Kawasaki ultra 250x service manual free download. Kawasaki JetSki Watercraft: Owner's and Service Repair Manuals PDF free download
In any case, jet skis should be kept in good condition at all times. Kawasaki STX D. Service Manual. Service Manual [e. Adobe Acrobat Document 3. Adobe Acrobat Document 1. Adobe Acrobat Document 6. Adobe Acrobat Document 4. Adobe Acrobat Document 2. Remember to keep complete records of main-tenance and repair with dates and any newparts installed. The Quick ReferenceGuide shows you all of the products systemand assists in locating their chapters.
Eachchapter in turn has its own comprehensive Ta-ble of Contents. For example, if you want ignition coil informa-. Then, use theTable of Contents on the first page of the chap-ter to find the Ignition Coil section.
WARNINGThis warning symbol identifies specialinstructions or procedures which, if notcorrectly followed, could result in per-sonal injury, or loss of life. CAUTIONThis caution symbol identifies specialinstructions or procedures which, if notstrictly observed, could result in dam-age to or destruction of equipment.
NOTEThis note symbol indicates points of par-ticular interest for more efficient and con-venient operation. Indicates a procedural step or work to bedone. Indicates a procedural sub-step or how to dothe work of the procedural step it follows. Italso precedes the text of a NOTE. Indicates a conditional step or what action totake based on the results of the test or inspec-tion in the procedural step or sub-step it fol-lows.
In most chapters an exploded view illustrationof the system components follows the Table ofContents. In these illustrations you will find theinstructions indicating which parts require spec-ified tightening torque, oil, grease or a lockingagent during assembly.
This model, JTB, is mounted with a four-stroke engine with supercharger. Therefore in this manual, such procedures,which are not shown in SMs for two-strokeengines, are explained thoroughly to cope withthe cases. Refer to the section, After submerging in. Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper-ation on watercraft, read the precautions given below.
To facilitate actual operations, notes, illustra-tions, photographs, cautions, and detailed descriptions have been included in each chapter wherevernecessary. This section explains the items that require particular attention during the removal andreinstallation or disassembly and reassembly of general parts.
Especially note the following:. You need the following items to use the KDS. KDS Software Version 2. 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 cablebetween the ignition switch immobilizer amplifier lead connectors 6-pin [B]. AdjustmentsAdjustments shall be made in accordance with the Periodic Maintenance Chart or whenever trou-.
Whenever runningof the engine is required during maintenance it is best to have the watercraft in water. CAUTIONDo not run the engine without cooling water supply for more than 15 seconds, especiallyin high revolutionary speed or severe engine and exhaust system damage will occur. Auxiliary CoolingAn auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjust-. If possible, always operate the watercraft in water rather than use an auxiliary cooling supply.
Obtain a standard garden hose [A] and a garden hoseadapter [B] as shown. Open the front storage compartment cover. Remove the flushing cap [A] on the brim of the storagecompartment. Screw a garden hose adapter [A] onto the flushing fitting[B]. Attach a garden hose [C] to a garden hose adapter andsecure the hose clamp [D]. Attach the garden hose to a faucet.
Do not turn on the water until the engine is running and turn itoff immediately when the engine stops. The engine requires 2. Excessive cooling supplymay kill the engine and flood the cylin-ders, causing hydraulic lock. Hydraulic lock will cause severe damage to the engine. If theengine dies while using an auxiliary cooling supply, the water must be shut off immediately. Rolling to the right side can cause water in the exhaustsystem to run into the engine, with possible engine damage.
Turningcounterclockwise can cause water in the exhaust system to run into the engine, with pos-sible engine damage. Put a clean clothor plastic sheet over the parts to protect from any foreignmaterials that may collect before re-assembly. Visually inspect removed parts for corrosion, discol-oration, or other damage.
Refer to the appropriate sectionsof this manual for service limits on individual parts. Replacethe parts if any damage has been found or if the part is be-yond its service limit. Gaskets, O-rings, Oil seals,Grease seals, circlips or cotter pins must be replaced withnew ones whenever disassembled. Then tighten them according to the specified se-quence to prevent case warpage or deformation which canlead to malfunction. Conversely when loosening the bolts,nuts, or screws, first loosen all of them by about a quar-ter turn and then remove them.
