing
Wher) boring and honing a cvlinder, note the fol·
lowing:
oTher'e are two sizes of oversize pistuns available.
Oversize pistons require oversize rings.
Oversize Pistons and Rings
0.5 mm Oversize
1.0 mm Oversize
oBeiore boring a cylinder, first measure the exact
diameter of the oversize piston, and then, according to
The standard clearance in the Service Data Section,
determine the rebore diameter. However', if the
amount of boring necessary would make the inside
diameter greater than 1.0 min o..'ersize, the cylinder
block must be replaced.
:JCylinder imide diameter must not vary more than 0.01
mm at any point,

CD -J eBe wary of measurements taken immediately after

boring since the heat affects cylinder diameter.
:::;In the case of a reborrd cylinder and oversize piston,
the ,ervice F,mit for the cylinder i, Hie diameter thaI
the cylinder wac, bored (Q plus 0.1 min and the ,ervice
1. Piston Diarne(er 2. 18 min limit for the piston i, the oversize piston original
diameter minus 0.15 mm. If the exact figure for the
rebored diameter is unknown, il can be roughly de·
termined by measul'ing the diameter aL the base of
Piston Diameter the cylinder.
Standard: 75.961 - 75.976 mm
Servil:e Limit: 75.81 mm

<'If the measurement is I,ess thJn the service limit, Piston Ring, Piston Ring Groove Inspection
replace the piston.
.Visually inspect Ihe piston rings and the pi,tcn ring
grooves.
lit If the ring; are worn unevenl\' or damaged, they mu~t
NOTE
be replaced.

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oAbnormal wear such as a marked diagonal pattern *If the piston ring groove are worn une..'enly or dam­
across the piston skirt may mean a bent connecting rod aged, the piston must be replaced and fined with new
or a misaligned crankshaft. rings.

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 ENGINE TOP END 5-9

Piston Ring End Gap

.Place the pis IOn ring inside the cylinder, u,ing thl:
piston to locate the ring squarely in place. Set it
close to the bottom of the cylinder. where cylinder
wear is low.
_Mea.sure the gap between lhe ends of lh~ ring Wil_h a
thic/"nc" gauge.
*If the gap is wider than the service limir, the ring is
worn excessively and must be replaced.

Plstoll Rin9 End Gilp

Standard Se"jce 1.imit
Top 0.20 - 0.40 mm 0.70 mm
Second 0.20 - 0.40 rom 0.70 rom

End Gep Mealurement

'--- ~ @) [Uf1
1":-
1
··• CD ~
M Dc]/
'(j I (J­
I>

1. Pistor Ring
2. Gap

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 ENGINE REMOVAL AND INSTALLATION 6-1

ENGINE REMOVAL AND INSTALLATION

Table of Contents

Exploded View " .. . .. .. . 6-2

Engine Removal/Installation. . . .. . .. . . . . .. .. .. . . . . . .. ... 6-3
Engine Rt:lnoval _. 6-3
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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 6-2 ENGINE REMOVAL ANO INSTALLATION

Exploded View

/
0i;
,
\

@J
@ / //6
\
~,
~~
~~
, A - 0

I
@
/1 '"
J

i ,
\
\
®©
L : Apply non-p~rmanent locking agent.
T1 : 22 N-m (2.2 kg-m. 16.0 ft-lb)
T2: 16 N·m (1.6 kg-m, 11.5 It-lbl
T3: 36 N-m (3.7 kg-m. 27 tt-Ib)

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 ENGINE REMOVAL AND INSTALLATION 6-3
............................................................................
Engine Removaillnstallation

Engine Removal
_Remove the following.
Engine Hood
Expansion Chamber

A. Starter Motor Cable

B. Battery Ground Cable
C. Inlet Cooling Hose

Oil Pump Hose (Inlet)

Pulse Hose

A Expansion Chamber B. Clamp

_DI,CQnnect the following.

Throttle Cable
Choke Cable
Fuel Hoses
Spark Plug Leads

A. Oil Pump Hose Onlet) B. Pulse Hose

_Open the ele..:tric case and disconnect the stator leads .

A. Throttle Cable C. Fuel Hoses

B. Choke Cable
A. Stator Leads B. Bolts

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Starter Motor Cable _Remove the engine bed mounting bolts.
Battery Ground Cable oTake OLH any shims under [he engine bed, and mark
Inlet Cooling Hose them so they may be put back ill the same place.

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 6·4 ENGINE REMOVAL AND INSTALLATION

eApply a non-permanent locking agent to the following

mounting bolts, and tighten them to the specified
torque (see Exploded View).
Engine Mounting Bolts
Engine Bed Mounting Bolts

_Check the gap between rhe engine bed and the dampers
by rocking the engine.
_If there is a ga9, insert a ~uitable shim between the
engine bed and the damper to achieve a good fit.

Shim Selectiofl
Shim No. Thickn~1
92025-3705 to.3 mm
92025-3706 to.5 mm
eRemove the engine. 92025-3707 n.D mm
_Remove the engine bed. 92025-3708 n,5 mm

eAfter installing the engine in the hull, check the

following.
Throttle Cable
Choke Cable
Oil Pump Bleeding
Fuel and Exhau5t Leak5

\ WARNING I
000 not run the engine in 8 closed area. Exhaust gases
contain carbon monoxide, 8 colorless, odorlen,
poisonous qal which can be lethal.

A. Mounting Bolts
COperate the engine only tor short periods without
cooling water. Stop the engine immediately jf ttle
temperature warning buzzer goes on. Overheating will
Engine Installation
cause severe engine and exhaust system damage.
eEngine installation is the reverse of removal. Note the
following.
eBe sure thele are no foreign objects and parts inside of
the hull.
_Check the coupling damper for wear and damage.
_Install the engine bed so that the small notches are
on the magneto end of the engine as shown.

1l' "Front"

o o
11=

o ![, 0 I' 1 ,0
1 ']!
, o

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 _., ----------_ ...•... _­

ENGINE BOTTOM END 7·'

ENGINE BOTTOM END

Table of Contents
Exploded View, . .. . . . . . , .....•.......... , n
Specifications. . . . . . . . . . . 1·3

Special Tools - . 7·3

Sealant , , . 7·3

Coupling
CouJ,Jling Removal
Coupling Installation Note
Coupling Damper Inspection ....
'
' .. '
"
' ' .-

......... -
" ., .. ,
'
"
.
'
.
7A
7-4
7A
7-4
..
Magneto Flywheel, , ........... , . 7A
Magneto Flywheel Removal , ' , 7A

Magneto Flywheel Installation . . , , ' . , . , . , . , , ' , .. ' . , ' . , . ' H

Stator, .... , , . , .... , , . , ­ , , . , ... ' .. , , ' , ... ' , .. , , ' 7·5

Stator Removal. , .' , .. , ' , , .. 7·5

Stator Installation Notes ' ' , , 7·6

Water Drain Valve ' -- ,, , , , 7·6

Water Drain Valve Removal. , '.' '., . 7·6

Water Drain Valve Installation , '. , . n

Crankcase Splitting _ - . . . . . , . . . . . . . .. ' . . . . . . . , . . . . . . . . . . 7·8
Crankcase Splitting . 7·8

Crankcase Assembly , , 7·8

Crankshaft Maintlmance , .. , ..... , ..... , ...........•......... 7·'0

Connecting Rod Bend/Twist. , . 7·'0
Connecting Rod Big End Radial Clearance , , .. 7·,0

Crankshaft Main Bearing Wear , ' 7·11

Crank91aft Runout ' ' , .. , . ' 7·11

Crankshaft Main Bearing Wear, , , .. " . 7-11

Crankshaft Assembly Specifications ' , 7-12

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 7-2 ENGINE BOTTOM
................... END
...... lew
Exploded V:·············· ..··· ..· ••..•.....•......•­ .
........ ., .
.. ......... ......... .............. ....... ........ .. ....

•
G .· A pp, y grease
I
L . Apply non •

t
lG· . A -permanent loe: .
M .' pplV liquid gasket kmg agent.
· Apply molybden ..
T1: 98 N-m (10.0 k .um disulfide grease.

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T2: 25 N-m {2 5 k 9 m. 72 ft·lbl
T:3: 7.8 N.m (~8 g-m, 18.0 tt-Ibl @©
. 0 kg,m, 69 in-Ibl

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 ENGINE BOTTOM ENO 7·3

Specifications

Item Standard Service Limit

I
Crankshaft:
I
Runout 0.04 mm 0.10 mm TIR
Connecting Rod Side crearnace 0.45 - 0.55 mm O.8mm
Connecting Rod Radial Clearance 0.045 - 0.055 mm 0.11 mm
Connecting Rod Bend 0.05 mm/l00 mm 0.2 mm/lOG mm
Connecting Rod Twist 0.15 mml100 mm 0.2 mm/100 mm

............ , - - - -- , - . Coupting Holder: 57001-1230

Special Tools
...........................................- .
Magneto Puller: 57001·259

Flywheel Holdo': 57001.1156 Sealant

Kawas"ki Bond (liquid gasketl: 92t04·1003

Rotor Puller: 57001·1099

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 - \

7-4 ENGINE BOTTOM END

Cou?ling Magneto Flywheel

... , " .
Coupling Removal Magneto Flywheel Removal
eRemove the engine (sec Engine Removal/Installation eRemDvC the following.
chapter). Engine Hood
eRemove the coupling damper and cover. Oil Tank and Brach:ct
eRemove the magneto cover. Water Box Muffler
eHolding the n,wheel with the holder (see Magneto Oil Pump
Flywheel Remon!), unscrew the coupl.ing with the e Remove the magneto cover.
coupling holder (special tool).

@
\

A. Holder: 57001-1156
A. Magneto Cover
B. Coupling Holder: 57001-1230

elnstall [he holder (special tool) on the flywheel with

Coupling Installation Nate three bolts{D: 8 mn', x L-IO mm).
eGredse to thr. coupling threads.
_Screw the coupling onto the crankshaft and tighten it
to the specified torque (see Exploded View).

000 not use the longer bolts, Longer bolts might hit the
charging coil and damage it.
Coupling Damper Inspection
_With the engine removed, remove the coupling damper
and inspect it for wear and deterioration.
*If it is grooved or misshapen, replaced it with a new
damper.
*If there is any doubt as to coupler condition, replace
it.

di41iiMiN<
A. Holder: 57001-1156
B. Bolts (D: 8 mm xL'. 10 mm)

beerdart
ePul1 the flywheei off the crankshaft. using the magneto
puller a.nd the rotor puller (special tools) and adapter
A. Wear Points bolt (D: 10 mm x L: 20 mm, Hex. 14 mm).

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 ENGINE BOTTOM END 7-5

A. Adapter Bolt(D: 10 mm xL: 20 mm, Hex. 14 mm) A. WoodrUff Key

_Apply a thin coat of engine oil to the flanged portion

of flywheel bolt.
_Tighten the flywheel bo!t to the specified torque (s.e1O'
Exp!oded View).
_Check that the knock pins are in place and replace the
G-ring if it is damaged,

A. Magneto Puller: 57001-259

B. Rotor Puller: 57001-1099

olf the flywheel is difficult to remove, turn the puller

shaft while tapping the head of the pUller shaft with a A. Knock Pins
hammer_Do not attempt to strike the grab bar or the
flywheel itself, Striking the bar or the flywheel can
cause the bar to bend or the magnets to lose their
_Apply a non-permanent locking agent to the threads of
magnetism.
the magneto cover mounting bolts, and tighten them
,ecurely.

Magneto Flywheel Installation

_Installation is the reverse of removal. Note the fol­ ................... , , , .
lowing, Stator
_Using a nigh flash-points solvents, clean off any oil

beerdart
or dirt that may be on the flywheel bolt, the crank­
shaft taper, or in the tapered hole in the flywheel. Stator Removal
_Fit the woodruff key securely in the crankshaft, before -Remove the magneto flywheel.
installing the magneto flywheel. eOpen the electric case.

