Kawasaki X-2 (JF800A6F) Jet Ski Watercraft Repair Service Manual 2006

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This workshop service repair manual PDF download for the 2006 Kawasaki Jet Ski Watercraft X-2 (JF800A6F) 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 :

Year – Model – Beginning Hull No.
2006 – JF800A6F – US-KAW60001□506

TABLE OF CONTENTS :

General Information
Periodic Maintenance
Fuel 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 : 99924-1378-01
Total Pages : 247

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.

tables
LIST OF ABBREVIATIONS
Required cooling water for the engine
Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
General Fasteners (stainless bolt and nut)
Idle Speed
Battery Terminal Voltage
Spark Plug Gap
Pop-off Pressure
Float Arm Level
Reed Warp
Cylinder Compression (Usable Range)
Cylinder Head Warp
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Oversize Pistons and Rings
Piston Ring End Gap
Shim Selection
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Runout (Either Location)
Pop Rivet Removal Drill Bit Size
Drive Shaft Runout
Impeller Outside Diameter
Pump Case Inside Diameter
Impeller Clearance
Rivet Removal Drill Bit Size
Terminal Voltage: 11.5 ∼ less than 12.8 V
Terminal Voltage: less than 11.5 V
Starter Motor Brush Length
Commutator Diameter
Charging Coil Output Voltage
Charging Coil Resistance
Regulator/rectifier Resistance
Crankshaft Sensor Resistance
3 Needle Arcing Distance
Winding Resistance
Primary Lead Connections
Ignition Coil Primary Peak Voltage
Crankshaft Sensor Peak Voltage
Start Switch Resistance
Stop Switch Resistance
Water Temperature Sensor Resistance
Inlet Air Temperature Sensor Resistance
toc
Read OWNER’S MANUAL before operating.
MAINTENANCE AND ADJUSTMENTS
EMISSION CONTROL INFORMATION
Foreword
General Information
Before starting to service a watercraft, careful reading of the
Adjustments
Auxiliary Cooling
Battery Leads
Edges of Parts
Cleaning solution
Cleaning Watercraft before Disassembly
Arrangement and Cleaning of Removed Parts
Storage of Removed Parts
Inspection
Replacement Parts
Installation, Assembly
Tightening Sequence
Torque
Force
Gasket, O-Ring
Liquid Gasket, Locking Agent
Press
Ball bearing
Oil Seal, Grease Seal
Lubrication
Circlips, Cotter Pins
Direction of Engine Rotation
Electrical Leads
Instrument
JF800-A1 Left Side View
JF800-A1 Right Side View
Hull No.
Engine No.
Prefixes for Units:
Units of Temperature:
Periodic Maintenance
The scheduled maintenance must be done in accordance with this c
The following tables list the tightening torque for the major fa
Fuel System
Idle Speed Adjustment
Carburetor Synchronization
Throttle Cable Adjustment
Torque –
Choke Cable Adjustment
Torque –
Fuel Filter Screen Cleaning
Fuel Vent Check Valve Inspection
Flame Arrester Cleaning and Inspection
Torque –
Throttle Shaft Spring Inspection
Engine Bottom End
Coupling Damper Inspection
Cooling and Bilge Systems
Cooling System Flushing
Bilge System Flushing
Impeller
Impeller Inspection
Steering
Steering Cable Inspection
Steering Cable Lubrication
Handlebar Pivot Lubrication
Hull/Engine Hood
Drain Plug Inspection
Electrical System
Battery Charging Condition Inspection
Battery Terminals Inspection
Spark plug inspection
Spark Plug Adjustment
Spark Plug Cleaning
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 System
Watercraft Strap Tool:
Throttle Cable Adjustment
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Torque –
Throttle Cable Removal
Throttle Cable Installation
Throttle Case and Cable Lubrication
Throttle Cable Inspection
