K-Tech News Vol.3 No.1
Contents
1. Model number frame number mileage and failure date are all required Remember that Ninja 1000 and KLR650 are not precise model designa tions but ZX1000 B3 and KL650 A4 are Also all Police Motorcycles Turn signal cancelling problems By Bill Zito National Police Motorcycle Coordinator If your local police agency has encountered repeat failures of the automatic turn signal cancelling device in the LH handlebar switch assembly this may be of help The failure can be caused by holding the turn signal switch in the ON position after the control unit has activated the solenoid in the switch assembly to cancel the turn signal Hold ing the switch ON overloads a small solid state fused link in the solenoid and burns it out The solenoid can be made operational again if you bypass the fuse Follow the service manual procedure to verify that the cancelling device in the LH switch assem bly is the problem and then perform the following surgery on the solenoid Start by taking the switch assembly off the handlebar The cancelling mechanism is contained in the bottom half of the case To get at it you ll need to remove three small screws two on the outside and one inside the housing Lift the mechanism out The solenoid unit is wrapped in white plas tic tape Carefully cut and open this tape on the underside opposite the white green wire Do not disturb the tape on the side where the white green wire is attac2. Orange Lead From Igniter White Lead From Magneto P Lead LOW HIGH TEST 2 Red Lead From Magneto Black Red P From Magneto Lead TEST 4 White Green Pp From P U Coil Lead TIPS FROM THE SPECIALISTS The Hot Line number A dealer exclusive Att the risk of seeming like we re beating a dead horse we must ask you again to remind all of your dealership personnel not to give the Product Support Hot Line num ber to customers Having a customer call the Hot Line significantly affects our ability to handle the calls from your service department especially during the busy season When a customer gets hold of a technician at Kawasaki on a toll free number no less he usually doesn t want to let go And since we don t want to be rude to the customer the call is seldom a short one While we re talking to the cus tomer your technician and the problem he s having must wait In addition calling the Hot Line can add to the customer s frustration and he may have been frustrated to start with He calls one number only to be referred to another Consumer Services The Hot Line staff wants to help cus tomers But we can do this best by giving the dealer the best technical assistance possible as quickly as possible We hope it doesn t come to this but if the ma customer s problem cannot be solved at gq the dealership he should be referred to fe Kawasaki Consumer Services not the 7 a WA Pr
3. Tech News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Regional Editors North and East Fred DeHart Central and South Walter Rainwater West and Corporate Patrick Kelly Contributors Randy Davis Bob Ellison Jerry Heil Donna Hood Micro Mike Jeffers Joe Nowocinski John Porno Steve Rice Ray St John Bill Zito Graphics Production Graphic Art Tim Bean G Thompson Copy Editor Pat Shibata Production Nickless Communications Published by Kawasaki All suggestions become the property of KMC Sending a service suggestion gives Kawasaki permission to publish and or use it without further consideration Specifications subject to change without notice 4 K Tech News GU ES T S P O T Motorcycle Mechanics Institute expands facilities and training on Kawasaki products by Don Church Manager Service Training and Communications Motorcycle Mechanics Institute whose training programs have been endorsed by Kawasaki Motors Corp U S A is nearing completion of a new educational building on its Phoenix Ariz campus When it s finished MMI will have 58 120 sq ft totally dedi cated to motorcycle tech nician training This state of the art training facility includes 10 class rooms 22 hands on shops and three dyno mometer test training labs Motorcycle Mechanics Institute wh
