K-Tech News Vol.10 No.4
Contents
1. manufacturers cooperated to establish a plan to reach this level with the least economic impact to manu facturers and consumers The first part of the plan is a gradual yearly reduction in emissions from 1999 to 2006 Secondly the emissions from every unit a manu facturer sells within a model year will be grouped together to form a corporate average This means a manufacturer could sell old technology craft as long as they sold enough clean burning craft to offset the differ ence Corporate averaging is currently used in the motorcycle and automo bile industries Manufacturers attain ing a corporate average cleaner than the standard set for that model year will earn emission credits These credits will be placed into a bank account For example Kawasaki is earning emis sion credits on our 98 1100 STX and 1100 ZXi because they are already fuel in t engine pulse certified to meet 1999 stan dards We are the only manufacturer to do this Emission credits can be saved traded or even sold between manufactur ers and industries Let s say Kawasaki for some reason didn t meet the corporate average stan dard for 1999 We could use our 1998 credits from the bank to help offset the difference It is possible that one manufacturer could buy credits from a competitor to avoid an EPA fine for a corporate average worse than the standard The most likely scenario is companies keepi2. N 44026 1662 MA be inclined to respond KX250 FORK i O HVY 42 43 NA 440261670 i NA EIS PAIAR ee Ea E _ on ie p TER ere E A A with so what _ KX250 SHOCK LIGHT 4 6 4 9 5 1 o WHITE __ 92145 1113 45 VIOLET P _KX250 SHOCK STD 48 5 1 5 3 RED 92145 1114 45 VIOLET rogressive springs aren t KX250 SHOCK HVY 5 0 5 3 5 5 YELLOW 92145 1115 45 VIOLET exactly a new idea So why is Kawasaki using hold the bike and rider gravity while still not bot like last year s bikes you them now Until recently read center of gravity toming on big jumps will understand that this the technology wasn t high while in turns A When you ride a new is one of the most signifi available to produce pro high center of gravity is KX125 K5 or KX250 K5 cant improvements in the gressive springs to not a good thing when your first impression long evolution of Kawasaki s production you are trying to go might be that the suspen motocross suspensions tolerances Now that this through a series of turns sion is too soft You The parts microfiche technology is available as fast as you can The should have an open for these models don t Kawasaki has developed progressive springs onthe mind and keep on riding give all of the spring rate superior front and rear 98 Kawasakis allow the You are riding on new information for stock or suspensions using pro suspension to soak up technology and it takes o
3. caps This will keep the chain from jump ing a tooth on the cams while you draw them down into the head WINTER 1997 1 K TECH NEws Continued from page 3 g km HC and 1 4 g km HC for motorcycles 700cc and above NOx emis sions are regulated sepa rately by the EPA and CARB CARB has recently announced plans to implement new motorcy cle emission standards for the near future Kawasaki introduced throttle position sensors K TRIC and catalytic converters in 1998 to reduce emissions and pro vide better throttle response fuel economy and more power for California models How much difference does a catalytic converter make Emissions levels of the 49 states 98 ZX 9R are 1 4 g km HC while the cat alyzed California model emits only 39 g km HC This reduction comes at the expense of only one horsepower or less than 7 of 1 of horsepower How much difference does the K TRIC system make While we don t have an exact comparison we can evaluate the ZX 6R The 97 ZX 6R pro duced 1 17 g km HC The 49 state 98 ZX 6R with a switch to Mikuni carbure tors the addition of K TRIC and very little else emits 75 g km HC The valve timing from 97 to 98 is the same The 98 California ZX 6R with cat alytic converter is cleaner still at 63 g km HC What does the future look like New technolo gy is coming soon Fuel injection and catalytic con verters will become popu lar in the next cen
4. every ripple and bump in the track Also these stiff springs WINTER 1997 9 K TECH NEws Cak Kawasaki Key Cutting Equipment Available by John Griffin Instructional Designer Instructor It is now possible to cut Kawasaki keys at your dealership thanks to Curtis Industries Curtis has already shipped out over 150 Kawasaki kits To order kits or replacement parts contact Curtis directly at 800 555 2878 Curtis currently has two Kawasaki kits Master kit 21238 599 95 is for dealers without any key cutting equipment It has everything needed to cut Kawasaki motorcycle keys and a few ATV keys The second Update kit 21239 239 95 is for dealers possessing Curtis equip ment for other OEMs This kit enables you to cut Kawasaki motorcycle keys and a few ATV keys A new kit to cut the majority of ATV and Mule keys will be available for sale in mid 1998 Dealer Note Be sure you and your customer record the key code from the factory supplied key ring tag Without a key code you cannot cut a key Write it on the A amp P checklist Owner s Manual the sales contract etc Kawasaki does not keep key codes on file for any vehicles VN1500 D1 D2 Exhaust Valve Kit by Gregg Thompson Product Support Supervisor The parts kit 99995 1431 for Service Bulletin MC97 07 Engine Stalling and Backfiring includes six 12mm x 21mm wash ers that have caused some dealers a little confusi
