Mokai ES-KAPE 2.0 User manual

OWNER'S MANUAL
ES-KAPE 2.0
Mokai Manufacturing, Inc. 13 Jeanne Drive Newburgh, NY 12550
[phone] (888) 50-MOKAI fax: [phone]
www.MOKAI.com
Rev: 052019

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Introduction 4
Owners Satisfaction 4
Owner/Operator Responsibilities 4
State and Federal Regulations 4
Safety Equipment 4
Factory Warranty Statement 5
MOKAI watercraft –Material and Mechanical Components 5
General Information 6
Assembling the MOKAI ES-Kape 2.0 7
Bow Section 7
Engine Bay to Cockpit Section 8
Electrical Connections: 8
12v Battery 8
Seat and Foot Brace: 9
System Descriptions 9
Engine Installation and Removal 9
Joy Stick Control Box: 10
Pump Installation and Removal 12
Fuel Tank and Carbon Canister 12
Operating Information and Pre-ride Check 13
Pre-Ride Check 13
Boarding 13
Shallow Water Operation 13
MOKAI Maintenance 14
Hull 14
Handles 14
Cleaning and Care 14
Storage 14
Engine Storage/Transport 15
Contact with Salt water 15
Engine Maintenance: 16
Specifications: 17
Troubleshooting: 18
Helpful Tips: 19

4
Introduction
Thank you for your purchase of a MOKAI ES-Kape 2.0 watercraft. Our
dedicated production team builds every MOKAI to the highest standards
available. We are certain you will be pleased with your decision.
We want to help you get the best results from your new MOKAI. This
manual is provided to aid you in the safe and reliable operation of your
watercraft. READ IT AND BECOME FAMILIAR WITH PROPER
OPERATING PROCEDURES BEFORE USE.
We suggest that you read the warranty policy to fully understand its coverage
and your responsibilities of ownership. We extend our best wishes for many
hours of safe, pleasurable boating. MOKAI Manufacturing recommends all
boaters take an approved safety course.
Sincerely,
MOKAI Manufacturing, Inc.
Mokai is a registered trade mark of Mokai Manufacturing, Inc.
All images © Mokai Mfg –Permission required.
Owners Satisfaction
Your satisfaction is important to MOKAI Manufacturing, Inc. If you have a
problem concerning the use or performance of your craft please contact the
company immediately at 845-566-8287.
Happy Customers are our best advertising. We will always make every effort
to remedy your concerns in the timeliest manner.
Owner/Operator Responsibilities
State and Federal Regulations
Check state and federal regulations before operating and always comply with
the regulations for the area in which you are operating. By Federal
Regulations the MOKAI is classified as a "Jet Boat."
Safety Equipment
The MOKAI watercraft is equipped with fire extinguisher, signal mirror and
whistle. We recommend all occupants wear a USCG approved personal
flotation device (PFD).

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Factory Warranty Statement
MOKAI watercraft –Material and Mechanical Components
MOKAI Manufacturing Inc.(herein MOKAI) warrants that each new MOKAI watercraft will
be free, under normal use and service, from defects in material and workmanship for a period
listed below from the date of sale to the Original Purchaser.
Warranty Periods:
Jet Pump Assembly Limited 10 Year Warranty
Drive Shaft Limited 5 Year Warranty
Engine (as regulated by Kohler-see manual) Limited 3 Year Warranty
Hull and all other components not specified above Limited 3 Year Warranty
LIMITATIONS and EXCLUSIONS: This Limited Warranty shall not apply to:
1. Any Jet Pump Assembly that has been subject to negligence, misuse, accident,
misapplication or over-speeding.
2. Any Jet Pump Assembly damaged due to operation of watercraft with removed or
altered intake grate.
3. Any Jet Pump Assembly that is being run with any non-factory issued Engine
Assembly.
4. Any Jet Pump Assembly that has been installed, repaired or altered by anyone other
than MOKAI in a manner which in MOKAI’s sole judgment adversely affects its
performance or reliability.
5. Any Jet Pump Assembly that has been fitted or repaired with parts or components not
manufactured or approved by MOKAI which in MOKAI’s sole judgment adversely
affects its performance or reliability.
6. Instances in which normal use has exhausted the life of a component.
Normal wear and tear, damaged caused by failure to provide proper maintenance, storage,
damage resulting from improper repairs, damage resulting from accident, fire, theft ,abuse,
misuse or neglect are excluded. Aftermarket modifications to engine, drive train, jet drive or
hull will void warranty.
The customer is responsible for all transportation costs in connection with any warranty work.
Return postage will be paid by MOKAI, when deemed a valid warranty claim, for US
customers only.
MOKAI Manufacturing Inc. reserves the right to modify, alter or improve any parts or
components without incurring any obligation to modify or replace parts or components
previously sold without such modification, alteration or improvement.
No person is authorized to offer any other warranty on behalf of MOKAI unless made in
writing and signed by an officer of MOKAI Manufacturing Inc.
This warranty, and MOKAI’s obligation here under, are in lieu of any other warranty or
obligations of any kind, express or implied, including warranties of merchantability or fitness
for a particular purpose. There are no warranties which extend beyond the description on the
face here-of. MOKAI shall in no event be liable for any consequential or incidental damages.
MOKAI watercraft placed in service as COMMERCIAL or Rental units are subject to a
warranty period of 1 (one) year from original purchase date.

