-
This workshop service repair manual PDF download for the 2004-2005 Kawasaki Jet Ski Watercraft STX-15F/JT1500-Ax has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Year - Model - Beginning Hull No.
2004 - JT1500-A1 - KAW60001 304
2005 - JT1500-A2 - US-KAW50001 405
TABLE OF CONTENTS :
General Information
Periodic Maintenance
Fuel System (DFI)
Engine Lubrication System
Exhaust System
Engine Top End
Engine Removal/Installation
Engine Bottom End
Cooling and Bilge Systems
Drive System
Pump and Impeller
Steering
Hull/Engine Hood
Electrical System
Storage
Appendix
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99924-1325-02
Total Pages : 438
This kawasaki manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
This kawasaki service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.
-
table
LIST OF ABBREVIATIONS
Units of Mass
Units of Volume
Units of Force
Units of Length
Units of Torque
Units of Pressure
Units of Speed
Units of Power
General Fasteners (stainless bolt and nut)
Throttle Lever Free Play
Engine Oil
Valve Clearance
Example
Example
Battery Terminal Voltage
Idle Speed
Throttle Sensor Output Voltage
Output Voltage at Sensor
Throttle Sensor Input Voltage
Input Voltage at ECU
Throttle Sensor Input Voltage
Input Voltage at Sensor
Throttle Sensor Output Voltage
Idle Speed
Output Voltage at ECU
Throttle Sensor Output Voltage
Output Voltage at Sensor
Throttle Sensor Resistance
Inlet Air Pressure Sensor Input Voltage
Input Voltage at ECU
Inlet Air Pressure Sensor Input Voltage
Input Voltage at Sensor Connector
Inlet Air Pressure Sensor Output Voltage
Output Voltage at ECU
Inlet Air Pressure Sensor Output Voltage
Output Voltage at Sensor Connector
Output Voltage Performance
Inlet Air Temperature Sensor Output Voltage
Output Voltage at ECU
Inlet Air Temperature Sensor Resistance
Water Temperature Sensor Output Voltage
Output Voltage at ECU
Vehicle-down Sensor Power Source Voltage
Power Source Voltage at Sensor
Vehicle-down Sensor Output Voltage
Output Voltage at Sensor
Injector Resistance
Injector Power Source Voltage
Power Source Voltage at Injector Connector
Injector Output Voltage
Output Voltage at Injector Connector
Fuel Line Maximum Pressure
Ignition Coil Input Voltage at Ignition Coil
Input Voltage at ECU
Water Temperature Sensor Output Voltage
Output Voltage at ECU
ECU Grounding Inspection
ECU Power Source Inspection
Testing Relay
Testing Relay
Idle Speed
Idle Speed
ISC Resistance
Fuel Pressure (idling)
Amount of Fuel Flow
Pump Power Source Voltage
Power Source Voltage at Pump Lead Connector
Pump Operating Voltage
Oil Pressure
Camshaft Journal, Camshaft Cap Clearance
Camshaft Journal Diameter
Camshaft Runout
Cam Height
Cylinder Compression
Cylinder Head Warp
Valve/Valve Guide Clearance (Wobble Method)
Valve Seating Surface Outside Diameter
Valve Seating Surface Width
Cylinder Inside Diameter
Piston Diameter
Piston Ring/Groove Clearance
Piston Ring Thickness
Piston Ring End Gap
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Clearance
Crankpin Diameter
Crankpin Diameter Marks
Connecting Rod Big End Bore Diameter Marks
Crankshaft Main Bearing Insert/Journal Clearance
Crankshaft Main Journal Diameter
Crankshaft Main Journal Diameter Marks
Crankcase Main Bearing Bore Diameter Marks
Crankshaft Side Clearance
Crankshaft ##3 Main Journal Width
Crankshaft Runout
Drive Shaft Runout
