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Kawasaki Ultra LX JT1500K Jet Ski Watercraft Shop Manual 2012 – 2015 – PDF DOWNLOAD
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Description
Kawasaki Ultra LX JT1500K Jet Ski Watercraft Shop Manual 2012 – 2015
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:490
DOWNLOADABLE:YES
FILE TYPE:PDF
KAWASAKI ULTRA LX JT1500K JET SKI WATERCRAFT SHOP MANUAL 2012 – 2015 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Kawasaki Ultra LX JT1500K Jet Ski Watercraft Shop Manual 2012 – 2015
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 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.
- Whenever 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, 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 adversely 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 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 Table 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.
TABLE OF CONTENTS:
Kawasaki Ultra LX JT1500K Jet Ski Watercraft Shop Manual 2012 – 2015
ULTRA LX JT1500K.......................................................... 1 Hyper-Linked Quick Index.................................................. 3 How to Use This Manual.................................................... 8 General Information....................................................... 11 Before Servicing...................................................... 12 Model Identification.................................................. 20 General Specifications................................................ 21 Unit Conversion Table................................................. 23 Periodic Maintenance...................................................... 25 Periodic Maintenance Chart............................................ 26 Torque and Locking Agent.............................................. 27 Specifications........................................................ 32 Special Tools......................................................... 33 Periodic Maintenance Procedures....................................... 34 Fuel System....................................................... 34 Throttle Control System Inspection............................ 34 Air Box Drain Caps Inspection and Cleaning.................... 35 Air Box Inspection and Cleaning............................... 35 Fuel Vent Check Valve Inspection.............................. 35 Fuel Pump Screen Cleaning..................................... 36 Throttle Shaft Spring Inspection.............................. 36 Engine Lubrication System......................................... 37 Engine Oil Change............................................. 37 Oil Filter Replacement........................................ 38 Engine Top End.................................................... 39 Valve Clearance Inspection.................................... 39 Engine Mounting Bolts Inspection and Tightness................ 42 Engine Bottom End................................................. 43 Coupling Damper Inspection.................................... 43 Cooling and Bilge Systems......................................... 43 Cooling System Flushing....................................... 43 Bilge System Flushing......................................... 44 Pump and Impeller................................................. 45 Impeller Inspection........................................... 45 Jet Pump Bearing and Seal Inspection.......................... 45 Steering.......................................................... 45 Steering Cable/Shift Cable Inspection......................... 45 Handlebar Pivot Lubrication................................... 46 Hull/Engine Hood.................................................. 46 Drain Plug Inspection......................................... 46 Electrical System................................................. 47 Battery Charging Condition Inspection......................... 47 Battery Terminals Inspection.................................. 47 Spark Plug Inspection......................................... 47 Lubrication....................................................... 48 All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check........... 51 Nuts, Bolts, and Fasteners Tightness Inspection............... 51 Hose and Hose Connect Inspection.............................. 51 Rubber Strap Inspection....................................... 53 Fuel Hose Replacement......................................... 53 Fuel System (DFI)......................................................... 55 Fuel System Diagram................................................... 57 Exploded View......................................................... 58 DFI System............................................................ 64 DFI Parts Location.................................................... 68 Specifications........................................................ 70 Special Tools and Sealant............................................. 71 DFI Servicing Precautions............................................. 72 DFI Servicing Precautions......................................... 72 Troubleshooting the DFI System........................................ 74 Outline........................................................... 74 Inquiries to Rider................................................ 78 DFI System Troubleshooting Guide...................................... 81 Self-Diagnosis........................................................ 85 Self-diagnosis Outline............................................ 85 Self-diagnosis Procedures......................................... 86 Service Code Character Reading................................ 89 Service Code Erasing.......................................... 89 Service Code Character Table...................................... 90 Throttle Position Sensor (Service Code/Character - 11/tPS)............ 92 Throttle Position Sensor Removal/Adjustment....................... 92 Throttle Position Sensor Input Voltage Inspection................. 93 Throttle Position Sensor Output Voltage Inspection................ 94 Throttle Position Sensor Resistance Inspection.................... 95 Intake Air Pressure Sensor (Service Code/Character - 12/bOSt)......... 97 Intake Air Pressure Sensor Removal................................ 97 Intake Air Pressure Sensor Installation........................... 97 Intake Air Pressure Sensor Input Voltage Inspection............... 98 Intake Air Pressure Sensor Output Voltage Inspection.............. 