Quick Reference Guide General information Fuel System . Engine Lubrication System _ Exhaust System L Engine Top End Engine Removal and Installation _ Engine Bottom End __ Cooling and Bilge Systems | Drive Shaft _ Pump and Impelier [ Handle Pole and Handiebar | Hull / Engine Hood c Electrical System __ Storage and Transporting _ Appendix oo Nn @ oH PB WD = (12 13 14 115 Imber with the black nach table of comtems, jon! table of contents for fact pages to tocate the specific topicForeword ‘This JET SKI 650SX watercraft Service Manual Supplement is designed to be used in conjuaction with the JET SKI X-2 watercraft Service Manual (P/N 99924-1069-01). The maintenance and repair procedures described in this supplement are only those that are unique to the JET SKI 650SX watercraft. Most service operations for this mode! remain identical to those described in the base Service Manual. Complete and proper servicing of the JET SKI 650SX watercraft therefore requires both this supplement and the base Service Manual ‘The base Service Manual and this Supplement are designed primary for use by "JET SKI" watercraft mechanics in a properly equipped shop. However, they contains enough detail and basic information to make them useful to the operator 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 camry out maintenarice and repair satisfactorily. Whenever the operator has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be cartied out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, the mechanics should read the text, thoroughly familiarize himself with the procedures before starting work, and then do the ‘work carefully in a clean area. Whenever special toals or equipment are specified, makeshift tools or equipment should not be used. Precision measure. ments 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, especially, 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 mainte. nance. ‘@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 pants are listed in the Parts Catalog @Follow the procedures in this manual carefully. Don't take shortcuts. @Remember to keep complete records of mainte nance and repair with dates and any new parts, installed How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems became the ‘manuat’s chapters. All information for a particular system from adjustment thoagh disassembly and inspection is located in a single chaptor 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 compre: hensive Table of Contents, The Periodic Maintenance Chart is located in the General information chapter. The chart gives a time schedule for required maintenance operations. Hf you want spark plug information, for example, go to the Periodic Mainteniance Chart frst. The chart tells you how frequently to clean and gap the plug, Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the fist page of the chapter to find the Spark Plug section. Whenever you see those WARNING and CAUTION symbois, heed their instructions! Always follow safe operating and maintenance practices, Cala ed result in personal injury. or loss of lif, CAUTION ‘This caution symbol identifies special instructions oF | 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 symbot indicates points of particular imerest for more efficient and canvenient operation, Indicates @ procedural step or work to be done. Indicates @ 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, oll, grease or a locking agent during assembly.GENERAL INFORMATION 1-1 1] General Information Table of Contents Before Servicing 4-2 Model identification. 15 General Specifications 1.6 Periodic Maintenance Chart 4-7 18 01-2 GENERAL INFORMATION Before Servicing Bofore starting to service a JET SKI watercraft, careful reading of the applicable section is recommended to eliminate unnecessary work, Photographs, diagrams, notes, cautions, warnings, and detailed descriptions 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 trouble- shooting or presence of symptoms indicate that adjustments may be required. Whenever running of the -quired during maintenance itis best to have the JET SKI watercraft in water. = ACAUTION Do not run the engine without cooling water supply for more than 18 seconds or severe engi ‘and exhaust system (2) Auxiliary Cooling An auxiliary cooling supply may be used if the JET SKI watercraft cannot be operated in water during adjustments. If possible, always operate the JET SKI watercraft in water rather than use an auxiliary cooling supply A. Fitting Cap A Garden Hose }osen the clamp and remove the cap. nnect the garden hose 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 requites 2.4 L/min (2.5 ats/min} at 1800 rpm (idle) and 7.0 min (7.4 qts/min) at 6000 (om, i ACAUTION Inautficient cooting supply will cause tho engine and/or exhaust system to overheat and severe damage will occur | Excessive cooling supply may kill the engine and flood the cylinder, 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 shet off | immediataly |GENERAL INFORMATION 1-3 (3) Din Before removal and disassembly, clean the JET SKI watercraft. Any sand entering the engine carburetor, ‘r other parts will work as an abrasive and shorten the life of the JET SKI watercraft. For the same reason, before installing 3 new part clean off any dust or metal filings, (4) Battery Ground Remove the ground (~) lead from the battery before performing any disassembly operations on the JET SKI watercraft. This prevents: (2) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electricat parts (5) Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, they should all be started in their holes and tightened to snug fit, Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, auts, or screws, first loosen all of them by about 2 quarter of tum and then remove them, Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated (6) Torque The torque values given in this Service Manual should always be adhered to. