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

1. Kawasaki Stx 1100

If a modification has been made since then, differences may exist between the content of these Kawasaki JetSki manuals and the actual watercraft. Illustrations in these manuals are used to show the basic principles of operation and work procedures in exact detail. These manuals are intended for use by technicians who already possess the basic knowledge and skills to service a Kawasaki Jetski and components.

Kawasaki Stx 1100

Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only. Never attempt to perform any work with out the assistance of a service manual. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the watercraft unsafe for the JetSki operator and passengers. Fix-Your Problems now with these service manuals available for download. RELATED SEARCHES FOR J O H N S O N / O U T B O A R D S A jet drive motor uses an impeller enclosed in a jet drive housing instead of the propeller used by traditional gear cases.

Outboard jet drives are designed to permit boating in areas prohibited to a boat equipped with a conventional propeller outboard drive system. The housing of the jet drive barely extends below the hull of the boat allowing passage in ankle deep water, white water rapids, and over sand bars or in shoal water which would foul a propeller drive. The outboard jet drive provides reliable propulsion with a minimum of moving parts.

It operates, simply stated, as water is drawn into the unit through an intake grille by an impeller. The impeller is driven by the driveshaft off the powerhead's crankshaft. Thrust is produced by the water that is expelled under pressure through an outlet nozzle that is directed away from the stern of the boat. As the speed of the boat increases and reaches planing speed, only the very bottom of the jet drive where the intake grille is mounted facing downward remains in contact with the water. The jet drive is provided with a reverse-gate arrangement and linkage to permit the boat to be operated in reverse. When the gate is moved downward over the exhaust nozzle, the pressure stream is deflected (reversed) by the gate and the boat moves stern drive.

Conventional controls are used for powerhead speed, movement of the boat, shifting and power trim and tilt. The jet impeller is a precisely machined and aluminum spiral. Close observation will reveal drilled recesses at exact locations used to achieve this delicate balancing. Excessive vibration of the jet drive may be attributed to an out-of-balance condition caused by the jet impeller being struck excessively by rocks, gravel or from damage caused by cavitation 'burn'. The term cavitation 'burn' is a common expression used throughout the world among people working with pumps, impeller blades, and forceful water movement.

These 'burns' occur on the jet impeller blades from cavitation air bubbles exploding with considerable force against the impeller blades. The edges of the blades may develop small dime-size areas resembling a porous sponge, as the aluminum is actually 'eaten' by the condition just described. Excessive rounding of the jet impeller edges will reduce efficiency and Visually inspect the intake grate and impeller with each use performance. Therefore, the impeller and intake grate (that protects it from debris) should be inspected at regular intervals. Before and after each use, make a quick visual inspection of the intake grate and impeller, looking for obvious signs of damage.

Always clear any debris such as plastic bags, vegetation or other items that sometimes become entangled in the water intake grate before starting the motor. If the intake grate is damaged, do not operate the motor, or you will risk destroying the impeller if rocks or other debris are drawn upward by the jet drive.

If possible, replace a damaged grate before the next launch. This makes inspection after use all that much more important. Imagine the disappointment if you only learn of a damaged grate while inspecting the motor immediately prior to the next launch.

An obviously damaged impeller should be removed and either repaired or replaced depending on the extent of the damage. If rounding is detected, the impeller can be placed on a work bench and the edges restored to as sharp a condition as possible, using a file. Draw the file in only one direction. A back-and-forth motion will not produce a smooth edge.

Take care not to nick the smooth surface of the jet impeller. Excessive nicking or pitting will create water turbulence and slow the flow of water through the pump.

For more details on impeller replacement or service, please refer to the information on Jet Drives in the Gearcase section of this manual. Poor operation of the jet drive depends maximum thrust. In order fir this to occur the clearance between the outer edge of the jet drive impeller and the water intake housing cone wall should be maintained at approximately 0.020-0.030 in. This distance can be checked visually by shining a flashlight up through the intake grille and estimating the distance between the impeller and the casing cone, as indicated in the accompanying illustrations. But, it is not humanly possible to accurately measure this clearance by eye. Close observation between outings is fine to maintain a general idea of impeller condition, but, at least annually, the clearance must be measured using a set of feeler gauges.

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Although some gauges may be long enough to make the measurement with the intake grate installed, removal is advised for access and to allow for a more thorough inspection of the impeller itself. Whenever working around the impeller, ALWAYS disconnect the negative battery cable and disconnect the spark plug leads to make sure the engine cannot be accidentally started during service.

Failure to heed this caution could result in serious personal injury or death in the event that the engine is started. When checking clearance, a feeler gauge larger than the clearance et drive impeller clearance is the gap between the edges of the impeller and its housing. Impeller clearance is adjusted by moving shims from below to above the impeller.

