K-Tech News Vol. 5 No. 4
Contents
1. E SPECIALISTS TIP Bayou 400 neutral switch Shortcut You ATV technicians might be interested to know that you do not have to remove the engine in a KLF400B in order to work on the neutral switch if you first remove the shift shaft by pulling it out the right hand side With the shift shaft out of the way there is enough room to get the bevel gear case out with the engine still in the frame To disconnect the rear drive shaft simply remove the swingarm pivot bolts with the chassis supported on the stands and swing the suspension arms and driveshaft housing rearward Although this method may not save you huge amounts of time it does eliminate the hassle of draining the coolant and allows you to inspect and operate the shift drum and detent mechanism from the right side while you are diagnosing a neutral switch problem Randy Davis A better camchain tensioner T he ZX900 Ninja ZL900 Eliminator M1000 A Ninja ZL1000 Eliminator and ZG1000 A1 through ZG 1000 A5 use a SCREW type camchain tensioner his style tensioner can Sometimes get pretty noisy after the bike has some miles on it All the ZX 10s and ZX11s a IS well as the ZG1000 A6 through A8 have a new de sign RATCHET type ten sioner These later style tensioners are sturdier than the older style and less likely to become noisy with time The latest part number for the new style tensioner is 12048 11132. U S A Inc 9950 Jeronimo Road Irvine CA 92718 Once again good luck to all TIPS FROM TH Clean air for your MULE 2010 by Gregg Thompson Sr Product Support Specialist All you MULE dealers out there should already know about the optional in take snorkel kit available for the KAF450 B1 MULE 1000 but you probably don t know that Kawasaki has recently developed a similar snorkel kit for the KAF540 C1 MULE 2010 As with the MULE 1000 kit this new kit allows the vehicle to draw its engine intake air and torque con verter cooling air from the relatively dust free environ ment at the top of the cab frame Installation of this snorkel kit will reduce the frequency of air cleaner service required when op erating the vehicle in ex tremely dusty conditions The kit is designed for the KAF540 C1 and does not fit the KAF540 D1 MULE 2020 without some modification The problem is the MULE 2020 has no air filter case in the air sup ply to the torque converter The pipe from the snorkel kit which is supposed to be connected to the torque converter air cleaner case could simply be capped off or con nected to the torque con verter inlet tube with an aftermarket hose If you have KAF540 C1 customers using their vehi cles in dusty conditions you should tell them about this optional kit The price is right and the benefits can be significant Order the kit using P N 99995 1258 O
3. der How about those service manuals are they current in good shape and in the proper order What about those special tools Have you replaced any missing or broken ones Is the parts depart ment aware of what your CONTINUED ON PAGE 10 12 K Tech News Knowing what to ask by Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 Most people who ride mo torcycles or watercraft have no idea what makes them tick They don t know what the parts in volved are called or what they do This can be a problem when the cus tomer tries to relate his or her problem to the service writer So as a service writer or technician you need to know what kind of questions to ask the cus tomer in order to avoid missing this potentially valuable source of diag nostic information Try asking the customer a series of questions logi cally ordered and worded in language you can both understand It s then up to you to decide what is perti nent to the problem you are trying to diagnose Consider the following leading questions CONTINUED ON PAGE 10 NEWS Make sure you sign up by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 S tudent attendance at Kawasaki training classes last fall was very good To insure that you attend the classes you need sign up early Training schedules are sent to your dealer ship each month during the training se