4. and later models Reduced ignition advance and other modi fications make the newer boats more sensitive to low compression If youre working on a JS550 that is hard to stat and it has compression below 110psi check ring wear end gap and m cylinder condition If those are in spec check cylinder length A few long cylinders that cause low compression have shown up in the field If you have a cylinder that measures longer than 116 25mm gasket surface to gasket surface call the Hot Line Gregg Thompson ee ee ee Oe ee ek S eS Consumer Services What you don t say iS Important When dealing with cus tomers what you don t say may be just as impor tant as what you do say For example don t say It can t be done Instead diffuse a customer s anger by saying lIl see what can do If you must later give the customer a nega tive answer at least he will appreciate your efforts to solve his problem lf you are at all uncer tain about the warranty Status tell the customer you will discuss the situa tion with Kawasaki to see if warranty consideration can be given Giving this type of response can less en the customer s dissatis faction and soften the news of denied warranty Be sure to follow through on your promise to discuss the situation with KMC and call the customer back as quickly as possible concerning the decision Procrastina tion and excuses
5. that is cold it s the cylinder In all engines the piston heats up and ex pands quicker than the cylinder In liquid cooled two stroke engines this unequal rate of expansion is far greater than in other engine designs The cold liquid in the water jackets draws the heat from the cylinder material more quickly than an air cooled design and a two stroke firing every time the piston C eee e Oe gt ee ES Too much too soon A cold seizure is usually easy to identify because of its unique four corner pattern The piston s ex pansion isnt perfect and becomes slightly square as it s heating up The highest points on the piston where it will con tact the cylinder first are usually near the outer edges of the intake and exhaust skirts see illus tration Thus the four corner seizure pattern There s no doubt today s liquid cooled two stroke engines provide unequalled performance and light weight but you do have to be careful warming them up Gregg Thompson comes up can rapidly heat up the piston A problem occurs when the engine is run too hard before it is completely warmed up and the piston outgrows the cylinder bore Four corner pattern KX125 250 CDI test values T he KX125 H1 and KX250 H1 CDI ignition systems can be tested with the Kawasaki CD Ignition Tester P N T56019 201 The test values and meter connections are as follows Fred DeHart TEST 1
6. 11 and ZX 6 see pages 2 and 3 Plus E Automatic video ROUTE LIST O SERVICE O PARTS Ol SALES see page 5 PLEASE RETURNTO SERVICE LIBRARY SHOP TALK TECHNICAL The ZX 11 Performance matched only by durability by Jerry Heil Training Development Coordinator Read the latest issues of my of the motorcycle magazines and you ll probably find some tidbits of information about the new ZX 11 For example Cycle found that its horse power at the rear wheel was 127bhp Other magazines have reported astronomical top speeds and measured quarter mile times in the low 10 second range Included in this article though are some details about this new bike that you may not have read about The semi downdraft 40mm Keihin carburetors do fit snugly between the perimeter frame rails How ever access to the float drain screws is easier than it looks White plastic cones guide a 3mm ball 2 K Tech News end hex driver the same driver used on the ZX 10 and ZX 50 special tool P N 57001 1269 to the head of the drain screw Attaching manometer hoses and adjusting linkage is also made easy The ZX 11 s cylinder is rotated forward 17 degrees but there s still plenty of room for valve lash measurement As on the ZX 10 the rocker arms slide sideways away from the valve This allows easy replacement of the valve shims which are the same as those used on the ZX 10 The ZX 11 and ZX 10
7. 4 1 E amp CH NEWS Spring 1990 The Kawasaki Technical Magazine Vol 3 No 1 Two Hot Kawasaki s advanced en gineering has made over whelming progress in the production of super perfor mance oriented motor cycles possible Proven technology and state of the art components are combined with innovative design in products that offer outstanding perfor mance and handling as ue well as added reliability oS S f Ed gt Two fine examples of 2 Ty motorcycles on the fore front of development for the 90s are Kawasaki s ZX1100 C1 ZX 11 and ZX600 D1 ZX 6 The ZX 11 is a super modified ZX 10 with features that include forward canted cylinders free breathing valve train with forced air induction adjustable front forks and dual semi floating four piston front calipers to name a few All new for 90 is the ZX 6 boasting a new high compression engine with microprocessor controlled digital ignition direct actuated valve train downdraft carburetors arced air cylinder head cooling front disc brakes with opposed four piston calipers and a host of other hot features i The ZX 11 is the most remarkable lt superbike we ve ever ridden If it were also the last it would forever be enough The ZX 6 is a bike that makes its In S d e own rules Rules that the rest of the 600 class will soon have to live by CYCLE WORLD March 1990 E nside the spectacular ZX
