K-Tech News Vol.1 No.1
Contents
1. The wiring leads are run directly to the wiring harness and to the ON OFF switch located on the handlebar Follow the detailed instructions included in the fan kit NOTE Cooling fan diagrams can be found in the general information 1 10 section of the KLF300 BAYOU Service Manual Supplement P N 99924 1100 51 The kit is available through Kawasaki s Accessory division Follow normal accessory ordering procedures or call the Accessory division 426 8208 CA or 800 423 5726 for assistance W Offer as a special for the month P N 99995 1012 New Products STA BIL When added to gasoline Sta Bil will prevent the formation of gum and varnish in the fuel system of stored vehicles and equipment for up to one year Squirt the recommended amount of Sta Bil in the fuel tank Drain the fuel from the float chamber then allow the treated fuel to refill the bowls Run the engine for a short time to get the Sta Bil through the jets in the carburetor It is a good idea to fully service your customer s Kawasaki before storage Consider offering a winterizing service to help boost service labor sales in the off season Sta Bil comes in package quantity of 1 P N 1104 ALUMA COOL A full strength engine coolant formulated with T Triazole for maximum corrosion protection in aluminum cooling systems Aluma Cool also contains foam and rust inhibitors Designed primarily for use in aluminum engines2. The Kawasaki Technical Magazine Vol 1 No 1 BAYOU I n t r od u ct j on by Tim Bean Program Developer Kawasaki is proud to introduce the KLP300 C1 Bayou for 1989 The engine is based on our reliable KLF300B with changes made to the head cams and cab extracting more low end torque for stump pulling power Heavy duty adjustable independent suspension powerful twin piston caliper front brakes and a dual range transmission make this 4x4 stand up to the toughest jobs around The drive train is a full time four wheel drive system with a trick limited slip differential up front See the article on Page 2 of this issue for a detailed look at the four wheel drive system And for a brief technical look at other new models for Kawasaki in 89 check out our 1989 Product Sales Guide You will be surprised at what you ll find n Specifications Po ENGINE O CHASSIS Displacement anicucsnnancaranaaeanaaaas 290 cc Front Wheel Travel secseeeeeeeee 4 3in Bore amp Stroke cceeeeae 76 0 x 64 0mm Rear Wheel Travel eseeeeeeeenes 4 7 in Maximum Horsepower 20 6500 RPM Wheelbase d i Maximum Torque Compression Ratio Carburetor ccceeeeeeeeeeeeeenes CVK 32 Engine Oil Capacity c eeeeeee 2 3 Qts Starting System 05 Electric amp Recoil Ignition System TCBI w Electronic Advance BONY aikushavatdiaratscuainsadnnic
3. Number Model Description You guys make a difference How MC88 01 EX250 F2L Vacuum Hose Routing can help you say Well Jeff Arruda from Clark Kawasaki of Orange California informed us of a problem he discovered while doing the A amp P ona 1988 EX250 F2L He questioned the location of the evap hoses on the fuel tank Sure enough the hoses were mislocated and so were the color coded stickers on the tank The result MC88 01 Recall bulletin Thanks Jeff Good injured V TWIN FAMILIARIZATION See Service Bulletin TR88 02 This 35 minute video explains service and design features unique to the 700 750 cc V Twin The color coded adhesive decals on the gas tanks of 1988 California emissions equipped EX250 F2L models are incorrectly placed MC88 06 ZX1000 B1 L B2 L Rear Wheel Hub Damper On eligible units the rear wheel hub damper may slip out of position and become damaged during hard acceleration allowing excessive move ment between the hub coupling sprocket carrier and the rear wheel hub MC88 07 ZX1000 A1 L A2 L Accessory Backrest Recall The eligible backrest is not as strong as it was intended to be If the backrest breaks the passenger could fall off the motorcycle and be Kawasaki has initiated this recall campaign to remove the eligible Z backrests from the market and from customers motorcycles UV88 01 KAF450 B1 Cargo Bed Handgrips Handgrips have been added to the KAF450 B1 c
4. formed and actually sold the first Kawasaki in the United States In addition to distributing Kawasaki products their parent company Masek Distributing Inc also distributes Mariner Outboard engines several lines of quality boats two golf car lines and a host of other power products Rocky Mountain Kawasaki has established a widespread reputation for service excellence particularly in dealing with problems relating to high altitude Their marine experience dates back to the 1940s and they have done an excellent job assisting their dealers through the explosive growth of the JET SKI watercraft line Editor Mike you can consider yourself a subscriber K Tech News is a quarterly magazine mailed automatically to all Kawasaki dealers at no charge Just check your regular weekly mailing from Kawasaki Publications Manager Executive Editor Editor in Chief Regional Editors North and East Central and South West and Corporate Technical Support Specialists Joe Nowocinski Sob Ellison Randy Davis Tevis Moffett John Porno Ken Osberg Gregg Thompson Steve Rice Graphics and Production Graphic Artist Tim Bean Computer Design Pat Shibata Kawasaki Graphic Services Dept Staff KAWASAKI K Tech News 1988 Kawasaki Motors Corp U S A Al Rights Reserved Published by Kawasaki All suggestions become the property of Kawasaki Motors Corp U S A Sending a suggestion gives Kawasaki permission to publish and or use i
