Kawasaki ULTRA 150 (JH1200-B1/B2/B3) Jet Ski Watercraft Repair Service Manual 2003-2005


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This workshop service repair manual PDF download for the 2003-2005 Kawasaki Jet Ski Watercraft ULTRA 150 (JH1200-B1/B2/B3) has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Year - Model - Beginning Hull No.
2003 - JH1200-B1 - KAW40001 203
2004 - JH1200-B2 - KAW20001 304
2005 - JH1200-B3 - US-KAW10001 405


TABLE OF CONTENTS :

General Information
Periodic Maintenance
Fuel System
Engine Lubrication System
Exhaust System
Engine Top End
Engine Removal/Installation
Engine Bottom End
Cooling and Bilge System
Drive System
Pump and Impeller
Steering
Hull/Engine Hood
Electrical System
Storage
Appendix


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99924-1308-03
Total Pages : 293


This kawasaki manual 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.

This kawasaki service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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tables
LIST OF ABBREVIATIONS
Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
General Fasteners (stainless bolt and nut)
Battery Terminal Voltage
Spark Plug Gap
Pop-off Pressure
Reed Warp
Oil Pump Output (pump pulley fully opened, engine: 3000 rpm for
Initial Torque for Temporal Tightening-
Initial Torque for Temporal Tightening-
Cylinder Compression (Usable Range)
Cylinder Head Warp
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Top & Second Piston Ring End Gap
Shim Selection
Crankshaft Sensor Air Gap (Clearance between the rotor projectio
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Runout [B]
Crankshaft Runout [C]
Drive Shaft Runout
Oil seal outside surface between the vene guide surface distance
Impeller Clearance
Impeller Clearance
Steering Position Sensor Clearance
Pop Rivet Removal Drill Bit Size
Terminal Voltage: 11.5 ∼ less than 12.6 V
Terminal Voltage: less than 11.5 V
Starter Motor Brush Length
Commutator Diameter
Charging Coil Output Test
Charging Coil Resistance Test
Regulator/Rectifier Inspection Unit: kΩ
Crankshaft Sensor Resistance
3 Needle Arcing Distance
Winding Resistance
Primary Lead Connections:
Ignition Coil Primary Peak Voltage
Connections
Crankshaft Sensor Peak Voltage
Throttle Sensor Input Voltage
Connections
Connections:
When the nozzle is full up position
When the nozzle is full down position
(1) Normal Voltage and Continuity
(2) Causes for Abnormal Results
Meter Reading
Throttle Sensor Output Voltage
Throttle Sensor Output Voltage
Water Temperature Sensor Resistance
Inlet Air Temperature Sensor Resistance
Steering Position Sensor Clearance
Steering Position Sensor Clearance
Connections to Steering Position Sensor Connector
Steering Position Sensor Input Voltage
Connections to steering Position Sensor Connector
Steering Position Sensor Output Voltage
toc
Read OWNER'S MANUAL before operating.
MAINTENANCE AND ADJUSTMENTS
EMISSION CONTROL INFORMATION
Foreword
General Information
Before starting to service a watercraft, careful reading of the
Especially note the following:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Two-Color Electrical
(20)
(21)
JH1200-B1 Left Side View
JH1200-B1 Right Side View
Outline
Kawasaki Smart Steering System Circuit
1. Cylinder
Comparison of Cylinders
Nikasil Plating
2. Balancer
Balancer
3. Carburetor and Throttle Sensor
Throttle Sensor
The Kawasaki JET SKI Watercraft Constant Velocity Carburetor
Idling
Full-Open
4. Oil Pump
Oil Pump
1. Pump
Pump
2. Trim Actuator
Trim Actuator
1. Block Diagram of Digital Igniter
2. Functions of Digital Igniter
Inlet Air Temperature Correction
Overheat Control
1. Engine Starter
2. Magneto
Prefixes for Units:
Units of Temperature:
Periodic Maintenance
The following table list the tightening torque for the major fas
Fuel System
Idle Speed Adjustment
Carburetor Synchronization
High Altitude Performance Adjustment
Carburetor Cable Adjustment
Oil Pump Cable Adjustment
Choke Cable Adjustment
Fuel Filter Screen Cleaning
Fuel Filter Inspection
Fuel Vent Check Valve Mounting
Fuel Vent Check Valve Inspection
Flame Arrester Cleaning