5. sion warranty To meet these stan dards Kawasaki altered the jetting and now vent crankcase vapors into the airbox On some models valve cover vapors are also routed to the airbox Vapors in the airbox are reburned in the combus tion process Street bikes have used this design for years Street Motorcycles Emission levels for street motorcycles have not changed in 1998 but Kawasaki introduced new technology to meet exist ing standards while pro ducing even more power The current EPA standard for street motorcycles is 2 5 g km HC The CARB standard for street motor buretors on the 1100 STX cal than ever for PWC this in the next issue cycles under 700cc is 1 0 and 1100 ZXi These technicians Kawasaki now offers Continued on page 12 WINTER 1997 3 K TECH NEws PISCATAWAY GRAND RAPIDS A few months ago I had occasion to tear down an engine that had obvi ously been assembled with the use of a large air wrench The clutch would n t disengage properly because the clutch nut had been over tightened to the point of distorting the bearing spacer behind the clutch hub Most of the larger bolts and nuts on the motor were rounded off and could not be loos ened The disassembly job took four hours longer than it should have I also needed to replace lots of rounded off nuts and bolts Air ratchets and other air tools can be great time savers when used proper ly and in some applica tions are indispens
6. 8 2 1 CH NEWS WINTER 1997 THE KAWASAKI TECHNICAL MAGAZINE VOL 10 NO 4 THE NEW EMISSION STANDARDS 5 p INSIDE Features Emission Standards 2 Regional Update 4 Tech Tips Service Handbooks 5 MC 97 08 Replaced 5 Maintenance Intervals 6 A amp P Check Lists 6 JH900 Porpoising High Altitude Specs 7 Watercraft Tuner s Tip 7 Product Support 8 KL650 A10 Transmission 8 Electrical Components 9 KX Suspension Key Cutting 10 VN1500 Exhaust Valve 10 ROUTE UIST SERVICE PARTS J SALES ZX 9R Information 11 RETURN TO SERVICE LIBRARY e Oy AU ON ar Ee ae ee SE LF ee so gt New Emission Standards Here s How They Affect You by John Griffin Instructional Designer Instructor In 1998 new emission regulations affect all of Kawasaki s product lines This article walks you through new emission standards and product developments for personal watercraft PWC ATVs Mules off road and street motorcycles Many of the new changes affect the complete United States If you think smog equip ment just affects Californians think again Personal Watercraft By the year 2006 PWCs must emit nearly 80 less emissions than they did in 1990 New technology will be required to meet this stringent level The Environmental Protection Agency EPA and PWC
7. 926 1025 01 dy dy E EEA 99926 1023 01 1 PEE ER 99926 1021 01 190 9 cc ccssscesscacaess 99926 1019 01 789 90 niii 99926 1017 01 174 88 secsessesssesess 99926 1013 01 were produced every year and covered two years The result was that each book overlapped the one before it and the one after it To cut costs and save paper Kawasaki has decided to produce the books every other year and continue to cover two model years in each one eliminating the overlaps Many older Service Specifications Handbooks are still available Notice MC 97 08 The Warranty Information section of Motorcycle Service Bulletin MC 97 07 refers to MC 97 08 when you are doing both of those Authorized Repair Repair is r eligible units with the symptoms ation if this repair is done at Claim Type 3 Description Exhaust Job Code 21250 alve Kit repairs at the same time But MC 97 08 has been deleted and replaced by MC 98 01 Please make a note in your copy of MC 97 07 Thanks Ray St John WINTER 1997 5 K TECH NEws lt D New Maintenance Intervals by Carlos Johnston Service Support Coordinator Latin America As most of you know for many years now Kawasaki has called for the first service on motor cycles to be at 500 miles the second one at 3 000 miles and then at 3 000 mile intervals from then on Before 1985 the valve clearances were to be checked at ever