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench, (7) Force Common sense should dictate how much force is necessary in assembly and disassembly. if a part seems especially difficult 10 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 removal of screws held by a locking agent) in order to avoid damaging the screw heads. (8) Edges Watch for sharp edges. especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or tuming it over, High Flash Point Solvent A high flash-point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (0) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smoath to avoid oll or compression leaks, (11) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine cooling passages and cause serious damage An example of @ non-permanent iocking agent commonly available in North America is Loctite Lock N' @ Seal (Blue). (12) Press A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly (13) Ball Bearing When installing a bali bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a bail beoring until it stops at the stop in the hole or an the shaft (14) Oil Seat and Grease Seal Replace any oil or grease seats that were removed with new ones, as removal generally damages seals. Whon pressing in a seal which hos manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver. which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole, (5) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shatt passes through a seal, apply a little lubricant, proferably high temperature grease on the lips 10 reduce rubber to nietal fiction,1-4 GENERAL INFORMATION (18) Citolip, Retaining Bing Replace any cichps and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing citclips and retaining rings, take care to compress or expand them only enough to install them and no more (17) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them (18) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative fm. During assembly, oil or grease (which ever is more suitable) shouid be applied to any rubbing surface which has lost its lubricative film, Old grease and diy oil should be cleaned off. Deteriorated grease has los its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmfut if used in an application for which they are not intended. (19) Electrical Wires All the electrical wires ate either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of ane color and a lesser amount of @ second color, so a two-color wire is identified by frst the primary color and then the secondary color. For example, a yellow wire with thin red stripes is vfered to as a "yellow/red” wire; it would be a "red yellow” wire ifthe colors were reversed to make red the main color. —-—__________ Wire (cross-section) ‘Name of Wire Color = | Veliow/Red ~ Yellow (20) Replacement Parts ‘When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (21) Inspection When paris have been disassembled, visually inspect these parts for the following conditions or ather damage. \f there is any doubt as to the condition of them, replace thom with new ones. Abrasi Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (22) Service Daa Numbers of service data in this text have faliowing meanings: andards" show dimensions or performances which brand-new parts or systems have. ‘Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts,GENERAL INFORMATION 1-5 Model Identification J8650-81 Left Side View JS65O-B1 Right Side View1-6 GENERAL INFORMATION General Specifications en ae | 2-snoka verzal twin, cankeave eed vl, weer sooed Olapaceren eam Bore ae Ske 780". 700mm Compesonfato [aad Maximum Horsepower 38.2 KW (52 PS) @6 000 r/min (rpm) Maximum Torque 64.7 N-m (6.6 kg-m, 47.7 ft-lb) @5 500 r/min (rpm) Ignition Magneto COL Lubrication System il injection (break-in period: Cit injection and fuel mixture 50 : 1) Carburetor Keinin CDK38-32 diaphragm type (36 mm venturi) Starting System Electric Starter Tuning Speci Spork Plug NGK BATES Gap 07 = 08mm Ignition Timing 17° BTDC @6 000 r/min (rpm) 2.0 mm @B 000 r/min (rpm) Carburetor idle Speed 41.250 +100 r/min (rpm) High Speed Needle Jet | §/8 turn open Low Speed Needle Jet | 11/4 turn open Compression P 865 ~ 1 325 kPa (88 - 13.5 kg/em*, 125 ~ 192 psi)(open throttle) Drive System: Coupling | Direct drive from engine Jet Pump: Type | Axial flow, single stage Thust | 2.060 N (210 kg, 463 1b) Steering | Steerable nozzle Braking Water drag Performance: j 1Maximum Speed | 67 km/h {Minimum Turing Radius | 28 mm 1Draft (Stationary) 220 mm +Fuel Consumption 49 L/h. @full throttle 1Cruising Range 81 km @tull throttle | 85 minutes Dimension: | Length | 2.205 mm width | 680 mm Height 760 mm Dry Weight 128 kg Fuel Tank Capacity 175 L including 4.0 L reserve Engine Oil: | Type | 2-stroke, N.M.M.A. Certified for Service TC-WIL Oil Tank Capacity 28L Electrical Equipment: Battery | 12V19 An Maximum Generator | Output 3.5 A @B 000 r/min (rpm) = The information shown here represents results under controlled conditions, and information may not be correct under other conditions. ‘Specification subject fo change without notice, and may not apply to every countryGENERAL INFORMATION 1-7 Periodic Maintenance Chart NOTE © Complete the Pre-Ride Checklist hefore each outing Frequency | Initial Every | Every 1 25 | 100 Description Hours Hours | Hours _Clean fue! fitter screens “Inspect fuel vent and engine oil vent check valves Inspect/ciean flame arester _Inspect impetler blade for damage (remove) inspact/replace coupling damper Inspeet/replace carburetor thrattle shaft spring (veplace carburetor if necessary) inspect steering cable1-8 GENERAL INFORMATION Torque and Locking Agent ‘The following tabies list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone seatant Letters used in the “Remarks” column mean. L_ : Apply a non-permanent locking agent to the threads. SS : Apply silicone sealant to the threads. S__. Tighten the fasteners following the specified sequence. Torque T Fastener | a Nem Fuel System: Carburetor Mounting Bolts 78 | totake Manifold Mounting Nuts ee | Air Intake Cover Bolts j | Throttle Case Socket Bolts | | ; pon Thttle Cable Threads oe | : pane Exhaust System: | | Exhaust Pipe Bolts ~ 10. mm Dia | 49 | 50 | 36 Water Pipe Joints | 98 | 10 87 in-ib ss Exhoust Manifold Mounting Nuts | 2 | 25 18.0 s Engine Top End: | ' Cylinder Head Nuts | 29 | 30 2 s Water Pipe Joint ese eee ae) 87 in-tb ss Cylinder Base Nuts [eeeeotaeee acs) 25 Engine Removal/Installation: \ | Engine Mounting Bolts eee oO uere eee e 28 L Engine Mount Boit |} 36 | a6 | 116 Flywheel Boit | 98 | 100 | 72 | Coupling ee ‘Magneto Cover Mounting Boks | 78 | ogo 6sinh | ok Crankcase Bolts ~ 6 mm Dia | 78 | 080 69int =| Ls Crankcase Bolts ~ 8 mm Dia 2 | 30 | 2 | us Water Drain Valve Mounting Bolts | | - | Water Drain Valve Cover Bolts | | Doon Drive System: It | / Coupling 39 40 29 Drive Shaft Holder Mounting Bolts 22 22 160 L Pump and Impetier: i Water Pine Joints 598 1 10 | BT inet ss Steering Nozzle Pivat Bolts | | | L Pump Outlet Mounting Bolts | | | L Pump Cap Bolts ; oo: | L Impeller 8 | 100 | 2 Pump Mounting Bolt | 22 22 | 60 | Pump Cover Mounting Bolts | 98 | 10) | B7in-h Grate Mounting Bolts i 98 | 10 | 87 in-Ib l LGENERAL INFORMATION 1-9 | | \ | Steoring | Handleber Clamp Bolts | Hance Gn Holder Srews | Handle Poe Pot Shak Net | ancl Poe Pivot Sha | Mande Pole Bocket Mounting Bots | Sonn oe Su | Steering Support Bracket Mounting Bolt | Cable Holder Bolts | Hult/Engine Hood: Bunre: clan Electrical Syston Scr cor Bots Ect Care Mounting Bots | Recir Reter oring one Cot loner Moontng bate | Spat Pigs | | __ Storer Motor Mouning Bots | This table relating tightening torque of the stainless bolt and the nut to thread diameter, lists the basic torque for the bolts and nuts, Use this table for only the bolts and nuts which do not require a specific torque value. General Fasteners(stainloss bolt and nut) Threads Torave dia(mm) | Nem kom | Teel 6 | 9-88] a60~080| 62-76int | 8 | t6-22/ 16-22 | Ne 30-41 19 39 60 | Torque kg-m 25 34 13 19 40 06 25 113 in-lb 13.7 29 52 in-Ib1-10 GENERAL INFORMATIONGENERAL INFORMATION 1-11 1, Start/Stop Switch Leads 2. Steering Cable 3. Throttle Cable MS w1-12 GENERAL INFORMATION 1 Battery 7. Positive Battery Cable 2 Oil Pump. 8. Oi Pump Outlet Hose 3. Cylinder Head 9. Negative Battery Cable tarter Motor 10, Oil Inlot Hose 3. Engine Bed 1. Stator Load G.Electic Case 12. Starter Motor Lead 13. Exhaust Pipe Drain HoseFUEL SYSTEM 2-1 Fuel System il Table of Contents Exploded View Intake Manifold, Reed Valve (2.15) Specifications Intake Manifold Removal (2-15) Special Toots Intake Manifold Installation Notes (2.15) Ful System Diagram Roed Valve Removal (2.18) Throttle Case and Cable. Reed Valve Installation Notes (2-16) Theottie Cable Adjustment Reed Valve Inspection (2-18) Throttie Cable Removal Disassembly, Valve Holder Inspection. 248) Throttle Cable Assembly/instalation Valve Stop Inspection 2.17) Throttie Cable Removal Fuel Tank. 2-12 Throttle Cable Installation Fue! Tank Removal 212 Throttle Case and Cable Lubrication Fuel Tank Installation 2.12 Throttie Case Inspection Fuel Tank Cleaning (247) Throttle Cable Inspection, Fuel filler and Tube Removal 2-12 Choke Cabie Fue! Filler and Tube Installation (2-18) Choke Cable Adjustment Fue! Filler Screen Cleaning (218) ake Cable and Knob Removal Fuel Vent Chock Valve. (2.19) Choke Cabio ane Krab Installation Fue! Vent Chack Valve Mounting (2-19) Choke Cabie Inspection Fue! Vani Chack Valve inspection (2.19) Choke Cable Lubrication Sediment Bow! 213, Carburotor Sediment Bow! Removal 213 Idle Speed Adjustment Sodiment Bow! tnstallation Note. 2.43 Mixture Screw Adjustment Fuel Tap, 243 High Anitude Performance Adjustment. Fue! Tap Romnovat. 243 Carburetor Removal Fue! Tap installation 213 arburetor instalation Fuol Tap Cleaning 218 Carburetor Disasser Carburetor Assembly. Carburetor Cleaning and inspection Float Arm Lave Inspection and Adiustment 2.10 Fuel Pump Disassambly 2.10 Fuel Pump Assombly Note an Flame Araster Flame Avrester Removal Flame Avrester installation Flame Acrester Cleaning2-2 FUEL SYSTEM Exploded View 1. Main Jet 2. Diaphragm Needle 3. Pilot Jet 4. Check Vale TH 78 Nem (0.8 kg-m, 69 in tb) L Apply @ non-permanent locking agent to the threads, G : Apply grease. SS : Apply an even layer of silicone sealant to the mating surface.FUEL SYSTEM 2-3 A 2 — f¥ re 4 * - » \-2-4 FUEL SYSTEM Specifications Carburetor Type Kahin CDKB 32, Size 36 men Vertu Mixture Screws Low Specst 41/4 1um open High Spoot 5/8 turn open Man jet 140 Pitor Jet 76 Float Am Level 15 +05 mm Idle Speed 1.250 +100 rpm (in water) 2.300 +100 rpm (out of water) Fuel Tank Capacity: 17.5 L fincluding 4.0 L reserve} Reed Valve Warp Service Limit: 0.2 mm Fuel System Diagram NOTE The reserve bose (marked RES} must always be ‘arrecteeto longer pipe insite the tank 1. Fuel Tank 2. Chock Valve 3. Vent Hose 4 Return Fuel Line 5 Main Fuel Line 6 Reserve Fuel Line 7. Carburetor/Fuei Pump 8. Fue! Line to Carburetor/Fuel Pump 9. Pulse Line 10. Fuel TapFUEL SYSTEM 2-5 Throttle Case and Cable Throttle Cable Adjustment The adjustment procedure is the same as in the base THROTTLE CLOSED THROTTLE OPEN (RELEASED) (APPLIED) A. Cable Holdor 8. Cable Detent ‘©Pull the throttle cable from the handle pole OLubricate the cable passage in the handle pole with a penetrating rust inhibitor. Throttle Cable Installation © Throttle cable instalation is the reverse of removal. Note the following @ Lubricate the outside of the new cable wi ng rust inhibitor, to ease cable installation @ Route the throttle cable according to the Ca section in the General information chapter, @Adjust the throttle cable (see Throttle Cable Adjust ment) Shait Lever