5. advantage of the digital ignition system is that any advance angle characteristics may be programmed in by the factory Advance characteristics may be as complex as needed for standard engine operation For example if knocking is liable to occur within certain RPM ranges the advance contour may be set to retard the spark slightly in those ranges This system results in easy starting reliable performance great gas mileage and low emissions It also makes doing a tuneup quick and easy For more details attend the next V Twin or Electrical Systems training class M 43 New Accessory Cooling Fan Kit Installation by Mike Jeffers Paris Publications Whew it s hot It must be every bit of a 100 degrees out here Another hour or so and we ll have this soil turned Man could sure stand a cool breeze right about now Well Kawasaki can t supply the the breeze for you but we can for your KLF300B model BAYOU Kawasaki is introducing an optional electric cooling fan to increase cooling air flow for hot days or heavy duty jobs This is especially helpful during low speed operation under high temperature To avoid con amp ant use and prolong fan life the fan operates at the flick of a switch located conveniently on the handlebar The fan clamps on right behind the upper A arm portion of the frame and Is held in place by two lower clamps and one upper clamp NOTE upper clamp is supported by a cross brace E E TECH NEWS
6. because of the comments made by some students in some of my classes noticed there was a lot of wasted time when a dealer did not have all the necessary information ready when he called the Hot Line With the new Hot Line computer system we must enter all the information before the log can be closed or any warranty authorization given If you are calling for warranty authorization you should also have all WEST REGION The demand on the dealer technician to keep up with changes in today s technology is no easy task And what about the new guy The person just getting started with Kawasaki has the toughest job Especially difficult is getting a handle on the operations of a profitable service department I m reminded of my experiences teaching Service Department Operations in NDO have realized that dealers need a great deal more training for their service managers the guys who actually run things on a day today basis So have drawn on my background as a Service Manager and other sources 12 K Tech News of their classes We want you to get to know these professionals So read on And if you have any questions about your service business or something technical give them acall Or better yet come to one How about some tips for K Tech News Send your tips to K Tech News Kawasaki Motors Corp U S A P O Box 25252 Santa Ana CA 92799 5252 We really want to hear from you e A desire to keep on lear
7. employees salaries but are you getting all the labor sales you should have coming to you What percentage of new bikes sold return for service Are they coming back far beyond the intervals recommended in the owner s manual maintenance schedule Do they come back only for the first service or never at all Does your overall selling plan include selling your services Each unit you sell new or used carries with it the potential labor hour sales that you should recover When a customer buys a unit your service sales go with it How many labor hours are not returning to your store Realizing the potential sellable hours you could capture will aid in planning service levels you can provide Taking a look at these three factors labor cost billable hours and first service to sales ratios is the first step toward realizing the service profits you deserve If you were not able to attend the Service Profit Seminar at the dealer show be sure to see your District Manager or plan to attend the next Service Department Operations class for details Our next feature will focus on the details of the K BOSS service business system So hold on tight while we grab a handful and Let the Good Times Roll 4 The Technical Magazine 5 SERVICE MERCHANDISING Test Tank Update by Ray St John Technical Writer Recently we ve been seeing increased interest in building a Jet Skid watercraft test tank Two articles have bee
8. tank allows simulationof real conditions The engine can be run without using auxiliary cooling water supply e A test tank puts load on the engine so certain problems can be diagnosed property starting difficulties high speed miss cooling system diagnosis etc Leakage water leaks can be found and repaired using a tank e Carburetor mixture tuning e Performance tuning for racing There are numerous aftermarket companies offering high performance parts A dealer can use a tank to demonstrate to the customer how these items can improve his JET SKI watercraft Actual performance increases can be measured 2 Key points when designing Elimination of air bubbles prevents cavitation e Water current speed control e Overflowing water splash e Exhaust gas outlet if possible run outside of tank keeping water clean e Environment impact noise exhaust gas oil e Easyaccess into tank water level working platform e Protection for boat sides and hull bottom 3 Keypoints when testing e Simulate rider weight place approximately 80 pound weight in tra e Font tie rope kick back prevention when throttling down e Scale for thrust e Tachometer B E T ECH NEWS Tips from the Specialists ZG1200 METER REPLACEMENT By Walter Rainwater and Randy Davis Here are some instructions to save time if you ever need to replace a meter or gauge on a ZG1200 Remove the meter and gauge assembly
