K-Tech News Vol.7 No.3
Contents
1. water The water level will go up accordingly You can speed the process by putting the lid on the container and shaking it If the gas is 10 percent alcohol approxi mately 1 2in of the gas will disappear and the water level will rise the same amount Gregg Thompson collecting dust from lack of use If one of them is a Voyager 1300 output shaft holder P N 57001 1044 you may be in luck You can recycle this tool into use as a KAF620 MULE 2500 series flywheel holder All you have to do is enlarge the holes slightly with a rat tail file and it will bolt right to the MULE flywheel This actually holds better and installs faster than the P N 57001 1313 tool shown in the Service Manual Now if we could just find a new use for those four cylinder ring compressor contraptions Jerry Heil TtieP os F ROM T H S PEC IAL ST S Try this new pump intake guide adhesive by John Pomo Product Support Specialist At the factory in Lincoln Neb Kawasaki installs the jet pump intake guide insert in 750 watercraft hulls using the same adhesive that keeps the rest of the hull together The fact that this adhesive is not available to dealers hasn t been a big problem in the past since it was not used to install any replaceable parts Now that the intake guide has been made available as a service part though you re going to need something to glue it in with We have always recom mend2. Q on the brown wires will turn on all the gauges Obviously if one of the red wires gets shorted to one of the brown wires any other way the result is the same This is what can happen if water gets in the tachometer There should be no voltage AC or DC on the brown wires when the engine is not running If the gauges are on when they shouldn t be check for that If you detect any ning and the black wires for a good ground connec tion to the electrical box and the engine Make sure the black wire from the stop switch is connected to the black wire from the igniter and nowhere else The black wire coming from the stop switch into the electrical box is not a ground unless the stop button is pushed If the black ground wire from the gauges is connected to that wire the gauges will voltage find the source not work unless of it and you ll solve the stop button is your problem pressed while In the gauges the engine is don t turn on at all running U scenario check the red wires for battery voltage the brown wires for an AC signal with the engine run ON SIGNAL GROUND POWER REGULATOR The Technical Magazine 7 SPECIALISTS XIR steering nozzle installation Watch those bushings by Randy Davis Product Support Specialist t has come to our attention that some con fusion exists over the procedure for assembling the steering nozzle on the JH750
3. D1 XIR Some technicians have been assembling it with the shoulder on the nylon bushing facing outward against the head of the pivot bolt Installed this way there will be some binding at the pivot point and the pivot bolts may eventually work loose and fall out or break Instead install the bushings as shown here with the shoulder on the inside of the steering nozzle Also note that the XiR has a different pivot bolt than you are used to seeing on Kawasaki steering nozzles It has a flanged head The flange on this bolt really serves no purpose though and the standard pivot bolt P N 92001 3701 from other JET SKI watercraft steering nozzles will work just fine in the XIR 0 NOTE It is very important to install pivot bolts with LOCTITE Lock N Seal or equivalent TIP Fast and dirty testing for alcohol in the gas We have published information in the past about the possible effects of running gasohol gas oline blended with small amounts of alcohol in our motorcycles and other products The problem is that quite often the dealer mechanic has no idea if there is any alcohol in the customer s gas or not No problem There s a simple test you can do right in your own kitchen to find out just kidding You should do this test in a well ventilated area away from any spark or flame never your kitchen Always be cautious when working with gasoline The test is based on the fact that alcoh
4. after the mechanism has reached the end its travel If an Xi is brought to you with the trim stuck in the down position the first thing you should do is apply battery voltage to the BL W and G W wires going from the handlebar switch to the trim motor Connecting the battery leads one way will turn the trim motor in one direction and reversing the leads 6 K Tech News LA collar P N 92148 3751 either a bad trim motor or the slide lever mechanism is jammed its probably the latter If the trim does move see the Summer 94 issue of K Tech News Vol 7 No 2 for details on the trim electrical system lf the trim mechanism n iS jammed AY Kawasaki has designed a new to help prevent this problem from repeating D Disassemble the slide II Sd lever mechanism make P N 92143 3751 sure all the moving parts are well greased and reassemble it with the new collar as shown here Install the collar with the recessed side facing the head of the drive screw Unfortunately this little job requires pulling the engine to get at the trim motor box The customer should be made aware of how this happens Usually when the customer is edu cated about it the problem doesn t return U Don t forget Service Contest No 1 must be postmarked no later than November 11th Great awards await 3 SPECIALISTS Tips from the field Faster cable replacement Kevin Williams from W
