Vol. 12, No. 4
Contents
1. 45v Battery 12v Fl and Ign 45v FI and Ign 45v The high output stator has separate coils for a 45 Volt system and a 12 Volt system zle s poppet valve spring pressure it sprays fuel into the combustion chamber It takes high pressure to overcome nor mal engine compression in the combustion cham ber Since the injector pro duces the high pressure a standard fuel pump and fuel lines are used at a regulated 25 psi Each injector is flow tested for fuel output These flow rates are pro grammed into the EMM map data to achieve near identical output in each cylinder for optimum combustion Each injector is marked with a serial number and the number cylinder it is installed in Make sure you keep the injectors with the correct cylinder To replace an injector you must use a computer linked to the EMM to tell it that you have installed a replace ment injector This changes the injection pro gram map for that cylin der to a special default setting To replace the EMM you must use the service utilities function in the diagnostic software to transfer data from the old EMM and program it into the replacement This may sound complicated but is a simple procedure Engine Management Module EMM The EMM is more than just the brain of this boat It also contains the regula tor rectifier for a 12 Volt system used for the bat tery and gauges as well as a 45 Volt system for the injectors an2. the oil because it obstructs your view of the oil level in the valve cover However if you do use a funnel pour the oil slowly enough that it does not rise and fill the valve cover higher than the vent hose fitting Please read service bul letin UV 00 02 for more details ENGINE NUMBER LOCATION The Kawasaki engine number is printed on a bar code label and lt i gt attached to the valve cover The number looks like this AF950AE000001 There is another number stamped into the crankcases by the engine manufacturer Daihatsu The Kawasaki engine number is the one you will use in normal com munications with KMC Valve Cover High Point in Vent Hose IDLE RPM The engine idle speed specified by Kawasaki for this engine is 850 950 RPM The engine will comfortably idle at much lower speeds however vibration felt by the occu pants will dramatically increase below 850 RPM Intake Manifold by Ray St John 2000 A13 Supervisor Technical Writing 2000 Bayou 220 Carb Adjustments use these settings on older model carburetors Revised manuals do not ship to you automatically The 2000 Bayou 220 has a new carburetor with a number of internal changes including jets and settings Jet changes include the main jet jet needle needle jet needle jet holder pilot jet and pilot air screw If you need to know exact details about any of those changes check the parts catalog As far as setti
3. condi tions may require different jetting Every track is different Every rider is different Ray St John KX125 L2 Carburetor Specifications Item Original Kit Slow pilot Jet 45 40 Power Jet 55 42 Needle Clip Position 3rd Groove 2nd Groove from top WINTER 1999 00 7 K TecH News Ultra 150 by Charles Yim Product Quality Engineer Have you ever run across an Ultra 150 with the choke control knob that was very hard to operate because of corro sion Your customers could experience this trouble especially if you are in an area with salt water nearby The Ultra 150 does not have an O ring on the choke knob shaft as do some other models Water can get in Referring Calls to Consumer e Services by Rick Roddewig Consumer Services Techni cal Analyst In Kawasaki Con sumer Services we often get calls from customers wanting to know why Kawasaki has denied their request for war ranty assistance In many such cases the dealer had referred his customer to us but has never actually contacted Kawasaki about the problem Often the cus tomer s next question to us is something like between the brass shaft and the aluminum bracket and cause corrosion Fresh water would proba bly never cause a func tional problem but salt water is very cor rosive and acts very quickly on dissimilar met als Where can I find another dealer in the area who can help me At y
