Jet Ski Mechanic Course

Lesson 1 • Tools, Equipment, and Workshop Setup

Covers hand tools, specialty PWC tools, lifting equipment, and proper workstation organisation. Correct tool selection prevents damage and improves repair efficiency.

Lesson 2 • Service Documentation and Technical Manuals

Teaches students to navigate factory service manuals, wiring diagrams, and parts catalogues. Accurate documentation habits reduce errors and support warranty compliance.

Lesson 3 • Shop Safety and Hazard Awareness

Introduces fire, chemical, electrical, and water hazards specific to PWC repair environments. Safety habits established here apply throughout the entire course.

Lesson 4 • Major Systems and Component Identification

Maps the hull, engine, jet pump, electrical, and fuel systems on a representative craft. Students gain the vocabulary needed for all subsequent diagnostic work.

Lesson 1 • Engine Performance Measurement

Introduces compression testing, leak-down testing, and power output evaluation methods. Baseline measurements guide repair decisions and verify post-repair quality.

Lesson 2 • Crankshaft, Bearings, and Seals

Examines crankshaft construction, main and rod bearings, and crank seal integrity. Seal failure is a leading cause of two-stroke engine damage and is emphasised here.

Lesson 3 • Cylinder, Piston, and Ring Assembly

Covers piston design, ring types, cylinder bore geometry, and wear measurement techniques. Students learn to assess components against manufacturer tolerances.

Lesson 4 • Two-Stroke Engine Operating Principles

Explains the intake, compression, power, and exhaust events within a single crankshaft revolution. Understanding this cycle is prerequisite to all engine diagnosis.

Lesson 1 • Pistons, Connecting Rods, and Crankshaft

Examines four-stroke piston design, rod bearing clearances, and crankshaft journal measurement. Proper clearances prevent oil starvation and premature bearing failure.

Lesson 2 • Supercharger Service and Inspection

Addresses supercharger rebuild intervals, impeller inspection, and intercooler service on high-performance PWC. Supercharger neglect is the primary cause of expensive engine failures.

Lesson 3 • Cylinder Head and Valve Train

Covers DOHC and SOHC configurations, valve clearance adjustment, and camshaft inspection. Valve train condition directly affects power output and fuel economy.

Lesson 4 • Four-Stroke Combustion Cycle

Explains intake, compression, power, and exhaust strokes and how valve timing governs efficiency. This cycle knowledge underpins all four-stroke diagnostic procedures.

Lesson 1 • Carburettor Adjustment and Synchronisation

Teaches idle mixture, float height, and throttle synchronisation on single and twin-carb setups. Proper synchronisation ensures smooth power delivery across the RPM range.

Lesson 2 • Carburettor Theory and Disassembly

Explains float, needle, jet, and emulsion circuits and guides students through systematic disassembly. Circuit understanding is essential for accurate jet selection and tuning.

Lesson 3 • Fuel Tanks, Lines, and Filters

Covers tank inspection, fuel line material requirements, primer bulb function, and filter service intervals. Contaminated fuel is a leading cause of carburettor and injector failure.

Lesson 4 • Fuel System Safety and Handling

Establishes safe fuel handling, vapour management, and fire prevention practices specific to marine environments. These protocols are mandatory before any fuel system work begins.

Lesson 1 • Electrical Fundamentals for Marine Technicians

Reviews voltage, current, resistance, and Ohm's Law as applied to marine electrical circuits. This foundation prevents misdiagnosis and component damage during testing.

Lesson 2 • Wiring Harness and Accessory Circuits

Teaches harness inspection, connector cleaning, and diagnosis of gauges, bilge pumps, and lighting circuits. Corrosion is the dominant failure mode in marine electrical systems.

Lesson 3 • Charging System Service

Explains stator output testing, rectifier-regulator function, and battery load testing for PWC charging systems. An undercharging system causes repeated starting failures on the water.

Lesson 4 • Ignition System Components and Operation

Covers CDI, TCI, and direct ignition systems, spark plug selection, and ignition timing principles. Correct timing is critical for power output and preventing detonation.

Lesson 1 • Wear Ring and Pump Housing Service

Details wear ring clearance measurement, replacement procedures, and pump housing inspection for cracks and erosion. Excessive clearance is the most common cause of thrust loss.

Lesson 2 • Driveshaft and Coupling Service

Examines driveshaft straightness, spline condition, rubber coupling wear, and bearing carrier inspection. Driveshaft imbalance causes vibration that accelerates engine and pump wear.

Lesson 3 • Impeller Inspection and Replacement

Covers impeller pitch selection, blade damage assessment, and removal using specialty tools. Damaged impeller blades cause vibration, cavitation, and reduced thrust.

Lesson 4 • Jet Pump Operating Principles

Explains how the impeller, wear ring, stator, and nozzle convert engine torque into thrust. Pump efficiency directly determines top speed and acceleration performance.

Lesson 1 • Damage Assessment and Repair Planning

Teaches systematic hull inspection, damage mapping, and repair cost estimation. Accurate assessment prevents under-repair and ensures structural integrity is restored.

Lesson 2 • Gelcoat Application and Colour Matching

Details gelcoat mixing, spray and brush application, and colour-matching techniques for seamless repairs. Poor colour matching is the most visible sign of an inferior repair.

Lesson 3 • Deck Hardware and Hatch Sealing

Covers removal and reinstallation of cleats, handles, and hatches with proper marine sealants. Improper sealing causes water ingress that leads to foam saturation and hull rot.

Lesson 4 • Hull Materials and Construction Methods

Explains fibreglass, SMC, and thermoplastic hull construction and how each material responds to impact. Material identification determines the correct repair approach.

Lesson 1 • Complete Engine Tune-Up Procedures

Covers spark plug replacement, ignition timing verification, valve adjustment, and fuel system cleaning as a coordinated service. Tune-up restores performance and extends engine life.

Lesson 2 • Quality Control and Test Ride Evaluation

Establishes post-repair quality checks, water test procedures, and customer delivery standards. A structured test ride confirms all repairs before the craft leaves the shop.

Lesson 3 • Pre-Season Inspection and Commissioning

Details a systematic pre-season checklist covering engine, fuel, electrical, hull, and pump systems. Commissioning catches off-season deterioration before the craft reaches the water.

Lesson 4 • Winterisation and Storage Procedures

Covers fuel stabilisation, fogging oil application, cooling system flush, and battery storage to prevent freeze and corrosion damage. Proper winterisation is the single best investment in longevity.