K-Tech News Vol. 4 No. 4
Contents
1. Bill Zito 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 suggestion gives Kawasaki permission to publish and or use it without further consideration Specifications subject to change without notice 4 K Tech News Kawasaki conquers Baja 1000 again by David Pyle Former Team Green Technician The final results can be summed up by using the motto of one of the most respected men in motor sports today Roger Pen ske Effort Results No statement could be closer to the truth when talking about Kawasaki s recent victory in the Baja 1000 For sure can t think of another race in which Kawasaki competes that requires so much pre race preparation Testing for this prestig ious off road event contin ues pretty much all year round Team Green uses both national hare and hounds and local district desert races as testing grounds for suspension engines and pipes A ra dar gun and tach are used to determine a bike s po tential with different pipes cylinders and gearing Because the Baja 1000 is laid out differently each year final settings must be chosen that will best match the course condi tions This year s course was relatively fast our race winning KX500 E4 was able to race across the dry lake beds and paved sections of the course2. air bubble uphill Take the master cylinder off the handlebar t s an unfortunate fact of life in the motorcycle fast lane that when your cus tomers gas up their bikes fuel is not always the only thing they re putting into their tanks Depending on the type and condition of the underground storage tanks at the gas stations they can also be adding a variety of contaminants in cluding water rust and dirt along with the gas Kawasaki vehicles are equipped with a fine mesh screen on the petcock to keep these contaminants out of the carburetors but tiny particles and water and hold it up with the hy draulic line straight and the ball end of the lever pointing up Now push on the front caliper forcing the piston al the way into the cali per body This will force a large volume of fluid uphill S into the My N reser AN VOIT N While holding the master cylinder high pump the caliper back up wait about a minute and then push the caliper lem was air trapped in the line this should take care of it If this procedure doesn t solve the problem look for a misaligned caliper mount or a bent or cupped disc David Pyle still get through and can cause trouble in the carbs Inspecting the carbs for these bad news intrud ers is a good procedure to include in a normal tune and service Just drain the fuel from each carb bowl into a cup and inspect it If it has anything i
3. 1 JF650 A6 Steering Shaft Break Available age Recall TR91 03 10 25 91 Technical Training Posters JS91 04 8 23 91 JL650 A1 OilTank Blockage and Wall Charts Available Factory Directed Modification TR91 04 10 25 91 Special Service Publications JS91 05 10 8 91 JF650 B1 2 Fuel Filler and Available Gasket Recall ALERT KX125 250 Service Manual corrections Make the following corrections in your copies of the KX125 250J Service Man ual P N 99924 1153 01 That s it Aren t you glad you saw this little gem of an article Ray St John Page 4 16 bottom The last photo on the page should show the rod being in Stalled with the slotted end outward The last sentence on the page should read Install the main valve rod A in the cylin der so that the slotted end B is on the outside See i us right Ed Page 13 4 Specifications The first sparkplug listed for the KX125 J1 should be NGK R6254k 105 The KX125 J1 sparkplug for A C E should be NGK R6252K 105 resistor type The Technical Magazine 5 TIPS FROM TH SPECIALISTS A plug or two for the KX line by Gregg Thompson f you ve run into trouble lately try ing to supply your 1992 KX125 J1 and KX250 J1 cus tomers with spark plugs this article is for you While research ing this article found six factory recommended plugs in the standard heat range for the 125 plus a couple more that can be used in a pinch The sta
4. 1991 1992 training season Jeff Chambers of Team Green will do his usual thorough job of updating your techni cians on the 1992 product Don t miss this opportunity Have a great new year as we start the next 25 years with Kawasaki O The Technical Magazine 11 R E G IONAL NEWS New and much improved by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 Hey it s time for a West Re gion update already Well out here in Irvine Calif we the Service Training and Communications de partment have been very busy working on various projects including K Tech News of course to keep you informed up to date and on the right track For example the new parts department video has been wrapped up and work has begun on the workbook which will be used in conjunction with the video The Flat Rate microfiche is being up dated to include the 92 models and eliminate dis crepancies among similar models We have also been busy revising the Electrical Troubleshooting Guide Police Motorcycle Mainte nance Manual and the Team Green student text CONTINUED ON PAGE 11 12 K Tech News Happy new leap year by Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 It s hard to believe it but a new leap year is upon us already There are many tell tale signs hordes of berserk shoppers swarm ing the malls here in At lanta in search of after Christm
