Service ManualTable of ContentsSmart Learning Operation mode (SLO) (JT1500-A2 model ∼)1Before Servicing1Model Identification1General Specifications1Unit Conversion Table1Periodic Maintenance Chart2Torque and Locking Agent2Specifications2Special Tools and Sealant2Periodic Maintenance Procedures2Throttle Control System Inspection2Air Filter Drain Caps Inspection and Cleaning2Air Filter Inspection and Cleaning2Fuel Vent Check Valve Inspection2Fuel Pump Screen Cleaning2Throttle Shaft Spring Inspection2Engine Oil Change2Oil Filter Replace2Air Suction Valve Inspection2Valve Clearance Inspection2Engine Mounting Bolts Inspection and Tightness2Coupling Damper Inspection2Cooling System Flushing2Bilge System Flushing2Impeller Inspection2Steering Cable/Shift Cable Inspection2Handlebar Pivot Lubrication2Drain Plug Inspection2Battery Charging Condition Inspection2Battery Terminals Inspection2Spark Plug Cleaning and Inspection2All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check2Nuts, Bolts, and Fasteners Tightness Inspection2Hose and Hose Connect Inspection2Rubber Strap Inspection2Fuel System Diagram3Exploded View3Removal/Installation3Specifications3Special Tools and Sealant3Inspection3DFI Parts Location3DFI System3Code/Character-31/dOS)3DFI Servicing Precautions3Self-Diagnosis3Self-diagnosis Outline3Service Code (Character) Table3Troubleshooting the DFI System344/InJ1, InJ2, InJ3, InJ4)3Fuel Injector Removal3Fuel Injector Installation3ment3Audible Inspection3Input Voltage Inspection3Injector Signal Test3Output Voltage Inspection3Injector Resistance Inspection3Resistance Inspection3Injector Unit Test3Injector Voltage Inspection3Injector Fuel Line Inspection3Removal3COL2)3Installation3Input Voltage Inspection3Input Voltage Inspection3Output Voltage Inspection3Code/Character-71/HEAt)3Code/Character-72/OILP)3Removal/Installation3Output Voltage Inspection3Sensor Resistance Inspection373/OILt)3Code/Character-14/AqUt)3Removal/Installation3Output Voltage Inspection3Removal/Installation3Sensor Resistance Inspection3Output Voltage Inspection3Sensor Resistance Inspection3Code/Character-76/OILH)3ECU3ECU Removal3ECU Installation3Removal/Installation3ECU Power Supply Inspection3Crankshaft Sensor Inspection3Main Fuse Inspection3Relay Assembly Removal3Relay Assembly Inspection3Throttle Lever, Cable and Case3ISC Resistance Inspection3Free Play Inspection3Throttle Cable Adjustment3Inlet Manifold Removal3Inlet Manifold Installation3sembly3Fuel Pressure Inspection3tion3Fuel Flow Rate Inspection3Throttle Cable Removal3Throttle Cable Installation3Lubrication3Throttle Cable Inspection3Fuel Filter Removal3Air Filter3Fuel Filter Installation3Air Filter Removal3Air Filter Installation3Fuel Pump Removal3Air Filter Disassembly3Fuel Pump Installation3Air Filter Assembly3Throttle Body Assy3Operating Voltage Inspection3Idle Speed Inspection3Fuel Pump Relay Removal3Fuel Pump Relay Inspection3Adjustment3Throttle Body Assy Removal3Fuel Tank Removal3Throttle Body Assy Installation3Fuel Tank Installation33-72 Fuel Tank Cleaning3Throttle Bore Cleaning3Fuel Filler and Tube Removal3Removal/Installation3Inspection3Exploded View4Engine Oil Flow Chart4Specifications4Special Tool and Sealant4Engine Oil and Oil Filter4Oil Level Inspection4Engine Oil Change4Oil Filter Replacement4Oil Cooler4Oil Cooler Removal4Oil Cooler Installation4Oil Cooler Disassembly4Oil Cooler Assembly4Oil Cooler Inspection4Breather Case and Oil Separator Tank4Breather Case Removal4Breather Case Installation4Oil