K-Tech News Vol. 3 No. 4
Contents
1. 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 Bob Ellison Jerry Heil Mike Jeffers Tevis Moffett John Porno Steve Rice Ray St John Mary Sola 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 American Watercraft Institute details by Don Church Manager Service Training and Communications Dept The American Watercraft Institute in Daytona Beach Florida offers a five week technical train ing program devoted sole ly to personal watercraft This program the only one of its kind in the country divides 200 hours of instruction into 13 sec tions Each section covers a different aspect of per sonal watercraft operation and repair Approximately 30 percent of the instruc tion is in the classroom with the other 70 percent providing hands on ex perience Class size is limited to a maximum of 20 students enabling in2. dividualized instruction The Institute currently has 20 personal watercraft from various manufac turers as training aids The American Water craft Institute is a division of the American Motor cycle Institute and there fore benefits from AMI s experience and many stu dent services including job placement For more information call or write American Watercraft Institute 1445 Skytrooper Road Daytona Beach FL 32114 800 874 0645 904 255 0295 Fla only J LS L Siad Daai a a pe r Be s Le i Hag hy Ri T yi in GUEST American Watercraft Institute graduates will profit from 200 hours of classroom and hands on training COMMUNICATIONS Micro by Micro Mike Jeffers Parts Publications Specialist S ince we last spoke have received many phone calls concerning microfiche decks microfiche subscriptions and microfiche equipment While am delighted to answer these calls it has occurred to me that many of you do not realize you already possess this information Periodically the Technical Publications department at KMC in conjunction with Micro K publishes parts bul letins Copies are then mailed to the dealer network Some of these bulletins explain in detail the Micro K functions noted above W The Micro K parts microfiche deck and subscription policies are explained in detail in Parts Bulletin General 89 01 issued Jan 6 1989 The details of parts microfiche
3. from vibration Before seal ing the intake tract connec tions it s best to com pletely disassemble and clean all the parts first sealing with Kawasaki Bond on reassembly Dirt is an enemy of all in ternal combustion en gines But with only a little extra attention it s easy to win the battle O E SPECIALISTS Check those fasteners Don t forget to check nuts bolts and fasteners during the pre delivery service on each and every vehicle you sell Your dealer ship is responsible to make sure things don t fall off the vehicle be tween delivery of a new unit and the first scheduled service Among the hardware you should not over look are those securing handle bars fairing parts suspension components brake components axles footpegs mufflers and handrails Gregg Thompson l Mule 1000 intake kit If your Mule 1000 customers are finding that in condi tions of extreme dust their air filters require more fre quent servicing than normal this will help An optional improved air intake system is now available for the Mule 1000 By adding a snorkel to the intake system air can be drawn from the relatively dust free environment above the cab frame rather than the floor areas as SNORKEL INTAKE KIT originally equipped The installation of this new intake kit will extend the air filter s service frequency in extreme operating conditions Because of the snorkel s length and dia
4. and quantity of fluid is used in each fork assem bly Always use fork or suspension fluid never use engine oil automatic transmission oil or hydraulic oil Refer to the Kawasaki service manual for the particular year model motorcycle you are work ing on to determine vis cosity and amount of fluid When checking the overall fluid level it is best to measure the level of fluid in each tube On the KZ1000 P series motorcycles this is done with the fork springs removed and the forks fully compressed You measure from the top of the fork tube to the top of the oil The level must be the same in both tubes MODEL LEVEL KZ1000 P1 P4 170 2mm KZ1000 P5 P10 157 2mm The front fork assembly is one of many systems on motorcycles that af fects rider control And as with other systems the forks require attention at specific intervals If you have any questions about the front fork assembly or other systems on the motorcycle always refer to the shop manual O TIPS FROM T H WEST CONTINUED FROM PAGE 12 lights Replace the faded old banners and posters on the wails with some new ones And don t forget about the shop equipment it could probably use some main tenance and cleaning up too Winter is a great time to analyze the service depart ment layout Is it as efficient as it could be Are related pieces of equipment such as the tire machine and the tire balancer pl