5. 8 30 91 All JET MATE Maximum Capa cities Label Replacement Check this list against your service bulle tin binder to see if you have everything the Service Training and Communica tions Department sent out during calen dar year 1991 The dates given are for the latest revisions if any If youre missing any of these and would like copies give us a call at 714 770 0400 Extension 2472 Number MR91 01 Racing Support Service Bulletins Number Date Title Subject Motorcycle RS91 01 1 18 91 KX80 R1 T1 Race Tuning Service Bulletins RS91 02 4 12 91 KX125 H2 Race Tuning Number Date Title Subject RS91 03 4 12 91 KX250 H2 Race Tuning MC91 01 3 8 91 Motorcycle Chronology Table l MC91 02 3 8 91 ATV Chronology Table Special Tool MC91 03 4 19 91 KZ1000 P8 9 10 Transmission Service Bulletins Bearing Recall l MC91 04 6 21 91 ZX600 D2 L Camshaft Knocking Number Date Title Subject Factory Authorized Repair SP91 01 2 8 91 MULE 500 New Special Tools MC91 05 8 16 91 Voyager Audio Repair Service SP91 02 7 19 91 MULE 500 Special Tool Mis assembled J ET SKI Watercraft PERTE ee Service Bulletins ecnnical I raining Service Bulletins Number Date Title Subject l l JS91 01 3 8 91 Watercraft Chronology Table Number Date Title Subject JS91 02 6 28 91 JL650 A1 JF650 B3 Cooling Sys TR91 01 10 25 91 Technical Training Video Tapes tem Blockage Factory Directed Available Modification TR91 02 10 25 91 Technical Training Manuals JS91 03 7 19 9
6. K Share terminal or parts price guide says to Gregg Thompson 200 mph repair man Congratulations once again to Hot Line staff member Steve Rice for winning his second straight Dragbike U S A OHC Funny Bike champi onship Steve clinched the title by taking the overall win at the last meet of the year in Gainesville Fla On his way to winning the 91 championship Steve eclipsed the 181 mph Funny bike record he set last year nailing down a new record of 7 088 sec at 192 mph Steve s bike has a turbo charged fuel injected al cohol burning 1260cc KZ1000 P10 based en gine housed in a hand built frame with an 80 in wheelbase and 10 inch year Steve was clocked at over 200 mph Steve says that one of the most enjoyable parts of going to races all over the country 35 000 miles this year is meeting in person some of the Kawasaki mechanics he talks to on the Hot Line What about setting all these records and winning back to back champion ships m just a motorcycle re pair man he says Please don t tell my mom Yeah right Steve Well next year be on the look out for one quick motorcy cle repair man at a drag strip near you O VN1500 Vulcan is avail able under a separate part number Order today Joe Nowocinski Have you ever found your self looking for an easy way to jack up a four wheeler or a bike without a center stand to work on the suspension or chang
7. Winter 1991 The Kawasaki Technical Magazine Vol 4 No 4 by Patrick Kelly Instructional Designer Instructor With the introduction of not one but two new high performance watercraft for 1992 Kawasaki has given he competition a stagger ing one two punch And not only will the competi tion be amazed but so will you the first time you take a spin on either the JS750 A1 750 SX or the JH750 A1 750 SS Never before has there been such high performance offered in a personal watercraft and it took Kawasaki s perform ance and engineering ex pertise to do it Start with the engines Although their respec tive hulls are unique every discussion of these new watercraft begins with their engines Both craft share the same in line twin cylinder 743cc two stroke engine Even though the new 750 en gine s overall layout is similar to the 650 series of engines it is completely new from the ground up It boasts a 4mm larger bore at 80mm and a 6mm longer stroke 76mm than the 650 engine This new engine fea tures an aluminum cylin der with cast iron liners which extend below the cylinder base to reduce piston slap The pistons are an aluminum silicon alloy with two steel gt ROUTE LIST O SERVICE PARTS O SALES Inside PLEAS ERETURN TOSERVICE LIBRARY E Service tips amp more S H O P TAL K TECHNICAL 1 2 3 Punch CONTINUED FROM PAGE 1 piston rings Th
