K-Tech News Vol.2 No.4
Contents
1. 0400 ext 2573 or fill out the illustration above the Micro K report card P N M99994 152 O 8 E TECH NEWS K TECH NEWS STAFF CONTRIBUTORS 1990 Kawasaki Motors Corp U S A Publisher Kawasaki Tech Services Randy Davis Bob Ellison KMC All rights reserved Publications Manager Don Church Mike Jeffers Tevis Moffett Executive Editor 0 Gary Herzog Ken Osberg John Porno Steve Rice Published by Kawasaki All suggestions Editor in Chief Gregg Thompson Mary Sola Ray St John Bill Zito become the property of KMC Sending a service suggestion gives Kawasaki per REGIONAL EDITORS GRAPHICS AND PRODUCTION mission to publish and or use it without North and East Fred DeHart Graphic Art Tim Bean G Thompson further consideration Specifications sub Central and South Walter Rainwater Copy Editor assesseer Pat Shibata ject to change without notice West and Corporate Patrick Kelly Production Nickless Communications The Technical Magazine 5 TIPS FROM THE SPECIALISTS Mule 1000 Transmission Short Cut ONTRARY TO WHAT the service manual tells us it is possible even practical to remove the transmis sion assembly from the Mule 1000 KAF450 without removing the engine STEVE RICE ILLUSTRATION Limited Slip Diff Oils for 4x4s HE KLF300 BAYOU 4x4 Owner s Manual calls for SAE 140 LSD GL 5 oil in the front differential It has come to our2. Train ing classes provide you with the what how and why necessary Gr ee t in gs l by Patrick Kelly West Region D LIKE TO take this op portunity to in troduce myself My name is Patrick Kelly and I m very pleased to be the new train ing instructor for the West Region have been an en thusiast of and have enjoyed working with Kawasaki pro ducts for many years My back ground consists of extensive formal training in the field of motorcycle mechanics as well The Service Department Make It to understand our products This understanding will make your job easier and increase your efficiency As you can see from read ing this issue of K Tech News our training classes have been restructured and new classes are being offered Make sure you read the technical training schedule bulletins as they ar rive at your dealership Sign up early look forward to meeting with you as we learn together Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 as practical experience from having been an owner of a Kawasaki dealership More recently was an instructor for a motorcycle mechanics school where gained teaching ex perience in all aspects of motor cycle operation and repair look forward to meeting all of you when you attend clas ses at the West Region training center Hope to see you soon Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 77
3. Your Compression Gauge Fool You HEN CHECKING compression on some of Kawasaki s liquid cooled four valve engines note that some aftermarket compression gauge adapters such as those made by Snap On may give incorrect i e low readings This is especially true when the smaller 10mm and 12mm spark plugs are used Why Well the space around the spark plug hole is very small on these engines some aftermarket gauge adapters don t fit properly and can leak Also many of our late model engines have over 200psi cranking pressure and some aftermarket adapters simply don t seal tightly enough at the cylinder head to prevent leakage at those high pressures The type of gasket and method of tightening the adapter will have an affect on this Sometimes an aftermarket adapter can be modified to work bet ter If you already have a complete or nearly complete compression tester set you may want to take this route But if you don t already have a complete compression gauge set you should consider buying the Spin On Oil Filters HE FIRST TIME an engine is started after an oil and filter change there will be a delay before oil pressure comes up while the oil lines and filter fill up with oil Most of this delay is caused by an empty oil filter You can significantly shorten this time by filling the new oil filter with oil before installing it Just set the fil ter on the bench open end up and pour oil into the center threaded