penetrat le Routing Throttle Case and Cable Lubrication @7The tubrication procedure is the same as in the base A. Locknut Throttle Cable Removal move the following pas, thro tle cable from the cable holder and the from the carburetor A. Apply aroase,2-6 FUEL SYSTEM Choke Cable Choke Cable Adjusument @7he adjustment procedure is the same as in the base Choke Cable and Knob Removal Disconnect the chok from the @Loosen the focknut and unscrew the cable housing from the holder C. Holder 8. Cable Housing the tip of the choke inner cable out of the pull remove the following pats, Choke Knobs Moter Pad A. Mounting Bott ‘@ Remove the choke knob shaft with the cable holder. ‘@Remove the E-ring and pull out the choke knob shaft from the cable NOTE When pulling the choke knab shat two detent balls and two spcings wil fallout of the cable holder. Do not u : ~ mh 4 GALL GY 2 Detent Bat 6. Washer pring 7. E-ring Choke Cable and Knob Installation instatiation eins Anpiy der and backs @Route the choke cable according to the Cable Routing section in th ral latormation chapt @Adjust the choke cable (see Choke Cable Adjustment) reverse of removal. Note the follow ct the O-ring and replace it, f necessary licone sealant to the mating surface of theCarburetor Mixture Screw Adjustment Since every carburetor is adjusted individually at the factory using a flow meter, specific mixture screw sett annot be given. After adjustmont, 2 cap is installed over each mixture screw head with the point straight down 10 identify proper mixture sorew settings for each unit. DO NOT CHANGE THESE SETTINGS. If the carburetor is tempered with and these settings cannot be relocated, set the mixture screws to the following guide line. NOTE er engine No. JFB50AE029996, the mixture screw cap is installed over each mixture screw head with the point straight down sel each screw. tucn itis until it seats lightly, and then, back it our the specified number of tums. Mocture Serew Caps Mixture Screw Low Speed Screw mW] High Speed © quidéeline represent o "starting point” from which onal fine tuning of the carburetor may be necessary Do nat farce the minture scraws into their seats You | could damage the screws ar the carburetor Operating the watercraft with the high speed screw | at too lean a setting (screwed in clockwise too far) | could cause serious engine damage, FUEL SYSTEM 2-7 High Ahitude Performance Adjustment \e norrnal carburetor settings are best for soa level, If the watercraft is used! at the higher elevations, the lower atmospheric preseu makes the carburetion richer. To ‘obtain the proper carburetor setting at higher elevations, turn in the high speed screw according to the following table [Tum the high speed screw in the tude m (ft o | normal position 1000 (3300) 2000 (6600) 3000 (10000) | 3/8 wm NOTE © The adjustment of the low speed screw is not required on the actual usage, Carburetor Removal @The removal procedure is the same as in the bese2-8 FUEL SYSTEM buretor Installation @The instalation procedure is the same as in the base for the following. aruretor mounting nuts, bend the Carburetor Disassembly @Remove the carburetor (see Carburetor Removal} einsc ureto} cover serows and take otf the carburetor cover A. Set Scrow © Main Jet 8. Float Am D. Pilot Jet @Femave the mounting screws and drop out the plate ‘and check valve, A. Screws B. Carburetor Cover ‘@Unserew the carburetor case screw and separate the carburetor case from the carburetor body. A. Serews B. Plate @To remove the mix screws, turn them counterclock: wise until they come aut, Do not lose the spring, washer, and O-ring each screw Carburetor Assembly @Assombiy is the reverse of following if the mixture sorows were removed, install them as A Screw 8. Carburetor Case shown sembly. Note the @Unscrow the f screw and romove th float Float valve @ Unscrew the main jet and the pi et.FUEL SYSTEM 2-9 8. Low sontrol aim spring in its hole and insta the rounded projection so ining and Inspection io the carburetor (see Carburetor Disassem: Solvent is toxic and flammable, Avoid prolonged | ontact with skin and keop away from open flame. Use only in a well-ventilated area. Eye protection should bbe worn when compressed air is ead to dry parte. Do not direct aie towards anyone. Use 25 psi maximum pozzle pressure, immerse all t solution metal parts in 2 carburetor cleaning ‘@ Rinse the pans in water When the pars are clean, dry them with compressed ait. {@ Blow out the air and fuel passages with compressed aie ‘inspect the check valve for damage or deterioration, and replace it if necessary. SIF the gasket un the check velve appears dam 1 bo replaced, ged, it 4, Main Jet et un 5. Pilot Jet may fea and m gm Needle NOTE the carburetor has been disassem and cleaned, starting the engine the fuel retuin host end blow through it until fuel appe at the at the the batiery. Pull of cearbur uel return fiting on the carburetor The fuel system is nove fall of fuel ‘ @) axe: jasoling is axtramely flammable and can be explosive | under certain conditions. Push the STOP button. Do hot smoke Mako sure the area is well ventilated and eee aes ‘row from any source of flame or sparks; this includes, ny appliance with a pilot ligt, B. Check Valve Jpber parts for damage Mixture Screws,2-10 FUEL SYSTEM O-ting and Gasket Between the Carburetor Case and Body Diaphragm on the Carburetor Cover By i) a} A. O-rings 8. Diaphragm: it any of these parts are not in good condition, replace thor (©Check the plastic tip on the diaphragm vaive needle. tt shauld be smooth, without any grooves, scratches, or ‘oars, Diaphragm Needle Wear r 1. Diaphragm Noodle 2. Diapiagm Needle Wear 1 the plastic tip is damaged. replace the needle, Float Arm Level Inspection and Adjustment (® Chock the float arm level 9 Measure from the plastic tip om the float arm to the ease. as shows, Float Arm Level Measurement C