5. sion chores up front while a Uni Trak rear suspen sion adjustable for com pression damping rebound damping spring preload and ride height handles the rear SHOP No discussion of the new ZX 6R would be com plete without mentioning its weight or lack thereof The ZX 6R is nearly 40lbs lighter than the ZX600 E The VN800 But maybe your interest lean towards the laid back bad to the bone cruiser scene In that case dis cussion about Kawasaki s 95 models would certainly center on the all new Vulcan 800 This is the latest generation of Kawa saki cruiser and is styled in the classically American tradition Firepower for the new VN800 A1 is provided by an all new 55 V twin engine In keeping with Sensational new ZX 6R ABOVE is 40lbs lighter than the ZX600 E The similarly all new Vulcan 800 BELOW also breaks new ground in the high technology department 2 K Tech News TALK TECHN CAL GPz 1100 Sport orientation with all day riding comfort the theme of simple is better the engine is fed by a single 36mm CDK carburetor with an accel erator pump The air filter can be accessed by re moving just one bolt and the whole carburetor by removing just two more bolts The engine does bene fit from liquid cooling even though at first glance and maybe second it appears to be air cooled Careful examination reveals a radiator carefully nestled between the frame d
6. years Rather than main tain a large stock of the same item all with differ ent graphics KMC and its dealers can reduce inven tory costs by keeping decals separate e Here is the exception KHI now sells some mid 1980s painted body parts for which decals are no longer available The only way to tell if you will receive one of these parts is the color code on the end of the part number For example if you order P N 36001 5219 B1 it subs to P N 36001 1190 B11 Since the original color code was B1 the new P N color code should be the same The extra 1 on the end of the color code signifies that the part has no graphics on it and that most likely the decals are not available e For decals that are not shown on the micro fiche see parts bulletin MC 90 01 If they are not mentioned on this bulletin they are not available q When replacing the coolant in 89 94 KX500 E models it is very impor tant to purge the air out of the cylinder head In this cylinder head there is a high coolant chamber that wraps around the spark plug hole Air can become trapped This can easily be prevented by loosening the bleed bolt at the top of the head and letting the air escape With the cooling system full loosen this bleed bolt about 1 2 turn wait for coolant to ooze out and then tighten Replace the washer on this bolt in this chamber and stay there even with the engine running Ob viously
7. a T Ee CH NEWS Fall 1994 NEW PRODUCTS The Kawasaki Technical Magazine The sensational VN800 Vulcan is one of three new models highlighting Kawasaki s exciting 95 motorcycle lineup YNF FOP tine ROR 95 watercraft Storm warning Kawasaki s new fleet of watercraft is set to take the industry by storm Our commitment to being the industry leader is con firmed with the introduction of not just one but four new watercraft for 1995 At the top of the line up is the awesome new benchmark setting 900 ZXi This new machine is powered by a 900cc ROUTE LIST SERVICE J PARTS three cylinder two stroke engine and we all know about Kawasaki s repu tation for incredible 900cc engines and two stroke triples The 900 ZXi officially labeled the JH900 A1 is completely new from stem to stern and takes Kawasaki watercraft to the next level of develop ment The boat features a new hull designed for great maneuverability and stability combined with a new powertrain which is highlighted by the new 900cc triple cylinder engine This smooth engine is all new and does not share critical dimensions or components with any of our other watercraft CONTINUED ON PAGE 3 I SALES PLEASERETURNTOSERVICELIBRARY Vol 7 No 3 by Patrick Kelly Instructional Designer Instructor Where does one begin in a discussion of new Kawasaki motorcycles for 1995 There are three complet
