K-Tech News Vol.5 No.2
Contents
1. Summer 1992 The Kawasaki Technical Magazine Vol 5 No 2 ZR1100 by Patrick Kelly Instructional Designer Instructor Maybe you caught a glimpse of this fine ma chine at the dealer meet ing in San Antonio last year or maybe you read a little about it in the March issue of Cycle World But nowhere did you get an answer to this question When do we get it Well you need not wait any longer because the ZR1100 is here CONTINUED ON PAGE 2 KX125 amp 250 by Ray St John Supervisor Technical Writing T he changes to the 93 KX125 J2 and KX250 J2 might seem pretty subtle until you get a look at them We re talking about more power throughout the rev range better han dling and braking and more durability After all the 92 models were real winners and you don t want to mess too much with that kind of success CONTINUED ON PAGE 4 ROUTE LIST O SERVICE O PARTS O SALES Inside PLEASE RETURNTO SERVICE LIBRARY E Service tips amp more ZR1100 CONTINUED FROM PAGE 1 The biggest ZR joins its 750cc brother in 93 to complete the ZR line up the days of the big and powerful standard motor cycle Like those big stand ards of yesteryear the newest ZR is big powerful and comfortable And like those bikes it is also very i p versatile equally at home commuting to work every day or playing on your fa vorite canyon road on the w2. piece of informa tion such as an FDM bulletin can be written type set printed and sent out to deal ers all in the same week Having our own system makes updating publications faster and easier as well For in stance we can update our train ing course materi als more frequen tly so students in our classes re ceive the latest informa tion available We are continually striv ing to improve our effi ciency Our goal To present you the best publi cations possible O Micro g 4e A low price microfiche reader Attention service manag ers This new small utility reader is the perfect addi tion to your service depart ment Don t let its low 150 price tag fool you this reader was made with durability and perform ance in mind It comes with many fea tures you would expect from much more expen sive readers Gear driven focus control snap out lens module for easy cleaning fanless cooling for quiet operation blue non glare screen built in carrying handle and a 12 month warranty except lamps and glass are all standard All of this is packaged into a unit that weighs un der 10 lbs and fits into a 13 1 2 x 15 5 8 x 15 1 4 box Top all this off with a savings of 69 over the Eyecom 1000 and you have an unbeatable combi nation Order via K Share or from your Distribution Center MR1 Reader P N M150081 150 00 Replacement Lamp P N M260115 14 50 Equ
3. to help seal out moisture Apply a small amount of dielectric compound to the spark plug terminal nut That s all there is to it David Pyle FAN WIRES SPECIALISTS Pa Sa Generators answers to noise and fuel questions We occasionally get calls on the Hot Line from deal ers asking for the noise levels and fuel consump tion rates of our portable generators In response to those requests Kawasaki printed and distributed a Sales Information Bulletin in Nov 1991 Our guess here though is that some personnel in some dealer ships don t get to see Sales Bulletins So here s the information that was in there in case you can use it but never saw it Incidentally that particu lar Bulletin also had a practical application chart on the back giving exam ples of tools and equip ment that can be run off each of our generators Ed NOISE LEVEL dB eee MODEL AT3 3 FT AT 23 FT 1 TANK OF GAS 1 M 7M APPROX GA550A 70 0 54 5 3 8 hours GD700A 70 0 54 5 3 8 hours GD700AS 70 0 54 5 3 8 hours NINJA GA 1000A 18 5 63 0 5 0 hours GA1400A 80 0 64 5 4 0 hours GA1800A 81 5 66 5 8 0 hours GA2300A 82 5 67 5 7 0 hours GA3200A AS 85 0 70 0 7 5 hours GE4000AS NA 69 5 8 5 hours GE4500AS NA 70 5 8 0 hours TECHNICALITIES A gripping situation on the new 750 watercraft This new design has some good news and some bad Handlebar grips a
4. 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 publish and or use it without further con sideration 6 K Tech News GUEST SPOT How are they produced by Pat Shibata Materials Distribution Mgr Have you ever found your self wondering how all those technical publica tions are produced Well our Service Training amp Commu nications Depart ment has its own computerized desk top publishing sys tem Having our own system makes creating publica tions faster and gives us more con trol over the looks of the final product While printed books like service and owner s manu als are produced in Japan most of our other publications like service and parts bulle tins are produced right here in Irvine Calif Our technical writers do the research and create the text using WordPer fect Any line art to be used in the publication is scanned into the system using DocuMaster and modified for the particular publication using Publish er s Paintbrush After all the pieces of the document are ready they are brought together using Ventura Software s Ventura Publisher page layout program which merges text and graphics right on our computer screen Paste up is a thing of the past Thanks to Kawasaki s own in house printing de partment an important
5. and pistons you might suggest the cus tomer go with the later style parts To make this change it will be necessary to use the older model 86 90 clearance specs and drill two oil holes in the ex haust skirt of the pistons Use the old piston as your guide when drilling oil holes in the newer model piston Although the minimum spec in the service man ual for piston cylinder clearance is 165mm FROM TH 0065 in we recommend no less than 180mm 007 in For slightly modified engines and for Stock boats that will be rid den hard you should pro bably start with 190mm 0075 in clearance A neat thing here is that the C model piston starts out about 1mm bigger so in many cases just honing to the new size will clean the bore depending on the extent of cylinder wear of course You don t end up wasting an over bore Get your gasket part numbers from A or B model fiche then find P Ns for pistons rings pins clips and top bear ings on the JS550 C1 2 fiche O SPECIALISTS Quick generator troubleshooting by Fred Dehart Tech Services Instructor Here is a quick step by step troubleshooting pro cedure for all Kawasaki generators with brushes GD700 through GE4500 that have no AC output O First make sure all cir cuit breakers and fuses if any are good and func tioning properly Leave all wiring con nected except to the volt age regulator All volt