99 Intake Air Temperature Sensor (Service Code/Character - 13/AIrt)......101 Intake Air Temperature Sensor Removal/Installation................101 Intake Air Temperature Sensor Output Voltage Inspection...........101 Intake Air Temperature Sensor Resistance Inspection...............102 Water Temperature Sensor (Service Code/Character - 14/AqUt)...........104 Water Temperature Sensor Removal/Installation.....................104 Water Temperature Sensor Output Voltage Inspection................105 Water Temperature Sensor Resistance Inspection....................106 Crankshaft Sensor (Service Code/Character - 21/CrAg)..................107 Crankshaft Sensor Removal/Installation............................107 Crankshaft Sensor Resistance Inspection...........................107 Crankshaft Sensor Peak Voltage Inspection.........................107 Camshaft Position Sensor (Service Code/Character - 23/CAA1)...........108 Camshaft Position Sensor Removal/Installation.....................108 Camshaft Position Sensor Resistance Inspection....................108 Camshaft Position Sensor Peak Voltage Inspection..................108 Vehicle-down Sensor (Service Code/Character - 31/dOS).................110 Vehicle-down Sensor Removal.......................................110 Vehicle-down Sensor Installation..................................111 Vehicle-down Sensor Input Voltage Inspection......................111 Vehicle-down Sensor Output Voltage Inspection.....................112 Immobilizer Amplifier (Service Code/Character - 35/Innb)..............115 Amplifier Input Voltage Inspection................................115 Blank Key Detection (Service Code/Character - 36/IgnI)................116 User Key Inspection...............................................116 Fuel Pump Relay (Service Code/Character - 45, 46/F-P1, F-P2)..........118 Fuel Pump Relay Removal/Installation..............................118 Fuel Pump Relay Inspection........................................118 Ignition Coils (Service Code/Character - 51, 52/COL1, COL2)...........120 Ignition Coil Removal/Installation................................120 Ignition Coil Primary Winding Resistance Inspection...............120 Ignition Coil Input Voltage Inspection............................120 System Relay (Service Code/Character - 57/rEL2).......................122 System Relay Removal/Installation.................................122 System Relay Inspection...........................................122 Engine Overheating (Service Code/Character - 71/HEAt).................124 Low Engine Oil Pressure (Service Code/Character - 72/OILP)............125 Oil Temperature Sensor (Service Code/Character - 73/OILt).............126 Oil Temperature Sensor Removal/Installation.......................126 Oil Temperature Sensor Output Voltage Inspection..................126 Oil Temperature Sensor Resistance Inspection......................127 ECU Main Relay (Service Code/Character - 75/rEL)......................128 ECU Main Relay Removal/Installation...............................128 ECU Main Relay Inspection.........................................128 Engine Oil Overheating (Service Code/Character - 76/OILH).............130 Red Warning Indicator Light (LED).....................................131 Light (LED) Inspection............................................131 Fuel Injectors........................................................132 Fuel Injector Removal.............................................132 Fuel Injector Installation........................................133 Fuel Injector Audible Inspection..................................133 Fuel Injector Resistance Inspection...............................134 Fuel Injector Power Source Voltage Inspection.....................135 Fuel Injector Output Voltage Inspection...........................136 Fuel Injector Fuel Line Inspection................................137 ECU...................................................................139 ECU Identification................................................139 ECU Removal.......................................................139 ECU Installation..................................................139 ECU Power Supply Inspection.......................................139 DFI Power Source......................................................143 Main Fuse Removal.................................................143 Main Fuse Installation............................................143 Main Fuse Inspection..............................................143 Throttle Lever, Cable and Case........................................144 Free Play Inspection..............................................144 Free Play Adjustment..............................................144 Throttle Case Removal/Disassembly.................................144 Throttle Case Assembly/Installation...............................145 Throttle Cable Removal............................................146 Throttle Cable Installation.......................................147 Throttle Cable Lubrication........................................147 Air Box...............................................................148 Air Box Removal...................................................148 Air Box Installation..............................................148 Air Box Disassembly...............................................148 Air Box Assembly..................................................149 Throttle Body Assy....................................................150 Idle Speed Inspection.............................................150 Throttle Body Assy Removal........................................150 Throttle Body Assy Installation...................................150 Throttle Body Assy Disassembly....................................150 Throttle Bore Cleaning............................................151 ISC (Idle Speed Controller) Removal/Installation..................151 ISC (Idle Speed Controller) Inspection............................151 ISC Resistance Inspection.........................................152 Intake Manifold.......................................................153 Intake Manifold Removal...........................................153 Intake Manifold Installation......................................153 Fuel Line.............................................................154 Fuel Hose Removal.................................................154 Fuel Hose Installation............................................155 Fuel Pressure Inspection..........................................155 Fuel Flow Rate Inspection.........................................156 Fuel Vent Check Valve.................................................158 Fuel Vent Check Valve Mounting....................................158 Fuel Vent Check Valve Inspection..................................158 Fuel Pump.............................................................159 