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Yesterday, PM. Jet Pump bearing inner race Most Views. Looking for bulletproofing only PWC News. All times are GMT The time now is AM. All rights reserved. Return Oil Passage from the oil cooler. Oil Passage Plug Oil Passage from oil pipe to camshaft cap.
Oil Passage to main oil passage. Supply oil passage to the main passage Oil Screen Oil Hose between the cylinder and oil pan Oil Seal. Oil Level Inspection This watercraft engine is equipped with a semi-dry sump. In the semi-dry sump engine, the oil level difference is very large between the level measured after just stopping and that after leaving for a long time.
It is necessary to check the specified amount of oil is in the engine before starting the engine every day. At this time use the cold mark of the level gauge. Then run the engine to lubricate the engine parts sufficiently. After that it is necessary to check the level by using hot mark of the level gauge. Whenever checking the engine oil level, keep the watercraft level side to side and fore to aft as much as possible.
If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause.
If the oil level is too high, remove the excess oil using a syringe or some other suitable device. If the oil level is too low, add the oil to the low level line through the oil filter opening see Periodic Maintenance chapter. Use the same type and make of oil that is already in the engine. Then at your earliest convenience, change the oil completely.
Ordinary standard Check The preliminary is checked before the ordinary check. Install the removed parts. Launch the watercraft. Start the engine for several minutes. Ride the watercraft and run the engine at about 5 rpm for 5 minutes. Stop the engine and let it cool down for 10 minutes. If the oil level is too high, drain the excess oil thoroughly from the dipstick tube [A] using commercially - available vacuum pump [B]. If the oil level is too low, add the oil to the high level line through the oil filler opening see Periodic Maintenance chapter.
Special Tool - Oil Filter Wrench: Loosen the clamp screws [B] and remove the oil cooler cooling hoses [C] from the oil cooler. Torque - Oil Cooler Assembly Bolts: 7. Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas which can be lethal. Remove the supply [D] and return [E] hoses. Install the oil hoses [D] temporarily with the nuts [E]. Holding the hose and tighten the bolt and nut of the hoses. Apply a non-permanent locking agent to the oil separator tank mounting screws.
If they are not, correct them. Inspect the breather hoses [A], breather pipes [B] and the inlet silencer drain caps for damage or signs of deterioration.
Squeeze the hoses. These hoses should not be hard and brittle, nor should be soft or swollen. Replace any damaged hoses. Check that the hoses and caps are securely connected. Usually water or oil does not collect at the bottom of the housing. In the event that water is drawn in through the duct, or if engine oil is blown back, drain the housing. Pull the inlet silencer drain plugs to drain the water or breather oil when changing engine oil. Unscrew the dipstick tube bolts [A] and pull out the dipstick tube [B].
Torque - Oil Pan Bolts: 7. Next, tighten the cylinder head side bolts. Secondary Oil Screen [B]. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents. If the screen is damaged, replace it. Apply grease to the O-ring [A]. Install the secondary oil screen [B]. Tighten the secondary screen bolts [C] temporarily.
JTB2 Clean the oil screen [A] with high-flash point solvent and remove any particles stuck to it. Torque - Oil Pump Body Bolts: 7. If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air.
WARNING Clean the relief valve in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low -flash point solvent. If cleaning does not solve the problem, replace the relief valve as an assembly. The relief valve is precisely made with no allowance for replacement of individual parts.
Apply a non-permanent locking agent to the relief valve. Install the relief valve. If the oil pressure is significantly below the specification, inspect the oil pump and relief valve. If the oil pump and relief valve are not at fault, inspect the rest of the lubrication system. Oil Pressure Standard:. Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed. Oil Pressure Standard: kPa 4.
Exhaust Manifold Exhaust Manifold Removal Exhaust Manifold Installation Exhaust Manifold Cleaning and Inspection Exhaust Pipe Exhaust Pipe Removal Exhaust Pipe Installation Exhaust Pipe Cleaning and Inspection Water Box Muffler Water Box Muffler Removal Water Box Muffler Installation S: Follow the specific tightening sequence. SY: Apply synthetic rubber adhesive. Check the hose routing and clamp screw position see Cable, Wire and Hose Routing in the Appendix chapter.
If there is excessive corrosion or if the gasket surfaces are so badly damaged that they will not seal properly, replace the part. If the two rings are damaged or warped, replace the rings. The paper tape can be burned out soon after firing. Install the joint tube to the exhaust pipe. Replace the exhaust pipe gasket to a new one. Install the exhaust pipe to the exhaust manifold and tighten the bolts.
If the rings are damaged or warped, replace the rings with new ones. If there is heat damage to the inlet spigot, check the cooling system for blockage see Cooling System Cleaning and Inspection and the fuel system for proper adjustment see Fuel System chapter. Clean Air System Air Suction Valve Removal Air Suction Valve Installation Air Suction Valve Check Clean Air System Hose inspection Cylinder Head Cover Cylinder Head Cover Removal Cylinder Head Cover Installation.
Camshaft Chain Tensioner Camshaft Chain Tensioner Removal Camshaft Chain Tensioner installation Camshaft, Camshaft Chain Camshaft Removal Camshaft Installation Piston TDC Finding Camshaft, Camshaft Cap Wear Camshaft Runout Cam Wear Camshaft Chain Removal Cylinder Head Cylinder Compression Measurement Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp Valve Clearance Check Valve Removal Valve Installation Valve Guide Removal Valve Guide Installation Valve Seat inspection Valve Seat Repair Cylinder, Pistons Cylinder Removal Piston Removal Cylinder Wear Piston Wear Piston Ring Groove Width Piston Ring Thickness Piston Ring End Gap Engine No.