6. exciting of these things is the introduction of new models for the coming year some of which are featured in this issue Preparation for the dealer meeting in the fall is also well underway The technical staff manning the Tech Hot Line is extra busy too with the many calls they receive each day during the summer season will be busy doing my part to support these activi ties will be updating all of the District Managers on the latest technical fea tures and benefits of the new 1993 models so they can inform you and keep 16 K Tech News you up to date will also be helping out on the Hot Line from time to time And of course we never forget around here that another new training season is just around the corner so we will also be busy planning new classes and writing down the new information we plan to include next year Take care lII look for ward to seeing all of you in the fall O Making plans for summer by Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 With the completion of the training season have begun making plans for summer In June along with several others from Kawasaki participated as judges in the Vocational In dustrial Clubs of America United States Skill Olym pics held in Louisville Ky The Skill Olympics pits stu dents in many vocations including motorcycle me chanics from all over the U S against each other to determine
7. more serious If the technician doesn t think to check for other problems he ll end up doing the job twice On the EN500 this in cludes all 454cc and 498cc engines in this fam ily oil leaking from the water pump drain could be caused by a worn bal ancer shaft bearing If the right hand bearing on the balancer shaft becomes worn excessively the shaft could begin to wob ble around and the seal begin to leak The leaking oil exits through the water pump drain hole For more information on this problem see the EN450 EX500 Oil Pressure atti c e in the Summer 1990 is sue of K Tech News or grid E 5 of the K Tech mi crofiche Ed On the VN750 oil or coolant leaking from the water pump drain might be caused by the locating n Aug 91 Kawasaki is sued a service bulletin with the latest information re garding Clarion s repair service for the Voyager audio system compo nents Unfortunately that information was not the 12 K Tech News circlio on the water pump shaft coming out of it s groove When this hap pens excessive end play in the shaft can result in a leak from either the oil seal or the mechanical seal Also the water pump impeller will grind away at the water pump cover right hand engine cover damaging itself and the cover AS To check for this prob lem just check for end play in the water pump shaft If the circlip is in place the impeller will be held tightly again
8. of the standard motorcycle up to a new level Stand ards are back and better than ever O S H OP TALK TECH The expansion chamber is designed to enhance the mid range and the si lencer has been lightened the end plates are now 0 8mm thick instead of 1 0mm and the baffle pipes are 1 0mm wall thick ness down from 1 2mm The piston no longer has the NCC coating on the skirt Vertical ribs in the intake port have elimi nated the need for this special expensive coating by stopping the piston from rocking in the bore As on the 125 the top of the piston is machined smooth to cut down carb on deposits and detona tion The machining lowers the piston s com pression height by 0 2mm The combustion chamber shape has more squish area to increase turbu lence and detonation resis tance Both the high and low speed compression ra tios drop slightly the low speed ratio to 10 2 1 and the high speed ratio to 8 7 1 Quicker throttle response on the 93 KX250 comes from reduced flywheel ef fect The weights of both the flywheel and the crank shaft are reduced The ignition timing curve is reprogrammed with more top end ad vance to take advantage of the drop in high speed compression ratio The KX250 s carburetor specs are similar to those on the new KX125 A new main nozzle has a higher primary choke 7 45mm up from 6 35mm with a slit in it for better atomiza tion The well around the main nozz
9. piece crankshaft which rides in five plain main bearings The crankshaft drives the clutch directly through the primary drive gear located on the left crankweb of number four cylinder The primary drive gear also drives a single counterbal ancer at twice crankshaft speed to help smooth out the engine s vibes SHOP TALK TECHNICAL The drivetrain on the ZX11 Like many The frame of our other four cylinder engines those found in the ZX7 and ZX6 to name two the ZR1100 engine features two oil pumps One oil pump supplies oil to the vital engine parts while the other supplies the oil cooler The oil filter is the internal type and is the familiar P N 16099 003 used on many other Kawasaki models The hydraulically actu ated clutch features a back torque limiter to re duce tire slippage under severe engine braking The basic construction is similar to the one used on The ZR1100 frame is a conventional one piece double cradle design con structed of high tensile Steel thin wall tubing TECHNICALITIES the ZX7 Nine driving plates utilizing a paper based friction compound and radial oil grooves com bine with eight knurled steel plates to transfer the 1100 s massive torque smoothly without deforma tion from heat In addition the clutch basket is drilled to reduce the adhesion of oil to the steel plates when the engine is cold The drilled clutch basket the paper based friction pla
10. real advantage here is from balanced rigidity be tween the inner and outer tubes Matching the rigid ity of the tubes will cut down on tube damage in hard landings at race speeds and allow better fork action under these su per stressful conditions An elongated oil lock piece starts the hydraulic cushioning effect sooner on the compression stroke to soften those front first landings The rear shocks fade resis tance is improved by in creasing the cylinder diameter from 44mm to 46mm for more capacity And more Front brake feel on both of these bikes is better thanks to a changed front master cylinder lever ratio The new KX125 J2 and KX250 J2 are lighter than last year s 125 and 250 models have fatter power curves handle better and stop better At least the color hasn t changed O The Technical Magazine 5 B TECH NEWS Summer 1992 Vol 5 No 2 1992 Kawasaki Motors Corp U S A KMO 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 Jerry Heil Tevis Moffett Joe Nowocinski Ken Os berg Keith Pestotnik John Porno David Pyle Steve Rice Ray St John Graphics Production Graphic Art Gregg Thompson Copy Editor