If the specified tighteningsequence is not indicated, tighten the fasteners alternatingdiagonally. Tighten fasteners to the specifiedtorque using a good quality torque wrench.
When necessary, remove screws that have a non-permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Remove old gaskets and clean the sealingsurfaces thoroughly so that no gasket material or othermaterial remains. Install new gaskets and replace usedO-rings when re-assembling. Do not applythem excessively. Excessive application can clog oil pas-sages and cause serious damage. Be sure to maintain proper alignment and usesmooth movements when installing.
Replace with new ones wheneverremoved. Press bearings with the manufacturer and sizemarks facing out. Press the bearing into place by puttingpressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facingout.
Make sure the seal is aligned properly when installing. Lubri-cation points are called out throughout this manual, applythe specific oil or grease as specified. Ro-tate the crankshaft to positive direction counter-clockwiseviewed from stern sinde. Unless instructed otherwise, electricalwires must be connected to those of the same color. Read the manufactures instructions thor-oughly before using the meter. Incorrect values may leadto improper adjustments.
Bore and Stroke 83 Compression Ratio 7. PerformanceMinimum Turning Radius 4. Overall Height 1 mm Electrical EquipmentBattery 12 V 18 AhMaximum Generator Output 16 A 14 V: This information shown here represents results under controlled conditions, and the informationmay not be correct under other conditions.
Units of VolumeL 0. Units of TorqueNm 0. Units of PressurekPa 0. Periodic Maintenance Chart Engine Lubrication System Engine Top End Engine Bottom End Cooling and Bilge Systems Pump and Impeller Electrical System The scheduled maintenance must be done in accordance with this chart to keep the watercraft ingood running condition.
The initial maintenance is vitally important and must not be neglected. Inspect fuel vent check valve Clean fuel pump screen e Inspect throttle shaft spring replacethrottle body if necessary e The following table list the tightening torque for the major fasteners, and the parts requiring use ofa non-permanent locking agent or silicone sealant. Letters used in the Remarks column mean:EO: Apply oil to the threads and seating surface. MO: Apply molybdenum disulfide grease oil solution. R: Replacement PartS: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant to the threads. Pulley Bolt 19 1. Upper Camshaft Chain Guide Bolts 12 1. Output Shaft SteeringHandlebar Clamp Bolts 16 1. Reverse Bucket Pivot Bolts 19 1. Crankshaft Sensor Cover Bolts 7. Use this table for only the bolts and nuts which do not require a specific torque value. All of thevalues are for use with dry solvent-cleaned threads. If the free play is incorrect, adjust the throttle cable. Check that the throttle lever moves smoothly from fullopen to close, and the throttle closes quickly and com-pletely in all steering positions by the return spring.
If the throttle lever does not return properly, check thethrottle cable routing, cable adjustments, and cable dam-age. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebarall the way to the right and left to ensure that the idle speeddoes not change. If the idle speed increase, check the throttle cable adjust-ment and the cable routing.
Check throttle cable adjustment. With the throttle lever released, the upper stop [A] on thethrottle pivot arm [B] should rest against the stopper [C]on the throttle body, and there should be slight slack inthe throttle cable. When the throttle lever is fully applied pulled , the lowerstop [D] on the pivot arm should be all the way up againstthe stopper on the throttle body. If necessary, adjust the throttle cable. Loosen and turn the locknuts [A] at the bracket until theupper stop on the pivot arm hits against the stopper onthe throttle body with slight cable slack.
Tighten the locknuts securely. Torque - Throttle Cable Locknuts: 20 Nm 2. NOTEMake sure that the throttle pivot arm stops against thestopper on the throttle body with the throttle lever re-leased. Inspect the air box [A] for water inside with its drain cap[B]. If there is water in the cap, remove the cap and dischargethe water. Disconnect the following from the oil separator tank. Install the special tool [A] onto the belt [D] so that the toolstip [B] is aligned with the tensioner plate bolt head [C].
Rotate the special tool keeping it at 90 degrees to thebelt until it touches [A] the face [B] of the idler. If the gauge indicator is without the area of recess, adjustthe belt tension. Loosen the idler bolt [A]. To weaken the belt tension, turn the adjuster [B] counter-clockwise. Start the tip of a screwdriver [A] to the injector [B]. Put Apply the grip end onto your ear, and listen whether the injector is clicking or not. A sound scope can also be used. Do the same for the other injector.
