K-Tech News Vol.11 No.4
Contents
1. 4 Look for air bubbles in the oil lines Dealers often blame this condition on the oil pump but in fact it s usually just that the vehicle was run out of oil The absence of air bubbles in the limes however does n t necessarily mean that it was NOT run out of oil After a top end seizure the engine will usually restart almost immedi ately and go In fact most engines are seized many times before finally get ting bad enough that the customer brings it in for repairs If the customer realized what has hap pened early enough the oil tank can be refilled and the vehicle run long enough to purge the air from the system leaving no trace of the real cause of the seizure Note On models that have the oil line s con nected to the intake manifold all 300s later 650s and early 750s it is normal to see air bubbles in the lines between the oil pump and the manifold Because there is no check valve at the manifold crankcase pressures can push air bubbles backward up the oil lines This does not affect oil flow on these models The oil continues to flow around the air bubbles at the normal rate 9 KVF300 Knocking Noise by Gregg Thompson Product Support Supervisor We have had a few calls from dealers who were experiencing trouble diagnosing a loud knock ing noise from the general area of the engine on Prairie 300 ATVs Usu ally the dealer was con vinced the noise was com ing from the torque co2. hand KLF220 A12 Blown Fuse Tip Recently we learned that later production KLF220 Bayous may blow their fuse due to misrouted wiring on some units At this time we re not sure how many units may be affected so we re giving you advance notice If the fuse blows on a late model 220 check for a melted brown wire near the exhaust pipe inside of the RH frame tube just to the rear of the engine The KLF220 main wire harness has a brown wire and a blue wire that conned to a rear brake lamp switch for some markets Normally these wires are tied to the outside of the RH frame tube On affected units the brown and blue wires may have no wire tie and may be routed inside of the RH frame tube closer to the exhaust pipe Service Bulletin MC98 information 04 which corrected the Standard Service Limit The brown wire has battery voltage when the ignition switch is ON and will piston diameter and pis oe ER blow the fuse if it becomes shorted to ground as in melted to the exhaust pipe ton to cylinder clearance 65 93 65 95 mm 65 78 mm On DC CDI equipped 220s 1996 and later models the engine will stop when specifications of the 7X600 C1 Service Man Histon cylinder the fuse blows Try to remember to check these wires on later units running ciearance ual because Kawasaki 0 05 0 082mm through your shop Keith Pestotnik WINTER 1998 8 K TECH NEWS KIPS Governor Spring A Mini Tune up by Craig Martin Team Green Motocr
3. new air box assembly complete with air filter the snorkel tube and inlet tray and new carburetor Jets Note If you install one of these kits pay close attention to the condition of all the duct conditions between the new air inlet and the air box after assembly Any leaks at these connections will reduce the effectiveness of the kit e KLF400 B ATV Snorkel Kit P N 99995 1350 Qty Description HIMEN a Treu I a somar NETS a lets a e ommal 2 m Jet Needle N2LF Cover Assembly 5 Boots p lease I ln uf mn 92081 1638 Spring Band WINTER 1998 7 K TECH NEWS Special Spark Plugs for the Ultra 1507 by Gregg Thompson Product Support Supervisor Kawasaki s powerful new JH1200 A1 engine subjects the spark plugs to such extreme condi tions that common spark plugs didn t have a good service life Even the toughest plugs com monly used in the motor cycle and watercraft industries today would either loosen over time or suffer a broken ground electrode Engine dam age resulting from either 1998 and 1999 LX 6R Pistons by John Griffin Instructional Designer Instructor The pistons for the 1999 ZX600 G2 are now the only pistons avail able for the 1998 ZX600 G1 If you remember we had a of these spark plug failures could vary widely but there is potential for severe top end damage to occur So the new Kawasaki Ultra 150 watercraft us