8. as bargains to name just one We in the motorcycle in dustry have seen the tell tale signs as well Sadly all the major motorcycle racing series off road motocross supercross hare scrambles drag and road racing and all the rest of them are over Happily Daytona is just one month away as write this What the coming of a new year means to us here in this office of course is another round of train ing classes We re work ing flat out to stay on top of all the model changes CONTINUED ON PAGE 11 Before you reach critical by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 Lately all my phone con versations have been problems that have esca lated to critical mass cri sis time lf your dealership has a technical problem parts problem or just a ques tion please call before frustration sets in The Product Support Hot Line is a toll free num ber Use it And feel free to call the regional off ice any time will gladly try to ans wer your questions com plicated or otherwise No one has all the an swers of course but we can t solve a problem if we don t hear about it And if we don t have the answer chances are we can direct you to someone who does North Region dealers please note There will be a Team Green Race Preparation class held in CONTINUED ON PAGE 11 Training Schedule East Region February JET SKI Watercraft Engines Fu
9. at just under 120 mph thanks to a 16 42 fi nal drive In stock form the KX500 is an extremely capable machine but to be com petitive in an event as gru eling as the Baja 1000 some changes are called for An adjustable steering damper is used to keep the big KX on the straight and narrow at extreme racing speeds Dunlop 695 Desert A T rear and K139 front tires designed to withstand the incredible heat and brutal impacts of the rocky Mexican desert replace the OEM rubber Water pump and ignition guards are added to the frame similar to those on a KDX250 as are a wel ded on skid pan and an aluminum rear disc guard Even the handlebars get some special atten tion First a Bar Snake is installed in the center then molten lead is poured in the ends and finally an aluminum plug is welded in the ends of the bar drilled and tapped to ew oe accept Ninja 750 bar end weights The result Greatly reduced vibration and rider fatigue The ignition is adapted from the Japanese ver sion of the KDX250 SR This ignition system pro duces enough wattage to power two 10 inch driving lights from just above idle and can be varied from 100 to 200 watts The lights are mounted in a lightweight frame that is rubber mounted on the tri ple clamps Four quick release pins hold the as sembly in place so that at sunset the lights can be installed on the bike in less than 10 secon
10. che Starting with this issue you will receive Micro k Tech on a regular basis with every Winter issue This way you will always have easy access to all the information An index at the top lists articles by subject rather than title so it s easy to find exactly what you re looking for We hope that you will find this new addi tion to be a useful tool O time you sell a new or used vehicle and give it to your customers When they see that card in their wallet they will remember your dealership Also leave some blanks at the parts counter for new custom ers They will be less like ly to remove this card from their wallet because it has important information about their own vehicle O Joe s Kawasaki Rt t Box 1 Midwest OH 44444 0000 216 55 5 BIKE Customer Service Card Model KX500 E3 Year 91 VIN JKAKXVE13MA004123 Eng KX500BE013145 Color Lime Green E Kawasaki The Technical Magazine 3 BEECH NEWS a eee is Ses aT Winter 1991 Vol 4 No 4 1991 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 Patrick Kelly Regional Editors North and East Fred DeHart Central and South Walter Rainwater Contributors Dave Behlings John Porno Joe Nowocinski David Pyle Steve Rice Mary Sola Ray St John
11. ds CONTINUED ON PAGE 11 COMMUNICATIONS ALERT New A amp P checklists When you assemble a new motorcycle or other Kawasaki product and pre pare it for customer deliv ery you fill out the Assem bly and Preparation A amp P Checklist This helps you remember those small but important items that can undermine a customer s confidence in your store and is a permanent record of your thoroughness There were two different Kawasaki A amp P checklists one for vehicles and one for watercraft Recently how ever we decided to make future checklists more product specific deleting many of the items that now must be crossed off because they do not apply to all products A amp P checklists are now available that cover motor cycles ATVs and utility ve hicles separately Free to authorized Kawasaki deal ers the checklists come 25 to the package You just received a ser vice bulletin SP91 01 with an initial supply of the new checklists for your use But here s the impor tant part All back orders on the old Kawasaki Ve hicle Dealer s A amp P Checklist P N 99995 590 07 are cancelled Order what you need of the new checklists from your Kawasaki Parts Distri bution Center NEW A amp P CHECKLIST PART NOS Productline Checklist P N Motorcycle 99964 1053 01 ATV 99964 1052 01 Utility Vehicle 99964 1051 01 91 service bulletin recap Marine Product Service Bulletins Date Title Subject
