K-Tech News Vol.11 No.2
Contents
1. unique frame in 99 In years past the KX125 and KX250 shared the same geometry and main frame dimensions other than engine mounts The 99 KX125 steering head is pulled back 15mm and the swingarm is 10mm shorter for quick response and better traction The KX250 uses the same successful geometry as in 98 Both bikes have a lighter and stronger swingarm The KX125 also gets impres sive U shaped DID rims that resist heavy mud buildup The front forks on both machines use new rubber bottoming dampers and longer bottoming cones to reduce bottoming and metal to metal impacts The outer fork tubes are smaller at the upper clamp from 54mm to 52mm and both the inner and outer tubes are stronger with more overlap for better action especially on slap down landings Several fork internals are now aluminum instead of steel to reduce unsprung weight New front axle clamps hold a lighter one SUMMER 1998 6 K TECH NEws piece axle with threads only beyond the clamping area that requires a new assembly procedure A lighter rear shock has high and low speed compression damping adjustability The 98 models had just a low speed adjuster High speed compression con trols quick shock move ments like hitting a curb bump or slamming onto flat ground after a large jump Low speed com pression controls slower shock movements like when landing smoothly on the downside of a double jump or2. cally boosts power from bottom to top because it sits closer to the piston and fits tighter in the cylinder to prevent blow by A deeper cover for the KIPS valve allows the valve to open easier The valve actually displaces enough air space that it generates air pressure trying to resist it opening Both models share changes to lighten the engines and reduce rotating weight helping them rev quicker Excess metal was carved from the kickstart primary clutch and transmission gears and a magnesium outer clutch cover drops some C weight The engine side of the new airbox is angled to speed airflow around the shock to the carburetor and a stiffer boot doesn t collapse under high rpm saving top end power The already potent KX250 motor features a few internal changes with a taller first gear ratio and more flywheel effect from 4 5 kg cm2 to 4 9 kg cm2 to more than offset the lighter rotating mass helping to tame the beast Chassis The 99 bikes are more nimble responding quicker to rider input without losing stability The frames are lighter with a flatter seat layout allowing riders to move freely and sit closer to the steering stem which dra matically quickens steering The main frame section on both bikes use thinner wall tubing and the top tubes are angled down more to allow a lower fuel tank and flatter seat A square section alu minum subframe reduces weight The KX125 gets its own
3. Simply opening the bleeder bolt on the cylinder head cannot bleed this air out By raising the front of the vehicle about 10 inches any air trapped in the hoses can flow into the radiator where it will be replaced by the coolant you add This procedure is particularly important when the system is being refilled after having been drained and during pre delivery service of new vehicles If enough air remains in the cooling system over heating may result because the coolant level inside the radiator is lower than the fan switch located just below the pressure cap If the coolant level is below the switch the switch cannot sense the coolant temperature and won t turn the fan on when needed Carbon Build Up in Vulcan Engines by Gregg Thompson Product Support Supervisor and Steve Rice Product Support Specialist As with all big V Twin motorcycle engines our Vulcan 800 and 1500 models have lots of bottom end torque That torque along with a pleasant low RPM exhaust note encourages the cus tomer to lug the engine a little or a lot Besides most Vulcan owners aren t in any big hurry to get where they re going anyway As a result many Vulcan engines don t see redline very often Some never do This riding style is pretty easy on the drive train and tires and such but it does have one draw back carbon build up in the cylinders Sometimes customers will begin expe riencing pro
4. be introduced soon Remember we will not go back in time to convert all old service manuals and other materials into elec tronic documents I hope this provides a better understanding of KIC and the role it plays One thing we are striving to avoid is KIC spilling VS MICRO K 12 times a year Current 10 years All Current 3 years None Most models over onto two CDs This is another reason to limit information and cau tiously consider enhance ments KIC Training CD Watch your mail closely in mid July because you will receive a new multimedia training tool on CD ROM Getting the Most out of KIC It will be sent to all K Share dealers at no charge The CD was designed to run on the same Micron computer you use for K Share or a similarly capable PC This training can help any employee in your store to use KIC quickly and effectively For those who have used KIC for a while it will take their knowledge to the next level The training consists of demon trations detailed explanations and quizzes to test student under standing There is an extremely handy Index that can be used as a reference to review specific KIC features There is also a Guided Tour with an overview of all the features of KIC A final quiz at the end of the program allows the students fo test their overall understanding of KIC Students can send their completed quiz to Kawasaki to receive a cer tificat