5. around the service department all summer but have simply been too busy to tackle For starters how about sprucing up the place After a long busy season your service area could probably use it Splash some fresh paint on the walls Hang some more CONTINUED ON PAGE 11 12 K Tech News SOUTH amp CENTRAL Motivation J ust do it by Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 Are you a self motivator Do you have difficulty keeping busy Well as my West Region col league Patrick Kelly writes see his column at left now really is the time of year to become motivated and do all the things around the shop you said you d do when you could get the time Straighten up your ser vice department and recover some lost space Repair those trade ins and get them ready for sale Throw away the real old junkers or at the very least cover them up Here s a tip that will help you improve the professional appearance of your service depart ment Hang all of your special tools on a single painted sheet of peg board With the tools CONTINUED ON PAGE 11 I m still getting calls by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 t s late November as write this and am still getting numerous calls from mechanics asking for copies of our training schedule As most of you know Kawasaki s Techni cal Services Department mails an upda
6. ings and one needle bearing at the sprocket end of the shaft Finger fol lowers similar to the ZX 11 design open the valves through tiny ultra light weight adjustment shims E Valve gear The valves have slender 4 5mm stems and 29mm intake side and 25mm exhaust side heads to let the engine breathe easily at high rom The small stems lighten the valves so much that only single valve springs are needed Light valves and low spring pressures mean less horsepower lost to opening and clos ing the valves The included angle be tween the valves is a mere 20 allowing a high compression ratio 10 8 1 PAM Gain oe St eee ge in the ZX 7 11 5 1 in the ZX 7R in a clean com pact combustion chamber The valve duration on the latest ZX 7 is a very mild 260 for optimum mid range torque The ZX 7R has 28 more duration on the intake side and 20 more on the exhaust for extended top end power Don t be fooled by those numbers the ZX 7 won t have to apologize to anybody for lack of power E Rings and liners The compression piston rings on both 91 ZX 7s are The engine of champions 0 8mm thick just like the ZX750 H2 s The differ ence is that the rings have barrel shaped faces and a beveled inner surface for better sealing at all en gine speeds The oil rings are 25 percent thinner than last year s at 1 5mm The cylinders mean while have dry liners in an open deck like
7. or hand grinder to remove the high spots where metal has trans Before you store for winter treated fuel from the fuel tank into the carburetor s and fuel lines It soeeds things up to drain the float bowls before doing this Kawasaki sells a stabi lizer called STA BIL The part number is 1104 Gregg Thompson Don t forget to recom mend gasoline stabilizer to all of your customers who are storing their motorcycles or watercraft for the winter If your shop is preparing a customer s vehicle for storage be sure to run the vehicle long enough to get the 8 K Tech News ferred from one taper to the other Be careful not to remove any metal from the undamaged portions of the taper Once the high spots are gone the two tapers can be lapped together for a perfect fit Put lapping compound on the crank taper and spin the flywheel against it while applying pressure Clean the compound off frequently and check the fit The dull grey areas on the tapers are the places making good contact The more contact the better the grip A fairly common miscon ception is that the wood ruff key is supposed to keep the flywheel from spinning In fact the key is normally there just for timing purposes It s the taper that holds the flywheel in place Lapping the flywheel to the crank ensures the best possible fit Even when both parts are new it s not a bad idea to lap the tapers qu
8. training tape distribution system give Kawasaki Technical Services Department a call at 714 770 0400 ext 2472 Ask for Pat Shibata and you re in business You ll receive up to four new training tapes every year but no more than four Each tape will per tain to your product mix you wont get anything you can t use Of course if you don t like a tape let us know and we ll buy it back from you And if that still isn t enough all of Kawasaki s other technical training tapes will be available to automatic subscribers at 30 percent off the usual dealer cost O E Hot Line Champion Steve owns tunes and rides the bike which is powered by a turbo charged alcohol burning 1260cc Kawasaki engine Enjoy the 1 plate Steve and more power to ya Ed Congratulations to Hot Line staff member and regular K Tech News con tributor Steve Rice for winning the Dragbike U S A 1990 OHC Fun nybike Championship The 90 championship was determined in Gaines ville Fla at the last points ace of the year While win ning both the meet and the series title Steve also set a new record in his class for top speed at 181 81 mph The Technical Magazine 5 T lPS F ROM T H Fighting dirt fighting dirty by Steve Rice Product Support Specialist The internal combustion engine was never in tended to run on dirt The finest dust is incredibly abrasive and damaging in the top end of any engine In four