4. Information Center are powerful tools that you can use to pro vide the best possible customer service ooo CAPS NUM SERL Top 100 Utility and Top 50 Generator Parts We have clicked on the Top 500 MC ATV Parts 3 then Search for Parts 4 which reveals a complete list of the 500 parts We then clicked on 11004 1121 5 to View Part Information 6 On your own K Share terminal using VSI you could check every customer owned vehicle that comes into your service department for any outstanding Recalls and FDMs Don t let those vehicles out of your shop without that repair campaign completed You can check if the current owner your customer is also the owner of record in Kawasaki s computer You could work on warranty claims or parts orders without having to compete with the parts people for the terminal You could learn to use KIC an ever improving service department tool to its full potential You can lease a K Share terminal from Kawasaki for a minimal monthly fee or for an insignificant one time charge you can load K Share into most any PC you have at your dealership WINTER 1998 6 K TECH NEWS Reprint KLF400 B Snorkel Kit In our Fall 1995 Vol 8 No 3 issue of K Tech News we ran an article about an air inlet snorkel kit for the early KLF400 B Bayou 4X4s This kit P N 99995 350 was a great modification for units that were used in dusty condi tions We highly recommend it for anyone
5. SUTTON COAST CYCLE WORLD anne GULFPORT MS SCOTT ALLEN COAST CYCLE WORLD e GULFPORT MS SCOTT DAILEY anna SPORTS CITY CYCLERY GREAT FALLS MT DUSTY SCHALLER n KAWASAKI OF LAS VEGAS LAS VEGAS NV CHRIS ADAMS nnns BIG 4 KAWASAKI nnn MARIETTA OH GREG BECKER s BIG 4 KAWASAKI MARIETTA OH JAMIE WHITE REHMERT CYCLE SALES VERSAILLES OH BRIAN BERTLER n AJAX KAWASAKI nnns OKLAHOMA CITY OK JIM WESTCOTT nnns AJAX KAWASAKI nnns OKLAHOMA CITY OK KENDELL ROBERTSON AJAX KAWASAKI nnns OKLAHOMA CITY OK JIM TRIBOU nnns WAYNE CYCLE SHOP WAYNESBORO V PAUL CROWE nnns TEAM WINNEBAGOLAND OSHKOSH WI Removing the clutch hub Special Tool Catalog nut on the VN1500 Correction engine Page 17 in the by Rob Taylor Supervisor Technical Writing Incorrect KVF300 A1 B1 Service Manual Tool Listing The KVF300 A1 B1 service manual P N 99924 1239 01 incorrectly states to use flywheel puller P N 57001 1403 to remove the flywheel The correct flywheel puller is P N 57001 1191 which is also liste
6. instructions on how to set ADVANCE ON ANY CLICK in Acrobat under File Preferences Full Screen This allows you to advance from screen to screen with a mouse click so you set the pace of the presentation and pause whenever you like to explain details to your customer One important feature that is quite important for you to know is this some screens have small buttons on them These buttons take you on a very informative in depth tour of some of the outstanding features of significant new models such as the Ultra 150 Vul can 1500 Drifter and ZRX1100 To order more copies of this CD call the Tech lraining Department at 949 770 0400 ext 2463 They are being offered at just 7 50 each How We Stack Up 1999 You may already have your free copies of the Stack Up If not you ll see them in the mail soon How We Stack Up 1999 compares all 99 model Kawasaki motorcycles ATVs personal watercraft and utility vehicles to their principle com petition in the market It lists the features and advantages from the Product Sales Guides and the specifications from the Quick Reference Guide The specifications for the competing models are also listed The book fits in your pocket so you can carry it with you on the sales floor Knowledge is power The more you know about the product the more effectively you can sell it So grab your copy of the How We Stack Up 1999 and go to it For addi tional co
7. who experiences a need for frequent dir deaner maintenance and or abnormal engine wear from dirt ingestion When we first ran the article in 95 the kit was very reasonably priced at 210 We feel certain there are still customers out there who could benefit greatly from adding this kit to their vehicle so we have reduced the price to 137 to make it easier for you to sell Here is a reprint of our original article for your informa tion Ed KLF400 B Air Inlet Snorkel Kit The 96 KLF400 B4 Bayou comes with an improved air intake sys tem for the engine Earlier models take air directly into the top of the air box under the seat This can be a very dirty environment in dusty con ditions The new B4 has a snorkel tube that goes for ward and upward from the airbox and draws air from under the fuel tank In dusty conditions the air under the fuel tank stays much cleaner than under the seat Obviously less dirt entering the air box means less air cleaner mainte nance But more impor tantly it reduces the chances of accelerated engine wear when air cleaner maintenance isn t as frequent or thorough as it should be The good news is that all the parts needed to update a KLF400 B1 B2 or B3 are available in kit form If you have cus tomers with 95 or earlier model KLF 400s who are encountering problems with too much dirt in the air box we suggest you recommend this kit to them The kit includes a