8. able On the other hand misuse of air tools will cost time money and your reputa tion as a good mechanic I consider air wrenches to be primarily disassem bly tools and even during disassembly they should be used with caution Too much force combined with a poor quality or worn socket can result in round ed nuts and bolts If used again not only are these nuts and bolts an eyesore there is also the possibility that because of the round ed corners they cannot be removed again On assembly hardware should not be tightened with an air wrench Too much force and you can break or stress bolts pull threads from expensive aluminum parts distort spacers and bearings and cause cosmetic damage Most fasteners require a specific torque So check the service manual and torque them to specifica tion by hand And the ser vice manuals will also tell you that some hardware such as connecting rod bolts and clutch hub nuts cannot be reused So read your service manual and look for this kind of infor mation During assembly starting your hardware with an air wrench is not advisable It s easy to cross thread aluminum parts doing this Here are some general rules for using air tools that can save time and earn you money Always use the proper size air tool for the job Set the tool to the low est possible setting that will accomplish the job If a locking agent was used on any of the fasten ers heat up the pa
9. ain bearing bores but those passages deliver oil only to the upper halves of the main bearings It is extremely impor tant when you are assem bling one of these crankcase sets that you do not get any case sealant into these oil passages at the main bearings That means one should apply a very thin layer of sealant to the mating surface of the lower half and don t get the sealant too close to the oil passages especial ly on the 5 bearing If any sealant squeezes into the oil passage there s a good chance it will cause oil starvation and a seri ous failure The Illustration in the new ZX900 C1 service manual for cam timing is incorrect The illustration shows the 30th pin well above the timing mark on the intake cam sprocket with the timing mark No Sealant in A DA this Groove pointing directly at what appears to be the 31st pin However in the drawing 30th the arrow indicating the 30th pin is actually point ing at the 29th pin And in reality when the cams are timed properly the mark on the sprocket will point between the 30th and 31st pins That puts the 30th pin just above the gasket surface and the 31st pin just below it once the cam caps are tightened down Note With the cams timed properly and laid into the head and the cam bearing caps loosely in Corrected place install the camchain Cam Timing tensioner before drawing Illustration for the cams down with the ZX900 C1 bearing
10. and when Once the work is done be sure to record it in the maintenance record page of the customer s Owners Manual This will give you an opportunity to remind the customer when his next service is recommended This helps the customer keep track of work done and encour ages him to bring the vehicle in for continued service work Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected OPERATION Spark plug clean and gap t Valve clearance check t Air suction valve checkt _ Whichever comes first Engine oil change 6 months Oil filter replace Evaporative emission control system CA checkt Drive chain wear check t D rabla nad sarnary nhanb L ODOMETER READING A amp P Check Lists Now in Crates by Ray St John Supervisor Technical Writing aie 5 a Ps A e NL a a O i vit Hi i You ve probably already seen it an Assembly and Preparation Check List included with the other printed materials in the crate with a new unit Starting in October 1997 Kawasaki started to put an A amp P Check List into every crate with new units for your convenience and to help ensure that the check list gets used every time a unit is set up and sold Of cou
11. ation is 253 kWhr The eventual lev el allowed in 2006 is 81 g kWhr Our 98 1100cc engine family is certified to produce 140 g kWhr New technology is required to get to 81 kWhr Three technolo gies appear to be able to reach this standard Direct injection two stroke engines can meet the stan dard by specially sealing the engine then using electronic fuel injectors to provide fuel in the com bustion chamber OMC Mercury and Bimota cur rently have systems in use like this Another possibili ty is a two stroke with a catalyst in the exhaust sys tem Finally a four stroke motor can meet the stan dard It is too early to say what each manufacturer is going to do but keep your eyes open What does this mean to you In 1998 you have constant velocity CV car fad 1 Ta In 1998 Kawasaki offers California model ATVs and KLX300Rs like this Bayou 220 Carburetor jetting is changed and crankcase vapors are now vented to this airbox Keihin carburetors use vacuum created by the motor to raise and lower a slide just like a street bike carburetor Fuel is only drawn into the motor when it turns enough rpm to burn efficiently regard less of throttle position These carbs are still pumper type however to handle the special fuel demands of two stoke watercraft The benefits are much improved throt tle response better fuel mileage and less emis sions In the next few years you w
