KAWASAKI JET SKI ULTRA 250X 260X 260LX Full Service & Repair Manual 2007-2012

ULTRA 250X ULTRA 260X ULTRA 260LX 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 j Periodic Maintenance 2 j Fuel System (DFI) 3 j Engine Lubrication System 4 j Exhaust System 5 j Engine Top End 6 j Engine Removal/Installation 7 j Engine Bottom End 8 j Cooling and Bilge Systems 9 j Drive System 10 j Pump and Impeller 11 j Steering 12 j Hull/Engine Hood 13 j Electrical System 14 j Storage 15 j Appendix 16 j

ULTRA 250X ULTRA 260X ULTRA 260LX 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 Assurance Division/Consumer Products and 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. © 2006 Kawasaki Heavy Industries, Ltd. 4th Edition (1):Nov. 26, 2009 (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) COUNTRY AND AREA CODES AT Austria DE Germany AU Australia EUR Europe CA Canada GB United Kingdom CAL California US United States CH Switzerland WVTA Whole Vehicle Type Approval

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 PREMIUM GRADE GASOLINE ONLY. A minimum of 90 octane of the antiknock 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 and California Air Resources Board. 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. * Digital Transistor Ignition System * Fuel Pump * Spark Plugs * Throttle Body and Internal Parts * Fuel Injectors * ECU * Supercharger with intercooler & relief-valves

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, thoroughly 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 Ta- ble 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 on 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 personal 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 particular 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 inspection 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. This model, JT1500B/E/F, is mounted with a four-stroke engine with supercharger. When the JET SKI ® watercraft is submerged and swamped, the four-stroke engine needs special care and systematic procedure for re- covery compared with the two-stroke engine. Therefore in this manual, such procedures, which are not shown in SMs for two-stroke engines, are explained thoroughly to cope with the cases. Refer to the section, After submerging in Chapter 9, Cooling and Bilge Systems for the summary and detailed procedures.

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification................................................................................................................. 1-10 General Specifications............................................................................................................ 1-14 Unit Conversion Table ............................................................................................................ 1-16

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on watercraft, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: Kawasaki Diagnostic System (KDS) Software KDS software that runs on Windows personal computer (PC) will be available as a diagnostic tool for watercraft with Kawasaki DFI system. You need the following items to use the KDS. Item P/No. KDS Software Version 3.□ (CD-ROM, Updated Version) 57001-1650 KDS3 Adapter 57001-1648 and 57001-1724 or 57001-1725 Communication Cables 57001-1649 and 57001-1688 or 57001–1745 KDS Adapter Cable 57001-1696 The connectors for the communication cable and KDS adapter cable are located in the front. Connect the communication cable to the KDS connector (4-pin) [A] and the KDS adapter cable between the ignition switch (immobilizer amplifier) lead connectors (6-pin) [B]. Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever trou- bleshooting 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, especially in high revolutionary speed or severe engine and exhaust system damage will occur. 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.

KAWASAKI JET SKI ULTRA 250X 260X 260LX Full Service & Repair Manual 2007-2012

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