1994 Kawasaki Jet Ski XiR / Xi-R / JH750 / 750 Service Manual Set (P/N 99924-1180–01, 99963-0062-51)

The XiR supplement is not a stand-alone rewrite of every procedure. Both referenced manuals are included here, so the technician has the shared repair procedures and the XiR corrections in one set.

Crankshaft repair scope: The base manual covers crankshaft inspection and assembly specifications, but not crankshaft disassembly. Internal rebuilding requires a properly equipped specialist shop.

Printable PDFs, Navigation, and Diagram Detail

Text search and wiring detail: Neither PDF supports text search or includes embedded bookmarks. Printed chapter guides and section contents provide navigation. Small wire-color codes and component labels in the checked wiring diagrams are readable when enlarged.

The ZIP contains two printable PDFs totaling 240 pages. The individual publication totals above already include four cover pages, nine preliminary title/reference/preface pages, and nine blank or otherwise empty pages.

Engine, Fuel-System, and Jet-Pump Service

The following selected service topics show the repair and diagnostic coverage. Further examples include storage preparation, return-to-service checks, lubrication points, and the unit-conversion table.

• Fuel and lubrication: Carburetor synchronization and internal service, throttle and choke controls, reed-valve inspection, fuel-tank components, and XiR premix lubrication.

• Engine repair: Step-by-step top-end disassembly and assembly, engine removal and alignment, crankcase splitting, flywheel and stator service, and crankshaft inspection.

• Drive and jet pump: Drive-shaft and holder service, bearing and seal installation, pump overhaul, impeller inspection, clearance checks, and XiR nozzle-spacer details.

• Exhaust, cooling, and bilge: Exhaust-pipe and expansion-chamber removal, manifold inspection, hose service, flushing, and cooling- and bilge-system flow diagrams.

• Steering and hull: Steering-cable adjustment and inspection, handlebar and steering-shaft service, hull replacement, hatch fittings, bumpers, and engine-hood hardware.

• Electrical diagnosis: Starting, charging, and ignition tests; the XiR wiring diagram and CDI resistance matrix; and fuel-level, temperature-warning, and LED-unit checks.

Written primarily for JET SKI mechanics in an equipped shop, these manuals also support owners performing basic maintenance and repair who understand mechanics, tool use, and workshop procedures.

XiR Fuel and Lubrication Differences

The water-cooled, two-stroke vertical twin uses crankcase reed induction, twin Keihin CDK40-34 diaphragm carburetors, and magneto CDI ignition. The supplement provides D1-specific jetting and mixture-screw data rather than leaving XiR tuning to the base-model settings.

Fuel-system detail: Procedures cover carburetor removal, cleaning, disassembly, assembly, and float-arm inspection, plus diaphragm-needle and check-valve checks. Reed-valve, holder, and stop inspection accompany service for the flame arrester, sediment bowl, tank, filler, filter screens, vent check valve, and fuel tap.

Fuel-pump removal and installation are covered, but the pump itself is not to be disassembled; suspected internal damage or leakage calls for unit replacement. The supplement also identifies the battery-removal change for XiR fuel-tank access.

Premix configuration: The XiR has no oil tank or oil pump, and its LED unit has no oil-level gauge. These differences matter when using base-manual pages that describe oil-injection components.

For carburetor work, the manual warns that forcing mixture screws into their seats can damage the screws or carburetor, while an excessively lean high-speed setting can damage the engine.

Engine Inspection and Installation

Top-end coverage includes compression measurement, cylinder-head warp, cylinder wear, piston measurement, piston-to-cylinder clearance, boring and honing, and piston-ring inspection. Standard dimensions and service limits support decisions about worn parts and replacement components.

The bottom-end chapter adds coupling and damper service, crankshaft runout, connecting-rod bend and twist, big-end clearances, and main-bearing inspection. Torque and locking-agent tables identify component-specific assembly requirements.

XiR alignment: There is no engine-alignment mark in the hull. The supplement describes visual coupler alignment and the reuse of retained engine-bed shims, giving the technician the XiR installation details alongside the shared engine procedures.

Exhaust, Cooling, and Pump Installation Details

The XiR exhaust section covers its exhaust-pipe and expansion-chamber installation and exhaust-manifold removal. The water-box muffler is molded into the hull and is not removable.

Cooling and bilge coverage includes breather and filter inspection, hose checks, and system flushing. The flow diagrams distinguish cooling-water routing from bilge suction, supporting investigation of restricted flow or poor bilge performance.

Pump and drive: Drive-shaft runout checks accompany holder disassembly and bearing/seal assembly. XiR pump instructions explain the wedge-shaped outlet-nozzle spacer, including its thicker-edge-at-bottom orientation, and identify the steering-only cable connection at the nozzle.

Impeller inspection and clearance data help distinguish pump wear from an engine problem when the engine runs normally but propulsion is poor. The pump-assembly section also warns that excessive pressing force can ruin the impeller grease seal.

Electrical Tests, Diagrams, and Factory Tools

Electrical coverage extends through the battery, starter relay, reduction gear, starter motor, charging coil, regulator/rectifier, pickup coil, ignition coil, CDI igniter, spark plugs, electric case, start/stop switch, sensors, LED unit, and fuse.

XiR test information: The supplement supplies the D1 lead-to-lead CDI resistance matrix, battery-orientation changes, and electric-case removal details. The base manual explains the associated tests and cautions that an unsuitable tester can give misleading CDI readings or damage the igniter.

Visual references include the JH750-D1 wiring diagram with wire-color key, cable/wire/hose routing views, fuel-system diagram, cooling- and bilge-system flow diagrams, pump-and-impeller exploded view, and electrical-system exploded view.

Factory-tool references include Compression Gauge 57001-221, Impeller Wrench 57001-1228, Coupling Holder 57001-1230, Drive Shaft Holder 57001-1327, Rotor Holder 57001-1368, and Kawasaki Hand Tester 57001-983.

Improper auxiliary-cooling use or laying the craft on its left side can allow water into the engine and cause hydraulic lock or serious internal damage. Fuel-system work, battery service, rotating pump components, and high-voltage ignition testing should be performed under the safety and isolation procedures in the manuals.

Examples of XiR Lubrication and Wear Specifications

The XiR lubrication chapter specifies a 25:1 gasoline-to-oil premix and provides a fuel-ratio chart. This is the lubrication arrangement for the D1, rather than the oil-injection system described in the base manual.

For internal engine inspection, the base manual lists standard piston-to-cylinder clearance at 0.095–0.115 mm. Its jet-pump section gives standard impeller clearance of 0.2–0.3 mm and a 0.6 mm service limit, alongside inspection guidance for the impeller and pump case.