12. de 5 F amp I If the customer is still a little hesitant about the buy but you can get him to sit down to discuss financing and show him how easy and fast he can get the ATV he usually leaves with the unit 6 Advertising We cover about a 100 mile radius with our advertising We want about people to know Hattiesburg Kawasaki where we are what we sell and how much it costs Radio TV and newspaper are our main sources We believe in advertising and we spend a lot of money doing it 7 Service We have five full time mechanics and our cus tomers know they can get service from factory trained mechanics on what they buy This is a top priority for the consumer 8 Reputation We have built the reputation over the years that we appreciate the busi WINTER 1997 4 K TECH NEWS ness and the customer will get the best possible deal he can We like selling motorcy cles ATVs and Jet Ski watercraft and plan on being here a long time By following these ideas you can increase success at your dealer ship Congratulations to Larry and Hattiesburg Kawasaki Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 IRVINE SEATTLE We are busy here at the Irvine training center with the training season in full swing Not only do we have training going on we are also on the road with our annual Product Update and new KIC Kawasaki Information Center semi
13. ill see clean burn ing new technology watercraft replacing our existing line up It will be exciting to see new engines and a challenge to learn new service and troubleshooting proce dures Technical training classes will be more criti California Air Resources Board The California Air Resources Board CARB began regulating the emis sions of automobiles in 1965 to reduce the drastic smog problem The federal government through the EPA didn t start automo bile emission regulations until 1972 California is the only state allowed by the federal government to establish regulations sepa rate from the EPA In 1998 ATVs off road motorcycles and Mule utility vehicles sold in California must meet emission levels established by CARB A closed course competition cate gory has been created for units not certified to meet the standard These units can only be used in limit ed riding areas We will go into greater detail about California model ATVs and KLX300Rs For 1998 all Mules are certified to meet CARB standards there are no 49 state models The emission standard for models with engines bigger than 225cc is slightly less than 9 g kWhr HC NOx or using another test proce dure based on emissions per distance like motorcy cles or cars 1 2 grams of hydrocarbons per kilome ter g km Mule emis sion related components are warranted for two years ATVs and off road motorcycles have no emis
14. nars Attendance has been very good especially in the mid West Region Questions from the techni cians in the Update semi nars have been helpful in resolving technical prob lems at the dealership lev el It s always amazing how different the prob lems are from region to region Denver might have a particular problem that the dealers in Salt Lake City or Seattle Tacoma have nev er encountered Not only do these problems we dis cuss in the seminars help us at the manufacturer level it also allows us to talk to technicians in the following classes just in case they run into the same problems Because of the limited area where a problem might exist we might not be able to help correct it on the spot but we can research and solve it when we get back to the office The KIC seminar was also well attended Our new full feature EPC electronic parts catalog KIC is quite a package Being part of the K SHARE program makes it even more diverse With instruction on basic Windows 95 procedures and the features of K SHARE and KIC we were able to help new or expe rienced dealership person nel KIC will be evolving over the next couple of years with new features and benefits to become the industry leader in EPCs Look for new semi nars in the upcoming year Rob Taylor 9950 Jeronimo Road Irvine CA 92618 714 770 0400 New Service Specifications Handbooks Available by Ray St John Supervi
15. ng their credits from one year to fuel in Keihin constant velocity carburetors on the 1100 ZXi and 1100 STX dramatically reduce emissions improve throttle response and reduce fuel consumption K TECH News Vol 10 No 4 Winter 1997 K TECH News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Communications Editor John Griffin Regional Editors Piscataway Grand Rapids Fred DeHart Atlanta Dallas Walter Rainwater Irvine Seattle Robert Taylor Contributors Craig Martin Ray St John Carlos Johnston Randy Davis Graphics Production Graphic Art Gregg Thompson Photography Dave Corey Production Holland Marketing Services 1997 Kawasaki Motors Corp USA All rights reserved Published by Kawasaki All suggestions become the property of KMC Sending a service suggestion gives Kawasaki permission to publish and or use it without further consideration Specifications subject to change without notice WINTER 1997 2 K TECH NEWS Emission Standards cont d the next to balance the flow of new clean mod els replacing older models In 1998 a non manda tory emission standard has been set at 278 grams per kilowatt per hour of hydrocarbons HC added with nitrogen oxides NOx This can be writ ten as 278 kWhr HC NOx The emission standard for 1999 the first year of regul
