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Introduction

These Kawasaki PWC JetSki (Jet Ski) manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning the PWC Watercraft. Read and refer to the other sections in this personal water craft manual for information regarding proper inspection and service procedures.

• These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of
these Kawasaki JetSki manuals and the actual watercraft.

• Illustrations in these manuals are used to show the basic principles of operation and work procedures in exact detail.

• These manuals are intended for use by technicians who already possess the basic knowledge and skills to service a Kawasaki Jetski and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only. Never attempt to perform any work with out the assistance of a service manual.

Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the watercraft unsafe for the JetSki operator and passengers. Fix-Your Problems now with these service manuals available for download.


KAWASAKI TROUBLESHOOTING SEARCHES:

ENGINE DOES NOT START OR IS HARD TO START
ENGINE LACKS POWER
POOR PERFORMANCE AT LOW AND IDLE SPEED
POOR PERFORMANCE AT HIGH SPEED

TROUBLESHOOTING
21-2
TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START
1. Spark Plug
Remove and inspect the spark plugs.
Are the spark plugs wet?
YES – • Incorrect spark plug heat range
• Incorrect spark plug gap
• Air intake duct or air box obstructed
NO – GO TO STEP 2.
2. Spark Test
Perform spark test.
Is there a weak spark or no spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Faulty ignition coil
• Faulty ignition pulse generator
• Faulty engine control module (ECM)
NO – GO TO STEP 3.
3. Fuel Injection System
Check the fuel injection system.
Is the fuel injection system normal?
NO – Faulty fuel injection system
YES – GO TO STEP 4.
4. Engine Starting Condition
Start the engine by following the normal procedure.
Does the engine start and then stop?
Yes – • Intake air leak
• Faulty idle air control valve
• Improper ignition timing (Faulty ECM or ignition pulse generator)
• Contaminated fuel
NO – GO TO STEP 5.
5. Cylinder Compression
Test cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
ENGINE LACKS POWER
1. Engine Speed
Accelerate lightly.
Does the engine speed increase?
NO – • Air intake duct or air box obstructed
• Restricted fuel flow
• Clogged exhaust system
• Restricted fuel tank breather line
YES – GO TO STEP 2.
2. Engine Knocking
Accelerate or run at high speed.
TROUBLESHOOTING
21-3
Is there knocking?
YES – • Use of poor quality fuel
• Worn piston and cylinder
• Excessive carbon build-up in combustion chamber
• Ignition timing too advance (Faulty ECM)
NO – GO TO STEP 3.
3. Spark Plug
Remove and inspect the spark plugs.
Are the spark plugs fouled or discolored?
YES – • Plug not serviced frequently enough
• Incorrect spark plug heat range
NO – GO TO STEP 4.
4. Engine Oil
Check the oil level and condition.
Is the oil level okay and free of contaminants?
NO – • Oil level too high
• Oil level too low
• Contaminated oil
YES – GO TO STEP 5.
5. Ignition Timing
Check the ignition timing.
Is the ignition timing correct?
NO – • Faulty engine control module (ECM)
• Faulty ignition pulse generator
YES – GO TO STEP 6.
6. Cylinder Compression
Test cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
NO – GO TO STEP 7.
7. Fuel Injection System
Check the fuel injection system.
Is the fuel injection system normal?
NO – Faulty fuel injection system
YES – GO TO STEP 8.
8. Engine Lubrication
Remove cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
NO – Clogged oil passage
YES – GO TO STEP 9.
9. Engine Over-heating
Test ride and check the engine condition
Is the engine over-heating?
YES – • Use of poor quality fuel
• Excessive carbon build-up in combustion chamber
• Loose or damaged water hose or clamp
TROUBLESHOOTING
21-4
• Restricted cooling water passage in engine
• Clogged water passage and filter in jet pump
• Damaged impeller or water jet stator
Check the turbocharger condition.
Is the turbocharger normal?
NO – • Faulty turbocharger
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Intake Air
Check for intake air leak.
Is there leaking?
YES – • Loose air intake system fasteners
• Damaged air intake system O-ring
NO – • GO TO STEP 2.
2. Spark Test
Perform spark test.
Is there weak or intermittent spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Faulty ignition coil
• Faulty ignition pulse generator
• Faulty engine control module (ECM)
NO – GO TO STEP 3.
3. Ignition Timing
Check the ignition timing.
Is the ignition timing correct?
NO – • Faulty engine control module (ECM)
• Faulty ignition pulse generator
YES – GO TO STEP 4.