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 7-6 ENGINE BOTTOM END

-Remove the grommet cap and disconnect the stator Stator Installation Notes
leads. _Grease the outer surface of the grommet.
eAlign the mark on the stator plate with the timing
mark on the crankcase.

A. Grommet Cap B. Stator leads

A. Align the marks.

• Remove the grommet with the stator leads.

Water Drain Valve

Water Drain Valve Removal

• Remove the following.
Engine Hood
A. Grommet 8. Screws Exhaust Pipe and Manifold (see Exhaust System
chapter)
Starter Motor (see Electrical system ch~pter)
eRe move the stator. eRemove the water drain valve.

--
;pr"
~

0\.

beerdart
-
7
A. Stator A. Mounting Bolts B. Water Drain Valve

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 .......
-----------------~-._._---

ENGINE BOTTOM END 7-7

A. Drain Hole

_Lock the water drain valve.

::::With the water drain valve knob pulled, tighten the
locknut.

1. Reed Valve Assembly 6. Control Valve

2. Gasket 7. E-Ring
3. Reed V;liv., Cover 8. SprinR
4. Cover Bolt 9. Control Valv\: Housing
5. Valve Cap 10. Mounting Bolt

eRemove the valve cap and then remove the E-ring to

disassemble the control valve.

A.. Lock.nut

_Install the ~s.semb[y on the lower crankcase h~lf.

-='App\y a non-permanent locking agent to the threads of
the water drain valve mounting bolts.
OLoosen the locknut just until till' water drain vJlve
knob returns by spring tension.
_After installing the water drain valve, check that the
control valve fits tightly in the drain hole.

Water Drain Valve Installation

_Installation is the reverse of removal. Note the fol­
lowing.
_Visually inspect the reed valves for cracks, folds, or
other damage.
*If there is any doubt as to the condition of a reed,
replace the reed valve assembly.
eApplya non-permanent lockingagcnt to the cover bolt

beerdart
threads.
e<::lean the drain hole and the valve cap.
_Visually inspect the valve cap, and replace it if neces­
sary. A. Control valve fits tightly.

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 7-8 ENGINE BOTTOM ENO

Crankcase Splitting

Crankcase Splitting
_Remove the engine (see Engine Removal/Installation
chap(~r).
eRemove the following parts from the engine.
E.xhaust Manifold
Carburetor
Intake Man ifold
Starter Motor
Cylinder Head
Cylinder Block
Pistons A. Pry Points
Water Drain Valve
Oil Pump
Coupling
Magneto Flywheel _Lift the crankshaft assembly out of the upper crank·
Reduction Gear case half.
Stator

NOTE
oAlways remove the coupling before removing the
magneto flywheel, or there won't be any way to hold
the crankshaft while unscrswing the coupHng.

Crankcase Assembly
eAssembly is the reverse of splitting. Note the fol­
_Remove tl",e 6 mm crankcase bolts first and then the 8 lowing.
mm bolts. eVisually inspect the crankshaft O-ring, and replace it
if necessary.
eGrease the inner surface of the collar.

A.6 mm Bolts B. 8 mm Bolts

A. D-Ring C. Apply grease.
'3. Collar

beerdart
.Pry the poims indicated in the figure to split the
crankcase halves apart, and then remove the lower eGrease the lips of the oil seals.
crankcase half. _Pack grease between the rear oil seals (coupling side).

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 ENGINE BOTTOM END 7-9

_Check that the knock pins are in place.

A. Pack grease.

_Install the oil seals as shown.

A. Knock Pins

_With a high flash-point solvent, clean off the mating

surfaces of the crankcases halves and wipe dry.
eApply liquid gasket to the mating surface of the lower
crankcase half.
_Install the lower crankcase half onto the upper half.
_Apply a non-permanent locking agent to the crankcase
bolts, and tighten them to the specified torque (see
Exploded View).
oThe tightening sequence numbers are marked on the
lower crankcase half.

Crankcase Bolts Tightening Order

1. Double Lips Seals
2. Single Lip Seal
v15~14

_PlaCt~ the crankshaft assembly in the upper crankcase

half,o that the po,ition ring on the crankshaft assem­ ~
r;i" "20­
blv fits into the groove in the crankcase.
71'­
IR~ "I
21
!--­

1\I~TI
Q III L 11 <41~ ,'-
~UlOC-- Hii'
n

beerdart
A. Po,ition Ring C. Cran",haft Assembly
B. Groove

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 7·10 ENGINE BOTTOM ENO

c;With the connecting rod held vertically, use a h"ight

Crankshaft Maintenance gauge to measwe the difference in the height 01 the
arbor above the surface plate over a 100 mm length to
determine the amount of connecting rod bend.
The crankshaft changes the ~eciprocating motor of *If connecting rod bend exceeds the service limit, the
:he piston into rotating motion to drive the jet pump. connecting rod or crankshaft must be replaced.
Cranbhaft trouble, such as excessive play or runout,
".\'ill multiply the stress caused by the intermittent force
on the piston and will result in not only rapid crankshaft Connl!eting Rod Bend
bearing wear, but also noise, power loss, vibration, and
shortened engine life. A defective crankshaft should Standard: Under 0.051100 mm
always be detected at an early stage and repaired im­ Service Limit: 0.2!100 mm
mediately.
The following explanation concerns the most common
cranbhaft problems and the method for measuring _Measure connecting rod twist.
plav, runout, and con-rod alignment, 1t does not cover cWith the crankshaft ~lill in the aiignmcnt jig, hold
crankshaft di5<lssembly because of the highly specialized the connecting rod horizQiltaily and measure the
equipment thaI is required. If crankshaft components amount that the arbor varies from being parallel with
become damaged or worn, the entire shaft should be the crankshaft over a 100 length of the arbor to
replaced as an assembly, or rebuilt by a properlv equip­ determine the amount of connecting rod twist.
ped ShOD.

Connecting Rod Twist

I lOa mm
~--""'-"""----

Connecting Rod Bend/Twisr

-Measure connecting rod bend.
OSet the crankshaft in an alignment jig or in V blocks
on a surface plate.

Connltcting Rod Eend

lOa mm

*If connecting rod twist e;>;:ceeds the service limit, the

conm:rting rod or crankshaft must be replaced.

C,;mnecting Rod Twist

Standard: Under 0.151100 mm
Service limit: 0.2/100 mm

Connecting Rod Big End Raida! Clearance

beerdart
_Check big end radial clearance.
c$elect an arbor of the same diameter as the connecting OSet the crankshaft in an alignment jig or on V blocks,
rod small end and at ICdst lOa mm long, and insert the and piace a dial gauge again,t the connecting rod big
arbar through the connecting rod small end. end.

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 ENGINE BOTTOM END 7-11

~ollnecting Rod Big End Radial Clearance *If the mea,urcd value exceed, the service limit, the
crankshaft should be either replaced or rebuilt.

Connecting Rod Big End Side Clearance

Standard~ 0.45 - 0.55 mm
Service Limit: 0.8 mm

CPush the connecting rod first towards the gauge and

then in the opposite direction. The difference between
the two gauge readings in the radial clearance.
*If the r<ldial clearance exceeds the service limit, the Crankshaft Main Bearing Wear
crankshaft assembly mu,t be replaced or disassembled _Wash the bearings in high flash·point solvent, blow
and the crankpin, needle bearing, and connecting rod them dry (DO NOT SPIN THEM), and lubricate them
big end examined for wear. with engine oil.

Connecting Rod Big End Raidal Clearance

Standard:
Service Limit:
0,45 - 0.55 mm
0.11 mm
I WARNING I
oSolvent is toxic and flammable. Avoid prolonged
contact with skin and keep away from open flame.
Use only in a well·ventilated area. Eye protectKIn
should be worn when compressed air is used to dry
parts. Do not direct air towards anyone. Use 172 kPa
(1.75 kg/cm 2 • 25 psi) maximum nozzle pressure.
Connecting Rod Big End Side Clearance
_Measure big end side clearance.
o Insert feeler gauges between the big end and either
crank l1alf to determine clearance. _Turn each bearing over br hand and see tl1at it m.lkes
no noise, turns smoothly, and has no rough spots.
*If any of the bearings are defective, replace them.
Connecting RDd Big End Side Clearance

r- Side Clearance

Crankshaft Runout
_Check crankshaft alignment by measuring runout.
oWith the crankshaft on V blocks, rotate the crankshaft
slowly and measure runout at each of the locations
shown.
*If the runout at any point exceeds the service limit,
the crankshaft must be either replaced or rebuilt.

beerdart
Crankshaft Runout (Either Location)
Standard: Under 0.04 mm Tl R
Service: 0.10 mm TlR

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 7-12 ENGINE BOTTOM END

Crankd'laft Runout

~
rr

V Blol;b

Crankshaft Assembly Specifications

If the crankshaft is disassembled, use these
specifications during rebuilding.

Crankshaft Assembly Specifications

0- 0.5 mm

0.2 - 0.4 mm

0.4 ~ 0.6 mm --j­

0.2 - 0.4 mm
0- 0.5 mm

beerdart
0.45 - 0.55 mm

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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
Bilge Pump . 8-3
Removal . 8-3
Installation
Bilge Switch
_
, ,
.
.
8-3
8-4
lEI
Cooling and Bilge System Hoses " . 8-4
Hose Removalll nstallation , . 84
Hose Inspection , .. , . 8-4
Cooling and Bilge System Flushing , . 8-4
Cooling System Flushing . 8-4
Bilge System Flushing . 8-5

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 8·2 COOLING AND BILGE SYSTEMS

Exploded View

- -,'
~ I'>

55: Apply silicone sealant.

T1: 9.8 N-m (1.0 kg-m. 87 in·lb)

beerdart
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 COOLING AND BILGE SYSTEMS 8-3

Installation
Bilge System -Put the damper between the bilge pump and bracket.

Bilge Pump:
F?emoval
• Remove the engine hood.
_Disconnect the following.
i:iiet Coating Hose
Bilge Hose
Bilge Pump Leads

A. Damper

-Install the bilge hose with the paint marks upward.

-.
.\. Iniet Cooling Hose Inspection
B. Bilge HDse -Using two auxiliary Wires, supply battery power to the
bilge pump.

Wire Connections
Brown +-7 Battery (+ I
Black ~ Battery (-I

*If the bilge pump does not turn at this timE'. the bilge
pump must be replaced.
_Visually check the bilge pump impeller.
oRemove the bottom cover.

A. Bilge Pump Leads

_Pullout the bilge pump leads from the pipe.

_Remove the bracket with the fuel pump.

A. Bottom Cover B. Screws

beerdart
A. Bracket clf the blades are damaged, replace the bilge pump
B. Bolts assembly.

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 8-4 COOLING AND BILGE SYSTEMS

_When installing the cooling sys.tem hoses, be sure to

use the same kind of clamp as the original.

Hose Inspection
_Check the hoses for hardening, cracking, checking,
cuts. abrasions, and breaks.
*If a hose is damaged in any way, replace it immediately

I,
and check all the other hoses for damage.

A. Impeller

Bilge Switch:
eRefer to the Electrical System chapter.

Cooling and Bilge System Flushing

Cooling and Bilge System Hoses Cooling System Flushing

..... - - . To prevent sand and salt deposits from accumulating
in the cooling system, it must be flushed occasionally.
Hose Removal/Installation Flush the system according to the Periodic Maintenance
eThe bilge system hose without clamps may be simply Chart or whenever there is little water flow from the
pulled off their fittings. bypass outlet on the left side of the hull.
_All the cooling system hoses are clamped It both ends. _Remove the fitting cap from coolin~ hose fitting; on the
Loosen the clamps and pull the hoses off. cylinder head.

0
I! ii
,
,
', '
,'

~/'
1

'--------.!I- 'b'
":
'~.~o!:' ====Jf=:ir:=:g::j
. . . . DIRECTION OF COOLING SYSTEM FLOW

<:==J

beerdart
DIRECTION OF BILGE SYSTEM FLOW

~ DIRECTION OF COMBINED EXHAUST AND COOLING WATER FLOW

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 COOLING AND BILGE SYSTEMS 8-5

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

cOperate the engine only for short periods without

cooling water. Stop the engine immediately if the
temperature warning buzzer goes on. Overheating will
cause $evere engine and exhaust system damage.