UW, UP | 1-Flost Am Level 8, CarbuetorCase 2 Paste tp Float Arm Love 10 ~ 20 mm >It the float arm level is incorrect, bend the float arm very slightly to change the float arm level Fuel Pump Disassembly @ Remove the carburetor. - AACAUTION The fuel pump contains delicate diaphragms that are tasty damaged, and guokets that most be reploced Unit ta dlessomblod. Therefore, the pup should [z be Gassemtied unless Teshage i event or damage is suspected. Have spare parts ‘@ Remove the fusl pump body screws, ‘® Coretully saperate the pump assembly into its individuat ‘compononts. There are two bedy castings, four gaskets, and two diaphragms. The assembly may be stuck ‘together, and care must be taken to avoid damaging the diaphragme and costings1, Gasket 3. Check Valve 2. Diapinragm Fue! Pump Assembly Note ‘@ Visually inspect the check valves, and replace them if necessary, © Use all new gaskets and replace other parts as required ® Apply 3 non pormanent locking agent to the fuel pump body screws threads, FUEL SYSTEM 2-11 Flame Arrester Flame Arrester Installation ©The Installation procedure is the same as in the base manual, except for the following ‘© After tightening the carburetor mounting bolts, bend the tab portions of the double washer aver the nut, OA new type flame arester is installed,242 FUEL SYSTEM Fuel Tank Fuel Tank Remo is the same as in the base ‘oliowing 5 should be dona with # siphon A. Mounting Bolts B. Sediment Bow! A Fuel Filler Cover 1B. Mounting SerowsFUEL SYSTEM 2-13 Sediment Bowl sediment bow! prevents water from ng the Fuel Tap Removal fuel tank, H thee is water in the sadiment bowl. crain it move the following ‘uel Hoses: uel Tap Knob Meter Pad Sediment Bow! Removal Fuel Tap Bracket Bolts @To remove only the sediment bow, unserew the ring @To remove the entie assembly, pull the hoses and A Bracket Bolts (@ Remove the fuel tap with the bracket 4 ‘@ Remove the fuel tap bolts anct pull au the fuel tap trom A Bois ©. Sediment Bow! the bracket B. Ring Nut D. Hoses Sediment Bow! Installation Note @ inspect th D-ring and replace i, f necessary A Fuol Tap Bolts Fuel Tap installation @ installation is the reverse of removal. Note the follow A.O-ing 9 B Ring Nut eApply silicone bracket install the fuet tap on the bracket, as shown alant to each end of the fuel tap2.14 FUEL SYSTEM A, Projection B. Apply silicone sealant Fuel Tap Cleaning @The cleaning procedure is tho s © Remove the main fuel hose from the carburetor init. me as in the base A Carburetor B. Main Fuel HoseENGINE LUBRICATION SYSTEM 3-1 Engine Lubrication System Table of Contents Oil Pump Bleeding Oil Pump Performance Test Oi Pump Removal Oil Pump Installation Olt Tank Oil Tank Removal Oil Tank installation Note. Oil Tank Cleaning 32 3-3 (3-3) (3-3) (3-3) (3-4) (3-6)3-2 ENGINE LUBRICATION SYSTEM Exploded Viewfications are only those thet a For all other data. refer to the base manua) il Tank Capacity 28h ENGINE LUBRICATION SYSTEM 3-3 it Tank Oil Tank Removal Drain the engine oil Disconnect the oil pump inlet hose @Unhook the rubber strap, A Oil Pump inlet Hose B. Rubber Strap @ Remove the oil tank and damper. Oi Tank Installation Note @P ut th bber damper in A. Rubber DamperEXHAUST SYSTEM 4-1 Exhaust System Table of Contents 4 | Lo Exploded View 4-2 Exhaust Pipe and Manifold 43 Exhaust Pipe and Manifold Removal 43 Exhaust Pipe and Manifold Installation 4:3 Exhaust Pipe and Manifoid Cleaning and inspection. (4-4) Water Box Muffler (4-4) Water Box Mutfler Removal (4-4) Water Box Muffler Installation: (4-5) Water Box Muffler Inspection ete 4B)4-2 EXHAUST SYSTEMExhaust Pipe and Manifold Exhaust Pipe and Manifold Removal eThe I procedure 's the same as in the base ‘manual, except for the following, nh Remove the Exhaust Pipe and Manitold Installation he instalation procedure is the same as in the base ‘manual, except for the fallowing, Install the exhaust manifold gaskets go that the arrow marks are up, A. Arrow Marks Tighten the following bok Exploded View). Exhaust Manifold Nuts xbaust Pipe Bolts Exhaust Pipe Mounting Bolts # to the specified torque (see EXHAUST SYSTEM 4-3ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View . sn 5-2 Specifications. (5-3) Special Tools. s (5-3) Engine Top End... 53 Disassembly and Assembly . 53 Engine Top End Disassembly . (5-4) Engine Top End Assembly 5-3 Maintenance and inspection (6-6) Compression Measurement . 6-7) Decarbonization (8-7) Cylinder Head Warp. . z (8-7) Cylinder Wear Inspection. (5-8) Piston Diameter Measurement. (5-8) Piston/Cylinder Clearance: (5-9) Boring and Honing . (6-8) Piston Ring, Piston Ring Groove Inspection (6-9) Piston Ring End Gap vond5-9) Piston, Piston Pin, Connecting Rod Wear Inspection (6-9)5-2 ENGINE TOP END Exploded View TH: 29 Nem (3.0 kg-m, 22 ft-tb) 12: 9.8 Nem (1.0 kg-m, 87 in-tb) 73: 34 Nom (3.5 kg-m, 25 ft-lb) “T4: 25 N-m (2.5 kg-m, 18.0 ft-Ib} SS : Apply silicone sealant to the thread (0 : Apply engine oil to the surface.Disassembly and Assembly: Engine Top End Assembly @The assombiy procedure s the same as in the base ENGINE TOP END 5-3ENGINE REMOVAL AND INSTALLATION 6-1 Engine Removal and Installation Table of Contents6-2 ENGINE REMOVAL AND INSTALLATION Exploded View TH: 36 N-m (3.7 kg-m. 28 Ft-tb) 72:16 N-m (1.8 kg-m. 11.6 ft-lb) 73: 22 N-m (2.2 kg-m, 16.0 ft-tb) 1: Apply a non-permanent locking agent to the threads,ENGINE REMOVAL AND INSTALLATION 6-3 Engine Removai/installation Engine Removal 10ve the Following part i Tank Exhaust Pipe Flagne Avrester (Optional for easy handling rutetor (Optional for easy handling) connect the foo park Pluss Starter Motor Lo the electnc case (see lectie Case Removal! sy in the Electric System chapter) 8 Bolts @ Disconnect the stator fead ca (0F leads from the electric case pectors, and pull out the Disconnect the inlet cooling hose from the bottom of bed mounting batts the exhaust mar ‘@ Remove the engi A. Mounting Boks @Slide the engine toward the front to disengoge the couplings, and then lift the engine out of the hull ‘@Remove the engine mounting belts, and separate the tengine bed and the engine. Engine Installation ©The installation procedure is the same as in the base manual, except for the following, Apply @ non-permanent locking agent 10 the engine mounting bolts, Tighten the following bolts to the specified torque (see xploded View) gine Mounting Bolts Engine Bod Mounting Boks Engine Mount Botts, (© Be sure the rubber damper is in place.6-4 ENGINE REMOVAL AND INSTALLATION A. DamperENGINE BOTTOM END 7-1 Engine Bottom End Table of Contents Exploded View 72 Specifications . 