4. wiring The wiring Well check the main wire har ness anyway The main wire harness on this model has a heavy stiff protective sheath made of ribbed plastic If the ribs or the edges of the plastic it is split lengthwise in order to be installed over the har ness rub against some thing else on the bike frame or fairing parts the result is a loud click Don t do a lot of me chanical teardown until you have checked this out first The fix is simply to take the fuel tank off and wrap the sheath with elec trical tape Fred DeHart CONTINUED FROM PAGE 12 needs will be in the com ing months What about the shop equipment like the air compressor or the fork lift have they been serviced recently Now is the time to han dle all of these items in preparation for the coming months Remember the old saying about an ounce of prevention Oh and don t forget if 10 K Tech News FROM THE SPECIALISTS Hard starting J S300 s E arly 300cc JET SKI watercraft had a problem with hard starting The most pronounced symp tom was an occasional window rattling after fire backfire in the exhaust while cranking Kawasaki initiated a repair campaign Bulletin JS 86 07 to re place the OEM igniter with a different one and a tim ing correction device But the same problem can exist even with the up date igniter and also in the newer units This is usu ally caused by the starter mo
5. It can be used in any engine of this family going all the way back to the original ZX900 A1 Gregg Thompson The Technical Magazine 7 TIPS FROM T H KDX200 water pump seals double lip mysteries revealed A single lip seal has been added to the 1991 KDX200 E3 water pump which is not shown in the service manual supple ment In addition to that the original KDX200 E1 service manual never ex plained which way the original double lip seal was supposed to be in stalled As shown in this draw ing the double lip seal SOFT SIDE DOUBLE SEAL should be installed with the soft side inward This is true of both early and late models In late mod els the single lip seal is in stalled outside of the double lip seal Don t forget to fill the spaces between the seals and the water pump shaft with waterproof grease on assembly Gregg Thompson HARD SIDE IMPELLER SINGLE SEAL Service Contest etails see Page 6 8 K Tech News E SPECIALISTS KX J etting I t seems as though every time a new model year of KX s comes out a new series of jet needles comes with it The following chart should make things easy to under and See the parts microfiche for part numbers KX125 J 2 KX250 2 KX500 E5 Leaner N1Ad NOZD N82P N1AK NOZE N82Q N1AL NOZF N82R N1AM NOZG N82S N1AN NOZH N82T N1BJ N1ED N89D N1BK N1EE N89E N1BL N1EF N89F N1BM N1EG N89G Richer N1
6. efficiency boost R am air induction uses a sealed intake system with air intakes located in the front of the motorcycle faking As the vehicle goes down the road air is forced or rammed into the airbox The result Airbox pressure that is greater than atmospheric pressure even at moderate speed While it is true that the amount of boost above atmos pheric pressure is small it must be remembered that on most motorcycles the airbox is a restriction to the intake system Thus as the engine demands more air the air box pressure may drop below atmospheric pressure The ram air system makes up this difference and more A side benefit of this system is that not only is the incoming air slightly pressurized but since it is drawn from the front of the vehicle it is relatively cooler and denser than drawn from other locations on the motorcycle This helps to boost efficiency too The end result About 5 7 percent more horsepower at high speed Patrick Kelly ZX1100 D1 The Technical Magazine 3 f TECH NEWS Winter 1992 Vol 5 No 4 1992 Kawasaki Motors Corp U S A KMC All rights reserved K Tech News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Communications Editor Patrick Kelly Regional Editors North and East Fred DeHart Central and South Walter Rainwater Contributors Randy Davis Jo
7. me chanics of today and workmanship and pride in tomorrow O PINELLAS TECHNICAL EDUCATION CENTERS secxomeoey We SOUTHERN ASSOCIAT naiai s August 21 1992 Mr Donald Church Kawasaki Motor Corp U S A ZEARWATER CAMPUS F Box 25252 BIOO 194TH AVENE CLEARWATER FL 34620 BAENA S1 Dear Mr Church Sante Ana CA 92718 2016 On behalf of Pinellas Technical Education Centers ST PETERSBURG CAMPUS H STAEET sr retain Hearn Clearwater Campus and the Pinellas County School system I am pleased to accept your generous gifts of service and training materials as prizes reri for Nicholas Cetrangola s second place finish in the 1992 VICA US Skill Olympics I am extremely proud of Nicholas and his accomplishments MARKETING OFFICE The motorcycle department at PTEC Clearwater has 301 ATH STREET SW always strived to give young men and women the skills necessary to sueceeed in the motorcycle industry as well as life and it is always an honor to receive recognition when one of these students excels beyond our expectations Employment Please accept my heart felt thanks for your recognition and I look forward to working more closely with you and Kawasaki Motor Corporation in the future Wide Me Slok Michael B Strohaber Instructor Motorcycle Repair Technology PIEC Clearwater xe D Bitting T Hall MS mj COMMUNICATIONS COMMUNICATIONS Micro EE by David P