8. BOSS 20 JET SKI User Relations Wkshop 20 Product Update 30 High Performance Engines May 1 2 Troubleshooting Electrical Systems 3 Product Update 7 Generators 8 9 Team Green Race Preparation 10 Service Department Operations K BOSS 14 16 JET SKI Watercraft 17 Product Update 29 30 Engines 31 High Performance Engines
9. F The ZX 6 has coolant pas sages around the spark plugs and near the center of the exhaust ports The cylinder liners are of the open top deck type which more effectively cool the upper portion of the cylinders Cool air is also ducted from the front of the fairing to the top of the cylinder head to lower the air temperature around the engine The improved lubrica tion system features two oil pumps one supplying oil to the oil cooler and transmission gears the other feeding pressurized oil to the engine A new spin on type oil filter com pletes the new lubrication package A new stronger clutch has been utilized on the ZX 6 Cable actuated it is basically the same as in the ZX750 F except that the number of both drive and driven plates has been reduced by one This allows the plates to be thicker providing in creased heat capacity and greater resistance to fade The ZX 6 clutch also fea tures a paper based com pound on the friction plates and has six damper springs with three different spring rates All in all the new ZX 6 engine and drivetrain pack age represents a giant leap forward in technol ogy resulting in a substan tial increase in useable power We believe the new engine is unmatched in its class for power and all around performance O The Technical Magazine e 3 EE TECH NEWS Spring 1990 Vol 3 No 1 1990 Kawasaki Motors Corp U S A KMO All rights reserved K
10. X 6 now playing on a VCR near you You ve seen all the flyers now the new Introduction To ZX 6 Service video itself is finally here The VHS format ZX 6 video is actually two programs in one Part one covers the innovative design and engineering of the ZX 6 explaining some of the manufacturing breakthroughs that make this incredible motorcycle available to and affordable by the knowledgeable motorcycle enthusiast The second portion covers removal disassembly assembly and installation of the ZX 6 engine This engine is entirely new and was designed from the ground up to have low overall weight and ultra compact dimensions As a result many details differ from other Kawasaki engines see Patrick Kelly s feature on page 3 Ed The ZX 6 videotape is paced for the experienced technician but even a beginner can profit from watching it If you haven t already taken advantage of Kawasaki s Automatic Tech Training Videotape Purchase Plan fill out the coupon inserted into this issue You ll get this tape for only 25 plus applicable sales tax and shipping charges 30 percent off the regular dealer price of 35 95 Ray St John The Technical Magazine 5 COMMUNICATIONS Micro i lt amp by Micro Mike Jeffers Parts Publications Specialist B y the time this issue finds its way to you all of the 90 model microfiche will have been released A convenient way of verify ing that your Micro K deck is up to da
11. aki ZX models We are sure the ZX 11 will keep your customers happy with its unmatched performance and durability O S H OP TAL K TECH NICAL The ZX 6 Unmatched all around performance by Patrick Kelly West Region Instructor The Kawasaki ZX 6 offi cially the ZX600 D1 is Kawasaki s latest high tech weapon in the battle for top honors in the 600cc sport bike category Kawasaki s newest 0 6 liter motorcycle has been created from the ground up and has little in com mon with previous Kawasaki middleweights The engine in the ZX 6 is completely new produc ing more horsepower and torque than the ZXG00 C which preceded it and features a new fuel induc tion system The airbox is 60 percent larger and feeds new 36mm down draft type carburetors that are a full 4mm larger than the conventional sidedraft carbs used on the C model These larger car buretors help boost high rom power output The cylinder has also been canted forward 15 degrees and the overall downdraft angle is 49 degrees giving the incom ing air fuel mixture a Straight shot into the com bustion chamber This improves the breathing and provides quicker throt tle response throughout the power band The valve train is the direct actuation type with replaceable shims for valve clearance adjust ment The intake valves use the same tappets as the ZX750 H but the ex haust valves use a new smaller tappet The shims are a new ty