73 Special Tool 7-3 Coupling 73 Coupling Removal 73 Coupling Installation Note (7-4) Coupling Damper Inspection (7-4) Magneto Flywheel 74 “Magneto Fiywhee! Removal Sra Dol Magneto Fiywheo! Installation 7-4 Stator 7-5) Stator Removal . 7-5) Stator Installation Note. (7-6) Water Drain Valve (7-6) Water Drain Valve Removal (7-6) Water Drain Valve Installation. (7-7) Crankcase Splitting 7-5 Crankcase Splitting : TD) Crankcaso Assembly 76 Crankshaft Maintenance: . . (7-9) Connecting Rod Bend/Twist 7 (7-9) Connecting Rod Big End Radial Clearance (7-40) Connecting Rod Big End Side Clearance (7-10) Crankshaft Runout (1-14) Crankshaft Main Bearing Wear (7-11) Crankshaft Assembly Specifications: (7-12)7-2 ENGINE BOTTOM END Exploded n 72: 13: 14, L ™ 6 1G ° 85 12 Wem (08ko-m, 600-6) 29 N-m (3.0 kg-m. 22 ft-tb) 2 Naot ieee) 98 N.m (10.0 kg-m, 72 ft-lb) — Apply a non-permanent locking agent to the ff) rea Aap molybdenum dieitde grossa Y Apply grease. eee eee ee Apply oil, Apply silicone seatnt.ENGINE BOTTOM END 7-3 Special Tool Coupling ‘See the base manual, replacing with the following. Coupling Removal @The cemoval procedure is the same as in the base manual, except for the following, ‘© Holding te flywhee! with the tlywheel holder (special tool), unscrew the coupling with the coupling hoider {special tool). © Be careful not to damage the crankease surface. Flywheel Holder A. Flywhee! Holder: 57001-1313 B. Coupling Holder: 57001-12307-4 ENGINE BOTTOM END Magneto Flywheel Magneto Flywheel Removal The removal procedure is the anual, except for te following Hold the flywheel with the fiywhee! holder (special tool) and vernave the ttyinee! bot same as in the base 1. Spring A. Flywheel Holder: 57001-1313 Magneto Flywheel instalation (©Tho instalation procedure is the some as in the base mania, except fo the folowing oly & thin coat of oii to the bearing face of the ;ywhee! Bolt Be sure the spring and washer are in place on the 2. WasherENGINE BOTTOM END 7-5 ure is the same as in the base The ¥S650-B1 has no tim cable connector Pump Disassembly @ The disassermbly procedure is tho same as in the base manual ‘©.Unserew the steering nozzle pivot bolts and remove the steenng nozzle 1. Pivot Boiss 2. Steering Nozzle PUMP AND IMPELLER 10-3HANDLE POLE AND HANDLEBAR 11-1 Handle Pole and Handlebar Table of Contents Exploded View . 112 Steering Cable 11-3 Steering Cable Adjustmant 11-3 Steering Cabie Removal 11-3 Steering Cable Installation 15 Steering Cabie inspection and Lubaiction 116 Handlebar 15 Handle Grip Removal. (11-6) Handle Grip Installation (11-6) Handlebar Removal 18 Handlebar Installation... : 418 Handlebar Steering Pivot Maintenance 18 Handle Pole and Bracket 7 Handle Pole Removal WT Handle Pole Installation 17 Handle Pole Bracket Removal 17 Handle Pole Bracket Instaliation : 17 Handle Pole Pad (See Huil/Engine Hood chapter)11-2 HANDLE POLE AND HANDLEBAR Exploded View Th: 33 Nem (3.4 kg-m, 26 ft-tb) a T2: 19 N-m (1.9 kg-m, 13.7 ft-tb) — Ta: 13 Nem (1.3 kg-m, 113 in-Ib) T4: 25 Nem (2.5 kg-m, 18.0 ft-1b) a ‘TS: 39 N-m (4.0 kg-m. 29 ft-Ib) UC Apply non:pormnenant locking \ | A agent to the threads. SS = Apply silicone sealant, G : Apply grease.HANDLE POLE AND HANDLEBAR 11-3 Steering Cable St ° ring Cable Adjustment "2 adjustment procedure is the same as in the base ‘manual, except for the following, ©The ball joint is mounted to the handlebar plate A. Cable Holder Remove the pump (see Pump and Impeller chapter) @ Disconnect the steering cable from the fitting at the rear of the hull (OUnscrew the large nut while holding the fitting in the hull with a wrench A. Ball Joint Steering Cable Removai (@ Remove the following perts Tank Nk Exhaust Pipe Bali Joints (steering cable each ond) (0 ACAUTION | | Never lay the watercraft on the right side. Water in the | exhaust system may drain back into the engine, causing | serious damage, C.O-ring the steering cable from she cable holder. cable from the cable detents in the engine11-4 HANDLE POLE AND HANDLEBAR A Detents ‘@ Remove the cable by carefully pulling the rear section nf the cable forward through the hull section of the cable down through the nd the front nde p ering Cable Installation Steering cable installation is the reverse of removal Note the following ‘@Foute the steering cable according to the Cable Routing section in information ch piece of curved rubber or plastic tubing over the rear cable end to guide the cable through the Hide a she A. Rubber Tubing > Lub instalation @Apply non-permanent locking agant to the cable nolder mounting bolts. @ Adiust the steering cable. the outside of the new cable to ease cable Steering Cable tnspection and Lubrication @7he inspection procadure is the same as in the base manual, excapt forthe folowing, (©The 8650.81 has no wim cable. A. Steering Cable B SeatHandlebar Handlebar Removal ‘@ Remove the following parts. Handlebar Cover (lower halt) Wiring Clamps Steering Cab) and ( @Remove ti stud, ing pivot A, Cinelip B. Nut lobar with the handlebar plate fron ® Romave the hay @Foke out u the has rate the handlebar fom HANDLE POLE AND HANDLEBAR 11-5 B. Handlebor Piste tallation at installation is the reverse of removal. Note