8. BN N1EH N89H Standard KX owner s manual discrepancy S ome owner s manuals that come with the KX125 J2 s and KX250 J2 s may list the standard jetting incorrectly he standard jetting is as follows KX125 2 KX250 2 Main Jet 160 162 Jet Needle N1AL 2nd Clip NOZF 8rd Clip Slide 5 0 7 0 Pilot Jet 52 50 Air Screw 11 2 11 2 The parts microfiche lists the standard jetting cor rectly David Pyle TIPS KX250 2 KIPS installation With the cylinder upside down on the bench and the exhaust port facing you slide the MAIN VALVE ROD 1 into the cylinder leaving approxi mately 010 020 of rod protruding from the gasket surface Then slide the LH KIPS VALVE 2 down into the bore being careful to align the VALVE EDGE 3 in the opened position with the edge of the port as you engage the spur gear with the main valve rod Rotate the valve closed and open once to check that the valve rod just barely protrudes beyond the gasket surface with the valve open valve edge flush with the port edge Rotate the LH valve so the TIMING TOOTH 4 on the gear is pointing toward you The valve will then be in the fully closed position Install the RH KIPS VALVE 5 into the cylin der and then slide the KIPS GOVERNOR ROD 6 into the cylinder from the right side Carefully lift the LH valve straight up without rotating it and slide the governor rod over until the TIMING MARK 7 on it lines up with the
9. NEWS Winter 1992 RaM by Patrick Kelly Instructional Designer Instructor Aerodynamically efficient fast powerful ram air in duction all terms that could be used to describe the latest Air Force fighter jet But in this case the terms are being used to describe a fighter of a dif ferent sort Kawasaki s lat est weapon in the fight for top dog status in the sport ing middleweight class the 1993 ZX600 E1 The twin ram air induc tion system is the biggest news on the new ZX600 El The twin ram air sys tem utilizes air intake ducts located just below the headlight to force air into the airbox as the vehi cle moves down the road See the Technicalities sidebar on page 2 But twin ram air induction is not all that is new about the ZX600 E1 The engine itself has been highly re fined and the frame and swingarm are all new Plus there are a host of other new goodies too The goal when upgrad ing the ZX600 engine was improved volumetric com bustion and mechanical ef ficiency along with lighter components for quicker revving This goal was achieved by a combination of engine refinements Starting with the valve train the valve stem diameters were reduced from 4 5mm down to 4 0mm and the area where the stem joins the head was thinned sig nificantly to allow better air flow through the ports A significant side effect is that the valves are lighter 15 per cent on the intakes a
10. True a wheel E Inspect a clutch E Disassemble two differ ent carburetors E Inspect and bleed a brake system E Use microfiche and manuals to find specs E Install a rear wheel and adjust the chain E Adjust control cables E Test electrical compo nents with a multimeter Even though this was Only the third year of the motorcycle contest we were well organized and pulled together as a team eliciting praise from Vo Tech teachers and Techni cal Committee members from other contests If you haven t heard of VICA you may be surprised to learn that there are presently 300 000 mem bers in 52 states The Vo cational Industrial Clubs of America was created in 1965 to raise the quality of education of students in trade industrial technical and health occupation pro grams VICA emphasizes total quality at work high ethical standards superior the dignity of work But the real key to VICA s suc cess has been involve ment active participation and ongoing support from industry VICA s partner ship with business and in dustry provides timely feed back to educators and keeps education relevant to current employer needs Kawasaki sent a pack age of training manuals video programs parts mi crofiche service manuals posters and other service materials to the schools of the 92 winners so these schools can continue to provide the high level of training necessary for pre paring the motorcycle
