Kawasaki 900ZXi & 750ZXi JetSki Complete Workshop Service Repair Manual 1995 1996 1997

Kawasaki ® ..JE~ 900ZXi/750ZXi JETSKI® Watercraft Service' Manual

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 number 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 specific topic required. Quick Reference Guide General Information Fuel System Engine Lubrication System Exhaust System Engine Top End Engine Removal and Installation [ Engine Bottom End ~ing and Bilge Systems I Drive System [iump and Impeller Steering Hull I Engine Hood [Electrical System I Storage [ Appendix

Kawasaki ® .JE:~ 900 ZXi/750 ZXi JET SKI® Watercraft Service Manual © Kawasaki Heavy Industries. Ltd. 1995 First Edition (1) : Apr. 28, 1995 (C)

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BOC BTDC °C DC F of ft 9 h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s} Fahrenheit foot,1eet gram(s) houris) liter(s) Ib m min N Pa PS psi r rpm TDC TIR V W o pound(s) meter(s) rninutets) newton (5) pascalts) horsepower pound(s) per square inch revolution revolution(s) perminute top dead center total indicator reading volt(s) watt(s) ohm(s) Read OWNER'S MANUAL before operating

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic infonnation to make it useful to the owner who desires 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. Whenever the owner has insufficient experience or doubts his ability to do the work. all adjustments, maintenance, and repair should be carried 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 substi- tute tools may adversely 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 rnainte- nance. • Use proper tools and genuine Kawasaki "JET SKI" watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki "J ET SKI" watercraft are introduced by the Special Tool 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 preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. 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 compre- hensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, 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 Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. AWARNING 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 o This note symbol indicates points of particular interest for more efficient and convenient operation. • Indicates a procedural step or work to be done. o 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.

GENIERAL INFORMiATI'ON 1-1 General Information Before Servic::ing -2 Model ldentifieation ..,.., '..'.' .'..'..'..'" .'.' '..' '..~. ' ,' ' ,.' .' ' ''..," .' ' , '.."' '..,, '..'' ',; -5 General Specifications -7 General Speciticatlons '., .'.' ." ,.. ,.' '..'..' , ,..,..'.' , '.", ' ' '.' ." ,..'..' '.."."." -8 Torque and Locking Agent -9 Period lc Mi 81 intenance Chart , ' '..' ' ,..'.' ..'." ' ' ,..' 11 -11 Technical Information - Mainten!ance Free Battery .,.., , ' ".,., ' '1! -12 (I) Construction -12 (' I, I) Main: Fe,'ature's., .., '.., '.. '., '. '.' ..' '..'..' '.' '.'. '.. '.' .. ,." ..,..'..'..' '.'." ' '.' .' .. ,., 1-12 (1,111,) Pr~nci,ple of Sea!l,ing Structure ".' " ' ,' 1 .. 1.2 ,(IV) Fililing the Batterv with EI,ectr-olyte ,..'.." ' , , ,., 1-13 (V) In! itial Charge ..'.' ..' ' ,. '.,. ,.' ..'. '.'. '.' ,.., '.'. '.. '.' '., '..'. '., ' ' '..'..' ,..'..'..' ' '..' ,..1,- '1~ 4 (VI,) Preca utions' '.'. ,,, .., '..'.. '.' ' ,.' '. '.' ". '.,. '., ..'..'. '.,. '' '.., '., '. ,., ..' ' ,.,1 -1,5, (VI,I) Interchangie,abiility withOrdinarv Battery ..' ' ,.'.,.1'-15, Special Tools, Sealant. "' '., '..'.' ..'..' '.., ' ,.' '..' ' ,." .., ' "..'..' " ' ,..'.' ..1 -16 C,able", Wi:re' and Hose Houtinq.. '.'. '.,. , ' '.' '..'.' '.' ..'.'.' ..,.'..,,'. "' "' ..,..'.."" '.,. '.' ..' '..'..'.., ,." ,1 -1 '9 http://ReadManuals.com

