K-Tech News Vol.2 No.3
Contents
1. dealership every month If you haven t seen the training schedule yet please make sure the bulletins are reaching your shop look forward to talking with you at a training class soon Be sure to sign up early to insure a place in the class of your choice Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 7227 pian To Attend by Jerry Heilm West Region ITH sum mer com ing to a close it s time to make plans to attend some of this year s Service Training clas ses Think of the areas you and your service personnel could improve upon Select from the schedule those classes you want to attend And call the West Region Training Center as soon as possible so we can reserve a spot for you in the next available class Jerry Heil 9950 Jeronimo Road Irvine CA 92718 714 770 0400 Call F or Mor e by Walter Rainwater South amp Central AWASAKI s Technical Training depart ment has incor porated new technical infor mation on the 1990 models in to the service training classes The new sched ule lists a course description and the dates of the classes offered in each of the five training regions You make the selection from over 16 classes on the schedule We list two months of training dates for each region This flexibility allows you to plan ahead so your service personnel 12 K Tech News can get the specific training they need If you h2. m Remove the tie rod assemblies with the ball joints by removing the cotter pin and mount gs ing nut from each ball joint m Place each tie rod and ball joint assem bly on a large piece of paper Mark the center of each ball joint and make a cor responding mark on the paper to record the original length of the right and left tie rod assemblies This will prevent having to make toe in adjustments after installing the new tie rods m Loosen the locknuts and remove the ball joints from the tie rods m Screw the wheel ball joint into the tie rod end closest to the crimp and tighten the ball joint locknut to 2 8 kg m 20 ft lb 27 N m of torque m Screw the ball joint of the steering shaft into the other end of the tie rod by turning clockwise 7 rotations NOTE Steeringshaft ball joints have light colored locknuts m Set the ball joint studs of each tie rod to face opposite directions m Position the tie rod assembly beside the marks that were placed on the paper Screw only the steering shaft ball joint in or out to align with the marks on the paper to obtain the original length m The difference between the original length and the new tie rod length must be within 1 mm m Torque the remaining ball joint locknuts to 2 8 kg m 20 ft lb 27 N m m Install each tie rod assembly with the fully screwed in ball joint connected to the wheel steering knuckle CAUTION If the direction is reversed the two tie rod assemblies will
3. For those of you whose shops do not yet have service customers and repair orders on computer we have a simple solution Since you do have a K SHARE computer you have the capabilities to record S your repair orders on computer Once this is done you can print out reports that will show you some in teresting things One advantage is the customer letters and mailing lists you can generate The software program that allows you to do all this is called PFS First Choice It is avail able from most computer software stores For more information on PFS First Choice software please contact Marge Lakin KMC s K SHARE manager at 714 770 0400 ext 2345 She will give you all the help you ll need to get started on your computer Now What Customers that bought at your dealership returned for periodic maintenance and are on the Good Times Protection Plan form a solid base for a customer follow up mailer So now what do you do What can you put in a service mailer to stimulate customer awareness of your existence during the cold wet months of winter There are two approaches One is to deal with only those cus tomers who are service customers A few ideas Offer winterizing and storage specials Offer discounts on the additional work suggested on the repair orders that was never done Hold an open house for ser vice after renovating or remodeling the service shop During the summer you can have custome
4. for example one gallon of Hi Speed Screw 5 8 5 8 3 4 fuel you move the cursor to the JF650B Lo Speed Screw 11 8 11 8 Fuel Add mode NOTE Every Hi Speed Screw 314 314 time the fuel button is pushed 0 2 ne i gallons is added to the display J5650A A aes lay ee a os Push the fuel button until 1 0 gal lon total shows Move the cursor to the Total Fuel Consumed mode and the added amount is automat ically entered into the computer memory The Fuel Add mode will NOTE The tuning specifications for the 650 models are based on the following standard jet sizes 88 89 JS650 A slow jet 48 only accept up to 2 0 gallons at 1990 JS650 A slow ie 459 one time To add more than 2 0 gal 1989 JB650 A slow jet 55 lons the cursor will have to be 1990 JB650 A slow ie 458 rotated around to the Fuel Add mode again and the remaining amount added Tevis Moffett Troubleshooting Pick Up Coils OME HARD TO FIND symptoms of a bad pick up coil are poor gas mileage or sluggish acceleration To test the pick up coil you should first check the resis tance as indicated in the appropriate service manual The next step is to check the AC voltage output from each pick up coil The trick is to probe the pick up coil connector terminals while the bike is running The read ing you get will be in AC voltage The amount will depend on the model and the rpm the reading at idle should be about 0 5V AC and about 2 0V AC
