K-Tech News Vol.7 No.1
Contents
1. A graphic comparison between the Xi TOP and new XiR BOTTOM hulls S H O P 675 pounds of thrust In spite of the XiR s performance nature It does retain some conve nience features There is still a fuel gauge located in front of the seat The temp erature warning system found on our other 750 watercraft is retained along with the tempera ise eet at ee ee na TALK TECHNI ture warning light which is located next to the fuel gauge The XiR has the same ample storage as the Super Sport and Super Sport Xi with compartments in the bow and also in the stern A hull drain makes cleaning and flushing the engine compartment a breeze CAL There are even stainless steel eye hooks at the stern and the bow to make trailering easier The XiR reinforces Kawasaki s leadership position in the watercraft industry and will firmly establish Kawasaki as the leader on the race course as well L The Technical Magazine 3 EETECH NEWS Spring 1994 Vol 7 No 1 1994 Kawasaki Motors Corp U S A KMC All rights reserved K Tech News Staff Publisher Kawasaki Tech Services Publications Manager Don Church Executive Editor Gary Herzog Editor in Chief Gregg Thompson Communications Editor Patrick Kelly Regional Editors North and East Fred DeHart Central and South Walter Rainwater Contributors Dave Behlings Jerry Heil Kenny Osberg John Porno D2. Fuel vapors from the fuel tank go through the blue hose to the separator pump This vacuum operated pump separates the liquid from the vapors and pumps the liquid fuel back into the tank through the red hose Vapors continue through another blue hose from the separator to the char coal canister The carbur etors are also vented to Charcoal canister the canister through the yellow hose See the note at the end of this article The canister is vented to atmosphere to allow proper venting of the fuel tank and carbs but the activated charcoal inside the canister prevents those nasty fumes from escaping into the air Its a good system because it works without any perfor mance penalty Federal law does not allow you to tamper with any emissions equip ment that come as standard equipment on a motorcycle This applies to the Califor nia evaporative emis sions equipment even though it s not actu ally required in your State In other words If it came on the bike it stays on the bike It is illegal for you to disable it in any way kind of like those smoke detectors in the airplane toilets NOTE Models equipped with ram air induction systems have a vacuum operated valve in the yellow vent line between the carbs and the charcoal canister This valve switches the carb vent from the canister to the ram air vent tubes when the engine is running This is done because the intake tract is pressuriz
3. filler neck That s good advice for the customer and some thing you need to be aware of too lf the fuel tank is over filled that is filled to the bottom of the filler neck or higher so much fuel will be forced out of the fuel tank vent into the blue tube and down the red return tube that the char coal canister will become fouled with liquid fuel 6 K Tech News Once that happens the system doesn t vent prop erly and you can get all the symptoms that go along with a plugged vent in the fuel system like hard starting throttle hesitations or apparently running out of fuel while a sustained highway speeds lf a California model comes into your shop with these symptoms discon nect the blue fuel tank vent line from the back of the tank and the yellow carb vent line from the charcoal canister and ride the bike If the symptoms are gone the problem is a fouled canister You can dry the canister out by setting it out in the warm sun for a couple days Or you can fix it ina few hours by connecting a low pressure air supply such as an aquarium pump to the blue vent line inlet on the canister and letting the pump blow air through it J E S P E C IAL S T S ZX1100 D rod bearings T here are numerous errors in the rod bearing selection charts in the ZX1100 D service manual There are errors in the chart on the speci fications pages pg 8 5 of the crankshaft trans miss
4. oil or grease on it before pushing the sprocket carrier into it Gregg Thompson P N 92160 1229 or 1246 Authorization or log number A Imost every day we get calls from dealers who cant figure out why they just had a claim rejected for no authorization when they had clearly filled out the authorization space on the claim with the number they had been given over the Hot Line We ask the dealer for his authorization number and we look it up in the com puter but we already know what s wrong Nearly every time we get one of these calls it turns out the dealer had called on the problem previously and was given a log number A log number is just a file number that allows us to find the record of this phone call the next time the dealer calls regarding the same problem When we do authorize that claim the log number plus the Hot Line techni Cian s initials becomes the authorization number However we usually don t complete the authorization until the work is completed many times things change between the first time the dealer calls about the problem and when the work is finally done When we give the auth orization number and ini tials we are authorizing submitting a claim for work youve already completed Remember any claim over 150 any claim for a cosmetic failure and or any repeat claim similar failure same vehicle will need authorization John Pomo COM M UN C