16. o my knowledge there is no magic formula High Altitude Specs In case you can make use of them here are some recommended high altitude for establishing a spon son s optimum shape length or mounting posi tion fore aft placement as well as angle It takes hours upon hours of test ing to determine the best all around sponson for a particular boat So don t be surprised when I offer this little hint which is not warranty authorization The 1997 and 1998 model JH1100 A2 A3 sponsons can be installed on any JH900 to reduce porpoising The 1997 model sponsons are red 59437 3711 6L left settings for our 98 KDX and KLX motorcycles These recommendations are for 6000ft and above Enjoy Ed Kawasaki High Altitude Jetting Specifications _ KDX and KLX Models and 59437 3712 6L right The 1998 model sponsons are black 59437 3711 6Z left and 59437 3712 6Z right They may not eliminate all signs of porpoising but they will function to dampen the boat s tenden cy to porpoise The steer ing will also become crisper without negatively affecting other characteris tics of the boat Watercraft Tuner s Tip by John Griffin Instructional Designer Instructor I recently dropped a small bolt into the hull of a watercraft After a
17. on These washers are spring seats for the inner springs on the intake and exhaust valves They are included in the kit because some of the VN1500 s covered by the bulletin came from the factory with single valve springs on six of eight Inner Valve Spring Seat eee valves The front cylinder had no spring seat for an exhaust valves had dual inner spring springs Of course the The confusion occurs valves that had single because some units cov springs from the factory ered by the bulletin came from the factory with dual springs on all the valves These units already have all the spring seats and don t need the six that are included in the kit This fact is not mentioned in the service bulletin so some dealers are left won dering if they are sup posed to use double spring seats on some of the valves No you are not If you run across one of the units that already has all the spring seats it needs just leave out the six that came with the kit WINTER 1997 0 K TECH NEws lt D ZX 9R Information Worth Special Attention by Gregg Thompson Product Support Supervisor Inthe new ZX 9R ZX900 C1 engine oil is delivered to the top end through the 5 far right main bearing There is a passage cast into the cases that carries the oil around the 5 main bearing shell and up through the upper case half to the top end There is a similar oil pas sage cast into the cases at each of the other m
18. ptional springs for both gressive springs even the smallest bumps some getting used to the forks and shocks Here Kawasaki has recog and let the bike settle When you realize that the is a table that provides all nized the need for plusher more in the corners pro bike is extremely plush the pertinent information initial suspension while viding a lower center of but still resists bottoming for all the springs still maintaining the bot mingresistnceofeai Locating Electrical Components er KX s In the past bot toming resistance was by Gregg Thompson controlled with oil and the Product Support Supervisor use of relatively stiff springs The stiff springs Have you ever spent more that have become com time than you wanted when mon in our industry have attempting to find an electrical a couple of drawbacks component on a bike If so it s that have also become probably because you didn t common The stiff spring know that there is a pretty nice that resists bottoming also electrical parts locator section in most of our newer service manuals produces a harsh ride Since about 1988 Kawasaki service manuals have come with this handy feature over small bumps The along with the exploded view drawing of the electrics and other general informa tion in the first few pages of the Electrical System Chapter Check it out Making use of this feature could save you quite a bit of time in the long run rider feels
19. rse using the A amp P Check List every time you deliver a new unit to a retail customer is part of your dealer sales and service agreement but it goes beyond that The A amp P process may involve several employ ees in ditferent parts of the store The check list helps track what s been done and what still needs to be done for a new unit Your customers know they are getting a unit properly set up and ready to go when they see the check list Signing the check list gives you a record that the unit was received by the retail customer in good condition and ready to Let the Good Times Roll WINTER 1997 6 K TECH NEws Adding Sponsons for a Smoother Ride JH900 Porpoising by Don Church Manager Service Training and Communications All personal watercraft porpoise to some extent Excessive porpoising seems to affect some per sonal watercraft and not others Differing water conditions usage styles and rider perceptions also change the way each boat is affected If you have a customer complaint involving excessive por poising on a JH900 you may want to consider changing the sponsons Just in case you haven t realized this important piece of information sponsons on personal watercraft have a signifi cant effect on a boat s han dling characteristics Sponsons affect turning bite tracking and that rhythmic rising and falling of the bow other wise known as porpois ing And t