5. Kawasaki offers a maintenance kit P N M99994 151 and supplies bulbs for all viewers including the older Bell amp Howell MDI viewers A complete list of microfiche viewers and acces sories offered is found on parts bulletin GEN 89 02 Equipment is ordered directly through your distribution center by using the part numbers provided O The Technical Magazine 3 GUEST SPOT Kawasaki Endorses Motorcycle Mechanics Institute by Don Church Manager Service Training amp Communications ET US ALL WELCOME the Motorcycle Mechanics In stitute into the Kawasaki family Kawasaki Motors Corp U S A has endorsed the training program at MMI because it is one of the finest motorcycle does a first rate job of maintaining this supply Its courses prepare students to work in and contribute to the profitability of a dealership while gaining the on the job ex perience it takes to become seasoned journeymen In less than 12 years the Motor cycle Mechanics Institute has grown from a small regional train ing center into the nation s largest technician training schools in the country To enhance MMI s training offerings we are now providing technical information on Kawasaki products which will be incorporated into its classes We all know that the vitality of the motorcycle industry depends on a supply of well trained career oriented students who can fill the demand for entry level technicians The Motorcycle M
6. inter fere with each other when the handlebar is fully turned to the right m Tighten the mounting nut to the specified torque Ball Joint Mounting Nut Torque 4 2 kg m 30 ft lb 41 N m m Install new cotter pins O The Technical Magazine 7 TIPS FROM THE SPECIALISTS JET SKF Watercraft Carb Tuning Chart USE THE FOLLOWING carburetor needle adjustment specifications when tuning 1988 89 and 90 model JET SKI watercraft Voyager Computer Memory UEL CONSUMED MODE Here is the procedure you fol low to set the total fuel consumed number on the Voyager computer MODEL ITEM 1988 1989 1990 Start out with a full tank Tum the JS300A Lo Speed Screw 111 16 1 15 16 1 15 16 T fe ae se aoe tl Hi Speed Screw 3 8 15 16 15 16 ay on the meter console will li Pi the bars showing a full ae JS300B Lo Speed Screw 1 3 4 1 3 4 1 3 4 Next move the cursor to the Total Hi Speed Screw 138 138 138 Fuel Consumed mode on the com JS440A Lo Speed Screw 1 7 8 puter display It will show 6 6 gal Hi Speed Screw 3 4 3 4 3 4 lons in this mode Push the fuel JS550A Lo Speed Screw 11 16 11 16 n a button once and hold it until the Hi Speed Screw 15 16 15 16 n a reading shows 0 0 zero Then the JS550B Lo Speed Screw ssh 11116 total fuel consumed will show in in Hi Speed Screw 15 16 crements of 0 2 until the 6 6 gal A7 re ons ie consumed nE SEE ADDING FUEL DURING A TRIP JF650A Lo Speed Screw 11 8 1 1 8 11 8 To add
7. Spring Height Standard Service Limit On page 8 2 correct the torque marks as shown at right m KDX200 C1 Owner s Service Manual P N 99920 1323 01 On page 9 4 the table of stator coil resistances is correct only if the stator has five leads If the stator has only four leads use the stator resis tance table found on page 9 4 of the KDX200 C2 Owner s Service Manual P N 99920 1371 01 m ZG1000 Concours P N 99924 1065 01 Engine oil capacities should be as follows Totally dry engine oil cooler and lines 3 7 liters Normal oil change with new filter 3 0 liters Normal oil change without new filter 2 7 liters m EX250E F NINJA and EL250A ELIMINATOR P N 99924 1066 01 In these manuals the top and second piston rings are described as being different but they are actually the same Another correction is needed on page 4 22 Just note that the second ring is the same as the first The specifications on page 4 5 are correct O and pull the bottom of the screen towards you The screen will then lift clear of the viewer The lens must also be dusted periodically It can be removed by swiveling the lens hood then lifting it out of its holder After wiping it clean reinstall by aligning the tab on the side of the lens with the matching slot on the holder The microfiche holder itself is cleaned by positioning it to the far right and lifting the upper glass clear To reinstall reverse the procedure
8. The Kawasaki Tec Fall 1989 by Tim Bean Program Developer HE BIGGEST NEWS IN MOTOCROSS this year will be Kawasakis perimeter frame a first in production motocross bike history This innovative frame design has several advantages stronger steering head stronger swingarm pivots better mass centralization and greater overall rigidity Combined with a new swingarm modified to increase rigidity the perimeter frame equipped KX250 H1 exhibits superb stability on rough tracks The mainframe is constructed of lightweight high tensile steel with a bolt on aluminum rear section and an aluminum steering stem to reduce weight The KX250 is fitted with a 41mm Kayaba cartridge fork see Jerry Heil s article on page 2 of this issue The cartridge design gives more constant damping force regardless of stroke speed with the smoothest possible initial compliance The fork features 16 way compression and 16 way rebound damping EE TECH NEWS agazine Vol 2 No 3 sive curve As in 89 the Uni Trak features an unstepped preload adjuster 16 way compres sion damping and 16 way rebound damping An extremely rigid aluminum swingarm of thin wall dual box section construction offers increased rigidity with no weight penalty New recessed one piece chain adjusters locate the rear axle securely Disc brakes are standard front and rear A dual piston front caliper provides excellent stopping power To minimize unsprung weight front a
