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

• Covers 1989-1995 Kawasaki Jet Ski TS models JF650-B1 through JF650-B7, with hull-number identification.
• The 337-page PDF set contains the TS Service Manual Supplement, P/N 99924-1122-54 (125 pages, 4th Edition, Feb. 21, 1995), and the included X-2 base Service Manual, P/N 99924-1069-06 (212 pages, 6th Edition, Sep. 3, 1990).
• Details Keihin carburetor and fuel-pump service, reed-valve and intake-manifold inspection, throttle/choke cable work, sediment-bowl cleaning, oil-pump bleeding and output testing, and high-altitude adjustment.
• Follows engine removal and installation, top-end disassembly and inspection, crankcase splitting, crankshaft and connecting-rod checks, coupling and flywheel service, and engine-bed alignment during reassembly.
• Documents exhaust-joint and shim work, cooling and bilge flushing, drive-shaft holder overhaul, pump and impeller disassembly, steering service, and hull/engine-hood component removal.
• Supplies model-specific wiring diagrams, starter-circuit tests, charging and regulator/rectifier checks, CDI and exciter-coil inspection, dynamic ignition-timing procedures, torque tables, wear limits, and adjustment data.

This factory set pairs the TS supplement with the X-2 base manual required for TS maintenance and repair. Kawasaki designed the books primarily for Jet Ski mechanics in properly equipped shops; operators with basic mechanical, tool, and workshop knowledge can use them for basic maintenance and repair, while work beyond their experience should be left to a qualified mechanic.

TS Model and Hull Coverage

The square represents the digit Kawasaki notes will vary from one watercraft to another.

How the Two-Manual Set Is Organized

The TS supplement's front chapters cover JF650-B1/B2; its 1991-1995 chapter records B3-B7-only changes. The X-2 volume supplies shared procedures, specifications, and troubleshooting. Its JF650-A-series addenda are X-2 content, not added TS coverage.

The covered TS uses Kawasaki's factory-specified 635 mL water-cooled two-stroke vertical twin, with crankcase reed induction, oil injection, magneto CDI, and a single-stage axial-flow jet pump.

The later-model chapter distinguishes the early Keihin CDK34 fuel arrangement from the JF650-B3-B7 Keihin CDKII 38-32 system. It also documents the revised exhaust-manifold gasket, changed bilge breather and filter mounting, B4-B7 pump-intake/grate seal, B5-B7 steering-holder hardware, and the fused B3-B7 electrical layout with its horizontally mounted electric case.

Engine, Fuel, and Driveline Repair Content

Fuel work covers throttle and choke controls, carburetor removal and disassembly, cleaning, float-arm inspection, fuel-pump service, the flame arrester, intake manifold, reed valves, sediment bowl, tank, filter, and priming. The lubrication chapter adds oil-pump bleeding, performance testing, removal, installation, and tank-vent checks.

For internal engine repair, the books cover compression measurement, decarbonizing, cylinder-head warp, bore and piston inspection, ring and pin checks, boring and honing, crankcase separation, and crankshaft, bearing, and connecting-rod inspection. Engine installation includes bed shimming, coupling alignment, oil-pump bleeding, and final leak and vibration checks. Separate chapters handle the drive-shaft holder bearing/seal stack, shaft runout, jet-pump teardown, pump-case wear, and impeller clearance.

JF650 Electrical Diagnosis and Factory Data

Electrical diagnosis includes starter-relay and starter-motor tests, charging-coil checks, a regulator/rectifier matrix, CDI and exciter-coil resistance data, switch-continuity checks, and ignition-timing inspection. Reference illustrations include the Fuel System Diagram, Cable, Wire, and Hose Routing, the Cooling, Bilge, and Combined Exhaust-Water Flow diagram, Drive Shaft Holder and Pump and Impeller exploded views, and separate early-model and JF650-B3-B7 Wiring Diagrams.

Specification sections collect component-specific torque and locking-agent requirements, carburetor setup data, oil-pump output, compression and wear limits, shaft runout, impeller clearances, and electrical values. Fault-finding charts trace hard starting, no spark, fuel or compression faults, rough running, lubrication trouble, overheating, low power, jet-pump performance, and steering problems.

Named service 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 electrical tables specify Kawasaki Hand Tester 57001-983, since other meters may not reproduce the listed resistance readings.

The cooling section warns that incorrect flush-water sequencing can send water back through the exhaust and cause severe internal engine damage. Carburetor cautions flag unit-specific factory mixture settings: forcing the screws against their seats can damage the screws or carburetor, while an excessively lean high-speed setting can damage the engine. Fuel work requires ventilation, and the charging-coil output test is performed with the watercraft out of the water.