Impeller Outside Diameter
Pump Case Inside Diameter
Impeller Clearance
Steering Position Sensor Clearance
Rivet Removal Drill Bit Size
Rivet Removal Drill Bit Size
Color Codes
Kawasaki-recommended chargers
Terminal Voltage: 11.5 ∼ less than 12.6 V
Terminal Voltage: less than 11.5 V
Starter Motor Brush Length
Commutator Diameter
Magneto Output Voltage
Stator Coil Resistance Test
Regulator/Rectifier Inspection Unit: k
Crankshaft Sensor Resistance
3 Needle Arcing Distance
Winding Resistance
Spark Plug Lead Resistance
Primary Lead Connections
Ignition Coil Primary Peak Voltage
Connections
Crankshaft Sensor Peak Voltage
Connections
Camshaft Position Sensor Peak Voltage
Steering Position Sensor Clearance
Steering Position Sensor Clearance
Connections to Steering Position Sensor Connector
Steering Position Sensor Input Voltage
Connections to Steering Position Sensor Connector
Steering Position Sensor Output Voltage
Meter Reading
Water Temperature Sensor Resistance
Oil Temperature Sensor Resistance
Output Voltage
Relay Assembly Circuit Inspection (with the battery disconnected
Relay Assembly Circuit Inspection (with the battery connected)
toc
Read OWNER'S MANUAL before operating.
MAINTENANCE AND ADJUSTMENTS
EMISSION CONTROL INFORMATION
Foreword
General Information
This watercraft is equipped with the Smart Learning Operation mo
Before starting to perform an inspection service or carry out a
Kawasaki Diagnostic System (KDS) Software
Adjustments
Auxiliary Cooling
Battery Ground
Edges of Parts
Solvent
Cleaning Watercraft before Disassembly
Arrangement and Cleaning of Removed Parts
Storage of Removed Parts
Inspection
Replacement Parts
Assembly Order
Tightening Sequence
Tightening Torque
Force
Gasket, O-ring
Liquid Gasket, Locking Agent
Press
Ball Bearing
Oil Seal, Grease Seal
Circlips, Cotter Pins
Lubrication
Direction of Engine Rotation
Electrical Wires
JT1500-A1 Left Side View
JT1500-A1 Right Side View
Prefixes for Units
Units of Temperature
Periodic Maintenance
The scheduled maintenance must be done in accordance with this c
The following table list the tightening torque for the major fas
Oil Filter Wrench:
Fuel System
Throttle Control System Inspection
Torque -
Air Filter Drain Caps Inspection and Cleaning
Air Filter Inspection and Cleaning
Fuel Vent Check Valve Inspection
Fuel Pump Screen Cleaning
Throttle Shaft Spring Inspection
Engine Lubrication System
Engine Oil Change
Torque -
Oil Filter Replace
Special Tool -
Torque -
Engine Top End
Air Suction Valve Inspection
Valve Clearance Inspection
Special Tool -
INLET VALVE CLEARANCE ADJUSTMENT CHART
EXHAUST VALVE CLEARANCE ADJUSTMENT CHART
Engine Mounting Bolts Inspection and Tightness
Torque -
Engine Bottom End
Coupling Damper Inspection
Cooling and Bilge Systems
Cooling System Flushing
Bilge System Flushing
Pump and Impeller
Impeller Inspection
Steering
Steering Cable/Shift Cable Inspection
Handlebar Pivot Lubrication
Hull/Engine Hood
Drain Plug Inspection
Electrical System
Battery Charging Condition Inspection
Battery Terminals Inspection
Spark Plug Cleaning and Inspection
Owner's Tool -
Owner's Tool -
Torque -
Lubrication
All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check
Nuts, Bolts, and Fasteners Tightness Inspection
Nut, Bolt and Fastener to be checked
Hose and Hose Connect Inspection
Rubber Strap Inspection
Fuel System (DFI)
Oil Pressure Gauge, 5 kgf/cm :
1.