12. apes automatically when they become available Because we expect to lower our cost per copy by being able to produce more copies of each tape we ve recently lowered the price to you by 30 percent It is now 25 00 plus ap plicable sales tax and ship ping This price break will be extended to cover all technical training tapes in our catalog for those dealers who sign on with the automatic program We will send up to four tapes in a calendar year but never more than four So this program can never cost you more than 100 per calendar year Plus we understand that if you carry only JET SKI watercraft you don t want tapes on motorcycles So we will send you only those tapes that cover the COM MUN CAT O N S Kawasaki products you carry in your store Frankly we expect that you ll like what you see and you ll decide to keep every tape we send But if you don t want a tape after t s been delivered auto matically just send it back or a full refund If you have not already enrolled in the automatic video tape distribution program here is another chance All you have to do is fill out and mail in the postage paid card bound into this issue O If for any reason the postage paid card is miss ing send your address including dealer number and authorized signature to Kawasaki Motors Corp U S A Tech Services Dept 9950 Jeronimo Rd Irvine CA 92718 Attn Automatic Video SS The Z
13. copy to each employee so he will know what is expected of him It might look like the one below Your service people are real assets Treat them as such O JOB TITLE Service Writer NAME OF SUPERVISOR John Doe Service Manager AREAS OF RESPONSIBILITY Maintain good customer relations Promote the dealership and its product lines SPECIFIC DUTIES Customer contact Greet customers in a friendly courteous manner Sell services offered by the dealership Write repair orders completely and realistically Assist technicians in diagnosing problems by recording all pertinent information on repair orders Solicit follow up business by contacting previous customers via telephone or mail e The Technical Magazine TIPS FROM THE Have the correct information ready California models are iden tified with an L as the last character for ex ample ZX1000 B3L When we ask for the frame number we need only the last sixdigits of the VIN for motorcycles and ATVs and the first five numbers after KAW or JKA of the HIN for watercraft If you have all this infor mation ready each time you call you ll soend less time on the phone with the Hot Line staff And so will we which means less time for you on hold wait ing for one of us to answer John Pomo have all the correct vehicle information ready lt is very important when calling the Hot Line to
14. ct your operation And the first impression of your service department is probably the most important therefore your service people are of prime importance to your dealership Service employees should have a pleasant manner be considerate of fellow employees and customers have experience and knowledge of products serviced and be competent in their positions The attitude of your service staff will greatly influence the satisfaction of your customers It is important that your employees have and main tain a good attitude Some items that affect attitude are working conditions fringe benefits fairness in dealing with the employees and customers work load salary structures etc Monitor your service department keep your employees busy watch their attitudes and you will make more money Your service department has several different types of employees The number will depend upon your shop size and may include service manager service writer line technician specialist technician assembly technician apprentice technician and or machinist A service manager is recommended for all dealerships In dealerships without a service manager one person should be designated as lead technician The lead tech nician performs the same duties as the service manager in addition to his duties as a mechanic To prevent any misunderstandings about each employee s responsibilities you should write job descriptions a different one for each position Give a