12. e a tire Well Kawasaki has a great solution The heavy duty Dual Scissor jack is solid sta ble and easy to use You won t believe how popular this tool will become in your shop A set of short adapters for low vehicles like the SPECIAL TOOLS Double duty tool siphons gas or water Remember the article in the Summer 91 issue of K Tech News entitled Coolant Pump Special Tool Well the same homemade tool also works just swell for si phoning water out of the bottom of a JET SKI wa tercraft before working on it And siphoning is a lot easier than turning the boat over to drain it As Hot Line Technician Ken Osberg explained the primer pump and hoses come from the Tan P N 57001 1238 P N 57001 1252 Dual Scissor Jack Short Adapters dem Sport TS To save you the trouble of looking up part numbers here they are again 49043 3702 92190 3715 Primer Pump Hoses qty 2 Joe Nowocinski wide Goodyear Racing Slick It s potential On other occasions during the Kawasaki s 192mph Hot Line staffer Rice on his other line The Technical Magazine 9 TIPS F ROM T H TIP High mileage mirrors High mileage ZG1200 Voyager VII s can develop a minor but irritating prob lem with the mirrors The mirror adjustment joint be comes looser as it wears and can get to where it will move out of adjustment from the wind at high speeds or when the vehi cle go
13. e rings upper ring a keystone type lower a rectangular type are plated with quick break in chrome plating porous coating which re tains oil for optimum lubri cation and low friction The 750 s intake system consists of an intake si lencer Keihin CDK II 40mm carburetor and two rankcase mounted eight petal reed valves Lubrica on is handled by Super lube automatic oil injection The 750 s exhaust gas ses travel through a pre muffler then an expansion chamber water box muf fler exhaust silencer a first in Kawasaki water craft history and finally an exhaust outlet in the stern The exhaust systems do vary slightly between the two craft with the 750 SS featuring a dry type of ex pansion chamber similar to the one used on the 650 TS and 650 SC The dry exhaust increases the engine s performance by waiting until after the expansion chamber to mix in the cooling water allow ing the expansion chamber to operate more efficiently Electronic ignition a first The biggest news about this new powerplant is the digital capacitive dis charge ignition CDI used for the first time on any personal watercraft Digital ignition uses a mi croprocessor and a pre determined timing data map to control the ignition timing very accurately throughout the rom range for optimum performance at all engine speeds For example the timing can be ideal for easy starting and also for maxi
14. eatures a larger dead rise angle as compared to our other stand up watercraft This combines excellent Straight line stability at the high speeds the boat is ca pable of with outstanding cornering ability The 750 SX also has the proven self righting and self cir cling features as found on all of Kawasaki s other fine stand up craft The 750 Super Sport also has a unique new hull design It too features a large dead rise angle for excellent straight line sta bility Special attention has been given to the SS s cornering ability as well It has been designed to keep its pump in the water and corner very pre dictably without surprises The 750 SS can also brag about such key items as an LED fuel gauge as well as LED s to warn of low oil level and overheat ing You can t fully appreci ate all the great features of these magnificent wa tercraft by reading about them or looking at a few photographs Just as noth ing can fully describe the thrill of riding a ZX 11 words alone can t fully de scribe the thrill of riding either of these new water craft except the feeling youll have the moment you push that throttle to the stop and hang on O Technical Services is pleased to announce the addition of David Pyle as Parts Publications Special ist His is the new voice you have heard if you ve called the Micro K depart ment recently David comes to us from earn Green where he has worked as a t
15. echnician for the last five years His re sponsibilities at Team 100 reward Here at Kawasaki Tech nical Services we have made a New Year s reso lution to get more tech tips from you hands on people at the dealer ships To that end begin ning with the new year we will send a 100 check to any Kawasaki Technician who submits a tip that we print in K Tech News Tips could include such things as creative diagnostic tech niques homemade spe cial tools time saving ideas quick solutions to common problems etc So send in your ideas lf we print it we ll send you a check for 100 Write to K Tech News c o Tech Services Dept Kawasaki Motors Corp U S A O Green included prepara tion of the KX500s which ridden by Ted Hunnicutt and Larry Roeseler have dominated the SCORE off road racing series for the last three years Before that David worked for two years in the West Region parts dis tribution center His techni cal background and ener getic attention to detail are what make David espe cially qualified for this posi tion In both of David s pre vious positions at KMC he worked extensively with the Micro K system and had lots of contact with dealership personnel David says he enjoys that contact with the dealer ship people and looks for Parts department time saver by David Pyle Micro K Specialist Here s an idea to save your Parts Department and your custo
