K-Tech News Vol.6 No.3
Contents
1. generator Service Manual Supplements and Base Manuals Motorcycle Supplement Base Manual Model of Base Model P N P N Manual KX60 B6 7 99924 1123 51 99924 1094 01 KX60 B4 KX80 L2 3 N2 3 99924 1123 51 99924 1094 01 KX80 L1 N1 KX125 G1 99924 1116 51 99924 1101 01 KX125 F1 KDX200 E2 4 99924 1136 51 99924 1114 01 KDX200 E1 EL250 B2 4 99924 1093 51 99924 1066 01 EX250 E1 EL250 E1 99924 1093 52 99924 1066 01 EX250 E1 EX250 F2 7 99924 1109 54 99924 1066 01 EX250 E1 KDX250 D1 3 99924 1143 51 99924 1114 01 KDX200 E1 KL250 D2 10 99924 1051 03 99924 1050 01 KL600 A1 KX250 G1 99924 1116 51 99924 1101 01 KX250 F1 EN500 A1 5 99924 1125 51 99924 1056 04 EN450 A1 EX500 A1 7 99924 1082 53 99924 1056 04 EN450 A1 KX500 E1 99924 1116 51 99924 110101 KX500 D1 KX500 E2 5 99924 1132 52 99924 1101 01 KX500 D1 KL600 B1 99924 1063 51 99924 1050 01 KL600 A1 ZL600 A1 2 99924 1073 51 99924 1055 04 ZX600 A1 ZX600 C1 4 99924 1081 52 99924 1055 04 ZX600 A1 ZX600 E1 4 99924 1116 51 99924 1128 02 ZX600 D3 KL650 A1 7 99924 1080 52 99924 1050 01 KL600 A1 ZX750 H2 99924 1126 51 99924 1112 01 ZX750 H1 ZX750 L1 2 99924 1160 51 99924 1139 02 ZX750 J1 ZX750 M1 2 99924 1160 51 99924 1139 02 ZX750 K1 ZL900 A1 2 99924 1077 51 99924 1048 05 ZX900 A1 ZL1000 A1 99924 1077 51 99924 1048 05 ZX900 A1 ZX1100 C1 4 99924 1127 52 99924 1098 02 ZX1000 B1 ZG1200 B1 7 99924 1089 52 92. and the KLF300 B1 service manual supple ment At left the latest listing of base manuals and supple ments available for motorcycles ATVs and watercraft O Po SERVICE CONTEST Service Contest 3 wrap up and award giving C ongratulations to those technicians who scored 85 percent or better on Serv ice Contest 3 which was significantly tougher than the first two contests Ev eryone whose name ap pears on the diploma printed on page 6 will re ceive a Snap On mini flashlight with magnetic base and useful fiber optic option We want to offer con gratulations again to the award winners of Con tests 1 and 2 and our special thanks to every one who participated in Kawasaki s 1993 Service Contest We hope to see you again in the 1994 Service Contest beginning next fall Don Church Manager Service Training and Communications Department Congratulations to the winners of Kawasaki Service Contest 3 who will each receive one of these trick Snap On mini flashlights The Technical Magazine 5 TECHNICIAN Award Winners K TECH NEWS Service Contest 3 DEALERSHIP LOCATION David Bjork Gary Bustillos David Moon Doug Engie Mike Nyholm Rayburn Sumner Jamie White Capitol Kawasaki Kawasaki Country Leer s Kawasaki Northern Kawasaki Northern Kawasaki Forsyth Kawasaki Rehmert Cycle Columbia S C Norco Calif Waterloo lowa Cloquet Minn Cloquet Minn Win
3. ally all profit To get one of these kits order P N K61080 050 Gregg Thompson CABLE BRACKET CABLE HOUSING ADJUSTER from the center It is hard to tell precisely but close is good enough If it is not close but you have per formed the cable adjustment as de scribed above you may have to move the shift shaft lever one tooth on the shift shaft spline O To double check your adjustment try the following method taken from the MULE 2510 2520 service manual 1 Start the engine and put the transmis sion shift lever into Forward F gear Leave the engine idling while performing this check 2 Pull back the detent lock on the High Low shifter on the dash 3 Starting with the High Low shifter halfway between the High and Low detents slowly move it upward until the gears begin to grind and then downward until the gears begin to grind 4 The gears should each begin to grind about the same distance GEARS GRIND HERE NOTE DISTANCE FROM CENTER ABOUT THE SAME The Technical Magazine 7 TIPS FROM TH Pressure testing two stroke engines Your common practice by Gregg Thompson Product Support Supervisor When you have a two stroke engine in your shop which is suffering from hard starting low power a bad idle and or poor throt tle response what s the first thing you should do Everyone knows the an swer to that one take a compression test That holds true of
4. Service Department Operations 16 18 Troubleshooting Elec Systems 22 23 Fuel Systems 24 Generator 29 30 MULE Service December ATV Service 2 Precision Measurement and Diagnostic Tool Usage 1315 JET SKI Watercraft 16 Service Department Operations 20 21 Fuel Systems 22 Generator