5. vapors from escaping into the air This evaporative emissions system simply captures vented fumes and stores them in a charcoal canister when the engine isnt running When the engine s running all fumes including those RETURN LINE RED SS TO RAM AIR DUCT TO CARB VENT VACUUM LINE Stored in the canister are sucked into the airbox and into the engine In some cases there are slight differences in the carburetor jetting or ignition specs but these differences have never resulted in any perfor mance loss The Califor nia bike is one pound heavier and more expen sive to produce That s about it Bikes built to California specs can be sold any VENT PIPE BLUE DOT TANK VENT LINE BLUE AZASS Oty w 4 S dle where in the United States the 49 state bikes cannot be sold in California There fore we build more Califor nia bikes than we think we ll need for that year to prevent running out in California Bikes not needed in California are sold wherever they are needed This evaporative emis sions system is virtually the same on all our models and consists of a separator pump charcoal canister and some hoses RETURN PIPE RED DOT VACUUM VALVE l4 RAM AIR MODELS CARB VENT TO RAM AIR Sa PURGE LINE GREEN CARB VENT a LINE YELLOW TANK VENT BLUE Separator pump The fuel tank is modified to allow connection of the hoses
6. 2 4 1 amp CH N WS Spring 1994 The Kawasaki Technical Magazine Vol 7 No 1 inn one a by Patrick Kelly Instructional Designer Instructor If you followed personal _ watercraft racing this past season you couldn t have missed it The competition probably wishes they had never seen it It was the Kawasaki Super Sport Xi modified _ by Performance Jet Ski and ridden to the IJSBA World and National Pro Runabout championships by John Stevens Now a version of this machine is available to the serious JET SKI water craft enthusiast Intro ducing the JH750 D1 or simply the XIR The hull The XIR is based on our Super Sport Xi with a few important differences One of the biggest differ ences is the hull The XiR hull is virtually identical to the one used on John Stevens championship winning boat It differs from the Xi hull from the bond line down There is now an extra strake on each side of the hull bottom This extra strake helps improve the XiR s cornering as well as its Straight line abilities Also for improved cornering and stability there are longer sponsons on the XiR hull These additions are especially effective in the rough water conditions found in competition CONTINUED ON PAGE 2 ROUTE LIST J SERVICE PARTS J SALES PLEASERETURNTOSERVICELIBRARY Inside E Service tips amp more The XIR CONTINUED FRO
7. A T I ON S CCELI COCPECRZ SERVICE Working on those first impressions by Mary Sola Assistant Manager Consumer Affairs T here s an old saying that you never get a second chance to make a first impression and in today s retail market that s par ticularly true Where do most of your customers get their first impression of your store For the majority of people that all important first contact comes over the telephone Let s face it Most poten tial customers let their fingers do the walking before they decide to buy and will call to find out information such as your location if you have a specific item or product pricing hours before they make a trip Your store may look great have the most merchandise at the best prices around but if people wont come in because they got a bad first impression over the telephone you re no different than the guy up the street with the hole in the wall store which has three parts for an 89 EL250 on the shelves at twice retail During my time in Con sumer Services lve had to call lots of dealers and I ve had lots of time to think about good phone manners while waiting on terminal hold So here are some suggestions came up with that are easy and cost next to nothing but which can yield large re wards when used effec tively and consistently 1 Pick up the phone People won t come in if they think you re not open and most people will ha