11. a less than state of the art chassis think again The frame is a new design constructed of pressed alu minum sheets These sheets are welded to gether and then joined to large hollow cast alumi num sections at the steer ing stem and swingarm pivot Building a frame this way is more expensive but the end result is a frame that is not only lighter but stronger as well Joining the new frame is a new swingarm The swingarm also uses a hol iow cast aluminum piece at the pivot area This large cast piece is joined to alu minum extrusions leading back to the rear axle The result is similar to the frame lighter and stronger TALK TECHNICAL Lighter and stronger E parts on the right vs D parts on the left photos clockwise from top left valves exhaust tappets pistons and piston pins ZX600 E1 New frame combines cast and pressed aluminum SHOP TALK TECHNICAL yi i E Wal Above Ram air intakes below the headlight Above right A sensational middleweight package The frame s geometry was revised as well The rake remains the same at 24 5 but the trail has been increased slightly to 96mm from 95mm and the wheelbase has been short ened considerably from 56 7 in down to 55 9 in The front and rear axles have been increased in di ameter for increased rigid ity to complement the new frame The brakes have also been updated with the front brakes fea
12. ason Ask your manager to be sure to show you the training schedule bulletin One Team Green class on the 1993 Green bikes will be held in the North Re gion and East Region dur ing February Make sure you sign up for the school in the region of your choice These will be the only Team Green schools held this training season Our Kawasaki service contest starts with this is sue of K Tech News Try your hand at winning some prizes and increase your service knowledge at the same time O Training East Region February 16 Product Update 93 17 18 Fuel Systems 23 25 Troubleshooting Elec Systems March 9 Product Update 93 10 11 Team Green Race Preparation JET SKI Watercraft 23 Service Department Operations 24 Parts Department Operations 25 Generator Fuel Systems North Region February 8 Product Update 93 9 10 Team Green Race Preparation 11 Precision Measurement and Diagnostic Tool Usage 12 Product Update 93 March 1 Product Update 93 2 4 JET SKI Watercraft 5 Product Update 93 Central Region February 8 Product Update 93 3 11 JET SKI Watercraft March 15 Precision Measurement and Diagnostic Tool Usage 16 Tune and Service 17 19 Engines 22 Engine Theory 23 25 JET SKI Watercraft 26 Service Department Operations South Region February 16 Product Update 93 1719 JET SKI Watercraft 22 Product Update 93 23 Service Department Operations 24 25 Team Green Race Preparat
13. e Nowo cinski David Pyle Steve Rice Mary Sola Ray St John Graphics Production Graphic Art Gregg Thompson Copy Editor Pat Shibata Production Nickless Communications Published by Kawasaki All suggestions become the property of KMC Sending a service sugges tion gives Kawasaki per mission to publish and or use it without further con sideration Specifications subject to change without notice 4 K Tech News Winners in Motorcycle Service Technology Contest announced by Don Church Manager Service Training and Communications Dept Six vocational students won the third annual Uni ted States Skill Olympics Motorcycle Service Tech nology Contest sponsored by the motorcycle industry and the Vocational Industrial Clubs of America VICA The winners see page 5 were announced at the Awards Session of the VICA National Leadership Conference held at the Kentucky Fair and Exposi tion Center in Louisville Ky The Motorcycle Serv ice Technology Contest was one of 55 hands on contests in trade techni cal and health related Fields Over 3 000 state champions competed in the day long contest The Motorcycle Service Technology Contest was made up of a written test developed by Motorcycle Mechanics Institute plus eight work stations spon sored by Kawasaki Honda Harley Davidson and Yamaha Each student had a half hour time limit to complete each of the fol lowing skill tests E
14. ion March 1 2 ATV Service 3 4 Fuel Systems 8 une and Service 9 11 Engines 29 31 JET SKI Watercraft West Region February 9 Product Update 93 10 11 Engines 16 18 JET SKI Watercraft 22 Service Department Operations 23 Product Update 93 24 une and Service 25 Precision Measurement and Diagnostic Tool Usage March Fuel Systems 2 Generator 3 Service Department Operations 4 ATV Service 8 9 Engines 10 Tune and Service 11 Precision Measurement and Diagnostic Tool Usage 23 25 Troubleshooting Elec Systems 29 31 JET SKI Watercraft