8. air trapped in a cylinder head coolant passage Is not good It can give the bike and then you a headache every third or fourth time it is torqued to prevent leaks David Pyle The Kawasaki Service contest is back We have made a few changes to the contest this time around The first quiz in this issue covers motorcycles and ATVs The second quiz in the next issue of K Tech News will cover MULEs and generators The third and final quiz will cover JET SKI watercraft These changes are designed to allow all of our dealers regardless of which product lines they carry a chance to win an award And for a little extra incentive the number of questions on each quiz has been reduced from 100 to 50 SERVICE CONTEST Return of the Kawasaki Service Contest Are you ready So get out that pencil put your thinking cap on and go for it e Deadline for the first contest is November 11th The contest is open to any Kawasaki dealership personnel The contestant may use any materials and infor mation available to ans wer the test questions A service contest will be mailed with each of the next two issues of k Tech News f more than one person from a dealership wishes to enter the contest it is the responsibility of the dealership to copy the answer sheet for the additional personnel Facsimiles of the answer sheet will be accepted The test must be mailed by the deadline and re
9. alts Kawasaki in Lake Havasu City Ariz wrote recently to tell us about a couple of time saving tools he made for working on Kawasaki 650 and 750 watercraft These home made tools make installing a new steering cable go faster and easier Normally to get a wrench on the large brass retaining nut where the steering cable exits at the back of the hull you have to remove the jet pump A socket won t work because of the cable sticking out and there s no room for an open end wrench Kevin cut some time off the job by making a special socket with a long T handle He welded a 2it long T handle to the side of a 27mm socket This allows the socket to slide over the cable and reach the nut When the cable is ready for removal Kevin s second special tool comes into the picture He has drilled and tapped both ends of a lin long piece of 1 4 inch aluminum rod to thread onto the end of the steer ing cable He then threads the other end of the new cable into the other end of the rod With the two cables connected like this the new one gets installed as the old one gets removed The rod needs a 5mm hole with 0 80mm thread pitch at each end You can make your own out of 1 4 in or 5 16 in rod like Kevin did or you can just order P N 46102 3703 from Kawasaki This is an 8x40mm piece of brass hex bar stock with a 5mm threaded hole all the way through it In other words it s a very long 5mm nut This part is long enoug
10. and fairing are sport oriented but still de signed for all day comfort So no matter what kind of street bike sparks your interests Kawasaki s 95 lineup is sure to give you and your fellow enthusiasts something to talk about J S HOP 95 Watercraft CONTINUED FROM PAGE 1 engines With three Keihin CDK38 carburetors a completely water jacketed exhaust system and many other interes ting new design features the new 900 produces a whopping 100 hp The powertrain is completed by an all new jet pump with a three blade stain less steel impeller for a maximum thrust of 732 pounds The ZXi also features electrically adjustable trim tachometer speed ometer and fuel gauge trim indicator and a new trigger type throttle The new 750 ZXi is the 900 ZXi s little brother and features the same basic hull design It is powered by a revised version of Kawasaki s dual carb 750 twin engine which produces 85 hp at 7000 rpm The 750 s jet pump also features a stainless steel three blade impeller Maximum thrust is a generous 679 pounds Also new for 95 are revised versions of two existing watercraft the Fi a TSN fl AA An a Pe ee A e y Tat my yj a Ate EET Highlights of the 95 personal watercraft line PHOTOS CLOCKWISE FROM AB JS750 SXi and the STS 750 The JS750 SXi is a dual carb version of the popular 750SX stand up lt features a revised version of our 750cc en
11. between NMMA TC W and TC Wll certified marine two cycle oils The newer TC WII certification test was designed to make some improvements where weaknesses were per ceived in some TC W certified oils Not all TC W oils had these weak nesses and as it turned out many of the TC WII certified oils had their own weaknesses So the marine manu facturers made some modifications to the test procedures and came up with a TC W3 certifi cation Apparently it isn t all that easy to design a test that can reliably simu late any and all real life conditions that could result in an oil failure Some weaknesses were dis covered in some of the TC W3 oils as well Back to the drawing board The marine manufac turers have put their heads together again and further modified the test proce dures for the TC W3 certification All the oils that currently hold the TC W3 certification will have to be retested and recerti fied according to the modi fied procedures before April 1995 How does this affect us First you should know that the problems that kept cropping up with the TC WII and early TC W3 oils were in outboard engines The conditions that resulted in these problems heavy load and constant throttle do not normally occur in personal watercraft However the TC W3 certification is going to supersede the TC WII certification which will soon be history By the end of 1995 oils will no longer be l