5. 2080 has a nylon gear and is used in all vehicles up to the end of A4 B4 and C4 produc 2 Steel Gear aS wy 4 Yy P N 59051 2112 Y Pinion tion The new KAF650 A5 B5 and C5 models will have the new camshaft part number 12044 2239 which uses a steel gear The new camshaft with the steel gear will fit in older engines but is not compatible with the old crankshaft pinion gear The new camshaft must be used with the new pinion gear part number 59051 2112 which must be pressed onto the crank shaft The crankshaft must be removed from the engine to press the old gear off and a new one on SUMMER 1998 8 K TECH NEws cV Carburetors 1100 Watercraft by Gregg Thompson Product Support Supervisor The 1998 JT1100 B1 STX and JH1100 A3 ZXi are the first Kawasaki personal water craft to come equipped with CV Constant Velocity style carburetors These carburetors do not have the traditional High and Low Speed mixture screws that we are used to seeing on Jet Ski Watercraft carburetors The lack of these adjustable mixture screws may be viewed as a bad thing by mechanics and customers who are accus tomed to tinkering with them to get the carbure tors just right for condi tions But the truth is with the exception of high alti tude usage these carbure tors should not need any tinkering One of the benefits of CV carburetors is that they tend to compe
6. 220 This model also receives the new air filter and molded pin accessory connector It received the propeller shaft boot protector during 1998 SUMMER 1998 1 y K TECH NEws
7. and drier air The 300s are fun to ride with new suspension settings taking advantage of the 300s lighter weight They also get the job done with a class leading rack capacity of 242 pounds and towing capacity of 1100 pounds The proven ergonomics full sized feel and nimble handling make the new Prairie 300s the most comfortable best performing machines in their class The Prairie 400 4x4 digital meter includes a speedometer odometer twin trip meters clock hour meter and even a warning icon for coolant tem perature The Other 99 ATVs Bayou 400 This model now features a dual element air filter just like the Prairie models with yellow hairy foam on the outside Grease is now applied on both ends of the filter to keep dirt out A new metal guard protects the rear pro peller shaft boot A molded pin connector instead of bullet con nectors allows easier accessory hookups Bayou 300 and Bayou 300 4x4 These models also have the greased dual element air filter rear propeller shaft boot pro tector and molded pin accessory connector They also feature a more durable 30 amp regulator rectifier from 25 amp with waterproof connectors Lakota 300 The Lakota receives the new 30 amp regulator rectifier and molded pin accessory connector Mojave 250 The Mojave like the complete ATV lineup gets a new front fender with a molded in section for the ATV usage warning label Bayou
8. at the slower rate until full Be aware that if the high rate charge is continued for much longer than 10 minutes the bat tery could overheat and be damaged Some battery chargers are equipped with a setting to give a SUMMER 1998 short high voltage bump start for dead batteries If your shop doesn t have a charger equipped with this fea ture you should look into getting one For your information if your charger has the ability Maintenance Free batteries can be charged at a slightly higher rate 15v to 16v than conventional batteries about 14 5v So back to the original question why the apparent increase in bat teries that need replacing We believe that one major cause is that the newer technology batteries are less tolerant than older style batteries of inade quate pre delivery charging and heavy dis charging during storage Regarding inadequate pre delivery charging there is a common miscon ception that the vehicle will charge a new battery to its full capacity Not true New batteries have only about an 80 charge when first serviced with acid and must be put ona charger for about 3 5 hours of charging at the normal 1 10 the rated ampere hour capacity before being installed in the vehicle If this is not 7 K TECH NEws done and the battery is installed in the vehicle without a full charge it will never be any better than the day it was installed in the vehicle Even if the ba