8. 9 March 30 Tacoma WA 949 770 0400 Ext 2452 February 19 Tulsa OK 817 589 1180 April 12 Grand Rapids MI 732 469 1221 April 21 Atlanta GA 404 349 2000 ext 4227 March 8 April 1 Piscataway NJ 732 469 122 March 19 April 1 April 12 April 15 April 29 2 Fuel Injection Cont d from page 2 each cylinder When the engine is started the ECU calcu lates injection time and controls idle speed based upon water temperature and air temperature Dur ing operation the ECU calculates the injection time in two different ways When there is a light load on the engine the ECU utilizes engine intake pressure and rpm called the D J method When the load becomes medium to heavy the ECU uses the K TRIC throttle position sensor and rpm called the o N method The ECU also uses the throttle position sensor to control ignition timing similar to other Kawasaki models re Iu a 7 py Matin m l y I T a By grounding pin no 37 on the ECU the DFI self diagno sis system will blink failure codes through the FI warn ing light in the speedometer face Two idle speed control valves under the RH air filter cover 3 o clock and 9 o clock positions alter the idle by opening and closing extra air passages into the intake An air temperature sensor lies at the 4 o clock position The compact fuel injectors deliver a fine spray
9. BILL BARKELL nnns CARES CYCLES BOISE ID BRYAN FRANKS nnns CARES CULES ee BOISE ID JOHN LORENZO CARES CYCLES BOISE ID ROBERT MOUNCE GARRETTS KAWASAKI nne KANGLEY IL RICK KING MACH Lettre HARRISBURG IL MARK HOLMES FDR KAWASAKI nnns UCAH KY BOB HOFFSES en K K MOTORS SPORIS nn PRESQUE ISLE ME ALAN BUSH CLASSIC MOTOR SPORTS TRAVERSE CITY MI JASON CYMER nnn JACKSON CYCLE JACKSON MN DOUG ENGIE NORTHERN KAWASAKI CLOQUET MN LARRY CEYMER nnn JACKSON CYCLE anne JACKSON MN DAVID MYERS nnn SPRINGFIELD KAWASAKI SPRINGFIELD MO DOUG FARNEN nn DOUG S CYCLE SHOP SALISBURY MO JEFF REDDICK anne ST LOUIS PWR SPORTS sss VALLEY PARK MO CHRIS PIERCE nn COAST CYCLE WORLD e GULFPORT MS DAVE SLAMANS nnns COAST CYCLE WORLD e GULFPORT MS JAMES SCOTT WITHY COAST CYCLE WORLD e GULFPORT MS MARK PIERCE nes COAST CYCLE WORLD e GULFPORT MS MIKE HOVER sns COAST CYCLE WORLD e GULFPORT MS RANDY
10. EH T CH NEWS WINTER 1998 THE KAWASAKI TECHNICAL MAGAZINE VOL 11 NO 4 KIPS bo vernor Spring Engine Oil Watercraft Engine Seizures 10 VF300 Knocking Noise 1 It s Almost Here Introducing Kawasaki s Newest Generation Fuel Injection System by Don Church Manager Service Training and Communications Judging by its styling alone the VN1500 J1 hearkens to a bygone era but underneath its smoothly flowing lines lies Kawasaki s newest generation digital fuel injection system Not only do Vulcan 1500 Drifter customers get a beautiful retro styled motorcycle but they also get the reliability and sophistication of modern technology So the bene fits of fuel injection such as easy starting improved fuel economy and excel lent driveability and power come as a welcome surprise The new Digital Fuel Injection DFI system replaces carburetors to supply the engine with an optimized air fuel ratio to compensate for a variety of temperature altitude and engine operating con ditions Kawasaki s new DFI system is a Sequential Multi port Fuel Injection utilizing two fuel injec tors each delivering a fine spray of fuel in the direc tion of each intake valve beginning at 60 degrees BTDC on every stroke The amount of fuel is con trolled by the duration that the injector is open Constant fuel pressure is This two piece throttle body a
11. center at Tulsa Technology Center in Bro ken Arrow Okla We also expanded the number of Service Update 99 semi nars to 35 locations and are expanding the number of classes held at the Tacoma and Orlando training centers The Orlando training center offers once a year training for Latin America dealers New Specialty classes for 1999 include Motorcy cle Fuel Injection JH1200 A1 Ultra 150 Service Department Management and Parts Department Management Rob Taylor 9950 Jeronimo Road K Tech News Service Contest 1 Award Winners Congratulations to all win ners Your award will be a Snap On pistol grip ratcheting screwdriver Technician Dealership ocation CRAIG FAITH nne SMITHS CYCLE RUSSELLVILLE AR GARY BUSTILLOS s BEAUMONT KAWASAKI BEAUMONT DOUG STONE ULTIMATE MOTORSPORTS FORT COLLINS CO MARK NEWMAN n ULTIMATE MOTORSPORTS FORT COLLINS CO WADE HAFENSTINE SUN ENTERPRISES nee THORNTON CO DANIEL HARRINGTON KAWASAKI OF OCALA n OCALA FL DANNY BARCLAY nn CYCLE WORKS cor to o ao esc CARROLLTON GA RAY SUMNER nnns MILLENIUM KAWASAKI LILBURN GA