20. rt to loosen the locking agent before using an air tool Use the proper six point impact sockets for a good grip Do not use worn sockets that fit the hardware loosely Do not tighten hard ware with an air wrench Hand tighten all hardware and use a torque wrench when applicable Always use proper safe ty equipment Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 908 469 1221 ATLANTA DALLAS Effective sales strategies can increase a dealership s success Hattiesburg Kawasaki is the Ichiban Dealer for ATVs in the East Region Larry Myatt the owner has been a Kawasaki deal er for 12 years Below he shares his guidelines for selling Kawasaki ATVs 1 Availability of the prod uct Units are delivered by Kawasaki on a timely basis This allows the dealer to plan ahead and advertise the prod uct 2 Kawasaki sales grams Financing programs through HRSI have been a big reason for pro selling 3 Salesmen Kawasakis Retail bonuses from Kawasaki for reaching sales goals is always a good reason for selling Kawasakis knowledge Explaining the features and believing in the product goes a long way in selling If the salesman knows the product and can explain the benefits he can sell the unit 4 Demo rides Usually if you can get the customer to ride the unit you can close the deal We keep units available to ride and encourage the customer to take a test ri
21. ses a small step in the shaft and a separate collar 92143 1721 to do the same job If you install the new style output shaft in an old transmission without this collar second gear on the output shaft will be pulled over against the cases and bind up the transmission when the sprocket nut is tightened Of course you would also need the new style sprocket nut and washer if you convert to the new style output shaft The old style sprocket will work fine on the new style shaft COLLAR 92143 1721 6 Bet ee NUT amp LOCK WASHER WINTER 1997 8 K TECH NEWS gt KX Suspension Progressive Springs by Craig Martin Technical Support Technician 1998 KAWASAKI 125 250 SPRING CHART For 1998 Kawasaki BIKE SIZE APPLICATION OPTION SPRINGRATE COLORCODE PARTNUMBER SPRINGCOLOR _ KX125 and KX250 motor Waz FORK LiGHT a NA aon686 A _kxi25 FORK SD 34a OOOO ONA O 4o20 O O NA cycles feature dual rate BC HW 042 T S E E O A progressive fork springs OKKI SHOCK LIGHT asaras VEUOW oain VIOLET KX125 4 SHOCK STD 4 6 4 915 1 WHITE 92145 111345 VIOLET and triple rate progressive KX125 SHOCK HWY 485 153 CRED o 92145 111445 0 VOET shock springs You might Ka FORK Gh e OOo NA 4402614668 M RRS KX250 FORK STD 4 43
22. sor Technical Writing The Service Specifications Handbooks are a terrific resource for the working technician The books list the most needed and most fre quently used specifica tions for working on motorcycles ATVs and JET SKI watercraft The motorcycle and ATV book for 1996 1997 is part num ber 99926 1028 01 The watercraft book covering the last two years is part number 99926 1029 01 Order these books from your Kawasaki Parts Distribution Center just like any other part num ber Please check the Parts Retail Price Guide part number 99995 400 02 for the latest dealer cost In years past the Service Spec Handbooks Service Specifications Handbooks for Motorcycle and ATVs Years Covered Part Number O6 OT eo 99926 1028 01 sh E e AE 99926 1026 01 O3 OA enone 99926 1024 01 sy Sk r pemereernee 99926 1022 01 sh h Y EAE 99926 1020 01 90 9 cecsssssscssesess 99926 1018 01 189 QO ceccsssssssesess 99926 1016 01 188 89 eccessessssesess 99926 1014 01 187 88 oeecccccoc0o 99926 1012 01 186 87 seccessessssesess 99926 1011 01 18586 ssssckcdecsvsenc 99926 1010 01 OA BS ossoeescccccooee 99926 1009 01 183 84 ecsessescssesess 99926 1008 01 82 83 seccessessssesess 99926 1007 01 OOD crises 99926 1006 01 i a aiia 99926 1001 01 TTB E 99997 753 Service Specifications Handbooks for JET SKI Watercraft Years Covered Part Number 796 97 seccsssessssesess 99926 1029 01 7QA 95 EA 99926 1027 01 el enero 99
