Aquanami jetKayak Service Manual

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2011
jetSurf
jetKayak
jetNami
POWERBOARD SERVICE MANUAL
Version 1.0
AQUANAMI, All Rights Reserved, 2011
AQUANAMI
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1 2 3 4 5 6 ... 82 83

Summary of Contents

Page 1 - AQUANAMI

2011 jetSurf jetKayak jetNami POWERBOARD SERVICE MANUAL Version 1.0 AQUANAMI, All Rights Reserved, 2011 AQUANAMI

Page 2 - WARNING

PRE-SEASON CHECKS • The pre-SESON check is very important prior to operating the watercraft. Always check the proper operation of critical controls, s

Page 3 - SAFETY NOTICE

PRE-SEASON CHECK LIST ITEM TO DO Start and Stop buttons Check operation. Safety Lanyard Check operation. Throttle Check operation. Steering system C

Page 4 - TABLE OF CONTENTS

General Care Take the watercraft out of the water every day to prevent marine organism growth. Should any water be present in the bilge, open the drai

Page 5 - AQN12345B111

STORAGE OPERATION CHECK LIST 1 Flush exhaust cooling system. 2 Remove, clean, recharge and store the battery. Charge the battery every three to fiv

Page 6 - ILLUSTRATIONS AND PROCEDURES

Flushing Exhaust Cooling System Flushing the exhaust cooling system with fresh water is essential to neutralize corroding effects of salt or other ch

Page 7 - MAINTENANCE CHART

Certain components in the engine compartment may be very hot. Direct contact may result in skin burn. Do not touch any electrical parts or jet pump ar

Page 8 - Product Maintenance Chart

REMOVAL, CLEAN AND STORAGE OF BATTERY The battery should be removed, cleaned and fully charged for storage when the powerboard is not expected to be

Page 9

CAUTION: Make sure the drain plug is properly secured after oil change and the access window is properly sealed with “O” ring and properly secured. No

Page 10 - PRE-SEASON CHECKS

DRAIN WATER-AIR SEPARATOR BOTTLE Located inside engine compartment. Retain water or contaminated fuel. Check the bottle periodically and drain water o

Page 11 - PRE-SEASON CHECK LIST

DRAIN ENGINE BREATHING OIL RETAINER Located in engine compartment. Retain oil mist and oil from engine breathing path. Check the bottle periodically

Page 12 - STORAGE PROCEDURES

This SERVICE MANUAL utilizes the following symbols: The Safety Alert Symbol means ATTENTION! A potential personal injury hazard. Indicates a potential

Page 13

Follow these safe boating fueling instructions carefully: • Turn off engine. • Do not insert the spout too far in filler neck. • Pour fuel slowly so

Page 14 - Proceed as follows:

CLEAN AND LUBRICATE BILGE AND HULL Clean the bilge with hot water and mild detergent or with bilge cleaner. Rinse thoroughly. Lift front end of water

Page 15 - Anticorrosion Treatment

LUBE ENGINE AND CARBURETOR Engine must be lubricated to prevent corrosion on internal parts. Fogging of the engine is recommended at the end of the

Page 16 - DRAIN ENGINE OIL

LUBRICATE THROTLE CABLE AND STEERING CABLE Water can get inside steering cables and throttle cable. The crystallization of salt water between cable a

Page 17 - DRAIN CARBURETOR FLOAT BOWL

SPECIAL PROCEDURES Water In Carburetor Once water gets into carburetor bowl, engine will not work properly. It may loose power and suddenly stop when

Page 18 - Water-Air

Jet Pump Water Intake and Impeller Cleaning Weeds, shells or debris can get caught on the intake grate, drive shaft and/or impeller. A clogged water i

Page 19

Capsized Watercraft If watercraft turns over, it will remain capsized. When watercraft is capsized, do not attempt to restart the engine. Operator sh

Page 20

Submerged Watercraft To limit damages to the engine, drain bilge as soon as possible. If it was submerged in salt water, spray bilge and all component

Page 21

Fuel-Flooded Engine When the engine does not start after several attempts, the engine may be fuel-flooded. Proceed as follows. Open engine cover, le

Page 22 - LUBE ENGINE AND CARBURETOR

ITEM UNIT DATA Engine Type 4 stroke Max power kW (hp) 7 (9.5) Number of cylinders 1 Displacement cm3 (cu in) 149.6 (9.2) Bore mm (in)

Page 23

Engine should be turned off and cold for all maintenance and repair procedures WARNING For your safety, understand and fol

Page 24 - SPECIAL PROCEDURES

ITEM UNIT DATA Fuel system Fuel tank capacity L (US gal) 7 (1.8) Play time at full throttle hours 2 Propulsion system Jet pump Aluminum/composit