5. better than the MULE 500 air fil ter for a couple of rea sons It has noticeably more paper in it which in creases the filtering capac ity while extending the life of the filter And both the foam outer sleeve and the paper inner element are available separately This will save the customer around 10 if all he needs to replace is the paper ele ment Even if your customer needs both paper and foam elements the KLF400 B parts are less expensive than the MULE 500 part Less expensive and better filtration that s a good combination To get the KLF400 parts order P N 11013 1217 for the paper inner element and P N 11013 1205 for the foam outer sleeve When servicing this fil ter take note of the follow ing The factory doesn t recommend oiling the foam outer sleeve Rea son If the oil from the foam sleeve gets into the paper element the paper element will be ruined We have found that while most oils will transfer to the paper element Bel Ray air filter oil doesn t The bottom line is that oil ing the foam sleeve will in crease the effectiveness of the filter and the life of the paper element as long as the oil stays off the pa per If you oil the foam ele ment use an oil that doesn t transfer to the pa per and use it sparingly The KLF400 B uses a rubber gasket to seal the air cleaner element to the spigot in the air box This gasket cannot be used in the KLF300 so use heavy PI
6. bottom line is that the filter with the re cessed threads P N 16097 1061 will fit all VN1500 engines but the filter without the recessed threads P N 16097 1064 fits only the VN1500 A8 The first microfiche we issued that included the 94 VN1500 A8 listed There has been some confusion regarding oil fil ters for the VN1500 A There are now two differ ent filters that are used which are not necessarily interchangeable The filter used on the VN1500 A1 through A7 is P N 16097 1061 The threads on this filter are re cessed back into the filter body to clear the hex nut on the threaded oil pipe in these earlier engines The VN1500 A8 has a straight threaded oil pipe with no hex nut so the oil filter for this engine P N 16097 1064 does not have the recessed threads PIN 16097 1064 FITS ONLY VN1500 A6 incorrect oil filter informa tion That microfiche card was dated June 1993 and covered the VN1500 A6 A7 A8 If you still have that microfiche anywhere in your dealership please discard it The corrected microfiche card is dated July 1993 O PIN 16097 1061 FITS ALL VN1500s TIPS FROM TH E SPECIALISTS When the brakes do the bleeding but you have the pain by Gregg Thompson Product Support Supervisor B leeding hydraulic brakes can be a frustrating and time consuming project especially if you don t have any pressure or vac uum brake bleeding equip ment at your shop Prob ems are
7. duct to lower intake noise The ZX900 B uses a digital ignition system which limits rom to 11 700 This new ignition system fires unique dou ble electrode spark plugs which improve combus tion efficiency at low and middle engine speeds Exhaust gasses exit this new engine package through an exhaust sys tem based on the ZX 7 s Unique to this system is a crossover pipe which con nects all cylinders to gether for improved low and mid range torque and rubber mounting not only at the silencer but un derneath the engine as well for reduced vibration and increased durability The ZX 9R s main frame is similar in con struction to the ZX 7 s using pressed aluminum sheets welded together and then joined to cast sections at the steering stem and swingarm pivot This frame construction al lows the frame to have maximum strength and ri gidity with the least weight possible The main differ ences from the ZX 7 s frame are a larger cast piece at the swingarm pivot and two aluminum downtubes underneath SHOP TALK TECHNICAL the engine The two re movable downtubes are a necessity since the ZX 9R s engine is rubber mounted in front for less vibration The ZX 9R s suspen sion is a recalibrated ver sion of the ZX 7R s fully adjustable suspension Up front are 41 mm inverted forks with 12 way rebound damping adjustment seven way compression damping adjustment and threaded spring preload adjuster
8. system and starts them moving up through the fluid An elec tric pencil works great for this Just turn it on place the pencil body against the various parts of the brake hydraulic system and the vibration will loosen the air bubbles and cause them to rise in the fluid quickly 4 Drain the master cylin der reservoir so it doesn t overflow and then as quickly as you can pry the brake pads apart with the screwdriver forcing the pis ton s all the way back up into the caliper This forces a large amount of fluid upward into the mas ter cylinder If the vehicle has dual discs repeat the proce dure with the other caliper Make sure to put a piece of wood or Styrofoam in the first caliper so fluid doesn t transfer from the second caliper back into it 5 Being careful to keep the reservoir topped off pump the caliper s up with fluid again 6 Now holding the cali per with the bleeder fitting at the highest point open the bleeder slightly and pry the pads apart again Any air left in the caliper will be forced out the bleeder O 750 watercraft exciter coil diagnostic test data Dealers have been asking us for a good diagnostic test for the new JS JH750 watercraft exciter coils So we did some tests with a few meters on some boats and came up with some procedures and some numbers Check the exciter coil in circuit that is with all wires connected AC volt age It is easy to do