9. rear and an easier to use automotive style shift pattern Prairie 400 4x4 and Prairie 400 The 99 Prairie 400 models are better in nearly every respect They have 3 more horse power and more torque a gt thanks to a flat top piston bumping compression from 9 2 1 to 10 2 1 and a freer flowing muffler New crankcases house a 1 1 lb lighter crankshaft that quickens throttle response and improves acceleration A new transmission eliminates the need for the extensive shifting linkage by replacing the shift drum with a cam plate to con trol the shift forks The shift lever links to the cases with one short shift rod instead of two A new Kawasaki Automatic Power Drive System KAPS yields a wider drive ratio spread and has fewer moving parts to make it lighter and more compact It also KVF400 4x4 The flagship 99 Prairie 400 4x4 has more power better handling and new features including its own front grille treatment Kawasaki Takes Aim at ATVs This new CVT system in all 99 Prairie models yields a wider gear ratio for more pulling power quicker acceleration and higher top speed runs cooler for longer belt life and more durability CVT Ratio Spread 1998 92 4 16 1 1999 81 4 2 1 Mechanics in wet and muddy areas will be happy to see improved sealing and protection for the rear drum brake The rear drum cover is now thicker steel and has a guard under it Special seals and O r
10. EE TECH NEWS SUMMER 1998 THE KAWASAKI TECHNICAL MAGAZINE VOL 11 NO 2 INSIDE Feature Kawasaki ATVs 1999 Green Bikes Regional Update News Parts Electronically Parts Coordinator Key Codes Service Contest Tech Tips Batteries Mule Torque KAF620 Camshatts 1100 Carbs F ZX 9R Valves i KX125 250 Seat i 1100 Starting SSS as NSR 2 i Mk ROUTE LIST O SERVICE O PARTS O SALES ii Vulcan Carbon Build Up 11 PLEASE RETURN TO SERVICE LIBRARY Ei ed Prairie 400 Cooling 11 a a D W a he SS SS i gt ae SS Va Tey by John Griffin Instructional Designer Instructor Kawasaki has taken another giant step in the erowing ATV market with thoroughly updated Prairie 400 models and the all new Prairie 300 4x4 and Prairie 300 These new models use the Prairie 400 platform with the easy to use con tinuously variable trans mission mated to an eco nomical air cooled Bayou 300 based motor Kawasaki worked overtime building the ATVs which customers want There are distinct equipment level differ ences between the pre mium 4x4 models the economical 2x4 models and even between the Prairie 400 and 300 models The premium 4x4 models come with speedometers digital on the 400 and analog on the 300 and composite racks All the Prairies have new creature comforts like a 12V DC cigarette lighter style outlet near the han dlebars molded pin accessory connector in the
11. Great Year We just completed our annual training meeting here at KMC to review the 97 98 training year And what a year it was In fact it was the best training season on record A total of 1497 students attended classes in Irvine Atlanta Piscataway Grand Rapids Dallas and Tacoma as well as our Service Update 98 and K Share KIC classes across the nation In the West region stu dent attendance increased by 64 percent This is partly due to the great attendance at our new training center at Bates Technical College in Tacoma Wash We have responded by adding even SUMMER 1998 4 K TECH NEws Regional News cont d more motorcycles Jet Ski watercraft and Mule utility vehicles at Bates The Police motorcycle course has been expanded into specialty classes that include Engine Service Chassis Service Fuel System Service and Electrical System Service on the KZ1000 P motor cycle These classes will be scheduled back to back so students can attend them all or just individually Classes will be held across the nation during the upcoming year To reg ister call 949 770 0400 ext 2452 We also support pri vate and public education Last year we donated 44 units to schools across the nation including motorcy cles Jet Ski watercraft and Mule utility vehicles These schools are a great resource for entry level technicians This year brings even more classes as the 1999 model year offers som
12. able chassis and unmatched capabilities They feature a version of the Bayou 300 motor that pumps out one and a half more The rear brake drum seals better is stronger and has more protection to fight leaks horsepower for an 8 increase New engine cases hold a strengthened Bayou crankshaft with a 3mm larger right hand main journal from 30mm to 33mm The cylinder tilts forward an addi tional 5 from 20 to 25 to increase ground clear This cutaway of the Prairie 300 4x4 shows the pumped up version of the Bayou 300 motor mated with KAPS on the Prairie 400 plat form Note the accessory plug near the handlebars and the new oil cooler ance New cam timing has longer duration and more lift to create the power gain The 99 KAPS system has settings to match the 300 s power delivery An oil cooler improves cooling ability and increases oil capacity from 2400cc to 3100cc A spin on cartridge type oil filter is easy to replace To increase airflow and aid cooling the front erille has no mesh screen The grille also has pre fabricated mounts so an accessory winch can be bolted right in A battery powered DC CDI ignition system improves low speed per formance A new regu lator rectifier boosts capacity to 30 amps from 25 amps to strengthen the charging system An electric carburetor heater prevents icing in cold damp conditions Snorkel air intakes for the airbox and CVT capture cleaner
