1992-1998 Kawasaki 900 PWC Jet Ski Repair Manual – PDF DOWNLOAD

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1992-1998 Kawasaki 900 PWC Jet Ski Repair Manual – PDF DOWNLOAD

FILE DETAILS:

1992-1998 Kawasaki 900 PWC Jet Ski Repair Manual – PDF DOWNLOAD

Language : English
Pages : 295
Downloadable : Yes
File Type : PDF
Size: 44.7 MB

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

1992-1998 Kawasaki 900 PWC Jet Ski Repair Manual – PDF DOWNLOAD

1- DESCRIPГION & OPERATION Shallow Water Operation 2-6
Flame Arrestors 2-7
BRIEF HISTORY 1-1 Fuel System 2-7
PRINCIPLES OF OPERATION 1-2 Excessive Noise 2-8
ENGINE & JET DRIVE 1-3 Automotive Replacements 2-8
Coo1ing System 1-4 BOATING ACCIDENТ REPORTS 2-8
Bilge Breather 1-5 SECURITY 2-8
IMPELLERS 1-6
REPL.\CEMENТ PARTS 1-6 3- TUNING
DEBRIS REMOVAL 1-6
REVERSE CAPAВILITY 1-7 INTRODUCTION 3-1
SPECIAL FE.\TURES 1-8 TUNE-UP SEQUENCE 3-1
RP:M Limiteг 1-8 COMPRESSION СНЕСК 3-2
Throtde Opening Limiter 1-8 SPARK PLUG INSPECTION 3-3
Self-Circling Mode 1-8 ELECTRICAL POWER SUPPL У 3-3
“Maintenance I<~ree11 Batteries 3-4
2- SAFETY Standard Batteries 3-4
INTRODUCTION 2-1 Jurnper СаЫеs 3-4
Craft Classification 2-1 CARBURETOR ADJUSTMENT 3-5
Information 2-1 Fuel & Fucl Tanks 3-5
Regulation Enforcement 2-2 Dгaining Fuel Tank 3-5
MINIMUM LEGAL REQUIRE– Lo,v Speed & Idle Adjustments 3-6
MENTS 2-2 SPECIAL TACHOMETER \VORDS 3-б
Peгsonal Flotation Devices 2-2 FUEL PUMPS 3-7
Fire Extinguisher 2-4 Remote Fuel Pump 3-7
MINIMUM LEGAL REGISTRA- Integral Fuel Pump 3-7
TION REQUIRE1’1ENTS 2-5 CRANKING MTR. & SOI,ENOID 3-8
SAFETY PRACTICES 2-5 Cranking Motor Tesr 3-8
Solenoid test 3-8
MOST IMPORTANT WORDS JET PUMP 3-8
IN THIS МANUAL 2-5 Gate Position 3-8
Impeller 3-8
Full Тhrottle Operation 2-5
Jumping Waves 2-6 4- МAINTENANCE
Alcohol & Substaпce Use 2-6
Age Restrictions 2-6 INТRODUCTION 4-1
Speed Restгictions 2-6 Mter Use Tasks 4-2
Page: 1 – Kawasaki – PWC Jet Ski 1992-1998 Repair Manual – http://www.ReadManuals.Com
4- МAINTENANCE (CONTINUED) Spark Plug Evaluation 5-8
4-2
Cooling CRANKING SYSTEM FAILURES 5-9
Flushing Cooling System 4-3 Faulty Symptoщs 5-10
Controlling Corrosion 4-3 Cranking Circuit Т ests 5-10
Pump Impeller 4-3 Cranking Motor Relay 5-12
SERIAL NUMBERS 4-4 Relay Removal 5-13
LUBRICATION 4-4 Relay Т esting 5-13
Relay lnstallation 5-14 Тhrottle СаЫе 4-5
CНARGING SYSTEM
Steeгing СаЫе 4-5 Fuel/Oil Mixture 4-7 1-‘fALFI.JNCTIONS 5-15
TROUBLESHOOTING CНARTS 5-16 11Break-in11 4-7
Jet Рuшр 4-7
INSPECTION & SERVICE 4-7 6- FUELAND OIL
Fuel Tank, Check Valve & Filter4-7