Throttle Shaft Spring Inspection
Engine Bottom End
Coupling Damper Inspection
Cooling and Bilge System
Cooling System Flushing
Bilge System Flushing
Pump and Impeller
Pump and Impeller Inspection
Steering
Steering Cable Inspection
Steering Cable Lubrication
Trim Cable Inspection
Trim Cable Lubrication
Handlebar Pivot Lubrication
Electrical System
Battery Charging Condition Inspection
Spark Plug Inspection
Spark Plug Adjustment
Spark Plug Cleaning
Lubrication
All Hoses, Hose Clamp, Nuts, Bolts and Fasteners Check
Nuts, Bolts, and Fasteners Tightness Inspection
Nut, Bolt, and Fastener to be checked
Hose and Hose Connect Inspection
Rubber Strap Inspection
Fuel System
Sealant -
Carburetor Cable Adjustment
Oil Pump Cable Adjustment
Throttle Case and Throttle Control Cable Removal
Throttle Case and Throttle Control Cable Installation
Torque -
Torque -
Throttle Control Cable Lubrication
Throttle Control Cable Inspection
Cable Removal
Cable Installation
Choke Cable Adjustment
Choke Knob and Cable Removal
Choke Knob and Cable Installation
Inspection
Lubrication
Idle Speed Adjustment
Carburetor Synchronization
Pilot Screw Removal/Installation
Carburetor Removal
Carburetor Installation
Torque -
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning and Inspection
Float Arm Level Inspection and Adjustment
Pop-off Pressure Inspection
Fuel Pump Removal/Installation
High Altitude Performance Adjustment
Removal
Installation
Torque -
Flame Arrester Cleaning
Inlet Manifold Removal
Inlet Manifold Installation
Torque -
Torque -
Reed Valve Inspection
Valve Holder Inspection
Valve Stop Inspection
Fuel Vent Check Valve Mounting
Fuel Vent Check Valve Inspection
Fuel Vent Pipe Removal
Fuel Vent Pipe Installation
Torque -
Torque -
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Filler and Tube Removal
Fuel Filler and Tube Installation
Fuel Filter Screen Cleaning
Fuel Filter Inspection
Removal
Installation
Cleaning
Engine Lubrication System
Oil Pump Bleeding
Torque -
Oil Pump Performance Test
Oil Pump Removal
Oil Pump Installation
Torque -
Torque -
Oil Tank Removal
Oil Tank Installation
Oil Tank Cleaning
Oil Filter Cleaning
Exhaust System
Kawasaki Bond (Silicone Sealant):
Removal
Installation
Torque -
Torque -
Torque -
Exhaust Pipe/Exhaust Chamber Cleaning and Inspection
Removal
Installation
Torque -
Cleaning and Inspection
Removal
Installation
Inspection
Engine Top End
Compression Gauge, 20 kgf/cm :
Disassembly and Assembly
Disassembly
Special Tools -
Assembly
Torque -
Torque -
Torque -
Torque -
Maintenance and Inspection
Compression Measurement
Special Tools -
Cylinder Head Warp Inspection
Cylinder Wear Inspection
Piston Diameter Measurement
Piston/Cylinder Clearance
Piston Ring, Piston Ring Groove Inspection
Piston Ring End Gap
Engine Removal/Installation
Removal
Installation
Torque -
Torque -
Engine Bottom End
Coupling Holder ##2:
Oil Filling
Removal
Special Tools -
Installation
Torque -
Coupling Damper Inspection
Magneto Flywheel Removal
Special Tool -
Special Tool -
Magneto Flywheel Disassembly
Magneto Flywheel Assembly
Torque -
Stater Clutch Gear and Starter Idle Gear Removal
Starter Clutch Gear and Starter Idle Gear Installation
Magneto Flywheel Installation
Torque -
Removal
Installation
Torque -
Torque -
Torque -
Torque -
Splitting
Assembly
Special Tool -
Torque -
Crankcase Check Valves Inspection
Upper Crankcase Check Valve Removal/Installation
Lower Crankcase Check Valve Removal/Installation
The crankshaft changes reciprocating motion of the piston into r
Connecting Rod Bend/Twist
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Main Bearing Wear
Crankshaft Runout
Cooling and Bilge System
Kawasaki Bond (Silicone Sealant):
Breather Removal
Breather Installation
Breather Cleaning and Inspection
Filter Removal/Installation
Filter Cleaning and Inspection
Hose Removal
Hose Installation
Hose Inspection
Cooling System Flushing
Bilge System Flushing
Drive System
Bearing Driver Set:
Drive Shaft Removal/Installation
Special Tool -
Torque -
Drive Shaft Holder Removal/Disassembly
Drive Shaft Holder Assembly/Installation
Special Tool -
Torque -
Drive Shaft Runout
Pump and Impeller