15. kage quantity one O RATE TIME CHANGE Your vn Dealer Prone tz n Well here it is just like we promised The Kawasaki service contest is inserted into this issue so get that pen out and put that thinking cap on We must receive your answer sheet back no later than March 5th so take a look at the rules below and then get to it Good luck e Contest is open to any full line dealership Service De partment personnel e The contestant may use any materials and informa tion available to answer the test questions e A Service Contest will be mailed with each of the next three issues of K Tech News starting with this Winter issue e f more than one service person from a dealership wishes to enter the contest it is the dealership s re sponsibility to copy the answer sheet for their addi tional personnel Facsimiles of the answer sheet will be accepted e There is a deadline for each test and return postage is the responsibility of the contestant e Any contestant who scores higher than 85 percent will receive a prize for that test e In order to compete for the grand prize all three tests must be completed and returned e The contestant with the highest overall score total for all three tests will win the grand prize In case of a tie there will be a run off e Winning contestants will be announced in the next edition of K Tech News e Send completed tests to Service Contest Kawasaki Motors Corp
16. nd 19 7 percent on the exhausts The Kawasaki Technical Magazine Vol 5 No 4 al Along with the lighter valves 35 percent lighter exhaust valve tappets are used These new tappets are coated with manga nese phosphate for faster break in and improved durability Because of the lighter valves and tappets lighter valve springs can be util ized Lighter valve springs result in improved mechan ical efficiency because it takes less power to open the valves leaving more power to drive the rear wheel CONTINUED ON PAGE 2 ROUTE LIST O PLEASE RETURNTO SERVICE SERVICE O PARTS O SALES LIBRARY Inside m Service tips amp more S HOP ZX600 E1 CONTINUED FROM PAGE 1 Along with the new valves and valve springs are new camshafts with in creased lift and duration The intake cam has gone from 280 of duration to 308 and the lift has in creased 0 1mm to 8 8mm The exhaust duration has increased from 280 to 292 while the lift remains unchanged at 8 2mm These duration numbers are not quite as radical as they might appear at first glance because the cam lobes are designed to open and close the valves relatively slowly for re duced valve train noise and increased durability Much of the duration is at a small amount of lift New 13 4 percent lighter slipper style pistons are used for reduced mechani cal friction and reduced re ciprocating mass These new pist
17. odified tool is used you run the risk of damaging the threads in the flywheel Joe Nowocinski LEAVE 0 5 TO 1 0mm y VULL ceecracsuest SERVICE by Mary Sola Customer Service Representative t s winter and a time when work in most dealerships slows down and some new ideas can be tried It s also a time for making resolutions to improve ourselves in some way over the coming year Maybe one of the resolutions your dealer ship can make for the coming year is to improve your store s responsiveness to your customers and now is a good time to start How do you know what your custom ers want and expect from your dealer ship How about asking them Customer satisfaction surveys are be ing used by many companies to improve customer service A simple questionnaire designed to find out what your customers think of the way you do business is a fairly easy and low cost way to get ideas If your store has not used customer surveys before you may want to start with a survey covering just one depart ment Some things to keep in mind when setting up a customer questionnaire are 1 Keep the survey questions simple How were you treated Was the work done well and Suggestions for im provement Yes and No answers probably work best but do ask for com ments too A printed postcard can work if you give enough space for comments and it doesn t have to be mailed You can attach a stamped
18. ons combine with flat valve surfaces instead of concave to increase the compression ratio to 12 1 from 11 5 1 New 7 9 percent lighter tapered style piston pins connect the rods to the pistons The lighter pistons and pins allow the use of lighter connecting rods as well down from 290 grams to 240 grams The new rods feature big end diame ters that are reduced in size from 33mm down to 30mm Reducing the rods big end diameters causes a large reduction in the amount of drag the journal generates again improv ing mechanical efficiency and leaving more power to drive the rear wheel To go with the lighter top end components the 2 K Tech News crankshaft and flywheel have also been reduced in weight Providing proof that the engineers left no stone unturned in their search for power the cylin der liners have been short ened 8 0mm to allow the air to move more freely un derneath the pistons in creasing high rpm power The exhaust gasses exit the engine through a spe cial 4 into 2 into 1 into 2 exhaust system This unique system features pipes which connect cylin ders 1 and 4 as well as cylinders 2 and 3 to help smooth out the exhaust gas flow particularly at about 6 000rpm A revised ignition timing data map completes this new engine package The end result of all these changes More horsepower throughout the rpm range But in case you think Kawasaki would put that wonderful power to waste in