4. hole It will take a minute for the oil to soak into the filter element and you ll have to top it off a couple of times A little oil may dribble out while you are spinning the filter onto the engine but the reduction in engine wear is well worth the minor clean up required Gregg Thompson genuine Kawasaki gauge and adap ters They are more expensive but they re especially designed for our engines and they work no hassles Here are the part numbers for the Kawasaki compression gauge and adapters 10mm and 12mm long and 12mm and 14mm short Gregg Thompson 57001 1018 12mm Adapter long 57001 1159 14mm Adapter short 57001 1179 10mm Adapter long 57001 221 Compression Gauge gauge only 57001 1183 12mm Adapter short EX500 Shift Return Spring AVE YOU EVER had an EX500 customer come into your shop complaining that his transmission would no longer shift and dis covered that the shift shaft return spring had popped off the back of the shift pawl In the past when the Hot Line technicians received calls about this we would suggest the dealer in stall a 1mm spacer on the shift shaft between the locating circlip and the transmission cover This reduced the end play in the shaft and proved to be an effective fix Recently however Kawasaki Quality Assurance people have identified the problem as the spring itself In current production a dif ferent spring is being used the old spring is no lo
5. ll have to remove the pump assembly and reseal the top and sides to the hull If you suspect the pump might not be sealed proper ly to the hull you can quickly and easily check it out Set the boat on its side if possible and remove the intake grate Then spray a soapy water solution all around the leading edge of the pump housing and blow high pres sure air in the back between the housing and the hull If it s not sealed properly you will soon see bubbles at the leading edge of the pump Gregg Thompson UAS Don t Drill That Hull Yet N THE PAST all JS300B late model JS440A and JS550A JET SKI watercraft hulls came with a reinforc ing plate inside the lower rear corners of the hull The plate was there to hold the rivets that fasten the stabi lizers to the JS550 hull The plate has been on all these boats for several years and many technicians have put 550 stabilizers on 300s and 440s assuming that the plate was in there However for part of the JS440 A14 production run the plate was not included in the hull JS440 A14s from hull number KAW00395H990 through KAW01005K990 do not have the plates and should not be drilled to ac cept the JS550 stabilizer without the reinforcing plate the rivets will not hold 8 K Tech News Please keep this information where you can find it if you ever take in a JS440 A14 to which you re consider ing adding the stabilizers Gregg Thompson Don t Let
6. the 1990 KX model bikes themselves Where there are differences between the writ ten materials and a bike the bike is probably right But just in case here are the correct standard jetting specs for the 1990 KX125 250 and 500 KX125 H1 KX250 H1 KX500 E2 Air Screw Opening 1 1 1 Throttle Valve Cutaway 6 7 7 Pilot Jet 52 60 60 Jet Needle N84C N85C N82M Jet Needle Clip Position Main Jet Gregg Thompson Fuel Injection Tip HEN DIAGNOSING a rich running condition on any of our fuel injected bikes especially one that s been stored for a long time don t forget the fuel return check valve in the fuel tank First check the fuel level in the filter If it is over 1 3 full replace it If fuel level is still high check fuel pressure If the fuel pressure is high over 36psi check the fuel return check valve in the fuel tank If it is corroded and stuck or blocked a rich condition will result Bob Ellison The Technical Magazine 11 REGIONAL NEWS aE Kawasaki i TRAINING eli t Ho wW by Fred DeHart North amp East Regions TRULY great tech nician is not just a person who can disas semble and as semble a piece of equipment The technician must also understand what each part is meant to do why it was designed to do it and how it gets the job done This type of un derstanding assures quick diag nosis of problems and proper assembly of components Kawasaki Technical
7. the engine are a little hard to get out with everything still in the chassis but you can do it By using this method you ll not only save time but also the aggravation of dealing with the cooling and electrical systems The same basic idea holds true for engine removal The difference is that when removing the engine you must disconnect all the cooling and electrics You can leave the rear axles in place which has the added benefit of leaving you free to roll the chassis around with the engine out When reconnecting the transmission and engine be careful with the O rings and gaskets Randy Davis 100cc Kits AWASAKI has developed 100cc kits for both 1990 KX80 models A new cylinder and piston increase the bore to 52 5mm for an actual final displacement of 99cc and increased compression ratio of 8 9 1 These kits will make the KX80 models even more competitive than they already are in 100cc class racing Horsepower and torque are increased throughout the entire rom range The kits also include a 48 tooth rear sprocket for the KX80 L3 49 tooth is standard and 52 tooth rear sprocket for the KX80 N3 54 tooth is stand ard to take full advantage of the power increase The kits may be purchased under P N 99995 1031 KX80 L3 or 99995 1032 KX80 N3 For more infor mation refer to Racing Support Bulletin RS89 09 Mike Jeffers KSF250 Kickstarter Gear Breakage F SOMEONE BRINGS A KSF250 Mojave into your shop with brok