8. M PAGE 1 The engine and pump location in this hull is also new The engine and pump have been moved rearward as far as poss ible Their new location moves both the center of mass and the pump inlet rearward helping to keep the pump hooked up in choppy waters The hull is constructed of carbon fiber reinforced RTM while the deck identical to the standard Super Sport is made of SMC The RTM bottom is gel coated inside and out and then painted on the outside to match the deck S H O P Also new is the seat To help the rider hang on under severe cornering the XiR seat is thicker than the Xi seat and has a non slip cover The engine in the XiR is basically identical to the one used in the Xi The exhaust system is how ever completely new from the exhaust manifold to the exhaust outlet The exhaust system now goes around the front of the engine makes a 90 degree turn and then enters the rear portion of the hull Inside the hull is a waterbox muffler The exhaust exits the top of the waterbox muffler and comes up through the hull TALK T EC H NI A rubber hose connects it to the other side of the hull where it goes back down into the hull to the exhaust outlet The outlet is loca ted in the jet pump tunnel facing the jet pump at a 90 degree angle This loca tion keeps exhaust noise to a minimum To maximize the effectiveness of the new exhaust the carburetor jetting has been recalibr
9. a ted The new exhaust system boosts horsepower output to 84 at 6750 rpm Another change to the engine package is a different igniter than the other 750 watercraft It has a higher rev limit potential to take advantage Eaman XiR wonders CLOCKWISE FROM ABOVE LEFT 743cc engine boasts a new igniter modified waterbox and high C A L of the engine s potential for modification Also for added simpli city and flexibility the Superlube oil injection system has been removed The engine is now lubrica ted by pre mix at a ratio of 50 1 The jet pump in the XiR is a standard 750 style jet pump with a few changes The biggest is a new three blade stainless steel impeller This is a varied pitch impeller for maxi mum acceleration with minimum cavitation The pitch varies from 9 to 17 The pump exit nozzle is also new Since the XiR does not utilize a trim adjustment system the performance pipe nozzle and pump are from the 750SX sponsons add considerably to cornering capabilities addi tional strakes molded into the new RTM carbon fiber hull improve straight line stability in rough racing conditions 2 K Tech News exit nozzle does not need mounting bosses for the nozzle trim pivot points Because of this the exit nozzle from the JS750SX is used A quick turn steering nozzle incorpor ating a vertical vane for more responsive corner ing completes the XiR pump The XiR generates
10. absorbers exhaust pipe and a unique heavily gusseted swingarm Many of the changes made to the stock machine are invisible One that s quite obvious is the lighting system developed over the last several years on the all conquering 500 s Designed in coopera tion with lighting producer PIAA the 650 s massive spotlights live in a spider web of steel tubing and connecting links Lights that turn with the handlebars are only the beginning The vibration that accompanies the in credible speeds reached in the Baja event is an other problem Then there are the weight concerns every ounce high and up front can be harmful to handling The beams themselves must be pro tected from flying rocks And the bulbs must be easy to change These are not simple garden variety challenges Coming up with solutions to the lighting problem alone took several thousand hours and dollars But make no mistake about it this amazing third place finish is a testimony to the outstanding capabilities of this durable new machine Taking nothing away from the expert preparation done by the Team Green staff the eye opening success of its first Baja 1000 appearance could never have been achieved with anything less than a great production vehicle Team Green s Johnson adds Contrary to the comments of some maga zine editors says Team Green s Johnson the KLX650 did not overheat in any one of its maiden outing
11. avid Pyle Steve Rice Mary Sola Ray St John Graphics Production Graphic Art Gregg Thompson Photography Dave Corey 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 con sideration Specifications subject to change without notice 4 K Tech News G U EST SPOT The KLX650 s stunning Baja success by Steve Nickless K Tech News Prod Asst As was mentioned in the last issue of K Tech News Kawasaki s Team Green racing division did the impossible once again by claiming an unprece dented sixth consecutive overall victory in last November s Baja 1000 Not to be overlooked in all the post race hoopla however was another similarly impressive achieve ment by Team Green in the same event the third place finish by its still new competition KLX650 Pushed to its limits by Baja veterans Paul Krause Garth Sweetland and Ted Hunicutt Jr the big four stroke machine surprised everyone except perhaps stock KLX650 customers in finishing so far up the field despite a time limited test program Indeed Team Green was forced to squeeze work in on this particular Kawasaki model around one of its most ambitious and successful sum mers of racing ever Busy on the desert and in the amateur motocross ranks the green tea