DFI System Wiring Diagram
Part Name
Terminal Numbers of ECU Connectors
There are a number of important precautions that should be follo
Special Tool -
Self-diagnosis Outline
Service Code (Character) Table
Note:
Memory of Service Code (Character)
Sample Diagnosis Sheet
Throttle Sensor Removal/Adjustment
Special Tool -
Torque -
Input Voltage Inspection
Special Tool -
Special Tool -
Output Voltage Inspection
Special Tool -
Special Tool -
Resistance Inspection
Special Tool -
CAUTION
Inlet Air Pressure Sensor Removal
Inlet Air Pressure Sensor Installation
Torque -
Input Voltage Inspection
Special Tool -
Special Tool -
Output Voltage Inspection
Special Tool -
Inlet Air Temperature Removal/Installation
Torque -
Output Voltage Inspection
Special Tool -
Sensor Resistance Inspection
Water Temperature Sensor Removal/Installation
Torque -
Output Voltage Inspection
Special Tool -
Sensor Resistance Inspection
Crankshaft Sensor Removal/Installation
Crankshaft Sensor Inspection
Camshaft Position Sensor Removal/Installation
Camshaft Position Sensor Inspection
This sensor has a weight [A] with two magnets inside, and sends
Vehicle-down Sensor Removal
Vehicle-down Sensor Installation
Torque -
Vehicle-down Sensor Inspection
Special Tool -
Special Tool -
Fuel Injector Removal
Fuel Injector Installation
Torque -
Audible Inspection
Injector Signal Test
Special Tool -
Injector Resistance Inspection
Special Tool -
Injector Unit Test
Injector Voltage Inspection
Special Tool -
Special Tool -
Injector Fuel Line Inspection
Ignition Coil ##1, ##4: Service Code 51-COL1
Ignition Coil Removal/Installation
Input Voltage Inspection
Special Tool -
Service Code/Character
Oil Temperature Sensor Removal/Installation
Torque -
Output Voltage Inspection
Special Tool -
Sensor Resistance Inspection
JT1500-A2 model ∼;
CAUTION
ECU Removal
ECU Installation
Torque -
ECU Power Supply Inspection
Special Tool -
ECU Power Source Circuit
Main Fuse Inspection
Relay Assembly Removal
Relay Assembly Inspection
Special Tool -
Free Play Inspection
Throttle Cable Adjustment
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Torque -
Throttle Cable Removal
Throttle Cable Installation
Torque -
Throttle Case and Cable Lubrication
Throttle Cable Inspection
Air Filter Removal
Air Filter Installation
Torque -
Air Filter Disassembly
Air Filter Assembly
Torque -
Idle Speed Inspection
High Altitude Performance Adjustment
Throttle Body Assy Removal
Throttle Body Assy Installation
Torque -
Throttle Body Assy Disassembly
Throttle Bore Cleaning
ISC (Idle Speed Controller) Removal/Installation
Torque -
ISC (Idle Speed Controller) Inspection
ISC Resistance Inspection
Special Tool -
Inlet Manifold Removal
Inlet Manifold Installation
Torque -
Torque -
Torque -
Torque -
Fuel Pressure Inspection
Special Tools -
Fuel Flow Rate Inspection
Fuel Vent Check Valve Mounting
Fuel Vent Check Valve Inspection
Fuel Filter Removal
Fuel Filter Installation
Torque -
Fuel Pump Removal
Fuel Pump Installation
Power Source Voltage Inspection
Special Tools -
Operating Voltage Inspection
Special Tools -