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Kohler Warranty
Warranty as regulated by Kohler Co. Please refer to the Kohler owner’s
manual for information and specific details.
General Information
The Hull and Engine of your MOKAI watercraft are identified by serial
numbers. These numbers are unique to your boat and may be required for
warranty, registration or to track in the event of theft.
The Hull Identification Number or HIN is located at the stern of the craft.
The Engine Serial Number is stamped into the Engine Block
and also on the label. ** Engine must remain upright during
transport and or storage. Improper handling can result in oil leakage
into the cylinder and carburetor –see troubleshooting**

7
Assembling the MOKAI ES-Kape 2.0
Bow Section
•Identify the (3) Bow Spools located on the Bow Bulkhead.
•Align the Bow Spools with the Front Cockpit Bulkhead
receiving keyholes. Allow Bow to drop into position. (note it
will not be fully secured at this step)
•Hand start the fastening bolt located at the top of the bow one
half turn.
•Use the provided wrench to fully tighten the bow in place.
approx. 25 turns.
(5/8 ratchet –provided located in storage pocket on seat back)

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Engine Bay to Cockpit Section
•Pull ENGINE Bay to COCKPIT Section.
Technique tip: Straddle or sit on top of rear Cockpit
section facing Engine Bay. Lift up slightly when pulling
Engine Bay onto (4) alignment pins.) Important: note that
the Engine Bay is seated squarely to Cockpit Section
before securing.
•Identify the (4) Fastening Bolt Spring Housing in the Engine
Bay section. Push in to engage and hand tighten. Use 5/8
ratchet wrench (provided) to fully tighten, ALTERNATING
tightening top and bottom fasteners.
Electrical Connections:
•In the cockpit section - Identify Control Box Wire Harness. This
is a keyed oriented connector. Plug into ECU port located above
fuel tank. To remove depress locking tabs. Separate using plug.
NEVER PULL FROM WIRES.
12v Battery
The Battery is located in the Engine Bay. To remove battery,
disconnect battery cable and release elastic strap. Do not operate
MOKAI without battery. Damage will occur to Electronics.
Disconnect when not in use for prolonged periods.

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Seat and Foot Brace:
•Install Seat: Place seat into cockpit. Slide seat back so seat pins
slide into bushings. Secure cotter pin to each seat pin.
•Retain cotter pins in storage holes located above bushings when
seat is removed.
•5/8 ratchet wrench and 5/32 Allen key are stored in pocket on
seat back.
•Install Adjustable Foot Brace with two 4 prong knobs.
System Descriptions
Engine Installation and Removal
To install Engine: Place Engine onto Stringer Rails within Engine
Bay. (Exhaust towards rear of craft) With Engine in full back
position, install Poly Chain Belt onto both drive sprockets.
HANDLE WITH CARE
Twisting/forcing belt into position will result in damage to the belt.
Slide engine forward and begin threading tension bolt by hand.
To complete engine fastening you will need to use the 5/8 ratchet to
fully tighten tension bolt. This will automatically set the factory
calibrated belt tension.
Connect the engine wire harness to the ECU in port marked engine.
Connect Battery
Feed Fuel line through bulkhead opening into cockpit. Connect to
tank.

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Joy Stick Control Box:
To Start Engine: Turn Ignition Key to START position and
release. (Safety lanyard key must be in to start).
To Stop Engine: While the Engine can be stopped various
ways we recommend switching the Ignition Key to OFF.
You can stop the boat in an emergency by pressing down on the
RED Safety kill switch located on starboard side under deck
hull. This safety key should be attached to your PFD as a
means to stop the boat in the event you become separated from
the boat –Emergency Stop.)
ACC 1- 12v, operated a 10amp plug located in the Engine Bay.
An accessory pigtail connector is included with your boat.
ACC 2- 12v, operates a 3amp snap plug located on the control
box wire harness.
FEMALE- POSITIVE –GRAY wire
MALE –NEGATIVE –BLACK wire

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MOKAI is controlled using a 2 axis joystick located on the starboard
side. Throttle is actuated by pushing forward. The joystick will return
to idle at the zero position when released. This same joystick is pushed
left or right to direct the steering nozzle left or right (respectively).
When not in use the control box can be removed from the receiver and
stowed under the deck as illustrated below:

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Pump Installation and Removal
In the event debris enters the jet pump or if service is required the jet
pump can be removed to clear the pump and then reinstalled.
1. Release over-center clamp
2. Release steering disconnect
3. Pull pump towards you. Removing engine is not required.
4. Use alignment pin for proper orientation when reinstalling.
Fuel Tank and Carbon Canister
The capacity of the MOKAI fuel tank is 3.6 gallons. This tank is
equipped with a carbon canister to prevent hydrocarbon vapors into the
atmosphere. The Fuel Tank on the MOKAI ES-Kape 2.0 is not portable.
If required, tank can be removed for inspection by removing locking
brackets and disconnecting vent line located port side.
DO NOT TIP COCKPIT GREATER THAN 30 degrees with fuel
tank installed. Carbon canister will be compromised.

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Operating Information and Pre-ride Check
Pre-Ride Check
General Inspection of Craft insuring modular sections are attached
properly.
Review Kohler pre-start checklist (pg 4-Kohler manual). Install
Engine, lock in place.
Check that Fuel Switch is in the ON (pointed down) position
Check Fuel and Vent Connect Lines
Secure Engine Cover
DO NOT OPERATE BOAT WITHOUT ENGINE COVER IN
PLACE. COVER IS REQUIRED FOR EFFECTIVE ENGINE
COOLING.
General inspection of Jet Pump
Check Steering
Check Emergency shut off lanyard key by starting engine and
pulling key or depressing button to ensure that engine stops.
(Can be done on dry land. If in water, board MOKAI before starting.)
Check Safety Equipment
Boarding
From land or dock, board the MOKAI at the center of the occupant
compartment. *IMPORTANT*
MOKAI is not designed for re-entry in deep water. In an emergency
situation, re-boarding is only possible from the bow or the stern. Do not
attempt to re-board from the sides of the MOKAI.
Shallow Water Operation
We recommend starting the MOKAI in 12 inches of clear water. The draft is
4-6 inches. Every MOKAI is equipped with an intake grate to protect debris
from entering the jet pump and causing damage when operating. Owner
assumes all liability for damage when operating with removed or altered
grate.
Debris hazards and loose vegetation tend to be found in shallow water and can
be sucked onto the intake grate. If this occurs you will notice a decrease in
speed due to the blockage of water flow to the jet drive.
Simply stop engine, debris should fall free from intake grate. If necessary,
remove any tangled debris from grate by hand before restarting.

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MOKAI Maintenance
Hull
MOKAI's hull is constructed of high impact, polyethylene plastic. Standard
adhesives, tapes and paints tend to not adhere to this material.
While the Hull is extremely durable, aggressive exposure to rocks and debris
can compromise the hull. The material can be repaired using a plastic welder
or soldering iron. In the event you experience a breech in the hull please call
the factory for additional information and supplies. This is not considered a
warranty item.
Handles
Your MOKAI is equipped with (2) handles. The Bow handle is designed to
allow you to pull the boat from the water. It should not be used in any load
bearing application. The cockpit handle is located on the front bulkhead,
which is accessed after removing the Bow. This handle can be used when
carrying or securing to your vehicle/trailer.
Cleaning and Care
It is best to store your MOKAI out of direct sunlight on a flat surface.
Clean with soapy water or spot clean with a Windex™ type product.
There is a drain plug located starboard side of cockpit section as well as the
one in the engine bay.
Seat covers can be cleaned with a damp cloth and air dried.
Storage
Short Term: We recommend covering the boat when not in use. Make sure
the engine/ muffler are cooled before covering.
Long Term: If storing outdoors remove Engine, Jet Drive, Battery & Seats.
Cover with provided weather cover.
We recommend storing the boat flat or with the entire length supported. The
Cockpit section can be stored vertically (on end).
Do not store the boat suspended or between saw horse like supports. This can
result in a distortion of the hull.
Drain the float bowl of the carburetor. We recommend the use of a fuel
stabilizer in the fuel tank.

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Engine Storage/Transport
It is important for the engine to remain upright during storage or transport.
Tipping the engine more than 30 degrees (carburetor moving towards the
floor) for a prolong period of time will result in oil seeping past the reed valve
in the value cover. Oil will then travel thru the engine vent line into the intake
manifold. When the engine is up righted this oil could stop the engine from
rotating and/or starting
You must take the following corrective action.
Corrective Action
Remove Spark Plug
Pull starter cord to cycle engine–excess oil will blow out spark plug hole.
Dry spark plug and re-install.
Remove air filter and clean with soap and water. Squeeze dry.
Wipe excess oil from air box.
Contact with Salt water
After use in a salt environment we recommend rinsing all areas of contact
with fresh water. Also, remove the engine and rinse the exterior for any salt
spray that may be present on the engine. Apply a light spray of corrosion
block to exterior of engine and linkage. Remove the jet drive and rinse.