9. usually caused by little nooks and cran nies inside the fittings and caliper s which can give air bubbles a place to hide from the flow of brake fluid Also when you manually bleed the brakes by pump ing up the pressure at the master cylinder and then bleeding it off at the fitting on the caliper a relatively small amount of fluid is be ing pushed downward through the system The air however would really like to float upward through he fluid so as you pump he pressure back up at the master cylinder the bubbles hat were pushed down the line have a tendency to float back upstream It s a three steps for ward two steps back situ ation Pressure and vacuum bleeding equip ment solves this problem by forcing a large quantity of fluid through the system in one direction with little or no interruption If you don t have any power bleeding equipment in your shop try the follow ing method the next time you have a tough brake bleeding job This method overcomes most of the problems described above without the use of power equipment 1 Remove the caliper from its bracket 2 Place a large flat blade screwdriver between the brake pads and pump the master cylinder until the pads grip the screwdriver 3 Take another screw driver and spend a little time tapping on the hoses and any fittings or junction blocks in the line going up to the master cylinder This helps dislodge any air bubbles in the
10. 18 minutes It will be mailed automatically to all Technical Training Video Club members The samples of sys tems covered in the video are drawn from Kawasaki s line of motorcycles and wa tercraft The information though is applicable to any charging or starting system on any Kawasaki product so the tape will certainly be a valuable training aid for utility vehicle and generator technicians too The Kawasaki Charg ing and Starting Systems Troubleshooting Manual will be available soon as a companion to the video The manual will include a self test to be sent to Kawasaki for grading The technician will receive a certificate of completion Ray St John This justin K Tech News Editor and long time Hot Line Sr Tech nician Gregg Thompson was recently promoted to Hot tine Supervisor He will continue to edit K Tech and answer calls as his schedule allows Congrats Gregg COMMUNICATIONS Service manual supplement system If you ve been reading K Tech News regularly for the last few years you ll surely recognize most of this article We ve revised the information in the table below to bring you up to date Ed Some Kawasaki models need one service manual and some need two Why is this Well in the beginning there is only one service manual which includes all the information the technician needs to maintain and repair a given model motorcycle watercraft utility vehicle or
11. 9924 1064 01 ZG1200 A1 ZN1300 A1 6 99924 1037 03 99924 1015 05 KZ1300 A1 ATV Supplement Base Manual Model of Base Model P N P N Manual KLF185 A1A A2 99924 1076 51 99924 1058 01 KLF185 A1 KLF300 B1 7 99924 1100 51 99924 1057 02 KLF300 A1 KLF300 C1 6 99924 1117 51 99924 1057 02 KLF300 A1 JET SKI Supplement Base Manual Model of Base Model PIN P N Manual JS300 A1 5 99924 1070 51 99924 1059 02 JS300 B1 JS440 A8 A16 99924 1091 52 99963 0054 02 JS440 A1 JS550 A3 8 99924 1075 51 99963 0051 01 JS550 A1 JS550 C1 3 99924 1148 51 99924 1120 01 JS550 B1 JF650 B1 6 99924 1122 53 99924 1069 06 JF650 A1 JS650 A1 4 99924 1087 53 99924 1069 06 JF650 A1 JS650 B1 4 99924 1147 51 99924 1069 06 JF650 A1 JH750 A1 2 99924 1155 51 99924 1156 01 JS750 A1 JH750 A3 99924 1177 51 99924 1156 01 JS750 A1 JH750 B1 2 99924 1177 51 99924 1156 01 JS750 A1 Take for example the KLF300 A1 The sturdy four wheeler originally had a comprehensive service manual all to itself But it was followed by a similar all terrain model the KLF300 B1 To save time and reduce costs the factory chose to produce only a service manual sup plement covering the unique features of the B1 model The supplement did not cover the basic information which originally appeared in the service manual for the older KLF300 A1 model So you need two separate books to have all the information on the KLF300 B1 the KLF300 A1 service manual which is called the base manual
