Kawasaki ULTRA 250X/260X/260LX Jet Ski Watercraft Repair Service Manual 2007-2010

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This workshop service repair manual PDF download for the 2007-2010 Kawasaki Jet Ski Watercraft ULTRA 250X, ULTRA 260X, ULTRA 260LX (JT1500xxx) has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

ULTRA 250X
ULTRA 260X
ULTRA 260LX

Year – Model
Beginning Hull No.

2007 – JT1500B7F
US-KAW30001□607
US-KAW39001□607

2008 – JT1500B8F
US-KAW40001□708
US-KAW49001□708

2009 – JT1500E9F
US-KAW10001□809
US-KAW19001□809

2009 – JT1500F9F
US-KAW90001□809

2010 – JT1500EAF
US-KAW70001□910
US-KAW79001□910

2010 – JT1500FAF
US-KAW80001□910

TABLE OF CONTENTS :

General Information
Periodic Maintenance
Fuel System (DFI)
Engine Lubrication System
Exhaust System
Engine Top End
Engine Removal/Installation
Engine Bottom End
Cooling and Bilge Systems
Drive System
Pump and Impeller
Steering
Hull/Engine Hood
Electrical System
Storage
Appendix

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99924-1377-04
Total Pages : 545

This kawasaki manual contains enough detail and basic information 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.