12. d on page 59 in the Kawasaki Special Tool catalog Don t forget this tool must be used with There is no special tool to hold the clutch assem bly while removing the clutch hub nut on a VN1500 engine Holding the clutch housing during nut removal with a hand tool will cause the clutch hub assembly to rotate with the nut This is because the Deceleration Torque Limiting Clutch featured on page 1 11 in the VN1500 D1 manual will engage causing the clutch plates to slip An air impact wrench is the only way to remove the nut To torque the clutch hub nut hold the primary gear bolt with a closed Kawasaki Special Tool catalog PN 99960 0065 03 has an incorrect part number PN 159001 6000 01 under tool description Cutter Set V S KM25 The correct part number should read T57001 6000 01 New special tools for the Drifter The all new VN1500 J1 Vulcan 1500 Drifter uses state of the art fuel injection The special tools for this model will be available in the near future We will publish a Special Tool Bulletin as Irvine CA 92618 rotor puller P N T57001 end wrench and torque the tools become avail 949 770 0400 291 the hub nut to 110 ft lb able WINTER 1998 5 K TECH NEWS New KIC Features by David Behlings Parts Data Coordinator Some of you have noticed ongoing changes to the KIC program like the addition of the Publi cations diagram the same as on microfiche grid A 2 T
13. e same part number would put out and most likely did not contribute to a seizure Below is a table show ing the output quantities we came up with after testing several new pumps of each part num ber These amounts are dif ferent from the specs printed in Kawasaki Ser vice Manuals Many fac tors contribute to the dif ferences Doing precise and repeatable oil pump output measurements is difficult Oil type and vis e cosity ambient tempera ture and of course pump rpm are all important fac tors affecting any pump s output We use a custom made fixture with an adjustable speed electric motor and tachometer that allows us to maintain very precise pump speeds It is very difficult using the engine in the boat or an electric drill to find the exact rpm called for in the spec and main tain it for 2 or 3 minutes After testing more than 100 oil pumps the rule of thumb I ve been preaching is if it pumps oil it s good We have never tested a pump that proved to have any kind of partial failure such as a substandard flow rate The Mikuni oil pump used on our watercraft engines is a simple and reliable positive displace ment mechanical pump capable of producing very high pressure but very low volume It can produce enough pressure to blow up an oil line like a balloon if the oil line is blocked off Which brings us to the question If not the oil pump what would be the cause of an apparently o
14. e of a need in very cold conditions for a carburetor warmer for the Prairie 400 ATV In response to that need Kawasaki developed an electronic carburetor heater kit Part Number 99995 1422 and made it available through amp 3 Collar Heater Heater Holder QOS Heater Stay Plate Silicone N A ire Lea Harness Clamp N Qn 7B Flanged be ange olt 6x14 p Controller Ri lectric Bracket d Lead Wire FI ange OS Bolt 6x14 I Relay Assembly If you run into one of these the solution is to put a shim in there to take up the gap Loosen the motor mount bolt pry the rubber damper all the way back into the cases and measure the gap Try to find a shim or washer that fits snuggly in the space without tightening the bolt Then install and tighten the bolt to the proper torque If you have trouble finding a shim around your shop you can order the U shaped engine mount shims from the old 750 H 2 motorcycle They are available in many sizes ranging from 2mm to 2 0mm thick and cost about a quarter apiece Because of their shape they can be installed with out removing the bolt WINTER 1998 1 1 K TEcH NEWS Caution The Drifter requires gasoline with a mini mum pump octane rating of 90 The Assembly and Preparation Sheet lists a 95 octane requirement Motorcycle Fuel Injection Training One Day Irvine CA 949 770 0400 Ext 2452 March 10 March 11 March 2
