Kawasaki TS 650 Jet Ski Service Manual Set, 1989–1995 (P/N 99924-1122-54)

The TS supplement provides model-specific changes and depends on the X-2 manual for shared service procedures. Together, the books connect TS maintenance and repair requirements with the underlying disassembly, inspection, and adjustment instructions.

The A-series supplements in the X-2 volume apply to the X-2, rather than extending TS model coverage.

PDF Text Search, Navigation, and Wiring Detail

Text access and diagram labels: Neither PDF supports text search or contains embedded bookmarks. Small wiring-diagram labels require zooming.

The ZIP contains two printable PDFs totaling 337 pages. Each book includes six opening pages and a rear cover; the totals also include six blank separator pages in the TS supplement and three in the X-2 manual.

Engine, Jet-Pump, and Electrical Service

These selected topics show the repair coverage without reproducing the full contents. Other sections include the periodic maintenance chart and storage and transport preparation.

• Fuel and intake: Carburetor and fuel-pump disassembly, throttle and choke cable adjustment, reed-valve inspection, and high-altitude tuning.

• Oil injection: Oil-pump bleeding, output testing, pump removal and installation, and oil-tank vent checks.

• Engine repair: Step-by-step top-end disassembly, crankcase splitting, engine removal and installation, and crankshaft and connecting-rod inspection.

• Exhaust and bilge systems: Exhaust-joint assembly and shimming, cooling and bilge flushing, and hose, filter, and breather service.

• Drive shaft, pump, and steering: Drive-shaft holder overhaul, impeller removal, pump bearing and seal replacement, and steering cable and holder service.

• Electrical diagnosis: Variant-specific wiring diagrams, starter-circuit tests, charging-system and CDI checks, and dynamic ignition-timing inspection.

Written primarily for Jet Ski mechanics in properly equipped shops, these books also support owners with basic mechanical, tool, and workshop knowledge performing basic maintenance and repair; work beyond that experience should be handled by a qualified mechanic.

TS Variants and Model-Specific Changes

The supplement's main chapters establish the JF650-B1/B2 procedures. Its 1991–1995 section adds the changes for B3–B7, including the later carburetor's integrated, crankcase-pulse-operated fuel pump.

Other revisions cover the exhaust-manifold gaskets, bilge breather and filter mounting, B4–B7 intake-grate seal, B5–B7 steering hardware, and the fused B3–B7 electrical layout with its horizontally mounted electric case. These distinctions help match service data and assembly details to the watercraft being repaired.

The TS powertrain uses a water-cooled two-stroke vertical twin with crankcase reed induction, oil injection, magneto CDI, and a single-stage axial-flow jet pump.

Carburetor, Fuel Supply, and Lubrication

Fuel-system coverage extends to float-arm inspection, flame-arrester cleaning, intake-manifold service, tank and filter cleaning, sediment-bowl service, and priming. The Fuel System Diagram and Cable, Wire, and Hose Routing illustrations identify the connections between these components.

A sediment-bowl troubleshooting note explains how an O-ring leak can cause stalling once the fuel level drops, even though the engine runs with a full tank.

The carburetor sections explain the individually established factory mixture settings and warn that forcing mixture screws into their seats can damage the screws or carburetor; an excessively lean high-speed setting can damage the engine. Fuel and solvent work requires ventilation and control of ignition sources.

Top-End Inspection and Crankcase Repair

Internal engine coverage includes compression measurement, decarbonizing, cylinder-head warp checks, cylinder and piston measurements, ring and pin inspection, and boring and honing guidance.

Reinstallation addresses engine-bed shims, coupling alignment, oil-pump bleeding, and final leak and vibration checks. Crankshaft coverage includes runout, bearing condition, connecting-rod alignment, and big-end clearances. Crankshaft disassembly and internal rebuilding are outside the described procedures; the manual directs that work to a suitably equipped shop.

Exhaust Alignment, Cooling, and Bilge Service

The exhaust chapters explain joint construction, muffler-bracket shimming, water-box muffler service, and inspection of passages, sealing faces, and rubber connections.

Cooling and bilge flow illustrations accompany the flushing procedures. The cooling cautions explain how incorrect flush-water sequencing can admit water through the exhaust and cause severe internal engine damage.

Drive-Shaft Holder, Impeller, and Steering

Drive Shaft Holder and Pump and Impeller exploded views show bearing, seal, and assembly relationships. Inspection instructions distinguish shaft runout, pump-case wear, impeller damage, and excessive tip clearance as separate checks.

Steering coverage includes cable adjustment and replacement, pivot bushings, steering-holder removal, and handlebar installation. Hull and engine-hood sections cover storage-case, panel, hatch, steering-cover, and other fitting removal, plus hull replacement and rubber-part attachment.

Starter, Charging, and Ignition Diagnosis

Electrical reference material includes starter-relay and starter-motor checks, armature and commutator inspection, charging-coil tests, regulator/rectifier resistance matrices, CDI and exciter-coil data, and switch-continuity checks. Separate early TS and B3–B7 Wiring Diagrams identify the applicable circuit layouts.

Troubleshooting charts distinguish starting, spark, fuel, compression, rough-running, lubrication, overheating, low-power, jet-pump, and steering faults. Torque and locking-agent tables accompany the component inspection limits and adjustment data.

Named equipment includes the Crankcase & Pump Case Stand 57001-1295, Flywheel Holder 57001-306, Magneto Puller 57001-259, Coupling Holder 57001-1230, Impeller Wrench 57001-1228, and Bearing Driver Set 57001-1129.

The CDI resistance checks specify Kawasaki Hand Tester 57001-983 because another meter may produce different readings. The charging-coil output test carries an electrical-shock warning against testing with the watercraft in the water.

Examples of Oil-Pump Output and Repair Clearances

The TS oil-pump test specifies an output of 5.9–7.2 mL at 3,000 r/min over two minutes. Its top-end inspection data give a standard piston-to-cylinder clearance of 0.084–0.094 mm.

For the shared jet-pump inspection, the base manual lists impeller tip clearance at 0.2–0.3 mm standard, with a 0.6 mm service limit.