16. el Systems Servicing the MULE 1000 2000 21 Servicing the MULE 500 Troubleshooting Elec Systems 28 Service Department Operations K BOSS North Region February No classes scheduled Central Region February No classes scheduled South Region February 3 MULE Dealer Orientation 4 5 Servicing the MULE 1000 2000 6 Servicing the MULE 500 10 11 ATV Service 12 Service Department Operations K BOSS 18 20 Troubleshooting Elec Systems 24 26 JET SK Watercrafl West Region February 10 12 Police Motorcycle Maintenance 13 Service Dept Operations K BOSS 19 21 Troubleshooting Elec Systems 24 26 JET SKI Watercraft 27 750 JET SKI Update
17. es over a sharp bump The real problem occurs when the customer finds out this joint cannot be tightened and the mirrors must be replaced at a cost of over 35 00 each If you havea customer who really objects to buying new mir rors there is a way to modify his so the pivot joint can be tightened The mod ification changes the appear ance of the 1 nd f 10 K Tech News mirror slightly so let the customer decide whether to do this or replace them To get at the joint use a hole saw to drill a 1 inch hole in the back of the mir ror body This gives you access to the adjusting nut which you can then reach and tighten with a 10mm swivel socket After the nut is tight use a cap Part Number 11012 1751 62 to plug the hole Bob Ellison R9 1 in diameter SPECIALISTS Sport Cruiser those dread decals by Gregg Thompson Senior Product Support Specialist T he Kawasaki Hot Line Staff has received several calls lately about decals n JL650 A1 s peeling up round the edges If you run into one of these try to find the Fall 1990 issue of K Tech News On page 8 is along article about de cal R amp R that should be of some help to you That particular article emphasizes trying to get most of the adhesive off with the decal And for our other watercraft the meth ods described work well Unfortunately the de als on the Sport Cruiser are another story If t
18. hese decals are exactly the right temperature you may get 50 percent or lore of the adhesive off with the decal Note The previous arti cle emphasizes that pull ing the decal straight up at a 90 angle to the surface is best for pulling up the adhesive with the decal The SC decals seem to take more adhesive with them when pulled back across the surface lf they are not exactly the right temperature nearly all the adhesive will Stay on the boat And even if 50 percent of the adhe sive comes off removing the other 50 percent can still be a big job To remove the adhe sive soak some shop or paper towels in 3M No 08984 adhesive cleaner and lay the wet towels over the adhesive Paper towels work well because they dont absorb so much of the cleaner but still do a good job of keeping the adhesive wet Make sure the wet towel is making contact with the adhesive completely for 5 10 min utes Then remove the towels and scrape the ad hesive with a plastic spat ula while it is still wet Most of the adhesive should scrape off What is left will clean off with the adhesive cleaner and a coarse terry cloth towel fairly easily Adhesive re movers such as the 3M product referenced above No 08984 can be pur chased at your local auto motive paint store and also many auto parts stores O COMMUNICATIONS Baja 1000 CONTINUED FROM PAGE 4 Other high tech sys tems include a NASCAR style q
19. ion units have shown some unusual piston wear that has been traced to this hard coating On later pro duction units and all spare parts pistons the ceramic coating has been modified and the bottom of the skirt is chamfered more The modified pistons do not ex hibit the same rapid wear The wear that occurs on the earlier piston may be mistaken for damage re sulting from a seizure In extreme cases it appears around the entire skirt and up the intake side of the piston Although the wear can look pretty bad at times it typically does not result in any performance loss or engine failure You can reduce an early piston s tendency to do this by increasing the chamfer at the bottom of the piston from 0 5mm to 2 0mm The later pistons already have a 2 0mm chamfer Gregg Thompson TIPS F ROM T H TIP You don t have to bleed Have you ever had trouble bleeding the front brake on a late model KX bike You bleed it and bleed it and just can t get that firm lever you know it should have The cause could be bub bles of air hiding out in the highest point of the hy draulic line As you pump fluid through the system youre trying to force these bubbles down that long hose toward the caliper But some of the bubbles may choose to obey other laws of physics and drift up hill creating a three steps forward two steps back situation Why not get all the laws of physics on your side by bleeding that