15. ealerships grow in all aspects including profitability Many people worked hard to make this video a success but the most important are the five dealers who appear in the tape Our special thanks to these dedicated dealers dedicated to their families their employees their communities and to the success of Kawasaki dealers all over the country They gave us their time opened their stores to us let us use their people gave us the benefit of their experience and encouraged us to produce what we believe to be an extremely worthwhile presentation These dealers are Mr Ted Nielsen Nielsen Enterprises Lake Villa Illinois Mr Mike Whalley Hooksett Kawasaki Hooksett New Hampshire Mr Charles Roc Northey Kawasaki of Lake Wales Lake Wales Florida Mr Sammy White Kawasaki City Irving Texas Mr Patrick Cody Wilson s Kawasaki Fresno California Ray St John 6 K Tech News W As usual if you have any questions please call the Micro K division of the Service Training and Com munications Department at KMC 714 770 0400 ext 2573 or fill out and send in the Micro K report card P N M99994 152 0 S H O P T AL K 1990 Team Green Race Preparation class by Jerry Heil Training Development Coordinator In the first three months it was offered over 75 tech nicians took advantage of the information presented in Kawasaki s new Team Green Race Preparation and Maintenance course The class is two days packed wi
16. en the contacts You may need to use fine grit wet dry sandpaper contact cleaner works well on dirt and oil but it won t remove corrosion lf after cleaning the contacts the fuse Is still getting too hot check the current flow through the fuse The amperage load might be very near the rating of the fuse If so the fuse element is getting hot and is probably near the melting point Check the load of individual com ponents downstream of that fuse to find the cause of the overload Usually you ll find the overload is caused by some added non original equipment Bob Ellison J S550 compression what s OK what s not Something technicians sometimes overlook when dealing with a hard start ing problem on a JS550 JET SKI watercraft is compression In fact when hard starting is a symptom with any engine compression should be checked however with the JS550 you might think compression is OK when it s really not The 550 engine is nota high compression en gine a good running stock boat will have only 120 130psi cranking pres sure You might think it s OK then with only 105psi After all that s less than 20 percent down from a really sharp stock engine In fact for late model engines the range given in the service manual is 78 112psi In reality if a JS550 s engine compression dips below 110psi starting will be affected This is espe cially true for 86
17. ert and attentive throughout the day Come to class with an open mind ready to learn No matter what level of knowledge or experience CONTINUED ON PAGE 11 12 K Tech News SOUTH amp CENTRAL Team Green Race Prep by Walter Rainwater When this issue of K Tech News arrives you will still have an oppor tunity to pre register and attend our new Team Green Race Preparation class We introduced this class because of dealer re quests and have held it several times Technicians that have attended have been very complimentary about the class content As with many of our training classes even the most experienced tech nician can learn some thing new and helpful Some of the tips can make their jobs easier and quicker others including this particular Team Green Race Prep class may help prevent some expen sive damage from occur ing while doing routine service Have a look at the training schedule on this page of the newsletter and select a class and CONTINUED ON PAGE 11 NORTH amp EAST Update your Skills by Fred DeHart B ecause of some un usually mild weather pat terns service work has been brisk at many dealer ships in the North and East Regions early in this new decade of the 90s By now your service department should have received the Technical Training bulletins outlining the class schedule through May If you are planning to attend clas ses sign up now before the
18. have many engine parts in common including rocker arms rocker shafts and Springs as well as valve guides valve springs and keepers The ZX 11 intake and exhaust valves are 1 5mm and 1 0mm larger than those in the ZX 10 respectively Its cams pro vide more duration for both intake and exhaust valves The ZX 11 s eight addi tional horsepower and 3 7 more ft lbs of torque re quire an increase in clutch capacity above that of the ZX 10 s clutch The outer diameter of the steel driven plates is increased 5mm to 151 mm Each of the eight driven plates is 2 9mm thick where the ZX 10 plates and six 2 6mm plates The increase in clutch pack volume yields improved heat absorption Capability and less clutch fade The friction plates meanwhile use a paper based compound instead of the cork compound used in the ZX 10 The paper compound has been used previously in KX models and provides more uniform friction char acteristics and improved wear under heavy loads The primary gear ratio on the ZX 11 Is taller at 1 638 1 than the ZX 10 s 1 732 1 Transmission ratios are the same in both models though the gears are different The ZX 11 s increased power requires that second third and fourth input gears and second and made from a stronger Steel alloy that contains nickel in addition to the chromium and molyb denum of the ZX 10 alloy The ZX 11 continues the tradition of refinement in the Kawas
