K-Tech News Vol. 3 No. 2
Contents
1. NEWS Summer 1990 The Kawasaki Technical Magazine Vol 3 No 2 GIT The ene High tech detalis ith all the fanfare and hoopla surrounding the spectacular new ZX 6 and ZX 11 the ZR550 B1 may have rolled into your store almost unnoticed The truth is that behind the ZEPHYR s under stated deep blue paint and clean sweeping lines lies a bike armed to the sprockets with aah features See Page 2 Inside M Service tips galore S H O P TAL K TECHNICAL The ZEPHYR High tech details by Jerry Heil Training Development Coordinator A quick look over before taking the handsome new ZR550 B1 ZEPHYR out for a morning ride reveals a long list of high tech details Eccentric chain ad justers on the swingarm ensure optimal wheel alignment and save time on chain ad justment The Swingarm itself is aluminum made of 75mm x 30mm box section extru sions and it boasts a grease fitting installed just in front of the tire to speed maintenance Rear wheel travel is a generous 4 5 in Piggyback style reservoir shocks give the bike a tradi tional look and make it easy to adjust spring preload by turning the cam collars The nitrogen gas charged shock absorbers have four way adjustable rebound and compression damp ing the rider can select the damping that best suits the road and load conditions The rear brake has a dual piston caliper and the 230mm disc has an effec tive diameter of 217mm2. U S A Technical Training Department P O Box 25252 santa Ana CA 92799 5252 Dealer cost is 2 99 plus 1 95 shipping and hand ling per order plus applicable sales taxes for California dealers You may send a check with your order or we can charge your parts account O The Technical Magazine 3 EETECH NEWS Summer 1990 Vol 3 No 2 1990 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 Regional Editors North and East Fred DeHart Central and South Walter Rainwater West and Corporate Patrick Kelly Contributors Jerry Heil Mike Jeffers Tevis Moffett Kenny Osberg Keith Pestotnik Sharon Reynolds Ray St John Bill Zito Graphics Production Graphic Art Gregg Thompson Copy Editor Pat Shibata Production Nickless Communications Published by Kawasaki All suggestions become the property of KMC Sending a service suggestion gives Kawasaki permission to publish and or use it without further consideration Specifications subject to change without notice 4 K Tech News GUEST S P O T Not just another pretty place by Tevis Moffett Product Support Specialist recently had the oppor unity to attend the annual Open House at Anderson s Cycle World in Bloomfield Hills Mich This event always held on he last S
3. called TC WII Although NMMA formerly BIA TC W oils are still on the market they will gradually be re placed by TC WII oils By 1994 licenses will no longer be granted for the manufac ture and sale of TC W oil Two of the new tests for the TC WII certification are in the areas of en durance testing and oil in jection system testing In the former the candidate oil is mixed with fuel at a 100 1 ratio In the original TC W certification a 50 1 gas oil mix was used In the oil injection phase of the procedure oils are tested to be sure they don t react to moisture or other types of oil by gell ing and thus blocking fuel injection lines Gregg Thompson a Is it oil pressure or is it fuel leval On both the ZX 11 and ZX 6 the oil pressure and fuel level warning systems are tied together When oil pressure is low the oil pressure sensor grounds both the oil warning light and the fuel level warning circuit relay Consequent ly any time the oil light comes on the fuel light also comes on The reason for this is to provide a test mode for the fuel warning system When the ignition switch is EN450 EX500 oil pressure If you ever run into a stub born oil pressure light one that won t go out on an EN450 or EX500 during the pre delivery ser vice or after rebuilding the engine there probably is no oil flow in the engine at all Apparently either the pump loses its prime or an airl