9. Winter 1990 The KawasdkKi NEWS Technical Magazine Vol 3 No 4 Two bikes one commitment One brand new Kawasaki ZX 7 for 1991 would have been news Two new from the ground up ZX 7s is absolutely incredible Kawasaki is out to rule the 750 class lock stock and barrel The all new ZX750 J1 NINJA ZX above left is aimed at the sport rider who wants the latest in street bike technology There ll be no mistaking Kawasaki s latest with its eye popping lime green vivid blue and brilliant white color scheme And while you can hang a license plate on the ZX750 K1 NINJA ZX 7R above right too it s really going to shine on the race track In truth the ZX 7R has just one mis sion in life the Superbike Cham pionship In the short time since its incep tion the ZX 7 has been engineered from the ground up twice and redeveloped once Now that s com mitment For more grab hold and turn the page ROUTE LIST O SERVICE PLEASE RET URNT O O PARTS SERVICE O SALES LIBRARY S H OP ZX 750 power by Ray St John Supervisor Technical Writing What we find in the new Ninja ZX 7 and ZX 7R Kawasaki models is one 750cc engine in two forms street and near race ready The basic design is all new with the cam chain on the right hand end of the engine unlike the original Ninja and the Concours Hollow camshafts ride in five bear ings each four plain bear
10. aced in the same area Are all resource materials such as microfiche viewer and service manuals located close together An efficient layout will help make the service shop more productive when the pace of service work ac celerates in the spring All too soon it ll be that time of year again O SOUTH amp CENTRAL CONTINUED FROM PAGE 12 Outlined in a contrasting color you ll have an impressive display and have a way to keep track of those expensive items And after painting the peg board you ll surely be motivated to paint the rest of the service department Look around there is plenty of work to be done a lot that should have been done much sooner Self motiva tion will get the work accomplished Like it says in those great Nike shoe ads Just do it O NORTH amp EAST CONTINUED FROM PAGE 12 regular chance to review service training schedules please check with your Service Manager or perhaps the dealership s Sales Department Can t find the training schedule anywhere Then do contact your regional sales off ice and we will send one to you Don t forget to keep in touch hope to speak with you soon at one of our classes O E SPECIALISTS Customer Service The Series GE does It Nordstrom does It and many Kawasaki dealers small and large do It too What is It Provide excellent customer service And while customer ser vice may have been just business buzzwords for the 80s ge
11. artment Operations K BOSS January 3 Shaft Drive 4 ATV Service 7 9 JETSKI Watercraft 10 Generator 14 15 Team Green Race Preparation 16 17 FuelSystems 24 Service Department Operations K BOSS 28 30 Police Motorcycle Maintenance
12. ator pump A link rod ac tuates the pump when the throttle bell crank rotates Air being lighter than fuel accelerates away from the fuel when the throttle valve is quickly opened When the air ar rives at the combustion chamber there is not enough fuel with it and a lean stumble or hesitation results To combat this Kawasaki engineers have included an accelerator pump which shoots a stream of fuel down each venturi toward the intake valves This supplies an enriched fuel mixture that arrives at the combustion chamber with the air The result Ultra smooth ac celeration Of course if this extra shot of fuel should arrive at the combustion chamber when engine rpm is low or the throttle not open wide enough an excessively rich mixture could occur sending hydrocarbon emissions sky high To en sure that this is a clean burning accelerator pump system a digital igniter and throttle switch control fuel delivery So when the throttle is more than 4 open and the engine is turning high enough rpms the solenoid opens and fuel is available to the accelerator pump When the rider twists the throttle quickly the ac celerator pump delivers the correct fuel ratio for smooth acceleration while limiting engine emissions It s Ingenious And its very very effective Jerry Heil The Technical Magazine 3 EETECH NEWS Winter 1990 Vol 3 No 4 1990 Kawasaki Motors Corp U S A KMC