If all the injectors click at a regular intervals, the injectors are good. The click interval becomes shorter as the engine speed rises. If either injector doesnt click, perform the Injector Signal Test for injector operation. Prepare Rating of Bulb [A]: 12 V, 3 3. Terminal Thickness [C]: 0. A larger terminal could damage the injector main harness connector, leading to harness repair or replacement. Remove Connect each nector [C]. Turn While the engine with the starter motor, watch the testcranking lights.
If the test lights flicker at regular intervals, the injector circuit in the ECU and the wiring are good. Perform the Injector Resistance Inspection. Crank the engine with the starter motor, and check to see if the hand oscillates at regular intervals. Special Tool - Hand Tester: If the test light doesnt flicker or the test hand doesnt oscillates , check the wiring and connectors again.
If the wiring is good, check the injector voltage. Remove the connector from the injector [A]. Disconnect Measure the injector resistance with the hand tester [B]. If the reading is out of the range, perform the Injector Unit Test. If the reading is normal, perform the Injector Unit Test for confirmation. Rating of Bulb [C]: 12 V, 3 3. The bulb works as a current limiter to protect the solenoid in the injector from excessive current.
Connect Open and [F] the end of the lead to the battery terminalconnect repeatedly. The injector should click. If the injector does not click, replace the injector. Turn Connect voltmeter [A] to the connector [B], with the needlea digital adapter set. Do not disconnect the connector. Remove Connect voltmeter [A] to the connector [B], with the needlea digital adapter set.
Apply soap and water solution to the areas [E] as shown. Watching the pressure gauge, squeeze the pump lever [H], and build up the pressure until the pressure reaches the maximum pressure.
If the pressure holds steady, the system is good. If the pressure drops at once, or if bubbles are found in the area, the line is leaking. Replace the delivery pipe, injectors and related parts. Repeat the leak test, and check the fuel line for no leakage. Joint Connector 4 Power 12V - Injector 5. Injector 4 6. Injector 3 7. Injector 2 8. Injector 1 9. Fuel Pump Relay. Joint Connector 9 Ground Cntrol. Such a shock to the ECU can damage it.
Connect Apply a non-permanent locking agent to the bolts and tighten them. Visually If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connector is cracked, bent, or otherwise damaged.
If no continuity, check the connector, the engine ground lead, or main harness, and repair or replace them if necessary.
Check Position the terminal in accordance with terminal numbers of ECU connector [B] in this chapter figure. Pushing the start button, run the engine 3 4 seconds. Remove Unscrew the throttle case mounting screws [C] separate the case halves [D]. Disconnect Slide the rubber boots [A] and rubber cap [B] out of the place. Unscrew the throttle cable fitting nut [C]. Lubricate Apply water ble end.
Tighten the cable fitting nut. Cover the cable fitting nut [B] with the rubber boot [C]. Take out the inner pad. Remove Slide the rubber boot out of the place.
Unscrew the throttle cable fitting nut. Remove the upper of the cable from the case. Use a screw driver end [A] to separate the cable tip [B] from the throttle lever catch. Cut Take the throttle cable [E] off the grommet. Pull down the throttle cable. Throttle Cable Check that the throttle lever moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by return spring.
If the throttle lever does not return properly, check the throttle routing, cable adjustments, and cable damage. If the idle speed increases, check the throttle cable adjustment and the cable routing. Remove the air box [A] from the engine compartment. Remove Remove the pulley bolt [A] and bolts [B], holding the pulley with a rotor holder [C] commercial available tool. Check Clean the the pulley. Spin If it is noisy, does not spin smoothly, or has any rough. Confirm whether the bearing absorbs water or salt water.
If it absorbs water or salt water, replace the pulley assy. Idle Speed Standard:. Install Route the harness and tighten the band correctly see Appendix chapter. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.
If any carbon accumulates, wipe the carbon off the throttle bore and throttle valve, using a cotton pad. Replace Install the motor [B] and tighten the screws [C].