Fuel Pump Removal.................................................159 Fuel Pump Installation............................................160 Fuel Pump Operation Inspection....................................162 Fuel Pump Operating Voltage Inspection............................163 Pressure Regulator Removal........................................164 Fuel Filter Cleaning..............................................164 Fuel Pump Screen Cleaning.........................................164 Fuel Tank.............................................................166 Fuel Tank Removal.................................................166 Fuel Tank Installation............................................167 Fuel Tank Cleaning................................................167 Fuel Filler and Hose Removal......................................167 Fuel Filler and Hose Installation.................................168 Engine Lubrication System.................................................171 Exploded View.........................................................172 Engine Oil Flow Chart.................................................174 Specifications........................................................180 Special Tools.........................................................181 Engine Oil and Oil Filter.............................................182 Oil Level Inspection..............................................182 Engine Oil Change.................................................184 Oil Filter Replacement............................................184 Oil Cooler............................................................185 Oil Cooler Removal................................................185 Oil Cooler Installation...........................................185 Oil Cooler Disassembly............................................186 Oil Cooler Assembly...............................................187 Oil Cooler Inspection.............................................187 Oil Separator Tank....................................................188 Oil Separator Tank Removal........................................188 Oil Separator Tank Installation...................................188 Blowby Gas System Inspection......................................188 Oil Pan...............................................................189 Oil Pan Removal...................................................189 Oil Pan Installation..............................................190 Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve.............191 Oil Pump Sprocket Removal.........................................191 Oil Pump Sprocket Installation....................................191 Oil Pump Removal..................................................192 Oil Pump Installation.............................................192 Oil Pump Inspection...............................................192 Oil Screen Removal................................................193 Oil Screen Installation...........................................193 Oil Pressure Relief Valve Inspection..............................193 Oil Pump Chain Removal/Installation...............................194 Oil Pressure Measurement..............................................195 Oil Pressure Measurement..........................................195 Oil Pressure Switch...................................................196 Oil Pressure Switch Removal.......................................196 Oil Pressure Switch Installation..................................196 Exhaust System............................................................197 Exploded View.........................................................198 Exhaust Manifold......................................................200 Exhaust Manifold Removal..........................................200 Exhaust Manifold Installation.....................................200 Exhaust Manifold Cleaning and Inspection..........................201 Exhaust Pipe..........................................................202 Exhaust Pipe Removal..............................................202 Exhaust Pipe Installation.........................................202 Exhaust Pipe Cleaning and Inspection..............................203 Water Box Muffler.....................................................204 Water Box Muffler Removal.........................................204 Water Box Muffler Installation....................................204 Exhaust Hose Inspection...........................................206 Engine Top End............................................................207 Exploded View.........................................................208 Specifications........................................................210 Special Tools and Sealant.............................................212 Cylinder Head Cover...................................................215 Cylinder Head Cover Removal.......................................215 Cylinder Head Cover Installation..................................215 Camshaft Chain Tensioner..............................................217 Camshaft Chain Tensioner Removal..................................217 Camshaft Chain Tensioner Installation.............................217 Camshaft, Camshaft Chain..............................................218 Camshaft Removal..................................................218 Camshaft Installation.............................................219 Piston TDC Finding................................................221 Camshaft, Camshaft Cap Wear Inspection............................222 Camshaft Runout Inspection........................................222 Cam Wear Inspection...............................................223 Camshaft Chain Removal............................................223 Cylinder Head.........................................................224 Cylinder Compression Measurement..................................224 Cylinder Head Removal.............................................225 Cylinder Head Installation........................................226 Cylinder Head Warp Inspection.....................................228 Valves................................................................229 Valve Clearance Inspection........................................229 Valve Removal.....................................................229 Valve Installation................................................229 Valve Guide Removal...............................................230 Valve Guide Installation..........................................230 Valve-to-Guide Clearance Measurement (Wobble Method)..............231 Valve Seat Inspection.............................................231 