• Switch off the engine, remove the garden hose, and

reinstall the fitting cap.

eAttach the gan.kn ho,e to the fittim;.

Bilge System Flushing
To prevent clogging, the bilge system should be
flushed out whenever you suspect it is blocked.
_Remove the bilge hose.
_Flu,h the bilge hose thoroughly with fresh water.
-Connect a 19 mm (% in.) inside diameter auxiliary hose
to the bilge hose fitting on the bulkhead, turn the
water on, and flush the bilge line out for several
minutes.

A. Garden Hose
eStart the engine and allow it to idle before turning on
the water.

0The engine must be running before the water is turned

on or water may flow back through the exhalnt pipe
into the engine, resulting in the possibility of severe
internal clamage.
A. Bilge Hose Fitting
elmmediately turn on the water and adjust Ihe flow <;0
_Remove the bilge Dump, from the engine compertment.
that a little trickle comes. out of the bypass outlet on _Remove the bottom cover of the bilge pump.
the left side ot the hull.
•

beerdart
A. Bottom Cover B. Screws
A. Bypass Outlet -Clean the impeller and bottom cover of any din.

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 DRIVE SHAFT 9·1

DRIVE SHAFT
Table of Contents

Exploded View . 9·2

Specifications , . 9·3
Special Tools . 9·3
Drive Shaft/Drive Shaft Holder , .. , . 9·4
Drive Shaft Removal!! nstallation . 9·4
Drive Shaft Holder Removal/Disassembly , . 9-4
Drive Shaft Holder Assembly/Installation . 9·5
Drive Shaft Runout. '.' . 9·5
Drive Shaft Cleaning . 9·6

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 9-2 DRIVE SHAFT
lew .. - .
E~~i~d~d'V"':""""""""""
.... . . ..
.- ......

®
I
•

~ @
I
@
I

G ·"A pply grease

L .A .
T1:· 22pply
N non­ permanent lock'
TZ' 39 -m /2.2 kg·m 160ft mg agent.
· N.m (40 k ' . -Ibl
. g-m, 29 ft-Ibl

beerdart
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 DRIVE SHAFT 9·3

Specifications

Item I
I
Standard Service Limit

Drive Shaft:
Drive Shaft Runout less than 0.2 mm 0.6 rnm

.......... __ . Bearing Driver Set: 57001-1129

Special Tools
......... _." - , .
Coupling Holder: 57001-1230

Drive Shaft Holder: WS6019-o03

~<~
o
...

Adapter: 57001·1231

beerdart
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 9-4 DRIVE SHAFT
.............................. , - . Drive Shaft Holder Removal/Disassembly
Drive Shaft/Drive Shaft Holder aRemove the drive shaft.
............................................................................ -Unscrew the mounting bolts and remove the drive ~haft
holder from the bulkhead.

Drive Shaft Removal/Installation

eRemove the engine (:iee Engine Removal/Installation
chapter l.
-Pull the drive ,haft out of the hull.

~.
•t lLo-e..P .:. .
A. Mounting Bolts
--­
aDisassemble the drive shaft holder.
cRcmove the circlip.

A. Drive Shaft

_Clamp the drive ,haft holder and adapter (special tools)

onto the drive shaft, and unscrew the coupling with the
coupling holder (special tool).

A. Circlip

OPress the small grease seal, and the large grc-lse seals,
bearing, and small grease seals corne out of the holder.
co;
Press

A. Coupling Hoider: 57001-1230

B. Drive Shaft Holder: W56019-003
C. Adapter: 57001-1231

_When installing the drive shaft, be careful of thc

-+-\---(j)
following items.

beerdart
oApply grease to the coupling threads· and tighten the
coupling to the spedfkd torque (see Exploded V;,ew).
oApply grease to the grease seal lips and the drive shaft G)
spline. 1 Sleeve 2. Blocks

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 DRIVE SHAFT 9-5

Drive Shaft Holder Assemblv/lnstallation _Install the circfip

_Replace the grease seals with new ones. _Grease to the bearing inner surface and grease se;;1
_Press the bearing and grease seals into the drive shaft lips.
holder, noting the following. _Install the drive shaft holcer on the bulkhead ,0 that
oUse a be;;ring driver set (special tool,: 57001.1129). the circlip side face toward the front.
Two Small Grease Seals _Apply a non-permanent loc,;ing agent to the dri\e shaft
One Bearing holder mounting bolts, tighten them loosely.
Two Large Greale Seals _Insta!! the drive shaft.
olnstall the seals so that the sides with lhe spring face _After installini:: the engine, tighten the drive shaft
outward. holder mounting bolts to the specified torque (see Ex­
oFili the gaps between the seals with grease. plodec View) to give proper coupling alignment.

Drive Shaft Runout

_Measure drive shaft runou: by supporting the shaft on
V blod:s and setting a dial gauge against the shaft at
each point shown.
_Turn the drive shaft slowly. The oifferf'nce betwef'n
the highest and lowest dial gauge reading is the runout.
*If anv measurement exceeds the service limit, replace
tne shaft.

Drive Shaft Runout

1. Large Grease Seals Standard: Len than 0.2 mm
2. Smad Grease Seals Service qmit: O.6mm
3. Bearing
4. Fill with grease.

Drive Shaft RUnOLlt

beerdart
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 9-6 DRIVE SHAFT

Drive Shaft Cleaning

Clean the drive shaft to prevent corrosion in accord­
ance with the Periodic Maintenance Chart.
_Remove the grate.
eFlush the drive shaft with fresh water, and wipe the
shaft.

•
•

eReplace the grate.

GApply a non-permanent locking agent to the grate
mounting bolts, and tighten them to the spc(;ified
torque (see Exploded View in the Pump and Impeller
chapter).

beerdart
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 PUMP AND IMPELLER 10-1

PUMP AND IMPELLER

Table of Contents

Exploded View . 10-2

Specifications , . 10-3
Special Tools _ . 10-3
Pump and ImpeJler , _ . 10-4
PumpRemoval . 10-4
Pump Installation. _ . 10-4
Pump Disassembly . 10-5
Pump Assembly
Pump and Impeller Inspection " .
. 10-6
10-7
Ell
Impeller Clearance ' . 10-7

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 10-2 PUMP AND IMPELLER
.....................................................................­ .
Exploded View
........................................................, .

/
@@

G : Apply grease.
l : Apply non-permanent locking agent.
58 : Apply silicone sealant.
T1: 9.8 N-m 11.0 kg-m, 81 in-lbl

beerdart
T2: 22 N·m (2.2 kg-m, 16.0 ft-lbl
T3: 98 N·m 110.0 kg·m, 72 ft-lbJ

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 PUMP AND IMPELLER 10-3

Specifications

Item Standar':1 Service Limit

-
Jet Pump:
I
Impeller Outside Diameter 139.5 - 139.6 mm - 138.5 mm
Pump Case Inside Diameter 140.0 -140.1 mm 141.1 mm
Impeller Clearance 0.2 -0.3 mm O.6mm

Bearing Driver Set; 57001-1129

Special Tools

Impeller Wrench: 57001-1228

"'\\.
\\

Oil Seal and Bearing Remover: 57001·1058

beerdart
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 ..---------------------------------------------------•• -~,.'_~--,-

10-4 PUMP AND IMPECLER

..................... , , , . _Unscrew the pump mounting bolts.
Pump and Impeller

Pump Removal
_Lift up the watercraft.
eRemove the following.
ReveT~e Cable Connector
Grate
Pump Cover

--
A. Mounting Bolts

_Cut the sealant at the pump intake area.

_Slide the pump to the rear.

A. Connector

Pump Installation
_Strip off all the old sealant around the pump intake,
_Grease the splines on the drive shaft with water resist­
ant grease.
eLiberally coaL [he outside edge of the pump intJ.ke area
with silicone sealant to form a seal bl"tween the pump
and the hull.

A. Pump Cover B. Grate

Steering Cable Connector

Coolin~ Hose

1. S,"Jlant

eSlip the pump into place.

eApply a non-permanent locking agent to the pump

beerdart
mounting bolt threads and tighten the bolts to the
specified torque (see Exploded View).
_Fili all gaps at the intake area of the pump with sili­
A Hose B. Cable Connector cone sealant.

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 PUMP AND IMPELLER 10-5

A. Sealant
A. Pump Outlet B. Mounting BollI
_CO,1nect the hose and the steering cable.
alnstall the pump cover and grate.
OApply J non·permanent locking agent to the mounting
bolts and tighten them to the specified torque (see
Exploded View).

A. Pump Cap B. Bolts

A. Mounting Bolts _Hold the shaft in a vise, taking care not to damage it.
Remove ,he impeller from the pump shaft with the
impeller wrench (special tool) and then pull out the
pump shafe
Pump Disassembly
_Remove the following.
Steering NOllie
Pump OULlet
Pump Cap

A. Impeller Wrench: 57001-1228

beerdart
A. Steering Nozzle B. Mounting Bolts _Pull out the bushing.

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 10-6 PUMP AND IMPELLER

Pump Assembly
eBefore installing the pump bearings, blow any dirt or
foreign particles out of the pump case with compressed
air.
_Install new bearings using the bearing driver set (special
tool).
Ot'ress the rear pump bearing into the pump case as far
as it will go.
Olnsert the collar and install the front pump bearing.

A. Bushing

eRemove the grease seals using th~ oil seal and b~3ring
-
remover (special tool).

57001-1129

eReplace tne grease seals with new ones, if necessarv,

and instatl them using the same special tool used for
bearing installation.
oPress each seal into the pump ca,e,o that the Side with
the spring face, outward. Fill the gap between the
seals with grease.
A. Oil Seal and Bearing Remover: _Push the bushing into the pump case.
• Remove the pump bearings. _Visually inspect the pump shaft O-rings, and replace
them if necessary.
_Grease the pump shaft and insert it from rear of the
Pump Bearing Removal
pump case.
_Screw on the impeller and tighten it to the specified
torque (see Exploded View).
_Visually inspect impeller grease seal, and replace il if
necessary.

CD-----­ .j==i
10
JI+t--it--@

0 \ 0
Q) A. Grease Seal

beerdart
1. Pump Case 3. Collar oWhen installing the grease ,eal, pack greas.e inside it.
2. Bearing -Be sure the O-ring in place on the pump cap ..

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 PUMP AND IMPELLER 10-7

0Mc~'iurc the impeller outside diameter.

*If the impeller is worn smaller than the service limit,
replace it.

Impeller Outside Diameter

Standard: 139.5 - 139.6 mm
Service Limit: 138.5 mm

eExamine the pump case.

*/f there are deep scratches inside the pump case,
A. O-rinfl replace it.

elnst~11 the plJrnp l:<lp, tlllO pump outlet, and the Heering
nOllie,
"I\pplya Ilon-permanent locking '\I':<'nt 10 Lht' thredlh (It
rhr following hnll<;,
Pump Cap Bolls
Pump Outlet Mounting BOI'ts
Steering Nozzle Mounting Bolts

Pump and Impeller Inspection

eExaminE' thO' impeller.
*If thert i<; pitting, deep ~cratches, 01' uther damage, A. Check for scratch",_
replMe rhe impeller.

oMeas~'rc the inside diameter of the pump case.

*If the pump case is worn beyond the service limit,
replace it.

Pump Case Inside Diameter

Standard: 140.0 -140.1 mm
Service Limit: 141.1 mm

1. Nick" 3. Scratche~
2. Pitting Impeller Clearance
elmpeller clearance i5 critical to rmrt, performance. It
the pump case and impeller are not vi'iibly damaged,
NOTE poor performance may be (;ilu'ied by too much impeller
oMinor nicks and gouges in tf?e impeller blades can be clearance.
eTo eheck impeller ciCJrallCe, remove the grate and

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removed with abrasive paper or careful filing. Smooth
leading edges are especially imponant to avoid cavita­ insert a feeler gauge between the tip of the impeller
tion. blade and the pump case.