12. D FROM PAGE 1 ZX 7 s open deck cylinder with dry liners The ZX 9R s engine retains the same compres sion ratio as the ZX 7 s 11 5 1 and also utilizes the same intake valves exhaust valves and intake and exhaust camshafts 2 K Tech News Although the transmis sion gear ratios remain un changed from the ZX750 L the primary gear ratio is changed from 1 754 1 to 1534 1 The clutch is also revised slightly to handle the ZX 9R s massive torque The driving plate friction mate rial is now paper based in stead of cork based to i ea au help resist deformation from heat Stronger clutch springs are also used to in crease the torque capacity To reduce noise gen erated from the engine a silent cam chain is used in stead of the ZX 7 s roller chain and a rubber damper is added to the outside of the right side of the cylinder i ety By Twin ram air ducts below the headlight feed fresh air over the frame rails to the air box BELOW ZX 9R s unique exhaust crossoverpipe for improved torque output Twin ram air ducts lo cated below the headlight feed fresh cool air back around the inside of the airing and over the frame rails to the airbox under neath the fuel tank The air flows through a large air cleaner element 15 percent larger than the ZX 7 s to Keihin CVKD 40mm carburetors up from the ZX 7 s 38mm carbs A resonance box is connected to each ram air
13. E E TECH NEWS Fall 1993 The Kawasaki Technical Magazine Vol 6 No 3 by Patrick Kelly Instructional Designer Instructor First the Z I Then the 900 Ninja Both became legends in their own time setting standards for mo torcycles for years to come and putting an indel ible stamp on the history of motorcycling Now there promises to be another legendary Kawasaki 900 the ZX 9R The ZX 9R officially designated the ZX900 B1 is based on the ZX750 L M It is engineered to of fer the latest in handling braking and suspension while at the same time pro viding a high level of com fort fit and finish The ZX 9R s powerful engine is basically a bored and stroked version of the ZX 7 engine The bore goes from 71mm up to 73mm and the stroke goes from 47 3mm to 53 7mm giving a displace ment of 899cc To handle the in creased displacement and torque the main bearings and rod bearings are in creased in diameter by 1mm The cases are also redesigned to clear the in creased stroke and the crankcase bolts are in creased in diameter 1mm to increase the clamping force of the crankcase by 32 percent Because of the ZX 9R s larger bore a closed deck cylinder with wet lin ers is used instead of the CONTINUED ON PAGE 2 Inside PLEASE RETURNTO SERVICE LIBRARY E Service tips amp more ROUTE LIST C SERVICE QO PARTS O SALES TALK TECHNICAL S H OP Power CONTINUE
14. N 11013 1205 grease to seal the air cleaner to the air box Be sure to fill the gap at the TIP FILL THIS GAP WITH GREASE GREASE THIS ENTIRE SURFACE pinch bolt with grease as well O Making that bevel gear case cap Stay put We ve had many calls spread out over the last eight years from dealers having trouble making the cap or seal on a VN750 bevel gearcase stay put Often by the time they call they have already tried several methods and adhesives with little or no success The cap just keeps popping out while the customer rides the bike Naturally when the cap pops out it results in a large oil leak and an unhappy customer The trick to making the cap stay installed is to 1 use a new cap 2 clean the inside of the bevel gear case seal holder with ace tone or lacquer thinner and then 3 apply cyano acrylate super glue to the seal before installing it The most common types of cyanoacrylate glue set up so fast that there isn t much room for error when using them We suggest you use a gel type cyano acrylate which takes longer to set up and is much easier to work with in situations like this where instant bonding is not desirable You can now order gel type cyanoacrylate glue di APPLY GEL TYPE CYANOACRYLATE GLUE rect from Kawasaki using P N KSGGA for a small 06 oz tube or P N TB1762B for a large 71 oz tube By the way this same method should be used
15. U e fe clockwise direction toward the cable to py TSAN Ee a T ae take up all the free play in the cable and the glue to adhere to the selector lever The slot for the pinch bolt types of plastic used in mak should be lined up with the cast in pointer ing motorcycle and ATV with the L mark on the subtransmis parts Also included are sion case woe sandpaper fiberglass cloth 4 Put the High Low selector lever into ON TRANS for eee i ae and High and check for free play in the ca eae oP MBRON a 9 Th aR A E ble by moving the shift shaft lever There should be a small amount of free play 5 If the cable needs adjustment it can be done at either the cable housing ad juster where it mounts to the bracket or at the cable end where it s attached to the shift shaft lever The easiest place to adjust it is at the cable housing adjuster but if there s not enough adjustment avail able there you will have to remove the shift shaft lever from the shaft in order to adjust the cable length Be sure to mark some handy glue remover for cleaning the glue off your fingers or for removing your forefinger from your thumb without surgery The kit is relatively inex pensive will do several re pairs and comes with good instructions With a little practice you will be able to make strong clean repairs for a fraction of the cost of a new part thus making your customer happy and what you do charge will be virtu