19. hed Once the tape has been opened you will find a small fused link in the ground wire This tiny fuse has failed causing an open in the coil circuit Bypass this fuse by soldering a jumper wire around it After in Stalling the jumper wire cover this area with electrical tape and re install the cancelling mechanism in the switch housing The nice thing about this repair is that it will probably be the last one of its kind for that vehicle O Jumper wire Fused Link Solenoid Coil 8 K Tech News SPECIALISTS New carb syncro tuner Kawasaki is proud to in troduce its new carb syncro tuner a high quality mercury manometer used to synchronize carburetors on all two and four cylinder Kawasaki four stroke engines This new tool is made of high impact plastic and has a large easy to read scale printed right on the case Hoses mercury and instructions are included Order yours today it is P N T56019 031B Joe Nowocinski TIPs ee Oe Hot Fuses Corrosion or current flow Occasionally the Hot Line will get a call about an older machine with a hot fuse box Sometimes the fuse will get so hot the solder melts out of it One cause of over heated fuses especially in older bikes is dirty or corroded fuse mounting clips The poor connection caused by the dirt or corrosion may cause arcing at that point and excessive heat To correct the problem remove the fuse and clean and tight
20. ich has an eastern campus in Orlando Fla provides entry level technician training on all types of motorcycles AS you may have read on these pages before Kawasaki is now providing MMI with a steady stream of current product information The ie Ei i ee te lee T AE ee eee s z school is using this to upgrade its programs to in clude better coverage of Kawasaki products Graduates of MMI s programs have proven to make excellent entry level technicians who develop rapidly into solid line should call MMS mechanics Dealers who are interested in interview ing or receiving resumes from these graduates graduate placement office in Phoenix at 1 800 528 7995 or in Orlando at l 800 342 9253 0 Photos this page New construction on MMI s Phoenix campus Automatic video You bet by Ray St John Senior Technical Writer K awasaki Heavy Indus ries in Japan has an in louse video studio and Staff KHI also has an am bitious program aimed at producing technical train ing video tapes covering he subjects most asked or by Kawasaki dealers in he U S Plans include the production of new product introductory programs such as the ZX 6 tape mentioned below Here in this country Kawasaki s Service Train ing and Communications Department has devel sped a new way for you to take advantage of this con tinuing effort Now you can Sign up to receive techni cal training video t
21. not be reprinted when present supplies are exhausted Catalogs currently avail able are 99995 625 JS400 A3 99910 1361 02 JS300 B2 99910 1365 03 JF650 A2 99960 0026 01 JS440 A6 99960 0028 50 JS550 A2 99960 2002 KG550A 99960 2022 GD700A 99960 2001 KG700 KG2600B 99960 2011 KG750B 99960 2012 KG1100B 99960 2005 KG1600A 99960 2016 GA1800A mewe wees Sto Sem Transmission Improve EA aas ae a ee ment article in the last CHG y ayr A sabe ar a teas os 9 n issue OARB80 A1 82 0131 Oct 82 Printed parts catalogs B 99910 1368 01 JS300 A1 99910 1372 01 JS440 A11 99960 0023 01 JS440 A3 A4 A4A Ad 99960 0026 02 JS440 A7 39960 2021 GD550A 39960 2013 KG550B 39960 2023 GD700AS 39960 2003 KG750A 99960 2004 KG1100A 99960 2020 GA1400A 99960 2014 KG1600B 99960 2017 GA2300A 99960 2015 KG2900B 99960 2008 KG4000A AS meanwhile are now avail Servicing Your Bottom Line Right after Christmas every Kawasaki motorcycle ATV and watercraft dealer in the country received a video tape entitled Servicing Your Bottom Line The tape was sent out free of charge and it was addressed directly to the dealer principal For Your Eyes Only was the dramatic announcement on the outside of the package Servicing Your Bottom Line was a special one time effort produced by Kawasaki s Tech Services Department urging all Kawasaki dealers to believe in the service end of their dealerships and their service personnel and to let their d