15. ellent avenue toward greater universal acceptance of personal watercraft Fred DeHart 201 Circle Drive N 107 Piscataway N 08854 908 469 1221 ATLANTA TULSA Tulsa Technology Center On December 1 K Tech Training officially opened Kawasaki s newest training center at the Tulsa Technology Center ITC in Broken Arrow Oklahoma We kicked off the week with the Service Update 99 seminar for 27 dealership employees and owners LE The course that ET cycle Engine Service was also well attended Danny Ray the Motorcycle Power Prod ucts Instructor had his shop ready The tool boards at each work sta tion are absolute works of art with everything so well organized students were able to go right to work with no time wasted The TTC South Cam pus is an ideal location for Kawasaki Dealer training Tulsa is a central location for many dealers in the surrounding states and is easy to get to by car or plane The Campus itself is beautifully maintained with plenty of parking and a cafeteria The pro grams offered at TTC such as Mechanical Tech nology and Machine Metal Technology are extremely well equipped In fact the administrative staff at TTC have been so supportive of our factory training program they installed a watercraft test tank before our first class A special note to deal ers considering Kawasaki training programs at TTC we have classes sched uled in Februa
16. es a More Durable 750 SXi Pro Floor Mat For your information the 1999 JS750 C1 SXi Pro comes with a thicker more durable floor mat than previous models This new mat is also adhesive backed so no glue is needed fo install it For your customers with older JS7 505 this new floor mat fits all models of the 750 stand up from 1992 to present Gregg Thompson used smaller pistons in cylinders 3 amp 4 than in cylinders 1 amp 2 The new piston P N 13001 1546 supercedes the old pis tons and fits all four cylinders of the ZX600 G1 or C2 When using the new pis tons use the follow ing service unique spark plug the materials used to make R6918C 9 which was designed to be used in this plug and very lim ited production quanti racing engines Since ties it will be more there is currently no expensive than most other mass production other spark plugs vehicle using this plug it Kawasaki has done will be available only everything possible to through Kawasaki deal keep the cost to the cus ers at least for now tomer reasonable Because of expensive To get the customers going on the right foot a set of plugs will be sent to each retail customer free of charge along with a letter explaining the need to always use this special spark plug in their Ultra 150 Also Kawasaki is working on implement ing an initial stocking program to help insure that the dealers always have these plugs on
17. his page reveals part numbers for Owner s Service and A amp P manu als and microfiche for all 1987 and newer models see K Tech News Spring 1998 In KIC Volume 1 for 1999 we added a whole new function The top Description GASKET HEAD cost 946 Pkg Qty T Iv MSRP 18 32 v On Hand IV Bin Add part to transaction selling parts are now offered in a scrol lable searchable list giv ing you the ability to click on the part number to access the parts informa tion window and then add parts to a Transaction Counter Sale K Share parts order or warranty K Share for Your Shop by Kenny Osberg Technical Support Oo M Price 0 00 Weight 10 0000 claim Previously the top selling parts lists were only displayed as an image of the printed book Access the lists under General Information 1 then Top Selling Parts Lists 2 for the Top 500 MC ATV Top 300 PWC Service Managers Have you ever asked your dealership owner for another K Share termina One for your shop Maybe it s time to do that After all this is the information age and informa tion can be turned into happy customers and income for your shop As Kawasaki continues to make more and more service related information available through K Share it becomes more and more apparent that you need your own K Share terminal right there in your service department Programs such as VSI Vehicle Service Inquiry and KIC Kawasaki