Fuel Pump Relay Removal
Fuel Pump Relay Inspection
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Filler and Tube Removal
Fuel Filler and Tube Installation
Torque -
Engine Lubrication System
Oil Pressure Gauge, 10 kgf/cm :
WARNING
Oil Level Inspection
Engine Oil Change
Oil Filter Replacement
Oil Cooler Removal
Special Tool -
Oil Cooler Installation
Torque -
Torque -
Oil Cooler Disassembly
Oil Cooler Assembly
Sealant -
Torque -
Oil Cooler Inspection
Breather Case Removal
Breather Case Installation
Torque -
Sealant -
Torque -
Oil Separator Tank Removal
Oil Separator Tank Installation
Torque -
Blowby Gas System Inspection
Oil Pan Removal
Oil Pan Installation
Torque -
Torque -
Oil Pump Sprocket Removal
Oil Pump Sprocket Installation
Torque -
Torque -
Oil Pump Removal
Oil Pump Installation
Torque -
Oil Pump Inspection
Oil Screen Removal
Oil Screen Installation
Torque -
Oil Pressure Relief Valve Inspection
Torque -
Oil Pump Sprocket Chain Removal
Oil Pressure Measurement
Special Tool -
Special Tool -
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Sealant -
Torque -
Exhaust System
Exhaust Manifold Removal
Exhaust Manifold Installation
Torque -
Torque -
Exhaust Manifold Cleaning and Inspection
Exhaust Pipe Removal
Exhaust Pipe Installation
Torque -
Exhaust Pipe Cleaning and Inspection
Water Box Muffler Removal
Water Box Muffler Installation
Water Box Muffler Inspection
Engine Top End
Valve Head Thickness
Valve Stem Bend
Compression Gauge, 20 kgf/cm :
Air Suction Valve Removal
Air Suction Valve Installation
Torque -
Air Suction Valve Check
Clean Air System Hose Inspection
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Sealant -
Torque -
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Torque -
Torque -
Camshaft Removal
Special Tool -
Camshaft Installation
Torque -
Special Tool -
Torque -
Piston TDC Finding
Special Tool -
Special Tool -
Special Tool -
Camshaft, Camshaft Cap Wear
Torque -
Camshaft Runout
Cam Wear
Camshaft Chain Removal
Cylinder Compression Measurement
Special Tools -
Torque -
Cylinder Head Removal
Cylinder Head Installation
Torque -
Torque -
Torque -
Torque -
Cylinder Head Warp
Valve Clearance Check
Valve Removal
Special Tools -
Valve Installation
Valve Guide Removal
Special Tool -
Valve Guide Installation
Special Tool -
Special Tool -
Valve-to-Guide Clearance Measurement (Wobble Method)
Valve Seat Inspection
Valve Seat Repair
Cylinder Removal
Piston Removal
Special Tool -
Piston/Cylinder Installation
Special Tools -
Cylinder Wear
Piston Wear
Piston Ring, Piston Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Engine Removal/Installation
Engine Removal
Engine Damper Removal
Engine Damper Installation
Torque -
Engine Installation
Torque -
Engine Bottom End
Oil Seal & Bearing Remover:
Coupling/Output Shaft Removal
Special Tools -
Special Tool -
Special Tool -
Coupling/Output Shaft Installation
Special Tool -
Torque -
Torque -
Torque -
Special Tools -
Torque -
Coupling Damper Inspection
Output Cover Oil Seal Replacement
Special Tool -
Oil Seal Inspection
Magneto Cover Bearing Replacement