8. 0 0400 A t t rac ti Ive by Walter Rainwater South amp Central S A PRO fit center the service de partment buys labor and parts at wholesale and markets them at retail The de l gree of success in marketing service determines the amount of profit 12 K Tech News The first step in marketing a product is to make it attractive and desirable to the consumer Most products are placed in at tractive packages covered with statements proclaiming their vir tues The physical appearance of the service department is the package for the service product CONTINUED ON PAGE 11 East Region Training Schedule Classes Held In Piscataway N J MARCH Fuel Systems Service Department Operations High Performance Engines ATV Service Parts Department Operations Generator 27 29 JET SKI Watercraft North Region Training Schedule Classes Held In Grand Rapids Mich MARCH 1 2 ATV Service Central Region Training Schedule Classes Held In Fort Worth Tex MARCH 26 27 Team Green Race Preparation 28 30 JET SKI Watercraft West Region Training Schedule Classes Held In Irvine Calif MARCH Voyager Familiarization 8 Generator 12 14 Police Motorcycle Maintenance 15 Shaft Drive 19 Service Department Operations 20 21 Team Green Race Preparation 22 Product Update 26 28 JET SKI Watercraft 29 High Performance Engines South Region Training Schedule Classes Held In Atlanta Ga MARCH JET SKI Water
9. CLUTCH 13088 13088 1051 PLATE FRICTION 13089 13089 1066 PLATE CLUTCH 13091 13091 1085 HOLDER CLUTCH PUSH ROD M To further simplify the ordering of painted parts the Color Combination Parts List has been added to all 1990 parts microfiche This list supplies the part number description and market area of all painted parts in an organized and easy to use chart In the accompanying example see below from the the ZX600 D1 microfiche 413095 13095 1149 HOUSING COMP CLUTCH 13116 13116 1126 ROD PUSH CLUTCH 13187 13187 1006 PLATE CLUTCH OPERATING 13231 13231 1062 RELEASE ASSY CLUTCH 13256 13256 1052 PISTON 43056 43056 1052 BREATHER BRAKE 43057 43057 1001 CAP BREATHER 92001 92001 1066 BOLT sFLANGED 6x18 92015 92015 1555 NUT 20MM 92022 92022 1719 WASHER a y a m nh mh ad oo a gt md md md md a 0 gt gt d N a h h h gt j OO 92022A 92022 17 there are two lists of painted parts one for MEN pondered T50FE015541 Seuss each color The lists will appear on the A L row The O indicates that the pat num gzo22c 92022 18 ber is applicable for the market area The e Eo X indicates that it is not applicable A single parts catalog may include up to five model Sara a a years and a model year may include more than one ci choice of colors or graphics Factor in the need for infor COLOR COMBINATION PARTS LIST mation on market area U S a
10. F E TECH NEWS Winter The Kawasaki Tech ical agazine Vol 2 No 4 by Tim Bean Program Developer NTRODUCING THE KL650B TENGAI Kawasaki s latest ad dition to the dual purpose family of motorcycling This bike combines proven engine technology from the KL650A with sleek frame mounted half fairing flush mount headlight aerodynamically efficient front fender and Ninja style turn signals The latest technological features make the Kawasaki Tengal the ultimate in dual purpose adventures Its air adjustable front fork offers 220mm of road absorbing travel with 4mm thick inner tube wall thickness for less deflection and a confidence inspiring ride Rock steady Uni Trak suspension design with five way preload and four way rebound damping helps keep the rear end planted firmly on all surfaces Bringing the Tengai down to speed quickly and smoothly are Balanced Actuation Calipers BAC with two different sized pis ROUTE LIST O SERVICE LJ PARTS LU SALES tons for spreading the braking force over a larger area of the disc and reducing abnormal pad wear At the rear is a powerful single disc brake both front and rear discs are protected by durable colored plastic covers Seating height is lowered by 30mm which in turn helps to lower the center of gravity for sure footed handling and control Other features include aesthetically appeal ing frame mounted instrumentation which in cludes speedometer tachometer and temp e