Separator Tank Removal4Oil Separator Tank Installation4Blowby Gas System Inspection4Oil Pan4Oil Pan Removal4Oil Pan Installation4Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve4Oil Pump Sprocket Removal4Oil Pump Sprocket Installation4Oil Pump Removal4Oil Pump Installation4Oil Pump Inspection4Oil Screen Removal4Oil Screen Installation4Oil Pressure Relief Valve Inspection4Oil Pump Sprocket Chain Removal4Oil Pressure Measurement4Oil Pressure Measurement4Oil Pressure Switch4Oil Pressure Switch Removal4Oil Pressure Switch Installation4Exploded View5Exhaust Manifold5Exhaust Manifold Removal5Exhaust Manifold Installation5Exhaust Manifold Cleaning and Inspection5Exhaust Pipe5Exhaust Pipe Removal5Exhaust Pipe Installation5Exhaust Pipe Cleaning and Inspection5Water Box Muffler5Water Box Muffler Removal5Water Box Muffler Installation5Water Box Muffler Inspection5Exploded View6Cylinder Head Removal6Specifications6Cylinder Head Installation6Special Tools and Sealant6Cylinder Head Warp6Clean Air System6Air Suction Valve Removal6Valve Clearance Check6Air Suction Valve Installation6Valve Removal6Air Suction Valve Check6Valve Installation6Valve Guide Removal6Inspection6Valve Guide Installation6Cylinder Head Cover66-12 Method)6Camshaft Chain Tensioner6Valve Seat Inspection6Valve Seat Repair6Removal6Cylinder Removal6Installation6Piston Removal6Camshaft, Camshaft Chain6Piston/Cylinder Installation6Camshaft Removal6Cylinder Wear6Camshaft Installation6Piston Wear6Piston TDC Finding6Wear6Camshaft Runout6Piston Ring Groove Width6Cam Wear6Piston Ring Thickness6Camshaft Chain Removal6Piston Ring End Gap6Cylinder Head6Measurement6Exploded View7Engine Removal/Installation7Engine Removal7Engine Damper Removal7Engine Damper Installation7Engine Installation7Exploded View8Specifications8Special Tools and Sealant8Coupling8Coupling/Output Shaft Removal8Coupling/Output Shaft Installation8Coupling Damper Inspection8Output Cover Oil Seal Replacement8Oil Seal Inspection8Magneto Cover Bearing Replacement8Ball Bearing Lubrication8Ball Bearing Inspection8Magneto Flywheel8Magneto Flywheel Removal8Magneto Flywheel Installation8Stator8Stator Removal8Stator Installation8Crankcase Splitting8Crankcase Splitting8Crankcase Assembly8Crankshaft and Connecting Rods8Crankshaft Removal8Crankshaft Installation8Connecting Rod Removal8Connecting Rod Installation8Connecting Rod Bend8Connecting Rod Twist8Connecting Rod Big End Side Clearance8Connecting Rod Big End Bearing Insert/Crankpin Wear8Crankshaft Main Bearing Insert/Journal Wear8Crankshaft Side Clearance8Crankshaft Runout8Exploded View9Bilge System9Breather Removal9Breather Installation9Breather Cleaning and Inspection9Filter Removal9Filter Installation9Filter Cleaning and Inspection9Cooling and Bilge System Hoses9Hose Removal9Hose Installation9Hose Inspection9Cooling and Bilge System Flushing9Cooling System Flushing9Bilge System Flushing9Cooling and Bilge System Flow Diagram9Water Pipe9Water Pipe Removal9Water Pipe Installation9After Submerging9Summary Procedures after Submerging9Detailed Procedures after Submerging9Exploded View10Specification10Special Tools and Sealant10Drive Shaft/Drive Shaft Holder10Drive Shaft Removal/Installation10Drive Shaft Holder Removal/Disassembly10Drive Shaft Holder Assembly/Installation10Drive Shaft Runout10Exploded View11Specifications11Special Tools and Sealant11Pump and Impeller11Pump Removal11Pump Installation11Pump Disassembly11Pump Assembly11Impeller Inspection11Impeller Outside