16. course whether it s a four stroke or a two stroke en gine But if its a two stroke engine there is something else you should do before taking the top end apart any time you have low compression Low compression in a two stroke engine often means there has been a seizure When repairing a seized top end in a two stroke engine a very im portant step in the repair process is to determine what caused the seizure in the first place There are a number of things that can cause a seizure in a two stroke engine but one of the most common is an air leak To find out if the engine you re working on has an air leak you must preform a crankcase pressure test You need a com pletely assembled engine less carburetor and ex haust pipe in order to pressure test it Once you ve taken the cylinder off you can no longer check that particular base gasket for leaks So if it was leaking and you didn t check it before taking the 9 K Tech News barrel off you ll never know it had a problem And what if the bot tom end has a leak You sure don t want to put the new top end together and then pressure test it only to find out a crankcase seal is leaking In many cases you can get away with lifting the head off looking at the cylinder wall for seizure marks and then putting the head back on to pres sure test it but play it smart and don t take the cylinder off until you ve pressure tested it When p
17. e to get the mat where you want it before it grabs a hold of you and the boat Order this glue from Kawasaki using P N TBI762B Ed 10 K Tech News from dealers about KLF300s that don t want to shift from neutral into first The common com plaint is that they have to blip the throttle rev the en gine a little to get it to shift out of neutral Normally when the en gine is idling in neutral there is enough friction in the primary centrifugal clutch to turn it slowly This of course causes the secondary multi plate clutch and the transmis sion input shaft to turn slowly as well This slow rotation of the input shaft allows the engagement WU LEN dogs clas there s no way it will go into gear until something causes the shaft to rotate something like blipping the throttle enough to engage the cen trifugal clutch just a little verse shaft each have a steel race pressed into the crankcases What have found is that sometimes one or more of these races is not pressed all the way into its bore in the cases The race then pushes against the thrust washer on the shaft caus ing just enough friction to stop the input shaft from turning at idle The fix for this other than just blipping the throt tle to put it in gear is to split the cases and drive each of these bearing races all the way into its bore O VN1500 oil filter confusion by David Pyle Parts Publications Specialist The
18. es from your lo cal auto parts store Get one of these tools and then get used to using it It should become one of the most valuable tools in your shop O If you don t already have one you can order a pres sure tester direct from Kawasaki P N T96000 0071 Decal dilemma We often get calls from dealers asking if the part they need comes with the decal installed or does the decal need to be ordered separately That s a very good question but there is an easy way for you to remember the answer If the vehicle has two wheels its body parts are shipped with decals If the vehicle comes with four wheels or no wheels then its body parts are shipped without decals This rule applies only to body parts and hulls All other parts swingarms etc come without decals Oh and last but not least don t forget to order the warning labels for any applicable parts David Pyle TIPS FROM TH E SPECIALISTS A more better KLF300 replacement air filter by Gregg Thompson Product Support Supervisor In the Summer 1992 is sue of K Tech News we told you about a higher quality replacement air fil ter for KLF300s The KAF 300 A1 MULE 500 filter which has a foam sleeve over a paper ele ment fits all KLF300s as well as KLF220s we re ported Well after a little more in house investigation we ve found that the KLF400 B air cleaner is also interchangeable with these other models and is really quite a bit