23. ttempting to recover it with my hands screw drivers and compressed air I found a solution I took a tape measure extended it about two feet then bent it in half at a 90 angle and used it to retrieve the bolt that was tucked well under the engine bed The tape mea sure works great because it is flexible and you can alter the length instantly WINTER 1997 7 K TECH NEWs Product Support Dealer Program by Gregg Thompson Product Support Supervisor We are pleased to announce the start of a new program designed to improve our awareness of new product problems and shorten our response time to solving them It s called the Product Support Dealer Program and it was put into opera tion the first week of December 1997 A small number of hand picked dealers will participate in the program and will be asked to pro vide early product infor mation to our Quality Assurance Group through the Technical Hotline These Product Support Dealers were selected based on the product lines they sell sales and service volume geographic loca tion climate and terrain and most of all their ser vice department s reputa tion and rapport with the Kawasaki Technical Hotline They will com municate with the Hotline every week to discuss product problems and potential solutions Our thanks go out to all the dealers participat ing in this program We are confident this program will contribute significant ly to o
24. tury which is right around the ti 8 Timing Ignition Timing A throttle position sensor ties into the ignition allowing a three dimensional timing map The timing now adjusts for rpm and engine load Fuel Cut Valve D Ne Nal SS An electronic solenoid in the float bowl works with the ignition to cut fuel flow with the rev limiter or if the ignition switch is turned off while the engine is still turning over Stainless steel honeycomb coated with platinum and rhodium oxidize carbon monoxides CO and hydrocarbons HC into harmless carbon dioxide CO2 and water H20 corner Currently the EPA standard for automobiles is a minuscule 25 g km HC and several European countries have stringent motorcycle standards CARB is planning tougher motorcycle standards as early as 2001 or 2002 It is possible a manufacturer may decide to produce certain models in just one low emission form for all countries This is the current state of affairs with emissions It is imperative to stay on top of technical changes As always Kawasaki offers technical training incorporating the latest equipment and repair techniques In the next issue we dive deeper into the California Air Resource Board s new rules for off road licensing and riding areas WINTER 1997 l 2 K TECH NEWs
25. ur on going efforts to make Kawasaki prod ucts the best that your customers can buy Cak 1996 KL650 A10 Transmission Change by Randy Davis Quality Assurance Engineer In midproduction of the 1996 KL650 A10 at engine number 32210 to be exact the transmission output shaft was changed The change was made basically to accommodate a new method of output sprocket attachment The old sprocket is attached with an offset spline lock ing plate and two bolts that attach the plate to the sprocket The new sprock et is attached by a nut that threads onto the output shaft with a bendable lock washer As long as you pay attention to the microfiche or KIC engine range information you won t OLD STYLE normally have any prob lem with this The key word there is normally You can get in trouble if you order the old style output shaft and it turns out to be on back order If it is on back order the part number for the old shaft 13128 1175 will substitute to the part number for the new shaft 13128 1203 but the new shaft is not an exact replacement for the old one The new style shaft can be used in the old transmissions KL650 A1 thru early A10 provided you use one other part from the new style trans mission The old output shaft has a shoulder machined 13128 1175 NEW STYLE 13128 1203 into it that locates the shaft against the big out put shaft bearing The new shaft u
26. y service Since 1985 the rules were relaxed a little and valves were scheduled to be adjusted on the second service and then at every other service 6000 miles Other manufacturers start with their first ser vice interval at 600 miles and then slightly higher miles between services than Kawasaki This may cause some confusion with new customers that may have owned other brands in the past and even with your service personnel if you sell other brands Beginning this year and starting with the All New models for 98 Kawasaki will be chang ing over to service inter vals similar to other man ufacturers This is being done to conform to industry standards and to reduce the impact on the customer of increas ingly expensive services The new service inter vals are at 600 4 000 7 900 12 000 15 000 20 000 and 24 000 miles with the first valve adjust ment and carburetor syn chronization at the third service 7 500 mi This means the customer has four required services in the first 12 000 miles including only one valve adjustment and carb 1 8 GENERAL INFORMATION synch The old mainte nance schedule required five services in the first 12 000 miles including 2 valve adjustments and carb synchs So before you give a quote for a tune and ser vice make sure you check either the correct Service Manual for that model or the customer s Owners Manual to know what kind of work is recom mended
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