12. e 18 Generators Central Region November Orea 95 Product Update 7 9 JET SKI Watercraft Lae 95 Product Update 13 15 Engines South Region October Olas 95 Product Update November 1 3 JET SKIP Watercraft TEE 95 Product Update 8 10 Engines iC 95 Product Update 15 16 Troubleshooting Elec Systems lle Service Department Operations 28 95 Product Update 29 30 ATV Service December Tinizi Precision Measurement and Diagnostic Tool Usage 19 20 MULE Service 21 22 ATV Service West Region November 1 3 JET SKI Watercraft TN 95 Product Update 8 10 Troubleshooting Electricat Systems ieee Portable Generator Service VO scores ATV Service WT aiea Precision Measurement and Diagnostic Tool Usage 18 Tune end Service 1 ies 95 Product Update 30 1 MULE Service December 13 15 JET SKI Watercraft
13. ed Kawasaki s Hull Repair Kit epoxy putty as an adhesive to use for installing one of these inserts This material does the job quite well maybe a little too well It cures so hard and adheres so well that if the job ever has to be done a second time on the same unit well you don t want to be the one who gets to do It Just recently we have learned of an air dry one part adhesive that we believe will do the job but wont be so difficult to remove The product called HV 350 is prod uced by Valco Cincinnati and is available from Kawa saki HV 350 is a urethane adhesive that stays flexi ble when it dries but is a lot tougher and adheres better than silicone In fact it may be a more permanent substance to use instead Getting a handle on microfiche navigation This past June had the pleasure of participating as a judge in the 94 VICA U S Skill Olympics The work station was involved in was Shop Procedures which was basically pre paring a repair order esti mate using a parts catalog microfiche While watching the con testants saw some inter esting problems come to lignht and the answers were right on the parts microfiche If you are not familiar with or are new to Micro K parts catalogs here are a few tips to help you find your way e Parts List Information Grid A 3 If you have any questions about how to look up a part number this grid will a
14. ely new models for 95 each one unique and exciting The ZX 6R If you are interested in the latest high tech street weapon the discussion would have to begin with the all new ZX 6R a roll ing showcase for all of Kawasaki s latest two wheel technology The engine in the new ZX600 F1 is all new and is more compact and much lighter than its predecessor And even more incredible it is more powerful too This was accomplished with a number of signifi cant changes the most obvious of which is a switch from driving the cams from the center of the crankshaft to driving the cams from the right hand end of the crankshaft This makes the crankshaft shorter and more rigid and also allows the intake and exhaust ports to be as Straight as possible Other new engine features include a cylinder that is canted farther for ward than before a steeper downdraft angle for the intake ports larger dia meter valves revised camshaft timing and an all new clutch and transmission CONTINUED ON PAGE 2 Inside WE Service tips amp more 95 Three for the road CONTINUED FROM PAGE 1 The ZX 6R s chassis is an equal to its state of the art engine Its rigid aluminum frame steep 24 rake 87mm trail and short 55 7in wheelbase assure quick responsive handling A conventional cartridge front fork adjustable for compres sion damping rebound damping and spring pre load handles the suspen
15. gine similar to the new 750 ZXis engine Its jet pump is upgraded too with a new stainless steel three blade impel ler The new power train is good for 628 pounds of thrust The STS is a higher performance version of the three seat ST model introduced last year It features the same engine VE LEFT The revolutionary 900 ZXi T ALK TECHNICAL as the 750 ZXi and it also gets a new three blade stainless steel impeller to boost thrust up to 654 pounds The STS also gets electrically adjustable trim mirrors tachometer fuel gauge and a trim indi cator Look for more detailed information on these exci ting new watercraft and their powertrains in future issues of K Tech News Pa trick Kelly ALT eS will turn heads anywhere it goes 750 ZXi is the 900 s little brother JS750 SXi is a dual carb version of the popular ahi ati aa E ja 750SX stand up STS is a hot rod version of the three seat ST SRE TT gx ST lt a gt ie lt os a fears rem Fr The Technical Magazine e 3 8 E TECH NEWS Vol 7 No 3 Fall 1994 1994 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 West Jerr
