K-Tech News Vol.4 No.2
Contents
1. HIGH PRESSURE AREA Without balance tab 2 K Tech News HIGH PRESSURE AREA With balance tab TA ee Se a Ge a a O we A A On O E exhaust outlet This helps keep the boat quiet by forcing the exhaust gases to exit under the water at low speeds At higher speed the exhaust exits above the water line but the noise is dampened by the wake generated by the craft Maximum output of the SC s engine is a heal thy 55 ps at 6000 rpm The jet pump is a single stage axial flow unit like the pumps found in our other 650 watercraft The output nozzle diameter has been reduced from 83mm to 82mm for im proved top speed and the steering nozzle has a balance tab resembling the one used on the JET MATE for easy steering The SC pump also has reverse for backing out of those tight spots A lever under the front of the seat engages reverse by lower ing the reverse bucket down over the nozzle directly reversing the flow of water from the pump Output from the SC s pump is a generous 463 pounds of thrust Another distinct feature of the SC is its hull Unlike other Kawasaki water craft the SC hull is a true 15 degree V shape This hull gives the SC great turning characteristics as well as excellent straight line stability with minimal porpoising Although the SC hull is not designed to self right if capsized it can be righted easily by one person The hull is constructed of Sheet2. MODEL SUPPLEMENT BASE MANUAL BASE MANUAL MODEL MOTORCYCLES AND ATVs KX60 B6 B7 99924 1123 51 99924 1094 01 KX60 B4 KX80 L2 L3 N2 N3 99924 1094 01 99924 1094 01 KX80 L1 N1 KX125 G1 99924 1116 51 99924 1101 01 KX125 F1 KLF185 A1A A2 99924 1076 51 99924 1056 01 KLF185 A1 EL250 B2 thru B4 99924 1093 51 99924 1066 01 EX250 E1 EL250 E1 99924 1093 52 99924 1066 01 EX250 E1 EX250 F2 thru F4 99924 1109 51 99924 1066 01 EX250 E1 KDX250 D1 99924 1143 51 99924 1114 01 KDX200 E1 KL250 D2 99924 1051 03 99924 1050 01 KL600 A1 KX250 G1 99924 1116 51 99924 1101 01 KXZ50 F1 KLF300 B1 thru B4 99924 1100 51 KLF300 A1 KLF300 C1 thru C3 99924 1117 51 KLF300 A1 EX500 A1 thru A5 99924 1082 51 EN450 A1 KX000 E1 99924 1116 51 KX500 D1 KX500 E2 thru E3 99924 1132 51 99924 1101 01 KX500 D1 KL600 B1 99924 1063 51 99924 1050 01 KL600 A1 ZL600 A1 A2 99924 1073 51 99924 1055 04 ZX600 A1 ZX600 C1 thru C4 99924 1081 52 99924 1055 04 ZX600 A1 KL650 A1_ thru A5 99924 1080 52 99924 1050 01 KL600 A1 ZX750 H2 99924 1126 51 99924 1112 01 ZX750 H1 ZL900 A1 A2 99924 1077 51 99924 1048 05 ZX900 A1 ZL1000 A1 99924 1077 51 99924 1048 05 ZX900 A1 ZX1100 C1 C2 99924 1127 52 99924 1098 02 ZX1000 B1 ZG1200 B1 thru B5 99924 1089 52 99924 1064 01 ZG1200 A1 ZN13Q00 A1 thru A6 99924 1037 03 99924 1015 05 KZ1300 A1 PERSONAL WATERCRAFT JS300 A1 thru A5 99924 1070 51 99924 1059 02 JS300 B1 JS440 A8 thru A15 99924 1091 52 99963 0054 02 JS440 A1 JS550 A3_ thru A8 99924 1075 51 99963005
3. 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 GUEST SPOT The Colorfile Filing System by Reynolds and Reynolds by Don Church Manager Service Training and Communications Dept Does your present sys tem for filing service and warranty records seem to be a drain on the Service Departments productivity Are your ideas for a cus tomer satisfaction follow up program thwarted by your present records filing system It happens Many dealer ships spend unnecessary hours retrieving refiling and searching for lost ser vice folders Thats why the Colorfile System was developed as a solution to your filing problems The end tab color coding combined with open shelf filing is based on a proven technique used in hospitals and doctors offices for 25 years The difference here is that this particular Color file System is based on the last six digits of the VIN instead of patient name File folders have four other spaces for sup plementary information such as model year date of last visit vehicles with Good Times Protection Plan coverage etc Color coding is based on the principle that the human eye sees and recognizes colors and pat terns
