K-Tech News Vol. 6 No. 4
Contents
1. rounded end cap replace the camchain guide also in order to insure proper function of the new ratchet style tensioner Our thanks to the Con cours Owners Group COG and their Con courier newsletter staff for alerting us to the possibil ity of problems when con verting to the newer style tensioner Ed SPECIALISTS Rear axle torque Important Yes by John Pomo Product Support Specialist When a motorcycle s rear axle has been loosened for any reason changing the rear tire adjusting the chain etc torquing it properly on reassembly is very impor tant on any model But on some chain drive models the consequences of not tightening the rear axle to the proper torque can be worse than you might think Models with the aluminum box section swingarm with the chain adjuster located inside the end of the swingarm tubing such as the ZX750 H1 and ZX600 D and E are susceptible to a unique failure if the axle is not torqued properly The lightweight chain adjuster cap on the end of the swingarm was designed to withstand only the light pressure applied when adjusting the chain with the axle nut loose lf the axle nut isn t torqued properly the axle will be pulled forward during hard acceleration easily breaking the chain adjuster cap by pulling the adjuster bolt right rough it The axle will continue to move forward on the left side cocking the wheel to the right until the chain fi nally climbs off the rear sprocket2. Tech News SPECIALISTS Generator high altitude jets Until recently our Portable Generator microfiche have not listed any optional jetting information for high altitude operation The relatively new GE4300 AS and GE5000 S microfiche do list alternate main jets for high altitude se but the altitude information is not real clear Recently we received some high altitude jetting speci fications for all Kawasaki generators We thought you might be able to make use of it so here it is This table lists main jets only Gregg Thompson Generator High Altitude Carburetor Adjustment Refer to the following main jet setting guide to get the proper mixture ratio for operation of generators at high altitude MODEL SEA LEVEL 3 000 6 500 ft std 6 500 ft and up KG550B 57 5 55 55 92063 2067 92063 2007 92063 2007 KG750B 75 72 5 70 KG1100B 92063 2002 92063 2062 92063 2059 KG1600B 87 5 85 82 5 92063 2004 92063 2097 92063 2003 KG2900B 92 5 90 87 5 92063 2006 92063 2081 92063 2004 KG4000A 87 5 85 82 5 92063 2004 92063 2097 92063 2003 KG5000A B 115 112 5 110 92063 2009 92063 2008 92063 2092 GA GD550A 57 5 55 55 GD700A 92063 2120 92063 2121 92063 2121 GA1000A 72 5 70 67 5 GA1400A 92063 2062 92063 2059 92063 2065 GA1800A 87 5 85 82 5 GA2300A 92063 2051 92063 2087 92063 2054 GA3200 91 3 90 87 5 92063 2094 92063 2052 92063 2051 GE2200A 72 70 68 GE2900A 92063 2232 92063 2233
3. for which the vehicle is des tined Parts bins behind each assembly line worker are also color coded so they can select and install Wal t to wa i to Y an M jmf Fa q ins a J s eye fa i ag a i ty By 2a a hy ay x the weld area is com E i pletely undetectable Still another CNC which stands for com puterized numerically controlled machine spins the tube into a wheel The spinning process makes the metal harder and stronger The center section is then welded in and every wheel is carefully and individu ally examined for porosity This superior quality is why Kawasaki also makes ATV wheels for Honda and Polaris Robots do a lot of weld ing at KMM Robots weld all the frames footpegs luggage racks and the like Some pieces of the aluminum frame for the ZX 6 are tack welded by a human worker but a robot finishes the job After welding and clean ing all Kawasaki frames receive a protective coat ing of paint The black frames on MULES and At KMM robots abound the correct parts simply by matching colors All the KLF220 KLF300 and KLF400 engines inci dentally are manufactured in another Kawasaki plant located in Maryville MO roughly 100 miles away We watched several fuel tanks being welded and individually pressure checked Some 94 model tanks are made with steel that has a galvanized coat ing to prevent rust In the paint department fu
4. for some friendly competitive events Kawasaki of Ocala furnishes the refreshments Jeff uses open houses with a variety of themes to help build customer loyalty One theme is directed to ward the off road and motocross customers This particu lar open house coincides with a motocross series in the region An open house designed for the street rider takes place during the summer ATVs and MULES are put on display and test ridden on an outdoor track during the open house in the fall of the year There are refresh ments at all open houses All 17 of the employees are motorcycle enthusiasts They promote and take part in road rides with the cus tomers Sometimes the customers and employees go for a trail ride after work Being in Florida watercraft are al ways the nucleus of a good time between the customers and employees Jeff s plan to build customer loyalty is easy to under Stand Help the customers to have fun on their Kawasakis Does it work You bet it does This year sales are double when compared to any year in the 28 year history of the dealership The customer loyalty idea is not new You are probably thinking Why didn t I think of that Well you should be thinking I can do that O CONTINUED FROM PAGE 12 job in the amount of time the customer is being charged for then your efficiency could use improving Reviewing one of our training tapes and its accompanying work book could help you improve your effic