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

These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of these Kawasaki JetSki manuals and the actual watercraft. Illustrations in these manuals are used to show the basic principles of operation and work procedures in exact detail. These manuals are intended for use by technicians who already possess the basic knowledge and skills to service a Kawasaki Jetski and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only.

Never attempt to perform any work with out the assistance of a service manual. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the watercraft unsafe for the JetSki operator and passengers. Fix-Your Problems now with these service manuals available for download. RELATED SEARCHES FOR J O H N S O N / O U T B O A R D S A jet drive motor uses an impeller enclosed in a jet drive housing instead of the propeller used by traditional gear cases. Outboard jet drives are designed to permit boating in areas prohibited to a boat equipped with a conventional propeller outboard drive system. The housing of the jet drive barely extends below the hull of the boat allowing passage in ankle deep water, white water rapids, and over sand bars or in shoal water which would foul a propeller drive.

The outboard jet drive provides reliable propulsion with a minimum of moving parts. It operates, simply stated, as water is drawn into the unit through an intake grille by an impeller. The impeller is driven by the driveshaft off the powerhead's crankshaft. Thrust is produced by the water that is expelled under pressure through an outlet nozzle that is directed away from the stern of the boat. As the speed of the boat increases and reaches planing speed, only the very bottom of the jet drive where the intake grille is mounted facing downward remains in contact with the water. The jet drive is provided with a reverse-gate arrangement and linkage to permit the boat to be operated in reverse.

When the gate is moved downward over the exhaust nozzle, the pressure stream is deflected (reversed) by the gate and the boat moves stern drive. Conventional controls are used for powerhead speed, movement of the boat, shifting and power trim and tilt. The jet impeller is a precisely machined and aluminum spiral.

Close observation will reveal drilled recesses at exact locations used to achieve this delicate balancing. Excessive vibration of the jet drive may be attributed to an out-of-balance condition caused by the jet impeller being struck excessively by rocks, gravel or from damage caused by cavitation 'burn'. The term cavitation 'burn' is a common expression used throughout the world among people working with pumps, impeller blades, and forceful water movement.

These 'burns' occur on the jet impeller blades from cavitation air bubbles exploding with considerable force against the impeller blades. The edges of the blades may develop small dime-size areas resembling a porous sponge, as the aluminum is actually 'eaten' by the condition just described.

Excessive rounding of the jet impeller edges will reduce efficiency and Visually inspect the intake grate and impeller with each use performance. Therefore, the impeller and intake grate (that protects it from debris) should be inspected at regular intervals.

Before and after each use, make a quick visual inspection of the intake grate and impeller, looking for obvious signs of damage. Always clear any debris such as plastic bags, vegetation or other items that sometimes become entangled in the water intake grate before starting the motor.

If the intake grate is damaged, do not operate the motor, or you will risk destroying the impeller if rocks or other debris are drawn upward by the jet drive. If possible, replace a damaged grate before the next launch. This makes inspection after use all that much more important. Imagine the disappointment if you only learn of a damaged grate while inspecting the motor immediately prior to the next launch. An obviously damaged impeller should be removed and either repaired or replaced depending on the extent of the damage. If rounding is detected, the impeller can be placed on a work bench and the edges restored to as sharp a condition as possible, using a file. Draw the file in only one direction.

A back-and-forth motion will not produce a smooth edge. Take care not to nick the smooth surface of the jet impeller. Excessive nicking or pitting will create water turbulence and slow the flow of water through the pump. For more details on impeller replacement or service, please refer to the information on Jet Drives in the Gearcase section of this manual. Poor operation of the jet drive depends maximum thrust.

In order fir this to occur the clearance between the outer edge of the jet drive impeller and the water intake housing cone wall should be maintained at approximately 0.020-0.030 in. This distance can be checked visually by shining a flashlight up through the intake grille and estimating the distance between the impeller and the casing cone, as indicated in the accompanying illustrations.

But, it is not humanly possible to accurately measure this clearance by eye. Close observation between outings is fine to maintain a general idea of impeller condition, but, at least annually, the clearance must be measured using a set of feeler gauges.

Although some gauges may be long enough to make the measurement with the intake grate installed, removal is advised for access and to allow for a more thorough inspection of the impeller itself. Whenever working around the impeller, ALWAYS disconnect the negative battery cable and disconnect the spark plug leads to make sure the engine cannot be accidentally started during service. Failure to heed this caution could result in serious personal injury or death in the event that the engine is started. When checking clearance, a feeler gauge larger than the clearance et drive impeller clearance is the gap between the edges of the impeller and its housing. Impeller clearance is adjusted by moving shims from below to above the impeller.