4. Andy Jr right is the current owner Micro E lt CONTINUED FROM PAGE 3 E A new microfiche that should be benefi cial to all of you is the Watercraft Service Bulletin microfiche P N 99961 0312 This includes all service bulletins from 1975 through 1989 and it will be updated yearly The service bulletin microfiche has been categorized into model segments such as JS300 A B JS400 440 A JS550 A B JF650 A B JS650 A and so forth The bulletins are listed in chronological order within each section This microfiche is a handy tool for cross checking past and present warranty work The individual service bulletins will still appear on Row N of the affected model microfiche WE When ordering painted parts on motor cycle microfiche please remember that the colors indicated in the part description do not necessarily describe the colors of the part itself but rather the overall paint scheme of the vehicle As you know many models have two or more color schemes so when ordering a fender for example keep in mind the primary colors of the vehicle If you re unsure of the color description check the Specification grids on Row A or the Title page WE As always would appreciate any sug gestions or inquiries from you You can reach this department by phone 714 770 0400 ext 2573 or you can fill out the Micro K report card P N M99995 152 O C Oe O ee os Oe F getting touring groups and local charities invo
5. Front brakes are 300mm discs of the semi floating type and have an effective diameter of 272mm Front calipers are dual piston type Both front and rear calipers use sintered 2 K Tech News bronze type rectangular brake pads though the parts are not interchange able from front to rear These brakes coupled to a 394 lb dry weight give the ZEPHYR truly im pressive stopping perfor mance Stout 39mm front fork tubes with 3mm wall thick ness support the front suspension Rake is 27 degrees and trail is 4 1 in ches Front wheel travel is 5 5 inches The frame is built from high tensile steel tubes with a 1 6mm wall thickness The ZEPHYR is 40mm longer than the GPz models with a wheelbase of 1440mm While throwing a leg over the ZEPHYR you will notice many more details The custom looking tex tured seat is wide comfort able and very low at just 30 3 inches off the ground The superbike style tubular handlebars pro vide a sporty but comfort able riding position The brake lever is four way ad justable and the clutch lever is five way adjus table to fit any size hand Push to cancel turn sig nals are a handy addition Dual trip odometers can be used to keep track of the distance from the last fuel stop and total trip mileage A quiet but healthy ex haust note comes from the four into one pipe Dual overhead cams bor rowed from the KZ550 H model open the single in take and exhau
6. The dealer is completely booked for three weeks or has suggested it doesn t look serious Try riding another 300 miles While we understand that summer is a very busy season for you we ask that you put yourself in the customer s shoes How would you feel if you were stranded and couldn t find anyone to help Any time someone at a Kawasaki dealership exerts extra effort aiding a stranded traveler everyone profits The customer goes on with his vacation confi dent again in both Kawasaki equipment and our dealer network and you can bet he won t hesitate to tell his friends about the experience As you know happy customers can be our best advertisers and it is much less costly to maintain a current customer than to develop a new one We do hope everyone has a great summer and that all your vacation plans go smoothly Sharon Reynolds Consumer Services The Technical Magazine 5 TIPS FROM T H S a O T O S S ES 650 J ET SKI engine lower end repair by Keith Pestotnik Rocky Mountain Kawasaki n the torn down 650cc JET SKI engine on your workbench in front of you you may find that some fretting has taken place in the main bearing bores of the crankcases The amount of fretting varies but usually is not bad E J F650 B 1 2 engine cover hook Inthe past the JF650 B1 and B2 engine cover hook was available only as an assembly Unfortunately the hook assembly is ex pensive and the
7. then keep an eye out for the October training schedule which will ar rive in plenty of time for you to reserve your place in class We look forward to seeing you then O SOUTH amp CENTRAL CONTINUED FROM PAGE 12 of informing customers what conditions need attention The checklist shown at right is a two part form you keep a copy and give the original to the customer You might have noticed the drive chain and sprockets were worn for instance but the customer chose not to have them replaced at the present time With the addi tional hard mileage these parts will accumulate during the summer they will surely need to be replaced in the fall Note this on the checklist and contact the customer later about replacement There are many repairs and services that fall under the heading of ultimately necessary but not urgent or preventative maintenance tire replacement fork oil change brake fluid change or maybe a new stainless Steel jet pump impeller A good service manager will con tact customers about service work during the winter By taking the time to make detailed notes on the checklist now you won t miss a potential winter customer Try to be complete Sometimes when you write down just a couple of words you forget what the original idea was With detailed notes you ll know exactly what you discussed with the customer timeters 300cc would 4 be the displacement of one cylinder in a 1200cc four cylinder eng