5. return to using just the low beam But there s more Since the pass switch takes power from the brown wire which is hot any time the ignition switch is on it al lows you to turn on the headlight with the engine stopped If the dimmer switch is in the Hi posi tion when you do this the power will go backwards through the dimmer and up the BIN lead to the headlight relay diode acti vating the relay and the headlight will stay on even when the pass switch is released If the dimmer switch is in the Lo position the headlight will go off when you release the switch O last year was taken di rectly out of an early own ers manual and was incorrect We re sorry about that Gregg Thompson 1994 KX J et Needle Chart KX125 K1 KX250 K1 K X500 E6 Leanest N1JO NOZG N82T N1KO N1EG N89H NiJN NOZF N82S N1KN N1EF N89G N1JM NOZE N82R N1KM N1EE N89F NiJL NOZD N82Q N1KL N1ED N89E NiJK NOZC N82P Richest NiKK N1EC N89D The Technical Magazine 5 TIPS FROM THE SPECIALISTS KLX650 headlight diode explorations by David Pyle Parts Publications Specialist Whether you are looking for the part number on the microfiche or for the part it self on a bike you will have a hard time finding the KLX650 C headlight relay diode This diode is the one integral to the sys tem that automatically turns on the headlight once the engine start but ton is released On Kawasaki street mo torcycles
6. taken reattaching the power supply to the regulator This is usually a brown wire and is at tached to the IG termi nal In this field excited type alternator this power lead can easily be at tached to the F terminal located very close to the IG terminal The F ter minal even has a screw identical to the one on the IG terminal Simply put if you attach the power lead to the F terminal the regulator will be rendered useless smoked the moment you turn the ignition switch on We know of several cases where the dealership tech nician correctly diagnosed a bad regulator but con nected the power lead to the F terminal on reas sembly When the alterna tor still put out no power the regulator was dead again the technician re placed the entire alterna tor thinking there was something else wrong with it that was causing it to eat regulators That s a very expensive and unnec essary repair caused by a very small error Jerry Heil TIPS FROM TH Camchain tensioners for early 900s 1000s n the Winter 1992 issue of K Tech News we printed an article telling you about a newer stur dier camchain tensioner for the ZX900A through ZG1000 engine family When the older screw style tensioner weakened and became noisy with age we explained it could be replaced by the latest ratchet type tensioner from the ZX11 REPLACE THIS TYPE WITHOUT CHA
7. 8 A T E amp CH NEWS Winter 1993 The Kawasaki Technical Magazine Vol 6 No 4 K SHARE The expansive Kawasaki Motors Manufacturing KMM plant in Lincoln Neb ated Ta pan K SHARE on line warranty claim processing by Patrick Kelly Instructional Designer Instructor A s you are reading this the new K Share on line war ranty claim processing sys tem will be up and running Even though many of you may already be using this system we thought we would review how the sys tem functions and its many features and benefits Perhaps the biggest benefit of this system is the increased parts handling al lowance For claims proc ROUTE LIST O SERVICE RETURNTO PLEASE essed through the K Share system parts handling goes from 10 percent to 25 per cent Paper claims will con aa PET nai s aaa a aa ST A th Bld j T pini e j Di n i i a Aii Sa 44 doom SERVICE O PARTS tinue to receive the 10 per cent handling allowance Good Times Protection Plan ar oe a cow E ccc O SALES LIBRARY CONTINUED ON PAGE 3 by Walter Rainwater South amp Central Region Instructor recently had the opportu nity to travel to Kawasaki Motors Manufacturing KMM in Lincoln Neb with our Service Contest Grand Award winner Gary Bustillos As you may re call Gary s award was a fully expense paid trip to his spectacular facility and thought K Tech News
8. 92063 2208 GE4000AS 90 87 5 85 GE4500AS 92063 2159 92063 2238 92063 2192 GE4300A 85 82 5 80 GE5000AS 92063 2245 92063 2246 92063 2247 OQ 92033 iQ ot 2033 So e Y 92033 GRID NO This grid covers Drive Shaft Front Ret No 43310 Part No 42034 Description SHAFT ASSY SHAFT DRIVE COQUPLING ASSY COUPLING BOOT DAIVE SHAFT SPIDER YOKE 02144 1276 460 2200 TIPS FROM TH CCELI COCHEZ SERVICE We ve got the right manual baby uh huh by Donna Hood Customer Service Representative It s snowmobile season A customer calls your dealer ship asking for an owner s manual for a 1980 Invader Your computer shows the manual has been discon tinued What can you do to help your customer Call KMC Customer Serv ices We have access to a variety of literature that can no longer be ordered through the Parts Depart ment Listed below are items that can be obtained through Customer Serv ices by either dealers or customers e Current model brochures e Older model brochures from 1980 Not all models are available We have some original brochures or can send a photocopy of the original brochure e Accessory brochures for all models e Warranty policies for all models e Sample copies of the Good Times Protection Plan Policy e Owners manuals for all models including gener ators We will photocopy the owner s manual for an older model if the