Special Tool -
Special Tool -
Ball Bearing Lubrication
Ball Bearing Inspection
Magneto Flywheel Removal
Special Tool -
Magneto Flywheel Installation
Special Tool -
Special Tool -
Torque -
Stator Removal
Stator Installation
Torque -
Torque -
Crankcase Splitting
Crankcase Assembly
Sealant -
Torque -
Torque -
Torque -
Torque -
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Wear
Crankshaft Main Bearing Insert/Journal Wear
Marking Position
Crankshaft Side Clearance
Crankshaft Runout
Cooling and Bilge Systems
Breather Removal
Breather Installation
Breather Cleaning and Inspection
Filter Removal
Filter Installation
Filter Cleaning and Inspection
Hose Removal
Hose Installation
Hose Inspection
Cooling System Flushing
Bilge System Flushing
Water Pipe Removal
Water Pipe Installation
CAUTION
Summary Procedures after Submerging
Detailed Procedures after Submerging
Drive System
Bearing Driver Set:
Drive Shaft Removal/Installation
Special Tool -
Torque -
Drive Shaft Holder Removal/Disassembly
Drive Shaft Holder Assembly/Installation
Special Tool -
Torque -
Drive Shaft Runout
Pump and Impeller
Oil Seal & Bearing Remover:
Pump Removal
Pump Installation
Sealant -
Torque -
Torque -
Torque -
Torque -
Pump Disassembly
Special Tools -
Special Tool -
Special Tool -
Special Tool -
Pump Assembly
Special Tool -
Torque -
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Special Tools -
Torque -
Torque -
Impeller Inspection
Impeller Outside Diameter Measurement
Pump Inspection
Impeller Clearance
Water Filter Cover Removal/Installation
Torque -
Steering
Box Wrench (27 mm):
Steering Cable Adjustment
Torque -
Steering Cable Removal
Special Tool -
Steering Cable Installation
Torque -
Torque -
Steering Cable Inspection
Steering Cable Lubrication
Handlebar Removal
Handlebar Installation
Torque -
Torque -
Steering Removal
Steering Installation
Torque -
Torque -
Torque -
Shift Cable Adjustment
Shift Cable Removal
Special Tool -
Shift Cable Installation
Torque -
Shift Cable Inspection
Shift Cable Lubrication
Reverse Bucket Removal/Installation
Torque -
Shift Lever Shaft Removal/Installation
Torque -
Hull/Engine Hood
Seat Removal
Seat Installation
Front Storage Compartment Cover Removal
Front Storage Compartment Cover Disassembly
Front Storage Compartment Cover Assembly
Torque -
Mirror Removal
Mirror Installation
Mirror Stay Removal
Mirror Stay Installation
Front Storage Pocket Removal
Front Storage Pocket Installation
Storage Pocket Disassembly/Assembly
Crossmember Removal
Crossmember Installation
Torque -
Handrail Removal
Handrail Installation
Drain Plug Housing Removal
Drain Plug Housing Installation
Exhaust Outlet Removal
Exhaust Outlet Installation
Stabilizer Removal
Stabilizer Installation
Torque -
Reboarding Step Removal
Reboarding Step Installation
To replace the hull, remove the various parts in the following s
NOTE
Rubber Parts Location
Rivet Removal
Rivet Installation
Front Bumper Removal
Front Bumper Installation
Rear Bumper Removal
Rear Bumper Installation
Side Bumper Removal
Side Bumper Installation
Electrical System
1.