11. SRNE of ee dss KX80 M2 3 N2 3 99924 1123 51 99924 1094 01 KX80 M1 N1 e wae Fe eee ec KX125 G1 99924 1116 51 99924 1101 01 KX125 F1 originally appeared in the service KLF185 A1A A2 99924 1076 51 99924 1058 01 KLF185 A1 manual for the older model the EL250 B2 3 4 99924 1093 51 99924 1066 01 EX250 E1 KLF300 A1 So you need two EX250 F2 3 4 99924 1109 51 99924 1066 01 EX250 E1 separate books to have all the in KL250 D2 7 99924 1051 03 99924 1050 01 KL600 A1 Cee AR KX250 G1 99924 1116 51 199924 1101 01 KX250 F1 SETE a a KLF300 B1 2 3 99924 1100 51 99924 1057 01 KLF300 A1 ine KLFS00 DI cen ca manual KLF300 C1 2 99924 1117 51 99924 1057 01 KLF300 A1 supplement O EX500 A1 2 3 4 99924 1082 51 99924 1056 02 EN450 A1 KX500 E1 99924 1116 51 99924 1101 01 KX500 D1 KL600 B1 99924 1063 52 99924 1050 01 KL600 A1 ZL600 A1 2 99924 1073 51 99924 1055 01 ZX600 A1 ZX600 C1 2 3 99924 1081 51 99924 1055 01 ZX600 A1 KL650 A1 2 3 99924 1080 52 99924 1050 01 KL600 A1 ZL900 A1 2 99924 1077 51 99924 1048 01 ZX900 A1 ZL1000 A1 99924 1077 81 99924 1048 01 ZX900 A1 ZG1200 B1 4 99924 1089 51 99924 1064 01 ZG1200 A1 ZN1300 A1 6 99924 1037 02 99924 1015 04 KZ1300 A1 PERSONAL WATERCRAFT JS300 A1 2 3 4 99924 1070 51 99924 1059 01 JS300 B1 JS440 A8 14 99924 1091 51 99963 0054 01 JS440 A1 JS550 A3 8 99924 1075 52 99963 0051 01 JS550 A1 JF650 B1 2 99924 1122 51 99924 1069 05 JF650 A1 JS650 A1 2 3 4 99924 1087 53 99924 1069 05 JF650 A1 The Techni
12. ak out the back If water leaks out from aroundany of the tubes seal those tubes to the hull in the back where the water is running out Use the Kawasaki Hull Repair Kit or some other sea going epoxy putty Do not use silicone sealant you want this repair to be permanent lf water leaks out from inside the driveshaft tube you must seal the front end of the tube to the bulkhead To do this you have to remove the driveshaft and bear REGIONAL NEWS South amp Central CONTINUED FROM PAGE 12 Are your technicians in uni form Is the floor clean Are the walls clean Is the shop well lighted Are the signs of profes sional quality Do you have your labor rate posted If you answer No to one or more of these ques tions you need to improve the packaging of your product to make it more desirable to your customers Once the service department is ready to make money it needs to be promoted just like your other profit centers The service depart ment already has a list of potential customers from your sales records The bottom line is that you and only you determine what your service business is and what it will be like in the future Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 Seal with epoxy putty 1990 KX Model Standard Carburetor Jetting OPS IT SEEMS there are some differences regarding standard car buretor jetting between the microfiche owner s manuals and
13. arned a B A in Business from the University of San Francisco Our newest Consumer Analyst Sharon Reynolds came to KMC in early November after working in the customer service department for a computer printer manufacturer for eight years Sharon graduated from Butler University in Indiana with a Bachelors Degree in English and has taken classes towards a Master s degree We look forward to providing the high quality customer service you and your customers have come to depend upon O Dae S rtment FOREGROUND Jan Raym STANDING L TO R Donna Hood Mary Sola and Sharon Reynolds ond by Bill Zito National Police Motorcycle Coordinator T ONE TIME OR ANOTHER as Kawasaki dealers servicing police motorcycles you have had questions comments and or com plaints about the Kawasaki police motorcycle Sometimes these en counters can be less than friendly and you might have found yourself wishing there was someone at Kawasaki Motors Corp U S A to whom you could go for assistance Well there is the Kawasaki Police Motorcycle Coordinator As the Police Motorcycle Coordinator work with and for Kawasaki over the United States In the months ahead articles pertaining to the police motorcycles and the police motorcycle program will begin appearing in K Tec News In the meantime if you or your local law enforcement agen have questions about the police motorcycle or its support prog