19. rt and the RFC form had to be sent to the ware house from which the part had originally been shipped Recently Kawasaki streamlined this process considerably Now you can send the RFC form copy of the packing slip and the part all at the same time No more wait ing for the RFC form to get to the warehouse and the authorization to get back to you before In addition for your convenience you can now send the part back to your master warehouse re gardless of what ware house it came from When sending parts back don t forget to in clude a copy of the pack ing slip and do make sure the part is in the original package with the item number label on it d Dented crankshafts by Steve Rice Product Support Specialist Some dealerships have received spare parts crank shafts from their warehouses which have caused them some concern The crankshafts in question had some dents in the outer surfaces on the flywheels It looked as though the crankshaft might have been dropped and in some cases the dealers were so concerned that they sent the crankshafts back to the warehouse From the Those dents may not be serious don t rush off to return that brand new crank parts we ve been able to inspect it appears these dents are from hand trueing done at the factory Functionally there doesn t seem to be anything wrong with the cranks If your dealership receives a crankshaf
20. self addressed card to the customer s copy of the repair order Now is a good time to Improve on responsiveness Listen to your unhappy customers They may have the best ideas for improvement 2 Designate one person to be in charge of the survey It is best to have only one person receive the surveys and review the comments This person can evaluate the answers received to rate the areas which need work Always respond to any unhappy customers with a card or letter acknowledging and thanking them for their comments Once enough surveys have been re ceived to get an idea where to focus the department s efforts a meeting should be held with those who will be involved in making the changes Start taking care of the simplest suggestions first and then work on more complicated problems once everyone has had more experience with changes and what works and what doesn t Continue to schedule regular meetings to go over survey results and also to evaluate changes that have been made If you start sending out a survey now by the time the busy spring and summer seasons come the questionnaire proce dure will be in place and the ideas given by customers could already be making a difference in how your customers see you Remember the cost of keeping a customer is about one tenth the cost of getting a new one Just a small increase in customer satisfaction can mean a big difference in your department s or store s profitabili
21. t from the parts warehouse with a suspicious dent in the flywheel don t package it up and send it right back Check the trueness of the crank first If it s true it s OK run it O O OOOO WINNERS OOOO O And the winners are Congratulations to the following winners of the 1992 United States Skill Olympics Motorcycle Service Tech nology Contest sponsored by the motorcycle industry and the Vocational Industrial Clubs of America VICA For details see this month s Guest Spot page 4 Secondary High School Division 1st David Gibbs Kearney High School Kearney Neb 2nd Chad Anderson Ramona High School Ramona Calif 3rd Carl Williams St Clair County Technical Education Ctr Port Huron Mich Postsecondary College Division 1st Todd Sigfrid Alexandria Tech College Alexandria Minn 2nd Nicholas Centrangola Pinellas Technical Education Ctr Clearwater Fla 3rd Charles Howard Elkhart Area Career Center Elkhart Ind The Technical Magazine 5 COMMUNICATIONS Don t forget those little green cards by Ray St John Supervisor Technical Writing Whenever a flat rate fiche goes out to you a green card is in the package What green card you ask The green card that says Suggested Flat Rate Time Change on it So what do do with it Well if you see a mis take in the flat rate fiche or if you don t think a par ticular flat rate time is fair