the following, ‘@ Apply a non-permanent lacking agent to the handlebar lamp screws and tighten tem to the specified torque (see Exploded View). {®.Groase the steering pivot thoroughly. @ Tighten the steering pivot nut to the specified torque (soe Exploded View) Handlebar Steering Pivot Maintenance 11 the steering pivot fools loase or overtight. the point may need lubrication oF the bushings may need to be replaced ® Remove the following parts Wiring Clamps Steering Cable (disconnect) Cable Holder @Take out the cieclip, and remove the nut handlebar to hang freo of the handle pole, @ Toke out the screws and remove the handle pole pad. Allow the A. Handle Pole Pad (@ Take out the bolts, Remove the steering support brackot by pulling i out the end of the hand’e pole and \gaging the steering from its bracket11-6 HANDLE POLE AND HANDLEBAR A Bolt A. Chack Surfaces for Wear ‘© Separato the nylon bushings from the handlebar plate ‘Arif the bushings are damaged or worn, replace them. ‘@When reassembling steering pivot, be sure to grease the new bushing well stud and check the surface for 1 Apply grease @Tighton the steering pivot nut to the specified torque (see Exploded View). id Surface “kif the stud is conroded or no thveads in th @Appiy 9 non -permane ng agent 10 the ste pivot stud acd tighten fe spocified torHandle Pole and Bracket Handle Pole Removal @ Remove the following parts Irom tho handle pole Stecring ndioba Plate with Handlebar Handle Pole Pad t Bracket ‘Remove the andi A Nut a @ Unscrew the pivot shaft, and ft th handle pole out 0 ne bracket Pole Jostaltation water cesistant grease Nd pivol shalt nut to the ae (see Exploded View) Handle Pole Bracket Removal @ Remove the hand @ ake out the bot 16 reverse of removal. Note HANDLE POLE AND HANDLEBAR 11-7 Cut away the 9 und th anct pull the bracket off the hull the bracket is to be repla dampe iges of the bracket, ° Handle Pole Bracket Installation dle pole installa se of removal. Note the aubber dampers are in place 19 surfaces et and hu of the handlebar bracket and the projections on. the hull, as shownRubber Pan: HULL/ENGINE FOOD 12-1 Hull/Engine Food Table of Contents12-2 HULL/ENGINE FOOD non-permanent locking L: Apply @ ads, agent to the thre:HULL/ENGINE FOOD 12-3 A. Front Bumper 8. Nuts ©. Bushing B. Handle Pole Pad & ‘@1/ the meter pad is 0 be removed, remove the following pants A. Rear Bumper ©. Bushing pee 8. Nuts Choke Knob Engine Hood Latch A. Side Bumper B Nuts A. Meter Pad B Screws ACAUTION Do not romova the pade unless it is absolutely necessary, because the screw holes in the hull or pad | framo may be damaged by ramoval | When instaling the pods, be careful not to overtighten l \-tappin12-4 HULL/ENGINE FOOD Hull Replacement ‘0 replace the hull, eemove the various parts in the following suggested order Battery and Pad Purp and Hose: Handle Pole with Cable Handle Pole Bracket Sediment Bowl and Bracket Oil Tank Fue Tank Exhaust Pipe Carburetor ine and Mounts or Box Mutfier rive Shaft and Shaft Holder Fuel Tap and Bracket Choke Knob and Cable Holder Engine Hood Latch ige Breather Bilge and Cooling Hoses el Filer Fuc! Filler Cover Hook Bypass Hose and Outlot Cabie Detents Fuel Hose Holder Bumpers The following parts cannot be removed from the hull ind must be replaced peau Labels Mate egistration Number (if any) ew hull is to be painted, do that first, Then install the parts removed in the reverse order of their removal. Finally, install the labels, decals, mats and the gistration numbers, Rubber Parts NOTE ‘he rubber parts on the watercraft are fastened in place with various adhesives. To replace a rubber part, use a ‘cement in the following table, or an equivalent. AWARNING | Read alt warnings and cautions on any solvents and | adhesives used. Many of these products are | Nammable, may be harmful to the skin and eyes, and | may give off harmful vapors. Use these solvents and | adhesives only in @ well-ventilated area and never near | [an open tame. [= Mat this Application: | Adnesive Engine Hood Gasket Fuel Tank Dampers Water Box Muffler | Dampers - | Tube Dampers Handlebar Grip [cyanoacrylate CementHULL/ENGINE FOOD 12-5 A. Engine Dam - | Be very careful that the part is positioned correctly when you apply the coment. may be Impossible 19 reposition the pert. Do not get any cyanoacrylate cement in your eyes oF ‘on your skin. If you do get some in your eyes. do not tty to wash it out, Contact # physician immediately! If you do get some on your fingers, do not touch any other part of your body: your fingers will stick to A. Fuel Tank Dampers Water Box Muffler DELECTRICAL SYSTEM 13-1 Electrical System Wiring Diagram Exploded View Specifications, Special Tools, Battery Precautions. Battery Removal Battery instalation Battery Cleaning, Electrolyte Level Inspection Battery Condition Battery intial Charging Battery Ordinary Charging Battery Test Charging Electie Starter System Starter Relay Statter Relay Removal Stattor Relay installation, Starter Relay Inspection Reduction Gear. Reduction Gear Removal Instatation Notes, Reduction Gear inspection Starter Motor Starter Motor Removal Starter Motor Installation Starter Motor Disassembly, Starter Motor Assembly Brush Inspection Brush Spring Inspection ‘Commutator Cleaning and inspection Amature Inspection Brush Plate tnspection Brush and Lead Assembly Inspection Starter Circuit Tests Table of Contents (13-5) (13-5) (13-6) (13-6) (13-6) (13.6) (13-7) (13-7) (13-7) 13.8) (13.8) (13.9) 13-5 13.6 13-5 13-6 13-5 3. 3- (13. 