4. reason that you were not aware of offer to cover the failure get ting you off the hook entirely By you taking the time to make the call your customer can be assured that you have made every effort to find a satisfactory solu tion If the Hotline decides to authorize the repair you re the hero If the Hotline agrees with your decision to deny coverage the call estab lishes the background needed to support your position if the customer contacts Kawasaki Con sumer Services WINTER 1999 00 8 K TECH News Diesel Mule Tidbits by Gregg Thompson Product Support Supervisor ADD OIL TO THE ENGINE CAREFULLY When filling a Kawasaki Diesel Mule engine with crankcase oil it is possible to add the oil too quickly overfilling the valve cover If this hap pens oil can run down the crankcase breather hose into intake manifold and past any open intake valve into the cylinder If enough oil gets into the cylinder a hydraulic lock will occur bending the connecting rod An engine with a bent connecting rod will run very rough and emit black smoke from the exhaust To avoid this problem observe the following steps Before adding the oil pull the engine oil dip stick upward a couple inches to allow the crankcase to breathe e Make sure the breather hose at the valve cover is installed correctly with a high spot in the middle see drawing It is best to not use a funnel when pouring
5. valuable a tool KIC is and have not learned to use it KIC Kawasaki Informa tion Center is part of K Share and is sent to K Share dealers on a CD ROM with updates every two months KIC has all of the parts information like a microfiche on CD but it offers much more KIC has all of the flat rate information service bul letins and even sales liter ature There is so much information available with just a few clicks of a mouse button K Share is full of fea tures to help dealers con duct business with Kawasaki Kawasaki con tinually adds new features like the latest Electronic Document Distribution EDD To keep you and all your employees up to date on K Share and KIC we are offering a one day training class at our train ing centers The course is great for new and experi enced users Please refer to the 2000 Training Schedule for the class dates nearest you and reg ister early K Share KIC is a valu able business tool Use it to its fullest extent Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 PISCATAWAY GRAND RAPIDS Power Parmer 6000 Low Oi LeveL Sensor On some Power Part ner 6000 Generators the low oil level sensor causes the engine to not start or quit even if the oil level is correct This could happen all the time occasionally or just in cold weather Disconnecting the lead wire to the switch will allow the engine to start and run
6. 4 Fuel Pump Leakage JH1100 A3 A4 RECALL J11100 B1 B2 JT900 B1 JS 99 05 Exhaust System JH1200 Al FDM Overheating Model VN1500 J1 L Motorcycle Bulletin Number Subject RECALL MC 99 04 Back Torque Limiter RECALL Spring Breakage 7G61000 B14 141 15 15L 2G1200 B13 13L 14 14L ATV RECALL Bulletin Number Subject Model 7X750 P4 41 5 S5L ATV 99 02 amp ATV 99 03 Steering 1997 99 RECALL issued 6 99 Knuckle Failure Prairie Models Tool Corner Mule 2510 Diesel There are nine tools needed to service the diesel engine and they are all now in stock These tools are shown in the Service Manual starting on page 1 17 All other drive train and chassis tools are the same as the 2510 gas model The first new tool is a dial gauge adapter 57001 1430 which is used with a dial gauge you supply to check the fuel pump adjust ment This adjustment is critical since it controls injection timing 2000 ZX 6R ZX 9R and ZX 12R These models share a new type of steering head bearings Instead of tapered roller bearings they use ball bearings held in races that require a new procedure to install or adjust them You will need two new head pipe driver tools 57001 1446 and 57001 1447 Check the A amp P sheets for new higher torque values for the steering stem locknut and head nut The 00 ZX 9R has a new engine mounting system requiring a special wrench 57001 1450 to adjust the frame to engine clearance during install
7. Griffin Regional Editors Piscataway Grand Rapids Fred DeHart Atlanta Tulsa Walter Rainwater Irvine Tacoma Robert Taylor Contributors David Behlings Alex Dell Rick Rod dewig Ray St John Charles Yim Graphics Production Graphic Art Gregg Thompson Photography John Griffin Production Holland Marketing Services 2000 Kawasaki Motors Corp U S A All rights reserved 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 chambers with access for one high pressure injector on the top and one extended nose spark plug NGK PZFR7G G in the side for each cylinder The pistons have a splash port dish formed in the crown to help atomize the fuel spray in the homoge neous mode more on this later The Injectors The EMM powers an electromagnet in the injec tors with 45 Volts to blast fuel into the cylinder at pressures over 250 psi up to 150 times per second The electromagnet moves an armature which acts like a high speed piston pressurizing the fuel in the nozzle end of the injector When this fuel pressure exceeds the noz Pas Stratified combustion is used below 5500 RPM Fuel is ignited just after it leaves the injector with the spark plug fir ing as many as 15 times to burn fuel more com pletely
