2007–2010 Kawasaki JET SKI Ultra 250X / 260X / 260LX Service Manual (P/N 99924-1377-04)

This Kawasaki factory service manual covers the 2007–2010 JET SKI Ultra 250X, 260X, and 260LX, including the JT1500B, JT1500E, and JT1500F variants. It is the 4th Edition, dated November 26, 2009, publication P/N 99924-1377-04.

• Engine repair: Engine removal, cylinder-head disassembly, valve-seat reconditioning, camshaft timing, piston inspection, crankcase separation, and crankshaft and connecting-rod bearing selection.

• DFI diagnosis: Service-code interpretation, sensor and injector tests, ECU power-supply checks, fuel-pressure and fuel-flow testing, and Idle Speed Controller (ISC) inspection.

• Supercharger and intake: Drive-belt replacement, pulley removal and shimming, air-bypass valve checks, intake-system inspection, and intercooler removal and installation.

• Lubrication and cooling: Oil-pump and cooler service, oil-pressure testing, semi-dry-sump oil checks, bilge-system inspection, and procedures for recovery after submersion.

• Pump and steering: Jet-pump disassembly, impeller wear-clearance checks, drive-shaft bearings and seals, reverse-cable adjustment, and Kawasaki Smart Steering System inspection.

• Electrical service: Starter-motor overhaul, charging and ignition tests, meter inspection, immobilizer amplifier checks, and FPO/SLO ignition-key registration procedures.

Written for trained mechanics in a properly equipped shop, this manual also supports basic maintenance and repair by owners who already understand mechanics, tools, and workshop procedures.

DFI Fault Isolation and Immobilizer Registration

Fault isolation: Service-code tables, ECU terminal views, and the DFI System Wiring Diagram connect reported faults with sensor, wiring, and power-supply checks, helping distinguish circuit problems from component faults.

Vehicle-down sensor and ISC inspections are included. The meter displays current service codes; retrieving or erasing stored fault history requires Kawasaki Diagnostic System (KDS) equipment.

Immobilizer service: Registration procedures cover spare FPO/SLO keys and replacement ECUs. Adding spare keys requires an existing registered key and the key-registration unit; JT1500EAF/FAF also require its adapter. Losing every registered key requires ECU replacement.

Engine and Supercharger Service

Adjustment and overhaul: The Periodic Maintenance Chart and Valve Clearance Adjustment Charts cover scheduled checks and shim selection. Exploded views and torque/locking-agent tables support valve-train, crankshaft, supercharger pulley-nut, and crankshaft-sensor fastener work.

Supercharger instructions distinguish early and later pulley attachments and document drive-belt replacement, pulley shimming, and belt measurement with Kawasaki’s specified gauge.

Retightening partially loosened camshaft-chain-tensioner mounting bolts can damage the tensioner and chain.

Oil Circuits, Cooling, and Jet-Pump Work

Fluid circuits: The Engine Oil Flow Chart maps lubrication routes, alongside service procedures for the semi-dry-sump system, oil separator tank, oil pump, and cooler. The Cooling and Bilge System Flow Diagram distinguishes cooling routes; related procedures cover the intercooler and water box muffler.

Submerged-engine recovery covers water removal and checks of the engine, fuel system, and supercharger. Starting a water-filled engine can damage internal parts.

Pump and hull work: Pump disassembly, impeller-clearance inspection, bearing and seal service, and steering/reverse adjustments are illustrated. Cable, Wire and Hose Routing views show variant-specific installation paths; storage procedures cover corrosion protection and return to service.

Fuel vapor in the engine compartment and ignition-system voltage require the manual’s stated service precautions.

A Preview of Valve, Belt, and Charging Data

These valve, belt, and charging figures are a small sample of the manual’s service data. For the covered models, intake valve clearance is 0.15–0.24 mm with the engine cold at room temperature.

The supercharger drive-belt inspection standard is 500–960 N, measured with the specified belt-tension gauge. The general specifications list maximum generator output as 16 A at 14 V.

PDF Text Search, Bookmarks, and Page Contents

Search and navigation: Body text and specification tables are searchable, and embedded bookmarks link to chapters and procedures. Wiring-diagram labels are image content rather than searchable text; small labels are readable when enlarged.

Supplied as one printable English PDF with 545 pages: 10 preliminary pages, 534 chapter and appendix pages, and one closing model-application/publication page. This total includes 12 blank pages and one page marked “Dummy Page.”