9. assis ground the other lead to the 16 pin on the control unit harness connector Your reading should show continuity to ground a reading of zero ohms resistance through the set switches Operate the switches and check the continuity With the lever pulled in clutch or brake the resistance should show open i e infinite resistance Be careful not to distort the female ter minals in the connector or you may create a new open circuit problem Randy Davis EX500 Won t Rev OU VE FINISHED the tune up on your customer s EX500 It starts and idles just fine Now it s time for the test ride Helmet on you fire up the bike put it in gear and go Suddenly at 3500rpm a bad hesita tion is present and get ting worse More revs and the hesitation turns into blubbering and an engine that will not rev at all past about 5000rpm Wha s wrong The likely cause is the car FLOAT VENT buretor float vent tube TUBE aiming into the air inlet on the rear of the air box When servicing the air fil ter it is very easy to dis locate this tube Often the tube ends up right at the air box inlet The higher you rev the engine the more vacuum is created at the air inlet This vacuum is actually pulling the air out of the float bowls and starving the engine of fuel Steve Rice Pitch Pins or Links NE METHOD for checking various kinds of chains for wear and stretch is to load the chain and measure its length The length spec
10. at 8 K Tech News 4000rpm Record these AC output specs and compare them to the specs you got from testing good pick ups on identical model bikes On bikes with two pick ups the most critical part of the test is the consistency in readings between the two pick up coils The voltage readings should be within 10 percent of each other If you don t have spark the likelinood of a bad pick up coil is greater than a secon dary coil or igniter failure Tevis Moffett TS Fuel Tap Installation HE FUEL HOSES going to the fuel valve on early TS model watercraft prior to hull 96450 may 0 be mismarked making it possible to install the hoses on the wrong spigot oN of the fuel valve Refer to the following illustration when installing the hoses and don t be confused MAIN Ken Ploeser RESERVE ON q RESERVE Cruise Control Tips HIGH PERCENTAGE of cruise control problems are nothing more than the result of one of the set switches being open All the set switches must be closed in order for the system to set These switches are the front and rear brake lever switches the clutch lever switch and the throttle switch NOTE These lever switches are separate switches unique to the cruise circuits they are not the brake light or clutch ignition interlock switches Test the continuity of the switches with the control unit unplugged and the transmission in high gear Connect one lead of your ohmmeter to ch
11. ather tube and start the engine Any leak will show up right away saving lots of time and frustration Tevis Moffett sages quickly without fabricating block off plates or using inner tube rubber Rubber freeze plugs can be found in most auto parts stores in sizes to fit almost any application Prices are usually under 5 John Pomo m ONE ITEM NOT FOUND in the Vacuum Pressure tool kit P N T96000 001 is the adjustable rubber freeze plug These are used to plug off intake or exhaust pas OCCASIONALLY WE ASK you to take pictures of damage cracks or paint flaws on JET SKI watercraft hulls This works very well if you prepare the surface first so the cracks show clearly on the photo Use charcoal or pencil lead powder to rub over the area then blow off the excess The camera and film should both be high quality If your pictures do not clearly show the problem it will hamper our ability to make a decision and maybe the processing of your claim Gregg Thompson m THE CORRECT tire pressure for the ZX750 H1 front tire is 36 psi and for the rear it is 41 psi Please update your Assembly and Preparation manual P N 99931 1229 01 page 10 to reflect the correct specs Ken Ploeser CONTINUOUS USE of a generator under verylight loading is typical So is the fact that many generators are not maintained properly by the user A generator may lose power or not rev up even though there is no mechanical or electrical failure Often the c