8. NEWS WINTER 1999 00 THE KAWASAKI TECHNICAL MAGAZINE VOL 12 NO 4 DIREG TO Tool Corner CD Sales Guides Service Bulletins KX Bladder Type Fork Shipping Costs VN800 Valve Correction KX125 Jetting Kit Ultra 150 Choke Consumer Calls Mule Tidbits Diesel Fuel Injection z Overheated Exhaust Q Q Q PELOT SERVIE ARD gii SFIS Kickster Gear a ass a 3 E gt Direct Injection and the new 1100 STX D I by John Griffin Instructional Designer Instructor The FICHT Direct Injection on the new 1100 STX D I is the most sophisticated induction system ever used ona Jet Ski Watercraft A brain called the Engine Manage ment Module EMM con trols unique fuel injectors to spray a precise amount of fuel directly into the combustion chamber for unmatched throttle response and acceleration Most of the fuel is sprayed into the cylinder after the exhaust port is closed by the piston so there is little waste It uses about 30 less fuel and nearly 50 less oil for about a 60 reduction in emissions The Engine The engine has many similarities with the 1100 STX because the FICHT system does not require radical changes to the bot tom end or cylinders The main change below the cylinder head is that the crankshaft now uses a double row bearing between the 1 cylinder and a new high output stator assembly The double row bear ing is lubricated directly Ficht engine with se
9. able to bump the compression ratio from 5 8 1 to 6 6 1 without detonation Diagnostic Software Technicians are thrilled with the diagnostic capa bilities of Kawasaki s FICHT system Dealers can now use a computer program to inspect and test nearly all facets of the injection and electrical system Your computer monitor will display error codes for any problems recognized by the EMM during operation You can check voltages and the condition of all onboard sensors some of them without even running the Jet Ski You can even view the percentage of time the rider has run the engine in each RPM range Training Direct Injection brings too many changes to dis cuss in this article Please attend the hands on 1100 STX DI training classes offered at each of our Training Centers Many classes have been resched uled so contact your Training Center for the latest schedule and sign up now WINTER 1999 00 2 K TecH News
10. ation There is also a new adapter 57001 1448 needed to measure charging output voltage with a multimeter To measure the primary peak voltage of a stick type ignition coil use adapter 57001 1449 To disassemble 00 ZX 12R front forks hold the fork cylinder with a new holder 57001 1443 while removing the allen bolt on the bottom of the fork A new fork spring com pressor 57001 1452 is required to compress the fork to loosen the push rod nut The procedure is almost impossible without the spring compres sor set The last special tool 57001 1445 aligns the scissortype primary gear on the clutch housing for installa tion Rob Taylor WINTER 1999 00 5 K TecH News 2000 KX Bladder type Fork Update by John Griffin Instructional Designer Instructor The bladder forks on the 2000 KX125 and KX250 are receiving great reviews Unfortu nately there have been several incorrect theories published about how these forks work even by myself in the last K Tech News Since then we have learned more about the inner workings of the bladder fork Bladder type Front Fork for Speed Sensitive Springing There are two types of springs at work in con temporary forks the metal spring and air pressure The air pres sure is affected by the size of the air chamber which can be altered by raising or lowering the fork oil level Raising the fork oil level increases air pressure as the fork collapses to bet
11. barometric pressure sensor housed inside the EMM senses altitude changes for consistent running even as high as 14 000 feet This sensor uses a delicate diaphragm that connects to a small hole on the outside of the EMM Do not use high air pressure to clean this cav ity or you will rupture the diaphragm Stratified and Homoge nous Combustion The engine uses a strat ified combustion mode from idle up to approxi mately 5500 RPM In this mode the injector waits until the piston closes the exhaust port then fires a dense plume of fuel at the spark plug Elsewhere in the combustion chamber the air fuel mixture is extremely lean The spark plug fires up to 15 times as the fuel passes by the electrode This unique multi strike ignition burns fuel thoroughly and keeps the spark plug insulator clean The homogenous com RPM profile romprofi doc This R amp D test boat knows only two throttle posi tions closed for no wake zones and wide open Diagnostic main menu mainmenu doc The diagnostic capabilities of the 1100 STX D I have brought cheers from technicians bustion mode starts above 5500 RPM In this mode injector timing advances and fuel is sprayed fur ther into the cylinder where it bounces off the top of the piston and dis perses throughout the combustion chamber in a uniform air fuel mixture The ignition timing also advances and the spark plug fires only once per cycle Engineers were