03. (13 03 “3 413 “13 03 “3 03 03 03 44) 11) 11) 31) 31) 12) 12) 13) 14) 14) 14) 15) 15) 15) Electc Case Electric Case Removai/Disassembiy Electric Case Assembily/lastallation Charging System ‘Charging Coit Testing, Regulator/Rectifier Testing Rectifier Circuit inspection Ignition System : CDI Igniter Removal/Installation CDI Igniter Winding Resistance CDI Igniter Internal Resistance Exciter Coil Inspection Spark Plug Removal Spark Plug Installation Spark Plug Inspection Spark Plug Cleaning Spark Plug Adjustment Ignition Timing inspection (dynamic) Verification of Timing Marks Switches Start/Stop Switch Removal Start/Stop Switch Instattation Start/Stop Switch Inspection 13.6 136 13-6 13.7 13-7 (03.47) 13.7 13-7 13.7 (13-19) 13-7 (13-20) (13-20) (13-20) (13.20) 93-21) (13-21) (93.21) (13-22) 13-8 13-8 (13-23) 13.813-2 ELECTRICAL SYSTEM Wiring Diagram + Spark Pigs Start Switch Stop Switch CDI Igniter Magneto 2 3 4 6 7.5 &ELECTRICAL SYSTEM 13-3 Exploded View 1. cbr igniter 2. Starter Relay 3. Regulator/Rectifier Th: 27 Nem (2.8 kg-m, 20 ft-tb) 72: 98 N-m (10 kg-m, 72 Ft-tb) L Apply @ non-permanent locking agant to the threads. M: Apply molybdenum disulfide grease. SS : Apply a thin coat of silicone sealant. G : Apply grease. ©: Apply @ thin coat of oil to the bearing face of the flywheel bolt.13-4 ELECTRICAL SYSTEMElectric Starter System Starter Relay: Starter Relay Removal ‘@Remove the elecic ease and open it (see Ek Removal A. Starter Relay @ Disconnect the starter relay leads. ‘@ Remove the nuts from the terminal on the starter ve ce the starter relay switch from the. lose any of the insulating washers aaael iter Relay Installation arte relay installation &§ the reverse of removal Note the followi slay leads (see Witing Diagram! ELECTRICAL SYSTEM 13-5 Starter Relay Inspection @ Test starter relay switch rotura. > Set ohmmoter to Rx 1 Q scale, Connect meter ieads to starter relay switch as shown. if resistance is infinite (20), the starter relay switch is ood. Proceed with activated resistance test. 2f resistance is less than infinite, the starter relay switch is not roturning and must be replaced (@ Test startor relay switch activated resistance, © Set ohmmeter to R x 1 O scale © Connect meter leads to starter relay switch as shown, Active starter relay switch by connecting a 12 V battery as shown, BATTERY 12 VOLT HIT the starter relay witch clicks and the ohmmeter indicates zero resistance, the starter relay switch is good. Hf the meter indicates high or infinite (ao) resistance, the Starter relay switch is defective and must be replaced.13-6 ELECTRICAL SYSTEM Electric Case Electric Case Removal/ Disassembly @Disconnact the following cable Battery Ground Cabie Batory Posi oF Motor ug Leads @Unscrew the DI ignite 2. Bolts @ Unscrew the grommet cap bolts and A. Grommet Cap Bolts B. Eloctric Case Bolts ‘Disconnect all the lead! connectors, Electric Case Assembly/Installation @Electric case assembly/instalation is the reverse of removal/disassombly. Note the following. ‘© Run the stator lgads through the electric case hole. ‘® Connect the leads. Refer to the Wiring Diagram. @Apnly a silicone sealant of the acotone type, such as ‘Thewe Bond 12078, to the notches of electric case. 1. Siticone Sealant (about 60 mm) ie Case 2. Ble Do not use other silicone sealant than the acetone type. oF the lead connectors will corrade with rust. Apply a non-permanent locking agent to the following bolts. Electric Case Bolts Grommet Cap Bolts Electrie Case Mounting Botts CDI Igniter Mounting BottsCharging System Charging Coil Testing (@ The testing procadure is the same as in the hase manual, xcept for the following. © Remove the electric case and open it (see Electric Case Romoval/ Disassembly) > Remove the stator leads from the electric case, > Reconnect the stator leads other than the yellow leads, ly inetalt the following parts to start the Spark Plug Leads Starter Motor Cable Flame Arrester Yellow Leads Rectifier Circuit Inspection @The inspection procedure is the same as in the base manual, except for the following, 81 regulator/rectifier iead is changed from 19 orange. ELECTRICAL SYSTEM 13-7 Ignition System CDI igniter Removal! installation ‘@Romove the viectric case, and open it (see Electric Case Romoval/Disacsembiy), ‘@ Disconnect the CDI ignitor loads. A. CDI Igniter Leads B. CDI Igniter installation is the reverse of removal Ground the black; yellow lead to the regulator/rectifies ‘mounting bolt CDI Igniter internat Resistance. The inspection procedure is the same as in the base 1 forthe following ‘Meter (+) Lead Connection Bk/R | BK/Y ek | BL | +500 +500 ee panne ese the these resistance twice, wait for 30 pacitor charging,13-8 ELECTRICAL SYSTEM Start/Stop Switch Removal move the following parts. le Cable (soe Fuel System chapter) ering Cable (sve Handle Pole and Handlebar chapter) Start/Stop Switch Wiring Connections (see Electric ‘Case Removal) Wiring Clamps ‘A Wining Clat @Carefully pull the start/stop switch wiring up through the handle pole © Romave the switch case mounting screws. A. Mounting Screws Start/Stop Switch Inspection 2 inspection procedure is the same as in the base manual, except for the following When testing the start switch, connect the ohmmeter A Orange Lead B. White Lead stop switch, connect the ohmmeter When testing a8 shown, A. Blue Lead B. Black LeadSTORAGE AND TRANSPORTING 14-1 Storage and Transporting Fuel System Engine. Table of Contents 14-2 (14-2) 14-2 14.2 (44-3) (14-3) (14.3) (14-3) (14-3) (14-3) (14-4) (14-4) (14-4) (14-4)14-2 STORAGE AND TRANSPORTING Preparation for Storage i the same as in the base A. Air Intake Cover 8. Bolts Lift out the flame arrester element with expanded met id clean with compressed air, if necessary (see Flame Anrester Cleaning in the Fuel System chapter) ©Spray @ penetrating rust inhibitor down the Reinstall the cover, apply a non-permanent locking rae ee agent to the threads of the air intake cover bolts and tighton securely Sys the following to remove any water which A. Sediment Bow! Remove the air intake cover from the carburetorAPPENDIX 15-1 Appendix Table of Contents 15-2 (15-3) (15-6)15-2 APPENDIX Lubrication Steering Cable Ball Joints, and Steering Nozzle Pivot A. Apply groase