12. be polite It doesn t take that much effort even when you re busiest or the customer is the worst Getting angry at an angry or impolite customer doesn t mean you win it means you lose Most people are aware at least on some level that they are not being reasonable and the fact that you are polite anyway can win many of them over in the long run 6 Always say Thank you End every conver sation with a thank you for calling if it s at all appropriate Even if you dont end up with the customer this time you might the next especially if the other guy doesn t remember the rules of good first impressions The Technical Magazine 11 A new face to follow by Patrick Kelly 9950 Jeronimo Road Irvine CA 92718 714 770 0400 The next issue of K Tech News will feature a new face gracing the top of this column That s because there will be a new person handling the training duties out here Let me be the first to officially welcome Jerry Heil to the West Region classroom Jerry is certainly not new to Kawasaki training as he has worked in the training department for over seven years and has been instructing the electrical troubleshooting class for some time He has spent the rest of his time researching and writing training manuals so he brings a wealth of Kawasaki knowledge to the classroom As for me I ll be around researching and writing training videos as well as coordinatin
13. by Steve Rice Product Support Specialist M ore and more these days we are getting con cerned calls from dealers in the Eastern half of the country wanting to know what they can do about a California bike that acciden tally got shipped to them Our answer is always the same Sell it and be happy The dealers and custo mers are usually con cerned that their California bike won t perform like the 49 state bikes that they are used to seeing They re sure this emissions choked bike won t be able to reach the amazing performance levels the one tested by their favorite magazine did Well have spent a lot of time preparing the bikes tested by the magazines those that you read about The truth is most of those amazing perfor mance figures are being recorded using box stock California spec motorcycles After all we are here in sunny California Just about the only time we use non California bikes is when it is a very early test on a new model and production units are not available yet To prepare one of the production bikes we do a partial tear down careful inspection and reassem bly of engine chassis brakes and so on We dont modify them and we dont remove or disable the California emissions equipment 8 K Tech News TO AIR Most of the time the California models are exactly like their 49 state equivalents but with a closed fuel tank and carburetor vent system to prevent fuel
14. ed at high speeds The carb vent must also be pres surized or no fuel will flow from the float bowl up through the jets See the Float Chamber Ram Air article in the Summer 93 issue of K Tech News L T oI PS FROM TH S PECI A L IST S Ninja rod bolt torquing procedures not in the book by Gregg Thompson Product Support Supervisor S ome of you may be con fused about the torquing procedures for connecting rod bolts in our late model high performance Ninja engines And understand ably so In some cases the service manual seems to contradict itself and in all cases the torquing method can be a little mystifying The text in the crank shaft transmission chapter of the ZX1100 C and ZX1100 D service manuals calls for 11ft lb of torque plus 120 degrees of rotation on the rod bolt nuts However on the exploded view page of that chapter these nuts have two callouts The O calls for oil to be applied to the nuts on assembly The 4 refers to a foot note that says See con necting rod installation This means look in the text for the torque speci fication Unfortunately it s real easy to mistake that 4 for a T4 and simply use the 13ft lb spec that goes with it listed at the bottom of the page Don t do that The proper torque spec as listed in the chapter text is 11ft Ib plus 120 of rotation Why the low torque spec plus 120 of rota