9. two things to the consumer a product and a service Are you a tuneup shop an overhaul shop a body shop Maybe you are a complaint department or a junk restoration department How does your service business fit into the overall business plan you projected Do you run your service department like the rest of your business or does it give you the business By evaluating the business activities you have engaged In year to date you can develop a plan of action for your service department Begin by pulling all the repair order hard copies for the last 90 days of business including all sales jobs parts and accessory internal work and the jobs performed to support the service department itself Hopefully you write a repair order for any and every job performed by service personnel Look at what types of jobs you are most frequently called upon to do Make a list of those jobs which yield the most profit with the least hassle This list is the beginning of your service menu the services your business sells to customers So that s a start on the type of services you provide Next and probably most important is to get a handle on the product you ve been selling through service Take I think I m making progress inventory on your service product Physical inventory of what you say Well it may not actually be a physical inventory but you should know precisely what you are selling The wholesale cost
10. versus the retail sales We are talking about TIME How many hours the store is open compared to the billable hours from service Selling hours of labor Yes your service product is time From the Repair Orders you pulled up to identify your services make a list of the total labor dollars sold Compare this total to the technician payroll paid out in the same time period If you divide the payroll your wholesale cost of labor hours by the total labor dollars billed out you ll have your percent labor cost per hour sold This figure will not be more than 50 in a profitable service department Labor Payroll _ ro Labor Dollars Sold gt 0 less Now compare the billable hours to the hours the service department is open and available to the customers you ll have the percent of billable labor hours This figure is either a pleasant surprise or a major cause of heart failure In either case billable hours indicate volume of services that have been sold It does not however indicate the amount of labor by Ken Ploeser hours out in the market that are rightfully yours to recover Billable Hours_ 4 Hours Open Billable hours the key to a profitable service operation Before you say you already do that take a check on how well you are filling the service labor pipeline You may keep good track of hours sold and collected by work order hard copies you certainly know how much money is going toward service
11. wheels are driven by the solid rear allows more metal in the valve seat Limited Slip drive shaft via a bevel gear set No area increasing heat dissipation A new differential is used on the rear axle of the cam profile reduces valve lift by about D iffe re n ti a 4x4 The front driveshaft connects to the 0 2 mm on both intake and exhaust Full limited slip differential Right and left half ignition advance occurs 800 RPM shafts drive the front wheels through sooner and is reduced 10 degrees to 30 Maximum Traction constant velocity joints i 3200 RPM The result is an engine Full Torque The limited slip front differential that delivers stumppulling power over a provides full traction during turning wider RPM range Even though peak The special tools listed below are while the steering effort at the power is reduced by less than one needed to do the following handlebars is greatly reduced horsepower the power starts at a lower RPM for more useable performance ideally suited for the nature of this 4x4 workhorse Py For further technical information t about the KLF300 C1 refer to the Service Manual P N 99924 1117 51 Wy 4 Be sure to look on the training e Sub transmission disassembly and assembly e Front final gear case pinion gear removal and assembly e Front final gear case pinion gear preload measurement Here S the Oe schedule for the upcoming ATV class special tools _ _ pec aS you ll
12. with a cooling system operating around 15 psi Aluma Cool protects between minus 84 F and plus 265 F when ENGINE COOLANT using a 50 50 mix ratio WARNING Packaged in quantities of a 12 one quart convenient easy pour bottles P N K61081 004 nn E 1 QUART S46 The Technical Magazine 11 REGIONAL NEWS Introduction by Don Church Please let us introduce to you the regional editors of K Tech News Do they look familiar to you Sure Many of you know them as your regional training instructors Take a look at their credentials These gentlemen have a tremendous amount of knowledge to share with you about Kawasaki and the industry we are in So who could serve better as editors of a service oriented publication like this NORTH amp EAST What makes one service technician or service manager better than another I m sure each of us has our own ideas on this subject Here are some of the key ingredients came up with e Fast safe reliable work the first time around e Efficient diagnosis of mechanical and electrical problems Up to date product knowledge e An ability to communicate with the customer e A working knowledge of service department operations e The ability to communicate with the manufacturers representatives CENTRAL amp SOUTH This summer had the opportunity to work on the Hot tine knew what the Hot tine responsibilities were but didn t know exactly what to expect