4. WIRE DIAMETER mm MARKING MODEL std 44026 1496 KDX250 D1 44026 1487 44026 1503 44026 1492 44026 1489 KX125 H2 44026 1486 44026 1491 KX250 H2 KX500 E3 The Technical Magazine 5 T lPs FROM THE ZX 50 K carb update by Jerry Heil Training Development Coordinator Some of our newer motor cycles like the ZX 6 and ZX 7 have the coolant recovery tank reservoir in a somewhat incon venient location under the side cowling To add coolant you must remove A sidebar in the Winter 1990 issue contained some preliminary information on the ZX750 K s new Keihin car buretor see K Tech News Vol 3 No 4 pg 3 Ed Here are some additional details on a key feature The new carb s accelerator pumps have access to fuel in the conventional manner through inlet check valves in the float bowls But the fuel solenoid rather than control ling fuel flow for the accelerator pumps is the heart of a new circuit an enricher system tion This is not a huge task but it seems like more than what should be necessary just to add a little coolant Well with just a few dol lars and a few extra minutes you can build a handy little special tool that will allow you to ad just the level in the recovery tank of any vehicle without having to get to the tank itself With two 3ft sections of fuel hose P N 92190 3715 will The enricher system supplies fuel
5. regional training centers and will be incorporating this system into the Ser vice Department Opera tions class We recom mend this system based on its important benefits and its potential for in creasing customer satis faction with your store O AE EEEIEI d La Lda Li dddo E ELLERS li ee rr ere ya x O piim an x TIPS Po TOOLS Mule 500 special tool 000S Some KAF300 A1 engine transmission alignment special tools P N 57001 1341 have been shipped to dealers misassembled The plastic centering pieces which are screwed to the steel plate are mounted on the wrong side Because the tool is not symmetrical it just won t work that way This drawing shows the tool assembled correctly If you have one of these in your inventory check it against the drawing NOTE When correctly assembled the plastic pieces should be screwed to the side of the plate with the part number Stamped in it Gregg Thompson FROM T H E SPECIALISTS Attention KX shops spring confusion by Gregg Thompson Sr Product Support Specialist Could you use some 1991 KX front fork spring rate information If your answer is yes here s some information which may help It gets a little confusing because the fac tory has chosen to identify the springs for any model as either the standard Spring or one of the two optional springs With this system none of the stand ard
6. Mold ing Compound SMC for strength and easy repairs The one feature of the new JL650 A1 that can t be described on paper is how much fun it is to ride Get your customers to try one and go ahead try out a Sport Cruiser yourself One ride is all you ll need to be convinced that Kawasaki s Sport Cruiser truly is a fresh new ex perience in personal watercraft O COMMUNICATIONS Service manual Supplement system This article first appeared in K Tech News 18 months ago We ve updated the chart however to include new models and new service manual supplements Ed Some model Kawasakis need one service manual some need two Why is this Well in the beginning a single service manual includes all the information a technician needs to maintain and re pair a given model motorcycle watercraft generator etc Then along comes something a little different The KLF300 A1 for instance which had a comprehensive ser vice manual all to itself was followed by a similar all ter rain model the KLF300 B1 In this sort of situation the factory chooses to produce only a service manual supple ment the latter covering only the unique features of the B1 model So you need two books to have all the informa tion on the KLF300 B1 the service manual for the older Al containing all the basic information called the base manual and the B1 service manual supplement O Supplements and base manuals
7. ad dressed a problem that oc curs when a jet pump housing is not sufficiently LOOK FOR AIR BUBBLES HERE sealed to the hull On all of our watercraft the pump housings are sealed to the hull with clear silicone sealant If this seal is not perfect it will allow air to be drawn forward from the back of the craft into the pump and any air drawn into the pump will reduce thrust especially at low vehicle speeds In ex treme cases the lack of thrust caused by a leak can prevent the vehicle from getting up on plane The problem is more noticeable and therefore more common on the big ger JET SKI models with the 65Occ engine FROM T H We have had some reports of new JL650 A1 Sport Cruisers coming from the factory with in adequate sealant Since this is a new model and we all know how important first impres sions are we suggest you check all SCs before delivering them to cus tomers If you don t have any water to put the boat into you can check it on the bench To bench test the pump seal for leaks you must have clear access to the pump area It s usually easiest to roll the boat up on its side Remove the in take grate and spray a heavy soap and water solu tion all around the leading edge of the pump housing Now with a pressure hose blow air into the rear between the pump hous ing and the hull and watch the leading edge of the housing for air bubbles If bubbles appear anywhere alo