Choke Cable Adjustment
Choke Cable Removal
Choke Cable Inspection
Choke Cable Lubrication
Choke Knob Removal
Choke Knob Installation
Idle Speed Adjustment
Mixture Screw Adjustment
High Altitude Performance Adjustment
Carburetor Synchronization
Carburetor Removal
Carburetor Installation
Torque –
Torque –
Carburetor Disassembly
Carburetor Assembly
Torque –
Torque –
Torque –
Torque –
Torque –
Carburetor Cleaning and Inspection
Pop-off Pressure Inspection
Float Arm Level and Diaphragm Inspection and Adjustment
Fuel Pump Removal
Fuel Pump Installation
Fuel Filter Inspection and Cleaning
Flame Arrester Removal
Flame Arrester Installation
Flame Arrester Cleaning
Inlet Manifold and Reed Valve Removal
Inlet Manifold and Reed Valve Installation
Torque –
Reed Valve Inspection
Reed Valve Holder Inspection
Reed Valve Stop Inspection
Fuel Tank Removal
Special Tool –
Fuel Tank Installation
Torque –
Fuel Tank Cleaning
Fuel Filler and Tube Removal
Fuel Filler and Tube Installation
Fuel Filter Screen Cleaning
Fuel Tap Removal
Fuel Tap Installation
Fuel Tap Cleaning
Exhaust System
Expansion Chamber Removal
Expansion Chamber Installation
Torque –
Torque –
Expansion Chamber Cleaning and Inspection
Exhaust Manifold Removal
Exhaust Manifold Installation
Torque –
Exhaust Manifold Cleaning and Inspection
Water Box Muffler Removal
Water Box Muffler Inspection
Engine Top End
Compression Gauge, 20 kgf/cm :
Disassembly and Assembly
Disassembly
Special Tool –
Assembly
Special Tools –
Torque –
Torque –
Torque –
Torque –
Maintenance and Inspection
Compression Measurement
Special Tools –
Cylinder Head Warp Inspection
Cylinder Wear Inspection
Piston Diameter Measurement
Piston/Cylinder Clearance
Boring and Honing
Piston Ring, Piston Ring Groove Inspection
Piston Ring End Gap
Engine Removal/Installation
Engine Removal
Engine Mount Removal
Engine Mount Installation
Torque –
Engine Installation
Torque –
Torque –
Engine Bottom End
Coupling Holder:
Removal
Special Tools –
Installation
Torque –
Coupling Damper Inspection
Removal
Special Tool –
Special Tool –
Installation
Torque –
Torque –
Removal
Installation
Splitting
Assembly
Sealant –
Torque –
The crankshaft changes the reciprocating motor of the piston int
Connecting Rod Bend/Twist
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Main Bearing Wear
Crankshaft Runout
Crankshaft Assembly Specifications
Cooling and Bilge Systems
Breather Removal
Breather Installation
Breather Cleaning and Inspection
Bilge Filter Removal
Bilge 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
Special Tool –
Drive Shaft Holder Assembly/Installation
Special Tool –
Sealant –
Torque –
Drive Shaft Runout
Pump and Impeller
Oil Seal & Bearing Remover:
Pump Removal
Pump Installation
Torque –
Torque –
Pump Disassembly
Special Tool –
Special Tool –
Special Tools –
Pump Assembly
Special Tool –
Special Tool –
Torque –
Torque –
Pump and Impeller Inspection
Impeller Outside Diameter Measurement
Impeller Clearance
Steering
Box Wrench (27 mm):
Steering Cable Adjustment
Steering Cable Removal
Special Tool –
Torque –
Steering Cable Installation
Torque –
Torque –
Steering Cable Inspection
Steering Cable Lubrication
Hand Grip Removal/Installation
Handlebar Removal
Handlebar Installation
Torque –
Torque –
Steering Removal
Steering Installation
Torque –
Torque –
Torque –
Hull/Engine Hood
Engine Hood Opening
Engine Hood Closing
Engine Hood Removal
Engine Hood Installation
Latch Removal
Latch Installation
Catch Removal
Catch Installation
Tool Holder Removal
Tool Holder Installation
Seat Removal
Seat Installation
Battery Bracket Removal
Battery Bracket Installation