13. blems from carbon in the engine at surprisingly low mileage The two most common symptoms of this are poor idling or low speed power from carbon on the valves and an abnormal knocking noise from carbon build up on the piston and com bustion chamber Also depending on what gaso line the customer is using detonation can result from excessive carbon in the combustion chambers Disassembling the engine to remedy this problem is a little too expensive to be doing every few thousand miles especially considering it s not covered by warranty However there are some chemicals available in the aftermarket which can reduce the amount of carbon in the combustion chambers The Kawasaki Accessories department is currently testing a gasoline additive for this very pur pose Keep your eyes open for this new product and in the mean time if you have a customer whose Vulcan motorcycle seems to be suffering from carbon build up in the engine call the Technical Hotline We may be able to help SUMMER 1998 1 1 K TECH NEWs Kawasaki ATVs Cont d from page 2 warning icon for coolant temperature It also has new lightweight alu minum rims rear hubs rack support frames and front skid plate To keep the price down the 2x4 model still comes with steel components and no speedometer Prairie 300 4x4 and Prairie 300 The new Prairie 300s shoot to the top of their class with a strong motor sturdy and comfort
14. e totally new units We will also be at the same cities for our Service Update 99 class These popular classes fill up quickly so sign up early Rob Taylor 9950 Jeronimo Road Irvine CA 92618 949 770 0400 Welcome Parts Data Coordinator Hi I m David Behlings the new Parts Data Coordinator I began this job in February and I feel com fortable answering your parts data questions because of my nine years as a technician at a top Kawasaki Ichiban dealer ship I have spent my last nine years here at KMC first as a shop technician and later as a Hot Line representative This Kawasaki back ground helps me to pro duce microfiche parts catalogs and update KIC The KIC program keeps me especially busy KMC has to be proud of coming out with an electronic parts catalog that had 1063 models in its first issue Managing and updating all of that data every two months is a sizable job and of course there are Write Down Those Key Codes by Carlos Johnston Service Support Coordinator Latin America As you may know Curtis Industries offers Kawasaki key cutting equipment This eliminates the need for expensive locksmiths or lock sets unless you don t know the key code Kawasaki does not presently track any key codes in our com puter or stamp key codes anywhere on the vehicle or locks It is critical to record the key code every time you have a chance to and make sure the cus
15. e of completion for their efforts SUMMER 1998 3 K TECH NEWs PISCATAWAY GRAND RAPIDS Record Key Codes on K Share You can record the key codes of your Kawasaki products in one of four dealer memo fields on your K Share VIP Vehicle Information Processing screen In this way you will always have the key code available To set up a dealer memo field for key codes do the following e Double click the K Share icon to open the K Share screen e Double click on the VIP icon Click on Registered or Not Registr units This brings up the VIP screen The dealer memo fields are positioned just to the right of the Prod Type field Go to the top of the screen and click on Options Click on Dealer Memo Field Maintenance e Choose one of the four dealer memo fields and type KEY CODE Click OK The dealer memo field you picked will now have the heading KEY CODE Now record key codes for your complete Kawasaki inventory into this field This may take a while but the time and expense of even one lost key set will pay for it As you receive new product from Kawasaki continue to record the key codes in this memo field Now if you or your customer ever need a key made the key code will be available Remember code books and cutting equipment can be obtained by calling Curtis Industries at 800 555 2878 Fred DeHart 201 Circle Drive N 107 Pisca
16. emove the camshafts you must first pull the engine This means the engine would have to be removed to do a valve adjustment That wouldn t make most cus tomers very happy would it The reason the service manual gives this proce dure is because the timing marks for the cams are on the outside of the sprockets The sprockets are so close to the frame that it is difficult to see the marks clearly By just peering in between the frame and the engine it is difficult to be certain the cams are timed correctly There is room however to slide a small mirror in there so the marks can be seen easily Or while you have the cams out to change the valve shims you can scribe timing marks on the backside of the sprockets where they can be seen easily without a mirror Please don t pull the engine to doa valve adjustment on a 1998 ZX 9R Note For other tips about camshaft installa tion on this model see the article on page 11 of the Winter 1997 issue of K Tech News SUMMER 1998 9 K TECH NEWS Front Seat Mount Modification on KX125 and 250 by Gregg Thompson Product Support Supervisor and Craig Martin Technical Support Technician We ve run across some cases where expert riders on KX125s and 250s have had the seat pop loose at the front mount when jumping Apparently when sitting down on the take off of big jumps the rider s weight hitting the seat can flex it enough to pull the fron