16. h the microfiche and saving time Taking a few minutes to become acquainted with the microfiche now can save you time when the parts counter becomes busy All the information is there its up to you to use it David Pyle The Technical Magazine 9 Zippity doo dah ZX 6 camshaft installation tip by Scott Buckley Product Support Technician Here s a tip that could save you lots of aggrava tion when you are doing a valve adjustment or top end repair on a ZX600 D E model If you ve ever pulled your hair out trying to get the camshafts back in without the exhaust cam jumping time you will want to try this First get the cams sitting in the head and timed correctly and the cam caps and bolts in place but not tightened down yet Next thread a long zip tie under one cam cap over the camchain and under the other cam cap then zip it together snugly over the top of both caps and the chain If you do this correctly the zip tie will keep downward pressure on the chain between the cam sprockets as the cam Caps are tightened down When the cam caps are torqued down install the camchain tensioner with the zip tie still in place Now while pressing down on the middle of the chain with your thumb cut the zip tie and rotate the crankshaft forward with a wrench so all the slack is taken up by the tensioner And there you are The cams are torqued down and still timed properly 10 e K Tech New
17. h to cut in half and make two tools and it only costs a few dollars Thanks for the good ideas Kevin Your check is in the mail As always when we put a dealership tech nician s idea into print in k Tech News we send him or her a 100 check Ed F ROM T H SPECIAL ISTS Turn ons and turn offs Xi gauge diagnostics by Gregg Thompson Product Support Supervisor We ve had a couple different kinds of failures in the gauges of the 94 JH750 B2 Xi that have been traced to several different causes The failures include the gauges don t turn on at all and the gauges are on all the time even with the engine off In the gauges on all the time scenario the gauges run the battery x a ALLY i wW STARTER RELAY dead if the customer doesn t disconnect them In these situations the cause is usually a short frequently caused by water in the tachometer or the LED gauge Other causes of this problem can be cross connected or shorted wires in the electrical box There are several brown wires and several red wires in the electrical box all with single bullet connectors The red wires are battery positive and the brown wires are AC signal wires that tell the gauges to turn on when the engine is running If one of the red bullet connectors accidentally gets connected to a brown bullet connector the resulting battery voltage IGNITER W Bk had R
18. icensed to be manufactured with the TC WII certification oils will have to be certified TC W8 Our Marine Product High Performance Oil will be reformulated to services Don t pass up an opportunity to send customers away from your Store with their questions answered and smiles on everyones faces The Hot Line is your direct source of technical and warranty information Kawasaki Consumer Services is here as the last step when you cant get information through normal means and is always ready to help you and your customers when needed But in many cases with just a simple toll free call you can be the hero U pass the NMMA TC W3 test by early next year However any oil that has already been certified TC W can still be manufactured and sold with that certification As of now Kawasaki plans to continue carrying its standard Marine Products Oil with no change in the formula It will continue to have the TC W certification This oil has been pro viding high quality lubrica tion in our JET SKI water craft for many years now It doesn t make much sense at this time to try to fix it and make it more expensive if it ain t broke Gregg Thompson The Technical Magazine e 11 RS EA iG O N A L N EWS The schedule is revised by Jerry Heil 9950 Jeronimo Road Irvine CA 92718 714 770 0400 This year s West Region training schedule is changed from previous years with