13. correct E Inadequate or incomplete description Make sure your description clearly and com pletely explains both the trouble vehicle symptoms or customer complaint and the cause the defect or failure that produced the symptoms Also describe what you did to fix it M No repair order included with Extended Coverage claims All Extended Coverage claims must have a copy of your service department repair order attached You ll notice that this list is dominated by the word omitted Most of the problems we encounter on warranty claims involve missing information Please review each claim before sending it in and remember that fewer errors on claims will result in faster payments to you Thanks Warranty Claims Department Police motorcycles front fork service by Bill Zito National Police Motorcycle Coordinator One of the most over looked components during routine service is the front fork assembly and the fluid contained in side the fork tubes This fluid serves two very im portant functions First it provides viscous hy draulic damping second it puts a lubricating film between moving parts within the fork assembly This fluid becomes con taminated with use and loses its ability to provide proper hydraulic damping The recommended change interval for the Kawasaki Police 1000 motorcycle is every 6 000 miles When changing the fluid it is important that the proper type viscosity
14. crofiche Simply turn to the correct list by using these three indicators found on each list Model designation color scheme and V I N Vehicle Identification Number Each painted cosmetic part will be listed and a part lumber given One thing to keep in mind is that the O indicates the part number is applicable for the market region indicated whereas the X means it is non ap plicable O New training video Watercraft Powertrains by Ray St John Supervisor Technical Writing A new technical training video has just been released Watercraft Powertrains covers Kawasaki s JET SKI watercraft powertrains from coupler to impeller This 23 minute tape contains a wealth of information any tech nician will find valuable For example it explains why dif ferent boats have different drive shafts and different drive shaft bearing holders why sealing the pump case to the hull is so important and how the water jet propul sion system differs from simple propellers For those dealers who have signed onto the automatic training video tape distribution system this video has probably already shown up in your store if you carry Kawasaki watercraft or are eligible to buy Kawasaki watercraft parts As usual your parts account will be billed at 30 percent off the regular dealer cost of 35 95 plus shipping and handling and appropriate sales taxes if any lf you d like to take advantage of the money saving automatic
15. decks and subscription prices deck subscrip tion options and billing cycles are also explained in full WE Parts Bulletin General 89 03 Understanding the Microfiche Title Strip issued Dec 9 1989 instructs the novice parts or service technician in selecting the proper parts microfiche by using the information included in the title strip WE Parts Bulletin General 90 01 Microfiche Viewers and Accessories issued Oct 5 1990 lists Micro K equip ment available fully explains the features and benefits of each piece of equipment and notes dealer cost at time of print Included in this bulletin is a list of soare main tenance parts and all accessories available from KMC WE As you may or may not know the parts microfiche did not include replacement decals for motorcycles prior to 1988 Parts Bulletin MC 90 01 issued Apr 27 1990 has a list of street legal motorcycle decals categorized by model year and decal description W An updated and easy to use Special Tool Catalog microfiche should be at your dealership by the time you receive this issue of K Tech News The catalog lists spe cial tools currently available through the 90 model year W would like to mention once more some of the new ad ditions to the parts microfiche To help simplify parts or dering and to lessen the research time needed for crash estimates Kawasaki has added the Color Combination Parts List to row A on many of the motorcycle parts mi
16. ehicle or engine vertical straight up and down when the camchain has slack in it There is a small cast boss in the bot tom crankcase just below the crankshaft camchain sprocket This boss is designed to keep the chain from climbing over the sprocket teeth while the engine is running However if the engine is leaned to one side as when the bike is on the sidestand with the cams out it is possible for the chain to sneak out from between that boss and the sprocket If that happens it s almost impossible to get the chain back onto the sprocket without drop ping the pan Gregg Thompson O eee e OR A ee Se ee S What s wrong with this picture by Gregg Thompson Sr Product Suppoft Specialist f you find yourself faced with a cracked Kawasaki watercraft hull that needs to be repaired under warranty the first thing you should do is call the Hot Line The Hot Line technician will probably ask you to take some pic tures of the damage and send them with a written es timate for inspection But taking good pictures of a crack in a nice white hull can be a little tricky A large percentage of the photos we receive dont serve any purpose because they don t clearly show the damage Most often the photos are either out of focus or over exposed Here are some suggestions for taking bet ter pictures that will allow us to see the damage Take the pictures in a well lighted area preferably out doors but not