18. il related top end seizure Consider the following 1 Check that all the oil lines are connected and not leaking Oil pooled on the engine compartment floor indicates a leak some where And leaks can cause oil starvation 2 If an oil line has become disconnected at either end the oil pump or the car buretor fitting there may be a stuck check valve involved The check valve at the carburetor fitting should open at less than 5 psi so it can be tested with a simple hand pump such as the one in your crankcase pressure tester Early models that have the oil line s con nected at the intake mani fold rather than the car buretor do not have check Jet Ski Models Model Year KMC Measured Flowrate 3000 rpm for 3 minutes valves at those fittings Oil Pump P N JT1100A B 1100STX 1997 1998 3 Look for hardened and JT900A 900STX 1997 1999 JH750C 750ZXi 1995 1997 16082 3718 9 3cc J1750B 750STS 1995 1998 cracked oil lines The hos tile conditions in the engine compartment can require occasional 16082 3713 7 0c replacement of oil lines JS750B 750SXi 1995 1996 JH750A E 750SS 1992 1997 JT7 50A 750ST 1994 1995 JF650A X2 1989 1994 JF650B TS 1989 1996 JB650 Jet Mate 1989 1992 JS650 6505X 1989 1993 due to hardening Even 16082 3710 56c small cracks in these lines can allow enough leakage to cause a seizure Cont d WINTER 1998 1 0 K TEcH NEWS Watercraft Engine Seizures cont d
19. n verters but couldn t find anything wrong with them The noise is nor mally heard loudest above idle and under our Accessories department r eee eee e By the middle of the second year of production this model was coming with a coolanHype carburetor heater as standard equipment So the KVFAOO A T and early production A2 are the only models that might need this kit which includes the heater plus a sensor controller relay and all the wires and brackets needed for a very clean installation Considering the complexity of this kit the original retail price of 175 was quite reasonable But since most of the units that could use this kit are beginning to get old we have decided to drop the price in order to make it more affordable for those customers who still could benefit from it So in mid January the retail price of the kit was reduced to 130 We hope this helps you sell these to some of your cold weather customers load The common problem turned out to be a gap between the frame and the engine cases at the lower rear motor mount In each case the motor mount bolt was tightened properly but there was still a gap between the frame and the rubber damper in the engine cases Sometimes the gap was not obvious in a visual inspection because the rubber damper in the engine case had worked its way out to contact the frame concealing the gap More ATV Kit News A couple years ago Kawasaki became awar
20. num bers Part Number Description Warranty Flat Rate Manual Dir Cost 99960007702 Moloreicle acscosaeso qud hesteiitcntene QVI ern 20 00 99960 0078 02 Jet Ski Watercraft essere nennen nnne nnns 20 00 27960007902 PN m E aaa 20 00 99960 0034 04 Utility Vehicle eese nennen nnne nnns 6 57 99960 0056 01 Portable Generator eese nennen nnne nnnennnennnt nnne 2 99 Prices Current at of 2 1 99 See the Parts Retail Price Guide for latest prices 1999 Model Information on CD ROM by Don Church Manager Service Training and Communications The Technical Services Division just mailed a CD ROM to Kawasaki Dealers containing 1999 Product Sales Guides for motorcycles ATVs Jet Ski Watercraft and Mule utility vehi cles The 1999 Quick Refer ence Guide with spec sheets that will print on 8 1 2 x 11 in paper New Model Presenta tions which are designed as slide shows that allow you to control the pace We encourage all deal ership employees to take a look at this CD Whether you work in ser vice parts or sales you can benefit by having this information close at hand All pages in the Product Sales Guides and Quick Reference Guide can eas ily be printed for you or your customer s refer ence The new model pre sentation slide shows are especially designed for the sales staff to use with customers Be sure to follow the
21. of fuel to each intake valve by using four tiny holes in the tip of each injector A failure diagnosis function programmed into the ECU is of major importance to service technicians If any sensor or actuator fails the tech nician can use a test lead to ground pin 37 on the ECU and decode the blinking display patterns shown by the FI warning light in the speedo assem bly The Tech Training Department has devel oped a one day Fuel Injec tion class covering the theory disassembly and diagnosis of this signifi cant new system for Kawasaki You will see this system used on future models so now is the time to learn about it Refer to the K Tech Train ing schedule and register right away It will bea popular class WINTER 1998 2 K TEcH NEWS