13. B E TECH NEWS Fall 1988 First Issue kK Tech News by Ken Ploeser Editor in chief You may remember the Hot Line News But now we call it K Tech News because it will give you information on what s going on in all departments of Technical Services There are a lot of things to talk about so the folks in Technical Services want to expand the line of communication You must provide quality services to your customer and we need to work hard to support you We will be including feature articles that focus on the operation of a protitable service business Guest spots on those dealers who have made it happen And of course letters we receive from you Shop Talk departments include technical information and explanations special tool tips parts news service information and more You ll hear the inside scoop from the Hot Line Specialists previewing new product information and keeping you up to date on the latest tricks You should file all K Tech issues in your Service and Warranty Binder under the Training tab We encourage your input If you have a service tip you would like to share or an article to contribute send it in You say yours is the top service department in your area Tell us about it you just might be in our next GUEST SPOT Please send all your contributions to K Tech News Kawasaki Motors Corp U S A WHAT S INSIDE Test Tank Service Tips Regional News
14. Hot Line News Publication regularly here at our new store Please advise as to how may subscribe Thank you Michael Hughes Service Manager GUEST SPOT by Don Church Manager Service Training and Communications In future issues the guest spot will feature Kawasaki dealers who have developed innovative ways of promoting and operating their service departments To get started take a look at the following questions Do you have an open house and offer free vehicle inspections Do you make customer satisfaction follow up mailings Do you offer discounts to club members Do you do specialty work such as painting Do you have a JET SKI watercraft test tank Do you winterize JET SKI watercraft and even offer winter storage Some of you can answer yes to these questions and some of you have other ideas that work well The Guest Spot is here for you to share your formula for a successful i e profitable service department with other Kawasaki dealers Oh and for those who answered no to these questions be sure to read Guest Spot in the next issue 4 K Tech News ROCKY MOUNTAIN KAWASAKI by Keith Pestotnik R M K Regional Service Manager Rocky Mountain Kawasaki located in western Nebraska is an independent distributor of Kawasaki products throughout the Rocky Mountain and high plains region They first began purchasing Kawasaki motorcycles in 1964 two years before KMC was
15. a particular situation Also you will be making any repairs that are required Ninety percent of our information about acustomer s problem comes from the dealer involved Your knowledge and opinion help us make the best decisions we can to keep the customers satisfied with you and Kawasaki The Technical Magazinee9 SERVICE TIPS New Digital Ignitions by Waiter Rainwater amp Jerry Heil The operation of the digital igniter is similar to the TCBI igniter TCBI stands for Transistor Controlled Breakerless ignition It replaced the mechanical switch or contact breaker points systems The transistor in a TCBI igniter is an electric switch a switch that is turned off and on by a small amount of electricity In a TCBI the source for this electricity is the pickup coil TCBI VERSUS DIGITAL The major difference between TCBI and digital ignition is the addition of a micro processor in the digital igniter The processor is placed between the pickup coil and the transistor The processor measures crankshaft angle and speed information through the signals from the pickup coil See illustration right Tabs on the rotor generate signals indicating crankshaft rotation One of the tabs is wider than the others to signal engine top dead center The microcomputer first converts the analog pickup coil signals to digital pulses It then measures the time between the The pulse timing converts directly to engine speed The m
16. afety hazard to small children and pets Keep them away from your test tank A locking cover over the whole tank would be a good way to keep leaves and other debris out It could also prevent an accident Inspect all the hardware regularly for corrosion damage Keep everything painted and sealed for tightness and protection You will have a lot of work invested in your test tank by the time it is finished but it can be a valuable tool for Jet Ski watercraft service and a real money maker I K The Technical Magazine 7 INSIDE TECH SERVICES by Joe Nowocinski Technical Support Supervisor We are proud to introduce our newest member of the Product Support Specialist team John Porno Coming to KMC directly from a topnotch Kawasaki dealership John brings his 20 years of technical experience to add to the Hot Line John excels in the world of motocross desert racing and most recently he placed first in CRC 4 Stroke Enduro in 1984 and finished second in CRC 200 cc Class Enduro in 1987 Can he be of assistance to you You bet Just call the Kawasaki dealer assistance Hot tine between the hours of 7 30 am and 3 30 pm PT When calling the Hot tine the information needed from you will be your dealer number your first name complete model designation the last six digits of the frame or the middle five of the hull number mileage ii applicable and failure date If a problem requires you to make a second call on the