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Engine Maintenance:
For more detailed information please refer to Kohler owner’s manual (pg6).
Maintenance Items
First
5 hours
Every
100 hours
(or annually)
Every
300 hours
Every
500
hours
Clean Engine & Check
oil level, check bolts
and nuts

(Daily)
Change Engine Oil
10W-30
(1.16 U.S. quart)


Clean Spark Plug

Clean Air Cleaner

Replace Air Cleaner
Element ***

Clean Fuel Cup

Clean & Adjust spark
plug & electrodes

Replace Spark Plug **
Recommend:
Champion: RC12YC

Check and adjust valve
clearance *

Remove carbon from
head *

Clean & adjust
carburetor *

* Note: As to the procedures for these items, please refer to the Service
manual or consult your nearest Kohler authorized service dealer.
**Note: Spark plug wrench supplied.
*** Note: DO NOT Oil air filter for use in MOKAI watercraft.

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Specifications:
Engine:
KOHLER, CH395: 9.5 hp
(See Manual for additional information)
Electric Start, 10 amp charging
system
Propulsion System:
MOKAI Manufacturing Pump
Axial Flow Jet Drive
Drive System:
Coupling
Gear box, clutch
Steering
Two Axis Joy Stick, Linear Actuated
Throttle
Two Axis Joy Stick, Servo Actuated
Dimensions:
Length (fully assembled)
134 inches
Width (at widest point)
36 inches
Height
20 inches
Weight: water ready, no fuel
200 lbs
Weight: Engine
67 lbs
Number of Passengers
1
Payload Limit MAX
215 lbs passenger
65 lbs gear (forward stowed)
Fuel Tank:
Run Time
Prevention
3.6 U.S. Gallon Capacity
Unleaded Gasoline
8 hours (approximate)
We recommend use of a fuel
stabilizer as per package instructions
to keep fuel fresh, prevent deposits,
improve oxygenate solubility and
prevention of alcohol & MTBE
reactions with metal to protect from
rust and corrosion.
Materials/Construction:
Hull (including engine cover,
center flotation and plenum)
Rotomolded, high impact
polyethylene with UV stabilizer
Fuel Tank
Aluminum
Seat, Weather Covers
Rotomolded, high impact
polyethylene. Fabric –Cordura brand
Nylon
Other Components
Anodized Aluminum, Stainless Steel,
Naval Brass, Delrin

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Troubleshooting:
Trouble
Possible Cause
Remedy
Engine will not start
Choke Off
Safety Lanyard not
attached
Out of Fuel
Engine key in the OFF
position
Dead Battery
Put Choke to on position
Attach Safety Lanyard
Refuel
Turn on
Pull cord located on
Engine.
Abnormal Pump
Performance
Weeds or debris clogging
intake grate
Weeds tangled around
drive shaft
Damage to drive shaft or
coupler
Pump inefficiency
Turn off engine, remove
debris, restart
Remove jet drive (on land),
remove tangled debris,
reinstall pump & restart.
Inspect. Call MOKAI
Manufacturing
Inspect (green) wear ring.
(located at the stern where the jet
drive attaches.) Replace.
No Fuel to Engine
Fuel lines not connected
Fuel Shut off closed
Clogged vent line
Connect lines
Open Valve
Blow line clear
Poor Performance
Dirty or clogged air filter
(Air filter should not be
oiled when used in
MOKAI application)
Clean or replace
(To quickly diagnose this issue,
remove air filter and start
engine. If performance
improves clean or replace air
filter.)

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Helpful Tips:
Tie Down Straps
Your MOKAI was shipped with (2) tie
down cam buckle straps.
(1) Black - 12 ft
(1) Yellow- 18 ft
Weather Cover Installation
(& use of & bow stays)
Attach Bungee loop to weather cover
spools at front of cockpit BEFORE
securing cover around opening, When
removing release from back first.
When storing your MOKAI with the
weather cover, tighten the bow straps
located on the underside of the cover,
to create a crowned top.
Spare 10 amp Fuse
A spare fuse is included with your
purchase. The fuse holder is located on
the engine wire harness.
Recharging Battery
Kohler engine is equipped with a
charging coil and will continually
charge battery while engine is running.
When Engine with dead battery is
started using mechanical pull cord the
battery will charge in 15-20 minutes.
Accessory Connector
Your MOKAI is equipped with (2)
12v. Accessory connections. This can
be used to connect running lights or a
similar low draw accessory.
See page 10 for additional information.
Muffler
Muffler will be HOT after operation.
Do not touch injury/ burns can
result!
Please phone MOKAI Manufacturing for help with any other issues:
888-50-MOKAI (888-506-6524)