This service and repair workshop manual covers Kawasaki Personal Watercraft (PWC) models from the 300-650 Series, manufactured between 1976 and 1991. These watercraft are powered by reliable two-stroke engines, available in 440 cc, 550 cc, and 650 cc displacements, and utilize Mikuni or Keihin carburetors. Engineered for performance and durability, these PWCs are designed for recreational use on the water, offering a robust platform for various water activities. The manual details specific models including JS300, JS400, JS440, JS550, JS650, and the JB650 Jet Mate, ensuring comprehensive support for a wide range of these classic Kawasaki machines.
The purpose of this manual is to provide detailed guidance for the repair, maintenance, and troubleshooting of your Kawasaki Personal Watercraft. It encompasses essential procedures such as engine tune-ups, fuel system servicing, lubrication recommendations, and detailed storage guidelines. The manual also includes in-depth troubleshooting for starting, charging, and ignition systems, as well as engine and steering issues. With clear instructions and technical specifications, this resource is an indispensable tool for owners, mechanics, and technicians seeking to maintain optimal performance and longevity of their 300-650 Series Kawasaki PWC.
Models Covered
JS300 (1976-1991)
JS300SX (1976-1991)
JS400 (1976-1991)
JS440 (1976-1991)
JS440SX (1976-1991)
JS550 (1976-1991)
JS550SX (1976-1991)
JS650SX (1976-1991)
JF650TS (1976-1991)
JL650SC (1976-1991)
JS650X-2 (1976-1991)
JB650 Jet Mate (1976-1991)
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Service Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE GENERAL INFORMATION
Manual organization Notes, cautions and warnings Safety first Service hints Engine operation Clearing a submerged Jet Ski Torque specifications Fasteners Lubricants RTV Gasket sealant Threadlocking compound Parts replacement Basic hand tools Special tools Mechanics tips Specifications
CHAPTER TWO TROUBLESHOOTING
Operating requirements Troubleshooting tools Starting system Charging system Ignition system Stop switch relay Fuel system Engine two-stroke pressure testing Steering
CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP
Operational check list Lubrication Recommended fuel mixture Fuel mixing Starter gear oil Control cable lubrication Periodic maintenance Fuel vent check valve inspection Oil tank vent valve fuel filter Flame arrester Impeller Rubber coupler On-shore cooling Steering cable adjustment Trim cable adjustment Throttle cable adjustment Choke cable adjustment Engine tune-up Retorque cylinder head Compression test Spark plug Ignition timing Carburetor adjustment Fuel mixture screw initial setting Fuel mixture adjustment idle speed Carburetor synchronization Storage Specifications
CHAPTER FOUR ENGINE (440 AND 550 CC)
Engine lubrication Service precautions Serial numbers Servicing engine in hull Removal installation Engine top end Cylinder Piston, pin and rings Crankcase and crankshaft Specifications
CHAPTER FIVE ENGINE (650 AND 750 CC)
Engine lubrication Service precautions Serial numbers Servicing the engine in the hull Engine Engine top end Cylinder Piston, pin and rings Reed valve assembly Crankcase and crankshaft Water drain valve Starter reduction gear Specifications
CHAPTER SIX DRIVE TRAIN
Drive shaft Jet pump Reverse system Specifications
CHAPTER SEVEN FUEL AND EXHAUST SYSTEMS
Flame arrestor Mikuni carburetor Keihin carburetor Fuel pump Fuel tank Main fuel valve Exhaust system Exhaust system cleaning and inspection Specifications
CHAPTER EIGHT ELECTRICAL SYSTEMS
Battery Charging system Electric starting system Capacitor discharge ignition CDI RPM limiter Electric box Bilge pump test Bilge blower Temperature sensor switch Stop and start switches Specifications
CHAPTER NINE OIL INJECTION SYSTEM
Oil pump service Oil tank Oil level sensor Oil tank check valve Oil pump Specifications
CHAPTER TEN BILGE SYSTEM
Vacuum-type bilge system Electric bilge system Specifications
CHAPTER ELEVEN STEERING AND HULL REPAIR
Steering assembly Trim adjuster Hull repair Deck frame Specifications
INDEX
WIRING DIAGRAMS
This manual can be used by anyone from a first time owneramateur to a professional technician.Easy to read type, And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
File Format PDF
Compatible All Versions of Windows & Mac
Language English
Requirements Adobe PDF Reader & WinZip
Models Covered
JS300 (1976-1991)
JS300SX (1976-1991)
JS400 (1976-1991)
JS440 (1976-1991)
JS440SX (1976-1991)
JS550 (1976-1991)
JS550SX (1976-1991)
JS650SX (1976-1991)
JF650TS (1976-1991)
JL650SC (1976-1991)
JS650X-2 (1976-1991)
JB650 Jet Mate (1976-1991)
***********************
Service Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE GENERAL INFORMATION
Manual organization Notes, cautions and warnings Safety first Service hints Engine operation Clearing a submerged Jet Ski Torque specifications Fasteners Lubricants RTV Gasket sealant Threadlocking compound Parts replacement Basic hand tools Special tools Mechanics tips Specifications
CHAPTER TWO TROUBLESHOOTING
Operating requirements Troubleshooting tools Starting system Charging system Ignition system Stop switch relay Fuel system Engine two-stroke pressure testing Steering
CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP
Operational check list Lubrication Recommended fuel mixture Fuel mixing Starter gear oil Control cable lubrication Periodic maintenance Fuel vent check valve inspection Oil tank vent valve fuel filter Flame arrester Impeller Rubber coupler On-shore cooling Steering cable adjustment Trim cable adjustment Throttle cable adjustment Choke cable adjustment Engine tune-up Retorque cylinder head Compression test Spark plug Ignition timing Carburetor adjustment Fuel mixture screw initial setting Fuel mixture adjustment idle speed Carburetor synchronization Storage Specifications
CHAPTER FOUR ENGINE (440 AND 550 CC)
Engine lubrication Service precautions Serial numbers Servicing engine in hull Removal installation Engine top end Cylinder Piston, pin and rings Crankcase and crankshaft Specifications
CHAPTER FIVE ENGINE (650 AND 750 CC)
Engine lubrication Service precautions Serial numbers Servicing the engine in the hull Engine Engine top end Cylinder Piston, pin and rings Reed valve assembly Crankcase and crankshaft Water drain valve Starter reduction gear Specifications
CHAPTER SIX DRIVE TRAIN
Drive shaft Jet pump Reverse system Specifications
CHAPTER SEVEN FUEL AND EXHAUST SYSTEMS
Flame arrestor Mikuni carburetor Keihin carburetor Fuel pump Fuel tank Main fuel valve Exhaust system Exhaust system cleaning and inspection Specifications
CHAPTER EIGHT ELECTRICAL SYSTEMS
Battery Charging system Electric starting system Capacitor discharge ignition CDI RPM limiter Electric box Bilge pump test Bilge blower Temperature sensor switch Stop and start switches Specifications
CHAPTER NINE OIL INJECTION SYSTEM
Oil pump service Oil tank Oil level sensor Oil tank check valve Oil pump Specifications
CHAPTER TEN BILGE SYSTEM
Vacuum-type bilge system Electric bilge system Specifications
CHAPTER ELEVEN STEERING AND HULL REPAIR
Steering assembly Trim adjuster Hull repair Deck frame Specifications
INDEX
WIRING DIAGRAMS
This manual can be used by anyone from a first time owneramateur to a professional technician.Easy to read type, And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
File Format PDF
Compatible All Versions of Windows & Mac
Language English
Requirements Adobe PDF Reader & WinZip
