Kawasaki 750SX JET SKI 1994–1998 Service Manual (P/N 99924-1156–01)

• Applies to 1994–1998 Kawasaki 750SX standup models, 1994–1995 750 ST, 1995–1997 750 STS, and 1998 750 STX watercraft variants
• P/N 99924-1156–01
• Features detailed exploded-view diagrams, torque specification tables, and routing schematics for all major shipboard systems
• Details engine bottom and top end clearances, fuel system tuning, and electrical reference values for the twin-cylinder 743 mL engine
• Delivers 522 pages of strictly maintenance-focused technical data
• Covers the jet pump, impeller, steering mechanism, drive system, and reverse bucket
• Outlines electrical system testing, LED warning units, trim motor boxes, ignition coils, and hull fittings

Document Content Walkthrough

This PDF service manual outlines critical parameters for the entire 750 watercraft line, providing structured data for inspection and maintenance tasks. It opens with a quick reference guide detailing shop procedures, locking agent requirements, and precise cable, wire, and hose routing. Moving deeper, the material breaks down fuel system components, including the Keihin CDK40-34 carburetor adjustment, reed valve inspection, and fuel tank service. When handling these fuel systems or performing pressure tests, always ensure proper shop ventilation and observe standard safety practices to mitigate ignition risks.

Further sections document the lubrication, exhaust, and cooling/bilge systems, providing standardized test values for pump output and pressure flushing sequences. The manual provides step-by-step instructions for jobs that usually require an expensive trip to the dealership, such as syncing dual carburetors, calibrating the reverse shift and trim cables, splitting the crankcase, and rebuilding the jet pump assembly. The latter portions focus heavily on engine top and bottom end rebuilds—such as piston-to-cylinder clearance, crankshaft runout, and drive shaft holder service—representing exactly what an OEM service publication covers for these models.

To streamline any diagnostic or troubleshooting workflow, the document is heavily illustrated with Wiring diagrams, Battery Standard Charge Time Charts, circuit diagrams, and periodic maintenance charts. By having this exact factory data directly at the workbench, mechanics can avoid the costly trial-and-error of blindly replacing components, ensuring a precise repair every time.

When executing a repair on these specific Kawasaki models, technicians must be highly aware of a few critical pitfalls. For instance, if the watercraft must be tilted for servicing, always roll it onto its left side; rolling it to the right can force trapped water in the exhaust system directly back into the engine cylinders, causing severe hydraulic lock. Furthermore, test-running the engine dry for more than 15 seconds will rapidly melt the exhaust couplers and cause catastrophic overheating.

Technical Data Preview

Key factory specifications included in this manual:

• Cylinder head torque: 29 N-m (22 ft-lb)
• Fuel tank capacity: 16 L (up to 46 L on select variants)
• Piston ring end gap: 0.25–0.40 mm (top and second rings)
• Flywheel bolt torque: 125 N-m (94 ft-lb)
• Engine oil pump output: 5.9–7.2 mL (at 3000 rpm across a two-minute test interval)

This reference provides the exact tolerances mechanics and owners need to safely overhaul the 1994–1998 Kawasaki 750 series drivetrain and chassis.