8. begin again in October All dealers will receive a copy of the winter class schedule but don t forget to watch this space in the Fall and Winter issues of K Tech News NORTH amp EAST Be sure to sign up early by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 K awasaki Technical Train ing classes run from Oc tober to May so by the time you read this column our 1990 91 training sea son will have ended Our new training schedule for the 1991 92 season should be arriving at your dealership some time in September Be sure to sign up early will be working on the Hot Line for two week ses sions during the months of July August and Septem ber hope to be talking with some of you during that time Be sure to call if you have questions we can help you with can also be reached at the East Region office any time you need assistance Please keep in touch during the busy summer months hope to be talk ing with you soon Have a great summer season O
9. for colors faster and at greater distances than it does letters or numbers So the Colorfile system is designed around a series of brightly colored pres sure sensitive mylar labels that are applied to the end tab of specially designed file folders Once the Colorfile folders are in place the major efficien cies become evident Mis files are reduced because they are usually obvious Filing and searching for folders goes faster be cause the eye can recog nize the proper filing section at a glance and from a distance as one ap proaches the file For quick retrieval of customer ser vice and warranty records this Sys tem works There are no doors and the open shelves are angled at 55 degrees so each file folders edge ex tends beyond the previous one This makes the color coded folder tabs easily visible and accessible The open shelf files use only about one half of the floor space required by conventional files Better still they cost up to 50 per cent less than the drawer type Besides being precise the Colorfile System is also extremely flexible which means it can be adapted to handle a multi brand and multi product environment Manufac turer Reynolds and Reynolds can help you design the Colorfile Sys tem for your store Call or write Reynolds and Reynolds Murlin amp Pine Streets Celina Ohio 45822 1 800 344 0996 Kawasaki is installing the Colorfile System in the
10. pressurized by the fuel pump to the accelerator pump discharge nozzles Veteran Kawasaki racing tuner Rob Muzzy who knows these carbs inside and out explains it this way The fuel solenoid instructs fuel to spray from the nozzle at certain throttle opening rom conditions to compensate for the mid range flat spot typical of large bore flat slide car buretors The igniter senses engine rom and opens the enricher solenoid valve when the engine spins between 1500 and 5000 rpm and the throttle is open more than 3 8ths A cam on the throttle shaft actuates a switch sending the throttle position signal to the igniter Once open fuel passes from the solenoid mounted below the main fuel supply valve to the enricher jet fit ting on the number one carb Fuel then enters each ac celerator pump chamber opens the outlet check valve and squirts out the discharge nozzle The accelerator pump inlet check valve prevents pres surized fuel from entering the float bowls and flooding the engine O 6 K Tech News the side cover and tail sec SPECIALISTS Coolant pump special tool work two straight connec tors brass tubing and a Kawasaki 650 Tandem Sport fuel primer bulb P N 49043 3702 you can build a hand pump that will do the job nicely To use the pump first disconnect the overflow hose from the filler neck to the recovery tank at the filler neck Then depend ing upon whether you re adding or removing coolant connect