Befor'e startinq to sa,rvice a watercraft, careful reading' of the applicable section is recommended to eliminate unnecessary work. Photoqraphs, diagrams, notes, cautions, warnings, and detaued descriptions, have been included wherever necessary. Nievertheless, even a detailed account has Hm~tations,a certain amount of basic knowledge is also required for successfulwork, Esp,ecialliy note the following,: (1) Adj ustments Adjustm,ents shall be made in accordancewhh the, P'eri,odicMaintenance,Cha:rt or whenever trouble- shooting or presence' of symptoms indicate thatadjustments mav be required, Whenever running of the ,engine is required during maintenance it is best to have the watercraft in water, CAUT10:N Do nolrUin i Ihe eng'lnewllhout cooling waler supply tor ,m,ore Ihan 1'5 seconds or sev,er',s engine and exhaus'lsysiem I da1magie wll',occur. (2) ,Auxiiiiary Cooling An auxiiiarv 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 auxHia:ry coolinq supply, eloos,enthe clamp and remove the cap [A] . • Conn ectthe garden hose' [B ]to the hose fitting (see above). ,.Attach the garden hose '1:0 a faucet :00 nottum on the water until the engine is running and turn it off immediatelv when theenqme stops. The engine requires .2.4 IL/min (2,,5 qts/min) at 18.00 rp,m and 7.0 t/min (7.4 qts/rnin) at 6000 rpm. Insufficient coonngsupply wlU cause the engine and/or ,exhausl syslem 10 ,overheat and seve,r,e damage win occur. : Excess,lve coollngsuppily may kill l1e engine andllood the cyl,lnder., caus,lng hydraulic lock. Hydraulic lock will cause i severe, da.m~a,g'e 10 Ihe ,engl'n.. Ilhe engine dies w'hlile U'sl!ng an auxiliary coollngsupp,ly" the w,aler ,musl be shut oft Immedlalte'ily. Alwa'ys lurnlhe bO,BI on lIB left side. IRoUlnglo the right side can cause w'81'er Inlhe exhausl syslem 10run Into the engine, ! wllh ;posslblie eng!lne dam'a,ge •. http://ReadManuals.com

(3) Dirt Before removal and disassemblv. cileanthe "Jet Ski" watercraft. Any sandenterinq th!eengine,calrbuir,etor, or other parts wiUwork as an abrasive and shorten the I:ife of the watercraft, For the same reason, before installinq a new part, clean off any dust or metal fiNngs. (4) Battery Ground Hernove the ground (-) 'lead from the batterv before performing any disassembly operations on the watercraft Th is,pirevents: (a) the possibility of accidentallv turning thee,ngin,e over whil'e partially disassembled, (b) sparksat electirica,1 connections which Wiitrl occur when they are disconnected., (c) damage to etectrical parts. (5) 'T~ghtening Sequence Generallv, when instaliinqa part with several! bolts, nuts, or screws, they should all be started In their holes and tiqhtensd to snuq fit, Then tighten themeveruv in across pettem, This lis to avoid distortion o,f the part and/or causing gasoroH leakag'e. Converselv when loosening the bolts, nuts" or screws, fiirst loosen alt of them by about a quarter of tumand then remove them, 'Wh,ere there isa tightening sequence indication in this Serv'iceMa,nual, the bolts.nuts, or screwsrnus't be tightened in the order and method indicated. (6) Torque The torque val1u,es given, in this Service :Mianuail should always be adhered to. Either too little, or too much torque may lead to serious dernaqe .. Use a IQ'ood quality, reliabte torque wr!ench. (7) Foree Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especialily difficult to remove or lnstalt stop and exammewhat mav be causing theproblem, Whenever tappinq is necesserv, tap li'ightliv using a wooden or plastic faced im,allet.Use,an impact driver for screws (particulartyfor the removal of screwsheld by a .Iocking agent) n in order to avoid damaging the screw heads. (B) Edges Watch for sharp edges, espec~alliv during imajorengiine disassembtv Bind sssemblv. Protect your hands with grloves or a piece of thick cloth when lifting the enqine or turning it over. (9)H ilg;h FII esh-Point Solvent A high Ilash-point solvent is recommended to reduce fire danger. A,co:mmercial :solventcommonly available ~n North America is Standard solvent (generic name). AtwaysfoUow manufacturer and container directions regarding the use of any solvent, (10) G,ask!et,O- Rilng Do not reuse a giasketor O-iring once it has been in service. The matinq surfaces around the gasket should be free of f01reignmia:tter and perfectly smooth to avoid oil or compression leaks. (11) Liquid 'Gasket, Non-Permla'nent Locking! Agent FoUow manufacturer's directions for cleaninq and preparing surfaces where these compounds win be used. Appliy sparingly. Excessive amounts mav blockengine cooling passaqesand cause serious damage. An example of a non-permanent loekinq aqentcommonlv available iln NorthAmeri,ca'is Loctite Lock !N"Seal (:Bliu,e). (12) Press A part installed using ai press or driver, such asa seat should first be coated with Oii'l on its outer or inner circumference so that i'l wilU go into place smoothlv. (1i 3)8.all Bearinq When installinq ,8 ban beariing, the bearing race which is affe·c1.ed by friction should be pushed bV a suitablle driver. Th;r:spreve:nts severe stress on the bans and races, and prevents races andbaillsfrom ibei.ng dented. Press a ball bearing! until ilt stops at the stop in the hole or on the shaft (14)OiiltSeal: and G.r:e,a:se Seal Heplace any' oill or greas.e seals that were removedwith new ones, as removetqenerallv damages seals, Wh'en pressing in a seal which has manufacturer's marks, press it in with the marks fa:cingout.. Seals should be pressed into place using a suitable driver, which contacts evenlv with the side' of seal, until the face of the seal is even with the end of the hole. http://ReadManuals.com