14. attention that this exact oil can be hard to find That s the bad news the good news is that you can substitute other limited slip differential LSD gear oils for the one listed in the manual without creating problems LSD oils are available at almost any automotive supply store The most common viscosity is 80W 90 but many manufacturers such as Val voline Pennzoil and Quaker State offer an 85W 140 LSD oil The impor tant thing is to make sure the oil you choose is GL 5 rated and formulated for limited slip differentials It will say so on the label In extreme conditions such as high heat or very hard use you should probably use either a straight 140W or an 85W 140 oil In the event that one of these LSD oils is not available in your area several manufacturers offer an LSD additive that can be mixed with any GL 5 oil to make it work in limited slip differentials non LSD 85W 140 GL 5 oil is easy to find LSD additive is available from most auto supply stores Kendall Oil suppliers and even your local Chevrolet dealer Kenny Osberg 6 K Tech News There really are no tricks to this time saving tip Remove both torque converters and covers Pry the axle shafts out of the differential disconnect the swing arms from the chassis and move the assemblies out of the way Now unbolt the transmission case from the en gine case and pull out the transmission assembly A few of the bolts connecting the transmission to
15. cal Magazine 3 SHOP TALK TECHNICAL Upside Down Forks Oil Level vs Air Volume by Gregg Thompson Tech Support Specialist NSTRUCTIONAL DESIGNER Jerry Heil did a good job of explaining the theory behind the inverted forks featured on Kawasaki s latest KX125 250 and 500 models in the last issue Now that the bikes are here weve heard that some technicians are getting a little sideways when working on the new upside down forks Confusion can arise when you attempt to check or adjust the oil level and find that it s higher than the stan dard spec even if you just rebuilt the forks yourself and very carefully set the oil level at the standard spec Can this happen You bet it can In fact it s Supposed to happen Are you confused by that fact Read on After rebuilding or when changing the oil in these new forks all the air must be purged burped from the fork assembly To do this the fork must be compressed and then filled to the top with oil NOTE During this procedure the spring must be removed but the nylon spring guide and cap must be installed on the fork rod Make sure that both rebound damping adjuster rods are inside the fork rod The long straight tube goes in first and the short machined piece goes on top see Figure 1 Purge the air from the fork cylinder by pumping the fork rod up and down Purge the air from between the inner and outer tubes by pumping the outer tube up and down While do
16. craft JET SKI Watercraft High Performance Engines High Performance Engines Team Green Race Preparation Generator EE
17. en kick starter gears be sure to take a compression test Since this engine has an automatic compression release KACR the kickstarter gears are not designed to handle a lot of compression during starting Cranking pressures should not be higher than about 120psi the book spec is 115psi If you run across one with broken starter gears and high cranking pres sures check the automatic compression release mechanism on the cam shaft If it seems to be operating properly but still has high compression call the Hot Line for more information John Porno Mule 1000 Trans Improvements NDER EXTREME USAGE some KAF450 B1 Mule 1000 s have suf fered major transmission failures Kawasaki believes this is the result of repeatedly shifting the transmission into gear when the engine is above a normal idle speed such as when the starting enrichener choke is on Though this is not what we consider normal usage it is fairly common and the resulting damage is considerable For this reason Kawasaki has modified some of the transmission parts Tires Why OEM OU MAY HAVE WONDERED why Kawasaki recommends using only OEM Original Equip ment from Manufacturer replace ment tires for its products The reason is that tires have a tremen dous overall affect on the handling characteristics of a motorcycle and different tires can affect different areas of performance What areas Both low and high speed handling traction respon