9. AF450 B1 and the 2000 series MULEs KAF540 C1 and KAF540 D1 you will have to machine another circlip groove in each axle to accept the new circlip in a new location On the MULE 1000 KAF450 B1 you must also machine 1 5mm of material off one end of the differential lock shifter so it will clear the new circlip when its in the unlocked mode On the MULE 2510 and 2520 KAF620 A1 and B1 you will have to re move some material from the shoulder that locates the bearing on the axle to make room for the new collar FYI The 2000 series and 2500 series rear axles are interchangeable The drawings shown at left should give you all the information you will need in order to modify the ax les to accept the new cir clip and collar NOTE This modification should not be performed except when multiple failures have occurred on that unit This article does not constitute a factory repair campaign and is not warranty authorization O FROM TH E SPECIALISTS KLF300 Don t knock these solutions We still get the occasional call from a dealer who is chasing his tail trying to find an elusive knocking noise in a KLF300 Most of the time when a dealer is chasing one of these phantom knocking noises we on the Hot Line refer him to the article printed in the Spring 1992 issue of K Tech News But it now seems worth re printing the article for those of you who never saw it or who have forgotten about it So here it i
10. In case you were wondering the chain coming off the rear sprocket especially under hard acceleration is not a good thing We think its a real good idea to check the service manual for the correct torque when tightening a rear axle Then use a torque wrench to make sure it s right You might be surprised at how much torque is required The ZX600 E manual for example calls for 80 ft lbs Try applying that much torque with your handy dandy Cres cent wrench If you have any customers who regularly do their own service work and whose motorcycles have this type chain adjuster you should probably pass this tip along them O The Technical Magazine 7 TIPS FROM TH E SPECIALISTS MULE usage triggered rear axle modifications by Randy Davis Product Quality Engineer S ome time after the first MULE utility vehicles be came available in 1988 we began receiving re ports from customers who had problems with rear ax les mysteriously pulling out of the differential Though infrequent these reports were quite trouble some due to the nature of the failure and the fact that the failure would sometimes repeat on the same unit after the repair was made Well we still haven t dis covered the cause of this strange failure but we be eve it is aggravated by MACHINE NEW CIRCLIP GROOVE 1 8MM WIDE SAME DEPTH AS SPLINES Ta KAF540 C D MACHINE NEW CIRCLIP GROOVE P N 92143 1221 P N 92033 1249 8
11. K Tech News rough or hilly terrain and or heavy vehicle loads Our belief that this is related to usage is sub stantiated by the fact that while the failure rate is ex tremely low we have sev eral cases of repeat failures even after all re lated parts have been re placed If you are dealing with one of these repeat offend ers and there are known cases affecting most MULE models from the 1000 to the 2510 you may want to consider per forming some surgery to modify the axles in order to eliminate this problem The modification we sug gest requires removing the PART SHOWN REVERSED TO ALLOW VIEW OF AREA TO BE MACHINED MACHINE THIS END KAF450 B axles machining them and then reinstalling them with a different circlip usually in a different loca on and a new collar that helps keep the circlip in the groove In the case of the MULE 2010 and 2020 models this modification will re quire splitting the cases in order to machine the left axle since there Is no re movable bearing holder gt MACHINE NEW CIRCLIP GROOVE 1 8MM WIDE SAME DEPTH AS SPLINES N EXISTING GROOVE 15 5 MM MACHINE 1 5MM FROM THIS END KAF450 B REMOVE MATERIAL FROM SHOULDER KAF620 A B KAF540 C B MACHINE NEW CIRCLIP GROOVE P N 92143 1221 P N 92033 1249 KAF620 A B MACHINE SHOULDER KAF540 C B KAF620 A B TIPS on that side On both the MULE 1000 K
12. NGING CAMCHAIN GUIDE But since then we have received a few reports not ing that when this modifi cation was tried on some older models it resulted in abnormal camchain noise This puzzled us because the newer tensioner has plenty of spring pressure and more reach than the older tensioner Well the problem seems to be with higher mileage units and is appar ently the result of a poor fit between the flat end on the new style tensioner and the concave surface on the old camchain guide So we must amend the original article When replacing an older screw type ten sioner with the ZX11 ratchet type tensioner make sure the old one has a flat end cap The early style tensioner used in most of the 84 87 en gines in this family has a rounded end cap that fits into a concave area on the chain guide By mid 87 though the factory had begun using another screw type tensioner which had a flat end cap The camchain guide in these later model engines had a convex surface to mate with a flat end cap on the tensioner REQUIRES USE OF NEW STYLE CAMCHAIN GUIDE TO REPLACE THIS TYPE That particular ten sioner was eventually re placed by the current ratchet style component which has a similar flat end and uses the same camchain guide This new est tensioner doesn t al ways work well with the original style concave camchain guide So what s the bottom line If the tensioner you are replacing has the