MO: Apply molybdenum disulfied oil solution S: Follow the specific tightening sequence. Closed coil end faces downward. A marking hollow exhaust side. M: Apply molybdenum disulfied grease.
MO: Apply molybdenum disulfied oil solution. R: Replacement Parts. TIR 0. When the vacuum is low, the vacuum switch valve should permit air to flow.
When the vacuum raises to valve closing pressure, it should stop air flow. Replace them if they are damaged. Sealant - Kawasaki Bond Silicone Sealant : The push rod does not return to its original position once it moves out to take up camshaft chain slack.
Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. This could upset the camshaft chain timing, and damage the valves. Always pull the chain taut while turning the crankshaft.
This avoids kinking the chain on the lower crankshaft sprocket. A kinked chain could damage both the chain and the sprocket. If the camshaft position sensor rotor is removed, install it as follows. While pushing the camshaft chain, tighten all camshaft bolts and chain guide bolts. Piston TDC Finding This job can be done when the engine is on the hull and during camshaft installation.
Turn the crankshaft counterclockwise again till the needle of the dial gauge will begin fluctuating. Turn the crankshaft clockwise till the needle of the dial gauge will stop fluctuating [B]. The top of the piston will be identified as the middle position of the range [C] where the needle will stop fluctuating and the identification mark formerly described.
Install: Camshaft see this chapter. Measure each clearance between the camshaft journal and the camshaft cap using plastigage [A]. Service Limit:. If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter Standard: Service Limit: If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again If the clearance still remains out of the limit, replace the cylinder head with camshaft cap.
If the runout exceeds the service limit, replace the camshaft. Camshaft Runout Standard: Service Limit:.
Cam Height Standard: Exhaust. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damaged will occur. Problem Cylinder compression is higher than usable range. Replace the gasket with a standard part. Replace damaged gasket and check cylinder head warp. Repair if necessary. Adjust the valve clearance. If the cylinder head is warped more than the service limit, replace it.
If the cylinder head is warped less than the service limit, repair the head by rubbing the lower surface on emery paper secured to a surface plate first No. This will warp the cylinder head. Soak the cylinder head in oil and heat the oil. Special Tool - Valve Guide Arbor,. The flange stops the guide from going in too far. Special Tool - Valve Guide Reamer,. Valve-to-Guide Clearance Measurement Wobble Method If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below.
Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide. If the outside diameter is too large or too small, repair the seat see Seat Repair. This valve seat cutter is developed to grind the valve for repair.
Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil. It will take off the diamond particles. Setting the valve seat cutter holder in position, operate the cutter in one hand.
Do not apply too much force to the diamond portion. After use, wash it with washing oil and apply thin layer of engine oil before storing. Marks Stamped on the Cutter The marks stamped on the back of the cutter [A] represent the following. Cutter angle [B] Outer diameter of cutter [C]. Operating Procedures Clean the seat area carefully. Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. Original Seating Surface [B].
If the outside diameter of the seating surface is within the specified range, measure the seat width as described below.
Check the seat after each turn. Check the seat outside diameter frequently to prevent overgrinding. If the seat width is within the specified range, lap the valve to the seat as described below. Correct Width [B]. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve clearance see Valve Clearance Adjustment section of Periodic Maintenance chapter. They fall out and score the cylinder wall. They could fall out and score the cylinder wall. Exhaust Side [B] Apply molybdenum disulfide oil solution to the cylinder bore, external of pistons and piston rings.
Insert the piston in the cylinder by two methods. Slip the piston bases [B] under the pistons to hold them level. Compress the piston rings using the piston ring compressor grips [D] and piston ring compressor belts [E] with chamfered side upward. If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. If the measurement is less than the service limit, replace the piston.
Piston Diameter Standard: The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. If the width of any of the two grooves is wider than the service limit at any point, replace the piston. If any of the measurements is less than the service limit on either of the rings, replace all the rings. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Set it close to the. Measure the gap between the ends of the ring with a thickness gauge [B].
Engine Removal Engine Damper Removal Engine Damper Installation Engine Installation Incorrect shims could cause drive shaft misalignment. If there is a gap, inspect a suitable shim [A] between the engine bracket and the damper to achieve a good fit. Shim Selection Part Number of Shim. Coupling Removal Coupling Installation Output Cover Oil Seal Replacement Oil Seal Inspection Magneto Cover Bearing Replacement Ball Bearing Lubrication Ball Bearing Inspection Magneto Flywheel Magneto Flywheel Removal Magneto Flywheel Installation Stator Removal Stator Installation Crankcase Splitting Crankcase Assembly Crankshaft and Connecting Rods Crankshaft Removal Model Identification General Specifications Unit Conversion Table The SLO mode reduces the maximum watercraft speed by approximately 30 percent for a use by unskilled operators.
To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following:.
You need the following items to use the KDS. The connectors for the communication cable and relay cable are located in the front of the battery. Connect the communication cable to the KDS connector 4-pin [A] and the relay cable between the relay assembly [B] connectors 8-pin [C]. 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. CAUTION Do not run the engine without cooling water supply for more than 15 seconds, especially in high revolutionary speed or severe engine and exhaust system damage will occur. Auxiliary Cooling An auxiliary cooling supply 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. Garden Hose Fitting of Adapter D. Robert Hernandez Friday, 31 July Hello there, I need to find a Service Manual for my Kawaski js stand up Jet ski, is it possible to get it from you, you can contact me at or sdanimal yahoo. David Sunday, 31 May Any chance to get it form you? Please send me an email if possible at carboot. If you have any questions, please contact us. E-mail: downloadboatmanuals gmail.
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