11. smooth on their outer surface to reduce the amount of break in re quired In addition the fork bushings and pistons are chamfered to assure smooth action at the begin ning of the suspension stroke The rear suspen sion features piggyback style reservoir shocks similar to the ones on the ZR750 and ZR550 These shocks feature four way compression and rebound damping as well as five way spring pre load adjust ment The rear suspen sion package is completed by a massive aluminum swingarm with eccentric chain adjusters And more This outstanding chas sis is completed by excel lent brakes The front brakes are four piston cali pers gripping huge 310mm front discs These excel lent brakes are very simi lar to the ones used to haul the ZX11 down from speed The rear brake Is a two piston caliper which employs pistons of differ ent sizes on the same side of the caliper to grip a 240mm disc Together these brakes give state of the art braking power Ad ditional items which make the biggest ZR more com petent and convenient A comfortable yet sporty up right riding position fuel gauge lockable helmet hooks retractable luggage strap hooks four way ad justable brake and clutch levers passenger grab rail and a centerstand The ZR also features a maintenance free battery natural rubber grips and large rubber mounted handlebar end weights to dampen vibrations The ZR1100 has stepped development
12. up of large or small gasket sur faces Using a stone also makes it easy to spot any nicks or surface irregulari ties in the part that might cause a leak later If you find yourself red in the face struggling with gaskets give this method a try and see if the job doesn t go a little quicker and more easily Kenny Osberg 14 K Tech News F R O M T H SPECIALISTS Fuel injection woes Hot Line ECUs to the rescue by John Pomo Product Support Specialist Diagnosing a running problem on a fuel injected model can be very time consuming Once you have verified the condition of the engine with a com pression and or leakdown test performed all the fuel injection system tests in the service manual and carefully checked all the Looking for a way to ease that gasket scraping a knife sharpen pain Try ing stone wiring and connectors in the system you might still have that big hanging over your head Every thing checks out good Well everything except the ECU the Brain the Black Box the Magic Box that thing which you can t test except to try a new one It s not likely you are go ing to have another fuel in jected bike just like this one in your shop at the same time that you can swap ECUs with Buying one on the off chance it will fix the bike and putting it on the shelf if it doesn t is not real popular with shop owners So what can you do Call the
13. 00C 125 122 120 115 112 92063 1069 92063 1073 92063 1072 92063 1118 92063 1117 KLF400B 120 118 115 112 110 92063 1072 92063 1071 92063 1118 92063 1117 92063 1114 No spark KLF220s Look closely at the stator assembly the ignition went out Unfortunately when everything is at rest the wire doesn t actually touch the bracket so a continuity test on the stator doesn t show the short So if you run across a KLF220 with an ignition problem like this and everything else checks out okay have a close look at the wires coming out of the stator where they wrap around the bracket Tevis Moffett Recently the Hot Line has received a few calls re garding intermittent spark or no spark on KLF220s that turned out to be failed stator assemblies In at least a couple of these cases the problem was found to be an exciter coil wire that had rubbed against the wiring harness bracket on the stator until it wore through the insula tion The bracket is groun ded so as soon as the wire made contact with it AA 4 I Hh Hl CHECK WIRE AT BRACKET The Technical Magazine 11 TIPS FROM T H Water pump leaks by Steve Rice Product Support Specialist On the EN500 and VN750 if you have fluids leaking from the water pump drain hole the prob lem may be more than just a seal On both of these models we have seen sev eral failures where the leak was caused by some thing considerably
14. Hot Line We have an assortment of ECUs here just for that purpose If you have done everything read the first paragraph of this article again before you call us we can send out an ECU for you to try After you have tried it you send it back to us and order a new one if you need it When you call make sure you have the model number frame number and Part Number of the ECU you need so we can make sure we send you the right one And again Don t call for an ECU until after you have done everything else O LE on a FROM TH TIP Is compression really just fine On the Hot Line we fre quently get calls from dealership technicians having trouble solving problems such as hard Starting poor or erratic idling or poor throttle re sponse One of the first questions we will ask is How is the compres sion Quite often the re sponse is Compression is fine real good no problem there but when we pursue it further it turns out compression is not as good as the techni cian The thought compression was within the Spec given in the manual some where in the middle let s say so the technician assumed it was OK But for an engine to run like new the can pression be very near the top end of the Usable Range in all cylinders If compres sion drops more than about 15 per cent below the top of the range i e to 165 psi w