22. oss Supervisor We all have the same results in mind when we freshen up a KX or KDX engine We are trying to get the power back to the way it was when the engine was new Unfortunately there is an item that is too often overlooked and can greatly reduce the effect of all your hard work That item is the KIPS Governor Spring The RPM at which the exhaust valve opens is controlled by this spring s rate and assembled pre load Under the extreme conditions that this spring is subjected to the spring tends to relax a lit tle lose some of its ten sion causing the exhaust valve to open at a lower RPM This happens gradu ally over several races so the rider is usually not aware of the resulting power loss With a weak ened spring the valve can open as much as 1000 RPM earlier than it is e Replace Spring rt D P A be o9 4997 po aA O i A O designed to The midrange power loss can be signifi cant Some professional tuners actually replace this spring before every race We don t think that is necessary but we do believe that every time you freshen up the top end of a KX or KDX engine you should also replace this spring The spring itself costs less than 5 and your customer will appreciate the difference it makes Drain the Engine Oil at PDI by Steve Rice Technical Support For some reason we have recently had a rash of dealers calling us to com
23. pies call 949 770 0400 ext 24 2 Ray St John Supervisor Technical Writing WINTER 1998 3 K TECH NEWS PISCATAWAY GRAND RAPIDS Jet Ski 1100STX Used for Patrol Duty In June of 1998 the New York State Office of Parks and Historic Preser vation s Bureau of Marine amp Recreational Vehicles purchased fourteen Jet Ski 1100STX personal water craft to be used for police patrol duty The units were deployed through out the state of New York in areas where the Bureau has jurisdiction According to the Bureau of Marine amp Recreational Vehicles the 1100STX has performed admirably Agility speed and the ability to cover the same type of water ways as other personal watercraft has made the Jet Ski 1100STX a great choice as a patrol unit A special 1100STX per sonal watercraft seminar was arranged for key per sonnel because the Bureau plans on maintaining these units at their own facilities Attending the three day seminar at Kawasaki s Piscataway N J Training Center were Mr Thomas P Watt Marine Service Represen tative and Mr James Dinsmore of Navigational Aids Their enthusiasm for personal watercraft was refreshing It was a pleasure having them Jet Ski personal water craft can be of great use in capacities other than pure recreation and this is a prime example of one such use The positive exposure of the 1100STX as a marine patrol unit is an exc
24. plain that the engine oil drain plug for some cus tomer s new ATV was left loose at the factory Unfor tunately the complaint usually comes from some one who is unhappily the because the drain plug fell rebuilding engine out the customer didn t notice and the engine seized for lack of oil Of course the customer is upset because his new ATV has a major engine failure and usually the dealer is upset because he thinks the factory screwed up by not tightening the drain plug properly The dealer is not made any happier when we tell him the factory did not screw up but he did One of the first items listed in the Preparation portion of the General Assembly and Preparation Manual and on the A amp P Checklist is Drain Engine Oil On the assembly line at KMM each vehicle is filled with oil and run for a brief period as part of the last BATTERY fill with electroly ENGINE OlL drain and refill FINAL GEAR CASE check o FUEL TANK AND TAP clea gasoline in fuel tank COOLANT RESERVE checks before crating That oil is then quickly drained the plug replaced The assembly and drain line workers who do this are concerned about not cross threading and not OVER tightening the drain plug They are not worried about under tightening it because the dealer is supposed to remove it to drain the remaining run up oil and then torque it prop erly during the Pre delive
25. ry Herzog Editor in Chief Gregg Thompson Communications Editor John Griffin Regional Editors Piscataway Grand Rapids Fred DeHart Atlanta Tulsa Walter Rainwater Irvine Tacoma Robert Taylor Contributors David Behlings Dave Corey Craig Martin Kenny Osberg Keith Pestotnik Steve Rice Ray St John Graphics Production Graphic Art Gregg Thompson Photography Don Church Dave Corey Randy Davis Production Holland Marketing Services 1999 Kawasaki Motors Corp U S A 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 1998 2 K TECH NEWS Warranty Flat Rate Paper Manuals Updated For 1999 by Dave Corey Writer Producer We continue to have good response to our Warranty Flat Rate paper booklets If you prefer to work from a book rather than microfiche these manuals are for you For your awareness however these manuals are not published as often as the microfiche versions and the fiche are not updated as often as KIC So if you want to rely on the Warranty Flat Rate books check on KIC or K Share to see if the part number on your book supersedes to a new number and order a new book Updated 99 Motorcycle ATV and Jet Ski Watercraft manuals are in stock Please note the new part