13. e symp toms check the battery for high voltage in the 16 18V range with the engine running or just plug in an other regulator rectifier O Beware the changes in the VN 50 A10 oil filter There have been some changes to the VN750 A10 oil filter and mounting plate that are not shown on the Original microfiche The 94 model VN750 A10 uses a P N 16097 1064 oil filter This new filter has a much smaller outside diame ter than the filter used on all previous VN750s The o ring diameter is also smaller on the new filter and the oil filter mounting plate is changed to correspond Please be aware that the old and new filters do not interchange The revised microfiche is dated Dec 1993 David Pyle The Technical Magazine 9 TIPS FROM THE SSR 7 n MULE 2510 rattling front drive shaft by Randy Davis Product Quality Engineer the pinion shaft spline and by filling the splines them selves with a very heavy waterproof grease The heavier the grease and the tougher the rubber damper the longer the re pair will last You can order P N 92075 1110 a thick rubber washer from Kawasaki for the damper or you can chase one down locally You can even make your own if you have some good material to use The damper needs to be about 5mm thick and fit over the pinion shaft Meanwhile Bel Ray waterproof grease seems to work very well in the splines O f you ve sold very many of the four w
14. el tanks are finished with two coats of color After the paint dries decals are ap plied before a final clear coat goes on All KMM produced vehi cles are run at the end of the assembly line Motor TA TECHNICAL cycles are run until the cool ing fan turns on An inspec tor checks for coolant leaks then the bike is dyno tested and the soeedome ter checked After each vehicle is passed it is wheeled to the crating area Gary and were over whelmed by the many amazing things we saw at the Lincoln plant incred ible machines like the ones that nail and staple crates together or the ones which bend handle bars The plant even has its own facility for recy cling cleaners and sol vents used in the various manufacturing processes If you are ever planning to be in the area urge you to have your dealer call beforehand and make arrangements for you to visit the Lincoln plant It will make you proud to be a part of the Kawasaki family O K SHARE K SHARE CONTINUED FROM PAGE 1 claims will continue to be reimbursed at retail for parts plus a 10 percent incentive bonus on the entire claim regardless of whether they are filed by K Share or through the mail Speed is another benefit of this new system The length of time between filing a claim and getting reim bursed for the claim can be greatly reduced in most cases It is our intent to proc ess all claims on the day they are trans
15. es three years of off road bikes and ATVs and all watercraft and gen erators Review this to see if youre properly equipped And see the Fall 93 issue of K Tech News Vol 6 No 3 for a discussion of service manual supple ments Ed OWNER S MANUALS Same as Service Manuals ex cept that the part numbers usually start with 99920 and there s no master list A amp P MANUALS This publi cation tells you how to put a product together and prepare it for retail sale A amp P manuals are avail able for all motorcycles ATVs watercraft and util ity vehicles About once or twice a year we send an A amp P materials index which provides you with the part numbers of all cur rent instructions For motorcycles and ATVs there is a general A amp P manual that covers all models and a supple ment for each individual model Because the crat ing generally doesn t change much some A amp P supplements were origi nally issued for the first service related materials year of a model now in its fifth or sixth year and they re beginning to look dated Don t worry They ll give you all the info you need to do the job right For now the watercraft and utility vehicle models each have their own A amp P manual though a general A amp P manual for watercraft with supplements for indi vidual models is in the works TECHNICAL TRAINING POSTERS VIDEOS AND MANUALS These are the items you need to call
16. heel drive MULE 2510s at your dealership you have prob ably had someone come in complaining of an an noying rattle in the front drive train that occurs only when the vehicle is in 2WD If you ve had this complaint but you haven t come up with a solution yet maybe we can offer some assistance There is no official factory fix for this the rattle is not con sidered abnormal but we can offer some sugges tions that will help reduce your customer s irritation The noise comes from clearance in the splines where the front propeller shaft connects to the pin ion shaft on the front differ ential We have found no way to completely elimi nate the noise but you can reduce it to an accept able level by installing a thick rubber damper on Small pieces for KLF300s Good news Until now the U joint couplers for the KLF300 C 4x4 s front drive shaft which connect the sub transmission to the front differential have only been available as assemblies The rear one included the pro peller shaft as part of the assembly Well we ve finally managed to make all the small pieces for the U joints and the propeller shaft available separately As of today the KLF300 C5 C6 microfiche is the only one showing these new part numbers see Grid D 4 Drive Shaft Front but the parts fit all KLF300 models from Cl through C6 The microfiche for the ear lier models will be updated as soon as possible David Pyle 10 K