Sediment Bowl 4-8 INTRODUCTION 6-1
Fuel Tank Filters 4-8 GENERAL CARВURETION
1 n-Line Filter 4-8 INFOR:MATION 6-1
Oil Filter 4-8 FПEL COMPONENTS & А V AILDrain
Plug 4-8 АВLЕ GAS 6-3
FLUSHING Leaded Gasoline 6-3
Cooling System 4-9 Fuel Filteг & Sediшeпt Bowl 6-4
Bilge Systeш 4-9 In-Line Fuel Filter б-4
IMPELLER CLEARANCE 4-9 Fuel Tank Screen Filteгs 6-4
PRE-SEASON PREPARATION 4-10 Air/Fuel Mixture 6-5
SEALANTS, LUBRICANTS, ЕТС. 4-13 Throttle & Choke V aJves 6-5
FIBERGLASS HlJLLS 4-14 FUEL Рt;-:МР 6-5
SUBMERGED ENGINE SERVICE4-14 Remote Pump 6-5
Salt Water Submersion 4-14 Iнtegral Fuel Pump 6-5
Submerged \Vhile Operatin.g 4-15 OIL INJECTION 6-5
Fresh Water Submersiop 4-15 Fue]/Oil Mixture 6-6
WINTER STORAGE 4-16 нвreak-in11 Lubrication 6-6
PRE-SEASON СНЕСК 4-17 Removing Fuel fгom System 6-7
ENGINE REVOLLТTION
5- ТROUBLESHOOTING LIMITER 6-7
TROUBLESHOOTING 6-7
INТRODUCTION ,lj-1 Fuel ProЫems 5-7
Lower than Normal RPM 5-1 Fuel Filter & Sediment Bowl 6-8
Higher than Normal RPM 5-1 “Sour11 Fuel 6-8
Engine TrouЬleshooting 5-2 Choke ProЫems 6-8
Cranking System Т est 5-2 Rough Enginc Idle 6-8
Ignition System Test 5-2 Excessive Fuel 6-9
Compression Test 5-3 Engine Surge 6-9
LЕАК. DOWN PROCEDURE 5-5 CARВURETOR MODELS 6-9
FUEL SYSTEM PROBLE:МS 5-5 SERVICE KEIHIN CDK-34 6-9
Engine Surge •• 5-6 Reшoval & DisasseшЬling 6-10
Rough Engine Idle 5-7 Cleaning & Inspecting 6-14
IGNITION SYSTEM FAlJL TS 5-7 Exploded D1·awing 6-15
Inteгщittent ProЬlems 5-8 AssemЫing 6-16
Page: 2 – Kawasaki – PWC Jet Ski 1992-1998 Repair Manual – http://www.ReadManuals.Com
Installation б-1 g
Priming 6-21
Mixtur~ Screws w/Limiter Сар~б-22
Idle AdJustment Screw 6-22
Low & High Speed Adjustmentб-22
High Altitude Operation 6-22
Choke СаЫе Adjustment 6-23
Throttle СаЫе Adjustment 6-23
SERVICE KEIHIN CDK-38 & 40
САRВ URETOR w/INTEGRAL
FUEL PUMP
Disassembling
“Front” Side
11Back11 Side
Cleaning & Inspecting
Exploded Drawing
AssemЫ:ing
Installation
Priming
Choke СаЫе Adjustment
Тhrottle СаЫе Adjustment
REMOTE FUEL PUMP
Theory of Operation
Pump Pressure Check
Pump Volume Check
Servicing Fuel Pump
Remo~al & DisassemЫing
Cleamng & Inspecting
AssemЫing
OIL INJECTION
Oil Mixture
“Break-in11 Period
Systeш Components
Oil Tank
Oil Injection Pump
System Inspection
Oil Pump Output Test
TrouЬleshooting
First Checks — Delivery
Purging Air from System
Purging Air from Pump
7- IGNITION
Rich Mixture
Тоо Cool
Fouled
Carbon Deposits
Overheating
Electrode Wear
CDI (CAPACITOR DISCНARGE
IGNITION) & CНARGING SYS. 7-4
Description & Operation —
Ignition Circuit 7-4
Opeгation 7-5