8. time or money saving service tip to share Send it to Editor K TECH NEWS Kawasaki Motors Corp U S A 9950 Jeronimo Irvine CA 92718 10 K Tech News Occasionally a KLF300 C 4x4 customer will report a sticking shift pedal the shift shaft does not return to the centered position after up or down shifting he notes If it doesn t return to the centered posi tion of course the clutch will stay disengaged and not transmit any power to the drive train This problem may be caused by sharp edges on one side of the shift shaft pawl and the secondary clutch cam release plate These parts are stamped from steel plate which leaves a sharp edge on one side of the part Some times this edge can cause excessive friction when the part is sliding against another causing it to stick The simple solution is to put a small radius on that sharp edge where needed Using a small RADIUS 4 I S T S grinder or file remove just enough material to radius the edge and no more The smoother those edges are the better they work Do not change the shape of the piece The illustration shows the CAM O O SHARE RELEASE INDICATED SHIFT SHAFT PAWL edges that may need at O tention Keith Pestotnik KAF450 B Mule kit If you have a KAF450 B MULE 1000 transmission apart to install the kit P N 99995 1193 see Mule 1000 Transmission Im provements in the Winter 89 issue of K Tech
9. whole thing had to be ordered lG just to replace a lost circlip or hinge pin Because of this Kawasaki has recently made the hinge pin washer and circlip E type available separately Gregg Thompson Note The part numbers are as follows Hinge Pin 92043 3728 E Clip 92033 3719 Washer 410S0800 6 e K Tech News enough to affect perfor mance until the engine is disassembled Then on reassembly it is virtually impossible to match up the fretting pattern be tween the main bearings and center seal and the crankcase halves To save the crankshaft and cases you must remove the high spots from the main bearings center seal and crankcase bores Try the following procedure 1 Clean the crankcase parting line then reas semble using the two dowels and all bolts Leave out the crankshaft and seals Properly torque the crankcase halves 2 Using a good quality rigid cylinder hone oil the bearing bores and the stones insert the hone into the bearing bores and rotate the hone only by hand Apply as much stone pressure as pos sible but do not drive the hone with a drill You do not want to clean the en tire bore only remove the high spots Go slowly and check your work often 3 Use a worn out 1 2 inch wide mill file to clean the labyrinth seal of the crankshaft Once again remove only the high spots here Do not attempt to clean its en tire surface 4 Remove any alumi
10. News check that all the needle bearing races in the two case halves are seated all the way in their bores If not the dogs on the new gears might clash when the transmission is in neutral Tapping lightly on each of these races will assure they are all the way in Tevis Moffett How to determine compression ratios 3 Fill a graduated burette with solvent or light machine oil 4 With the spark plug hole in a vertical position measure how much liquid it takes to fill the combus tion chamber to the bot tom of the spark plug hole Now you ll need to do some math 5 Add the amount of solvent you poured into the cylinder in milliliters for example 35ml to the displacement of the cylinder in cubic cen Whether you are building a drag bike or blueprinting a Classic you need to know how to determine the actual compression ratio of each cylinder Here s how to go about it 1 With the piston at Top Dead Center TDC smear a little grease around the edge of the crown to seal the piston and cylinder 2 Install the cylinder head gasket and cylinder head with valves in place Torque the head to specs WEST CONTINUED FROM PAGE 12 to help you get your skills up to speed Of course we know you are too busy to attend training classes now but our training season begins again in October In the meantime keep track of those areas in which you would like to improve your skills and