Diameter Measurement11Pump Inspection11Impeller Clearance11Water Filter Cover Removal/Installation11Exploded View12Special Tool and Sealant12Steering Cable12Steering Cable Adjustment12Steering Cable Removal12Steering Cable Installation12Steering Cable Inspection12Steering Cable Lubrication12Handlebar12Handlebar Removal12Handlebar Installation12Steering12Steering Removal12Steering Installation12Reverse System12Shift Cable Adjustment12Shift Cable Removal12Shift Cable Installation12Shift Cable Inspection12Shift Cable Lubrication12Reverse Bucket Removal/Installation12Shift Lever Shaft Removal/Installation12Exploded View13Fittings13Seat Removal13Seat Installation13Front Storage Compartment Cover Removal13Front Storage Compartment Cover Disassembly13Front Storage Compartment Cover Assembly13Mirror Removal13Mirror Installation13Mirror Stay Removal13Mirror Stay Installation13Front Storage Pocket Removal13Front Storage Pocket Installation13Storage Pocket Disassembly/Assembly13Crossmember Removal13Crossmember Installation13Handrail Removal13Handrail Installation13Drain Plug Housing Removal13Drain Plug Housing Installation13Exhaust Outlet Removal13Exhaust Outlet Installation13Stabilizer Removal13Stabilizer Installation13Reboarding Step Removal13Reboarding Step Installation13Hull Replacement13Rubber Parts13Rubber Parts Location13Rivet Removal13Rivet Installation13Front Bumper Removal13Front Bumper Installation13Rear Bumper Removal13Rear Bumper Installation13Side Bumper Removal13Side Bumper Installation13Parts Location14Crankshaft Sensor Inspection14Exploded View14Ignition Coil Removal14Wiring Diagram14Ignition Coil Installation14Specifications14Ignition Coil Inspection14Special Tools and Sealant14Precautions14Removal14Electrical Wiring14Wiring Inspection14Installation14Battery14Removal14Inspection14Installation14Igniter Removal/Installation14Electrolyte Filling14Igniter Inspection14Initial Charge14Spark Plug Removal14Precautions14Spark Plug Installation14Interchange14Spark Plug Inspection14Charging Condition Inspection14Spark Plug Adjustment14Refreshing Charge14Spark Plug Cleaning14Electric Starter System14Starter Relay Removal14Starter Relay Installation14Magnet Removal14Starter Relay Inspection14Starter Motor Removal14Magnet Installation14Starter Motor Installation14Starter Motor Disassembly14Steering System14Starter Motor Assembly14Brush Inspection14Clearance14Inspection14Voltage Inspection14Armature Inspection14Brush Lead Inspection14Voltage Inspection14Sensors14Inspection14tion14tion14Speed Sensor Inspection14Reduction Gear Inspection14Fuel Level Sensor Inspection14Charging System14Magneto Output Voltage14tion14Throttle Sensor Inspection14Removal/Installation14Regulator/Rectifier Inspection14Inspection14Regulator Inspection14Ignition System14Inspection14Crankshaft Sensor Removal14Crankshaft Sensor Installation14Inspection14Timing Rotor Removal14Timing Rotor Installation14Display Function Inspection14MODE/SET Button Inspection14Characters/LED Inspection14Buzzer Inspection14model ∼)14Removal14Installation14Inspection14Circuit Inspection14Switches14Switch Inspection14Inspection14Tachometer Inspection14Inspection14Preparation for Storage15Cooling System15Bilge System15Engine Oil15Fuel System15Engine15Air Filter15Battery15Engine Mounting Bolts15Lubrication15General15Removal from Storage15Lubrication15General Inspection15Fuel System15Test Run15Cable, Wire and Hose Routing16Troubleshooting Guide16Size: 8.02 MBPages: 438Language: EnglishOpen manual