With the engine idling, open and close the throttle lever. If the idle speed is within the standard, the ISC operates properly. If the idle speed is out of the specified range, inspect the audible operation.
If the ISC does not sound, replace the steeping motor. Measure the ISC resistance with the hand tester. Special Tool - Kawasaki Hand Tester: Disconnect Disconnect the throttle cable [B] end from the throttle body. Disconnect the harness bolts [B]. Tighten the delivery pipe mounting bolts [B]. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
Start Measure the fuel pressure with the engine idling. Fuel Pressure idling Standard:. The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the fuel filter and measure the fuel pressure again. Remove the fuel pressure gauge and adapter.
Run the fuel hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. Turn Wait until engine cools down. Open the the fuel tank cap [A] to lower the pressure in the tank.
Prepare the fuel supply hose from the fuel delivery Disconnect pipe, and set the measuring cylinder and fuel supply hose. Be sure to hold the measuring cylinder vertical. Turn Push the start button for 3 seconds. Measure the discharge for 3 seconds. After inspection, connect the fuel hose. Start the engine and check for fuel leakage. Such a shock to the pump can damage it. Pull the lanyard key off the stop button.
Disconnect the joint lock. Pull Pull the fuel hose joint [B] out of the fuel pump pipe. Cut Loosen the lower side clamp screw [E] on the rubber fuel pump holder. Pressing down the rubber holder onto the fuel pump, tighten the small diameter clamp [E]. Insert the fuel pump with rubber holder and O-ring into the tank so its fuel hose fittings face starboard side see Cable, Wire, and Hose Routing in Appendix chapter.
And press down the pump so the O-ring [A] completely contacts the top surface of the tank [E]. Tighten the large diameter clamp [F] securely. The main fuel hose is larger than the return fuel hose. If the reading is good, the power source voltage is normal. Inspect the operating voltage. If the reading stays on battery voltage but the pump doesnt work, replace the pump. If the ground and power supply are good, check the fuel pump wiring. System Relay 6.
Fuel Pump Relay 7. Main ECU Relay 8. Joint Connector 3 Switch 12V 9. Fuel Pump. Main Fuse 20A Gasoline is extremely flammable and can be explosive under certain conditions.
Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Remove Unhook the fuel tank straps [A]. Remove Drain the tank into a suitable container. Make sure the area is well ventilated and free from any source of flame or spark; this includes any appliance with a pilot light.
It may be necessary to put a few marbles or pieces of clean gravel into the tank and shake it, to knock loose any foreign matter in the bottom. WARNING Clean the tank in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
Do not use gasoline or a low-flash point solvent to clean the tank. Note Fit [B] the parting line of tube to mark on the tank. Install the lower clamp [A] so that its screw head screw points straight line [B] or inclined line [C]. WARNING Clean the parts in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
Do not use gasoline or a low-flash point solvent. Replace Tighten the fuel filler tube clamp screws. Engine Oil Flow Chart Special Tool and Sealant Engine Oil and Oil Filter Oil Level Inspection Oil Cooler Oil Cooler Removal Oil Cooler Installation Oil Cooler Disassembly Oil Cooler Assembly Oil Cooler Inspection Breather Case and Oil Separator Tank Breather Case Removal Breather Case Installation Oil Separator Tank Removal Oil Separator Tank Installation Blowby Gas System Inspection Oil Pan Oil Pan Removal Oil Pan Installation Oil Pump Sprocket Removal Oil Pump Sprocket Installation Oil Pump Removal Oil Pump Installation Oil Pump Inspection Oil Screen Removal Oil Screen Installation Oil Pressure Relief Valve Inspection Oil Pump Sprocket Chain Removal Oil Pressure Measurement Oil Pressure Switch Oil Pressure Switch Removal Oil Pressure Switch Installation EO: Apply engine oil.
MO: Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1. R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant see text. Oil Level Inspection This watercraft engine is equipped with a semi-dry sump. In the semi-dry sump engine, the oil level difference is very large between the level measured after just stopping and that after leaving for a long time.
It is necessary to check the specified amount of oil is in the engine before starting the engine every day. At this time use the cold mark of the level gauge. Then run the engine to lubricate the engine parts sufficiently.