11. aturday in February has been a tradi ion for over 40 years in he southeastern Michigan own Motorcycle en thusiasts in the area have come to not only expect it but look forward to it left thinking we could all learn something from his very special promo tional event and how Anderson s Cycle World is operated To attract potential new customers Anderson s of fers refreshments and door prizes throughout the Jay of the Open House At the end of the day two Grand Prizes are given away Winners need not be present but to be eligible for these and other door prizes customers fill out a form with information about themselves These forms are used to develop a mailing list for future sales events and promo tions The door prizes and refreshments meanwhile add to the festive atmos phere while encouraging on the spot sales A real crowd pleasing part of the event is indoor short track racing Anyone with a valid motorcycle driver s license can race Andy Anderson Sr center started the business in but he must supply his own helmet and boots Long pants and shirts are also required but there s no problem finding them during winter in Michigan The open house is held in February to give poten tial customers an early first look at the new years products Anderson s advertises on local TV and radio stations as well as in newspapers Word is further spread by i 1942
12. cal skills and knowledge up to the chal lenge or do you find your self spending more than your fair share of time troubleshooting and repair ing each job lf the answer to that last question is yes then you should consider technical raining from Kawasaki We offer a wide variety of classes covering every thing from JET SKI watercraft to generators CONTINUED ON PAGE 11 12 e K TechNews SOUTH amp CENTRAL Service busy You bet by Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 By the time you read this you will be in the busiest part of the season Your service department will be full to bursting with your customer s motorcycles and watercraft in for repairs or service And of course all your customers will be anxious to get their bikes and boats back quickly so they can ride Many want only the ab solutely necessary repairs performed now This then is the time to make sure your service records are complete and accurate and your follow up system n place so you can con tact the customer about additional service work later Don t forget about the Visual Inspection Check list P N 99995 769 which is available from Kawasaki specifically for the purpose CONTINUED ON PAGE 11 Training Schedule East Region North Region Central Region South Region West Region KMC Instructors are working now on the 1991 Program schedule Classes will begin agai
13. ce manager there for 11 years told me their employee turnover is very low He attributes this to the way Andy treats his employees According to Chuck Andy works hard to make all his employees feel as though they belong and does what he can to help them solve problems as they arise was reminded that no matter how large or small a business is it will al ways benefit from an owner who treats his employees with fairness and genuine concern And along with several hundred past present and future customers had a wonderful chance to ex perience the result first hand at Anderson s very successful winter Open House O Pe enna neem n ee EEA Chee ee gt p Ene Be nice to travelers many or us toil 50 weeks a year anticipating those two weeks we are free to relax and get away on vaca tion So do our customers For many of them vaca tion time has finally arrived We all know how wonderful it is when our vacations work out just as planned and travels are both worry and trouble free But sometimes vacations do not go so smoothly Consider the plight of a customer who experiences a mechanical failure while on vacation He may wind up stuck in a strange city possibly far from home in need of a Kawasaki dealer s service The success of this particular vacation is suddenly put in the dealer s hands Unfortunately Consumer Services receives more than a few desperate calls from stranded travelers
14. ine 6 Divide the sum of the two numbers 335 in our example by the amount of sol AEBRLUARRSVERSEULAASURRERURLALUERR EULESS The result is the compres sion ratio of that cylinderin our example as outlined below the ratio is 9 57 to 1 Step 5 35ml 300cc 335 Step 6 335 35 9 57 Result CR 9 57 1 Easy even if you arent a mathematician pei yX Steve Rice into the cylinder Q 35ml V1 V2 a SCA V1 Your cus EE Visual Inspection Checkilat f Kawasaki tomers will owen vevos really ap a ume preciate the DAYTIME PHONE ____ off season oleae pean red gem been ph onasiga hji o reminder e e amemon L Se _ regular use mee ao Ooo of this ra S i fran Sige E checklist _ will help a as cep your ge te service ee department anette O O Sse o busyall P ce Ms eget year round Ca ee a er ea Hranemiedeg Thank you for letting us service your vehicte a Service D The Technical Magazine 11 REGIONA L NEWS WEST Up to your elbows now by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 As this issue of K Tech News reaches you you are probably up to your elbows in grease The phone is ringing off the hook and the work orders are stacking up The sounds of air tools spin ning and engines running fill the air The service season is at its peak But are you keeping up with the pace Are your techni
