Kawasaki 900 STX 2004–2006 PWC Base Service Manual (JT900-E1)

This Kawasaki 900 STX service manual contains 16 chapters of base-manual content for 2004-2006. Factory identification, specification, and wiring pages are labeled JT900-E1; some model/year applications require a separate supplement, which is not included.

Searchable PDF and Chapter Bookmarks

Search and diagram detail: An OCR text layer supports searches across the manual, and embedded bookmarks open chapters and selected subsections. Occasional OCR errors can affect individual search terms. Small wiring labels require zooming for comfortable reading.

Supplied as one printable 244-page PDF in English, including one introductory note page and seven otherwise blank pages.

Engine, Jet-Pump, and Smart Steering Service

Selected coverage: These highlights are not a complete table of contents. Additional topics include fuel-vent check-valve inspection and battery storage care.

• Engine repair: Step-by-step top-end disassembly and reassembly, compression testing, complete engine removal and installation, crankcase splitting, and crankshaft/connecting-rod checks.

• Fuel and oil injection: Carburetor removal, cleaning, overhaul and synchronization, high-altitude adjustment, throttle/choke/oil-pump cable setup, reed-valve inspection, and oil-pump bleeding and performance testing.

• Jet pump and drive: Drive-shaft holder and pump disassembly, bearing and seal replacement, impeller service, and shaft-runout and wear-clearance inspection.

• Steering and reverse: Steering-cable adjustment, handlebar and steering-shaft service, reverse-bucket and shift-cable work, plus Smart Steering cable setup.

• Electrical diagnosis: Ignition fault isolation, charging and starter tests, sensor and multifunction-meter checks, and Smart Steering sensor/actuator diagnosis with wiring diagrams and flowcharts.

• Maintenance and reference: Periodic maintenance charts, cooling and bilge flushing, storage preparation and return-to-service checks, exploded views, torque/locking-agent tables, and routing illustrations.

Written for trained mechanics working in an equipped shop, the manual also supports owners handling basic maintenance and selected repairs who understand mechanical fundamentals, proper tool use, and workshop practice. Owners who lack that experience are referred to qualified mechanics.

Engine Inspection and Fuel-System Repair

Top-end repair data covers cylinder-head warp, cylinder wear, piston diameter, piston-to-cylinder clearance, ring-groove condition, and ring end gap. These specifications support measured inspection when evaluating parts during a rebuild.

Bottom-end sections add coupling-damper inspection, magneto flywheel and stator removal, crankcase assembly, connecting-rod clearances, main-bearing wear, and crankshaft runout. Crankshaft scope: Inspection and assembly replacement are covered; internal crankshaft disassembly is not included.

The fuel section details vacuum-piston and diaphragm checks for the triple Keihin CDCV carburetors, plus intake-manifold, flame-arrester, fuel-tank, and fuel-tap service. Separate sections handle the oil tank and filter, expansion chamber, exhaust manifold, and water-box muffler.

Fuel-pump limit: The pump is covered for removal and installation. The manual directs replacement for leakage or suspected internal damage and specifically excludes pump disassembly.

Jet Pump, Drive, Steering, and Hull

The engine drives the jet pump directly. Drive-shaft holder service specifies bearing and grease-seal arrangement, coupling alignment, and runout checks; pump coverage adds bracket sealing, pump-shaft and pump-cap bearing service, and impeller/pump-case wear inspection.

Shift-lever shaft removal and installation are also covered. The hull chapter addresses the hatch cover, mirrors, stabilizers, storage case, crossmember, bumpers, trim seals, and other rubber parts, along with a hull-replacement sequence.

Electrical Diagnosis, Diagrams, and Tools

Electrical repair coverage includes digital DC-CDI igniter tests, charging-coil and regulator/rectifier checks, battery charging, and starter-motor overhaul. Smart Steering procedures add sensor and magnet installation, sensor-clearance inspection, input/output-voltage checks, and actuator removal and installation. Switch and fuse tests are included.

Reference material includes the Fuel System Diagram, JT900-E1 Wiring Diagram, Kawasaki Smart Steering System Circuit, Flow Chart of Kawasaki Smart Steering System, and Ignition System Troubleshooting chart. Illustrated Cable, Wire and Hose Routing views show harness and hose placement.

Named service tools include Piston Pin Puller Assembly 57001-910, Flywheel Puller Assembly 57001-1405, Impeller Holder 57001-1393, Impeller Wrench 57001-1228, Hand Tester 57001-1394, and Needle Adapter Set 57001-1457.

Repair Cautions

Excessive force during impeller grease-seal installation can damage the seal. The CDI igniter can be damaged by disconnecting it with the ignition on or disconnecting battery leads while the engine is running.

Fuel-system work, high-voltage ignition tests, rotating-component checks, and engine-running procedures require the stated fire-prevention, electrical, and cooling-water precautions.

Float-Arm and Impeller Clearance Preview

The carburetor inspection section specifies a float-arm level of 1.0–2.0 mm, measured from the arm’s plastic tip to the carburetor case.

For the jet pump, blade-tip-to-case clearance is specified at 0.15–0.3 mm, with a 0.6 mm service limit. The associated wear checks distinguish impeller wear from pump-case wear when investigating poor propulsion performance.