17. argo bed to make it easier to tilt up and down PG88 01 GD700 A1 AS1 Hard StartIng Some eligible units may have an incorrectly wound generator stator coil This results in hard starting TECHNICAL TRAINING MANUALS Kawasaki is making available manuals used in product support training courses They were created specifically for technical instruction and contain a wealth of information not found in any other publication Each manual is richly illustrated and covers the subject matter with simple concise explanations This material is easily understood by all skill levels To order refer to Service Bulletin TR86 03 or contact Technical Training 714 770 0400 ext 2466 JET SKI WATERCRAFT See Service Bulletin TR88 02 This one hour video on JET SKI watercraft maintenance covers technical features along with general maintenance and inspection procedures on the JS550A JS300B and JF650A models ZX750 R NINJA See Service Bulletin TR88 02 Kawasaki has developed this 18 minute video tape highlighting engine removal and disassembly with helpful hints that will reduce service time BONUS As an added bonus you will receive a FREE video reference manual with each tape order as a quick reference guide when working in the shop To order call Ray at 714 770 0400 ext 2466 Electrical Fundamentals JET SKI Watercraft Video Reference High Performance Engines ZX900 Engine Series Familiarization V Twin Engine Familia
18. continue smoothly with troubleshooting or other action that was started earlier The new system allows Consumer Services Team Green Quality Assurance and Warranty Administration shared usage of the system with the Hot Line Warranty repair authorizations and related warranty information make up an important segment of the system When a warranty repair is authorized the specific unit data has been verified against existing Kawasaki records before the authorization number is given to you That means the model frame job codes and warranty period have already been verified so that necessary corrections can be made When the claim is submitted it will process quickly We are proud of our new system s capabilities We started development of this elaborate contact logging system about 18 months ago Many refinements and features were considered tested and added during the past season to perfect a system that is also user friendly It is just another example of Kawasaki s goal to be number one in the way we do business W E TEST TANK TIPS By Kenny Osberg 1 The purpose and usage of a JET SKI watercraft test tank are Atest tank boosts the image of the dealership This means that customers get the impression that the dealer is serious about a high level of service and the dealer is committed to the JET SKI watercraft business e Measuring thrust helps diagnose engine and pump performance The test
19. e 12V 14AH Maximum Charging Output 329 V A 17 4 ft lb 5500 RPM Front Tire Size Rear Tire Size si Ground Clearance 2 0 seeeeeeeee 8 9 in Minimum Turning Radius 9 5 ft Fuel Tank Capacity seeeeeeeenes 2 9 gal Fitfal DIV A Shaft Track Front Rear 0 eseeeeeeeee 33 2 33 1 in Dry Weight asin ics neice roca aiaia 567 Ib NOTE Specifications subject to change without notice The Technical Magazine 1 SHOP TALK TECHNICAL KLF300 C1 LUMITED SLIP DIFERENTIAL 2 RANGE SUB TRANSMISSION Four Wheel Drive by Jerry Heil Program Developer The new KLF300 C1 4x4 is here It To extend engine life the shares Kawasaki technology with the piston to cylinder clearances have 2 wheel drive B2 model But of course been tightened up by enlarging the the big news is the full time four wheel piston diameter and the top and second drive All wheels are driven by the two ring groove widths have been reduced speed subtransmission that fits up to Other variations from the B2 model the left side of the transmission case A have helped broaden the power band stub shaft extends from the front and These changes include reshaping of the rear of the subtransmission combustion chamber Squish area is Each end of the splined stub shaft enlarged and angled up slightly A COUPLING drives a front and rear driveshaft The smaller 12 mm NGK D8EA spark plug s s s rear
20. from the brackets You must replace the meter or gauge from the rear of the assembly You cannot remove the meter face plate to replace a gauge or meter Instead remove the rear panel by taking out all the screws on the back panel of the assembly Leave all screws wires and bulbs in their original position in the terminals and sockets With the screws loose the entire sub harness wire will easily lift off the back of the meter case Then remove the original meter or gauge by cutting the shaft The original pointer is permanently fixed on the shaft and cannot be removed Install the new meter or gauge The replacement unit has a threaded shaft so the pointer can be installed with the cap and retainer The electrical connections at the rear panel are marked so reconnecting the wires is made easy Replace the assembly in the brackets and the job is complete QUICK TIPS MODEL JET SKI watercraft e SYMPTOM Poor top end performance new boats e CAUSE Silicone plugging exhaust outlet in hull e CURE Cut out with screwdriver or knife MODEL JET SKI watercraft e SYMPTOM Premature ring cylinder wear e CAUSE Hone finish on cylinder bore too fine e CURE Use 220 grit stone when finish honing cylinder bore Kawasaki Product Support HOT LINE 954 3900 800 432 7093 Ca Only CONSUMER SERVICES Consumer Services Oh yes the complaint department right Well not always As the only department within KMC