Special Timing Words 7-5
TrouЬleshooting CDI 7-5
Spark Plugs 7-5
Compression 7-6
Testing Ignition Components 7-7
Elec. Вох Removal — 550 & 650 7-8
Elec. Вох Removal — АН Others 7-8
Exciter Coil Test — 550 7-9
Pulser Coil Test — 550 7-9
Exciteг Coil Test — 650 7-9
Igniter Test — 550 & 650 7-10
lgniter Removal — 550 & 650 7-10
Ign.Coil Winding Test — 550 &
650 — Secondary Winding 7-10
Ign. Coil Winding Test — 750,
900 & 1100 — Primary 7-11
Secondary Winding 7- 12
CDI Igniters — Removal.
Installation 7-12
Pickup Coil — 750, 900 & 1100 7-12
IGNITION TIMING ADJUSTMENТS
Timing — 550 & 650
Dynamic Check
Magneto AssemЫy
Adjusting Timing
CНARGING CIRCUIT 7-17
Description & Operation 7-17
TrouЫeshooting 7-19
Testing Coil Output 7-19
Coil Resistance Test 7-21
INTRODUCTION & СНАРТЕR Exciter Coil Test — 750 7-21
COVERAGE 7-1 – Exciter Coil Test — 900 7-21
SPARK PLUG EV ALUATION 7-1 Charging Coil Output — 1100 7-21
Correct_Color . 7-2 Charg. Coil Resistance — 1100 7-21
Page. З – Kawasak1 – PWC Jet Ski 1992-1998 Repair Manual – http://www.ReadManuals.Com
8- ENGINE EXPLODED DR.i-\ WINGS 8-55
AssemЫing Continues 8-57
INТRODUCTION & СНАРТЕR Piston I nstallation 8-58
ORGANIZATION 8-1 Reed Block/Intake Manifold 8-61
ТWO-CYCLE ENGINE Exhaust Manifold Installation 8-61
DESCRIPГION & OPERATION 8-2 Cylinder Head Installation 8-61
Intake/Exhaust 8-2 Flywheel Installation 8-63
Lubrication 8-2 Coupler Installation 8-63
Physical Laws 8-2 Flywheel Cover Installation 8-64
Actual Opeгation 8-3 Oi] Рuш р I 11stallatio11 8-64
Timing 8-3 Cranking Motor Installation 8-65
SERVICE ТWO-CYLINDER ENGINE INSTALL.\.TION
ENGINES 8-3 THREE-CYLINDER SERIES 8-65
Preliшinaгy Task — Engine Engine Support Equipment 8-66
Overhaul 8-1 CLEANING & INSPECTING
Removal 8-4 ALL ENGINES 8-67
DisassemЫing 8-9 Reed Block Ser,1ice 8-68
Cranking Mtr. Rешщгаl 8-10 Crankshaft Service 8-68
11Pulling11 Fly,vheel 8-11 Connecting Rod Service 8-70
Magneto A”semЫy 8-13 Piston Service 8-70
Block DisassemЬling 8-14 Cyliпder Block Service 8-74
Ai,semЫing & Installation 8-20 Piston Clearance 8-75
Exploded Drawings 8-21 Honing Cylinder ‘\,Valls 8-75
Lower Half 8-26 Block & Cyl. Head Warpage 8-77
Piston Installation 8-28 SEALANTS, LUBRICANTS, ЕТС. 8-78
Block Installation · 8-30
Cylinder Head 8-31 9- ELECTRJCAL
Flywheel Installation 8-34
Cranking Motor Installation 8-37 INTRODПCTION 9-1
Engine Installation 8-39 BAТГERIES 9-1
Engine Alignment 8-39 PvV С В atteries 9-1
Fuel Tank Installation 8-41 Construction 9-1-
Oil Tank Installation 8-42 Battery Ratings 9-2
SERVICE THREE-CYLINDER