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 10-8 PUMP AND IMPELLER

A. Blade C. Feeler Gauge

B. Case

Impeller Clearance
Standard: 0.2 -0.3 mm
Service Limit: O.6mm

*If impeller clearance is incorrect, determine jf it is due

to wear or damage (see Pump and Impeller Inspection).

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 STEERING 11-1

STEERING
Table of Contents

Exploded View . 11-2

Steering Cable .......................•..................... 11-3
Adjustment . 11-3
Removal . 11-3
Insta lIation . 11-3
Inspection . 11-4
Lubrication . 11-4
Control Stick . 11-5
Removal . 11-5
Installation .....................................•.....
Disassembly .
11-5
11-6 III
Assembly , . 11-6
Steering Bracket . 11-6
Removal . 11-7
Installation . 11-8
Reverse System . 11-8
Shift Cable Adjustment . 11-8
Shift Cable Removal . 11-9
Shift Cable Installation . 11-10
Shift Cable Inspection . 11-10
Shift Cable Lubrication . 11-10
Reverse Bucket Removal/Installation . 11-10

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 1. Steering Shaft Clamp
2. Main Bracket
3. Cable Joint Arm
G • Apply grease. t locking agent.
. rmanen
l : Apply non-pe 87 in-Ib)
T1 : 9.8 N-m (1.0 kg-m,
T2: 22 N-m (2· 2 kg-m, 16 ft-Ib)

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 STEERING 11·3
-Loosen the locknut and take the ball joint off the ball.
Steering Cable

Adjustment
• Position the 'control stick in the upright position.

B. Locknut

oHold the steering nozzle in the center of the pump

cavity.
-Center the control stick and then turn the ball joint
until the hole aligns with the ball.
-Connect the ball joint and tighten the locknut.
-Check that the steering nozzle is centered in the pump
cavity.
Removal
-Remove the following.
Pump Cover
Jet Pump
Engine Hood
-Disconnect the ball joint at each end of the steering
cable.

A. ,'\Jozzle Centered B. Equal

-If necessary adjust the steering cable.

-Remove the engine hood.
-The steering rod should have a length of 118 - 120
mm.

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A. 118 -120 mm A. Ball Joint

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 11-4 STEERING
_ Loosen the locknut and then remove the ball joint and -Pullout the steering cable toward the front.
locknut from the cable rear end. -Unhook the cable from the cable holder.

A. Locknut B. Ball Joint

A. Cable Holder

-Unscrew the cable nut while holding the fitting with a

wrench.

Installation
-Installation is the reverse of removal. Note the fol­
lowing.
-Tighten the cable nut to the specified torque.
-Adjust the steering cable.

Inspection
A. Nut B. Fitting -Examine the steering cable.
*If the cable or cable housing is kinked or frayed, re­
place the cable.
-Slide off the E-ring, washer, and G-ring. *If the seal at either end of the cable is damaged in any
way, replace the cable.

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A. E-Ring C. G-Ring
B. Washer A. Seal

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 STEERING 11-5

e Be certain that the cable moves freely in both direc­ eOpen the electric case.
tions. e Remove the start/stop switch leads from the electric
oDisconnect the ball joint at each end of the cable. case.
oSlide the outer sleeve away from the ball slightly, and
lift the cable from the ball.
oSlide the inner cable back and forth in the cable
housing.
* If the cable does not move freely, replace it.

Lubrication

NOTE
o The steering cable is sealed at each end and does not A. Start/Stop Switch Leads
require lubrication. If the seals are damaged, the
cable must be replaced.
• Disconnect the throttle cable from the carburetor.

Control Stick
A. Throttle Cable

Removal
• Remove the following. eRemove the control stick.
Engine Hood
Steering Case

• ••
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A. Control Stick B. Steering Case A. Control Stick B. Mounting Bolts

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 11-6 STEERING

Installation
el nstallation is the reverse of removal. Note the fol­
lowing.
eConnect the start/stop switch leads. Refer to the @)
wiring diagram.
eCheck and adjust the· following, after control stick
installation.
Steering Cable
Throttle Cable
Choke Cable

A. Cap B. Screws

e Remove the start stop switch

e Remove the throttle lever.

Disassembly
e Remove the following.

A. Start/Stop Switch
B. Screws

A. Control Stick Pivot C. Steering Case

B. Boot
Assembly
-Assembly is the reverse of disassembly. Note the
following.

J -The stop switch has white and black leads.

-The start switch has red/white and green/white leads.
elnstall the throttle lever is in position.
eApply grease to the upper and lower control stick

-
joints (see Exploded View].
eApply grease to the throttle lever collar (see Exploded
View).
eCheck that the throttle outer cable end is in the groove
of the upper stick.
eTighten the control stick mounting bolt to the
specified torque (see Exploded View).
-Check and adjust the following, after installation.

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Throttle Cable
Choke Cable
A. Screws B. Covers Steering Cable

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 STEERING 11-7

Steering Bracket

Removal
- Disconnect the ball joints of the steering cable and
rod.

A. Throttle Lever B. Throttle Outer Cable End

-I nstall the clamps.

A. Ball Joints C. Steering Cable

B. Steering Rod

- Remove the right side bracket.

A. Clamps B. Leads

-Check that the grommet for the throttle cable, start

and stop leads is in place.

A. Right Side Bracket B. Bolts

1. Throttle Cable -Remove the following for main bracket removal.

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2. Leads Steering Case (see Hull chapter)
3. Lower Left Control Stick Control Stick
4. Grommet Steering Shaft

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 11-8 STEERING
*If the bushings are damaged or worn, replace them.
-Clean the steering shaft, and check the surface for
corrosion and wear.
-Check and adjust the following, after installation.
Throttle Cable
Choke Cable
Steering Cable

A. Steering Shaft B. Clamp Bolts

- Remove the main bracket.

Reverse System
..................................................................................
Shift Cable Adjustment
-Check the shift cable adjustment.
oWhen the shift lever is in the F position, the damper on
the top of the reverse bucket should stop against the
top of the pump outlet.
.
, oWhen the shift lever is in the R position, the dampers
on the bottom of the reverse bucket should stop
against the end of the pump cover.

Forward Position

A. Bracket B. Bolts

Installation
-Installation is the reverse of removal. Note the fol­
lowing.
-Tighten the following bolts to the specified torque
(see Exploded View).
Steering Shaft Clamp Bolts
Main Bracket Mounting Bolts Reverse Position
Cable Joint Arm Pivot Bolt
-Check the bushings for damage and wear.

1. Steering Nozzle 4. Shift Cable

" 2. Bucket 5. Jet Pump
3. Jet Pump Cover

*If the dampers do not stop where they should the

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shift cable must be adjusted.
-Disconnect the shift cable ball joint and loosen the
locknut.
A. Check Surfaces for Wear

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 STEERING. 11-9

_ Loosen the locknut and then remove the ball joint and
locknut from the cable rear end.

A. Ball joint B. Locknut

-Turn the ball joint on the cable to adjust the shift

cable. A. Locknut B. Ball joint
-Connect the ball joint and check cable adjustment
again. -Unscrew the cable nut while holding the fitting with a
-When adjustment is correct, tighten the shift cable
wrench.
locknut.

Shift Cable Removal

- Remove the following.
Pump Cover
jet Pump
Engine Hood
-Disconnect the ball joint at each end of the shift cable.

A. Nut B. Fitting

-Slide off the E-ring, washer, and D-ring.

.....

• A. E-Ring
B. Washer
C. D-Ring

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.Pull out the cable toward the front.
A. Ball Joint -Unhook the cable from the cable holder.

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 11·10 STEERING

eBe certain that the cable moves freely in both

directions.
o Disconnect the ball joint at each end of the cable.
oSlide the outer sleeve away from the ball slightly, and
lift the cable from the ball.
oSlide the inner cable back and forth in the cable
housing.
*If the cable does not move freely, replace it.

A. Cable Holder

Shift Cable Lubrication

NOTE
o The shift cables are sealed at each end and does not
require lUbrication. If the seals are damaged, the cable
Shift Cable Installation must be replaced.
elnstallation is the reverse of removal. Note the fol­
lowing.
eTighten the cable nut to the specified torque (see Ex­
ploded View).
eAdjust the shift cable.

Reverse Bucket Removal/Installation

Shift Cable Inspection eDisconnect the ball joint at rear end of the shift cable.
eExamine the shift cable.
*If the cable or cable housing is kinked or frayed, re­
place the cable.
*If the seal at either end of the cable is damaged in any
way, replace the cable.

A. Ball Joint

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eRemove the pump cover.
A. Seal e Remove the reverse bucket.

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 STEERING 11-11

A. Reverse Bucket B. Pivot Bolts

-I nstallation is the reverse of removal. Note the fol­

lowing.
oApply a non-permanent locking agent to the reverse
bucket pivot bolts, and tighten them to the specified
torque (see Exploded View).
oAfter installation, check the shift cable adjustment.

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 HULL ,12-1

HULL
Table of Contents

Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

Engine Hood/Steering Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . 12-4
Engine Hood Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Steering Case Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Steering Case Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Back Rest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Removal/I nstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Hu II Replacement ,............. 12-6

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 12-2 HULL
............................................................................
....
Exploded View . .

,./
~/

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 HULL 12-3

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 12-4 HULL

Engine Hood/Steering Case

Engine Hood Removal/Installation

eUnscrew the engine hood mounting screws.

A. Cable Holder

e Remove the engine hood.

elnstallation is the reverse of removal. Note the fol­
lowing.
oCheck the reverse system function, after installation.
,
/ ....;..
~;

A. Engine Hood B. Screws

,
Steering Case Removal
eRemove the engine hood.
eUnscrew the steering case screws.
eRemove the choke knob shaft.

A. Engine Hood B. Screws

eDisconnect the starter lockout switch lead.

A. Starter Lockout Switch Lead

A. Screws B. Choke Knob Shaft
•
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eRemove the steering case.
eRemove the ball joint at the shift cable. eRemove the switch cover screws and disconnect the
eDisconnect the shift cable from the cable holder. lead connectors.

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 HULL. 12-5

I
A. Screws A. Blower Fan Switch B. Bilge Pump Switch

Back Rest

Remo val/lnstallation
-Unscrew the mounting bolts.

-Remove the following.

Blower Fan Switch
Bilge Pump Switch
Engine Shut-Qff Switch
Igryition Switch

A. Cap

A. Mounting Nuts

Steering Case Installation A. Mounting Bolts

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-Installation is the reverse of removal. Note the fol­
lowing.
-Install the bilge pump and blower fan switch as shown. - Remove the back rest.
OThe blower fan switch has yellow and red leads. - Installation is the reverse of removal.

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 12·6 HULL

Hull Replacement

To replace the hull, remove the following parts.

Engine Hood
Back Rest
Steering Case
Battery
Blower Fan
Fuel Tank
Electric Case
Oil Tank and Tank Rest
Control Stick and Brackets
Exhaust Pipe and Tube
Water Box Muffler
Engine and Mounts
Fuel. Pump
Bilge Pump
Drive Shaft and Shaft Holder
Fuel Tap
Jet Pump
Steering and Shift Cables
Hull Grips
Rubber Strap Hooks
Dampers

The following parts cannot be removed from the hull

and must be replaced.
Decals
Labels
Registration Number (if any)

If the new hull is to be painted, do that first. Then

install the parts removed in the reverse order of their
removal. Finally, install the labels, decals, mats and
the registration numbers.