JT1500-A1
JT1500-A1
JT1500-A2 ∼
JT1500-A2 ∼
Hand Tester:
There are a number of important precautions that should be follo
Wiring Inspection
Special Tool -
Removal
Installation
Electrolyte Filling
Initial Charge
Precautions
1)
2)
3)
4)
Interchange
Charging Condition Inspection
Refreshing Charge
Starter Relay Removal
Starter Relay Installation
Torque -
Torque -
Starter Relay Inspection
Special Tool -
Starter Motor Removal
Starter Motor Installation
Torque -
Starter Motor Disassembly
Starter Motor Assembly
Torque -
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Special Tool -
Brush Lead Inspection
Special Tool -
Brush Plate and Terminal Bolt Inspection
Reduction Gear Removal/Installation
Reduction Gear Inspection
Electric Starter Circuit
Magneto Output Voltage
Regulator/Rectifier Removal/Installation
Torque -
Regulator/Rectifier Inspection
Special Tool -
Regulator Inspection
Charging System Circuit
WARNING
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Torque -
Torque -
Sealant -
Torque -
Timing Rotor Removal
Special Tools -
Timing Rotor Installation
Torque -
Crankshaft Sensor Inspection
Ignition Coil Removal
Ignition Coil Installation
Torque -
Ignition Coil Inspection
Camshaft Position Sensor Removal
Camshaft Position Sensor Installation
Torque -
Camshaft Position Sensor Inspection
Special Tool -
Igniter Removal/Installation
Igniter Inspection
Special Tools -
Special Tool -
Special Tools -
Special Tool -
Special Tool -
Spark Plug Removal
Spark Plug Installation
Spark Plug Inspection
Spark Plug Adjustment
Spark Plug Cleaning
Ignition System Circuit
Steering Position Sensor and Magnet Removal
Steering Position Sensor and Magnet Installation
Inspection of Kawasaki Smart Steering System
Steering Position Sensor Clearance
Steering Position Sensor Input Voltage Inspection
Special Tool -
Steering Position Sensor Output Voltage Inspection
Special Tool -
Steering Position Sensor Circuit
Speed Sensor Removal/Installation
Speed Sensor Inspection
Fuel Level Sensor Inspection
Special Tool -
Throttle Sensor Removal/Installation
Throttle Sensor Inspection
Water Temperature Sensor Inspection
Inlet Air Temperature Sensor Inspection
Oil Temperature Sensor Inspection
Display Function Inspection
MODE/SET Button Inspection
SLO (Smart Learning Operation) Mode Inspection (JT1500-A2 model
Fuel Level Gauge/Symbol/FUEL Characters/Warning Light Inspection
Speedometer Inspection
Speed Sensor Electric Source Inspection
Tachometer Inspection
Battery Symbol/bAt Characters/LED Inspection
Buzzer Inspection
Multifunction Meter Circuit
Removal
Installation
Circuit Inspection
Switch Inspection
Special Tool -
Ignition Switch
Start Switch
Stop Switch
Tether Switch
Engine Oil Pressure Switch Connections *
Inspection
Storage
During the winter, or whenever the watercraft will not be in use
Cooling System
Bilge System
Engine Oil
Fuel System
Engine
Air Filter
Battery
Engine Mounting Bolts
Torque -
Lubrication
General
Lubrication
General Inspection
Fuel System
Test Run
Appendix
NOTE
Engine Doesn't Start, Starting Difficulty
Starter motor not rotating
Starter motor rotating but engine doesn't turn over
Engine won't turn over
No fuel flow
Engine flooded
No spark; spark weak
Fuel/air mixture incorrect
Compression Low
Poor Running at Low Speed
Spark weak
Fuel/air mixture incorrect
Engine stalls easily
Compression low
Hesitation
Poor acceleration
Stumble
Surge
Backfiring when deceleration
After fire
Run-on (dieseling)
Other
Poor Running or No Power at High Speed
Firing incorrect
Fuel/air mixture incorrect
Compression low
Knocking
Miscellaneous
Overheating
Firing incorrect
Fuel/air mixture incorrect
Compression high
Engine load faulty
Lubrication inadequate
Oil cooler incorrect
Sensor incorrect
Over Cooling
Sensor incorrect
Abnormal Engine Noise
Knocking
Piston slap
Valve noise
Other noise
Oil Pressure Warning Light Goes On
Battery Trouble
Battery discharged
Battery overcharged
Poor Performance through Engine Runs Properly
Jet pump
Poor Steering Control (Since faulty steering is dangerous, this
Handlebar hard to turn
Engine Activates Slow Down Mode
Cooling water temperature gets high
Low oil pressure
Water temperature sensors malfunction, wiring open or short
Vehicle-down sensor malfunction, wiring open or short
Oil temperature sensor gets high
Oil temperature sensor malfunction, wiring open or short
-
Kawasaki STX-15F/JT1500-Ax Jet Ski Watercraft Repair Service Manual 2004-2005.pdf
Source : Sitelux.com