15. er can leak if the exhaust has overheated not enough water flow or simply worn out normally after lots of hours If you have to take one of these couplers apart for some reason like poor high speed performance pay very close attention on disassembly and reassembly There are lots of parts in those things And when reassem bling it don t use any sea ant on the gaskets This can ooze into the water passages when you tighten the bolts and even a partial blockage can result in other problems Reduced water flow will almost certainly result in overheating damage somewhere most likely at the waterbox down stream of the blockage but damage can also occur at the engine or in other parts of the exhaust system All other sit down 750 s except the XiR an exhaust manifold with a JH750 A1 2 round exit hole for the ex haust gasses The JH750 B Xi exhaust manifold mean while has a larger oval exit hole JH750 A3 s and JT750 A1 s also have this oval part The trick is that all the parts round hole or oval have the same bolt pattern The performance prob lems come from using the wrong gasket at that con nection If the oval gasket is used with the round manifold water from the cooling system leaks into the exhaust stream And since the exhaust Is sup posed to stay dry all the way to the water box un welcome water at the mani fold really detunes the pipe If
16. g new model technical 12 K Tech News information I ll get back to the classroom occasion ally too instructing product update classes l Il look forward to seeing you then J Summer activity starts by Walter Rainwater 6110 Boat Rock Blvd S W Atlanta GA 30378 404 349 2000 Att the end of April training classes will be over for the season My summer plans include being a judge at the Vocational Industrial Clubs of America VICA Skill Olympics this year s event will take place in Kansas City Kawasaki Motors Corp always participates in the motor cycle troubleshooting section of the Skill Olym pics by providing motor cycles and personnel l Il also be working at some touring events this summer Maybe I ll see you there Revised service training classes will begin in the fall look for the schedule in the mail A new K Tech Service Contest will also begin in the fall It will have fewer questions per test making it easier for you to earn one of the prizes L Too much SNOW by Fred DeHart 201 Circle Drive N 107 Piscataway NJ 08854 201 469 1221 The North and East Regions have had more than enough snow and rain this winter When spring arrives your Cus tomers will be more than ready Take advantage of the service training classes left this season before the spring rush begins Train your personnel now After the training season is past will be busy assistin
17. g the Hot Line with their dealer calls and attending some of the rider rallies with Team Tour look forward to talking with you either on the phone or in person LJ Training Schedule East Region April 5 6 Fuel Systems i Generator 12 Service Department Operations 13 Pads Department Operations 19 21 JET SKI watercratt 26 28 Troubleshooting Elec Systems North Region March 26 29 30 31 MULE Service Team Green Race Preparation April No classes scheduled Central Region March 28 30 JET SKI Watercraft 31 Tune and Service April 19 21 JET SKI Watercraft 22 MULE 500 25 Tune and Service 26 28 Engines South Region April 4 Service Department Operations 5 Tune and Service 6 7 Troubleshooting Elec Systems 11 13 JET SKI watercraft 14 Generator West Region March 29 Service Department Operations 30 31 Engines April 5 7 JET SKI watercraft 8 Precision Measurement and Diagnostic Tool Usage 12 14 Troubleshooting Elec Systems 26 27 Team Green Race Preparation 28 Fuel Systems 29 Tune and Service
18. ion chapter as well as the chart in the text pg 8 13 of that chapter Not only are the two charts full of errors but they are different from each other as well Mostly what you have to be careful of is the part numbers for the bearings They are all incorrect on both charts However you should also note that the chart on the specifications page has a none on the top line under the Crank pin Diameter Marking heading It should have an O in that space In your ZX1100 D service Manual the Connecting Rod Big End Bearing selection charts Should look like the chart below Make the appro priate corrections in your service manuals Gregg Thompson Con Rod Big End Crankpin Bearing Insert Bore Diameter Diameter Marking Marking size Color Part Number O O Blue 92028 1680 None None O None White 92028 1681 None O Black 92028 1679 Connecting rod big end bearing insert selection chart Watercraft general assembly and prep manual f you re a Kawasaki JET SKI watercraft dealer you recently received your free copy of the Kawasaki Watercraft General Assem bly and Preparation manual This book is designed to be used with supplementary A amp P sheets covering those parts of the preparation of each model which are unique to it Earlier this year you got the A amp P sheet for the 1994 model Super Sport Xi You were instructed to use it with the A amp P ma