21. icro processor comes from the factory with stored timing information This stored information is called the map data The processor then tells the transistor the best time to turn off and in turn fire the sparkplug The map data is a list of delay times The delay time is the time between when the pickup coil generates its fire signal and when the transistor is told to turn off by the processor The list has one delay time assigned for every 50 RPM segment of the entire range of engine RPM VACUUM SENSOR The optimum ignition timing is found in the map data by referring to the engine speed that was just measured The optimum ignition timing map data is converted into an elapsed time from the TYPICAL TIMING DATA MAP SAONVACV 10 K Tech News IGNITION COILS MICRO COMPUTER ANALOG DIGITAL pickup coil signal In other words the optimum ignition timing is figured as the time from when the pickup coil signal is received and when the processor signals the transistor This of course is when the coil fires the spark plug In addition to changing spark timing with RPM larger displacement engines perform better if timing is changed when demand for power changes Manifold vacuum is a measure of throttle position or power demand The VN1500 s digital igniter measures manifold vacuum boost and adjusts the timing advance according to vacuum map data information see illustration left The real
22. ling EXPERIENCE 20 years motorcycle mechanic With KMC since February 1986 Service Training Instructor New Dealer Training e Hot Line Support W Fred DeHart Office 201 Circle Dr No 107 Piscataway N J 08854 201 469 1221 Walter Rainwater Office 6110 Boat Rock Blvd S W Atlanta GA 30378 1 464 349 2000 Ken Ploeser Office 9950 Jeronimo Rd Irvine CA 92718 1 714 770 0400
23. n run in two different Kawasaki publications and a number of dealers have built tanks Their practical experiences showed us how we could change our tank design for the better So we made some changes and here they are Basically our tank is twelve feet long and about eight feet wide Suggested dimensions are on the illustrations You may want to increase dimensions to suit your own needs It has a wall down the middle so the water will flow around the tank in a circle If the water circulates around or under the boat the pump will cavitate and lose thrust The walls are strong enough to hold the weight of the water and absorb the jet pump s thrust We suggest that you build your test tank so that the bottom is below ground level about twelve to fourteen inches This makes it easier to load the boat into it and also gets the footings below the frost line Of course you may have to adjust this depending on the frost line depth in your area UNPERGROUNP FOOTINGS SLAB BOTTOM ARE POURED CONCRETE WITH J RE EAR OR WIRE MEH The footings and slab bottom are of poured concrete strengthened with 3 8 re bar or wire mesh If you have a contractor doing this work make sure and tell him what you re going to use it for He ll know how much reinforcement to use Also be sure to put a 12 x12 footing under the center wall All the walls are 8 x8 x16 concrete blocks Use 3 8 re bar between each course of blocks and at the corners a
24. need 2 K Tech News COMMUNICATIONS e24 amp TrECH news M C R O HE by Micro Mike Jeffers Parts Publications Do you realize that there is a lot of information besides part numbers included on each microfiche General specifications tuning information and a library of reference material part numbers concerning each model are but a few of the features Also included is a parts number indexwhich lists every part number for the specified model Bulletins or any special gasket kits that may effect the product are included in a specific section at the bottom of the fiche Reproductions of service bulletins are added during each update of the microfiche Taking time to use the microfiche fully will save you time in the long run Beginning with 1988 models Kawasaki street legal vehicle parts microfiche include decal part numbers Prior to 1988 the decal part numbers can be found on Parts bulletin C 86 02 Kawasaki has microfiche decks and subscriptions especially designed for your needs If you have any suggestions regarding microfiche call Micro Mike Jeffers Kawasaki Service Training and Communications Department at 714 770 0400 ext 2573 BULLETINS NEW Vulcan 88 exploded view engine parts poster is now available Order it from the Kawasaki Technical Services Department Take a look at Service Bulletin TR88 01 to see all the posters available RECAP1988 FDM FAR RECALL by Ray St John Technical Writer Bulletin