18. etting the oil level in a fork is really a round about way of adjust ing the air volume in the fork The above procedure will provide an accurate and consistent air volume in both forks After the initial adjust ment the air volume in the fork can be changed by ad ding or subtracting a precise oil volume If you re experimenting with air volumes oil levels keep accurate records of oil added or removed after the initial set up The next time you change the oil set the oil level the same way and then add or subtract oil again to get the air volume where you want it O COMMUNICATIONS Next verify that the description found in the part M l C RO E E description line B is correct Look for different colors by Micro Mike Jeffers Parts Publications Specialist effective frame number ranges that may apply Finally confirm that the part number applies to the HEN USING THE PARTS MICROFICHE are you correct market area The market areas are indicated by confused by the dotted lines below the part the abbreviations US for United States CN for description Do you know what these lines are used for Canada and CA for California example C For explanations of this and other 275 aspects of the parts ordering system read DEn the Parts List Introduction section on Row A of every parts microfiche tg Part No Description Spec Code 11012 11012 1569 CAP PUSHROD A 13087 13087 042 HUB
19. ing this take care to keep the oil level topped off so that it stays above the two large holes near the top of the inner tube After purging the air from the assembly let it sit for about five minutes so that any suspended air bubbles can surface 4 e K Tech News With the fork compressed and the damper rod all the way down draw the oil out to the desired level Now the oil level in the inner tube is at the desired level the oil between the inner and outer tubes however is still full to the top Fig 2 So the first time the fork assembly is extended from the fully compressed position oil will be forced from be tween the tubes into the inner tube through the holes at the top of it This raises the oil level in the inner tube If the fork is extended to the full length of its normal travel the oil level will be raised about 30mm Fig 3 NOTE Before the spring and fork cap are in stalled on the damper rod it is possible to extend the fork about 200mm more than the fork normally travels Be careful not to do this since it will force all the oil out from between the inner and outer tubes Some oil needs to remain in there to lubricate the bushings Because of the trans fer of oil from between the tubes into the inner tube the oil level will never again measure the same as it did when you set it at assembly see Fig 4 If this seems like a strange or impractical way of setting the oil level remember that s
20. m ramp angle is very shallow and the valve movement is very slight relative to crank movement It is impossible to tell within a degree or two when the valve first begins to move Farther up the cam ramp the valve is being opened much more rapidly and it is easy to detect valve movement at very small amounts of crankshaft movement Thus accuracy that is impos sible to obtain at valve opening is easy to achieve at 1 0mm of valve lift In some cases the manufacturer s checking specs may not be known In the case of Kawasaki OEM cams checking specs are not provided by the manufacturer To accurately set the cam timing you must use an ar bitrary checking height say 1 0mm and measure the opening and closing numbers at that lift From those specs you compute lobe center and com pare it to the lobe center computed from the service manual specs Once you get used to thinking lobe centers you ll begin to use LIFT DURATION and LOBE CENTER as indicators of what performance charac teristics a cam will provide Lobe center is not only just as important as lift and duration it s the only one of those specs a tech nician can adjust Gregg Thompson A Tip From Consumer Services F YOUR CUSTOMERS need to contact Consumer Services regarding a Kawasaki product be sure and tell them we will need the unit s identifica tion number Most of the records at KMC are accessed by ID number and when we have a VIN or HIN we can easily and accura