15. age regulator wires should be disconnected Be sure that the brushes themselves are in good condition and are making contact with the copper slip rings on the ro tor Corrosion or dirt on the slip rings will cause a loss of AC output Start the generator and connect a fully charged 12 volt battery directly to the brushes Be sure to main tain the correct polarity Then plug an electric drill into the AC outlet and see if it operates If it runs at all then you know the con trol panel main coil in the stator and field coil in the rotor are good The 12 volt battery does not cre ate enough of a magnetic field in the rotor to pro duce 120 volts but it will produce enough to power the drill If the generator runs the drill during the above test there are only two components that could be the problem One is the voltage regulator and the other is the sub coil which is part of the stator NOTE There is also a chance that the generator has been fixed by jumping 12 volts to the brushes The rotor can sometimes lose its residual magnet ism preventing AC output applying 12 volts to the brushes restores this re sidual magnetism Be sure to check for proper generator operation be fore proceeding with fur ther troubleshooting To verify the condition of the sub coil check its AC output Hook a mul timeter on the lowest AC voltage range to the two leads from the sub coil usually
16. allation as well O Bayou air filter pre delivery prep oil s well that ends well Depending on how long the vehicle has been in the crate between the date it was manufactured and when your dealership finally prepares it for deliv ery the foam air filter in a KLF300 or KLF220 Bayou could be completely dry of oll The air filter is oiled at the factory on assembly but the oil slowly drains out during storage Since a single stage foam filter depends on the oil that s in it to function properly these air filters should al 10 K Tech News ways be checked during the pre delivery service If you service a vehicle and then it sits for a while be fore being sold you should recheck it before delivering the vehicle Remember when servic ing one of these filters al ways grease the joint be tween the air filter holder and the air box with heavy grease That joint will leak dirt into the engine if it is not greased properly Also grease both ends of the element at each air filter servicing This is an extremely important step in preventing severe dam age to the engine from dirt Gregg Thompson GREASE TIPS FROM THE SPECIALISTS High altitude jetting for ATVs and MULES by Gregg Thompson Sr Product Support Specialist jet changes for all our ATVs and Utility vehicles at alti tudes all the way up to 15 000 feet The following chart details those recommended main jet specifications As y
17. amage to the cylinder is some aluminum from the piston sticking to the wall The piston of course is toast but the cylinder may be in much better shape than it seems To find out you must first remove the aluminum from the cylinder Get a small container of muriatic acid from a local pool supply store and a small artist s brush from your favorite art supply store Dab some acid on the aluminum in the cylinder taking care not to get it on any other exposed aluminum it will etch any aluminum it lands on it doesn t care The acid will bubble and smoke as it dissolves the aluminum When it stops bub bling wipe it off with a damp towel Repeat this process if necessary until all the transferred aluminum is re moved Now pass a ball bottle brush hone through the bore a few times and have a look A few light scratches in the cylinder won t significantly affect performance es pecially in the larger engines You do need to look carefully for any cracks in the bridges between ports When a piston seizes it creates lots of pressure If the cylinder is cracked anywhere it cannot be used Kenny Osberg The Technical Magazine 15 R E G I O NAL N EWS Abuzz with activity by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 T he corporate offices here in the West region are abuzz with people pre paring for the many activi ties that come with summer and fall in the mo torcycle industry The most
18. e Fight ing Dirt Fighting Dirty arti cle in the Winter 1990 issue of K Tech News or Grid F 4 of the K Tech mi crofiche Ed One way to reduce the damage done to the en gine when a KLF300 is used in these extreme conditions is to start with a better air filter element F ROM T H There just happens to be one available from Kawa saki if you know what P N to order The KAF300 A1 MULE 500 air filter P N 11029 1004 fits the KLF300 Bayou and fea SPECIALISTS tures a foam outer with pa per inner filter With the foam outer filter oiled prop erly this is an extremely ef fective filtration system It still requires cleaning but because of the paper ele FILL GAP GREASE THIS ENTIRE SURFACE WITH GREASE ment it is much more for giving if maintenance is not as frequent as it should be There are drawbacks to using this filter so it s probably not for everyone Since the paper ele ment can t be cleaned it does have to be re placed every so often and it is quite a bit more expensive than the stock part NOTE On the MULE 500 this filter uses a rubber gasket to help seal the joint between the filter and the air box That gasket can not be used in the 300 Bayou so use heavy grease to seal this joint Be sure to fill the gap at the pinch bolt with grease The 300 Bayou OEM filter assembly is designed the same in this area and needs to be greased before in St
19. ed last year is installed from the beginning of 93 produc tion The clutch is rein forced with more ribs to extend its service life The engine 250 The big news on the 93 KX250 is the new guillo tine type KIPS valve in the J2 model s top end The new valve is very similar to the one in the KX125 and allows the main exhaust port to be a lot wider at the top The new valve also controls the port much more accu rately and fits the piston better for less gas leakage in the low speed position Result Much more top end and more low end and mid range power too The inlet and Boyesen ports are larger this year and in combination with in creased crankcase com pression this pumps up the lower half of the power band considerably ZR1100 CONTINUED FROM PAGE 3 As a convenient servicing feature the right down tube unbolts for easy en gine access The ZR1100 chassis has a rake of 27 and trail of 110mm com bined with a relatively short wheelbase of 59 inches This gives the ZR1100 nim ble handling characteris tics well suited to moder ate sport riding as well as easy handling around town The engine mounts to the frame at six points there are two front rubber mounts and four rear solid mounts Topping off the stout frame is an excellent sus 4 K Tech News pension package The front Suspension consists of conventional forks with an inner tube diameter of 43mm The fork springs are buffed