11. springs are marked The optional springs are marked with one or more small grooves in one end of the springs Unfortunately the stand ard spring for one model might be the same spring rate as an optional spring for another This results in a different part number for two springs with apparent ly identical specs Also KX80 RI KX80 T SPRING O D 28mm the marking on the spring is not always adequate to allow you to identify just what spring it is The following tables identify the springs that fit a certain model or group of models by part number spring rate spring length number of coils wire diameter and markings For standard springs no markings the model is listed O PART SPRING SPRING NUMBER WIRE MARKING MODEL std NUMBER RATE LENGTH OF DIAMETER kg mm mm COILS mm 44026 1482 27 482 5 3 8 44026 1479 28 483 49 3 8 none KX80 RI 44026 1484 28 482 49 3 8 i 44026 1480 29 482 5 3 8 none KX80 T 44026 1483 29 483 51 3 8 Ill 44026 1485 30 484 50 3 8 ll KDX200 E3 SPRING O D 35 5mm PART SPRING SPRING NUMBER WIRE MARKING MODEL std NUMBER RATE LENGTH OF COILS DIAMETER kg mm mm mm 44026 1430 28 499 36 4 3 44026 1401 29 493 35 4 3 none KDX200 E3 44026 1431 30 498 4i 4 5 i KXI25 H2 K DX250 D1 KX250 H2 KX500 E3 SPRING O D 38mm PART NUMBER SPRING RATE kg mm 44026 1502 SPRING LENGTH mm NUMBER OF COILS
12. victim of the runaround The Technical Magazine 11 REGIONA L NEWS WEST Burning the midnight oil by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 lt s that time of year al ready The training season is over and summer ac tivities are in full swing For you that means busi ness is booming We here at KMC are plenty busy too Work on the Product Sales Guide highlighting all the information on the new models for 92 will be in full swing by the time you read this So will work on other projects a new generator sales manual a new flat rate microfiche reference manuals for some of our latest training videos plus revisions to the training classes A major project we ll be tackling is a completely new Parts Department Operations class to help you maximize the profit potential of your parts department The busier you get of course the busier the per 12 K Tech News sa an re i a T n he K kis Ma w sonnel on the Hot Line be come So busy in fact that the training instructors from each region will be helping man the lines from time to time to assist with the extra large volume of dealer calls Rest assured that while you are working diligently to serve your customers needs we ll be burning the midnight oil to help serve your needs better too O SOUTH amp CENTRAL Planning for SUCCESS by Walter Rainwater 6110 Boat Ro
13. with a 12 digit Hull Identification Number HIN New Coast Guard regulations required a change in the HIN starting with the 1985 model year The original 12 digit HIN can be broken down into four sec tions of characters that are easily deciphered The chan ges made to the HIN for 1985 require a little more decoding Pre 1985 Hull Identification Number KAW 12345 07 83 MAKE PRODUCTION PROD PROD SEQUENCE MONTH YEAR Beginning with the 1985 model year the production month and production year sections were combined into a single two digit code A two digit model year was added to the end of the sequence These changes produced the 12 digit HIN we still use today E 1985 present Hull Identification Number K A W 12345 C5 91 MODEL YEAR MONTH AND YEAR OF MANUFACTURE PRODUCTION SEQUENCE IDENTIFIES KAWASAKI AS THE MANUFACTURER KEY TO MONTH AND YEAR C5 INDICATES MONTH INDICATES YEAR OF MANUFACTURE OF MANUFACTURE A JANUARY 1985 B FEBRUARY 1986 C MARCH 1987 D APRIL 1988 etc The HIN is always located on the starboard side of the craft near or on the stern For additional model identification information refer to the following publications CO Watercraft Chronology Service Bulletin published each year lists all models produced since 1973 O Parts Catalog Microfiche provides HIN and engine number ranges colors and publication part numbers In our next issue we ll
14. 1 01 JS500 A1 JS550 C1 99924 1148 51 99924 1120 01 JS550 B1 JF650 B1 B2 99924 1122 52 99924 1069 06 JF650 A1 JS650 A1 thru A4 99924 1087 53 99924 1069 06 JF650 A1 SC video now available The service training video covering the JL650 A1 SC is now available If you are on the automatic training video mailing program you ve probably already seen this 26 minute tape It covers those unique features and service areas of the SC where it differs from other JET SKI watercraft models The first section of the tape covers design features the second section shows how to right a capsized SC and the third and final part concerns maintenance This video tape is designed not only to familiarize your techni cians with the SC but to be used in your showroom to stir buyer interest You can even use it to introduce this unique watercraft to proud new owners and to entertain people waiting for service on busy days Ray St John MICRO K Are you assuming by Chuck Crawford Micrographics Specialist t has recently come to my attention that many people working with Micro K parts microfiche in Kawasaki dealerships assume that the reference number is al ways the same as the function code the first five digits of the part number It s true the two are usual y the same but they re not always the same Therein lies a potential snag A problem can occur when someone assumes the ref erence number is the same as the first fiv