12. continuously Be sure to confirm the unit is at the proper oil level before disconnecting the sensor switch lead wire If you encounter this problem the Kawasaki Small Engine Division developed a kit P N 99916 2152 to fix it The kit consists of a new oil level sensor switch bracket and a spacer that better positions the sensor in the crankcase These parts are pre assembled and can be bolted directly in place of the old parts Power Partner 6000 engines above 57823 should have the new parts installed from the factory If you install the oil level sensor kit parts it s recommended that you also install a new ignition controller P N 21177 2064 with a third wire lead The third wire is an external ground that should be bolted to the engine along with the ignition ground wire The old controller could burn out the reed switch con tacts in the oil level sensor due to high current levels when the switch shuts off the ignition in a low oil level situation If you have any prob lems obtaining these parts contact Mr Jerry Hooker at the Kawasaki Grand Rapids Parts Department 616 949 6500 Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 732 469 1221 WINTER 1999 00 4 K TECH News g 2000 Product Sales Guides on CD Kawasaki has distributed a CD ROM containing the new Product Sales Guides and Quick Reference Guide again this year Even though your store received on
13. d ignition sys tem Water from the engine cooling system flows through the EMM s water jacket to fight heat Continued on pg 12 WINTER 1999 00 3 K TecH News IRVINE TACOMA Diese Mute Notes Note 1 If you plan to check engine compression on a Diesel Mule keep this in mind You will need the unique compression gauge adapter 57001 1431 and a compression gauge that has a range up to 1 000 psi Make sure you find the fused brown wire under the seat and remove the fuse before you turn the engine over If you don t the engine can start while you are checking compression Note 2 The Diesel Mule valve guides are replaceable with an oversize guide When installing a new valve guide DO NOT hammer the guide into the head using the driver The guides are pre sized and have a slightly larger ID than the final specifica tion When installed in the head the interference fit will put the guide into proper specification Install the guide into the head using the guide dri ver and a PRESS Ham mering the guide into place with the driver could distort the guide making it unusable since there is no reamer avail able Rob Taylor 9950 Jeronimo Road Irvine CA 92618 949 770 0400 ATLANTA TULSA Can You KIC While recently con ducting the 2000 Service Update Seminars I learned there was a large percentage of attendees that have still never used KIC They don t realize how
14. during an over heated condition the blue plastic outer sleeve of the cable can become melted and discolored The cable may continue to function but its life expectancy will no doubt be short ened and the customer won t like the looks of it As with the sensor har ness careful routing is the key to prevention There is a black rubber cable holder near the water muffler This holder can be reposi tioned to hold the trim cable away from the muf fler To do this you must peel it off the hull and re glue it Rotating it slightly is usually all it takes to provide the necessary clearance for the cable Before gluing the holder make sure it and the hull surface are very clean Use an instant glue such as Kawasaki P N TB1762B The JT1100A B and JT900B models can also experience Multi Func tion meter failures due to melted sensor wires As with the Ultra 150 careful routing of the speedome ter sensor wire harness can prevent this expen sive failure WINTER 1999 00 l 0 K TECH News KSF250 Kickstarter Gear Confusion by Alex Dell Product Support Specialist When ordering replacement parts for the kickstarter idler gears on the Mojave ATV it should be noted that there was a running mid year design change on the 1998 model KSF250 A12 The parts microfiche shows two separate drawings and identifies the engine number range for each Except for some very minor differences the drawings look