19. luid with considerable force from the caliper up through the line and into the master carbs are different than in the 2 and 3 carbs There are no identifying numbers on the main jet holders so you have to look at the hole patterns in the emulsifier tubes to tell the difference Now since neither the parts microfiche nor the service manual give you any info about this we will The main jet holders look like those in the drawing at left The jet needles you find in the bikes should be N67T for the 1 and 4 carbs and N67U for the 2 and 3 carbs At the time of this writing the microfiche shows two different needle numbers N74H and N74J this information is wrong We should have a correc ted fiche out soon J cylinder reservoir taking any trapped air bubbles with it It also helps to crack the banjo bolt loose and squeeze the brake lever forcing a little fluid out at each connecting point in the system Sometimes a small air bubble trapped in one of these fittings can be a little stubborn Make this the last thing you do after the whole system has been assembled and bled See When the brakes do the bleeding but you have all the pain article in the Fall 93 Vol 6 No 3 issue of K Tech News for more information on this same subject David Pyle The Technical Magazine 7 TIP S FROM TH E SPA a GCI A L S T S California emissions motorcycles explorations
20. m s man power was spread thin Obviously the stock KLX was a fine platform from which to begin The time element was only one of the challenges Team Green boss Mark Johnson and his techni clans accepted in undertaking the KLX650 Baja bike project Another was the formidable speed and reliability baseline already established by the team s awesome two stroke KX50Os Turning a production enduro motorcycle even one as sturdy as the new KLX into a race bike capable of taking Baja style punishment for nearly 16 hours is no easy feat Team Green approached this one as they do all new machines by looking at every component and sub system in light of the com petition rule book and Kawa saki s overall objectives In desert racing relia bility is job one In the grueling 1 000 miles of Baja it s a big job no matter what bike you are preparing But engineering for reliability is made much more complicated by the need for speed It wasn t enough just to finish the race For Team Green the objective was to finish high in the stand ings The team couldn t just dive in and start beef ing up stock components In some areas they had to Start from scratch with new and costly processes or materials to save weight rather than add it There s no catalog to turn to either Team Green was forced to hand fabricate or farm out to specialists the fab rication of many compo nents including shock
21. n ual for the 93 model Xi Well now you can use it the way it was meant to be used with the Kawa saki Watercraft General A amp P Manual Ray St John Kawasaki 2 Tol att fie prep hy manual TIP S FROM TH S PE C A L S T S ZX 9R service tips to save you a little fumbling by David Behlings Product Support Specialist Tank removal Here s a tip that might save you a little fumbling Most of us figure we can remove a fuel tank without reading the service manual right It s simple If it s got front mounting bolts re move those and then get the seat off Loosen the back of the tank probably a couple bolts and lift the back of the tank enough to reach in and disconnect the fuel line s and fuel sensor Now brace your self Some tanks weigh more than 40 lbs when full of gas and yank that dude off there Well that sounds about right for most of our bikes But the ZX 9R has some thing else to remember a fuel knob that is right in the middle of the main LH frame member the pet cock is inside the frame the knob is on the outside Before you lift the tank off the bike you should remove the fuel knob from the petcock there s a small Phillips screw in the center of it That way you don t take a chance on breaking it off when you lift the tank up Carburetor parts While working on some production ZX 9R s here we noticed some intere
22. n Assembly and Preparation sheet for the new XiR To make sure that everyone who needed the A amp P sheet got one we packed them in the crate with the boat This is a limited produc tion model so we did not do a general mailing of the A amp P the way we would for a high production quantity model Ray St John How We Stack Up 94 Recently you received a supply of How We Stack Up 1994 booklets We hope you have already put them to use training your sales staff in the features and benefits of the 94 Kawasakis The booklet is designed to be carried in a sales person s pocket at all times to help out in answering customers questions If you need more copies call your Distict Manager your Regional Sales Manager or the Technical Services Divi sion of Kawasaki Motors Corp U S A 714 770 0400 x2472 Ray St John The Technical Magazine 5 S FROM TH Charcoal canister fouling by Gregg Thompson Product Support Supervisor You dealer technicians who are not real familiar with the California Evap orative Emissions system could be fooled into some unnecessary diagnostic work if the customer doesn t read and follow he instructions in his owners manual So here s little briefing The owners manual for any of our street legal our stroke bikes tells the customer the one who takes the time to read it not to fill the gas tank so full that the fuel rises into the