Page 25

TROUBLE SHOOTING 31

Page 26 - Capsized Watercraft

The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to show all causes for al

Page 27 - Water-Flooded Engine

ENGINE WILL NOT START - CONTINUE Engine turns regularly, but does not start Low battery voltage Recharge or replace battery Empty fuel Refill fuel D

Page 28 - Fuel-Flooded Engine

ENGINE WILL NOT START - CONTINUE No spark Spark plug faulty, fouled or worn out Check spark plug condition Spark plug cap not connected or loose Tig

Page 29 - POWER PLANT SPECIFICATION

ENGINE HARD TO START OTHER OBSERVATION POSSIBLE CAUSES REMEDY Hard to start Defect fuel pump Replace Idle adjustment Readjust idle Intake valve and

Page 30

ENGINE MISFIRES, RUN IREGULARLY OR STALLS OTHER OBSERVATION POSSIBLE CAUSES REMEDY Engine misfires, runs irregularly or stalls Empty, stale or

Page 31 - TROUBLE SHOOTING

ENGINE CAN NOT REACH TOP SPEED, AND DOES NOT HAVE POWER OTHER OBSERVATION POSSIBLE CAUSES REMEDY Jet pump related issues Weeds and debris trapped in

Page 32 - ENGINE WILL NOT START

ENGINE STOPS RUNNING OTHER OBSERVATION POSSIBLE CAUSES REMEDY Engine dies during operation Engine running out of fuel Refill fuel High engine tempera

Page 33

THROTTLE CABLE NOT RETURN BACK FULLY OTHER OBSERVATION POSSIBLE CAUSES REMEDY Stick throttle lever and throttle cable not return back fully Salt or c

Page 34 - Tighten and seal the spark

TABLE OF CONTENTS SAFETY NOTICE .. .. ... .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. .. 3 INTRODUCTION .. .. ... ... ... .. ..

Page 35 - ENGINE HARD TO START

PROPULTION SYSTEM Jet Assembly And Weed Cutter: Jet Pump Jet Pump Parts 40

Page 36

Stator and Impeller Intake and weed cutter 41

Page 37 - Clean and remove blockage

Propulsion System Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other

Page 38 - ENGINE OVER HEAT

Jet Impeller Removal Procedure: 1. Remove the Allen head screws from the heat exchanger and the ride plate. Remove Phillips head screws. Remove ride p

Page 39

Jet Impeller Install Procedure: Follow the reverse steps to install the impeller and stator. Make sure use appropriate jet pump bearing grease for bea

Page 40 - PROPULTION SYSTEM

Tight all hoses, electric conduit, and rubber seal boot inside engine compartment. Make sure jet is aligned with the engine. Install the steering ar

Page 41 - Intake and weed cutter

ENGINE Engine Assembly: Engine, top view 46

Page 42 - Propulsion System Part List:

Engine, right view Engine, left view 47

Page 43

Engine Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other informatio

Page 44

Engine Removal Procedure: Disconnect the rubber connector between the exhaust pipe and muffler. Move the rubber connector to the engine side Disconnec

Page 45

INTRODUCTION This service manual covers :  Jetsurf  Jetkayak  Jetkayak GT  Jetnami  Jetnami GT The information and component/system description

Page 46 - Engine Assembly:

Engine Removal Procedure (continued): Disconnect the throttle cable Remove air box Cut the plastic ties to disconnect electric connectors to the eng

Page 47 - Engine, right view

Install engine. Hand tight the four M10x40 bolts. You should be able to move engine for slightly. The engine needs to be aligned with the jet at later

Page 48 - Engine Part List:

Engine Installation Procedure (continue): Connect all the cooling hoses, fuel hoses and secure them in place using plastic ties Connect electric conne

Page 49 - Engine Removal Procedure:

ELECTRIC SYSTEM Control Box: Control box Control box and wiring 53

Page 50

Jetsurf Electric Switches (Continue): Jetsurf handle switches and wiring Kill switch, start switch and stop switch 54

Page 51 - Engine Install Procedure:

Jetkayak Electric Switches: Jetkayak center control wiring Jetkayak joystick control switches Jetkayak center control kill switch wiring 55

Page 52

Jetnami Electric Switches: Jetnami kill switch Jetnami electric wiring Jetnami handle switches 56

Page 53 - ELECTRIC SYSTEM

Electric Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other informat

Page 54

Jetsurf Switch Assembly Removal Procedure: Trace the three wires from handle to control box, Disconnect the 3 wires from the control box. Disconnect

Page 55 - Jetkayak Electric Switches:

Jetsurf Switch Assembly Install Procedure: Follow the reverse steps to install the electric switch provided. Pay attention to the followings: •

Page 56 - Jetnami Electric Switches:

ILLUSTRATIONS AND PROCEDURES The illustrations and pictures show the typical construction of the different assemblies and, in all cases, may not repr

Page 57 - Electric Part List:

Jetkayak Switch Assembly Removal Procedure: Pull out the electric wires. Apply soap or Vaseline on electric wire and the rubber seal for easy pulling.