This kawasaki service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table
Periodic Maintenance
Periodic Maintenance Chart
Torque and Locking Agent
Specifications
Special Tools
Periodic Maintenance Procedures
Fuel System
Throttle Control System Inspection
Air Box Drain Cap Inspection and Cleaning
Supercharger Drive Belt for Wear/Damage and Belt Tension Inspection
Supercharger Gear Oil Level Inspection
Fuel Vent Check Valve Inspection
Fuel Pump Screen Cleaning
Throttle Shaft Spring Inspection
Engine Lubrication System
Engine Oil Change
Oil Filter Replacement
Engine Top End
Air Suction Valve Inspection (JT1500B7F Model)
Valve Clearance Inspection
Engine Mounting Bolts Inspection and Tightness
Engine Bottom End
Coupling Damper Inspection
Cooling and Bilge Systems
Cooling System Flushing
Bilge System Flushing
Pump and Impeller
Impeller Inspection
Steering
Steering Cable/Shift Cable Inspection
Handlebar Pivot Lubrication
Hull/Engine Hood
Drain Plug Inspection
Electrical System
Battery Charging Condition Inspection
Battery Terminals Inspection
Spark Plug Inspection
Lubrication
All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check
Nuts, Bolts, and Fasteners Tightness Inspection
Hose and Hose Connect Inspection
Rubber Strap Inspection
Fuel Hose Replacement
Apply Corrosion Protection Coating to the Supercharger Rotors
Replace Grease Seal
Fuel System (DFI)
Fuel System Diagram
Exploded View
Specifications
Special Tools and Sealant
DFI Parts Location
DFI System
DFI Servicing Precautions
Self-Diagnosis
Self-diagnosis Outline
Service Code (Character) Table
Troubleshooting the DFI System
Throttle Sensor (Service Code/Character-11/tPS)
Throttle Sensor Removal/Adjustment
Input Voltage Inspection
Output Voltage Inspection
Resistance Inspection
Inlet Air Pressure Sensor (Service Code/Character-12/bOSt)
Inlet Air Pressure Sensor Removal
Inlet Air Pressure Sensor Installation
Input Voltage Inspection
Output Voltage Inspection
Inlet Air Temperature Sensor (Service Code/Character-13/AIrt)
Inlet Air Temperature Removal/Installation
Output Voltage Inspection
Sensor Resistance Inspection
Water Temperature Sensor (Service Code/Character-14/AqUt)
Water Temperature Sensor Removal/Installation
Output Voltage Inspection
Sensor Resistance Inspection
Charging Temperature Sensor (Service Code/Character-19/PrET)
Charging Temperature Sensor Removal/Installation
Output Voltage Inspection
Sensor Resistance Inspection
Crankshaft Sensor (Service Code/Character-21/CrAg)
Crankshaft Sensor Removal/Installation
Crankshaft Sensor Inspection
Camshaft Position Sensor (Service Code/Character-23/CAA1)
Camshaft Position Sensor Removal/Installation
Camshaft Position Sensor Inspection
Vehicle-down Sensor (Service Code/Character-31/dOS)
Vehicle-down Sensor Removal
Vehicle-down Sensor Installation
Vehicle-down Sensor Inspection
Immobilizer Amplifier (Service Code/Character-35/IdA)
Amplifier Input Voltage Inspection
Key Collation Error (Service Code/Character-36/IdEr)
User Key Inspection
Ignition Coils (Service Code/Character-51, 52/COL1, COL2)
Ignition Coil Removal/Installation
Input Voltage Inspection
Engine Overheating (Service Code/Character-71/HEAt)
Low Engine Oil Pressure (Service Code/Character-72/OILP)
Oil Temperature Sensor (Service Code/Character-73/OILt)
Oil Temperature Sensor Removal/Installation
Output Voltage Inspection
Sensor Resistance Inspection
Main (ECU) Relay and System Relay (Service Code/Character-75/rEL)
Relay Assembly Removal
Relay Assembly Inspection
Engine Oil Overheating (Service Code/Character-76/OILH)
Charging (Intake) Temperature Overheating (Service Code/Character-78/CHAr)
Fuel Injectors
Fuel Injector Removal
Fuel Injector Installation
Audible Inspection
Injector Signal Test
Injector Resistance Inspection
Injector Unit Test
Injector Voltage Inspection
Injector Fuel Line Inspection
ECU
ECU Removal
ECU Installation
ECU Power Supply Inspection
DFI Power Source
Main Fuse Inspection
Relay Assembly Removal
Relay Assembly Inspection
Throttle Lever, Cable and Case
Free Play Inspection
Throttle Cable Adjustment
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Throttle Cable Removal
Throttle Cable Installation
Throttle Case and Cable Lubrication
Throttle Cable Inspection
Air Box
Air Box Removal
Air Box Installation
Supercharger
Supercharger Removal
Supercharger Installation
Supercharger Disassembly
Supercharger Assembly
Supercharger Drive Belt Replacement
Air Bypass System
Relief Valve Inspection
Blow off Valve Inspection