15. Summer 1991 The Kawasaki Technical Magazine NEWS Vol 4 No 2 F f se E Y 1 Ey s ead 2 Lie k k vee i a y E n Aai oe er tot tc ie Oe a T by Patrick Kelly Instructional Designer Instructor The JL650 A1 better known as the Sport Cruiser or SC is Kawasaki s latest entry into the growing two passenger personal watercraft market The SC s innovative design proves once again that Kawasaki is the leader in the personal watercraft industry ROUTE LIST O SERVICE PLEASE RETURNT O O PARTS SERVICE Surely the SC s most outstanding feature is its unique side by side seating arrangement For the first time in personal watercraft history riders sit beside each other instead of fore and aft This exclusive feature allows both passengers to fully share the riding experience both can see where the craft is headed and no longer have to shout at each other in order to communicate If that alone isn t enough Kawasaki designed the SC so that either rider can operate the craft without changing seating positions The boat s steering wheel can be moved to any one of three positions left right or center simply by stopping the craft and pulling an adjustment lever before Sliding the wheel to another position The Sport Cruiser shares the same basic drive train as Kawasaki s other 650 watercraft gt Inside E SC explorations O SALES LIBRARY S H O P l
16. ck Blvd S W Atlanta GA 30378 404 349 2000 T he prime objective of a new dealership is to make a profit as soon as pos sible The ways new owners go about achiev ing this often leave me wondering Why didn t think of that One business plan that admire for being so well thought out was con ceived by Vince Von Eberstein the owner of the just opened Gulf ii fe ee e Coast Kawasaki located in Orange Beach Alabama Von Eberstein had a lot of good ideas For one he arranged for his service manager George Istre to attend Kawasaki Technical Training classes before his shop was open for business For another he hosted a Demo Days promotion for our JET SKI watercraft product after only being open two weeks Von Eberstein was ably assisted by service manager Istre and Kawasaki District Manager Chris Ousley The Demo Days promo tion was held on a Satur day and Sunday at the oceanfront where he demonstrated the Sport Cruiser Tandem Sport and JET MATE as well as the X 2 and 650SX models The bottom line Vince attributes the sale of 11 JET SKI watercraft and eight trailers to Demo Days And his service department was well trained ready to prep and maintain all those boats from the start O Training Schedule East Region North Region Central Region South Region West Region KMC instructors are work ing now on the 1992 Train ing Program schedule Classes will
17. crack the code on Vehicle Iden tification Numbers VINs Dave Corey Two stroke pressure testing Before you tear down the top end of any two stroke engine with low compres sion consider what might have caused the poor compression readings If you believe the engine may have been seized don t remove the head and cylinder until you have pressure and vac uum tested the engine One of the most com mon causes of seizures in two stroke engines is an air leak An air leak in a crankshaft seal crank case seam intake tract gasket or the base gasket can lean out the engine to the point of seizing Obviously you want to perform this test before you take the engine apart you don t want to rebuild the top end and then find out a crankshaft seal is leaking Also determining the cause of a seizure and eliminating that is just as important as fixing the damage If you don t already have a crankcase pres sure tester Kawasaki has one for you P N T96000 001 As you use this kit on various engines you ll find you have to make some plates and buy some ex pandable freeze plugs But eventually you ll have every thing you need to pressure test all the engines you nor mally work on Remember An ounce of prevention diagnostic test ing is worth P paeton of cure wrenching Gregg Thompson OSE O D a En O a ee Oz We ee ok A er by Sharon Willeke Customer Service Representative Our las