12. ause is a heavy carbon build up in the spark arrestor and combustion chamber First check the spark arrestor for signs of excessive carbon build up at the exhaust outlet Then check the compression If carbon deposits are evident or the compression reading is high a simple decarboning job should cure the problem Bob Ellison m A NEW CYLINDER HEAD is used on the KX125 G1 starting with engine 008802 The new head P N 11001 1308 has a combustion chamber volume of 4 19cc reduced from 4 67cc on the original head The increase in compression will yield increased performance output Be sure the fuel race gas being used is fresh and that the oil mix ratio is according to factory specs Ken Ploeser m A BEEFED UP OIL TANK CAP for the TS watercraft is now available The original cap had a tendency to crack if tightened with excessive force The new part replaces the original one even if you order the old part number The new number is 16115 3709 Refer to service bulletin JS89 04 for warranty claim information Ken Ploeser 10 K TechNews Trickle Charger Timer N TOURING MODELS the clock memory circuit and com puter all drain the battery while the bike is parked Two weeks may be enough time to cause a good but older battery to go dead and new batteries may sulfate from a low current drain on them while the bike is parked for extended periods We all know that a trickle charger is the answer to this prob lem Kawasaki o
13. ave any questions about the content of a class call your local Kawasaki training cen ter for all the information We have five training centers and you are welcome to attend any one you choose The monthly schedule is not the same for all training centers so be sure to check out the schedule listed here And please call to enroll at least five days before the scheduled class date Hope to see you soon Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 a lt T ECHi Kawasaki TRAINING East Region Training Schedule Classes Held In Piscataway N J OCTOBER Motorcycle Electrical Systems Carburetion Fuel Injection JET SKI Watercraft Ninja Engine Family Familiarization V Twin Engine Familiarization 750 Turbo NOVEMBER 21 Service Dept Operations K BOSS 22 Fuel Injection 29 30 ATV Service North Region Training Schedule Classes Held In Grand Rapids Mich NOVEMBER 6 8 JET SKI Watercraft 9 10 ATV Service West Region Training Schedule C asses Held In Irvine Calif OCTOBER 3 Voyager Familiarization 4 Shaft Drive 17 ATV Service 30 Product Update NOVEMBER 7 9 Motorcycle Electrical Systems South Region Training Schedule Classes Held In Atlanta Ga OCTOBER 2 4 JET SKI Watercraft 5 JET SKI High Performance 9 10 Engines 16 High Performance Engines 17 V Twin Engine Familiarization 18 Ninja Engine Family Familiarization 23 26 Motorcycle Electrical Sy
14. ction in the spring Get out your customer service file and send each JET SKI watercraft owner a letter explaining how and why his boat should be winterized Offer a special com manuals and service bulletins if you are not familiar with this procedure m Drain the gas from the tank and leave the cap loose to prevent con densation m Drain the fuel sediment bowl and clean or replace the filter m Start the engine and run it at 15 second intervals allowing five minutes to cool between intervals Do this until all available fuel in the carburetor is used up m Another method is to add Sta Bil fuel stabilizer to the gas before draining and then run it through the engine box has never been flushed out this may be a good opportunity to do it now Replace the resonator m Remove the battery and clean the outside surfaces with a baking soda and water solution Check the battery electrolyte level and refill with distilled water if necessary Fully charge the battery and store it in as cool a location as possible to keep it from losing its charge A fully charged battery will not freeze until 76 Fahrenheit m f the watercraft has grease fit tings for the forward bearing hous ing and pump housing fill them bined storage and winterization package or if you really don t have the space offer winterization only Be sure these jobs are scheduled for a time when your fall work load is slowing down C
15. e Mechanics Institute 2844 West Deer Valley Road Phoenix AZ 85027 602 869 9644 or 800 528 7995 Motorcycle Mechanics Institute 4065 L B McLeod Road Suite A Orlando FL 32811 305 423 1514 800 342 9253 O B E TECH NEWS 1989 Kawasaki Motors Corp U S A KMC All rights reserved Published by Kawasaki All suggestions become the property of KMC Sending a service suggestion gives Kawasaki per mission to publish and or use it without further consideration Specifications sub ject to change without notice 4 K Tech News K TECH NEWS STAFF Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Ken Ploeser REGIONAL EDITORS North and East Fred DeHart Central and South Walter Rainwater West and Corporate Ken Ploeser TECH SUPPORT SPECIALISTS Joe Nowocinski Bob Ellison Randy Davis Tevis Moffett John Porno Ken Osberg Gregg Thompson Steve Rice GRAPHICS AND PRODUCTION Graphic Art 0 2 2 eee eee eee Tim Bean Copy ECON a s e vada eet aed wtes Pat Shibata Production Nickless Communications FEATURE Keeping Satisfied Customers by Ken Ploeser Tech Services HINK OF HOW MANY customers have walked through your dealership in the last 10 months From the hundreds or even thousands of those people surely many left as satisfied paying customers But how