20. mers time and avoid mistakes How many times has a customer come into your Store to order parts and given your parts person the wrong year or model information for his or her vehicle For example The cus tomer has a KX500 E3 91 he bought it in De cember 1990 and he re members that year not the model year So you or der a rear disc for him which of course has holes 90 version instead of slots 91 Most dealerships have ex perienced this kind of thing ward to more of the same in his new job He clearly understands how impor tant Micro K is to the deal ership and already has some ideas about how to improve the usefulness and accuracy of this impor tant tool Dave s only request If you have any problem with a Kawasaki Micro K product please call him or send in a Micro K Report Card O So how can you avoid the cost in time involved in an RFC not to mention having a dissatisfied cus tomer My suggestion is to have business cards handy with your store s name address and phone number printed on them and space for your cus tomer s vehicle or hull I D number engine number and vehicle color Fill out one of these cards every Micro K Tech Good news No more hunting all over the shop for a back issue of K Tech News knowing that a someone has it at home b someone has lost it or c someone has hidden it from you All past issues of K Tech are now on microfi
21. mum top 2 K Tech News end power In addition the digital ignition s rev limiter is much more accurate controlling engine rom to 8000 100 while conven tional analog ignitions are only accurate to 250rpm This new ignition works in conjunction with a water temperature sensor lo cated in the water bypass line to limit engine rom to 3500 anytime the cooling water temperature rises above 194 F Patrick Kelly Easy mainte nance pump The wonderful new 750 engine is matched to an all new jet pump The new 750 jet pump is an axial flow single stage pump similar in layout and size to the 650 series of pumps having an impeller that is the same diameter at 140mm The impeller is all new in design and fea tures a varied pitch with a specially contoured trailing blade edge to help mini mize cavitation erosion The scoop section of the pump is now part of the hull making pump sealing easier when removing and replacing the pump The pump driveline also fea tures a rubber damper to absorb shock loads and re duce driveline noise What do all these power plant and jet pump fea tures add up to Well how about a whopping 63 hp and 551 Ibs of thrust on the 750 SX and an even more incredible 69 hp and 570 Ibs of thrust on the 750 SS Impressive hulls The hulls on these new craft are as impressive as their powerplants The 750 SX has been designed with the aggressive rider in mind Its hull f
22. n it turn the fuel valve on pri and allow some fuel to run through the bowl flushing out any other debris that is in there This same procedure also works well for flush ing any contaminants out of the float valve When a carburetor has a problem in again If the prob SPECIALISTS A couple of quickies t s a fairly common practice for dealer mechanics to use grease as an anti seize compound on spark plug threads This is not a good idea because the grease acts as an insulator and can actually change the heat range of the plug Anti seize compounds specifically formu lated for this application have metallic particles in them to improve their conductive properties mM Have you ever had trouble getting a woodruff key to stay in place while you put the flywheel on Try putting a drop of super glue or even some heavy ma rine type grease on it to hold it Tip the leading edge of the key down slightly so its less likely to catch the edge of the key way in the fly wheel when you Slide it on As you tighten the fly wheel on the ta per the super glue will break loose and allow the key to seat properly in the groove Steve Rice TIP overflowing fuel while the engine is running it s usu ally caused by debris caught in the valve The debris doesn t flow through the valve because the valve only opens a tiny bit to allow enough fuel flow to sup ly the engine When the fl
23. ndard plug for the US model KX125 J1 is the NGK R6254K 105 The Canadian resistor plug R6252K 105 is virtu ally identical and can be in terchanged These are racing type plugs with a special short ground electrode that is very resis tant to breakage The microfiche also lists the R4630A 105 which is the same as the R6254K 105 but with a platinum center electrode This plug Warm em up first by John Pomo Product Support Specialist R emoving brake discs from any of our KX models can be a little difficult because of the locking agent used at the factory on the mounting bolts We have even heard of a few guys using a hammer and impact driver to get them loose not a good idea The small mounting flanges on the hub which these bolts thread into can be easily bro ken by using an impact driver To remove these bolts and any bolt se cured by a locking agent use a propane torch to heat the bolts first Then remove the bolts with a wrench while they are still hot O 6 K Tech News costs a lot more and the only real advantage it of fers is increased wear re sistance As another alternate for the R6254K 105 the R6254E 105 can be used The only difference here is it comes with a 0 6mm gap instead of 0 8mm Be cause of the short ground electrode on these racing plugs the gap is not con sidered adjustable but the 0 6mm gap will work If you are looking for something a little more common the mic