21. nd Canada and or parts ZX600 D1 required to meet emission control standards California plus all optional equipment available and you realize a lic Sonic Blue Candy Atlantic Blue GX 1 2 9o O i TcAT CN US Description lot of Information IS required i iD CAP FORK G GRAY x o x FORK FRONT G GRAY 3D COVER C CNT G There isn t room enough in the catalogs to have S cess ae S x ox PPELEFT FORK OUTER BLACK separate illustrations for each individual part nor would a Adie yo ioe the differences be readily apparent In the Kawasaki o amscomp swinc c Gray me cae RCE parts catalogs this problem of space has been solved FenoenassveronT c a sue x10 x TANK COMP UEL C A BLUE by using a single illustration accompanied by reference o Srav FR an amp emay x10 x LEATHER SEAT BLACK numbers The dotted line items are used to give Specific x coven sioe in suue rue x o x COWLING FR A BLUE a i 7 ae 3X COVER SIOE RH BLUE BLUE xiojx COWLING UPP BLUE BLUE information relating to the conditions noted above jE WHEEL ASSY FR G GRAY x o x COWLING LWR BLUE BLUE 3E WHEEL ASSY RR G GRAY xjojx MIRROA ASSY LH C A BLUE So when working with dotted lines follow this pro cedure Check to make sure the part number applies to WE Please direct all inquiries on microfiche related mat the model year listed in the quantity column see A on ters to Mike Jeffers 714 770
22. nger available and the new part number substitutes auto matically So if you run into this problem on a 1989 or earlier EX500 just order the shift shaft return spring shown on the microfiche and you will get the new improved part Gregg Thompson The Technical Magazine 9 TIPS FROM THE SPECIALISTS New Math Calculating Lobe Centers AVE YOU EVER had trouble remembering the formula for computing camshaft lobe centers If so here s a formula that might be easier for you to remember To show you how it works we ll use the cam specs listed in the service manual for the ZX 7 in take cam Open 35 degrees BTDC Before Top Dead Center Close 65 degrees ABDC After Bottom Dead Center To get the lobe center subtract the smaller number from the larger number 65 35 30 Add 180 to that number 30 180 210 Divide that number by 2 210 2 105 The lobe center for the ZX 7 intake camshaft is at 105 degrees After Top Dead Center Steve Rice 10 K Tech News Why Lobe Centers IGH PERFORMANCE camshaft manufacturers supply checking specifications with their cams Checking specs are valve opening and closing times at a certain amount of valve lift The cam manufacturer specifies the amount of lift 050 and 1 0mm are common checking heights and what the cam timing should be at that amount of valve lift The reason for doing this is that when the valve first begins to open the ca
23. ottle is opened but the boat won t go says the customer The problem is most noticeable when accelerating from a dead stop or coming out of a turn The slipping clutch sensation is caused by either cavitation or an im proper seal between the pump housing and the hull Cavitation is the formation of gas bubbles a partial vacuum in the water as it passes through the pump some cavitation occurs in all of our jet pumps during normal use You ve seen the effects of cavitation in the pitting that occurs at the base of the blades on stock aluminum impellers Excessive cavitation can be the result of damage to the leading edge of the impeller blades or pump guide vanes a rough transition between the hull and pump housing cobby silicone job or a foreign object such as seaweed in the intake grate A poor seal between the pump housing and the hull will result in air being drawn into the pump from around the pump housing This can sometimes be hard to spot The silicone will usually remain in place attached to the pump housing even though it has been separated from the hull This problem is much more noticeable in the larger heavier vehicles such as the Tandem Sport TS and the JET MATE Usually it results from insufficient amounts of silicone between the pump housing and the hull Simply adding more silicone to the outside along the leading edge of the pump housing will probably not solve the problem most likely you
24. ra please feel free to contact me at 714 770 0400 ext 2576 Mond through Friday 8 30 a m to 5 00 p m Pacific time dealers and law enforcement agencies all The Police Motorcycle Support Program A Special Program For A Special Vehicle h cy m ay look forward to assisting you with your police motorcycle needs O Bill Zito Police Motorcycle Coordinator 2 K Tech News COMMUNICATIONS Service Manual Supplement System by Ray St John Senior Technical Writer OME MODEL KAWASAKIS need one service manual some need two Why is this Well in the beginning there is only one service manual including all the in formation the technician needs to know to maintain and repair a rvice given model motorcycle watercraft generator etc Lets use for discussion s Vehicle Manual Supplement Service Manual Supplements and Base Manuals sake an example the KLF300 A1 This sturdy four wheeler which had a comprehensive service manual all to itself was followed by a similar all terrain model the MOTORCYLES AND ATVs KLF300 B1 To save time and reduce costs the factory chose to MODEL SERVICE BASE MANUAL MODEL OF produce only a service manual MANUAL SUPP PART NO BASE MANUAL supplement to cover the unique KX60 B6 99924 1123 51 99924 1094 01 KX60 B4
