2011-2013 Kawasaki JetSki ULTRA 300X 300LX Service Repair Manual JetSki WaterCraft

ULTRA 300X ULTRA 300LX JET SKI ® Watercraft Service Manual

is a trademark of Kawasaki Heavy Industries, Ltd. registered in U.S.A., Japan, Austria, Benelux, Sweden, Denmark, Switzerland, France, Canada, Finland, Norway, Greece, Italy, U.K., Portugal, Thailand, and Taiwan. KAWASAKI JET SKI ® is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.

This quick reference guide will assist you in locating a desired topic or 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 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 (DFI) 3 Engine Lubrication System 4 Exhaust System 5 Engine Top End 6 Engine Removal/Installation 7 Engine Bottom End 8 Cooling and Bilge Systems 9 Drive System 10 Pump and Impeller 11 Steering 12 Hull/Engine Hood 13 Electrical System 14 Storage 15 Appendix 16

ULTRA 300X ULTRA 300LX JET SKI ® 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 Division/Motorcycle & Engine Company/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 JET SKI ® 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. © 2010 Kawasaki Heavy Industries, Ltd. Third Edition (0):May 7, 2012

LIST OF ABBREVIATIONS A ampere(s) KDS Kawasaki Diagnostic System ABDC after bottom dead center km/h kilometers per hour AC alternating current L liter(s) Ah ampere hour lb pound(s) APS Accelerator Position Sensor LCD Liquid Crystal Display ATDC after top dead center LED Light Emitting Diode BBDC before bottom dead center LSI Large Scale Integration BDC bottom dead center m meter(s) BTDC before top dead center min minute(s) °C degree(s) Celsius mph miles per hour cmHg centimeters of mercury N newton(s) CPU Central Processing Unit O.D. Outside Diameter cu in Cubic inch(s) oz ounce(s) DC direct current Pa pascal(s) DFI Digital Fuel Injection PS horsepower ECU Electronic Control Unit psi pound(s) per square inch ETV Electronic Throttle Valve qt quart(s) F farad(s) r revolution °F degree(s) Fahrenheit rpm revolution(s) perminute FPO Full Power Operation s second(s) ft foot, feet SLO Smart Learning Operation g gram(s) TDC top dead center gal gallon(s) TIR total indicator reading h hour(s) TPS Throttle Position Sensor HP horsepower(s) TVS Twin Vortices Series IC Integrated Circuit V volt(s) in. inch(s) W watt(s) ISC Idle Speed Control Ω ohm(s) COUNTRY AND AREA CODES AT Austria DE Germany AU Australia EUR Europe BR Brazil GB United Kingdom CA Canada US United States CAL California WVTA Whole Vehicle Type Approval CH Switzerland

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 GRADE GASOLINE ONLY with an octane rating equal to or higher than that shown below. Minimum Octane Rating: Antiknock Index* 90 Research Octane Number (RON) 95 *: The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON). 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 and California Air Resources Board. 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. Evaporative Emission Control System The evaporative emission control system for this watercraft consists of low permeation fuel hoses. 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. * Fuel Pump * Spark Plugs * Fuel Injectors * ECU * Supercharger with intercooler & relief-valves

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 car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly 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 servic- ing Kawasaki JET SKI ® watercraft are intro- duced by the Service 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 symbols, heed their instructions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situa- tion which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury. This manual contains four more symbols which will help you distinguish different types of information.

NOTE ○ This note symbol indicates points of par- ticular 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 inspec- tion 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. This model, JT1500H/J, is mounted with a four-stroke engine with supercharger. When the JET SKI ® watercraft is submerged and swamped, the four-stroke engine needs special care and systematic procedure for re- covery compared with the two-stroke engine. Therefore in this manual, such procedures, which are not shown in SMs for two-stroke engines, are explained thoroughly to cope with the cases. Refer to the section, After submerging in Chapter 9, Cooling and Bilge Systems for the summary and detailed procedures.

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2011-2013 Kawasaki JetSki ULTRA 300X 300LX Service Repair Manual JetSki WaterCraft

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