Ampere-Hour 9-2
ENGINE 8-45
Cold Cranking Perf ormancc 9-2
Engine Reшoval 8-45
Reseгve Capacity 9-2
Exhaust Manifold Removal 8-46
\1/att-Hour 9-2
Eпgine Disasseшbliпg 8-47
Installation 9-2
Service 9-2
Cranking Motor Removal 8-48
Testiнg 9-4
Pulling the Fl ywheel 8-48
Cylinder Head Removal 8-50
Hydrometers 9-5
Exhaust Manifold Removal 8-51
Cl1argiпg 9-6
Intake Manifold Removal 8-51
Installing 9-6
Block DisassemЬling 8-52
Jumper СаЫеs
Сгапkсаsе Separation 8-54
Storage 9-7
Crankshaft Disassembling 8-54
TACHOMETER 9-7
· ELECTRICAL SYSTEM — GENASSEMBLING
& INSTALLATION ERAL INFORМATION 9-8
THREE-CYLINDER ENGINE 8-54 Cranking Motor Circuit 9-8
Page: 4 – Kawasaki – PWC Jet Ski 1992-1998 Repair Manual – http://www.ReadManuals.Com
Ignition 9-9
CRANKING MOTOR CIRCUIT 9-9
Тhеогу о[ Operation 9-9
Cranking Motor N oises 9-1 О
Faulty Symptoms 9-11
CRANKING MOTOR TROUBLESHOOTING
9-11
Circuit Tests 9-11
Motor Relay Removal
for Testing 9-12
Relay Testing 9-14
Relay Iнstallation 9-14
CRANKING MOTOR SERVICE 9-15
Desc1·iprion 9-15
Diagrams Inside Elec. Вох 9-16
Motor Remova] 9-18
DisassemЫing 9-18
Cleaning & Inspecting 9-21
Testing Motor Parts 9-24
Assembling 9-26
Installation 9-27
TESTING OTHER ELECTRICAL
COMPONENTS 9-30
Start Button Test 9-31
Safety Switcl1 9-31
Stop Switch 9-31
Stop Switch Relay 9-31
Electric Bilge Purnp 9-32
Electric Fan 9-32
Ternperature Warning Sys. 9-32
Overheat Buzzer 9-33
ELECTRIC TRIM SYSTEM 9-33
10 JET PUMP
INТRODUCTION
Model Identificatioн and
10-1
Chapter Coverage 10-1
Jet Pump Descгiption 10-2
Axial Flow 10-2
Mixed Flo,v 10-2
IMPELLERS 10-3
Cavitation Burns 10-3
Cooling Water and Bilge Hosesl0-4
IMPELLER-TO-PПMP CASE
CLEARANCE 10-5
AxiaJ Flow Pump 10-5
Mixed Flow Pump 10-6
JET PIJMP SERVICE 10-6
Removal 10-7
Impeller Alignment 10-9
DisassemЬling 10-1 О
Impeller Reшoval 10-12
Impelleг Shaft Removal 10-13
Cleaning & Inspecting 10-15
Exploded Dгюvings 10-1 б
AssemЫing 10-20
Shimming Procedures — 550 10-21
Impeller Installation –550 10-23
Irnpeller Installation — All
Others 10-25
Pump Installation 10-27
BEARING HOUSING SERVICE 10-30
Removal 10-30
DisassemЫing 10-31
Cleaning & Inspecting 10-32
11 CONТROL ADJUSTMENTS
INTRODПCTION
STEERING CABLE
REVERSE САВLЕ
TRIM САВ1.Е
APPENDIX
METRIC CONVERSION СНАRТ
RECOMMENDED TORQПE
VALUES
ENGINE SPECIFICATIONS AND
TUNE-lТP ADJUSТ:MENТS
WIRING DIAGRAМS & COLOR
CODE IDENТIFICATION
Model 550 Series
Model 650 Series
11odel 7 50 Series
Model 750 Hi-Performance
Model 900 Hi-Performance
Model 1100 Hi-Performance

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