'1-4 ,GENERAL INF'ORMATION (15) Seal Guide Aseal ,guide is required for certain o ill! or g,re:ase seals duringinstailation to avoid da,mage to the seal lips. Before 8, shaft passes, throug,h a seal, app,ly a II,itt,le, lubricant, preferablyhig,h temperature grease on the lips to reduce' 'rubber to metal friction. (16) Circlip. Retain.ing Ring! Replace any circlips and retaining rings thst were removed with ,new ones, ,as removal weakens and deforms them. When instaIUngcirclip,s, and retaininq rinqs, take care to compress or expand them only enouqh to install them and no more, (17) Cotter Pin Beplaceanv cotter pins that were removed with new ones, as removal deforms and breaks them. (18) Lubrication Engline wear ,is generaUy at its maximum while the engine is war,ming up and before aU the rubbing surfaces have an adequate lubric,8\tiv,ef'iI'!m. Du!ring assembly, oil or g',rea:se (whichever is. mora suitable) should beapplied to any rubbing surface which has lost its, tubricative fitm.O'd glrease, and dilrty alii should be cleaned off. Detenorated grease has lost its tubricative quali:ty andmav contain abrasive for,e'ign particles, Don't use just any oi,l or grease. S,om,e oils and greases in particular should be used only in certain applications: and mav be harmful if used in a:n epplication for which they are not intended. (19) Eli,ectr,icaIW.res AU the electrical wires areeither single-colo!r or two-coior and, with onily a fsw exceptions, must be connected towires of the same color. On any of the two-coilor 'wires ther,a is a greater amount of one color and a lesser amount of a second cotor, so a tw'o-cof,or wire is identified byfiirst the p!rim:ary color and then the seconda.rycolor. For' e'xamp,I,e, a v,e,uow wilrewith th,in red stripes is ref,erlred to as a "yellowlred H wi,re'; it would be ,a "'red/yeUow" wire Ii' the colors were reversed to make red the main color. 'Wire (cross-section) Nairne of Wire Color Red Wire 'Strands Yenow Red Y·eUow/Red (20) Re'pla,oement Parts When there is a replacement. instruction replace these parts with new oneseverv time they are removed, These' replacement parts wiU be dalmaged or lose their ori,ginal function once' removed, (21 )I.nsp'ection When parts have been disassembled, visuaillv inspect these parts for the, following conditions or other da'mag,e'. If there is any doubt a'S to the condition of them, replace them wi,th ne,w ones. Abrasion Crack Hardening Warp Bent Dent Scratch We'air Color chanqe Deterioration Seizure' (22) Se':rviice Data Numbers of servi'ce data i1n this text have'foUowingmeanings: "Standards": Show dime,nsi,ons, or performances which brand-new parts or systems have. "Service limits": Indicate the usablelim'i'ts., ·llf the measurement shows excessive wear or deteriorated performance, replace the damaged parts. http://ReadManuals.com

Kawasaki 900ZXi & 750ZXi JetSki Complete Workshop Service Repair Manual 1995 1996 1997

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