20. eekends But that is where the similarities end because The ZR1100 s air cooled four is all new but there s no mistaking its heritage a _ TECHNICALITIES ZR1100 video available The introductory video on the new ZR1100 is now available If you belong to the Tech Training Video Club you will be receiving your copy soon This 16 minute tape covers the ZR1100 s most interesting features from its all new engine to its distinctive retro bike styl ing The tape is aimed at the trained technician but is general enough to play for interested customers as a sales tool Order Introduction to the ZR1100 by calling Kawasaki s Service Training and Communications De partment at 714 770 0400 ext 2472 We ll put your copy in the mail and bill you just 35 95 plus shipping handling and applicable sales taxes if any lf you d like to get this tape for 30 percent off call the number listed and join our Tech Training Video Club There s no membership fee and no dues just savings on every video tape we offer You ll receive up to four new videos a year at the reduced price of 25 00 Some are even less We ll only send videos covering your product mix You won t get anything you can t use Ray St John K Tech News everything those bikes did the ZR1100 does even better The engine Let s explore the fea tures of the ZR1100 en gine all new but with a layout that is very similar to the pro
21. ew owners don t think about washing the hull flushing the cool ing system drying the bilge and all those other little jobs experienced own ers take for granted From your point of view as a Kawasaki dealer the best part of this tape is the understanding your cus tomers will gain of the complexities of JET SKI watercraft maintenance and the level of expertise needed to do it right Ray St John NOTE You can still get this tape by calling Kawasaki s Service Training and Communica tions Department at 714 770 0400 ext 2472 ec ot ALERT Recalls and repairs Recalls are the subject of new legislation enacted by Congress amending the National Traffic and Motor Vehicle Safety Act of 1966 The new law states that all recalled vehicles not yet sold must be re paired before retail sale The bottom line here is the penalty for non compli ance a fine of up to 1 000 per unit sold with out repair Under the new law deal ers must repair unsold eli gible units before retail sale This applies to all street legal vehicles which have been recalled for a safety defect As in the past federal law requires manufactur ers to maintain accurate follow up records on re pairs performed on eligible units Dealers must submit a Warranty Claim form for each repair and or inspec tion the best way KMC has of verifying that deal ers did make the repair and thus complied with the
22. hen the top of the range is 200 psi there will prob ably be some deterioration in dition of the en gine The symp toms will be more or less severe depending on where the compression is getting away intake valves rings etc The symptoms of low compression are hard starting rough idle and poor throttle response If any of these symptoms ex ist make sure compres sion really is good Gregg Thompson the running con TECHNICALITES J S550 compression reminder For some reason service manuals for the 1983 1990 JS550s say cylinder compression should be 78 112 psi Those of you who are familiar with our 550s know that this is not true A good running 550 engine should develop 115 130 psi Below 115 psi they will definitely begin to develop starting and idling problems Write the correct numbers 115 130 psi in your serv ice manual or have them tattooed inside your eyelids right now Also be aware that the JS550 C model with the aluminum cylinder has much higher compression than the older engines about 200 psi SPECIALISTS Eat some aluminum save a cylinder by Kenny Osberg Product Support Specialist t has come to our attention that some of you out there are throwing away perfectly good KX cylinders Don t do that The material used to coat the cylinder wall in the electrofusion process is extremely hard and often it sur vives a seizure without serious damage Many times the only d
23. igured we had bet ter give you the new num bers lem He takes a piece of heavy steel strap flat stock that will fit through the race he says some found in motorcycle crates works well and tack welds it to the race The strap and race can then be driven out as one piece It s a simple technique and it should save you lots of time as well as leaving the wheel undamaged by the ordeal Great tip Thanks Vince your 100 is on its way Ed 100 reward We re looking for hot tips to share and there s 100 in it for you if we end up printing yours Write K Tech News c o the Tech Services Dept Kawasaki Motors Corp CLARION FACTORY SERVICE CENTER From inside California 310 327 9100 From outside California 800 347 8667 JS H750 spark plug cap double check If you have a JS750 or JH750 that you think might have intermittent spark check the spark plug cap engagement into the coil lead You might just save yourself some time Here is a tip that will help you ensure the spark plug cap is making good contact Unscrew the cap from the lead Trim the lead insulation back to expose 1 8 of wire Fan the wire out over the end of the insulation and trim any wire that sticks out past the insula tion Apply dielectric grease to the wire to prevent cor rosion in the future Re install by screwing on clockwise until tight Install a zip tie P N 92037 1173
24. ipment shipped from clos est KMC Dist Center SS ee 7 STRESS ee eS re De als See E oti haa ag ie ee m 9 Eii t on peer a eat a ee i icai j i a t aa eee Aa tte ae Yn i eo omen ee en aa ah TN Sy 7 ay i a a 7 Y a A Be f I rn aho Ta ge o ea ee 4 he iv i k e ke cOMMUNICATION S Kawasaki watercraft general mainte nance and storage tips video T he Kawasaki Watercraft General Maintenance and Storage Tips video is now available directly from your Kawasaki Parts Distri bution Center as Part Number 99969 3014 This interesting and informative video tape is attractively packaged and priced for retail sale The video carries a sug gested retail of 19 95 but your 100 percent profit margin as a Kawasaki dealer allows you to dis count this tape heavily or even include it free with purchase of a new water craft The program is 24 min utes long and is aimed at the novice mechanic or in terested owner Main top ics covered are pre ride checklist after ride mainte nance preparation for stor age removal from storage and special proce dures Of all of these perhaps the most valuable for a new owner is the pre ride checklist It will help him remember the little things like putting oil in the oil tank and charging the bat tery before he leaves for the beach The after ride mainte nance information will help increase customer satis faction Many n