17. iency Investing in some new tools could help make you faster Attending a Kawasaki training school could make a big difference in your efficiency Whatever you resolve hope your new year is a great one and hope to see you in a training class soon O The Technical Magazine 11 R E G Resolutions by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 lts time for you to start thinking about your New Year s resolutions What are they going to be I ve got a couple of sugges tions for you How about resolving to improve your job skills If you re a techni cian this would mean im proving your productivity and efficiency Productivity is a meas ure of how many hours you spend during the day clocked on a work order Improving your productiv ity means less time wasted between work or ders Consciously try to limit the amount of time you waste between jobs can help you improve your productivity Efficiency is a measure of how much time it takes you to do a given job vs how much time the cus tomer is being charged for If on the average you are not completing a given CONTINUED ON PAGE 11 12 K Tech News I ONAL Loyalty by Walter Rainwater 6110 Boat Rock Blvd SW Atlanta GA 30378 404 349 2000 J eff Lewis owns Kawa saki of Ocala After work ing for another dealer for eight years Jeff decided he wanted a dealership of his own This he was fi nal
18. is a different way to go about getting every different Kawasaki publication In truth though there are just a few basic ways to get stuff from KMC One way is to use its part number Another is just to give us a call You can get anything with a part number on it by ordering using that num ber except for a few post ers that are imported by the Technical Training De partment These have part numbers on them that are used by Kawasaki in Ja pan and select other mar kets but not in the U S A By calling you can get any Kawasaki technical publication you want If we dont have a way to get it for you we ll tell you Straight out But usually if you want it and you call us welll find a way Here though is some more specific advice SERVICE MANUALS Order by part number Just look at the back of the book near the bottom If you don t have a copy of the book to look at refer to grid A 2 of the parts microfiche for the model in question Most Kawasaki service manuals those produced during the last 10 years or so have part numbers that begin with 99924 The last two numbers like 01 or 02 are edition numbers The higher the number the more up to date the book If you order an 01 and get an 02 you have what you need just a newer edition NOTE Service manuals now ship with a list detail ing what books you should have to take care of the last five years of street mo torcycl
19. it as well The most common questions asked at the show concerned availability of bulbs for the Microfiche readers and Microfiche storage units Kawasaki stocks these products along with many other microfiche components in all of our distribution centers Part numbers and prices of the available items can be found on Parts Bulletin Gen 92 02 Order any of these items the same way you order all your spare parts from K Share or from your master warehouse really enjoyed meeting and talking to so many of you at the Dealer Meeting Along with you look forward to a great year in 94 e P S We had a couple of requests at the dealer meet ing for printed parts catalogs for KX models so we looked into it There is enough interest i e retail poten tial to offer them And so we are offering printed cata logs for all 94 KX KDX and KLX models Refer to Parts Bulletin MC93 01 O 1994 KX Jet DOAKIE Noos akin RE t s time again for the an nual KX jet needle expla nation and chart As usual there is no information on the microfiche to help you figure out what needle to order if you want a richer or leaner one Each model has two groups of needles avail able with five needles in each group For each model these groups are just 1 2 clip position differ ent from each other For example on the KX125 the NiJM needle from the N1J_ group is 1 2 clip position leaner than the OEM standard N1KM nee dle fro
20. ly able to purchase in April 1992 Based on his prior work ing experience Jeff knew that customer loyalty was one of the secrets to a suc cessful business Jeff and his employees set about building customer loyalty in many ways Kawasaki of Ocala is a Team Green dealer They have a contingency pro gram for 35 riders and plan on supporting as many as 50 One of their employees goes to the lo cal motocross races with their version of the Team Green Support van and provides technical support and parts for their racers In the spring Jeff holds a demo day for watercraft CONTINUED ON PAGE 11 N EWS Sign up early by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 have gotten good re ports from riders who have had the chance to ride our 1994 KX models If you want to learn more about the new motocross machinery and get solid advice on rebuilding front and rear Kawasaki sus pension systems be sure to attend this training sea son s Team Green class Team Green classes are only held once each training season We will hold one in the North Re gion and one in the East Region sometime near the end of Feb or March 94 Specific dates have not yet been finalized so be sure to check upcoming is sues of K Tech News and the training bulletins that are sent to your dealer ship every month Fall classes held through Dec filled rapidly so if you plan to attend in the futu
