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

• Coverage: Covers the 1994 Kawasaki JET SKI XiR, model JH750-D1, with beginning hull number KAW05001□C494; the boxed digit varies from one machine to another.
• Included factory manuals: 240 PDF pages total — the 45-page April 1994 First Edition (1) JH750-D1 Service Manual Supplement, P/N 99963-0062-51, plus the 195-page Base Service Manual, P/N 99924-1180-01.
• Fuel and lubrication systems: Covers D1-specific twin-carburetor tuning data, throttle and choke controls, carburetor synchronization and internal service, reed valves, fuel-tank hardware, and the XiR premix layout with no oil tank or oil pump.
• Engine repair depth: Includes top-end disassembly and assembly, compression and cylinder/piston inspection, engine removal and alignment, flywheel and stator service, crankcase splitting, crankshaft inspection, and coupling-damper checks.
• Jet pump, drive, and chassis work: Details drive-shaft and holder service, pump disassembly and assembly, impeller inspection and clearance, XiR outlet-nozzle spacer orientation, steering components, hull fittings, and engine-hood hardware.
• Electrical diagnosis: Provides the JH750-D1 wiring diagram, electrical-system exploded views, starting and charging tests, ignition-system procedures, a model-specific CDI igniter resistance matrix, and checks for the LED, fuel-level, and temperature-warning circuits.

The XiR supplement is not a stand-alone rewrite of every procedure. Kawasaki directs the technician to Base Service Manual P/N 99924-1180-01 for work shared with the JH750-B1 platform, then supplies the JH750-D1 pages needed wherever the XiR hardware, routing, specifications, or installation details differ. Both referenced manuals are included here, so the technician has the shared repair procedures and the XiR corrections in one set.

JH750-D1 Configuration and Service Scope

The covered craft uses the 743cc, water-cooled, two-stroke vertical twin with crankcase reed induction, twin Keihin CDK40-34 diaphragm carburetors, magneto CDI ignition, direct drive, and a single-stage axial-flow jet pump. D1-specific data covers carburetor jetting, mixture-screw ranges, idle adjustment, component-specific torque and locking-agent tables, cable/wire/hose routing, electrical test values, wear limits, and inspection specifications.

One of the most important XiR differences is lubrication. The D1 uses a 25:1 gasoline/oil premix and has no oil tank or oil pump; the XiR LED unit therefore has no oil-level gauge. The supplement also specifies the battery position, the unique exhaust installation, and the D1 fuel-tank removal change rather than leaving those details to the base-model instructions.

Repair and Diagnostic Procedures

Fuel-system coverage includes throttle and choke cable adjustment, removal, inspection, and lubrication; carburetor synchronization, removal, disassembly, assembly, cleaning, and float-arm inspection; fuel-pump service; flame-arrester cleaning; reed-valve, holder, and stop inspection; and service for the tank, filler, filter screens, vent check valve, and fuel tap.

Engine repair procedures cover top-end disassembly and assembly, compression measurement, cylinder-head warp, cylinder wear, piston measurement, piston-to-cylinder clearance, boring and honing, and piston-ring inspection. The bottom-end chapter adds coupling and damper service, magneto flywheel and stator work, crankcase splitting and assembly, connecting-rod checks, main-bearing inspection, and crankshaft runout. XiR engine installation is especially model-specific: there is no alignment mark in the hull, so the manual uses visual coupler alignment and retained engine-bed shims.

The exhaust section documents XiR exhaust-pipe and expansion-chamber removal and installation, exhaust-manifold removal, and the water-box muffler molded into the hull, which is not removable. Cooling and bilge coverage includes hose service, breather and filter inspection, system flushing, and dedicated flow diagrams. Drive and pump sections address drive-shaft removal, holder disassembly and seal/bearing assembly, shaft runout, pump overhaul, impeller clearance, and the XiR wedge-shaped spacer between the pump body and outlet nozzle. The spacer is indexed with its thicker edge at the bottom, and the XiR nozzle carries only the steering-cable connection described in the supplement.

Electrical repair and testing extend 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, temperature sensor, fuel-level sensor, LED warning unit, and fuse. Storage preparation, removal from storage, lubrication points, symptom-based troubleshooting, and a unit-conversion table are also included.

Diagrams, Test Data, and Factory Tools

Useful visual references include the JH750-D1 cable, wire, and hose routing views, fuel-system diagram, cooling- and bilge-system flow diagrams, pump-and-impeller exploded view, electrical-system exploded view, and the full JH750-D1 wiring diagram with wire-color key. The CDI igniter page provides a lead-to-lead internal-resistance chart rather than a single pass/fail value.

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. The carburetor section warns against forcing mixture screws into their seats, which can damage the screws or carburetor, and an overly lean high-speed setting can damage the engine. During pump repair, the impeller grease seal must not be pressed heavily because the seal can be ruined. 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.