Valve Seat Repair.................................................232 Cylinder, Pistons.....................................................237 Cylinder Removal..................................................237 Cylinder Installation.............................................237 Piston Removal....................................................238 Piston Installation...............................................239 Cylinder Wear Inspection..........................................240 Piston Wear Inspection............................................240 Piston Ring, Piston Ring Groove Wear Inspection...................240 Piston Ring Groove Width Inspection...............................241 Piston Ring Thickness Inspection..................................241 Piston Ring End Gap Inspection....................................241 Engine Removal/Installation...............................................243 Exploded View.........................................................244 Engine Removal/Installation...........................................246 Engine Removal....................................................246 Engine Damper Removal.............................................248 Engine Damper Installation........................................248 Engine Installation...............................................248 Engine Bottom End.........................................................251 Exploded View.........................................................252 Specifications........................................................254 Special Tools and Sealant.............................................256 Coupling/Output Shaft.................................................257 Coupling Removal..................................................257 Coupling Installation.............................................257 Output Shaft Removal..............................................257 Output Shaft Installation.........................................258 Coupling Damper Inspection........................................260 Output Cover Oil Seal Replacement.................................260 Oil Seal Inspection...............................................260 Alternator Cover Bearing Replacement..............................260 Ball Bearing Lubrication..........................................261 Ball Bearing Inspection...........................................261 Alternator Rotor......................................................262 Alternator Rotor Removal..........................................262 Alternator Rotor Installation.....................................262 Stator Coil...........................................................263 Stator Coil Removal...............................................263 Stator Coil Installation..........................................263 Crankcase Splitting...................................................264 Crankcase Splitting...............................................264 Crankcase Assembly................................................266 Crankshaft and Connecting Rods........................................270 Crankshaft Removal................................................270 Crankshaft Installation...........................................270 Connecting Rod Removal............................................271 Connecting Rod Installation.......................................271 Connecting Rod Bend Inspection....................................275 Connecting Rod Twist Inspection...................................275 Connecting Rod Big End Side Clearance.............................275 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection....276 Crankshaft Main Bearing Insert/Journal Wear Inspection............277 Crankshaft Side Clearance Inspection..............................280 Crankshaft Runout Inspection......................................280 Cooling and Bilge Systems.................................................281 Exploded View.........................................................282 Bilge System..........................................................284 Breather Removal..................................................284 Breather Installation.............................................284 Breather Cleaning and Inspection..................................284 Filter Removal....................................................284 Filter Installation...............................................285 Filter Cleaning and Inspection....................................285 Cooling and Bilge System Hoses........................................286 Hose Removal......................................................286 Hose Installation.................................................286 Hose Inspection...................................................286 Cooling and Bilge System Flushing.....................................287 Cooling System Flushing...........................................287 Bilge System Flushing.............................................287 Cooling and Bilge System Flow Diagram.................................288 Water Pipe............................................................290 Water Pipe Removal................................................290 Water Pipe Installation...........................................290 After Submerging......................................................291 Summary Procedures after Submerging...............................292 Detailed Procedures after Submerging..............................293 Drive System..............................................................295 Exploded View.........................................................296 Specification.........................................................298 Special Tools.........................................................299 Drive Shaft/Drive Shaft Holder........................................300 Drive Shaft Removal...............................................300 Drive Shaft Installation..........................................300 Drive Shaft Holder Removal/Disassembly............................300 Drive Shaft Holder Assembly/Installation..........................302 Drive Shaft Runout Inspection.....................................303 Pump and Impeller.........................................................305 Exploded View.........................................................306 Specifications........................................................308 Special Tools and Sealant.............................................309 Pump and Impeller.....................................................310 Pump Removal......................................................310 Pump Installation.................................................311 