22. the rider saw heard smelled or felt If there was a noise calls were performed If you run into this situ ation simply order the parts listed below sepa rately rather than the kit number Remember to list the individual parts on the claim form so you get cred ited the proper amount Ed Steering Shaft 13107 3728 Washer 92200 3722 O Ring 670B2020 was it a squeal or a grind How loud was it Where did it come from 2 When did you notice something was wrong Many possible causes can be eliminated by knowing how long the vehicle con tinued to run despite the apparent problem 3 Has any service work been done recently It helps to know if you re fol lowing up on someone else s work If the answer is yes a whole new realm of possibilities awaits 4 Is problem intermit tent or continuous Has it gotten worse better or remained unchanged Knowing how a problem has developed should help you narrow down the possibilities and will cer tainly give you a handle on where to start looking Remember a really good diagnostician works on the rider first O COMMUNICATIONS EXTRA ALERT JHJ S750 flywheel puller warning Before removing fly wheels on JH750s and JS750s you may have to make a small modification to your flywheel puller P N T57001 1099 To im prove thread engagement grind the relief on the 18mm end down to where itis only 0 5 to 1 0mm long If an unm
23. timing tooth on the LH valve spur gear Drop the valve down so it engages the rod Rotate the RH valve so the timing tooth points toward the mark on the governor rod and install the IDLER SPUR GEAR 8 Install the VALVE COLLARS 9 and the governor rod re taining screw Turn the cylinder right side up and slide the guil FROM TH lotine assembly main ex haust valve into the cylin der Install the retaining screws Put the pin through the valve with the shoulder to the left side and the ACTUATING LEVER 12 onto the pin Pull both the governor rod and the MAIN EXHAUST VALVE 10 all the way out so that all the valves are fully open Now slide the MAIN VALVE SHAFT 11 into place through the ac tuating lever keeping the hole in the shaft aligned with the hole in the actuat ing lever as the gear en gages the main valve rod Install the allen screw through the actuating lever O E SPECIALISTS Key to Illustration 1 MAIN VALVE ROD 2 LH KIPS VALVE 3 VALVE EDGE 4 TIMING TOOTH 5 RH KIPS VALVE 6 GOVERNOR ROD 7 TIMING MARK 8 IDLER GEAR 9 COLLAR 10 MAIN EXHAUST VALVE 11 MAIN VALVE SHAFT 12 ACTUATING LEVER The Technical Magazine 9 TIPS ZX 7 When things finally Start to click I f you have a ZX750 K1 2 owner complaining of a loud clicking noise that seems to come from his front forks or fairing when he applies the brakes don t forget to check the
24. tor turning the engine over just slightly slower than normal Either a slightly discharged battery or worn starter motor can result in this Listening to one with this problem you wouldn t say the starter motor was turning slowly it sounds about the same as a good one Again the most pro nounced symptom is the occasional booming back fire from the exhaust Hard starting can be caused by lots of other things most notably low compression so don t for get to make other appro priate checks But on JS300 s if there s hard starting and a big bang from the exhaust every now and then you should definitely suspect the bat tery and starter motor Gregg Thompson X 2 steering shaft kits no longer available f you come across a JF650 A6 X 2 watercraft which is still eligible for the Steering Shaft Breakage Recall JS 92 03 you may have to follow a differ ent procedure regarding the parts The kit which is re ferred to as the Shaft As sembly in the bulletin is no longer available Deal ers have apparently been ordering the kits for re pairs other than the Re call and we simply ran out of kits before all the Re your technical skills are not quite prepared for the coming months Kawasaki technical training is in full swing right now Sign up to get yourself ready too O CONTINUED FROM PAGE 12 1 Can you describe the problem Encourage sense oriented observa tions Ask what
25. turing thin ner discs combined with the same reliable four pis ton calipers The rear brake features a new sin gle piston caliper and a 10mm larger brake disc To keep driveline lash to a minimum a new rear wheel coupling damper is used This new damper is a unique design with holes located in the damper rub ber itself The holes allow the damper to absorb the rear wheel torque very pro gressively for lash free ac celeration and deceleration Surrounding the modern engine and chassis pack age is a new aerodynami cally designed fairing This new fairing not only pro vides increased rider pro tection from the elements but also is more aerody namically efficient This wonderful new mid dleweight not only per forms it does so without sacrificing rider comfort and convenience The rid ing position is roomy and comfortable with the handlebars being closer to the seat for a less crouched riding position And for convenience a fuel gauge has been added to accom pany the speedometer ta chometer and temperature gauges There is a new maintenance free battery so checking electrolyte level is a thing of the past All this and a center stand too The Kawasaki ZX600 El like the latest state of the art jet fighter is prepared for take off ready to battle the compe tition on the race track and the sales floor Ready to take them on and equipped to win O TECHNICALITIES Ram air an