22. oduct Support Hot Line aa A gm Steve Rice Illustration E _ Gregg Thompson WEST eee CONTINUED FROM PAGE 12 you may have it is always possible to learn something The right sealant for the job new Generally the students in all the classes have a When sealing the center For sealing engine center wide variety of experience and backgrounds By par cases of any motorcycle cases a very thin almost ticipating in discussion and sharing your thoughts and or watercraft engine transparent coat on the ideas you ll be assured of learning something new make sure to use a sealing surfaces is all Coming to class well prepared makes it possible to sealant that is highly gas that s needed A good way take full advantage of the training courses offered by and oil resistant Most to apply the sealant Kawasaki and maximizes your learning potential Next sealants labeled silicone without wasting any is to time you attend make the most of it and remember the sealant are not oil resis use a small 14 inch or so Boy Scout motto Be Prepared tant at all In some cases paint brush Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 they can actually create a Kawasaki Bond is 714 770 0400 leak that may not have manufactured by Three occurred if you didn t use Bond Co Ltd of Japan any sealant These CONTINUED FROM PAGE 12 sealants soften rapidly date for your dealership personnel to attend Our Spring when exposed to oil
23. or schedule concludes at the end of May Enroll now in the gas and provide a sort of Team Green Race Preparation class or other class of wick a path connecting your choice inside to outside for the oil Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 NORTH amp EAST CONTINUED FROM PAGE 12 Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 to follow The only sealant Kawasaki recommends for engines is the white Kawasaki Bond P N 56019 120 It is very ex pensive so dont waste it Other gas and oil resistant sealants are available from Three Bond of America Inc 20815 Hig gins Court Torrance CA 90501 213 320 3342 Randy Davis The Technical Magazine 11 REGIONAL NEWS WEST Come to class prepared by Patrick Kelly n order to get the most from time spent at your regional training center it helps to come to class well prepared Here are a few suggestions Review the subject mat ter before coming to class Write a note listing those items which are well un derstood and those items which are unclear to you Be sure to write down any questions you have beforehand just to make Sure you remember to ask them Get a good night s rest before coming to class If you are traveling a long distance try to arrive early enough the day before class starts to assure a good night s sleep This will help you to remain al
24. pe not used on any previous U S model so be sure to order a selection for your Ser vice Department Intake valve diameter has been increased from 21 5mm on the ZX600 C to 26mm on the ZX 6 while exhaust valve diameter has been in creased from 19mm to 22mm Valve stem diameter meanwhile has been reduced to 4 5mm on both intake and ex haust valves The included angle of the valves is a narrow 30 degrees com pared to 36 5 degrees on the ZX600 C This makes possible a very compact pentroof type combustion chamber allowing superior combustion efficiency The large 64mm pistons result in a very oversquare 64mm x 46 6mm bore and stroke The large bore makes room for the big new valves and the short stroke makes a 14 000rom redline possible Piston rings are new too The top and second rings are 2mm thinner at 8mm and the oil control ring is 5mm thinner at 1 5mm Due to their lighter weight these thinner rings are less likely to flutter at high rom Although the pis ton and rings are new the piston pins and connect ing rods are the same as in the ZX600 C engine The ZX 6 engine does have a completely new crankshaft which turns in Six plain type main bear ings the ZX600 C has five main bearings The increased horse power output demanded improvements be made to the cooling and lubrication systems The radiator and oil cooler are now the same as those found on the larger ZX750
25. te is to use the Micro K Index as a refer ence The date of issue on each microfiche A on il lustration should be the same as the date on the Index B Be sure to dis card outdated fiche To ob tain individual replace ment microfiche order by part number C M A transmission kit was added to the KAF450 B1 Mule 1000 microfiche P N 99961 0269 in February able for the KAF540 C1 Mule 2010 and KAF540 D1 Mule 2020 You may order the catalogs by using P N 99960 0031 01 Mule 1000 99960 0032 01 Mule 2010 and or 99960 0033 01 Mule 2020 WE We re having a parts catalog clearance sale Except for utility vehicles Kawasaki has discon March 1990 Kawasaki Micro K Index This eS pow to help you keep current with the latest Microfiche updates and new issues New or revised microfiche included in this mailing are nated 1 Check each item on the iet against your microfiche referring to model name part number and date of issue 2 Discard outdated fiche that are replaced by revieed fiche in this mailing Always use microfiche with the most recent date 3 To obtain individual replacement microfiche order by part number in the normal manner tinued production of printed parts catalogs We still have limited quantities of some early model parts catalogs in stock though and we are offering them for sale at a clearance price of only 2 00 each The catalogs listed will