23. ng up after five or six rings so make it a rule to have the phone picked up after two or at the most three rings 2 Give the name of the store and ask how you may help Customers may hang up without saying anything if they think they got the wrong number Answering the phone with a yeah might work at home but for a business it shows a lack of professionalism which can really hurt 3 Don t leave people on hold for longer than 30 seconds Make an experiment Without looking at a clock or counting but with a phone in your hand try to judge how long a minute is After about 10 seconds you ll probably think it s time someone picked up Everyone has horror Stories about being left on hold for what seems like centuries don t let the Stories be about your dealership Come back immediately if the depart ment or person the call is for doesn t answer right away Take a message rather than keep a person on hold unless they ask to stay there and keep checking back Remember the more people you leave on hold the fewer incoming calls you can take and that can mean less business coming in the store 4 Return calls Over the years I ve left hun dreds of messages for people who never got back to me and every time it happened my Opinion of the dealership dropped a little It s just good manners to return calls if possible within 10 20 minutes Good manners can only win you friends 5 Always
24. on the less clamping force That s why the service manuals call for oil to be applied to the nut on assembly If you don t apply oil to the nut even though you use the correct torquing procedure the clamping force will be reduced If you use an old bolt not only will the clamping force be reduced but the bolt will be more likely to fail in use NOTE When rebuilding a bottom end in one of these engines check plastigauge the bearing clearances using the old rod bolts Then use your new bolts for the final assembly This will allow you to torque the new bolts just the one time Also don t forget to put molybdenum disulfide grease on the back side of the upper bearing shell on final assembly This helps absorb the shock to the bearing during combus tion LJ N i s es we we ew we I ES We g 2 ec E A gwo gt oa HF i ay a s ava 3 PT ji pa 4 E t The Technical Magazine 9 T IP S FROM TH E S P E CIAL S T S 750 J ET SKI watercraft exhaust do s and don ts by Kenny Osberg Product Support Specialist Manifold gaskets Several recent calls to the Hot Line concerning water craft poor performance problems that were eating up technicians lunch hours big time turned out to be caused by a very simple problem The JH750 A1 and A2 SuperSports had problems Rubber parts or seals inside the coupl
25. re not supposed to come on replacement parts last year however some were supplied by mistake A chart in K Tech New Vol 5 No 1 shows vehicle type and whether its parts come with decals or not J CATION S Missing numbers S ome of you may have noticed in the latest Retail Price Guide that there are some numbers missing To be more precise any part number that has been canceled for 10 or more years is no longer shown in the guide This causes some problems when looking up parts on the older micro fiche We don t change the part numbers on the microfiche every time there is a part number change of course If we did your inventory could have stock with no refer ence to it and we would be sending out so many microfiche that you would need a second mail box So what would do Well for starters would keep a few old price guides around for reference But if it s too late and you ve already recycled your old ones here are a few tips Model Application Guide Using the M A G will help you find the latest substitute numbers for old parts you have in stock so that you can go back to the price guide for pricing info K Share Run an Item Status Inquiry on K Share If you enter any number on K Share it will show the latest substitute number even if it is not shown in the retail price guide Dave Pyle XIR assembly and prep B elieve it or not there is already a