16. echanics Institute motorcycle technician training in stitute With state of the art facil ities in both Phoenix Arizona and Orlando Florida the Institute each year enrolls more than 1 700 men and women who are interested in pursuing careers in the fast paced motorcycle industry To develop a general under standing of today s motorcycles and to qualify for entry level employment as motorcycle tech nicians students at MMI begin their training with a six month Motorcycle Technician Career Pro gram Like all courses at MMI the career program is hands on per mitting students to immediately put their new found skills to work in areas such as carburetion and fuel systems electrical systems trans missions suspensions and trouble shooting The Advanced Career Program meanwhile is a highly intensive three month course which provides students with advanced skills in several areas two stroke perfor mance four stroke performance advanced machine shop ad vanced electrical systems special ized equipment JET SKI water craft and snowmobiles and shop management Look for representatives from MMI at the Dealer Meeting in Miami Beach Florida and find out more about it The Institute has a very organized and active student placement office for matching its students with dealers all over the country For those not at the Dealer Meeting MMI can be contacted by writing or calling E Motorcycl
17. er with the starter to coat the pis ton piston rings and cylinder with oil Replace the spark plugs m Remove the exhaust resonator and pour three ounces of anti freeze into the muffler box to prevent any residual water left in the box from freezing If the water m Wash the water craft inside and out then drain all water from the engine compartment by turning the watercraft on its left side and dry it off m Spray the engine and metal parts with WD 40 or Bel Ray 6 in 1 m Wax the outside of the JET SKI watercraft m Cover and store the boat in a clean dry place with the hood blocked up to provide ventilation and prevent distorting the strap Ready For Fun If proper winterization is ac complished now the JET SKI watercraft will be ready to provide lots of fun and good times for your customer in the spring O TIPS FROM THE SPECIALISTS Finding Those Amps O SAFELY AND accurately measure the charging system s output in amperage you will need to install an ammeter in series at the ground side of the battery But wait If you electric start the engine you will fry your meter unless it measures up to 250 amps So make a jumper cable that connects across your ammeter probes while cranking the engine over Once the engine fires disconnect this jumper wire leaving the ammeter con nected in series with the battery and the ground strap Next rev the engine until the meter indicates a charging a
18. ffers a Yuasa trickle charger in the accessories catalog P N K56019 005 for 12 volt systems The tip is to advise your customer to plug the charger into a lamp timer available at most hardware or home improvement stores Just set the timer to go on daily for three to five hours to avoid prolonged use of the trickle charger Overcharging may even tually weaken the battery Tevis Moffett Consumer Service Tips OMETIMES A PART necessary to fix a unit is on back order You have checked with your local distribution center but the informa tion you have been given isn t satis factory or isn t specific enough for your customers Consumer Ser vices can help in determining back No LOCTITE On Plastics LTHOUGH THE LOCTITE Company recommends that their many types of thread locking agents not be used on any plastics someone occasionally forgets and ends up with a badly damaged plas tic component LOCTITE will at tack and deteriorate any plastics on any Kawasaki product it is known to cause immediate and un repairable cracking crazing and softening of plastic Please think of LOCTITE and plastic the way you do brake fluid and paint keep them away from each other Keith Pestotnik KX Carb Tool O COMPLETELY disassemble the carburetors on KX125 250 and 500 models you will need a special socket available from Snap On tools It is the 1120 Tamper proof Torx bit with a hole in the end to accommodate t
19. he special tamper proof screw head design The aluminum center block in side the float bowl contains the main and pilot jet system This block must be removed and in spected before you dip the carb in cleaner Do not submerge the rub ber O rings in carb cleaner these are not available as replacement parts Fred DeHart order status However if you need to refer customers to us for parts in formation it is essential that you give them the model designation of their product and the correct part number for the part s in question Given the model and parts num bers we in Consumer Services can quickly research the situation and provide the service necessary to help keep your customer satisfied Mary Sola Using ZX750 H1 Special Tools by Ken Ploeser EW SPECIAL TOOLS exclusive to the ZX750 H1 have been developed and are available now These include a fork cylinder holder P N 57001 1297 and a fork piston rod puller P N 57001 1298 The fork cylinder holder is used to remove and install the front fork cylinder using the following procedure P N 57001 1297 FORK CYLINDER HOLDER Remove the cap assembly from each fork tube top then remove the spring and pour out the fork oil Clamp the fork outer tube in a vise but be extremely careful not to damage or distort the tube in any way Put the fork cylinder holder into the inner tube with its square end inward so that it fits into the square rece