17. enter and the continuing popularity of other Electronic Parts Catalogs EPCs nearly every Kawasaki dealer can look up parts elec tronically Although KIC contains information not available on other EPCs it is still essentially a tool for selling and ordering all Kawasaki parts It has value added features such as service bulletins war ranty flat rate codes and sales literature to extend its usefulness to other areas of a dealership KIC was never intended to completely replace a Micro K deck As you know we have continually added infor mation to the microfiche making them a critical archive of information in addition to an up to date working tool at the parts counter In fact Micro K is KIC 6 times a year Distribution Available Service Bulletins Available Sales Literature Assembly amp Prep Sheets None still the quickest method for Kawasaki to send you model information because production lead time is short and the sub scription service provides a mailing every month Microfiche provide a backup to paper service bulletins and Assembly amp Preparation sheets for example and are still very inexpensive and effective We strongly advise every dealership to maintain at least one Micro K sub scription KIC is one piece in KMC s overall strategy of providing information electronically KMC s Electronic Document Distribution System EDD is another piece in our overall plan that will
18. ings help prevent leakage and a new steel labyrinth plate helps prevent damage that causes leakage The King of the Hill Prairie 400 4x4 gets a new digital meter and its own unique look with aggres sive cat eye headlights and front grill treatment The digital meter features a speedometer odometer twin trip meters clock hour meter and a Cont d on page 12 SUMMER 1998 2 K TECH NEWS K TECH News Vol 11 No 2 Summer 1998 K TECH News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Communications Editor John Griffin Regional Editors Piscataway Grand Rapids Fred DeHart Atlanta Dallas Walter Rainwater Irvine Tacoma Robert Taylor Contributors Dave Behlings Carlos Johnston Craig Martin Keith Pestotnik Charles Yim Steve Rice Graphics Production Graphic Art Gregg Thompson Photography Dave Corey Production Holland Marketing Services 1998 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 if without further consideration Specifications subject to change without notice Micro K vs Electronic Parts Catalogs by Don Church Manager Service Training and Communications With the recent intro duction of KIC Kawasaki Information C
19. nsate for conditions temperature humidity and modest alti tude changes automati cally Since the slide is raised by the pressure dif ference between the ambient air in the engine compartment and the intake manifold the slide doesn t move until there is a sufficient drop in mani fold pressure to draw fuel from the jets The slide movement is slowed just enough to prevent a lean bog but not enough for the operator to perceive any delay in response Unfortunately we have had some early complaints of a throttle hesitation right off idle These com plaints typically come from customers who want to stab the throttle from idle to wide open and have the engine respond instantly We feel that if the throttle is opened just a little slower than instantaneously the vehicle will respond without hesitation However if you have a throttle hesitation com plaint we suggest you remove the pilot screw plug and clean the pilot passage and adjust the screw If the problem per sists give the Technical Hotline a call If you have customers who regularly use their PWC at altitudes above 5000 ft you might want to order and install these optional jets to gain the best possible performance up there Pilot Jet 32 Main Jet 160 P N 16158 3723 P N 92063 3722 ZX 9R Valve Adjustment by Gregg Thompson Product Support Supervisor The service manual for the 1998 ZX900 C1 says that in order to r
20. ow your knowledge and win awards SUMMER 1998 5 K TECH NEWS by John Griffin Instructional Designer Instructor The KX125 and KX250 are the big news for 1999 with more power less weight and improved handling The KX60 received a new connecting rod with an improved big end bearing and silver plated thrust washers to enhance durability The rest of the green bike line up is unchanged except for attractive new graphics and colors especially the KDX models Engine Kawasaki Throttle Responsive Ignition Control K TRIC is now on two KX models The KX125 and KX250 have The new Keihin PWK S shorty carburetors feature a throttle position sensor tied to the ignition the power jet system and a shorter body with the slide needle and main jet 12mm closer to the intake port 1999 Green Bikes new Keihin PWK S shorty carburetors with a throttle position sensor connecting to the ignition Ignition timing varies with different throttle settings and engine RPM for better engine response and more power especially from 0 to 1 3 throttle The carbu retors are called shorty because the body is actu ally shorter like the works bikes with the main jet slide and needle 12mm closer to the intake port to enhance throttle response and top end The KX125 has new port timing for more top end power and revised intake and scavenging pathways to add torque A new KIPS valve dramati