21. m the N1K_group The jet needle chart in the owners manual does not list the needles in a true Leanest to richest order because it doesn t take into consideration this half Step difference between the two groups The chart at right lists the available needles for each model in the correct order from leanest top to richest bottom Keep in mind that each needle is only 1 2 clip position differ ent from the one above or below it on the chart Re fer to the microfiche to get the part number of any by David Pyle Parts Publication Specialist While hunting for the headlight relay diode in the new KLX650 see that article on page 6 we stumbled across an inter esting little feature of the KLX headlight system There is a PASS switch on the back side of the LH handlebar switch case We found that when you operate that switch bat tery power is routed from a chassis brown power lead around the headlight high low switch to the R Bk lead going to the high beam The obvious purpose of this switch is to momentarily turn on your high beam while you ride along at night with your low beam on As long as the dimmer switch is on Lo and the pass switch is pulled to the on posi tion both elements in the lS E will be on Re needle you want to order The indicates the Standard needle P S The jet needle chart for the 93 models printed in K Tech News lease the pass switch to
22. manual is no longer available Cost is free e Service manuals for all models including gener ators available to custom ers directly from Customer Services Cost 24 95 for base manual 10 95 for supplement and 3 50 for postage e Microfiche for all mod els Cost 2 00 each e Snowmobile owner s manuals Cost free may be a photocopy of the original manual e Snowmobile service manuals Cost 24 95 plus 3 50 postage May be a photocopy of the original manual e Reprints of magazine articles eservice Specification Manuals Cost 6 95 e Model Recognition Manuals Cost 12 95 e Good Times magazines e Jet Sports magazines Cl You want it Customer Service has it Brochures Microfiche Warranty policies Good Times magazines Owners manuals Jet Sports magazines Service Manuals Article reprints Good Times Protection Plan policies and more SPECIALISTS NORTH amp EAST CONTINUED FROM PAGE 12 early All that is necessary is to call your regional sales office and ask for the sales secretary She will be happy to register you for the training class you wish to attend look forward to talking with you in class very soon Remember the busy season is just around the corner Act now O SOUTH amp CENTRAL CONTINUED FROM PAGE 12 where prospective customers can take a test ride Later in the summer there is a fun day where the customers bring their watercraft
23. mitted so it s possible to submit a claim and receive credit the very next day Of course in order for that to occur the war ranty claim must be a valid one and the claim must be filled out correctly The sys tem checks each claim for technical accuracy before assigning it a claim number and sending it to a warranty analyst for review lf the claim has a techni cal error Such as missing or incorrect information the system will notify you that the claim is in error and will highlight the fields where the errors occurred Once the error free claim is received by Kawasaki it is reviewed by aclaims analyst who will determine if additional infor mation is required If it s de termined that the claim can be paid without any addi tional information from you your parts account will be credited that night The K Share warranty claim system offers greater convenience too For ex ample Good Times Protec tion Plan claims no longer require you to send in a copy of the work order You should keep these copies on file however in case we request them If we do re quest that any paper docu ment or parts be returned to us that s now easier be cause the system allows you to print mailing labels with all pertinent claim infor mation on them If you are sending in parts for more than one claim in the same box be sure to include cop ies of all applicable claims Oh and don t forget to tag all retu
24. ov 93 Baja 1000 but also with the amazing performance of its brand new KLX650 Ridden brilliantly by off road veterans Paul Krause Garth Sweetland and Ted Hunicutt Jr the state of the art four stroke machine finished third overall in its Baja debut Team Green hand fabri cated everything from clutch housing to lighting system to Spaceage exhaust system on the prototype 650 which ha shown extremely well in its first season of competition We ll have more in the next issue of K Tech News S Nickless ALERT KLF300 Igniter failures A couple of dealers have reported to us that failed KLF300 igniters may have been caused by high volt age from a bad regulator In each case the dealer had replaced the igniter to correct a no spark condi tion Shortly after the first re pair the vehicle came back with no spark again This time technicians at each of these dealerships checked the charging system and found that it was charging at very high voltage 16 18V at the battery when revved up it is conceivable that high voltage in this system could have damaged the igniters in these cases It s probably best to do a quick charging voltage test whenever re placing an igniter on a KLF300 See page 9 of this issue for more KLF300 igni tion charging system info Ed Ninja alter nator repair When replacing the volt age regulator in any of our larger Ninjas from the 750s up to the 1100s care must be