After that it is necessary to check the level by using hot mark of the level gauge. Whenever checking the engine oil level, keep the watercraft level side to side and fore to aft as much as possible. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light.
If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause. If the oil level is too low, add the oil to the low level line through the oil filter opening see Periodic Maintenance chapter. Use the same type and make of oil that is already in the engine. If the engine oil type and make are unknown, use any brand of the specified oil to top off the level in preference to running the engine with the oil level low.
Then at your earliest convenience, change the oil completely. Ordinary standard Check The preliminary is checked before the ordinary check. Install the removed parts.
Launch the watercraft. Start the engine for several minutes. Ride the watercraft and run the engine at about 5 rpm for 5 minutes. Stop the engine and let it cool down for 10 minutes. Also make the fuel tank [A] full if it is not full as shown to keep the watercraft level. If the oil level is too high, drain the excess oil thoroughly from the dipstick tube [A] using a commercially-available vacuum pump [B].
If the oil level is too low, add the oil to the high level line through the oil filler opening see Periodic Maintenance chapter. Loosen the clamp screws [B] and remove the oil cooler cooling hoses [C] from the oil cooler. Remove Place a rag or cloth [C] under the oil filter to receive the remaining oil.
Unscrew Unscrew the oil passage bolt [B] and remove the oil cooler [C]. Fit the O-ring on the oil cooler [B] securely. Torque - Oil Passage Bolt: 78 Nm 8. Torque - Oil Filter: 18 Nm 1. Remove Turn the oil bly bolts [B]. Apply silicon sealant to the joints and tighten them. Sealant - Kawasaki Bond Silicone Sealant : Torque - Oil Cooler Assembly Bolts: 7. Install the oil cooler see Oil Cooler Installation. Start If the water and oil leak, replace the O-rings.
Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas which can be lethal. Breather Case Installation If the breather pipe [A] removed, install the pipe as follow. Apply grease to the O-ring [B].
Install the O-ring to the short length pipe side [C] of the breather pipe. Apply a non-permanent locking agent to the oil separator tank mounting screws.
Tighten: Be careful not to drop the nuts. If they are not, correct them. Inspect the breather hoses [A], breather pipes and the air filter drain caps for damage or signs of deterioration. Squeeze the hoses. These hoses should not be hard and brittle, nor should be soft or swollen. Replace any damaged hoses.
Check that the hoses and aps are securely connected. The drain cap catches the water or oil from the bottom of the air box housing. Usually water or oil does not collect at the bottom of the housing. In the event that water is drawn in through the duct, or if engine oil is blown back, drain the housing.
Pull the air box drain plugs to drain the water or breather oil when changing engine oil. Unscrew the dipstick tube bolts [A] and pull out the dipstick tube [B]. Torque - Oil Pan Bolts: 7. Apply Apply a bolts. Tighten First, tighten the oil pan side bolt. Next, tighten the cylinder head side bolts. Unscrew Pull out the pump sprocket [F] together with the oil pump sprocketoil chain [G]. Install Insert the tab [C] of the spring plate in the hole [D] of the crankcase.
Pull Remove the outer rotor [C]. Install Apply molybdenum oil solution to the shaft. Assemble the pin [B]disulfide , inner rotor [C] onto the oil pump shaft [D]. Insert Be sure the dowel pin [E] is in place in the pump body. Fit the new O-ring [F] to the groove of the pump body. Fit the oil pump cover and tighten the cover bolts. Remove Visually inspect the oil pump outer, inner rotors and cover. If there is any damage or uneven wear, replace the rotors and cover.
Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents. While cleaning the screen, check for any metal particles that might indicate internal engine damage. If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air.
WARNING Clean the relief valve in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low -flash point solvent. If cleaning does not solve the problem, replace the relief valve as an assembly.
The relief valve is precisely made with no allowance for replacement of individual parts. Apply a non-permanent locking agent to the relief valve. Install the relief valve.
Split the camshaft chain [A] and the oil pump sprocket Remove chain [B]. Launch Start the engine for several minutes. Run the engine pressure gauge. E-mail: downloadboatmanuals gmail. Motors Boats. Here you can free download Kawasaki service manuals. Service Manual [en]. Jet Ski STX. Comments: Connect to Facebook. Use quick search! Contact us. Kawasaki STX D.