20. i car tridge front forks to reduce the amount of air in the fork oil Air mixed with the oil makes damp ing erratic To prevent this oil enters at the bottom of the cartridge only after any air inside has risen to the top of the fork The damping action remains predict able even on the toughest tracks Compression Damping Rebound and compression damping on the inverted forks are both 16 way adjustable Turning the adjustment screws varies the amount of oil bypassing the damp ing valves The suspension can thus be adjusted to suit both rider style and track conditions 2 KTech News The mechanics of compression damping is as follows as the front tire strikes a bump the fork inner tube and attached cartridge are pushed up The size of the cham ber below the cartridge piston decreases and the chamber above the cartridge piston increases Oil passes out of the lower chamber through the check valve on the pis ton and into the upper chamber of e A O C38 Tt KX Inverted Fork Components the cartridge Damping at the check valve is fixed The oil flow rate is progressively damped by the compression washer stack as oil moves out the bottom of the cartridge into the inner tube The amount of oil bypassing the washer stack depends on the setting of the adjustable valve Rebound Damping As for rebound damping when the tire and wheel move down the inner tube and cartridge move awa
21. ification listed in Kawasaki service manuals is the chain length measured from center of pin to center of pin The way you count the pins is the key to obtain ing the correct measurement 20 LINK LENGTH Drive chain pins are counted out starting with the first pin as number one and continuing to the 21st pin Cam chains however are counted out starting with the first pin as number zero The next second pin is thus number one and so on to pin number 20 In either case the chain pitch the distance between pin centers is being measured So 21 pins equals 20 links Ist n 20th 21st MEASURE THIS LENGTH CHAIN LENGTH MEASUREMENT Confused A link is also called a side plate Both terms are com monly used to describe the length of a chain A chain length always has two fewer pins and one less side plate than you count for deter mining its length Where is the missing link It s the master link of course The real challenge is to find the master link on an endless chain Randy Davis The Technical Magazine 9 TIPS FROM THE SPECIALISTS Briefly E OIL LEAKS ARE EASY to locate and pinpoint by using the following tech nique Clean the suspected area thoroughly with a spray washer Then care fully clean the engine surface with lacquer thinner a residue free solvent Let the area dry and spray on a dry powder such as Arid dry spray or Desenex powder Pinch off the crankcase bre
22. kis Limited Warranty Emissions Warranties or Good Timer Protection Plan If you decide to use gasohol be sure to follow these simple cautions ONever use gasohol with an octane rating lower than the minimum octane rating specified by Kawasaki for this product ONever use gasohol containing more than 10 ethanol grain alcohol ONever use gasohol containing more than 5 methanol wood alcohol Gasoline con taining methanol must also be blended with cosolvents and corrosion inhibitors ONever use gasohol for extended periods and never store this product with gasohol in the fuel system OGasoline containing alcohol can cause paint damage Be extra careful not to spill gasohol during refueling MICRO E lt by Micro Mike Jeffers Parts Publications Specialist OST 1990 MODEL MICROFICHE have been delivered and should now be nestled in the ap propriate spots in your immaculately kept microfiche decks The white section Other Products now in cludes JET SKI watercraft JET MATE Mule and Trailer microfiche Your microfiche deck will contain microfiche matching the products you carry To fully capitalize upon the many benefits the microfiche parts system offers periodic maintenance to the equipment is required The interior of the viewer must be dusted and the mirror wiped clear of any ac cumulated dirt at regular intervals Do this by removing the blue screen Hold the tab at the bottom then lift up Clutch
23. many of them soon for got just how helpful you were the last time they stopped in How many liked the service you gave but don t have any special reason to return to the dealership The point Its your job to give them a special reason to return or they may never return at all Follow Up How do you keep customers ex cited about their Kawasakis and coming back regularly to your dealership One way is to keep them informed Remember the old saying out of sight out of mind Well that s exactly what happens when you don t focus your efforts on communicating with customers It s called follow up and the first building blocks in creating an effec tive customer follow up program are your service records Now is the time to gather to gether all records of service trans actions with consumers Retail work and warranty claims reflect a majority of your service customers to date From these repair orders you can pull up a list of all the peri odic maintenance jobs performed Especially important are the first services and subsequent periodic services performed over a period of time for the same customer Also pull up repair orders that reflect work performed for cus tomers on the Good Times Protec tion Plan By categorizing the repair orders you will have groups of customers to contact If your service department is automated the task of pulling up customer records is relatively easy