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 ELECTRICAL SYSTEM 13-1

ELECTRICAL SYSTEM
Table of Contents

Wiring Diagram 13-2 Spark Plug Removal 13-19

Exploded View 13-3 Spark Plug Installation 13·19
Specifications 13-5 Spark Plug Inspection ., 13-19
Special Tools 13-5 Spark Plug Cleaning 13-19
Battery 13-6 Spark Plug Adjustment 13-19
Precautions 13-6 Ignition Timing Inspection
Battery Removal 13-6 (dynamic) _ 13·20
Battery Installation 13-6 Verification of Timing Marks 13·20
Electrolyte Level Inspection 13-7 Electric Case _ 13-21
Battery Condition _ 13-7 Removal/Disassembly 13-21
Battery Initial Charging .....•..•..•.13-8 Assembly/Installation. __ 13-21
Battery Ordinary Charging 13-9 Blower Fan System ...............••••.13-22
Battery Test Charging 13-9 Blower Fan Removal 13-22
Electric Starter System 13-9 Blower Fan Inspection 13-22
Starter Relay 13-9 Temperature Warning System 13-23
Removal 13-9 Temperature Sensor Inspection 13-23
Installation Notes 13-10 SWitches . . . . . . . . . . 13-23
Inspection _ 13·10 Start/Stop Switch 13-23
Reduction Gear 13-10 Removal/Installation 13-23
Removal/I nstallation Notes 13-10 Ignition Switch 13-24
Inspection . . . . . . . . 13-11 Removal/I nstallation 13-24
Starter Motor 13-11 Engine Shut-off Switch/Bilge Pump
Removal 13-11 Switch/Blower Fan Switch 13-24 ~
Installation 13-11 Removal/Installation 13-24 ~
Disassembly 13-12 Switch Inspection 13-25
Assembly 13-12 Fuse 13-25
Brush Inspection 13-13 Inspection 13-25
Brush Spring Inspection 13-13
Commutator Cleaning
and Inspection 13·13
Armature Inspection _ 13·14
Brush Plate Inspection 13-14
Brush and Lead
Assembly Inspection 13-14
Charging System 13-16
Charging Coil Testing 13-16
Regulator/Rectifier Testing 13-16
Removal 13-16
Installation 13-17
Inspection . ' 13-17
IgnitionSystem 13-17
COl Igniter Removal 13-17

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COl Igniter Winding Installation 13-17
COl Igniter Internal Inspection 13-18
Exciter Coil Inspection 13-18

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 .............................................................................
Wiring Diagram
..............................................................................

Ignition Switch

I~: I %t~~r4
Engine Shut-off Switch Bilge Pump Switch

I~~F I ~
W BK
When lanyard is installed
Start/Stop Switch When lanyard is removed

Start Switch Stop Switch Starter Lockout Switch Blower Fan Switch

I~~F I k§
R/PU G/W W BK Shift lever Position G/W BK/Y
Free For R position
Push on Engine starting position

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 ELECTRICAL SYSTEM 13-2

[
i Y8@
= I
~3
BAR (j)
I

Lm±~
I
-R. :R
Magneto 1_ _'

RI

r
>­
.....
lit ,fr;
-

,
~w@
II BK ,
>­
.K~
CIl ::l
Q~O:O:::l Q.CI::=:ll: I I
CIlCllCll~ ~>:: ll:I
~;:
I
r R"'fr,U @ t ~ I
~I a:~e" [

~~@I
")..­
1
R
:.(
i
a:
~ -«::== ,,
I
lXl
II
~
-BK­ ~ I

a:
::l
....a:
Q.
~
. ~-w- fl
..... 0::
I
!; :.(
!D
,I
I
!
!C-_ _I-_ ,i
Y/R 1
>­
,
1::::;0:.!!J • __.....J

~ /1
al ~
' I
n
R/PU~ !
~ CD ~B~.J I
LJ ....>- "J
:.( Buzzer
!D
.: 1 .1_ BKJ

~
-1 BK
/1 e,,:.c::J

-g @ ~J w­
~

I BK-
BK
Color Code
Black
B L:--+-_--,-=.BI;.;.u.:..e---I
/ BR
--+------4
Brown
Electric Case
q:;i ___
Ii BK/Y
G/W
G
Gy
Green
Gray
LG Light Green
Starter Lockout o Orange
1. Starter Relay 7. Start Switch Switch P Pink
2. CDI Igniter 8. Stop Switch PU Purple
3. Regulator/Rectifier 9. Engine Shut-off Switch
10. Ignition Switch R Red
4. Blower Fan Switch
5. Bilge Pump Switch 11. Main Fuse 20A w White
6. Fuse SA x 2 Y Yellow

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 ELECTRICAL SYSTEM 13·3

Exploded View

3~O
/ ~~
G : Apply grease.

_@ @ ~ ~ c @T2'27N... 12.• k..... 20lt.,bJ

11
/ ®
@@
1. Regulator/Rectifier
2. Starter Relay
3. CDI Igniter
4. Ignition Switch
5. Engine Shut-off Switch
6. Bilge Pump Switch
7. Blower Fan Switch

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8. Fuse

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 13-4 ELECTRICAL SYSTEM

G : Apply grease. 9. Temperature Sensor

L : Apply non-permanent locking agent. 10. Warning Buzzer
T3: 98 N-m (10.0 kg-m, 72 ft-Ib)

----
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 ELECTRICAL SYSTEM' 13·5

Specifications

Item Standara service Limit

Battery:
Type 12 V 50 Ah (20·HR)/40 Ah (5-HR) --­
Specific gravity of electrolyte 1.280@20°C (68°F) ---­

Electric Starter System:

Starter motor: Brush length 12.5 mm 6.5mm
Commutator diameter 28mm 27 mm

Charging System:
Regulator/rectifier output voltage Battery voltage ­ 14.5±0.5 V --­
Charging coil output voltage 42V ---­
Charging coil resistance
Brown <-+ Brown 0.3- 0.6 n --­
Green <-+ BlacklYellow 13.6 ­ 20.5 Q --­
Ignition System:
Ignition timing 17° BTDC @6,000 r/min (rpm) --­
Ignition coil: secondary winding resistance 2.1 - 3.1 kQ --­
Spark plug: Type I\JGK BR7ES --­
Gap 0.7 ­ 0.8 mm --­
Exciter coil resistance 1.0 ­ 1.6 kn --­

Special Tools

Top Dead Center Finder: 57001-402 Hand Tester: 57001·983

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 13-6 ELECTRICAL SYSTEM

l
Battery "
/
Precautions
Following a few simple rules will greatly extend the
life of the battery.
oWhen the level of the electrolyte in the battery is low,
add only distilled water to each cell, until the level is at
the upper level line marked on the outside of the
battery. Ordinary tap water is not a substitute for
distilled water and will shorten the life of the battery.
oNever add sulphuric acid solution to the battery. This
will make the electrolyte solution too strong and will
ruin the battery within a very short time.
oAvoid quick-eharging the battery. A qUick-charge will A. Battery Straps
damage the battery plates.
oNever let a good battery stand for more than 30 days
without giving it a supplemental charge, and never let a
discharged battery stand without charging it. If a
battery stands for any length of time, it slowly
self-discharges. Once it is discharged, the plates
sulphate (turn white), and the battery will no longer
take a charge.
oKeep the battery well-charged during cold weather so
that the electrolYJ:e does not freeze and crack open the
battery. The more discharged the battery becomes, the
more easily it freezes. Battery Installation
oDON'T INSTALL THE BATTERY BACKWARDS. eBe sure the battery dampers are in position in the
The negative side is grounded. battery compartment.

Battery Removal

I WARNING'
OBattery electrolyte contains sulphuric acid which is
poisonous and causes severe burns. When installed in
the battery, electrolyte generates hydrogen gas which
under certain conditions is flammable and explosive.
Keep all flames and sparks (cigarettes, etc.) away and
always wear eye protection when working on or near
the battery.
A. Dampers
eDisconnect the battery cables.

I WARNING t ePlace the battery in position.

aTo prevent possible personal injury and damage to olnstall the battery with the negative (-) terminal
electrical components, always disconnect the grounded toward the bow (forward).
cable first. eHook the battery straps.
eConnect the battery cables, positive first.

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eUnhook the battery straps. OAfter attaching both cables, coat the terminals and
eCarefully lift the battery from the engine com­ cable ends with grease to prevent corrosion.
partment. oSlide the protective boot over each terminal.

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 ELECTRICAL SYSTEM 13-7

Hydrometer

Read
here

A. Protective Boots

Electrolyte Level InSPfiction

-Remove the battery.
-Visually check the electrolyte level in the battery. 1. Read here.

oLook for sediment and white sulfation inside the cells.

...... @

A. Level Lines

*If the level of electrolyte in any cell is below the lower

level line on the battery case, add distilled water only
to that cell.
-I nstall the battery.

A. Sulfation here.
B. Sediment here.

Battery Condition
eBefore charging, check battery condition by testing the
-See the Battery Troubleshooting Guide in Battery Test

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specific gravity of the electrolyte in each cell.
oDrawa little fluid from the cell with a hydrometer. Charging.
oRead the level of the electrolyte on the floating scale. *If the specific gravity is below 1.280 the battery needs
This is the specific gravity of the electrolyte. to be charged.

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 13-8 ELECTRICAL SYSTEM
NOTE
oThe specific gravity of the electrolyte varies with
I WARN1NG I
changes in temperature, so the specific gravity reading oKeep the battery away from sparks and open flames
must be corrected for the temperature of the electro­ during charging, since the battery gives off an explosive
lyte. gas mixture of hydrogen and oxygen. When using a
oCelsius: Add 0.007 points to reading for each lOoC battery charger, connect the battery to the charger
above 20°C or subtract 0.007 points for each lOoC before turning on the charger. This procedure prevents
below20°C. sparks at the battery terminals which could ignite any
oFahrenheit: Add 0.004 points to reading for each battery gases.
10°F above 68°F or subtract 0.004 points for each
10°F below 68°F.

*If the specific gravity of any of the cells is more than

0.050 away from any other reading, the battery will
probably not accept a charge. It is generally best to
000 not use a high rate battery charger, as it typically
replace a battery in this condition.
*If the specific gravity of all the cells is 1.280 or more employed at automotive service stations, unless the
charger rate can be reduced to the level required.
the battery is fully charged.
Charging the battery at a rate higher than specified may
ru in the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shorting. Higher-than-normal charging rates also cause
the plates to shed active material. Deposits will
Battery Initial Charging accumulate, and can cause internal shorting.
Before being placed in service, a new battery should olf the temperature of the electrolyte rises above 4S C
o
be given an initial charging. (115°F) during charging, reduce the charging rine to
-Fill each cell to the upper level line on the battery case lower the temperature, and increase charging time
with fresh electrolyte at a temperature of 30°C (86°F) proportionately.
or less. Let the battery stand about 30 minutes before
charging.

NOTE GTurn the charger off, then disconnect it from the

off the electrolyte level drops, add electrolyte to the battery.
upper level line before charging. -Check battery voltage. Battery voltage should be 12 ­
13 V.
- Leaving the caps off the cells, connect the battery to a -Check the specific gravity of each cell with a hydrom­
charger, set the charging rate at 1/10 the battery eter (see Battery Condition).
capacity, and charge it for 10 hours. For example, if *If the voltmeter or hydrometer readings are below
the battery is rated at 50 Ah, the charging rate would those specified, additional charging is necessary before
be 5 A. the battery can be installed.

Battery Charging RatelTime Table (12V 50Ah)

1.280
1.28 Fully Charged
1.24
1.20
1.16 1.140
1.12 Sample I
1.08
1.04
1.00
• • • • •.• • • • • • . •.• • •.•.• • • • •.• • • • • • • 12~o~~6. j••••••••••••••••••••• :~~t~~y d;"h'~'d ••

at 2A charge rate 5 10 15 20 25 30 35 37.5

at 3A charge rate 5 10 15 20 25
at 4A charge rate 5 10 15 19

beerdart
at SA charge rate 5 10 15
Hours of Charging Time at Rates Shown

------ -- - - -

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 ELECTRICAL SYSTEM 13-9

Battery Troubleshooting Guide

Good Battery Suspect Battery Action

(+) chocolate color white (sulphated); + plates

Plates Replace
(-) gray broken or corroded
Sediment none, or small amount sediment up to plates, causing short Replace
Voltage above 12 V below 12 V Test charge
Electrolyte Level above plates below top of plates Fill and test charge
above 1.200 in all cells; no two below 1.100, or difference of more
Specific Gravity Test charge
cells more than 0.020 different than 0.020 between two cells

Battery Ordinary Charging Battery Test Charging

eRemove the battery from the hull (see Battery -If the battery is suspected of being defective, sulfated,
Removal). or unable to take a charge, consult the Battery
eCiean off the battery (see Battery Cleaning). Troubleshooting Guide table.
elf any of the cells are low, fill them to the LOWER eTo test charge a battery, perform the ordinary charging
level line with distilled water only. The electrolyte will procedure and monitor the battery voltage and other
expand during charging, and the level will rise. signs as mentioned below.
eConnect a charger to the battery BEFORE plugging it
in or turning it on.