21. squatting under acceleration Every detail has been considered The grips are softer and have a flat pat tern on the palm side The rear axle adjuster bolts are 10mm instead of 8mm A new clutch cable is easier to adjust and routed for easier clutch pull New rear brake pads have a thicker backing plate and ceramic coating to control heat and eliminate warping The Uni Trak linkage bearings are revised to be lighter and easier to reassemble Kawasaki thought of it all so you wouldn t have to CD Where Have All the Batteries Gone by Gregg Thompson Product Support Supervisor Over the past few years we have noticed that dealers are replacing batteries in vehicles at an ever increasing rate To make matters worse it seems that the newer tech nology batteries especially Maintenance Free are the ones being replaced most frequently In trying to figure out what is behind this trend we ran across a little known fact about charging dead batteries If the bat tery is discharged and the surface voltage is below 11 5V the battery may need to be shocked back to life with a high voltage charge up to 25V for about 10 minutes Then continue charging at the normal rate of about 1 10 the ampere hour rating of the battery until fully charged This quick high voltage charge is needed to get the plates to begin receiving the charge Once they begin receiving the charge they will continue to charge
22. st will reach the inlet and be drawn into the torque converter cover Dirt is very hard on any moving part and the torque converters and belt are no exception This new torque con verter air cleaner can be installed on older models at the customer s expense with just a very small modification The air cleaner housing is C mounted to a frame tube using a steel bracket One hole must be drilled through the frame tube to accept the mounting bolt The filter assembly itself will serve as a template for drilling the hole Simply assemble and install it and drill the hole where the bracket is The filter and housing and all the parts needed to install it on an older KAF620 are now listed as Optional Parts on the microfiche for the A1 A3 B1 B3 and C1 C3 If you have customers using their pre 1998 2500 Series Mule UVs in dusty conditions you should let them know about this new Torque Converter filter and recommend that they purchase one Don t forget that once you ve installed one of these on an older unit that vehicle now has another maintenance item to remember KAF620 Camshafts by Dave Behlings Parts Data Coordinator As some of you may have noticed there are now two camshafts listed on the microfiche for the KAF620 A B and C 2500 series Mule Utility amp P N 49118 2080 J Nylon Gear zy P N 59051 2340 Pinion Vehicles The old style camshaft part number 49118
23. t mounting slot off the retaining washer Of course the seat stays in place because of the rear mounts but being loose at the front can be something of a distraction to the rider If you know of someone who has experienced this problem or is a fast enough rider that you think he might experience it in the future we have a sugges tion You can replace the retaining washer on the fuel tank with a larger fender washer that has been modified to fit the mounting slot in the seat base Simply take a large washer that has a 6mm or 1 4 inch I D and grind amp Discard old washer parallel flats on each side to produce a long narrow washer that is the same width as the original washer C 98 JH JT 1100 Hard Starting by Gregg Thompson Product Support Supervisor and Charles Yim Product Quality Engineer We have had some reports of 1998 JH1100 A3 and JT1100B1 Jet Ski watercraft with hard starting problems Of course whenever hard starting is a problem the first thing we suggest is to verify the engine condi tion by performing a com pression test A sharp engine should have 120 125psi Even a new engine could have a compression problem so don t overlook this important check Beyond that we do have some more specific sug gestions that can help with the 98 1100s We inspected some car buretor sets from vehicles with starting problems and every one of them had improperl