25. rature gauge New semi knobby TRIAL MAX tires provide a smooth ride on highway surfaces with longer wear and reduced road noise The dual purpose Tengai offers Freedom To Roam m INSIDE Customer Service Tips Galore and More RETURN TO SERVICE GUEST SPOT Meet The Consumer Services Department HERE HAVE BEEN some personnel changes made in the Consumer Services De partment recently and now seems like a good opportunity to in troduce the members of the group Mary Sola Supervisor has been with KMC as a Consumer Analyst for almost 10 years Prior to coming to Kawasaki Mary worked as a social worker She has a B A in English from UCLA and is currently working on a Master s in Business Administration Consumer Services Assistant Jan Raymond has also been with KMC over nine years six of them in Consumer Services Jan worked as a receptionist at the old Garry Street building and then for R amp D before joining the Consumer Services staff Jan has had previous customer ser vice experience in the retail automo tive field Donna Hood Consumer Ana lyst has been with the department for over two years having started her Kawasaki career as a temporary summer clerical worker Donna has had extensive public relations ex perience working for a variety of non profit organizations all over the country She graduated from the University of Kentucky with a degree in English and has recently e
26. sive ness to road conditions straight line Stability vs cornering response and wear Aftermarket tires may improve one performance area only to reduce performance in another a high traction tire may have less high speed stability for instance Kawasaki spends hundreds of hours testing before deciding on an OEM tire but this testing is done with OEM candidate tires not after market products Testing is expen sive and time consuming the same tests must be done with each tire for each model since a tire s characteristics can vary from one model to another and Kawasaki cannot do it for aftermarket tires When recommending replace ment tires offer advice based on the collective experience of your personnel Always let the customer decide but remember you can t go wrong recommending OEM tires Gregg Thompson to improve durability For a limited time all these modified parts will be avail able in kit form If a KAF450 B1 comes into your shop with a damaged transmission call the Hot Line for information about the kit The kit P N 99995 1193 in cludes some parts which have not been modified Gregg Thompson The Technical Magazine 7 TIPS FROM THE SPECIALISTS JET SKI Clutch Slipping F COURSE THERE IS NO CLUTCH in a JS650 JET SKI watercraft but every now and then a dealer must diagnose what really does seem to be a slip ping clutch The engine runs fine and revs up in the water when the thr
27. tely check on warran ty status repair history or previous contacts to either the Hot Line or Con sumer Services Generally this information allows us to quickly answer a customer s questions and helps us to resolve a complaint faster and more efficiently Mary Sola Tandem Sport Water From The Bulkhead FEW JF650 B1 TANDEM SPORTS have had a mysterious problem with water leaking into the en gine compartment through various holes in the bulk head Some dealers have mistakenly tried to fix this by sealing the holes in the bulkhead where the water was coming through Problem is there isn t supposed to be any water behind the bulkhead in the first place ing holder Fill any gap between the end of the driveshaft tube and the bulkhead with epoxy putty After performing this repair be sure to thoroughly drain the water from behind the bulkhead by tipping the back end of the boat up and letting it set for a while You may need to drill a small drain hole near the bottom edge of the bulkhead Gregg Thompson The real source of the water is not the bulkhead holes but instead one or more of the tubes that connect the pump area of the hull to the bulkhead These include the cooling water tube bilge pump tube steering cable tube and driveshaft tube lf you have a TS with this taking on water problem check all four of these tubes for leakage The easiest way to do this is to fill the engine compartment with water and watch it le
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