Pump Disassembly..................................................314 Pump Assembly.....................................................317 Impeller Inspection...............................................322 Impeller Outside Diameter Measurement.............................322 Pump Inspection...................................................322 Impeller Clearance Inspection.....................................322 Water Filter Cover Removal/Installation...........................323 Steering..................................................................325 Exploded View.........................................................326 Special Tools.........................................................328 Steering Cable........................................................329 Steering Cable Adjustment.........................................329 Steering Cable Removal............................................329 Steering Cable Installation.......................................331 Steering Cable Inspection.........................................331 Steering Cable Lubrication........................................332 Handlebars............................................................333 Handlebar Removal.................................................333 Handlebar Installation............................................333 Steering..............................................................335 Steering Removal..................................................335 Steering Installation ............................................337 Adjustable Steering Holder Disassembly............................339 Adjustable Steering Holder Assembly...............................340 Reverse System........................................................342 Shift Cable Adjustment............................................342 Shift Cable Removal...............................................342 Shift Cable Installation .........................................343 Shift Cable Inspection............................................344 Shift Cable Lubrication...........................................344 Reverse Bucket Removal/Installation...............................344 Shift Lever Shaft Removal/Installation............................344 Hull/Engine Hood..........................................................347 Exploded View.........................................................348 Sealant...............................................................352 Fittings..............................................................353 Seat Removal......................................................353 Seat Installation.................................................353 Front Storage Compartment Cover Removal/Installation..............354 Front Storage Compartment Cover Disassembly.......................354 Front Storage Compartment Cover Assembly..........................355 Front Cover Removal/Installation..................................356 Center Storage Lid Removal/Installation...........................357 Side Cover Removal................................................358 Side Cover Installation...........................................359 Front Access Cover Removal/Installation...........................359 Center Access Cover Removal/Installation..........................359 Mirror Removal/Installation.......................................359 Handrail Plate Removal............................................360 Handrail Plate Installation.......................................360 Handrail Removal/Installation.....................................360 Drain Plug Housing Removal........................................360 Drain Plug Housing Installation...................................360 Exhaust Outlet Removal............................................361 Exhaust Outlet Installation.......................................361 Stabilizer Removal................................................361 Stabilizer Installation...........................................361 Reboarding Step Removal...........................................361 Reboarding Step Installation......................................361 Hull Replacement......................................................362 Rubber Parts..........................................................363 Rubber Parts Location.............................................363 Blind Rivet Removal...............................................365 Blind Rivet Installation..........................................365 Front Bumper Removal..............................................365 Front Bumper Installation.........................................365 Rear Bumper Removal...............................................365 Rear Bumper Installation..........................................365 Side Bumper Removal...............................................366 Side Bumper Installation..........................................366 Air Duct Removal..................................................366 Air Duct Installation.............................................367 Electrical System.........................................................369 Parts Location........................................................371 Exploded View.........................................................374 Wiring Diagram........................................................378 Specifications........................................................380 Special Tools and Sealant.............................................381 Precautions...........................................................382 Electrical Wiring.....................................................383 Wiring Inspection.................................................383 Battery...............................................................384 Battery Cover Removal/Installation................................384 Battery Removal...................................................384 Battery Installation..............................................385 Battery Activation................................................385 Precautions.......................................................388 Interchange.......................................................389 Charging Condition Inspection.....................................389 Refreshing Charge.................................................389 Electric Starter System...............................................391 Starter Relay Removal.............................................391 Starter Relay Installation........................................391 Starter Relay Inspection..........................................391 Starter Motor Removal.............................................392 