19. ion is growing at an excellent pace We hope this cutaway will help to draw attention to the importance of getting people out on the water Safely said USCG Capt William Horan Horan said the JET SKI watercraft cutaway will be used for educational dem onsitrations throughout the southwestern U S and will be seen by thousands It will be used to draw attention to the Coast Guard Auxiliary s new PWC safety course Horan presented Kawa saki with a U S Coast Guard certificate of appre ciation commending the manufacturer for its con tinued commitment to boating safety Anyone interested in participating in a PWC safety course can call the Coast Guard Auxiliary s Safe Boating Hotline at 800 869 SAIL J u S Coast Guard representatives including Capt William Horan second from right take delivery of a cutaway 750 Super Sport watercraft donated by Kawasaki and MMI VICA U S Skill Olympics Last June the Voca tional Industrial Clubs of America VICA held its U S Skill Olympics in Kansas City Mo For the fifth year Kawasaki parti cipated in the Motorcycle Service Technology Con test by sponsoring two work stations Shop Procedures and Using a Multimeter J C DeLaney of the Motorcycle Industry Council and Steve Ehle of the Motorcycle Mechanics Institute served as co chairpersons of the tech nical committee which comprised representatives from the participating manufactu
20. ls with each service or 2 Call the Kawasaki Hot tine for answers to your customer s technical or warranty related ques tions You can be the one who helps your customers instead of KMC s Consumer Services Either no 1 or no 2 is likely to send your customers away with smiles on their faces but only one of them is likely to put a smile on your face too For example If you think a unit qualifies for a recall FDM or FAR and can t find the information on your microfiche or bulletins call the Hot Line for the answer If a vehicle does qualify you can do the repair immediately without authorization regardless of the age and warranty status of the unit Telling the customer to call Kawasaki to find out can cause delays in handling the inquiry If you aren t sure a repair will be covered under warranty call the Hot Line with details and get an immediate answer Do not charge the customer and then refer him or her to Consumer services for possible reimbursement This is very inconvenient for the customer and more time consuming and costly for us You are the customer s direct source of technical and warranty information Do what you can and use the Hot Line to get answers to questions and solve problems for your customers without having to refer them to Consumer TC W TC WII TC W3 Where s it all headed A few years ago we published a couple of articles explaining some of the differences
21. nswer them It also includes a list of ab breviations a key to Spec codes Canada California etc and an explanation of the Kawasaki part number structure Reading this grid is a must e Pictorial Index These indexes located on the first two grids of each row from Row B down show pictorially in condensed form all of the grids in that row By reviewing the pictorial index you can save the time of having to sweep through each row to find the grid you re looking for These indexes are also very helpful if you are not sure where a part is located on a vehicle e Grid Index This list of grids is the biggest time saver on each microfiche Found on every parts grid to the right of the parts list a simple glance at the grid index can give you the location of the next grid you need For example You are on grid B 4 looking up the part number for a base gasket The next part of silicone for sealing pump housings on other models This adhesive should be in stock by the time this article is published so if watercraft service work order some and give it a try You can order a 3 35 oz tube of HV 350 using P N 710XX 155 or the same tube plus a Tube Grip dispenser using P N 710XX 156 O number you need is for an air filter element Go to the index and find air cleaner The index will direct you to grid B 5 This list is ex tremely helpful in elimina ting wandering throug
22. ol likes to blend with water and goes to it readily In fact if you put water and gasohol together in a glass contain er you can actually see the action in the liquid as the alcohol is drawn out of the gasoline into the water For the test you need a glass container with a lid 8 K Tech News A tall thin container works best a test tube would work fine Put a small amount of water and a large amount of the suspect gas into this container one part water and 10 parts gas is good If your container is at least 6in tall put 1 2in of water in first Mark the top of the water with a piece of tape Now add 5in of the gas making a total of 5 1 2in of liquid in the container If you let that sit long enough any alcohol that s in the gas will migrate into the TECHNICALITIES New old tools for MULES The MULE 500 trans mission alignment tool now looks a lot different and costs 100 less If you order P N 57001 1341 you will receive 157001 1341 and it will look nothing like the tool pictured in the Service Manual This new tool allows you m T57001 1341 to check engine to tram mission alignment on the MULE 500 simply by removing the drive belt cover and drive belt and then inserting the tool on the pulleys This is an old trick from our snowmobile days Meanwhile if your shop has been around for a while 57001 1044 you may have a bunch of older special tools that are
