KAWASAKI JET SKI ULTRA 150 JH1200 PWC Full Service & Repair Manual 2003-2005

ULTRA150 JET SKI ® Watercraft Service Manual

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 num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference Guide General Information 1 Periodic Maintenance 2 Fuel System 3 Engine Lubrication System 4 Exhaust System 5 Engine Top End 6 Engine Removal/Installation 7 Engine Bottom End 8 Cooling and Bilge System 9 Drive System 10 Pump and Impeller 11 Steering 12 Hull/Engine Hood 13 Electrical System 14 Storage 15 Appendix 16

LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) perminute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h hour(s) Ω ohm(s) L liter(s) Read OWNER’S MANUAL before operating.

MAINTENANCE AND ADJUSTMENTS Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine Sl engine repair establishment or individual. EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane of the antifknock index is recommended. The antiknock index is posted on service station pumps. Emission Control Information To protect the environment in which we all live, Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental Protection Agency. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this engine. The fuel, ignition and exhaust systems of this engine have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. Maintenance Proper maintenance and repair are necessary to ensure that watercraft will continue to have low emission levels. This Service Manual contains those maintenance and repair recommenda- tions for this engine. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards. Tampering with Emission Control System Prohibited Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related parts. * CDI Ignition System * Flame Arrester * Fuel Filter Screen * Spark Plugs * Carburetor and internal parts

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your "JET SKI" watercraft: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki "JET SKI" watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki "JET SKI" watercraft are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don’t take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta- ble of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE ○ This note symbol indicates points of particular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification................................................................................................................. 1-5 General Specifications............................................................................................................ 1-6 Technical Information-Kawasaki Smart Steering System (Carburetor Type).......................... 1-8 Technical Information-Engine ................................................................................................. 1-12 Technical Information-Propulsion System .............................................................................. 1-18 Technical Information-Igniter .................................................................................................. 1-19 Technical Information-Electrical Parts .................................................................................... 1-22 Unit Conversion Table ............................................................................................................ 1-23

1-2 GENERAL INFORMATION Before Servicing Before starting to service a watercraft, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip- tions have been included wherever necessary. Nevertheless, even a detailed account has limitations, 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. 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. (2) 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. • Loosen the clamp and remove the cap [A]. • Connect the garden hose [B] to the hose fitting (see above). • Attach the garden hose to a faucet. Do not turn on the water until the engine is running and turn it off immediately when the engine stops. The engine-requires 2.4 L/min (2.5 qts/min) at 1 800 r/min (rpm) and 7.0 L/min (7.4 qts/min) at 6 000 r/min (rpm). CAUTION Insufficient cooling supply will cause the engine and/or exhaust system to overheat and severe damage will occur. Excessive cooling supply may kill the engine and flood the cylin- ders, causing hydraulic lock. Hydraulic lock will cause severe damage to the engine. If the engine dies while using an auxiliary cooling supply, the water must be shut off immediately. Always turn the boat on its left side. Rolling to the right side can cause water in the exhaust system to run into the engine, with possible engine damage.

GENERAL INFORMATION 1-3 Before Servicing (3) Dirt Before removal and disassembly, clean the “Jet Ski” watercraft. Any sand entering the engine will 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 Disconnect the ground (–) wire from the battery before performing any disassembly operations on the “Jet Ski” watercraft. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery (5) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assem- bled in the same way. It is preferable to mark and record the locations and routing whenever possible. (6) Tightening Sequence When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-turn before removing them. (7) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (8) 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 removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. (9) Edges Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over. (10)High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com- monly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (11)Gasket, O-ring Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks. (12)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage. (13)Press When using a press or driver to install a part such as a drive shaft holder bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (14)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component.

1-4 GENERAL INFORMATION Before Servicing (15)Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally dam- ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks, press it in with the marks facing out. (16)Circlip, Retaining Ring, and Cotter Pin When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the “Jet Ski” watercraft is driven, leading to a major problem. (17)Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. 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 intended. (18)Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. Replacement parts will be damaged or lose their original function once they are removed. There- fore, always replace these parts with new ones every time they are removed. Although the pre- viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts. (19)Electrical Wires All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stripe 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. Unless instructed otherwise, electrical wires must be connected to wires of the same color. Two-Color Electrical (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 (21)Specifications Specification terms are defined as follows: "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.

GENERAL INFORMATION 1-5 Model Identification JH1200-B1 Left Side View JH1200-B1 Right Side View

KAWASAKI JET SKI ULTRA 150 JH1200 PWC Full Service & Repair Manual 2003-2005

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