17. electrolyte solution in a maintenance free bat tery releases gasses at a much slower rate Under normal conditions the bat tery doesn t vent at all and the gasses are absorbed back into the electrolyte You must be careful how ever not to charge the bat tery at too high a rate There is a pressure relief valve in the battery which will vent gasses when pressures get too high but fluid that has been lost this way cannot be replaced In storage the main tenance free battery dis charges internally at a almost six months Initial servicing of a new Yuasa maintenance free battery is pretty slick The electrolyte for these bat teries is supplied in a spe cial container When inverted and pushed into the filler openings the con tainer automatically dis penses the fluid into the battery with no spilling and no mess DO NOT punc ture or remove the foil seals on the electrolyte container They are pierced automatically as you push the container down into the filler ports in the battery To seal the bat tery push the cap strip down into the filler ports until the strip is flush with the top of the battery After 10 minutes check the bat tery voltage If it is below 12 5v charge the battery at 1 1 5A for two to five hours before putting it into use If it is below 11 5v charge it for at least 10 hours O The Technical Magazine 9 i i ae ees Is it premix or is It Straight H ave you eve
18. formance work Representatives from the Serdi Corporation demonstrated a new high tech method of cutting valve seats in four stroke engines The Serdi Micro is a new seat cutting tool that will cut all the valve angles in one operation with its unique cutting tip The work spindle that holds the cutter is adjustable to accommodate any valve angle and it can cut seats from 14mm to 48mm The inexpensive replaceable cutter tips can be ordered in any angle or width desired Serdi offers several kits tailored to your needs and budget If you have ae shoul oot the Serdi Micro please contact p Qe oe LTE TOTS Ben Peccoux at 2 the Serdi Cor poration telephone 404 493 8220 J Nowocinski If your shop has a lot of high per formance business check out this new F high tech valve seat cutting tool from the Serdi Corp FROM THE SPECIALISTS Save a taper by Gregg Thompson Sr Product Support Specialist Have you ever thrown away a crankshaft be cause there was some fret ting metal transfer on the flywheel taper and you couldn t get the flywheel to stay on In fact any damage to the tapers of the crankshaft or flywheel will reduce the grip when the parts are bolted together However the parts can often be saved even though this kind of damage has occurred The trick is to remove any high spots from both tapers and then lap both parts together Use a flat file
19. garm looks a lot like the one on last year s factory F I racer The axles and swingarm pivot are a generous 25mm in diameter for rigidity and hollow for light weight Ray St John S H O P L a Se a O A Oe A On O E carbs with flat slides opened directly by the throttle linkage They have no diaphragms or pistons and when you twist the grip all the way they are open To meet emissions standards the ZX 7R s carbs come with some unique and interesting features see sidebar Crank drivetrain Moving the cam chain to one end of the crank shaft let Kawasaki s en gineers shorten the crank decrease the distance be tween bearings and reduce the diameter of the journals It is lighter and more rigid than the 90 model s crank The transmission shafts are spaced slightly farther apart in the new engine allowing the gears to be larger in diameter and thus stronger The primary drive gears are specially manufactured for strength and low noise The clutch has eight fric tion and seven steel plates for increased heat and torque handling capacity The steel plates are knurled to prevent the clutch from sticking when the engine is cold and the friction plates are radially grooved to allow good oil flow for clutch cooling A magnesium cylinder head cover pulser cover and output sprocket cover contribute to overall weight reduction Dual oil pumps in the lubrication system one for the oil cooler and o