18. e numbers of the P N and copies down the reference number plus the last four numbers from the part number It s surprisingly easy to write down the reference number without notic ing that it s not the same as the first half of the P N Here s an example of a reference number that is dif ferent from the first five numbers of the part number mshaft Ter The bot Camshatt Tensioner ani ral line of a Part No Description t story IS this Be care e e ne ful not to de 12044 1034 CAMSHAFT VALVE Si on the 12046 1019 SPROCKET CAMSHAFT reference 4 number when 12048 1111 TENSIONER ASSY CAM COPYING down ak KZ550DE064687 th 1018 GUIDE CHAIN CAM HE mt num 12053 1022 GUIDE CHAIN CAM FR e part nu 12053 1113 GUIDE CHAIN CaM RA ber from the 13107 1142 SHAFT 8X25 BOLT FLANGED 6X11 microfiche O The Technical Magazine 3 EETECH NEWS Summer 1991 Vol 4 No 1 1991 Kawasaki Motors Corp U S A KMO 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 Dave Behlings Dave Corey Chuck Crawford Jerry Heil Kenny Osberg Sharon Willeke Ray St John Graphics Production Graphic Art Gregg Thompson
19. ng the sides or top of 29RE DELIVER SPECIALISTS the leading edge the pump must be removed and re sealed To ensure a good seal the sides and too of the pump housing must have an unbroken 1 inch SILICONE SEALANT ON 650 MODELS PRESSURE HOSE SILICONE SEALANT 1 WIDE wide strip of silicone making good contact with the pump and hull at the leading edge of the pump Use only automotive type clear RTV silicone not the general purpose household silicone sealant found at paint and hard ware stores Always let the silicone dry overnight before putting the boat in the water O ALERT Cooling system blockage on some new SC amp TS J ET SKIs The boat won t be the only thing that overheats if it goes out on its maiden voyage and the cooling hose fitting on the jet pump is plugged with sealant Refer to Service Bulletin JS91 02 COOLING SYS TEM BLOCKAGE Eligible Units Hull ID Number Range JL650 A1 KAW903130D191 thru 91070 JF650 B3 KAW414250191 thru 42154 ption Claim Type 3 Job Code 21182 The Technical Magazine gt 9 T IlPs FROM T H Hull repairs under warranty do s and don ts by Gregg Thompson Sr Product Support Specialist M ake sure your service personnel are aware that according to the Kawasaki Warranty Policies and Pro cedures Manual P N 99969 0210 01 water craft hull repairs under warranty must be auth orized prior t
20. nt formulated to match that silver It s now available in Spray cans and quarts t Tan lor Rit lorRie a W a T s k The Technical Magazine 7 TIPS FROM T H Crankshaft seals Which way do they go by Gregg Thompson Senior Product Support Specialist Have you ever started to put the bottom end of a JET SKI watercraft engine back together and found you couldn t remember which way the seals were supposed to face Well don t feel like the Lone Ranger It s happened to most of us at one time or another The diagrams shown here should help if you get stumped in the future O SSS N SSS N BOW CRANKSHAFT STERN gt P N 92049 1047 P N 92049 1047 ront ear Magneto flywheel Starter clutch coupler Tapered End No taper JS300 A B BOW CRANKSHAFT STERN P N 92049 3704 P N 92049 3705 P N 92049 3706 Front Rear inner Rear outer Magneto F lywheel Coupler end Coupler end Tapered end No taper No taper Seal No FPU5307210 Seal No FWJ15307210 Seal No 530726 JF650 A1 A2 BOW CRANKSHAFT STERN P N 92049 3705 P N 92049 3705 P N 92049 3706 Front Rear inner Rear outer Magneto F lywheel Coupler end Coupler end Tapered end No taper Seat No FWt15307210 No taper Sea No FWJ15307210 Seal No 530726 All 650 models except JF650 A1 A2 8 K Tech News E SPECIALISTS BOW CRANKSHAFT P N 92050 507 Front Magnet
