2004-2006 Kawasaki 900 STX Jet Ski Service Manual
Original Kawasaki service manual covers all maintenance and repair aspects of Kawasaki Jet Ski 900 STX.
Kawasaki P/N 99924-1327-03 covers the following models:
Year 2004 - Model JT900-E1 - Hull # begins KAW70001x304
Year 2005 - Model JT900-E2 - Hull # begins US-KAW60001x405
Year 2006 - Model JT900E6F - Hull # begins US-KAW20001x506
x - this digit in the hull number changes from one machine to another.
Manual chapters:
- General Information
- Periodic Maintenance
- Fuel System
- Engine Lubrication System
- Exhaust System
- Engine Top End
- Engine Removal/Installation
- Engine Bottom End
- Cooling and Bilge System
- Drive System
- Pump and Impeller
- Steering
- Hull/Engine Hood
- Electrical System
- Storage
- Appendix
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Full list of manual chapters:
Cover
Table of Contents
Foreword
General Information
Before starting to service a watercraft, careful reading of the
Especially note the following
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Two-Color Electrical
(20)
(21)
JT900-E1 Left Side View:
JT900-E1 Right Side View:
Outline
Kawasaki Smart Steering System Circuit
Prefixes for Units:
Units of Temperature:
Periodic Maintenance
The following table list the tightening torque for the major fas
All Hoses and Hose Clamps Check
Hoses and Hose Connections Inspection
Rubber Strap Inspection
Fuel System
Carburetor Cable Adjustment
Oil Pump Cable Adjustment
Choke Cable Adjustment
Idle Speed Adjustment
Carburetor Synchronization
Fuel Filter Inspection
Fuel Filter Screen Cleaning
Fuel Vent Check Valve Mounting
Fuel Vent Check Valve Inspection
Flame Arrester Cleaning
Carburetor Throttle Shaft Spring Inspection
Engine Bottom End
Coupling Damper Inspection
Cooling and Bilge Systems
Cooling System Flushing
Bilge System Flushing
Filter Cleaning and Inspection
Pump and Impeller
Impeller Inspection
Steering
Steering Cable Inspection
Steering Cable Adjustment
Torque -
Steering Cable Lubrication
Shift Cable Inspection
Shift Cable Adjustment
Shift Cable Lubrication
Handlebar Pivot Lubrication
Electrical System
Battery Charging Condition Inspection
Spark Plug Inspection
Spark Plug Adjustment
Spark Plug Cleaning
General Lubrication
All Nuts, Bolts, and Fasteners Check
Nuts, Bolts, and Fasteners Tightness Inspection
Nut, Bolt and Fastener to be checked
Fuel System
The throttle control cable is actually an assembly of three cabl
Carburetor Cable Adjustment
Oil Pump Cable Adjustment
Throttle Case and Throttle Control Cable Removal
Throttle Case and Throttle Control Cable Installation
Torque -
Torque -
Choke Cable Adjustment
Choke Knob and Cable Removal
Choke Knob and Cable Installation Notes
Torque -
Cable Removal
Cable Installation
Idle Speed Adjustment
High Altitude Performance Adjustment
Carburetor Synchronization
Carburetor Removal
Carburetor Installation Notes
Torque -
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning and Inspection
Float Arm Level Inspection and Adjustment
Fuel Pump Removal/Installation Note
Flame Arrester Removal
Installation Notes
Torque -
Flame Arrester Cleaning
Intake Manifold Removal
Intake Manifold Installation
Torque -
Torque -
Reed Valve Inspection
Valve Holder Inspection
Reed Stop Inspection
Fuel Tank Removal
Fuel Tank Installation Note
Removal
Installation Notes
Cleaning
Fuel Filter Inspection
Engine Lubrication System
Oil Pump Bleeding
Torque -
Oil Pump Performance Test
Oil Pump Cable Removal
Oil Pump Cable Installation Note
Torque -
Oil Pump Removal
Oil Pump Installation
Torque -
Oil Tank Removal
Oil Tank Installation
Oil Tank Cleaning
Oil Filter Cleaning
Exhaust System
Expansion Chamber Removal
Expansion Chamber Installation Notes
Torque -
Torque -
Cleaning and Inspection
Exhaust Manifold Removal
Exhaust Manifold Installation Notes
Torque -
Exhaust Manifold Cleaning and Inspection
Water Box Muffler Removal
Water Box Muffler Installation Notes
Water Box Muffler Inspection
Engine Top End
Compression Gauge, 20 kgf/cm :
Disassembly and Assembly
Disassembly
Special Tool -
Assembly Notes
Special Tools -
Torque -
Torque -
Compression Measurement
Special Tools -
Cylinder Head Warp Inspection
Cylinder Wear Inspection
Piston Diameter Measurement
Piston/Cylinder Clearance
Piston Ring, Piston Ring Groove Inspection
Piston Ring End Gap
Engine Removal/Installation
Removal
Installation Notes
Torque -
Torque -
Engine Bottom End
Rotor Puller Adapter, 8:
Removal
Special Tools -
Installation Notes
Torque -
Coupling Damper Inspection
Removal
Special Tool -
Special Tool -
Special Tool -
Installation Notes
Special Tool -
Torque -
Torque -
Torque -
Removal
Installation Notes
Torque -
Splitting
Assembly
Sealant -
Torque -
The crankshaft changes the reciprocating motion of the piston in
Connecting Rod Bend/Twist
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Main Bearing Wear
Crankshaft Runout
Cooling and Bilge System