15. lved Kawasaki Team Green off road rider Larry Roeseler and dirt track road racing star Bubba Shobert were on hand this year to talk motorcycles and sign autographs In spite of a Surprise snow storm turn out was im pressive and 160 vehicles were sold Not bad for one day in February in the mid dle of a snow storm Anderson s also has two smaller open houses Anderson s provides the motorcycles for the other courses the rider brings his own All students must bring their own helmets and dress properly Owner Andy Anderson under stands that promoting rider safety is not only good for the individual rider but also the motor cycle industry in general came back from my visit with the impression that the employees at Anderson s are like one big family And big is the Indoor short track races heip entertain the crowd at appropriate times during the year One focuses on watercraft and the other on ATVs Special events and programs are always scheduled to promote customer aware ness and interest in whatever product line the open house is intended to spotlight This year Anderson s Cycle World has begun of fering rider training programs There are three different courses Riding and Street Skills Ex perienced Rider Course and Performance Based For the basic course Riding and Street Skills correct word At peak times of the year Anderson s has about 100 employees Chuck Heil servi
16. n in October All dealers will receive a copy of the winter class schedule but don t forget to watch this space in the Fall and Winter issues of k Tech News NORTH amp EAST Diagnostic tools by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 With service work begin ning to pile up at the door your Service Department IS going to need all the help it can get this summer Here is a list of what consider the basic diag nostic tools a dealership s Service Department should have How many does your Service Depart ment have available LiVacuum pressure tester OLeakdown tester O Compression gauge OOil pressure gauge OTiming light OCoil tester O Multimeter C1CDI tester OCarb sticks or vacuum gauge set O Fuel level gauges O Dial bore gauge O Dial indicator and stand LIFull set of micrometers O Torque wrench O Air pressure gauge O Feeler gauges O Plastigage Some of you may believe that many of these tools are useful only for making adjustments But all of the tools listed can also help you diagnose problems as well Take a timing light for example This is one of the only tools that will indi cate whether the electronic advance is working properly It can also show whether or not a spark plug is firing in side the cylinder under compression Give some thought to the other tools listed and see how many ways you can think of to use them for diagnostic pu
17. num transferred to the main bearings using a similar technique again grind carefully 5 Tho roughly clean and prepare all the parts for final assembly 6 Clean and dry the crankcase bear ing bores the outer diameter of the main bear ings and the crankshaft labyrinth seal using Kawasaki Contact Cleaner P N K61080 001C 7 Apply a thin pink smear of LOCTITE Stud and Bearing Mount red P N K61079 002 to the bearing bore of both crankcase halves Use it sparingly Less is better than more 8 Continue with reas sembly following proce dures outlined in the Service Manual Do not vary on torque values or patterns O HINT Mounting the crank shaft in red LOCTITE on a new engine will prevent fretting in the future Water spots ls your otherwise shiny new JET SKI watercraft suffering from water spot discoloration The prob lem is probably mineral deposits in the water left to dry on the boat You can clean the decals with a hard water spot remover bathroom cleaner Lime Away and Shower Power are two brands that work well Kenny Osberg SH OP ie oe All 650 J ET SKI cylinders are not alike by Gregg Thompson Sr Product Support Specialist There have been some changes made in JS and JF650 cylinders over the years resulting in a list of several part numbers for what seem to be nearly identical parts Some changes were simply refinements for prod