20. gt Twist lock plugs The Kawasaki GE4000 and GE4500 series gener ators have one 240v and one 120v twist lock type outlet The matching twist lock plugs do not come standard with the gener ator They are however available from your local electrical supply store The NEMA designation for the appropriate twist lock plug is embossed on the front of each of these out lets The 240v four prong outlet uses an L14 20 plug and the 120v three prong outlet uses an L5 30 plug Gregg Thompson S a oa ed One Ae ae IST S No muss no fuss no maintenance by Jerry Heil Training Development Coordinator New to Kawasaki motor cycles this year is the Maintenance Free Battery which can be found on much slower rate At room temperature a convention al battery will drop from a full charge to 70 percent charge in about 2 1 2 months The same drop in charge with a main tenance free battery takes both 91 ZX 7 models and the 750 Zephyr Main tenance free means just that with only a few spe cial considerations The electrolyte solution in an ordi nary battery re leases oxygen and hydrogen gasses readily at normal charging and discharging rates A vent is required to prevent pressures that could crack the battery case The vent of course allows the gasses to es cape and water must be added occasionally to maintain the proper electrolyte dilution and fluid level The
21. ickly to check the fit And when one part is new and the other is used the tapers should be lapped together even if there is no damage visible on the old part O ie a a ne a on One T H E Voyager sound tips When a Voyager customer comes to you with a man gled and shredded cassette tape in his hand complain ing about his tape eating cassette deck don t re place the deck without first cleaning it Clarion has reported to us that a large percentage of the cassette decks returned to them for repairs needed nothing more than cleaning There are lots of cassette head cleaning tapes available in just about any store that sells blank tapes You should have one in your shop and recom mend that your customers buy one too Because of the Voyager tape decks location it s out there in the breeze it needs cleaning a lot more fre quently than a home or car stereo unit Frequent clean ing will extend the life of the tape head and other internal parts and will greatly reduce the chance that a deck will eat the customer s favorite tape Incidentally Clarion has also reported that many dead radios are being replaced when they needed only a fuse The Voyager XII radio has two inline fuses that should be checked any time the unit fails to come on or doesn t light up The fuses are located inside the fairing behind the headlight The Voyager 1300 does not have these fuses Bob Ellison
22. in direct sunlight Direct sunlight is too bright and the photo of the hull will be overexposed the crack washed out completely by the reflective white hull It s best to take the picture on a sunny day in the shade of a building n Don t use a flash Like the sun a camera flash reflecting off the glossy white hull will overexpose the area you re trying to show n Increase the visibility of the crack Rub some charcoal or graphite pencil lead into the crack Then wipe with a clean cloth The char coal will wipe right off the paint but stay in the fibers of the cracked area WE Make sure your pictures are in focus If you re using a Polaroid camera don t get too close Most Polaroid cameras won t focus any closer than about three feet or so The same holds true for many point and shoot auto focus 35mm cameras Check on the lens bezel or look in the owner s manual to find the minimum distance for your camera E Remember if you take a picture that doesn t clearly show the damage don t send it Take another one We cant make a decision about warranty authorization if we cant see the problem O The Technical Magazine 7 TIlPs I High tech valve seats The Technical Hotline staff was recently introduced to a new high tech method for cutting valve seats and we would like to pass this information on to you This tool may be especially interesting to those shops that do a lot of cylinder head work or high per
23. ind that there are fewer of them Exceptional customer service starts with the idea that service is the store s main product and the single most important item the shop has to offer In future issues we ll try to offer some specific ideas tips and strategies for helping you to help your customers Stay tuned Mary Sola Primer Bulb run for a day or more a few squeezes of the primer bulb before the first start up will ensure quick and easy starting This is one of those little pieces of information that can save a lot of aggravation Gregg Thompson lf you have a 650 Tandem Sport customer complain ing of hard starting be sure to ask him if he is using the primer bulb before starting Actually it would be a good idea to tell all your Tandem Sport customers that any time the vehicle has not been 11 The Technical Magazine REGIONAL NEWS WEST It s that time of year by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 It s that time of year when the volume of work flowing into the service depart ment slows to a reason able level In fact in some cases it becomes what a few dealers call the slow season the perfect time to enjoy being caught up with all of the service work and take a breather think however that most people out here in the west think of this as the catch up season It s a good time to do all the things you ve wanted to do