24. mperage higher than the loads on the system This is called the break even rpm Obviously higher loads require higher rpm to break even Now you can measure the in dividual loads amperage draw on the system To do this simply reverse the connections polarity of your ammeter probes Then with the engine off turn on the stop light horn turn signals and any ac cessories Write down the readings and then add up the total amp draw on the system Police bikes and touring bikes seem to suffer most from excessive loads on the battery Be sure to check for shorts or excessive amp draw from every electrical acces sory since it may be impossible for a charging system to handle exces sive current loads Tevis Moffett 4 x 4 Tie Rod Adjustment by Tim Bean Program Developer O PREVENT INTERFERENCE between tie rod ends when the steering is turned to full lock the repair procedure below should be followed The ball joints that connect to the wheel end of the tie rods must be screwed all the way flush with the end of the tie rod This allows the ball joints at the inner end of the tie rod to be adjusted out further Some KLF300 s have short tie rods which must be replaced Refer to Recall Bulletin MC89 04 The repair procedure described in the bulletin should be followed when adjust ing the steering tie rods on any KLF300 model even if it is not eligible for the recall The procedure is as follows Repair Procedure
25. nd rear brake pistons are made of resin while the rear brake rotor is now made of stainless steel The KX250 bodywork gives the rider plenty of freedom to move comfortably The fuel tank is slimmer and the new side cover number plate mounts flush making the bike even nar rower in the mid section O E INSIDE Happy Customers Inverted Forks and More ROUTE LIST O SERVICE O PARTS O SALES RETURN TO SERVICE SHOP TALK TECHNICAL Inverted Forks On 1990 KX125 250 500 by J Heil Instructional Designer HE INVERTED FORK featured on Kawasaki s latest KX125 250 and 500 models is another signifi cant advance in reducing unsprung weight The steel inner tube of the inverted fork is shorter and smaller in diameter and therefore the whole assembly is lighter than con ventional forks Reduced weight permits the suspension to move more freely responding more quickly to changes in terrain The large diameter aluminum outer tube held in the triple clamps is a thick walled casting This rigid construction gives the inverted fork equipped motor cycles extremely precise steer ing control Component Parts While the appearance of the fork is at first unusual the parts that make up the assembly are nearly the same as conventional forks The accompanying illus tration shows the components that are available as spare parts The new KX cartridge fork started with a design objective similar to other Kawasak
26. riding the bike for 10 minutes Then with no weight on the bike first open the air bleed screw on both forks then close them Watch for additional info on these inverted forks which are standard on 90 KX125s 250s and 500s in the months to come O COMMUNICATIONS Service Manual Corrections On page 5 11 the Clutch Spring Height Measurement table should look like this by Ray St John Senior Technical Writer ENTER THESE CORRECTIONS in your shop s service manuals and be miles ahead of the game m VULCAN 88 SE P N 99924 1078 01 On page 1 8 the torque table for the engine lubrication system should look like this Engine Lubrication System Crankcase Oil Nozzle 2 9 0 30 26 in Ib Oil Pressure Relief Valve 20 2 0 14 5 Oil Pressure Switch 15 1 5 11 0 Engine Drain Plug 20 2 0 DR 4 Oil Filter V8 V 8 13 0 Oil Screen Plug 20 2 0 Oil Pipe Banjo Bolts 12 1 2 104 in Ib ZX 10 P N 99924 1098 01 KLR250 P N 99924 1051 01 and 02 Add the following information to the Fuel Tank section Gasoline and Alcohol Blends Blends of gasoline and alcohol called gasohol can be used on an occasional basis however continued use is not recommended Switch back immediately to gasoline which doer not contain alcohol if you experience any operating irregularities Any deterioration of fuel system components or degradation of performance resulting from the use of gasohol will not be covered by Kawasa