[ WARNING I
oKeep the battery away from sparks and open flames
during charging, since the battery gives off an explosive
gas mixture of hydrogen and oxygen. When using a
battery charger, connect the battery to the charger
before turning on the charger. This procedure prevents
sparks at the battery terminals which could ignite any
battery gases.

eSet the charge rate and time according to the battery ••••••••••••••••••••••• I ' •••••• I I II ••••••••••• '" ••••••••••••••••••••• ' . ' •••

condition previously determined (see Battery Electric Starter System

Condition), using the table. • ••••• II •••••••••••••••••••••••••••••••••••••••• II ••••••••••••••••••••••••••

Starter Relay:
Removal
e Disconnect the battery grou nd cable.
000 not use a high rate battery charger, as is typically
eOpen the electric case.
employed at automotive service stations, unless the
charger rate can be reduced to the level required.
Charging the battery at a rate higher than specified may
ruin the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shorting. Higher-than-normal charging rates also
cause the plates to shed active material. Deposits will
accumulate, and can cause internal shorting.
olf the temperature of the electrolyte rises above 4SoC
(11SoF) during charging, reduce the charging rate to
lower the temperature, and increase charging time
proportionately.

-Turn the charger off or unplug it, then disconnect it

from the battery.

beerdart
eCheck battery condition (see Battery Condition).
*If the battery condition indicates that it is not fully
charged, additional charging time is necessary. A. Electric Case B. Bolts

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 13-10 ELECTRICAL SYSTEM

-Disconnect the following.

Starter Motor Cable
Battery Cable
Starter Relay Lead Connectors

*If resistance is less than infinite, the starter relay switch

is not returning and must be replaced.
-Set ohmmeter to R x 1 51 scale.
-Connect meter leads to starter relay as shown.
-Activate starter relay switch by connecting a 12 V
battery as shown.
A. Starter Relay

Installation
-Installation is the reverse of removal. Note the fol­
lowing.
-Connect the ground lead (black) to the COl igniter
mounting bolt.
-Connect the battery cable to the relay (+) terminal
having red lead.

*If the starter relay switch clicks and the ohmmeter

indicates zero resistance, the starter relay switch is
good.
* If the meter indicates high or infinite (00) resistance,
the starter relay switch is defective and must be re­
placed.

A. Relay (+) Terminal B. Red Lead

Reduction Gear:
Removal/Installation Notes
-Before removing the reduction gear, remove the

beerdart
Inspection magneto flywheel (see Engine Bottom End chapter).
-Set ohmmeter to R x 1 51 scale. -When installing the reduction gear, apply a molyb­
-Connect meter leads to starter relay as shown. denum disulfide grease to both ends of its shaft.

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 ELECTRICAL SYSTEM 13-11

eRelease the pinion gear. The pinion gear must return

to the initial position rapidly.
*If the pinion gear does not function properly, replace
it.

~tarter
Motor:
Removal
eRe move the exhaust pipe and manifold (see Exhaust
System chapter).
eDisconnect the battery ground cable.
eDisconnect the starter motor cable.
- Remove the starter motor.
A. Grease

Inspection
eRotate the pinion gear counterclockwise. The gear
must be rotate freely.

'@

A. Mounting Bolts B. Starter Motor Cable

000 not tap the starter motor shaft or body. Tapping

on the shaft or body could damage the motor.

A. Free B. Pinion Gear

Installation
-Starter motor installation is the reverse of removal.
eRotate the piniOn gear clockwise all the way. The Note the following.
pinion gear will be advanced along the reduction gear -Clean the starter motor lugs and the cran kcase where
shaft, and stopped against the stopper. the starter motor is grounded.

beerdart
A. Stopper A. Clean here.

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 13-12 ELECTRICAL SYSTEM

eApply a 'Small amount of engine oil to the O-ring. eRemove the nut and the terminal bolt, and then
eApply a non-permanent locking agent to the starter remove the brush and the plastic holder.
motor mounting bolt threads.
eConnect the battery ground cable to the bottom starter
motor mounting bolt.

Disassembly
-Unscrew the retaining screws and remove both end
covers.

A. Brushes C. Terminal Bolt

B. Holder D. Yoke

Assembly
elnstall the terminal bolt as shown.

A. Screws

ePul1 the armature out the pinion gear end.

eRemove the brush plate from the leads.

A. Nut E. Small Insulator

B. Spring Washer F. Terminal Bolt
C. Washer G. O-ring
D. Large Insulator H. Plastic Holder

elnstall the brush plate as follows.

beerdart
olnstall the brush plate on the yoke fitting the brush
A. Brush Plate C. Yoke leads into the notches in the plate. Fit the brush plate
B. Brush Lead tongue into the yoke notch.

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 ELECTRICAL SYSTEM 13-13

Brush Inspection
eMeasure the length of each brush.
*If any is worn down to the service limit, replace all the
brushes.

,4

®/
A. Tongue D. Notches
B. Notch E. Brush Leads
C. Brush Plate
olnsert the armature into the yoke.
oKeeping the motor upright, install the brush springs.
Fit the spring on the spring post halfway; the post must
be positioned in the D-shaped end of the spring. Turn
the other end of the spring a half turn clockwise, and Starter Motor Brush Length
fit the end in the brush groove. Push the spring onto Standard: 12.5 mm
the post to the stepped portion. Service Limit: 6.5 mm

Brush Spring Inspection

-Check that the brush springs are in place and will snap
the brushes firmly into place.
*If not, reinstall or replace the spring.

A. Half Turn Clockwise D. Brush

B. Spring E. Brush Groove
C. Spring Post
Commutator Cleaning and Inspection
-Smooth the commutator surface if necessary with fine
emery cloth, and clean out the grooves.
aTa install the end covers on the yoke, align the mark
on the each end cover with the marks on the yoke.

beerdart
A. Align the marks. 1. Commutator 2. Emery Cloth

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 13-14 ELECTRICAL SYSTEM

eMeasure the diameter of the commutator. Even if the foregoing checks show the armature to be
*Replace the starter motor with a new one if the good, it may be defective in some manner not readily
commutator diameter is less than the service limit. detectable with an ohmmeter. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.

Brush Plate Inspection

eUsing the x 1 n ohmmeter range, measure the resist­
ance between the brush an and the brush plate.
*If there is not close to zero ohms, the brush plate has
an open and the brush plate must be replaced.
eUsing the highest ohmmeter range, measure the re­
sistance between the brush plate and the brush holders.
*If there is any reading at all, the brush holder has a
short and the brush plate must be replaced.

1. Commutator Segment 3. Shaft

2. Diameter

Commutator Diameter
Standard: 28mm
Service Limit: 27mm

Armature Inspection
eUsing the x 1 n ohmmeter range, measure the resist­
A. Brush C. Brush Holder
ance between any two commutator segments.
*If there is a high resistance or no reading (00) between B. Brush Plate
any two segments, a winding is open and the starter
motor must be replaced.

Brush and Lead Assembly Inspection

eUsing the x 1 n ohmmeter range, measure the resist­
ance between the brushes.
*If there is a high resistance or no reading (00), a lead is
open and the brush and lead assembly must be re­
placed.

1. Segment 2. Shaft

eUsing the highest ohmmeter range, measure the resist­

beerdart
ance between the commutator and the shaft.
*If there is any reading at all, the armature has a short
and the starter motor must be replaced.

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 ELECTRICAL SYSTEM 13·15

Electric Starter Circuit

R
To Stator

R/PU

1. Starter Button 5. Starter Relay

2. Starter Lockout Switch 6. Starter Motor
3. Main Switch 7. Battery
4. Main Fuse (20A)

Charging System Circuit

To COl Igniter

r - - - - - - - t : o - - - BR - - - - . . . . ,
r------i>!D----BR - - - . . . . ,
BK

l:l ~ a: oa
£Q
a:: ~BKI
>­
i2
oa
J @

beerdart
1. Magneto 4. Load 7. Starter Relay
2. Regulator/Rectifier 5. Ignition Switch 8. Battery
3. Control Circuit (Ie) 6. Main Fuse (20A)

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 13-16 ELECTRICAL SYSTEM
............................................................................ Charging Coil Resistance Test
Charging System
Meter Standard
Item Connection
Setting Value

Charging Coil Testing: Brown +-+ Brown 0.3 -0.6 Q

Charging
eOpen the electric case. RxlQ Green +-+ Black/ 13.6 ­
Coil
e Remove the magneto leads off the electric case. Yellow 20.5 n
eTemporarily connect the magneto leads except the
charging coil leads (brown).
fllf the coil has norma.! resistance, but the voltage check
shows the charging system to be defective, then the
permanent magnets in the flywheel have probably
weakened, necessitating flywheel replacement.

Regulator/Rectifier:
Removal
eDisconnect the battery ground cable.
eOpen the electric case.

A. Charging Coil Leads

eWith a multimeter, check the charging coil output (in

circuit) according to the following table with the
engine running at approximately 3,000 rpm.

I WARNING I
aTo avoid electrical shock, do not perform this test with
the watercraft in the water.

A. Electric Case B. Bolts

aOperate the engine only for short periods without

eRemove the regulator/rectifier.
cooling water. Stop the engine immediately if the
temperature warning buzzer goes on. Overheating will
cause severe engine and exhaust system damage.

Charging Coil Output Test

Meter Standard
Item Connection
Setting Value
Charging 250
Brown +-+ Brown 42 V
Coil VAC

*If the charging coil output voltage is correct, check the

regulator according to the regulator test procedure.

beerdart
*If the charging coil output voltage is low, check the
charging coil resistance with a multimeter according to
the following table. A. Regulator/Rectifier

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 ELECTRICAL SYSTEM 13-17

Instal/ation e Remove the following.

eApply a non-permanent locking agent to the following Spark Plug Caps
bolts, and tighten them to the specified torque.
Regulator/Rectifier Mounting Bolts
Electric Case Bolts

Inspection
eWith a multimeter set to the R x 1 k n range, test the
regulator/rectifier according to the following table.

Regulator/Rectifier Resistance Test

(Unit: kn)
Tester Positive (+) Lead Connction
Lead Redl
Brown Brown Black
Color Purple

~
-0 Red/
o:l
III 20 -100 20 -100 15 - 80 A. Spark Plug Cap
Purple
-
-l

~
I

III Brown 1- 5 30 - 200 20 -100

-z>
o:lc Grommet Cap Bolts
~
COo
zIl.l._
....u Brown 1- 5 30 - 200 20 -100 CDr Igniter Lead Connectors
.... Il.l
Il.lC CDr Igniter Mounting Bolts

~
~c
~8 Black 2 - 10 1- 5 1- 5

Measure with the Kawasaki Hand Tester 57001-983.

A tester other than the Kawasaki Hand Tester may show
different readings.

* If any of the values obtained do not agree with the

above table, the regulator/rectifier must be replaced.

Ignition System

COl Igniter Removal

e Disconnect the battery ground cable.
eOpen the electric case. A. Grommet Cap C. CDI Igniter
B. Bolts

eRemove the CDr igniter.

COl Igniter Installation

elnstallation is the reverse of removal. Note the fol­
lowing.
eApply a non-permanent locking agent to the removed

beerdart
bolts, and tighten them to the specified torque.
eConnect the ground leads to the CDI igniter mounting
A. Electric Case B. Bolts bolt.

