1994–1998 Kawasaki 750SX, 750 ST, 750 STS & 750 STX Jet Ski Service Manual Set

The model-specific supplements describe changes to the base manual’s service procedures. The STS update chapters also rely on the ST supplement and preceding updates.

Coverage limitations: The ST/STS portion skips printed pages 11-8–11-9, 16-18–16-19, 16-32–16-33, 16-38–16-39, and 18-2–18-3; these pages are absent from the PDF.

The STX wiring sheet depicts three ignition coils and three spark plugs, while its engine specification lists a twin-cylinder engine. That wiring sheet requires particular caution when identifying the applicable ignition circuit.

PDF Format and Chapter Navigation

Text search and wiring detail: An embedded OCR text layer supports searches through the service text. Circuit-label recognition is unreliable, and small wiring labels require zooming. PDF bookmarks provide navigation to the main volumes, chapters, and many individual procedures.

One printable, English-language 522-page PDF, including the introductory information page, publication covers and front matter, and 18 unnumbered, otherwise blank pages.

Engine, Jet Pump, and Trim Service

The following selected topics illustrate the repair coverage rather than reproduce the full contents. Other sections address storage preparation and corrosion protection.

• Engine repair: Step-by-step engine removal, top-end disassembly, crankcase separation, piston inspection, and crankshaft condition checks, with assembly views and service limits.

• Carburetors and fuel delivery: Keihin CDK40-34 service, dual CDK40-31 synchronization, reed-valve inspection, throttle and choke adjustment, and fuel tank service.

• Lubrication and cooling: Oil-pump bleeding and output testing, cooling and bilge flushing, hose inspection, and exhaust-system removal and assembly information.

• Jet pump and driveline: Pump disassembly and reassembly, impeller inspection, clearance measurement, drive shaft holder service, and coupling alignment information.

• Steering, trim, and reverse: Steering cable adjustment, standup handle-pole service, reverse bucket checks, and variant-specific trim cable and motor-box procedures.

• Electrical diagnosis: Starter and charging tests, ignition-coil checks, LED warning-unit diagnosis, sensor inspection, wiring diagrams, and switch continuity tables.

Written primarily for trained mechanics in properly equipped shops, these manuals also support owners undertaking basic maintenance and repair with the mechanical knowledge and tools specified for the work.

Internal Engine and Driveline Repair

The engine sections document piston-to-cylinder clearance, cylinder wear, ring inspection, connecting-rod play, and crankshaft runout. Exploded views connect assembly details with torque, lubrication, and locking-agent requirements.

Crankshaft inspection and assembly dimensions are included, but the base manual expressly excludes a crankshaft disassembly procedure because specialized equipment is required. It directs crankshaft rebuilding to a properly equipped shop.

Drive shaft holder service covers bearings and seals, with alignment information for engine installation. Factory tool references include Impeller Wrench 57001-1228 and Rotor Holder 57001-1368.

Carburetor Variants and Fuel-System Checks

The fuel sections distinguish the single-carburetor arrangement from the dual-carburetor setup used in the STS and STX material. The Fuel System Diagram and Cable, Wire and Hose Routing drawings show the associated fuel, pulse, oil, and control connections.

Step-by-step synchronization procedures accompany the dual-carburetor information. Carburetor cleaning, diaphragm and needle inspection, and float-arm checks provide detail beyond mixture adjustment alone; the fuel pump is treated as a replacement unit rather than an internally rebuildable assembly.

When handling these fuel systems, ensure proper shop ventilation and observe the manual’s precautions against ignition risks.

Cooling, Exhaust, and Hull Service

The cooling and bilge sections explain flushing and obstruction checks, while the exhaust material addresses expansion chambers, joints, and water box mufflers. Hull sections cover fittings, hatch hardware, bumpers, and bonded rubber parts.

Handling cautions differ between variants: using the wrong rolling direction can allow exhaust water into the engine. The cooling cautions also explain how running without an adequate water supply can damage the engine and exhaust system.

Electrical Tests and Trim Fault Isolation

The Warning/Indicator Lights System Wiring Diagram links the LED unit with the fuel, oil, and temperature sensors. Battery Standard Charge Time Charts accompany the charging information, including the sealed-battery material in the later supplements.

The Electric Trim Nozzle Troubleshooting Guide and trim-control voltage and continuity tables help relate a malfunction to its power supply, wiring, switches, motor, or sensors before replacement parts are selected. Later updates distinguish revised trim controls, limit switches, and reverse-switch operation.

Preview: Piston-Ring, Fastener, and Oil-Pump Data

For the 750SX top end, the standard end gap is 0.25–0.40 mm for both the top and second piston rings.

The base manual lists cylinder-head nut torque at 29 N-m (22 ft-lb) and flywheel bolt torque at 125 N-m (94 ft-lb), alongside the relevant assembly requirements.

Its oil-pump performance test specifies an output of 5.9–7.2 mL at 3000 rpm over two minutes. This value belongs to the base-manual test, rather than serving as a blanket specification for every supplement.