18. ock occurs between the pump and the filter and no oil flows This con dition can usually be cor rected by taking the oil filter off and the spark plugs out and cranking the engine over until oil Starts to flow from the filter mounting plate This problem could result in a delayed failure of the balancer bearings after several hundred miles The first symptom of balancer bearing failure is usually oil leaking from the water pump drain hole The oil seal leaks because the worn bearings allow excessive radial move ment in the balancer shaft Tevis Moffett FROM T H turned on before the en gine is started there is no oil pressure so the oil light and fuel warning circuit relay are both turned on by the oil pressure send ing unit If the fuel level warning system is function ing properly the fuel lights will come on A diode between the oil pressure and fuel level warning circuits prevents the fuel level warning sys tem from turning on the oil SPECIALISTS V customers NEN know that if their fuel and oil warning lights come on together while the engine your lem is oil pressure light It wouldn t hurt to let is running the real prob Gregg Thompson Police Motocycles To cool or not too cool by Bill Zito National Police Motorcycle Coordinator In my travels around the country some of the most often asked questions are about installing aftermarket oil coolers on police moto
19. problem When perform O ing this test you can visual ly inspect this inlet fitting to make sure it is LINE FROM CARB LINE TO PUMP 023 RESTRICTOR Installed properly Keith 1 QT OIL Pestotnik BOTTLE The Technical Magazine 7 TIPS FROM T H SPECIALIST ES Which J ET SKI oil should I use You may have noticed that Kawasaki s Fall Winter Accessories Catalog shows two Marine Product Oils The Marine Product Engine Oil is the same as the original JET SKI TC W Oil the Marine Product High Per formance Oil is the new NMMA certified TC WII oil see the separate Tips item This new classifica tion tests oils to be sure they flow smoothly under conditions typical of oil in jection systems where oils are likely to sit for a long period and be subjected to heat and moisture JET SKI Oil or Marine Product Engine Oil as it is now called has proven to be a superior quality oil and also functions well in oil injection systems It is still highly recommended by Kawasaki for all JET SKI watercraft But if the customer must use a dif ferent brand of oil Kawasaki owner s manuals recommend that a TC WII oil be used to guard against the use of an inferior TC W oil since there is a wide range of quality of TC W oils another reason why the TC WII classification was developed Within the next few years TC W oils will be replaced completely by TC WII oils The High Performance Oil i
20. r needed The suspen sion engine and chassis work well together on all types of roads O COMMUNICATIONS Updated The J ET SKI Watercraft Training Manual by Ray St John Supervisor Technical Writing The JET SKI Watercraft Training Manual updated recently to include the JS650SX JB650 JET MATE and other p 89 models is now avail able to all Kawasaki dealers This new book used in Kawa saki s Technical Training classes explains how all the systems of i Kawasaki s water craft work including the jet pump the carburetor the fuel vent check valve the stop switch relay cir cuit and many others The manual is 48 pages long and includes many detailed drawings and diagrams This manual is not a substitute for your at tendance at the training classes of course but is nonetheless a valuable resource Order Part Num ber 99929 1033 02 Dealer cost as of this printing is still only 4 17 Micro by Micro Mike Jeffers Parts Publications Specialist the Parts Retail Price Guide for the latest pricing information WE Copies of the Service Specifications Handbook covering all JET SKI watercraft from 1974 through 1988 are still available Meanwhile we ve added a new one covering 88 and 89 models Information on Well it s summertime again Your parts and service counters are crowded with customers wanting things yesterday The last thing you need