Oil Seal & Bearing Remover:
Pump Removal
Pump Installation
Torque -
Torque -
Torque -
Torque -
Pump Disassembly
Special Tools -
Special Tool -
Pump Assembly
Special Tool -
Special Tool -
Special Tools -
Torque -
Torque -
Torque -
Pump and Impeller Inspection
Impeller Clearance
Steering
Steering Cable Adjustment
Torque -
Steering Cable Removal
Steering Cable Installation
Torque -
Torque -
Steering Cable Inspection
Steering Cable Lubrication
Trim Cable Adjustment
Torque -
Trim Cable with Trim Actuator Removal
Trim Cable Installation
Torque -
Trim Cable Inspection
Trim Cable Lubrication
Removal
Installation
Torque -
Remove
Installation
Torque -
Hull/Engine Hood
Hatch Cover Removal/Installation
Hatch Cover Installation
Hatch Cover Bracket Removal
Hatch Cover Bracket Installation
Rear View Mirror Removal
Rear View Mirror Installation
Crossmember Removal
Crossmember Installation
Torque -
Grip and Rear Duct Removal/Installation
Torque -
Stabilizer Removal
Stabilizer Installation
Torque -
Storage Cover Assembly
To replace the hull, remove the various parts in the following s
NOTE
Rubber Parts Location
Front Bumper Removal/Installation
Rear Bumper Removal/Installation
Side Bumper Removal
Side Bumper Installation
Electrical System
Hand Tester:
Removal
Installation
Electrolyte Filling
Initial Charge
Precautions
1)
2)
3)
4)
Interchange
Charging Condition Inspection
Refreshing Charge
Battery Standard Charge Time Chart
Starter Relay:
Removal
Installation
Inspection
Special Tool -
Starter Motor:
Starter Motor Removal
Starter Motor Installation
Torque -
Starter Motor Disassembly
Starter Motor Assembly
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Special Tool -
Brush Assembly Inspection
Special Tool -
Rear Cover Assembly Inspection
Starter Motor Clutch Inspection
Electric Starter System Circuit
Charging Coil Testing
Special Tool -
Regulator/Rectifier Removal/Installation
Regulator/Rectifier Inspection
Special Tool -
Charging System Circuit
WARNING
Crankshaft Sensor Inspection
Special Tool -
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Special Tool -
Igniter Removal/Installation
Igniter Inspection
Special Tools -
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Spark Plug Removal
Spark Plug Installation
Torque -
Spark Plug Inspection
Spark Plug Adjustment
Spark Plug Cleaning
Ignition System Circuit
Trim Actuator Inspection
Special Tool -
Electronic Control Unit Inspection
Electronic Control Unit Inspection
Electric Trim System Circuit
Front Electric Case Removal/Disassembly
Front Electric Case Assembly/Installation
Rear Electric Case Removal/Disassembly
Rear Electric Case Assembly/Installation
Speed Sensor Inspection
Special Tool -
Oil Level Sensor Inspection
Special Tool -
Fuel Level Sensor Inspection
Special Tool -
Throttle Sensor Removal/Installation
Throttle Sensor Inspection
Special Tool -
Throttle Sensor Adjustment
Water Temperature Sensor Inspection
Special Tool -
Inlet Air Temperature Sensor Inspection
Special Tool -
Display Function Inspection
Fuel Level Gauge/Symbol/Warning Light Inspection
Oil Level Gauge/Symbol/Warning Light Inspection
Trim Indicator Inspection
Speedometer Inspection
Speed Sensor Electric Source Inspection
Special Tool -
Tachometer Inspection
Battery Symbol/Warning Light Inspection
Heat Symbol/Warning Light Inspection
MODE/SET Button Inspection
Multifunction Meter Circuit
Switch Inspection
Ignition Switch
Inspection
Steering Position Sensor and Magnet Removal
Steering Position Sensor and Magnet Installation
Smart Steering System Inspection
Steering Position Sensor Clearance
Steering Position Sensor Input Voltage Inspection
Special Tool -
Steering Position Sensor Output Voltage Inspection
Special Tool -
Smart Steering Actuator Removal
Smart Steering Actuator Installation
Torque -
Torque -
Torque -
Smart Steering Actuator Inspection
Smart Steering System Circuit
Storage
During the winter, or whenever the watercraft will not be in use
Cooling System
Bilge System
Fuel System
Engine
Battery
Lubrication
General
Lubrication
General Inspection
Fuel System
Test Run
Appendix

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