19. if one of these caps pops out of the bevel gear case on some other model such as the old ZL se ries Eliminator Gregg Thompson CLEAN INSIDE WITH ACETONE OR LACQUER THINNER The Technical Magazine 9 In the KLF300 trans mission the needle bear ing on the small end of the input shaft and the two needle bearings on the re TIPS FROM THE SPECIALISTS Stubborn shifting KLFs As promised by Keith Pestotnik dogs in the gears to mesh Mass q uanti Rocky Mountain Kawasaki easily when the transmis j sion is shifted into first gear IES J su per Over the years I have re But if the shaft is not g lue ceived a number of calls rotating and the An article in the last issue of K Tech News Vol 6 No 2 Summer 1993 ex plained the different types of glues you should use when installing rubber parts on Kawasaki JET SKI watercraft In that ar tide we promised to get you a part number by which you could order gel type cyanoacrylate su per glue in large enough quantities to install the large floor mats on our sit down watercraft ThreeBond of Amer ica Inc offers the right stuff in a 0 71 oz tuba That s over 10 times as much glue as you get in the more common smaller size containers But in ad dition to its availability in a large tube this glue is handy because it stays where you put it and it goes off a little stower than regu lar super glues you ll have a little more tim
20. k plugs clean air filters ad just chains set valve lash and so on JET SKI water craft service and motorcy cle engines ZXs V twins and all the rest Question 3 Apparently no one has a problem with the shorter technical train ing season Questions 4 7 It looks like you want the Service Contest to have fewer questions per segment and you want it presented in the winter when you have the time to work on it Watch for some revi sions here Question 8 There were very few additional com ments but one stood out Thanks for listening We have one thing to say in re turn Thanks for letting us know what you want from the Service Training and Communications Depart ment O The parts microfiche revised Grid A 2 of the parts microfiche lists P Ns of the technical pub lications available for the product covered on that fiche To clar ify the service manual vs supplement question we have changed the grid layout to tell you what model the base man ual covers so it won t be a surprise when it arrives at your store This will make it easier to explain to your customer why you ordered a KL600 manual for his KL250D and why he needs the supplement as well David Pyle Pp VIDEO Charging and Starting Systems video now available A new videotape from the Technical Training Depart ment covers the theory of operation of most of Kawasaki s charging and electric starting systems in just
21. ntest has been positive With some modifi cations we will start an LEFT to RIGHT Gary Bustillos Director of Technical Services Gary Herzog and KMC President Henry Noda TIPS FROM TH SPECIALISTS MULE 2510 high low cable adjust by Randy Davis Product Quality Engineer Some KAF620 A1 MULE 2510 custom ers have experienced problems with their sub transmission not wanting to stay in the low range while under load as in go ing up a steep hill Nor mally what is needed is just a cable adjustment but some dealers have ex perienced trouble getting it adjusted so it fully en gages and thus stays in both low and high ranges If you run into a situ ation like this adjust the cable as follows TIP Plastic repair kit f you ve been throwing away fairing parts side cov ers and fenders for small cracks or broken mounting tabs you might want to con sider a different approach to save your customer some money Kawasaki offers a plastic repair kit made by ThreeBond Company that the shaft before removing the lever so you can reinstall if in the same position on the splines there is no mark from the 1 Put the High Low selector lever on the dashboard into Low 2 Raise the cargo bed and find the High Low shift shaft lever on the sub factory quickly and permanently re transmission Ren pairs this kind of damage 3 Push on the lever end in a counter LEVER YR
22. ressure test ing an engine ideally you want it to be air tight but a small amount of leakage is acceptable We recom mend the 6 lb 6 min rule of thumb Pump the engine up to 6 psi and it should take at least 6 min utes for that pressure to bleed off You should also vac uum test the engine in case there is a seal that is inclined to leak more in than it does out When is compression low enough to warrant a pressure test In most cases our service manu als give extremely wide compression tolerances For example the new 750cc JET SKI water craft manuals call for 121 187 psi The truth is if one of these engines was down 20 percent from the top of that spec to say 150 psi it could have a problem If it s the same on both cylinders normal wear may be the cause and the symptoms might be fairly mild But if one cylinder is 175 psi and the other is 150 psi there may well have been a light sei zure Pressure testing the engine might help pinpoint the cause of the seizure and could therefore pre vent a repeat failure If you don t already have a pressure tester in your shop you can order one from Kawasaki using P N T96000 001 This pressure vacuum tester E SPECIALISTS comes with a variety of plugs and gaskets to help you seal up the intake and exhaust ports on various engines You will want to supplement these with some expandable freeze plugs that you can get in various siz