15. e CD you can order additional copies for only 10 00 each These publications have detailed information on every 2000 model and the valuable KAW PEDIA The Tech Features sheets towards the back of each book are full of technical highlights The Quick Reference Guide contains specifications in a format that simplifies model comparisons Contact us at 949 770 0400 ext 2463 to order extra CDs Note this CD contains Adobe Acrobat Reader 4 0 which is used to view the documents and search for information This CD will run with the 3 0 version if you already have that installed on your PC Don Church Manager Service Training and Communications Reminder Important Service Bulletins by Don Church Manager Service Training and Communications Kawasaki has recently issued some important service bulletins Reac quaint yourself with these bulletins now It is likely that many customers will wait until spring to have these repairs made since their machines are cur rently in storage Make this a policy in your service department use the K Share Vehicle Service Inquiry VSI to check the warranty his tory of every Kawasaki you take in for service VSI will show you if a unit is eligible for a Recall or Factory Directed Modi fication FDM Plus it will show you if a claim has already been submit ted for the repair Jet Ski Watercraft Bulletin Number Subject Model JS 99 03 Steering Cable RECALL Nut Failure JS 99 0
16. from the upper chamber to com press the bladder 1 At slow fork speeds the oil has more time to NEED ART FROM JOHN flow down past the washer and bushing so the bladder really gets compressed so more oil moves from the top of the fork to the bottom lowering the fork oil level in the upper cham ber 2 At high fork speeds the oil can t flow fast enough down past the washer and bushing so the bladder does not get as compressed and more oil stays up by the fork cap for a higher fork oil level Oil Level Rule A rule of thumb for oil level in our 46mm forks is that 1cc of oil 1mm of fork oil level So if the bladder fork can vary the oil in the upper chamber by 30cc that equals a fork oil level that can vary as much as 30mm Servicing The service proce dures are identical to last gt WINTER 1999 00 6 K TecH News Special Shipping Costs on Warranty Claims by Gregg Thompson Product Support Supervisor Occassionally dealers call the Hotline and ask us to authorize reimburse ment for air shipping costs on parts for a warranty claim Usually this hap pens when the repair has been delayed for some reason and the customer is getting anxious It is not our policy to reimburse dealers for shipping costs on war ranty parts Instead deal ers receive a 25 handling credit for all the parts on any claim submitted over K Share If a claim has 300 dealer cost in parts the ha
17. ndling credit is 75 That money is supposed to pay for shipping and handling costs at your end It should easily do that and in many cases will even cover air ship ping Remember you get that extra 25 for all parts on the claim including the ones you already have in stock Be aware that there are handling costs involved in placing either a small reg ular order or any emer gency order Small regular orders any order below 350 dealer cost carry a 5 handling charge Any emergency order regard less of the dollar amount carries a 10 handling charge In both cases nor mal ground shipping is paid by KMC We realize that to expe dite warranty repairs it is sometimes necessary to place small emergency orders But whenever pos sible you should put your small warranty parts orders together with regu lar stocking orders in order to avoid those han dling charges and take full advantage of the 25 han dling credit The next time you need to air ship war ranty parts you ll already be way ahead of the game In case you re wonder ing claims submitted by mail using the old paper forms receive a 10 han dling credit on the parts Bladder type Fork Update cont d year except there is one tip to follow When refilling the forks with oil leave out the new washer under the spring until you have bled the forks and are ready to set the oil level With the washer in place it takes a long time fo