21. rcycles Kawasaki Motors Corp U S A does not recommend the installation of oil coolers on our police motorcycles Police motorcycles encounter high engine temperatures only while being operated at very low speeds such as in a parade In order for an oil cooler to be effective it must have sufficient air flow through it and at low vehicle speeds there is simply not enough air flow to significantly lower the oil temperature some oil coolers can even create problems under these conditions because of the police motorcycle engine s low pressure lubrication system Under nor mal conditions with the engine warm the system produces about 3psi at 3 000rom The addition of the oil cooler radiator lines and fittings can result in much lower pressures In some oases the added restriction can result in no oil delivered to the top end below 3 000rpm Kawasaki recommends an oil and filter change after the vehicle has been operated in a manner which would create very high engine temperatures If the vehicle is being operated in high ambient temperatures above 90 F you may want to shorten the interval between oil chan ges And always use a high quality 20W 50 oil that specifies it is for motorcycle four stroke engines The distinction is important Motorcycle four stroke engine oils are formulated for high temperatures but they re also designed to lubricate the transmission without breaking down The high loads and wiping action of the transmi
22. rposes In future issues we will dis cuss some of these tools and their uses O
23. s recommended for customers who have modified their boats or ride aggressively It provides extra protection in severe use conditions Don Church 8 K Tech News K TECH extra Metric conversion chart When measuring parts and figuring clearance it is always a good idea to use metric precision measuring tools if possible This eliminates the need for mathematical con version It s faster and there s little possibility of error There are times however when a technician will need to convert from metric to U S specifications or vice versa In this and following issues of K Tech News we will include an insert with one or more handy conversion charts printed on it We suggest you make copies of these for each of your service personnel and post or file the originals somewhere in your shop for easy reference Fred DeHart e TC W vs TC WII What s the difference Recently the Boating In dustry Association BIA joined with several other marine industry organiza tions to form the National Marine Manufacturers As sociation NMMA At the same time it was decided to develop a new test pro cedure for certifying marine two stroke oils In so doing the NMMA chose new engines to be used for certification test ing which in turn required some changes be made to the test procedures Addi tional changes were made in order to improve the quality of the oils that were certified The new certification is
24. ssion gears result in shear damage to the polymers in the oil The polymers are what allow the oil to maintain high viscosities at high temperatures Motorcycle oils are formulated to resist this molecular shear and thus retain their lubrication qualities in a motor cycle engine longer than other oils Tell your police motorcycle customers that KMC recommends they save them selves the inconvenience and expense of installing oil coolers and just to change the oil more often under extreme conditions Then sell them a quality motorcycle oil O The Technical Magazine 9 T IPS F ROM T H E SVP EC ee E 4 x 4 sticky shift pedal Golf tees and battery plugs Did you ever pull off a two stroke oil line or a fuel tank gas line and then wonder what to do with the oil or gas that was sud denly flowing all over your work area You probably grabbed the first bolt or screw that would plug the line and forced it in But here are two better ideas First golf tees work surprisingly well for plug ging oil lines and most small fuel lines Keep a few in your tool box at all times Second those red packaging plugs that come out of the battery vents can be used to cover the pipe protruding from most oil tanks and some fuel petcocks Recycle a few of those into your tool box and save time later looking for that bolt you stuck into the oil line because you weren t thinking ahead Fred DeHart Have a
25. st valve in each cylinder The reliable new ZEPHYR uses valves tappets and shims com mon to all the KZ550 en gines Air and oil together cool the four cylinder engine A large capacity oil cooler keeps oil viscosity uniform for strong performance longer engine life and lower hydrocarbon emis sions The carburetors are Keihin CVK30s the GPz model had 26mm carbs and a large capacity air box is used A digital ignition trig gered by a single pulse coil keeps the spark plugs firing with just the right ad vance for the best pos sible performance The advantage of digital igni tion is that a very complex and effective advance curve is possible Maxi mum spark advance angle is 36 degrees with plugs firing 13 degrees BIDC at idle The con struction of the ZEPHYR en gine is similar to the GPz 550 models The cylinder is anadvanced design with in creased cool ing fin density while the cylin der head is hardened using a new heat treatment process Big end rod bear ings are made from ultra tough Kelmet The transmission is a six speed with fifth and sixth gears overdriving the countershaft The fifth gear ratio is 0 961 sixth is a tall 0 851 The result of these en gine and transmission im provements is that the ZEPHYR s engine runs smoother at lower rpm s and pulls strongly through the mid range At highway speeds the engine is ex tremely smooth and no balancer shafts are used o