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 13·18 ELECTRICAL SYSTEM
(unit: kl1)

Meter (+1 Lead Connection

Meter
Range
x 1 kn
PU G BK(l) w BK(2)

1\
* * *
500 500 500
I
PU j j ~
I
I ~ ~ ~

* *

1\ 500 * 500 500

G
00
• •
00
00
•
~

A. Ground Leads c:
0
.~

"c:

1\
<II
c:
0
U BK(l)
"0
3-4 20- 30 ~
0
III
<II
...J

CDllgniter Inspection
eMeasure the secondary winding resistance.
I
~
~
W
*
40 ­
• 11\
200-1000
150
*
14 ­ 22

50 ­
I
150
*
14 -22

50 - 150
I
*

50 ­
14 - 22
•150

1\
oPul1 the spark plug cap off the lead.
oConnect an ohmmeter between the spark plug leads. i BK(2) 3-4 20 - 30 I a 00

OSet the meter to the x 1 kU range, and read the meter.

'I
I

*= If measuring these resistance twice, wait for 30

Ignition Coil Winding Resistance minutes for capacitor charging.
Secondary windings: 2.1 - 3.1 kU
Measure with the Kawasaki Hand Tester 57001-983.
A tester other than the Kawasaki Hand Tester may show
different readings.

Exciter Coil Inspection

PU~_ CJ If the spark is weak or absent at the spark plug, and

~\~K(2)
the COl igniter is found to be functioning properly, and
BK(lr
\
? the wiring is all in good condition and properly con­
nected (check for loose or corroded conditions); the
G
cause may be a short or open in the exciter coil, or loss
of magnetism in the flywheel magnets. With a multi­
1. COl Igniter meter set to the proper range, measure the resistance
between the leads shown in the following table.

*If the secondary winding does not have the correct

resistance, replace the COl igniter.
eMeasure the internal resistance. Exciter Coil Resistance Tests
OSet the ohmmeter to the x 1 kQ range, and connect it Meter Standard
to the leads from the COl igniter to check the internal Item Connection
Setting Value

beerdart
resistance of the COl igniter.
*If the readings do not correspond to the table, replace Exciter Rx Black 1­
Coil lOOn Purple ­ /Yellow 1.6 kn
the COl igniter.

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 ELECTRICAL SYSTEM 13-19

* If the resistances in this test are found to be less than *If the insulator appears dry and sooty the fuel/air
the proper values, there is probably a short in the ex­ mixture is overly rich (see Carburetor Adjustments in
citer coil. the Fuel System chapter).
*No reading (00) indicates an open circuit. elf the insulator and electrodes are wet and oily, an
*In either case, replace the coil. improper oil type or an excess oil output may be the
*If, however, the coil check out good, the cause is most cause.
likely a loss of magnetism in the flywheel, necessitating *If the ceramic insulator is cracked, replace the plug.
flywheel replacement. *If the electrodes are badly worn or burned, replace the
plug.
eExamine the spark plug threads.
*If the threads are damaged, replace the plug.
Spark Plug Removal
ePull off the spark plug caps.
eUnscrew the spark plugs.
aBe careful to avoid breaking the ceramic on the spark
plugs.

Spark Plug Cleaning

e(lean the electrodes and the ceramic insulator around
the center electrode with an abrasive blasting device.
Spark Plug Installation aBe certain that all abrasive particles are removed from
eBe sure the spark plug threads are clean and dry. the plug.
eTighten the spark plugs to the specified torque (see e(lean the entire plug in a high flash point solvent.
Exploded View).
aBe careful to avoid breaking the ceramic on the spark
plugs.
e(onnect the spark plug caps.

Spark Plug Adjustment

eMeasure the spark plug gap.
Spark Plug Inspection OCheck the distance between the electrodes with a feeler
eRemove the spark plugs (see Spark Plug Removal). gauge or a wire gauge.

1II~11l1I111l11I1I.1

CD -.Jllil[~SP~A;R:K
GAP PLUG
•
------r
1. Threads 3. Electrodes
2. Ceramic Insulator
Spark Plug Gap
0.7 - 0.8 mm (0.028 - 0.032 in)

eExamine the ceramic insulator and electrodes.

*If the insulator appears glazed or very white, or if there

beerdart
are gray metallic deposits on the electrodes, com­ *If the gap is not within specifications, adjust it.
bustion chamber temperatures are too high. Refer eAdjust the gap by carefully bending the side electrode
to Troubleshooting. with a tool designed for this purpose.

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 13-20 ELECTRICAL SYSTEM

Ignition Timing Inspection (dynamic) -When the ignition timing is p'roperly adjusted, remove
-Remove the magneto breather plug. the timing light and the tachometer.
-Attach a timing light and a tachometer following the
manufacturer's instructions.
-Start the engine and run it at approximately 6,000
rpm.
eDirect the timing light at the notch and timing mark on
the flywheel. oWhen adjusting the stator, be careful not to damage the
eThe timing is correct if the mark al igns with the projec­ coils.
tion.

Verification of Timing Marks

The accuracy of the timing marks can be checked
with the top dead center finder (special tool).
e Remove the magneto cover.
eRemove the spark plug from the front cylinder and
install the top dead center finder (special tool) in the
plug hole.

A. Projection B. Timing Mark

eShut off the engine.

000 not run the engine for more than 15 seconds

without cooling water.
oTake care not to over-rev the engine while running it
with no load.

*If the timing is incorrect, remove the flywheel, loosen

the stator screws, and reposition the stator as necessary
to correct the timing. Tighten the screws and recheck
the timing. A. Top Dead Center Finder: 57001402

-Position the piston at top dead center.

eTurn the flywheel clockwise until the dial gauge reads
the value shown in the table.

Piston Position at Timing Mark

Distance from TOe: 2.0 mm

eReinstal1 the magneto cover and remove the magneto

beerdart
breather plug.
eThe timing mark on the flywheel should align with the
A. Stator Set Screws projection on the magneto cover at this point.

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 ELECTRICAL SYSTEM 13-21

*If it does not, set the piston at the specified position

BTDC (before top bead center) and make a new timing
mark on the flywheel just under the projection.
-Check the ignition timing.

NOTE
oWhen inspecting ignition timing after verifying the
timing marks with a dial gauge, use your new timing
mark.

- Remove the t6p dead center finder and replace the A. Grommet Caps B. Bolts
spark plug and plug lead.
-Disconnect the battery cable, starter motor cable, and
wire leads.
• Remove the electric case.

Electric Case

Removal/Disassembly
- Remove the engine hood.
-Disconnect the battery ground cable.
-Open the electric case. Assembly/Insta//ation
• Run the wire leads through the electric case hole.
To Starter
Motor To Battery
I

A. Electric Case B. Bolts

beerdart
eRemove the grommet caps.

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 13-22 ELECTRICAL SYSTEM

oConnect the battery cable to the relay (+) terminal Blower Fan Inspection
having red lead. eUsing two auxiliary wires, supply battery power to the
eConnect the wire leads. Refer to the Wiring Diagram. blower fan.
eConnect the ground leads (black) to the CDI igniter
mounting bolt. Wire Connections
eApply a non-permanent locking agent to all the Blue Lead Battery 1+1
removed bolts, and tighten them to the 'specified Black lead Battery (-I
torque. *If the fan does not turn at this time, the fan is defec­
eApply water resistant grease to the O-ring of electric tive and must be replaced.
case. eRemove the blade cover, and check the fan blades.

A. Apply grease.
A. Fan Blades

*If the fan blades are damaged, replace the blower fan
assembly.
•• - •••••••••••••••••••• 11.1 II" 1 I.

Blower Fan System

..................... I _ ..

Blower Fan Removal

e Loosen the clamp.
eDisconnect the fan leads.
eUnscrew the mounting bolts.

11~> en 0
+

~~ ~
~R/f
~~-aJ I 0)~~ LJ
J__

beerdart
1. Blower Fan 5. Starter Relay
2. Blower Fan Switch 6. lVtain Fuse (20A)
1. Blower Fan 3. Ignition Switch 7. Battery
2. Mounting Bolts 4. Fan Fuse (SA)

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 ELECTRICAL SYSTEM 13-23

eSuspend the sensor in a container of water so that the

Temperature Warning System temperature sensing projection is submerged.
eSuspend a thermometer in the water.
A temperature sensor is installed on the bypass hose.
Whenever the cooling water temperature rises to 95°C
(203°F) or higher, the contacts in the temperature
sensor does and sound the warning buzzer. If the
warning buzzer gose on, stop the engine immediately
and check the cooling system.

CD @
[Jiwpu

~ rR---£»-R~
R--..., BK
1. Temperature Sensor

-- NOTE
To Spark Plug o o The sensor and thermometer must not touch the
® container sides or bottom.
,. Warning Buzzer 4. Ignition Switch
2. COl Igniter 5. Starter Relay .Place the container over a source of heat and gradually
3. Temperature Sensor 6. Battery rise the temperature of the water while stirring gently.

Temperature Sensor Connections

Rising temperature: From OFF to ON
000 not let the engine continue running when the
at 95°C (203°F)
warning buzzer goes on. Prolong engine operation will
result in sever damage from overheating. Failling temperature: From ON to OFF
at SSoC (190°F)
ON: Less than 0.5 n
OFF: More than 1 Mn
Temperature Sensor Inspection
e Remove the temperature sensor.

Switches

Start/Stop Switch:
Removal/Installation

beerdart
eOpen the electric case.
,a. eRemove the grommet cap.
A. Temperature Sensor eDisconnect the start/stop switch leads.

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 13-24 ELECTRICAL SYSTEM

A. Start/Stop Switch Leads B. Grommet Cap A. Ignition Switch Leads B. Grommet Cap

eDisassemble the control stick (see Steering chapter). eRemove the steering cover (see Steering chapter).
eRemove the start/stop switches. eRemove the ignition switch.

•
A. Start Switch C. Screws A. Ignition Switch B. Mounting Nut
B. Stop Switch

elnstallation is the reverse of removal.

elnstallation is the reverse of removal. OApply a non-permanent locking agent to the electric
oThe stop switch has white and black leads. case bolts.
oConnect the start/stop switch leads. Refer to the
Wiring Diagram.
oApply a non-permanent locking agent to the electric
case bolts.

Ignition Switch: Engine Shut-off Switch/Bilge Pump Switchl

Removal/Installation Blower Fan Switch:

beerdart
eOpen the electric case. Removal/Installation
e Remove the grommet cap. eRemove the steering cover (see Steering chapter).
eDisconnect the ignition switch leads. eUnscrew the mounting nuts, and remove the switches.

------- -- --- -- - --_._---­

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 ELECTRICAL SYSTEM 13-25

as
Bilge Pump Switch

I ~~F I I
Blower Fan Switch

l I ~~F I ;:oJOO: I
®
A. Mounting Nuts C. Bilge Pump Switch
B. Engine Shut-off Switch D. Blower Fan Switch

_Installation is the reverse of removal. Note the fol·

lowing.
oThe blower fan switch has yellow and red leads.

Switch Inspection:
-Using an ohmmeter, check to see that only the con­ Fuse
nections shown in the table have continuity (about • 11.11 1'1' I ••• II II 1 1 I"

zero ohms).
*If the switch has an open or short, repair it or replace Inspection
it with new one. -While pushing the fuse cap, turn it counterclockwise,
and then remove the cap with the fuse.
Ignition Switch

1~:I~IR~ I
Start/Stop Switch
Start Switch Stop Switch
R/PU G/W W BK
Free
Push on

Engine Shut-off Switch

W BK A. Main Fuse 20A C. Bilge SA
When lanyard is installed B. Fuse Cap D. Blower SA
When lanyard is removed

-I nspect the fuse element.

Starter Lockout Switch *If it is blown out, replace the fuse. Before replacing a
Shift lever Position G/W BK/Y blown fuse, always check the amperage in the affected

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F or R position circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components
Engine starting position for a short circu it.

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 13-26 ELECTRICAL SYSTEM

oWhen replacing a fuse. be sure the new fuse matches

the specified fuse rating for that circuit. Installation of
a fuse with a higher rating may cause damage to wiring
and components.