25. law If you fail to submit a Warranty Claim form for a unit that is subsequently sold and registered the new owner will receive a recall letter requesting the return of the unit to you for repair Of course you want to avoid the cus tomer getting a letter about a repair you already performed so please sub nit those Claim forms ina timely manner O The Technical Magazine 7 TIPS FROM TH AVR testing made easy by Patrick Kelly Instructional Designer Instructor The Automatic Voltage Regulator or AVR on gen erators can be difficult to diagnose The usual pro cedure is to check all other components and if everything else is okay then try replacing the AVR There is however a bet ter way A handful of 9 volt batteries and a single test lamp can be used to bench test the AVR and determine if it is working or not The procedure is quick simple and quite ac curate if done properly You will need to gather up the following materials 1 A fully charged 12 volt battery 2 A 12 volt lamp and socket an old turn signal or running light works well 3 Three 9 volt dry cell batteries with leads Now continue using the following troubleshooting procedures Remove the AVR from the generator For ease of testing it is also helpful to remove the connector s from the leads Hook the 12 volt bat tery up to the sub coil in put leads on the AVR yellow red and black red on older models
26. le increases from 3 6mm in diameter to 5 0mm The pilot outlet is 93 KX125 and 250 detail close ups CLOCKWISE FROM TOP LEFT Larger diameter front axle is lighter and stronger new floating disc has six rivets flush rear axle is clean and light carb refinements improve low end power delivery only 12 5mm from the main nozzle to smooth the transition from pilot to main system The intake reeds are still carbon fiber type but the material is changed for increased du rability The chassis The frame shared by both of these bikes is all new To reduce frame weight wall thickness is down on the headpipe 2 3mm to 1 8mm and the rear center frame bracket 2 0mm to 1 6mm The Swingarm wall thickness is reduced and the rear axle bracket is now an alumi num extrusion instead of a casting The front axle s outer diameter is up 3mm to 20mm allowing the wall thickness to be reduced along with the weight with out loss of rigidity The front forks push rods are now aluminum in stead of steel for even more weight reduction Spring wire diameters are smaller on both ends though the spring rates are the same The Uni Trak rods are slimmer and the number of rivets in the full floating discs is down from eight to six to again save weight Additional weight reduc tion comes from a thinner wall fuel tank and a narrow front fender A small weight saving is realized from the thinner fork outer tubes but the
27. n the meantime keep reading K Tech News and if you have any service problems or questions please give me a call will be available at the East region office 908 469 1221 or on the Kawasaki Technical Hot Line 800 854 3800 Keep in touch we need and value your in put and please have a great summer season O
28. or light green red and green on newer models Hook the test lamp up to the brush output leads from the AVR blue white and green on older mod els or light green white and light green black on newer models The light bulb should light if the cor rect connections have been made If the bulb does not light then the AVR is bad If the bulb does light reverse the po larity of the 12 volt battery hook up and make sure the bulb still lights The bulb must light with polar ity of the 12 volt battery either way If the bulb still lights proceed with the testing Connect all three 9 volt batteries in series for a total of 27 volts and con nect them to the AVR pick up circuit leads light green and blue on all mod els The test lamp should go out Reverse the polar ity of this last connection and again the lamp Sub Coll Circuit Newer models Older models should go out The lamp lust go out with the polar ity of the 27 volts either ray Now hook up just one of the 9 volt batteries to the AVR pick up circuit leads The bulb should re main lit If the AVR passes all of SPECIALISTS Voltage Regulator Voltage Regulator these tests it is probably okay Remember it is a good idea to check the AVR even when replacing other components just to be sure that the AVR did not cause the failure of any thing else O KLF400 Bayou valve noise vs customer satisfac
29. ou use this chart bear in mind that these specs are calculated and not the result of testing as was the case with the specs given in pre vious issues Use this table only as a starting point for jetting and as a source of part numbers for the optional main jets that are available O A couple of times in past issues we have published small articles with some suggested high altitude jetting changes for some ATV or Utility products These sugges tions came from Rocky Mountain Kawasaki RMK our distributor in the Rocky Mountain states and were the re sults of testing done at those altitudes Now Kawasaki Heavy Industries KHI our parent company in Japan has sent us some suggested main ALTITUDE MODEL SEA LEVEL 2 000 9 000 8 000 11 500 STD 5 000 FT 8 000 FT 11 500 FT 15 000 FT KAF300A 105 102 5 100 97 5 95 92063 2218 92063 2236 92063 2173 92063 2163 92063 2167 KAF450B LH 102 100 98 95 92 92063 1115 92063 1008 92063 1005 92063 1001 92063 1004 KAF450B RH 105 102 100 98 95 92063 1009 92063 1115 92063 1008 92063 1005 92063 1001 KAF540 122 5 120 117 5 112 5 110 C D E 92063 1389 92063 2203 92063 2117 92063 2010 92063 2237 KLF220A 115 112 5 110 107 5 102 5 92063 076 92063 075 92063 1038 92063 073 92063 1028 KSF250A 132 130 125 122 120 92063 1076 92063 1075 92063 1069 92063 1073 92063 1072 KLF300B 135 132 128 125 122 92063 1014 92063 1076 92063 1074 92063 1069 92063 1073 KLF3