25. re try to sign up CONTINUED ON PAGE 11 Training Schedule East Region January 11 13 Engines 14 Modern Engine Theory 20 26 MULE Service 27 Generator February 8 10 JET SKI Watercraft 15 Service Department Operations 16 17 Team Green Race Preparations 23 24 Fuel Systems 25 Parts Department Operations North Region January 17 19 JET SKI Watercraft 20 Modern Engine Theory 21 Generator February No classes scheduled March 28 29 MULE Service 30 31 Team Green Race Preparations April Service Department Operations Central Region February 22 Precision Measurement and Diagnostic Tool Usage 23 25 JET SKI Watercraft 28 Generator March Fuel Systems 2 3 Troubleshooting Electrical Systems South Region January 13 Service Department Operations 17 18 ATV Service 19 Tune and Service 20 Precision Measurement and Diagnostic Tool Usage 24 25 MULE Service 26 27 TroubleshootingElec Systems 31 ModernEngine Theory February 1 3 Engines 7 8 ATV Service 9 10 Team Green Race Preparation 14 16 JET SKI Watercraft 17 Generators West Region January 13 ATV Service 18 20 Troubleshooting Elec Systems February 1 2 MULE Service 3 ATV Service 7 Precision Measurement and Diagnostic Tool Usage 8 9 Engines 10 Generator JET SKI Watercraft 17 Service Department Operations 22 Fuel Systems 23 Modern Engine Theory 24 Tune and Service
26. readers would enjoy read ing about the many inter esting things we saw there First let me give you a little history Kawasaki Mo ors Manufacturing was es tablished in 1974 Kawa saki becoming the first Japanese vehicle manu facturer to establish a manufacturing facility in the United States Since then KMM s eastern Ne braska factory has contin ued to grow and expand today it employs almost 1 000 people You may remember celebrating KMM s produc tion of its one millionth ve hicle when a 1991 model JS650 rolled off the as sembly line in August 1990 Many were sur prised to learn then that KMM manufactures not only motorcycles but also ATVs JET SKI watercraft and utility vehicles produc ing an average of 450 to 500 total units a day In fact KMM builds 27 differ ent versions of Kawasaki vehicles for export to coun tries around the world CONTINUED ON PAGE 2 Inside WE Service tips amp more SHOP TALK TECHNICAL KMM tour CONTINUED FROM PAGE 1 The plant was recently ex panded to accommodate the manufacture of the new ST watercraft plus construction of a 110 000 sq ft addition is under way now with completion scheduled for the first of the year ABOVE Custom made press for produc As Gary and toured the plant we were not sim ply looking at people bolt ing together vehicles on various assembly lines We learned about some of the more intere
27. rned warranty parts with the Kawasaki part tag P N 99995 407 The rest of the system re mains much the same as the one we ve been using for years But now you can process your claims faster more conveniently and re ceive more credit for it too O The Technical Magazine 3 EETECH NEWS Winter 1993 Vol 6 No 4 1993 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 Jerry Heil Donna Hood John Pomo David Pyle 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 GUEST SPOT In search of by Ray St John Supervisor Tech Writing f you ve ever had to stop work just to wonder where you were supposed to go to get service manuals blowup posters a list of Owners manuals part numbers for A amp P sheets or the like you re not alone Sometimes it seems there
28. s Ed by Gregg Thompson Product Support Supervisor f you have a 1990 or older KLF300 B or C model with a mysterious knocking noise at low en gine rpm the solution could be easier than you think If the noise sounds just like a rod knock and is louder when the engine is hot but goes away just above idle why not try a new IC igniter Oh that makes perfect sense you say Not Well strange as it may seem that was the solu tion in aa lot of cases where the symptoms were just as described above Apparently the audible knock was the result of incorrect ignition timing at low rom due to a faulty ig niter The knock worsened as the engine warmed up which does make sense if the noise is the result of detonation Hey if you think the IC igniter remedy is a strange one here s an even more unlikely solution to the same problem Several nits with the same low rom knock also had a problem with the engine suddenly stopping at low speeds bringing the vehi cle to an abrupt halt These units did not re PARTS UPDATE spond to replacing the ig niters After disassembling and inspecting the clutches transmission and in one case even the engine the problem turned out to be a faulty regulator rectifier That s right The knock ing noise and engine stall ing at low speeds was caused by a faulty regula tor So if a vehicle shows up in your shop suffering from some of thes