26. th how to do it and where to find it infor mation Students receive printed step by step descriptions of engine race preparation techni ques used by the same mechanics who prepared Larry Roeseler s Baja win ning bike The techniques are also demonstrated to the class by Team Green mechanics fresh from the prior weekend of com petition Operation of Kayaba in verted forks is explained in the text material and fork service techniques are demonstrated in the classroom Uni Trak shock disassembly and assem bly techniques are also covered in detail The Team Green class student binder is worth its weight in work orders when you consider the valuable tips and refer ence materials it contains The materials list includes ways to make inexpensive tools to get you started and plans for the more fancy ones when you have time Were you one of the lucky 75 who signed up early or are you being left behind Reserve a seat in the next Team Green Race Preparation and Maintenance class at your Kawasaki Regional Train ing Center and stay ahead of the competition O Sa Instructors Erick Poston left and Pa trick Kelly right demonstrate service of inverted forks to West Region technicians E Service Department personnel requirements by Walter Rainwater South amp Central Region Instructor The single most important asset of any Kawasaki Service Department is its people People refle
27. weather breaks and you find you re too busy to go He who hesitates will miss the opportunity Our new Team Green Race Preparation and Maintenance class has been very well received by those who have attended This is a good time to take advantage of the season and update your skills on the new KX motocross machinery hope to see you at one of our classes soon CONTINUED ON PAGE 11 hs Training Schedule East Region April 24 26 JET SKI Watercraft 27 Product Update May 8 Parts Department Operations 9 41 JET SKI Watercraft 14 JET SKI User Relations Wkshop 15 Service Department Operations K BOSS 16 17 Team Green Race Preparation 18 Product Update North Region April 18 19 Team Green Race Preparation May 3 JET SKI User Relations Wkshop 21 Service Department Operations K BOSS 22 Parts Department Operations 23 24 Team Green Race Preparation 25 Product Update Central Region April 30 JET SKI User Relations Wkshop May 1 Product Update 2 Team Green Race Preparation 3 4 JET SKI Watercraft South Region April 19 JET SKI High Performance 23 26 Troubleshooting Electrical Systems 7 High Performance Engines 8 9 Team Green Race Preparation 10 Product Update 11 JET SKI User Relations Wkshop JET SKI Watercraft 17 JET SKI High Performance 21 Product Update 22 24TroubleshootingElectricalSystems West Region April 19 Service Department Operations K
28. when handling warranty decisions and complaints will result in angry customers Donna Hood Consumer Services The Technical Magazine 9 T lPSs ee Which crankshaft The first JF and JS650 crankshafts were located in the cases by a dowel pin in the center seal Since then the design has been changed twice If you are ordering either a crankshaft or crankcases for a 650 JET SKI watercraft be very careful to order the correct one by engine number If you are ordering both cases and crankshaft it s probably best to order the latest part numbers Once again select the part num bers off the microfiche carefully For your information the first design with the dowel pin in the center seal is superseded by a second design which has a haltf circle retaining ring in the front center main bearing Both crankcase and crankshaft retain the dowel pin hole for com patibility with the earlier parts The third design has a thinner full circle retaining ring in the front center main bearing This is not compatible or interchange able with either of the ear lier designs unless the crankshaft and cases are replaced as a set Gregg Thompson 10 K Tech News m a ae Oe T H E Cold seizure H ave you ever heard of a cold seizure Does cold seizure sound like a con tradiction in terms Maybe it won t after a short ex planation When a cold seizure oc curs It s not the piston
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