24. ng customer service In pre vious issues See K Tech News Vol 3 No 4 and Vol 4 Nos 1 and 2 Ed weve talked about attitude and have outlined some steps you can take to keep customers coming back to your store as well as point ing out the types of behav ior that drive them away So you have the right attitude and really want to make your store known for its excellent customer service What now Work on your communication Good communication with your customers is a must First become aware of how you are communi cating Did you know that over 80 percent of what coo rac tet SERVICE we communicate is non verbal It s how you say what you say that s most important Pay particular attention to your body lan guage and the tone of your voice when talking to customers both in person and over the phone secondly really listen to Over 80 per cent of what we communi cate IS non verbal what your customers are telling you don t just wait for your turn to talk Active listening is probably the cornerstone of good com munication as it shows re spect and interest Few of us can resist feeling good about someone who s in Part 4 Did you know terested in what we have to say and who treats us with respect some other tips 1 Non verbal contact Nod make eye contact Have your posture show interest Don t try to do two things at once when a customer is talking to you
25. oat bowl is drained the float drops to the bottom allowing the valve to open wide Then when you turn on the fuel it will usually rinse the cul prit right out Dave Behlings The Technical Magazine 7 Tot PS FROM TH SPECI A L S T S Police bikes Making the most of chains and sprockets by Bill Zito National Police Motorcycle Coordinator P art of the curriculum in our Police Motorcycle Maintenance course is a discussion of proper drive chain maintenance and service life expectancy The Kawasaki Police 1000 motorcycle comes equipped with a high qual ity endless O ring chain Even when the Police 1000 motorcycle is sub jected to rather severe en forcement usage the OEM drive chain and sprockets should have a minimum service life of 15 000 to 20 000 miles providing proper mainte nance and adjustment procedures are observed Because the lubricant for the pin and bushing is sealed in with O rings the chain needs only light exterior lubrication In fact for long life it is just as im portant that the chain be kept clean Dirt is very abra sive and will wear the chain and sprockets prematurely As part of routine main tenance the chain should be cleaned and lubed about every 200 miles With the bike on its center stand spin the rear wheel and spray a light coat of chain lube on both sides of the rollers Then with a clean towel grasp the lower chain run and turn
26. on your Tune and Service list John Pomo 8 K Tech News GS Proper chain tension and wheel alignment are key providing the proper amount of chain slack and making sure the rear wheel is aligned properly If the chain is too tight not only will the chain and sprockets wear rapidly but the transmission bear ing on the output shaft be hind the front sprocket will fail prematurely The chain requires 1 2 to 1 6 inches of slack measured at the middle of the bottom chain run with the bike on the center stand With less slack than this the chain will be pulled tighter than a bow string at some point in the suspension travel putting enormous pressures on the final drive components The specified chain slack may seem exces sive to you but it is cor rect and very important for long chain and sprocket life O T H SPECIALISTS N Ock ack quick jack Look alike filters Most Kawasaki spin on type oil filters look virtually identical on the outside They will physically inter change from one model to another From time to time the Hot Line gets calls from dealers wondering if they can stock just one of these seemingly interchange able filters and sell it for all models it will fit In a word no While they may look the same all of these fil ters are different internally and have different flow rates As a rule it is nota good idea to interchange these filters unless your