26. ry and E y NE followed that FT D week Motor again in April Sign up and check us out We have a pool of twenty two current motorcycles watercraft ATVs and utility vehicles for our courses If there is a Kawasaki class not on the schedule that you want to attend by all means call me Our schedule is not cast in stone I can add it In conclusion I want to offer special thanks to Bud Sanders and Danny Ray of TIC Tod Ham mock Kawasaki s local District Sales Manager and the Kawasaki dealers attending our first classes for making our new train ing site a success Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30376 404 349 2000 k Non AMOR 1 D uM 4 ZZ j t IRVINE TACOMA New Service Training Classes Thanks to the techni cians who made last WINTER 1998 4 K TECH NEWS Regional News cont d year s training season a great success We had record attendance in all regions With all the new products introduced for 1999 we look to do even better this year We have a simple idea for technical training make it simple understandable and offer classes at all levels The Professional Master and Specialty courses meet those needs Learn more about each course in the 98 99 National Training Schedule bulletin TR 98 01 or the Kawasaki Cata log of Resource Materials PN 99960 2017 01 We now have seven training centers with the opening of our newest training
27. ry service You should be filling out an A amp P Checklist for each unit you sell If you are doing this you must check or ignore the little box next to the words ENGINE OIL drain and refill Please make sure that whoever does the pre delivery services at your store knows to drain the oil and then properly torque the drain bolt before filing the engine with new oil WINTER 1998 9 K TECH NEWS Jet Ski Watercraft Engine Seizures Thinking About Blaming the Oil Pump by Charles Yim Product Quality Engineer About a year ago we started testing so called bad Jet Ski watercraft oil pumps collected nationwide from our dealers Since then we have flow tested a total of 112 pumps Each one of these pumps was replaced under warranty as the cause of an engine seizure In most cases the dealer had tested the pump output and decided it was inade quate Amazingly when we tested them only two of these 112 pumps were actually defective That s right just two One pump was missing an internal part and didn t pump any oil at all not a drop The other one was dam aged internally and the shaft was very hard to turn It too did not pump any oil Apparently some debris had gotten into this pump and caused the worm gear teeth to strip This may have been the result of a faulty or removed strainer in the oil tank The other 110 pumps were all within 1076 plus or minus of what a new pump of th
28. ssembly is the heart of the DFI system The left half is the intake manifold housing two injectors and the fuel pressure regulator The right half houses two throttle plates and the throttle position sensor maintained in the system by the fuel pump The DFI system also controls the ignition system to fur ther enhance driveability and performance Inside the Electronic Control Unit ECU is an analog digital converter a 16 bit central processing unit and the control pro grams in memory The control unit is also equipped with a self diag nosis system to help pin point problems a fail safe function and a back up memory function The DFI system takes input from the sensors applies corrections to a basic programmed amount of fuel and con trols the actuators to opti mize the air fuel mixture ratio There are some other special functions of the ECU For example the fuel pump continues to supply fuel at 41 psi to the injectors as long as the ignition is ON A vehicle down sensor signals the ECU to shut off the fuel pump if the motorcycle falls over The ECU main tains a stable idle speed and good throttle response during engine warm up by opening and closing the idle speed con trollers to allow the cor rect amount of air into Cont d on page 12 K TECH News Vol 11 No 4 Winter 1998 K TECH News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Ga
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