30. re an accessory item that your custom ers often purchase to customize the look of their personal watercraft Well on the new Kawasaki 750s JH750 A1 and JS750 A1 it s not going to be as easy as it used to be On these models a large washer is welded to each end of the handlebar The grips are molded onto the bars over these washers news associated with it The good news is that the grips cannot loosen with use and slip off or spin around on the bar The bad news is that the grips are not replace able they come only as an assembly with the bar Aftermarket grips are going to be very difficult to install Joe Nowocinski The Technical Magazine 13 TIPS Everyones Favorite job t s never been much fun to scrape gaskets espe cially in older engines Un fortunately new laws pre venting the use of asbes tos in gaskets haven t helped matters any These new asbestos free gaskets are proving to be even larder to remove when the engine has some time on it than the old type were What saves me time is taking the parts to the sol vent tank and scraping the gaskets at the same time clean the parts take a conventional scraper with me and also a knife sharp ening stone The stone can be used to remove the remainder of the gas ket and clean up the sur face once the bulk of the gasket has been removed with the scraper actually keep a large and a small stone in my tool box for clean
31. squish area This increases turbulence in the combustion chamber to help control detonation under severe conditions The piston crown is ma chined smooth to help with this also The com pression height of the pis ton is reduced 0 2mm by the machining but the com pression ratios are un changed 9 1 1 at low speeds and 8 1 1 at high speeds The cylinder s main ex haust and scavenging ports are redesigned and the KIPS sub exhaust ports main valve and pas sages are wider The KIPS now cuts in at 8 800 rom up 400 rpm from last year to complement the other engine changes The expansion chamber is also new along with a new ignition timing curve to help all the other changes work together The flywheel effect of the rotating parts is decreased for quicker acceleration Detail changes inside the carburetor are good TALK TECHNICAL for the lower half of the rev range The primary choke height has been in creased to 7 45mm from 6 35mm last year and it now has a slit in it for im proved atomization The well around the primary choke is larger in diame ter 5 0mm up from 3 6mm Finally the pilot outlet is closer to the main outlet by 9 8mm to smooth the transition from pilot to main system The piston skirt fits the cylinder wall a little closer to cut mechanical noise and the cylinder extends down into the crankcase 5mm farther to reduce pis ton slap The stronger con necting rod introduc
32. st the me chanical seal Any free play in the shaft with the impeller installed indicates a problem If the circlip has come out of the groove the cases must be split to re place it Do not put the old circlip back in the groove order a new one O SPECIALISTS Tip from the field Removing Stubborn bearing races When was the last time a customer brought you a bike needing new wheel bearings and when you took out the axle the inner race and balls just fell out leaving you no way to drive out what was left of the outer race If your shop is anything like Willow s Kawasaki in Cheshire Conn you prob ably run into this problem fairly often It s especially common among off road riders who aren t real maintenance oriented Getting that thin outer race out of the wheel can be both frustrating and time consuming and it often leaves the inside of the wheel somewhat the worse for wear read dinged up Willow s Vince Stas kiewicz has a quick and easy solution to this prob DATA ee ee ee eee ee eee oe eee ey Update your records new Clarion phone numbers latest information for very long Shortly after that bul letin was published a new telephone area code was created for the area where Clarion is located so the company had to change its phone numbers Until recently the phone company would tell you the new number if you di aled the old one On June 1 they stopped doing that so we f
33. tes with radial oil grooves and the knurled steel plates help the transmis sion to slip into gear smoothly when the engine is cold The ZR1100 s wide power band means that the transmission needs only five speeds Second through fifth gears have specially finished gear teeth for reduced mechani cal losses and less gear noise The dogs of third through fifth are also un dercut slightly for positive gear shifts Final drive to the rear wheel is through a No 530 X ring chain similar to the chain used on the ZX11 and ZX7 The K ring chain seals dirt out and lubrication in better than an O ring chain for Superior durability The lubrication system features the largest oil cooler ever fitted to a Kawasaki with a capacity of 5400 Kcal hr 50 per cent larger than the one Pee ale LN Ln i Electronic wizardry Dual plugs dual coils digital igniter and a load sensor Keeping up with demand Firing the ZR1100 The ZR1100 has a new approach to light ing the fire in its massive combustion chambers To ensure the flame front rages across the 75mm diameter com bustion chamber without detonation two spark plugs per cylinder are installed Dual plugs ignite a pair of flame fronts which speed up combustion for rapid Starts with less chance of detonation and lower emissions One plug from each cylinder pair is fired by one of four dual output ignition coils The plug wire arrangement is simi lar to other fo