Page 58 - Disconnect the 3 wires from

Jetkayak Switch Assembly Install Procedure: Follow the reverse steps to install the electric switch assembly. Pay attention to the followings: •

Page 59

Jetnami Switch Assembly Removal Procedure: Remove kill switch Pull out electric wires Push out the round rubber seal of electric wires. Apply soap or

Page 60

Jetnami Switch Assembly Install Procedure: Follow the reverse steps to install the electric switch assembly. Pay attention to the followings: •

Page 61

SPEED/THROTTLE CONTROL Throttle Cable And Trigger: Throttle cable to carburetor Throttle cable in Jetsurf handle Throttle cable in joystick handle Thr

Page 62

Jetsurf Throttle Cable Removal Procedure: Disconnect Armpole from Hull. Disconnect the throttle cable from carburetor. Open handle and disconnect thro

Page 63

Jetkayak and Jetnami Throttle Cable Removal Procedure: Disconnect the throttle cable from carburetor. Open the rubber seal. Apply soap or Vaseline on

Page 64 - SPEED/THROTTLE CONTROL

COOLING SYSTEM Cooling System and Flow Heat Exchanger Engine Thermo Valve Coolant Tank Coolant Expansion Bottle CLOSED LOOP COOLING Main cooling circ

Page 65

Figure 5.2. Water cool pump and hoses Engine water pump Cooling System and Flow CLOSED LOOP COOLING Main cooling circulation in Main cooling circulat

Page 66 - Open the rubber seal. Apply

Cooling System Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other in

Page 67 - COOLING SYSTEM

MAINTENANCE CHART Routine maintenance is necessary for all mechanical products. A periodic inspection contributes to the product’s good performance,

Page 68 - Cooling System and Flow

EXHAUST SYSTEM Exhaust system cooling and flow Outside cooling water from jet Bilge vacuum siphon Cleaning and flushing Exhaust path 70

Page 69 - Cooling System Part List:

Flushing hose check valve Flushing quick connector Bilge siphon pump head 71

Page 70 - EXHAUST SYSTEM

Exhaust System Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other in

Page 71 - Bilge siphon pump head

FUEL SYSTEM 1. Air vent 2. Check valve A with pressure 3. Check valve B without pressure 4. Fuel filter 5. Fuel pump 6. Primer bulb 7. Water-air separ

Page 72 - Exhaust System Part List:

Fuel System Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other infor

Page 73 - FUEL SYSTEM

STEEING SYSTEM Steering Assembly At Jet Nozzle: Rear steering arm and steering nozzle Steering rotary assembly 75

Page 74 - Fuel System Part List:

Steering rotary parts Steering rotary at joystick 76

Page 75 - STEEING SYSTEM

Steering System Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other i

Page 76 - Steering rotary at joystick

Assemble Steering Pulley Procedure: Insert brass sleeve into steering pulley house Insert brass sleeve into steering pulley cover Slip rubber boot, tw

Page 77 - Steering System Part List:

If this is the first pulley to install, adjust the inside nut to middle position and tight second nut to prevent bolt loose. If one pulley already in

Page 78

10 hrs 50 hrs or 100 hrs or 200 hrs or ITEM 6 months 12 months 24 months GENERAL Lubrication/corrosion protection L L L L ENGINE Engine oil

Page 79

BILGE PUMP, WATER CENSOR Bilge and water sensor Bilge installed in engine compartment Bilge manual switch and connector 80

Page 80 - BILGE PUMP, WATER CENSOR

Bilge Pump, Water Censor And Manual Switch Removal Procedure: For FX, start here. For other models, skip to 3rd step. Loose clamps, and slip the rubbe

Page 81 - Procedure:

Bilge Pump Assembly Install Procedure: Follow the reverse steps of bilge assembly removal procedure to install the bilge pump, water censor and manua

Page 82

HULL Hull Part List: (Please use Parts Catalog to order your parts. Parts Catalog provides part numbers indicating model, model year and other informa

Page 83 - Hull Part List:

PROPULSION SYSTEM Jet set (including impeller) I I I I Mechanic seal set (drive shaft) I I I Automatic vacuum siphon pump IC IC IC IC

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