4. Fuel Injection System
Check the fuel injection system.
Is the fuel injection system normal?
NO – Faulty fuel injection system
POOR PERFORMANCE AT HIGH SPEED
1. Ignition Timing
Check the ignition timing.
Is the ignition timing correct?
NO – • Faulty engine control module (ECM)
• Faulty ignition pulse generator
YES – GO TO STEP 2.
2. Fuel Injection System
Check the fuel injection system.
Is the fuel injection system normal?
NO – Faulty fuel injection system
YES – GO TO STEP 3.
TROUBLESHOOTING
21-5
3. Valve Timing
Check the valve timing.
Is the valve timing correct?
NO – Camshafts not installed properly
YES – GO TO STEP 4.
4. Valve Spring
Check the valve springs.
Are the valve springs fatigued?
YES – Faulty valve spring

COMPONENT LOCATION
SERVICE INFORMATION
COMBINATION METER
SPEEDOMETER/SPEED SENSOR
TACHOMETER
FUEL GAUGE/FUEL LEVEL SENSOR
INDICATORS
HANDLEBAR SWITCH
MAIN RELAY
OFF-THROTTLE STEERING SYSTEM

SERVICE INFORMATION
GENERAL
• Use an electric heating element to heat the coolant mixture for the engine coolant temperature sensor inspection. Keep
flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection.
• Check the battery condition before performing any inspection that requires proper battery voltage.
• A continuity test can be made with the switches installed on the watercraft.
• The following color codes are used throughout this section.
SPECIFICATIONS
TORQUE VALUE
TOOLS
Bu = Blue G = Green Lg = Light Green R = Red
Bl = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow
ITEM SPECIFICATIONS
Bulb Warning indicator LED
Fuse Main fuse 30 A
Sub fuse 7.5 A X 3, 5 A X 2
Tachometer peak voltage 10.5 V minimum
Off-throttle steering limit switch nut 2.9 N·m (0.3 kgf·m, 2.2 lbf·ft)
Speed sensor wire setting nut 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft)

WARNING BUZZER
Fit the safety lanyard clip to the base of the engine
stop switch.
Connect the Green/yellow and Green wire terminals
of the 10P green connector with a jumper wire.
The warning buzzer should sound.
If the warning buzzer does not sound, check the
power input line (page 19-5).
If the power input line is normal, check the following:
– open circuit in the Green/yellow wire between
the combination meter and warning buzzer
– faulty warning buzzer
– open circuit in the Red/blue wire between the
warning buzzer and junction connector

SPEEDOMETER/SPEED SENSOR
SYSTEM INSPECTION
Remove the passenger grab rail page 3-5.
Disconnect the speed sensor 2P yellow connector.
Fit the safety lanyard clip to the base of the engine
stop switch.
Measure the voltage between the Blue/white (+) and
Black/orange (–) wire terminals of the wire harness
side connector.
There should be battery voltage.
• If there is no voltage, check the Blue/white and
Black/orange wires. If the wires are OK, replace
the combination meter.
• If there is battery voltage, replace the speed sensor
with a known-good one and check the speedometer
operation.
SPEED SENSOR REMOVAL/
INSTALLATION
Remove the jet pump (page 14-8).
Disconnect the speed sensor 2P yellow connector.
Remove the wire setting nut, wire holder and the
speed sensor.
Insert the speed sensor 2P connector through the
wire holder hole.
Install the wire holder into the hole and tighten it.
Align the locating mark on the wire with the wire
holder end, install the wire setting nut and tighten it.
Connect the speed sensor 2P connector.
Install the jet pump page 14-24.
TACHOMETER
SYSTEM INSPECTION
Remove the storage box page 3-8.
Release the wire bands.
Disconnect the combination meter 8P gray connector.

FUEL GAUGE/FUEL LEVEL SENSOR
SYSTEM INSPECTION
Remove the storage box page 3-8.
Disconnect the fuel pump 5P connector.
Fit the safety lanyard clip to the base of the engine
stop switch and check the fuel gauge.
All segments and low fuel indicator should blink
and the warning buzzer should beep.
Pull the safety lanyard clip off of the engine stop
switch.
Connect the Gray/white and Gray/black wire terminal
of the 5P connector with a jumper wire.
Fit the safety lanyard clip to the base of the engine
stop switch and check the fuel gauge.
All segments and low fuel indicator should blink
and the warning buzzer should beep.
If the fuel gauge, low fuel indicator and warning
buzzer do not function properly, replace the combination
meter (page 19-4).
Remove the fuel pump assembly page 8-82.
Connect the fuel pump 5P connector.
With the fuel level sensor float at the top (FULL)
position, fit the safety lanyard clip to the base of the
engine stop switch and check the fuel gauge


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