27. particularly an angry one 2 Make noises yes see etc Most of us think the other person isn t listening if we don t get some feedback 3 Ask open ended questions Asking ques tions that give customers a chance to explain also gives them a chance to fin ish with their anger and get ready to move to re solving the problem 4 Restate Rephrasing what customers say in your own words shows that you understand what their concerns are and that you sympathize with the feelings they ve ex pressed O REGIONAL NEWS cont CONTINUED FROM PAGE 12 The biggest news out here in the west region though is our newly refur bished and re equipped training shop We have spent some needed time and money on updating our tools and equipment to make your training ex perience more rewarding So if you haven t visited us in a while come on back and see us If you have never visited us you have no more excuses lII look forward to seeing you real soon O SOUTH amp CENTRAL CONTINUED FROM PAGE 12 and some new techniques we cant wait to pass along to you Come take a class or three in this new year Meanwhile to all com petitors promoters deal ers race fans and heavily addicted Xmas shoppers hope your new year will be enjoyable and successful O CONTINUED FROM PAGE 12 Grand Rapids January 29 and 30 1992 at the re gional offices This will be the only Team Green class scheduled during the
28. rofiche also lists the B10EVX the X at the end indicates a platinum center electrode The B10EV is the same fine wire plug but with out the platinum These are not racing type plugs and should be changed more often the ground electrode can fatigue and break off under extreme conditions or extended use Also listed on the micro fiche are the ND W31ES ZU and W31ESR ZU the Nippon Denso equivalent HOT TIP of the standard NGK plugs The story is a little differ ent with the KX250 Other than the standard NGK R6254E 9 the microfiche lists only the resistor plug R6252E 9 and the plati num plug R4630A 9 This doesn t give you a lot of alternatives if you can t get the standard plug for some reason The B9EVX is not listed because of a tendency to fatigue in this engine and lose its ground electrode Because of this poten tial problem you should stick with the racing style plug whenever possible But if you don t have the racing plug any port ina storm the B9EV or B9EVX will work Just bear in mind that the ground electrode is a little fragile for this engine so change the plug often Most spark plugs can be ordered from Kawasaki using the spark plug num ber i e R6254K 105 as the part number O TIP KX250 J 1 piston news T he 1992 KX250 J1 pis ton has a hard ceramic composite coating around the bottom of the skirt de signed to increase piston durability Early product
29. the rear wheel backwards to wipe off the dirt and excess lube Always turn the wheel backwards to avoid pulling your hand into the rear sprocket never use the engine to rotate the chain while you clean it If the chain has a heavy dirt build up it should be removed from the motorcy cle for proper cleaning Af ter taking it off clean it using a light lubricant like Kawasaki Multi lube WD 40 or Bel Rey 6 in 1 Do not use cleaning solvents like those found in parts washers which attack the O rings or high pressure power washers Use only soft bristle brushes i e nylon or plastic never metal wire type TECHNICALITIES After the chain has been cleaned spray a light coat of chain lube over the rollers both sides and let it set while you clean the sprockets and the area around the engine sprocket Another important part of chain maintenance is adjustment This includes h a KZ1000P Police tune and service tip When doing a Tune and Service on a KZ1000P Police model don t forget to check the mechani cal timing advancer It must be lubed and operate freely If this is overlooked and it becomes dry it can stick and not operate smoothly Also the springs can rust or get weak When these con ditions occur the advance mechanism malfunctions result ing in poor throttle response and an unhappy motor officer So help keep your customers happy by putting this little item
30. uick fuel setup and a modified swingarm with chamfered wheel spacers and brake pads to speed up rear wheel changes With an air wrench on the axle and nine carefully placed well rehearsed pit crew members the end re sult is a refuel rider change and rear wheel change in under 20 sec onds from engine stop to engine start This year s winning bike made four rear wheel changes all for fresh tires But even meticulous preparation the fastest bike the best planning and the quickest pit crews cant guarantee race wins Having riders like eight time Baja 1000 winner Larry Roeseler four time winner Ted Hunnicutt Jr and motocross champ Marty Smith helps your chances considerably Tal ented yes but it was this trio s dedication to training and pre running that really set them apart The 1991 Baja 1000 boasted an incredible 42 Kawasaki entries That s up 50 percent from 28 in 90 The riders did their part the pit crews did their job and the end result was First Overall Vehi Cle plus 500cc 125cc and Class 50 wins The Kawasaki crew puts forth a more intense and dedicated effort than the rest of the competitors combined The results Four consecutive Baja 1000 overall wins guess Roger Penske has a point O by Mary Sola Consumer Services Assistant Manager Now that the summer is over and the pace is a lit tle less hectic we can re sume our how to series on providing outstandi
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