18. ng changes go the revised service manual will contain that information but that manual is not yet available Until the new manual comes out please refer to the table below It would be a good idea to pencil the Y2K specs into your current manual to make it easier to find Do not try to Bayou 220 Carb Adjustments 21 8mm 22 6mm Model Years Float Height Air Screw Setting 1988 thru 1999 Al thru A12 1 1 2 turns out 2 5 8 turns out WINTER 1999 00 9 K TecH News Diesel Fuel Injection by DENSO The new KAF950 A1 Diesel Mule Utility Vehicle sports a fuel injection system manufactured by DENSO formerly Nippon Denso of Japan The heart of this system is the pump a fairly large and complicated compo nent located just below the intake manifold and mounted to the gear case at the end of the engine block From time to time you may have units in your shop that require ser vice to the fuel injection pump There is a timing adjustment that with the help of a special tool P N 57001 1430 and a dial indicator you can perform in your shop But beyond that any internal repairs or recondi tioning must be done at an authorized DENSO Service Center where they have the proper equipment including a flow bench and trained techni cians to perform such work These authorized service centers can also perform maintenance on the injectors If you have a KAF950 with running problems caused by the fuel injection pump or no
19. nsor layout Use sensor ppt with arrows amp letters or sensor jpg and K amp D can add their own No caption by the oil pump witha new fourth oil line con necting to the cases The other bearings connecting rods cylinders and pis tons are lubricated in a more traditional manner ee ia An all new hull softens the ride by reducing wave shock while new sponsons improve cornering A revised jet pump and more powerful engine boost thrust to 851lb ft for a craft that is 8 mph faster and has quicker acceleration Stor age is nearly doubled to 23 5 gallons with a new tub under the front hood Intake system with oil pipe jt11 00int jpg Lubrication is handled by oil pumped through nozzles into the air stream and by an extra oil line pumping oil into the cases for a new dou ble row 1 main bear Oil is pumped from the variable output pump into each intake where it is picked up by the air stream between the throt tle plates and new six petal reed valves Because there is no fuel to dilute the oil much less is required The top end of the engine is all new The cylinder head has new bell shaped combustion WINTER 1999 00 2 K TECH News K TECH News Vol 12 No 4 Winter 1999 00 K TECH News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Communications Editor John
20. our dealership you frequently have to make decisions whether to honor a customer s request for repairs under warranty When your answer is no regardless of how you deliver it your customer will probably not be pleased Sometimes a customer will even ask for a repair to be cov ered when the vehicle is not in warranty Again the same results if you say no If your customer really presses the issue and won t take your no for an answer we suggest you first call the lt gt Choke Knob Corrosion To reduce the w can install an O ring P N 670B1508 on the shaft Before installing the O Kawasaki Technical Hot line and discuss it with them This way you can discuss the technical aspects of the situation and explain your deci sion to the Hotline tech nician Your reasons for denying the warranty request will be accu rately recorded includ ing any technical details that support that deci chances of this hap M pening a Add O Ring here P N 67081508 A ring it s a best to disassemble the choke control assembly clean it and lubricate all moving parts with a waterproof grease such as Kawasaki P N MC 11 Then reassemble it installing the O ring between the 8mm washer and the bracket as shown here Note If the mechanism is already corroded and bind ing order new parts and assemble it with the O ring sion In addition the Hotline technician may for some
21. r the oil to flow into the lower leg There is a new cartridge rod holder P N 57001 1442 which you will need for disassembling these forks This tool does not work on L1 models VN800 Valve Clearance Correction by John Griffin Instructional Designer Instructor VNS8OO A B C all years 0 10 0 15mm 0 20 0 25mm Intake Valve Clearance Exhaust Valve Clearance This is the correct intake and exhaust valve clearance for all VN800 models A B and C for all years The Service Manual for the VN800 A and supplement for the VN800 B Classic show an incorrect exhaust valve clearance range Please correct your man vals 2000 KX125 JETTING KIT Recently Kawasaki began sending a jetting kit to all original registered owners of 2000 KX125 L2 units Some owners feel that the original jet ting is rich at low to mid range throttle openings so Kawasaki is sending out this kit to ensure cus tomer satisfaction The kit includes a leaner slow pilot jet power jet and instructions to raise the jet needle clip one notch You can help by submitting the warranty regis tration quickly whenever you sell a new KX125 L2 Kawasaki uses that information to send out the kits You can even promise this freebie to help sell new units The kits are not available to anyone but the original retail purchaser though the parts are still sold separately Remember this jetting is still just a starting point for fine tuning Your