Normal Failed

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-- -------~
 STORAGE AND TRANSPORTING 14-1

STORAGE
Table of Contents

Preparation for Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . 14-2
Bilge System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
General , 14-3
Removal from Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
LUbrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14-3
Test Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4

III

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 14·2 STORAGE AND TRANSPORTING
-Start the engine and run it only for short periods until
Preparation for Storage all fuel in the carburetor is used up.

During the winter, or whenever the watercraft will

not be in use for a long period of time, proper storage
is essential. It consists of checking and replacing missing OOperate the engine only for short periods without
or worn parts; lubricating parts to ensure that they do cooling water. Stop the engine immediately if the
not become rested; and, in general, preparing the water­ temperature warning buzzer goes on. Overheating will
craft so that when the time comes to use it again, it will cause severe engine and exhaust system damage.
be in top condition. e Remove the air intake cover from the carburetor.

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

Bilge System
-Clean the bilge system (see Bilge System Flushing in
in the Cooling and Bilge System chapter).

A. Air Intake Cover B. Bolts

Fuel System

I WARNING I e Lift out the flame arrester and clean it, if necessary
(see Flame Arrester Cleaning in the Fuel System
chapter)
oGasoline is extremely flammable and can be explosive eSpray a penetrating rust inhibitor down the carburetor
under certain conditions. Push the STOP button. Do bore.
not smoke. Make sure the area is well ventilated and elnstall the flame arrester with the flat face downward.
free from any source of flame or sparks; this includes e Reinstall the cover, apply a non-permanent locking
any appliance with a pilot light. agent to the threads of the air intake cover bolts and
tighten securely.

eDrain the fuel tank. This should be done with a siphon

or pump.
eClean the filter screens (see Fuel Filter Screen Cleaning
in the Fuel System chapter).

Engine
eRemove the spark plugs and pour one ounce of motor
oil into each cylinder.

000 not use too much oil, or the crank seals may be
damaged when the engine is next started.

eGround the spark plugs, turn the engine over several

times with the starter motor to coat the cylinder walls
with oil, then replace the spark plugs.

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e Remove the exhaust tube and pour three ounces of
automobile antifreeze into the water box muffler.
A. Siphon Hose Replace the exhaust tube.

--- -- --- -- -- ---~ ----~

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 STORAGE AND TRANSPORTING 14-3
Battery
Removal from Storage
- Remove the battery (see Battery Removal in the
Electrical System chapter).
-Clean the exterior with a solution of baking soda and
water (one heaping tablespoon of baking soda in one
Lubrication
cup of water). Rinse thoroughly with water.
-Carry out all recommended lubrication procedures (see
Lubrication in the Appendix chapter).

000 not allow any soda solution to enter the battery.

-Check the electrolyte and fill to the upper level mark

with distilled water, if necessary.
-Check the specific gravity with a hydrometer and
recharge if necessary. General Inspection
-Cover both battery terminals with grease. -Check for binding or sticking throttle, choke, or
-Store the battery in a cool, dry place. Do not expose steering mechanism. The throttle lever must return
it to freezing temperatures. fully when released.
-Clean and gap spark plugs (see Spark Plug Cleaning and
Spark Plug Adjustment in the Electrical System
NOTE chapter).
oCheck the battery at least every 30 days and recharge -Check all rubber hoses for weathering, cracking, or
if necessary. A neglected battery will gradually lose looseness.
its charge and begin to sulfate (plates turn white). -Remove the jet pump cover. Check cooling hose
Once this reaction has begun, the battery usually for weathering, cracking or looseness.
cannot be salvaged. - Replace them if necessary. Replace the cover and
tighten securely.
-Check the fire extinguisher for a full charge.
-Check the battery, charge if necessary, and clean the
terminals. Install the battery (see Battery Installation
in the Electrical System chapter).

Lubrication
-Carry out all recommended lubrication procedures (see Fuel System
Lubrication in the Appendix chapter). -Check and clean or replace the fuel filter screens as
necessary (see Fuel Filter Screen Cleaning in the Fuel
System chapter).
-Inspect the engine oil tank vent check valve (see
Engine Lubrication System chapter).

I WARNING _
oGasoline is extremely flammable and can be explosive
under certain conditions. Push the STOP button. Do
General not smoke. Make sure the area is well ventilated and
-Wash the watercraft and dry it thoroughly, making sure free from any source of flame or sparks; this includes
to drain the engine compartment completely. any appliance with a pilot light_

-After refueling and before starting the engine, run the

blower fan for 4 minutes to ventilate the engine com­
partment.
OUse only a mild detergent in water to wash the hull.
Harsh solvents may attack the surface or smear the
colors.
I WARNING I
o A concentration of gasoline fumes in the engine com­
- Apply a good grade of wax to all exterior hull surfaces. partment can cause a fire or explosion.

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- Lightly spray all exposed metal parts with a penetrat­
ing rust inhibitor. _Check for fuel leaks. Repair if necessary.
-Cover the watercraft and store it in a clean, dry place. -Check the engine oil level. Fill the oil tank with the
specified oil up to the F (Full) mark.

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 14-4 STORAGE AND TRANSPORTING

Test Run

I WARNING'
o Do not run the engine in a closed area. Exhaust gases
contain carbon monoxide, a colorless, odorless,
poisonous gas. Breathing exhaust gas leads to carbon
monoxide poisoning, asphyxiation, and death.

-Start the engine and run it only for short periods.

Check for fuel, oil and exhaust leaks" Any leaks must
be repaired"

oOperate the engine only for short periods without

cooling water. Stop the engine immediately if the
temperature warning buzzer goes on. Overheating will
cause severe engine"and exhaust system damage.
000 not run the engine at maximum speed out of the
water. Severe engine damage may result.

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--_.--­
 APPENDIX 15-1

APPENDIX
Table of Contents

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

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~--- ~-~.- ----
 15-2 APPENDIX

Lubrication

As in all marine craft, adequate lubrication and

corrosion protection is an absolute necessity to provide
long, reliable service. Refer to the Periodic Maintenance
Chart for the frequency of the following items:
• Lubricate the following with a penetrating rust in­
hibitor.

Choke Cable, and Throttle Cable

A. Apply grease.

Steering Cable Ball Joints. and Nozzle Pivot

1. Pressure Cable Luber: K56019-021

• Lubricate the throttle cable ends and choke cable ends

with a high quality waterproof grease.

A. Nozzle Pivot B. Ball Joint

A. Apply grease.
Shift Cable Ball Joints, and Bucket Pivot

A. Apply grease.

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-- ---
A. Ball Joint

- --
B. Bucket Pivot

-------
 .._ -------------------------------------- ----_.,_ •..~--

APPENDIX 15-3

Troubleshooting

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 154 APPENDIX

Fault in 1 Wrong mixture screw

Carburetor 2 Obstruction in fuel passage or outlet
3 Diaphragm leaking or damaged
Fuel mixture 4 Float arm not adjusted
too lean

Poor fuel supply (fuel filter screens,

Other hoses, or vent line clogged)
2 Carburetor mounting loose
3 Faulty fuel pump
Fuel System
1 Diaphragm needle dirty or damaged
Fault in 2 Float arm not adjusted
Carburetor 3 Choke not adjusted
Engine mis­ Fuel mixture 4 Mixture screw not adjusted
fires, does too rich
not run Flame Arrester
smoothly Clogged

Ignition
Timing
Wrong
1 Reduced ignition coil output
Electrical System
2 High voltage insulation breakdown
3 Spark plug fouled
Weak Spark 4 Spark plug gap wrong
5 Poor wiring connection, spark plug cap
6 Faulty COl igniter
7 Faulty magneto
8 Battery voltage low
Engine Lubrication System 1 Oil line clogged
2 Faulty oil pump

During normal
1 Slight piston seizure
cruising I 2 Piston ring broken or sticking
L 3 Main bearing worn or damaged

During sudden - Excessive clearance between connecting

rod small end and piston pin, or between
acceleration
pin and piston
L..- 2 Excessive connecting rod big end
clearance

Abnormal engine
sound
Pinging
-
~
1
2
Ignition timing too advanced
Carbon accumulation in cylinder head
3 Poor quality gasoline
~ 4 Spark plug wrong heat range

When the engine is - 1 Excessive piston clearance

idling while cold ' - 2 Piston rings worn

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' - 3 Piston worn
'----- 4 Connecting rod bent, twisted

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 APPENDIX 15-5

1 Spark plug gap or heat range wrong

Ignition System 2 Ignition timing wrong
,..;.---:...----~3 Reduced ignition coil output
4 Loose wiring connection in ignition
circuit

1 Insufficient fuel supply to carburetor

2 Carburetor diaphragm damaged
3 Pulse line leaking or clogged
Fuel System 4 High speed nozzle clogged
5 Throttle valve does not fully open
6 Fuel filter screen clogged
7 Faulty fuel pump

1 Flame arrester clogged

Other 2 Muffler or exhaust system clogged
Low engine ~-------~ 3 Water or foreign matter in gasoline or engine oil
Power ­ This 4 Exhaust gas leak in engine compartment
trouble often
has more than
one cause, and
trouble symptoms
may not be clear Overheating

Heavy Fuel
Consumption

Poor performance
though engine runs
properly Jet Pump Intake area obstructed
Impeller or pump case damaged
Excessive clearance between impeller and
pump case
Reverse system maladjusted

Poor Steering Control Stick hard

1 Steering maladjusted
Control to turn 2 Bushings damaged or cracked
~::..:..:..;;...:,.::..:..:.._--------------------+--
3 Steering shaft bent
4 No lubricant on steering nozzle pivot
5 Steering cable damaged or improperly
routed

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 15-6 APPENDIX

Units of Length:
Unit Conversion Table
km x 0.6214 = mile
m x 3.281 = ft
Prefixes for Units:
mm x 0.03937 = in
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,000
Units of Torque:
centi c x 0.01
milli m x 0.001 N-m x 0.1020 = kg-m
micro JJ. x 0.000001 N-m x 0.7376 = ft-Ib
N-m x 8.851 in-Ib
kg-m x 9.807 ~
N-m
kg-m x 7.233 ~
ft-Ib
Units of Mass: kg-m x 86.80 = in-Ib
kg x 2.205 ~ Ib
9 x 0.03527;: oz

Units of Pressure:
kPa x 0.01020 kg/em 2
Units of Volume: kPa x 0.1450 = psi
L x 0.2642 = gal (US) kPa x 0.7501 ::: em Hg
L x 0.2200 = gal (imp) kg/cm 2 x 98.07 kPa
L x 1.057 qt (US) kg/em 2 x 14.22 = psi
L x 0.8799 = qt (imp) em Hg x 1.333 ::: kPa
L x 2.113 = pint (US)
L x 1.816 pint (imp)
mL x 0.03381 = oz (US)
mL x 0.02816 = oz (imp) Units of Speed:
mL x 0.06102 = eu in km/h x 0.6214 = mph

Units of Force: Units of Power:

N x 0.1020 kg . kW x 1.360 :::
PS
N x 0.2248 Ib kW x 1.341 HP
kg x 9.807 = N PS x 0.7355 = kW
kg x 2.205 = Ib PS x 0.9863 ;:
HP

Units of Temperature:

OF ·4
OF
32 68 104 176 212 248 284
·40 ·20 :0 20 : 40 60 I
80 100; 120 140 160 :180 200 : 220 240 ; 260 280: 300 320
, ,
I
I :I I I I' 'I I

I I
I I I I
I I I'I I
I I, I i
I I ;1 I II, I I i
I I !: 120I I I

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I I I I
·40 -20: 0 : 20 40 : 60 80 ,I 100 :140 160
'17.8 4.4 26.7 48.9 71.1 93.3 138
°c 116
°c

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 5
-

MODEL APPLICATION
Year Model Beginning Hull No.
1989 JB650-A1 J KA00001 H889 or J B650A·OOOOO1
1990 JB650-A2 JKA000011990 or JB650A-000501
1991 JB650-A3 J KA00001 G091 or J B650A-001801
1992 JB650-A4 J KAOOO01 C192

I,

_-c Kawasaki
.4<AWASAKI HEAVY INDUSTRIES, LTD.
Consumer Products Group

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Part No. 99924-1121-03 Printed in Japan

"

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