24. taway NJ 08854 908 469 1221 ATLANTA DALLAS Wals Mart Goes to School As you probably have heard WalsxMart is pur chasing many Kawasaki Mules for use in the Courtesy Patrol of their W Kawasaki i TECHNICAL TRAINING Fe ES CLASSROOM 2 parking lots They are using the KAF620 and KAF300 models at various locations In the future they will continue to replace their present vehi cles with Mules Kawasaki recently held a Mule Familiarization class in Atlanta for some employees of Waly Mart This was not the usual technical class with hands on training These atten dees including National Manager David Jones are district and divisional managers and supervi sors They are responsible for the upkeep and main tenance on Mules in their area They learned of the capabilities and limits of the Mules The most important reason for the class was to familiarize them with routine and daily maintenance sched ules They don t want any downtime so preventive maintenance is vital Many WalxMarts do not have any service capa bilities None of them have trained personnel or parts for Mules This is the perfect opportunity for Kawasaki dealers to con tact their local WalsxMart manager or supervisor and work out a deal to service their Mules Good business is where you find it Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 IRVINE TACOMA A
25. tomer is aware of this information recommend you record the key code on the A amp P checklist your K Share VIP screen see Fred DeHart s article in this issue the Owners Manual during PDI and on the sales contract at the time of sale It s also a good idea to always record key codes on repair orders when customers bring vehicles in for service You ll be the hero if a customer loses his keys and you not only have a key cutter but you ve also taken the time to record his key code And if you lose the customer s key while a bike is in for service having a key cutter and the cus tomer s key code will save you much embarrassment and trouble The KEY is for you to faithfully record your customer s key codes Call Curtis Industries 800 555 2878 for information on key cutting equipment occasional errors If you find errors on KIC please print out that page write an explana tion of the problem then mail or fax it to me If you find microfiche problems it is also helpful to use KIC to print out the page so you can identify the error This seems to be the best method to communicate parts data problems If you need quicker help just call David Behlings 9950 Jeronimo Rd Irvine CA 92618 949 770 0400 ext 2573 Fax 949 460 5629 The New Kawasaki Service Contest is Coming The upcoming issue of K Tech News will have Part One of the new Kawasaki Service Contest This is your chance to sh
26. ttery is removed and put ona charger at a later date it will never reach its full potential Obviously a bat tery with reduced poten tial is more likely to fail than a fully charged one Regarding discharging during storage newer style higher capacity bat teries use thinner insula tors between the positive and negative plates When the battery sits in a dis charged state damage can occur to these insulators Though newer technology batteries discharge in storage at a slower rate than older technology bat teries once discharged they are less likely to return to their full capacity Remember batteries that become damaged as a result of improper storage are not covered by war ranty Air Filters for Mule Torque Converters by Gregg Thompson Product Support Supervisor All the 1998 and later KAF620 Mule Utility Vehicles come with a new air filter in the inlet tract for the torque converter cover As in previous years these models draw air for the engine and the torque converter through the top rear tube of the cab frame But in the past air for the torque converter went unfiltered straight into the converter cover Filtration isn t actually needed in most applica tions because at the top of the cab frame the air is normally clean enough for the needs of the torque converter However in extremely dusty condi O x Drill hole for r O a tions large amounts of du
27. y assembled choke valves The choke valves were not centered properly in the throttle bore and would not close all the way The choke plate screws are installed and then staked at the factory but they can be loosened enough to move the choke plates about one turn To do this use a new 2 Philips screw driver to avoid damaging the screws and loosen the screws on all three choke plates just enough that you re able to move the plates Close the choke all the way to center the plates in the carburetor bore and tighten all the choke plate screws while holding the choke closed tightly Because of play in the linkage the choke plate farthest from the cable arm will not quite close tightly but this is accept able Make sure the choke knob stays all the way out when you let go of it Tighten the friction nut if needed Also the pilot screws should be removed the passages cleaned and the screws reinstalled and adjusted approximately 1 3 4 turns out If stubborn hard starting persists call the hotline We have some other parts coming that can help No Gap Here SUMMER 1998 0 K TECH NEWs Prairie 400 Cooling System Air Bleeding by Keith Pestotnik Senior Product Quality Engineer Whenever servicing the cooling system on any model 97 99 KVF400 it is a good idea to elevate the front of the vehicle when adding coolant The shapes of the radiator hoses are such that they tend to trap air
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