26. the added material in the water jack et you can drill and tap the bosses and use it on the Tandem Sport O a Lean mean water machine On Kawasaki JET SKI watercraft any leak between the fuel tank and the fuel pump can result in a lean run ning condition that can be tough to diagnose Because the fuel is being drawn rather than pumped through those lines a leak doesn t necessarily result in any visible fuel leakage Instead air leaks into the lines and is pumped to the carburetor causing the lean condition With a test tank and one easy to make special tool you can quickly and easily determine whether a problem is caused by a fuel system air leak The special tool is simply a remote fuel system made from an oil bottle a fuel filter some fuel line and an inline restrictor Disconnect the fuel supply line from the fuel pump which is on the carburetor on 440 and 550A models and the fuel return line from the carburetor Then con nect the lines to the remote tank and run the vehicle in your test tank If the lean running condition has disap peared inspect the boat s fuel system very carefully for air leaks That is almost certainly the cause of the prob lem On JS440 and 550 models that have the fuel pump mounted on the carburetor the fuel inlet fitting is mounted with a single screw on the outside plate of the fuel pump If it is installed off center it can leak air directly into the pump and can trigger the same
27. to deal with is an irate customer who has just received a JET SKI watercraft hull only to find out that it does not include the hardware pads etc Several of the watercraft microfiche have been revised particularly the Hull sections Please check closely and make sure that all the parts required are in cluded when ordering the hull part number Assemblies are indicated with an enclosing box or circle If the parts are not circled they are not part of the assembly and must be ordered separately CONTINUED ON PAGE 4 f tool itis al so a useful new Training Manual check the latest Parts Retail Price Guide before ordering O timing port durations oil capacities carburetor ad justments engine clear ances and pump thrust are but a few of the many speci fications listed in this book Besides being a handy ser vice department a _88 89 Mode ii quick reference guide for providing informa tion to your customers Order Part Number 99926 1015 01 Dealer cost of this new Handbook is 4 17 as of this writ ing Just as with the ZX 11 poster Anew ZX 11 poster is on it s way This ghost view of the ZX1100 C1 is beautifully detailed and will be a real interest grabber in your shop or show room Kawasaki ZX1100 C1 The new poster should be available by the time you read this from Kawasaki s Technical Training Depart ment Call 714 770 0400 Ext 2472 to order or write Kawasaki Motors Corp
28. uct im JS650B Cylinder MATERIAL ADDED provement some were needed for a specific model application The fol lowing is a list of the part numbers and a brief description of the changes and model application 11005 3702 This is the Original 650 cylinder and it fits X 2s and SXs 11005 3705 This part su persedes the above and has an improved cylinder liner design The O D at the top of the liner was in creased from 82 5mm to 86 5mm to reduce the chances of head gasket leakage This part fits all X 2s and SXs 11005 3707 This part is modified for mounting the fuel pump assembly to the cylinder on the TS model which was introduced in 1989 Bosses are added to the outside of the cylinder as well as inside the water jacket so the fuel pump can be bolted directly to it This cylinder can be used on all 650s MOUNTING BOSSES 11005 3708 There are several versions of this part number Depending on when it was manufac tured one of these cylinders may have the Fuel pump mounting bos ses and the added material inside the water jacket or the mounting bosses outside but no added material inside the water jacket or no mount ing bosses and no added material inside the water jacket The 3708 cylinder will bolt up to all 650 models including the JET MATE except the TS However if you happen to get your hands on the ver sion with both the mount ing bosses and
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