34. tion We have had some com plaints about loud valve train noise in the new KLF 400 B1 Bayou Although the valve noise should not result in any abnormal wear or failure customer perception sometimes is that this noise is not good To help improve cus tomer satisfaction Kawa saki is recommending 8 K Tech News closer valve clearance tol erances The new cold valve clearances Intake 0 12mm 0 17mm Exhaust 0 20mm 0 23mm To ensure the lowest possible valve noise with Out sacrificing perform ance adjust the exhaust valve clearance right at 0 20mm O TIPS Older model J S550 piston ring wear by Keith Pestotnik Rocky Mountain Kawasaki The 86 JS550 A5 through 90 JS550 B1 JET SKI watercraft have a tendency to wear piston rings more quickly than al most any other Kawasaki model This wear pro duces symptoms that in clude hard starting and what may seem like inter mittent carburetion prob lems bogging or incon sistent air fuel mixture requirements at idle Boats getting regular usage may need fresh rings annually to give consistent and trouble free performance Although a more dura ble ring has not been made available for the A and B models the JS550 C1 C2 features a different style piston util izing two steel rings These dual rings wear much longer than the older single ring design If an out of warranty 550 A or B model comes into your shop needing new rings
35. ur cylinder Kawasakis there are just twice as many wires From the igniter to the spark plugs there are two complete and separate ignition systems for each cylinder making the system even more reliable and easy to trou bleshoot The digital igniter has a single right side mounted pulse coil and four sepa rate triggering transistors for each of the four ignition coils improving reliability A key feature of the ZR1100 s ignition is the load sensor As you know twisting the throttle open when a bike is under load translates into decreased vacuum at the intake manifold and increased possi bility of detonation Limiting that possibil ity in this system is a vacuum transducer located under the tank Signaled by the transducer the igniter selects a different Spark advance data map for the load then selects the optimum spark timing for the current engine rom Five data maps are stored in the igniter to provide the perfect profile of spark timing to match the rider s demand for power Jerry Heil The Technical Magazine 3 KX125 amp 250 CONTINUED FROM PAGE 1 The engine 125 The power increase in the KX125 is traceable to a number of changes In creased port and reed valve area help pump up mid range and top end power An aluminum cover on the crank web in creases crankcase com pression for better low and mid range torque as well as improved throttle response The cylinder head is changed to in crease
36. ven ZG1200 en gine It s an air cooled in line four cylinder displa cing 1062cc s from a bore of 73 5mm and a stroke of 62 6mm Peak horse power 93ps is reached at a low 8000 rpm Peak torque 65 ft lbs is reached at just 7000 rpm This modern air cooled engine features special ducts to direct extra cool ing air to the number two and three cylinders A cen tral cam chain drives the dual overhead camshafts which open one 39mm in take valve and one 34mm exhaust valve per cylinder The valve train is the fa miliar and ultra reliable shim under bucket de sign In fact the buckets and shims are the same as those used in virtually every shim under bucket air cooled engine we ve ever made including the KZ550 KZ650 KZ750 and the GPz1100 The combustion chambers a semi spherical design for maximum thermal effi ciency combine with flat topped pistons to provide a 9 1 1 compression ratio Because this engine is air cooled and has such a large bore two spark plugs per cylinder are used Using two plugs re duces the distance the flame front must travel thus minimizing any ten dency to detonate A side effect of using two plugs is that the ignition timing needs much less ad vance with just 2 5 be fore top dead center at 1000 rpm The ignition tim ing is controlled by a so phisticated digital ignition with automatic load sens ing see sidebar next page The ZR1100 engine uses a forged one
37. who is the most competent It is always in teresting to see how skill ful the students are Also during the summer months am working on the Hot Line answering dealer service calls al ways enjoy having the op portunity to talk with dealers and help them with their problems In between all of this will be completing plans for an exciting new Kawasaki service contest It is a contest but the con testants do not compete di rectly against each other The number of prizes to be given away will depend on the number of winners That is enough of a pre view for now keep an eye on future issues of K Tech News for contest details O Training Schedule East Region North Region Central Region South Region West Region KMC instructors are work ing now on the 1993 Train ing Program schedule Classes will begin again in October All dealers will re ceive a copy of the winter class schedule but don t forget to watch this space in the Fall and Winter is sues of K Tech News It s Summer Sales time now by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 Training classes were offi cially over for the season as of the end of May The summer sales season is fi nally here and it s time to put all that information you learned in class to good use Service training classes will begin again in the fall of course Be sure to watch your mail for the fall training schedule I
38. yellow red and black red on older models and light green red and green on newer models Start the generator De pending on the size of the generator the sub coil will put out about 1 2 to 3 volts AC if it s good If the sub coil does not produce AC voltage then the stator will have to be replaced be cause the sub coil is inter nally wound with the stator lf the sub coil checks out okay then the voltage regulator is bad Replace it Also see AVR testing made easy on Page 8 NOTE This trouble shooting procedure is fast it only takes about 15 mins and it locates the problem component most of the time But if steps 3 and 4 don t result in any AC output i e it still won t run the drill then the sta tor rotor or panel assem bly may be causing the problem and further trou bleshooting with the shop manual and multimeter will be required O The Technical Magazine 9 TiP Ss A better air filter for the KLF300 Bayou by Gregg Thompson Sr Product Support Specialist Some KLF300 B C mod els are being used in ex tremely dusty conditions and in those conditions the air cleaner may need servicing as fre quently as every couple of days Unfortunately most us ers don t give their air cleaners anywhere near that much attention When the air cleaner element gets choked off with dirt the air finds other ways of getting into the engine When it does it takes the dust with it see th
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