23. owntubes radiator hoses are hidden too helping the VN retain that classic air cooled look A gear driven counter balancer and rubber engine mounts make this modern V twin smooth Single overhead cams open four valves per cylin der making sure that the VN800 goes as well as it shows The VN s chassis features a wide Showa front fork a unique Uni Trak rear Suspension with hard tail look a 21 inch front tire and 16 inch rear tire Both wheels are spoked in keeping with the classic styling The speedometer rests on the fuel tank and is cable driven off of the rear wheel helping to keep the front end clean and uncluttered The GPz 1100 But let s say that for 95 you are interested ina powerful versatile sport ing machine at an econo mical price Then the new Kawasaki GPz 1100 would definitely enter the conversation here The engine in the ZX1100 E1 is based on the legendary ZX 11 engine with a few changes to smooth out its incredible power delivery It features a new cylinder head with sidedraft intake ports mounting smaller CDK 36mm carburetors Cam shafts with 10 less dura tion and a new 4 into 2 exhaust system complete the engine s transformation The chassis is based on an economical one piece double cradle steel frame and steel swingarm A sturdy 41 mm front fork graces the front end while a Uni Trak system with an adjustable rear shock sup ports the rear The riding position
24. rers and the Snap On Tools Corp The skills contest pro vided students with a written skills test and nine meaningful work stations designed to serve as a competency based model for entry level technicians in motorcycle dealerships There were 34 contestants this year all winners of their state contests com peting for numerous prizes offered by the sponsors of the contest Kawasaki offered a substantial library of ser vice and training videos and manuals to the schools of the first second and third place finishers in both the secondary and post secondary divisions Don Church VICA medalists TOP ROW L to R Thomas Noyes Post secondary we Division winner Chris Hawks and Chris Hen drickson BOTTOM ROW L to R Mark Sagers Secondary Division winner Anthony Kaller and Thomas Pickup Micro K by David Pyle Parts Publications Specialist ve talked before about decals and whether they come on painted parts or not but just when we had some easy rules to follow we find an exception to those rules Here are the rules again then I ll give you the exception e Decals do come ap plied on all motorcycle body parts This includes all types dirt street and dual purpose e Decals are not sup plied on any ATV JET SKI watercraft generator or MULE utility vehicle replacement parts The reason is that these vehi cles tend to use the same body hull parts for several
25. s KZ1000 P jumpy tach According to Kawasaki Police Bike Coordinator Bill Zito unsteady or inac curate tachometers on KZ1000 P models can be caused by uneven ignition pick up coil air gaps If the pick up coil plate is installed slightly off center so that the air gaps are unequal the tachometer needle may bounce up and down while the vehicle is ridden at a constant speed If you have this com plaint from a customer make sure the pick up coil air gaps are both the same A potentially tricky prob lem could turn out to be a snap to fix Steve Rice TECHNICALITIES A little known fact KX125 250 throttle grip position H ere s a little known fact about the newer style 92 95 KX125 and KX250 throttle assem blies The tabs or splines on the grip assembly have a small pointer molded into them to correspond with a notch in the rotor that pulls the cable This pointer allows you to easily realign the grip after maintenance so that the KX125 KX250 wear on the grip is returned to its original position and feels comfor table in the rider s hand Always assemble the throttle with the point on the grip aligned with the notch in the cable rotor David Pyle C OM M U N CCELI COCHECECRZ SERVICE IC ATI ON S A hero in the eyes of your customers by Donna Hood Consumer Services Representative How can you look like a hero in the eyes of your customers 1 Give away 100 bil