21. o f lywhee Tapered end Seal No AE1748 STERN gt P N 92049 3006 Rear inner Coupler end No taper Seal No AWt747P P N 92049 3005 ear outer Coupler end No taper Seal No AE1748P JS440 A4 thru A15 JS550 A1 thru A8 JS550 B1 BOW P N 92049 3006 Front Magneto fiywheel Tapered end Seal No AW1747P STERN P N 92049 3006 Rear inner Coupler end No taper Seal No AW1747P P N 92049 3005 Rear outer Coupler end No taper Sea No AE1748P JS550 C1 TIP Don t melt the plastic T he 650 family of JET SKI watercraft 650SX X 2 and TS have plastic thrust nozzles with brass inserts that the directional nozzle pivot screws mount to When installing those pivot screws a non perma nent locking agent should e used But removing the crews can then be difficult Applying heat to the area with a torch to loosen the locking agent will melt the plastic not a good idea The trick of course would be to heat just the bolt not the plastic Well you can do just that with a high power soldering gun or large soldering iron Just hold the heat source against the head of the pivot screw until it s hot and the screw should come right out Kenny Osberg TIPS by Gregg Thompson Sr Product Support Specialist n the Winter 1989 issue of K Tech News we ran an article entitled JET SKI Clutch Slipping see Vol 2 No 4 pg 8 Ed That article
22. o your do ing the work In most cases what the Hot Line technician will re quire is an estimate and some pictures that show the damage This is impor tant don t send us pic tures that are out of focus or so over exposed that the damage doesn t show See What s Wrong With This Picture K Tech News Vol 3 No 4 pg 7 Ed We have to see the damage in order to decide whether the estimate is reasonable If the repair estimate is from an outside body shop it must include the labor in hours and material costs itemized in dividually On minor repairs under lOO a combined material and labor dollar amount is usually OK When you receive a Kawasaki watercraft that has hull damage and you are considering repairing it under warranty do the following m Work up an estimate for in house repairs or ob tain a written estimate for sublet repairs E Call the Hot Line and discuss the problem with the technician m f requested take some good quality photos showing the damage and mail the photos and es timate to the Hot Line tech nician at KMC E Do the repair only after the Hot Line techni cian has called you back and authorized it O 10 K Tech News SPECIALISTS Decoding Kawasaki watercraft hull ID numbers Here s some information you can use to make the iden tification of Kawasaki watercraft easier From their introduction in 1973 Kawasaki watercraft have come
23. t article focused on repeat business and of fered several good tips for encouraging the customer to return to your store This time we present the flip side and show you types of behavior that can drive customers out the door possibly never to return Just as everything you do for a customer will eventually get a return for you everything you do not do for a customer will stunt the growth of your business We have all en countered service person nel who have helped us decide to take our busi ness elsewhere They are the rude the crude and the indifferent and they can destroy an organiza tion Hopefully they are not working at your dealer ship Try to eliminate the fol lowing behaviors when ever you recognize them in your store 1 APATHY an attitude that tells the customer you could not care less about serving him Comedian George Carlin calls this the DILLIGAD look the one that says Do Look Like Give A Damn Take a genuine interest in your customer s con cerns As minor as they may seem to you they are Quite major to your cus tomers coostacswtEe SERVIC 2 RUDENESS coldness hostility unfriendliness any behavior that says to the customer You are bothering me please go away We all learned common courtesy as children Get back to basics 3 GOING BY THE BOOK hiding behind a set of company policies that leave no room for dis cretion in
24. the ap propriate hose from your pump to the overflow hose Stick your special pump s other hose into a bottle of 50 50 coolant mix and you re ready to trans fer fluid There s no mess little fuss and lots of time saved Kenny Osberg Bonus Tip Bonus Tip Bonus Tip Bonus E In case you haven t discovered this already Liquid laundry detergent bottles with the no drip caps work great for storing coolant in your shop Kenny Osberg TT PS AFTERMARKET Different treads for the ZX 6 T he factory has tested and approved some aftermarket tires for use on the ZX600 D1 L and D2 L What this means is these tires in matched sets only can be used on the ZX600 D models without the rider experiencing any appreciable deterioration in han dling characteristics Check the ap propriate owners manual for approved optional tires on other models Re member the hand ling characteristics of any one tire will vary somewhat from one model motor cycle to another Gregg Thompson FROM T H ZX600 D1 L D2 L SET ONLY SET ONLY SET ONLY FRONT METZELER METZELER PIRELLI 110 70 V17 V250 120 60 ZR17 120 60 ZR17 ME1 Front Racing ME1 Front Comp K MP7 Spot l Tubeless Tubeless Tubeless REAR METZELER METZELER PIRELLI 160 60 VB17 160 60 ZR17 160 60 ZR17 ME1 Comp K ME1 Comp K MP7 Sport Tubeless Tubeless Tubeless TIP Does the battery rattle f you pull the bat tery out of a new ara JET SKI