23. rst one you see scheduled The class will not be held again this season Another reminder to all technicians who have the occasion to speak with our very capable Hot Line staff Make sure you know the specific year and model of the Kawasaki product you are working with Have the mileage and frame number avail able before you call If you are calling for authoriza tion on a completed job be sure to have a claim number and the job codes available The Hot Line staff can answer more calls if they get all this info without waiting O Training Schedule East Region November 2 4 Engines 5 Precision Measurement and Diagnostic Tool Usage 911 JET SKP Watercraft 23 Parts Department Operations Service Department Operations 30 Modern Engine Theory December 1 2 Fuel Systems 7 9 Troubleshooting Elec Systems 1416 JET SKI Watercraft 17 Generator North Region November 15 16 Fuel Systems 17 19 Engines Central Region December 7 Modern Engine Theory 8 10 Engines 1345 JET SKI Watercraft 16 Service Department Operations South Region November 1 3 Engines Modern Engine Theory 4 Precision Measurement and Diagnostic Tool Usage 911 JET SKI Watercraft 15 16 ATV Service 17 16 MULE Service 29 30 Troubleshooting Elec Systems December 1 2 ATV Service West Region November Precision Measurement and Diagnostic Tool Usage 2 3 Engines 4 Modern Engine Theory 8 10 JET SKI Watercraft 11
24. s The fork springs are buffed on the outside to eliminate break in and the fork bushings are chamfered to eliminate stiction In the rear a nitrogen charged gas shock with a remote reservoir is used This shock has 20 way compression damping ad justment as well as four way rebound damping adjustment Spring pre load is adjusted with a threaded collar and ride height is adjusted by a threaded upper shock mount The Uni Trak link age characteristics are identical to the ZX 7R s and the swingarm with the exception of longer chain adjusters is identi cal too Braking chores up front are handled by dual 320mm discs gripped by four piston calipers The calipers use two pistons of the same bore on each side of the disc In the rear a single piston caliper is used along with a 230mm disc A unique feature of the rear brake system is that the caliper bolts directly to the swingarm and no torque rod is used The ZX 9R rides on the same wide 17 inch rims as the ZX 7 Tires are ZR rated radials 120 70 17 at the front and 180 55 17 at the rear Although the ZX 9R offers racer replica per formance it does not do so at the expense of re finement and rider com fort The handlebar position footpeg location and seat are all designed with both function and comfort in mind The fair ing is larger than the ZX 7 s providing improved protection from wind and rain The inner portion of
25. sh and or use it without further con sideration Specifications subject to change without notice 4 K Tech News GUEST SPOT Technical training survey results are in by Ray St John Question 2 We asked Supervisor Technical Writing you which training sub During the last week in July this year the Service Training and Communica tions Department at Kawa saki mailed out a survey form Its aim To find out what you want from this winters technical training season and what you thought of the recently completed Service Contest Here is a summary of the results Question 1 The video tape everybody most wants to see is on engine diagnostics including two stroke pressure and vac uum testing finding oil leaks oil pressure and compression testing and carburetor vs ignition problems Next in popular ity is a tape on power trains with segments on motorcycle transmissions and final drives and ATV automatic clutches re verse and dual mode and limited slip differentials A lot of you voted for a tape on the 750 JET SKI wa tercraft covering engine disassembly and assem bly carburetion and other new features A fair amount of interest was also expressed in MULE 2500 series service PARTS jects you wanted most and you said electrical troubleshooting We hear you Next we had a four way tie between motorcy cle fuel systems periodic maintenance procedures how to change spar
