This Seloc repair manual covers 1973-1991 Kawasaki Personal Watercraft, including 300 Series, 440 Series, 550 Series, 650 Series, Jet Mate, and SC. All models.
Book Excerpt: 1973-1991 Kawasaki 300, 440, 550 and 650 Series, plus Jet Mate and SC Personal Watercraft Repair Manual
IMPELLER-TO-PUMP CASE CLEARANCE | ALL AXIAL AND MIXED FLOW JET PUMPS
The following procedure may be performed with the watercraft elevated on saw horses enabling a person to work underneath, or with the watercraft on its side allowing access to the rock grate and impeller.
If the impeller-to-pump case clearance is to be determined with the watercraft raised on saw horses, the battery may be left secured in the craft.
If the watercraft is to be positioned on its side, first disconnect the electrical leads at both battery terminals, and then remove the battery from the watercraft.
Remove the three bolts and washers securing the rock grate to the jet pump. If the seal between the hull and the pump housing is broken, or the foam packing is damaged, reseal the housing and intake area with silicone sealant to prevent impeller cavitation.
Insert a feeler gauge between each impeller blade and the pump case and determine the clearance. Make a note of all three clearances, one for each blade. Calculate the average of the three clearances.
On a new craft the clearance will be what the manufacturer refers to as the "standard" clearance - the first column. The second column is the "service limit". This value is the maximum allowable clearance.
CLEANING AND INSPECTING
Inspect the flywheel for cracks or other damage, especially around the inside of the center hub. A damaged flywheel can be EXTREMELY dangerous. The forces exerted on the flywheel while it is spinning at high rpm are sufficient to shatter an unbalanced damaged flywheel. Inspect the magnets to see if they are held tightly around the outer circumference of the flywheel rim. Check the surface of the magnets for fractures and grooves.
Grooves around the inner perimeter would indicate a component mounted on the stator plate is not aligned properly or the component is loose. Fractured or damaged magnets cannot be replaced. Both the magnets and flywheel share the same part number, therefore attempting to remove the magnets would be a pointless task. If magnets or the flywheel is defective, the entire flywheel must be replaced.
Check to be sure small metal particles have not become attached to the magnets. Verify each magnet has good magnetism by using a screwdriver or other suitable tool.
Thoroughly clean the inside taper of the flywheel and the taper on the crankshaft to prevent the flywheel and the taper on the crankshaft to prevent the flywheel from "walking" on the crankshaft during operation.
Test the magneto assembly to verify it is not loose. Attempt to lift each component on the plate. There should be little or no evidence of movement.
Subject: 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Kawasaki 300, 440, 550, 650, Jet Mate, SC service, maintenance, repair. ISBN-10: 0893300322 | ISBN-13: 9780893300326 | Seloc 9200