25. the name of cus tomer satisfaction bk Increasing your knowledge and awareness will give you more con fidence in handling customer problems When problems are handled well cus tomers don t go away mad JJ Know when to bend rules Use your common sense to decide what is the best solution to each set of circumstances 4 THE RUNAROUND sending the frustrated cus tomer on a wild goose chase from one party to another often with the cus tomer returning to Point A where he explodes and takes others with him Part 3 Don t let them go away mad Take the time to learn more about how your or ganization operates and offer to go the extra mile for the customer Dont say It s not my job These unfortunate be haviors can be modified by actively listening to your customer and demonstrating a willing ness to help Increasing your knowledge and awareness will give you more confidence in han dling customer problems When problems are hand led well customers dont go away mad Summer is here and it is time to dust off those Kawasaki Exceptional Customer Service materials and put your skills to work Remember the Mo ment of Truth is any situa tion in which a customer comes in contact with your organization and forms an impression Let s avoid the turnoffs listed in this ar ticle because you never get a second chance to make a first impression Have a great summer O A
26. water craft to fill it with acid and hear something rattling around inside don t worry Some batteries come from the manufacturer with a couple of anti Sulfation tablets in side them These tablets rattle around in there until electrolyte is added Dave Behlings Se ee OR A Se gt ee gt ZX cooling system mystery solved by Gregg Thompson Senior Product Support Specialist We ve received a handful of reports on the Hot Line about ZX600 Ds with confusing overheating symptoms The engines were definitely overheating and boiling the coolant but the fan wouldn t go on And there was noth ing wrong with the fan system The clue that most of these mechanics missed in their initial diagnosis was that the radiator was not getting hot even when the coolant boiled over That spells circula tion troubles It turned out that a plastic plug was left in side one of the water pump pipes at the factory Remember this one if you ever have a new vehicle that overheats but the fan doesn t go on O Il an i Ag KESS d i i k3 es ACCESSORIES a ZX 6 ZX 11 frame paint The part numbers are Spray can K61062 671C Quart can K61063 671C We ve had a lot of calls on the Hot Line asking for paint to match the silver on the ZX 6 and ZX 11 frames and swingarms Until now we haven t had an answer But due to popular request the Kawasaki Accessories Department has had pai
27. y G The engine is the familiar 635cc two stroke twin with 76mm x 70mm bore and stroke Other features the SC s engine shares with the other 650s are CD ignition 7 2 1 com pression ratio oil injection crankcase reed induction JLESO A CONTINUED FROM PAGE 1 TECHNICALITIES and a Keihin CDK38 32 carburetor with a 36mm bore The exhaust system features a dry type ex haust similar to the one used on the TS Water is not mixed with the ex haust gases in this system until the water box This keeps water out of the tuned portion of the expan sion chamber improving performance throughout the rom range The SC s exhaust sys tem also features a stern SC power steering The JL650 A1 Sport Cruisers jet pump steer ing nozzle features a ver ticle tab located in the water flow near the nozzles pivot axis This tab is designed to reduce the effort required to steer the craft When the nozzle is turned the force of the water exiting the pump pushes on the inner wall of the nozzle creating a large high pressure area which tries to force the nozzle back to a straight ahead position The balance tab found in the SC nozzle diverts some of the water away from the nozzle s inner wall This reduces the high pressure area and as a result sig nificantly reduces the steering effort There is a similar tab in the steering nozzle of the JET MATE pump for the same reason Patrick Kelly
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