24. meter the car buretors must be re jetted to lean the mixture The intake kit P N 99995 1222 contains all parts necessary to make the conversion including the jets and needles for the carburetors Dealer cost for the kit is 107 97 Complete installation including re jetting should take less than an hour David Corey TIPS F ROM TH See ee Don t forget those spokes In today s high tech world of motorcycles wire spoke wheels are becoming rare if not a thing of the past Because of this they are sometimes overlooked It is very important to check spoke tightness at pre delivery set up and at normal service intervals Bikes ridden off road should be checked every time out and es pecially after the initial prevent excessive wheel runout and subse quent dam if N ET Lys i 1 1 k OSS Snel 25 break in ride This will DS CASS 4 A t Wf a A A OALA j GFK O F Ri 4 OR OF proper size wrench and go around the rim turning each spoke nipple a small amount Keep doing this going around the rim until all the spokes are snug This will help keep the rim aligned and concentric with the hub John Porno Aa eS Se ga N SHUAN D a N T age to the rim XX SNS S or to the hub spokes always use the I Careful with the camchain H ere s a tip for the next time you take the cams out of a ZX600 ZG1200 or ZN1300 engine Always have the v
25. ne for the en gine and transmission prevent oil pressure drop to critical engine parts One engine in two forms sharing a single promise performance O TECHNICALITIES The Z 7R carb ingenious and effective Setting the 91 ZX750 K apart from the J model 750 are its new Keihin CR flat slide carburetors The J s are 38mm CVKD versions of the constant velocity carburetor that has mixed fuel in just about every model of motorcycle produced in the last decade The ZX 7R s 39mm carbs are a corn plete departure from con stant velocity types more like a much updated ver sion of the type used on the original Z 1 Kawasaki Since the ZX 7R intake tract is angled up 47 from the horizontal the slide would normally be tipped over 47 from the vertical In this position gravity and manifold vacuum work together to create lots of friction between the slide and the carb body To counteract this the slides are Teflon coated and angled in the carburetor body back toward the ver tical In addition two rollers located on each side of the slide further reduce fric tion The resulting reduc tion in effort to move the slides gives the rider very precise throttle control An accelerator pump provides up scale throttle response while maintain ing low exhaust emissions Fuel from the inter car buretor fuel supply line passes through an exter nal line to a shut off solenoid then on to the diaphragm type accel er
26. nine good service will be the underlying concept and practice for every successful operation in the 90s No longer is it enough just to give good customer ser vice only exceptional service will gain and keep cus tomers As you know keeping customers is the key to surviving in today s economic climate OK you ve gotten the idea that service is a good deal for you as well as being good for your customers Where do you go from there What are the most important ele ments in providing customer service How do you move from good to excellent And how do you handle the cus tomer who makes you wonder why you ever got into this business in the first place Good questions and ones we ll be trying to answer in the next few issues of K Tech News E We ll start with attitude Attitude is probably the single most important factor in delivering customer ser vice excellence That we re here to help mentality must come from the store s owner and it must be shared by everyone who works in the shop no matter how much or how little direct contact with customers he or she may have All of the store s employees have to work together all of the time to solve problems and provide service When everyone thinks of him herself as being on the customer s side ideas for delivering great customer ser vice seem to come more easily Suddenly handling that difficult customer isn t as hard as it used to be either In fact you ll probably f