Throttle Body Assy
Idle Speed Inspection
High Altitude Performance Adjustment
Throttle Body Assy Removal
Throttle Body Assy Installation
Throttle Body Assy Disassembly
Throttle Bore Cleaning
ISC (Idle Speed Controller) Removal
ISC (Idle Speed Controller) Inspection
ISC Resistance Inspection
Inlet Manifold
Inlet Manifold Removal
Inlet Manifold Installation
Fuel Line
Fuel Hose Removal
Fuel Hose Installation
Fuel Pressure Inspection
Fuel Flow Rate Inspection
Fuel Vent Check Valve
Fuel Vent Check Valve Mounting
Fuel Vent Check Valve Inspection
Fuel Pump
Fuel Pump Removal
Fuel Pump Installation
Power Source Voltage Inspection
Operating Voltage Inspection
Fuel Pump Relay Removal
Fuel Pump Relay Inspection
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Filler and Tube Removal
Fuel Filler and Tube Installation
Engine Lubrication System
Exploded View
Engine Oil Flow Chart
Specifications
Special Tool and Sealant
Engine Oil and Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Replacement
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 (JT1500B7F Model)
Breather Case Installation (JT1500B7F Model)
Oil Separator Tank Removal
Oil Separator Tank Installation
Blowby Gas System Inspection
Oil Pan
Oil Pan Removal
Oil Pan Installation
Oil Pump Sprocket, Oil Pump and Oil Pressure Relief Valve
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 Chain Removal
Oil Pressure Measurement
Oil Pressure Measurement
Oil Pressure Switch
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Exhaust System
Exploded View
Exhaust Pipe and Muffler Body
Exhaust Pipe and Muffler Body Removal
Exhaust Pipe and Muffler Body Installation
Exhaust Pipe and Muffle Body Cleaning and Inspection
Exhaust Manifold
Exhaust Manifold Removal
Exhaust Manifold Installation
Exhaust Manifold Cleaning and Inspection
Water Box Muffler
Water Box Muffler Removal
Water Box Muffler Installation
Water Box Muffler Inspection
Engine Top End
Exploded View
Specifications
Special Tools and Sealant
Clean Air System
Air Suction Valve Removal (JT1500B7F Model)
Air Suction Valve Installation (JT1500B7F Model)
Air Suction Valve Check (JT1500B7F Model)
Clean Air System Hose Inspection (JT1500B7F Model)
Cylinder Head Cover
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Camshaft, Camshaft Chain
Camshaft Removal
Camshaft Installation
Piston TDC Finding
Camshaft, Camshaft Cap Wear
Camshaft Runout
Cam Wear
Camshaft Chain Removal
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Warp
Valves
Valve Clearance Check
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve-to-Guide Clearance Measurement (Wobble Method)
Valve Seat Inspection
Valve Seat Repair
Cylinder, Pistons
Cylinder Removal
Piston Removal
Piston/Cylinder Installation
Cylinder Wear
Piston Wear
Piston Ring, Piston Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Engine Removal/Installation
Exploded View
Engine Removal/Installation
Engine Removal
Engine Damper Removal
Engine Damper Installation
Engine Installation
Engine Bottom End
Exploded View
Specifications
Special Tools and Sealant
Coupling
Coupling/Output Shaft Removal
Coupling/Output Shaft Installation
Coupling Damper Inspection
Output Cover Oil Seal Replacement
Oil Seal Inspection
Magneto Cover Bearing Replacement
Ball Bearing Lubrication
Ball Bearing Inspection
Magneto Flywheel
Magneto Flywheel Removal
Magneto Flywheel Installation
Stator
Stator Removal
Stator Installation
Crankcase Splitting
Crankcase Splitting
Crankcase Assembly
Crankshaft and Connecting Rods
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Wear
Crankshaft Main Bearing Insert/Journal Wear
Crankshaft Side Clearance
Crankshaft Runout
Cooling and Bilge Systems
Exploded View
Sealant
Bilge System
Breather Removal
Breather Installation
Breather Cleaning and Inspection
Filter Removal
Filter Installation
Filter Cleaning and Inspection
Cooling and Bilge System Hoses
Hose Removal
Hose Installation
Hose Inspection
Cooling and Bilge System Flushing
Cooling System Flushing
Bilge System Flushing
Intercooler
Intercooler Removal
Intercooler Installation
Intercooler Disassembly/Assembly
Cooling and Bilge System Flow Diagram
Check Valve Inspection (JT1500E9F ∼ /F9F ∼ Models)
After Submerging
Summary Procedures after Submerging
Detailed Procedures after Submerging
Drive System
Exploded View
Specification
Special Tools
Drive Shaft/Drive Shaft Holder
Drive Shaft Removal/Installation
Drive Shaft Holder Removal/Disassembly
Drive Shaft Holder Assembly/Installation
Drive Shaft Runout