Starter Motor Installation........................................392 Starter Motor Disassembly.........................................393 Starter Motor Assembly............................................393 Brush Inspection..................................................394 Commutator Cleaning and Inspection................................395 Armature Inspection...............................................395 Brush Lead Inspection.............................................395 Brush Plate and Terminal Bolt Inspection..........................396 Reduction Gear Removal/Installation...............................396 Reduction Gear Inspection.........................................396 Charging System.......................................................398 Alternator Removal/Installation...................................398 Alternator Output Voltage Inspection..............................398 Regulator/Rectifier Removal/Installation..........................399 Regulator/Rectifier Inspection....................................399 Regulator Inspection..............................................399 Ignition System.......................................................402 Crankshaft Sensor Removal.........................................402 Crankshaft Sensor Installation....................................403 Timing Rotor Removal..............................................403 Timing Rotor Installation.........................................403 Crankshaft Sensor Inspection......................................404 Crankshaft Sensor Peak Voltage Inspection.........................404 Ignition Coil Removal.............................................405 Ignition Coil Installation .......................................406 Ignition Coil Inspection..........................................407 Ignition Coil Primary Peak Voltage Inspection.....................408 Camshaft Position Sensor Removal/Installation.....................409 Camshaft Position Sensor Inspection...............................410 Camshaft Position Sensor Peak Voltage Inspection..................410 IC Igniter Inspection.............................................411 Spark Plug Removal................................................411 Spark Plug Installation...........................................411 Spark Plug Inspection.............................................411 Spark Plug Adjustment.............................................411 Spark Plug Cleaning...............................................411 Kawasaki Smart Steering (KSS) System..................................414 Steering Position Sensor and Magnet Removal.......................414 Steering Position Sensor and Magnet Installation..................414 Kawasaki Smart Steering System Inspection.........................415 Steering Position Sensor Clearance Inspection.....................415 Steering Position Sensor Input Voltage Inspection.................415 Steering Position Sensor Output Voltage Inspection................416 Sensors...............................................................418 Speed Sensor Removal..............................................418 Speed Sensor Installation.........................................419 Speed Sensor Inspection...........................................419 Fuel Level Sensor Inspection......................................420 Water Temperature Sensor Removal/Installation.....................420 Water Temperature Sensor Inspection...............................421 Oil Temperature Sensor Removal/Installation.......................421 Oil Temperature Sensor Inspection.................................422 Water Temperature Sensor (for Meter Unit) Removal/Installation....422 Water Temperature Sensor (for Meter Unit) Inspection..............423 Air Temperature Sensor (for Meter Unit) Removal/Installation......423 Air Temperature Sensor (for Meter Unit) Inspection................424 Multifunction Meter...................................................426 Meter Unit Removal................................................426 Meter Unit Installation...........................................426 Meter Unit Operation Inspection...................................427 Meter Unit Inspection.............................................431 Immobilizer System....................................................436 Operational Cautions..............................................436 Key Registration..................................................436 Immobilizer System Parts Replacement..............................445 Immobilizer System Inspection.....................................446 Relay Assembly........................................................448 Relay Assembly Removal............................................448 Relay Assembly Installation.......................................448 Relay Assembly Inspection.........................................448 Switches..............................................................450 Switch Inspection.................................................450 Fuse..................................................................451 Fuse Inspection...................................................451 Storage...................................................................453 Preparation for Storage...............................................454 Cooling System....................................................454 Discharging water in the exhaust system...........................454 Bilge System......................................................455 Engine Oil........................................................455 Fuel System.......................................................455 Engine............................................................456 Air Box...........................................................456 Battery...........................................................456 Lubrication.......................................................457 Lube Jet Pump Bearings/Seals......................................457 Cleaning..........................................................457 Removal from Storage..................................................458 Lubrication.......................................................458 General Inspection................................................458 Fuel System.......................................................458 Test Run..........................................................459 Appendix..................................................................461 Cable, Wire and Hose Routing..........................................462 Troubleshooting Guide.................................................486
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