27. r wondered if that gas can over there or that customer s JET SKI watercraft has premix or straight fuel in it You smelled it poured some in a glass to check the color dipped your fingers in it and you still weren t sure Well you might want to try this Take a strip of plain white paper like typing paper and dip it into the fuel in question Then dip another strip into some gasoline you know is straight After both strips have dried you will be able to see a slight dif ference between the two if the questionable gas is premix The oil in the premixed gas will not evaporate and it will leave the paper looking slightly damp and discolored The more oil there is in the gas the greater the dif ference between the two Strips of paper Tevis Moffett 10 K Tech News F ROM T HE SPECIALISTS Attention service managers n order for us to process your warranty claims quickly and efficiently we need you to completely and legibly fill out all the appropriate blanks on the claim form The follow ing is a list of the problems we most often see on warranty claims WE Dealer number is omitted or incorrect WE Failure and repair dates are omitted These are required on all claims The failure date is the day the customer first notified you of the problem W Purchase date omitted on claim types 4 and 5 Spare part and accessory claims must include a purchase date E Claim type omitted or in
28. stroke engines it can work its way past the rings and collect in the through cracks in any of the rubber parts Air cleaner service for off road vehicles should al ways include a careful in spection of the intake connections and clamps And be sure to grease the foam seal on the back of the filter element generously to ensure a perfect seal against the air crankcase oil damaging the bottom end as well How do dirt and dust get into the intake tract There are several poten tial sources The air filter of course is designed to pass air with as little resis tance as possible without passing any dirt Today s air filters normally do a very good job of this But as the filter collects dirt it restricts air flow more and more As the restriction in creases the air begins to find other ways to get in and all of them are downstream of the air fil ter As the air leaks past the various connections in the intake tract down stream of the filter it car ries fine dirt with it Dirt comes in through loose worn or misassembled connections and or 6 K TechNews box Kawasaki s Marine Grease P N W61080 016 is excellent for this Sealing all the connec tors in the intake system with Kawasaki Bond P N 56019 120 greatly reduces the chances of dirt getting past them Kawasaki Bond is not af fected by the gas and oll present in the intake tract and remains pliable enough that it won t crack
29. ted training schedule to your dealer ship every month starting in late September This mailer lists the class selec tions for all regions and generally covers a two month span For instance your dealership should recently have received the schedule of training clas ses in January and February 1991 Technical Training clas ses are also listed on the back page of K Tech News so if you havent seen a schedule recently look to your right lf you aren t getting a CONTINUED ON PAGE 11 Training Schedule East Region December 4 7 Engines 11 12 Fuel Systems 13 High Performance Engines 18 Service Department Operations K BOSS 19 20 ATV Service January 3 4 Fuel Systems 8 11 Engines 22 24 JET SKI Watercraft 29 High Performance Engines 30 31 Troubleshooting Electrical Systems North Region January 15 Service Department Operations K BOSS 16 17 Team Green Race Preparation 18 HighPerf JET SKI Watercraft Central Region January February 28 High Performance Engines 29 1 Engines South Region December 3 5 JETSKI Watercraft 10 High Performance Engines 11 14 Engines 17 20 Troubleshooting Electrical System January 7 9 JETSKI Watercraft 14 15 ATV Service 16 Service Department Operations K BOSS 17 Generator 21 24 Engines West Region December 10 11 Troubleshooting Electrical System 12 Generators 13 Voyager Familiarization 17 19 JET SKI Watercraft 20 Service Dep
30. the ZX600 D engine This design results in better cooling at the top of the cylinders where they are hottest and most likely to distort The larger diameter cylinder liners have eS 0 Ge ee D Oe we A On O S shorter skirts to allow the air in the crankcase to move freely from cylinder to cylinder as the pistons rise and fall This cuts pumping losses and in creases high rom power notably E Carburetion The 91 ZX 7 has 38mm constant velocity carburetors like the 90 model for good fuel mileage low exhaust emissions and superior driveability on the street The R model is equipped with Keihin FVKD 39mm TECHNICALITIES Suspension Upside down forks are the big news in front sus pension today And both new ZX 7s have them But they don t have the same ones While they share springing and damping rates the ZX 7R has 41mm diameter tubes 2 K Tech News with 2 3mm thick walls while the ZX 7 has 43mm tubes 2 0mm thick The R model forks are unique in having seven way adjus table compression damp ing Both models have threaded preload adjusters and 12 way rebound damp ing adjustment The rear suspension on both new bikes features gas charged shocks and bottom linkage Uni Trak Rear suspension preload is infinitely adjustable and rebound damping is four way adjustable The rear shock on the ZX 7R only has a remote reservoir as well as 20 way adjustable compression damping The swin
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