Breather Removal
Breather Installation
Breather Cleaning and Inspection
Filter Removal/Installation
Filter Cleaning and Inspection
Hose Removal
Hose Installation
Hose Inspection
Cooling System Flushing
Bilge System Flushing
Drive System
Bearing Driver Set:
Drive Shaft Removal/Installation
Special Tool -
Torque -
Drive Shaft Holder Removal/Disassembly
Drive Shaft Holder Assembly/Installation
Special Tool -
Torque -
Drive Shaft Runout
Pump and Impeller
Oil Seal and Bearing Remover:
Pump Removal
Pump Installation
Sealant -
Torque -
Sealant -
Torque -
Torque -
Torque -
Pump Disassembly
Special Tools -
Special Tool -
Special Tool -
Special Tool -
Pump Assembly
Special Tool -
Torque -
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Special Tools -
Torque -
Special Tool -
Torque -
Torque -
Pump and Impeller Inspection
Impeller Clearance
Water Filter Cover Removal/Installation
Torque -
Steering
Box Wrench (27 mm):
Steering Cable Adjustment
Steering Cable Removal
Special Tool -
Steering Cable Installation
Torque -
Torque -
Steering Cable Inspection
Steering Cable Lubrication
Handlebar Removal
Handlebar Installation Note
Torque -
Torque -
Removal
Installation Notes
Torque -
Torque -
Torque -
Shift Cable Adjustment
Shift Cable Removal
Special Tool -
Shift Cable Installation Notes
Torque -
Shift Cable Inspection
Shift Cable Lubrication
Reverse Bucket Removal/Installation
Torque -
Shift Lever Shaft Removal/Installation
Sealant -
Torque -
Hull/Engine Hood
Hatch Cover Removal
Rear View Mirror Removal/Installation
Stabilizer Installation
Torque -
Storage Case Removal/Installation
Storage Case Cover Assembly
Crossmember Removal/Installation
Torque -
To replace the hull, remove the various parts in the following s
NOTE
Rubber Parts Location
Front Bumper Removal/Installation
Rear Bumper Removal/Installation
Side Bumper Removal
Side Bumper Installation
Electrical System
Dummy Page
Hand Tester:
Battery Removal
Battery Installation
Charging Condition Inspection
Refreshing Charge
Starter Relay Removal
Starter Relay Installation
Inspection
Special Tool -
Special Tool -
Reduction Gear Removal/Installation Notes
Reduction Gear Inspection
Starter Motor Removal
Starter Motor Installation Notes
Torque -
Starter Motor Disassembly
Starter Motor Assembly
Starter Motor Brush Inspection
Starter Motor Brush Spring Inspection
Starter Motor Commutator Cleaning and Inspection
Starter Motor Armature Inspection
Starter Motor Brush Plate Inspection
Starter Motor Brush and Lead Assembly Inspection
Charging Coil Testing
Regulator/Rectifier Removal/Installation
Regulator/Rectifier Inspection
Special Tool -
Charging System Circuit
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Torque -
Crankshaft Sensor Inspection
Ignition Coil Removal
Ignition Coil Installation Note
Ignition Coil Inspection
CDI Igniter Inspection
Ignition Coil Primary Peak Voltage
Special Tools -
Crankshaft Sensor Peak Voltage
Special Tool -
Special Tool -
Air Temperature Sensor Input Voltage Inspection
Special Tool -
Water Temperature Sensor Input Voltage Inspection
Special Tool -
Special Tool -
Overheat Diagnosis Output Voltage Inspection
Special Tool -
Spark Plug Removal
Spark Plug Installation
Torque -
Spark Plug Inspection
Spark Plug Adjustment
Spark Plug Cleaning
Ignition System Circuit
Removal
Installation Notes
Torque -
Disassembly
Assembly Notes
Throttle Sensor Removal/Installation
Throttle Sensor Inspection
Special Tools -
Throttle Sensor Adjustment
Fuel Level Sensor Inspection
Special Tool -
Oil Level Sensor Inspection
Special Tool -
Air Temperature Sensor Inspection
Water Temperature Sensor Removal/Installation
Silicone Grease -
Torque -
Water Temperature Sensor Inspection
Speed Sensor Inspection
Special Tool -
Display Function Inspection
Fuel Level Gauge/Symbol/FUEL Characters/ Warning Light Inspectio
Oil Level Gauge/Symbol/OIL Characters/ Warning Light Inspection
Speedometer Inspection
Speed Sensor Electric Source Inspection
Tachometer Inspection
Battery Symbol/bAt Characters/ Warning Light Inspection
Heat Symbol/Heat Characters/ Warning Light Inspection
MODE/SET Button Inspection
Multifunction Meter Circuit
Steering Position Sensor and Magnet Removal
Steering Position Sensor and Magnet Installation
Smart Steering System Inspection
Steering Position Sensor Clearance Inspection
Steering Position Sensor Input Voltage Inspection
Special Tool -
Steering Position Sensor Output Voltage Inspection
Special Tool -
Smart Steering Actuator Removal
Smart Steering Actuator Installation
Torque -
Torque -
Torque -
Smart Steering Actuator Inspection
Smart Steering System Circuit
Switch Inspection
Special Tool -
Ignition Switch
Starter Button
Stop Button
Inspection
Storage
During the winter, or whenever the watercraft will not be in use
Cooling System
Bilge System
Fuel System
Engine
Battery
Lubrication
General
Lubrication
General Inspection
Fuel System
Test Run
Appendix