29. sting tech nicalities of modern manu facturing and I d like to share with you some of the fascinating things we Saw af ee eis 8 ee ge te ing watercraft hulls has a 3 000 ton One of the first things you notice at KMM is the widespread usage of ro bots This is not surpris ing since Kawasaki Heavy Industries KHI is a leading producer of in dustrial robots Robots are everywhere In the water craft area robots are used for many tasks including applying the adhesive to capacity BELOW Superior quality wheels emerge from an intricate process 2 K Tech News the hull and deck as they are joined together A particularly impres sive example of robotic technology is the machine that cuts all openings in the watercraft hulls Its hole cutting tool is a 40 000 psi jet stream of water It was amazing to watch it cut holes in hulls like the one for the ex haust outlet so quickly and accurately Then there is the press that makes the SMC hulls It is gigantic with a capac ity of 3 000 tons When KHI discovered it needed a press of this size there wasn t one available anywhere in the world so Kawasaki engineers de signed and built one them selves to suit their unique needs The molds used in this press to make Kawa saki s watercraft hulls are a two piece design and weigh 150 000 Ibs lt was fascinating to see the array of 70 ton molds one for each hull style lined up next to
30. the even more enormous press Other manufacturers now using molds nearly this size need about eight hours to change molds in their presses personnel at Lincoln can change molds in less than one hour Everything about this press is huge including the price The press itself cost approximately 6 mil lion while the molds run between 1 and 2 million each KMM receives ship ments of SMC material about twice a week Every batch is checked for qual ity and glass content A machine cuts the SMC material automatically and a worker places the pieces on a form A robot picks up these cut pieces and places them on the mold in the press A robot is used for this dangerous job because the molds are heated to 290 degrees After the cured hull piece leaves the press it goes to a worker who trims off excess material with a dia mond tip saw As with everything else here Kawasaki uses state of the art equipment for making its components Take ATV wheels for example Each wheel Starts life as a flat piece of steel that is rolled into a tube and welded in a f machine Another ma 4 chine shaves the weld on both sides Except for heat discoloration f SHOP ATVs are emission free E coat painted and powder coated for extra durability The assembly lines are wild On the ATV line for instance the frame starts with a production tag at tached This tag is color coded indicating the particular country
31. this diode or di ode pack is normally located in the junction box But not on the KLX650 On this bike it is neatly wrapped inside electrical tape on the main wire harness just below the headlight relay The headlight relay is mounted on the headlight bracket just behind the headlight and once you ve found the relay it s relatively easy to find the diode There will be a bulge in the wire har ness 2 3 inches below the headlight relay That s the diode Unwrap the tape and you ll find the diode mounted in a harness con nector The connector has a one way hook that has to be probed with a pick to release the diode At the time I m writing this article finding the di ode on the microfiche is even harder than finding it on the bike That s be cause it s not on the cur rent microfiche This will be corrected on the next revision If you need one before that ar rives the part number is 49018 1059 and they are in stock O 6 K Tech News COMPETITION KLX650 stars in Baja 1000 t required more time than anticipated to design fabri cate and assemble some of the wildly exotic aftermarket components and sub systems At least one of its riders professed a preference for the vastly more developed KX500 Nonetheless Kawa saki s Team Green racing department really showed off its incredible off road racing prowess not only with an unprecedented sixth consec utive overall win in the late N
32. to get Kawasaki s corporate number in Irvine Calif is 714 770 0400 Use ext 2472 well process your order quickly Training service bulletin TR93 02 dated Oct 1 1993 lists all Technical Training Video Tapes avail able TR93 03 July 16 1993 lists all Technical Training Posters TR93 05 Oct 1 1993 lists all Technical Training Manu als and Video Reference Guides Use these to or der what you need for this winter s training season SPECIAL SERVICE PUBLI CATIONS Training Service bulletin TR93 04 dated Oct 1 1993 lists the Service Specifications Handbooks for motorcy cles and watercraft and the Model Recognition Manuals These books all have part numbers Order them just like you would a service manual That s about it The one thing you need to know in the end is If you have any questions give us a call We re here to help O COMMUNICATIONS ee 50 pass or fall E E Info feeding frenzy by David Pyle Park Publication Specialist Wow We had a lot of activity at the Micro K booth at the Kawasaki dealer meeting in Dallas The new MR 1 microfiche readers were very popular We also set up quite a few dealership service departments with Micro K decks and subscriptions as well Even though the sale is over the prices for Micro K equipment have been held so they remain the same as shown on Parts Bulletin GEN 92 02 dated May 22 1992 This bulletin has more important information in cluded on
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