Pump and Impeller
Exploded View
Specifications
Special Tools and Sealant
Pump and Impeller
Pump Removal
Pump Installation
Pump Disassembly
Pump Assembly
Impeller Inspection
Impeller Outside Diameter Measurement
Pump Inspection
Impeller Clearance
Water Filter Cover Removal/Installation
Steering
Exploded View
Special Tools
Steering Cable
Steering Cable Adjustment
Steering Cable Removal
Steering Cable Installation
Steering Cable Inspection
Steering Cable Lubrication
Handlebar
Handlebar Removal
Handlebar Installation
Steering
Steering Removal
Steering Installation
Adjustable Steering Holder Disassembly
Adjustable Steering Holder Assembly
Reverse System
Shift Cable Adjustment
Shift Cable Removal
Shift Cable Installation
Shift Cable Inspection
Shift Cable Lubrication
Reverse Bucket Removal/Installation
Shift Lever Shaft Removal/Installation
Hull/Engine Hood
Exploded View
Fittings
Seat Removal (JT1500B7F ∼ B8F/E9F ∼ Models)
Seat Installation (JT1500B7F ∼ B8F/E9F ∼ Models)
Seat Removal (JT1500F9F ∼ Models)
Seat Installation (JT1500F9F ∼ Models)
Front Storage Compartment Cover Removal
Front Storage Compartment Cover Disassembly
Front Storage Compartment Cover Assembly
Center Storage Lid Removal/Installation
Side Cover Removal
Side Cover Installation
Front Access Cover Removal/Installation
Center Access Cover Removal/Insatallation
Mirror Removal/Installation
Handrail Plate Removal
Handrail Plate Installation
Handrail Removal/Installation
Drain Plug Housing Removal
Drain Plug Housing Installation
Exhaust Outlet Removal
Exhaust Outlet Installation
Stabilizer Removal
Stabilizer Installation
Reboarding Step Removal
Reboarding Step Installation
Hull Replacement
Rubber Parts
Rubber Parts Location
Rivet Removal
Rivet Installation
Front Bumper Removal
Front Bumper Installation
Rear Bumper Removal
Rear Bumper Installation
Side Bumper Removal
Side Bumper Installation
Air Duct Removal
Air Duct Installation
Electrical System
Parts Location
Exploded View
Wiring Diagram
Specifications
Special Tools and Sealant
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Cover Removal/Installation
Battery Removal
Battery Installation
Electrolyte Filling
Initial Charge
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Electric Starter System
Starter Relay Removal
Starter Relay Installation
Starter Relay Inspection
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Brush Lead Inspection
Brush Plate and Terminal Bolt Inspection
Reduction Gear Removal/Installation
Reduction Gear Inspection
Charging System
Magneto Output Voltage
Regulator/Rectifier Removal/Installation
Regulator/Rectifier Inspection
Regulator Inspection
Ignition System
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Timing Rotor Removal
Timing Rotor Installation
Crankshaft Sensor Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Camshaft Position Sensor Removal
Camshaft Position Sensor Installation
Camshaft Position Sensor Inspection
Igniter Removal/Installation
Igniter Inspection
Spark Plug Removal
Spark Plug Installation
Spark Plug Inspection
Spark Plug Adjustment
Spark Plug Cleaning
Kawasaki Smart Steering System
Steering Position Sensor and Magnet Removal
Steering Position Sensor and Magnet Installation
Inspection of Kawasaki Smart Steering System
Steering Position Sensor Clearance
Steering Position Sensor Input Voltage Inspection
Steering Position Sensor Output Voltage Inspection
Sensors
Speed Sensor Removal/Installation
Speed Sensor Inspection
Fuel Level Sensor Inspection
Throttle Sensor Removal/Installation
Throttle Sensor Inspection
Water Temperature Sensor Inspection
Inlet Air Temperature Sensor Inspection
Oil Temperature Sensor Inspection
Charging Temperature Sensor Inspection
Multifunction Meter
Meter Unit Inspection
Immobilizer System
Operational Cautions
Key Registration
Immobilizer System Parts Replacement
Immobilizer System Inspection
Relay Assembly
Relay Assembly Removal
Relay Assembly Installation
Relay Assembly Inspection
Switches
Switch Inspection
Fuse
Inspection
Storage
Preparation for Storage
Cooling System
Bilge System
Engine Oil
Fuel System
Engine
Battery
Engine Mounting Bolts
Lubrication
Supercharger
General
Removal from Storage
Lubrication
General Inspection
Fuel System
Supercharger
Test Run
Appendix
Cable, Wire and Hose Routing
Troubleshooting Guide

 

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Kawasaki ULTRA 250X/260X/260LX Jet Ski Watercraft Repair Service Manual 2007-2010.pdf

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