22. ter resist the fork collapsing The Compromise Designers and riders must always compro mise between a high oil level to resist bottoming and a low level for sup ple action What if you could have an oil level that varies while you hit abump If you land hard it gives you a high oil level and if you land smoothly it gives you a low oil level The Bladder Enter the Bladder type front fork that offers speed sensitive spring ing One internal bladder per leg acts as a sec ondary air chamber that is variable in size The primary air chamber is between the oil and cap The bladder covers the cartridge and acts like a balloon compressed by the fork oil surrounding it The Oil Divider A new washer A and NEED ART FROM JOHN lt gt bushing B rest on a pis ton mounted on top of the cartridge assembly They make the bladder work by dividing the oil chambers as fork speed increases When you hit a bump oil is pushed from the top of the fork above the cartridge down into the bladder area by flowing around the washer and the semi sealing bushing So What Is It Doing The bladder has an air capacity of 70cc which can be compressed to absorb or hide a simi lar amount of oil Since the cartridge rod dis places 26 30cc of oil into the bladder area it leaves up to 40cc avail able to absorb oil from the top of the fork The only variable is how much oil 0 40cc will get pushed down
23. the same However as of this writing the KIC system shows the same draw ings but does not iden tify the engine number range for each drawing The parts are not inter changeable so please be careful when ordering these parts The idler gear we are discussing is the one that fits on the small end of the transmission out put shaft The new gear has a larger LD to match an increase in the diameter of the trans TA S l 7 EARLY STYLE Up to Engine Number 026491 mission shaft where the idler gear rides The early shaft and gear are 17mm and are used in engine numbers up to 026491 The late parts are 19mm and are used in engine num bers 026492 and up In addition to the gear the collar washer and snap ring were also changed to fit the new shaft It might be worth putting a copy of this article in your Mojave service manual as a reminder should you ever have to repair the kickstarter gears on a KSF250 A12 19mm I D 9 Se tan A atots Ti 11974 u gt enad 1 ai ECTE K Engine Number 026492 and Up Tia LATE STYLE Winter 1999 00 f K Tec News 1100 STX D I Cont d build up It also has an internal temperature sen sor which activates the Speed Limiting Opera tional Warning S L O W system to reduce engine RPM if the EMM begins to overheat Excessive voltage over 45V and high engine temperature also activate S L O W A
24. zzles call the Kawasaki Hotline and we can put you in touch with the nearest DENSO Service Center Ed Side Effects from Overheated Exhaust by Charles Yim Product Quality Engineer We have received some reports of damage that has occurred to other components on the Ultra 150 as a result of exhaust overheating problems The potential for over heating in the exhaust is addressed by the FDM Bulletin JS 99 05 and actual overheating of exhaust systems is fairly rare However if over heating does take place residual damage can occur to things which are in contact with or very close to the water muffler The two items most likely to be damaged by an overheated water box are the speedometer sen sor wire harness and the trim cable These are both routed very close to and often touching the water muffler If the speedometer sensor wire harness melts it usually shorts one of the power leads which in turn damages the multi function meter If this happens both the meter and the sensor must be replaced If your customer complains of a dead speedometer check the sensor wire harness for signs of melting To prevent this from hap pening route the sensor harness so it will not touch the muffler Adding an extra stick on zip tie holder P N 13280 3706 will help with this Make sure the area you stick the zip tie holder to is very clean and smooth If the trim cable is in contact with the water muffler
Download Pdf Manuals
Related Search