26. s And by the end of the year Mark notes it was making more power than the two stroke 500 LJ Micro K by David Pyle Parts Publications Specialist In the last few months have received quite a few questions regarding the circled letters that are shown on some parts grids The purpose of these letters is to make it easier to find a part and he point where it attaches on a vehicle Many times there is not enough room on the illustration to spread out all the parts in the proper location By showing the circled letter next to the part and next to its location on the frame identifying the correct parts is made easier In the sample lustration of the KX250 K1 Frame Fittings grid here are circled letters A thru E These letters show he correct location of A he top motor mount bolt the front motor mount bolt C the bottom motor C OMMUN mount bolt and D and E the top and bottom chain rollers and bolts It would be far too confusing to try and connect the lines with the parts and the frame Just remember When you see a part with a letter in a circle next to it there will be another letter in a circle somewhere else on the page showing its proper location have also received some calls regarding decals on street bikes What decals come on painted body parts All decals come on painted body parts Most plastic emblems have to be ordered separately ZX 1100 D tank emblems a
27. s ting things about the inter nal carburetor parts The jet needles and main jet holders in the 1 and 4 2 AND 3 CARBS 1 AND 4 CARBS ee TIP The old brake system pre bleed trick have found a trick that helps save time bleeding a brake system when rebuilding or replacing a brake caliper have had excellent luck with this method on KX brakes and am sure it will work on any hydraulic system The trick is to assemble the system with an already full caliper Start with the new or rebuilt caliper in your hand Have the pis ton s almost fully exten ded in the caliper This leaves the largest possible space for fluid in the cali per Pouring brake fluid in through the banjo bolt hole fill the caliper all the way to the top of the threads Now with your thumb over the hole turn and shake the caliper to loosen any air bubbles that might be trapped in there Top it off with fluid again and at tach the banjo bolt and line us ing new crush washers we never re use the old ones right lf the brake line is empty you should force some fluid up into it through the bleeder fitting on the caliper A syringe works well for this Be careful not to push any air into the caliper while you do this Now you are going to give the whole system a power flush from the bottom up by rapidly pushing the pis ton s all the way into the caliper This pushes all the f
28. the round gasket is used with the oval mani fold the gasket protrudes into the exhaust stream dis rupting the flow of gasses Either way perfor mance especially top end suffers significantly Technicians beware Pipe coupler Water entering the ex haust stream at the coup ler between the exhaust pipe and the expansion chamber in all sit down 750 watercraft models will also cause performance 10 K Tech News ZX600 D rear sprocket damper We ve had a few calls recently from dealers who were confused by a change that has been made in the rear sprocket damper for the ZX600 D s The original damper for this model was a one piece unit with small drive cushions and larger decel eration cushions That damper was relatively smooth and flat on both sides see the accom panying illustration But it has been replaced by a new part which is significantly different dif ferent enough that some dealers were sure they received the wrong part If you order one of these the part or kit that you will receive is actually three separate parts All three parts are identical to each other and are installed in the wheel to make up the complete damper To install them drop the dampers into the wheel with the funny P N 92160 5001 looking two story bumps pointing outward toward the sprocket as indicated in the illustration The damper is a tight fit so you might want to put a little
29. tion This method called Angle Controlled Tight ening is specified in all our latest four cylinder liquid cooled engines Some manuals even give a bolt stretch specification Why do they all call for oil to be applied to the nuts before assembly And why do all the models with this torquing method Say never to reuse an old rod bolt The answer to these questions is in the term clamping force the actual pressure applied to the two parts being bolted together The purpose of all the above described procedures is to consis tently achieve the proper clamping force Because of many variables that can affect any given situation the more conventional torquing method and hardware can result in widely varying clamping forces In fact one bolt could actually be applying almost twice as much clamping force as the other bolt in the same rod with the same torque The high tech stretch bolts used in our very high perfor mance modern Ninja engines combined with proper assembly proce dures can greatly narrow the range of clamping force produced by apply ing the specified torque In other words this method is much more precise than conventional torquing with conventional hardware The friction created between the threads of the nut and the threads of the bolt and between the thrust surface of the nut and the rod will affect the clamping force produced at a given torque setting The more fricti
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