25. ning This last point is extremely important The day we feel we know enough is the day we take a step backward So take a self check how do you stack up K Tech News is just one of the tools you can use to enhance your knowledge Make plans to attend the service training classes starting again this October hope to be talking with you soon EXPERIENCE 23 years as motorcycle mechanic Started with Kawasaki in 1973 Service Training Instructor Hot Line Support e Warranty Assistance W the job codes ready as well as the claim number and parts used Part numbers are not needed Occasionally a dealer forgets that the HOT LINE is for dealers only and not for consumers When a consumer gets on the HOT LINE considerable time is wasted The phone number for consumers to call is 714 770 0400 With a little help from you the HOT LINE can be quicker and more beneficial to all Kawasaki dealers EXPERIENCE Over 16 years with Kawasaki Service Training Instructor Warranty Assistance Hot Line Support W within the Technical Services Department to upgrade the Service Department Operations class After 12 weeks of intensive work on this project we can provide you with a realistic approach to operating your service department Nota bunch of notebooks and blank forms that bury you in paperwork urge you to sign up for the upcoming Service Department Operations course Look for the October 1988 course schedule in the weekly mai
26. rization 750 Turbo Police Motorcycle Maintenance The Technical Magazine 3 LETTERS City of North Las Vegas Police Department Las Vegas Nevada Dear Sirs In December 1987 this Department purchased eight KZ1000 Police motorcycles from a local dealership Kawasaki of Las Vegas Since that time we have experienced some minor problems that were not unexpected from brand new equipment The point of this fetter is not to dwell on the problems but rather to comment on the service provided by Kawasaki of Las Vegas Whenever a motorcycle was taken to the dealership we received prompt satisfactory service that we found refreshing On some occasions breakdowns occurred in the field Kawasaki of Las Vegas immediately sent a service mechanic to the field and repaired the motorcycle on the spot Their after sale service is excellent Everyone we have dealt with at the dealership both in sales and service was more than cooperative fair and excellent representatives of the Kawasaki Motor Corporation All our experiences with Kawasaki of Las Vegas have been excellent We hope this letter might commend the dealership for their professional attitude Sincerely J L Zohner Chief of Police and Lt K Kiphart Traffic Bureau Commander Editor don t think much of a comment is necessary You get the point Tucson Kawasaki 5225 East 22nd Street Tucson Arizona 85711 Dear Sirs am interested in receiving Kawasaki
27. s shown to reinforce the concrete corner fillets The walls can also be made of poured concrete If so they must be poured at the same time as the slab and footings or the seam between the bottom and sides will be very hard to seal Set J bolts in the side and center wails above the first and third courses These will hold the baffle mount angle irons in place Be sure the J bolts are in a vertical line and directly across from each other Set the eye bolts into the end walls above the fourth course just at or above the waterline Build the walls about eight courses tall at the high end and five at the low end When the walls are full height slide a piece of re bar into each hole so it goes all the way to the foundation Fill the PLFFLE TO CONTRd WATER CIRCULATION DRILLED ALUM PLATE OR 6 K Tech News CONCRETE BLOCKS holes with poured concrete Be sure to do the center dividing wall too It s free standing so it needs all the help it can get Cap the walls with mortar Make it a little rounded Build forms in the corners of the tank and pour concrete into them for corner fillets These smooth the water flow around the corners so the larger the tank the larger they should be The re bar protruding across the corners holds them in place Plaster the inside of the tank and ail around the center wall Use two 1 4 coats for best results This is similar to waterproofing a basement So if you know something tha
28. same unit a log number will be given to you by the Hot tine technician When you call back give the log number to the Hot Line technician first Then he can recall your original file more quickly M A John Pomo New Computer System __ by Gary Herzog Product Support Manager We have a great new computerized system that provides a more efficient state of the art means to log store update access and analyze product support related contact information Whet this means to you is that whenever you contact us we can immediately access more information to assist you with resolution of technical consumer or warranty situations It also means that valuable product quality assurance information is constantly being extracted from your input so that product problems are quickly identified and resolved While talking to a Hot tine technician the little clicks and beeps you hear in the background are coming from their computer terminals As you provide product or consumer information and comments they are typing the data into the on line main frame computer system The computer responds by displaying on the terminal screen related support information that can be drawn from several existing banks of data At that time a special notice may also appear on 8 e K Tech News their screen to alert them that a prior contact has been logged about the same customer or vehicle They can quickly reference the previous information and
