2004-2006 Kawasaki JT900 STX JetSki Watercraft Repair Manual

900 STX JET SKI ® Watercraft Service Manual

is a trademark of Kawasaki Heavy Industries, Ltd. registered in U.S.A., Japan, Austria, Benelux, Sweden, Denmark, Switzerland, France, Canada, Finland, Norway, Greece, Italy, U.K., Portugal, Thailand, and Taiwan. KAWASAKI JET SKI is a trademark of Kawasaki Heavy Industries, Ltd. registered in Australia.

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference Guide General Information 1 Periodic Maintenance 2 Fuel System 3 Engine Lubrication System 4 Exhaust System 5 Engine Top End 6 Engine Removal/Installation 7 Engine Bottom End 8 Cooling and Bilge System 9 Drive System 10 Pump and Impeller 11 Steering 12 Hull/Engine Hood 13 Electrical System 14 Storage 15 Appendix 16

900 STX JET SKI ® Watercraft Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your "JET SKI" watercraft dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2003 Kawasaki Heavy Industries, Ltd. Third Edition (1) :Sep. 7, 2005 (K)

LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) perminute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h hour(s) Ω ohm(s) L liter(s) Read OWNER’S MANUAL before operating.

MAINTENANCE AND ADJUSTMENTS Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine Sl engine repair establishment or individual. EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane of the antifknock index is recommended. The antiknock index is posted on service station pumps. Emission Control Information To protect the environment in which we all live, Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental Protection Agency. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this engine. The fuel, ignition and exhaust systems of this engine have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. Maintenance Proper maintenance and repair are necessary to ensure that watercraft will continue to have low emission levels. This Service Manual contains those maintenance and repair recommenda- tions for this engine. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards. Tampering with Emission Control System Prohibited Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related parts. *CDI System *Frame Arrester *Spark Plugs *Carburetor and Internal Parts *Fuel Filter Screen

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your "JET SKI" watercraft: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki "JET SKI" watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki "JET SKI" watercraft are intro- duced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don’t take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents of the first page of the chapter to find the ignition coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification................................................................................................................. 1-6 General Specifications............................................................................................................ 1-7 Technical Information – Kawasaki Smart Steering System (Carburetor Type) ....................... 1-9 Unit Conversion Table ............................................................................................................ 1-13

1-2 GENERAL INFORMATION Before Servicing Before starting to service a watercraft, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip- tions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Especially note the following (1) Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting or presence of symptoms indicate that adjustments may be required. Whenever running of the engine is required during maintenance it is best to have the watercraft in water. CAUTION Do not run the engine without cooling water supply for more than 15 seconds or severe engine and exhaust system damage will occur. (2) Auxiliary Cooling An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjustments. If possible, always operate the watercraft in water rather than use an auxiliary cooling supply. • Obtain a standard garden hose [A] and a garden hose adapter [B] as shown. C. Garden Hose Fitting of Adapter D. Flushing Fitting of Adapter E. Thread: Rp3/4 F. Clamp ○ Optional part (P/No. 92005–3748) is available as a garden hose adapter. • Open the front storage compartment cover. • Remove the flushing cap [A] on the brim of the storage compartment. • Screw a garden hose adapter [A] onto the flushing fitting [B]. • Attach a garden hose [C] to a garden hose adapter and secure the hose clamp [D]. • Attach the garden hose to a faucet. Do not turn on the water until the engine is running and turn it off immediately when the engine stops. The engine requires 2.4 L/min (2.5 US qts/min) at 1 800 rpm and 7.0 L/min (7.4 US qts/min) at 6 000 rpm.

2004-2006 Kawasaki JT900 STX JetSki Watercraft Repair Manual

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