26. turn postage is the responsibility of the contestant Any contestant who scores 85 percent or higher will win an award for that contest In order to compete for the grand award all three tests must be com pleted and returned e The contestant with the highest score total for the three tests will win the grand award In case of a tie there will be a run off Winning contestants will be announced in the next issue of K ech News Send completed tests to Service Contest No 1 Kawasaki Motors Corp U S A 9950 Jeronimo Rd Irvine CA 92718 Good luck to all 0 The Technical Magazine 5 TIP S F ROM T H 94 Xi electric trim help will turn it the other way If the nozzle does not move the problem is by Gregg Thompson Product support supervisor We have had lots of calls this summer about JH750 B2 Xi electric trim systems sticking in the full down position Some dealers have gone through the process of checking all the electrics in the trim sys every case we ve heard of where the trim nozzle has gotten stuck all the way down the cause has been a jammed drive mechanism slide lever assembly Apparently at one end of its travel the trim motor is capable of torquing the slide lever against the shoulder on the drive screw tight enough that the motor cant break it loose in the other direction This hap pens when the customer continues to hold the trim adjust button down
27. two separate training sessions offered The first training ses sion will begin Nov 1 1994 and end Dec 15 The second session will begin Jan 30 1995 and end April 5 In the last several years very few students have attended classes held around the Christmas holidays or when the selling season kicks into gear in the spring To make better use of your time as well as ours no classes will be held during those periods We will offer every class during both winter training sessions none will be cancelled due to low enrollment So call 714 770 0400 ext 2452 and ask Linda to sign you up today for your favorite class U 12 K Tech News Increase your Knowledge by Waiter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 K awasaki Technical Training will resume shortly Check out the new training schedule as it arrives at your dealership and sign up for the Classes of you choice With some great new products for 95 we will have plenty of information to share with you in class am looking forward to seeing you there The Kawasaki Service contest is back again this year the rules are listed elsewhere in this issue of K Tech News You really can increase your know ledge of Kawasaki prod ucts by participating and you have a chance to win some useful tools as well You compete against no one but yourself in this contest If you score over 85 percent you win It s f
28. un it s challenging and it s beneficial Good luck O Are you ready to win by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 In this Fall 94 issue of k Tech News we kick off Our second annual Service Contest Every dealership mechanic has a chance to win some great awards So plan on entering have spoken to many technicians this summer who for some reason do not see K Tech regularly Note that back issues are printed in their entirety on microfiche available as P N 99961 5007 01 Also some back issues and additional copies of the current issue may be obtained from the Tech nical Services department Technical Training classes will resume in November in all regions Be sure to ask your service manager to show you the training schedule when it arrives at your dealership Schedules are mailed out monthly once the training season begins U Training Schedule East Region October S 95 Product Update November 1 3 0 Troubleshooting Electrical Systems 8 10 JET SKI Watercraft men 95 Product Update 29 30 Fuel Systems December arene Precision Measurement and Diagnostic Tool Usage 6 8 JET SKIP Watercraft es 95 Product Update Toe Service Department Operations 14 0 95 Product Update loce Parts Department Operations 19 20 Engines 21 22 Fuel Systems North Region November 14 16 JET SKI Watercraft A Seca 95 Product Updat
29. y Heil Contributors Scott Buckley Randy Davis Donna Hood John Porno David Pyle Steve Rice Ray St John Kevin Williams Graphics Production Graphic Art Gregg Thompson Photography Dave Corey Don Church Eric Putter Copy Editor Pat Shibata Production Nickless Communications Published by Kawasaki All suggestions become the prop erly of KMC Sending a service suggestion gives Kawasaki per mission to publish and or use it without further consideration Specifications subject to change without notice 4 e K Tech News A unique boating education tool K awasaki Motors Corp U S A has given the U S Coast Guard a new way to look at boating education a full size cutaway of a Kawasaki JET SKI water craft that literally gives students a look inside a modern PWC The project began in early 1994 when the Coast Guard indicated to Kawasaki its educational interest in the expanding personal watercraft industry Responding to that interest KMC sent two of its 750 Super Sport watercraft to the Florida based Marine Mechanics Institute For the next four months about 20 MMI students worked to cut away key areas of the watercraft s hull and inner components allowing for a cross sec tional look at the workings of a personal watercraft The final product affords students a unique view of the engine pump gas tank impeller and steering system The personal water craft populat
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