29. t without further consideration Gary Herzog Ken Ploeser Fred DeHart Walter Rainwater Ken Ploeser Keith Pestotnik Technical training for dealers Technical assistance to dealers Consumer Services Warranty Administration Keith started his career with R M K in 1984 His dealership experience involved managing service departments for different franchised brands He always remained close to his toolbox with a primary focus on Kawasaki products He can offer today s Kawasaki technician some very solid advice on a timely basis RMK dealers can call Keith for advice and technical assistance at 308 436 5818 FEATURE E ETECH NEWS Service 1990 A Business An entrepreneurial enterprise which when well planned will result in the viable pursuit of happiness health and profit EVALUATE Your Service Business Service 1990 It s only 1988 Did miss something Well its quite possible The 1989 models are here already and 1990 will be upon us before we know it We all talk about planning and now is the time to do it If ever there was a good opportunity to get a handle on the service operation of your business now is it Hold it Wait a second before you explode out of the starting blocks The only way to really plan for the future is to get a clear picture of where you ve been and where you are right now So the question is what is your service business As you know every business provides
30. t works in your area to seal a basement it ll probably work well here too Our design goes one step further by coating the inside with swimming pool sealant Let the plaster cure thoroughly before applying the sealant Clean the tank first and then follow the sealant manufacturer s instructions to the letter Roof over the tall end of the tank to keep the water from splashing out Brace it to withstand the expected snow load in your area BX 8X16 CONCRETE PLO WALLS WIH 26 RE RAZ 2 8 THIEL PolbED CLRETE PLASTER ALL MEADE WALLS WITH THO 14 COATE Scales to measure the thrust are readily available Check feed stores agricultural implement supply houses even bait and tackle shops may have something you can use Get at least a 100 pound capacity scale Use a lever to give your scale enough of an advantage to absorb about 600 pounds of thrust Of course you can get fancy too and get an industrial grade scale that can handle the entire thrust toad directly If you build a scale and lever set up like we ve pictured here you can see the scale from the operator s position beside the boat The cable connecting the back of the boat to the scale must be strong enough to absorb shock loadings five times the total thrust If you plan on a maximum thrust load of 600 pounds then the cable must support 3000 pounds safety We suggest 1 4 plastic coated stainless steel cable This will have enough strength and flexibili
31. that deals directly with the retail customer Consumer Services handles questions about every aspect of the company sales service and parts In fact out of the 2 000 to 3 000 contacts we receive each month about half are from people who simply need a little information such as the location of local dealers the part number for an H2 front tire the quarter mile time of the ZX10 or a brochure on the KLF300 or a little help such as a lost owner s manual an out of print snowmobile manual or a source of parts for a 1969 A7 Most of these customers can be helped immediately or within several hours In situations involving prices sales pans ordering or technical questions other than very simple ones customers are usually referred to a dealer Okay we can take care of the simple things ourselves That brings us back to the complaints the problems the unhappy customers by Mary Sola Senior Consumer Analyst We know that most consumer complaints are resolved at the dealership level and we never hear about them We also know that in most cases we can t solve the problems we hear about by ourselves we need to work with you OUR GOAL IS TO HELP YOU MAKE AND KEEP HAPPY CUSTOMERS ONES WHO WILL COME BACK AGAIN AND AGAIN FOR PRODUCTS SERVICE OR PARTS When a consumer lets us know of a problem we will usually contact the dealer After all we need your help we need to know what you see and what you think about
32. ty to work properly and will not weaken because of corrosion 8 lt TECH NEWS Tip Use these drawings to solicit bids from your local contractors NOTE You can enlarge the tank Just be sure you keep the proportions constant For a bow tether 3 8 or 1 2 nylon rope is good The bow tether keeps the boat from banging against the walls during testing and from crashing backward with the water flow when the throttle is released at the end of the test run Finally when you start using your test tank experiment with the baffle so the water flows smoothly around the tank without backing up around or under the boat Different boats and different size tanks may need different baffling so take your time and work out the best combination for you You may use concrete blocks as we show for adjustability or you may decide to use an aluminum plate with holes drilled in it If you use concrete blocks leave them loose The angle irons will hold them in place Many personal watercraft now have the exhaust outlet on the right so you might want to set up a fan to blow the fumes away from the operator Any electrical equipment near water must meet special standards Consult a professional electrician or contractor SECURITY AND SAFETY ARE IMPORTANT CONSIDERATIONS Check local ordinances for required fencing or other security devices to keep small children from falling into the tank Thirty inches of water is a definite s
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