26. ston Salem N C Versailles Ohio Gary Bustillos is Service Contest Grand Award winner Congratulations to Gary Bustillos for completing all three tests with the highest cumulative score in the 1993 Kawasaki Service Contest Bustillos was presented with the Grand Award at Kawasaki Motor Corp U S A head quarters in Irvine Calif on Sept 17 After being given a tour of KMC s offices and the West Region Distribu tion Center Gary was pre sented with his award by Henry Noda president of KMC and Gary Herzog Di rector of Technical Services What was Gary s award Well inside the specially engraved mini Snap On tool box were tickets for an expense paid visit to Kawasaki Mo 6 K Tech News tors Manufacturing in Lin coln Neb There he will be given a VIP tour of the first Japanese vehicle manufacturing plant estab lished in the United States We want to thank all of the Kawasaki technicians who participated in the 1993 Service Contest We recognize that the invest ment of your time and ef fort was considerable Now that the contest is over you will be receiving your test results along with the correct answers for those questions you missed If you have any questions or would like an explanation of the correct answers for some ques tions please call your re gional training instructor other contest in the fall of 94 Keep those pencils handy O The response to the service co
27. the cowling is painted for a sophisticated look Clutch and brake levers are four way adjustable for rider preference There is a handy storage space for a lock under the seat Instrumentation in cludes a fuel gauge along with a speedometer ta chometer dual tripmeters and a water temperature gauge Welcome the ZX 9R to the Kawasaki Ninja fam ily The power and preci sion of the new ZX 9R promise to set new stand ards for motorcycles to come and stir the passion of motorcycling for an other generation O A new radiator increases the cooling capacity over the ZX 7 by 11 5 percent BELOW To save weight the rear brake caliper is bolted directly to the swingarm The Technical Magazine 3 EETECH NEWS Fall 1993 Vol 6 No 3 1993 Kawasaki Motors Corp U S A KMC All rights reserved K Tech News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Communications Editor Patrick Kelly Regional Editors North and East Fred DeHart Central and South Walter Rainwater Contributors David Corey Randy Davis Keith Pestotnik David Pyle Ray St John Graphics Production Graphic Art Gregg Thompson Copy Editor Pat Shibata Production Nickless Communications Published by Kawasaki All suggestions become the property of KMC Sending a service sugges tion gives Kawasaki per mission to publi
28. this at the multiconnector just in side the electrical box Per form the test with the spark plugs in the engine and the spark plug leads removed and grounded Make sure the stop switch lanyard is in the switch that is in the run posi tion If the stop switch is n the off position lanyard pulled out your readings will be inaccurate Crank the engine with the starter motor and probe the red and purple wires with your meter leads Switch your meter leads on the wires and check again With most meters you will get 60 80 VAC one way and 9 12 VAC the other Meters vary some what so you should prob ably check a couple of known to be good ignitions if you can to see what your meter says Note that some digital meters will ac tually read the higher volt age no matter which way the meter is connected Gregg Thompson The Technical Magazine 11 This time less iS more by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 T his years training season will begin in November and end in April instead of beginning in October and ending in May as it has in previous years At first this may seem as though we are offering you less but in actuality we are try ing to offer you more Let me explain We have found that Oct and May are typically our slow est months in the training season Sometimes there are so few students that we end up having to can cel a class Shortening the
29. train ing season gives students more time to make plans to attend and should have the added benefit of filling up the classes A full class anywhere from eight to 12 students gives every one the opportunity to learn from each others ex periences O 12 K Tech News SOUTH amp CENTRAL NORTH amp EAST New and improved by Walter Rainwater 6110 Boat Rock Blvd SW Atlanta GA 30378 404 349 2000 T he new training season thrills me Our 93 94 train ing season will begin in Nov after the Oct dealer show in Dallas Be sure to look at the schedule in this issue Many of our classes have been changed to in clude information on the exciting 94 models Dealers have re quested it and Kawasaki Technical Training has re sponded We plan to have a limited number of road schools this season high lighting information on the 94 models Look for sepa rate schedules and an nouncements about road schools in your area The Service Contest was enthusiastically re ceived this past season and so we will continue it with a few changes in for mat probably just to keep things interesting Watch for more details O It s back to work by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 J ust a reminder that one Team Green class will again be held in both the North and East regions this training season If you want to attend be sure to sign up for the fi
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