Electric Case Bracket Removal
Electric Case Bracket Installation
Seat Hook Removal
Seat Hook Installation
Drain Plug Housing Removal
Drain Plug Housing Installation
Exhaust Outlet Removal
Exhaust Outlet Installation
Rivet Removal
Rivet Installation
Front Bumper Removal
Front Bumper Installation
Corner Bumper Removal
Corner Bumper Installation
Side Bumper Removal
Side Bumper Installation
Rear Bumper Removal
Rear Bumper Installation
NOTE
Rubber Parts Location
Electrical System
Hand Tester:
JF800-A1
Battery Removal
Battery Installation
Battery Management
Precautions
1)
2)
3)
4)
Interchange
Charging Condition Inspection
Refreshing Charge
Charging Condition Inspection
Reduction Gear Removal/Installation
Reduction Gear Inspection
Starter Motor Removal
Starter Motor Installation
Torque –
Starter Motor Disassembly
Starter Motor Assembly
Torque –
Brush Inspection
Brush Spring Inspection
Commutator Cleaning and Inspection
Armature Inspection
Brush Plate Inspection
Brush and Lead Assembly Inspection
Starter Relay Removal
Starter Relay Installation
Starter Relay Inspection
Special Tool –
Special Tool –
Charging System Inspection
Regulator/Rectifier Removal
Regulator/Rectifier Installation
Torque –
Regulator/rectifier Inspection
WARNING
Crankshaft Sensor Inspection
Special Tool –
Ignition Coil Removal
Ignition Coil Installation
Torque –
Ignition Coil Inspection
CDI Igniter Removal
CDI Igniter Installation
Torque –
Ignition Coil Primary Peak Voltage Inspection
Special Tools –
Crankshaft Sensor Peak Voltage Inspection
Special Tools –
Spark Plug Removal
Spark Plug Installation
Torque –
Spark Plug inspection
Spark Plug Adjustment
Spark Plug Cleaning
Electric Case Removal
Electric Case Installation
Torque –
Electric Case Disassembly
Torque –
Torque –
Torque –
Start/Stop Switch Removal
Start/Stop Switch Installation
Start/Stop Switch Inspection
Special Tool –
Special Tool –
A water temperature sensor is installed on the exhaust Pipe. Whe
Water Temperature Sensor Removal
Water Temperature Sensor Installation
Torque –
Water Temperature Sensor Inspection
Special Tool –
Inlet Air Temperature Sensor Removal
Inlet Air Temperature Sensor Installation
Inlet Air Temperature Sensor Inspection
Special Tool –
Switch Inspection
Special Tool –
Start Switch
Stop Switch
Tether Switch
Fuse Inspection
Storage
During the winter, or whenever the watercraft will not be in use
Cooling System
Bilge System
Fuel System
Torque –
Engine
Battery
Lubrication
General
Lubrication
General Inspection
Fuel System
Test Run
Appendix
Starting difficulty or failure to start
Ignition System
Spark
No spark
Fuel system (check that fuel tank contains fuel)
Outside Carburetor
Inside Carburetor
Battery/Starter System
Engine starts but stops right away
Compression
Fuel System
Outside Carburetor
Inside Carburetor
Electrical System
Engine misfires, does not run smoothly
Fuel System
Fuel mixture too lean
Fault in Carburetor
Other
Fuel mixture too rich
Fault in Carburetor
Other
Electrical System
Other
Weak Spark
Abnormal engine sound
During normal cruising
During sudden acceleration
Pinging
When the engine is idling while cold
Low engine power (This trouble often has more than one cause, an
Ignition System
Fuel System
Other
Overheating
Heavy Fuel Consumption
Poor performance though engine runs properly
Jet Pump
Poor steering control (Since faulty steering is dangerous, this
Handlebar pivot nut too tight

 

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Kawasaki X-2 (JF800A6F) Jet Ski Watercraft Repair Service Manual 2006.pdf

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