27. rs fill out customer cards for future mailings From these cards you can solicit service work The second approach is to com bine the service customer lists with parts and sales customer lists In this way a tie in can be made to service For example any parts specials or close outs can be of fered with installation KX race kits can be offered through Team Green specials Schedule a spe cial week for KX bike services And what about all those JET SKI watercraft out there Of all the new JET SKI watercraft sold over the spring and summer how many are due for service Offer a special to IISBA members on ac cessories and hop up services Every person who bought a new or used vehicle from your dealer ship should be contacted in some way perhaps with a survey of all customers which will remind them of the good times they have ex perienced with their Kawasaki and let them know you are inviting them to visit the dealership soon Keeping in touch with your cus tomers during the slow times will be the key to a good winter and a great spring selling season O The Technical Magazine 5 SERVICE MERCHANDISING JET SKF Watercraft Winter Service by Fred DeHart Training Instructor North and East Regions OW IS THE TIME for ser vice departments in the North and East to think about JET SKI water craft winterization as a way of generating additional service in come and assuring their customers satisfa
28. ss in the cylinder top While stopping the cylinder from turning with the holder remove the Allen bolt from the tube bottom then remove the cylinder CYLINDER CYLINDER HOLDER THE PISTON ROD PULLER meanwhile is used to bleed the air from the fork oil and to install the cap assembly on the fork tube top The procedure is as follows Hold the outer tube vertically in a vise Again be careful Pour the specified amount of fork oil into the tube Screw the piston rod puller onto the pis ton rod top end P N 57001 1298 FORK PISTON ROD PULLER Slowly move the piston rod up and down with the puller to bleed the air from the fork oil After the air is bled slide the fork spring into the fork tube with the piston rod puller still attached Pull the piston rod up with the puller Remove the puller from the pis ton rod end and install the cap as sembly Tighten the locknut to the specified torque Screw the fork cap into the fork tube and you re finished O FORK PISTON ROD PULLER PISTON ROD The Technical Magazine 11 REGIONAL NEWS Sign Up Now by Fred DeHart m North amp East Regions OU should be aware by now that Service Train ing classes com menced in Oc tober and will 9 continue through May 1990 The training schedule is listed here to remind you to get signed up as soon as possible The Training Bulletins are mailed to your
29. stems 30 Service Dept Operations K BOSS 31 Parts Department Operations NOVEMBER 1 Generators 2 Shaft Drive 6 8 JET SKI Watercraft 9 JET SKI High Performance Engines Motorcycle Electrical Systems
30. ustomer Approval Now that you have contacted all your past customers what should be done to winterize their JET SKI watercraft First poe Ss with a waterproof marine grease m Lube all cables front and rear m Spray WD 40 or Bel Ray 6 in 1 into the magneto housing to prevent rust from condensation m Check the pump housing and impeller for wear or damage and clean out any sand weeds etc This is a good time to do a complete pump bearing inspection and service inspect the boat for any major problems cosmetic technical or especially safety re lated Note the items you feel need attention on the repair order and make sure the customer is aware of all the items you find Next review these with the cus tomer and get proper approval before proceeding with the job Consider taking a photo of the watercraft before work is done to verify its before condition A Winterization Primer Here are the basics of a winterization program m Flush out the cooling and bilge systems Consult the proper 6 K TechNews m Take out the flame arrestor and clean it Spray Bel Ray 6 in 1 or WD 40 down the carburetor bore Inspect the flame arrestor carefully you may want to install a new one m Remove the spark plugs and pour about an ounce of motor oil into each cylinder Don t use too much or you will damage the en gine when it is next started Leav ing the plugs out turn the engine ov
31. y from the piston The size of the chamber above the cartridge piston decreases and the chamber below increases Oil flow is redir ected by the check valve out of the upper chamber through the re bound washer stack The rebound adjuster valve permits some oil to bypass the washers and flow up and out the top of the piston rod Maintenance All forks require the proper oil and springing to tune the suspension to the track and rider the new inverted fork is no exception A suspension set up chart will soon be available from Team Green to help with this Clean fresh oil is essential to proper fork operation Team Green suggests changing the fork oil after every two to three hours of hard riding Fill the fork with oil to a level above the desired height Pump the piston rod and outer tube 10 times each to remove all the air The piston rod should pull up the entire length of its stroke with uniform resistance Jerks or gurgling noises indicate that air remains in the fork Pump a few more times When all the air is removed set the fork oil level according to the service manual NOTE If you need to hold the fork in a vise be sure to grip the fork outer tube gently so you do not distort the aluminum This can happen so be careful Fork Air Pressure The center screw on the fork cap is the rebound damping adjust ment The other screw is the air bleed Proper air pressure is zero Set the pressure by first
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