26. ty O TRAINING New look service training schedules In addition to offering pared to highlight the we ll be happy to send some new courses this season Modern Engine Theory Tune and Serv ice and Precision Meas urement and Diagnostic Tool Usage we have re vised the look of our train ing course schedules Each dealer now receives a schedule specially pre courses offered in that re gion A student may still at tend courses offered in other regions To obtain a schedule of courses of fered in another region simply call the Training Ad ministration office at 714 770 0400 ext 2452 and one out to you Also a complete listing of all upcoming classes will continue to appear on the back page in every issue of K Tech News Pat Shibata The Technical Magazine 11 RIJETO IONAL Are you ready by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 T he new year is here al ready Soon it will be that time when the customers start rolling in the door both the service door and the sales door Is your service department ready for it Is your service sys tem in place That is are you set with the supplies you will need in the com ing months Do you have enough work orders Is your service scheduling system functioning prop erly both for retail custom ers and the sales depart ment Is your microfiche deck up to date and in or
27. yle Parts Publications Specialist In the back of almost every deck of microfiche is a spe cial tool that many shops rarely use It s the Model Appli cation Guide which turns your microfiche reader into a remote terminal of the Kawasaki Motors Corp U S A mainframe computer There are many things the Model Application Guide can help you do For example when you re trying to de cide how many of a part to stock a quick look at the Guide will tell you that part number 11012 1084 a radia tor reserve tank cap fits over 200 models Or if you have a part on the shelf but are not sure of the models the part fits the Guide can answer your question Another way to take advantage of the Model Applica tion Guide is with substitute part numbers For instance say you have seven 11009 1252 reed valve gaskets in stock The retail price guide shows that gasket as being canceled But the Guide will show you that 11009 1252 subs to 11009 1950 so you add the old gaskets to the new in your parts stock to rotate the old gaskets out O PARTS More good news from those good times parts people In the past if your dealer ship wanted to send a part back to the warehouse you first had to submit a Request For Credit RFC form to the warehouse then wait for that form to be returned to you with the authorization Only then could you send the part back with acopy of the 2 packing slip and the authorization The pa
28. you fill out the card and drop it in the mail We pay the postage What happens then Kawasaki s Service Training and Communica tions Department receives the card and immediately investigates the informa tion you ve given us What do you mean by investigates Well if you have indeed found an error we correct it in the next issue of the fiche but we immediately make the correction in Kawasakis computerized warranty flat rate system to cut short the error If you ve found what you feel is an unfair time allow SUGGESTED FLAT Dealer Numbat 1A 6 K Tech News ance we send your com ments on to Kawasaki in Japan where all the flat rate time studies are done The time in question is studied by an experi enced trained technician working only with hand tools no air wrenches When we get the word back from Japan we make any needed changes at that time Does that mean that any flat rate time changes suggest are not likely to be accepted Maybe yes maybe no It all depends on the time study done in Japan But you can bet that if a time change is called for we ll get it into the computer right away and into the next issue of the fiche for sure Any other questions Yeah lm gonna send you a bundle of those things How do get more green cards Just order Part No M99994 153 from your Kawasaki Parts Distribu tion Center They re a no dealer cost item pac
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